Toro DH 220 Lawn Tractor Riding Product Operator's Manual

Form No. 3362-319 Rev B
DH 220 Lawn Tractor
Model No. 74593—Serial No. 290000001 and Up
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
Figure 2
Read this information carefully to learn how to operate
and maintain your product properly and to avoid injury
and product damage. You are responsible for operating
the product properly and safely.
1. Safety alert symbol
This manual uses 2 other words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a
dealer, or to register your product.
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.
Contents
Introduction................................................................. 2
Safety ........................................................................... 3
Safe Operation Practices for Riding Rotary
Lawn Mowers................................................... 3
Toro Riding Mower Safety .................................... 5
Sound Pressure..................................................... 5
Sound Power ........................................................ 5
Vibration.............................................................. 5
Slope Chart .......................................................... 6
Safety and Instructional Decals ............................. 7
Product Overview ...................................................... 10
Controls ............................................................. 10
Operation................................................................... 10
Adding Fuel ....................................................... 10
Using Stabilizer/Conditioner.............................. 11
Filling the Fuel Tank........................................... 11
Checking the Engine Oil Level............................ 11
Using the Parking Brake...................................... 11
Positioning the Seat ............................................ 12
Operating the Headlights.................................... 12
Using the Cruise Control .................................... 12
Hour Meter ........................................................ 12
Using the Blade Control (PTO)........................... 12
Setting the Height of Cut .................................... 13
Adjusting the Discharge Baffle............................ 13
Adjusting the Mower Gauge Wheels ................... 13
Starting the Engine............................................. 13
Stopping the Engine ........................................... 14
Using the Safety Interlock System ....................... 15
Testing the Safety Interlock System ..................... 16
Pushing the Machine Manually............................ 16
Driving the Machine Forward or
Backward ....................................................... 17
Stopping the Machine......................................... 17
Using the Bag on Demand .................................. 18
Emptying the Grass Collector............................. 18
Towing Attachments .......................................... 18
Operating Tips ................................................... 19
Maintenance............................................................... 20
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.
© 2009—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
Safety
Recommended Maintenance Schedule(s) ................ 20
Lubrication............................................................. 21
Greasing and Lubricating the Machine ................ 21
How to Grease the Machine................................ 21
Where to Add Grease ......................................... 22
Engine Maintenance............................................... 22
Servicing the Air Cleaner .................................... 22
Servicing the Engine Oil ..................................... 23
Servicing the Spark Plug ..................................... 25
Fuel System Maintenance ....................................... 26
Draining the Fuel Tank....................................... 26
Replacing the Fuel Filter ..................................... 26
Electrical System Maintenance................................ 27
Replacing the Fuse.............................................. 27
Servicing the Headlights ..................................... 27
Servicing the Battery........................................... 28
Drive System Maintenance ..................................... 30
Checking the Tire Pressure ................................. 30
Servicing the Brake............................................. 30
Belt Maintenance.................................................... 31
Adjusting the Blade Drive Belt ............................ 31
Servicing the Grass Collector.................................. 31
Removing the Grass Collector ............................ 31
Installing the Grass Collector.............................. 31
Cleaning the Grass Collector and Tunnel............. 31
Mower Deck Maintenance ...................................... 32
Servicing the Blades............................................ 32
Removing the Mower ......................................... 33
Installing the Mower........................................... 34
Adjusting the Height Adjustment Cable Rod
Assembly ....................................................... 34
Storage....................................................................... 35
Troubleshooting......................................................... 37
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.
3
Preparation
– stay alert for humps and hollows and other
hidden hazards;
• 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.
– 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;
Operation
– change into neutral and set the parking brake;
• 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;
– 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;
4
Sound Pressure
– before making height adjustment unless
adjustment can be made from the operator’s
position.
This unit has a maximum sound pressure level at the
operator’s ear of 82 dBA, based on measurements of
identical machines per EN 836 and ISO 11201.
• 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.
Sound Power
Maintenance and Storage
This unit has a guaranteed sound power level of 100
dBA, based on measurements of identical machines per
ISO 11094.
