Toro Z Master Professional 5000 Series Riding Mower, Riding Product Operator's Manual
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Form No. 3424-998 Rev A
Z Master
®
Professional 5000
Series Riding Mower
with 60in TURBO FORCE ® Side Discharge
Mower
Model No. 74915—Serial No. 403004519 and Up
Register at www.Toro.com.
Original Instructions (EN)
*3424-998* A
It is a violation of California Public Resource Code
Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.
The enclosed engine owner's manual is supplied for information regarding the US Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.
Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of
Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower. Please refer to the engine manufacturer’s information included with the machine.
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Use of this product may cause exposure to chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Introduction
This rotary-blade, riding lawn mower is intended to be used by professional, hired operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. It is not designed for cutting brush or for agricultural uses.
Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.
Visit www.Toro.com for product safety and operation training materials, 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.
identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Important: With your mobile device, you can scan the QR code (if equipped) on the serial number decal to access warranty, parts, and other product information.
g233771
Figure 1
1.
Model and serial number location
© 2018—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Model No.
Serial No.
2
This manual identifies potential hazards and has safety messages identified by the safety-alert symbol
(
Figure 2 ), which signals a hazard that may cause
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
serious injury or death if you do not follow the recommended precautions.
Figure 2
Safety-alert symbol g000502
This manual uses 2 words to highlight information.
Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Contents
Safety ....................................................................... 4
General Safety ................................................... 4
Slope Indicator ................................................... 5
Safety and Instructional Decals .......................... 6
Product Overview ................................................... 12
Controls ........................................................... 12
Specifications .................................................. 13
Before Operation ................................................. 14
Before Operation Safety ................................... 14
Adding Fuel ...................................................... 15
Performing Daily Maintenance.......................... 15
Breaking in a New Machine .............................. 15
Using the Rollover-Protection System
(ROPS) ......................................................... 16
Using the Safety-Interlock System .................... 17
Positioning the Seat.......................................... 18
Unlatching the Seat .......................................... 18
Changing the Seat Suspension......................... 18
During Operation ................................................. 18
During Operation Safety ................................... 18
Operating the Parking Brake............................. 20
Operating the Mower Blade-Control Switch
(PTO) ............................................................ 21
Operating the Throttle....................................... 21
Operating the Choke ........................................ 21
Starting the Engine ........................................... 22
Shutting Off the Engine..................................... 22
Using the Motion-Control Levers....................... 23
Driving the Machine .......................................... 23
Using the Side Discharge ................................. 24
Adjusting the Height of Cut ............................... 25
Adjusting the Anti-Scalp Rollers........................ 26
Adjusting the Flow Baffle Cam Locks ................ 26
Positioning the Flow Baffle................................ 27
Operating Tips ................................................. 28
After Operation .................................................... 29
After Operation Safety ...................................... 29
Using the Fuel-Shutoff Valve............................. 29
Using the Drive-Wheel-Release Valves ............ 29
Transporting the Machine ................................. 30
Maintenance ........................................................... 32
Maintenance Safety.......................................... 32
Recommended Maintenance Schedule(s) ........... 32
Lubrication .......................................................... 33
Greasing the Machine....................................... 33
Adding Light Oil or Spray Lubrication ................ 33
Greasing the Mower Deck ................................ 34
Lubricating the Caster-Wheel Hubs .................. 35
Engine Maintenance ........................................... 36
Engine Safety ................................................... 36
Servicing the Air Cleaner .................................. 36
Servicing the Engine Oil.................................... 38
Servicing the Spark Plug................................... 40
Checking the Spark Arrester ............................. 41
Fuel System Maintenance ................................... 42
Replacing the Fuel Filter ................................... 42
Servicing the Fuel Tank..................................... 42
Electrical System Maintenance ........................... 43
Electrical System Safety ................................... 43
Servicing the Battery......................................... 43
Servicing the Fuses .......................................... 44
Drive System Maintenance .................................. 45
Checking the Seat Belt ..................................... 45
Checking the Roll-Bar Knobs ............................ 45
Adjusting the Tracking ...................................... 46
Checking the Tire Pressure............................... 46
Checking the Wheel Lug Nuts........................... 46
Checking the Wheel-Hub Slotted Nut................ 46
Adjusting the Caster-Pivot Bearing ................... 47
Using the Clutch Shim ...................................... 47
Cooling System Maintenance .............................. 49
Cleaning the Engine Screen and Engine-Oil
Cooler ........................................................... 49
Cleaning the Engine-Cooling Fins and
Shrouds ........................................................ 50
Checking and Cleaning the Hydraulic-Unit
Shrouds ........................................................ 50
Brake Maintenance ............................................. 51
Adjusting the Parking Brake.............................. 51
Belt Maintenance ................................................ 52
Inspecting the Belts .......................................... 52
Replacing the Mower Belt ................................. 52
Replacing the Hydraulic Pump-Drive
Belt................................................................ 53
Controls System Maintenance ............................. 54
Adjusting the Control-Handle Position .............. 54
Adjusting the Motion-Control Linkage ............... 55
Adjusting the Motion-Control Damper ............... 56
Adjusting the Motion-Control Neutral-Lock
Pivot.............................................................. 56
Hydraulic System Maintenance ........................... 57
Hydraulic System Safety................................... 57
Servicing the Hydraulic System ........................ 57
Mower Deck Maintenance.................................... 59
Leveling the Mower Deck.................................. 59
Servicing the Cutting Blades ............................. 61
Removing the Mower Deck ............................... 62
3
Replacing the Grass Deflector .......................... 63
Cleaning .............................................................. 64
Cleaning under the Mower Deck ....................... 64
Disposing of Waste........................................... 64
Storage ................................................................... 65
Storage Safety.................................................. 65
Cleaning and Storage ....................................... 65
Troubleshooting ...................................................... 66
Schematics ............................................................. 68
Safety
This machine has been designed in accordance with
ANSI B71.4-2012.
General Safety
This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury.
Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
• Always keep the roll bar in the fully raised and locked position and use the seat belt.
• Do not operate the machine near drop-offs, ditches, embankments, water, or other hazards, or on slopes greater than 15 degrees.
• Read and understand the contents of this
Operator’s Manual before starting the engine.
• Do not put your hands or feet near moving components of the machine.
• Do not operate the machine without all guards and other safety protective devices in place and working on the machine.
• Keep children and bystanders out of the operating area. Never allow children to operate the machine.
• Stop the machine, shut off the engine, and remove the key before servicing, fueling, or unclogging the machine.
Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol, which means
Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death.
You can find additional safety information where needed throughout this manual.
4
Slope Indicator
Figure 3
You may copy this page for personal use.
1.
The maximum slope you can operate the machine on is 15 degrees . Use the slope chart to determine the degree of slope of hills before operating.
Do not operate this machine on a slope greater than 15 degrees.
Fold along the appropriate line to match the recommended slope.
2.
Align this edge with a vertical surface, a tree, building, fence pole, etc.
3.
Example of how to compare slope with folded edge g011841
5
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 missing.
decalbatterysymbols
Battery Symbols
Some or all of these symbols are on your battery.
1.
Explosion hazard
2.
No fire, open flame, or smoking
3.
Caustic liquid/chemical burn hazard
4.
Wear eye protection.
5.
Read the Operator's
Manual.
6.
Keep bystanders a safe distance away from the battery.
7.
Wear eye protection; explosive gases can cause blindness and other injuries.
8.
Battery acid can cause blindness or severe burns.
9.
Flush eyes immediately with water and get medical help fast.
10.
Contains lead; do not discard decal93-7818
93-7818
1.
Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb).
decal99-8936
99-8936
4.
Neutral
5.
Reverse decaloemmarkt
Manufacturer's Mark
1.
This mark indicates that the blade is identified as a part from the original machine manufacturer.
1.
Machine speed
2.
Fast
3.
Slow
1.
Grease
58-6520 decal58-6520 decal106-2655
106-2655
1.
Warning-do not touch or approach moving belts; remove the ignition key and read the instructions before servicing or performing maintenance.
6
106-5517
1.
Warning—do not touch the hot surface.
decal106-5517
110-2068
1.
Read the Operator's Manual .
decal110-2068 decal112-9028
112-9028
1.
Warning—stay away from moving parts; keep all guards and shields in place.
decal107-3069
107-3069
1.
Warning–there is no rollover protection when the roll bar is down.
2.
To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down.
3.
Read the Operator's Manual ; drive slowly and carefully.
116-5988
1.
Parking brake—engaged 2.
Parking brake—disengaged decal116-5988 decal116-8726
116-8726
1.
Read the Operator’s Manual for the recommended hydraulic fluid.
110-2067 decal110-2067
7
decal117-3848
117-3848
1.
Thrown object hazard—keep bystanders a safe distance away from the machine.
2.
Thrown object hazard, mower-do not operate the machine without the deflector, discharge cover, or grass collection system in place.
3.
Cutting/dismemberment of hand or foot—stay away from moving parts; keep all guards and shields in place.
1.
Read the Operator’s
Manual .
2.
Lock
126-4398
3.
Unlock decal119-6807
1.
Warning—no step
119-6807 decal126-4398 decal126-2055
126-2055
1.
Wheel lug nut torque 129 N∙m (95 ft-lb) (4x)
2.
Wheel hub nut torque 319 N∙m (235 ft-lb)
3.
Read and understand the Operator’s Manual before performing any maintenance, check torque after first 100 hours then every 500 hours thereafter.
1.
PTO
2.
Parking brake
3.
Neutral g224114
126-5641
4.
Operator-presence switch
5.
See user’s guide for operating condition code
8
1.
Fuse location
2.
Relay location
3.
Main—20 A
126-7875
4.
Auxiliary—15 A
5.
Start relay
6.
Not used decal126-7875
1.
Read the Operator's
Manual .
decal127-0326
127-0326
3.
