Toro Z400 Z Master, With 48in 7-Gauge Side Discharge Mower Riding Product Operator's Manual

Form No. 3354-550 Rev B
Z400 Z Master® with 48in,
7-Gauge Side Discharge
Mower
Model No. 74412—Serial No. 260000001 and Up
Register your product at www.Toro.com
Original Instructions (EN)
Warning
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: This engine is not equipped
with a spark arrester muffler. It is a
violation of California Public Resource Code
Section 4442 to use or operate the engine
on any forest-covered, brush-covered, or
grass-covered land. Other states or federal
areas may have similar laws.
Figure 1
1. Model and serial number location
This spark ignition system complies with Canadian
ICES-002
Model No.
Serial No.
The enclosed Engine Owner’s Manual is
supplied for information regarding the US
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance, and warranty.
Replacements may be ordered through the
engine manufacturer.
This manual identifies potential hazards and has
safety messages identified by the safety alert
symbol (Figure 2), which signals a hazard that may
cause serious injury or death if you do not follow
the recommended precautions.
Introduction
Figure 2
Read this information carefully to learn how to
operate and maintain your product properly and
to avoid injury and product damage. You are
responsible for operating the product properly
and safely.
1. Safety alert symbol
This manual uses 2 other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
You may contact Toro directly at www.Toro.com
for product and accessory information, help
finding a dealer, or to register your product.
Contents
Whenever you need service, genuine Toro parts,
or additional information, contact an Authorized
Service Dealer or Toro Customer Service and have
the model and serial numbers of your product
ready. Figure 1 identifies the location of the model
and serial numbers on the product. Write the
numbers in the space provided.
© 2005—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Introduction ....................................................... 2
Safety .................................................................. 4
Safe Operating Practices ...................... 4
Slope Chart ......................................... 7
Safety and Instructional Decals ............ 8
Product Overview ............................................. 12
Controls ........................................... 12
Operation.......................................................... 13
Adding Fuel ...................................... 13
Checking the Engine Oil Level ........... 14
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Using the Rollover Protection
System (ROPS).................. 14
Think Safety First .............................. 15
Operating the Parking Brake .............. 16
Starting and Stopping the
Engine .............................. 16
Operating the Power Take Off
(PTO) ............................... 18
The Safety Interlock System............... 18
Driving Forward or Backward ............ 19
Stopping the Machine ........................ 20
Adjusting the Height-of-Cut .............. 20
Adjusting the Anti-Scalp
Rollers............................... 20
Positioning the Seat ........................... 21
Unlatching the Seat............................ 21
Pushing the Machine by Hand............ 21
Using the Side Discharge ................... 22
Transporting Machines ...................... 22
Loading Machines ............................. 23
Operating Tips .................................. 24
Maintenance...................................................... 25
Recommended Maintenance
Schedule(s) ............................... 25
Lubrication................................................ 26
Greasing and Lubrication................... 26
Greasing the Mower Deck and Belt
Idlers................................. 26
Engine Maintenance.................................. 27
Servicing the Air Cleaner ................... 27
Servicing the Engine Oil .................... 28
Servicing the Spark Plugs ................... 30
Fuel System Maintenance .......................... 31
Replacing the Fuel Filter .................... 31
Servicing the Fuel Tank...................... 31
Electrical System Maintenance................... 32
Servicing the Battery.......................... 32
Servicing the Fuses ............................ 33
Drive System Maintenance......................... 34
Adjusting the Tracking....................... 34
Checking the Tire Pressure................. 35
Checking the Wheel Hub Slotted
Nut ................................... 35
Adjusting the Caster Pivot
Bearing.............................. 35
Cooling System Maintenance ..................... 36
Cleaning the Air Intake Screen ........... 36
Cleaning the Cooling System.............. 36
Brake Maintenance .................................... 36
Adjusting the Parking Brake ............... 36
Belt Maintenance....................................... 37
Inspecting the Belts ........................... 37
Replacing the Mower Belt .................. 37
Replacing the Pump Drive
Belt ................................... 38
Adjusting the Push Arms ................... 39
Controls System Maintenance.................... 39
Adjusting the Control Handle
Neutral Position ................ 39
Hydraulic System Maintenance .................. 40
Servicing the Hydraulic
System............................... 40
Setting the Hydraulic Pump
Neutral Position ................ 42
Mower Deck Maintenance ......................... 44
Leveling the Mower at Three
Positions ........................... 44
Servicing the Cutting Blades............... 46
Replacing the Grass Deflector............ 49
Cleaning .................................................... 49
Cleaning Under the Mower ................ 49
Waste Disposal .................................. 49
Storage.............................................................. 50
Troubleshooting................................................ 51
Schematics ........................................................ 54
3
Safety
hair, loose clothing or jewelry may get tangled
in moving parts.
Improper use or maintenance by the operator or
owner can result in injury. To reduce the potential
for injury, comply with these safety instructions
and always pay attention to the safety alert symbol,
which means CAUTION, WARNING, or
DANGER-“personal safety instruction." Failure
to comply with the instruction may result in
personal injury or death.
• Inspect the area where the equipment is to be
used and remove all objects such as rocks, toys
and wire which can be thrown by the machine.
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
– Never refuel or drain the machine indoors.
• Use extra care when handling gasoline and
other fuels. They are flammable and vapors
are explosive.
– Use only an approved container
– Never remove gas cap or add fuel with
engine running. Allow engine to cool
before refueling. Do not smoke.
This product is designed for cutting and recycling
grass or, when equipped with a grass bagger, for
catching cut grass. Any use for purposes other
than these could prove dangerous to user and
bystanders.
• Check that operator’s presence controls,
safety switches and shields are attached and
functioning properly. Do not operate unless
they are functioning properly.
Safe Operating Practices
Operation
The following instructions are from ANSI
standard B71.4-2004.
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from
holes and hidden hazards.
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility
to explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
• Never let children or untrained people operate
or service the equipment. Local regulations
may restrict the age of the operator.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself
or herself, other people or property.
• Be sure all drives are in neutral and parking
brake is engaged before starting engine. Start
the engine only from the operator’s position.
Use seat belts.
• Never raise mower with the blades running.
• Never operate without the PTO shield, or
other guards securely in place. Be sure all
interlocks are attached, adjusted properly, and
functioning properly.
• Never operate with the discharge deflector
raised, removed or altered, unless using a grass
catcher.
• Do not change the engine governor setting or
overspeed the engine.
• Stop on level ground, lower implements,
disengage drives, engage parking brake, shut
off engine before leaving the operator’s
position for any reason including emptying the
catchers or unclogging the chute.
Preparation
• Evaluate the terrain to determine what
accessories and attachments are needed to
properly and safely perform the job. Only use
accessories and attachments approved by the
manufacturer.
• Wear appropriate clothing including hard hat,
safety glasses and hearing protection. Long
• Stop equipment and inspect blades after
striking objects or if an abnormal vibration
occurs. Make necessary repairs before
resuming operations.
4
• Keep hands and feet away from the cutting
units.
• Never carry passengers and keep pets and
bystanders away.
• Be alert, slow down and use caution when
making turns. Look behind and to the side
before changing directions.
• Slow down and use caution when crossing
roads and sidewalks. Stop blades if not
mowing.
• Be aware of the mower discharge direction and
do not point it at anyone.
• Do not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading
the machine into a trailer or truck.
• Use care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
• Always avoid sudden starting or stopping on
a slope. If tires lose traction, disengage the
blades and proceed slowly off the slope.
• Follow the manufacturer’s recommendations
for wheel weights or counterweights to
improve stability.
• Use extreme care with grass catchers or other
attachments. These can change the stability of
the machine and cause loss of control.
Using the Rollover Protection System
(ROPS)
• Keep the roll bar in the raised and locked
position and use the seat belt when operating
the machine.
• Be certain that the seat belt can be released
quickly in the event of an emergency.
• Be aware there is no rollover protection when
the roll bar is down.
• Check the area to be mowed and never fold
the ROPS in areas where there are slopes, drop
offs or water.
• Lower the rollbar only when absolutely
necessary. Do not wear the seat belt with the
roll bar folded down.
• Check carefully for overhead clearances (i.e.
branches, doorways, electrical wires) before
driving under any objects and do not contact
them.
Slope Operation
• Do not mow slopes greater than 15 degrees.
• Do not mow near drop-offs, ditches, steep
banks or water. Wheels dropping over edges
can cause rollovers, which may result in serious
injury, death or drowning.
• Do not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause
sliding and loss of control.
• Do not make sudden turns or rapid speed
changes.
• Use a walk behind mower and/or a hand
trimmer near drop-offs, ditches, steep banks
or water.
• Reduce speed and use extreme caution on
slopes.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass
can hide obstacles.
• Watch for ditches, holes, rocks, dips, and rises
that change the operating angle, as rough
terrain could overturn the machine.
• Avoid sudden starts when mowing uphill
because the mower may tip backwards.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels
may cause drive wheels to slip and cause loss
of braking and steering.
Maintenance and storage
• Disengage drives, lower implement, set
parking brake, stop engine and remove key
or disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning
or repairing.
• Clean grass and debris from cutting units,
drives, mufflers, and engine to help prevent
fires. Clean up oil or fuel spillage.
• Let engine cool before storing and do not store
near flame.
• Shut off fuel while storing or transporting. Do
not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use jack stands to support components when
required.
5
• Carefully release pressure from components
with stored energy.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
• Use care when checking blades. Wrap the
blade(s) or wear gloves, and use caution when
servicing them. Only replace blades. Never
straighten or weld them.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Charge batteries in an open well ventilated
area, away from spark and flames. Unplug
charger before connecting or disconnecting
from battery. Wear protective clothing and use
insulated tools.
• Keep all parts in good working condition and
all hardware tightened. Replace all worn or
damaged decals.
• Use only Toro approved attachments.
Warranty may be voided if used with
unapproved attachments.
6
Slope Chart
7
Safety and Instructional
Decals
Safety decals and instructions are easily visible to the operator and are located near any
area of potential danger. Replace any decal that is damaged or lost.
58-6520
1. Grease
1-403005
66-1340
1-523552
65-2690
1-633818
68-8340
98-4387
54-9220
1. Warning—wear hearing protection.
8
98-5954
107-1687
103-2644
Battery Symbols
Some or all of these symbols are on your battery
105-7798
1.
Explosion hazard
2.
No re, open ame, or
smoking.
3.
Caustic liquid/chemical
burn hazard
Wear eye protection
4.
107-1613
5.
9
Read the Operator’s
Manual.
6.
Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can cause
blindness and other injuries
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
10. Contains lead; do not
discard.
107-2112
108-1050
107-2102
Manufacturer’s Mark
1. Indicates the blade is identied as a part from the original
machine manufacturer.
107-8445
10
107-9309
1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard.
2. Read the Operator’s Manual.
108-5278
1. Read the Operator’s Manual.
108-5995
1. Fast
2.
