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Form No. 3360-462 Rev
C
DH 2
2
0 Lawn Tractor
Model No. 74592—Serial No. 280000001 and Up
Register at www.Toro.com.
Original Instructions (EN)
Introduction
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.
Figure 1
1.
Model and serial number location
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.
© 2008—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..................................................... 5
Sound Power ........................................................ 5
Vibration.............................................................. 6
Slope Chart .......................................................... 7
Safety and Instructional Decals ............................. 8
Product Overview ...................................................... 11
Controls ............................................................. 11
Operation................................................................... 11
Adding Fuel ....................................................... 11
Using Stabilizer/Conditioner.............................. 12
Filling the Fuel Tank........................................... 12
Checking the Engine Oil Level............................ 12
Using the Parking Brake...................................... 12
Positioning the Seat ............................................ 13
Operating the Headlights.................................... 13
Using the Cruise Control .................................... 13
Hour Meter ........................................................ 13
Using the Blade Control (PTO)........................... 13
Setting the Height of Cut .................................... 14
Adjusting the Discharge Baffle............................ 14
Adjusting the Mower Gauge Wheels ................... 14
Starting the Engine ............................................. 14
Stopping the Engine ........................................... 15
Using the Safety Interlock System ....................... 16
Testing the Safety Interlock System ..................... 17
Pushing the Machine Manually............................ 17
Driving the Machine Forward or
Backward ....................................................... 18
Stopping the Machine......................................... 18
Using the Bag on Demand .................................. 19
Emptying the Grass Collector............................. 19
Towing Attachments .......................................... 19
Operating Tips ................................................... 20
Maintenance............................................................... 21
Recommended Maintenance Schedule(s) ................ 21
Lubrication............................................................. 22
Greasing and Lubricating the Machine ................ 22
How to Grease the Machine................................ 22
Where to Add Grease ......................................... 23
Engine Maintenance............................................... 23
Servicing the Air Cleaner .................................... 23
Servicing the Engine Oil ..................................... 24
Servicing the Spark Plug ..................................... 26
Fuel System Maintenance ....................................... 27
Draining the Fuel Tank ....................................... 27
Replacing the Fuel Filter ..................................... 27
Electrical System Maintenance................................ 28
Replacing the Fuse.............................................. 28
Servicing the Headlights ..................................... 28
Servicing the Battery........................................... 29
Drive System Maintenance ..................................... 31
Checking the Tire Pressure ................................. 31
Servicing the Brake............................................. 31
Belt Maintenance.................................................... 32
Adjusting the Blade Drive Belt ............................ 32
Servicing the Grass Collector.................................. 32
Removing the Grass Collector ............................ 32
Installing the Grass Collector.............................. 32
Cleaning the Grass Collector and Tunnel ............. 32
Mower Deck Maintenance ...................................... 33
Servicing the Blades............................................ 33
Removing the Mower ......................................... 34
Installing the Mower........................................... 35
Adjusting the Height Adjustment Cable Rod
Assembly ....................................................... 35
Storage ....................................................................... 36
Troubleshooting......................................................... 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
– 5° when mowing on side hills;
– 10° when mowing uphill;
– 15° when mowing 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;
– engage clutch slowly, always keep machine in gear, especially when travelling 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.
• 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.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.
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.
Sound Pressure
This unit has a maximum sound pressure level at the operator’s ear of 77 dBA, based on measurements of identical machines per EN 836 and ISO 11201.
Sound Power
This unit has a guaranteed sound power level of 100 dBA, based on measurements of identical machines per
ISO 11094.
5
Vibration
This unit does not exceed a hand/arm vibration level of
1.6 m/s2, based on measurements of identical machines per EN 836 and EN 1033.
This unit does not exceed a whole body vibration level of 1.6 m/s2, based on measurements of identical machines per EN 836 and EN 1032.
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.
Manufacturer’s Mark
1.
Indicates the blade is identified as a part from the original machine manufacturer.
104-2853
1.
