Toro 30094, 30096, 30098, 30099 Operator's Manual

FormNo.3361-911RevA

CommercialWalk-BehindMower

FloatingDeck,T-Bar,Gearwith36in40in
48inor52inTURBOFORCE

ModelNo.30094—SerialNo.290000001andUp

ModelNo.30096—SerialNo.290000001andUp

®

CuttingUnit

ModelNo.30098—SerialNo.290000001andUp

ModelNo.30099—SerialNo.290000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

Theenclosed

Engine Owner’ s Man ual

forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCalifornia
EmissionControlRegulationofemissionsystems,
maintenance,andwarranty.Replacementsmaybe
orderedthroughtheenginemanufacturer.

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineT oroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Introduction.................................................................2

Safety...........................................................................4

SafeOperatingPractices.......................................4

ToroMowerSafety...............................................5

SlopeChart..........................................................7

SafetyandInstructionalDecals.............................8

ProductOverview......................................................10

Controls.............................................................10

©2009—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Specications.....................................................11

Attachments/Accessories...................................11

Operation...................................................................12

AddingFuel.......................................................12

CheckingtheEngineOilLevel............................13

ThinkSafetyFirst...............................................13

UsingtheParkingBrake......................................13

StartingandStoppingtheEngine........................13

OperatingtheMowerPowerTakeOff

(PTO)............................................................14

TheSafetyInterlockSystem................................15

DrivingForwardorBackward.............................15

UsingtheLowerControlBar..............................15

StoppingtheMachine.........................................16

TransportingMachines.......................................16

SideDischargingorMulchingtheGrass..............17

AdjustingtheHeight-of-Cut...............................17

AdjustingtheAnti-ScalpRollers.........................17

AdjustingtheHandleHeight..............................18

AdjustingtheFlowBafe...................................19

PositioningtheFlowBafe.................................20

UsingtheMid-SizeWeight..................................21

Maintenance...............................................................22

RecommendedMaintenanceSchedule(s)................22

Lubrication.............................................................22

HowtoGrease...................................................22

LubricatingtheCasterandWheel

Bearings.........................................................23

GreasingtheTransmissionCouplers...................23

GreasingthePTODriveBeltIdlerandMower

DeckBeltIdler...............................................23

EngineMaintenance...............................................24

ServicingtheAirCleaner....................................24

ServicingtheEngineOil.....................................25

ServicingtheSparkPlugs....................................27

FuelSystemMaintenance.......................................28

DrainingtheFuelTank.......................................28

ReplacingtheFuelFilter.....................................28

ElectricalSystemMaintenance................................29

ServicingtheFuse..............................................29

DriveSystemMaintenance.....................................30

AdjustingtheControlBar...................................30

CheckingtheTirePressure.................................30

ReplacingtheCasterWheelFork

Bushings........................................................31

ServicingtheCasterWheelandBearings.............31

AdjustingtheElectricClutch..............................32

CoolingSystemMaintenance..................................33

CleaningtheAirIntakeScreen............................33

BrakeMaintenance.................................................33

ServicingtheBrakes...........................................33

BeltMaintenance....................................................34

ReplacingtheTractionDriveBelt........................34

ReplacingtheTransmissionBelt.........................34

ReplacingtheMowerBelt...................................35

ReplacingthePTODriveBelt.............................36

AdjustingthePTODriveBeltIdlerSpring

Anchor...........................................................37

MowerDeckMaintenance......................................37

ServicingtheCuttingBlades...............................37

CorrectingtheMowerQualityofCut..................39

FrameSetUp.....................................................40

CheckingtheMowerDeckFront-to-Rear

Pitch...............................................................41

ChangingtheMowerDeckFront-to-Rear

Pitch...............................................................42

CheckingtheMowerDeckSide-to-Side

Height............................................................42

ChangingtheMowerDeckSide-to-Side

Height............................................................43

MatchingHeightofCut......................................43

ReplacingtheGrassDeector.............................44

Storage.......................................................................45

CleaningandStorage..........................................45

Troubleshooting.........................................................46

Schematics.................................................................48

3

Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
CAUTION,WARNING,orDANGER-“personalsafety
instruction."Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

SafeOperatingPractices

–Useonlyanapprovedcontainer

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

–Neverrefuelordrainthemachineindoors.

•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator’sposition.

•Besureofyourfootingwhileusingthismachine,
especiallywhenbackingup.Walk,don’trun.Never
operateonwetgrass.Reducedfootingcouldcause
slipping.

•Slowdownanduseextracareonhillsides.Besure
totravelsidetosideonhillsides.Turfconditions
canaffectthemachine’sstability.Usecautionwhile
operatingneardrop-offs.

•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguards
notsecurelyinplace.Besureallinterlocksare
attached,adjustedproperly ,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Stoponlevelground,disengagedrives,engage
parkingbrake,shutoffenginebeforeleavingthe
operator’spositionforanyreasonincludingemptying
thecatchersoruncloggingthechute.

