Toro 75955 Operator's Manual

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Page 1

FormNo.3414-602RevC

ZMaster

Professional5000

SeriesRidingMower

with52inTURBOFORCE Mower

ModelNo.75955—SerialNo.400000000andUp

SideDischarge

Registeratwww.T oro.com. OriginalInstructions(EN)

*3414-602*C

Page 2

ThissparkignitionsystemcomplieswithCanadian ICES-002

ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty, traction,andsafetyofthemachine.Failureto useoriginalToropartscouldcauseserious injuryordeath.Makingunauthorizedchanges totheengine,fuelorventingsystem,may violateEPAandCARBregulations.

Replaceallpartsincluding,butnotlimited to,tires,belts,blades,andfuelsystem componentswithoriginalToroparts.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

g029954

Figure1

1.Modelandserialnumberlocation

Pleaserefertotheenginemanufacturer’sinformation includedwiththemachine.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Introduction

Thisrotary-blade,ridinglawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional,hired operators.Itisdesignedprimarilyforcuttinggrasson well-maintainedlawnsonresidentialorcommercial properties.Itisnotdesignedforcuttingbrushorfor agriculturaluses.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

g000502

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Y ouareresponsiblefor operatingtheproductproperlyandsafely .

YoumaycontactT orodirectlyatwww.T oro.com forproductsafetyandoperationtrainingmaterials, accessoryinformation,helpndingadealer,orto registeryourproduct.

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Page 3

Contents

Safety.......................................................................4

GeneralSafety...................................................4

SlopeIndicator...................................................5

SafetyandInstructionalDecals..........................6

ProductOverview...................................................12

Controls...........................................................12

Specications..................................................13

BeforeOperation.................................................14

BeforeOperationSafety...................................14

RecommendedFuel.........................................14

UsingStabilizer/Conditioner.............................15

FillingtheFuelTank..........................................15

CheckingtheEngine-OilLevel..........................15

BreakinginaNewMachine..............................15

UsingtheRolloverProtectionSystem

(ROPS).........................................................16

ThinkSafetyFirst..............................................17

UsingtheSafety-InterlockSystem....................17

UnlatchingtheSeat..........................................19

AdjustingtheMyRide™Suspension

System..........................................................20

DuringOperation.................................................21

DuringOperationSafety...................................21

OperatingtheParkingBrake.............................22

OperatingtheMowerBlade-ControlSwitch

(PTO)............................................................23

OperatingtheThrottle.......................................23

OperatingtheIgnitionSwitch............................23

StartingtheEngine...........................................23

ShuttingOfftheEngine.....................................24

UsingtheMotion-ControlLevers.......................25

DrivingtheMachine..........................................25

StoppingtheMachine.......................................26

UsingtheSideDischarge.................................26

AdjustingtheHeightofCut...............................27

AdjustingtheAnti-ScalpRollers........................28

AdjustingtheFlowBafeCamLocks................29

PositioningtheFlowBafe................................29

OperatingTips.................................................31

AfterOperation....................................................32

AfterOperationSafety......................................32

UsingtheFuel-ShutoffValve.............................32

UsingtheDrive-Wheel-ReleaseValves............32

TransportingtheMachine.................................33

LoadingtheMachine........................................34

Maintenance...........................................................35

RecommendedMaintenanceSchedule(s)...........35

Pre-MaintenanceProcedures..............................36

MaintenanceandStorageSafety......................36

Lubrication..........................................................37

AddingLightOilorSprayLubrication................37

GreasingtheMowerDeck................................37

GreasingthePump-Belt-IdlerArm....................37

GreasingtheCaster-WheelBearings...............38

LubricatingtheCaster-WheelHubs..................38

EngineMaintenance...........................................39

EngineSafety...................................................39

ServicingtheAirCleaner..................................39

ServicingtheEngineOil....................................41

ServicingtheSparkPlug...................................43

CheckingtheSparkArrester.............................45

FuelSystemMaintenance...................................45

ServicingtheElectronicFuel-Injection

System..........................................................45

ReplacingtheLow-PressureFuel

Filter..............................................................45

ServicingtheHigh-PressureFuelFilter.............46

ServicingtheFuelT ank.....................................46

ElectricalSystemMaintenance...........................46

ElectricalSystemSafety...................................46

ServicingtheBattery.........................................46

ServicingtheFuses..........................................48

Jump-StartingtheMachine...............................48

DriveSystemMaintenance..................................50

CheckingtheSeatBelt.....................................50

CheckingtheRolloverProtectionSystem

(ROPS)Knobs..............................................50

AdjustingtheTracking......................................50

CheckingtheTirePressure...............................51

CheckingtheWheel-LugNuts..........................51

CheckingtheWheel-HubSlottedNut................51

AdjustingtheCaster-PivotBearing...................51

UsingtheClutchShim......................................52

CoolingSystemMaintenance..............................54

CleaningtheEngineScreenandEngine-Oil

Cooler...........................................................54

CleaningtheEngine-CoolingFinsand

Shrouds........................................................54

CheckingandCleaningtheHydraulic-Unit

Shrouds........................................................55

BrakeMaintenance.............................................55

AdjustingtheParkingBrake..............................55

BeltMaintenance................................................56

InspectingtheBelts..........................................56

ReplacingtheMowerBelt.................................56

ReplacingtheHydraulicPump-Drive

Belt................................................................57

ControlsSystemMaintenance.............................58

AdjustingtheControl-HandlePosition..............58

AdjustingtheMotion-ControlLinkage...............59

AdjustingtheMotion-ControlDamper...............60

AdjustingtheMotion-ControlNeutral-Lock

Pivot..............................................................60

HydraulicSystemMaintenance...........................61

HydraulicSystemSafety...................................61

ServicingtheHydraulicSystem........................61

MowerDeckMaintenance....................................63

LevelingtheMowerDeck..................................63

ServicingtheCuttingBlades.............................66

RemovingtheMowerDeck...............................68

ReplacingtheGrassDeector..........................70

Cleaning..............................................................70

CleaningundertheMower................................70

CleaningtheSuspensionSystem.....................70

Page 4

DisposingofWaste...........................................70

Storage...................................................................71

CleaningandStorage.......................................71

Troubleshooting......................................................72

Schematics.............................................................75

Safety

Thismachinehasbeendesignedinaccordancewith ANSIB71.4-2012.

GeneralSafety

Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriouspersonalinjury.

Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.

•Readandunderstandthecontentsofthis

Operator’sManualbeforeyoustarttheengine. Ensurethateveryoneusingthisproductknows howtouseitandunderstandsthewarnings.

•Donotputyourhandsorfeetnearmoving

componentsofthemachine.

•Donotoperatethemachinewithoutallguards

andothersafetyprotectivedevicesinplaceand workingonthemachine.

•Keepclearofanydischargeopening.Keep

bystandersasafedistanceawayfromthe machine.

•Keepchildrenoutoftheoperatingarea.Never

allowchildrentooperatethemachine.

•Stopthemachineandshutofftheenginebefore

servicing,fueling,oruncloggingthemachine.

Improperlyusingormaintainingthismachinecan resultininjury.T oreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafety-alertsymbol,whichmeans Caution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.

Youcanndadditionalitemsofsafetyinformationin theirrespectivesectionsthroughoutthismanual.

Page 5

SlopeIndicator

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge

g011841

Page 6

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

58-6520

1.Grease

93-7818

decal58-6520

decal106-2655

106-2655

1.Warning—donottouchorapproachmovingbelts;remove theignitionkeyandreadtheinstructionsbeforeservicing orperformingmaintenance.

decal93-7818

1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto1 15to149N∙m(85to110 ft-lb).

99-8936

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

decal106-5517

106-5517

1.Warning—donottouchthehotsurface.

decal110-2067

110-2067

decal99-8936

Page 7

decal112-9028

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin place.

decal114-4466

114-4466

1.Main(25A)3.Charge(25A)

2.PTO(10A)4.Auxiliary(15A)

decal107-3069

107-3069

1.Warning—thereisnorolloverprotectionwhentherollbaris down.

2.Toavoidinjuryordeathfromarolloveraccident,keepthe rollbarinthefullyraisedandlockedpositionandwear theseatbelt.Lowertherollbaronlywhenabsolutely necessary;donotwearthetheseatbeltwhentherollbaris down.

3.ReadtheOperator'sManual;driveslowlyandcarefully.

decal110-2068

110-2068

1.ReadtheOperator'sManual.

decal136-5508

136-5508

1.Beltrouting

decal115-9625

115-9625

1.Parking brake—disengaged

2.Parkingbrake—engaged

Page 8

116-1716

1.Fuel6.Hourmeter

2.Empty

3.Half

7.PTO

8.Parkingbrake

4.Full9.Neutral

5.Battery

10.Operator-presenceswitch

116-4858

decal116-1716

decal117-0346

117-0346

1.Fuelleakhazard—readtheOperator'sManual;donot

decal116-4858

attempttoremovetherollbar;donotweld,drill,ormodify therollbarinanyway.

116-8726

1.ReadtheOperator’sManualforrecommendedhydraulic uid.

decal116-8726

decal117-3848

117-3848

1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

2.Thrownobjecthazard,mower—donotoperatethemachine withoutdeector,dischargecover,orgrasscollection systeminplace.

3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts;keepallguardsandshieldsinplace.

Page 9

decal117-3864

117-3864

1.ReadtheOperator’s

Manual.

1.Fast

2.Variablespeedcontrol

2.Filltobottomofllerneck;

121–7586

3.Slow

4.Powertakeoff(PTO)

126-2055

warning—donotoverll thetank.

decal126-4398

126-4398

1.ReadtheOperator’s manual

2.Lock

decal121-7586

decal126-2055

3.Unlock

1.Wheellug-nuttorque129N∙m(95ft-lb)(4x)

2.Wheelhub-nuttorque319N∙m(235ft-lb)

3.ReadandunderstandtheOperator’smanualbefore performinganymaintenance,checktorqueafterrst100 hoursthenevery500hoursthereafter.

1.ReadtheOperator's

2.Height-of-cut

Manual.

decal127-0326

127-0326

3.Removethekeyfrom theignitionandreadthe Operator'sManualbefore performingmaintenance orservicingthemachine.

Page 10

decalbatterysymbols

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

132-5063

1.Camlock2.Camunlock

1.Explosionhazard

6.Keepbystandersasafe distancefromthebattery.

2.Nore,opename,or smoking

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.

3.Causticliquid/chemical

decal132-5063

burnhazard

4.Weareyeprotection.9.Flusheyesimmediately

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

5.ReadtheOperator's

Manual.

10.Containslead;donot discard

decaloemmarkt

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

125–9383

1.Checkhydraulicuidevery50operatinghours.3.Checkthetirepressureevery50operatinghours.

2.ReadtheOperator’sManualforinformationonlubricating themachine.

4.ReadtheOperator’sManualbeforeservicingorperforming maintenance.

decal125-9383

Page 11

132-0871

Note:Thismachinecomplieswiththeindustrystandardstabilitytestinthestaticlateralandlongitudinaltestswiththemaximum

recommendedslopeindicatedonthedecal.ReviewtheinstructionsforoperatingthemachineonslopesintheOperator’sManualas wellastheconditionsinwhichyouwouldoperatethemachinetodeterminewhetheryoucanoperatethemachineinthoseconditions onthatdayandatthatsite.Changesintheterraincanresultinachangeinslopeoperationforthemachine.Ifpossible,keepthe cuttingunitsloweredtothegroundwhileoperatingthemachineonslopes.Raisingthecuttingunitswhileoperatingonslopescan causethemachinetobecomeunstable.

decal132-0871

1.Warning—readtheOperator’sManual;donotoperatethis machineunlessyouaretrained;wearhearingprotection.

4.Ramphazard—whenloadingontoatrailer ,donotusedual ramps;onlyuseasingularrampwideenoughforthemachine andthathasaninclinelessthan15°;backuptheramp(in reverse)anddriveforwardofftheramp.

2.Cutting,dismembering,andentanglementhazard—keep handsawayfrommovingparts;keepallguardsandshieldsin

5.Bodilyharmhazard—donotcarrypassengers;lookbehind youwhenmowinginreverse.

place.

3.Thrownobjecthazard—keepbystandersaway.6.Tippinghazardonslopes—donotuseonslopesnearopen water;donotuseonslopesgreaterthan15°.

132–5067

decal132-5067

Page 12

ProductOverview

HourMeter

Thehourmeterrecordsthenumberofhoursthe enginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance(Figure6).

FuelGauge

Thefuelgaugeislocatedwiththehourmeter,and thebarslightupwhentheignitionswitchisintheON position(Figure6).

Theindicatorlightappearswhenthefuellevelislow (approximately1gallonremaininginthefueltank).

Safety-InterlockIndicators

Figure4

1.Side-dischargedeector

2.Height-of-cutdeck-lift

pedal

3.Parking-brakelever10.Fuelcap

4.Transportlock11.Mowerdeck

5.Controls12.Casterwheel

6.Motion-controllevers13.Front-shockassembly

7.Rollbar

8.Rear-shockassembly

9.Seatbelt

Controls

Becomefamiliarwithallthecontrolsbeforeyoustart theengineandoperatethemachine(Figure4and

Figure5).

g029631

Therearesymbolsonthehourmeterthatindicate withablacktrianglethattheinterlockcomponentis positionedcorrectly(Figure6).

