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Mid-Size ProLine T-Bar Hydro, 15 HP

Toro Mid-Size ProLine T-Bar Hydro, 15 HP User manual

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Operator’s Manual
Original Instructions (EN)
Register your product at www.Toro.com
Form No. 3352–601
Mid–Size Mower
Proline T–Bar Hydro 15hp with 112 cm Side
Discharge Mower
Model No. 30299TE—Serial No. 250000001 and Up
2
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contact us at www.Toro.com
All Rights Reserved
Printed in the USA
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . . . .
Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13. . . . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . . .
Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Wheels 14. . . . . . . . . . . . . . . . . .
Installing the Upper Handle 15. . . . . . . . . . . . . . . . . .
Installing the Control Rods 15. . . . . . . . . . . . . . . . . .
Activating the Battery 16. . . . . . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 18. . . . . . . . . . . . . .
Operating Mower Blade Control (PTO) 18. . . . . . . .
The Safety Interlock System 19. . . . . . . . . . . . . . . . .
Driving Forward or Backward 19. . . . . . . . . . . . . . . .
Placing Machine in Neutral 20. . . . . . . . . . . . . . . . . .
Stopping the Machine 20. . . . . . . . . . . . . . . . . . . . . .
Transporting Machines 20. . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 21. . . . . . . . . . . . . . . .
Side Discharge or Mulch Grass 21. . . . . . . . . . . . . . .
Adjusting the Height-of-Cut 21. . . . . . . . . . . . . . . . .
Adjusting Gage Wheels 22. . . . . . . . . . . . . . . . . . . . .
Adjusting Center Gage Wheels 22. . . . . . . . . . . . . . .
Tips for Mowing Grass 23. . . . . . . . . . . . . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 24. . . . . . . . .
Servicing the Air Cleaner 25. . . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 26. . . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 27. . . . . . . . . . . . . . . . . . . .
Greasing the Bearings and Bushings 28. . . . . . . . . . .
Cleaning the Cooling Systems 28. . . . . . . . . . . . . . . .
Checking the Tire Pressure 29. . . . . . . . . . . . . . . . . .
Page
Servicing the Fuse 29. . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Tank 30. . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter 30. . . . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 30. . . . . . . . . . . . . . .
Adjusting the By-pass Valve 32. . . . . . . . . . . . . . . . .
Servicing the Cutting Blades 33. . . . . . . . . . . . . . . . .
Correcting the Mower Quality of Cut 34. . . . . . . . . .
Checking the Deck Side-to-Side Leveling 35. . . . . . .
Replacing the Traction Belt 36
. . . . . . . . . . . . . . . . . .
Replacing the Mower Belt 36. . . . . . . . . . . . . . . . . . .
Replacing the Drive Belt 36. . . . . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch 37. . . . . . . . . . . . . . . . .
Adjusting the Machine Neutral 38. . . . . . . . . . . . . . .
Servicing the Battery 38. . . . . . . . . . . . . . . . . . . . . . .
Replacing the Caster Wheel Fork Bushings 39. . . . . .
Caster Wheel and Bearings Service 40. . . . . . . . . . . .
Replacing the Grass Deflector 41. . . . . . . . . . . . . . . .
Wiring Diagram 42. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Diagram 43. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 43. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
m–3097
Figure 1
1. Location of the model and serial numbers
3
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
This machine meets or exceeds the B71.4–2004
specifications of the American National Standards
Institute in effect at the time of production.
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—2004.
Training
• Read the Operator’s Manual and other training material.
If the operator(s) or mechanic(s) can not read English it
is the owner’s responsibility to explain this material to
them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Never refuel or drain the machine indoors.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine from
the operator’s position.
4
• Be sure of your footing while using this machine,
especially when backing up. Walk, don’t run. Never
operate on wet grass. Reduced footing could cause
slipping.
• Slow down and use extra care on hillsides. Be sure to
travel side to side on hillsides. Turf conditions can
affect the machine’s stability. Use caution while
operating near drop-offs.
• Slow down and use caution when making turns and
when changing directions on slopes.
• Never raise deck with the blades running.