• 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.
Vibration
• Allow the engine to cool before storing in any
enclosure.
This unit does not exceed a hand/arm vibration level of
1.4 m/s2, based on measurements of identical machines
per EN 836 and EN 1033.
• To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of
grass, leaves, or excessive grease.
This unit does not exceed a whole body vibration level
of 0.52 m/s2, based on measurements of identical
machines per EN 836 and EN 1032.
• 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
Slope Chart
6
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.
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.
104-2854
1. Mowing in reverse
enabled.
2. Parking brake
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.
7
3. Empty the grass collector
4. Power take-off (PTO)
104-2903
1. Warning, tipping
4. Cutting/dismemberment
hazard—do not drive
hazard of hand or foot,
across slopes greater than
mower blade—disconnect
5 degrees, down slopes
the spark plug wire and
greater than 15 degrees,
read the instructions
or up slopes greater than
before servicing or
10 degrees.
performing maintenance;
stay away from moving
part.s
2. Warning—read the
5. Crushing/dismemberment
Operator’s Manual.
hazard of
bystanders—keep
bystanders a safe distance
from the machine.
3. Thrown object hazard,
mower—keep bystanders
a safe distance from the
machine.
104-3233
1. Choke
2. On
3. Off
4. Pull the knob out to start
the PTO.
5. Push the knob in to stop
the PTO.
6. Power take-off (PTO)
104-3233
1. Choke
2. On
3. Off
8
4. Pull the knob out to start
the PTO.
5. Push the knob in to stop
the PTO.
6. Power take-off (PTO)
104-3239 and 104-3240
1. Height of cut
2. Decrease
3. Increase
104-3234
1. Fast
2. Continuous variable
setting
3. Slow
4. Engine—stop
5. Headlights
6. On
104-3241
7. Engine—start
1. Forward
4. Slow
2. Continuous variable speed 5. Fast
3. Neutral
6. Reverse
104-3237
1. Parking brake
104-3243
1. To drive the machine, push 2. To push the machine, pull
the lever in.
the lever out.
104-3238
1. Starting procedure
2. Read the Operator’s
Manual.
3. Check the engine oil level.
4. Raise the mower.
5. Put the tractor in neutral.
6. Lock the parking brake.
7. If the engine is cold, move
the throttle control lever to
Choke.
8. Start the engine.
9. Unlock the parking brake.
106-8552
1. Collect grass
9
2. Recycle
Product Overview
Operation
Controls
Note: Determine the left and right sides of the
machine from the normal operating position.
Become familiar with the controls (Figure 3) before you
start the engine and operate the machine.
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.
2.
3.
4.
5.
6.
7. Forward speed pedal
Ignition/light switch
Throttle control lever
8. Reverse speed pedal
Brake pedal
9. Choke lever
Parking brake lever
10. Hour meter
Blade control (PTO) knob 11. Cruise control
Hood opening
12. Bag-on-demand pedal
10
• It cleans the engine while it runs
• It eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
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.
Important: Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner
to the gasoline.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any
gasoline that spills.
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.
• 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.
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.
• 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.
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.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on the
ground.
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.
• If this is not possible, refuel such equipment
on a truck or trailer from a portable
container, not from a gasoline dispenser
nozzle.
Using the Parking Brake
Always set the parking brake whenever you stop the
machine or leave it unattended.
• 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.
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.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the traction unit to
provide the following benefits:
Note: The clutch/brake pedal should stay in the
depressed (locked) position.
• It keeps gasoline fresh during storage of 90 days
or less. For longer storage it is recommended that
the fuel tank be drained.
Releasing the Parking Brake
1. Push down on the brake pedal (Figure 3).
11
Hour Meter
Note: The parking brake lever should release.
2. Gradually release the brake pedal.
The hour meter is located on the instrument panel
(Figure 3) and shows the total operating hours of the
machine.
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.
Using the Blade Control (PTO)
The blade control (PTO) knob engages and disengages
power to the blades.
