Toro 79548, 74548, 79549, 79553, 74549 Operator's Manual

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Page 1

FormNo.3368-458RevA

GrandStand

Mower

With48in,52inor60inTURBOFORCE CuttingUnit

ModelNo.74538—SerialNo.311000001andUp

ModelNo.74539—SerialNo.311000001andUp

ModelNo.74548—SerialNo.311000001andUp

ModelNo.74549—SerialNo.311000001andUp

ModelNo.74553—SerialNo.311000001andUp

ModelNo.79548—SerialNo.311000001andUp

ModelNo.79549—SerialNo.311000001andUp

ModelNo.79553—SerialNo.311000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww .T oro.com.OriginalInstructions(EN)

Page 2

WARNING

G015228

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002.

Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.

WARNING

Removingstandardoriginalequipmentpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.FailuretouseoriginalT oro partscouldcauseseriousinjuryordeath.Making unauthorizedchangestotheengine,fuelorventing system,mayviolateEPAandCARBregulations.

Replaceallpartsincluding,butnotlimitedto,tires, belts,blades,andfuelsystemcomponentswith originalT oroparts.

YoumaycontactTorodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.

Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

Figure1

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Theenclosed

Engine Owner’ s Man ual

issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.

Introduction

Thisrotary-blade,ridinglawnmowerisintendedto beusedbyresidentialhomeownersorprofessional, hiredoperators.Itisdesignedprimarilyforcutting grassonwell-maintainedlawnsonresidential orcommercialproperties.Itisnotdesignedfor cuttingbrushorforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythefollowingwords:

•Dangersignalsanextremehazardthatwillcause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

•Warningsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.

•Cautionsignalsahazardthatmaycauseminor ormoderateinjuryifyoudonotfollowthe recommendedprecautions.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizesgeneral informationworthyofspecialattention.

Contactusatwww.T oro.com.

PrintedintheUSA.

AllRightsReserved

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Contents

Introduction.................................................................2

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

SafeOperatingPractices.......................................4

ToroMowerSafety...............................................5

SlopeIndicator.....................................................7

SafetyandInstructionalDecals.............................8

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

Controls.............................................................13

Specications.....................................................14

Operation...................................................................15

AddingFuel.......................................................15

CheckingtheEngineOilLevel............................16

BreakingInaNewMachine................................16

ThinkSafetyFirst...............................................16

OperatingtheParkingBrake...............................16

OperatingtheMowerBladeControlSwitch

(PTO)............................................................17

OperatingtheThrottle.......................................17

OperatingtheChoke..........................................17

OperatingtheIgnitionSwitch.............................18

UsingtheFuelShut-OffValve............................18

StartingandStoppingtheEngine........................18

TheSafetyInterlockSystem................................20

OperatingthePlatform......................................21

DrivingForwardorBackward.............................21

StoppingtheMachine.........................................22

UsingtheRotationIndicator...............................23

PushingtheMachinebyHand.............................23

TransportingMachines.......................................23

LoadingMachines..............................................24

SideDischargingorMulchingtheGrass..............25

AdjustingtheHeight-of-Cut...............................25

AdjustingtheAnti-ScalpRollers(60inch

MowerDecksOnly).......................................25

AdjustingtheFlowBafe...................................25

PositioningtheFlowBafe.................................26

UsingtheMid-SizeWeight..................................27

Maintenance...............................................................28

RecommendedMaintenanceSchedule(s)................28

PremaintenanceProcedures....................................29

RaisingtheMowerforAccess.............................29

ReleasetheCushionforRearAccess...................30

Lubrication.............................................................31

HowtoGrease...................................................31

LubricatingtheMachine.....................................31

GreasingtheFrontCasterPivots.........................31

LubricateCasterWheelHubs.............................32

EngineMaintenance...............................................33

ServicingtheAirCleaner....................................33

ServicingtheEngineOil.....................................33

ServicingtheSparkPlug.....................................36

FuelSystemMaintenance.......................................37

DrainingtheFuelTank.......................................37

ServicingtheFuelFilter......................................38

ElectricalSystemMaintenance................................38

ServicingtheBattery...........................................38

ServicingtheFuses.............................................40

DriveSystemMaintenance.....................................40

AdjustingtheTracking.......................................40

CheckingtheTirePressure.................................41

AdjustingtheCasterPivotBearing......................42

ServicingtheCasterWheelandBearings.............42

AdjustingtheElectricClutch..............................43

CoolingSystemMaintenance..................................44

CleaningtheAirIntakeScreen............................44

CleaningtheCoolingSystem...............................44

BrakeMaintenance.................................................44

ServicingtheBrake.............................................44

BeltMaintenance....................................................46

ReplacingtheMowerDeckBelt..........................46

ReplacingthePumpDriveBelt...........................47

ControlsSystemMaintenance.................................48

AdjustingtheMotionControlHandle

Positions........................................................48

HydraulicSystemMaintenance...............................50

ServicingtheHydraulicSystem...........................50

MowerDeckMaintenance......................................53

ServicingtheCuttingBlades...............................53

CorrectingtheMowerQualityofCut..................54

ReplacingtheGrassDeector.............................57

Cleaning.................................................................58

CleaningUndertheMower.................................58

WasteDisposal...................................................58

Storage.......................................................................59

CleaningandStorage..........................................59

Troubleshooting.........................................................60

Schematics.................................................................62

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Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.

Improperuseormaintenancebytheoperatoror ownercanresultininjury.Toreducethepotential forinjury,complywiththesesafetyinstructions andalwayspayattentiontothesafetyalertsymbol

,whichmeansCAUTION,WARNING,or DANGER-“personalsafetyinstruction."Failureto complywiththeinstructionmayresultinpersonalinjury ordeath.

–Useonlyanapprovedcontainer

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

–Neverrefuelordrainthemachineindoors.

•Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.

Operation

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.

•Neverrunanengineinanenclosedarea.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner’sresponsibilitytoexplain thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Onlystartengine fromtheoperator’sposition.

•Besureofyourfootingwhileusingthismachine, especiallywhenbackingup.Walk,don’trun.Never operateonwetgrass.Reducedfootingcouldcause slipping.

•Slowdownanduseextracareonhillsides.Besure totravelsidetosideonhillsides.Turfconditions canaffectthemachine’ sstability.Usecautionwhile operatingneardrop-offs.

•Slowdownandusecautionwhenmakingturnsand whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguards notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

•Stoponlevelground,disengagedrives,engage parkingbrake(ifprovided),shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

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•Lookbehindanddownbeforebackinguptobesure ofaclearpath.

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesifnot mowing.

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Usecarewhenloadingorunloadingthemachine intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.

Maintenanceandstorage

•Disengagedrives,setparkingbrake,stopengineand removekeyordisconnectsparkplugwire.Waitfor allmovementtostopbeforeadjusting,cleaningor repairing.

•Cleangrassanddebrisfromcuttingunit,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake. Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectthebatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthenegative terminalrstandthepositivelast.Reconnectthe positiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.

•UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)before operatingunderanyobjectsanddonotcontact them.

•Slowdownbeforemakingturnsanduseextra caution.

•Usecautionwhenridingtheplatformovercurbs, rocks,roots,orotherobstructions.

•Lookbehindanddownbeforebackinguptobesure ofaclearpath.Useextracarewhenoperationin reverse.

•Neverjerkthecontrols;useasteadymotion.

•Whenloadingorunloadingthemachine,useonefull widthrampthatiswideenoughtoextendbeyond thewidthofthemachine.

•Nevercarrypassengers.

•Nevercarrycansorequipmentonthemachine.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.

•Usecautionneardrop-offs,ditches,orembankments. Themachinecouldsuddenlyturnoverifawheel

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goesovertheedgeofaclifforditch,orifanedge cavesin.

•Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.

•Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.

•Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.

•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice asrequired.

Page 7

SlopeIndicator

G011841

Figure2

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.

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

3.Exampleofhowtocompareslopewithfoldededge.

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SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

93-7010

1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

2.Thrownobjecthazard,mower—keepthedeectorinplace.

3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts.

106-5517

1.Warning–DoNottouchthehotsurface.

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

93-7818

1.Warning—readtheOperator’sManualforinstructionson torquingthebladebolt/nutto85-1 10ft-lb(115-149N-m).

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe distancefromthebattery .

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

10.Containslead;donot discard.

110-2067

110-2068

1.ReadtheOperator’sManual.

Page 9

115-4186

1.Interval

2.PowerTake-off(PTO)

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

115-4212

1.Hydraulicoillevel3.Warning—donottouch thehotsurface.

2.ReadtheOperator’s

Manual.