Increase discharge opening when mowing long, wet grass.
2.
Decrease discharge opening when mowing short, dry grass.
1.
Explosion hazard—wear eye protection.
2.
Caustic liquid/chemical burn hazard—to perform first aid, flush with water.
93-7276
3.
Fire hazard—no fire, open flames, or smoking.
4.
Poison hazard—keep children a safe distance from the battery.
1.
Mowing in reverse enabled.
2.
Parking brake
104-2854
3.
Empty the grass collector
4.
Power take-off (PTO)
93-7824
1.
Thrown object hazard—keep bystanders a safe distance from the machine.
2.
Thrown object hazard, mower—keep the deflector in place.
3.
Cutting/dismemberment of hand or foot—stay away from moving parts.
99-5340
1.
KeyChoice—turn to enable reverse mowing.
8
104-2903
1.
Warning, tipping hazard—do not drive across slopes greater than
5 degrees, down slopes greater than 15 degrees, or up slopes greater than
10 degrees.
2.
Warning—read the
Operator’s Manual.
4.
Cutting/dismemberment hazard of hand or foot, mower blade—disconnect the spark plug wire and read the instructions before servicing or performing maintenance; stay away from moving part.s
5.
Crushing/dismemberment hazard of bystanders—keep bystanders a safe distance from the machine.
3.
Thrown object hazard, mower—keep bystanders a safe distance from the machine.
1.
Choke
2.
On
3.
Off
104-3233
4.
Pull the knob out to start the PTO.
5.
Push the knob in to stop the PTO.
6.
Power take-off (PTO)
9
1.
Choke
2.
On
3.
Off
104-3233
4.
Pull the knob out to start the PTO.
5.
Push the knob in to stop the PTO.
6.
Power take-off (PTO)
1.
Height of cut
2.
Decrease
104-3239 and 104-3240
3.
Increase
1.
Fast
2.
Continuous variable setting
3.
Slow
4.
Engine—stop
104-3234
5.
Headlights
6.
On
7.
Engine—start
1.
Parking brake
104-3237
104-3241
1.
Forward 4.
Slow
2.
Continuous variable speed 5.
Fast
3.
Neutral 6.
Reverse
104-3243
1.
To drive the machine, push the lever in.
2.
To push the machine, pull the lever out.
104-3238
1.
Starting procedure
4.
Raise the mower.
5.
Put the tractor in neutral.
6.
Lock the parking brake.
2.
Read the Operator’s
Manual.
7.
If the engine is cold, move the throttle control lever to
Choke.
3.
Check the engine oil level.
8.
Start the engine.
9.
Unlock the parking brake.
1.
Collect grass
106-8552
2.
Recycle
10
Product Overview
Controls
Become familiar with the controls (Figure 3) before you
start the engine and operate the machine.
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 (85 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.
Figure 3
1.
Ignition/light switch
2.
Throttle control lever
3.
Brake pedal
4.
Parking brake lever
7.
8.
9.
10.
Forward speed pedal
Reverse speed pedal
Choke lever
Hour meter
5.
Blade control (PTO) knob 11.
Cruise control
6.
Hood opening 12.
Bag-on-demand pedal
11
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.
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 3) down and hold it.
2. Turn the parking brake lever (Figure 3)
counterclockwise and gradually take your foot off the brake pedal.
Note: The clutch/brake pedal should stay in the depressed (locked) position.
Releasing the Parking Brake
1. Push down on the brake pedal (Figure 3).
12
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
Hour Meter
The hour meter is located on the instrument panel
(Figure 3) and shows the total operating hours of the
machine.
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
Figure 4
1.
Adjustment knobs
2. Move the seat to the desired position and tighten the knobs.
Operating the Headlights
The headlights are an integral function of the ignition switch. Turn the ignition key clockwise to the Lights position.
Using the Cruise Control
1. Accelerate the machine to the desired speed.
2. Push the cruise control switch On (Figure 3).
3. To decelerate, push the cruise control switch Off or slowly apply the brake pedal.
Note: Note: The battery must be fully charged for the cruise control to operate reliably.
