Toro DH 140 Lawn Tractor Riding Product Operator's Manual

Form No. 3363-994 Rev C

DH 140 Lawn Tractor

Model No. 74560—Serial No. 310000001 and Up

G012435

To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.

Original Instructions (EN)

Introduction

This rotary-blade, riding lawn mower is intended to be used by residential homeowners. It is designed primarily for cutting grass on well-maintained lawns on residential properties. It is not designed for cutting brush or for agricultural uses.

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.

You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.

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.

1.

Safety alert symbol

Figure 2

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.

G012436

Figure 1

1.

Model and serial number location (under the seat)

1

Model No.

Serial No.

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.

© 2012—The Toro® Company

8111 Lyndale Avenue South

Bloomington, MN 55420

2

Contact us at www.Toro.com.

Printed in the USA

All Rights Reserved

Contents

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

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

Safe Operation Practices for Riding Rotary

Lawn Mowers................................................... 4

Toro Riding Mower Safety .................................... 5

Sound Pressure..................................................... 6

Sound Power ........................................................ 6

Hand-Arm Vibration............................................ 6

Whole Body Vibration.......................................... 6

Slope Indicator..................................................... 7

Safety and Instructional Decals ............................. 8

Product Overview ........................................................ 9

Controls ............................................................... 9

Specifications ....................................................... 9

Operation................................................................... 10

Adding Fuel ....................................................... 10

Using Stabilizer/Conditioner.............................. 10

Filling the Fuel Tank........................................... 10

Checking the Engine Oil Level............................ 10

Using the Parking Brake...................................... 10

Positioning the Seat ............................................ 11

Using the Blade Control (PTO)........................... 11

Setting the Height of Cut .................................... 11

Starting the Engine ............................................. 12

Stopping the Engine ........................................... 13

Using the Safety Interlock System ....................... 13

Testing the Safety Interlock System ..................... 14

Pushing the Machine Manually............................ 15

Driving the Machine Forward or

Backward ....................................................... 15

Stopping the Machine......................................... 16

Emptying the Grass Collector............................. 16

Mulching the Grass ............................................ 16

Optional Towing Hitch....................................... 17

Operating Tips ................................................... 17

Maintenance............................................................... 18

Recommended Maintenance Schedule(s) ................ 18

Lubrication............................................................. 18

Greasing and Lubricating the Machine ................ 18

How to Grease the Machine................................ 18

Where to Add Grease ......................................... 20

Engine Maintenance............................................... 20

Servicing the Air Cleaner .................................... 20

Servicing the Engine Oil ..................................... 21

Servicing the Spark Plug ..................................... 23

Fuel System Maintenance ....................................... 24

Draining the Fuel Tank ....................................... 24

Replacing the Fuel Filter ..................................... 24

Electrical System Maintenance................................ 25

Replacing the Fuses ............................................ 25

Servicing the Battery........................................... 25

Drive System Maintenance ..................................... 27

Checking the Tire Pressure ................................. 27

Servicing the Brake............................................. 27

Servicing the Grass Collector.................................. 28

Removing the Grass Collector ............................ 28

Installing the Grass Collector.............................. 28

Cleaning the Grass Collector and Tunnel ............. 29

Mower Deck Maintenance ...................................... 29

Servicing the Blades............................................ 29

Removing the Mower ......................................... 30

Installing the Mower........................................... 30

Adjusting the Front-to-Rear Blade Slope ............. 31

Leveling the Mower from Side-to-Side ................ 31

Checking and Setting the Cutting Height ............. 32

Installing the Adjustable Links ............................ 33

Storage ....................................................................... 34

Troubleshooting......................................................... 35

Schematics ................................................................. 37

3

Safety

Safe Operation Practices for

Riding Rotary Lawn Mowers

Read and understand the contents of this manual before operating the machine.

The safety alert symbol (Figure 2) is used to alert you

to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The following instructions are from the CEN standard

EN 836:1997.

This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious injury or death.

Training

• Read the instructions carefully. Be familiar with the controls and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations can restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers should seek and obtain professional and practical instruction. Such instruction should emphasize:

– the need for care and concentration when working with ride-on machines;

– control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

◊ insufficient wheel grip;

◊ being driven too fast;

◊ inadequate braking;

◊ the type of machine is unsuitable for its task;

◊ lack of awareness of the effect of ground conditions, especially slopes;

◊ incorrect hitching and load distribution.

Preparation

• While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Warning —Fuel is highly flammable.

– Store fuel in containers specifically designed for this purpose.

– Refuel outdoors only and do not smoke while refuelling.

– Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

– If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

– Replace all fuel tanks and container caps securely.

• Replace faulty silencers.

• Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

Operation

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral.

• Do not use on slopes of more than

– 10° when mowing on side hills;

– 15° when mowing uphill or downhill.

• Remember there is no such thing as a safe slope.

Travel on grass slopes requires particular care. To guard against overturning:

– do not stop or start suddenly when going up or downhill;

– machine speeds should be kept low on slopes and during tight turns;

4

– stay alert for humps and hollows and other hidden hazards;

– never mow across the face of the slope, unless the lawn mower is designed for this purpose.

• Use care when pulling loads or using heavy equipment.

– Use only approved drawbar hitch points.

– Limit loads to those you can safely control.

– Do not turn sharply. Use care when reversing.

– Use counterweight(s) or wheel weights when suggested in the instruction handbook.

• Lightning can cause severe injury or death. If you see lightning or hear thunder in the area, do not operate the machine; seek shelter.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards or without safety protective devices in place.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

• Before leaving the operator’s position:

– disengage the power take-off and lower the attachments;

– change into neutral and set the parking brake;

– stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and disconnect the spark plug wire(s) or remove the ignition key

– before clearing blockages or unclogging chute;

– before checking, cleaning or working on the lawn mower;

– after striking a foreign object. Inspect the lawn mower for damage and make repairs before restarting and operating the equipment;

– if the machine starts to vibrate abnormally (check immediately).

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment

– before refuelling;

– before removing the grass catcher;

– before making height adjustment unless adjustment can be made from the operator’s position.

Maintenance and Storage

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure.

• To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Check the grass catcher frequently for wear or deterioration.

• Replace worn or damaged parts for safety.

• If the fuel tank has to be drained, this should be done outdoors.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• When machine is to be parked, stored or left unattended, lower the cutting means unless a positive mechanical lock is used.

Toro Riding Mower Safety

The following paragraph contains safety information specific to Toro products that is not included in the

CEN standard.

Use only Toro-approved attachments. The warranty may be voided if you use the machine with unapproved attachments.

5

Sound Pressure

This unit has a sound pressure level at the operator’s ear of 85.8 dBA, which includes an Uncertainty Value (K) of 0.8 dBA. The sound pressure level was determined according to the procedures outlined in EN 836.

Sound Power

This unit has a guaranteed sound power level of 99.1

dBA, which includes an Uncertainty Value (K) of 0.4

dBA. The sound power level was determined according to the procedures outlined in ISO 11094.

Hand-Arm Vibration

Measured vibration level for left hand = 2.7 m/s 2

Measured vibration level for right hand = 3.5 m/s 2

Uncertainty Value (K) = 1.2 m/s 2

Measured values were determined according to the procedures outlined in EN 836.

