Groundsmaster® 7210 Series Traction Unit

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do not use the seat belt when the roll bar is in the lowered position.

Lowering the Roll Bar

Lower the roll bar as shown in Figure 12.

Note: Push the bar forward to relieve pressure on the pins.

Figure 11

Note: Secure the roll bar so that it does not damage the hood.

Raising the Roll Bar

Raise the roll bar as shown in Figure 11.

Figure 12

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do not use the seat belt when the roll bar is in the lowered position.

You can adjust the height of cut from 2.5 to 15.8 cm (1 to 6 inches) in 6 mm (1/4 inch) increments by relocating the stop pin into different hole locations.

1. With the engine running, push the deck-lift switch up until the mower deck is fully raised and release the switch immediately (Figure 24).

2. Rotate the stop pin until the roll pin in it lines up with the slots in the holes in the height-of-cut bracket and remove it (Figure 13).

3. Select a hole in the height-of-cut bracket corresponding to the height of cut desired, insert the pin, and rotate it down to lock it in place (Figure 13).

   Note: There are 4 rows of hole positions (Figure 13). The top row gives you the height of cut listed above the pin. The second row down gives you the height listed plus 6 mm (1/4 inch). The third row down gives you the height listed plus 12 mm (1/2 inch). The bottom row gives you the height listed plus 18 mm (3/4 inch). For the 15.8 cm (6 inch) position, there is only 1 hole, located in the second row. This does not add 6 mm (1/4 inch) to the 15.8 cm (6 inch) position.

   

   Figure 13

   1. Stop pin
   2. Height-of-cut stop

4. Adjust the anti-scalp rollers and skids as required.

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

To adjust, move the lever sideways to unlock the seat (Figure 16).

Figure 16

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 17).

Figure 17

1. Seat-suspension knob

To access the hydraulic and other systems under the seat, unlatch the seat and swing it forward.

1. Use the seat position adjustment lever to slide the seat all the way forward.

2. Pull the seat latch forward and lift up to unlatch the seat (Figure 18).

   

   Figure 18

   1. Seat latch

Always engage the parking brake when you stop the machine or leave it unattended.

Engaging the Parking Brake

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.

Figure 19

Releasing the Parking Brake

Figure 20

Note: The glow plug light illuminates for 6 seconds when you turn the ignition key to the RUN position. Turn the ignition to the START position after the light goes out.

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

Important: Operate the machine with the throttle lever in the SLOW position in both the forward and reverse directions for 1 to 2 minutes after changing the engine oil, overhauling either the engine, transmission, or wheel motor, and when you start the engine for the first time. Operate the lift lever and PTO lever to ensure that they operate properly. Shut the engine off, check fluid levels, and check for oil leaks, loose parts, and any other noticeable malfunctions.

Figure 21

Note: Leave the throttle midway between the SLOW and FAST positions until the engine and hydraulic system warm up.

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. Always operate in the FAST throttle position when running powered attachments.

1. Release the parking brake.

   Note: The engine shuts off if you move the motion-control levers out of the NEUTRAL-LOCK position with the parking brake engaged.

2. Move the levers to the center, unlocked position.

3. Drive the machine as follows:

   • To move straight forward, slowly push the motion-control levers forward (Figure 22).

   • To move straight rearward, slowly pull the motion-control levers rearward (Figure 22).

   • To turn, slow the machine by pulling back on both levers and then push forward on the lever on the opposite side from which you want to turn (Figure 22).

   • To stop, pull the motion-control levers to the NEUTRAL position.

   Note: The farther you move the motion-control levers in either direction, the faster the machine moves in that direction.

   

   Figure 22

   1. Motion-control lever—NEUTRAL-LOCK position
   2. Center, unlocked position
   3. Forward
   4. Backward
   5. Front of the machine

Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

1. Move the machine to the job site.

2. Whenever possible, set the throttle to high idle.

3. Engage the PTO switch.

4. Gradually move the motion-control levers forward and slowly drive the machine over the mowing area.

5. Once the front of the cutting units are over the mowing area, lower the cutting units.

6. Cut grass so that the blades can cut and discharge clippings at a high rate while producing a good quality of cut.

   Note: If the cutting rate is too high, the quality of cut may deteriorate. Reduce the ground speed of the machine or reduce the width of cut to regain high idle engine speed.