• Never operate with the PTO shield, or other guards not
securely in place. Be sure all interlocks are attached,
adjusted properly, and functioning properly.
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Do not change the engine governor setting or overspeed
the engine.
• Stop on level ground, disengage drives, engage parking
brake (if provided), shut off engine before leaving the
operator’s position for any reason including emptying
the catchers or unclogging the chute.
• Stop equipment and inspect blades after striking objects
or if an abnormal vibration occurs. Make necessary
repairs before resuming operations.
• Keep hands and feet away from the cutting unit.
• Look behind and down before backing up to be sure of
a clear path.
• Keep pets and bystanders away.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
• Be aware of the mower discharge direction and do not
point it at anyone.
• Do not operate the mower under the influence of
alcohol or drugs.
• Use care when loading or unloading the machine into or
from a trailer or truck.
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Maintenance and storage
• Disengage drives, set parking brake, stop engine and
remove key or disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning or
repairing.
• Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Set parking brake. Never
allow untrained personnel to service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Remove spark plug wire before making any repairs.
• Use care when checking blades. Wrap the blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
Toro Mower Safety
The following list contains safety information specific to
Toro products and other safety information you must know.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
This product is designed for cutting and recycling grass or,
when equipped with a grass bagger, for catching cut grass.
Any use for purposes other than these could prove
dangerous to user and bystanders.
General Operation
• Allow only responsible adults who are familiar with the
instructions to operate the machine.
• Be sure the area is clear of other people before mowing.
Stop the machine if anyone enters the area.
• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
• Slow down before turning. Sharp turns on any terrain
may cause loss of control.
5
• Turn off blades when not mowing.
• Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and any
moving parts while engine is running.
• Stop the engine before removing the grass catcher or
unclogging the chute.
• Mow only in daylight or good artificial light.
• Watch for traffic when operating near or crossing
roadways.
• Do not touch equipment or attachment parts which may
be hot from operation. Allow to cool before attempting
to maintain, adjust or service.
• Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
Slope Operation
Slopes and ramps are a major factor related to
loss-of-control and accidents, which can result in severe
injury or death. All slopes and ramps require extra caution.
If you feel uneasy on a slope, do not mow it.
DO
• Remove obstacles such as rocks, tree limbs, etc. from
the mowing area.
• Watch for holes, ruts or bumps. Tall grass can hide
obstacles.
• Use slow speed so that you will not have to stop while
on the slope.
• Use extra care with grass catchers or other attachments.
These can change the stability of the machine.
• Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed or direction.
• Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades.
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
• Mow slopes side to side.
DO NOT
• Do not mow slopes greater than 15 degrees.
• Avoid turning on slopes. If you must turn, turn slowly
and gradually downhill, if possible.
• Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly turn over if a wheel goes
over the edge of a cliff or ditch, or if an edge caves in.
• Do not mow on wet grass. Reduced traction could cause
sliding.
• Do not use a grass catcher on steep slopes. Heavy grass
bags could cause loss of control of the machine.
• Do not mow up and down slopes.
Service
• Never store the machine or fuel container inside where
there is an open flame, such as near a water heater or
furnace.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good condition.
• Never tamper with safety devices. Check safety systems
for proper operation before each use.
• Use only genuine replacement parts to ensure that
original standards are maintained.
• Check brake operation frequently. Adjust and service as
required.
6
7
Slope Chart
Fold along appropriate line
Align this edge with a vertical surface
(Tree, Building, Fence post, pole, etc.)
Example: Compare
slope with folded
edge.
8
9
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
93-9353
1. Shut off the fuel by turning the fuel shutoff valve clockwise
before transporting the machine.
93-8069
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
93-7273
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Cutting hazard of hand or
foot—stay away from
moving parts.
93-7818
1. Warning—read the Operator’s Manual for instructions on
torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-lb.).
93-7824
1. Thrown object hazard—stay a safe distance from the machine.
2. Thrown object hazard, mower—keep the deflector in place.
3. Cutting/dismemberment of hand or foot—stay away from
moving parts.
