Groundsmaster® 7210 Traction Unit

• Read the Operator's Manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

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

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

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

• Do not carry passengers.

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

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

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

    • insufficient wheel grip, especially on wet grass;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

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

    • incorrect load distribution.

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

• Safety equipment including a hard hat, safety glasses, and hearing protection should be worn.

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

• Check that the operator’s presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• Warning—fuel is highly flammable.

  • Store fuel in containers specifically designed for this purpose.

  • Refuel outdoors only and do not smoke while refueling.

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

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

  • Replace all fuel tank and container caps securely.

• Replace faulty silencers/mufflers.

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

• Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions.

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

• Mow only in daylight or in good artificial light.

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

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • do not stop or start suddenly when on a slope;

  • use slow speeds on slopes and during tight turns;

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

• Watch out for traffic when crossing or near roadways.

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

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

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

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

• Before leaving the operator's position:

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

  • change into neutral and set the parking brake;

  • stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and remove the ignition key:

  • before clearing blockages or unclogging chute;

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

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

  • if the machine starts to vibrate abnormally (check immediately and make necessary repairs before resuming operation).

• Do not operate the mower under the influence of alcohol or drugs.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

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

• Stop the engine and disengage drive to attachment before refuelling.

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

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

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

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

• Replace worn or damaged parts for safety.

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

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

• When machine is to be parked, stored or left unattended, lower the mower deck.

Important: Use only ultra-low sulphur diesel fuel. Fuel with higher rates of sulfur degrades the diesel oxidation catalyst (DOC), which causes operational problems and shortens the service life of engine components.Failure to observe the following cautions may damage the engine.

• Never use kerosene or gasoline instead of diesel fuel.

• Never mix kerosene or used engine oil with the diesel fuel.

• Never keep fuel in containers with zinc plating on the inside.

• Do not use fuel additives.

43.5 L (11.5 US gallons)

Important: The fuel tanks are connected, but the fuel does not transfer quickly from one tank to the other. It is important when filling that you park on a level surface. If you park on a hill, you may inadvertently overfill the tanks.

Important: Do not overfill the fuel tanks.

Important: Do not open the fuel tanks when parked on a hill. The fuel could spill out.

1. Park the machine on a level surface.

   Important: The fuel tanks are connected, but the fuel does not transfer quickly from one tank to the other. It is important when filling that you park on a level surface. If you park on a hill, you may inadvertently overfill the tanks.

2. Shut the engine off and set the parking brake.

3. Clean around each fuel tank cap and remove the cap.

   Important: Do not open the fuel tanks when parked on a hill. The fuel could spill out.

4. Add fuel to both fuel tanks, until the level is even with the bottom of the filler neck (Figure 11). Do not over fill the fuel tanks.

   

   Figure 11

   1. Bottom of the filler neck

5. Install the fuel tank caps securely. Wipe up any fuel that may have spilled.

Note: If possible, fill the fuel tanks after each use. This will minimize possible buildup of condensation inside the fuel tank.

1. Move the motion control levers (Figure 17) out to the neutral locked position.

2. Pull up and back on the parking brake lever to set the parking brake (Figure 13).

   Note: The parking-brake lever should stay firmly in the engaged position.

   

   Figure 13

   1. Parking-brake lever

   Warning

   The parking brake may not hold the machine parked on a slope and could cause personal injury or property damage.

   Do not park the machine on slopes unless the wheels are chocked or blocked.

Push forward and down on the parking brake lever to release the parking brake (Figure 14).

Figure 14

1. Parking-brake lever

1. Raise the roll bar up and lock it into place, sit on the seat, and fasten the seat belt.

2. Ensure that the motion controls are in the neutral locked position.

3. Set the parking brake; refer to Setting the Parking Brake.

4. Move the PTO (power take-off) switch to the off position (Figure 15).

   

   Figure 15

   1. Ignition switch
   2. Throttle control
   3. Power take off switch (PTO)

5. Turn the ignition key clockwise to the Run position (Figure 16).

   

   Figure 16

   1. Ignition switch
   2. Off
   3. Run
   4. Start

6. After the glow plug indicator light dims, turn the key to the Start position. When the engine starts release the key.

   Important: Use starting cycles of no more than 15 seconds per minute to avoid overheating the starter motor.

   Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely drained.

   Important: When the engine is started for the first time, or after an engine oil change, or an overhaul of the engine, transmission, or wheel motor, operate the machine with the throttle lever in the Slow position in both the forward and reverse directions for 1 to 2 minutes. Also operate the lift lever and PTO lever to ensure proper operation of all parts. Then shut the engine off and check fluid levels, check for oil leaks, loose parts, and any other noticeable malfunctions.

   Caution

   Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, or other malfunctions.

1. Disengage the PTO, move the motion control levers to the neutral locked position, set the parking brake, and move the throttle lever to the Slow position.

2. Turn the ignition key to the Off position (Figure 16). Wait for all moving parts to stop before leaving the operating position.

3. Remove the key before transporting or storing machine.

   Important: Make sure to remove the key as the fuel pump or accessories may run and cause the battery to lose charge.

   Caution

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

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

• Over time, the DPF accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 18 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%	Perform a parked regeneration as soon as possible; refer to Parked Regeneration.
Level 2: Engine Warning	Figure 19 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

• The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter.

• Ash is a residue of the regeneration process. Over time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust.

• The computer for the engine calculates the amount of ash accumulated in the DPF.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of a system advisory or an engine fault to indicate the accumulation of ash in the DPF.

• The advisory and faults are indications that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Advisory or Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: System Advisory	Figure 20 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 21 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 85%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 3: Engine Warning	Figure 22 Check EngineSPN 3720, FMI 0	None	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 4: Engine Warning	Figure 23 Check EngineSPN 3251, FMI 0	Engine speed at max torque + 200 rpm	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	The InfoCenter does not display an icon indicating passive regeneration.
		During passive regeneration, the DPF processes high-heat exhaust gasses; oxidizing harmful emissions and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs as a result of low-engine speed, low-engine load, or after the computer detects back pressure in the DPF	When the assist/reset-regeneration icon is displayed in the InfoCenter, an assist regeneration is in progress.
		During assist regeneration, the computer controls the intake throttle to increase the exhaust temperature, enabling assist regeneration to occur.
		Refer to Assist DPF Regeneration.
Reset	Occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level	When the assist/reset-regeneration icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs every 100 hours to reset baseline sensor readings
		During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
		Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Parked	Soot buildup occurs as a result of prolonged operation at low-engine speed or low-engine load. May also occur as a result of using incorrect fuel or oil	When the parked-regeneration icon is displayed in the InfoCenter, a regeneration is requested.
	The computer detects back pressure due to soot buildup and requests a parked regeneration
		• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
		• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked Regeneration.
Recovery	Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration	When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
		Contact your Authorized Toro Distributor to have a service technician perform the recovery regeneration.
		• A recovery regeneration requires up to 4 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Recovery Regeneration.

• Passive regeneration occurs as part of normal engine operation.

• While operating the machine, run the engine at full-engine speed when possible to promote DPF regeneration.

Figure 24

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 24).

• The computer takes control of the intake throttle to increase the temperature of the engine exhaust.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the assist regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the assist regeneration is processing.

  Important: Allow the machine to complete the assist regeneration process before shutting off the engine.

  Note: The assist regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 25

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 25).

• The computer takes control of the intake throttle and changes the fuel injection operation to increase the temperature of the engine exhaust.

  Important: The assist/reset-regeneration icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the reset regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.

  Important: Allow the machine to complete the reset regeneration process before shutting off the engine.

  Note: The reset regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 26

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 26).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 27) and the engine computer derates engine power to 85%.

  

  Figure 27

  Important: If you do not complete a parked regeneration within 2 hours, the engine computer derates engine power to 50%.

• A parked regeneration requires 30 to 60 minutes to complete.

• If you are authorized by your company, you need the PIN code to perform the parked-regeneration process.

• If you ignore the request for a parked regeneration (displayed in the InfoCenter) and continue to operate the machine, a critical amount of soot builds up in the DPF.