Battery-IndicatorLight

IfyouturntheignitionkeytotheONpositionfora fewseconds,thebatteryvoltagedisplaysinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure6).

Figure5

1.PTOswitch

2.Throttlecontrol5.Ignitionswitch

3.Malfunctionindicatorlight

(MIL)

4.Hour

6.Fuses

meter/Safety-interlock display/Fuelgauge

g008950

Figure6

1.Fuelgauge(bars)4.Safety-interlocksymbols

2.Batterylight

g013112

3.Hourmeter

5.Lowfuel-indicatorlight

ThrottleControl

Thethrottlecontrolstheenginespeed,andithasa continuous-variablesettingfromtheSLOWtoFAST position(Figure5).

Page 13

Blade-ControlSwitch(Power Takeoff)

Theblade-controlswitch(PTO)engagesand disengagespowertothemowerblades(Figure5).

Specications

Note:Specicationsanddesignaresubjectto

changewithoutnotice.

Width

IgnitionSwitch

Usethisswitchtostartthemowerengine.Ithas3 positions:START,RUN,andOFF.

Motion-ControlLevers

Usethemotion-controlleverstodrivethemachine forward,reverse,andturneitherdirection.

Neutral-LockPosition

UsetheNEUTRAL-LOCKpositionwiththe safety-interlocksystemtoengageandtodetermine theNEUTRALposition.

Fuel-ShutoffValve

Closethefuel-shutoffvalve(undertheseat)when transportingorstoringthemower.

Electronic-ControlUnit

WithoutDeck

DeectorUp157cm(62inches)

DeectorDown192cm(76inches)

135cm(53inches)

Length

RollBarUp

RollBarDown

211cm(83inches)

215cm(85inches)

Height

RollBarUpRollBarDown

179cm(71inches)127.8cm(50.3inches)

Weight

ModelWeight

75955

587kg(1,295lb)

Malfunction-IndicatorLight

Theelectronic-controlunit(ECU)continuously monitorstheoperationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the malfunction-indicatorlight(MIL)illuminates.

TheMIListheredlightlocatedintherightconsole panel.

OncetheMILilluminates,makeinitialtroubleshooting checks;refertotheMILsectionunderTroubleshooting

(page72).

Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedService Dealerisnecessary.

Attachments/Accessories

AselectionofT oroapprovedattachmentsand accessoriesisavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.T oro.comforalistofallapprovedattachments andaccessories.

Page 14

Operation

containersontheground,awayfromyourvehicle beforelling.

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

BeforeOperation

BeforeOperationSafety

GeneralSafety

•Neverallowchildrenoruntrainedpeopleto

operateorservicethemachine.Localregulations mayrestricttheageoftheoperator.Theowner isresponsiblefortrainingalloperatorsand mechanics.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Knowhowtostopthemachineandshutoffthe

enginequickly.

•Checkthatoperator-presencecontrols,safety

switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.

•Beforemowing,alwaysinspectthemachineto

ensurethattheblades,bladebolts,andcutting assembliesareingoodworkingcondition. Replacewornordamagedbladesandboltsinsets topreservebalance.

•Inspecttheareawhereyouwillusethemachine

andremoveallobjectsthatthemachinecould throw.

•Evaluatetheterraintodeterminetheappropriate

equipmentandanyattachmentsoraccessories requiredtooperatethemachineproperlyand safely.

FuelSafety

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlingfuel.Fuelvaporsare ammableandexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporaddfueltothefuel

tankwhiletheengineisrunningorwhilehot.

•Donotrefuelthemachineindoors.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

•Donotllcontainersinsideavehicleoronatruck

ortrailerbedwithaplasticliner.Alwaysplace

•Removetheequipmentfromthetruckortrailer

andrefuelitwhileitisontheground.Ifthisisnot possible,thenrefuelfromaportablecontainer ratherthanafuel-dispensernozzle.

•Donotoperatethemachinewithouttheentire

exhaustsysteminplaceandinproperworking condition.

•Keepthefuel-dispensernozzleincontactwith

therimofthefueltankorcontaineropeningat alltimesuntilfuelingiscomplete.Donotusea nozzlelock-opendevice.

•Ifyouspillfuelonyourclothing,changeyour

clothingimmediately.Wipeupanyfuelthatspills.

•Neveroverllthefueltank.Replacethefuelcap

andtightenitsecurely.

•Storefuelinanapprovedcontainerandkeepit

outofthereachofchildren.Neverbuymorethan a30-daysupplyoffuel.

•Donotllthefueltankcompletelyfull.Addfuelto

thefueltankuntilthelevelis6to13mm(1/4to 1/2inch)belowthebottomofthellerneck.This emptyspaceinthetankallowsfueltoexpand.

–Avoidprolongedbreathingofvapors.

–Keepyourfaceawayfromthenozzleandfuel

tankopening.

–Avoidcontactwithskin;washoffspillswith

soapandwater.

RecommendedFuel

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse.

Neverusegasolinethatcontainsmorethan 10%ethanolbyvolume,suchasE15(contains

15%ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessyouuseafuel stabilizer.

•Donotaddoiltogasoline.

Page 15

Using Stabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsfuelfreshduringstorageof90daysorless

(drainthefueltankwhenstoringthemachinefor morethan90days)

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel

system,whichcauseshardstarting

Important:Donotusefueladditives

containingmethanolorethanol.

Addthecorrectamountoffuelstabilizer/conditioner tothefuel.

Note:Afuelstabilizer/conditionerismost

effectivewhenmixedwithfreshfuel.Tominimize thechanceofvarnishdepositsinthefuelsystem, usefuelstabilizeratalltimes.

FillingtheFuelTank

1.Parkthemachineonlevelground.

2.Shutofftheengineandengagetheparking

brake.

3.Cleanaroundthefuel-tankcap.

4.Fillthefueltanktothebottomofthellerneck

(Figure7).

Note:Donotllthefueltankcompletelyfull.

Theemptyspaceinthetankallowsthefuelto expand.

g027726

Figure7

CheckingtheEngine-Oil Level

Beforeyoustarttheengineandusethemachine, checktheoillevelintheenginecrankcase;referto

CheckingtheEngine-OilLevel(page41).

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhen new,placingadditionalloadontheengine.Allow 40to50hoursofbreak-intimefornewmachinesto developfullpowerandbestperformance.

Page 16

UsingtheRollover ProtectionSystem(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keep therollbarinthefullyraisedlockedposition andusetheseatbelt.

Ensurethattheseatissecuredtothe machine.

WARNING

Thereisnorolloverprotectionwhentheroll barisinthedownposition.

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbar isinthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

•Checkcarefullyforoverheadclearances (i.e.,branches,doorways,electricalwires) beforedrivingunderanyobjectsanddo notcontactthem.

Important:Lowertherollbaronlywhen

absolutelynecessary.

Important:Ensurethattheseatissecuredto

themachine.

1.Tolowertherollbar,applyforwardpressureto theupperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sothey arenotengaged(Figure8).

3.Lowertherollbartothedownposition(Figure

8).

Figure8

1.ROPSknob

2.PulltheROPSknobout androtate90degrees

4.Toraisetherollbar,raisetherollbartothe

operateposition,rotatetheknobssothatthey movepartiallyintothegrooves(Figure8).

5.Raisetherollbartothefulluprightpositionwhile

pushingontheupperrollbarandthepinssnap intopositionwhentheholesalignwiththepins (Figure8).

3.Rollbarintheupright position

4.Rollbarinthefolded position

Important:Alwaysusetheseatbeltwiththe

rollbarintheraisedposition.

6.Pushontherollbarandensurethatbothpins areengaged.

g008943

Page 17

ThinkSafetyFirst

CAUTION

Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.

DANGER

Operatingthemachineonwetgrassorsteep slopescancauseslidingandlossofcontrol.

•Donotoperateonslopesgreaterthan15 degrees.

•Reducespeedanduseextremecautionon slopes.

•Donotoperatethemachinenearwater.

DANGER

Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury, death,ordrowning.

Donotoperatethemachineneardrop-offs.

DANGER

Operatingthemachinewhiletherollbaris downmayleadtoseriousinjuryordeathin theeventofarollover.

Alwayskeeptherollbarinthefullyraisedand lockedpositionandusetheseatbelt.

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Useprotectiveequipmentforyoureyes,ears,hands, feet,andhead.

g009027

Figure10

1.Weareyeprotection.2.Wearhearingprotection.

UsingtheSafety-Interlock System

WARNING

Ifsafety-interlockswitchesaredisconnected ordamaged,themachinecouldoperate unexpectedlycausingpersonalinjury.

1.SafeZone—usethe machinehereonslopes lessthan15degreesor atareas.

2.DangerZone—usea walk-behindmowerand/or ahandtrimmeronslopes greaterthan15degrees andneardrop-offsor water.

Figure9

3.Water

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdaily,andreplaceanydamaged switchesbeforeoperatingthemachine.

Understandingthe Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe enginefromstartingunless:

•Theparkingbrakeisengaged.

g000963

•Theblade-controlswitch(PTO)isdisengaged.

•Themotion-controlleversareintheNEUTRAL-LOCK

position.

Thesafety-interlocksystemalsoisdesignedtoshutoff theenginewhenthetractioncontrolsaremovedfrom thelockedpositionwiththeparkingbrakeengagedor ifyourisefromtheseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglelightsupinthecorrespondingsquare.

Page 18

Figure11

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

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Page 19

TestingtheSafety-Interlock System

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorized ServiceDealerrepairthesafetysystemimmediately .

1.Sittingontheseat,engagetheparkingbrake

andmovetheblade-controlswitch(PTO)tothe ONposition.Trystartingtheengine;theengine shouldnotstart.

2.Sittingontheseat,engagetheparkingbrake

andmovetheblade-controlswitch(PTO)tothe OFFposition.Moveeithermotion-controllever (outoftheNEUTRAL-LOCKposition).Trystarting theengine;theengineshouldnotstart.Repeat fortheothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,

movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,disengage theparkingbrake,engagetheblade-control switch(PTO),andriseslightlyfromtheseat;the engineshouldshutoff.

UnlatchingtheSeat

Tounlatchtheseat,pushtheseatlatchforward (Figure12).

g204507

Figure12

4.Sittingontheseat,engagetheparkingbrake,

movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,center eithermotioncontrolandmove(forwardor reverse);theengineshouldshutoff.Repeatfor othermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake,

movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Trystartingthe engine;theengineshouldnotstart.

Page 20

AdjustingtheMyRide™ SuspensionSystem

TheMyRide™suspensionsystemadjuststoprovide asmoothandcomfortableride.Youcanadjustthe rear2-shockassembliestoquicklyandeasilychange thesuspensionsystem.Positionthesuspension systemwhereyouaremostcomfortable.

AdjustingtheRear-Shock Assemblies

Theslotsfortherear-shockassemblieshave detentpositionsforreference.Y oucanpositionthe rear-shockassembliesanywhereintheslot,notjust inthedetentpositions.

Thefollowinggraphicshowsthepositionforasoftor rmrideandthedifferentdetentpositions(Figure13).

Adjusttherear-shockassemblies(Figure14).

g030024

Figure13

1.Firmestposition3.Detentsintheslots

2.Softestposition

Note:Ensurethattheleftandrightrear-shock

assembliesarealwaysadjustedtothesamepositions.

g030065

g030019

Figure14

Page 21

DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible

foraccidentsthatmaycausepersonalinjuryor propertydamage.

•Wearappropriateclothing,includingeye

protection;slip-resistant,substantialfootwear;and hearingprotection.Tiebacklonghairanddonot wearjewelry.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Nevercarrypassengersonthemachineandkeep

bystandersandpetsawayfromthemachine duringoperation.

•Operatethemachineonlyingoodvisibilitytoavoid

holesorhiddenhazards.

•Avoidmowingonwetgrass.Reducedtraction

couldcausethemachinetoslide.

•Ensurethatalldrivesareinneutral,theparking

brakeisengaged,andyouareintheoperating positionbeforeyoustarttheengine.

•Keepyourhandsandfeetawayfromthecutting

units.Keepclearofthedischargeopeningatall times.

•Lookbehindanddownbeforebackinguptobe

sureofaclearpath.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscureyour vision.

•Donotmowneardrop-offs,ditches,or

embankments.Themachinecouldsuddenlyroll overifawheelgoesovertheedgeoriftheedge givesway.

•Stopthebladeswheneveryouarenotmowing.

•Stopthemachineandinspectthebladesafter

strikinganobjectorifthereisanabnormal vibrationinthemachine.Makeallnecessary repairsbeforeresumingoperation.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalkswiththe machine.Alwaysyieldtheright-of-way.

•Disengagethedrivetothecuttingunitandshut

offtheenginebeforeadjustingtheheightof cut(unlessyoucanadjustitfromtheoperating position).