1. Raise the seat and loosen the adjustment knobs
(Figure 4).
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).
Figure 4
1. Adjustment knobs
2. Move the seat to the desired position and tighten
the knobs.
Figure 5
Operating the Headlights
3. Disengaged
1. Blade control (PTO)
2. Engaged
The headlights are an integral function of the ignition
switch. Turn the ignition key clockwise to the Lights
position.
Note: The blade control (PTO) light on the dash
turns on when you engage the blades (PTO) as
shown in Figure 6.
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.
Figure 6
1. Grass collector warning
light
2. Parking brake light
12
3. Blade control (PTO) light
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).
Figure 8
1. Plate
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.
2. Nuts
3. Tighten the nuts.
4. Install the grass collector; refer to Installing the
Grass Collector.
1. Push and hold in the button on the height-of-cut
lever (Figure 7).
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).
Figure 7
1. Height-of-cut lever
Figure 9
2. Shift the height-of-cut lever to the desired position.
1. Wheel
2. Bottom hole
3. Release the button.
Adjusting the Discharge
Baffle
Starting the Engine
1. Open the fuel shut-off valve located between the
fuel tank and the engine (Figure 10).
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
grass (Figure 8).
13
5. When starting a cold engine, shift the throttle
control lever to the Choke position (Figure 12).
Figure 10
1. Fuel shut-off valve
Figure 12
Note: The valve handle should align with the fuel
hose.
1.
2.
3.
4.
2. Sit down on the seat.
3. Set the parking brake; refer to Setting the parking
Brake.
Throttle control lever
Fast
Slow
Start
5. Lights
6. On
7. Off
Note: To start a warm engine, shift the throttle
control lever to the Fast position.
4. Disengage the blades (PTO). Refer to Figure 11.
6. Shift the throttle control lever to the Slow position
(Figure 12).
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.
Figure 11
1. Blade control (PTO) knob
2. Engaged
3. Disengaged
4. Choke
5. On
6. Off
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
Note: The engine will not start if the blades (PTO)
are engaged.
14
the engine before you stop it. You may stop the
engine in an emergency by turning the ignition key
to Off.
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).
Using the Safety Interlock
System
Service Interval: Before each use or daily
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.
Figure 13
1. KeyChoice switch
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.
You could back over a child or bystander
while the mower blades or other attachment is
engaged and cause serious injury or death.
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.
• Always look backward and down before
backing up the machine.
• Do not mow in reverse unless it is absolutely
necessary.
• Do not insert the KeyChoice key unless it is
absolutely necessary.
• Use the KeyChoice switch only if you are
certain that no children or other bystanders
will enter the mowing area.
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.
KeyChoice®
Setting the
Operate in Reverse
• 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.
Switch to
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
1. Engage the blades (PTO).
2. Insert the KeyChoice key into the switch (Figure 13).
15
3. Turn the KeyChoice key.
engine is running, release the parking brake and rise
slightly from the seat: The engine should stop.
A red light on the front console (Figure 14) turns
on, indicating that the interlock is disabled.
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.
Figure 14
1. Operating-in-reverse light
6. Shift the blade control (PTO) knob to the Disengage
position: The operating-in-reverse warning light
should turn off.
4. Operate the machine in reverse and complete your
task.
5. Disengage the blades (PTO) to activate the
interlock.
Pushing the Machine Manually
6. Remove the KeyChoice key and put it in a safe place
out of the reach of children.
Important: Always push the machine manually.
Never tow the machine because it may damage
the transaxle.
Testing the Safety Interlock
System
To Push the Machine
1. Park the machine on a level surface.
2. Disengage the blades (PTO).
If the safety interlock switches are disconnected
or damaged, the machine could operate
unexpectedly, causing personal injury.
3. Set the parking brake.
4. Stop the engine and wait for all moving parts to
stop.
• Do not tamper with the interlock switches.
5. Remove the ignition key.
• Check the operation of the interlock
switches daily and replace any damaged
switches before operating the machine.
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.
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:
8. Release the parking brake.
Note: This disengages the drive system and allows the
wheels to turn freely (Figure 15).