Slow
1. Choke
2. Engine—stop
3.
4.
Engine—run
Engine—start
3. Neutral
4. Reverse
110-0439
5. Fast
6. Continuous variable setting
11
7. Slow
8. Power take-off (PTO)
Product Overview
Using the Hour Meter
The hour meter (Figure 5) records the number
of hours the engine has operated. It operates
when the engine is running. Use these times for
scheduling regular maintenance.
Figure 5
1. Hour meter
Using the Fuel Shutoff Valve
The machine has 2 fuel tanks, one on the left side
and the other on the right side. Each tank connects
to a check valve and then to a tee. From there a
common fuel line leads to the engine (Figure 6).
Figure 3
1.
2.
3.
4.
5.
Rollbar
Fuel cap (both sides)
Seat belt
Motion control lever
Height-of-cut lever
6.
7.
8.
9.
10.
Side discharge
Front caster wheel
Controls
Mower deck
Parking brake lever
Close the fuel shutoff valve before transporting
or storing the machine.
Controls
Become familiar with all the controls before you
start the engine and operate the machine (Figure 3
and Figure 4).
Figure 6
1. Fuel shutoff valve
Figure 4
1.
2.
3.
4.
5.
Hour meter
Ignition switch
Glow plug switch
Glow plug light
Engine Temperature light
6.
7.
8.
9.
Throttle control
PTO Switch
Audible alarm
Fuel selector valve
12
Operation
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite the gasoline vapors. A fire
or explosion from gasoline can burn you and
others and can damage property.
Note: Determine the left and right sides of the
machine from the normal operating position.
Adding Fuel
• Always place gasoline containers on the
ground away from your vehicle before
filling.
Use Unleaded Regular Gasoline suitable for
automotive use (85 pump octane minimum).
Leaded regular gasoline may be used if unleaded
regular is not available.
• Do not fill gasoline containers inside
a vehicle or on a truck or trailer bed
because interior carpets or plastic truck
bed liners may insulate the container and
slow the loss of any static charge.
Important: Never use methanol, gasoline
containing methanol, or gasohol containing
more than 10% ethanol because the fuel
system could be damaged. Do not mix oil
with gasoline.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and
others and can damage property.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Fill the fuel tank outdoors, in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Never fill the fuel tank inside an enclosed
trailer.
• Do not fill the fuel tank completely full.
Add gasoline to the fuel tank until the
level is 1/4 to 1/2 inch (6 to 13 mm)
below the bottom of the filler neck. This
empty space in the tank allows gasoline
to expand.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors can cause
serious injury and illness.
• Avoid prolonged breathing of vapors.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
a spark.
• Keep face away from nozzle and gas tank
or conditioner opening.
• Keep gas away from eyes and skin.
• Store gasoline in an approved container
and keep it out of the reach of children.
Never buy more than a 30-day supply of
gasoline.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
• Do not operate without entire exhaust
system in place and in proper working
condition.
• Keeps gasoline fresh during storage of 90 days
or less. For longer storage it is recommended
that the fuel tank be drained.
13
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
There is no rollover protection when the roll
bar is in the down position.
Important: Do not use fuel additives
containing methanol or ethanol.
• Lower the roll bar only when absolutely
necessary.
Add the correct amount of gas
stabilizer/conditioner to the gas.
• Do not wear the seat belt when the roll
bar is in the down position.
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline. To
minimize the chance of varnish deposits in the fuel
system, use fuel stabilizer at all times.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance
permits.
• Check carefully for overhead clearances
(i.e. branches, doorways, electrical wires)
before driving under any objects and do
not contact them.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove
the cap.
Important: Lower the roll bar only when
absolutely necessary.
3. Add unleaded regular gasoline to both fuel
tanks, until the level is 1/4 to 1/2 inch (6 mm
to 13 mm) below the bottom of the filler neck.
1. To lower the roll bar, loosen the front knobs
(Figure 9).
This space in the tank allows gasoline to
expand. Do not fill the fuel tanks completely
full.
2. Remove the hairpin cotter pins and remove the
two pins (Figure 8).
3. Lower the roll bar to the down position. There
are two down positions. See Figure 7 for the
positions.
4. Install fuel tank caps securely.
5. Wipe up any gasoline that may have spilled.
4. Install the two pins and secure them with the
hairpin cotter pins (Figure 8).
Checking the Engine Oil
Level
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer
to Checking Oil Level in Engine Maintenance,
page 27
Using the Rollover
Protection System (ROPS)
To avoid injury or death from rollover: keep
the roll bar in the raised locked position and
use the seat belt.
Figure 7
1. Full down position
Ensure that the rear part of the seat is
secured with the seat latch.
2.
Down position with bagger
installed
Important: Ensure that the rear part of
the seat is secured with the seat latch.
14
Think Safety First
5. To raise the roll bar, remove the hairpin cotter
pins and remove the two pins (Figure 8).
6. Raise the roll bar to the upright position and
install the two pins and secure them with the
hairpin cotter pins (Figure 8).
Please read all safety instructions and symbols
in the safety section. Knowing this information
could help you or bystanders avoid injury.
Important: Always use the seat belt with
the roll bar in the raised position.
Operating on wet grass or steep slopes can
cause sliding and loss of control.
Wheels dropping over edges can cause
rollovers, which may result in serious injury,
death or drowning.
There is no rollover protection when the roll
bar is down.
Always keep the roll bar in the raised and
locked position and use the seat belt.
Read and follow the rollover protection
instructions and warnings.
To avoid loss of control and possibility of
rollover:
• Do not operate near drop-offs or near
water.
• Do not operate on slopes greater than
15 degrees.
Figure 8
1. Roll bar
2. Raised position
3.
4.
• Reduce speed and use extreme caution
on slopes.
Pin
Hairpin cotter pin
• Avoid sudden turns or rapid speed
changes.
Important: Tighten the front knobs
against the center roll bar ends (Figure 9).
Figure 9
1. Front handle
15
Setting the Parking Brake
1. Move the motion control levers (Figure 18) out
to the neutral lock position.
2. Pull up and back on the parking brake lever to
set the parking brake (Figure 12). The parking
brake lever should stay firmly in the engaged
position.
Parking brake may not hold machine
parked on a slope and could cause
personal injury or property damage.
Do not park on slopes unless wheels are
chocked or blocked
Figure 10
1. Safe Zone-use the Z Master 3.
here on slopes less than
15 degrees or at areas.
2. Use walk behind mower
and/or hand trimmer near
drop-offs and water.
Water
Releasing the Parking Brake
Push forward and down on the parking brake lever
to release the parking brake (Figure 12).
This machine produces sound levels in
excess of 85 dBA at the operators ear and
can cause hearing loss through extended
periods of exposure.
Wear hearing protection when operating
this machine.
Use protective equipment for your eyes, ears, feet,
and head.
Figure 12
1. Parking brake-ON
2. Parking brake-OFF
3.
Brake Stop
Starting and Stopping the
Engine
Figure 11
1. Warning— wear hearing protection
Starting the Engine
1. Sit on the seat and move the motion controls
to neutral locked position.
2. Set the parking brake; refer to Setting the
Parking Brake.
3. Move the PTO (power take off) switch to the
Off position (Figure 13).
Operating the Parking
Brake
Always set the parking brake when you stop the
machine or leave it unattended.
16
Figure 15
1.
2.
2.
Throttle—slow
6. Turn the ignition key to Start. When the
engines starts, release the key (Figure 16).
Figure 13
1. PTO—on
Throttle—fast
PTO—off
Important: Do not engage starter for
more than 10 seconds at a time. If engine
fails to start allow 30 second cool-down
period between attempts. Failure to follow
these instructions can burn out starter
motor.
4. Move the choke control to the on position
before starting a cold engine (Figure 14).
Note: A warm or hot engine may not require
choking. After engine starts, move choke
control to Run position.
Figure 16
1.
2.
2.
3.
Start
7. After the engine starts, move the choke to off
(Figure 14). If the engine stalls or hesitates,
move the choke back to on for a few seconds,
then move the throttle lever to desired setting.
Repeat this as required.
Figure 14
1. Choke—on
Off
Run
Choke—off
Stopping the Engine
5. Move the throttle control to the Fast position
before starting a cold engine (Figure 15).
1. Push the PTO to the off position (Figure 13).
2. Move the throttle lever midway between the
slow and fast positions (Figure 15).
3. Let the engine idle for 60 seconds.
4. Turn the ignition key to the off position and
remove the key (Figure 16).
5. Close the fuel shut off valve before transporting
or storing the machine.
17
Important: Make sure that the fuel
shut off valve is closed before transporting
or storing the machine, as fuel leakage
may occur. Set the parking brake before
transporting. Make sure to remove the key
as the fuel pump may run and cause the
battery to lose charge.
Children or bystanders may be injured
if they move or attempt to operate the
tractor while it is unattended.
Figure 17
Always remove the ignition key and
set the parking brake when leaving the
machine unattended, even if just for a
few minutes.
1. PTO-On
2.
PTO-Off
Disengaging the PTO
Operating the Power Take
Off (PTO)
To disengage, push the PTO switch to the off
position (Figure 17).
The power take off (PTO) switch starts and stops
the mower blades and any powered attachments.
The Safety Interlock System
Engaging the PTO
If safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
1. If the engine is cold, allow the engine to warm
up 5 to 10 minutes before engaging the PTO.
2. While seated in the seat, release the pressure on
the traction control levers and place in neutral.
• Do not tamper with the interlock
switches.
3. Place the throttle in the fast position.
• Check the operation of the interlock
switches daily and replace any damaged
switches before operating the machine.
Note: Engaging the PTO with the throttle
at the half or less position will cause excessive
wear to the drive belts.
Understanding the Safety Interlock
System
4. Pull out on the power take off (PTO) switch to
engage it (Figure 17).
The safety interlock system is designed to prevent
the engine from starting unless:
• You are sitting on the seat.
• The parking brake is engaged.
• The power take off (PTO) is disengaged.
• The motion control levers are in the neutral
locked position
The safety interlock system also is designed to stop
the engine when the traction controls are moved
from the locked position with the parking brake
18
engaged or if you rise from the seat when the PTO
is engaged.
Machine can spin very rapidly. Operator
may lose control of machine and cause
personal injury or damage to machine.
Testing the Safety Interlock System
Test the safety interlock system before you use
the machine each time. If the safety system
does not operate as described below, have an
Authorized Service Dealer repair the safety system
immediately.
• Use caution when making turns.
• Slow the machine down before making
sharp turns.
Driving Forward
1. Sitting on the seat, engage the parking brake
and move the PTO to on. Try starting the
engine; the engine should not crank.
1. Release the parking brake; refer to Releasing
the Parking Brake in Operation, page 13.
2. Sitting on the seat, engage the parking brake
and move the PTO to off. Move either motion
control lever (out of neutral locked position).
Try starting the engine; the engine should not
crank. Repeat for other control lever.