Remove the key from the ignition and read the
Operator's Manual before performing maintenance or servicing the machine.
2.
Height-of-cut
1.
Belt routing
136-5508 decal136-5508
1.
Warning—read the
Operator's Manual .
decal127-6663
127-6663
2.
Crushing hazard—1)
Engage the parking brake, shut off the engine, and remove the key; 2) Jack the machine using a manufacturer-approved jack, and always use a jackstand.
9
decal125-9383
125-9383
1.
Check the hydraulic fluid every 50 operating hours.
2.
Read the Operator’s Manual for information on lubricating the machine.
3.
Check the tire pressure every 50 operating hours.
4.
Read the Operator’s Manual before servicing or performing maintenance.
1.
Fast
2.
Slow
3.
Choke
4.
PTO
137-9209
5.
Engine—stop
6.
Engine—run
7.
Engine—start
10 decal137-9209
decal132-0871
132-0871
Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. If possible, keep the cutting units lowered to the ground while operating the machine on slopes. Raising the cutting units while operating on slopes can cause the machine to become unstable.
1.
Warning—read the Operator’s Manual ; do not operate this machine unless you are trained; wear hearing protection.
2.
Cutting, dismembering, and entanglement hazard—keep hands away from moving parts; keep all guards and shields in place.
3.
Thrown object hazard—keep bystanders away.
4.
Ramp hazard—when loading onto a trailer, do not use dual ramps; only use a singular ramp wide enough for the machine and that has an incline less than 15°; back up the ramp (in reverse) and drive forward off the ramp.
5.
Bodily harm hazard—do not carry passengers; look behind you when mowing in reverse.
6.
Tipping hazard on slopes—do not use on slopes near open water; do not use on slopes greater than 15°.
decal133-8062
133-8062
11
Product Overview
Controls
Become familiar with all the controls before you start the engine and operate the machine.
Control Panel
1.
Height-of-cut deck-lift pedal
2.
Transport lock
3.
Parking-brake lever
4.
Controls
5.
Motion-control levers
Figure 4
6.
Roll bar
7.
Seat belt
8.
Fuel cap
9.
Mower deck
10.
Caster wheel g027333
1.
Blade-control switch
(power takeoff)
2.
Choke control
3.
Throttle control
Figure 5
4.
Hour meter/Safety-interlock display
5.
Key switch g233557
Hour Meter
The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular
The hour meter displays when you are operating the machine and momentarily when you shut off the engine. The display turns off after 5 minutes.
Refer to the Software Guide for more information.
12
Figure 6
1.
Safety-interlock indicators 3.
Information screen
2.
LED status light g231075
Fuel Gauge
When the fuel-tank level is low, the LED status light flashes a red light and the fuel-level symbol on the screen flashes.
Refer to the Software Guide for more information.
Safety-Interlock Indicators
There are symbols on the hour meter that indicate with a black bar that the interlock component is positioned
).
Attachments/Accessories
A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories.
To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.
Throttle Control
The throttle controls the engine speed, and it has a continuous-variable setting from the S LOW to F AST position (
Choke Control
Use the choke control to start a cold engine.
Blade-Control Switch (Power
Takeoff)
The blade-control switch, represented by a power-takeoff (PTO) symbol, engages and disengages power to the mower blades (
).
Key Switch
The key switch, used to start and shut off the engine, has 3 positions: O
FF
, R
UN
, and S
TART
. Refer to
.
Motion-Control Levers
Use the motion-control levers to drive the machine
forward, reverse, and turn either direction ( Figure 4 ).
Specifications
Note: Specifications and design are subject to change without notice.
Width
Without deck
Deflector up
Deflector down
135 cm (53 inches)
157 cm (62 inches)
192 cm (76 inches)
Length
Roll bar up
Roll bar down
Height
Roll bar up
Roll bar down
Weight
569 kg (1,255 lb)
211 cm (83 inches)
215 cm (85 inches)
179 cm (71 inches)
119 cm (47 inches)
Neutral-Lock Position
Use the N EUTRAL LOCK position with the safety-interlock system to engage and to determine the N EUTRAL position.
Fuel-Shutoff Valve
Close the fuel-shutoff valve when transporting or storing the machine; refer to
.
13
Operation
Note: Determine the left and right sides of the machine from the normal operating position.
Before Operation
Before Operation Safety
General Safety
• Never allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
• Become familiar with the safe operation of the equipment, operator controls, and safety signs.
• Know how to stop the machine and shut off the engine quickly.
• Check that operator-presence controls, safety switches, and shields are attached and functioning properly. Do not operate the machine unless they are functioning properly.
• Before mowing, always inspect the machine to ensure that the blades, blade bolts, and cutting assemblies are in good working condition.
Replace worn or damaged blades and bolts in sets to preserve balance.
• Inspect the area where you will use the machine and remove all objects that the machine could throw.
• Evaluate the terrain to determine the appropriate equipment and any attachments or accessories required to operate the machine properly and safely.
• Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground, away from your vehicle before filling.
• Remove the equipment from the truck or trailer and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than a fuel-dispenser nozzle.
• Do not operate the machine without the entire exhaust system in place and in proper working condition.
• Keep the fuel-dispenser nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
• If you spill fuel on your clothing, change your clothing immediately. Wipe up any fuel that spills.
• Never overfill the fuel tank. Replace the fuel cap and tighten it securely.
• Store fuel in an approved container and keep it out of the reach of children. Never buy more than a 30-day supply of fuel.
• Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 6 to 13 mm (1/4 to
1/2 inch) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.
– Avoid prolonged breathing of vapors.
– Keep your face away from the nozzle and fuel tank opening.
– Avoid contact with skin; wash off spills with soap and water.
Fuel Safety
• To avoid personal injury or property damage, use extreme care in handling fuel. Fuel vapors are flammable and explosive.
• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
• Use only an approved fuel container.
• Do not remove the fuel cap or add fuel to the fuel tank while the engine is running or while hot.
• Do not refuel the machine indoors.
• Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.
14
Adding Fuel
Recommended Fuel
• For best results, use only clean, fresh (less than
30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).
• Ethanol : Gasoline with up to 10% ethanol
(gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and
MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Never use gasoline that contains more than
10% ethanol by volume , such as E15 (contains
15% ethanol), E20 (contains 20% ethanol), or E85
(contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.
• Do not use gasoline containing methanol.
• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.
• Do not add oil to gasoline.
Note: Do not fill the fuel tank completely full.
The empty space in the tank allows the fuel to expand.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide the following benefits:
• Keeps fuel fresh longer when used as directed by the fuel-stabilizer manufacturer
• Cleans the engine while it runs
• 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 fuel stabilizer/conditioner to the fuel.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.
Filling the Fuel Tank
1.
Park the machine on a level surface.
2.
Engage the parking brake.
3.
Shut off the engine and remove the key.
4.
Clean around the fuel-tank cap.
5.
Fill the fuel tank to the bottom of the filler neck
(
).
Figure 7
Performing Daily
Maintenance
Before starting the machine each day, perform the
Each Use/Daily procedures listed in
.
g027726
Breaking in a New Machine
New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow
40 to 50 hours of break-in time for new machines to develop full power and best performance.
15
Using the
Rollover-Protection System
(ROPS)
WARNING
To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt.
Ensure that the seat is secured to the machine.
WARNING
There is no rollover protection when the roll bar is in the down position.
• Lower the roll bar only when absolutely necessary.
• Do not wear the seat belt when the roll bar is in the down position.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance permits.
• Check carefully for overhead clearances
(i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.
Lowering the Roll Bar
Important: Lower the roll bar only when absolutely necessary.
1.
To lower the roll bar, apply forward pressure to the upper part of the roll bar.
2.
Pull both knobs out and rotate them 90 degrees
so they are not engaged ( Figure 8 ).
3.
Lower the roll bar to the down position ( Figure
g228804
Figure 8
1.
Roll bar in the upright position
2.
ROPS knob in the latched position
3.
Pull the ROPS knob out.
4.
Rotate the ROPS knob 90 degrees.
5.
ROPS knob in the unlatched position
6.
Roll bar in the folded position
Raising the Roll Bar
Important: Always use the seat belt with the roll bar in the raised position.
1.
Raise the roll bar to the operating position and rotate the knobs until they move partially into
).
2.
Raise the roll bar to the full upright position while pushing on the upper roll bar so that the pins snap into position when the holes align with the
).
3.
Push on the roll bar and ensure that both pins are engaged.
16
Using the Safety-Interlock
System
WARNING
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.
Understanding the
Safety-Interlock System
The safety-interlock system is designed to prevent the engine from starting unless:
• The parking brake is engaged.
• The blade-control switch (PTO) is disengaged.
• The motion-control levers are in the N
EUTRAL
-
LOCK position.
The safety-interlock system also is designed to shut off the engine when the motion-control levers are moved from the N
EUTRAL
-
LOCK position with the parking brake engaged or if you rise from the seat when the PTO is engaged.
The hour meter has symbols to notify the user when the interlock component is in the correct position.
When the component is in the proper position for starting the engine, a black bar displays below the corresponding icon.
Testing the Safety-Interlock
System
Service Interval: Before each use or daily
Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized
Service Dealer repair the safety system immediately.
1.
Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the O N position. Try starting the engine; the engine should not start.
2.
Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the O FF position. Move either motion-control lever out of the N EUTRAL LOCK position. Try starting the engine; the engine should not start. Repeat for the other control lever.
3.
Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the O
FF position, and move the motion-control levers to the N
EUTRAL
-
LOCK position. Now start the engine. While the engine is running, disengage the parking brake, engage the blade-control switch (PTO), and rise slightly from the seat; the engine should shut off.
4.
Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the O FF position, and move the motion-control levers to the N EUTRAL LOCK position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should shut off. Repeat for other motion control.