93-7828
1. Thrown object hazard, mower—do not operate the mower with
the deflector up or removed; keep the deflector in place.
2. Cutting/dismemberment hazard of hand or foot, mower
blade—stay away from moving parts.
10
93-7316
1. Thrown object hazard—stay a safe distance from the machine.
2. Thrown object hazard, mower—keep the deflector in place.
3. Cutting/dismemberment of hand or foot—stay away from
moving parts.
93-7819
1. Remove the ignition key and read the instructions before
servicing or performing maintenance.
2. Height of cut settings
95-5850
1. Forward 2. Reverse
95-5851
1. To adjust the pressure valve, loosen the jam nut, rotate the
valve clockwise to close it, rotate the valve counterclockwise
1/2 turn, then tighten the jam nut to lock it in place.
2. Read the instructions before servicing or performing
maintenance.
95-5862
1. Unlock 2. Lock
95-5893
1. Warning—engage the parking brake when parking on a hill.
11
98-4387
1. Warning—wear hearing protection.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection;
explosive gases can
cause blindness and
other injuries
5. Wear eye protection
6. Read the Operator’s
Manual.
7. Keep bystanders a safe
distance from the battery.
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.
106-0807
1. Disengage 2. Engage
95-1545
1. Warning—read the Operator’s Manual.
2. Thrown object hazard—keep bystanders a safe distance from the machine.
3. Thrown object hazard, mower—keep the deflector in place.
4. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.
5. Warning—stop the engine before leaving the machine.
6. Fast 7. Slow 8. Continuous variable setting 9. Lock
12
106-0685
1. Choke
2. Fast
3. Continuous variable setting
4. Slow
5. Engine—stop
6. Engine—run
7. Engine—start
8. To engage the power
take–off (PTO), move the
control bar to the handle,
then pull the knob.
13
Gasoline and Oil
Recommended Gasoline
Use Unleaded Regular Gasoline suitable for automotive
use (85 pump octane minimum). Leaded regular gasoline
may be used if unleaded regular is not available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Never fill the fuel tank inside an enclosed trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 in. (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Warning
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
• 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 gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at all
times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around fuel tank cap and remove the cap. Add
unleaded regular gasoline to fuel tank, until the level is
1/4 to 1/2 inch (6 to 13 mm) below the bottom of the
filler neck. This space in the tank allows gasoline to
expand. Do not fill the fuel tank completely full.
3. Install fuel tank cap securely. Wipe up any gasoline that
may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine, check the
oil level in the engine crankcase; refer to Checking the
Engine Oil Level, page 26.
14
Setup
Note: Determine the left and right sides of the machine
from the normal operating position.
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Step
Description Qty. Use
1
Wheel
Net
2
8
Installing the drive wheels
2
Upper handle
Flange bolt, 3/8 x 1 inch (25 mm)
Flange nut, 3/8 inch
1
4
6
Installing the upper handle
3
Clevis pin
Washer
Hairpin cotter
1
1
2
Installing the control rods
4
No parts needed Activating the battery
5
Hydraulic filter 1 Use for initial hydraulic filter change
6
Operator’s manual
Engine operator’s manual
Parts catalog
Registration card
1
1
1
1
Read before operating
Ordering parts
Fill out and return to Toro
1
Step
Installing the Drive Wheels
1. Mount wheels to wheel motor hubs with 8 lug nuts
(Fig. 2). Torque bolts to 55 ft.–lb. (75 N
.
m).
m–2634
1
2
3
Figure 2
1. Wheel
2. Hub
3. Lug nut
15
2
Step
Installing the Upper Handle
1. Align upper handle with mounting holes in rear frame
(Fig. 3). Select high, medium or low position for lower
mounting hole.
2. Secure each side with 2 flange bolts (3/8 x 1 in.) and 2
flange nuts (Fig. 3). Torque bolts to 25 ft.–lb. (34 N
.
m).
m–3063
1
2
3
4
Figure 3
1. Upper handle
2. Rear frame
3. Flange bolt, 3/8 x 1 in.
4. Flange nut, 3/8 in.
3
Step
Installing the Control Rods
Before installing and adjusting control rods loosen quick
release levers and move reference control bar all the way
forward.