7. When the cutting units are over the far edge of the mowing area, lift the cutting units.

8. Perform a tear-shaped turn to quickly line up for your next pass.

The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust.

The DPF regeneration process uses heat from the engine exhaust to incinerate the soot accumulated on the soot filter, converting the soot to ash, and clears the channels of the soot filter so that filtered engine exhaust flows out the DPF.

The engine computer monitors the accumulation of soot by measuring the back pressure in the DPF. If the back pressure is too high, soot is not incinerating in the soot filter through normal engine operation. To keep the DPF clear of soot, remember the following:

• Passive regeneration occurs continuously while the engine is running—run the engine at full engine speed when possible to promote DPF regeneration.

• If the back pressure in the DPF is too high or a reset regeneration has not occurred for 100 hours, the engine computer signals you through the InfoCenter when reset regeneration is running.

• Allow the reset regeneration process to complete before shutting off the engine.

Operate and maintain your machine with the function of the DPF in mind. Engine load at high idle (full throttle) engine speed generally produces adequate exhaust temperature for DPF regeneration.

Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter.

DPF Soot Accumulation

• Over time, the diesel particulate filter 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 DPF.

• 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 27 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 or Recovery Regeneration.
Level 2: Engine Warning	Figure 28 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%.	Perform a recovery regeneration as soon as possible; refer to Parked or Recovery Regeneration.

DPF Ash Accumulation

• 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 an engine fault to indicate the accumulation of ash in the DPF.

• The fault messages indicate 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	Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 29 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 2: Engine Warning	Figure 30 Check EngineSPN 3720, FMI 16	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 3: Engine Warning	Figure 31 Check EngineSPN 3251, FMI 0	Engine speed at maximum 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

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

Type of Regeneration	Conditions that cause 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 because of low-engine speed, low-engine load, or after the computer detects the DPF is becoming obstructed with soot	• The InfoCenter does not display an icon indicating assist regeneration.
		• During assist regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Assist DPF Regeneration.
Reset	Occurs every 100 hours	• When the high exhaust-temperature icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level
		• During reset regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Reset Regeneration.

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

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Parked	Occurs because the computer detects back pressure in the DPF due to soot buildup	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #188 displays in the InfoCenter, a regeneration is requested.
	Also occurs because the operator initiates a parked regeneration
	May occur because you set the InfoCenter to inhibit reset regeneration and continued operating the machine, adding more soot when the DPF already needs a reset regeneration	• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
	May result from using the incorrect fuel or engine oil	• 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 parked regeneration.
		Refer to Parked or Recovery Regeneration.
Recovery	Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
		• A recovery regeneration requires up to 3 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 Parked or Recovery Regeneration.

Accessing the DPF Regeneration Menus

Accessing the DPF Regeneration Menus

1. Access the Service menu, press the center button to scroll down to the DPF REGENERATION option (Figure 32).

   

   Figure 32

2. Press the right button to select the DPF Regeneration entry (Figure 32).

Time Since Last Regeneration

Access the DPF Regeneration menu, press the center button to scroll down to the LAST REGEN field (Figure 33).

Use the LAST REGEN field to determine how many hours you have run the engine since the last reset, parked, or recovery regeneration.

Figure 33

Technician Menu

Important: For operating convenience, you may decide to perform a parked regeneration before the soot load reaches 100%, provided the engine has run more than 50 hours since the last successful reset, parked, or recovery regeneration.

Use the technician menu to view the current state of engine regeneration control and view the reported soot level.

Access the DPF Regeneration menu, press the center button to scroll down to the TECHNICIAN option, and press the right button to select the Technician entry (Figure 34).

Figure 34

• Use the DPF operation table to understand the current state of DPF operation (Figure 35).

  

  Figure 35

  .

  DPF Operation Table

  State	Description
  Normal	The DPF is in normal-operating mode—passive regeneration.
  Assist Regen	The engine computer is performing an assist regeneration.
  Reset Stby	The engine computer is trying to run a reset regeneration, but 1 of the following conditions prevents regeneration:	The regen inhibit setting is set to ON.
  		The exhaust temperature is too low for regeneration.
  Reset Regen	The engine computer is running a reset regeneration.
  Parked Stby	The engine computer is requesting that you run a parked regeneration.
  Parked Regen	You initiated a parked regeneration request and the engine computer is processing the regeneration.
  Recov. Stby	The engine computer is requesting that you run a recovery regeneration.
  Recov. Regen	You initiated a recovery regeneration request and the engine computer is processing the regeneration.

