LT2240 Compact Triple 4-Wheel Drive Turf Mower

Important: The horn sounds when an engine coolant overheat condition occurs. Shut off the engine immediately, and repair the machine before starting the engine again.

Press the horn button to provide an audible warning (Figure 5).

Figure 5

1. Horn button

• To increase the engine speed, move the throttle-control lever (Figure 6) forward.

• To decrease engine speed, move the throttle-control lever rearward.

Note: Engine speed influences the speed of the other functions, i.e. ground speed, reel speed and cutting unit lift rate.

Figure 6

1. Throttle control lever

The auto reverse limited-lift switch controls whether cutting units can rise automatically to the limited lift position when driving the machine backward.

• To enable auto reverse-limited lift, press the top of the auto reverse limited-lift switch (Figure 7).

  The LED light in the switch illuminates when limited lift in reverse is enabled.

• To shut off auto reverse-limited lift, press the bottom of the auto reverse limited-lift switch.

Figure 7

1. Auto reverse limited-lift switch

The ignition switch has 4 positions to control the engine and machine electrical power.

Figure 8

1. STOP
2. START
3. PREHEAT
4. RUN /AUXILIARY ON

Use the lift-control switches to raise and lower the cutting units (Figure 9).

Figure 9

1. Left (front) cutting-unit lift switch
2. Rear cutting-unit lift switch
3. Right (front) cutting-unit lift switch

• To run the cutting units, press the top of the cutting-unit drive switch (Figure 10).

  The LED light in the switch illuminates when the cutting units are running.

• To shut off the cutting units, press the bottom of the cutting-unit drive switch.

  Important: Always shut off cutting units when you are not cutting.

  

  Figure 10

  1. Cutting-unit drive switch

Important: Do not operate the mower with the parking brake engaged, and do not engage the parking brake while the mower is moving.

Important: The parking brake operates on the front wheels only. Do not park the mower on a slope.

To engage the parking brake, pressing the smaller (orange) locking button, and moving the brake switch forward (Figure 11).

Note: The LED light in the switch illuminates when the parking brake is engaged and the ignition key is turned to the RUN position.

Figure 11

1. Locking button (orange)
2. Parking-brake switch

The hydraulic transmission provides the machine with service-brake effect. When you release the forward or reverse travel pedals, or reduce engine speed the transmission produces service-brake effect and ground speed slows or stops the machine. To increase the transmission-braking effect, push the transmission pedal into the NEUTRAL position. Only the front wheels provide service brake effect.

If the service brake is damaged or ineffective, shut off the engine, engage the parking brake remove the key, and have the machine repaired.

The battery charge warning light illuminates when low battery charge occurs (Figure 13).

Figure 13

1. Low battery charge warning light

The engine-oil pressure warning light illuminates when the oil pressure is too low (Figure 14).

Figure 14

1. Low engine-oil pressure warning light

The engine coolant warning light illuminates, the horn is actuated, and the cutting units stop (Figure 15).

Figure 15

1. Engine coolant overheating warning light

The hour meter shows the total hours that the machine has been operated (Figure 16).

Figure 16

1. Hour meter

The transmission neutral indicator light illuminates when the traction pedals are in the NEUTRAL position and the ignition key is turned to the RUN position (Figure 17).

Note: You must engage the parking brake for the transmission neutral indicator light to illuminate.

Figure 17

1. Transmission neutral indicator light

Turn the ignition key to position PREHEAT. The engine preheat indicator light illuminates and the glow plugs energize to help start a cold engine. (Figure 18).

Important: Attempting to start a cold engine before using the preheat may cause unnecessary battery wear.

Figure 18

1. Engine pre-heat indicator light

Move the lever upward to adjust the forward/backward position of the seat. Release the lever to lock the seat in position (Figure 21).

Figure 21

1. Lever

Rotate the handle clockwise to increase suspension stiffness and counterclockwise to decrease the stiffness. The dial indicates when the seat suspension is adjusted for the operator’s weight (kg); refer to Figure 22.

Figure 22

1. Lever
2. Dial

To adjust seat height incremental, manually lift the seat. To lower the seat, lift it beyond the highest setting, allow it to drop to the lowest setting, and if needed manually lift the seat to the desired height (Figure 23).