1.
Blade control (PTO)
2.
Engaged
Figure 5
3.
Disengaged
Note: The blade control (PTO) light on the dash turns on when you engage the blades (PTO) as
1.
Grass collector warning light
2.
Parking brake light
Figure 6
3.
Blade control (PTO) light
13
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 1 to
4 inches (25 to 102 mm).
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 to the blades.
1. Push and hold in the button on the height-of-cut
1.
Plate
Figure 8
2.
Nuts
3. Tighten the nuts.
4. Install the grass collector; refer to Installing the
Grass Collector.
Adjusting the Mower Gauge
Wheels
The mower front gauge wheels guide the mower over uneven ground. The mower wheels must always be in
the bottom (lowest) hole in the wheel bracket (Figure 9).
1.
Height-of-cut lever
Figure 7
2. Shift the height-of-cut lever to the desired position.
3. Release the button.
Adjusting the Discharge
Baffle
The discharge baffle changes the size of the discharge opening to assist the operation of the bag fill indicator.
1. Remove the grass collector; refer to Removing the
Grass Collector.
2. Loosen the 2 nuts on the mowing conditions plate and slide the plate up if you are mowing short, dry grass, or slide it down if you are mowing long, wet
1.
Wheel
Figure 9
2.
Bottom hole
Starting the Engine
1. Open the fuel shut-off valve located between the
fuel tank and the engine (Figure 10).
14
5. When starting a cold engine, shift the throttle
control lever to the Choke position (Figure 12).
1.
Fuel shut-off valve
Figure 10
Note: The valve handle should align with the fuel hose.
2. Sit down on the seat.
3. Set the parking brake; refer to Setting the parking
Brake.
4. Disengage the blades (PTO). Refer to Figure 11.
1.
Throttle control lever
2.
Fast
3.
Slow
4.
Start
Figure 12
5.
Lights
6.
On
7.
Off
Figure 11
1.
Blade control (PTO) knob 4.
Choke
2.
Engaged
3.
Disengaged
5.
6.
On
Off
Note: The engine will not start if the blades (PTO) are engaged.
Note: To start a warm engine, shift the throttle control lever to the Fast position.
6. Shift the throttle control lever to the Slow position
7. Turn the ignition key clockwise and hold it in the
Start position (Figure 12). When the engine starts,
release the key.
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 Fast (Figure 12).
Stopping the Engine
1. Move the throttle control lever to Slow (Figure 12).
Note: If the engine backfires, shift the throttle control lever to the Fast position before stopping the engine.
2. Turn the ignition key to Off (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 Off. This allows the engine to cool
15
the engine before you stop it. You may stop the engine in an emergency by turning the ignition key to Off.
Using the Safety Interlock
System
Service Interval: Before each use or daily 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).
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.
1.
KeyChoice switch
Figure 13
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
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).
16
3. Turn the KeyChoice key.
A red light on the front console (Figure 14) turns
on, indicating that the interlock is disabled.
Figure 14
1.
Operating-in-reverse light
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
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.
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).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
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.
8. Release the parking brake.
Note: This disengages the drive system and allows the
wheels to turn freely (Figure 15).
17
1.
Operate position
Figure 15
2.
Push position
To Operate the Machine
1. Set the parking brake.
2. Push the drive control in to the Operate position
(Figure 15) 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.
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
1.
Traction control pedal
Figure 16
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
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.
Stopping the Machine
1. Release the traction control pedal or reverse speed pedal.
2. Disengage the blades (PTO).
Turn the ignition key to Off.
3. Set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake.
Note: Remove the keys from the ignition and
KeyChoice switches.
18
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.
Using the Bag on Demand
You can activate or deactivate the bag on demand feature while the machine is mowing or is stopped. If you are bagging grass that is tall and thick, raise the height-of-cut and mow at a slower speed.
1. Move the bag-on-demand lever (Figure 3) forward
to bag the grass clippings.