Whole Body Vibration

Measured vibration level = 1.6 m/s 2

Uncertainty Value (K) = 0.44 m/s 2

Measured values were determined according to the procedures outlined in EN 836.

6

Slope Indicator

G01 1841

Figure 3

This page may be copied for personal use.

1.

The maximum slope you can safely operate the machine on is 10 degrees when mowing on side hills and 15 degrees when mowing uphill or downhill. Use the slope chart to determine the degree of slope of hills before operating.

Do not operate this machine on a slope greater than 15 degrees.

Fold along the appropriate line to match the recommended slope.

2.

Align this edge with a vertical surface, a tree, building, fence pole, etc.

3.

Example of how to compare slope with folded edge.

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.

93-7276

1.

Explosion hazard—wear eye protection.

2.

Caustic liquid/chemical burn hazard—to perform first aid, flush with water.

3.

Fire hazard—no fire, open flames, or smoking.

4.

Poison hazard—keep children a safe distance from the battery.

99-5340

1.

KeyChoice—turn to enable reverse mowing.

119-2725

1.

Warning—read the Operator's Manual .

2.

Warning—remove the spark plug wire before performing any maintenance on the machine.

3.

Tipping hazard—do not operate on slopes greater than 10 degrees.

4.

Thrown object hazard; crushing hazard, bystanders—keep bystanders a safe distance from the machine.

5.

Cutting hazard of hand or foot—stay away moving parts, keep all guards and shields in place.

119-2726

1.

Thrown object hazard—keep bystanders a safe distance from the machine.

2.

Cutting hazard of hand or foot—stay away moving parts, keep all guards and shields in place.

8

Product Overview

Controls

Become familiar with the controls (Figure 4 and Figure 5)

before you start the engine and operate the machine.

2

3

1

G012437

Figure 4

1.

Height-of-cut lever

2.

Grass collector dump lever

3.

Dashboard controls

2

1

3

4

7

8

5

6

G012474

Figure 5

1.

Operating-in-reverse indicator light

5.

Brake pedal

2.

Blade control (PTO) knob 6.

Parking brake

3.

Ignition switch

4.

Throttle control lever

7.

Forward speed pedal

8.

Reverse speed pedal

Specifications

Model

74560

Weight

262 kg

Length

232 cm

Width

95 cm

Height

104 cm

9

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Adding Fuel

Use unleaded regular gasoline suitable for automotive use (95 pump octane minimum). You may use leaded, regular gasoline if unleaded gasoline is not available.

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.

DANGER

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.

• Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.

• 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.

• Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark.

• 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.

• Always place gasoline containers on the ground away from your vehicle before filling.

• 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.

• When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, refuel such equipment on a truck or trailer from a portable container, not from a gasoline dispenser nozzle.

• If you must use a gasoline dispenser, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the traction unit to provide the following benefits:

• It keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

• It cleans the engine while it runs

• It eliminates gum-like varnish buildup in the fuel system, which causes hard starting

Important: Do not use fuel additives containing methanol or ethanol.

Add the correct amount of gas stabilizer/conditioner to the gasoline.

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 a fuel stabilizer/conditioner at all times.

Filling the Fuel Tank

1. Stop the engine and wait for all moving parts to stop.

2. Clean around the fuel tank cap and remove it.

3. Add unleaded regular 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.

Do not fill the fuel tank completely full.

Note: This space in the tank allows gasoline to expand.

4. Install the fuel tank cap securely.

5. Wipe up any gasoline that may have spilled.

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 the Engine Oil Level in Servicing the Engine Oil in the

Maintenance section.

Using the Parking Brake

Always set the parking brake whenever you stop the machine or leave it unattended.

Setting the Parking Brake

1. Push the brake pedal (Figure 5) down and hold it.

2. Set the parking brake.

10

• For machines with a parking brake handle: Turn

the parking brake handle (Figure 6) clockwise

and gradually take your foot off the brake pedal.

1

G015674

1.

Parking brake handle

Figure 6

• For machines with a parking brake switch: Slide

the parking brake switch over (Figure 7) and

gradually take your foot off the brake pedal.

1

1.

Adjustment knobs

Figure 8

1.

Parking brake switch

Figure 7

G015675

Note: The clutch/brake pedal should stay in the depressed (locked) position.

Releasing the Parking Brake

1. Push down on the brake pedal (Figure 5).

Note: The parking brake lever should release.

2. Gradually release the brake pedal.

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.

1. Raise the seat and loosen the adjustment knobs

(Figure 8).

2. Move the seat to the desired position and tighten the knobs.

Using the Blade Control (PTO)

The blade control (PTO) knob engages and disengages power to the blades.

Engaging the Blades

1. Depress the brake pedal to stop the machine.

2. Pull the blade control (PTO) knob out to the

Engaged position (Figure 5).

Disengaging the Blades

1. Depress the brake pedal to stop the machine.

2. Push the blade control (PTO) knob into the

Disengaged position (Figure 5).

Setting the Height of Cut

Use the height-of-cut lever to raise and lower the mower to the desired cutting height. You can set the cutting height to 7 different positions from approximately 30 to 80 mm (1-1/4 to 3-1/8 inches).

Important: You must set the height-of-cut lever to the highest position (7) when you transport the machine off the lawn to prevent damaging the blades.

1. Push and hold in the button on the height-of-cut

lever (Figure 9).

11

1

G 012441

1

Figure 9

1.

Height-of-cut lever

2. Shift the height-of-cut lever to the desired position.

3. Release the button.

Starting the Engine

1. Open the fuel shut-off valve located between the

fuel tank and the engine (Figure 10).

G015676

1.

Throttle control lever

Figure 11

Note: To start a warm engine, shift the throttle control lever to the Fast (rabbit) position.

6. Shift the throttle control lever to the Slow (turtle)

position (Figure 11).

7. Turn the ignition key clockwise and hold it in the

Start position (Figure 12).

Note: When the engine starts, release the key.

4

3

2

1.

Fuel shut-off valve

Figure 10

1

G012447

Note: The valve handle should align with the fuel hose.

2. Sit down on the seat.

3. Set the parking brake; refer to Using the Parking

Brake.

4. Disengage the blades (PTO); refer to Figure 5.

Note: The engine will not start if the blades (PTO) are engaged.

5. When starting a cold engine, shift the throttle control lever to the Choke (all the way up) position

(Figure 11).

1.

Ignition key

2.

Start

Figure 12

3.

On

4.

Off

Important: If the engine does not start after

15 seconds of continuous cranking, turn the ignition key to Off and let the starter motor cool for 2 minutes; refer to Troubleshooting.

8. After the engine starts, slowly shift the throttle control lever to the Fast (rabbit) position.

12

Stopping the Engine

1. Move the throttle control lever to the Slow (turtle)

position (Figure 11).

Note: If the engine backfires, shift the throttle control lever to the Fast (rabbit) position before stopping the engine.

2. Turn the ignition key to the Off position (Figure 12).

Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key to the Off position. This allows the engine to cool before you stop it. You may stop the engine in an emergency by turning the ignition key to the Off position.

Using the Safety Interlock

System

Service Interval: Before each use or daily

CAUTION

If the safety interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

• Replace switches every 2 years regardless of whether they are operating properly or not.