•Neverrunanengineinanareawhereexhaust

gasesareenclosed.

•Neverleavearunningmachineunattended.

•Beforeleavingtheoperatingposition(including

toemptythecatchersortounclogthechute),do thefollowing:

–Stopthemachineonlevelground. –Disengagethepowertake-offandlowerthe

attachments. –Engagetheparkingbrake. –Shutofftheengineandremovethekey. –Waitforallmovingpartstostop.

•Donotoperatethemachinewhenthereistherisk

oflightning.

•Donotusethemachineasatowingvehicle.

•Donotchangethegovernorspeedoroverspeed

theengine.

•Useaccessoriesandattachmentsapprovedby

Toroonly.

RolloverProtectionSystem (ROPS)Safety

•Donotremovetherollbarfromthemachine.

•Ensurethattheseatbeltisattachedandthatyou

canreleaseitquicklyinanemergency.

•Alwayswearyourseatbeltwhentherollbarisup.

•Checkcarefullyforoverheadobstructionsanddo

notcontactthem.

•Keeptherollbarinsafeoperatingconditionby

thoroughlyinspectingitperiodicallyfordamage andkeepingallthemountingfastenerstight.

•Replaceadamagedrollbar.Donotrepairoralter

it.

SlopeSafety

•Establishyourownproceduresandrulesfor

operatingonslopes.Theseproceduresmust includesurveyingthesitetodeterminewhich slopesaresafeformachineoperation.Always usecommonsenseandgoodjudgmentwhen performingthissurvey.

•Slopesareamajorfactorrelatedtoloss-of-control

andtip-overaccidents,whichcanresultinsevere injuryordeath.Operatingthemachineonany sloperequiresextracaution.

•Operatethemachineatalowerspeedwhenyou

areonaslope.

•Ifyoufeeluneasyoperatingthemachineona

slope,donotdoit.

•Watchforholes,ruts,bumps,rocks,orother

hiddenobjects.Uneventerraincouldoverturnthe machine.T allgrasscanhideobstacles.

•Choosealowgroundspeedsoyouwillnothave

tostoporshiftwhileonaslope.

•Arollovercanoccurbeforethetireslosetraction.

Page 22

•Avoidoperatingthemachineonwetgrass.Tires

maylosetraction;regardlessifthebrakesare availableandfunctioning.

•Avoidstarting,stopping,orturningthemachine

onaslope.

•Keepallmovementonslopesslowandgradual.

Donotsuddenlychangethespeedordirectionof themachine.

•Donooperatethemachineneardrop-offs,ditches,

embankments,orbodiesofwater.Themachine couldsuddenlyrolloverifawheelgoesoverthe edgeortheedgecavesin.Establishasafetyarea betweenthemachineandanyhazard(2machine widths).

OperatingtheParking Brake

Alwaysengagetheparkingbrakewhenyoustopthe machineorleaveitunattended.

DisengagingtheParkingBrake

g029829

Figure16

EngagingtheParkingBrake

WARNING

Theparkingbrakemaynotholdthemachine parkedonaslopeandcouldcausepersonal injuryorpropertydamage.

Donotparkonslopesunlessthewheelsare chockedorblocked.

Figure15

g029632

Page 23

OperatingtheMower Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

EngagingtheBlade-Control Switch(PTO)

Note:Engagingtheblade-controlswitch(PTO)with

thethrottlepositionathalforlesscausesexcessive weartothedrivebelts.

Figure17

DisengagingtheBlade-Control Switch(PTO)

g008946

Figure19

OperatingtheIgnition Switch

1.TurntheignitionkeytotheSTARTposition (Figure20).

Note:Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformore

g008945

than5secondsatatime.Iftheenginefails tostart,allowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Note:Youmayneedmultipleattemptstostart

theenginewhenyoustartitthersttimeafter thefuelsystemhasbeenwithoutfuelcompletely.

Figure18

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweentheFAST andSLOWpositions(Figure19).

AlwaysusetheFASTpositionwhenturningonthe mowerdeckwiththeblade-controlswitch(PTO).

g009174

g008947

Figure20

2.Turntheignitionkeytoshutofftheengine.

StartingtheEngine

1.Raisetherollbarupandlockitintoplace,siton theseat,andfastentheseatbelt.

2.MovethemotioncontrolstotheNEUTRAL-LOCK position.

3.Engagetheparkingbrake;refertoEngagingthe

ParkingBrake(page22).

4.Movetheblade-controlswitch(PTO)totheOFF position(Figure21).

5.Movethethrottlelevermidwaybetweenthe SLOWandFASTpositions.

Page 24

ShuttingOfftheEngine

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.

Alwaysremovetheignitionkeyandengage theparkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchtotheOFF position.

Figure21

6.TurntheignitionkeytotheSTARTposition (Figure22).

Note:Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformore

than5secondsatatime.Iftheenginefails tostartallowa15-secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Note:Additionalstartingcyclesmaybe

requiredwhenstartingtheenginefortherst timeafterthefuelsystemhasbeenwithoutfuel completely.

Figure22

g029634

g029635

Figure23

Important:Makesurethatthefuel-shutoffvalve

isclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.Engagethe parkingbrakebeforetransporting.Makesurethat youremovethekeyasthefuelpumpmayrunand causethebatterytolosecharge.

g008947

Page 25

UsingtheMotion-Control

DrivingtheMachine

Levers

Thedrivewheelsturnindependently,poweredby hydraulicmotorsoneachaxle.Y oucanturn1side inreversewhileyouturntheotherforward,causing themachinetospinratherthanturn.Thisgreatly improvesthemachinemaneuverabilitybutmay requiresometimeforyoutoadapttohowitmoves.

Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolintheFASTpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.

CAUTION

Machinecanspinveryrapidly.Operatormay losecontrolofmachineandcausepersonal injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

DrivingForward

Figure24

1.Motion-control lever—NEUTRAL-LOCK position

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

Note:Theenginestopswhenyoumovethe

g004532

traction-controlwiththeparkingbrakeengaged.

Tostop,pullthemotion-controlleverstotheNEUTRAL position.

1.Disengagetheparkingbrake;referto

DisengagingtheParkingBrake(page22).

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotion-control leversforward(Figure25).

Page 26

StoppingtheMachine

Tostopthemachine,movethetraction-controllevers toneutral,andthenmovethemtothelockedposition, disengagetheblade-controlswitch(PTO),andturn theignitionkeytotheOFFposition.

Engagetheparkingbrakewhenyouleavethe machine;refertoEngagingtheParkingBrake(page

22).Remembertoremovethekeyfromtheignition

switch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.

Alwaysremovetheignitionkeyandengage theparkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

Figure25

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotion-control leversrearward(Figure26).

g008952

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthat dispersesclippingstothesideanddowntowardthe turf.

DANGER

Withoutagrassdeector,dischargecover,or acompletegrass-catcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris willcauseinjuryordeath.

•Neverremovethegrassdeectorfrom themowerbecausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytoclearthedischargearea ormowerbladesunlessyoumovethe blade-controlswitch(PTO)totheOFF position,rotatetheignitionkeytotheOFF position,andremovethekey.

Figure26

g008953

•Makesurethatthegrassdeectorisinthe downposition.

Page 27

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhas2positions,andisusedwith thedeck-liftpedal.ThereisaLOCKpositionanda UNLOCKpositionforthetransportposition(Figure27).

AdjustingtheHeight-of-CutPin

Theheight-of-cutisadjustedfrom25to140mm(1 to5-1/2inches)in6mm(1/4inch)incrementsby relocatingtheclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeck-liftpedalwithyourfoot,and raisethemowerdecktothetransportposition (alsothe140mm(5-1/2inches)cuttingheight position)asshowninFigure28.

3.Toadjust,rotatethepin90degreesandremove thepinfromtheheight-of-cutbracket(Figure

28).

4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesired,and insertthepin(Figure28).

5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.

Figure27

Transport-LockPositions

1.Transportlock3.UNLOCKposition—does

2.LOCKposition—mower decklocksintotransport position

notlockthemowerdeck intotransportposition

g027343

Figure28

1.Deck-liftpedal

2.Cut-of-heightpin

g032377

3.Transportlock

Page 28

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.

1.Disengagetheblade-controlswitch(PTO),move

themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Adjusttheanti-scalprollersasshowninFigure

29,Figure30,andFigure31.

Figure31

1.Anti-scalproller4.Flangenut

2.Spacer

3.Bushing

5.Bolt

g000944

Figure29

1.Anti-scalproller4.Flangenut

2.Spacer

3.Bushing

1.Anti-scalproller3.Flangenut

2.Bushing4.Bolt

5.Bolt

Figure30

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g000943

Page 29

AdjustingtheFlowBafe

PositioningtheFlowBafe

CamLocks

Thisprocedureisapplicableonlytomachineswiththe ow-bafelocks.Certainmodelshavenutsandbolts inplaceoftheow-bafelocksandcanbeadjusted thesame.

Youcanadjustthemower-dischargeowfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.

1.Disengagetheblade-controlswitch(PTO),move

themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Toadjustthecamlocks,swingtheleverupto

loosenthecamlock(Figure32).

4.Adjustthebafeandcamlocksintheslotsto

thedesireddischargeow.

5.Swingtheleverbackovertotightenthebafe

andcamlocks(Figure32).

Thefollowingguresareonlyrecommendations foruse.Adjustmentsvarybygrasstype,moisture content,andtheheightofthegrass.

Note:Iftheenginepowerdrawsdownandthe

mowergroundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggestedusefor thispositionisasfollows:

•Short,lightgrassmowingconditions

•Dryconditions

•Smallergrassclippings

•Propelsgrassclippingsfartherawayfromthe

mower

6.Ifthecamlocksdonotlockthebafeintoplace

oritistootight,loosentheleverandthenrotate thecamlock.

Note:Adjustthecamlockuntilyouachievethe

desiredlockingpressure.

Figure32

g005832

Figure33

PositionB

Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.

g027727

g005833

Figure34

Page 30

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows:

•Tall,densegrassmowingconditions

•Wetconditions

•Lowerstheengine-powerconsumption

•Allowsincreasedgroundspeedinheavyconditions

Figure35

g005834

Page 31

OperatingTips

UsingtheFastThrottleSetting

dropontoyourlawn.T oavoidthis,moveontoa previouslycutareawiththebladesengagedoryou candisengagethemowerdeckwhilemovingforward.

Forbestmowingandmaximumaircirculation,operate theengineattheFASTposition.Airisrequiredto thoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower inuncutgrass.Alwaystrytohave1sideofthemower freefromuncutgrass,whichallowsairtobedrawn intothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethat thecuttingheightofthemowerdoesnotscalpany unevenground.However,thecuttingheightusedin thepastisgenerallythebestonetouse.Whencutting grasslongerthan15cm(6inches)tall,youmaywant tocutthelawntwicetoensureanacceptablequality ofcut.

CuttingaThirdoftheGrassBlade

Itisbesttocutonlyaboutathirdofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrows moreslowly.

KeepingtheUndersideofthe MowerClean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

MaintainingtheBlade(s)

Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.T earingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.Checkthe mowerbladesaftereachuseforsharpness,and foranywearordamage.Filedownanynicksand sharpenthebladesasnecessary.Ifabladeis damagedorworn,replaceitimmediatelywitha genuineT ororeplacementblade.

AlternatingtheMowingDirection

Alternatethemowingdirectiontokeepthegrass standingstraight.Thisalsohelpsdisperseclippings whichenhancesdecompositionandfertilization.

MowingatCorrectIntervals

Grassgrowsatdifferentratesatdifferenttimesof theyear.T omaintainthesamecuttingheight,mow moreofteninearlyspring.Asthegrassgrowthrate slowsinmidsummer,mowlessfrequently .Ifyou cannotmowforanextendedperiod,rstmowata highcuttingheight,thenmowagain2dayslaterata lowerheightsetting.

UsingaSlowerCuttingSpeed

Toimprovecutquality,useaslowergroundspeed incertainconditions.

AvoidingCuttingTooLow

Whenmowinguneventurf,raisethecuttingheight toavoidscalpingtheturf.

StoppingtheMachine

Ifyoumuststoptheforwardmotionofthemachine whilemowing,aclumpofgrassclippingsmay

Page 32

AfterOperation

AfterOperationSafety

Usingthe Drive-Wheel-Release Valves

GeneralSafety

•Cleangrassanddebrisfromthecuttingunits,

mufers,andenginecompartmenttohelpprevent res.Cleanupoilorfuelspills.

•Shutoffthefuelbeforestoringortransportingthe

machine.

•Disengagethedrivetotheattachmentwhenever

youaretransportingornotusingthemachine.

•Usefull-widthrampsforloadingthemachineinto

atrailerortruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps shouldbedirecteddownandoutwardfromthe machine.

•Allowtheenginetocoolbeforestoringthemachine

inanyenclosure.

•Neverstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

UsingtheFuel-Shutoff Valve

Thefuel-shutoffvalveislocatedundertheseat.Move theseatforwardtoaccessit.

Closethefuel-shutoffvalvefortransport,maintenance, andstorage.

Ensurethatthefuel-shutoffvalveisopenwhen startingtheengine.