• View the soot load which is measured as the percentage of soot in the DPF(Figure 36); refer to the soot-load table.

  Note: The soot load value varies as the machine is operated and DPF regeneration occurs.

  

  Figure 36

  Soot-Load Table

  Important Soot Load Values	Regeneration State
  0% to 5%	Minimum soot load range
  78%	The engine computer performs an assist regeneration.
  100%	The engine computer automatically requests a parked regeneration.
  122%	The engine computer automatically requests a recovery regeneration.

Reset Regeneration

Caution

The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people.

• Never operate the engine in an enclosed area.

• Make sure that there are no flammable materials around the exhaust system.

• Never touch a hot exhaust system component.

• Never stand near or around the exhaust pipe of the machine.

Figure 37

• The high exhaust-temperature icon displays in the InfoCenter (Figure 37).

• The engine computer adjusts engine settings to raise the exhaust temperature.

  Important: The high exhaust-temperature 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 and high load 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: Whenever possible, allow the machine to complete the reset regeneration process before shutting off the engine.

Periodic Reset Regeneration

If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration.

Setting the Inhibit Regen

Reset Regeneration Only

Note: If you set the InfoCenter to inhibit regeneration, the InfoCenter displays ADVISORY #185 (Figure 38) every 15 minutes while the engine requests a reset regeneration.

Figure 38

A reset regeneration produces the elevated engine exhaust. If you are operating the machine around trees, brush, tall grass, or other temperature-sensitive plants or materials, you can use the Inhibit Regen setting to prevent the engine computer from performing a reset regeneration.

Important: When you shut off the engine and start it again, the inhibit regen setting defaults to OFF.

1. Access the DPF Regeneration menu, press the center button to scroll down to the INHIBIT REGEN option, and press the right button to select the Inhibit Regen entry (Figure 39).

   

   Figure 39

2. Press the right button to change the inhibit regeneration setting from On to Off (Figure 39) or from Off to On (Figure 40).

   

   Figure 40

Allowing a Reset Regeneration

The InfoCenter displays the high exhaust-temperature icon when the reset regeneration is in process.

Note: If INHIBIT REGEN is set to ON, the InfoCenter displays ADVISORY #185 (Figure 41). Press button 3 to set inhibit regeneration setting to OFF and continue with the reset regeneration.

Figure 41

Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 42) to inform you to set the engine to full throttle (high idle).

Figure 42

Note: When the reset regeneration completes, the high exhaust-temperature disappears from the InfoCenter screen.

In an emergency, you can move the machine a very short distance by actuating the bypass valves in the hydraulic pump and pushing the machine.

Important: Always push the machine by hand and never a long distance. Never tow the machine, because damage to the hydraulic system may occur.

Important: The bypass valves must be open whenever you push or tow the machine. Close the valves once you have pushed or towed the machine to the desired location.

1. Lift the seat; refer to Unlatching the Seat

2. Locate the bypass valves (Figure 61) and rotate each bypass valve counterclockwise 1 turn.

   Note: This allows hydraulic fluid to bypass the pump, enabling the wheels to turn.

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

   

   Figure 61

   1. Right bypass valve
   2. Left bypass valve

3. Ensure that the parking brake is disengaged and push the machine to the desired location.

4. Close the valves by rotating each valve 1 clockwise turn (Figure 61).

   Note: Do not overtighten the valves.

5. Torque the valves to approximately 8 N∙m (71 in-lb).

   Important: Ensure that the bypass valves are closed before you start the engine. Running the engine with open bypass valves causes the transmission to overheat.

Use a heavy-duty trailer or truck to transport the machine. 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, your family, pets, or bystanders avoid injury.

1. If you are using a trailer, connect it to the towing vehicle, and connect the safety chains.

2. If applicable, connect the trailer brakes.

3. Load the machine onto the trailer or truck; refer to Loading the Machine.

4. Shut off the engine, remove the key, engage the parking brake, and close the fuel valve.

5. Use the tie-down loops on the machine to securely fasten it to the trailer or truck with straps, chains, cable, or ropes (Figure 62).

   

   Figure 62

   1. Traction unit tie-down loops

Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Drive the machine up ramps in reverse and drive it down ramps in a forward direction (Figure 63).