2. Move the levers to the center, un-locked
position.
3. To go forward, slowly push the motion control
levers forward (Figure 18).
Note: The engine will kill if the traction
control levers are moved with the parking
brake engaged.
3. Sitting on the seat, engage the parking brake,
move the PTO switch to off and move the
motion control levers to neutral lock position.
Now start the engine. While the engine is
running, release the parking brake, engage the
PTO and rise slightly from the seat; the engine
should stop.
To go straight, apply equal pressure to both
motion control levers (Figure 18).
To turn, move the motion control lever toward
neutral in the direction you want to turn
(Figure 18).
4. Sitting on the seat, engage the parking brake,
move the PTO switch to off and move the
motion control levers to neutral lock position.
Now start the engine. While the engine is
running, center either motion control and
move (forward or reverse); the engine should
stop. Repeat for other motion control.
The farther you move the traction control
levers in either direction, the faster the machine
will move in that direction.
To stop, pull the motion control levers to the
neutral position.
5. Sitting on the seat, disengage the parking brake,
move the PTO switch to off and move the
motion control levers to neutral lock position.
Try starting the engine; the engine should not
crank.
Driving Forward or
Backward
The throttle control regulates the engine speed as
measured in RPM (revolutions per minute). Place
the throttle control in the fast position for best
performance. Always operate in the full throttle
position when mowing.
Figure 18
1.
2.
19
Motion control
lever-neutral lock position
Center un-lock position
3.
Forward
4.
Backward
Driving Backward
1. Move the levers to the center, un-locked
position.
2. To go backward, slowly pull the motion control
levers rearward (Figure 18).
To go straight, apply equal pressure to both
motion control levers (Figure 18).
To turn, release pressure on the motion control
lever toward the direction you want to turn
(Figure 18).
To stop, push the motion control levers to the
neutral position.
Figure 19
1. Height of cut lever
Stopping the Machine
To stop the machine, move the traction control
levers to neutral and move to locked position,
disengage the power take off (PTO), and turn the
ignition key to off.
2.
Clevis Pin
Adjusting the Anti-Scalp
Rollers
Whenever you change the height-of-cut, adjust the
height of the anti-scalp rollers.
Set the parking brake when you leave the machine;
refer to Setting the Parking Brake in Operation,
page 13. Remember to remove the key from the
ignition switch.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Children or bystanders may be injured if
they move or attempt to operate the tractor
while it is unattended.
3. After adjusting the height-of-cut, adjust the
rollers by removing the flange nut, bushing,
spacer, and bolt (Figure 20 , Figure 21 and
Figure 49 ).
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even if just for a few minutes.
Note: The two middle rollers will not have a
spacer (Figure 21).
Adjusting the Height-of-Cut
4. Select a hole so the anti-scalp roller is
positioned to the nearest corresponding
height-of-cut desired.
The height-of-cut is adjusted from 1-1/2 to
4-1/2 inch (38 to 114 mm) in 1/4 inch (6 mm)
increments by relocating the clevis pin into
different hole locations.
1. Raise the height-of-cut lever to the transport
position (also the 4-1/2 inch (114 mm) cutting
height position) (Figure 19).
2. To adjust, remove the clevis pin from the
height-of-cut bracket (Figure 19).
3. Select a hole in the height-of-cut bracket
corresponding to the height-of-cut desired
and, insert the clevis pin (Figure 19).
4. Move the lever to the selected height.
5. Install the flange nut bushing, spacer, and bolt.
Torque to 40-45 ft-lb (54-61 N•m) (Figure 20 ,
Figure 21 and Figure 49 ).
6. Repeat this adjustment on the other anti-scalp
rollers.
20
Figure 22
1.
Adjustment lever
Unlatching the Seat
Figure 20
1. Anti-scalp roller
2. Spacer
3. Bushing
4.
5.
Push the seat latch rearward to unlatch the seat.
This will allow access to the machine under the
seat (Figure 23).
Flange Nut
Bolt
Figure 23
1.
2.
Seat latch
Fuel cap
3.
Seat
Figure 21
1. Anti-scalp roller
2. Bushing
3.
4.
Pushing the Machine by
Hand
Flange Nut
Bolt
Important: Always push the machine
by hand. Never tow the machine because
hydraulic damage may occur.
Positioning the Seat
The seat can move forward and backward.
Position the seat where you have the best control
of the machine and are most comfortable.
Pushing the Machine
1. Disengage the power take off (PTO) and
turn the ignition key to off. Move the levers
to neutral locked position and apply parking
brake. Remove the key.
2. Rotate the by-pass valves counterclockwise
1 turn to push. This allows hydraulic fluid to
Important: To adjust, move the lever
sideways to unlock seat (Figure 22).
Slide the seat to the desired position and release
lever to lock in position.
21
by-pass the pump enabling the wheels to turn
(Figure 24).
Without the grass deflector, discharge
cover, or complete grass catcher assembly
mounted in place, you and others are
exposed to blade contact and thrown debris.
Contact with rotating mower blade(s) and
thrown debris will cause injury or death.
Important: Do not rotate by-pass valves
more than 1 turn. This prevents valves
from coming out of the body and causing
fluid to run out.
3. Disengage parking brake before pushing.
• Never remove the grass deflector from
the mower because the grass deflector
routes material down toward the turf.
If the grass deflector is ever damaged,
replace it immediately.
Changing to Machine Operation
Rotate the by-pass valves clockwise 1 turn to
operate machine (Figure 24).
Note: Do not over tighten the by-pass valves.
• Never put your hands or feet under the
mower.
The machine will not drive unless by-pass valves
are turned in.
• Never try to clear the discharge area or
mower blades unless you move the power
take off (PTO) to the off position, rotate
the ignition key to off and remove the
key.
• Make sure the grass deflector is in the
down position.
Transporting Machines
Use a heavy-duty trailer or truck to transport the
machine. Ensure that the trailer or truck has all
necessary lighting and marking as required by law.
Please carefully read all the safety instructions.
Knowing this information could help you, your
family, pets or bystanders avoid injury.
Figure 24
1. Side console controls
2. By-pass valve
3.
Hydraulic pumps
Using the Side Discharge
To transport the machine:
The mower has a hinged grass deflector that
disperses clippings to the side and down toward
the turf.
• Securely fasten the machine to the trailer or
truck with straps, chains, cable, or ropes.
• Lock the brake and block the wheels.
• Secure a trailer to the towing vehicle with
safety chains.
Driving on the street or roadway without
turn signals, lights, reflective markings,
or a slow moving vehicle emblem is
dangerous and can lead to accidents
causing personal injury.
Do not drive machine on a public street
or roadway.
22
Loading Machines
Use extreme caution when loading units on trailers
or trucks. One full width ramp that is wide enough
to extend beyond the rear tires is recommended
instead of individual ramps for each side of the
unit (Figure 25). The lower rear section of the
tractor frame extends back between the rear
wheels and serves as a stop for tipping backward.
Having a full width ramp provides a surface for the
frame members to contact if the unit starts to tip
backward. If it is not possible to use one full width
ramp, use enough individual ramps to simulate a
full width continuous ramp.
Loading a unit onto a trailer or truck
increases the possibility of backward
tip-over and could cause serious injury or
death.
• Use extreme caution when operating a
unit on a ramp.
• Use only a single, full width ramp; Do
Not use individual ramps for each side
of the unit.
• If individual ramps must be used, use
enough ramps to create an unbroken
ramp surface wider than the unit.
The ramp should be long enough so that the
angles do not exceed 15 degrees (Figure 25). A
steeper angle may cause mower components to get
caught as the unit moves from ramp to trailer or
truck. Steeper angles may also cause the unit to tip
backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This
will minimize the ramp angle. The trailer or truck
should be as level as possible.
• Do not exceed a 15 degree angle between
ramp and ground or between ramp and
trailer or truck.
• Avoid sudden acceleration while driving
unit up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing
unit down a ramp to avoid tipping
backward.
Important: Do Not attempt to turn the unit
while on the ramp; you may lose control and
drive off the side.
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a
ramp. Both maneuvers can cause the unit to tip
backward.
Figure 25
23
1.
Trailer
3.
2.
Full width ramp
4.
Not greater than
15 degrees
Full width ramp—side view
Operating Tips
Long Grass
Fast Throttle Setting
If the grass is ever allowed to grow slightly longer
than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then cut the grass
again using the lower, normal setting.
For best mowing and maximum air circulation,
operate the engine at the fast throttle position. Air
is required to thoroughly cut grass clippings, so
do not set the height-of-cut so low as to totally
surround the mower by uncut grass. Always try to
have one side of the mower free from uncut grass,
which allows air to be drawn into the mower.
When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may
drop onto your lawn. To avoid this, move onto a
previously cut area with the blades engaged.
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure the
cutting height of the mower does not scalp any
uneven ground. However, the cutting height used
in the past is generally the best one to use. When
cutting grass longer than six inches tall, you may
want to cut the lawn twice to ensure an acceptable
quality of cut.
Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up
inside the mower, cutting quality will eventually
become unsatisfactory.
Cut 1/3 of the Grass Blade
Blade Maintenance
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows
more slowly.
Maintain a sharp blade throughout the cutting
season because a sharp blade cuts cleanly without
tearing or shredding the grass blades. Tearing and
shredding turns grass brown at the edges, which
slows growth and increases the chance of disease.
Check the cutter blades daily for sharpness, and
for any wear or damage. File down any nicks
and sharpen the blades as necessary. If a blade is
damaged or worn, replace it immediately with a
genuine TORO replacement blade.
Mowing Direction
Alternate mowing direction to keep the grass
standing straight. This also helps disperse clippings
which enhances decomposition and fertilization.
Mow at Correct Intervals
Normally, mow every four days. But remember,
grass grows at different rates at different times.
So to maintain the same cutting height, which is a
good practice, mow more often in early spring. As
the grass growth rate slows in mid summer, mow
less frequently. If you cannot mow for an extended
period, first mow at a high cutting height; then
mow again two days later at a lower height setting.
Cutting Speed
To improve cut quality, use a slower ground speed
in certain conditions.
Avoid Cutting Too Low
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height
to ensure that uneven turf is not cut too short.
24
Maintenance
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the rst 8 operating
hours
• Check the hydraulic uid.
• Change the hydraulic lter and oil.
Before each use or daily
•
•
•
•
•
Check the safety system.
Check the engine oil level.
Clean the air intake screen.
Check the mower blades.
Clean the mower deck.
Every 25 hours
•
•
•
•
•
•
Grease the mower deck and spindles.
Grease the mower belt idler arm.
Grease the pump belt idler arm.
Grease the drive belt idler arm.
Clean foam air cleaner element.
Check the hydraulic uid.
Every 50 hours
• Check the paper air cleaner element.
• Check the tire pressure.
• Check pump drive belt.
Every 100 hours
•
•
•
•
•
•
Every 150 hours
• Lubricate the machine with light oil (Refer to Lubrication).