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjury.

Shutofftheengine,removethekey,andallow allmovingpartstostopbeforeaccessingthe drive-wheel-releasevalves.

WARNING

Theengineandhydraulicdriveunitscan becomeveryhot.Touchingahotengineor hydraulicdriveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunits tocoolcompletelybeforeaccessingthe drive-wheel-releasevalves.

Thedrive-wheel-releasevalvesarelocatedinthe backofeachhydraulic-driveunit,undertheseat.

Note:Makesurethatthereleasevalvesareinthe

fullyhorizontalpositionwhenoperatingthemachine; otherwise,severedamagetothehydraulicsystem canoccur.

1.Disengagetheblade-controlswitch(PTO),turn theignitionkeytotheOFFposition,movethe leverstotheNEUTRAL-LOCKposition,engagethe parkingbrake,andremovethekey.

2.Rotatetherelease-valveleversverticallyto pushthemachine.Thisallowshydraulicuidto bypassthepump,enablingthewheelstoturn (Figure37).

Figure36

1.ONposition2.OFFposition

3.Disengagetheparkingbrakebeforepushing themachine.

g008948

Page 33

Figure37

g029831

1.Verticaltopushthe machine

2.Horizontaltorunthe machine

4.Rotatethereleasevalvelevershorizontallyto runthemachine(Figure37).

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall thenecessarybrakes,lighting,andmarkingas requiredbylaw.Pleasecarefullyreadallthesafety instructions.Knowingthisinformationcouldhelpyou, yourfamily,pets,orbystandersavoidinjury .

WARNING

Drivingonthestreetorroadwaywithout turnsignals,lights,reectivemarkings,ora slow-moving-vehicleemblemisdangerous andcanleadtoaccidents,causingpersonal injury.

g029641

Figure38

1.Tractionunittie-downloops

Donotdrivethemachineonapublicstreet orroadway.

1.Ifyouareusingatrailer,connectittothetowing vehicle,andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Shutofftheengine,removethekey,engagethe parkingbrake,andclosethefuelvalve.

5.Usethetie-downloopsonthemachineto securelyfastenittothetrailerortruckwith straps,chains,cable,orropes(Figure38).

Page 34

LoadingtheMachine

Useextremecautionwhenloadingorunloading machinesontoatraileroratruck.Useafull-width rampthatiswiderthanthemachineforthisprocedure. Backthemachineuptherampanddriveitforward downtheramp(Figure39).

Figure39

g028043

1.Backthemachineupthe

ramp.

2.Drivethemachineforward downtheramp.

Important:Donotusenarrowindividualramps

foreachsideofthemachine.

WARNING

Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga machineonaramp.

•Ensurethattherollbarisintheupposition andusetheseatbeltwhenloadingor unloadingthemachine.Ensurethattheroll barwillclearthetopofanenclosedtrailer.

•Useonlyafull-widthramp;donotuse individualrampsforeachsideofthe machine.

•Donotexceeda15-degreeanglebetween therampandthegroundorbetweenthe rampandthetrailerortruck.

1.Full-widthrampinstowed position

2.Sideviewoffull-width rampinloadingposition

3.Notgreaterthan 15degrees

g027996

Figure40

4.Rampisatleast4times aslongastheheightof thetrailerortruckbedto theground

5.H=heightofthetraileror truckbedtotheground

6.Trailer

•Ensurethatthelengthoframpisatleast 4timesaslongastheheightofthetrailer ortruckbedtotheground.Thisensures thattherampangledoesnotexceed15 degreesonatground.

•Backthemachineuptherampanddriveit forwarddowntheramp.

•Avoidsuddenaccelerationordeceleration whiledrivingthemachineonarampas thiscouldcausealossofcontrolora tip-oversituation.

Page 35

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheellug-nuttorque.

•Checkthewheel-hubslotted-nuttorque.

•Checktheparkingbrakeadjustment.

•Changethehydraulicltersandhydraulicuidwhenusinganytypeofuid.

•Checkthesafetysystem.

•Checktheengine-oillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulic-unitshrouds.

•Inspecttheblades.

•Cleanunderthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm(ifapplicable).

•Checkthesparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulic-uidlevel.

•Lubricatethemowerdeck-liftpivots.

•Changetheengineoil(moreoftenindirtyordustyconditions).

•Checkandcleanengine-coolingnsandshrouds.

Every150hours

Every200hours

Every250hours

Every300hours

Every500hours

Every600hours

Yearlyorbeforestorage

•Inspecttheprimarylterandtheair-inletscreen.

•Changetheengine-oillter.

•Check,cleanandregapthesparkplug.

•Replacethefuellter(moreoftenindirtyordustyconditions).

•ChangethehydraulicltersandhydraulicuidwhenusingMobil®1uid(more oftenindirtyordustyconditions).

•Replacetheprimaryairlter(moreoftenindustyorsandyconditions).

•Checktheinnerairlter.

•Checkthewheellug-nuttorque.

•Checkthewheel-hubslotted-nuttorque.

•Adjustthecaster-pivotbearing.

•Checktheparkingbrakeadjustment.

•ChangethehydraulicltersandhydraulicuidwhenusingToro®HYPR-OIL™500 hydraulicuid(moreoftenindirtyordustyconditions).

•Replacetheinnerairlter.

Monthly

Yearly

•Checkthebatterycharge.

•Greasethepump-belt-idlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcaster-wheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecaster-wheelhubs.

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineowner'smanualforadditionalmaintenanceprocedures.

Page 36

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Pre-Maintenance Procedures

MaintenanceandStorage Safety

•Beforerepairingthemachinedothefollowing:

–Disengagethedrives. –Engagetheparkingbrake. –Shutofftheengineandremovethekey. –Disconnectthespark-plugwire.

•Parkthemachineonalevelsurface.

•Cleangrassanddebrisfromthecuttingunit,

drives,mufers,andenginetohelppreventres.

•Cleanupoilorfuelspills.

•Lettheenginecoolbeforestoringthemachine.

•Donotstorethemachineorfuelnearamesor

drainthefuelindoors.

•Donotallowuntrainedpersonneltoservicethe

machine.

•Usejackstandstosupportthemachineand/or

componentswhenrequired.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectthebatteryorremovethespark-plug

wirebeforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositiveterminal last.Connectthepositiveterminalrstand negativelast.

•Usecarewhencheckingtheblades.Wrapthe

blade(s)orwearthicklypaddedgloves,anduse cautionwhenservicingthem.Onlyreplaceblades; donotstraightenorweldthem.

•Keepyourhandsandfeetawayfrommoving

parts.Ifpossible,donotmakeadjustmentswith theenginerunning.

•Keepallpartsingoodworkingcondition

andallhardwaretightened,especiallythe blade-attachmentbolts.Replaceallwornor damageddecals.

•Neverinterferewiththeintendedfunctionofa

safetydeviceorreducetheprotectionprovided byasafetydevice.Checktheirproperoperation regularly.

•Toensureoptimumperformanceandcontinued

safetycerticationofthemachine,useonly genuineT ororeplacementpartsandaccessories. Replacementpartsandaccessoriesmadeby othermanufacturerscouldbedangerous,and suchusecouldvoidtheproductwarranty.

•Checktheparkingbrakeoperationfrequently.

Adjustandserviceasrequired.

Page 37

Lubrication

Greasemorefrequentlywhenoperatingconditions areextremelydustyorsandy.

GreaseType:No.2general-purposelithium-based ormolybdenum-basedgrease

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Cleanthegreasettingswitharag.

Note:Makesurethatyouscrapeanypaintoff

thefrontofthetting(s).

4.Connectagreaseguntothetting.

5.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings.

6.Wipeupanyexcessgrease.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Greasethemower-deckidlerpulleypivotuntil greasecomesoutthebottom(Figure42).

4.Ifyourmachinehasgreasablespindles,grease the3spindlebearingsuntilgreasecomesout thelowerseals(Figure42).

AddingLightOilorSpray Lubrication

ServiceInterval:Every100hours

Lubricatethedeck-liftpivots.

Figure41

g009029

Figure42

Greasingthe Pump-Belt-IdlerArm

ServiceInterval:Yearly—Greasethepump-belt-idler

arm.

Greasethepump-belt-idlerarm(Figure43).

g017050

GreasingtheMowerDeck

ServiceInterval:Every50hours—Greasethemower

deckspindlesandidlerarm(if applicable).

Important:Makesurethatthecuttingunit

spindlesarefullofgreaseweekly.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

g009030

Figure43

Page 38

GreasingtheCaster-Wheel

Lubricatingthe

Bearings

ServiceInterval:Yearly—Greasethefrontcaster

pivots(moreoftenindirtyordusty conditions).

Yearly—Repackthefrontcaster-wheelbearings (moreoftenindirtyordustyconditions).

1.Removethedustcapandadjustthecaster pivots.

Note:Keepthedustcapoffuntilgreasingis

done.

2.Removethehexplug.

3.Threadagreasettingintothehole.

4.Pumpgreaseintothettinguntilitoozesout aroundthetopbearing.

5.Removethegreasettinginthehole.

6.Installthehexpluganddustcap(Figure44).

Caster-WheelHubs

ServiceInterval:Yearly

1.Shutofftheengine,waitforallmovingpartsto stop,removethekey ,andengagetheparking brake.

g006115

Figure45

1.Sealguard2.Spacernutwithwrench

ats

2.Raisethemowerforaccess.

3.Removethecasterwheelfromthecasterforks.

4.Removethesealguardsfromthewheelhub.

5.Removeaspacernutfromtheaxleassemblyin thecasterwheel.

Figure44

7.Greasethecaster-wheelbearings(Figure44).

Note:Thread-lockingadhesivehasbeen

appliedtolockthespacernutstotheaxle.

g029643

6.Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly.

7.Pryoutsealsandinspectbearingsforwearor damageandreplaceifnecessary.

8.Packthebearingswithgeneral-purposegrease.

9.Insert1bearingand1newsealintothewheel.

Note:Replacetheseals.

10.Iftheaxleassemblyismissingbothspacernuts, applyathread-lockingadhesiveto1spacernut andthreaditontotheaxlewiththewrenchats facingoutward.

Note:Donotthreadthespacernutallof

thewayontotheendoftheaxle.Leave approximately3mm(1/8inch)fromtheouter surfaceofthespacernuttotheendoftheaxle insidethenut.

11.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

12.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.

Page 39

13.Insertthesecondbearingandnewsealintothe wheel.

EngineMaintenance

14.Applyathread-lockingadhesivetothesecond spacernut,andthreaditontotheaxlewiththe wrenchatsfacingoutward.

15.Torquethenutto8to9N∙m(75to80in-lb), loosen,thentorqueto2to3N∙m(20to25in-lb).

Note:Makesurethattheaxledoesnotextend

beyondeithernut.

16.Installthesealguardsoverthewheelhub,and insertthewheelintothecasterfork.

17.Installthecasterboltandtightenthenutfully.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe castertire.Thetireshouldnotspinfreely(more than1or2revolutions)orhaveanysideplay.If thewheelspinsfreely,adjustthetorqueonthe spacernutuntilthereisaslightamountofdrag. Applyanotherlayerofthread-lockingadhesive.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keepyourhands,feet,face,clothing,and otherbodypartsawaythemuferandother hotsurfaces.

EngineSafety

Shutofftheenginebeforecheckingtheoiloradding oiltothecrankcase.

ServicingtheAirCleaner

ServiceInterval:Every150hours

Every300hours/Yearly(whichevercomes rst)—Replacetheprimaryairlter(moreoften industyorsandyconditions).

Every300hours—Checktheinnerairlter.

Every600hours—Replacetheinnerairlter.

Note:Checktheltersmorefrequentlyifthe

operatingconditionsareextremelydustyorsandy .

RemovingtheFilters

1.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,andengage theparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Releasethelatchesontheaircleanerand pulltheair-inletcoverofftheair-cleanerbody (Figure46).

4.Cleantheair-inletscreenandcover.

5.Installtheair-inletcoverandsecureitwiththe latches(Figure46).

Page 40

Figure46

1.Air-inletcover3.Air-cleanerbody

2.Air-inletscreen4.Latch

10.Inspecttheprimarylterfordamagebylooking intothelter,whileshiningabrightlightonthe outsideofthelter.

Note:Holesinthelterwillappearasbright

spots.Ifthelterisdamaged,discardit.

ServicingthePrimaryFilter

•Iftheprimarylterisdirty,bent,ordamaged,

replaceit.

•Donotcleantheprimarylter.

g030481

ServicingtheSafetyFilter

Replacethesafetylter,nevercleanit.

6.Releasethelatchesontheaircleanerandpull theair-cleanercoverofftheair-cleanerbody (Figure46).

7.Cleantheinsideoftheair-cleanercoverwith compressedair.

8.Gentlyslidetheprimarylteroutofthe air-cleanerbody(Figure46).

Note:Avoidknockingthelterintothesideof

thebody.

9.Removetheinnerlteronlyifyouintendto replaceit.

Important:Neverattempttocleantheinner

lter.Ifthesafetylterisdirty,thenthe primarylterisdamaged.Replaceboth lters.