116-3290

117-0456

1.Heightofcut(HOC)—high3.Heightofcut(HOC)—low

2.Heightofcut (HOC)—medium

119-0217

1.Warning—stoptheengine;stayawayfrommovingparts; keepallguardsandshieldsinplace.

119-1854

1.Adjustmentknobfortractiondrivespeed.

116-3267

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119-7382

120-6412

1.Belttensionadjustment;readtheOperator’sManualfor moreinformation.

120-6424

1.Cutting/dismembermenthazard,hand—disengagethe powertake-off(PTO),stoptheengineandwatchforall movingpartstostop.

117–3626

1.Warning—readtheOperator’sManual.5.Thrownobjecthazard—keepbystandersasafedistancefrom

2.Warning—donotoperatethismachineunlessyouaretrained.6.Warning—engagetheparkingbrake,stoptheengine

3.Thrownobjecthazard—keepdeectorinplace.

4.Cutting,dismembermenthazardofhandorfoot—stayaway frommovingpartsandkeepallguardsandshieldsinplace.

themachine.

andremovethesparkplugwirebeforeperformingany maintenanceonthemachine.

7.Warning—engagetheparkingbrakeandstoptheengine beforeleavingthemachine.

8.Slidingandlossofcontrolhazard—donotoperatethe machineneardrop-offsorwater;keepasafedistancefrom drop-offs.

Page 11

1.Tractioncontrol

2.Fast4.Neutral

1.Parkingbrake—disengage

2.Parkingbrake—engage

3.Slow

3.PowerT ake-off (PTO)—engage

4.PowerT ake-off (PTO)—disengage

119-8727

5.Reverse

6.PowerT ake-off

119-8728

5.Enginespeed

6.Fast

7.Operatorpresenceswitch

(PTO)—disengage

7.Continuousvariablesetting

8.Slow

Page 12

ProductOverview

G015229

g015395

Figure3

48inchand52inchmachines

1.Sidedischargechute7.Controllevers

2.Battery8.Manualtube

3.Engine

4.Fuelshut-offvalve(behind cushion)

5.Fueltank11.Mowerdeck

6.Controls

9.Platform(downposition)

10.Hydraulictank

12.Frontcasterwheel

Figure4

60inchmachine

1.Sidedischargechute7.Controllevers

2.Battery8.Manualtube

3.Engine

4.Fuelshut-offvalve(behind cushion)

5.Fueltank11.Mowerdeck

6.Controls

9.Platform(downposition)

10.Hydraulictank

12.Frontcasterwheel

Page 13

Controls

g015230

g015396

1 2 3 4 5 6

Becomefamiliarwithallthecontrols(Figure5)before youstarttheengineandoperatethemachine.

Figure5

48inchand52inchmachines

1.Parkingbrakelever

2.Choke9.Platformlatch

3.Hourmeter10.Throttlecontrol

4.Ignitionswitch11.Rightmotioncontrollever

5.Fuelgauge

6.Height-of-cutlever13.Leftmotioncontrollever

7.Fuelcap

8.Height-of-cutpin

12.Bladecontrolswitch(PTO)

Figure6

60inchmachine

1.Parkingbrakelever8.Fuelcap

2.Choke9.Platformlatch

3.Hourmeter10.Throttlecontrol

4.Ignitionswitch11.Rightmotioncontrollever

5.Fuelgauge

6.Height-of-cutlever13.Leftmotioncontrollever

7.Height-of-cutpin

12.Bladecontrolswitch(PTO)

HourMeter

Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance (Figure7).

FuelGauge

Thefuelgaugeislocatedonthetop,middleofthetank (Figure5).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandindicatewith ablacktrianglethattheinterlockcomponentisinthe correctposition(Figure7).

BatteryIndicatorLight

IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure7).

Page 14

1.Safetyinterlocksymbols

2.Batterylight

ThrottleControl

Figure7

3.Hourmeter

www.Toro.comforalistofallapprovedattachments andaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

48inchmowers:

Widthwithdeectordown63.5inches(161.3cm)

Lengthwithplatformdown74inches(188cm)

Lengthwithplatformup58inches(147.3cm)

Height

Weightwith20hpengine

48inches(121.9cm)

881(399.6kg)

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengage theelectricclutchtodrivethemowerbladeswiththe rightsidemotioncontrolleverinthecenter,un-locked position.Pulltheswitchuptoengagethebladesand release.Todisengagetheblades,pushthebladecontrol switch(PTO)downormoveorreleasetherightside motioncontrolleverintotheneutrallockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Off,RunandStart.

MotionControlLevers

Weightwith24hpengine

52inchmowers:

Widthwithdeectordown67.5inches(171.4cm)

Lengthwithplatformdown74inches(188cm)

Lengthwithplatformup58inches(147.3cm)

Height

Weightwith20hpengine

Weightwith24hpengine

60inchmowers:

Widthwithdeectordown75.67inches(192.2cm)

Lengthwithplatformdown74inches(188cm)

Lengthwithplatformup58inches(147.3cm)

Height

Weightwith26hpengine

888(402.8kg)

48inches(121.9cm)

883(400.5kg)

900(408.2kg)

48inches(121.9cm)

925(419.5kg)

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

FuelShut-offValve

Closethefuelshut-offvalve(locatedbehindthe operatorcushionontherighthandsideofthefueltank) whentransportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto

Page 15

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

UseUnleadedRegularGasolinesuitablefor automotiveuse(85pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.

Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontainingmore than10%ethanolbecausethefuelsystemcouldbe damaged.Donotmixoilwithgasoline.

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipeup anygasolinethatspills.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Fill thefueltanktothebottomofthellerneck. Theemptyspaceinthetankallowsgasolineto expand.Overllingmayresultinfuelleakage ordamagetotheengineoremissionsystem(if equipped).

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening .

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Important:Donotusefueladditives containingmethanolorethanol.

Addthecorrectamountofgas stabilizer/conditionertothegas.

Page 16

Note:Afuelstabilizer/conditionerismost

g015231

G012565

effectivewhenmixedwithfreshgasoline.To minimizethechanceofvarnishdepositsinthefuel system,usefuelstabilizeratalltimes.

FillingtheFuelT ank

Note:Donotllthefueltankcompletelyfull.Fillthe

fueltanktothebottomofthellerneck.Theempty spaceinthetankallowsthegasolinetoexpand.

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefueltankcap.

4.Fillthefueltanktothebottomofthellerneck. Ensurethereisemptyspaceinthetanktoallowthe gasolinetoexpand

Figure8.

BreakingInaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew, placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.

CAUTION

Thismachineproducessoundlevelsinexcessof 85dBAattheoperator’searandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Figure8

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse,check theparkingbrakeforproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit. RefertoServicingtheParkingBrake.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileit isunattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

SettingtheParkingBrake

Pulltheparkingbrakeleverrearwardandoverinto engagedposition(Figure9).

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelinEngineMaintenance.

Page 17

Figure9

G008945

G009174

G008946

1.Parkingbrakeengaged2.Parkingbrakereleased

Figure11

OperatingtheThrottle

ReleasingtheParkingBrake

Pullthebrakeleverbackandoverintotheslotand pushtheparkingbrakeleverforward.

OperatingtheMowerBlade ControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedinconjunction withtherightsidemotioncontrollevertoengageand disengagethemowerblades.

EngagingtheMowerBlades(PTO)

1.Toengagethemowerblades,movetherightside motioncontrollevertothecenter,un-locked position.

2.Pullthebladecontrolswitch(PTO)upandrelease itwhileholdingdowntherightsidemotioncontrol leverinthecenter,un-lockedposition.

ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure12).

Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).

Figure12

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostartthe engine.

Figure10

DisengagingtheMowerBlades(PTO)

Thefollowingaretwooptionsfordisengagingthe mowerblades.

•Pushthebladecontrolswitch(PTO)downtothe offposition.

•Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.

2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(

Figure13).

3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure13).

Page 18

G008959

Figure13

START

RUN

STOP

G008947

g015365

G008948

1.On2.Off

Ensurethefuelshut-offvalveisopenwhenstarting theengine.

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition

1.On2.Off

Figure15

(Figure14).Whentheenginesstarts,releasethekey.

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese

StartingandStoppingthe Engine

instructionscanburnoutthestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Movetherightmotioncontrollevertoneutral lockedposition.

4.Settheparkingbrake;refertoSettingtheParking Brake.

5.Movethebladecontrolswitch(PTO)totheOff position.

6.MovethethrottlelevermidwaybetweentheSlow

Figure14

andFastpositions.

Note:Awarmorhotenginemaynotrequire choking.