Every 200 hours
• Replace the oil lter.
• Replace the fuel lter.
• Change the hydraulic lter and oil.
Every 500 hours
• Check the wheel hub slotted nut.
• Adjust the caster pivot bearing.
Yearly
Replace the paper air cleaner element.
Change the engine oil.
Check the spark plugs.
Check and clean engine cooling ns and shrouds.
Inspect the belts for cracks and wear.
Check the hydraulic hoses.
• Grease the front caster pivots (more often in dirty or dusty conditions).
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you
do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
25
Lubrication
Greasing and Lubrication
Lubricate the machine when shown on the Check
Service Reference Aid decal (Figure 26). Grease
more frequently when operating conditions are
extremely dusty or sandy.
Grease Type: General-purpose grease.
How to Grease
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Figure 26
3. Clean the grease fittings with a rag. Make
sure to scrape any paint off the front of the
fitting(s).
Where to Add Light Oil or Spray
Lubrication
4. Connect a grease gun to the fitting. Pump
grease into the fittings until grease begins to
ooze out of the bearings.
Lubricate the machine in the following areas with
spray type lubricant or light oil. Lubricate every
150 hours.
5. Wipe up any excess grease.
• Seat switch actuator.
Greasing the Front Caster Pivots
• Brake handle pivot.
Lubricate the front caster pivots once a year.
• Brake rod bushings.
1. Remove the dust cap and adjust the caster
pivots. Keep the dust cap off until greasing
is done. Refer to Adjusting the Caster Pivot
Bearing in Drive System Maintenance, page 34.
• Motion control bronze bushings.
Greasing the Mower Deck
and Belt Idlers
2. Remove the hex plug. Thread a grease zerk
into the hole.
3. Pump grease into the zerk until it oozes out
around the top bearing.
The mower deck must be lubricated weekly or
every 25 hours. Grease with No. 2 general purpose
lithium base or molybdenum base grease.
4. Remove the grease zerk in the hole. Install the
hex plug and cap.
Important: Make sure cutting unit spindles
are full of grease weekly.
Where to Add Grease
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
Lubricate the grease fittings as shown on the
Check Service Reference Aid decal (Figure 26).
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
3. Remove the belt covers.
26
4. Grease the three spindle bearings under the
pulleys until grease comes out the lower seals
(Figure 27).
Removing the Foam and Paper
Elements
5. Grease the idler arm on the mower deck
(Figure 27).
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
1. Disengage the PTO and set the parking brake.
6. Grease the fittings on the push arms
(Figure 27).
3. Clean around the air cleaner to prevent dirt
from getting into the engine and causing
damage (Figure 28).
4. Unscrew the cover knob and remove the air
cleaner cover (Figure 28).
5. Remove the wing nut and remove the air
cleaner assembly (Figure 28).
6. Carefully pull the foam element off the paper
element (Figure 28).
Figure 27
Engine Maintenance
Servicing the Air Cleaner
Service Interval/Specication
Foam element: Clean it after every 25 operating
hours.
Paper element: Check it after every 50 operating
hours. Replace it after every 200 operating hours
or yearly, which ever comes first.
Figure 28
1.
2.
3.
4.
Inspect the foam and paper elements and replace
them if they are damaged or excessively dirty.
Cover knob
Cover
Foam element
Wing nut
5. Paper element
6. Stud
7. Engine
Note: Service the air cleaner more frequently
(every few operating hours) if the operating
conditions are extremely dusty or sandy.
Cleaning the Foam Air Cleaner
Element
Important: Do not oil the foam or paper
element.
1. Wash the foam element in liquid soap and
warm water. When the element is clean, rinse
it thoroughly.
27
2. Dry the element by squeezing it in a clean cloth.
Do not wring it as this may cause damage.
3. Put oil on the element and squeeze it to
distribute the oil.
Important: Replace the foam element
if it is torn or worn.
Figure 30
1. Paper element
2.
Rubber seal
Servicing the Engine Oil
Figure 29
1. Foam element
2.
Service Interval/Specication
Oil
Change the engine oil as follows after every
100 operating hours.
Servicing the Paper Air Cleaner
Element
Note: Change the oil more frequently when the
operating conditions are extremely dusty or sandy.
1. Do not clean the paper filter. Replace it after
100 operating hours (Figure 28).
Oil Type: Detergent oil (API service SF, SG, SH,
or SJ)
2. Inspect the element for tears, an oily film, or
damage to the rubber seal.
Crankcase Capacity: 64 ounces (1.9 liter) with the
filter.
3. Replace the paper element if it is damaged.
Viscosity: Refer to the table below
Installing the Foam and Paper
Elements
Important: To prevent engine damage,
always operate the engine with the complete
foam and paper air cleaner assembly installed.
1. Carefully slide the foam element onto the
paper air cleaner element (Figure 28).
2. Place the air cleaner assembly onto the air
cleaner base and secure it with the wing nut
(Figure 28).
3. Place the air cleaner cover into position and
tighten the cover knob (Figure 28).
Figure 31
Checking the Engine Oil Level
1. Park the machine on a level surface.
2. Disengage the PTO, turn the ignition key to
off, and remove the key.
28
3. Wait for all moving parts to stop before leaving
the operating position and then chock or block
tires.
7. When oil has drained completely, close the
drain valve.
8. Remove the drain hose (Figure 33).
4. Clean around the oil dipstick (Figure 32) so
that dirt cannot fall into the filler hole and
damage the engine.
Note: Dispose of the used oil at a recycling
center.
Figure 32
1. Oil dipstick
2. Filler tube
3.
End
5. Unscrew the oil dipstick and wipe the end
clean (Figure 32).
Figure 33
1.
6. Slide the oil dipstick fully into the filler tube,
but do not thread onto tube (Figure 32).
Oil drain valve
2.
Oil drain hose
9. Slowly pour approximately 80% of the
specified oil into the filler tube (Figure 32).
7. Pull the dipstick out and look at the end. If the
oil level is low, slowly pour only enough oil into
the filler tube to raise the level to the Full mark.
10. Check the oil level; refer to Checking the
Engine Oil Level.
Important: Do not overfill the crankcase
with oil and run the engine; engine damage
can result.
11. Slowly add the additional oil to bring it to the
Full mark.
Changing the Oil
Changing the Oil Filter
1. Start the engine and let it run five minutes.
This warms the oil so it drains better.
Replace the oil filter every 200 operating hours or
every other oil change.
2. Park the machine so that the drain side is
slightly lower than the opposite side to assure
the oil drains completely.
Note: Change the oil filter more frequently when
the operating conditions are extremely dusty or
sandy.
3. Disengage the PTO and set the parking brake.
1. Drain the oil from the engine; refer to
Changing the Engine Oil.
4. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
2. Remove the old filter (Figure 34).
5. Slide the drain hose over the oil drain valve.
6. Place a pan below the drain hose. Rotate oil
drain valve to allow oil to drain (Figure 33).
29
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
3. Disconnect the wires from the spark plugs
(Figure 35).
Figure 34
1. Oil lter
2. Rubber gasket
3.
Adapter
3. Pour new oil in through the center hole of the
filter. Fill it to the bottom of the threads.
Figure 35
1. Spark-plug wire
4. Apply a thin coat of new oil to the rubber
gasket on the replacement filter (Figure 34).
2.
Spark plug
5. Install the replacement oil filter to the filter
adapter, turn the oil filter clockwise until
the rubber gasket contacts the filter adapter,
then tighten the filter an additional 3/4 turn
(Figure 34).
4. Clean around the spark plugs to prevent dirt
from falling into the engine and potentially
causing damage.
6. Fill the crankcase with the proper type of new
oil; refer to Servicing the Engine Oil.
Checking the Spark Plugs
7. Run the engine for about 3 minutes, stop the
engine, and check for oil leaks around the oil
filter.
8. Check the engine oil level and add oil if needed.
1. Look at the center of the spark plugs
(Figure 36). If you see light brown or gray on
the insulator, the engine is operating properly.
A black coating on the insulator usually means
that the air cleaner is dirty.
Servicing the Spark Plugs
2. If needed, clean the spark plug with a wire
brush to remove carbon deposits.
5. Remove the spark plugs and the metal washers.
Service Interval/Specication
Check the spark plugs after every 100 operating
hours.
Ensure that the air gap between the center and
side electrodes is correct before installing the spark
plug. Use a spark plug wrench for removing and
installing the spark plugs and a gapping tool/feeler
gauge to check and adjust the air gap. Install a new
spark plugs if necessary.
Figure 36
Type: Champion® RCJ8Y or equivalent Air Gap:
0.030 inch (0.75 mm)
1. Center electrode insulator
2. Side electrode
Removing the Spark Plugs
1. Disengage the PTO and set the parking brake.
30
3.
Air gap (not to scale)
Important: Always replace the spark
plugs when it has a black coating, worn
electrodes, an oily film, or cracks.
3. Check the gap between the center and side
electrodes (Figure 36). Bend the side electrode
(Figure 36) if the gap is not correct.
Installing the Spark Plugs
1. Install the spark plugs and the metal washer.
Ensure that the air gap is set correctly.
Figure 37
2. Tighten the spark plugs to 16 ft-lb (22 N⋅m).
1.
2.
3. Connect the wires to the spark plugs
(Figure 36).
Fuel shutoff valve
Hose clamp
3.
4.
Fuel line
Fuel lter
6. Squeeze the ends of the hose clamps together
and slide them away from the filter (Figure 37).
7. Remove the filter from the fuel lines.
8. Install a new filter and move the hose clamps
close to the filter (Figure 37).
9. Open the fuel shutoff valve.
Fuel System
Maintenance
Replacing the Fuel Filter
Replace the fuel filter after every 200 operating
hours or yearly, whichever occurs first.
Servicing the Fuel Tank
Never install a dirty filter if it is removed from the
fuel line.
1. Disengage the PTO, move the motion control
levers to the neutral locked position, and set
the parking brake.
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and
others and can damage property.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
• Drain gasoline from the fuel tank when
the engine is cold. Do this outdoors in
an open area. Wipe up any gasoline that
spills.
3. Allow the machine to cool down.
4. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
• Never smoke when draining gasoline,
and stay away from an open flame or
where a spark may ignite the gasoline
fumes.
5. Close the fuel shutoff valve (Figure 37).
1. Park the machine on a level surface to ensure
that the fuel tanks drain completely.
2. Disengage the power takeoff (PTO), set the
parking brake, stop the engine, and remove
the key.
3. Close the fuel shutoff valve (Figure 37).
4. Loosen the hose clamp at the fuel filter and
slide it up the fuel line away from the fuel filter
(Figure 37).
31
Removing the Battery
5. Disconnect the fuel line from the fuel filter
(Figure 37).
6. Open the fuel shutoff valve.
Battery terminals or metal tools could short
against metal machine components causing
sparks. Sparks can cause the battery gasses
to explode, resulting in personal injury.