Understanding the Safety Interlock

System

The safety interlock system is designed to prevent the engine from starting unless:

• You are sitting on the seat.

• The brake pedal is depressed.

• The blade control (PTO) knob is in the Disengaged position.

• The traction control pedal is in Neutral.

The safety interlock system stops the engine if you rise from the seat and the traction control pedal is not in the Neutral position, the parking brake is not set, or the blade control (PTO) knob is in the Engaged position.

The safety interlock system is designed to stop the mower if:

• You shift into Reverse with the blades (PTO) engaged.

• You remove the bag or dump the grass.

Setting the KeyChoice

®

Switch to

Operate in Reverse

The interlock feature on the machine prevents the power take-off (PTO) from operating when you back up the machine. If you operate the machine in reverse with the blades (PTO) engaged (i.e., with the mower blades or other attachment running), the engine will stop.

Do not mow in reverse unless it is absolutely necessary.

If you need to use the blades (PTO) while backing up, turn off the interlock feature using the KeyChoice

switch located near the seat bracket (Figure 13).

13

1.

KeyChoice switch

Figure 13

DANGER

You could back over a child or bystander while the mower blades or other attachment is engaged and cause serious injury or death.

• Do not mow in reverse unless it is absolutely necessary.

• Do not insert the KeyChoice key unless it is absolutely necessary.

• Always look backward and down before backing up the machine.

• Use the KeyChoice switch only if you are certain that no children or other bystanders will enter the mowing area.

• Be very observant after deactivating the interlock because the sound of the engine may prevent you from noticing that a child or bystander has entered the work area.

• Always remove both the ignition and KeyChoice keys and put them in a safe place out of the reach of children or unauthorized users when you leave the machine unattended.

1. Engage the blades (PTO).

2. Insert the KeyChoice key into the switch (Figure 13).

3. Turn the KeyChoice key.

A red light on the front console (Figure 5) turns on,

indicating that the interlock is disabled.

4. Operate the machine in reverse and complete your task.

5. Disengage the blades (PTO) to activate the interlock.

6. Remove the KeyChoice key and put it in a safe place out of the reach of children.

Testing the Safety Interlock

System

CAUTION

If the safety interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

Test the safety interlock system before you use the machine each time. If the safety interlock system does not operate as described below, have an Authorized

Service Dealer repair the safety interlock system immediately. While sitting in the seat, perform the following checks:

1. Set the parking brake, shift the blade control (PTO) knob to the Engage position, and turn the ignition key to Start: The engine should not crank.

2. Shift the blade control (PTO) knob to the Disengage position, release the parking brake, and turn the ignition key to Start: The engine should not crank.

3. Set the parking brake, shift the blade control (PTO) knob to Disengage, and start the engine. While the engine is running, release the parking brake and rise slightly from the seat: The engine should stop.

4. Shift the blade control (PTO) knob into the

Disengage position, put the traction control pedal in Neutral, and start the engine. While the engine is running, shift the blade control (PTO) knob into the Engage position and put the traction control pedal in Reverse: The engine should stop.

5. Shift the blade control (PTO) knob into the

Disengage position and put the traction control pedal in Neutral. Start the engine, shift the blade control (PTO) knob into the Engage position, and turn the KeyChoice key and release it: The operating-in-reverse warning light should illuminate.

6. Shift the blade control (PTO) knob to the Disengage position: The operating-in-reverse warning light should turn off.

14

Pushing the Machine Manually

Important: Always push the machine manually.

Never tow the machine because it may damage the transaxle.

To Push the Machine

1. Park the machine on a level surface.

2. Disengage the blades (PTO).



5. Remove the ignition key.

6. Remove the grass collector; refer to Removing the

Grass Collector.

7. Pull the drive control (located at the rear of the

machine) out to the Push position (Figure 14).

Note: This disengages the drive system and allows the wheels to turn freely.

Driving the Machine 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.

To go forward:

1. Release the parking brake; refer to Releasing the

Parking Brake.

2. Place your foot on the traction control pedal and slowly press on the pedal to move forward

(Figure 15).

1

2

1 2

1.

Push position

G012449

Figure 14

2.

Operate position

8. Release the parking brake.

To Operate the Machine


2. Push the drive control in to the Operate position

(Figure 14) to engage the drive system.

Note: The machine will not drive unless the drive control is in the Operate position.

3. Install the grass collector; refer to Installing the

Grass Collector.

G015677

1.

Forward control pedal

Figure 15

2.

Reverse speed pedal

Note: To increase the speed, push the traction control pedal down. To decrease the speed, release the pressure on the traction control pedal.

To go backward:

1. Release the parking brake; refer to Releasing the

Parking Brake.

2. Place your foot on the reverse speed pedal and slowly press on the pedal to move backward

(Figure 15).

Note: To increase the speed, push the reverse speed pedal down. To decrease the speed, release the pressure on the reverse speed pedal.

Important: To avoid transmission damage, always release the parking brake before moving the traction control pedal or the reverse speed pedal.

Important: To prevent damage to the mower, always set the mower to the highest cutting position when you drive the machine off the lawn.

15

Stopping the Machine

1. Release the traction control pedal or the reverse speed pedal.


Turn the ignition key to the Off position.

3. Set the parking brake if you leave the machine unattended; refer to Using the Parking Brake.

Note: Remove the keys from the ignition and

KeyChoice switches.

CAUTION

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition and KeyChoice keys and set the parking brake when leaving the machine unattended, even if it is just for a few minutes.

Emptying the Grass Collector

When the grass collector is full, a buzzer sounds, and the grass collector must then be emptied.

Important: To prevent the discharge tunnel from getting clogged, disengage the blades (PTO) when the buzzer sounds.

1. If the locking pin is in the locked position, unlock

it (Figure 16).

1

4. Empty the grass collector.

5. Before returning the grass collector to the operating position, move the machine forward to clear the grass collector of the deposited grass.

6. Slowly lower the dump lever to return the grass collector to the operating position.

Mulching the Grass

To mulch the grass clippings, you must install a mulch plug in the machine.





Grass Collector.

5. Insert the mulch plug (Figure 18) into the discharge

opening at the rear of the machine, and hook it into

the hole in the discharge chute(Figure 19).

2

1

G012451

2

Figure 17

1.

Pull the grass collector dump lever forward to empty the grass.

1.

Top support bar

G012470

Figure 16

2.

Locking pin

Figure 18

2. Disengage the blades (PTO) and move the throttle to the Slow position.

3. Pull the grass collector dump lever forward to tilt

the grass collector (Figure 17).

1.

Mulch plug

16

Figure 19

1.

Mulch plug installed in the discharge chute at the rear of the machine

2.

Discharge chute

Important: Ensure that the mulch plug is seated properly so that it will not come into contact with the blades.


Grass Collector.

Optional Towing Hitch

The machine is capable of towing non-ground-engaging attachments with a maximum weight of 150 kg (331 lb).


Grass Collector.

2. Install the attachment to the towing hitch located at

the lower rear part of the machine (Figure 20).