2.Turntheignitionkeytostoptostoptheengine.

UsingtheFuelShut-OffValve

Closethefuelshut-offvalvefortransport,maintenance, andstorage(Figure15).

Page 19

Figure16

START

RUN

STOP

G008947

7.TurntheignitionkeytotheStartposition (Figure14).Whentheenginesstarts,releasethekey.

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

StoppingtheEngine

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

Figure17

1.Off3.Start

2.Run

Figure18

Important:Makesurefuelshutoffvalveisclosed

beforetransportingorstoringthemachine,asfuel leakagemayoccur.Beforestoringthemachine, pullwireoffsparkplug(s)topreventpossibilityof accidentalstarting.

Page 20

TheSafetyInterlockSystem

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe mowerbladesfromrotatingunless:

•Therightsidemotioncontrolleverismovedtothe center,un-lockedposition.

•Thebladecontrolswitch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostopthe mowerbladesifyoumoveorreleasetherightside motioncontrolleverintotheneutrallockposition.

Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglewilllightupinthecorrespondingsquare.

2.Settheparkingbrake.

3.Movetherightsidemotioncontrollevertothe center,un-lockedposition.Thebladesshould

notrotate.

4.Movethemotioncontrolleversforward.The engineshouldkill.

5.Starttheengineandreleasetheparkingbrake.

6.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

7.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.

8.Moveorreleasetherightsidemotioncontrollever intotheneutrallockposition.Thebladesshould

stoprotatingandtheenginecontinuestorun.

9.Pushthebladecontrolswitchdownandmove therightsidemotioncontrollevertothecenter, un-lockedposition.

10.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.

11.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.

Figure19

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe machineeachtime.

Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately.

1.Starttheengine;refertoStarting andStoppingtheEnginein StartingandStoppingtheEngine(page18).

12.Withtheenginerunning,pullupthebladecontrol switch(PTO)andreleasewithoutholdingright sidemotioncontrollevertothecenter,un-locked position.Thebladesshouldnotrotate.

WARNING

Theoperatorplatformisheavyandmaycause injurywhenloweringandraisingtheoperator platform.Theplatformmaysuddenlydropifnot supportedwhenthelatchpinispulledout.

•Donotputhandsorngersintheplatform pivotareawhenloweringorraisingtheoperator platform.

•Makesuretheplatformissupportedwhenthe latchpinispulledout.

•Makesurethelatchsecurestheplatformwhen foldingitintheupposition.Pushittight againstthecushionforthelatchpintolock intoplace.

•Keepbystandersawaywhenraisingorlowering theplatform.

Page 21

OperatingthePlatform

G015233

Themachinecanbeusedwiththeplatformintheup ordownposition.Itistheoperator’spreferenceon whichpositiontouse.

OperatingtheMachinewiththe PlatformUp

Operatingthemachinewiththeplatformupis recommendedwhen:

•Mowingneardrop-off’s

•Mowingsmallareaswherethemachineistoolong

•Areaswithlowoverhangingbranchesorobstacles

•Loadingthemachinefortransport

•Drivingupslopes

Toraisetheplatform,pullthebackoftheplatformup sothelatchpinandknoblockitintoplace.Pushittight againstthecushionforthelatchpintolockintoplace.

OperatingtheMachinewiththe PlatformDown

Operatingthemachinewiththeplatformdownis recommendedwhen:

•Mowingmostareas

•Drivingacrossslopes

•Drivingdownslopes

Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatchpin andthenpulltheknoboutandlowertheplatform.

Figure20

1.Platformup

2.Platformdown

3.Pulltheknobouttorelease theplatform

DrivingForwardorBackward

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

CAUTION

Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.

Slowthemachinedownbeforemakingsharpturns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

Page 22

G015234

3 4

1.Frontreferencebar

2.Leftcontrollever

3.Rearreferencebar

Figure21

4.Rightcontrollever

5.Rightcontrolleverinthe neutrallockposition

Figure22

DrivingBackward

3.Togoforward,movethespeedcontrollevertothe desiredspeed.

4.Slowlypushthemotioncontrolleversforward (Figure22).

1.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

2.Slowlypullthemotioncontrolleversrearward

Figure23).

(

Note:Theenginewillkillifamotioncontrollever ismovedwiththeparkingbrakeengaged.

Thefartheryoumovethemotioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.

Tostop,pullthemotioncontrolleversbacktothe neutralposition.

Figure23

StoppingtheMachine

Tostopthemachine,movethemotioncontrolleversto neutral,movetherightsidemotioncontrolleverinto theneutrallockposition,disengagethepowertakeoff (PTO),andturntheignitionkeytooff.

Page 23

Settheparkingbrakewhenyouleavethemachine;refer

G015493

1 2

toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

UsingtheRotationIndicator

Theslotsinthetopofthebeltcoversallowthe operatortoverifyifthebladeshavestoppedrotating afterdisengagingthepowertake-off(PTO)switch.

Disengagethepowertake-off(PTO)switch,stopthe engine,removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

ToPushtheMachine

1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.

2.Opentheby-passvalveonbothpumpsbyturning themcounterclockwise1to2turns.Thisallows hydraulicuidtoby-passthepumpsandthewheels toturn(

Note:Rotatetheby-passvalvesamaximumof2 turnssothevalvedoesnotcomeoutofthebody causinguidtorunout.

Figure25).

Figure24

52inchmowerdeckshown

1.RotationIndicator-slots inthetopofthebeltcover

2.Sidedischargechute

PushingtheMachinebyHand

Theby-passvalvesallowthemachinetobepushedby handwithouttheenginerunning.

Important:Alwayspushthemachinebyhand. Nevertowthemachinebecausehydraulicdamage mayoccur.

Figure25

1.Pumpby-passvalve

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

6.Closetheby-passvalves,butdonotovertighten them.

Important:Donotstartoroperatethe machinewiththeby-passvalvesopen.Damage tosystemmayoccur.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby law .Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.

Totransportthemachine:

1.Raisetheplatformofthemachinebeforedrivingup ontothetrailerortruck.

Page 24

2.Ifusingatrailer,connectittothetowingvehicle

G015235

andconnectthesafetychains.

3.Ifapplicable,connectthetrailerbrakes.

4.Loadthemachineontothetrailerortruck.

5.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

6.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(

Figure26

1.Tractionunittiedownloop

Figure26).

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit( Theplatformwhendownandlockedintoposition, extendsbackbetweentherearwheelsandservesasa stopfortippingbackward.Havingafullwidthramp providesasurfacefortheplatformtocontactifthe unitstartstotipbackward.Withtheplatformup,afull widthrampprovidesasurfacetowalkonbehindthe unit.Theoperatorshoulddetermineifitisbesttohave theplatformupordownwhenloading,dependingon conditions.Ifitisnotpossibletouseonefullwidth ramp,useenoughindividualrampstosimulateafull widthcontinuousramp.

Figure27).

WARNING

Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.

•Useextremecautionwhenoperatingauniton aramp.

•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•Donotexceeda20degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.

•Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

Therampshouldbelongenoughsothattheangles donotexceed20degrees(

Figure27).Asteeperangle maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.

Figure27

1.Trailer3.Notgreaterthan 20degrees

2.Fullwidthramp4.Fullwidthramp—sideview

Page 25

SideDischargingorMulching

AdjustingtheAnti-Scalp

theGrass

Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

DANGER

Withoutthegrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.

•Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthemower.

•Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthepower takeoff(PTO)isoff.Rotatetheignitionkeyto Off.Alsoremovethekeyandpullthewire(s) offthesparkplug(s).

Rollers(60inchMowerDecks Only)

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

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethenutandboltpositiontheanti-scalp rollersandinstallthenutandbolt.Ensurethe spacersandbushingsareinstalledasshown.

AdjustingtheHeight-of-Cut

Theheight-of-cutcanbeadjustedfrom1to5inches (25to127mm)in1/4inch(6mm)increments.

1.Movetheheight-of-cutlevertothetransport position(allthewayup).

2.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(

3.Lowertheheight-of-cutlevertothepin(Figure28).

Figure28).

Figure29

1.Bushing4.Bolt

2.Anti-scalproller5.Nut

3.Spacer

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlockand bafetogivethebestqualityofcut.

1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.

Figure28

1.Height-of-cutholes3.Height-of-cutlever

2.Height-of-cutpin

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Toadjustthecamlock,swingtheleveruptoloosen thecamlock(

Figure30).

Page 26

4.Adjustthebafeandcamlockintheslottothe desireddischargeow .

5.Swingtheleverbackovertotightenthebafeand camlock(

Figure30).