Figure 63

1. Drive the machine up the ramp in reverse.
2. Drive the machine forward down the ramp.

Important: Do not use narrow individual ramps for each side of the machine.

Figure 64

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15°
4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5. “H” indicates the height of the trailer or truck bed to the ground.
6. Trailer

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Lubricate more often in dirty or dusty conditions because dirt can get into the bearings and bushings and cause accelerated wear.

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: Improper wash-down procedures can negatively affect bearing life. Do not wash down the machine when it is still hot and avoid directing high-pressure or high-volume spray at the bearings or seals.

The gear box is designed to operate with SAE EP90W gear lube. Although the gearbox comes from the factory with lubricant, check the level of the lubricant in the cutting unit before operating it and as recommended in the Daily Maintenance Checklist.

1. Check the air-cleaner body for damage, which could possibly cause an air leak. Replace a damaged air-cleaner body.

2. Check the air-intake system for leaks, damage, or loose hose clamps.

3. Service the air-cleaner filter (Figure 66).

   Important: Do not over-service the air filter.

   

   Figure 66

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

4. Be sure that the cover is seated correctly and seals with the air-cleaner body.

Note: If the foam gasket in the cover is damaged, replace it.

Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract.

Important: Do not clean the used filter to avoid damage to the filter media.

Important: Do not use a damaged filter.

Important: Do not apply pressure to the flexible center of the filter.

Figure 67

• 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 70

• If engine faults , , or in the InfoCenter (Figure 71) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 71

  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.

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

1. Clean the area around the fuel filter head (Figure 72).

   

   Figure 72

   1. Fuel Filter head
   2. Fuel Filter

2. Remove the filter and clean the filter head mounting surface (Figure 72).

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.

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 you are storing the machine for an extended period.

Inspect the fuel lines 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 you are storing the machine more than 30 days, remove the battery and charge it fully. Either store it on a shelf or on the machine. Do not connect the cables if you store it 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 74). 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 1 at a time, checking if any are blown.

Important: 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 for a diagram of each fuse and its amperage (Figure 75).

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

Figure 74

1. Side panel cover
2. Latch

Figure 75

Maintain the air pressure in the front and rear tires (Figure 76). The correct air pressure is 124 kPa (15 psi) in the rear tires and 103 kPa (25 psi) in the caster wheels. Uneven tire pressure can cause an uneven cut.

Note: Check the tires when they are cold to get the most accurate pressure reading.

Figure 76

1. Obtain a new caster-wheel assembly, cone bearings, and bearing seals from your Authorized Toro Distributor.

2. Remove the locknut from the bolt (Figure 77).

   

   Figure 77

   1. Locknut
   2. Bearing spacer
   3. Outer bearing seal
   4. Cone bearing
   5. Inner bearing seal
   6. Spacer
   7. Caster wheel
   8. Axle bolt
   9. Caster fork

3. Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

4. Discard the old caster wheel and bearings.

5. Assemble the caster wheel by pushing the cone bearings and seals, packed with grease, into the wheel hub, positioned as shown in Figure 77.

6. Slide the spacer into the wheel hub through the bearings, captivating the spacer inside the wheel hub with 2 bearing spacers.

   Important: Ensure that the seal lips are not folded inward.

7. Install the caster-wheel assembly between the castor fork and secure it in place with the bolt and locknut.

8. Tighten the locknut until the wheel no longer spins freely, then back it off just until the wheel spins freely.

9. Attach a grease gun to the grease fitting on the caster wheel and fill it with No. 2 lithium grease.

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti freeze. The capacity of the cooling system is 7.5 L (6 US qt).

1. Check the level of the coolant in the expansion tank (Figure 78).

   Note: The coolant level should be between the marks on the side of the tank.

   

   Figure 78

   1. Expansion tank

2. If coolant level is low, remove the expansion-tank cap and replenish the system.

   Important: Do not overfill.

3. Install the expansion-tank cap.

Clean the radiator to prevent the engine from overheating.

Note: If the mower deck or engine shuts off due to overheating, 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 (345 kPa or 50 psi), compressed air. Repeat from the front of the radiator and the other fan side.

   Important: Do not use water.