2. Move the bag-on-demand lever rearward to stop bagging the grass clippings and recycle them.
Emptying the Grass Collector
When the collector warning light (Figure 6) comes on
and the buzzer sounds, the grass collector is full and must be emptied.
Important: To prevent the discharge tunnel from getting clogged, disengage the blades (PTO) when the warning light comes on and the buzzer sounds.
1. Disengage the blades (PTO) and move the throttle to the Slow position.
2. Pull out the telescoping dump lever and push it forward and down to tilt the grass collector
Figure 17
1.
Pull up
2.
Push forward and down
3.
Telescoping dump lever
3. Empty the grass collector.
4. Before returning the grass collector to the operating position, move the machine forward to clear the grass collector of the deposited grass.
5. Slowly lower the telescoping dump lever to return the grass collector to the operating position.
Towing Attachments
The machine is equipped for towing attachments with a maximum weight of 150 kg (331 lb.).
1. Remove the grass collector; refer to Removing the
Grass Collector.
2. Install the attachment to the towing hitch located at
the lower rear part of the machine (Figure 18).
19
1.
Towing hitch
Figure 18
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.
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.
• Use the washout port to clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, the cutting quality will eventually become unsatisfactory.
• 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.
20
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
After the first 5 hours
After the first 25 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 blade drive belt adjustment.
• 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.)
• Clean and oil the air cleaner foam element.
• Check the spark plug.
• Check the tire pressure.
• Clean the outside of the engine.
• Change the engine oil. (Change the engine oil more frequently when operating the machine in extremely dusty or sandy conditions.)
• Adjust the blade drive belt.
• Replace the air cleaner paper element. (Replace the air cleaner more frequently if the operating conditions are extremely dusty or sandy.)
• Change the engine oil filter.
• 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.
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.
21
Lubrication
Greasing and Lubricating the
Machine
Service Interval: Every 25 hours/Yearly (whichever comes first)—Grease and lubricate the machine. (Grease and lubricate it more frequently when operating it in dusty or sandy conditions.)
How to Grease the Machine
Grease the machine with a general-purpose grease.
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
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.
22
Where to Add Grease
Figure 19
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—grease fitting
Shaft hub for lifting the mower housing
Motion link ball joints
Brake pedal hubs
Parking brake ring
Steering bearing
Left and Right Spindle—grease fittings
Mower housing hinged pins
Front axle pivot pins
Front axle pivot pins
2
6
2
2
4
2
1
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
25
25
When removed
When removed
25
Grease
Oil
Oil
Oil
Grease
Grease
Grease
Grease
Grease
Oil
Grease
Grease
Oil
Oil
Grease
Oil
Engine Maintenance
Servicing the Air Cleaner
Service Interval: Every 25 hours—Clean and oil the air cleaner foam element.
Every 100 hours/Yearly (whichever comes first)—Replace the air cleaner paper element. (Replace the air cleaner more frequently if the operating conditions are extremely dusty or sandy.)
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Open the hood.
23
Removing the Foam and Paper
Elements
1. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage.
2. Unscrew the knobs and remove the air cleaner cover
1.
Knob
Figure 20
2.
Air cleaner cover cover
3. Lift out the paper cartridge and the 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.
3. Saturate the element in engine oil.
4. Squeeze the element in a clean, absorbent cloth to remove excess oil.
Important: Replace the foam element if it is torn or worn.
Paper Element
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. Install the foam element with the mesh side up.
Note: Ensure that the rubber seal is flat against the air cleaner base.
2. Position the paper element on the foam element in the air cleaner base.
3.
Install the air cleaner cover and knobs (Figure 21).
4. Tighten the knobs snugly.
5. Close the hood.
Servicing the Engine Oil
Oil Type: Detergent oil (API service SF, SG, SH, SJ, or higher)
Crankcase capacity: 1.9 liters (64 oz.)
Viscosity: See the oil table (Figure 22).
1.
Foam element
Figure 21
2.