• If a recovery regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 39) and the engine computer derates engine power to 85%.

  

  Figure 39

  Important: If you do not complete a recovery regeneration within 15 minutes, the engine computer derates engine power to 50%.

• Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot.

• A recovery regeneration requires up to 4 hours to complete.

• You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor.

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

• You are sitting on the seat or the parking brake is engaged.

• The power take-off (PTO) is disengaged.

• The motion-control levers are in the neutral locked position

• The engine temperature is below the maximum operating temperature.

The safety interlock system also is designed to stop the engine when the traction controls are moved from the neutral locked position with the parking brake engaged. If you rise from the seat when the PTO is engaged there is a 1-second delay and then the engine stops.

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. Sitting on the seat, engage the parking brake and move the PTO to on. Try starting the engine; the engine should not crank.

2. Sitting on the seat, engage the parking brake and move the PTO to off. Move either motion control lever (out of neutral locked position). Try starting the engine; the engine should not crank. Repeat for other control lever.

3. Sitting on the seat, engage the parking brake, move the PTO switch to off and move the motion control levers to the neutral locked position. Now start the engine. While the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop within 2 seconds.

4. Without an operator on the seat, engage the parking brake, move the PTO switch to off and move the motion control levers to the neutral locked position. Now start the engine. While the engine is running, center either motion control; the engine should stop within 2 seconds. Repeat for the other motion control.

5. Without an operator on the seat, disengage the parking brake, move the PTO switch to off, and move the motion control levers to the neutral locked position. Try starting the engine; the engine should not crank.

The machine is equipped with a standard control module (SCM) monitoring system that tracks the function of various key systems. The SCM is located under the right control panel. Access it through the side panel cover (Figure 40). To open the side panel cover, release the 2 latches and pull out on it.

Figure 40

1. Latches
2. Side panel cover

On the face of the SCM are 11 LEDs that illuminate to indicate various system conditions. Seven of these lights can be used by the operator for system diagnosis. Refer to Figure 41 for a description of what each light means. For details on using the rest of the SCM functions, refer to the Service Manual, available through your Authorized Toro Distributor.

Figure 41

1. High temperature shutdown—the engine temperature has exceeded safe levels and the engine has been shut down. Check the cooling system.
2. High temperature warning—the engine temperature is approaching unsafe levels and the mower deck has been shut down. Check the cooling system.
3. Operator is in the seat
4. The PTO is On
5. The parking brake is not engaged
6. Controls are in Neutral
7. The SCM is receiving power and is operational

The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

1. To adjust, move the lever sideways to unlock the seat (Figure 43).

   

   Figure 43

   1. Back rest knob
   2. Seat suspension knob
   3. Lumbar support adjustment knob
   4. Seat position adjustment lever

2. Slide the seat to the desired position and release lever to lock in position.

3. Verify that the seat has locked into place by attempting to move it back and forth.

The seat can be adjusted to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

Without sitting on the seat, turn the knob in front either direction to provide the best comfort (Figure 43).

Figure 44

1. Seat suspension knob
2. Operator weight setting

The back of the seat can be adjusted to provide a comfortable ride. Position the back of the seat where it is most comfortable.

To adjust it, turn the knob, under the right-side arm rest, in either direction to provide the best comfort (Figure 43).

The back of the seat can be adjusted to provide a customized lumbar support for your lower back.

To adjust it, turn the knob, under the left-side arm rest, in either direction to provide the best comfort (Figure 43).

1. Disengage the power take-off (PTO) and turn the ignition key to off. Move the levers to the neutral locked position and apply the parking brake. Remove the key.

2. Lift the seat.

3. Rotate each by-pass valve counterclockwise 1 turn (Figure 45).

   This allows hydraulic fluid to by-pass the pump enabling the wheels to turn.

   Important: Do not rotate the by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out.

   

   Figure 45

   1. Right by-pass valve
   2. Left by-pass valve

4. Disengage the parking brake before pushing.

Rotate each by-pass valve clockwise 1 turn and hand tighten them (torque of approximately 8 N-m (71 in-lb) (Figure 45).