Installing the Left Control Rod
1. Slide clevis pin through rod fitting and mounting hole
in control bracket (from outside). Secure with washer
and hairpin cotter (Fig. 4).
2. Remove hairpin cotter and rod from upper control bars.
3. Press and hold upper control bars against reference bar,
so stop hits.
4. Push rod full forward until bearing is against control
bracket stop. Thread rod in or out of fitting on control
bracket until rod aligns with holes in upper control bars
(Fig. 4).
5. When rod and holes in upper control bars line up, turn
rod one additional turn, so rod is shorter.
Note: Upper control bar stop must hit reference bar before
roller hits control bracket stop.
6. Connect rod to upper control bars with previously
removed hairpin cotter.
m–3064
1
3
2
5
4
6
Figure 4
1. Control rod–left
2. Control bracket
3. Rod fitting
4. Clevis pin
5. Washer
6. Hairpin cotter
Installing the Right Control Rod
1. Slide rod into control bracket and secure with hairpin
cotter (Fig. 5).
2. Remove hairpin cotter and rod from upper control bars.
3. Press and hold upper control bars against reference bar,
so stop hits.
4. Push rod full forward until bearing is against control
bracket stop. Loosen wing nut and thread turnbuckle in
or out until rod aligns with holes in upper control bars
(Fig. 4).
5. When rod and holes in upper control bars line up, rotate
turnbuckle one additional turn, so rod is shorter.
Note: Upper control bar stop must hit reference bar before
roller hits control bracket stop.
6. Connect rod to upper control bars with previously
removed hairpin cotter, tighten wing nut and
turnbuckle.
16
m–3103
1
3
2
5
4
Figure 5
1. Control rod–right
2. Control bracket
3. Hairpin cotter
4. Wing nut
5. Turnbuckle
Adjusting the Tracking
1. After completing assembly check machine tracking.
Operate machine by holding upper control bar against
reference bar with wheel drive engaged.
2. If machine does not track straight, moves more right or
left, adjustment is required.
3. Loosen wing nut on right control rod and rotate
turnbuckle in or out to change tracking. Secure
turnbuckle in position with wing nut (Fig. 5).
4. Check for proper tracking.
Note: Control rods must be adjusted if handle height
position is changed.
4
Step
Activating the Battery
Bulk electrolyte with 1.260 specific gravity must be
purchased from a local battery supply outlet.
1. Remove the battery from the machine.
Important Be careful not to damage the long vent tube
when removing the battery.
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and robber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
2. Remove filler caps from the battery. Slowly pour
electrolyte into each cell until the electrolyte level is up
to the lower part of the tube (Fig. 6).
1
2
3
m–1262
Figure 6
1. Filler caps
2. Electrolyte
3. Lower part of the tube
3. Leave the covers off and connect a 3 to 4 amp battery
charger to the battery posts (Fig. 7). Charge the battery
at a rate of 4 amperes or less for 4 hours (12 volts).
17
4
1
2
3
m–1254
Figure 7
1. Positive post
2. Negative post
3. Charger red (+) wire
4. Charger black (–) wire
Charging battery produces gasses that can explode
and cause serious injury.
• Keep cigarettes, sparks and flames away from
battery.
• Make sure the ignition switch is off.
• Ventilate when charging or using battery in an
enclosed space.
Warning
4. When the battery is fully charged, disconnect the
charger from the electrical outlet then from the negative
and positive battery posts (Fig. 7).
5. Slowly pour electrolyte into each cell until the level is
once again up to the upper line on the battery case
(Fig. 6) and install covers.
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Think Safety First
Please carefully read all the safety instructions and symbols
in the safety section. Knowing this information could help
you, your family, pets or bystanders avoid injury.
The use of protective equipment for eyes, hearing, feet and
head is recommended.
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Caution
1
2
Figure 8
1. Warning—wear hearing protection.
Controls
Become familiar with all the controls (Fig. 9) before you
start the engine and operate the machine.
Throttle Control – The throttle control has three positions:
fast, slow and choke.