Important:Donotattempttocleanthesafety

lter.Ifthesafetylterisdirty ,thentheprimary lterisdamaged.Replacebothlters.

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandthe coverinstalled.

1.Ifinstallingnewlters,checkeachlterfor shippingdamage.

Note:Donotuseadamagedlter.

2.Iftheinnerlterisbeingreplaced,carefullyslide itintothelterbody(Figure47).

3.Carefullyslidetheprimarylterovertheinner lter(Figure47).

Note:Ensurethattheprimarylterisfully

seatedbypushingontheouterrimwhile installingit.

Important:Donotpressonthesoft,inside

areaofthelter.

1.Innerlter

2.Primarylter

3.Air-cleanercover

4.Installtheair-cleanercoverandsecurethe latches(Figure47).

g012997

Figure47

4.Latch

5.Air-cleanerbody

Page 41

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSJorhigher)

OilCapacity:withalterchange—1.9L(2.0USqt);

withoutalterchange—1.60L(54.4oz)

Viscosity:Seethetablebelow.

Figure48

Note:Useofsyntheticoilhaving5W-20or5W-30

ratingisacceptable,upto4°C(40°F).

Note:Syntheticoilsprovidebetterstartinginextreme

coldbelow-23°C(-10°F).

g029644

g012991

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothing,andother bodypartsawayfromthemuferandother hotsurfaces.

Important:Donotoverllthecrankcasewithoil

becausedamagetotheenginemayresult.Donot runenginewithoilbelowtheLowmarkbecause theenginemaybedamaged.

1.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition(Figure49).

g194611

Figure49

Page 42

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirtyordusty conditions).

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunfor5minutes.

Note:Thiswarmstheoilsothatitdrainsbetter.

2.Parkthemachinesothattherearisslightly lowerthanthefronttoensurethattheoildrains completely.

3.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

4.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition(Figure50).

5.Slowlypourapproximately80%ofthespecied oilintothellertubeandslowlyaddthe additionaloiltobringittotheFullmark(Figure

51).

g029644

Figure51

g194610

6.Starttheengineanddrivetoaatarea.

7.Checktheoillevelagain.

Figure50

g027734

Page 43

ChangingtheEngine-OilFilter

ServicingtheSparkPlug

ServiceInterval:Every200hours

Note:Changetheengine-oilltermorefrequently

whenoperatingconditionsareextremelydustyor sandy.

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page42).

2.Changetheengine-oillter(Figure52).

ServiceInterval:Every200hours—Check,clean

andregapthesparkplug.

Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewspark plug(s)ifnecessary.

Type:Champion

AirGap:0.76mm(0.030inch)

Torque:24.4to29.8N-m(18to22ft-lb)

g029644

RemovingtheSparkPlug

1.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

2.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

XC12YC,orequivalent

Figure52

3.Removethelefthydraulic-unitshroudinthe orderlistedwithFigure53.Thisgivesyou accesstothefrontsparkplug.

g027477

Note:Ensuretheoil-ltergaskettouchesthe

engine,andthenturntheoillteranextra3/4 turn.

3.Fillthecrankcasewiththepropertypeofnew oil;refertoChangingtheEngineOil(page42).

Page 44

CheckingtheSparkPlug

Important:Replacethesparkplug(s)whenit

has:ablackcoating,wornelectrodes,anoilylm, cracksorreuseisquestionable.

Ifyouseelightbrownorgrayontheinsulator,the

g029645

engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.

Setthegapto0.76mm(0.030inches).

g027479

Figure55

1.Pullthistabouttothe

sideinthedirectionofthe arrow

2.Pulltheshroudoffthis

frametabinthedirection ofthearrow

4.Removethesparkplug.

g009919

Figure53

3.Pulltheshroudoffthis frametabinthedirection ofthearrow

4.Shroud

g029646

Figure54

5.Installthelefthydraulic-unitshroud(Figure53).

g027478

Page 45

InstallingtheSparkPlug

Tightenthesparkplug(s)to24.4to29.8N-m(18to 22ft-lb).

Figure56

CheckingtheSpark Arrester

ForModelswithaSparkArrester

ServiceInterval:Every50hours

WARNING

FuelSystem Maintenance

WARNING

Fuel-systemcomponentsareunderhigh pressure.Theuseofimpropercomponents canresultinsystemfailure,fuelleakage,and possibleexplosion.

Useonlyapprovedfuellinesandfuellters.

ServicingtheElectronic Fuel-InjectionSystem

Thismachinecontainsanelectronicfuel-injection system.Itcontrolsthefuelowunderdifferent operatingconditions.

g027735

Theelectronic-controlunit(ECU)continuously monitorstheoperationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the malfunction-indicatorlight(MIL)illuminates.TheMIL istheredlightlocatedintherightconsolepanel.

OncetheMILilluminates,makeinitialtroubleshooting checks;refertotheMILsectionunderTroubleshooting

(page72).

Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedService Dealerisnecessary.

Hotexhaustsystemcomponentsmayignite fuelvaporsevenafteryoushutofftheengine. Hotparticlesexhaustedduringengine operationmayigniteammablematerials. Firemayresultinpersonalinjuryorproperty damage.

Donotfuelorruntheengineunlessaspark arresterisinstalled.

1.Shutofftheengine,waitforallmovingpartsto stop,removethekey ,andengagetheparking brake.

2.Waitforthemufertocool.

3.Ifthereareanybreaksinthescreenorwelds areobserved,replacethearrester.

4.Ifthescreenisplugged,removethearrester andshakelooseparticlesoutofthearrester, andcleanthescreenwithawirebrush(soakin solventifnecessary).

5.Installthearresterontheexhaustoutlet.

Replacingthe Low-PressureFuelFilter

ServiceInterval:Every200hours/Y early(whichever

comesrst)

Thefuellterislocatedneartheengineonthefront orrearsideoftheengine.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Waitforthemachinetocooldown.

4.Closethefuel-shutoffvalveundertheseat (Figure57).

Page 46

Figure57

1.Fuellter

2.Hoseclamp

5.Squeezetheendsofthehoseclampstogether andslidethemawayfromthelter(Figure57).

6.Removethelterfromthefuellines.

7.Installanewlterandmovethehoseclamps closetothelter(Figure57).

8.Openthefuel-shutoffvalve.

3.Fuelline

ElectricalSystem Maintenance

ElectricalSystemSafety

•Disconnectthebatterybeforerepairingthe

machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.

•Chargethebatteryinanopen,well-ventilated

area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated

g008963

tools.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

Important:Installthefuellinehosesandsecure

withplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineaway fromcomponentsthatcancausefuellinedamage.

Servicingthe High-PressureFuelFilter

Donotattempttoservicethehigh-pressurefuel lter.Thehigh-pressurelterisintegratedwithin thefuel-pumpmodule.Thefuellterandother componentsinsidethefuel-pumpmodulearenot serviceable.

Important:Donotattempttoopenthefuel-pump

module.

EnsurethatanAuthorizedServiceDealerreplaces thefuel-pumpmodulewiththehigh-pressurefuellter.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.

ServicingtheBattery

ServiceInterval:Monthly

DANGER

Batteryelectrolytecontainssulfuricacid whichisfatalifconsumedandcausessevere burns.

Donotdrinkelectrolyteandavoidcontact withskin,eyes,orclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.

Page 47

RemovingtheBattery

InstallingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

WARNING

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.

•Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative (black)cable.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.RemovethebatteryasshowninFigure58.

Note:Positionthebatteryinthetraywiththeterminal

postsoppositefromthehydraulictank(Figure58).

g032526

Figure59

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthat canexplode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged

(1.265specicgravity).Thisisespecially importanttopreventbatterydamagewhenthe temperatureisbelow0°C(32°F).

Figure58

1.Chargebatteryfor10to15minutesat25to30 Aor30minutesat10A.

2.Whenthebatteryisfullycharged,unplug thechargerfromtheelectricaloutlet,then disconnectthechargerleadsfromthebattery posts(Figure60).

3.Installthebatteryinthemachineandconnect thebatterycables;refertoInstallingtheBattery

(page47).

Note:Donotrunthemachinewiththebattery

disconnected,electricaldamagemayoccur.

g027728

Page 48

Figure60

1.Positivebatterypost

2.Negativebatterypost

3.Red(+)chargerlead

4.Black(-)chargerlead

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheckthe component/circuitforamalfunctionorshort.

1.Thefusesarelocatedontheconsoletotheright oftheseat(Figure61).

2.Toreplacethefuses,pulloutonthefuseto removeit.

3.Installanewfuse(Figure61).

Jump-StartingtheMachine

1.Checkandcleancorrosionfromthebattery terminalsbeforejump-starting.Ensurethatthe connectionsaretight.

CAUTION

Corrosionorlooseconnectionscan causeunwantedelectricalvoltagespikes atanytimeduringthejump-starting procedure.

Donotattempttojump-startthemachine

g000960

withlooseorcorrodedbatteryterminals, ordamagetotheengineorEFImay occur.

DANGER

Jump-startingaweakbatterythatis crackedorfrozenorhasalowelectrolyte leveloranopen/shortedbatterycellcan causeanexplosion,resultinginserious personalinjury.

Donotjump-startaweakbatteryifthese conditionsexist.

2.Makesurethattheboosterbatteryisagood andfullychargedlead-acidbatteryat12.6Vor greater.

Note:Useproperlysizedjumpercableswith

shortlengthstoreducevoltagedropbetween systems.Makesurethatthecablesarecolor codedorlabeledforthecorrectpolarity.

Figure61

1.Optionalaccessory(15A)4.Main(25A)

2.Charge(25A)5.Console

3.PTO(10A)

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamage theEFIsystem.

Becertainofbattery-terminalpolarity andjumper-cablepolaritywhenhooking upthebatteries.

WARNING

g020464

Batteriescontainacidandproduce explosivegases.

•Shieldyoureyesandfacefromthe batteriesatalltimes.

•Donotleanoverthebatteries.

Note:Ensurethattheventcapsaretightand

level.Placeadampcloth,ifavailable,overany ventcapsonbothbatteries.Alsoensurethatthe

Page 49

machinesdonottouchandthatbothelectrical systemsareoffandatthesameratedsystem voltage.Theseinstructionsarefornegative groundsystemsonly.

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswired tothestarterorsolenoidasshowninFigure62.

g029644

Figure62

1.Positive(+)cableon

dischargedbattery

2.Positive(+)cableon

boosterbattery

3.Negative(–)cableonthe

boosterbattery

4.Negative(–)cableonthe

engineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecableto thepositiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.Makethenalconnectionontheengineblockof thestalledmachine(nottothenegativebattery post),awayfromthebattery,andstandback (Figure63).

g012785

1.Engineblock

Figure63

2.Negative(–)cable

g013117

7.Startthemachineandremovethecablesin thereverseorderofconnection(disconnectthe negativecablefromtheengineblockrst.).

Page 50

DriveSystem Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Inspecttheseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacetheseat beltifitisdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

WARNING

Toavoidinjuryordeathfromrollover:keep therollbarinthefullyraisedlockedposition andusetheseatbelt.

Ensurethattheseatissecuredtothe machine.

Checkthatboththemountinghardwareandtheknobs areingoodworkingcondition.Makesurethatthe knobsarefullyengagedwiththerollbarintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged(Figure64).

Figure64

1.ROPSknob(locked

position)

2.PulltheROPSknobout,

androtateit90degreesto changetherollbarposition

3.Rollbarintheupright position

4.Rollbarinthefolded position

AdjustingtheTracking

1.Disengagetheblade-controlswitch(PTO).

2.Drivetoanopenatarea,movethe motion-controlleverstotheNEUTRAL-LOCK position.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotion-controlleversalltheway forwarduntiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

•Ifittrackstotheright,loosentheboltsand

adjusttheleftstopplaterearwardonthe leftT-slotuntilthemachinetracksstraight (Figure65).

•Ifittrackstotheleft,loosentheboltsand

adjusttherightstopplaterearwardonthe

g008943

Page 51

rightT-slotuntilthemachinetracksstraight (Figure65).

6.Tightenthestopplate(Figure65).

Figure65

Leftcontrollevershown

CheckingtheWheel-Lug Nuts

Checkandtorquethewheellugnutsto122to129 N∙m(90to95ft-lb).

CheckingtheWheel-Hub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

Checkandensurethatthetorqueoftheslottednutis 286to352N∙m(211to260ft-lb).

Note:Donotuseanti-seizecompoundonwheelhub.

g029647

1.Controllever3.Stopplate

2.Bolt

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthefrontandreartiresat 90kPa(13psi).Uneventirepressurecancausean unevencut.Checkthetireswhentheyarecoldtoget themostaccuratepressurereading.

Figure66

g029648

Figure67

1.Slottednut

AdjustingtheCaster-Pivot Bearing

ServiceInterval:Every500hours/Y early(whichever

comesrst)

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

g001055

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethedustcapfromcasterandtighten thelocknut(Figure68).

4.Tightenthelocknutuntilthespringwashersare at,andthenbackoffa1/4turntoproperlyset thepreloadonthebearings(Figure68).

