Groundsmaster® 7200 and 7210 Series 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.

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

• 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.

• To avoid personal injury or property damage, use extreme care in handling fuel. Fuel can be is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• 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).

• 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.

• The ROPS is an integral and effective safety device. Keep a folding ROPS in the raised and locked position and use the seat belt when operating the machine.

• Lower a folding ROPS temporarily only when absolutely necessary. Do not wear the seat belt when folded down.

• Be aware there is no rollover protection when a folded ROPS is in the down position.

• Be certain that the seat belt can be released quickly in the event of an emergency.

• Check the area to be mowed and never fold down a folding ROPS in areas where there are slopes, drop offs or water.

• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Keep the ROPS in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight.

• Replace a damaged ROPS. Do not repair or revise.

• Do not remove the ROPS.

• Any alterations to a ROPS must be approved by the manufacturer.

• 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.

• Use care when loading or unloading the machine into a trailer or truck.

• Use full width ramps for loading machine into trailer or truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine

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. Glow plug light
   4. Power take off switch (PTO)

5. Move the throttle lever midway between the Fast and Slow positions (Figure 15).

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

   The glow plug light will turn on for 6 seconds.

   

   Figure 16

   1. Ignition switch
   2. Off
   3. Run/glow plug
   4. Start

7. After the glow plug indicator light goes out, turn the key to the Start position. When the engines starts release the key.

   Important: Use starting cycles of no more than 15seconds 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.

8. Leave the throttle midway between the Slow and Fast positions until the engine and hydraulic system warm up.

   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. Let the engine idle for 60seconds.

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

4. 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.

The deck-lift switch raises and lowers the mower deck (Figure 18). The engine must be running for you to use this lever.

Figure 18

1. Deck-lift switch

• To lower the mower deck, push the deck-lift switch down (Figure 18).

  Important: When the mower deck is lowered, it will be set in a float/idle position.

• To raise the mover deck, push the deck-lift switch up (Figure 18).

Important: Do not continue to hold the switch up or down after the mower has fully raised or lowered. Doing so will damage the hydraulic system.

Note: To lock the mower deck in a raised position, raise the deck past the 15 cm (6 inch) position, remove the height of cut stop pin and place the pin in the 15 cm (6 inch) height-of-cut position (Figure 20).

The power take off (PTO) switch starts and stops the mower blades and some powered attachments.

1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO.

2. While seated in the seat, release the pressure on the traction control levers and place them in neutral.

3. Pull up on the PTO switch to engage it (Figure 19).

   

   Figure 19

   1. PTO switch

To disengage, push the PTO switch to the off position.

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 31).

   

   Figure 31

   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 31).

Figure 32

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 31).

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 31).

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 1turn (Figure 34).

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

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

   

   Figure 34

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

4. Disengage the parking brake before pushing.

Rotate each by-pass valve clockwise 1turn and hand tighten them (torque of approximately 8 N-m (71 in-lb) (Figure 34).

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

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

To maintain enough power for the machine and deck while mowing, operate the engine at the fast throttle position and adjust your ground speed for conditions. A good rule to follow is to decrease ground speed as the load on the cutting blades increases; and increase ground speed as the load on the blades decreases.

Alternate mowing direction to avoid making ruts in the turf over time. This also helps disperse clippings, which enhances decomposition and fertilization.

To improve cut quality, use a slower ground speed in certain conditions.

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short.

Remove approximately 25 mm (1 inch) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to slow down the forward speed and/or raise the height-of-cut to the next higher setting.

Important: If cutting more that 1/3 of the grass blade off, or in sparse long grass or dry conditions, the use of flat sail blades is recommended to reduce air-borne chaff, debris, and deck drive component strain.

If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting.

Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

To reduce the risk of fire hazard, keep the engine, muffler, battery compartment, parking brake, cutting units, and fuel storage compartment free of grass, leaves, or excessive grease. Clean up any spilled oil or fuel.

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the blades daily for sharpness, and for any wear or damage. Sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

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.

The gear box is designed to operate with SAE EP90W gear lube. Although the gear box 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. 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 39) shows red or every 400 hours (more frequently in extremely dusty or dirty conditions). Do not over service the air filter.