6.Ifthecamdoesnotlockthebafeintoplaceoritis tootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilthedesiredlocking pressureisachieved.

Figure31

PositionB

Figure30

1.Camlock

2.Lever

3.Rotatecamtoincreaseor decreaselockingpressure

4.Slot

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure31).The suggesteduseforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

Usethispositionwhenbagging(Figure32).

Figure32

PositionC

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe mower.

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure33).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheToro SFSmower.

Page 27

Figure33

UsingtheMid-SizeWeight

•Weightsareinstalledtoimprovehandling,balance andimproveperformance.Weightscanbeaddedor removedtocreateoptimizedperformanceunder differentmowingconditionsandforoperator preference.

•Itisrecommendedthatweightsbeaddedor removedoneatatimeuntilthedesiredhandingand balanceisachieved.

Note:ContactanAuthorizedServiceDealertoorder aW eightKit.

WARNING

Excessiveweightchangescaneffecthandlingand operationofthemachine.Thiscouldcauseserious injurytoyouorbystanders.

Makeweightchangesissmallincrementsonly .

Evaluatethemoweraftereachweightchangeto ensurethemachinecanbeoperatedsafely.

Page 28

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulicuidlevel.

•Changethehydrauliclter.

•Checkthesafetyinterlocksystem.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrakes.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.

•Greasetheliftlinkage(moreoftenindirtyordustyconditions).

•Greasethemowerdeckspindles(moreoftenindirtyordustyconditions).

•Checkthepaperaircleanerelement.

•Checkthetirepressure.

•Checkthehydraulicuidlevel.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Check,cleanandregapthesparkplug.

•Checkthebattery.

•Checktheelectricclutch.

•Checkandcleanenginecoolingnsandshrouds.

•Checkthemowerdeckbelt.

•Checkthepumpdrivebelt.

•Checkthehydraulichoses.

Every200hours

Every250hours

Every500hours

Every800hours

Beforestorage

Yearly

Important:Refertoyour

•Replacethepaperaircleanerelement.

•Changetheengineoillter.

•ChangethehydrauliclterandhydraulicoilwhenusingMobil®1oil.

•Adjustthecasterpivotbearing.

•ChangethehydrauliclterandhydraulicoilwhenusingToro®HYPR-OIL™500 hydraulicoil.

•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Replacethefuellter.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.

Page 29

Premaintenance

g015408

Procedures

RaisingtheMowerforAccess

Thefrontofthemowercanberaisedandsupportedon itsbackforaccessunderthemachineformaintenance.

1.Raisetheplatform.RefertoOperatingthePlatform inOperation.

2.Removethebattery.

1.Cap

2.Pieceofplastic

Figure35

3.Hydraulictank

Figure34

1.Wingnut4.Positivebatterycable

2.Batterycover5.Battery

3.Negativebatterycable

3.Drainthefuelfromthefueltank.RefertoDraining theFuelTankinMaintenance.

4.Removethecapofthehydraulictankandplace apieceofplasticovertheopeningandinstallthe hydrauliccap.Thiswillsealthehydraulictankand preventitfromleakingout.

5.Withtwopeople,raisethefrontofthemowersoit restsonthedrivetiresandtheplatformintheup position.

6.Performanymaintenanceonthemachine.

7.Withtwopeople,lowerthefrontofthemowerto theground.

8.Removetheplasticunderthehydraulictankcap.

9.Installthebatteryforthemachine.

Page 30

Figure36

1.Removebattery

2.Withtwopeople,liftthe frontendofthemower (ensuretheplatformisup)

ReleasetheCushionforRear Access

Thecushioncanbereleasedforrearaccesstothe machineformaintenanceoradjustment.

1.Lowertheplatform.

2.Removethehairpincotterpinsoneachsideofthe cushion.

3.Slidethelargewasherswithplasticbushingstothe inside.

4.Removethecushionandlowerittotheplatform.

5.Performanymaintenanceoradjustmentonthe machine.

6.Raisethecushionandslideitontothepinsonboth sidesofthemachine(Figure37).

1.Plasticbushingwithlarge washer

2.Cushionbracketwithkey hole

Figure37

3.Hairpincotterpin

7.Slidethelargewashersplasticbushingsintothe cushionbracketandsecurethemwithahairpin cotterpin(

Figure37).

Page 31

Lubrication

G015236

g015589

GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.

HowtoGrease

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.

5.Wipeupanyexcessgrease.

LubricatingtheMachine

ServiceInterval:Every50hours—Greasethelift

linkage(moreoftenindirtyordusty conditions).

Figure39

Every50hours—Greasethemower deckspindles(moreoftenindirtyor dustyconditions).

Every800hours/Yearly(whichever comesrst)—Greasethefrontwheel bearings(moreoftenindirtyordusty conditions).

Every800hours/Yearly(whichever comesrst)—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).

Usethefollowinggraphicsforlocatingthegreasepoints.

Figure40

GreasingtheFrontCaster Pivots

ServiceInterval:Yearly

Lubricatethefrontcasterpivotsonceayear.

1.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance Section.

2.Removethehexplug.Threadagreasezerkintothe hole.

Figure38

3.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

4.Removethegreasezerkinthehole.Installthehex plugandcap.

Page 32

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.

Figure41

1.Sealguard2.Spacernutwithwrench ats

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

13.Torquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Makesure axledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

Important:Topreventsealandbearingdamage, checkthebearingadjustmentoften.Spinthecaster tire.Thetireshouldnotspinfreely(morethan1or 2revolutions)orhaveanysideplay.Ifthewheel spinsfreely,adjusttorqueonspacernutuntilthere isaslightamountofdrag.Reapplythreadlocking adhesive.

4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthespacer nutstotheaxle.Removetheaxle(withtheother spacernutstillassembledtoit)fromthewheel assembly.

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.Packthebearingswithageneral-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Thesealsmustbereplaced.

8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontotheaxle withthewrenchatsfacingoutward.DoNotthread spacernutallofthewayontotheendoftheaxle. Leaveapproximately1/8inch(3mm)fromthe outersurfaceofthespacernuttotheendoftheaxle insidethenut.

9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.

10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

Page 33

EngineMaintenance

CleaningtheFoamAirCleanerElement

ServiceInterval:Every25hours

ServicingtheAirCleaner

ServiceInterval/Specication

Inspectthefoamandpaperelementsandreplacethem iftheyaredamagedorexcessivelydirty.

Note:Servicetheaircleanermorefrequently(every fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy.

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage

Figure42).

(

4.Unscrewthecoverknobsandremovetheaircleaner cover(

5.Unscrewthehoseclampandremovetheaircleaner assembly(

6.Carefullypullthefoamelementoffthepaper element(Figure42).

Figure42).

1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis tornorworn.

ServicingthePaperAirCleaner Element

ServiceInterval:Every50hours—Checkthepaperair

cleanerelement.

Every200hours—Replacethepaper aircleanerelement.

1.Donotcleanthepaperlter,replaceit(Figure42).

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair cleanerelement(

2.Placetheaircleanerassemblyontotheaircleaner baseorhoseandsecureit(Figure42).

3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure42).

Figure42).

Figure42

FSModelEngineShown

1.Cover

2.Hoseclamp4.Foamelement

3.Paperelement

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Checkthe

engineoillevel.

Aftertherst8hours—Changethe engineoil.

Every100hours—Changetheengine oil.(moreoftenindirtyordusty conditions)

Every200hours—Changetheengine oillter.

Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.

Note:Therearedifferentoilcapacitiesforthedifferent modelslistedinthismanual.Ensurethecorrectamount ofoilisused.

Page 34

Important:Remembertoadd80%oftheoiland

g015238

G008792

thengraduallyllittothefullmarkonthedipstick.

OilType:Detergentoil(APIserviceSF,SG,SH,SJ

orSL)

CrankcaseCapacityfor20hpand25hpEngines:

58ounces(1.7liter)withthelterremoved;51ounces (1.5liter)withoutthelterremoved

CrankcaseCapacityfor24hpand26hpEngines:

71ounces(2.1liter)withthelterremoved;61ounces (1.8liter)withoutthelterremoved

Viscosity:Refertothetablebelow

Figure43

CheckingtheEngineOilLevel

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure44).

Figure44

ChangingtheEngineOil

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.

Page 35

3.DisengagethePTO,movethemotioncontrollevers

g015238

G008796

totheneutrallockedpositionandsettheparking brake.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure45).

Figure46

Figure45

5.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure46).

ChangingtheEngineOilFilter

Note:Changetheengineoilltermorefrequently

whenoperatingconditionsareextremelydustyorsandy .

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Placearagundertheoilltertosoakupanyspilled oil.