Paper element
Cleaning the Foam and Paper Elements
Foam Element
24
Figure 22
Checking the Engine Oil Level
Service Interval: Before each use or daily
1. Park the machine on a level surface.
2. Disengage the blades (PTO).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
6. Open the hood.
7. Clean around the dipstick (Figure 23 ) so that dirt
cannot fall into the filler hole and damage the engine.
12. Stop the engine and wait for 30 seconds.
13. Check the oil level again and add oil if necessary.
Important: Do not overfill the crankcase with engine oil and run the engine; engine damage may result.
Changing the Engine Oil
Service Interval: After the first 5 hours
Every 50 hours (Change the engine oil more frequently when operating the machine in extremely dusty or sandy 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.
3. Disengage the blades (PTO).
4. Set the parking brake.
5. Stop the engine and wait for all moving parts to stop.
6. Remove the ignition key.
7. Open the hood.
8. Place a pan below the oil drain plug.
9. Remove the oil drain plug to allow oil to drain
1.
Dipstick/fill hole
2.
Metal end
Figure 23
3.
Filler tube
1.
Drain plug
Figure 24
8. Unscrew the dipstick and wipe the metal end clean
9. Screw the dipstick fully onto the filler tube
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.
11. Start the engine and let it idle for 30 seconds.
10. When oil has drained completely, insert the drain plug and tighten it securely.
Note: Note: Recycle the used engine oil properly.
11. Clean around the dipstick and unscrew the cap
12. Slowly pour approximately 80% of the engine oil
into the filler tube (Figure 23). Refer to Servicing
the Engine Oil.
13. Check the engine oil level; refer to Checking the
Engine Oil Level.
25
Changing the Engine Oil Filter
Service Interval: Every 100 hours
1. Drain the oil from the engine; refer to Changing the
Engine Oil.
2. Remove the old filter and wipe off the adapter gasket
Figure 26
1.
Spark plug wire
1.
Engine oil filter
2.
Gasket
Figure 25
3.
Adapter
3. Apply a thin coat of new engine oil to the rubber
gasket on the new filter (Figure 25).
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
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
Checking the Spark Plug
1. Look at the center of the spark plug (Figure 27).
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.
Removing the Spark Plug
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Open the hood.
6. Disconnect the wire from the spark plug (Figure 26).
Figure 27
1.
Center electrode insulator 3.
Air gap (not to scale)
2.
Side electrode
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 27) 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 26).
4. Close the hood.
26
Fuel System
Maintenance
Draining the Fuel Tank
Drain the fuel tank when you will not be using the machine for more than 30 days.
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.
2. Disengage the blades (PTO).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
6. Open the hood.
7. Squeeze the ends of the hose clamp together and slide it up the fuel line toward the fuel tank
8. Pull the fuel line off the fuel filter (Figure 28) and
allow the gasoline to drain into an approved fuel container or a drain pan.
Note: Now is the best time to install a new fuel filter because the fuel tank is empty.
9. Install the fuel line onto the fuel filter.
10. Slide the hose clamp close to the fuel filter to secure
both the fuel line and the fuel filter (Figure 28).
Replacing the Fuel Filter
Service Interval: Every 100 hours/Yearly (whichever comes first)
The best time to replace the fuel filter (Figure 28) is
when the fuel tank is empty. Never install a dirty fuel filter after it has been removed from the fuel line.
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Close the fuel shut-off valve (Figure 29).
1.
Hose clamp
2.
Fuel line
Figure 28
3.
Fuel filter
27
1.
Fuel shut-off valve
Figure 29
6. Open the hood.
7. Squeeze the ends of the hose clamps together and
slide them away from the old fuel filter (Figure 29).
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. Close the hood.
Electrical System
Maintenance
Replacing the Fuse
The electrical system is protected by fuses. They are
located beneath the hood, near the fuel tank (Figure 30).
If a fuse goes out, check the circuit wiring for a short.
1.
Bulb holder
2.
Reflector
3.
Tab (2)
Figure 31
4.