Note: Do not over tighten the by-pass valves.

The machine will not drive unless the by-pass valves are turned inward.

The machine has grease fittings that must be lubricated regularly with No. 2 general-purpose, lithium-based grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation. Lubricating bearings and bushings daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate the grease fittings immediately after every washing, regardless of interval specified.

1. Wipe the grease fittings clean so that foreign matter cannot be forced into the bearing or bushing.

2. Pump grease into the fittings.

3. Wipe off excess grease.

Note: Bearing life can be negatively affected by improper wash down procedures. Do not wash down the unit when it is still hot and avoid directing high-pressure or high volume spray at the bearings or seals.

1. Check the air cleaner body for damage, which could possibly cause an air leak. Replace a damaged air cleaner body. Check the whole clean air intake system for leaks, damage, or loose hose clamps.

2. Service the air cleaner filter when the air cleaner indicator (Figure 49) shows red or every 400 hours (more frequently in extremely dusty or dirty conditions). Do not over service the air filter.

   

   Figure 49

   1. Air cleaner cover
   2. Air cleaner latch
   3. Gasket
   4. Filter
   5. Air cleaner body
   6. Air cleaner indicator
   7. Rubber outlet valve

3. Be sure the cover is seated correctly and seals with the air cleaner body.

• If advisory message displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.

  

  Figure 52

• If engine faults , , or in the InfoCenter (Figure 53) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 53

  1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

  2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

  3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF.

Drain water or other contaminants from water separator (Figure 54) daily.

1. Place a clean container under the fuel filter.

2. Loosen the drain plug on the bottom of the filter canister and open the vent on the top of the canister mount.

   

   Figure 54

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

4. Remove the filter canister and clean the mounting surface.

5. Lubricate the gasket on the filter canister with clean oil.

6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn.

7. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.

The engine fuel filter should be replaced after every 400 hours of operation.

1. Clean the area around the fuel filter head (Figure 55).

   

   Figure 55

   1. Fuel Filter head
   2. Fuel Filter

2. Remove the filter and clean the filter head mounting surface (Figure 55).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the Engine Operator's Manual, included with the machine, for additional information.

4. Install the dry filter canister, by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

5. Start the engine and check for fuel leaks around the filter head.

Drain and clean fuel tank every 2 years. Also, remove and clean the in-line strainers after draining the tank. Use clean diesel fuel to flush out the tank.

Important: Drain and clean the tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period.

Check the fuel lines and connections. Inspect them for deterioration, damage, chaffing, or loose connections.

Keep the top of the battery clean. If you store the machine in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where the temperature is cool.

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning it. Do not remove the fill caps while cleaning the battery.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on a shelf or on the machine. Leave the cables disconnected if it is stored on the machine. Store the battery in a cool environment to prevent the battery from discharging rapidly. To prevent the battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.265 to 1.299.

The fuses are located under the control panel. Access them through the side panel cover (Figure 56). To open the side panel cover, release the 2 latches and pull out on it.

If the machine stops or has other electrical system issues, check the fuses. Grasp each fuse in turn and remove them one at a time, checking to see if any are blown. If you need to replace a fuse, always use the same type and amperage rated fuse as the one you are replacing, otherwise you could damage the electrical system (refer to the decal next to the fuses (Figure 57) for a diagram of each fuse and its amperage).

Note: If a fuse blows frequently, you probably have a short in the electrical system and should have it serviced by a qualified service technician.

Figure 56

1. Latches
2. Side panel cover

Figure 57

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti freeze. Check the level of the coolant in the expansion tank at the beginning of each day before starting the engine. The capacity of the cooling system is 7.5 liters (6 quarts).

1. Check the level of the coolant in the expansion tank (Figure 58). The coolant level should be between the marks on the side of the tank.

   

   Figure 58

   1. Expansion tank

2. If coolant level is low, remove the expansion tank cap and replenish the system. Do not overfill.

3. Install the expansion tank cap.

To prevent the engine from overheating, the radiator must be kept clean. Normally, check the radiator daily and, if necessary, clean any debris off these parts. However, it will be necessary to check and clean the radiator frequently in extremely dusty and dirty conditions.