Important:Spilledoilmaydrainunderthe engineandontotheclutch.Oilspilledonthe clutchmaydamagetheclutch,causetheblades tostopslowlywhentheclutchisswitchedoff andcausetheclutchtoslipwhentheclutchis switchedon.Wipeupanyspilledoil.

3.Changetheengineoillter(

Figure47).

Page 36

g015238

G012845

3/4

RemovingtheSparkPlug

g015238

G008794

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Figure47

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

4.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.

ServicingtheSparkPlug

ServiceInterval:Every100hours

Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.

Figure48

CheckingtheSparkPlug

Important:Nevercleanthesparkplug(s).Always

replacethesparkplug(s)whenithas:ablack coating,wornelectrodes,anoilylm,orcracks.

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.

Setthegapto0.030inches(0.75mm).

Figure49

TypeforallEngines:NGK

AirGap:0.030inch(0.75mm)

BPR4ESorequivalent

Page 37

InstallingtheSparkPlug

G015200

g015239

Tightenthesparkplug(s)to16ft.-lb(22N-m).

Figure50

FuelSystem Maintenance

DrainingtheFuelTank

Note:Thereisnootherrecommendedwaytodrain

fuelfromthetank,otherthanusingasyphonpump.A syphonpumpcanbepurchasedatahardwarestore.

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.

1.Parkthemachineonalevelsurface.Disengagethe powertakeoff(PTO),settheparkingbrake,turnthe ignitionkeytoOffandremovethekey.

2.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(Figure52).

3.Removethefuelcap.

4.Insertasyphonpumpintothefueltank.

5.Usingthesyphonpump,drainthefuelintoaclean gascan(

6.Wipeupanyspilledfuel.

Figure51).

Figure51

1.Fuelcap

Page 38

ServicingtheFuelFilter

ElectricalSystem

ReplacingtheFuelFilter

ServiceInterval:Every800hours/Yearly(whichever

comesrst)

Neverinstalladirtylterifitisremovedfromthefuel line.

Note:Notehowthefuellterisinstalledinorderto installthenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Closefuelshut-offvalve(behindtheoperator cushion).

4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(

Figure52).

Maintenance

ServicingtheBattery

ServiceInterval:Every100hours

Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof fourpartswaterandonepartbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.

Voltage:12V

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Figure52

1.Hoseclamp3.Filter

2.Fuelline

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose tothelter.

7.Openthefuelshut-offvalve.

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.

•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

Page 39

WARNING

Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.

•AlwaysDisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.

•AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative(black) cable.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Lifttheblackrubbercoveronthenegativecable. Disconnectthenegativebatterycablefromthe negative(-)batteryterminal(

4.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure53).

Figure53).

Figure53

1.Wingnut4.Positivebatterycable

2.Batterycover5.Battery

3.Negativebatterycable

5.Removethebatteryholddownplate(

Figure53)and

removethebattery.

InstallingtheBattery

1.Placethebatteryontothemachine(Figure53).

2.Securethebatterywiththeholddownplate,j-bolts, andlocknuts.

3.First,installthepositive(red)batterycableto positive(+)batteryterminalwithanut,washerand

Figure53).Slidetherubbercoveroverthepost.

bolt(

4.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminalwithanut, washerandbolt( overthepost.

Figure53).Slidetherubbercover

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).

1.Removethebatteryfromthechassis;referto RemovingtheBattery.

2.Checktheelectrolytelevel;refertoCheckingthe ElectrolyteLevel.

3.Makesurethellercapsareinstalledinbattery. Chargebatteryfor1hourat25to30ampsor6 hoursat4to6amps.

4.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure54).

5.Installthebatteryontothemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

Page 40

Figure54

g015401

g015241

1.PositiveBatteryPost

2.NegativeBatteryPost

3.Red(+)ChargerLead

4.Black(-)ChargerLead

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance.Ifafuseblows,checkthecomponent orcircuitforamalfunctionorshort.

1.Releasethecushionfromtherearofthemachine.

DriveSystem Maintenance

AdjustingtheTracking

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

1.Pushbothcontrolleversforwardthesamedistance.

2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.

3.Releasethecushionfromtherearofthemachine.

4.Rotatetherightcableadjustmenttopositionthe rightmotioncontrolinthecenterofthecontrol panelneutrallockslot(

Figure57).

2.Pulloutonthefusetoremoveorreplaceit Figure55).

(

3.Installthecoverunderthecusion.

Note:Ensurethecorrectsizefuseisinstallwiththe correctwirecolorasshownin

Figure55.

Figure56

1.Leftmotioncontrollever

2.Rightmotioncontrollever4.Alignthecontrollevers

3.Neutrallockedposition

fronttoback

5.Rotatetheleftcableadjustmenttomatchtheleft wheelspeedtothepreviouslysetrightwheelspeed. Adjustinquarter-turnincrementsuntilthemachine tracksstraight.

Note:Onlyadjusttheleftcabletomatchtheleft wheelspeedtotherightwheelspeed.Donotadjust therightwheelspeedasthiswillpositiontheright motioncontrolleveroutofthecenterforthecontrol panelneutrallockslot.

Figure55

1.Fuses

Page 41

g015369

1 2

1.Leftcableadjustment

G015609

1 6

2 3 4

Figure57

2.Rightcableadjustment

4.Ifadjustmentisneeded,loosenthejamnutand adjustthebolttothecorrectdistance.Tightenthe jamnutafteradjustingthebolt(Figure58).

5.Testthesafetyinterlocksystembeforeoperation. Referto

TheSafetyInterlockSystem(page20).

6.Checkforpropertracking.

Note:Ifthemachinewillnotstartafteradjusting thetracking,makesureproximityswitchtargetaligns withboltattachedtomotioncontrollever.Referto AdjustingtheProximitySwitch(page41).

7.Repeatthecableadjustmentuntilthetrackingis correct.

8.Checkthatthemachinedoesnotcreepfromneutral withtheparkbrakesdisengaged.

Important:DoNotrotatethelinkagetoofar,as thismaycausethemachinetocreepinneutral.

AdjustingtheProximitySwitch

Usethisprocedureifthemachinewillnotstartafter adjustingthetracking.

1.Checkandensuretheboltattachedtothemotion controlleveralignswiththeproximityswitchtarget (

Figure58).

2.Ifneeded,loosentheboltsandadjusttheproximity switchuntilthetargetalignswithboltattachedtothe motioncontrollever(Figure58).

3.Checkthedistanceofthebolttotheproximity switch.Itneedstobebetween0.050and0.090 inches(1.27to2.29mm)(Figure58).

Figure58

1.Proximityswitchtarget4.Boltattachedtothemotion controllever

2.Proximityswitch5.Distancebetween0.050 and0.090inches(1.27to

2.29mm)isneeded

3.Boltsandnuts6.Jamnut

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat12-14psi (83-97kPa).Uneventirepressurecancauseanuneven cut.

Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.

Page 42

Figure59

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethedustcapfromcasterandtightenlock

Figure60).

nut(

4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(

Figure60).

Figure60

1.SpringWashers3.DustCap

2.LockNut

ServicingtheCasterWheel andBearings

Thecasterwheelsrotateonarollerbearingsupportedby aspannerbushing.Ifthebearingiskeptwelllubricated, wearwillbeminimal.Failuretokeepthebearingwell lubricatedwillcauserapidwear.Awobblycasterwheel usuallyindicatesawornbearing.

1.Removethelocknutandwheelboltholdingthe casterwheeltothecasterfork(

Figure61).

Important:Makesurespringwashersare installedcorrectlyasshowninFigure60.

5.Installthedustcap(Figure60).

Figure61

1.Locknut

2.WheelBolt5.RollerBearing

3.Bushing

4.SpannerBushing

Page 43

2.Removeonebushing,thenpullthespannerbushing androllerbearingoutofthewheelhub(Figure61).

3.Removetheotherbushingfromthewheelhub andcleananygreaseanddirtfromthewheelhub

Figure61).

(

4.Inspecttherollerbearing,bushings,spannerbushing andinsideofthewheelhubforwear.Replaceany defectiveorwornparts(Figure61).

5.Toassemble,placeonebushingintothewheelhub. Greasetherollerbearingandspannerbushingand slidethemintothewheelhub.Placethesecond bushingintothewheelhub(

Figure61).

6.Installthecasterwheelintothecasterforkand securewiththewheelboltandlocknut.Tightenthe locknutuntilthespannerbushingbottomsagainst theinsideofthecasterforks(

Figure61).

7.Greasethettingonthecasterwheel.