1

G012452

Operating Tips

• For the best performance, operate the engine at the maximum speed. The mower requires air to thoroughly cut grass clippings, so do not set the height-of-cut too low or completely surround the mower in uncut grass. Always leave one side of the mower free from uncut grass to allow the air to be drawn into the mower.

• Cut the grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. When cutting grass longer than

6 inches (15 cm) tall, cut the lawn twice to ensure an acceptable appearance.

• It is best to cut only about 1/3 of the grass blade when mulching. Do not cut more than that unless the grass is sparse or it is late fall when grass grows more slowly.

• Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings and enhances decomposition and fertilization.

• Grass grows at different rates at different times of the season. 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 the grass is longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual, cut the grass at that setting, and then cut the grass again at the lower, normal setting.

• If you must stop the machine while mowing, you may leave a clump of grass clippings on your lawn.

To avoid this, do the following:

– Engage the blades and move to a previously cut area.

– Disperse the clippings evenly by raising the mower 1 or 2 height-of-cut settings while driving forward with the blades engaged.

• Maintain sharp blades throughout the season. Sharp blades cut grass cleanly without tearing or shredding the grass blades. Tearing and shredding the grass turns it brown at the edges, which slows its growth and increases the chance of disease. Every 30 days, check the blades for sharpness and file down any nicks.

Figure 20

1.

Towing hitch

17

Maintenance


Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 5 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Yearly or before storage

Maintenance Procedure

• Change the engine oil.

• Check the safety interlock system.

• Check the engine oil level.

• Check the battery electrolyte level.

• Check the brake.

• Check the blades.

• Clean the mower housing.

• Grease and lubricate the machine. (Grease and lubricate it more frequently when operating it in dusty or sandy conditions.)

• Service the air cleaner foam element. (Service it more frequently when operating the machine in dusty or dirty conditions.)

• Check the spark plug.

• Check the tire pressure.

• Clean the outside of the engine.

• Change the engine oil. (Change it more frequently when operating the machine in dusty or dirty conditions.)

• Service the air cleaner paper element. (Service it more frequently when operating the machine in dusty or dirty conditions.)

• Change the engine oil filter. (Change it more frequently when operating the machine in dusty or dirty conditions.)

• Replace the spark plug.

• Replace the fuel filter.

• Check the front-to-rear blade slope. (Also check it whenever you install the mower.)

• Perform all the maintenance procedures listed above.

• Check the belts for wear and cracks.

• Drain the fuel tank.

• Paint chipped surfaces.

• Charge the battery and disconnect the cables.

Important: Refer to your engine operator’s manual for additional maintenance procedures.

CAUTION

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 before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Lubrication

more frequently when operating it in dusty or sandy conditions.)

Greasing and Lubricating the

Machine

Service Interval: Every 25 hours/Yearly (whichever comes first)—Grease and lubricate the machine. (Grease and lubricate it

How to Grease the Machine

Grease the machine with a general-purpose grease.



18



5. Clean the grease fittings with a rag. Scrape any paint off the front of the fittings.

6. Connect a grease gun to each fitting and pump grease into it.

7. Wipe up any excess grease.

19

Where to Add Grease

Figure 21

1

10

11

12

8

9

4

5

2

3

6

7

13

14

15

16

Item Name

Front wheel—grease fittings

Steering ball joints

Steering sector gear

Steering pinion gear

Steering shaft bearing

Steering shaft bearing

Motion lever

Shaft hub for lifting the mower housing

Motion link ball joints

Traction idler pulley belt—grease fitting

Brake pedal shaft pivot points

Parking brake ring

Steering bearing

Left and Right Spindle—grease fittings

Mower housing hinged pins

Front axle pivot pins

1

2

6

2

4

1

2

1

1

1

4

1

1

1

1

Quantity

(pumps)

2

Interval (hours) Lubricant

25

50

50

25

50

50

50

50

50

50

50

50

25

25

When removed

When removed

Grease

Oil

Grease

Oil

Oil

Grease

Grease

Grease

Grease

Oil

Grease

Grease

Oil

Oil

Grease

Oil

Engine Maintenance

Servicing the Air Cleaner

Service Interval: Every 25 hours—Service the air cleaner foam element. (Service it more frequently when operating the machine in dusty or dirty conditions.)

Every 100 hours—Service the air cleaner paper element. (Service it more frequently when operating the machine in dusty or dirty conditions.)






20

Removing the Foam and Paper

Elements

1. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage.

2. Pull up on the air cleaner cover handle and rotate it

toward the engine (Figure 22).

2

1

1.

Air cleaner cover

G012454

Figure 22

2.

Air cleaner cover handle

3. Remove the air cleaner cover.

4. Carefully slide the paper element and the foam

element from the blower housing (Figure 23).

2

1

1. Lightly tap the paper element on a flat surface to remove dust and dirt.

2. Inspect the element for tears, an oily film, and damage to the rubber seal.

Important: Never clean the paper element with pressurized air or liquids, such as solvents, gasoline, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.

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. Place the foam element and paper element into the blower housing.

Note: Ensure that the rubber seal is flat against the air cleaner base.

2. Align the tabs on the air cleaner cover with the slots

of the blower housing (Figure 23). Hook the handle

onto the cover and press down on the handle to lock the cover in place.

Servicing the Engine Oil

Oil Type: Detergent oil (API service SF, SG, SH, SJ, or higher)

Crankcase capacity: 48 oz. or (1.4 l) with filter; 44 oz. or

(1.3 l) without filter

Viscosity: See the oil table (Figure 24).

G012455

1.

Paper element

2.

Foam element

3.

Air cleaner cover

Figure 23

5

4

4.

Tab

5.

Slot

3

Cleaning the Foam and Paper Elements

Foam Element

1. Wash the foam element in liquid soap and warm water and rinse it thoroughly.

2. Dry the element by squeezing it in a clean cloth.

Note: Do not oil the foam element.

Important: Replace the foam element if it is torn or worn.

Paper Element

Figure 24

Checking the Engine Oil Level



21





6. Open the hood.

7. Clean around the dipstick (Figure 25) so that dirt

cannot fall into the filler hole and damage the engine.

2

1




7. Open the hood.

8. Place a pan below the drain plug.

9. Remove the drain plug to allow the oil to drain

(Figure 30).

G012453

1

1.

Oil drain plug

Figure 26

1.

Dipstick

Figure 25

2.

Metal end

G012456

8. Unscrew the dipstick and wipe the metal end clean

(Figure 25).

9. Screw the dipstick fully onto the filler tube

(Figure 25).

10. Unscrew the dipstick again and look at the metal end. If the engine oil level is low, slowly pour only enough oil into the filler tube to raise the level to the

Full mark on the dipstick.

Important: Do not overfill the crankcase with engine oil and run the engine; engine damage may result.

10. When the oil has drained completely, insert the drain plug and tighten it securely.

Note: Recycle the used engine oil properly.

11. Clean around the dipstick and unscrew the cap

(Figure 25).

12. Slowly pour approximately 80% of the engine oil

into the filler tube (Figure 25).

13. Check the engine oil level; refer to steps 9 and 10 of

Checking the Engine Oil Level.

Changing the Engine Oil

Service Interval: After the first 5 hours

Every 50 hours (Change it more frequently when operating the machine in dusty or dirty conditions.)