Note: Allow gasoline to drain into a fuel
container can or drain pan (Figure 37).
Note: Now is the best time to install a new
fuel filter because the fuel tank is empty.
• When removing or installing the battery,
do not allow the battery terminals to
touch any metal parts of the machine.
7. Install the fuel line onto the fuel filter. Slide
the hose clamp close to the fuel filter to secure
the fuel line (Figure 37).
• Do not allow metal tools to short between
the battery terminals and metal parts of
the machine.
Electrical System
Maintenance
Incorrect battery cable routing could
damage the machine and cables causing
sparks. Sparks can cause the battery gasses
to explode, resulting in personal injury.
Servicing the Battery
Warning
CALIFORNIA
Proposition 65 Warning
• Always Disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
• Always Reconnect the positive (red)
battery cable before reconnecting the
negative (black) cable.
1. Disengage the PTO, move the motion control
levers to the neutral locked position, and set
the parking brake.
Battery electrolyte contains sulfuric acid
which is a deadly poison and causes severe
burns.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Do not drink electrolyte and avoid contact
with skin, eyes or clothing. Wear safety
glasses to shield your eyes and rubber gloves
to protect your hands.
3. Unlatch the seat and tilt the seat up.
4. First disconnect the negative battery cable
and ground wire from the negative (-) battery
terminal (Figure 38).
5. Slide the red terminal boot off the positive
(red) battery terminal. Then remove the
positive (red) battery cable (Figure 38).
32
Charging the Battery
Charging the battery produces gasses that
can explode.
Never smoke near the battery and keep
sparks and flames away from battery.
Important: Always keep the battery
fully charged (1.265 specific gravity). This
is especially important to prevent battery
damage when the temperature is below 32°F
(0°C).
1. Charge battery for 10 to 15 minutes at 25 to 30
amps or 30 minutes at 4-6 amps.
2. When the battery is fully charged, unplug
the charger from the electrical outlet, then
disconnect the charger leads from the battery
posts (Figure 39).
Figure 38
1.
2.
3.
4.
5.
6.
Battery
Terminal boot
Positive battery cable
Negative battery cable
Ground wire
Bolt (1/4 x 3/4 inch)
7.
8.
9.
10.
11.
Washer (1/4 inch)
Locknut (1/4 inch)
Battery clamp
J-bolts
Wingnut (1/4 inch)
6. Remove both wing nuts (1/4 inch) securing
the battery clamp (Figure 38).
7. Remove the battery.
Installing the Battery
1. Position battery in the tray with the terminal
posts toward the engine (Figure 38).
2. First, install the positive (red) battery cable to
positive (+) battery terminal.
3. Then install the negative battery cable and
ground wire to the negative (-) battery terminal.
Figure 39
4. Secure the cables with 2 bolts (1/4 x 3/4 inch),
2 washers (1/4 inch), and 2 locknuts (1/4 inch)
(Figure 38).
1.
2.
5. Slide the red terminal boot onto the positive
(red) battery post.
Positive Battery Post
Negative Battery Post
3.
4.
Red (+) Charger Lead
Black (-) Charger Lead
3. Install the battery in the machine and connect
the battery cables; refer to Installing the
Battery.
6. Secure battery with J-bolts, hold down clamp
and 2 washers (1/4 inch), and 2 wing nuts (1/4
inch) (Figure 38).
Note: Do not run the machine with the
battery disconnected, electrical damage may
occur.
Servicing the Fuses
The electrical system is protected by fuses. It
requires no maintenance, however, if a fuse blows
check component/circuit for malfunction or short.
33
Drive System
Maintenance
Fuse:
• Main, F1-30 amp, blade-type
• Charge circuit, F2-25 amp, blade-type
• Optional head light kit, 10 amp, blade-type
Adjusting the Tracking
1. Raise the seat to gain access to the fuse holder
(Figure 40).
Note: Determine the left and right sides of the
machine from the normal operating position.
2. To replace the fuses, pull out on the fuse to
remove it.
The machine has a knob for adjusting the tracking
located under the seat.
3. Install a new fuse (Figure 40).
Important: Adjust the handle neutral and
hydraulic pump neutral before adjusting
the tracking. Refer to Adjusting the Handle
Neutral in Controls System Maintenance,
page 39 and Adjusting the Hydraulic Pump
Neutral in Hydraulic System Maintenance,
page 40.
1. Push both control levers forward the same
distance.
2. Check if the machine pulls to one side. If it
does, stop the machine and set the parking
brake.
3. Unlatch the seat and tilt the seat forward to
access the tracking knob.
4. To make the machine go right, turn the knob
towards the rightside of the machine. Refer to
Figure 41.
5. To make the machine go left, turn the knob
towards the leftside of the machine. Refer to
Figure 41.
6. Repeat adjustment until the tracking is correct.
Figure 40
1. Main, 30 amp
4.
2. Charge circuit, 25 amp
5.
3. For optional head light kit,
10 amp
Ignition switch
Throttle lever
Figure 41
1. Pump rod
2. Turn this way to track left
34
3.
4.
Tracking knob
Turn this way to track right
Checking the Tire Pressure
Check the pressure at the valve stem after every
50 operating hours or monthly, whichever occurs
first (Figure 42).
Maintain the air pressure in the front and rear tires
at 13 psi (90 kPa).. Uneven tire pressure can cause
uneven cut. Check the tires when they are cold to
get the most accurate pressure reading.
Figure 43
1.
2.
Slotted Nut
Two threads or less
showing
3.
4.
Hole in threaded shaft
Washer (if needed)
5. Check the distance from bottom of slot in nut
to inside edge of hole. Two threads or less
should be showing (Figure 43).
6. If more than two threads are showing remove
nut and install washer between hub and nut.
7. Torque the slotted nut to 125 ft-lb. (170 N•m)
(Figure 43).
Figure 42
8. Tighten the nut until the next set of slots line
up with the hole in the shaft (Figure 43).
Checking the Wheel Hub
Slotted Nut
9. Replace the cotter pin.
Adjusting the Caster Pivot
Bearing
Check after every 500 operating hours.
The slotted nut needs to be torqued to 125 ft-lb
(170 N•m).
Check after every 500 operating hours or at
storage, which ever comes first.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
3. Remove the cotter pin.
3. Remove the dust cap from caster and tighten
lock nut (Figure 44).
4. Torque the slotted nut to 125 ft-lb (170 N•m)
(Figure 43).
4. Tighten the locknut until the spring washers
are flat and then back off a 1/4 turn to properly
set the pre-load on the bearings (Figure 44).
Important: Make sure spring washers
are installed correctly as shown in
Figure 44.
5. Install the dust cap (Figure 44).
35
3. Remove the air intake screen, recoil starter and
fan housing (Figure 45).
4. Clean the debris and grass from the engine
parts.
5. Install air intake screen, recoil starter and fan
housing (Figure 45).
Figure 44
1. Spring Washers
2. Lock Nut
3.
Dust Cap
Cooling System
Maintenance
Figure 45
1. Air intake screen
2. Fan housing
3. Recoil starter
Cleaning the Air Intake
Screen
4.
5.
Bolt
Nut
Brake Maintenance
Before each use remove any build-up of grass, dirt
or other debris from the cylinder and cylinder head
cooling fins, air intake screen on flywheel end, and
carburetor-governor levers and linkage. This will
help insure adequate cooling and correct engine
speed and will reduce the possibility of overheating
and mechanical damage to the engine.
Adjusting the Parking Brake
Check the parking brake for proper adjustment.
1. Check tire pressure of all 4 tires. Refer to
Checking the Tire Pressure.
2. Disengage the brake lever (lever down).
Cleaning the Cooling System
3. Measure the distance vertically between the
front of the brake bar and the crown of the
tire; the measurement should be 7/8 inch to 1
inch (22 to 25 mm) (Figure 46).
Clean the air intake screen from grass and debris
before each use.
Check and clean cooling fins and engine shrouds
every 100 hours or yearly, which ever comes first.
4. If the measurement is not correct, proceed to
the following steps.
1. Disengage the PTO and set the parking brake.
5. Remove the hairpin and cotter pin from the
brake linkage (Figure 47).
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
36
Figure 46
1. Brake linkage
2. Yoke
3.
Hair pin and cotter pin
6. Adjust the yoke clockwise to shorten the
distance; counterclockwise to lengthen distance
(Figure 46).
7. Measure the distance vertically between the
front of the brake bar and the crown of the
tire; the measurement should be 7/8 inch to 1
inch. (Figure 47).
Figure 47
8. Repeat steps through if additional adjustment
is needed.
9. Engage the parking brake, with the lever up
and ensure the brake bar engages the tire
(Figure 47).
1.
2.
Brake lever
Tire
3.
Brake bar
4.
5.
7/8 to 1 inch (22 to 25 mm)
Vertical line from the front
of brake bar to the tire
crown
Belt Maintenance
10. Measure the length of the spring; the
measurement should be 2-3/4 inch (74 mm)
between the washers (Figure 47).
Inspecting the Belts
Inspect all belts every 100 hours.
Check belts for cracks, frayed edges, burn marks
or any other damage. Replace damaged belts.
Replacing the Mower Belt
The signs of a worn mower belt are squealing
while the belt is rotating, blades slipping while you
are cutting grass, frayed belt edges, burn marks,
and cracks. Replace the mower belt if you detect
any of these signs.
1. Disengage the PTO, move the motion control
levers to the neutral locked position, and set
the parking brake.
37
Note: Do not increase the belt tension
beyond the point where the fixed idler arm
stops.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
3. Remove the belt covers over the outside
spindles.
4. Loosen the fixed idler arm and adjust it to
relieve the belt tension on the fixed idler pulley
(Figure 48).
9. While holding the belt in tension, tighten the 2
bolts that secure the fixed idler arm.
10. Remove the ratchet or breaker bar from the
square hole in the fixed idler arm.
11. Install the belt covers over the outside spindles.
Replacing the Pump Drive
Belt
Check the pump drive belt for wear after every
50 operating hours.
1. Remove the mower belt first; refer to Replacing
the Mower Belt.
Figure 48
1. Fixed idler arm
2. Square hole
3. Fixed Idler pulley
4.
5.
6.
2. Remove the bolt from the clutch stop and
unplug the clutch electrical wire (Figure 50).
Mower belt
Belt guide
Spring-loaded idler pulley
3. Pull the spring loaded idler to the side.
4. Remove the traction belt from the engine and
the hydraulic pump pulleys (Figure 50).
5. Remove the old belt.
6. Install the new belt through the belt guide and
on the pulleys (Figure 48).
7. Insert a ratchet with a short extension or a
breaker bar into the square hole in the fixed
idler arm (Figure 49).
5. Install the new belt around the engine and the
hydraulic pump pulleys (Figure 50).
6. Pull the spring-loaded idler to the side and
align the belt.
7. Release the pressure on the spring loaded idler
(Figure 50).