AdjustingtheElectricClutch

Figure62

1.Adjustingnut3.Feelergauge

2.Slot

ServiceInterval:Every100hours—Checktheelectric

clutch.

Theclutchisadjustabletoensureproperengagement andproperbraking.

1.Inserta0.015–0.021inch(0.381-0.533mm)feeler gaugethroughoneinspectionslotinthesideofthe assembly.Makesureitisbetweenthearmatureand therotorfrictionsurfaces.

Thegapneedstobeatleast.015inches(0.381mm) andnotmorethan.021inches(0.533mm).

2.Ifadjustmentisneeded,usea.015inch(0.381mm) feelergaugetoseteachofthethreeadjustmentslot positions.Tightenthelocknutsuntilthereisslight bindingonthefeelergaugebutitcanbemoved easilywithintheairgap(

Figure62).

3.Repeatthisfortheremainingslots.

4.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.

Page 44

CoolingSystem

g015409

Maintenance

BrakeMaintenance

ServicingtheBrake

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

Beforeeachuseremoveanybuild-upofgrass,dirt orotherdebrisfromthecylinderandcylinderhead coolingns,airintakescreenonywheelend,and carburetor-governorleversandlinkage.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine.

CleaningtheCoolingSystem

ServiceInterval:Every100hours—Checkandclean

enginecoolingnsandshrouds.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removetheairintakescreenandfanhousing

Figure63).

(

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing (Figure63).

Beforeeachuse,checkbrakesonbothalevelsurface andslope.

Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.

CheckingtheParkingBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengagethe PTO.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Releasethebrake.Thebrakebarsshouldliftoff thetiresandthehandlevershouldtravelforwardto theendoftheslotinthecontrolpanel.Adjustthe brakeifneeded.

4.Engagethebrakeleveruntilthebrakebarsrst contactthetire(

5.Measurethegapfromthefrontofthehandlever totheendoftheslotinthecontrolpanelwhenthe brakebarcontactsthetire.Thismeasurementneeds tobe3/4inch(19mm).Adjustthebrakeifneeded

Figure64).

(

Figure64).

1.Guardandengineair intakescreen

Figure63

2.Fanhousing

Page 45

g015240

6.Loosenthejamnut(

g015371

2 3

5 6

Figure65).

7.Rotatetheyoke.Totightenthebrake,rotatethe yokeup.Toloosenthebrake,rotatetheyokedown

Figure65).

(

8.Securetheyoketolowerbrakeleverwiththehairpin cotterpinandclevispin(Figure65).

9.Tightenthejamnut(Figure65).

10.Checkthebrakeoperationagain;refertoChecking theBrake.

Figure64

1.Handlever

2.Frontofhandlever

3.3/4inch(19mm)gap

4.Frontofslot

5.Brakebar

6.Brakebarjusttouching thetire

AdjustingtheBrakes

Iftheparkingbrakedoesnotholdsecurely ,an adjustmentisrequired.

1.Checkthebrakebeforeyouadjustit;referto CheckingtheBrakes.

2.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeOperation.

5.Toadjustthebrake,removethehairpincotter andclevispinfromthelowerbrakeleverandyoke

Figure65).

(

Figure65

1.JamNut4.Hairpincotterpin

2.Yoke5.Flatwasher

3.Clevispin

6.Lowerbrakelever

11.Afterthebrakeisadjusted,theleverswitchneeds tobechecked.

12.Checkthegapbetweenthebrakeleverandtheface oftheswitchasshownin

Figure66.Thegapneeds

tobean1/8inch(3mm)withthebrakeengaged.

13.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch.

Page 46

g015393

5 2

BeltMaintenance

ReplacingtheMowerDeck Belt

ServiceInterval:Every100hours—Checkthemower

deckbelt.

Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofaworndeckbelt.Replacethedeckbeltif anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Unlatchandremovethebeltcovers.

4.Loosenthefrontidlerpulleybylooseningthenut.

1.1/8inch(3mm)gap neededbetweenswitch andbrakelever

2.Brakelever

3.Switch

Figure66

4.Switchbutton

5.Faceoftheswitch

5.Removethewornmowerbelt(

Figure67).

6.Installthenewmowerbeltaroundthedeckpulleys andclutchpulley(

Figure67).

7.Usingaratchetintheidlerarm,tightentheidler pulleyuntilthespringisstretched6-1/2inches(165 mm)fromhooktohook(Figure67).

8.Tightenthefrontidlerpulleybytighteningthenut.

9.Installthebeltcoversontothecuttingunitand securethelatches.

Page 47

G015595

Figure67

G015402

1.6-1/2inches(165mm) fromhooktohook

2.Spring5.Squareholeforratchet

3.Springloadedidler

4.Ratchet

6.Nut

ReplacingthePumpDriveBelt

ServiceInterval:Every100hours—Checkthepump

drivebelt.

1.DisengagethePTOandsettheparkingbrake.

Figure68

1.Hydraulicpumps

2.Idlerpulley5.Pumpdrivebelt

3.Clutchpulley6.Shoulderbolt,nutand

4.Clutchretainer

washerconnectedto enginedeck

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethemowerdeckbelt.

4.Tiltthemachineonit’sback.Referto Pre-Maintenanceatthebeginningofthe MaintenanceSection.

5.Removetheshoulderbolt,nutandwasherfromthe enginedeckandconnectedtothespring(

Figure68).

6.Removethepumpdrivebelt(Figure68).

7.Installthenewbeltaroundclutchandthetwopump pulleys.

8.Installthespringontotheshoulderboltandwasher andconnectittotheenginedeckwiththenut

Figure68).

(

9.Lowerthemachinetotheoperatingposition. RefertoPre-Maintenanceatthebeginningofthe MaintenanceSection.

10.Installthemowerdeckbelt.

Page 48

ControlsSystem

g015372

Maintenance

AdjustingtheMotionControl HandlePositions

AdjustingtheRightSideMotionControl Lever

Ifthemotioncontrolleversdonotalignhorizontally , adjusttherightsidemotioncontrollever.

Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.

1.DisengagethePTO,movetherightsidemotion controllevertotheneutralpositionandsetthe parkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pushtherightmotioncontrolleverdownoutof lockedneutralposition(

Figure69).

4.Checkifitalignshorizontallywiththeleftmotion controllever(Figure69).

Figure70

1.Switchscrews

2.Cam

3.Nutandbolt

9.Afterthecamisadjusted,theleverswitchneedsto bechecked.

10.Checkthegapbetweenthecontrolleverandswitch asshowninFigure71.Thegapneedstobean1/8 inch(3mm)withtherightmotioncontrolleverin theneutral,unlockedposition.

11.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch(

Figure70andFigure71).

Figure69

1.Leftmotioncontrollever3.Checkthehorizontal

2.Rightmotioncontrollever inneutrallockedposition

alignmenthere

4.Rightmotioncontrollever

5.Toadjusttherightmotioncontrolleverhorizontally, thecamneedstobeadjusted.

6.Releasethecushionfromtherearofthemachine.

7.Loosenthenutandboltholdingthecam(Figure70).

8.Adjustthecamuntilitalignswiththeleftmotion controlleverandtightenthenutandboltforthe cam.

Page 49

g015373

1 2 3

Figure71

g015241

g015369

1 2

1.Switch

2.1/8inch(3mm)

3.Rightmotioncontrollever intheneutralunlocked position

12.Tightentheswitchscrews.

AdjustingtheNeutralPostionforthe MotionControlLevers

Figure72

1.Leftmotioncontrollever

2.Rightmotioncontrollever4.Alignthecontrollevers

3.Neutrallockedposition

fronttoback

2.Rotatetherightcableadjustmenttoplacetheright motioncontrolleverinthecenteroftheneutrallock slotinthecontrolpanel.

3.Rotatetheleftcableadjustmenttoplacetheleft motioncontrolleveralignmentequalwiththe rightmotioncontrollever.Thiswillprovidean approximateequaltrackingoftheleftwheelspeed totherightwheelspeed.

4.Checkforpropertracking.RefertoAdjustingthe TrackingintheMaintenanceSection.

Important:Ensurethetrackingofthemoweris correctafteradjustingthemotioncontrollevers. Adjustingthetrackingandaligningthemotion controlleversfronttobackisthesameprocedure

Figure72).

(

Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.

Ifthemotioncontrolleversdonotalignfronttoback, ortherightsidecontrolleverdoesnotmoveeasilyinto theneutrallockposition,adjustmentisrequired.

1.Afterthehorizontalalignmentisnished,checkthe fronttobackalignment(Figure72).