1. Start the engine and let it run for 5 minutes.

Note: This warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower than the other side to ensure that the oil drains completely.


Changing the Engine Oil Filter

Service Interval: Every 100 hours (Change it more frequently when operating the machine in dusty or dirty conditions.)

1. Drain the oil from the engine; refer to Changing the

Engine Oil.

2. Remove the old filter and wipe off the adapter gasket

surface (Figure 27).

22

3

1.

Engine oil filter

2.

Gasket

Figure 27

3.

Adapter

1

1.

Spark plug

2.

Spark plug wire

G012457

2

Figure 28

3.

Front of engine

3. Apply a thin coat of new engine oil to the rubber

gasket on the new filter (Figure 27).

4. Install the new filter to the filter adapter by turning it clockwise until the gasket contacts the filter adapter.

5. Tighten the filter an additional 1/2 to 3/4 turn

(Figure 27).

6. Fill the crankcase with the proper type of new engine oil; refer to Checking the Engine Oil Level.

7. Clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage.

8. Remove the spark plug and the metal washer

(Figure 28).

Checking the Spark Plug

1. Look at the center of the spark plug (Figure 29).

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 Plug

Service Interval: Every 25 hours—Check the spark plug.

Every 100 hours—Replace the spark plug.

Use a Champion RC12YC or equivalent spark plug.

Ensure that the air gap between the center and side electrodes is 0.030 inch (0.76 mm) before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap.

Figure 29

1.

Center electrode insulator 3.

Air gap (not to scale)

2.

Side electrode

Removing the Spark Plug





5. Open the hood.

6. Disconnect the wire from the spark plug (Figure 28).

Important:

Do not clean the spark plug.

Always replace the spark plug when it has a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side electrodes

(Figure 29) and bend the side electrode if the gap

is not correct.

Installing the Spark Plug

1. Install the spark plug and metal washer. Ensure that the air gap is set correctly.

2. Tighten the spark plug to 15 ft-lb (20.4 N-m).

3. Connect the wire to the spark plug (Figure 28).

4. Close the hood.

23

Fuel System

Maintenance

Draining the Fuel Tank

Drain the fuel tank when you will not be using the machine for more than 30 days.

DANGER

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.

• Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area.

Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine so that the left front side is slightly lower than the right side to ensure that the fuel tank drains completely.





6. Close the fuel shut-off valve located under the front of the fuel tank.

7. Loosen the hose clamp at the fuel filter and slide it

up the fuel line away from the fuel filter (Figure 30).

1 2

3

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

10. Install the fuel line onto the fuel filter.

11. Slide the hose clamp close to the fuel filter to secure

the fuel line (Figure 30).

Replacing the Fuel Filter

Service Interval: Every 100 hours/Yearly (whichever comes first)

The best time to replace the fuel filter (Figure 30) is

when the fuel tank is empty. Never install a dirty fuel filter after it has been removed from the fuel line.






6. Close the fuel shut-off valve (Figure 31).

1

1.

Fuel shut-off valve

Figure 31

G012459

7. Squeeze the ends of the hose clamps together and

slide them away from the old fuel filter (Figure 31).

8. Remove the old fuel filter from the fuel line.

9. Install a new fuel filter and move the hose clamps close to it.

10. Open the fuel shut-off valve.

1.

Fuel filter

2.

Hose clamp

G012458

Figure 30

3.

Fuel line

8. Pull the fuel line off the fuel filter (Figure 30).

9. Open the fuel shut-off valve and allow the gasoline to drain into an approved fuel container or a drain pan.

24

Electrical System

Maintenance

Replacing the Fuses

The electrical system is protected by fuses. They are

located beneath the hood, near the fuel tank (Figure 32).

If a fuse goes out, check the circuit wiring for a short.

1

2

1.

Fuses

G012460

Figure 32

To replace a fuse, pull up to remove the old fuse from the socket. Insert a new fuse by pushing it down into the socket.

Note: Ensure that the new fuse has the same amperage as the old fuse that you are replacing.

Removing the Battery

WARNING

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.

• When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

• Do not allow metal tools to short between the battery terminals and the metal parts of the machine.





5. Lift up the seat to see the battery.

6. Lift the rubber cover up off the negative (black) cable.

7. Disconnect the negative (black) ground cable from

the battery post (Figure 33).

3

Servicing the Battery

Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda. Apply a light coating of grease to the battery terminals to prevent them from corroding.

Battery voltage and amperage: 12 volts, 190 cold cranking amps

2

1

G012463

Figure 33

1.

Rubber cover

2.

Negative cable (black), boot not shown for clarity

3.

Positive cable (red)

25

WARNING

Routing the battery cables improperly could damage the machine and cables, causing sparks.

Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

• Always connect the positive (red) battery cable before connecting the negative (black) cable.

8. Lift the rubber cover up off the positive (red) cable.

9. Disconnect the positive (red) cable from the battery

post (Figure 33).

10. Remove the battery hold down rod.

11. Remove the battery from the chassis.

Installing the Battery

1. Place the battery into the chassis with the battery

posts toward the rear of the machine (Figure 33).

2. Secure the battery in the chassis with the hold down rod.

3. Using the bolt and wing nut, connect the positive

(red) cable to the positive (+) battery post (Figure 33).

Slide the rubber cover over the battery post.

4. Using the bolt and wing nut, connect the negative

(black) cable to the negative (–) battery post

(Figure 33). Slide the rubber cover over the battery

post.

Checking the Electrolyte Level


1. Tip the seat forward to see the battery.

2. Look at the side of the battery. The electrolyte must

be up to the upper line (Figure 34).

1.

Filler caps

2.

Upper line

Figure 34

3.

Lower line

Note: do not allow the electrolyte to fall below the

lower line (Figure 34).

3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery.

DANGER

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• 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.

• Fill the battery where clean water is always available for flushing the skin.

Adding Water to the Battery

The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution.

1. Clean the top of the battery with a paper towel.

2. Remove the filler caps (Figure 34).

3. Slowly pour distilled water into each battery cell until the level is up to the lower part of the tube

(Figure 34).

Important: Do not overfill the battery.

Electrolyte (sulfuric acid) can severely corrode and damage the chassis.

4. Replace the filler caps.

Charging the Battery

WARNING

Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery.

Important: Always keep the battery fully charged

(1.260 specific gravity), especially below 32°F (0°C) to prevent battery damage.

1. Remove the battery from the chassis; refer to

Removing the Battery.

2. Check the electrolyte level; refer to Checking the

Electrolyte Level.

3. Remove the filler caps from the battery and connect a 2 amp battery charger to the battery posts.

4. Charge the battery at a rate of 2 amps or less for 4 hours (12 volts).

Do not overcharge the battery.

26

5. When the battery is fully charged, install the filler caps.

6. Install the battery in the chassis; refer to Installing the Battery.

Drive System

Maintenance

Checking the Tire Pressure

Service Interval: Every 25 hours/Yearly (whichever comes first)

Maintain the air pressure in the front tires at 100 kPa and in the rear tires at 80 kPa. Check the pressure at the

valve stem (Figure 35). Check the tires when they are

cold to get the most accurate pressure reading.

Figure 35

1.

Valve stem

Servicing the Brake

The brake is located on the right side of the rear axle,

inside the rear tire (Figure 36).