Slots
5.
Terminals
8. Push and rotate the bulb counterclockwise about
1/4 turn until it stops and remove the bulb from the
Figure 30
1.
Main/battery
2.
Interlock, electric clutch, and cruise control
3.
Full bag buzzer
4.
Extra fuse
To replace a fuse, pull up to remove it from the socket.
Push down to insert it.
• Main/ Battery—15 amp
• Interlock, electric clutch, and cruise control—10 amp
• Full bag buzzer—5 amp
1.
Bulb
2.
Metal pins
Figure 32
3.
Bulb holder
4.
Slots
Servicing the Headlights
Specification: Bulb # 1156, automotive type
Removing the Bulb
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Open the hood.
6. Disconnect the wire connectors from both of the bulb holder terminals.
7. Rotate the bulb holder 1/4 turn counterclockwise
and remove it from the reflector (Figure 31).
Installing the Bulb
1. Align the metal pins on the base of the bulb with the slots in the bulb holder and insert the base into the
2. Push and rotate the bulb clockwise until it stops.
3. Align the tabs on the bulb holder (Figure 32) with
the slots in the reflector.
4. Insert the bulb holder into the reflector and rotate it
1/4 turn clockwise until it stops.
5. Connect the wire connectors to the terminals on the bulb holder.
28
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
Removing the Battery
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.
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Open the hood to see the battery (under the dash panel).
6. Lift the rubber cover up off the negative (black) cable.
7. Disconnect the negative (black) ground cable from
Figure 33
1.
Negative cable (black), boot not shown for clarity
2.
Positive cable (red)
3.
Front of machine
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
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
29
(Figure 33). Slide the rubber cover over the battery
post.
Checking the Electrolyte Level
Service Interval: Before each use or daily
1. Tip the seat forward to see the battery.
2. Remove the filler caps. If the electrolyte is not up
to the lower part of the tube (Figure 34), add the
required amount of distilled water; refer to Adding
Water to the Battery.
Important: Do not overfill the battery.
Electrolyte (sulfuric acid) can severely corrode and damage the chassis.
4. Replace the filler caps.
Charging the Battery
1.
Filler Caps
2.
Lower part of the tube
Figure 34
3.
Plates
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.
5. When the battery is fully charged, install the filler caps.
6. Install the battery in the chassis; refer to Installing the Battery.
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
30
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 120 kPa and in the rear tires at 100 kPa. Check the pressure at
the valve stem (Figure 35). Check the tires when they are
cold to get the most accurate pressure reading.
1.
Valve stem
Figure 35
Servicing the Brake
The brake is located on the right side of the rear axle,
inside the rear tire (Figure 36).
Checking the Brake
Service Interval: Before each use or daily
1. Park the machine on a level surface.
2. Disengage the blades (PTO).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
6. Pull the drive control out to the Push position
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.
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 15) 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.
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.
31
Belt Maintenance
Adjusting the Blade Drive Belt
Service Interval: After the first 25 hours—Check the blade drive belt adjustment.
Every 50 hours—Adjust the blade drive belt.
1. Remove the mower; refer to Removing the Mower.
Note: You must remove the mower to adjust the blade drive belt properly.
2. Remove the V-belt pulley and the idler arm assembly
3. Remove the belt cover.
4. Loosen the 2 hex nuts on the idler pulley (Figure 37).
Servicing the Grass
Collector
Removing the Grass Collector
1. Use 2 hands to tip the grass collector forward
Figure 38
1.
Hex nuts
2.
Mower belt
3.
M10 nut
Figure 37
4.
30 N of force
5.
5 mm
5. Adjust the M10 nut until the belt flexes 5 mm with
6. Rotate the belt 3 revolutions.
7. Check the belt tension and adjust it if necessary.
8. Tighten the 2 hex nuts on the idler pulley.
9. Install the mower; refer to Installing the Mower.
2. Carefully slide the assembly rearward off the support brackets.
Installing the Grass Collector
1. Lift the grass collector assembly with 2 hands.
2. Tip the collector forward approximately 40 degrees and slide it onto the 2 support brackets at the rear of
Note: Ensure that the arrow on the top of the grass collector aligns with the arrow on the machine. The mower will not function when the grass collector is not in place.