5.
Sit on the seat, disengage the parking brake, move the blade-control switch (PTO) to the O FF position, and move the motion-control levers to the N EUTRAL LOCK position. Try starting the engine; the engine should not start.
g231781
Figure 9
1.
Black bars display when the interlock components are in the proper position for starting the engine.
17
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 ( Figure 10 ).
Changing the Seat
Suspension
The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable.
To adjust it, turn the knob in front either direction to
provide the best comfort ( Figure 12 ).
g019754
Figure 10
Unlatching the Seat
To unlatch the seat, push the seat latch forward
(
1.
Seat latch
Figure 11
2.
Seat g019768
Figure 12
1.
Seat-suspension knob g008956
During Operation
During Operation Safety
General Safety
• The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage.
• Wear appropriate clothing, including eye protection; long pants; slip-resistant, substantial footwear; and hearing protection. Tie back long hair and do not wear loose clothing or loose jewelry.
• Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.
• Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
• Never carry passengers on the machine and keep bystanders and pets away from the machine during operation.
• Operate the machine only in good visibility to avoid holes or hidden hazards.
• Avoid mowing on wet grass. Reduced traction could cause the machine to slide.
18
• Ensure that all drives are in neutral, the parking brake is engaged, and you are in the operating position before you start the engine.
• Keep your hands and feet away from the cutting units. Keep clear of the discharge opening at all times.
• Look behind and down before backing up to be sure of a clear path.
• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision.
• Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel goes over the edge or if the edge gives way.
• Stop the blades whenever you are not mowing.
• Stop the machine, shut off the engine, remove the key, and inspect the blades after striking an object or if there is an abnormal vibration in the machine. Make all necessary repairs before resuming operation.
• Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way.
• Disengage the drive to the cutting unit, shut off the engine, and remove the key before adjusting the height of cut (unless you can adjust it from the operating position).
• Never run an engine in an area where exhaust gases are enclosed.
• Never leave a running machine unattended.
• Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following:
– Stop the machine on level ground.
– Disengage the power takeoff and lower the attachments.
– Engage the parking brake.
– Shut off the engine and remove the key.
– Wait for all moving parts to stop.
• Do not operate the machine when there is the risk of lightning.
• Do not use the machine as a towing vehicle unless it has a hitch installed.
• Do not change the governor speed or overspeed the engine.
• Use only accessories and attachments approved by Toro.
• This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.
Figure 13
1.
Wear hearing protection.
g229846
Rollover Protection System
(ROPS) Safety
• Do not remove the roll bar from the machine.
• Ensure that the seat belt is attached and that you can release it quickly in an emergency.
• Always wear your seat belt when the roll bar is up.
• Check carefully for overhead obstructions and do not contact them.
• Keep the roll bar in safe operating condition by thoroughly inspecting it periodically for damage and keeping all the mounting fasteners tight.
• Replace a damaged roll bar. Do not repair or alter it.
Slope Safety
• Slopes are a major factor related to loss of control and rollover accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, do the following:
– Review and understand the slope instructions in the manual and on the machine.
– Use an angle indicator to determine the approximate slope angle of the area.
– Never operate on slopes greater than 15 degrees.
– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation.
Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.
• Identify hazards at the base of the slope. Do not operate the machine near drop-offs, ditches, embankments, water, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe distance (twice the width of the machine) between the machine and any hazard. Use a walk-behind machine or a hand trimmer to mow the grass in these areas.
19
• Avoid starting, stopping, or turning the machine on slopes. Avoid making sudden changes in speed or direction; turn slowly and gradually.
• Do not operate a machine under any conditions where traction, steering, or stability is in question.
Be aware that operating the machine on wet grass, across slopes, or downhill may cause the machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped.
• Remove or mark obstacles such as ditches, holes, ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine.
• Use extra care while operating with accessories or attachments, such as grass-collection systems.
These can change the stability of the machine and cause a loss of control. Follow directions for counterweights.
• If possible, keep the deck lowered to the ground while operating on slopes. Raising the deck while operating on slopes can cause the machine to become unstable.
Operating the Parking
Brake
Always engage the parking brake when you stop the machine or leave it unattended.
Engaging the Parking Brake
Park the machine on a level surface.
Figure 15
Disengaging the Parking Brake
g027334
Figure 16 g027335 g221745
Figure 14
1.
Safe Zone—use the machine here on slopes less than 15 degrees or flat areas.
2.
Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15 degrees and near drop-offs or water.
3.
Water
4.
W=width of the machine
5.
Keep a safe distance
(twice the width of the machine) between the machine and any hazard.
20
Operating the Mower
Blade-Control Switch (PTO)
The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.
Engaging the Blade-Control
Switch (PTO)
Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Operating the Choke
Use the choke to start a cold engine.
1.
Pull up the choke knob to engage the choke before using the key switch (
).
2.
Push down the choke knob to disengage the
choke after the engine has started ( Figure 20 ).
Figure 17
Disengaging the Blade-Control
Switch (PTO)
g008945
1.
O N position
Figure 20
2.
O FF position g008959 g009174
Figure 18
Operating the Throttle
You can move the throttle control between F AST and
S LOW positions (
Always use the F
AST position when engaging the PTO.
Figure 19 g008946
21
Starting the Engine
Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start, wait
15 seconds between attempts. Failure to follow these instructions can burn out the starter motor.
Note: You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system.
Shutting Off the Engine
CAUTION
Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.
Always remove the key and engage the parking brake when leaving the machine unattended.
Figure 21 g032328 g027337
Figure 22
Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine, as fuel leakage may occur. Engage the parking brake before transporting. Make sure that you remove the key as the fuel pump may run and cause the battery to lose charge.
22
Using the Motion-Control
Levers
WARNING
The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine.
• Use caution when making turns.
• Slow the machine down before making sharp turns.
Driving Forward
Note: The engine shuts off when you move the traction-control with the parking brake engaged.
To stop the machine, pull the motion-control levers to the N
EUTRAL position.
1.
Disengage the parking brake; refer to
Disengaging the Parking Brake (page 20)
.
2.
Move the levers to the center, unlocked position.
3.
To go forward, slowly push the motion-control levers forward (
Figure 23
1.
Motion-control lever—N EUTRAL LOCK position
4.
Backward
2.
Center, unlocked position 5.
Front of machine
3.
Forward g004532
Driving the Machine
The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves.
The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the F
AST position for best performance. Always operate in the full throttle position when mowing.
Figure 24 g008952
23
Driving Backward
1.
Move the levers to the center, unlocked position.
2.
To go backward, slowly pull the motion-control levers rearward (
Figure 25 g008953
Using the Side Discharge
The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
DANGER
Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.
• Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.
• Never put your hands or feet under the mower deck.
• Never try to clear the discharge area or mower blades unless you move the blade-control switch (PTO) to the O FF position, rotate the key switch to the O FF position, and remove the key from the key switch.
• Make sure that the grass deflector is in the down position.
24
Adjusting the Height of Cut
Using the Transport Lock
The transport lock has 2 positions, and is used with the deck-lift pedal. There is a L
OCK position and an U NLOCK position for the transport position of the
).
Adjusting the Height-of-Cut Pin
The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations.
1.
Move the transport lock to the lock position.
2.
Push on the deck-lift pedal with your foot, and raise the mower deck to the transport position
(also the 140 mm (5-1/2 inch) cutting height position) as shown in
3.
To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (
4.
Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, and
5.
Push on the deck lift, pull back on the transport lock, and slowly lower the mower deck.
g229103
Figure 26
Transport-Lock Positions
1.
Transport lock knob 3.
U NLOCK position—The mower deck does not lock into the transport position.
2.
L OCK position—The mower deck locks into the transport position.
1.
Deck-lift pedal
2.
Cut-of-height pin
Figure 27
3.
Transport lock g027343
25
Adjusting the Anti-Scalp
Rollers
Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers.
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Adjust the anti-scalp rollers as shown in
, and
.
1.
Anti-scalp roller
2.
Spacer
3.
Bushing
Figure 30
4.
Flange nut
5.
Bolt
1.
Anti-scalp roller
2.
Spacer
3.
Bushing
Figure 28
4.
Flange nut
5.
Bolt
1.
Anti-scalp roller
2.
Bushing
Figure 29
3.
Flange nut
4.
Bolt g029957 g029955 g029956
Adjusting the Flow Baffle
Cam Locks
This procedure is applicable only to machines with the flow-baffle locks. Certain models have nuts and bolts in place of the flow-baffle locks and can be adjusted the same.
You can adjust the mower-discharge flow for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut.
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
To adjust the cam locks, swing the lever up to
loosen the cam lock ( Figure 31 ).
4.
Adjust the baffle and cam locks in the slots to the desired discharge flow.
5.
Swing the lever back over to tighten the baffle and cam locks (
6.
If the cam locks do not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock.
Note: Adjust the cam lock until the desired locking pressure is achieved.
26
Position B
Use this position when bagging. Always align it with the blower opening.
g027727
Figure 31
Positioning the Flow Baffle
The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass.
Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
Position A
This is the full rear position. The suggested use for this position is as follows:
• Short, light grass mowing conditions
• Dry conditions
• Smaller grass clippings
• Propels grass clippings farther away from the mower
Figure 33 g005833
Position C
This is the full open position. The suggested use for this position is as follows:
• Tall, dense grass mowing conditions
• Wet conditions
• Lowers the engine-power consumption
• Allows increased ground speed in heavy conditions
Figure 32 g005832
Figure 34 g005834
27
Operating Tips
Using the Fast Throttle Setting
For best mowing and maximum air circulation, operate the engine at the F AST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck.
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure that the cutting height of the mower deck does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use.
When cutting grass longer than 15 cm (6 inches) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.
Cutting a Third of the Grass Blade
It is best to cut only about a third of the grass blade.
Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.
Alternating the Mowing Direction
Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.
Mowing at Correct Intervals
Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting.
Using a Slower Cutting Speed
To improve cut quality, use a slower ground speed in certain conditions.
Avoiding Cutting Too Low
When mowing uneven turf, raise the cutting height to avoid scalping the turf.
Stopping the Machine
If you must stop the forward motion of the machine while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward.
Keeping the Underside of the
Mower Deck Clean
Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
Maintaining the Blade(s)
Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the mower blades after each use for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.
28
After Operation
After Operation Safety
General Safety
• Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
• Shut off the fuel and remove the key before storing or transporting the machine.
• Disengage the drive to the attachment whenever you are transporting or not using the machine.
• Allow the engine to cool before storing the machine in any enclosure.
• Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.
Using the Fuel-Shutoff
Valve
The fuel-shutoff valve is located under the seat. Move the seat forward to access it.
Close the fuel-shutoff valve for transport, maintenance, and storage.
Ensure that the fuel-shutoff valve is open when starting the engine.
Using the
Drive-Wheel-Release
Valves
WARNING
Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury.
Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel-release valves.
WARNING
The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns.
Allow the engine and hydraulic-drive units to cool completely before accessing the drive-wheel-release valves.
The drive-wheel-release valves are located in the back of each hydraulic-drive unit, under the seat.
Note: Make sure that the release valves are in the fully horizontal position when operating the machine; otherwise, severe damage to the hydraulic system can occur.
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Rotate the release-valve levers vertically to push
Note: This allows hydraulic fluid to bypass the pump, enabling the wheels to turn.
4.
Disengage the parking brake before pushing the machine.
g008948
1.
O N position
Figure 35
2.
O FF position
29
1.
Vertical to push the machine
Figure 36
2.
Horizontal to run the machine g024246
5.
Rotate the release valve levers horizontally to run the machine (
).
Transporting the Machine
Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
WARNING
Driving on the street or roadway without turn signals, lights, reflective markings, or a slow-moving-vehicle emblem is dangerous and can lead to accidents, causing personal injury.
Do not drive the machine on a public street or roadway.
Selecting a Trailer
WARNING
Loading a machine onto a trailer or truck increases the possibility of tip-over and could
cause serious injury or death ( Figure 37 ).
• Use only a full-width ramp; do not use individual ramps for each side of the machine.
• Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.
• Ensure that the length of the ramp is at least 4 times as long as the height of the trailer or truck bed to the ground. This ensures that the ramp angle does not exceed 15 degrees on flat ground.
30
1.
If using a trailer, connect it to the towing vehicle and connect the safety chains.
2.
If applicable, connect the trailer brakes and lights.
3.
Lower the ramp, ensuring that the angle between the ramp and the ground does not
).
4.
Back the machine up the ramp ( Figure 38 ).
g027996
Figure 37
1.
Full-width ramp in stowed position
2.
Side view of full-width ramp in loading position
3.
Not greater than
15 degrees
4.
Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5.
H=height of the trailer or truck bed to the ground
6.
Trailer g028043
Figure 38
1.
Back the machine up the ramp.
2.
Drive the machine forward down the ramp.
5.
Shut off the engine, remove the key, and engage the parking brake.
6.
Tie down the machine near the front caster wheels and the rear bumper with straps, chains, cable, or ropes (
). Refer to local regulations for tie-down requirements.
Loading the Machine
WARNING
Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death.
• Use extreme caution when operating a machine on a ramp.
• Back the machine up the ramp and drive it forward down the ramp.
• Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a tip-over situation.
1.
Tie-down loops
Figure 39
Unloading the Machine
1.
Lower the ramp, ensuring that the angle between the ramp and the ground does not
).
2.
Drive the machine forward down the ramp
(
).
g027338
31
Maintenance
Maintenance Safety
• Before repairing the machine do the following:
– Disengage the drives.
– Engage the parking brake.
– Shut off the engine and remove the key.
• Park the machine on a level surface.
• Clean grass and debris from the cutting unit, drives, mufflers, and engine to help prevent fires.
• Clean up oil or fuel spills.
• Do not allow untrained personnel to service the machine.
• Use jack stands to support the machine and/or components when required.
• Carefully release pressure from components with stored energy.
• Disconnect the battery before making any repairs.
Disconnect the negative terminal first and the positive terminal last. Connect the positive terminal first and negative last.
• Use care when checking the blades. Wrap the blade(s) or wear thickly padded gloves, and use caution when servicing them. Only replace blades; do not straighten or weld them.
• Keep your hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
• Keep all parts in good working condition and all hardware tightened, especially the blade-attachment bolts. Replace all worn or damaged decals.
• Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their proper operation regularly.
• Use only genuine Toro replacement parts.
• Check the parking brake operation frequently.
Adjust and service as required.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
After the first 100 hours
After the first 250 hours
Before each use or daily
Every 50 hours
Every 100 hours
Every 200 hours
Every 250 hours
Maintenance Procedure
• Check the wheel lug-nut torque.
• Check the wheel-hub slotted-nut torque.
• Check the parking brake adjustment.
• Change the hydraulic filters and hydraulic fluid when using any type of fluid.
• Check the safety system.
• Check the air cleaner for dirty, loose or damaged parts.
• Check the engine-oil level.
• Check the seat belt.
• Check the roll bar knobs.
• Clean the engine screen and the oil cooler.
• Check and clean the hydraulic-unit shrouds.
• Inspect the blades.
• Clean the mower deck.
• Check the spark arrester (if equipped).
• Check the tire pressure
• Inspect the belts for cracks and wear.
• Check the hydraulic-fluid level.
• Lubricate the mower deck-lift pivots.
• Change the engine oil (more often in dirty or dusty conditions).
• Check and clean engine-cooling fins and shrouds.
• Change the engine-oil filter (more often in dirty or dusty conditions).
• Check the spark plug(s).
• Replace the fuel filter (more often in dusty, dirty conditions).
• Service or replace the air-cleaner foam element (more often under dusty, dirty conditions).
• Change the hydraulic filters and hydraulic fluid when using Mobil® 1 fluid (more often in dirty or dusty conditions).
32
Maintenance Service
Interval
Every 500 hours
Monthly
Yearly
Yearly or before storage
Maintenance Procedure
• Replace the air-cleaner paper element (more often under dusty, dirty conditions).
• Replace the spark plug(s).
• Check the wheel lug-nut torque.
• Check the wheel-hub slotted-nut torque.
• Adjust the caster-pivot bearing.
• Check the parking brake adjustment.
• Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions).
• Check the battery charge.
• Grease the pump-belt-idler arm.
• Grease the front caster pivots (more often in dirty or dusty conditions).
• Repack the front caster-wheel bearings (more often in dirty or dusty conditions).
• Lubricate the caster-wheel hubs.
• Paint chipped surfaces.
• Check all maintenance procedures listed above before storage.
Important: Refer to your engine owner's manual for additional maintenance procedures.
CAUTION
If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.
Remove the key from the switch before you perform any maintenance.
Lubrication
Greasing the Machine
Grease more frequently when operating conditions are extremely dusty or sandy.
Grease Type: No. 2 lithium or molybdenum grease
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Clean the grease fittings with a rag.
Note: Make sure that you scrape any paint off the front of the fitting(s).
4.
Connect a grease gun to the fitting.
5.
Pump grease into the fittings until grease begins to ooze out of the bearings.
6.
Wipe up any excess grease.
Adding Light Oil or Spray
Lubrication
Service Interval: Every 100 hours
Lubricate the deck-lift pivots.
Figure 40 g017050
33
Greasing the Mower Deck
Service Interval: Yearly—Grease the pump-belt-idler arm.
Yearly—Grease the front caster pivots (more often in dirty or dusty conditions).
Yearly—Repack the front caster-wheel bearings
(more often in dirty or dusty conditions).
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Grease the mower deck idler-pulley pivot until
grease comes out the bottom ( Figure 41 ).
5.
Remove the dust cap and adjust the caster pivots.
Note: Keep the dust cap off until greasing is done.
6.
Remove the hex plug.
7.
Thread a grease fitting into the hole.
8.
Pump grease into the fitting until it oozes out around the top bearing.
9.
Remove the grease fitting in the hole.
10.
Install the hex plug and dust cap (
).
Figure 41
4.
Grease the drive-belt-idler arm (
).
g185957 g027339
Figure 43
11.
Grease the caster-wheel bearings ( Figure 43 ).
Figure 42 g009030
34
Lubricating the
Caster-Wheel Hubs
Service Interval: Yearly
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
1.
Seal guard g006115
Figure 44
2.
Spacer nut with wrench flats
12.
Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.
13.
With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease.
14.
Insert the second bearing and new seal into the wheel.
15.
Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward.
16.
Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen, then torque to 2 to 3 N∙m (20 to 25 in-lb).
Note: Make sure that the axle does not extend beyond either nut.
17.
Install the seal guards over the wheel hub, and insert the wheel into the caster fork.
18.
Install the caster bolt and tighten the nut fully.
Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust the torque on the spacer nut until there is a slight amount of drag.
Apply another layer of thread-locking adhesive.
3.
Raise the mower for access.
4.
Remove the caster wheel from the caster forks.
5.
Remove the seal guards from the wheel hub.
6.
Remove a spacer nut from the axle assembly in the caster wheel.
Note: Thread-locking adhesive has been applied to lock the spacer nuts to the axle.
7.
Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.
8.
Pry out seals and inspect bearings for wear or damage and replace if necessary.
9.
Pack the bearings with a general-purpose grease.
10.
Insert 1 bearing and 1 new seal into the wheel.
Note: Replace the seals.
11.
If the axle assembly is missing both spacer nuts, apply a thread-locking adhesive to 1 spacer nut and thread it onto the axle with the wrench flats facing outward.