Figure 23

1. Handle

Pull the handle outward to adjust the seat backrest angle. Release the handle to lock the seat backrest in position (Figure 24).

Figure 24

1. Handle

Raise the cutting units to the TRANSPORT position and secure the arm-latch pins to the latches with the bails (Figure 26).

Figure 26

1. Bails (front cutting-unit arm latches)

Raise the cutting units to the TRANSPORT position, push down the latch handle for the rear cutting-unit arm, and move the handle forward and up (Figure 27).

Figure 27

1. Latch handle (rear cutting-unit arm latch)

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Remove the hairpins from the roll-bar pins in the pivot brackets of the lower roll-bar frame (Figure 29).

   

   Figure 29

   1. Roll-bar pin
   2. Pivot bracket upper (lower roll-bar frame)
   3. Hairpin
   4. Upper roll bar

3. While supporting the weight of the upper roll bar, remove the roll-bar pins from the pivot brackets (Figure 29).

4. Carefully lower the upper roll bar until it rests on the stops of the lower roll-bar frame.

5. Insert the roll-bar pins in the lower holes of the pivot brackets (Figure 30).

   

   Figure 30

   1. Roll-bar pin (lower position)

6. Secure roll-bar pins to the pivot brackets with the hairpins.

1. Remove the hairpins that secure the roll-bar pins to the pivot brackets of the lower roll-bar frame.

2. Remove the roll-bar pins from the pivot brackets (Figure 31).

   

   Figure 31

   1. Roll-bar pin

3. Raise the upper roll bar until the holes in the roll bar align with the pivot brackets (Figure 32).

   

   Figure 32

   1. Roll-bar pin
   2. Pivot bracket upper hole (lower roll-bar frame)
   3. Hairpin
   4. Upper roll bar

4. Insert the roll-bar pins through the upper holes of the pivot brackets and the upper roll bar (Figure 32).

5. Secure roll-bar pins to the pivot brackets with the hairpins (Figure 32).

Important: If you are starting the engine for the first time, the engine has shut off due to lack of fuel, or you have performed maintenance on the fuel system—you must bleed the fuel system before starting the engine; refer to Bleeding the Fuel System.

Important: This machine is fitted with an engine start lockout; refer to Understanding the Operator-Presence Controls.

Use the 3 lift-control switches to raise or lower the cutting units independently.

When the cutting unit drive switch is in the ON position and the cutting units lowered, momentarily move the 3 lift-control switches (Figure 37) rearward.

Note: The cutting units shut off immediately and raise to approximately 150 mm (6 inches) above ground level.

Figure 37

1. Lift-control switches

With auto-limited lift in reverse engaged, driving the machine in reverse causes the cutting units to automatically raise to the limited-lift position.

Important: The cutting units continue to run while driving in reverse with the auto-limited lift in reverse engaged.

The cutting unit drive engages only when you sit in the operator’s seat; refer toUnderstanding the Operator-Presence Controls.

Figure 39

1. Forward
2. Off
3. Reverse

A variable hydraulic weight transfer system provides improved tire grip with the grass surface—traction assistance.

Hydraulic pressure from the cutting-unit lift system provides a lifting force that reduces the weight of the cutting units on the ground and transfers the weight downward to the tires. This action is known as weight transfer.

Note: Adjust the amount of weight transfer to suit operating conditions.

1. Park the machine on a level surface, engage the parking brake, lower the cutting units to the ground, and wait for all moving parts to stop.

   

   Figure 40

   1. Weight transfer hand wheel
   2. Lock wheel

2. At the left side of the machine below the storage compartment, loosen the lock wheel of the weight transfer manifold 1/2 turn counterclockwise while holding the hand wheel steady (Figure 40).

3. Rotate the weight transfer hand wheel (Figure 40) as follows:

   • counterclockwise to reduce weight transfer

   • clockwise to increase weight transfer

   Note: The recommended setting for the weight transfer/traction assistance is to increase the weight transfer until the cutting units start to lift, then rotate the hand wheel 1/2 turn counterclockwise.