1

27

G012465

1.

Brake adjusting nut

Figure 36

If the machine takes more than 1 m (3 ft.) to stop at high speed in the highest gear, adjust the brake.

Checking the Brake







6. Pull the drive control out to the Push position

(Figure 14).

7. If the rear wheels lock and skid when you push the machine forward, you do not need to adjust the brake. If the wheels turn and do not lock, adjust the brake; refer to Adjusting the Brake.

Servicing the Grass

Collector

Removing the Grass Collector

1. Lock the locking pin on the grass collector

(Figure 37).

1

Adjusting the Brake

1. Check the brake before you adjust it; refer to

Checking the Brake.

2. Ensure that the drive control is in the Operate

position (Figure 14) and that the parking brake is on.

3. Turn the brake adjusting nut clockwise until you

cannot push the machine (Figure 36).

4. Release the parking brake and ensure that the rear wheels rotate freely when you push the machine.

If they do not, turn the brake adjusting nut counterclockwise just enough so that you can push the machine.

5. Check the brake operation again; refer to Checking the Brake.

1.

Top support bar

2.

Locking pin

2

G012470

Figure 37

3.

Locking pin (unlocked position)

4.

Locking pin (locked position)

2. Lift up the collector using the top support bar

(Figure 37).

Installing the Grass Collector

1. Hang the top support bar onto the 2 notches in the support bracket at the rear of the machine

(Figure 38).

2

28

1.

Top support bar

1

G012467

Figure 38

2.

Notches in collector support bracket

Note: Ensure that the grass collector is properly seated on the mower. The mower will not function unless the grass collector is properly attached.

2. Unlock the locking pin to allow for emptying the grass collector.

Mower Deck

Maintenance

Cleaning the Grass Collector and Tunnel






Grass Collector.

6. Clean the collector bag with pressurized water.

7. Wipe the area around the full-bag sensor.

8. Clean the inside of the discharge tunnel all the way to the mower.


Grass Collector.

Note: Allow the bag to dry thoroughly before installing it.

Servicing the Blades



To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades.

DANGER

Worn or damaged blades 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.

• Inspect the blades periodically for wear or damage.

• Replace worn or damaged blades.

Inspecting the Blades

1. Remove the mower; refer to Removing the Mower.

2. Inspect the cutting edges (Figure 39). If the edges

are not sharp or have nicks, remove the blades and sharpen them; refer to Sharpening the Blades.

1

3

2

29

4

5

6

7

Figure 39

4.

Bent edge

5.

Washer

6.

Bolt

G012468

1.

Blade driver

2.

Shear pin (2)

3.

Blade

3. Inspect the blades, especially the bent edges

(Figure 39). If you notice any wear or damage in this

area, immediately install new blades.

4. If the shear pins are broken, replace them

immediately (Figure 39).

Important: If the shear pins are broken, the mower belt may be damaged. Inspect the belt; if the belt is damaged, contact an Authorized Service Dealer.

Removing the Blades

1. Remove the mower; refer to Removing the Mower.

2. Carefully tip the mower over.

3. Remove the bolts, washers, and blades (Figure 39).

Wedge a block of wood between each blade and the mower to lock the blade when you are removing each bolt.

Note: The right blade has a left-hand threaded bolt.

4. Inspect all parts; replace any that are worn or damaged.

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of

each blade (Figure 40). Maintain the original angle.

The blade retains its balance if you remove the same amount of material from both cutting edges.

Removing the Mower






6. Disconnect the wire from the spark plug.

7. Move the height-of-cut lever to the lowest position.

8. If the mulch plug is installed, remove it; refer to

Removing the Mulch Plug.

9. Remove the belt from the clutch pulley (Figure 42).

Figure 40

1.

Sharpen at original angle

2. Check the balance of each blade by putting it on

a blade balancer (Figure 41). 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 back side of the blade. Repeat this step until each blade is balanced.

1.

Blade

Figure 41

2.

Balancer

Installing the Blades

1. Install the blades, washers, and blade bolts

(Figure 39).

Important: The bent edges of the blades must be pointing toward the top of the mower to ensure proper cutting.

2. Tighten the blade bolts to 37 ft-lb (50 N-m).

1.

Links

2.

Front linkage

Figure 42

3.

Belt—indicated at the point around clutch pulley

(not shown)

10. Remove the 2 bolts and nuts from the front linkage, and pull apart the front linkage to remove it from the machine.

11. Remove the pins from the 4 rear links and remove

the links from the tractor (Figure 42).

Note: You can leave the links attached to the mower

as shown in (Figure 42).

12. Lift up on the mower end of the discharge chute to free the mower from the notches in the discharge chute.

13. Pull the mower deck out from under the left side of the machine.

Installing the Mower

Reverse the procedure for Removing the Mower.

30

Adjusting the Front-to-Rear

Blade Slope

Check the front-to-rear blade slope whenever you install the mower.

1. Measure the distance between the front tip of the left

blade and the flat surface (Figure 43). Repeat for the

rear tip of the left blade.

1.

Linking rod

Figure 44

View from left side of machine

2.

Nuts

Note: Shorten the linking rod to decrease the blade slope; extend the linking rod to increase the blade slope.

3. Ensure that the front-to-rear blade slope is correct, then check the side-to-side level of the mower; refer to Leveling the Mower from Side-to-Side.

Figure 43

Top and side views of mower housing

1.

Blades front to rear

2.

Front tip of left blade

3.

Measure here

4.

Rear tip of left blade

Note: The distance from the front tip of the left blade to the flat surface should be approximately 6 mm (1/4 inch) lower than the distance from the rear tip of the left blade and the flat surface. If so, go to

Leveling the Mower from Side-to-Side. Otherwise, go to the next step.

2. To obtain the proper height distance between the front and rear tips of the left blade, adjust the length of the linking rod (located on the left side of the

machine) (Figure 44).

Leveling the Mower from

Side-to-Side

The mower blades must be level from side to side. Check the side-to-side level whenever you install the mower or if you notice that your lawn has an uneven appearance.

1. Carefully rotate the blades side to side (Figure 45).

31

Figure 45


1.

Blades side to side

2.

Outside edges of blades

3.

Measure here

2. Measure between the outside cutting edges and

the flat surface (Figure 45). Ensure that the

measurements are within 3 mm (1/8 inch) of each other. If they are not, go to the next step.

3. Loosen the nuts on the front and rear adjustable links (located on the right side of the mower) so that the links are free to move through the trunnions

(Figure 46 and Figure 47).

Figure 46

Front adjustable link (view from front of machine)

1.

Front adjustable link

2.

Nuts

3.

Trunnion blade slope. (Also check it whenever you install the mower.)

Before you check the slope, inflate the front and rear tires to the recommended air pressure; refer to Checking the Tire Pressure. If the front of the mower is not within

4 to 11 mm (1/8 to 3/8 inch) lower than the rear of the mower, adjust the blade slope.

Check and adjust the cutting height of the blades whenever you install the mower.


2. Ensure that the air pressure in the tires are set to the recommended level; refer to Checking the Tire

Pressure.