Note: Do not thread the spacer nut all of the way onto the end of the axle. Leave approximately 3 mm (1/8 inch) from the outer surface of the spacer nut to the end of the axle inside the nut.
35
Engine Maintenance
Engine Safety
• Shut off the engine before checking the oil or adding oil to the crankcase.
• Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.
Servicing the Air Cleaner
Service Interval: Before each use or daily—Check the air cleaner for dirty, loose or damaged parts.
Every 250 hours—Service or replace the air-cleaner foam element (more often under dusty, dirty conditions).
Every 500 hours—Replace the air-cleaner paper element (more often under dusty, dirty conditions).
This engine is equipped with a replaceable, high-density paper and foam air-cleaner element.
Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air-cleaner system. Keep this area clean. Also, check for loose or damaged components. Replace all bent or damaged air-cleaner components.
Note: Operating the engine with loose or damaged air-cleaner components could allow unfiltered air into the engine, causing premature wear and failure.
Note: Service the air cleaner more often under dusty, dirty conditions.
Removing the Filters
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Release the latches on the air cleaner and pull the air-inlet cover off the air-cleaner body
(
).
4.
Clean the air-inlet screen and cover.
5.
Install the air-inlet cover and secure it with the
).
g012996
1.
Air-inlet cover
2.
Air-inlet screen
Figure 45
3.
Air-cleaner body
4.
Latch
6.
Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body
(
).
7.
Clean the inside of the air-cleaner cover with compressed air.
8.
Gently slide the primary filter out of the
).
Note: Avoid knocking the filter into the side of the body.
9.
Remove the inner filter only if you intend to replace it.
Important: Never attempt to clean the inner filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters.
36
1.
Inner filter
2.
Primary filter
3.
Air-cleaner cover
Figure 46
4.
Latch
5.
Air-cleaner body
10.
Inspect the primary filter for damage by looking into the filter, while shining a bright light on the outside of the filter.
Note: Holes in the filter will appear as bright spots. If the filter is damaged, discard it.
g012997
Installing the Filters
Important: To prevent engine damage, always operate the engine with both air filters and the cover installed.
1.
If you are installing new filters, check each filter for shipping damage.
Note: Do not use a damaged filter.
2.
If you are replacing the inner filter, carefully slide it into the filter body (
3.
Carefully slide the primary filter over the safety
).
Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it.
Important: Do not press on the soft, inside area of the filter.
4.
Install the air-cleaner cover and secure the
).
Servicing the Foam Element
1.
Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.
2.
Dry the element by squeezing it in a clean cloth.
Important: Replace the foam element if it is torn or worn.
Servicing the Paper Element
1.
Gently tap the paper element to dislodge dirt.
Note: Do not wash the paper element or use pressurized air, as this will damage the element.
Note: Replace a dirty, bent, or damaged element. Handle the new element carefully; do not use if the sealing surfaces are bent or damaged.
2.
Clean the air-cleaner base as required, and check the condition.
37
Servicing the Engine Oil
Engine Oil Specifications
Oil Capacity: with a filter change—1.8 L (61 fl oz); without a filter change—1.6 L (54 fl oz)
Viscosity: See the table below.
g017552
Figure 47
Checking the Engine-Oil Level
Service Interval: Before each use or daily
Note: Check the oil when the engine is cold.
Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Note: Ensure that the engine is cool so that the oil has had time to drain into the sump.
3.
To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and
dipstick before removing it ( Figure 48 ).
Figure 48 g194611
38
Changing the Engine Oil
Service Interval: Every 100 hours (more often in dirty or dusty conditions).
Note: Dispose of the used oil at a recycling center.
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 opposite side to ensure that the oil drains completely.
3.
Disengage the blade-control switch (PTO) and engage the parking brake.
4.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
5.
Drain the oil from the engine (
6.
Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the
additional oil to bring it to the Full mark ( Figure
g008804
Figure 50
7.
Start the engine and drive to a flat area.
8.
Check the oil level again.
g027660
Figure 49 g027734
39
Changing the Engine-Oil Filter
Service Interval: Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions).
1.
Drain the oil from the engine; refer to
Changing the Engine Oil (page 39)
.
2.
Change the engine-oil filter (
).
Servicing the Spark Plug
Service Interval: Every 200 hours—Check the spark plug(s).
Every 500 hours—Replace the spark plug(s).
Type: Champion XC12YC
Air Gap: 0.76 mm (0.03 inch)
Removing the Spark Plug
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Clean the area around the base of the plug(s) to keep dirt and debris out of the engine.
4.
Locate and remove the spark plug(s) as shown in
g009922 g027477
Figure 51
Note: Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra
3/4 turn.
3.
Fill the crankcase with the proper type of new oil (
Figure 52 g027478
Checking the Spark Plug
Important: Do not clean the spark plug(s).
Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.
If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.
Set the gap to 0.76 mm (0.03 inch).
40
Figure 53
Installing the Spark Plug
Figure 54 g206628 g028109
Checking the Spark
Arrester
For Machines with a Spark
Arrester
Service Interval: Every 50 hours
WARNING
Hot exhaust-system components may ignite fuel vapors even after you shut off the engine.
Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.
Do not refuel or run the engine unless the spark arrester is installed.
1.
Park the machine on a level surface, disengage the PTO, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Wait for the muffler to cool.
4.
If you see any breaks in the screen or welds, replace the arrester.
5.
If the screen is plugged, remove the arrester, shake loose particles out of the arrester, and clean the screen with a wire brush (soak the screen in solvent if necessary).
6.
Install the arrester on the exhaust outlet.
41
Fuel System
Maintenance
Replacing the Fuel Filter
Service Interval: Every 200 hours (more often in dusty, dirty conditions).
Important: Install the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that can cause fuel line damage.
The fuel filter is located near the engine on the left front of the engine.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Allow the machine to cool down.
4.
Close the fuel-shutoff valve under the seat.
5.
Replace the fuel filter ( Figure 55 ).
6.
Open the fuel-shutoff valve.
Servicing the Fuel Tank
Do not attempt to drain the fuel tank. Ensure that an
Authorized Service Dealer drains the fuel tank and services any components of the fuel system.
Figure 55 g027753
42
Electrical System
Maintenance
Electrical System Safety
• Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
• Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Servicing the Battery
Service Interval: Monthly
Removing the Battery
WARNING
Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.
• When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
• Do not allow metal tools to short between the battery terminals and metal parts of the machine.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Remove the battery as shown in
.
Figure 56 g027728
WARNING
Incorrectly removing the cables from battery 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.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
43
Charging the Battery
WARNING
Charging the battery produces gasses that can explode.
Never smoke near the battery and keep sparks and flames away from the battery.
Important: Always keep the battery fully charged
(1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F).
1.
Remove the battery from the chassis; refer to
Removing the Battery (page 43)
.
2.
Charge the battery for 10 to 15 minutes at 25 to
30 A or for 30 minutes at 10 A.
Note: Do not overcharge the battery.
3.
When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery
4.
Install the battery in the machine and connect the battery cables; refer to
.
Note: Do not run the machine with the battery disconnected; electrical damage may occur.
Installing the Battery
Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (
).
Figure 58
Servicing the Fuses
g032526
The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuses are located on the console to the right of the
).
To replace a fuse, remove the cover, pull out on the fuse to remove it, and install a new fuse.
Figure 57
1.
Positive (+) battery post 3.
Red (+) charger lead
2.
Negative (–) battery post 4.
Black (–) charger lead g000960
44
1.
Auxiliary, 15 A
2.
Main, 20 A
Figure 59
3.
Start relay
4.
Open g231345
Drive System
Maintenance
Checking the Seat Belt
Service Interval: Before each use or daily
Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged.
Checking the Roll-Bar
Knobs
Service Interval: Before each use or daily
WARNING
To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt.
Ensure that the seat is secured to the machine.
• Check that both the mounting hardware and the knobs are in good working condition.
• Make sure that the knobs are fully engaged with the roll bar in the raised position.
Note: The upper hoop of the roll bar may need to be pushed forward or pulled rearward to fully engage both knobs (
and
g228804
Figure 60
1.
Roll bar in the upright position
2.
Roll-bar knob in the latched position
3.
Pull the roll-bar knob out and rotate it 90 degrees.
4.
Rotate the roll-bar knob 90 degrees.
5.
Roll-bar knob in the unlatched position
6.
Roll bar in the folded position
45
1.
Engaged g228981
Figure 61
2.
Partially engaged—do not operate with the roll bar in this position.
Adjusting the Tracking
1.
Disengage the blade-control switch (PTO).
2.
Drive to an open flat area, move the motion-control levers to the N
EUTRAL
-L
OCK position.
3.
Move the throttle midway between fast and slow.
4.
Move both motion-control levers all the way forward until they both hit the stops in the T-slot.
5.
Check which way the machine tracks.
• If it tracks to the right, loosen the bolts and adjust the left stop plate rearward on the left T-slot until the machine tracks straight
• If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight
6.
Tighten the stop plate ( Figure 62 ).
Checking the Tire Pressure
Service Interval: Every 50 hours/Monthly (whichever comes first)
Maintain the air pressure in the rear tires at 90 kPa
(13 psi). Uneven tire pressure can cause uneven cut.
Check the tires when they are cold to get the most accurate pressure reading.
Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance.
g001055
Figure 63 g010153
Checking the Wheel Lug
Nuts
Check and torque the wheel lug nuts to 122 to 129
N∙m (90 to 95 ft-lb).
Checking the Wheel-Hub
Slotted Nut
Service Interval: After the first 100 hours
Every 500 hours
Check and ensure that the torque of the slotted nut is
286 to 352 N∙m (211 to 260 ft-lb).
Note: Do not use anti-seize compound on wheel hub.
1.
Control lever
2.
Bolt
Figure 62
Left control lever shown
3.