Cleaning the Grass Collector and Tunnel
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Remove the grass collector; refer to Removing the
Grass Collector.
6. Clean the collector bag with pressurized water.
7. Wipe the area around the full-bag sensor.
32
8. Ensure that the bag on demand is in the bagging mode and clean the inside of the tunnel all the way to the mower.
9. Install the grass collector; refer to Installing the
Grass Collector.
Note: Allow the bag to dry thoroughly before installing it.
Mower Deck
Maintenance
Servicing the Blades
Service Interval: Before each use or daily
Note: Determine the left and right sides of the machine from the normal operating position.
To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades.
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.
33
1.
Blade driver
2.
Shear pin (2)
3.
Blade
4.
Bent edge
Figure 39
5.
Spacer
6.
Washer
7.
Bolt
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
Important: If the shear pins are broken, the mower belt may be damaged. Inspect the belt; refer to
Adjusting the Blade Drive Belt.
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.
2. Position the blades 90 degrees to each other
Figure 42
3. Tighten the blade bolts to 37 ft-lb (50 N-m).
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.
Removing the Mower
1. Park the machine on a level surface.
2. Disengage the blades (PTO).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
6. Disconnect the wire from the spark plug.
7. Move the height-of-cut lever to the lowest position.
8. Pull the idler arm assembly in and remove the V-belt
1.
Blade
Figure 41
2.
Balancer
Installing the Blades
1. Install the blades, washers, and blade bolts
Important: The bent edges of the blades must be pointing toward the top of the mower to ensure proper cutting.
34
5.
Rear pins
Figure 43
1.
Idler pulley and idler arm assembly
2.
V-belt
3.
Engagement spring
4.
Rear hairpin clips
7.
Front pin
8.
Engine pulley
9.
V-belt pulley
10.
Front suspension M12 nuts
11.
Bag-on-demand assembly
(not shown)
6.
Front hairpin clips
Note: The bag-on-demand assembly is not shown for the purpose of clarity.
9. Disconnect the spring from the engagement lever
10. Release the mower from the tunnel by lifting the tunnel off the 2 welded pins and pulling the tunnel rearward approximately 4 inches (10 cm). Secure the tunnel to prevent it from falling down.
11. Remove the hairpin clips from the 2 rear pins and
Note: You may need a pliers to pull out the second pin.
12. Remove the hairpin clip from the front pin and
13. Remove the V-belt from the engine pulley
14. Slide the mower out from beneath the machine.
Adjusting the Height
Adjustment Cable Rod
Assembly
Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front-to-rear 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.
1. Park the machine on a level surface.
2. Disengage the blades (PTO).
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
6. Disconnect the wire from the spark plug.
7. Move the lower pin of the front adjustment suspension into the bottom position of the slotted holes by adjusting the 2 nuts (M12) on the front
8. Move the height-of-cut lever to position 1.
Note: The front mower gauge wheels must rest on the ground.
9. Adjust the M8 locknut at the end of the height adjustment rod assembly until the rod is slightly taut
Installing the Mower
Reverse the procedure for Removing the Mower.
1.
M8 locknut
Figure 44
2.
Height adjustment rod
35
Storage
1. Disengage the blades (PTO).
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
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.
36
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.
2. Set the parking brake.
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.
2. Contact an Authorized Service Dealer.
3. Contact an Authorized Service Dealer.
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.
8. Adjust the carburetor idle speed and idle mixture.
9. Contact an Authorized Service Dealer.
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.
8. Contact an Authorized Service Dealer.
37
Problem
There is abnormal vibration.
The blades do not rotate.
The cutting height is uneven.
The cruise control will not engage or will not stay engaged.
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.