4. Tighten the lock wheel (Figure 40).

1. Park the machine on a level surface.

2. Move the traction pedal to the NEUTRAL position, engage the parking brake, and shut off the cutting units.

3. Lower the cutting units to the ground or securely lock them in the transport positions.

4. Shut off the engine, remove the key, and wait for all moving parts to stop.

5. Release all stored energy devices.

6. Check that all moving parts are stationary.

7. Using a suitable strong wooden instrument, remove the blockage. Ensure that the wooden instrument is properly supported in the cutting unit and avoid using excessive force to prevent damage.

8. Remove the wooden instrument from the cutting unit before starting the engine.

9. Repair or adjust the cutting unit if required.

• Use full-width ramps for loading the machine onto a trailer or truck.

• Tie the machine down securely.

Ensure that the towing vehicle can control the combined weight of both vehicles; refer to Specifications.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Lower the cutting units.

4. Shut off the engine and remove the key.

5. Wait for all movement to stop.

6. Allow the machine to cool before adjusting, servicing, or cleaning it.

1. Move the platform-latch handle (Figure 51) toward the front of the machine until the latch hooks clear the locking bar.

   

   Figure 51

   1. Platform-latch handle

2. Raise the platform (Figure 52).

   Note: The gas lift cylinder assists lifting the platform.

   

   Figure 52

1. Lower the platform carefully (Figure 53).

   Note: The gas lift cylinder helps support the platform.

   

   Figure 53

2. As the platform nears the fully lowered position, move the platform-latch handle (Figure 54) toward the front of the machine.

   Note: This ensures that the latch hooks clear the locking bar.

   

   Figure 54

   1. Platform-latch handle
   2. Locking bar

3. Fully lower the platform and move the platform-latch handle toward the rear of the machine until the latch hooks fully engage the locking bar (Figure 55).

   

   Figure 55

   1. Platform-latch handle

1. At the left side of the operator’s platform, open the door of the storage compartment (Figure 56).

   

   Figure 56

   1. Washer
   2. Knob
   3. Storage compartment

2. Remove the 3 knobs and 3 washers that secure the storage compartment to the machine, and remove the compartment (Figure 56).

1. Align the holes on the bottom of the storage compartment with the holes in the chassis brackets.

2. Assemble the storage compartment to the machine with the 3 knobs and 3 washers (Figure 57)

   

   Figure 57

   1. Washer
   2. Knob
   3. Storage compartment

3. Close the storage-compartment door.

Note: Use jack stands to support the machine when you lift it.

• Front—under the front arm mount

• Rear—axle tube on the rear axle

Figure 58

1. Front left lift point
2. Front right lift point
3. Rear lift point

Important: Before raising the mower ensure that the lifting equipment is in good condition, and capable of supporting the weight of the machine securely.Minimum lift capacity: 2,000 kg (4,409 lb)

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the ignition key.

4. Ensure that the ground under the lifting device is level and firm.

5. Align and ensure the lifting equipment is secure against one of the lifting points on the machine; refer to Locating the Lift Points.

6. If raising the front of the machine, chock the rear wheels to prevent the machine from rolling away.

   Note: The parking brake operates only on the front wheels.

7. Support the machine with jack stands.

Important: Lubricate the bearings, bushings, and pivot points immediately after every washing, regardless of the service interval listed.

Grease specification: No. 2 lithium grease.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Use 1 pump of grease on the height-of-cut adjusters and 3 pumps of grease on all other grease fittings.

   • Refer to Figure 59 for the grease fitting locations.

   • Replace any damaged grease fittings.

Figure 59

1. Grease every 50 hours
2. Grease daily

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. Turn the ignition key to the ignition RUN position.

   Note: Do not start the engine.

4. At the left side of the engine, disconnect the red/blue wire terminal from the engine temperature switch (Figure 60).

   

   Figure 60

   1. Temperature switch

5. Touch the metal terminal of this wire onto a suitable earth point, ensuring that the metal surfaces make good contact.

   Note: The horn sounds and the engine coolant temperature warning light illuminates to confirm operation.

   Important: If the system is malfunctioning, make repairs before operating the mower.