8. Install the mower belt.
Figure 49
1. Ratchet with short
extension or breaker bar
2.
Square hole
8. To increase the belt tension, rotate the ratchet
or breaker bar counterclockwise to move
the fixed idler arm until you feel increased
resistance and the spring-loaded idler pulley
stops moving.
Figure 50
1. Belt
2. Clutch electrical wire
3. Clutch stop
38
4.
5.
6.
Bolt
Clutch
Idler
Adjusting the Push Arms
3. Tilt the seat forward.
4. Begin with either the left or right motion
control lever.
If needed, adjust the push arms to increase or
decrease the mower belt tension.
1. Loosen the jam nut and rotate the ball
joint counterclockwise, one turn at a time
(Figure 51).
5. Move lever to the neutral position but not
locked (Figure 52).
Figure 51
3.
1. Push arm
4.
2. 13-1/2 inch (343 mm)
nominal at 15 degree twist
Jam nut
Ball joint
Figure 52
1.
2.
2. Adjust each side the same amount. Each
push arm should have a nominal length of
13-1/2 inch (34 cm) at a 15 degree twist
(Figure 51).
Neutral locked position
Control lever
3.
Neutral position
6. Pull the lever back until the clevis pin (on the
arm below the pivot shaft) contacts the end
of the slot (just beginning to put pressure on
the spring) (Figure 53).
Note: Increase the tension by lengthening the
push arms; decrease the tension by shortening
the push arms.
Controls System
Maintenance
Adjusting the Control
Handle Neutral Position
If the motion control levers do not align or move
easily into the console notch, adjustment them.
Adjust each lever, spring, and rod separately.
Note: The motion control levers must be
installed correctly. See Installing the Motion
Control Levers in the Setup Instructions.
1. Disengage the PTO, move the motion control
levers to the neutral locked position, and set
the parking brake.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
39
Hydraulic System
Maintenance
Servicing the Hydraulic
System
Checking the Hydraulic Fluid
Fluid Type: Mobil 1 15W-50 synthetic motor oil or
equivalent synthetic oil.
Important: Use oil specified or equivalent.
Other fluids could cause system damage.
Hydraulic System Oil Capacity: 67 ounces (2.0 l)
Check the hydraulic fluid level:
• Before the engine is first started.
• After the first 8 operating hours.
• After every 25 operating hours.
Figure 53
1.
2.
3.
4.
5.
Clevis pin in slot
Nut
Nut-Left hand thread
Adjustment bolt
Pump rod
6.
7.
8.
9.
Note: There are two ways of checking the
hydraulic oil. One is when the oil is warm and one
is when the oil is cold. The baffle inside the tank
has two levels depending if the oil is warm or cold.
Double nuts
Jam nut
Yoke
Ball joint
1. Position the machine on a level surface and set
the parking brake.
7. Check where the control lever is relative to the
notch in the console (Figure 52). It should be
centered, allowing the lever to pivot outward
to the neutral lock position.
2. Clean the area around filler neck of hydraulic
tank (Figure 54).
3. Remove the cap from the filler neck. Look
inside to check if there is fluid in the reservoir
(Figure 54).
8. If adjustment is needed, loosen the nut and
jam nut against the yoke (Figure 53).
9. Apply slight rearward pressure on the motion
control lever, and turn the head of the
adjustment bolt in the appropriate direction
until the control lever is centered in the neutral
lock position.
4. If there is no fluid, add fluid to the reservoir
until it reaches the cold level of the baffle.
5. Run the machine at low idle for 15 minutes to
allow any air to purge out of the system and
warm the fluid. Refer to Starting and Stopping
the Engine in Operation, page 13.
Note: Keeping rearward pressure on the
lever will keep the pin at the end of the slot and
allow the adjustment bolt to move the lever to
the appropriate position.
6. Recheck the fluid level while the fluid is warm.
The fluid should be between cold and hot.
7. If required, add fluid to the hydraulic tank.
10. Tighten the nut and jam nut (Figure 53).
Note: The fluid level should be to the top
of the hot level of the baffle, when the fluid
is hot (Figure 54).
11. Repeat on the opposite side of machine.
8. Install the cap on filler neck.
40
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Important: Do not substitute automotive
oil filter or severe hydraulic system damage
may result.
Figure 54
1. Cap
2. Bafe
3.
4.
3. Place a drain pan under filter, remove the old
filter and wipe the filter adapter gasket surface
clean (Figure 55).
Cold uid level-full
Hot uid level-full
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury.
• If hydraulic fluid is injected into the
skin it must be surgically removed
within a few hours by a doctor familiar
with this type of injury. Gangrene
may result if this is not done.
Figure 55
1.
• Keep body and hands away from pin
hole leaks or nozzles that eject high
pressure hydraulic fluid.
Hydraulic lter
4. Apply a thin coat to the rubber gasket on the
replacement filter (Figure 56).
• Use cardboard or paper to find
hydraulic leaks.
5. Install the replacement hydraulic filter onto the
filter adapter. Do not tighten.
• Safely relieve all pressure in the
hydraulic system before performing
any work on the hydraulic system.
6. Fill the hydraulic tank with hydraulic fluid until
the fluid overflows the filter and then turn
the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the
filter an additional 1/2 turn (Figure 56).
• Make sure all hydraulic fluid hoses
and lines are in good condition and
all hydraulic connections and fittings
are tight before applying pressure to
hydraulic system.
7. Clean up any spilled fluid.
8. Add fluid to the cold level of the baffle in the
hydraulic tank.
Replacing the Hydraulic Filter and Oil
9. Start the engine and let it run for about two
minutes to purge air from the system. Stop
the engine and check for leaks. If one or
both wheels will not drive, refer to Bleeding
Hydraulic System.
Change the hydraulic filter and oil:
• After the first 8 operating hours.
• Change yearly after the first 200 operating
hours.
10. Recheck the fluid level while the fluid is warm.
The fluid should be between cold and hot.
Use summer filter above 32°F (0°C)
11. If required, add fluid to the hydraulic tank. Do
not overfill.
Use winter filter below 32°F (0°C)
41
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin
it must be surgically removed within a
few hours by a doctor familiar with this
type of injury. Gangrene may result if
this is not done.
• Keep body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
Figure 56
1. Hydraulic lter
2. Gasket
3.
Adapter
• Use cardboard or paper to find hydraulic
leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on
the hydraulic system.
Bleeding the Hydraulic System
The traction system is self bleeding, however, it
may be necessary to bleed the system if fluid is
changed or after work is performed on the system.
• Make sure all hydraulic fluid hoses
and lines are in good condition and
all hydraulic connections and fittings
are tight before applying pressure to
hydraulic system.
1. Raise rear of the machine so wheels are off the
ground and support with jack stands.
2. Start the engine and run at low idle speed.
Engage the lever and traction on one side and
spin the wheel by hand.
Setting the Hydraulic Pump
Neutral Position
3. When the wheel begins to spin on its own,
keep it engaged until wheel drives smoothly.
(minimum 2 minutes)
Note: Adjust the handle neutral first. That needs
to be correct before the following adjustment can
be made.
4. Check the hydraulic fluid level and add as
required to maintain proper level.
This adjustment must be made with drive wheels
turning.
5. Repeat this procedure on the opposite wheel.
Checking the Hydraulic Hoses
Mechanical or hydraulic jacks may fail to
support machine and cause a serious injury.
After every 100 operating hours, check the
hydraulic hoses for leaks, loose fittings, kinked
lines, loose mounting supports, wear, weather and
chemical deterioration. Make necessary repairs
before operating.
• Use jack stand when supporting
machine.
• Do not use hydraulic jacks.
Note: Keep areas around the hydraulic system
clean from grass and debris build up.
42
Engine must be running so motion control
adjustment can be performed. Contact with
moving parts or hot surfaces may cause
personal injury.
Keep hands, feet, face, clothing and other
body parts away from rotating parts, muffler
and other hot surfaces.
1. Raise the frame and block up the machine so
drive wheels can rotate freely.
2. Disconnect the electrical connector from
the seat safety switch. Temporarily install
a jumper wire across terminals in the wiring
harness connector.
Figure 57
3. Unlatch the seat and slide seat forward.
1.
2.
4. Disconnect the seat rod and tilt the seat fully
forward.
Tracking knob
Pump rod
3.
Adjustment bolt
Setting the Left-hand Hydraulic Pump
Neutral Position
Setting the Right-hand Hydraulic
Pump Neutral Position
1. Start the engine, open the throttle 1/2 way and
release parking brake. Refer to Starting and
Stopping the Engine in Operation, page 13.
1. Loosen the locknuts at the ball joints on the
pump control rod (Figure 58).
2. Start the engine, open throttle 1/2 way and
release parking brake. Refer to Starting and
Stopping the Engine in Operation, page 13.
Note: The motion control lever must be in
neutral while making any adjustments.
Note: The motion control lever must be in
neutral while making any adjustments.
2. Adjust the pump rod length by rotating the
knob, in the appropriate direction, until the
wheel is still or slightly creeping in reverse
(Figure 57).
Note: The front nut on the pump rod has
left-hand threads.
3. Move the motion control lever forward and
reverse, then back to neutral. The wheel must
stop turning or slightly creep in reverse.
3. Adjust the pump rod length by rotating double
nuts on the rod, in the appropriate direction,
until the wheel is still or slightly creeps in
reverse (Figure 58).
4. Open the throttle to fast. Make sure wheel
remains stopped or slightly creeps in reverse,
adjust if necessary.
4. Move the motion control lever forward and
reverse, then back to neutral. The wheel must
stop turning or slightly creep in reverse.
5. Open the throttle to fast. Make sure the wheel
remains stopped or slightly creeps in reverse,
adjust if necessary.
6. Tighten the locknuts at the ball joints
(Figure 58).
43
Mower Deck
Maintenance
Leveling the Mower at Three
Positions
Important: There are only three measuring
positions needed to level the mower.
Preparing the Machine
1. Position mower on a flat surface.
2. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
3. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
4. Check tire pressure of all four tires. If needed,
adjust to 13 psi (90 kPa)
5. Lower the mower to the 3 inch (76 mm)
height-of-cut position.
6. Inspect the four chains. The chains need to
have tension.
Figure 58
1. Double nuts
2. Pump rod
3.
4.
Locknut
Ball joint
Note: Adjust the rear chains to the top of the
slot, where they are attached to the mower.
• If one rear chain is loose, lower (loosen) the
front support arm on the same side. Refer to
Adjusting the Front-to-Rear Mower Pitch.
• If one front chain is loose, raise (tighten) the
front support arm for that chain. Refer to
Adjusting the Front-to-Rear Mower Pitch.
Electrical system will not perform proper
safety shut off with jumper wire installed.
• Remove jumper wire from wire
harness connector and plug
connector into seat switch when
adjustment is completed.
Leveling the Mower Side-to-Side
1. Position the right blade front-to-rear
(Figure 59).