   

   Figure 39

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

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

Drain water or other contaminants from water separator (Figure 42) daily.

1. Place a clean container under the fuel filter.

2. Loosen the drain plug on the bottom of the filter canister.

   

   Figure 42

   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.

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.

1. Park the machine on a level surface. Ensure that the fuel tank is at least half full.

2. Unlatch and raise the hood.

3. Place a rag under the air-bleed screw on the fuel-injection pump and open it (Figure 43).

   

   Figure 43

   1. Fuel-injection pump bleed screw

4. Turn the key in the ignition switch to the On position.

   The electric fuel pump will begin operation, thereby forcing air out around the air bleed screw.

   Caution

   The engine may start during this procedure. Moving fans and belts in a running engine can severely injure you or bystanders.

   Keep hands, fingers, loose clothing/jewelry, and hair away from the engine fan and belt during this procedure.

5. Leave the key in the On position until a solid stream of fuel flows out around the screw.

6. Tighten the screw and turn key to the Off position.

   Note: Normally, the engine should start after above bleeding procedures are followed. However, if engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air from the Injectors.

Note: Use this procedure only if the fuel system has been purged of air through normal priming procedures and engine will not start; refer to Bleeding the Fuel System.

1. Place a rag under the pipe connection coming from the injection pump to the No. 1 injector nozzle as illustrated in Figure 44.

   

   Figure 44

   1. Pipe connection from the injection pump to the No. 1 injector nozzle

2. Move the throttle to the Fast position.

3. Turn the ignition key the Start position, and watch the fuel flow around the connector.

   Caution

   The engine may start during this procedure. Moving fans and belts in a running engine can severely injure you or bystanders.

   Keep hands, fingers, loose clothing/jewelry, and hair away from the engine fan and belt during this procedure.

4. Tighten the pipe connector securely when it attains a solid flow.

5. Turn the key to the Off position.

6. Repeat this procedure for the remaining nozzles.

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 45). 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 46) 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 45

1. Side panel cover
2. Latches

Figure 46

Check the pressure after every 50operating hours or monthly, whichever occurs first (Figure 47).

Maintain the air pressure in the front and rear tires. The correct air pressure is 124 kPa (18 psi) in the rear tires and 172 kPa (25 psi) in the caster wheels. Uneven tire pressure can cause an uneven cut. Check the tires when they are cold to get the most accurate pressure reading.

Figure 47

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

2. Remove the locknut from the bolt holding the caster wheel assembly between the caster fork (Figure 48).

   

   Figure 48

   1. Nut
   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 48.

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 nut 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 general-purpose, lithium-based grease.

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 49). The coolant level should be between the marks on the side of the tank.

   

   Figure 49

   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 50).

   

   Figure 50

   1. Bolts
   2. Seat plate

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

   

   Figure 51

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

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 51).

   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 52) after every 100 operating hours.

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

2. If the deflection is not 10mm (3/8inch), loosen the alternator mounting bolts (Figure 52). 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 52

   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 53).

   

   Figure 53

   1. Bolts
   2. Seat plate

3. Loosen the 2 screws securing the interlock switch (Figure 54).

   

   Figure 54

   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 54).

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 55).

   

   Figure 55

   1. Bolts
   2. Seat plate

4. Move the control lever to the neutral position but not locked (Figure 57).

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 56).

   

   Figure 56

   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 57).

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

   

   Figure 57

   1. Neutral position
   2. Neutral locked position

7. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 56).

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 56).

   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 56).

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 58).

   

   Figure 58

   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 56).

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 59).

   

   Figure 59

   1. Bolts
   2. Seat plate

4. Loosen the jam nut on the stop bolt for one of the control levers (Figure 60).

   

   Figure 60

   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 61)

   

   Figure 61

   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 62) and tighten the bolts, securing the levers to the posts.

   

   Figure 62

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 63) from the filler neck.

   

   Figure 63

   1. Dipstick
   2. Fill cap

6. Remove the dipstick and wipe it with a clean rag (Figure 63).

7. Place the dipstick into the filler neck; then remove it and check level of fluid (Figure 63).

   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 64).

   

   Figure 64

   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 64).

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; refer to Hydraulic System Maintenance.

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 Hydraulic System Maintenance.