Blade Control Bail – Control bail used in conjunction with
deck engagement switch (PTO) to release blade brake and
engage clutch to drive mower blades. Release bail to
disengage mower blades.
Blade Control Switch (PTO) – Pull switch used in
conjunction with control bail to release clutch brake and
engage clutch to drive mower blades.
Upper Control Bar – Push forward on control bar to
engage forward traction operation, release to stop. Pull
back on control bar to go backwards. Release either side of
control bar to turn right or left.
Reference Handle – Limits forward travel of control bar to
pre-set position to help maintain desired ground speed and
direction of travel. It is locked in position with quick
release levers.
Ignition Switch – Key switch is used with the electric
starter. Switch has three positions: start, run and off.
18
Fuel Shut–off Valve – (Under fuel tank) Close fuel
shut–off valve when transporting or storing mower.
Hour Meter – Shows total hours that machine has been
operated. Only operates with ignition key in the on
position.
2
3
7
1
4
5
6
8
m–6658
Figure 9
1. Throttle control
2. Blade control bail
3. Blade control switch
(PTO)
4. Upper control bar
5. Reference handle
6. Quick release lever
7. Ignition switch
8. Hourmeter
Starting and Stopping the
Engine
Starting the Engine
1. Make sure spark plug wire(s) are installed on spark
plug(s) and fuel valve is open.
2. Move the throttle control to the choke position before
starting a cold engine.
Note: A warm or hot engine may not require choking.
After engine starts, move choke control to the run position.
3. Turn ignition key to start to energize the starter. When
engines starts, release key.
Important Do not engage starter for more than 10
seconds at a time. If the engine fails to start allow 30
second cool-down period between attempts. Failure to
follow these instructions can burn out starter motor.
4. When engine starts move the throttle control to the fast
position.
Stopping the Engine
5. Move the throttle lever to the slow position (Fig. 10).
Note: If the engine has been working hard or is hot, let it
idle for a minute before turning the ignition key off. This
helps cool the engine before it is stopped. In an emergency,
the engine may be stopped by turning the ignition key to
off.
6. Turn the ignition key to off (Fig. 10).
1
2
m–6658
Figure 10
1. Throttle lever 2. Ignition key
7. Pull wire off spark plug(s) to prevent possibility of
accidental starting before transporting or storing
machine.
8. Close fuel shut off valve, under fuel tank, before
transporting or storing machine.
Important Make sure fuel shut off valve is closed
before transporting or storing machine, as fuel leakage may
occur.
Operating Mower Blade
Control (PTO)
The blade control switch (PTO) in conjunction with the
blade control bail engages and disengages power to the
electric clutch and mower blades.
Engaging the Mower Blades (PTO)
1. Release the upper control bar to stop the machine
(Fig. 11).
2. To engage blade, squeeze blade control bail against
upper control bar (Fig. 11).
3. Pull blade switch (PTO) up and release. Hold blade
control bail against control bar while operating.
4. Repeat procedure to engage mower blades if blade
control bail is released.
19
1
3
m–6658
2
Figure 11
1. Upper control bar
2. Blade control bail
3. Blade control switch
(PTO)
Disengaging the Mower Blades (PTO)
1. Release the blade control bail to disengage blades
(Fig. 11).
The Safety Interlock System
If 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.
Caution
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
mower from starting unless the control bar is in the neutral
position and to prevent the blades from rotating when the
blade control is released.
Testing the Safety Interlock System
Test the safety interlock system before you use the machine
each time. If the safety system does not operate as
described below, have an Authorized Service Dealer repair
the safety system immediately.
1. Set the machine on a flat, open area.
2. Push the control bar full forward.
3. Rotate the ignition key to the start position and slowly
move the control bar back to neutral. The engine should
not crank until control bar is within 5
°
of neutral
position.
4. Start the engine; refer to Starting and Stopping the
Engine, page 18. With engine running and control bar in
neutral position, squeeze control bail against control bar
(Do not press deck engagement switch), clutch should
not engage and blades must not rotate.
5. Continue holding the blade control bail and press the
rocker switch forward to on and release. The clutch
should engage and the mower blades begin rotating.