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
16
Figure 16
1. Traction control pedal
2. Reverse speed pedal
Figure 15
1. Operate position
Note: To increase the speed, push the traction
control pedal down. To decrease the speed, release
the pressure on the traction control pedal.
2. Push position
To Operate the Machine
To go backward:
1. Set the parking brake.
1. Release the parking brake; refer to Releasing the
Parking Brake.
2. Push the drive control in to the Operate position
(Figure 15) to engage the drive system.
2. Place your foot on the reverse speed pedal and
slowly press on the pedal to move backward
(Figure 16).
Note: The machine will not drive unless the drive
control is in the Operate position.
Note: To increase the speed, push the reverse
speed pedal down. To decrease the speed, release
the pressure on the reverse speed pedal.
3. Install the grass collector; refer to Installing the
Grass Collector.
Driving the Machine Forward
or Backward
Important: To avoid transmission damage, always
release the parking brake before moving the
traction control pedal or the reverse speed pedal.
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.
Important: To prevent damage to the mower,
always set the mower to the highest cutting
position when you drive the machine off the lawn.
To go forward:
Stopping the Machine
1. Release the parking brake; refer to Releasing the
Parking Brake.
1. Release the traction control pedal or reverse speed
pedal.
2. Place your foot on the traction control pedal
and slowly press on the pedal to move forward
(Figure 16).
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.
17
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.
Figure 17
1. Pull up
2. Push forward and down
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.
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.
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.
Towing Attachments
Important: To prevent the discharge tunnel from
getting clogged, disengage the blades (PTO) when
the warning light comes on and the buzzer sounds.
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).
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).
Figure 18
1. Towing hitch
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.
19
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 25 hours
• Check the blade drive belt adjustment.
Before each use or daily
•
•
•
•
•
•
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.
Every 25 hours
• 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.
Every 50 hours
• 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.
Every 100 hours
• 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.)
Yearly or before storage
•
•
•
•
•
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.
20
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.
21
Where to Add Grease
Figure 19
Item
Name
Quantity
(pumps)
Interval (hours)
Lubricant
1
Front wheel—grease fittings
2
25
Grease
2
Steering ball joints
4
50
Oil
3
Steering sector gear
1
50
Grease
4
Steering pinion gear
1
25
Grease
5
Steering shaft bearing
1
50
Oil
6
Steering shaft bearing
1
50
Oil
7
Motion lever—grease fitting
1
50
Grease
8
Shaft hub for lifting the mower housing
1
50
Oil
9
Motion link ball joints
4
50
Oil
10
Brake pedal hubs
2
50
Oil
11
Parking brake ring
1
50
Oil
12
Steering bearing
1
25
Grease
13
Left and Right Spindle—grease fittings
2
25
Grease
14
Mower housing hinged pins
6
When removed
Grease
15
Front axle pivot pins
2
When removed
Grease
16
Front axle pivot pins
2
25
Grease
Engine Maintenance
operating conditions are extremely
dusty or sandy.)
Servicing the Air Cleaner
1. Disengage the blades (PTO).
Service Interval: Every 25 hours—Clean and oil the air
cleaner foam element.
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
Every 100 hours/Yearly (whichever
comes first)—Replace the air cleaner
paper element. (Replace the air
cleaner more frequently if the
4. Remove the ignition key.
5. Open the hood.
22
Removing the Foam and Paper
Elements
Cleaning the Foam and Paper Elements
1. Clean around the air cleaner to prevent dirt from
getting into the engine and causing damage.
1. Wash the foam element in liquid soap and warm
water and rinse it thoroughly.
2. Unscrew the knobs and remove the air cleaner cover
(Figure 20).
2. Dry the element by squeezing it in a clean cloth.
Foam Element
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.
Figure 20
1. Knob (4)
2. Air cleaner cover
Installing the Foam and Paper Elements
3. Lift out the paper cartridge and the foam element.
(Figure 21)
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 20).
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.)
Figure 21
1. Foam element
Viscosity: See the oil table (Figure 22).