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

4. Close the hood.

1. Stop the machine, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 79).

   

   Figure 79

   1. Bolt
   2. Control panel

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

   

   Figure 80

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

4. Move the switch up or down on the bracket until the distance between the brake-shaft sensor and the switch plunger is 4 mm (5/32 inch) as shown in Figure 80.

   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-LOCK position.

      Note: The engine should shut off. If not, check the adjustment that you made to the switch.

7. Install the front panel.

1. Apply 44 N (10 lb) of force to the alternator belt, midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 81).

   

   Figure 81

   1. Mounting bolt
   2. Alternator

3. Increase or decrease the alternator-belt tension.

4. Tighten the mounting bolts.

5. Check the deflection of the belt again to ensure that the tension is correct.

1. Stop the machine, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 82).

   

   Figure 82

   1. Bolt
   2. Control panel

3. Loosen the 2 screws securing the interlock switch (Figure 83).

   

   Figure 83

   1. Control lever
   2. Neutral-interlock switch
   3. Screw
   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 the lever and switch body is 0.4 to 1 mm (0.015 to 0.045 inch) as shown in Figure 83.

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 position, adjustment is required. Adjust each lever, spring, and rod separately.

1. Disengage the PTO, move the control lever to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off 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 84).

   

   Figure 84

   1. Bolt
   2. Control panel

4. Move the control lever to the NEUTRAL position but not locked (Figure 86).

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) as shown in Figure 85.

   

   Figure 85

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

6. Check where the control lever is relative to notch in the console (Figure 86).

   Note: The control lever should be centered, allowing lever to pivot outward to the NEUTRAL-LOCK position.

   

   Figure 86

   1. NEUTRAL position
   2. NEUTRAL-LOCK position

7. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 85).

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 85).

   Note: Rearward pressure on the lever keeps 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 85).

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

11. Install the front panel.

Make this adjustment with the drive wheels turning.

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

2. Slide the 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 the terminals in the wire 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-LOCK position while you make 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 87).

   

   Figure 87

   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.

   Note: The wheel must stop turning or slightly creep in reverse.

8. Move the throttle lever to the FAST position.

   Note: 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 85).

11. Move the throttle lever to the SLOW position and shut off the engine.

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

    Warning

    The electrical system does not perform proper safety shutoff with the jumper wire installed.

    • Remove the jumper wire from the wire harness connector and plug the connector into the seat switch when you complete adjustment.

    • Never operate the machine with the jumper installed and the 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-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off 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 88).

   

   Figure 88

   1. Bolt
   2. Control panel

4. Loosen the jam nut on the stop bolt for a control lever (Figure 89).

   

   Figure 89

   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.

   Note: If you want to reduce the maximum machine speed, back each stop bolt out an equal amount toward the control lever until you reach the desired maximum speed. You may need to test your adjustment several times.

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.

11. Ensure that the machine drives straight and does not turn when both control levers are pushed all the way forward.

    Note: If the machine turns, the stop bolts are not evenly set and you need to adjust them further.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off 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 90).

   

   Figure 90

   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 and tighten the bolts, securing the levers to the posts (Figure 91).

   

   Figure 91

Check the level of the hydraulic fluid before you first start the engine and daily thereafter.

1. Position the machine on a level surface.

2. Move the motion-control levers to the NEUTRAL-LOCK position and start the engine.

   Note: Run the engine at the lowest possible rpm to purge the system of air.

   Important: Do not engage the PTO.

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

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

5. Remove the hydraulic fill cap from the filler neck (Figure 92).

   

   Figure 92

   1. Dipstick
   2. Fill cap

6. Remove the dipstick and wipe it with a clean rag (Figure 92).

7. Place the dipstick into the filler neck; then remove it and check the level of fluid (Figure 92).

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

   Important: Do not overfill.

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

9. Check all hoses and fittings for leaks.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off 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 93).

   

   Figure 93

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

4. Clean the area around the hydraulic fluid filter and remove the filter (Figure 93).

5. Immediately install a new hydraulic fluid filter.

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

7. Fill the reservoir to the proper level (approximately 5.7 L or 6 US qt); refer to Checking the Hydraulic System.

8. Start the engine and check for oil leaks. Allow the engine to run for about 5 minutes, then shut it off.

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

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

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

3. Raise the mower to the transport position.

4. Raise the front of the machine using jack stands.

5. Thoroughly clean the underside of the mower with water.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants. Dispose of these according to your state and local regulations.