Page 52

Important:Makesurethatthespring

washersareinstalledcorrectlyasshownin

Figure68.

5.Installthedustcap(Figure68).

Figure68

1.Springwashers

2.Locknut

3.Dustcap

RemovingtheClutchShim

1.Shutofftheengine,waitforallmovingpartsto stop,removethekey ,engagetheparkingbrake, andallowthemachinetocoolcompletelybefore startingtheseinstructions.

2.Usinganaircompressor,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers(Figure70).

g010868

Figure70

g001297

3.Checktheconditionofthewire-harnessleads, connectors,andterminals.

Note:Cleanorrepairasnecessary.

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchnolonger engagesconsistently,theshimcanberemovedto extendtheclutchlife.

Figure69

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brake-mountingbolt

4.Verifythat12Vispresentattheclutchconnector whentheblade-controlswitch(PTO)switchis engaged.

5.Measurethegapbetweentherotorand armature.Ifthegapisgreaterthan1mm(0.04 inch),proceedwiththefollowingsteps:

A.Loosenbothbrake-mountingbolts1/2to1

fullturnasshowninFigure71.

Note:Donotremovethebrakepolefrom

theeldshell/armature.Thebrakepole hasworntomatchthearmatureandneeds tocontinuetomatchafteryouremovethe shimtoensureproperbraketorque.

g010869

g010870

Figure71

1.Brake-mountingbolt

Page 53

B.Usingneedle-nosepliers,orbyhand,hold

thetabandremovetheshim(Figure72).

Note:Donotdiscardtheshimuntilproper

clutchfunctionhasbeenconrmed.

g010873

Figure74

1.Feelergauge

Figure72

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

D.Torqueeachbolt(M6x1)to13N∙m(10

ft-lb)+/-0.7N∙m(0.5ft-lb).

E.Usinga0.25mm(0.01inch)thickfeeler

gauge,verifythatagapispresentbetween therotorandthearmaturefaceonboth sidesofthebrakepoleasshowninFigure

73andFigure74.

Note:Duetothewaytherotorandthe

armaturefaceswear(peaksandvalleys)it issometimesdifculttomeasurethegap accurately.

g010871

•Ifthegapislessthan0.25mm(0.01

inch),theninstalltheshim;referto

Troubleshooting(page72).

•Ifthegapissufcient,proceedtothe

safetycheckinstepF.

F.Performthefollowingsafetycheck:

i.Sitontheseatandstarttheengine.

ii.Makesurethatthebladesdonot

engagewiththeblade-controlswitch (PTO)intheOFFposition,andthat theclutchisdisengaged.

Iftheclutchdoesnotdisengage, installtheshimagain;referto

Troubleshooting(page72).

iii.Engageanddisengagethe

blade-controlswitch(PTO)10 consecutivetimestoensurethatthe clutchisfunctioningproperly.

1.Feelergauge

g010872

Figure73

Page 54

CoolingSystem

Cleaningthe

Maintenance

CleaningtheEngineScreen andEngine-OilCooler

ServiceInterval:Beforeeachuseordaily

Removeanybuildupofgrass,dirt,orotherdebris fromtheoilcooler(Figure75).

Engine-CoolingFinsand Shrouds

ServiceInterval:Every100hours/Y early(whichever

comesrst)

1.Disengagetheblade-controlswitch(PTO)and engagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removetheair-intakescreen,therecoilstarter, andthefanhousing(Figure76).

4.Cleanthedebrisandgrassfromtheengine parts.

5.Installtheair-intakescreen,therecoilstarter,

g029644

andthefanhousing(Figure76).

Figure75

Removeanybuildupofgrass,dirt,orotherdebris fromtheenginescreen.Thishelpsensureadequate coolingandcorrectenginespeedandreducesthe possibilityofoverheatingandmechanicaldamageto theengine(Figure75).

g009191

g004218

Figure76

1.Engineguard4.Fanhousing

2.Engineair-intakescreen

3.Bolt

5.Screw

Page 55

CheckingandCleaningthe Hydraulic-UnitShrouds

BrakeMaintenance

ServiceInterval:Beforeeachuseordaily

1.Disengagetheblade-controlswitch(PTO)and engagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Movetheseatforward.

4.Cleanthedebrisandgrassfromthe hydraulic-unitshrouds(Figure77).

5.Positiontheseat.

AdjustingtheParking Brake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Note:Thisproceduremustbefollowedafterthe

rst100hoursorwhenabrakecomponenthasbeen removedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagetheblade-controlswitch(PTO),move themotioncontrolleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

3.Shutofftheengine,waitforallmovingpartsto stop,andremovethekey .

4.Raisethebackofthemachineandsupportthe machinewithjackstands.

g029645

DANGER

Mechanicalorhydraulicjacksmayfail tosupportmachineandcauseaserious injury.

1.Hydraulic-unitshrouds

Figure77

•Usejackstandswhensupporting machine.

•Donotusehydraulicjacks.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrive-wheelreleasehandleto

g009920

thereleasedposition;refertoUsingthe

Drive-Wheel-ReleaseValves(page32).

8.Checktoseeifthereisavisiblegapbetween theL-bracketandthelinkagestop(Figure78).

Page 56

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating; bladesslippingwhencuttinggrass;frayedbeltedges; burnmarks;andcracks,whicharesignsofaworn mowerbelt.Replacethemowerbeltifanyofthese conditionsoccur.

Figure78

LeftSideShown

1.L-bracket4.Rearlinkageassembly

2.Linkagestop

3.Gap

9.Disengagetheparkingbrake,thelevershould beinthedownposition.

10.Turnthewheelhubbyhandinbothdirections relativetothecaliper;thewheelhubshould movefreelybetweenthecaliper.

11.Ifagapisneededorthewheelhubdoesnot movefreely:

A.Disengagetheparkingbrake.

B.Disconnectandne-tunetherearlinkage

assembly:

5.Caliper

6.Wheelhub

•Shortenthelinktocreateagap.

•Lengthenthelinktoallowwheelhub

movement.

C.Connecttherearlinkageassembly.

12.Engagetheparkingbrakeandcheckthegap.

13.Repeatsteps9through13untilavisiblegapis achievedandthewheelhubrotatesfreely.

14.Repeatthisprocedureforthebrakeonthe oppositeside.

15.Rotatethedrive-wheelreleasehandleto theoperatingposition;refertoUsingthe

Drive-Wheel-ReleaseValves(page32).

g026961

ReplacingtheMowerBelt

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Lowerthemowertothe76mm(3inch) height-of-cut.

4.Removethebeltcovers(Figure79).

g027729

Figure79

1.Pushthetabdown2.Removethebeltcover

5.Usearatchetinthesquareholeintheidlerarm toremovetensionontheidlerspring(Figure80).

6.Removethebeltfromthemower-deckpulleys.

7.Removethebeltguideonthespring-loaded idlerarm(Figure80).

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleys andtheclutchpulleyundertheengine(Figure

80).

16.Installthereartiresandtorquethelugnuts;refer toCheckingtheWheel-LugNuts(page51).

17.Removethejackstands.

Page 57

Figure81

g027730

Figure80

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt

3.Spring-loadedidlerpulley

4.Ratchet

armfortheratchet

6.Idler-greasetting

7.Beltguide

10.Installthebeltguideontheidlerarm(Figure80).

11.Usingtheratchetinthesquarehole,installthe idlerspring(Figure80).

Note:Makesurethatthespringendsare

seatedintheanchorgrooves.

12.Installthebeltcovers(Figure81).

1.Positionthebeltcover.3.Ensurethatthetabis underthemetalcatch.

2.Slidethebeltcoverunder

thesidecatches.

g017627

ReplacingtheHydraulic Pump-DriveBelt

1.Disengagetheblade-controlswitch(PTO)and

engagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethemowerbelt;refertoReplacingthe

MowerBelt(page56).

4.Raisethemachineandsupportitwithjack

stands(Figure82).

Page 58

Figure82

1.Idlerpulley

2.Clutchpulley6.Squareholeintheidler

3.Pump-drivebelt7.Idlerspring

4.Righthydraulic-pump pulley

5.Lefthydraulic-pumppulley

arm

ControlsSystem Maintenance

Adjustingthe Control-HandlePosition

Thereare2heightpositionsforthecontrol levers—highandlow.Removetheboltstoadjustthe heightfortheoperator.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

g009039

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Loosentheboltsandangenutsinstalledinthe levers(Figure83).

4.Aligntheleversinthefront-to-rearpositionby bringingtheleverstogethertotheNEUTRAL position,andslidethemuntiltheyarealigned, thentightenthebolts(Figure83).

5.Usearatchetinthesquareholeintheidlerarm toremovetheidlerspring(Figure82).

6.Unhooktheidlerspringfromtheframe(Figure

82).

7.Removethebeltfromthehydraulic-unit-drive pulleysandtheenginepulley.

8.Installthenewbeltaroundenginepulleyand the2drivepulleys.

9.Usingaratchetinthesquareholeintheidler arm,installtheidlerspringtotheframe(Figure

82).

10.Installthemowerbelt;refertoReplacingthe

MowerBelt(page56).

Figure83

1.Bolt

2.Handle4.Nut

g029726

3.Controllever

Page 59

Figure84

5.Iftheendsofthelevershitagainsteach other,refertoAdjustingtheMotion-Control

Neutral-LockPivot(page60).

4.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.

Note:Theswitchisapartoftheseatassembly.

5.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwire harness.

6.Starttheengineandrunitatfullthrottleand disengagethebrake.

Note:Thebrakemustbeengagedandthe

motion-controlleversmustbeouttostart theengine.Theoperatordoesnothaveto beintheseat,becauseofthejumperwire beingused.

7.Runtheunitforatleast5minuteswiththedrive leversatfullforwardspeedtobringthehydraulic

g009195

uiduptotheoperatingtemperature.

Note:Themotion-controlleversneedsto

beinneutralwhilemakinganynecessary adjustments.

8.Bringthemotion-controlleversintotheNEUTRAL position.

6.Repeattoadjustthecontrollevers.

Adjustingthe Motion-ControlLinkage

Locatedoneithersideofthefueltank,belowtheseat arethepump-controllinkages.Rotatingthepump linkagewithawrench(1/2inch)allowsnetuning adjustmentssothatthemachinedoesnotmovein neutral.Anyadjustmentsshouldbemadeforneutral positioningonly.

WARNING

Enginemustberunninganddrivewheels mustbeturningsomotioncontroladjustment canbeperformed.Contactwithmovingparts orhotsurfacesmaycausepersonalinjury.

Keepyourngers,hands,andclothingclear ofrotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeck-lift pedal,andremovetheheight-of-cutpin.

9.Adjustthepumpcontrolrodlengthsbyrotating thedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepin reverse(Figure85).

2.Lowerdecktotheground.

3.Raisetherearofmachineupandsupportitwith jackstands(orequivalentsupport).

Note:Raisethemachinejusthighenoughto

allowthedrivewheelstoturnfreely.

g029649

Figure85

1.Doublenuts

10.Movethemotion-controlleverstothereverse positionandwhileapplyingslightpressureto

Page 60

thelever,allowthereverse-indicatorspringsto bringtheleversbacktoneutral.

Note:Thewheelsmuststopturningorslightly

creepinreverse.

11.Shutofftheunit,removethejumperwirefrom thewireharness,andplugtheconnectorinto theseatswitch.

12.Removethejackstands.

Adjustingthe Motion-Control Neutral-LockPivot

Youcanadjusttheangednuttoobtainthedesired motion-controlleverresistancewhenmovingittothe NEUTRAL-LOCKposition.SeeFigure87foradjustment options.

13.Raisethedeckandinstalltheheight-of-cutpin.

14.Checkthatthemachinedoesnotcreepin neutralwiththeparkbrakesdisengaged.

Adjustingthe Motion-ControlDamper

Youcanadjustthetopdamper-mountingbolttoobtain thedesiredmotion-controlleverresistance.Referto

Figure86formountingoptions.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

•Formoreresistance,tightentheangednut.

•Forlessresistance,loosentheangednut

3.Tightenthejamnut.

g008621

Figure87

1.Flangednut2.Jamnut

Figure86

RightMotionControlShown

1.T orquethelocknutto23N-m(17ft-lb).Theboltmust protrudepasttheendofthelocknutaftertorquing.

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

g008620

Page 61

HydraulicSystem

7.Remove1dipstickfromthehydraulicreservoir (Figure88).

Maintenance

HydraulicSystemSafety

•Ensurethatallhydraulic-uidhosesand

linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretothehydraulicsystem.

•Keepyourbodyandhandsawayfrompinhole

leaksornozzlesthatejecthigh-pressure hydraulicuid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembeforeperforminganyworkonthe hydraulicsystem.

•Seekimmediatemedicalattentionifuid

isinjectedintoskin.Injecteduidmustbe surgicallyremovedwithinafewhoursbya doctor.

ServicingtheHydraulic

8.Wipethedipstickoffandthreadthedipstickinto thereservoir.

9.Removethedipstickandlookattheend(Figure

88).