6. Release the blade control bail. The clutch must
disengage and the blades stop rotating.
7. Release the blade control bail (PTO), then push the
blade control switch (PTO) to the on position without
holding the blade control bail. The clutch must not
engage and the blades must not rotate.
8. If all the above conditions are not met have an
Authorized Service Dealer repair the safety system
immediately.
Driving Forward or Backward
The Enhanced T–Bar control system is designed to provide
easy and comfortable operation of the hydrostatic drive.
The control regulates ground speed, as well as forward,
reverse and neutral functions, as well as steering direction.
The throttle control regulates the engine speed as measured
in rpm (revolutions per minute). Place the throttle control in
the fast position for best performance.
Operate the machine with the engine speed set at slow or
medium when learning how to use the controls. Practice
driving the machine in a level open area.
Selecting Ground Speed
1. Place the quick release levers in the unlock position
(Fig. 12).
2. Move the reference bar forward or backward to set the
desired forward speed. The pointer indicates
approximate ground speed (Fig. 12). When the bar is in
the full forward position the ground speed is
approximately 6 mph. When the reference bar is in the
middle position the ground speed is approximately
3 mph.
Note: In normal conditions, a 2.5 to 3.0 mph ground speed
(middle position of the reference bar) is best for cutting
performance. Use a faster ground speed for light cutting or
transport. Use a slower ground speed in heavy cutting
loads.
3. Place the quick release levers in the lock position
(Fig. 12).
20
Driving Forward
1. To go forward, slowly press on the upper control bar
against the reference bar (Fig. 12).
2. To go straight, apply equal pressure to both ends of the
upper control bar (Fig. 12).
3. To turn, release pressure on the upper control bar side
toward the direction you want to turn (Fig. 12).
4. Adjust reference bar to maintain a comfortable pre-set
ground speed (Fig. 12).
5. To stop, release the upper control bar to stop both
wheels (Fig. 12).
Note: If the front of the deck lifts off the ground when the
upper control bar is quickly pushed forward or the machine
is unable to drive uphill, an adjustment may be needed.
Refer to: Adjusting By-pass Valve on page 32.
1
2
m–6658
3
Figure 12
1. Upper control bar
2. Reference control bar
3. Quick release lever
Driving Backward
1. To go backward, slowly pull the control bar rearward
(Fig. 12).
2. To go straight, apply equal pressure to both ends of the
upper control bar (Fig. 12).
3. To turn, release pressure on the upper control bar side
away from the direction you want to turn (Fig. 12).
4. To stop, release the upper control bar to stop both
wheels (Fig. 12).
Placing Machine in Neutral
Release the upper control bar to stop. The machine will
automatically return to neutral. When in neutral, the
hydrostatic drive system will provide dynamic braking so
the machine will not roll.
Note: Very slow drive motion with engine running and the
control in neutral is normal. Excessive drive motion when
the control is in neutral may indicate adjustment is needed.
Refer to: Adjusting the Machine Neutral on page 38.
Stopping the Machine
1. To stop, release the upper control bar to stop both
wheels (Fig. 12).
2. Release the blade control bail (PTO), to stop the mower
blades. Move the engine speed throttle control to to the
slow position.
3. Turn the ignition key to off. Remember to remove the
key from the ignition switch.
Important If the machine is on a slope, block the
wheels to prevent the machine from slowly rolling.
Important If the machine will be left unattended, close
the fuel shut off valve and disconnect the wire(s) from the
spark plug(s).
Children or bystanders may be injured if they
move or attempt to operate the machine while it is
unattended.
Always remove the ignition key and chock or block
tires when leaving the machine unattended, even if
just for a few minutes.
Caution
Transporting Machines
Use a heavy-duty trailer or truck to transport the machine.
Ensure that the trailer or truck has all necessary lighting
and marking as required by law. Please carefully read all
the safety instructions. Knowing this information could
help you, your family, pets or bystanders avoid injury.
To transport the machine:
• Chock or block wheels.
• Securely fasten the machine to the trailer or truck with
straps, chains, cable, or ropes.
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