3. Disengage the blades (PTO) and set the parking brake.

4. Stop the engine, wait for all moving parts to stop, and remove the ignition key.

5. Disconnect the wire from the spark plug.

6. Move the height-of-cut lever to the middle (4) position.

Carefully rotate the blades front to rear (Figure 48).

Figure 47

Rear adjustable link (view from right side of machine)

1.

Rear adjustable link

2.

Nuts

3.

Trunnion

Checking and Setting the

Cutting Height

Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front-to-rear

Figure 48


1.

Blades front to rear

2.

Front tip of left blade

3.

Measure here

4.

Rear tip of left blade 4. Raise or lower the right side of the mower housing by turning the nuts until the distance from the outside

edges of the blades to the flat surface (Figure 45) are

within 3 mm (1/8 inch) of each other, and tighten the nuts on the front and rear adjustable links.

7. Measure the distance between the front tip of the left

blade and the flat surface (Figure 48).

Note: The distance should be 55 mm (2-1/8 inch).

If it is, go to step Adjusting the Front-to-Rear Blade

Slope. Otherwise, go to the next step.

8. Loosen the jam nut on at the end of the turnbuckle

(on the right side of the machine; refer to Figure 49),

and adjust the turnbuckle until the distance between

32

the front tip of the left blade and the flat surface is

55 mm (2-1/8 inch).

Figure 49

Height-of-cut linkage (on right side of machine)

1.

Turnbuckle 2.

Jam nut

Note: You may need to move the height-of-cut lever to the lowest (1) position before you adjust the turnbuckle. Return the cutting height setting to the middle (4) position before checking the distance between the front tip of the left blade and the flat surface.

Note: To raise the blade tip, turn the turnbuckle clockwise; to lower the blade tip, turn the turnbuckle counterclockwise.

9. Tighten the turnbuckle jam nut.

Installing the Adjustable Links

If you install a replacement adjustable link, you must approximately adjust the new adjustable link before setting the cutting height, adjusting the front-to-rear slope, and leveling the mower from side-to-side.

Install the front or rear adjustable link as shown in

Figure 50.

33

Figure 50

1.

Front adjustable link: 55 mm (2-1/8 inches)

Rear adjustable link: 50 mm (2 inches)

Storage





5. Remove the grass collector and clean it; refer to

Grass Collector.

6. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean the dirt and chaff from the outside of the engine cylinder head fins and blower housing.

Important: You can wash the machine with a mild detergent and water. Do not use pressurized liquids to wash the machine.

Pressurized liquids may damage the electrical system or wash away necessary grease at the friction points. Avoid using water excessively, especially near the control panel, lights, engine, and battery.

7. Check the brake; refer to Brake.

8. Service the air cleaner; refer to Servicing the Air

Cleaner.

9. Grease the chassis; refer to Greasing and Lubricating the Machine.

10. Change the engine oil and filter; refer to Servicing the Engine Oil.

11. Check the tire pressure; refer to Checking the Tire

Pressure.

12. When storing the machine over 30 days, prepare it as follows:

A. Add a petroleum-based stabilizer/conditioner to the fuel in the tank according to the instructions from the stabilizer manufacturer.

Do not use an alcohol-based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times.

B. Run the engine for 5 minutes to distribute the conditioned fuel through the fuel system.

C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Draining the Fuel Tank

D. Start the engine and run it until it stops.

E. Choke or prime the engine.

F. Start and run the engine until it will not start again.

G. Recycle the old fuel according to local codes.

H. Close the fuel shut-off valve.

Important: Do not store stabilizer/conditioned gasoline over 90 days.

13. Remove and inspect the spark plug; refer to Servicing the Spark Plug. With the spark plug removed from the engine, pour 2 tablespoons of engine oil into the spark plug hole. Use the electric starter to crank the engine and distribute the oil inside the cylinder.

Install the spark plug, but do not connect the wire to the spark plug.

14. Disconnect the negative battery cable. Clean the battery and battery terminals. Check the electrolyte level and charge it fully; refer to Servicing the Battery.

Leave the negative battery cable disconnected from the battery during storage.

Important: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32°F (0°C). You can store a fully charged battery during the winter without recharging.

15. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is worn or damaged.

16. Paint all scratched or bare metal surfaces with paint available from an Authorized Service Dealer.

17. Store the machine in a clean, dry garage or storage area. Remove the ignition and KeyChoice keys from the mower and keep them in a memorable place.

Cover the machine to protect it and keep it clean.

34

Troubleshooting

Problem

The starter does not crank.

The engine overheats.

The machine does not drive.

The engine will not start, starts hard, or fails to keep running.

The engine loses power.

Possible Cause Corrective Action

1. The blade control (PTO) knob is engaged.

2. The parking brake is not on.

3. The battery is dead.

4. The electrical connections are corroded or loose.

5. A fuse is blown.

6. A relay or switch is damaged.

1. Move the blade control (PTO) knob to the Disengaged position.


3. Charge the battery.

4. Check the electrical connections for good contact.

5. Replace the fuse.

6. Contact an Authorized Service Dealer.

1. The engine load is excessive.

2. The oil level in the crankcase is low.

3. The cooling fins and air passages under the engine blower housing are plugged.

1. Reduce the ground speed.

2. Add engine oil to the crankcase.

3. Remove the obstruction from the cooling fins and air passages.

1. The drive control is in the Push position.

1. Move the drive control to the Operate position.

2. The traction belt is worn, loose, or broken.

3. The traction belt is off the pulley.



1. The operator is not seated.

2. The fuel tank is empty.

3. The air cleaner is dirty.

1. Sit on the seat.

2. Fill the fuel tank with gasoline.

3. Clean or replace the air cleaner element.

4. Install the wire on the spark plug.

4. The spark plug wire is loose or disconnected.

5. A spark plug is pitted, fouled, or the gap is incorrect.

6. The choke is not closing.

7. There is dirt in the fuel filter

8. The idle speed is too low or the mixture is incorrect.

9. Dirt, water, or stale fuel is in the fuel system.

10. The fuel shut-off valve is closed.

5. Install a new, correctly-gapped spark plug.

6. Adjust the throttle cable.

7. Replace the fuel filter.



10. Open the fuel shut-off valve.

1. The engine load is excessive.

1. Reduce your ground speed.

2. The air cleaner is dirty.

3. The oil level in the crankcase is low.

4. The cooling fins and air passages under the engine blower housing are plugged.

5. The spark plug is pitted, fouled, or the gap is incorrect.

8. Dirt, water, or stale fuel is in the fuel system.

2. Clean the air cleaner element.

3. Add engine oil to the crankcase.

4. Remove the obstruction from the cooling fins and air passages.

5. Install a new, correctly-gapped spark plug.

6. The vent hole in the fuel cap is plugged.

6. Clean or replace the fuel cap.

7. There is dirt in the fuel filter.

7. Replace the fuel filter.


35

Problem

There is abnormal vibration.

The blades do not rotate.

The cutting height is uneven.