Important:Donotoverllthehydraulic

unitswithoilasdamagemayoccur.Donot runthemachinewiththeoilbelowtheadd mark.

10.IftheoillevelisattheAddmark,slowlypour onlyenoughoilintothehydraulicreservoirto raisetheleveltotheFullorHline.

11.Installthedipstick.

12.Repeattheprocedurefortheoppositedipstick.

System

Hydraulic-FluidType:T oro

hydraulicuidorMobil

HYPR-OIL

115W-50.

Important:Usethespecieduid.Otheruids

coulddamagethehydraulicsystem.

EachHydraulicSystemFluidCapacity:1.5L(52

oz)persidewithlterchange

CheckingtheHydraulicFluid

ServiceInterval:Every50hours—Checkthe

hydraulic-uidlevel.

1.Positionthemachineonalevelsurface.

2.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

3.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

4.Allowtheengineandthehydraulicsystemto coolfor10minutes.

™

500

g015459

Figure88

Eitherdipstickisusedinthemachine

1.Full3.H—meanshighlevel

2.Add4.Dipsticklocationsunder seat

Note:Theoillevelonthedipstickisincorrect

whentheoilischeckedandtheunitishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksof hydraulic-systemreservoirs(Figure88).

Page 62

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury .

•Ifhydraulicuidisinjectedintothe skinitmustbesurgicallyremoved withinafewhoursbyadoctorfamiliar withthistypeofinjury.Gangrenemay resultifthisisnotdone.

•Keepyourbodyandhandsawayfrom pinholeleaksornozzlesthateject high-pressurehydraulicuid.

•Usecardboardorpapertond hydraulicleaks.

•Safelyrelieveallpressureinthe hydraulicsystembeforeperforming anyworkonthehydraulicsystem.

•Makesurethatallhydraulichoses andlinesareingoodcondition,and allhydraulicconnectionsandttings aretightbeforeapplyingpressureto thehydraulicsystem.

ReplacingtheHydraulicFluidand Filters

ServiceInterval:Aftertherst250hours—Change

thehydraulicltersandhydraulic uidwhenusinganytypeofuid.

Every250hours—Changethehydrauliclters andhydraulicuidwhenusingMobil (moreoftenindirtyordustyconditions).

Every500hours—Changethehydraulic ltersandhydraulicuidwhenusingT oro HYPR-OIL dirtyordustyconditions).

Toreplacethehydraulicuid,theltersneedtobe removed.Replacebothatthesametime;referto

ServicingtheHydraulicSystem(page61)fortheoil

specications.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Raisethemachineandsupportitwithjack stands(Figure89).

™

500hydraulicuid(moreoftenin

1uid

Figure89

1.Jackstands

4.Removeboththemowerbeltandthepump-drive belt;refertoReplacingtheMowerBelt(page

56)andReplacingtheHydraulicPump-Drive Belt(page57).

Note:Thispreventsoilfromgettingonthe

belts.

5.Placeadrainpanunderthelter,removethe oldlter,andwipethesurfaceclean(Figure90).

g008970

Page 63

MowerDeck Maintenance

LevelingtheMowerDeck

SettinguptheMachine

Note:Ensurethatthemowerdeckislevelbefore

matchingtheheightofcut(HOC).

1.Positionthemoweronaatsurface.

2.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

3.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe

g008968

Figure90

Bottomviewofthemachine

1.Filterlocations

2.Hydrauliclter

operatingposition.

4.Checktirepressureofthedrivetires.

5.Ifneeded,adjustto90kPa(13psi).

6.Positionthemowertothe76mm(3inches) height-of-cutposition.

6.Applyathincoatofhydraulicuidtotherubber gasketonthereplacementlter(Figure90).

7.Installthereplacementhydrauliclter.

8.Installthepump-drivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine (Figure89).

10.Addoiltothehydraulicreservoirandcheckfor anyleaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.

13.Shutofftheengineandcheckforleaks.

14.Checktheoillevelwhiletheoiliscold.

15.Ifrequired,addoiltothehydraulicreservoir.

Note:Donotoverll.

LevelingtheDeck

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop, removethekey,andengagetheparkingbrake.

3.Checkthetirepressureinthedrivetires.

Note:Properinationpressureforthetiresis

90kPa(13psi).

4.Positionthetransportlockinthelatching position.

5.Pushthedeck-liftpedalallthewayforwardand thedecklatchesatthe14cm(5-1/2inches) transportposition(Figure91).

Page 64

Figure91

10.Fine-tunetheadjustmentnutonthefrontdeck liftassemblybyturningit(Figure93).

Note:T oincreasetheheight,turnthe

adjustmentnutclockwise;todecrease,turn counterclockwise.

Note:Ifthefrontdecklinksdonothaveenough

adjustmenttoachieveaccuratecutheight,the single-pointadjustmentcanbeutilizedtogain moreadjustment.

g190360

1.Deck-liftpedal

2.Height-of-cutpin

3.Transportlock

6.Inserttheheight-adjustmentpinintothe7.6cm (3inches)cutting-heightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthe levelsurfacetothefronttipoftheblade(Postion A)asshowninFigure92.

Note:Themeasurementshouldread7.6mm

(3inches).

g027344

Figure93

1.Adjustmentnut3.Reardeckadjustment

2.Jamnut4.Frontdeckadjustment

11.T oadjustthesingle-pointsystem,loosenthe 2boltsatthebottomoftheheight-of-cutplate (Figure94).

1.7.6cm(3inch)atposition Aiscorrect

2.8.3cm(3-1/4inch)at positionBiscorrect

g009196

Figure92

3.Measureherefromthe bladetiptothehard surface

4.MeasureatpositionAand Bonbothsides

Page 65

Figure94

1.Boltsatthebottomoftheheight-of-cutplate

12.Ifthedeckistoolow,tightenthe single-point-adjustmentboltbyrotatingit clockwise.Ifthedeckistoohigh,loosen thesingle-point-adjustmentboltbyrotatingit counterclockwise(Figure95).

15.Onbothsidesofthedeck,measurefromthe levelsurfacetothebacktipoftheblade(postion B)asshowninFigure92.

Note:Themeasurementshouldread8.3cm

(3-1/4inches).

16.Finetunethescrewadjusterbyturningittoget

8.3mm(3-1/4inches)height(Figure95).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

17.Measureuntilall4sidesarethecorrectheight.

18.Tightenallofthenutsonthedeck-lift-arm

g029636

assemblies.

19.Lowerthedischargechute.

Note:Loosenortightenthesingle-point

adjustmentboltenoughtomovethe height-of-cutplatemountingboltsatleast1/3 thelengthoftheavailabletravelintheirslots. Thisregainssomeupanddownadjustmenton eachofthe4decklinks.

Figure95

1.Single-pointadjustmentbolt

g017036

13.Tightenthe2boltsatthebottomofthe height-of-cutplate(Figure94).

Note:Inmostconditions,thebackbladetip

shouldbeadjusted6.4mm(1/4inch)higher thanthefront.

14.T orquethe2boltsto37to45N∙m(27to33ft-lb).

Page 66

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement, youmaywanttokeepextrabladesonhand.

BladeSafety

Awornordamagedbladecanbreak,andapieceof thebladecouldbethrowntowardyouorbystanders, resultinginseriouspersonalinjuryordeath.Tryingto repairadamagedblademayresultindiscontinued safetycerticationoftheproduct.

•Inspectthebladesperiodicallyforwearordamage.

•Usecarewhencheckingtheblades.Wrapthe

bladesorweargloves,andusecautionwhen servicingtheblades.Onlyreplaceorsharpenthe blades;neverstraightenorweldthem.

•Onmulti-bladedmachines,takecareasrotating1

bladecancauseotherbladestorotate.

BeforeInspectingorServicingthe Blades

1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.

2.Shutofftheengine,removethekey,and disconnectthespark-plugwiresfromthespark plugs.

g006530

Figure96

1.Cuttingedge3.Wear/slotforming

2.Curvedarea4.Crack

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure96).

2.Iftheedgesarenotsharporhavenicks,remove andsharpentheblade;refertoRemovingthe

Blades(page67)andSharpeningtheBlades (page67).

3.Inspecttheblades,especiallyinthecurvedarea.

4.Ifyounoticeanycracks,wear,oraslotforming inthisarea,immediatelyinstallanewblade (Figure96).

Page 67

CheckingforBentBlades

RemovingtheBlades

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Rotatethebladesuntiltheendsfaceforward andbackward.

4.Measurefromalevelsurfacetothecutting edge,positionA,oftheblades(Figure97).

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalance,orifthebladeisbent.T o ensureoptimumperformanceandcontinuedsafety conformanceofthemachine,usegenuineToro replacementblades.Replacementbladesmadeby othermanufacturersmayresultinnonconformance withsafetystandards.

1.Holdthebladeendusingaragora thickly-paddedglove.

2.Removethebladebolt,thecurvedwasher,and thebladefromthespindleshaft(Figure98).

Figure97

1.Measureherefromblade tohardsurface

2.PositionA

5.Rotatetheoppositeendsofthebladesforward.

6.Measurefromalevelsurfacetothecuttingedge

ofthebladesatthesamepositionasinstep4 above.

Note:Thedifferencebetweenthedimensions

obtainedinsteps4and6mustnotexceed3 mm(1/8inch).

Note:Ifthisdimensionexceeds3mm(1/8

inch),thebladeisbentandmustbereplaced.

WARNING

Abladethatisbentordamagedcould breakapartandcouldseriouslyinjureor killyouorbystanders.

•Alwaysreplaceabentordamaged bladewithanewblade.

•Donotleorcreatesharpnotchesin theedgesorsurfacesoftheblade.

g000975

g004536

Figure98

1.Sailareaoftheblade3.Curvedwasher

2.Blade4.Bladebolt

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatboth endsoftheblade(Figure99).

Note:Maintaintheoriginalangle.

Note:Thebladeretainsitsbalanceifthesame

amountofmaterialisremovedfrombothcutting edges.

g000552

Figure99

1.Sharpenatoriginalangle.

2.Checkthebalanceofthebladebyputtingiton abladebalancer(Figure100).

Page 68

Note:Ifthebladestaysinahorizontalposition,

thebladeisbalancedandcanbeused.

Note:Ifthebladeisnotbalanced,lesome

metalofftheendofthesailareaonly(Figure98).

Figure100

1.Blade2.Balancer

3.Repeatthisprocedureuntilthebladeis balanced.

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure

101).

Important:Thecurvedpartoftheblade

mustbepointingupwardtowardtheinside ofthemowertoensurepropercutting.

2.Installthespringdiskandbladebolt(Figure

101).

Note:Thespring-diskconemustbeinstalled

towardthebolthead(Figure101).

3.T orquethebladeboltto115to150N∙m(85to 110ft-lb).

RemovingtheMowerDeck

Lockoutthespring-loadeddeckarmsbeforeservicing orremovingthemowerdeck.

WARNING

Deck-liftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe

g000553

storedenergycancauseseriousinjuryor death.

Donotattempttodisassemblethedeckfrom thefrontframewithoutlockingoutthestored energy.

1.Shutofftheengine,waitforallofthemoving partstostop,removethekey,andengagethe parkingbrake.

2.Removetheheight-adjustmentpinandlower thedecktotheground.

3.Placetheheightadjustmentpininthe7.6cm(3 inch)cutting-heightlocation.

Note:Thislocksthedeck-liftarmsinthelowest

positionwhenthedeckisremovedandthe storedenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(Figure102).

6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(Figure102).

Figure101

1.Sailareaoftheblade3.Springdisk

2.Blade4.Bladebolt

g004536

Page 69

Figure102

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt

3.Spring-loadedidlerpulley

4.Ratchet

armfortheratchet

6.Idlergreasetting

7.Beltguide

7.Removeandretainthehardwareonbothsides ofthedeckasshowninFigure103.

g029652

Figure103

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removetheshoulderboltandnut.

4.Removetheshoulderboltandnut.

g009038

8.Raisethedeckstrutsandsecuretheminthe raisedposition.

9.Slidethedeckouttotherightsideofthe machine.

Page 70

ReplacingtheGrass Deector

WARNING

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsatyouor bystanders,resultinginseriousinjury.Also, contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyou installacoverplate,mulchplate,grass deector,orbagger.

1.Removethelocknut,bolt,spring,andspacer holdingthedeectortothepivotbrackets (Figure104).

Cleaning

CleaningundertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andsettheparkingbrake.

2.Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Raisethemowertothetransportposition.

CleaningtheSuspension System

Note:Donotcleantheshockassemblieswith

pressurizedwater(Figure105).

g015594

Figure104

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

2.Removedamagedorworngrassdeector.

3.Placespacerandspringontothegrassdeector.

PlaceaJ-endofspringbehinddeckedge.

5.Springinstalled

7.J-hookendofspring

Note:EnsurethataJ-endofspringisinstalled

behinddeckedgebeforeinstallingtheboltas showninFigure104.

4.Installtheboltandnut.

5.PlaceaJ-hookendofspringaroundgrass

deector(Figure104).