Note: If the mower deck or engine shuts off due to overheating, first check the radiator for excessive buildup of debris.

Clean the radiator as follows:

1. Open the hood.

2. Working from the fan side of the radiator, blow out debris with low pressure (50 psi) compressed air (do not use water). Repeat the step from the front of the radiator and again from the fan side.

3. After the radiator is thoroughly cleaned, clean out debris that may have collected in the channel at the radiator base.

4. Close the hood.

1. Stop the machine, move the deck lift switch fully into the neutral-locked position, set the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 59).

   

   Figure 59

   1. Bolts
   2. Control panel

3. Loosen the 2 jam nuts securing the parking brake interlock switch to the mounting bracket.

   

   Figure 60

   1. Brake-shaft sensor
   2. Jam nuts
   3. Parking-brake-interlock switch
   4. 3.9 mm (5/32 inch )

4. Move the switch up or down on the bracket until the distance between the brake shaft sensor and the switch plunger is 3.9 mm (5/32 inch) (Figure 60).

   Note: Make sure that the brake-shaft sensor does not contact the switch plunger.

5. Secure the switch jam nuts.

6. Test the adjustment as follows:

   1. Ensure that the parking brake is engaged and you are not sitting on the seat, then start the engine.

   2. Move the control levers out of the neutral locked position.

      The engine should stop. If not, recheck the adjustment you made to the switch.

7. Install the front panel.

Check the condition and tension of the belts (Figure 61) after every 100 operating hours.

1. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb.) is applied on the belt midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 61). Increase or decrease the alternator belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct.

   

   Figure 61

   1. Mounting bolt
   2. Alternator

1. Stop the machine, move the deck lift switch fully into the neutral-locked position, set the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 62).

   

   Figure 62

   1. Bolts
   2. Control panel

3. Loosen the 2 screws securing the interlock switch (Figure 63).

   

   Figure 63

   1. Control lever
   2. Neutral interlock switch
   3. Screws
   4. 0.4 to 1 mm (0.015 to 0.045 inch )

4. Holding the control lever against the frame, move the switch toward the lever until the distance between lever and switch body is 0.4 to 1 mm (0.015 to 0.045 inch ) (Figure 63).

5. Secure the switch.

6. Repeat steps 3 to 5 for the other lever.

7. Install the front panel.

If the motion control levers do not align with the neutral slots when released from the reverse drive position, adjustment is required. Adjust each lever, spring, and rod separately.

1. Disengage the PTO, move the control lever to the neutral locked position, and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the bolts securing the front panel and remove the panel (Figure 64).

   

   Figure 64

   1. Bolts
   2. Control panel

4. Move the control lever to the neutral position but not locked (Figure 66).

5. Pull the lever back until the clevis pin (on an arm above the pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Figure 65).

   

   Figure 65

   1. Clevis pin
   2. Slot
   3. Jam nuts
   4. Adjustment bolt
   5. Yoke

6. Check where the control lever is relative to notch in console (Figure 66).

   Note: It should be centered allowing lever to pivot outward to the neutral lock position.

   

   Figure 66

   1. Neutral position
   2. Neutral locked position

7. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 65).

8. Applying slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the neutral lock position (Figure 65).

   Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.

9. Tighten the nut and jam nut (Figure 65).

10. Repeat steps 4 through 9 for the other control lever.

11. Install the front panel.

This adjustment must be made with drive wheels turning.

1. Raise the frame onto stable jack stands so that the drive wheels can rotate freely.

2. Slide seat forward, unlatch it, and swing it up and forward.

3. Disconnect the electrical connector from the seat safety switch.

4. Temporarily install a jumper wire across terminals in the wiring harness connector.

5. Start the engine, ensure that the throttle lever is midway between the Fast and Slow positions, and release the parking brake.

   Note: The motion control levers must be in the neutral locked position while making any adjustments.