Possible Cause Corrective Action

1. The blades are bent or unbalanced.

1. Install a new blades.

2. The blade mounting screws are loose.

2. Tighten the blade mounting screws.

3. The engine mounting bolts are loose.

4. There is a loose engine pulley, idler pulley, or blade pulley.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

5. The engine pulley is damaged.

6. The blade drive belt is damaged.



1. The blade drive belt is worn, loose, or broken.

2. The blade drive belt is off the pulley.

3. The grass collector is not in place.



3. Install the grass collector.

1. The tire pressure is incorrect.

1. Set the tire pressure.

2. The mower is not level.

3. The underside of the mower is dirty.

2. Adjust the height adjustment cable rod assembly.

3. Clean the underside of the mower.

4. The blade mounting screws are loose.

4. Tighten the blade mounting screws.

5. The blade drive belt tension is incorrect.


36

Schematics

G015678

Electrical (Rev. A)

37

Notes:

38

International Distributor List

Distributor: Country:

Atlantis Su ve Sulama Sisstemleri Lt Turkey

Balama Prima Engineering Equip.

Hong Kong

B-Ray Corporation Korea

Casco Sales Company

Ceres S.A.

CSSC Turf Equipment (pvt) Ltd.

Puerto Rico

Costa Rica

Sri Lanka

Cyril Johnston & Co.

Equiver

Femco S.A.

G.Y.K. Company Ltd.

Geomechaniki of Athens

Guandong Golden Star

Hako Ground and Garden

Hako Ground and Garden

Hayter Limited (U.K.)

Hydroturf Int. Co Dubai

Hydroturf Egypt LLC

Prato Verde

Irriamc

Irrigation Products Int'l Pvt Ltd.

Northern Ireland

Mexico

Guatemala

Japan

Greece

Egypt

Italy

Portugal

India

Phone Number:

90 216 344 86 74

852 2155 2163

82 32 551 2076

787 788 8383

506 239 1138

94 11 2746100

44 2890 813 121

52 55 539 95444

502 442 3277

81 726 325 861

30 10 935 0054

China

Sweden

Norway

United Kingdom

86 20 876 51338

46 35 10 0000

47 22 90 7760

44 1279 723 444

United Arab Emirates 97 14 347 9479

202 519 4308

39 049 9128128

351 21 238 8260

86 22 83960789

Distributor:

Jean Heybroek b.v.

Maquiver S.A.

Maruyama Mfg. Co. Inc.

Agrolanc Kft

Mountfield a.s.

Munditol S.A.

Country:

Netherlands

Phone Number:

31 30 639 4611

Colombia

Japan

57 1 236 4079

81 3 3252 2285

Hungary 36 27 539 640

Czech Republic 420 255 704 220

Argentina 54 11 4 821 9999

Oslinger Turf Equipment SA Ecuador

Oy Hako Ground and Garden Ab Finland

Parkland Products Ltd.

Prochaska & Cie

RT Cohen 2004 Ltd.

New Zealand

Austria

Israel

593 4 239 6970

358 987 00733

64 3 34 93760

43 1 278 5100

972 986 17979

Riversa

Sc Svend Carlsen A/S

Solvert S.A.S.

Spypros Stavrinides Limited

Surge Systems India Limited

Spain

Denmark

France

Cyprus

India

34 9 52 83 7500

45 66 109 200

33 1 30 81 77 00

357 22 434131

91 1 292299901

T-Markt Logistics Ltd.

Toro Australia

Toro Europe NV

Hungary

Australia

Belgium

36 26 525 500

61 3 9580 7355

32 14 562 960

European Privacy Notice

The Information Toro Collects

Toro Warranty Company (Toro) respects your privacy. In order to process your warranty claim and contact you in the event of a product recall, we ask you to share certain personal information with us, either directly or through your local Toro dealer.

The Toro warranty system is hosted on servers located within the United States where privacy law may not provide the same protection as applies in your country.

BY SHARING YOUR PERSONAL INFORMATION WITH US, YOU ARE CONSENTING TO THE PROCESSING OF YOUR PERSONAL INFORMATION

AS DESCRIBED IN THIS PRIVACY NOTICE.

The Way Toro Uses Information

Toro may use your personal information to process warranty claims and to contact you in the event of a product recall. Toro may share your information with Toro's affiliates, dealers or other business partners in connection with any of these activities. We will not use personal information provided for warranty purposes for marketing, nor shall we give or sell personal information provided for warranty purposes to any other company for marketing. We reserve the right to disclose personal information in order to comply with applicable laws and with requests by the appropriate authorities, to operate its systems properly or for our own protection or that of other users.

Retention of your Personal Information

We will keep your personal information as long as we need it for the purposes for which it was originally collected or for other legitimate purposes

(such as regulatory compliance), or as required by applicable law.

Toro's Commitment to Security of Your Personal Information

We take reasonable precautions in order to protect the security of your personal information. We also take steps to maintain the accuracy and current status of personal information.

Access and Correction of your Personal Information

If you would like to review or correct your personal information, please contact us by email at [email protected].

Australian Consumer Law

Australian customers will find details relating to the Australian Consumer Law either inside the box or at your local Toro Dealer.

374-0269 Rev D

The Toro Warranty

Conditions and Products Covered

The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the Toro Product listed below if used for residential purposes* if defective in materials or workmanship.

The following time periods apply from the date of purchase:

Products

Walk Power Mowers

Rear Engine Riders

Lawn & Garden Tractors

Electric Hand Held Products

Snowthrowers

Consumer Zero Turn

Warranty Period

2 year limited warranty






Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure:

1.

Contact your seller to arrange service of the product. If for any reason it is impossible for you to contact your seller, you may contact any

Toro Authorized Distributor to arrange service.

2.

Bring the product and your proof of purchase (sales receipt) to the

Service Dealer. If for any reason you are dissatisfied with the Service

Dealer’s analysis or with the assistance provided, contact us at:

Customer Care Department, Consumer Division

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Manager: Technical Product Support: 001–952–887–8248

*Original Purchaser means the person who originally purchased the Toro

Product

*Residential purposes means use of the product on the same lot as your home. Use at more than one location, or institutional or rental use, is considered commercial use, and the commercial use warranty would apply.

See attached Distributor List

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.

Limited Warranty for Commercial Use

Toro Consumer Products and attachments used for commercial, institutional, or rental use, are warranted against defects in materials or workmanship for the following time periods from the date of original purchase:

Products

Walk Power Mowers

Rear Engine Riders

Lawn & Garden Tractors

Electric Hand Held Products

Snowthrowers

Consumer Zero Turn

Warranty Period

90 day warranty

90 day warranty

90 day warranty

90 day warranty

90 day warranty

45 day warranty

Items and Conditions Not Covered

This express warranty does not cover the following:

•

Cost of regular maintenance service or wear parts, such as rotor blades (paddles), scraper blades, belts, fuel, lubricants, oil changes, spark plugs, cable/linkage or brake adjustments

•

Any product or part which has been altered or misused and requires replacement or repair due to accidents or lack of proper maintenance

•

Repairs necessary due to failure to use fresh fuel (less than one month old), or failure to properly prepare the unit prior to any period of non-use over one month

•

Engine and transmission. These are covered by the appropriate manufacturer’s guarantees with separate terms and conditions

All repairs covered by these warranties must be performed by an

Authorized Toro Service Dealer using Toro approved replacement parts.

General Conditions

The purchaser is covered by the national laws of each country. The rights to which the purchaser is entitled with the support of these laws are not restricted by this warranty.

374-0268 Rev A

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