Important:Thegrassdeectormustbeable

torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothe fulldownposition.

g030538

Figure105

DisposingofWaste

Engineoil,batteries,hydraulicuid,andengine coolantarepollutantstotheenvironment.Disposeof theseaccordingtoyourstateandlocalregulations.

Page 71

Storage

effectivewhenmixedwithfreshfueland usedatalltimes.

Note:Afuelstabilizer/conditionerismost

CleaningandStorage

1.Disengagethepowertakeoff(blade-control switch(PTO),engagetheparkingbrake,and turntheignitionkeytotheOFFposition.Remove thekey.

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especially theengineandhydraulicsystem.Cleandirtand chafffromtheoutsideoftheenginecylinder headnsandblowerhousing.

Important:Youcanwashthemachine

withmilddetergentandwater.Donot pressure-washthemachine.Avoid excessiveuseofwater,especiallynearthe controlpanel,engine,hydraulicpumps,and motors.

3.Checkthebrake;refertoAdjustingtheParking

Brake(page55).

4.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page39).

5.Greasethemachine;refertoLubrication(page

37).

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Shutofftheengine,allowittocool,and

drainthefueltank;refertoServicingthe

FuelTank(page46)intheMaintenance

Section.

D.Starttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleaccording

tolocalcodes.

Important:Donotstore

stabilizer/conditionedfuelover 90days.

13.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageor storagearea.

16.Removethekeyfromtheignitionswitch andkeepitoutofreachofchildrenorother unauthorizedusers.

6.Changethecrankcaseoil;refertoChangingthe

EngineOil(page42).

7.Checkthetirepressure;refertoCheckingthe

TirePressure(page51).

8.Changethehydrauliclters;refertoReplacing

theHydraulicFluidandFilters(page62).

9.Chargethebattery;refertoChargingtheBattery

(page47).

10.Scrapeanyheavybuildupofgrassanddirt fromtheundersideofthemower,thenwashthe mowerwithagardenhose.

Note:Runthemachinewiththeblade-control

switch(PTO)engagedandtheengineathigh idlefor2to5minutesafterwashing.

11.Checktheconditionoftheblades;referto

ServicingtheCuttingBlades(page66).

12.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachinefor storageasfollows:

A.Addapetroleumbased

stabilizer/conditionertofuelinthe tank.Followmixinginstructionsfrom thestabilizermanufacturer.Donotuse analcohol-basedstabilizer(ethanolor methanol).

17.Coverthemachinetoprotectitandkeepitclean.

Page 72

Troubleshooting

Problem

Themalfunction-indicatorlight(MIL) comeson.

Thestarterdoesnotcrank.

PossibleCauseCorrectiveAction

1.Theengineistoohot.

2.Thereisoldfuelinthefueltank.2.Usenewfuel.

3.Thefuel-shutoffvalveisnotopen completely.

4.Theaircleanerisdirty.4.Makesurethattheaircleanerand

5.Thebatteryisnotcharged.

6.Incorrectfuelltersarebeingusedor thefuelltersaredirty.

7.Theconnectionstothesensors electronic-controlunit(ECU)andfuel injectorsarenotsecuredproperly .

8.Thereislowvoltagefromthebattery.

9.Afuseisblown.9.Checkandreplaceanyblownfuses.

1.Theblade-controlswitch(PTO)is engaged.

2.Theparkingbrakeisdisengaged.2.Engagetheparkingbrake.

3.Themotion-controlleversarenotin theNEUTRAL-LOCKposition.

4.Theoperatorisnotseated.

5.Thebatteryisdead.

6.Theelectricalconnectionsare corrodedorloose.

7.Thefuseisblown.7.Replacethefuse.

8.Therelayorswitchiswornor damaged.

1.Shutofftheengineandletitcool.

3.Openthefuel-shutoffvalve.

precleanerareclean.Replaceif necessary.

5.Chargeorreplacethebattery.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

8.Ensurethatyouareusingagood12V batteryandthatitisfullycharged.

1.Movetheblade-controlswitch(PTO) tothedisengagedposition.

3.Ensurethatthemotion-controllevers areintheNEUTRAL-LOCKposition.

4.Sitontheseat.

5.Chargethebattery.

6.Checktheelectricalconnectionsfor goodcontact.

8.ContactanAuthorizedServiceDealer.

Theenginedoesnotstart,startshard,or failstokeeprunning.

1.Thefueltankisempty.1.Fillthefueltank.

2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thethrottleisnotinthecorrect position.

5.Thereisdirtinthefuellter.5.Replacethefuellter.

6.Thereisdirt,water,orstalefuelinthe fuelsystem.

7.Theaircleanerisdirty.

8.Theseatswitchisnotfunctioning properly.

9.Theelectricalconnectionsare corroded,loose,ordamaged.

10.Therelayorswitchiswornor damaged.

11.Thesparkplugisfouledorimproperly gapped.

12.Thespark-plugwireisnotconnected.

4.Besurethatthethrottlecontrolis midwaybetweentheslowandfast positions.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheair-cleaner element.

8.Checktheseat-switchindicator. Replacetheseatifnecessary .

9.Checktheelectricalconnections forgoodcontact.Cleanthe connectorterminalsthoroughlywith electrical-contactcleaner,apply dielectricgrease,andmakethe appropriateconnections.

10.ContactanAuthorizedServiceDealer.

11.Adjustorreplacethesparkplug.

12.Checkthespark-plugwireconnection.

Page 73

Problem

PossibleCauseCorrectiveAction

Theenginelosespower.

Theengineoverheats.

Themowerpullstotheleftorright(with leversfullyforward)

Themachinedoesnotdrive.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandtheairpassages abovetheengineareplugged.

5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

6.Thereisdirtinthefuellter.6.Replacethefuellter.

7.Thereisdirt,water,orstalefuelinthe fuelsystem.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandtheairpassages abovetheengineareplugged.

1.Thetrackingneedsadjustment1.Adjustthetracking.

2.Thetirepressureinthedrivetiresis notcorrect.

1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.

2.Thepumpbeltisworn,loose,or broken.

3.Thepumpbeltisoffapulley.3.Changethebelt.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

5.Thehydraulic-uidlevelislowortoo hot.

2.Cleantheair-cleanerelement.

4.Removetheobstructionfromthe coolingnsandtheairpassages.

7.ContactanAuthorizedServiceDealer.

3.Removetheobstructionfromthe coolingnsandtheairpassages.

2.Adjustthetirepressureinthedrive tires.

2.Changethebelt.

5.Addhydraulicuidtothereservoirsor letitcooldown.

Themachinevibratesabnormally .

Themachineproducesanunevencutting height.

Thebladesdonotrotate.

1.Thecuttingblade(s)is/arebentor unbalanced.

2.Theblademountingboltisloose.2.Tightentheblademountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Theenginepulley ,idlerpulley,orblade pulleyisloose.

5.Theenginepulleyisdamaged.

6.Thebladespindleisbent.

7.Themotormountislooseorworn.

1.Theblade(s)is/arenotsharp.1.Sharpentheblade(s).

2.Thecuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Themowerdeckisnotlevel.

4.Theundersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.

6.Thebladespindleisbent.

1.Themowerdeckbeltisworn,loose, orbroken.

2.Themowerdeckbeltisoffpulley.

3.Thepumpdrivebeltisworn,loose,or broken.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

3.Levelthemowerdeckfromside-to-side andfront-to-rear.

6.ContactanAuthorizedServiceDealer.

1.Installanewdeckbelt.

2.Installthemowerdeckpulleyand checktheidlerpulley,idlerarm,and springforcorrectpositionandfunction.

Checkthebelttensionorinstallanew belt.

Page 74

Problem

PossibleCauseCorrectiveAction

Theclutchdoesnotengage.

1.Thefuseisblown.1.Replacethefuse.Checkthecoil

2.Thereislowvoltagesupplyatthe clutch.

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead

5.Therotor/armatureairgapistoolarge.

resistance,batterycharge,charging system,andwiringconnections,and replacecomponentsifnecessary.

2.Checkthecoilresistance,battery charge,chargingsystem,andwiring connectionsandreplacepartsif necessary.

wireorelectricalsystem.Cleanthe connectorcontacts.

5.Removetheshimorreplacetheclutch.

Page 75

Schematics

S R

PK PK

LTGR

PK R BK

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

LAMP

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

ECU

REG

START

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KOHLER EFI

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

(IGNITION)

KEY SW

OPTIONAL

ACCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = T

V = VIOLET

W = WHITE

WireDiagram(Rev .A)

g013119

Page 76

TheToroWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment(LCE)

RidingProduct

ConditionsandProductsCovered

TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuanttoanagreement betweenthem,jointlypromisetorepairtheT oroProductslistedbelowifdefectivein materialsorworkmanship.

Thefollowingtimeperiodsapplyfromtheoriginaldateofpurchase:

ProductsWarrantyPeriod

GrandStand

•Engines

ZMaster

•Engines ZMaster

•Engines

ZMaster

•Engines

ZMaster

•Engines

ZMaster

•Engines

TITANHD1500Series

7000SeriesMowers

8000SeriesMowers

3000SeriesMowers

5000SeriesMowers

6000SeriesMowers

Mowers

5yearsor1,200hours

3years

5yearsor1,200hours 3years 5yearsor1,200hours

3years

5yearsor1,400hours

3years

4yearsor1,200hours

2years

3years

4yearsor500Hours

•EnginesToro–4yearsor500hours

TITANHD2000Series

•Engines

TITANHD2500Series

•Engines

Kohler–3years

4yearsor1000Hours

4yearsor750Hours

Kawasaki–3years

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply .

Whicheveroccursrst.

SomeenginesusedonT oroProductsarewarrantedbytheenginemanufacturer .

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures describedintheOperator'sManual.Suchroutinemaintenance,whetherperformedby adealerorbyyou,isatyourexpense.

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:

1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,accessourwebsiteat www.T oro.com.Youmayalsocallthenumberslistedinitem#3tousethe 24-hourT oroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered underwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith theassistanceprovided,contactusat:

ToroWarrantyCompany

CustomerCareDepartment,RLCDivision

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

888-865-5676(U.S.Customers)

888-865-5691(Canadacustomers)

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot coverthefollowing:

•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil

changes,sparkplugs,airlters,bladesharpeningorwornblades,cable/linkage adjustments,orbrakeandclutchadjustments

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenaltered,misused,neglected,orrequires

replacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedToroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult

Operator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan

10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro ServiceDealerusingToroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheToro Productscoveredbythiswarranty ,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty .

Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse) andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto thedurationoftheexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages, orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry, province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheT oroimporter.Ifallother remediesfail,youmaycontactusatT oroWarrantyCompany .

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.

374-0252RevK

Toro 75955 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GeneralSafety

BeforeOperationSafety

GeneralSafety

FuelSafety

RecommendedFuel

Using Stabilizer/Conditioner

FillingtheFuelTank

CheckingtheEngine-Oil Level

BreakinginaNewMachine

UsingtheRollover ProtectionSystem(ROPS)

ThinkSafetyFirst

UsingtheSafety-Interlock System

Understandingthe Safety-InterlockSystem

TestingtheSafety-Interlock System

UnlatchingtheSeat

AdjustingtheMyRide™ SuspensionSystem

AdjustingtheRear-Shock Assemblies

DuringOperationSafety

GeneralSafety

RolloverProtectionSystem (ROPS)Safety

SlopeSafety

OperatingtheParking Brake

DisengagingtheParkingBrake

EngagingtheParkingBrake

OperatingtheMower Blade-ControlSwitch(PTO)

EngagingtheBlade-Control Switch(PTO)

DisengagingtheBlade-Control Switch(PTO)

OperatingtheIgnition Switch

OperatingtheThrottle

StartingtheEngine

ShuttingOfftheEngine

DrivingtheMachine

DrivingForward

StoppingtheMachine

DrivingBackward

UsingtheSideDischarge

AdjustingtheHeightofCut

UsingtheTransportLock

AdjustingtheHeight-of-CutPin

AdjustingtheAnti-Scalp Rollers

PositionA

PositionB

PositionC

AfterOperationSafety

Usingthe Drive-Wheel-Release Valves

GeneralSafety

UsingtheFuel-Shutoff Valve

TransportingtheMachine

LoadingtheMachine

MaintenanceandStorage Safety

AddingLightOilorSpray Lubrication

Greasingthe Pump-Belt-IdlerArm

GreasingtheMowerDeck

EngineSafety

ServicingtheAirCleaner

RemovingtheFilters

ServicingthePrimaryFilter

ServicingtheSafetyFilter

InstallingtheFilters

ServicingtheEngineOil

CheckingtheEngine-OilLevel

ChangingtheEngineOil

ChangingtheEngine-OilFilter

ServicingtheSparkPlug

RemovingtheSparkPlug

CheckingtheSparkPlug

InstallingtheSparkPlug

CheckingtheSpark Arrester

ServicingtheElectronic Fuel-InjectionSystem

Replacingthe Low-PressureFuelFilter

ElectricalSystemSafety

Servicingthe High-PressureFuelFilter

ServicingtheFuelTank

ServicingtheBattery

RemovingtheBattery

InstallingtheBattery