Figure73

1.Leftcableadjustment

2.Rightcableadjustment

Page 50

HydraulicSystem

G012005

4 1 3

Maintenance

ServicingtheHydraulic System

HydraulicOilType:Toro hydraulicoilorMobil

HydraulicSystemOilCapacity:67oz.(2.0l)

Important:Useoilspecied.Otheruidscould causesystemdamage.

HYPR-OIL

115W-50syntheticmotoroil.

™

7.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmuid. RefertoStartingandStoppingtheEngine.

8.Rechecktheuidlevelwhiletheuidiswarm.If required,adduidtothereservoiruntilitisbetween thehotlevelandthecoldlevel.

Note:Theuidlevelshouldbebelowthehotlevel

500

ofthebafe,whentheuidiswarm(

9.Installcaponllerneck.

Figure74).

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every50hours

Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoilis cold.Thebafeinsidethetankhastwolevelsdepending iftheoiliswarmorcold.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoff theengine.

3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulic tank(Figure74).

•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

ReplacingtheHydraulicFluid

ServiceInterval:Every250hours—Changethe

hydrauliclterandhydraulicoilwhen usingMobil

1oil.

Figure74

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

5.Removecapfromllerneck.Lookinsidetocheck theuidlevelinthereservoir.(Figure74).

6.Adduidtothereservoiruntilitreachesthecold levelofthebafe.

Every500hours/Yearly(whichever comesrst)—Changethehydraulic lterandhydraulicoilwhenusing

Toro oil.

Note:Changethehydraulicuidmorefrequentlyin severeconditionsorinahotoperatingclimate.

HYPR-OIL

™

500hydraulic

WARNING

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.

Page 51

1.DisengagethePTOandsettheparkingbrake.

g015242

3 2

g015243

ReplacingtheHydraulicFilter

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Removehydraulicreservoircap.

4.Locatethefronthydraulichoseunderthehydraulic tankandplacedrainpanunderthetank(

Figure75).

5.Loosenthehoseclampandmoveitdownthehose.

6.Removethefronthydraulichoseandallowtheuid torunoutofthetank.

ServiceInterval:Aftertherst8hours

WARNING

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.

3.Locatethelterandplacedrainpanunderlter

Figure76).

(

Figure75

1.Hydraulictank3.Fronthydraulichose

2.Hydrauliclter

7.Changethehydrauliclter.RefertoReplacingthe HydraulicFilter.

8.Connectthehydraulichoseunderthetank.

9.Adduidtothetankuntilitreachesthecoldbafe ofthetank.

Important:Useoilspeciedorequivalent. Otheruidscouldcausesystemdamage.

10.Installthehydraulictankcap.

11.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.

12.Checktheleveloftheuidandadduid,ifrequired.

Donotoverll.

Figure76

1.Hydraulictank

2.Hydrauliclter

4.Removetheoldlterandwipethelteradapter gasketsurfaceclean(Figure77).

5.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.

6.Installreplacementhydrauliclterontothelter adapter.Turntheoillterclockwiseuntiltherubber gasketcontactsthelteradapter,thentightenthe lteranadditional1/2turn(

Figure77).

Page 52

Figure77

1.Hydrauliclter

2.Gasket

3.Adapter

7.Cleanupanyspilleduid.

8.Checktheuidinthereservoir,adduidtothetank untilitreachesthecoldbafeofthetank.

Important:Useoilspeciedorequivalent. Otheruidscouldcausesystemdamage.

9.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.

10.Rechecklevelandadduid,ifrequired.Donot

overll.

Checkhydraulichosesandhosesforleaks,loosettings, kinkedhoses,loosemountingsupports,wear,weather andchemicaldeterioration.Makenecessaryrepairs beforeoperating.

Note:Keepareasaroundhydraulicsystemcleanfrom grassanddebrisbuildup.

Note:Extendedoperatingtimeathightemperatures inahotclimatemayleadtodeteriorationofhosesand seals.Inspectmorefrequentlyinahotclimateand changehydraulicoilandltermorefrequently.

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafewhours byadoctorfamiliarwiththistypeofinjury. Gangrenemayresultifthisisnotdone.

•Keepbodyandhandsawayfrompinholeleaks ornozzlesthatejecthighpressurehydraulic uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemifuidischangedorafter workisperformedonthesystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsofftheground.

4.Starttheengineandmovethethrottlecontroltoidle position.

Ifthedrivewheeldoesnotrotate,itispossibleto assistthepurgingofthesystembycarefullyrotating thetireintheforwarddirection.

5.Checkthehydraulicuidlevelasitdropsadduid asrequiredtomaintaintheproperlevel.

6.Repeatthisprocedurefortheoppositewheel.

7.Thoroughlycleantheareaaroundeachofthecharge pumphousings.

•Makesureallhydraulicuidhosesandhosesare ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto hydraulicsystem.

CheckingtheHydraulicLines

ServiceInterval:Every100hours

Page 53

MowerDeck Maintenance

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.

WARNING

Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator’s orbystander’sarea,resultinginseriouspersonal injuryordeath.

•Inspectthebladesperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagetheblades andsettheparkingbrake.Turntheignitionkeytooff. Removethekeyanddisconnectthesparkplugwires fromthesparkplugs.

InspectingtheBlades

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromalevelsurfacetothe cuttingedge,positionA,oftheblades(Figure79 ).Notethisdimension.

Figure79

1.Measureherefromblade tohardsurface

2.PositionA

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure78).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea.Ifyou noticeanycracks,wear,oraslotforminginthisarea immediatelyinstallanewblades(

Figure78

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

Figure78).

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).If thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith

anewblade.

•Neverleorcreatesharpnotchesinthe

edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum

Page 54

performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.

1.Holdthebladeendusingaragorthickly-padded glove.

2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(

Figure80).

Figure82

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure83).

Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.

2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead

Figure83).Torquethebladeboltto85-110ft-lb

( (115-150N-m).

Figure80

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure81).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

Figure81

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer( horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly( procedureuntilthebladeisbalanced.

Figure82).Ifthebladestaysina

Figure80).Repeatthis

Figure83

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeT owardsBoltHead

CorrectingtheMowerQuality ofCut

Ifonedeckbladecutslowerthantheother,correctas follows.

Note:Tireairpressureiscriticalintheseprocedures. Makesurethereartireshavecorrectpressure.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating

Page 55

position.Disconnectthesparkplugwire(s)from

G015244

thesparkplug(s).

2.LocatetheU-platesonthesideoftheenginedeck (Figure85).

3.Adjustthetirepressureinthereartiresto12-14psi (83-97kPa).

4.Checkthatthebladesandspindleshaftsarenot bent.RefertoCheckingforBentBlades.

5.Settheheight-of-cuttothe3inch(7.6cm)position. RefertoAdjustingtheHeight-Of-CutinOperation.

6.Performthestepsinthefollowingproceduresin order.

CheckingtheMowerDeckSide-to-Side Height

1.Adjustthereartirepressure.

2.Ensurethebladesarenotbent.RefertoChecking forBentBlades.

3.Positionthebladesside-to-side.MeasureatBand Clocationsfromalevelsurfacetothecuttingedge ofbladetips(

Figure84).

3.LoosentheU-plateononesideandadjustitupor downtomakethedifferencebetweenmeasurements BandCnomorethana1/4inch(6mm)(

Figure85).

4.ProceedtoCheckingtheMowerDeckFront-to-Rear Pitch.

Figure84

1.Measurefromalevel surface

2.MeasurebladeatpointsB andC

4.ThedifferencebetweenmeasurementsBandC shouldbenomorethan1/4inch(6mm).IIfitis notcorrect,proceedtoChangingtheMowerDeck Side-to-SideHeight.

ChangingtheMowerDeckSide-to-Side Height

Changingtheside-to-sideheightisdonebyadjusting thereartirepressureandU-platesonthesideofthe enginedeck.

Figure85

1.U-plate2.Nutsandbolts

CheckingtheMowerDeckFront-to-Rear Pitch

1.Adjustthetirepressureinthereartiresto specications.

2.Positiononebladefront-to-rear.MeasureatAand Blocationsfromalevelsurfacetothecuttingedge ofthebladetips(

3.Themowerbladeshouldbea1/4inch(6mm)lower infrontatAthanintherearatB.Rotatebladesand repeatforotherblades.Ifitisnotcorrect,proceed toChangingtheDeckFront-to-RearPitch.

Figure86).

1.Changethereartirepressure.Dothistothe correspondingsidethatneedsadjustment.

Page 56

Figure86

G015245

G015246

1.MeasurebladeatpointsA andB

2.Measurefromalevel surface

ChangingtheMowerDeck Front-to-RearPitch

Changingthefront-to-rearpitchisdonebyadjustingthe frontheight-of-cutposts.

mowerdeckisbuilta1/4inch(6mm)lowerthanthe frontlipofthemowerdeck.