2. Paper element
23
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.
Figure 22
Checking the Engine Oil Level
2.
Service Interval: Before each use or daily
1. Park the machine on a level surface.
3.
4.
5.
6.
7.
8.
9.
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.
Note: This warms the oil so that it drains better.
Park the machine so that the drain side is slightly
lower than the other side to ensure that the oil drains
completely.
Disengage the blades (PTO).
Set the parking brake.
Stop the engine and wait for all moving parts to stop.
Remove the ignition key.
Open the hood.
Place a pan below the oil drain plug.
Remove the oil drain plug to allow oil to drain
(Figure 24).
Figure 24
Figure 23
1. Dipstick/fill hole
2. Metal end
1. Drain plug
3. Filler tube
10. When oil has drained completely, insert the drain
plug and tighten it securely.
8. Unscrew the dipstick and wipe the metal end clean
(Figure 23).
Note: Note: Recycle the used engine oil properly.
11. Clean around the dipstick and unscrew the cap
(Figure 23).
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.
9. Screw the dipstick fully onto the filler tube
(Figure 23).
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.
24
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
surface (Figure 25).
Figure 26
1. Spark plug wire
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 26).
Figure 25
3. Adapter
1. Engine oil filter
2. Gasket
3. Apply a thin coat of new engine oil to the rubber
gasket on the new filter (Figure 25).
Checking the Spark Plug
4. Install the new filter to the filter adapter by turning it
clockwise until the gasket contacts the filter adapter.
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.
5. Tighten the filter an additional 1/2 to 3/4 turn
(Figure 25).
6. Fill the crankcase with the proper type of new engine
oil; refer to Checking the Engine Oil Level.
Servicing the Spark Plug
Service Interval: Every 25 hours—Check the spark
plug.
Figure 27
Every 100 hours—Replace the spark
plug.
1. Center electrode insulator
2. Side electrode
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.
3. Air gap (not to scale)
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.
Removing the Spark Plug
1. Disengage the blades (PTO).
Installing the Spark Plug
2. Set the parking brake.
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.
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).
25
Fuel System
Maintenance
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).
Draining the Fuel Tank
Drain the fuel tank when you will not be using the
machine for more than 30 days.
Replacing the Fuel Filter
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.
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).
• 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
(Figure 28).
Figure 29
1. Fuel shut-off valve
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.
Figure 28
1. Hose clamp
2. Fuel line
3. Fuel filter
26
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.
Figure 31
1. Bulb holder
2. Reflector
3. Tab (2)
4. Slots
5. Terminals
8. Push and rotate the bulb counterclockwise about
1/4 turn until it stops and remove the bulb from the
bulb holder (Figure 32).
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
Figure 32
• Interlock, electric clutch, and cruise control—10
amp
1. Bulb
2. Metal pins
3. Bulb holder
4. Slots
• Full bag buzzer—5 amp
Servicing the Headlights
Installing the Bulb
Removing 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
holder (Figure 32).
1. Disengage the blades (PTO).
2. Push and rotate the bulb clockwise until it stops.
2. Set the parking brake.
3. Align the tabs on the bulb holder (Figure 32) with
the slots in the reflector.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
5. Open the hood.
4. Insert the bulb holder into the reflector and rotate it
1/4 turn clockwise until it stops.
6. Disconnect the wire connectors from both of the
bulb holder terminals.
5. Connect the wire connectors to the terminals on the
bulb holder.
7. Rotate the bulb holder 1/4 turn counterclockwise
and remove it from the reflector (Figure 31).
27
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.
Figure 33
1. Negative cable (black),
boot not shown for clarity
2. Positive cable (red)
3. Front of machine
• 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.
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.
1. Disengage the blades (PTO).
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
2. Set the parking brake.
3. Stop the engine and wait for all moving parts to stop.
4. Remove the ignition key.
• Always connect the positive (red) battery
cable before connecting the negative (black)
cable.
5. Open the hood to see the battery (under the dash
panel).