5. Contact an Authorized Service Dealer.
6. Install a new blade drive belt.
1. The blade drive belt is worn, loose, or broken.
2. The blade drive belt is off the pulley.
1. Install a new blade drive belt.
3. The grass collector is not in place.
2. Install the blade drive belt and adjust it for the correct tension.
3. Install the grass collector.
1. The tire pressure is incorrect.
1. Set the tire pressure.
2. The mower is not level.
2. Adjust the height adjustment cable rod assembly.
3. Clean the underside of the mower.
3. The underside of the mower is dirty.
4. The blade mounting screws are loose.
4. Tighten the blade mounting screws.
5. The blade drive belt tension is incorrect.
5. Adjust the blade drive belt.
1. The battery is not fully charged.
1. Charge the battery.
38
International Distributor List
Country: Distributor:
Atlantis Su ve Sulama Sisstemleri Lt
Balama Prima Engineering Equip
Turkey
Hong Kong
B-Ray Corporation
Casco Sales Company
Ceres S.A
CSSC Turf Equipment (pvt) Ltd
Cyril Johnston & Co
Equiver
Femco S.A.
G.Y.K. Company ltd.
Geomechaniki of Athens
Guandong Golden Star
Hako Gorund and Garden
Hayter Limited (U.K.)
Hydroturf Int. Co Dubai
Hydroturf Egypt LLC
Ibea S.p.A.
Irriamc
Jean Heybroek b.v.
Lely (U.K.) Limited
Maquiver S.A.
Maruyama Mfg. Co. Inc.
Metra Kft
Mountfield a.s.
Munditol S.A.
Oslinger Turf Equipment SA
Oy Hako Ground and Garden Ab
Parkland Products Ltd
Prochaska & Cie
RT Cohen 2004 Ltd
Riversa
Roth Motorgerate GmBh & Co
Sc Svend Carlsen A/S
Solvert S.A.S
Spypros Stavrinides Limited
Surge Systems India Limited
T-Markt Logistics Ltd
Toro Australia
Toro Europe BVBA
Korea
Puerto Rico
Costa Rica
Sri Lanka
Northern Ireland
Mexico
Guatemala
Japan
Greece
China
Sweden
United Kingdom
United Arab Emirates
Egypt
Italy
Portugal
Netherlands
United Kingdom
Colombia
Japan
Hungary
Czech Republic
Argentina
Ecuador
Finland
New Zealand
Austria
Israel
Spain
Germany
Denmark
France
Cyprus
India
Hungary
Australia
Belgium
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
86 20 876 51338
46 35 10 0000
44 1279 723 444
97 14 347 9479
202 519 4308
39 0331 853611
351 21 238 8260
31 30 639 4611
44 1480 226 800
57 1 236 4079
81 3 3252 2285
36 1 326 3880
420 255 704 220
54 11 4 821 9999
593 4 239 6970
358 987 00733
64 3 34 93760
43 1 278 5100
972 986 17979
34 9 52 83 7500
49 7144 2050
45 66 109 200
33 1 30 81 77 00
357 22 434131
91 1 292299901
36 26 525 500
61 3 9580 7355
32 14 562 960
374-0102 Rev B
The Toro Warranty
Conditions and Products Covered
The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship. The following time periods apply 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
2-year limited warranty
2-year limited warranty
2-year limited warranty
2-year limited warranty
2-year limited warranty
2-year limited warranty
* “Original purchaser” means use the person who originally purchased Toro products.
* “Normal residential purposes” means use of the product on the same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply.
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
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 your seller or the Service Dealer.
If for any reason you are dissatised with the Service Dealer’s analysis or with the assistance provided, contact the Toro importer or contact us at:
Customer Care Department, Consumer Division
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Manager: Technical Product Support: 001-952-887-8248
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.
Items and Conditions Not Covered
This express warranty does not cover:
•
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.
•
Engine and transmission. These are covered by the appropriate manufacturer’s guarantees with separate terms and conditions.
All repairs covered by this warranty 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.
374-0101 Rev A
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