2. Measure the right blade at the B location, from
a level surface to the cutting edge of the blade
tip (Figure 59).
3. Record this measurement. This measurement
needs to be 3-1/8 to 3-1/4 inches.
4. Position the left blade front-to-rear (Figure 59).
5. Measure the left blade at the C location
(Figure 59), from a level surface to the cutting
edge of the blade tip .
6. Record this measurement. This measurement
needs to be 3-1/8 to 3-1/4 inches (79 to
83mm).
• Never operate this unit with jumper
installed and seat switch bypassed.
7. After both pump neutrals are set, shut off the
machine.
8. Remove the jumper wire from the wire harness
connector and plug the connector into the seat
switch.
9. Install the seat rod and lower the seat into
position.
10. Remove the jack stands.
44
Figure 59
1. Measure here from blade
to hard surface
2.
Figure 60
Measure at B and C
1.
2.
3.
4.
7. If the measurements at positions B or C are
not correct, loosen the bolt attaching the rear
chain to the rear support arm (Figure 60).
Rear chain
Rear support arm
Bolt
Jam Nut
5. Adjustment bolt
6. Front swivel
7. Front support arm
Adjusting the Front-to-Rear Mower
Pitch
8. Loosen the jam nut under the rear support
arm and adjust the adjustment bolt to get
a measurement of 3-1/8 to 3-1/4 inches
(Figure 60).
1. Position the right blade front-to-rear
(Figure 61).
Note: It is recommended that both sides of
the mower are adjusted the same distance.
2. Measure the right blade at the A location, from
a level surface to the cutting edge of the blade
tip (Figure 61).
9. Tighten the jam nut under the rear support
arm and tighten the bolt securing the chain to
the rear support arm.
10. Adjust the opposite side if needed.
Figure 61
1.
Measure here from blade
to hard surface
2.
Measure at A and B
3. Record this measurement.
45
4. Measure the right blade at the B location, from
a level surface to the cutting edge of the blade
tip (Figure 61).
5. Record this measurement.
6. The mower blade should be a 1/4 to 3/8 inch
(6 to 10 mm) lower at position A than at
position B (Figure 61). If it is not correct,
proceed to the following steps.
Note: Both of the front swivels need to be
adjusted the same amount to maintain equal
chain tension.
7. Loosen the front swivel jam nuts, at the front
of the right and left swivels, approximately a
1/2 inch (13 mm) (Figure 60).
Figure 62
1.
2.
3.
4.
8. Adjust the lift nuts on both the left and the
right side of the machine to achieve 1/4 to
3/8 inch (6 to 10 mm) lower in front at A than
in the rear at B (Figure 60).
10-1/2 inch (26.7 cm)
Front nut
Spring jam nut
Front swivel
5.
6.
7.
8.
Swivel jam nut
Lift nut
Front support arm
Large washer
Servicing the Cutting Blades
9. Tighten both swivel jam nuts against the front
swivel to lock the height.
Maintain sharp blades throughout the cutting
season because sharp blades cut cleanly without
tearing or shredding the grass blades. Tearing and
shredding turns grass brown at the edges, which
slows growth and increases the chance of disease.
10. Check to make sure there is equal tension on
the chains and adjust again if needed.
Adjusting the Compression Spring
Check the cutter blades daily for sharpness, and
for any wear or damage. File down any nicks
and sharpen the blades as necessary. If a blade is
damaged or worn, replace it immediately with a
genuine Toro replacement blade. For convenient
sharpening and replacement, you may want to
keep extra blades on hand.
1. Raise the mower lift lever to the transport
position.
2. Check the distance between the two large
washers, it needs to be 11-1/8 inches (28.2 cm)
for 52 inch mower decks and 10-1/2 inches
(26.7 cm) for 60 inch mower decks (Figure 62).
3. Adjust this distance, by loosening the spring
jam nut and turning the nut in front of each
spring (Figure 62).
A worn or damaged blade can break, and a
piece of the blade could be thrown into the
operator’s or bystander’s area, resulting in
serious personal injury or death.
Note: Turning the nut clockwise will shorten
the spring; counter-clockwise will lengthen the
spring.
• Inspect the blade periodically for wear
or damage.
4. Lock the nut into position by tightening the
spring jam nut (Figure 62).
• Replace a worn or damaged blade.
Inspect and check the blades every 8 hours.
46
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the
blade control (PTO), and set the parking brake.
Turn the ignition key to Off. Remove the key.
Inspecting the Blades
1. Inspect the cutting edges (Figure 63). If the
edges are not sharp or have nicks, remove and
sharpen the blades. Refer to Sharpening the
Blades.
2. Inspect the blades, especially the curved area
(Figure 63). If you notice any damage, wear,
or a slot forming in this area (Figure 63),
immediately install a new blade.
Figure 64
1.
Measure here from blade
to hard surface
2.
Position A
4. Rotate the opposite ends of the blades forward.
5. Measure from a level surface to the cutting
edge of the blades at the same position as
in step 3 above. The difference between the
dimensions obtained in steps 3 and 4 must not
exceed 1/8 inch (3 mm). If this dimension
exceeds 1/8 inch (3 mm), the blade is bent
and must be replaced; refer to Removing the
Blades and Installing the Blades.
Figure 63
1. Cutting Edge
2. Curved Area
3.
Wear/slot Forming
A blade that is bent or damaged could
break apart and could seriously injure or
kill you or bystanders.
Checking for Bent Blades
• Always replace bent or damaged
blade with a new blade.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
• Never file or create sharp notches in
the edges or surfaces of blade.
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Removing the Blades
3. Rotate the blades until the ends face forward
and backward (Figure 64). Measure from a
level surface to the cutting edge, position A, of
the blades (Figure 64). Note this dimension.
Blades must be replaced if a solid object is hit,
if the blade is out of balance or is bent. To
ensure optimum performance and continued
safety conformance of the machine, use genuine
Toro replacement blades. Replacement blades
made by other manufacturers may result in
non-conformance with safety standards.
47
Contact with a sharp blade can cause serious
injury.
Figure 66
Wear gloves or wrap sharp edges of the
blade with a rag.
1. Blade
1. Hold the blade end using a rag or
thickly-padded glove.
2.
Balancer
Installing the Blades
2. Remove the blade bolt, spring disk and blade
from the spindle shaft (Figure 67).
1. Install the blade onto the spindle shaft
(Figure 67).
Important: The curved part of the blade
must be pointing upward toward the inside
of the mower to ensure proper cutting.
Sharpening the Blades
2. Install the spring disk and blade bolt. The
spring disk cone must be installed toward the
bolt head (Figure 67). Torque the blade bolt to
85-110 ft-lb (115-150 N•m).
When sharpening blade, pieces of blade
could be thrown and cause serious injury.
Wear proper eye protection when sharpening
blade.
1. Use a file to sharpen the cutting edge at both
ends of the blade (Figure 65). Maintain the
original angle. The blade retains its balance if
the same amount of material is removed from
both cutting edges.
Figure 67
1. Sail Area of Blade
2. Blade
3. Spring Disk
Figure 65
1. Sharpen at original angle
2. Check the balance of the blade by putting it on
a blade balancer (Figure 66). If the blade stays
in a horizontal position, the blade is balanced
and can be used. If the blade is not balanced,
file some metal off the end of the sail area only
(Figure 67). Repeat this procedure until the
blade is balanced.
48
4.
5.
Blade Bolt
Cone Towards Bolt Head
Replacing the Grass
Deector
An uncovered discharge opening could
allow the lawn mower to throw objects in
the operator’s or bystander’s direction and
result in serious injury. Also, contact with
the blade could occur.
• Never operate the lawn mower unless
you install a cover plate, a mulch plate, or
a grass chute and catcher.
Figure 68
• Make sure the grass deflector is in the
down position.
1. Remove the locknut, bolt, spring and spacer
holding the deflector to the pivot brackets
(Figure 68). Remove the damaged or worn
grass deflector.
1.
2.
3.
Bolt
Spacer
Locknut
4.
Spring
5. Spring installed
6. Grass Deector
7. L end of spring, place
behind deck edge before
installing bolt
8. J hook end of spring
Cleaning
2. Place the spacer and spring onto grass
deflector. Place the L end of spring behind
deck edge.
Cleaning Under the Mower
Note: Make sure the L end of the spring is
installed behind the deck edge before installing
the bolt as shown in Figure 68.
Remove the grass buildup under the mower daily.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set
the parking brake.
3. Install the bolt and nut. Place the J hook
end of the spring around the grass deflector
(Figure 68).
2. Stop the engine, remove the key, and wait for
all moving parts to stop before leaving the
operating position.
Important: The grass deflector must be
able to lower down into position. Lift the
deflector up to test that it lowers into the
full down position.
3. Raise the mower to the transport position.
4. Lift the front of the machine and support the
machine using jack stands.
Waste Disposal
Engine oil, batteries, hydraulic oil, and engine
coolant are pollutants to the environment.
Dispose of these according to your state and local
regulations.
49
Storage
A. Add a petroleum based
stabilizer/conditioner to fuel in the
tank. Follow mixing instructions from
the stabilizer manufacturer. Do not use
an alcohol based stabilizer (ethanol or
methanol).
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to Off.
Remove the key.
2. Remove grass clippings, dirt, and grime from
the external parts of the entire machine,
especially the engine and hydraulic system.
Clean dirt and chaff from the outside of the
engine cylinder head fins and blower housing.
Note: A fuel stabilizer/conditioner is
most effective when mixed with fresh fuel
and used at all times.
B. Run the engine to distribute conditioned
fuel through the fuel system (5 minutes).
Important: You can wash the machine
with mild detergent and water. Do
not pressure wash the machine. Avoid
excessive use of water, especially near the
control panel, engine, hydraulic pumps,
and motors.
C. Stop the engine, allow it to cool, and drain
the fuel tank; refer to Servicing the Fuel
Tank in Fuel System Maintenance, page 31.
D. Restart the engine and run it until it stops.
E. Dispose of fuel properly. Recycle as per
local codes.
3. Check the brake; refer to Servicing the Brake
in Brake Maintenance, page 36.
Important: Do not store
stabilizer/conditioned fuel over
90 days.
4. Service the air cleaner; refer to Servicing the
Air Cleaner in Engine Maintenance, page 27.
5. Grease the machine; refer to Greasing and
Lubrication in Lubrication, page 26.
13. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
6. Change the crankcase oil; refer to Servicing the
Engine Oil in Engine Maintenance, page 27.
14. Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service
Dealer.
7. Check the tire pressure; refer to Checking the
Tire Pressure in Drive System Maintenance,
page 34.
15. Store the machine in a clean, dry garage or
storage area. Remove the key from the ignition
switch and keep it out of reach of children or
other unauthorized users. Cover the machine
to protect it and keep it clean.
8. Change the hydraulic filter; refer to
Servicing the Hydraulic System in
Hydraulic System Maintenance, page 40.