Stop plate
46
g001297
1.
Spring washers
2.
Locknut
Figure 65
3.
Dust cap g024121
Figure 64
1.
Slotted nut
Adjusting the Caster-Pivot
Bearing
Service Interval: Every 500 hours/Yearly (whichever comes first)
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Remove the dust cap from caster and tighten
).
4.
Tighten the locknut until the spring washers are flat, and then back off a 1/4 turn to properly set the preload on the bearings (
).
Important: Make sure that the spring washers are installed correctly as shown in
.
5.
Install the dust cap ( Figure 65 ).
Using the Clutch Shim
Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, you can remove the shim to extend the clutch life.
1.
Armature
2.
Field shell
3.
Rotor
4.
Brake-mounting bolt
Figure 66
5.
Brake spacer
6.
Re-gap shim
7.
Brake pole g010869
Removing the Clutch Shim
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
47
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (
Note: Do not discard the shim until the clutch is functioning properly.
Figure 67 g010868
4.
Check the condition of the wire-harness leads, connectors, and terminals.
Note: Clean or repair as necessary.
5.
Verify that 12 V is present at the clutch connector when the blade-control switch (PTO) switch is engaged.
6.
Measure the gap between the rotor and armature. If the gap is greater than 1 mm (0.04
inch), do the following steps:
A.
Loosen both brake-mounting bolts 1/2 to 1 full turn as shown in
.
Note: Do not remove the brake pole from the field shell/armature. The brake pole has worn to match the armature and needs to continue to match after you remove the shim to ensure proper brake torque.
g010871
Figure 69
1.
Shim
C.
Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers.
D.
Torque each bolt (M6 x 1) to 12.3 to 13.7
N∙m (9.5 to 10.5 ft-lb).
E.
Using a 0.25 mm (0.01 inch) thick feeler gauge, verify that a gap is present between the rotor and the armature face on both sides of the brake pole as shown in
and
.
Note: Due to the way the rotor and the armature faces wear (peaks and valleys) it is sometimes difficult to measure the gap accurately.
g010872
Figure 70
1.
Feeler gauge g010870
1.
Brake-mounting bolt
Figure 68
B.
Using needle-nose pliers, or by hand, hold
the tab and remove the shim ( Figure 69 ).
48
Figure 71
Cooling System
Maintenance
g010873
Cleaning the Engine Screen and Engine-Oil Cooler
Service Interval: Before each use or daily
Remove any buildup of grass, dirt, or other debris
from the oil cooler and the engine screen ( Figure 72 ).
1.
Feeler gauge
• If the gap is less than 0.25 mm (0.01
inch), then install the shim; refer to
Using the Clutch Shim (page 47)
.
• If the gap is sufficient, proceed to the safety check in step
F.
Perform the following safety check: i.
Sit on the seat and start the engine.
ii.
Make sure that the blades do not engage with the blade-control switch
(PTO) in the O FF position, and that the clutch is disengaged.
If the clutch does not disengage, install the shim again; refer to
Using the Clutch Shim (page 47)
.
iii.
Engage and disengage the blade-control switch (PTO) 10 consecutive times to ensure that the clutch is functioning properly.
Figure 72 g008804 g009191
Remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to
).
49
Cleaning the
Engine-Cooling Fins and
Shrouds
Service Interval: Every 100 hours/Yearly (whichever comes first)
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Remove the air-intake screen, the recoil starter,
and the fan housing ( Figure 73
).
4.
Clean the debris and grass from the engine parts.
5.
Install the air-intake screen, the recoil starter,
and the fan housing ( Figure 73
).
Checking and Cleaning the
Hydraulic-Unit Shrouds
Service Interval: Before each use or daily
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Move the seat forward.
4.
Clean the debris and grass from the hydraulic-unit shrouds (
5.
Position the seat.
g009922
1.
Engine guard
2.
Engine air-intake screen
3.
Bolt
Figure 73
4.
Fan housing
5.
Screw g004218
Figure 74
1.
Hydraulic-unit shrouds g015117
50
Brake Maintenance
Adjusting the Parking
Brake
Service Interval: After the first 100 hours
Every 500 hours thereafter
Note: Perform this procedure at the recommended service interval or when a brake component has been removed or replaced.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Raise the back of the machine and support the machine with jack stands.
CAUTION
Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the machine to fall, which could cause injury.
Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.
4.
Remove the rear tires from the machine.
5.
Remove any debris from the brake area.
6.
Rotate the drive-wheel release handle to the released position; refer to
Drive-Wheel-Release Valves (page 29)
.
7.
Check to see if there is a visible gap between
the L-bracket and the linkage stop ( Figure 75 ).
1.
L-bracket
2.
Linkage stop
3.
Gap
Figure 75
Left Side Shown
4.
Rear linkage assembly
5.
Caliper
6.
Wheel hub g026961
8.
Disengage the parking brake, the lever should be in the down position.
9.
Turn the wheel hub by hand in both directions relative to the caliper; the wheel hub should move freely between the caliper.
10.
If a gap is needed or the wheel hub does not move freely:
A.
Disengage the parking brake.
B.
Disconnect and fine-tune the rear linkage assembly:
• Shorten the link to create a gap.
• Lengthen the link to allow wheel hub movement.
C.
Connect the rear linkage assembly.
11.
Engage the parking brake and check the gap.
12.
Repeat steps
through
until a visible gap is achieved and the wheel hub rotates freely.
13.
Repeat this procedure for the brake on the opposite side.
14.
Rotate the drive-wheel release handle to the operating position; refer to
Drive-Wheel-Release Valves (page 29)
.
15.
Install the rear tires and torque the lug nuts; refer to
Checking the Wheel Lug Nuts (page 46)
.
16.
Remove the jack stands.
51
Belt Maintenance
Inspecting the Belts
Service Interval: Every 50 hours
Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.
Replacing the Mower Belt
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Lower the mower to the 76 mm (3 inch) height-of-cut.
4.
Remove the belt covers ( Figure 76 ).
g009038
Figure 77
1.
Clutch pulley
2.
Mower belt
5.
Square hole in the idler arm for the ratchet
6.
Idler-grease fitting
3.
Spring-loaded idler pulley 7.
Belt guide
4.
Ratchet
1.
Push the tab down
Figure 76
2.
Remove the belt cover g027729
5.
Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (
).
6.
Remove the belt from the mower-deck pulleys.
7.
Remove the belt guide on the spring-loaded idler arm (
8.
Remove the existing belt.
9.
Install the new belt around the mower pulleys and the clutch pulley under the engine (
10.
Install the belt guide on the idler arm ( Figure 77
).
11.
Using the ratchet in the square hole, install the idler spring (
Note: Make sure that the spring ends are seated in the anchor grooves.
12.
Install the belt covers ( Figure 78 ).
52
1.
Position the belt cover
Figure 78
3.
Ensure that the tab is under the metal catch
2.
Slide the belt cover under the side catches g027730
Replacing the Hydraulic
Pump-Drive Belt
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Remove the mower belt; refer to
.
4.
Raise the machine and support it with jack stands (
g009039
1.
Idler pulley
2.
Clutch pulley
3.
Pump-drive belt
4.
Right hydraulic-pump pulley
Figure 79
5.
Left hydraulic-pump pulley
6.
Square hole in the idler arm
7.
Idler spring
5.
Use a ratchet in the square hole in the idler arm
to remove the idler spring ( Figure 79 ).
53
6.
Unhook the idler spring from the frame ( Figure
7.
Remove the belt from the hydraulic-unit-drive pulleys and the engine pulley.
8.
Install the new belt around engine pulley and the 2 drive pulleys.
9.
Using a ratchet in the square hole in the idler
arm, install the idler spring to the frame ( Figure
10.
Install the mower belt; refer to
.
Controls System
Maintenance
Adjusting the
Control-Handle Position
There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Loosen the bolts and flange nuts installed in the levers (
).
4.
Align the levers in the front-to-rear position by bringing the levers together to the N EUTRAL position, and slide them until they are aligned,
then tighten the bolts ( Figure 81
).
1.
Bolt
2.
Handle
Figure 80
3.
Control lever
4.
Nut g009040
54
Figure 81
5.
If the ends of the levers hit against each other, refer to
.
6.
Repeat to adjust the control levers.
Adjusting the
Motion-Control Linkage
Located on either side of the machine, below the seat, are the pump-control linkages. Rotating the end nut with a 1/2-inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.
WARNING
The engine must be running and the drive wheels turning so that you can perform the adjustments. Contact with moving parts or hot surfaces may cause personal injury.
Keep your fingers, hands, and clothing clear of rotating components and hot surfaces.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Push the deck-lift pedal, and remove the height-of-cut pin.
g009195
4.
Lower deck to the ground.
5.
Raise the rear of machine up and support it with jack stands (or equivalent support).
Note: Raise the machine just high enough to allow the drive wheels to turn freely.
6.
Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat.
Note: The switch is a part of the seat assembly.
7.
Temporarily install a jumper wire across the terminals in the connector of the main wire harness.
8.
Start the engine and run it at full throttle and disengage the brake.
Note: Before starting the engine, ensure that the parking brake is engaged and that the motion-control levers are out. You do not have to be in the seat.
9.
Run the machine for at least 5 minutes with the drive levers at full forward speed to bring the hydraulic fluid up to the operating temperature.
Note: The motion-control levers must be in neutral while making any necessary adjustments.
10.
Bring the motion-control levers into the N EUTRAL position.
11.
Adjust the pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (
55
Figure 83
Right Motion Control Shown
1.
Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing.
2.
Most resistance (firmest feel)
3.
Damper
4.
Medium resistance (medium feel)
5.
Least resistance (softest feel) g008620 g027409
Figure 82
1.
Double nuts
12.