6. Turn the ignition key to the ignition STOP position, and remove the key.

7. Close and latch the hood.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. Check the air filter-blockage indicator (Figure 61).

   Important: If the indicator is red, inspect the primary air filter and replace it if it is dirty or damaged; refer to Replacing the Primary Air Filter.

   

   Figure 61

   1. Filter-blockage indicator

4. If the filter-blockage indicator is not red, close the hood.

5. Close and latch the hood.

Check the air-cleaner body for damage that could cause an air leak. Replace the air-cleaner body if damaged. Check the whole intake system for leaks, damage, or loose hose clamps.

Note: Service the primary air filter when the filter-blockage indicator (Figure 61) is red. Changing the air filter frequently increases the chance of dirt entering the engine when the filter is removed.

Important: Ensure that the cover is seated correctly and seals with the air-cleaner body.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. Before removing the air-filter cover, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed outside of the filter canister.

   Note: This cleaning process prevents debris from migrating into the intake when the filter is removed.

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

   

   Figure 62

   1. Air-filter cover
   2. Primary air filter
   3. Canister
   4. Dirt ejection port

4. Remove the cover from the air-cleaner body.

5. Remove the primary air filter (Figure 62).

   Important: Do not clean and reuse a used element because of possible damage to the filter element.

6. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body.

   Important: Do not use a damaged element.

7. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.

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

8. Clean the dirt ejection port located in the air-filter cover. Remove the rubber outlet valve from the cover, clean the cavity in the valve, and install the outlet valve into the air-filter cover.

9. Align the dirt ejection port air-filter cover between 3 o’clock to 5 o’clock when viewed from the end, assemble the cover to the canister, and secure the cover.

10. Close and latch the hood.

The air filter has a secondary, safety filter element inside the primary air filter to prevent dislodged dust and other items from entering the engine while changing the main element.

Replace the safety filter; never clean it.

Important: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters.

Figure 63

1. Air-filter cover
2. Primary air filter
3. Canister
4. Safety filter

You must bleed the fuel system before starting the engine if any of the following situations have occurred:

• Initial start-up of a new machine.

• Engine has ceased running due to lack of fuel.

• Maintenance has been performed upon fuel system components; i.e., filter replaced, separator serviced, etc.

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

2. Open the hood.

3. Turn the key in the ignition switch to the ON position and crank the engine.

   Note: The mechanical pump sucks fuel out of the tank, fill the fuel filter and fuel hose and force the air into the engine. This could take some time to fully purge all the air out of the system and the engine might fire erratically until all air is purged out. When all air is purged and the engine is running smoothly, it should be run for a few minutes to ensure that it is fully purged.

   If required, a mechanical priming pump is provided at the mechanical fuel pump.

Important: Replace the fuel filter canister periodically to prevent wear of the fuel injection pump plunger or the injection nozzle, due to dirt in the fuel.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. Place a clean container under the fuel filter canister (Figure 69).

4. Use a hose pinch tool to pinch the inlet and outlet filter hoses to prevent fuel flow in and out of the filter.

5. Loosen the drain valve at the bottom of the filter canister and open the vent screw at the top of the canister mount and drain the fuel from the filter.

   

   Figure 68

   1. Vent screw
   2. Drain valve

6. Tighten the drain valve at the bottom of the filter canister and close the vent screw at the top of the canister mount.

7. Clean the area around the fuel filter and filter head (Figure 69).

   

   Figure 69

   1. Filter head
   2. Fuel filter

8. Remove the filter canister and clean the filter head (Figure 69).

9. Lubricate the gasket on the new filter canister with clean diesel fuel.

10. Install the new filter canister by hand until the gasket contacts the mounting surface.

11. Remove the inlet hose pinch tool and open the vent screw on the top of the filter head.

    The fuel filter is gravity-fed and will gradually fill. Once clean fuel purges from the vent screw, close the vent screw and remove the hose pinch tool from the filter outlet hose.

12. Close and latch the hood.

13. Prime the fuel system; refer to Bleeding the Fuel System.

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

Keep the terminals and the entire battery case clean because a dirty battery slowly discharges. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse it with clear water.