5.For60inchmowerdecks,tightentheliftlinks Figure89).

(

6.Tightenboththefrontandrearnuts.

7.Checkthefront-to-rearpitchofthecuttingunit.

8.Ifthedimensionsarenotcorrect,adjustthefront

andrearnutsoneithersidetogetthecorrect front-to-rearpitch(

Figure88).

1.Place3piecesof2x4woodunderthemowerdeck asshowninFigure87.Standthe2x4’sonthe4inch part.

Figure87

1.2x4pieceofwoodundermowerdeck

2.For48and52inchmowerdecks,loosenboth thefrontandrearnutsontheadjustmentrods (Figure88).

Figure88

48and52inchmowerdecks

1.Adjustmentrods3.Frontnuts

2.Rearnuts

3.For60inchmowerdecks,loosenboththefront andrearnutsandliftlinksontheadjustmentrods (Figure89).

4.Theweightofthemowerdeckmustberestingonall threeofthe2x4’s(Figure88).Thebacklipofthe

Page 57

G015501

1 2

Figure89

g015336

60inchmowerdecks

Figure90

1.Measurefromalevel surface

2.MeasurebladeatpointA

4.Themeasurementshouldbe3inch(7.6cm).

5.Ifitdoesnotmeasurecorrectly,locatethe height-of-cutrodontherightsideofthemachine

Figure91).

(

6.Adjusttheadjustmentboltuntilthebladetipsmatch 3inches(7.6cm)(Figure91).

1.Adjustmentrods

2.Rearnuts4.Frontnuts

3.Liftlink

MatchingHeightofCut

1.Checkthereartirepressure.

2.Settheheight-of-cuttothe3inch(7.6cm)position. RefertoAdjustingtheHeight-Of-CutinOperation.

3.Withthemachineonlevelsurface,positiononeblade front-to-rear.MeasureatAandfromlevelsurfaceto thecuttingedgeofthebladetips(

Figure90).

Figure91

1.Height-of-cutrod

2.Adjustmentbolt

ReplacingtheGrassDeector

WARNING

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.

Page 58

1.Removethelocknut,bolt,springandspacerholding

g015594

6 2

thedeectortothepivotbrackets(Figure92). Removedamagedorworngrassdeector.

Figure92

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring

5.Springinstalled

7.Jhookendofspring

2.Placespacerandspringontograssdeector.Place oneJendofspringbehinddeckedge.

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethefrontofthemachineandusejackstandsto supportthemower.

WasteDisposal

Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.

Note:MakesureoneJendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown

Figure92.

3.Installboltandnut.PlaceoneJhookendofspring aroundgrassdeector(Figure92).

Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.

Page 59

Storage

CleaningandStorage

1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytooff.Removethe key.

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideofthe engine’scylinderheadnsandblowerhousing.

Important:Youcanwashthemachinewith milddetergentandwater.Donotpressurewash themachine.Avoidexcessiveuseofwater, especiallynearthedrivesystemandengine. Pressurewashingcanforcedirtandwaterinto criticalparts,suchasspindlebearingsand electricalswitches.

3.Checkthebrake;refertoServicingtheBrakein BrakeMaintenance(page44).

4.Servicetheaircleaner;refertoServicingtheAir CleanerinEngineMaintenance(page33).

hole.Nowusethestartertocranktheengineand distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.

11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

12.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachineto protectitandkeepitclean.

5.Greasethemachine;refertoGreasingand Lubricationin

6.Changetheengineoil;refertoServicingtheEngine inEngineMaintenance(page33).

7.Checkthetirepressure;refertoCheckingtheTire PressureinDriveSystemMaintenance(page40).

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefuel

tank;refertoServicingtheFuelTankin FuelSystemMaintenance(page37),oroperate engineuntilitstops.

D.Restartengineandrununtilitstops.Repeat,on

Chokeuntilenginewillnotrestart.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Lubrication(page31).

Note:Donotstorestabilizer/conditioned gasolineover90days.

9.Removethesparkplug(s)andcheckits condition;refertoServicingtheSparkPlugin EngineMaintenance(page33).Withthespark plug(s)removedfromtheengine,pourtwo tablespoonsofengineoilintothesparkplug

Page 60

Troubleshooting

Problem

Enginewillnotstart,startshard,orfails tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Fueltankisemptyorshut-offvalve closed.

2.Chokeisnoton.

3.Sparkplugwireislooseor disconnected.

4.Sparkplugispitted,fouled,orthegap isincorrect.

5.Aircleanerisdirty.

6.Dirtinthefuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

8.Thegapbetweenthesafetyinterlock switchesisnotcorrect.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesunder theengineblowerhousingareplugged.

5.Sparkplugispitted,fouled,orthegap isincorrect.

6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

7.Dirtinthefuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel system.

1.Fillfueltankwithgasolineandopen valve

2.Movethechokelevertochokeposition.

3.Installwireonsparkplug.

4.Installanew,correctlygappedspark plug.

5.Servicetheaircleanerelement.

7.ContactanAuthorizedServiceDealer .

8.ContactanAuthorizedServiceDealer .

2.Servicetheaircleaner.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

5.Installanew,correctlygappedspark plug.

8.ContactanAuthorizedServiceDealer .

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesunder theengineblowerhousingareplugged.

1.Hydraulicoilreservoirlow.1.Addhydraulicoiltothereservoir.

2.Airinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.

3.Pumpdrivebeltslipping.3.Replacethepumpdrivebelt.

4.Pumpdrivebeltidlerspringmissing.4.Replacethepumpdrivebeltidler

5.Pumpby-passvalvesareopen.5.Tightentheby-passvalves.

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or bladepulley.

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

1.Blade(s)notsharp.1.Sharpentheblade(s).

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

3.Mowerdeckisnotlevel.3.Levelthemowerdeckside-to-side

4.Mowerdeckpitchiswrong.

5.Undersideofmowerdeckisdirty.5.Cleantheundersideofthemower

6.Tirepressureisnotcorrect.6.Adjustthetirepressure.

7.Bladespindlebent.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

spring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer .

6.ContactanAuthorizedServiceDealer .

position.

4.Adjustthefront-to-rearpitch.

deck.

7.ContactanAuthorizedServiceDealer .

Page 61

Problem

PossibleCauseCorrectiveAction

Bladesdonotrotate.

1.Pumpdrivebeltisworn,looseor broken.

2.Pumpdrivebeltisoffpulley .

3.Mowerdeckbeltisworn,looseor broken.

4.Mowerdeckbeltisoffpulley .

5.Brokenormissingidlerspring.5.Replacethespring.

6.Electricclutchoutofadjustment.

7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer .

8.Damagedelectricclutch.

9.Safetyinterlocksystempreventsblade rotation.

10.PTOswitchisfaulty.10.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.

3.Installnewdeckbelt.

4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.

6.Adjusttheclutchairgap.

8.ContactanAuthorizedServiceDealer .

9.ContactanAuthorizedServiceDealer .

Page 62

Schematics

HydraulicSchematic(Rev .A)

Page 63

G015606

ElectricalSchematic(Rev .A)

Page 64

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment (LCE)

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:

ProductsWarrantyPeriod

AllMowers

•Engine

Seeenginemanufacturer’swarranty

•Battery90daysPartsandLabor 1yearPartsonly

•BeltsandTires90days

•Attachments1year

21in.HeavyDutyMowers1yearcommercialUse

2yearsResidentialUse

Mid-SizeWalk-BehindMowers GrandStand

Mowers

•Frame

ZMaster

Z400,Z500Mowers4yearsor1,200hours

•Frame

ZMaster

G3Mowers

•Frame

SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer.

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe

tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin

normaluse,itwillberepairedorreplaced,atT oro’soption,underwarrantyatnocostforparts

andlabor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor

corrosionarenotcovered.

2years 5yearsor1,200hours Lifetime(originalowneronly)

Lifetime(originalowneronly) 5yearsor1,200hours Lifetime(originalowneronly)

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:

1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,refertotheYellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww.T oro.com.Youmayalsocallthenumbers listedinitem#3tousethe24-hourT oroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer .Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty .

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:

RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1 196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator’sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:

•Costofregularmaintenanceserviceorwearparts,suchaslters,

fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear ,accidents,orlackof propermaintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel

system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.

•Pickupanddeliverycharges.

GeneralConditions

Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingT oroapprovedreplacementparts.

NeitherTheT oroCompanynorT oroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty ,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty

Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee information,contacttheT oroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany .

374-0252RevC