6. Lift the rubber cover up off 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.
7. Disconnect the negative (black) ground cable from
the battery post (Figure 33).
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
28
Important: Do not overfill the battery.
Electrolyte (sulfuric acid) can severely corrode
and damage the chassis.
(Figure 33). Slide the rubber cover over the battery
post.
Checking the Electrolyte Level
4. Replace the filler caps.
Service Interval: Before each use or daily
Charging the Battery
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.
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.
Figure 34
1. Filler Caps
2. Lower part of the tube
4. Charge the battery at a rate of 2 amps or less for 4
hours (12 volts). Do not overcharge the battery.
3. Plates
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
(Figure 34).
29
Drive System
Maintenance
Checking the Brake
Checking the Tire Pressure
2. Disengage the blades (PTO).
Service Interval: Before each use or daily
1. Park the machine on a level surface.
3. Set the parking brake.
Service Interval: Every 25 hours/Yearly (whichever
comes first)
4. Stop the engine and wait for all moving parts to stop.
5. Remove the ignition key.
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.
6. Pull the drive control out to the Push position
(Figure 15).
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.
Figure 35
3. Turn the brake adjusting nut clockwise until you
cannot push the machine (Figure 36).
1. Valve stem
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.
Servicing the Brake
The brake is located on the right side of the rear axle,
inside the rear tire (Figure 36).
5. Check the brake operation again; refer to Checking
the Brake.
Figure 36
1. Brake adjusting nut
If the machine takes more than 1 m (3 ft.) to stop at
high speed in the highest gear, adjust the brake.
30
Belt Maintenance
Servicing the Grass
Collector
Adjusting the Blade Drive Belt
Removing the Grass Collector
Service Interval: After the first 25 hours—Check the
blade drive belt adjustment.
1. Use 2 hands to tip the grass collector forward
(Figure 38).
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
(Figure 43).
3. Remove the belt cover.
4. Loosen the 2 hex nuts on the idler pulley (Figure 37).
Figure 38
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
the machine (Figure 38).
Figure 37
1. Hex nuts
2. Mower belt
3. M10 nut
4. 30 N of force
5. 5 mm
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.
5. Adjust the M10 nut until the belt flexes 5 mm with
30 N of force (Figure 37).
6. Rotate the belt 3 revolutions.
7. Check the belt tension and adjust it if necessary.
Cleaning the Grass Collector
and Tunnel
8. Tighten the 2 hex nuts on the idler pulley.
9. Install the mower; refer to Installing the Mower.
1.
2.
3.
4.
5.
Disengage the blades (PTO).
Set the parking brake.
Stop the engine and wait for all moving parts to stop.
Remove the ignition key.
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.
31
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.
Mower Deck
Maintenance
9. Install the grass collector; refer to Installing the
Grass Collector.
Servicing the Blades
Note: Allow the bag to dry thoroughly before
installing it.
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.
Figure 39
1.
2.
3.
4.
Blade driver
Shear pin (2)
Blade
Bent edge
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
immediately (Figure 39).
32
Important: If the shear pins are broken, the mower
belt may be damaged. Inspect the belt; refer to
Adjusting the Blade Drive Belt.
2. Position the blades 90 degrees to each other
(Figure 42).
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.
Figure 42
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.
3. Tighten the blade bolts to 37 ft-lb (50 N-m).
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.
Figure 40
5. Remove the ignition key.
1. Sharpen at original angle
6. Disconnect the wire from the spark plug.
7. Move the height-of-cut lever to the lowest position.
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.
8. Pull the idler arm assembly in and remove the V-belt
from the pulley (Figure 43).
Figure 41
1. Blade
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.
33
Installing the Mower
Reverse the procedure for Removing the Mower.
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.
Figure 43
1. Idler pulley and idler arm
assembly
2. V-belt
3. Engagement spring
4. Rear hairpin clips
5. Rear pins
7. Front pin
1. Park the machine on a level surface.
8. Engine pulley
9. V-belt pulley
10. Front suspension M12
nuts
11. Bag-on-demand assembly
(not shown)
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. Front hairpin clips
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
suspension (Figure 43).