Inspect all electrical connections and cables and replace any which are damaged or corroded. Spray a good-quality water inhibitor onto exposed connections to prevent moisture ingress.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. At the back of the bulkhead, remove the fuse-block cover (Figure 71)

   

   Figure 71

   1. Fuse holder (maxi fuse)
   2. Maxi fuse-holder cover
   3. Fuse-block cover
   4. Fuse block (ACT/ATO blade)

4. Check for open fuses.

5. Replace any open fuse with a fuse of equal amperage capacity (Figure 72).

   

   Figure 72

   1. 50A (Main power)
   2. 40A (ECU)
   3. 50A (Glow plugs)
   4. Empty
   5. 15A (12V aux power)
   6. 10A (Hazard lights—optional)
   7. 10A (Headlights—optional)
   8. 10A (Air-ride seat—optional)
   9. 10A (Beacon—optional)
   10. 10A (System power—optional)
   11. 10A (Horn)

6. Install the fuse-block cover (Figure 71).

7. Close and latch the hood.

Check the air pressure in the front and rear tires. Refer to the following chart for the correct pressure.

Important: Maintain correct tire pressure in all tires to ensure correct contact with the turf.

Torque the wheel nuts in a crossing pattern to the following values:

Front wheels: 200 N∙m (148 ft-lb)

Rear wheels: 100 N∙m (74 ft-lb)

Check the condition and security of the cable and operating mechanism at the speed-control pedals and transmission pump ends.

• Remove buildup of dirt, grit, and other debris.

• Ensure that the ball joints are securely anchored and check that the mounting brackets and cable anchors are tight and free from cracks.

• Inspect end fittings for wear, corrosion, broken springs, and replace if necessary.

• Ensure that the rubber seals are correctly located and are in good condition.

• Ensure that the articulating sleeves supporting the inner cable are in good condition and firmly attached to the outer cable assembly at the crimped connections. If there are any signs of cracking or detachment install a new cable immediately.

• Check that sleeves, rods, and inner cable are free from bends, kinks, or other damage. If they are not, install a new cable immediately.

• With the engine shut off, operate the pedal controls through the entire range and ensure that the mechanism moves smoothly and freely to the neutral position without sticking or hanging up.

  

  Figure 73

  1. Outer cover
  2. Rubber seal
  3. Sleeve
  4. Rod end

To prevent excessive tire wear and ensure safe machine operation, the front and back of the rear wheels must align within 5 mm (0.20 inch) or less.

1. Turn the steering wheel to align the rear wheels in the straight ahead.

2. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

3. At axle height, measure the distance between the front of the rear wheels and between the rear of the rear wheels.

   Note: The wheels are aligned if the difference between the front and rear measurements are 5 mm (0.20 inch) or less.

   

   Figure 74

   1. Front measurement
   2. Rear measurement

4. If the difference between the front and rear measurements is greater that 5 mm (0.20 inch), align the rear wheels; refer to Adjusting Rear Wheel Toe-In

1. At the front of the rear wheel, loosen the 2 jam nuts securing the track rod assembly to the rod ends (Figure 75).

   

   Figure 75

   1. Track rod assembly
   2. Jam nut
   3. Rod end

2. Align the wheels by rotating the track rod (Figure 75).

   Note: Use the wrench flats of the track rod to turn it.

3. At axle height, measure the distance between the front of the rear wheels and between the rear of the rear wheels.

   Note: The wheels are aligned if the difference between the front and rear measurements are 5 mm (0.20 inch) or less.

   

   Figure 76

   1. Front measurement
   2. Rear measurement

4. Repeat steps 2 and 3 until the wheels are aligned.

5. Tighten the 2 jam nuts to secure the track rod assembly and the rod ends (Figure 75).

Note: To prevent the engine from overheating, keep the radiator and oil cooler clean. Normally, check them daily and, if necessary, clean any debris off these parts. Check and clean more frequently in dusty and dirty conditions.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Clean the outside of the screens in the hood (Figure 77).