Move the motion-control levers to the REVERSE position and while applying slight pressure to the lever, allow the reverse-indicator springs to bring the levers back to neutral.
Note: The wheels must stop turning or slightly creep in reverse.
13.
Shut off the machine.
14.
Remove the jumper wire from the wire harness and plug the connector into the seat switch.
15.
Remove the jack stands.
16.
Raise the deck and install the height-of-cut pin.
17.
Check that the machine does not creep in neutral with the park brakes disengaged.
Adjusting the
Motion-Control
Neutral-Lock Pivot
You can adjust the flanged nut to obtain the desired motion-control lever resistance when moving it to the
N EUTRAL -L OCK position. See
for adjustment options.
1.
Loosen the jam nut.
2.
Tighten or loosen the flanged nut to the desired feel.
• For more resistance, tighten the flanged nut.
• For less resistance, loosen the flanged nut
3.
Tighten the jam nut.
Adjusting the
Motion-Control Damper
You can adjust the top damper-mounting bolt to obtain the desired motion-control lever resistance. Refer to
for mounting options.
g008621
1.
Flanged nut
Figure 84
2.
Jam nut
56
Hydraulic System
Maintenance
Hydraulic System Safety
• Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
• Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
• Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.
6.
Remove 1 dipstick from the hydraulic reservoir
(
).
7.
Wipe the dipstick off and thread the dipstick into the reservoir.
8.
Remove the dipstick and look at the end ( Figure
Important: Do not overfill the hydraulic units with fluid, as damage may occur. Do not run the machine with fluid below the add mark.
9.
If the fluid level is at the add mark, slowly pour only enough fluid into the hydraulic reservoir to raise the level to the full or H line.
10.
Install the dipstick.
11.
Repeat the procedure for the opposite dipstick.
Servicing the Hydraulic
System
Hydraulic-Fluid Specifications
Hydraulic-Fluid Type: Toro ® HYPR-OIL ™ 500 hydraulic fluid or Mobil ® 1 15W-50.
Important: Use the specified fluid. Other fluids could damage the hydraulic system.
Each Hydraulic-System Fluid Capacity: 1.5 L (52 oz) per side with filter change
Checking the Hydraulic Fluid
Service Interval: Every 50 hours—Check the hydraulic-fluid level.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Allow the engine and the hydraulic system to cool for 10 minutes.
Note: The fluid level on the dipstick is incorrect when the fluid is checked and the machine is hot.
4.
Move the seat forward.
5.
Clean the area around the dipsticks of hydraulic-system reservoirs (
1.
Full
2.
Add g015459
Figure 85
Either dipstick is used in the machine
3.
H —means high level
4.
Dipstick locations under seat
57
Replacing the Hydraulic Fluid and
Filters
Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid.
Every 250 hours—Change the hydraulic filters and hydraulic fluid when using Mobil ® 1 fluid
(more often in dirty or dusty conditions).
Every 500 hours—Change the hydraulic filters and hydraulic fluid when using Toro ®
HYPR-OIL ™ 500 hydraulic fluid (more often in dirty or dusty conditions).
To replace the hydraulic fluid, the filters need to be removed. Replace both at the same time; refer to
Hydraulic-Fluid Specifications (page 57)
for the fluid specifications.
1.
Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Raise the machine and support it with jack stands (
Figure 86
Figure 87
Bottom view of the machine
1.
Filter locations 2.
Hydraulic filter g008968 g008970
6.
Apply a thin coat of hydraulic fluid to the rubber
gasket on the replacement filter ( Figure 87 ).
7.
Install the replacement hydraulic filter.
8.
Install the pump-drive belt and the mower belt.
9.
Remove the jack stands and lower the machine
(
).
10.
Add fluid to the hydraulic reservoir and check for any leaks.
11.
Clean up any spilled fluid.
12.
Start the engine and let it run for about 2 minutes to purge air from the system.
13.
Shut off the engine and check for leaks.
14.
Check the fluid level while the fluid is cold.
15.
If required, add fluid to the hydraulic reservoir.
Note: Do not overfill.
1.
Jack stands
4.
Remove both the mower belt and the pump-drive belt; refer to
Replacing the Mower Belt (page
and
Replacing the Hydraulic Pump-Drive
.
Note: This prevents fluid from getting on the belts.
5.
Place a drain pan under the filter, remove the old filter, and wipe the surface clean (
).
58
Mower Deck
Maintenance
Leveling the Mower Deck
Leveling the Deck
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Check the tire pressure in the drive tires; refer to
Checking the Tire Pressure (page 46)
.
4.
Position the transport lock in the latching position.
5.
Push the deck-lift pedal all the way forward and the deck latches at the 14 cm (5-1/2 inches)
transport position ( Figure 88
).
9.
On both sides of the deck, measure from the level surface to the front tip of the blade (Postion
A) as shown in
Note: The measurement should read 7.6 mm
(3 inches) g009196
2.
8.3 cm (3-1/4 inch) at position B is correct
Figure 89
1.
7.6 cm (3 inch) at position
A is correct
3.
Measure here from the blade tip to the hard surface
4.
Measure at position A and
B on both sides
10.
Fine-tune the adjustment nut on the front
deck-lift assembly by turning it ( Figure 90 ).
Note: To increase the height, turn the adjustment nut clockwise; to decrease the height, turn the nut counterclockwise.
Note: If the front deck links do not have enough adjustment to achieve accurate cut height, the single-point adjustment can be utilized to gain more adjustment.
g027343
1.
Deck-lift pedal
2.
Height-of-cut pin
Figure 88
3.
Transport lock
6.
Insert the height-adjustment pin into the 7.6 cm
(3 inches) cutting-height location.
7.
Release the transport lock and allow the deck to lower to the cutting height.
8.
Raise the discharge chute.
59
Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots.
This regains some up and down adjustment on each of the 4 deck links.
g017036
1.
Whizlock nut
2.
Adjuster screw
Figure 90
3.
Jam nut
4.
Yoke g027344
Figure 92
1.
Single-point adjustment bolt
11.
To adjust the single-point system, loosen the
2 bolts at the bottom of the height-of-cut plate
(
).
g027345
13.
Tighten the 2 bolts at the bottom of the height-of-cut plate (
Note: In most conditions, the back blade tip should be adjusted 6.4 mm (1/4 inch) higher than the front.
14.
Torque the 2 bolts to 37 to 45 N∙m (27 to 33 ft-lb).
15.
On both sides of the deck, measure from the level surface to the back tip of the blade (postion
B) as shown in
Note: The measurement should read 8.3 cm
(3-1/4 inches)
16.
Fine tune the screw adjuster by turning it to get
8.3 mm (3-1/4 inches) height ( Figure 90
).
To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise.
17.
Measure until all 4 sides are the correct height.
18.
Tighten all of the nuts on the deck-lift-arm assemblies.
19.
Lower the discharge chute.
Figure 91
1.
Bolts at the bottom of the height-of-cut plate
12.
If the deck is too low, tighten the single-point-adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single-point-adjustment bolt by rotating it
counterclockwise ( Figure 92 ).
60
Servicing the Cutting
Blades
To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand.
Blade Safety
A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product.
• Inspect the blades periodically for wear or damage.
• Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.
• On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate.
1.
Cutting edge
2.
Curved area
Figure 93
3.
Wear/slot forming
4.
Crack
Checking for Bent Blades
1.
Rotate the blades until the ends face forward and backward.
2.
Measure from a level surface to the cutting edge, position A
, of the blades ( Figure 94 ).
g006530
Before Inspecting or Servicing the
Blades
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs.
Inspecting the Blades
Service Interval: Before each use or daily
1.
Inspect the cutting edges ( Figure 93 ).
2.
If the edges are not sharp or have nicks, remove and sharpen the blade; refer to
.
3.
Inspect the blades, especially in the curved area.
4.
If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade
(
).
g000975
Figure 94
1.
Measure here from blade to hard surface
2.
Position A
3.
Rotate the opposite ends of the blades forward.
4.
Measure from a level surface to the cutting edge of the blades at the same position as in step
above.
Note: The difference between the dimensions obtained in steps
and
must not exceed 3 mm (1/8 inch).
Note: If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced.
61
Removing the Blades
Replace the blades if they hit a solid object, or if the blade is out of balance or bent.
1.
Hold the blade end using a rag or thickly padded glove.
2.
Remove the blade bolt, curved washer, and
blade from the spindle shaft ( Figure 95 ).
1.
Blade
Figure 97
2.
Balancer g000553
3.
Repeat this procedure until the blade is balanced.
g004536
Installing the Blades
1.
Install the blade onto the spindle shaft ( Figure
Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting.
2.
Install the curved washer and blade bolt (
Note: Install the curved-washer cone toward the bolt head.
3.
Torque the blade bolt to 115 to 150 N∙m (85 to
110 ft-lb).
1.
Sail area of the blade
2.
Blade
Figure 95
3.
Curved washer
4.
Blade bolt
Sharpening the Blades
1.
Use a file to sharpen the cutting edge at both
).
Note: Maintain the original angle.
Note: The blade retains its balance if the same amount of material is removed from both cutting edges.
Figure 96
1.
Sharpen at original angle.
g000552
2.
Check the balance of the blade by putting it on a
).
Note: If the blade stays in a horizontal position, the blade is balanced and can be used.
Note: If the blade is not balanced, file some metal off the end of the sail area only (
).
Removing the Mower Deck
Lock out the spring-loaded deck arms before servicing or removing the mower deck.
WARNING
Deck-lift arm assemblies have stored energy.
Removing the deck with out releasing the stored energy can cause serious injury or death.
Do not attempt to disassemble the deck from the front frame without locking out the stored energy.
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Place the height adjustment pin in the 7.6 cm (3 inch) cutting-height location.
Note: This locks the deck-lift arms in the lowest position when the deck is removed and the stored energy in the deck spring is released.