Note: The bag-on-demand assembly is not shown
for the purpose of clarity.
9. Disconnect the spring from the engagement lever
(Figure 43).
8. Move the height-of-cut lever to position 1.
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.
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
(Figure 44).
11. Remove the hairpin clips from the 2 rear pins and
remove the pins (Figure 43).
Note: You may need a pliers to pull out the second
pin.
12. Remove the hairpin clip from the front pin and
remove the pin (Figure 43).
13. Remove the V-belt from the engine pulley
(Figure 43).
14. Slide the mower out from beneath the machine.
34
Storage
1.
2.
3.
4.
5.
Disengage the blades (PTO).
Set the parking brake.
Stop the engine and wait for all moving parts to stop.
Remove the ignition key.
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).
Figure 44
1. M8 locknut
2. Height adjustment rod
B.
C.
D.
E.
F.
G.
35
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and
used at all times.
Run the engine for 5 minutes to distribute the
conditioned fuel through the fuel system.
Stop the engine, allow it to cool, and drain the
fuel tank; refer to Draining the Fuel Tank
Start the engine and run it until it stops.
Choke or prime the engine.
Start and run the engine until it will not start
again.
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.
Possible Cause
1. The blade control (PTO) knob is
engaged.
1. Move the blade control (PTO) knob to
the Disengaged position.
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.
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.
1. Reduce the ground speed.
2. The oil level in the crankcase is low.
3. The cooling fins and air passages
under the engine blower housing are
plugged.
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.
1. Sit on the seat.
2. The fuel tank is empty.
3. The air cleaner is dirty.
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.
The engine loses power.
Corrective Action
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.
6. The vent hole in the fuel cap is plugged.
7. There is dirt in the fuel filter.
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.
37
5. Install a new, correctly-gapped spark
plug.
6. Clean or replace the fuel cap.
7. Replace the fuel filter.
8. Contact an Authorized Service Dealer.
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.
3. The engine mounting bolts are loose.
4. There is a loose engine pulley, idler
pulley, or blade pulley.
5. The engine pulley is damaged.
6. The blade drive belt is damaged.
2. Tighten the blade mounting screws.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Install a new blade drive belt.
1. The blade drive belt is worn, loose, or
broken.
1. Install a new blade drive belt.
2. The blade drive belt is off the pulley.
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.
3. The underside of the mower is dirty.
4. The blade mounting screws are loose.
5. The blade drive belt tension is incorrect.
2. Adjust the height adjustment cable rod
assembly.
3. Clean the underside of the mower.
4. Tighten the blade mounting screws.
5. Adjust the blade drive belt.
1. The battery is not fully charged.
1. Charge the battery.
38
International Distributor List
Distributor:
Atlantis Su ve Sulama Sisstemleri Lt
Balama Prima Engineering Equip
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 Ground and Garden
Hako Ground and Garden
Hayter Limited (U.K.)
Hydroturf Int. Co Dubai
Hydroturf Egypt LLC
Ibea S.p.A.
Irriamc
Irrigation Products Int'l Pvt Ltd
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
Country:
Turkey
Hong Kong
Korea
Puerto Rico
Costa Rica
Sri Lanka
Northern Ireland
Mexico
Guatemala
Japan
Greece
China
Sweden
Norway
United Kingdom
United Arab Emirates
Egypt
Italy
Portugal
India
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
47 22 90 7760
44 1279 723 444
97 14 347 9479
202 519 4308
39 0331 853611
351 21 238 8260
86 22 83960789
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 D
The Toro Warranty
Conditions and Products Covered
Instructions for Obtaining Warranty Service
The Toro® Company and its afliate, 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:
If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:
Products
Walk Power Mowers
Rear Engine Riders
Lawn & Garden Tractors
Electric Hand Held Products
Snowthrowers
Consumer Zero Turn
2.
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
1.
Bring the product and your proof of purchase (sales receipt) to your seller
or the Service Dealer.
If for any reason you are dissatised 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
* “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
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.
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