   

   Figure 77

3. Unlatch and open the hood (Figure 77).

4. Clean the inside of the hood screens with compressed air (Figure 77).

5. Thoroughly clean all debris out of the engine area.

6. Clean the oil cooler with low-pressure (50 psi) compressed air (Figure 78).

   

   Figure 78

   1. Oil-cooler latches

7. Rotate the oil cooler latches inward, and pivot the oil cooler (Figure 78 and Figure 79).

   

   Figure 79

   1. Radiator

8. Working from the fan side of the radiator , blow out debris with low-pressure (50 psi) compressed air (Figure 79). Repeat this step at the front of the radiator, and again from the fan side. Thoroughly clean both sides of the oil cooler.

   Important: Do not use water to clean the radiator and oil cooler.

9. Clean out any debris that may have collected on other parts of the machine with compressed air.

10. Pivot the oil cooler up and secure it with the latches.

11. Close and latch the hood.

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of coolant in the expansion tank at the beginning of each day before starting the engine.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

   

   Figure 80

3. Check the level of the coolant in the expansion tank (Figure 81).

   Note: The coolant level is normal when it is between the marks on the side of the tank.

   

   Figure 81

   1. Expansion tank

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

   Note: Do not overfill.

5. Install the expansion-tank cap.

6. Close and latch the hood.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

   

   Figure 82

3. Check the condition of the belt.

   Note: Replace the belt if it is worn or damaged.

4. Apply 10 kg (22 lb) of force against the alternator belt (Figure 83), midway between the pulleys.

   Note: The belt should deflect 10 mm (3/8 inch).

   

   Figure 83

   1. Tension bracket bolt
   2. Alternator tension bolt
   3. Belt
   4. Alternator pivot bolt
   5. Alternator

5. If the belt tension is incorrect, perform the following:

   • If belt deflection is less than 10 mm (3/8 inch), loosen the alternator pivot bolt and tension bolt (Figure 83), and reduce the belt tension.

   • If belt deflection is greater than 10 mm (3/8 inch), loosen the alternator pivot bolt and tension bolt (Figure 83), and increase the belt tension.

     Note: If needed, loosen the tension bracket bolt (Figure 83).

6. Tighten the bolts (Figure 83).

7. Check the deflection of the belt again to ensure correct belt tension.

8. Close and latch the hood.

With the engine shut off, operate the forward and reverse travel pedals through the full range of articulation and ensure that the mechanism returns freely to the NEUTRAL position.

Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; refer to Checking the Hydraulic Fluid Level.

Recommended hydraulic fluid: Toro PX Extended Life Hydraulic Fluid; available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums.

Note: A machine using the recommended replacement fluid requires less frequent fluid and filter changes.

Alternative hydraulic fluids: If Toro PX Extended Life Hydraulic Fluid is not available, you may use another conventional, petroleum-based hydraulic fluid having specifications that fall within the listed range for all the following material properties and that it meets industry standards. Do not use synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use products only from reputable manufacturers who stand behind their recommendation.

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Important: Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, thoroughly flush of conventional fluid from the hydraulic system. The hydraulic fluid is available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums from your authorized Toro distributor.

The reservoir is filled at the factory with high-quality hydraulic fluid. The best time to check the hydraulic fluid is when it is cold.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Check the sight-level gauge on the side of the tank.

   Note: The hydraulic-fluid level needs to align with the upper mark.

3. If additional hydraulic fluid is needed, remove the storage compartment; refer to Removing the Storage Compartment.

4. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 84).

   

   Figure 84

   1. Hydraulic-tank cap
   2. Fluid tank
   3. Sight-level gauge

5. Remove the cap and fill the tank with the specified hydraulic fluid to the upper mark on the sight-level gauge.

   Important: Do not overfill the tank with hydraulic fluid.

6. Install the cap onto the tank.

7. Install the storage compartment; refer to Installing the Storage Compartment.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. At the left side of the machine, clean the area around the filter head and place a drain pan under the filter (Figure 85).

   

   Figure 85

   1. Filter head
   2. Hydraulic fluid return filter

4. Remove the return filter (Figure 85).

5. Lubricate the gasket of the new return filter with clean hydraulic fluid.

6. Assemble the filter to the filter head, and tighten the filter by hand until the gasket contacts the mounting surface, then rotate it an additional 1/2 turn (Figure 85).