4.
Remove the belt covers.
62
5.
Lift up the floor pan and insert a ratchet into the
square hole in the deck idler ( Figure 98 ).
6.
Rotate the deck idler clockwise and remove the mower belt (
g010252
Figure 99
1.
Right stabilizer
2.
Deck strut (right side shown)
3.
Remove the shoulder bolt and nut.
4.
Remove the shoulder bolt and nut.
8.
Raise the deck struts and secure them in the raised position.
9.
Slide the deck out to the right side of the machine.
g009038
Figure 98
1.
Clutch pulley
2.
Mower belt
5.
Square hole in the idler arm for the ratchet
6.
Idler grease fitting
3.
Spring-loaded idler pulley 7.
Belt guide
4.
Ratchet
7.
Remove and retain the hardware on both sides of the deck as shown in
.
Replacing the Grass
Deflector
WARNING
An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur.
Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system.
1.
Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets
(
).
2.
Remove the damaged or worn grass deflector
(
).
63
Cleaning
Cleaning under the Mower
Deck
Service Interval: Before each use or daily
1.
Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Raise the mower deck to the T
RANSPORT position.
1.
Bolt
2.
Spacer
3.
Locknut
4.
Spring
Figure 100
5.
Spring installed
6.
Grass deflector
7.
J -hook end of spring g015594
3.
Place the spacer and the spring onto grass deflector.
4.
Place 1 J -hook end of the spring behind the deck edge.
Note: Make sure that 1 J -hook end of the spring is installed behind the deck edge before installing the bolt as shown in
.
5.
Install the bolt and the nut.
6.
Place 1 J -hook end of the spring around the
).
Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position.
Disposing of Waste
Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.
64
Storage
Storage Safety
• Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it.
• Do not store the machine or fuel near flames or drain the fuel indoors.
• Remove the key and store it in a safe place out of the reach of children.
Cleaning and Storage
1.
Disengage the blade-control switch (PTO), and engage the parking brake.
2.
Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
3.
Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing.
Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors.
4.
Check the parking brake operation; refer to
Operating the Parking Brake (page 20)
.
5.
Service the air cleaner; refer to
.
6.
Grease the machine; refer to
.
7.
Change the crankcase oil; refer to
.
8.
Check the tire pressure; refer to
.
9.
Change the hydraulic filters; refer to
Replacing the Hydraulic Fluid and Filters (page 58)
.
10.
Charge the battery; refer to
.
11.
Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose.
Note: Run the machine with the blade-control switch (PTO) engaged and the engine at high idle for 2 to 5 minutes after washing.
12.
Check the condition of the blades; refer to
Servicing the Cutting Blades (page 61)
.
13.
Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows:
A.
Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol).
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times.
B.
Run the engine to distribute conditioned fuel through the fuel system for 5 minutes.
C.
Shut off the engine, allow it to cool, and drain the fuel tank.
D.
Start the engine and run it until it stops.
E.
Dispose of fuel properly. Recycle the fuel according to local codes.
Important: Do not store fuel containing stabilizer/conditioner longer than the duration recommended by the fuel-stabilizer manufacturer.
14.
Remove and check the condition of the spark plug(s); refer to
Servicing the Spark Plug (page
. With the spark plug(s) removed from the engine, pour 30 ml (2 tablespoons) of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).
15.
Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
16.
Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.
17.
Store the machine in a clean, dry garage or storage area. Remove the key from the switch and keep it out of reach of children or other unauthorized users. Cover the machine to protect it and keep it clean.
65
Troubleshooting
Problem
The starter does not crank.
The engine does not start, starts hard, or fails to keep running.
The engine loses power.
The engine overheats.
Possible Cause
1. The blade-control switch is engaged.
2. The parking brake is disengaged.
3. The motion-control levers are not in the N EUTRAL LOCK position.
4. You are not sitting in the operator’s seat.
5. The battery is dead.
6. The electrical connections are corroded or loose.
7. A fuse is blown.
8. A relay or switch is damaged.
Corrective Action
1. Disengage the blade-control switch.
2. Engage the parking brake.
3. Move the motion-control levers outward to the N EUTRAL LOCK position.
4. Sit on the operator’s seat.
5. Charge the battery.
6. Check the electrical connections for good contact.
7. Replace the fuse.
8. Contact an Authorized Service Dealer.
1. The fuel tank is empty.
2. The fuel-shutoff valve is closed.
3. The oil level in the crankcase is low.
4. The throttle is not in the correct position.
1. Fill the fuel tank.
2. Open the fuel-shutoff valve.
3. Add oil to the crankcase.
4. Be sure that the throttle control is midway between the slow and fast positions.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
5. There is dirt in the fuel filter.
6. Dirt, water, or stale fuel is in fuel system.
7. The air cleaner is dirty.
8. The seat switch is not functioning properly.
9. The electrical connections are corroded, loose, or damaged.
5. Dirt, water, or stale fuel is in the fuel system.
7. Clean or replace the air-cleaner element.
8. Check the seat-switch indicator.
Replace the seat if necessary.
9. Check the electrical connections for good contact. Clean the connector terminals thoroughly with electrical-contact cleaner, apply dielectric grease, and make the appropriate connections.
10. Contact an Authorized Service Dealer.
10. The relay or switch is worn or damaged.
11. The spark plug is fouled or improperly gapped.
12. The spark-plug wire is not connected.
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.
4. The air cleaner is dirty.
11. Adjust or replace the spark plug.
12. Check the spark-plug wire connection.
1. The engine load is excessive.
1. Reduce the ground speed.
2. The air cleaner is dirty.
3. The oil level in the crankcase is low.
4. The cooling fins and the air passages above the engine are plugged.
2. Clean the air-cleaner element.
3. Add oil to the crankcase.
4. Remove the obstruction from the cooling fins and the air passages.
5. The vent hole in the fuel cap is plugged.
5. Clean or replace the fuel cap.
6. There is dirt in the fuel filter.
6. Replace the fuel filter.
7. There is dirt, water, or stale fuel in the fuel system.
7. Contact an Authorized Service Dealer.
1. Reduce the ground speed.
2. Add oil to the crankcase.
3. Remove the obstruction from the cooling fins and air passages.
4. Clean or replace the air-cleaner element.
5. Contact an Authorized Service Dealer
66
Problem
The machine pulls to the left or right (with levers fully forward)
The machine does not drive.
The machine vibrates abnormally.
The cutting height is uneven.
The blades do not rotate.
The clutch does not engage.
Possible Cause Corrective Action
1. The tracking needs adjustment
2. The tire pressure in the drive tires is not correct.
1. Adjust the tracking.
2. Adjust the tire pressure in the drive tires.
1. The bypass valves are not closed tight.
1. Tighten the bypass valves.
2. The pump belt is worn, loose, or broken.
3. The pump belt is off a pulley.
4. The idler spring is broken or missing.
5. The hydraulic fluid level is low or too hot.
2. Change the belt.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to the reservoirs or let it cool down.
1. The cutting blade(s) is/are bent or unbalanced.
2. The blade mounting bolt is loose.
3. The engine mounting bolts are loose.
4. The engine pulley, idler pulley, or blade pulley is loose.
5. The engine pulley is damaged.
6. The blade spindle is bent.
7. The motor mount is loose or worn.
1. The blade(s) is not sharp.
2. A cutting blade(s) is/are bent.
3. The mower is not level.
1. Install new cutting blade(s).
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Contact an Authorized Service Dealer.
1. Sharpen the blade(s).
2. Install a new cutting blade(s).
3. Level the mower from side-to-side and front-to-rear.
4. Adjust the anti-scalp wheel height.
4. An anti-scalp roller (if applicable) is not set correctly.
5. The underside of the mower deck is dirty.
6. The tire pressure is incorrect.
7. A blade spindle is bent.
5. Clean the underside of the mower deck.
6. Adjust the tire pressure.
7. Contact an Authorized Service Dealer.
1. Install a new deck belt.
1. The mower deck belt is damaged, worn, loose, or broken.
2. The mower deck belt is off the pulley.
3. The pump drive belt is worn, loose, or broken.
4. The idler spring is broken or missing.
2. Install the mower belt on the deck pulley and check the idler pulley, idler arm, and spring for correct position and function.
3. Check the belt tension or install a new belt.
4. Replace the spring.
1. The fuse is blown.
1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary.
2. There is low voltage supply at the clutch.
2. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary.
3. The coil is damaged.
4. There is inadequate current supply.
3. Replace the clutch.
4. Repair or replace the clutch lead wire or electrical system. Clean the connector contacts.
5. The rotor/armature air gap is too large.
5. Remove the shim or replace the clutch.
67
Schematics
CAP
CAP
Electrical Schematic (Rev. A)
68 g224051
Notes:
Notes:
California Proposition 65 Warning Information
What is this warning?
You may see a product for sale that has a warning label like the following:
WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov.
What is Prop 65?
Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into
California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to inform the public about exposure to these chemicals.
Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with the product. Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the
California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is ‘safe’ or ‘unsafe.’” Many of these chemicals have been used in everyday products for years without documented harm. For more information, go to https://oag.ca.gov/prop65/faqs-view-all .
A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2) has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.
Does this law apply everywhere?
Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs.
How do the California warnings compare to federal limits?
Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning at levels that are far lower than federal action limits. For example, the Prop 65 standard for warnings for lead is 0.5 μg/day, which is well below the federal and international standards.
Why don’t all similar products carry the warning?
•
Products sold in California require Prop 65 labelling while similar products sold elsewhere do not.
•
A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies making similar products may have no such requirement.
•
The enforcement of Prop 65 is inconsistent.
•
Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a product does not mean that the product is free of listed chemicals at similar levels.
Why does Toro include this warning?
Toro has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and use. Toro provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from Toro products may be negligible or well within the
“no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.
Rev A
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