6. Adjust the pump rod length on one side by rotating the hex shaft, in the appropriate direction, until the corresponding wheel is still or slightly creeping in reverse (Figure 67).

   

   Figure 67

   1. Right pump rod
   2. Left pump rod
   3. Ball joint
   4. Bolt
   5. Jam Nut
   6. Hex shaft
   7. Ball joint

7. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse.

8. Move the throttle lever to the Fast position. Make sure that the wheel remains stopped or slightly creeps in reverse; adjust it if necessary.

9. Repeat steps 6 through 8 for the other side of the machine.

10. Tighten the jam nuts at the ball joints (Figure 65).

11. Move the throttle lever to the Slow position and stop the engine.

12. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch.

    Warning

    Electrical system will not perform proper safety shut off with jumper wire installed.

    • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed.

    • Never operate this unit with jumper installed and seat switch bypassed.

13. Lower the seat into position.

14. Remove the jack stands.

1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the bolts securing the front panel and remove the panel (Figure 68).

   

   Figure 68

   1. Bolts
   2. Control panel

4. Loosen the jam nut on the stop bolt for one of the control levers (Figure 69).

   

   Figure 69

   1. Stop bolt
   2. Control lever
   3. Jam nut
   4. 1.5 mm (0.060 inch)

5. Thread the stop bolt all the way in (away from the control lever).

6. Push the control lever all the way forward until it stops and hold it there.

7. Thread the stop bolt out (toward the control lever) until there is a gap of 1.5 mm (0.060 inch) between the head of the stop bolt and the control lever.

8. Tighten the jam nut to secure the stop bolt in place.

9. Repeat steps 4 through 8 for the other control lever.

10. Install the front panel.

Note: If you wish to reduce the maximum machine speed, set the speed for both control levers as directed above, then back each stop bolt out an equal amount toward the control lever until you reach the maximum speed you desire (you will likely have to test your adjustment several times). Ensure that the machine drives straight and does not turn when both control levers are pushed all the way forward. If the machine turns, you do not have the stop bolts evenly set and will need to adjust them further.

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Loosen the bolts securing the control levers (Figure 70)

   

   Figure 70

   1. Control lever
   2. Control-lever post
   3. Bolts

4. Have someone push the control-lever posts (not the control levers) all the way forward into the maximum speed position and hold them there.

5. Adjust the control levers so that they line up (Figure 71) and tighten the bolts, securing the levers to the posts.

   

   Figure 71

Check the level of the hydraulic fluid before the engine is first started and daily thereafter.

1. Position the machine on a level surface.

2. Place the controls in the neutral locked position and start the engine.

   Note: Run engine at lowest possible RPM to purge the system of air. Do not engage the PTO.

3. Raise the deck to extend lift cylinders, stop the engine, and remove the key.

4. Raise the seat to access the hydraulic fluid tank.

5. Remove the hydraulic fill cap (Figure 72) from the filler neck.

   

   Figure 72

   1. Dipstick
   2. Fill cap

6. Remove the dipstick and wipe it with a clean rag (Figure 72).

7. Place the dipstick into the filler neck; then remove it and check level of fluid (Figure 72).

   Note: If level is not within notched area of the dipstick, add enough high quality hydraulic fluid to raise level to within the notched area. Do not overfill.

8. Replace the dipstick and thread the fill cap finger-tight onto filler neck.

9. Check all hoses and fittings for leaks.

1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Place a large pan under the hydraulic reservoir and transmission case and remove the plugs, draining all of the hydraulic fluid (Figure 73).

   

   Figure 73

   1. Hydraulic reservoir drain plug
   2. Filter
   3. Transmission case drain plug

4. Clean the area around the hydraulic oil filter and remove it (Figure 73).

5. Immediately install a new hydraulic oil filter.

6. Install the hydraulic reservoir and transmission case drain plugs.

7. Fill the reservoir to the proper level (approximately 6 quarts); refer to Checking the Hydraulic System.

8. Start the engine and check for oil leaks. Allow the engine to run for about five minutes, then shut it off.

9. After 2 minutes, check the level of the hydraulic fluid; refer to Checking the Hydraulic System.