7. Start the engine and let it run for 2 minutes to purge air from the system.

8. Shut off the engine, remove the key, and check for leaks.

9. Close and latch the hood.

1. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance.

2. Unlatch and open the hood.

3. At the left side of the machine, clean the area around the filter head and place a drain pan under the filter housing (Figure 86).

   

   Figure 86

   1. Filter head
   2. Element
   3. Filter housing

4. Remove the filter housing from the filter head and remove the element (Figure 86).

   Note: Discard the filter element.

5. Install a new filter element onto the filter head (Figure 86).

6. Thread the filter housing onto the filter head, and tighten the housing.

7. Start the engine and let it run for 2 minutes to purge air from the system.

8. Shut off the engine, remove the key, and check for leaks.

9. Close and latch the hood.

Refer to your authorized Toro distributor for a new dampener kit.

1. Raise the platform; refer to Raising the Platform.

2. Remove the washers and nuts that secure the dampener to the transmission pump and bracket (Figure 87).

   

   Figure 87

   1. Dampener
   2. Washer
   3. Nut

3. Remove the dampener.

4. Use the hardware supplied in the dampener kit to secure the new dampener to the transmission pump and bracket.

5. Lower the platform; refer to Lowering the Platform.

If the fluid becomes contaminated, contact your authorized Toro distributor to flush the system. Contaminated fluid looks milky or black when compared to clean fluid.

Use this process to restore the sharp cutting edges to reels and bedknives, which are needed for good-quality grass cutting.

This process removes a small amount of metal to restore the cutting edges. If the blade edges are seriously worn or damaged, remove the cutting unit and have the reels and bedknife ground.

1. Engage the parking brake, lower the cutting units, shut off the engine, and remove the key.

2. Adjust the reels to the bedknives to obtain light contact.

3. Apply a coat of medium-grade detergent-based carborundum paste to the cutting edges of the reels with a long-handled brush.

   80-Grit Carborundum Paste

   Part Number	Quantity
   63-07-088	45 kg (1 lb)
   63-07-086	11 kg (25 lb)

   

   Figure 90

4. Sit on the operator seat, start the engine, and set the engine speed to idle.

   Warning

   If you touch the cutting units when the engine is running, the cutting unit could seriously injure you.

   • Ensure that the area surrounding the cutting units is clear of people.

   • Keep hands and feet clear of the cutting units during the period when the mower engine is running.

5. Press cutting unit drive switch to the REVERSE (backlap) position for a short period. Listen to the grinding action.

6. Operate the cutting unit drive switch to the OFF position. When the cutting unit stops running, shut off the engine and remove the key.

7. Thoroughly clean the blade edges and adjust the bedknives to the reels.

8. While rotating the reels by hand, check along the cutting edges that the reel can cleanly cut a thin piece of paper.

9. If further back lapping is needed, repeat steps 2 through 8.

10. Thoroughly clean off all traces of the carborundum paste from the reels and bedknives.

• Grind reel blades or bedknives to correct excessively rounded or distorted reel edges or bedknife edges.

  Important: Replace the bedknives at the end of their wear life.

• Grind new blades on their holders prior to fitting.

• When grinding reel blades or the bedknives are needed, it is essential that they are ground at the same time.

  Note: The only exception to this rule is when a new reel is installed, in which case only grind the bedknife.

• Have your authorized Toro dealer grind your reel blades and bedknives on a quality, well-maintained reel/bedknife grinding machine.

1. Inspect the seat belt for wear, cuts, and other damage. Replace the seat belt(s) if any component does not operate properly.

2. Clean the seat belt as necessary.

Check the machine for loose and missing fasteners.

Note: Tighten any loose fasteners; replace any missing fasteners.

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

When disposing of hazardous waste products, take them to an authorized disposal site. Do not allow waste products to contaminate surface water, drains, or sewage systems.

Important: Dispose of hazardous substances correctly.Do not dispose of batteries with a separate collection mark into general waste.When disposing of hazardous waste products, take them to an authorized disposal site.

Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.