9. Charge the battery; refer to Servicing the
Battery in Electrical System Maintenance,
page 32.
10. Scrape any heavy buildup of grass and dirt
from the underside of the mower, then wash
the mower with a garden hose.
Note: Run the machine with the PTO
engaged and the engine at high idle for 2 to
5 minutes after washing.
11. Check the condition of the blades;
refer to Servicing the Cutting Blades in
Mower Deck Maintenance, page 44.
12. Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows:
50
Troubleshooting
Problem
Starter does not crank
Possible Cause
1. Blade control (PTO) is
engaged.
2. Parking brake is not on.
3. Operator is not seated.
4. Battery is dead.
5. Electrical connections
are corroded or loose.
6. Fuse is blown.
7. Relay or switch is
defective.
Engine will not start, starts
hard, or fails to keep
running.
1. Fuel tank is empty.
2. Air cleaner is dirty.
3. Dirt in the fuel lter.
4. Dirt, water, or stale fuel
is in the fuel system.
Engine loses power.
1. Engine load is excessive.
2. Air cleaner is dirty.
3. Oil level in the crankcase
is low.
4. Cooling ns and air
passages above the
engine are plugged.
5. Vent hole in the fuel cap
is plugged.
6. Dirt in the fuel lter.
7. Dirt, water, or stale fuel
is in the fuel system.
Engine overheats.
1. Engine load is excessive.
2. Oil level in the crankcase
is low.
3. Cooling ns and air
passages above the
engine are plugged.
51
Corrective Action
1. Move the blade contro
(PTO) to disengaged.
2. Set the parking brake.
3. Sit on the seat.
4. Charge the battery.
5. Check the electrical
connections for good
contact.
6. Replace the fuse.
7. Contact an Authorized
Service Dealer.
1. Fill the fuel tank with
fuel.
2. Clean or replace the air
cleaner element.
3. Replace the fuel lter.
4. Contact an Authorized
Service Dealer.
1. Reduce the ground
speed.
2. Clean the air cleaner
element.
3. Add oil to the crankcase.
4. Remove the obstruction
from the cooling ns and
air passages.
5. Clean or replace the fuel
cap.
6. Replace the fuel lter.
7. Contact an Authorized
Service Dealer.
1. Reduce the ground
speed.
2. Add oil to the crankcase.
3. Remove the obstruction
from the cooling ns and
air passages.
Problem
Machine does not drive.
Abnormal vibration.
Possible Cause
1. By pass valve is not
closed tight.
2. Drive or pump belt is
worn, loose or broken.
3. Drive or pump belt is off
a pulley.
4. Broken or missing idler
spring.
5. Hydraulic uid level is
low or too hot.
1. Tighten the by pass
valve.
2. Change the belt.
1. Cutting blade(s) is/are
bent or unbalanced.
2. Blade mounting bolt is
loose.
3. Engine mounting bolts
are loose.
4. Loose engine pulley,
idler pulley, or blade
pulley.
5. Engine pulley is
damaged.
6. Blade spindle is bent.
1. Install new cutting
blade(s).
2. Tighten the blade
mounting bolt.
3. Tighten the engine
mounting bolts.
4. Tighten the appropriate
pulley.
7. Motor mount is loose or
worn.
Uneven cutting height.
Corrective Action
1. Blade(s) not sharp.
2. Cutting blade(s) is/are
bent.
3. Mower is not level.
4. Underside of mower is
dirty.
5. Tire pressure is not
correct.
6. Blade spindle bent.
52
3. Change the belt.
4. Replace the spring.
5. Add hydraulic uid to
reservoir or let it cool
down.
5. Contact an Authorized
Service Dealer.
6. Contact an Authorized
Service Dealer.
7. Contact an Authorized
Service Dealer.
1. Sharpen the blade(s).
2. Install new cutting
blade(s).
3. Level the mower
from side-to-side and
front-to-rear.
4. Clean the underside of
the mower.
5. Adjust the tire pressure.
6. Contact an Authorized
Service Dealer.
Problem
Blades do not rotate.
Possible Cause
1. Drive belt is worn, loose
or broken.
2. Drive belt is off pulley.
3. Deck belt is worn, loose
or broken.
4. Deck belt is off pulley.
5. Broken or missing idler
spring.
53
Corrective Action
1. Check the belt tension.
2. Install the drive belt
and check adjusting
shafts and belt guides for
correct position.
3. Install a new deck belt.
4. Install the deck pulley
and check the idler
pulley, idler arm and
spring for correct
position and function.
5. Replace the spring.
Schematics
Wire Diagram (Rev. A)
54
Evaporative Emission Control Warranty Statement
California Evaporative Emission Control Warranty Statement
Your Warranty Rights and Obligations
Introduction
The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty
on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and
equipped to meet the State’s stringent anti-smog standards. The Toro® Company must warrant the evaporative emission control
system on your equipment for two years provided there has been no abuse, neglect or improper maintenance of your equipment.
Your evaporative emission control system may include parts such as: fuel lines, fuel line ttings, and clamps.
Manufacturer’s Warranty Coverage:
This evaporative emission control system is warranted for two years. If any evaporative emission-related part on your equipment is
defective, the part will be repaired or replaced by The Toro® Company.
Owner’s Warranty Responsibilities:
• As the equipment owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual.
•
•
The Toro® Company recommends that you retain all receipts covering maintenance on your equipment, but The Toro® Company
cannot deny warranty solely for the lack of receipts.
As the equipment owner, you should however be aware that The Toro® Company may deny you warranty coverage if your emission
warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modications.
You are responsible for presenting your equipment to an Authorized Service Dealer as soon as the problem exists. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty
coverage, you should contact The Toro® Company at 1-952–948–4027 or call us toll free at the number listed in your Toro
Warranty statement.
Defects Warranty Requirements:
1.
2.
3.
The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.
General Evaporative Emissions Warranty Coverage. The emission warranty parts must be warranted to the ultimate purchaser and
any subsequent owner that the evaporative emission control system when installed was:
A. Designed, built, and equipped so as to conform with all applicable regulations; and
B. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.
The warranty on evaporative emissions-related parts will be interpreted as follows:
A. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions must be
warranted for the warranty period of two years. If any such part fails during the period of warranty coverage, it must be
repaired or replaced by The Toro® Company. Any such part repaired or replaced under the warranty must be warranted for a
time not less than the remaining warranty period.
B. Any warranted part that is scheduled only for regular inspection in the written instructions must be warranted for the warranty
period of two years. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce
the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for a time not less
than the remaining warranty period.
C. Any warranted part that is scheduled for replacement as required maintenance in the written instructions must be warranted
for the period of time prior to the rst scheduled replacement point for that part. If the part fails prior to the rst scheduled
replacement, the part must be repaired or replaced by The Toro® Company. Any such part repaired or replaced under
warranty must be warranted for a time not less than the remainder of the period prior to the rst scheduled replacement point
for the part.
D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to
the owner at an Authorized Service Dealer.
E. Notwithstanding the provisions of subsection (D) above, warranty services or repairs must be provided at an Authorized
Service Dealer.
F. The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective,
provided that such diagnostic work is performed at an Authorized Service Dealer.
G. Throughout the evaporative emission control system’s two year warranty period, The Toro® Company must maintain a supply
of warranted parts sufcient to meet the expected demand for such parts.
H. Manufacturer approved replacement parts must be used in the performance of any warranty maintenance or repairs and must
be provided without charge to the owner. Such use will not reduce the warranty obligations of The Toro® Company.
I. The use of any add-on or modied parts will be grounds for disallowing a warranty claim made in accordance with this
article. The Toro® Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an
add-on or modied part.
J. The Toro® Company shall provide any documents that describe the warranty procedures or policies within ve working
days of request by the Air Resources Board.
Emission Warranty Parts List:
The following lists includes the parts covered under this warranty:
• Fuel Lines
• Fuel Line Fittings
• Clamps
374-0092 Rev A
LCE
The Toro Total Coverage Guarantee
A Limited Warranty
Conditions and Products Covered
Items and Conditions Not Covered
The Toro® Company and its afliate, Toro Warranty Company,
pursuant to an agreement between them, jointly promise
to repair the listed Toro Products if defective in materials or
workmanship.
This warranty applies to:
• ProLine Mid-Size Walk Power Mowers and Accessories
• Z Master Mid-Mount ZRTs and Accessories
• Z Master Outfront ZRTs and Accessories
• Groundsmaster 120 OFRs and Accessories
The following time periods apply from the date of purchase:
Components
Engines
Hydraulic Systems
Traction Unit Frame
Carrier Frame
Deck Shells
Deck Spindles
Warranty Period
2 years
2 years
2 years
2 years
2 years
3 years Parts
2 years Labor
2 years
1 year
Z500 Series Clutches
Remaining Components
This warranty includes the cost of parts and labor, but you must
pay transportation costs.
Some engines used on Toro LCE Products are warranted by the engine manufacturer.
Instructions for Obtaining Warranty Service
If you think that your Toro Product contains a defect in materials
or workmanship, follow this procedure:
1. Contact any Toro Authorized or Master Service Dealer
to arrange service at their dealership. To locate a dealer
convenient to you, access our website at www.Toro.com.
You may also call our Toro Customer Care Department toll
free at 888–577–7466 (U.S. customers) or 877–484–9255
(Canada customers).
2. Bring the product and your proof of purchase (sales receipt)
to the Service Dealer.
If for any reason you are dissatised with the Service Dealer’s
analysis or with the assistance provided, contact us at:
Owner Responsibilities
You must maintain your Toro Product by following the
maintenance procedures described in the operator’s manual.
Such routine maintenance, whether performed by a dealer or by
you, is at your expense.
There is no other express warranty except for special emission
system coverage on some products. This express warranty does
not cover the following:
• Cost of regular maintenance service or parts, such as lters,
fuel, lubricants, tune-up parts, blade sharpening, brake and
clutch adjustments.
• Any product or part which has been altered or misused
or required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system
prior to any period of non-use over three months.
• Pickup and delivery charges.
All repairs covered by this warranty must be performed by an
Authorized Toro Service Dealer using Toro approved replacement
parts.
General Conditions
Repair by an Authorized Toro Service Dealer is your sole remedy
under this warranty.
Neither The Toro® Company nor Toro Warranty Company is liable
for indirect, incidental or consequential damages in connection
with the use of the Toro Products covered by this warranty,
including any cost or expense of providing substitute equipment
or service during reasonable periods of malfunction or non-use
pending completion of repairs under this warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts,
so the above exclusions and limitations may not apply to you.
All implied warranties of merchantability (that the product is t
for ordinary use) and tness for use (that the product is t for
a particular purpose) are limited to the duration of the express
warranty.
This warranty gives you specic legal rights, and you may also
have other rights which vary from state to state.
LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-577-7466 (U.S. customers)
877-484-9255 (Canada customers)
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor
(Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s
service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us
at Toro Warranty Company.
374-0037 Rev E