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

4

•Keeppetsandbystandersaway .

•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopbladesifnot
mowing.

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Usecarewhenloadingorunloadingthemachine
intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

Maintenanceandstorage

•Disengagedrives,setparkingbrake,stopengineand
removekeyordisconnectsparkplugwire.Waitfor
allmovementtostopbeforeadjusting,cleaningor
repairing.

•Cleangrassanddebrisfromcuttingunit,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.
Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectthebatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositivelast.Reconnectthe
positiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyoumust
know .

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore
mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowtocoolbefore
attemptingtomaintain,adjustorservice.

•UseonlyToroapprovedattachments.Warrantymay
bevoidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)before
operatingunderanyobjectsanddonotcontact
them.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeel
uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from
themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide
obstacles.

•Usecautionneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifawheel
goesovertheedgeofaclifforditch,orifanedge
cavesin.

•Useextracarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machine.

•Keepallmovementonslopesslowandgradual.Do
notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade
attachmentbolts.Keepequipmentingood
condition.

•Nevertamperwithsafetydevices.Checksafety
systemsforproperoperationbeforeeachuse.

5

•Useonlygenuinereplacementpartstoensurethat
originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice
asrequired.

6

SlopeChart7SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof

82- 2280

REV ERSE  TRAC T I ON DRI V E

potentialdanger.Replaceanydecalthatisdamagedorlost.

82-2280

82-2290

43-8480

95-2814

52-2010

66-1340

1.Warning—wearhearingprotection.

68-8340

98-0776

98-3256

98-4387

98-5954

8

106-0699

104-8185

110-2067

104-8186

104-8569

110-2068

1.ReadtheOperator’sManual.

105-7798

106-0635

9

105-0884

110-4971

1.Engine—stop

2.Engine—Start3.EngagebalethenpulloutonthePTO
toengagetheblade.

ProductOverview

Figure3

1.Sidedischargechute5.Controls

2.Mowerdeck6.Handle

3.Recoilstarter

4.Gastank

7.Casterwheel

Controls

Becomefamiliarwithallthecontrols(Figure4)before
youstarttheengineandoperatethemachine.

Figure4

1.Gearshiftlever

2.Powertakeoffswitch
(PTO)

3.Chokecontrol

4.Lowerhandle10.Throttlecontrol

5.Lowercontrolbar11.Ignitionswitch

6.Parkingbrake
lever-releasedposition

7.Bladecontrolbail

8.Uppercontrolbar

9.Upperhandle

12.Fuelshut-offvalve

ThrottleControl

Thethrottlecontrolhastwopositions:FastandSlow.

Choke

Usethechoketostartacoldengine.

10

BladeControlBail

Specications

Thebailisusedinconjunctionwiththepowertakeoff
switch(PTO)toengagetheclutchtodrivethemower
blades.Releasethemowercontrolbailtodisengagethe
mowerblades.

PowerTakeOffSwitch(PTO)

Thispullswitchisusedinconjunctionwiththeblade
controlbailtoengagetheclutchtodrivethemower
blades.

GearShiftLever

Thetransmissionhasveforwardspeeds,neutraland
reverse,andhasanin-lineshiftpattern.

Important:Donotshiftwhileunitismoving,as
transmissiondamagemayoccur.

UpperControlBar

Shifttothedesiredgearandpushforwardontheupper
controlbartoengageforwardtractionoperationand
pullbacktobrakeforwardmovement.Pullbackon
rightsideofuppercontrolbartoturnrightandleftside
toturnleft.

LowerControlBar

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

36inchmowers:

Widthwithdeectordown51–1/8inches(130cm)

Length

Heightwithhandleinlowest
position

Weight

40inchmowers:

Widthwithdeectordown55–1/2inches(141cm)

Length

Heightwithhandleinlowest
position

Weight

48inchmowers:

Widthwithdeectordown63–1/2inches(161cm)

Length

Heightwithhandleinlowest
position

Weight

82–3/4inches(210cm)

41–3/16inches(105cm)

588lb(267kg)

79–1/2inches(202cm)

41–3/16inches(105cm)

596lb(270kg)

82inches(208cm)

41–3/16inches(105cm)

649lb(294kg)

Shifttransmissiontoreverseandsqueezethelower
controlbarandhandletogethertoengagerearward
tractionassistoperation.

ParkingBrakeLever

Pullbackonuppercontrolbarandswingbrakeleverup
againsttheupperhandle(Figure4).

IgnitionSwitch

Thisswitchisusedinconjunctionwithrecoilstarterand
hastwopositions:RunandOff.

RecoilStarter

Pullrecoilstarterhandletostartengine(notshownin
Figure4).

FuelShut-offValve

Closethefuelshut-offvalvewhentransportingor
storingmower.

52inchmowers:

Widthwithdeectordown67–5/8inches(171.7cm)

Length

Heightwithhandleinlowest
position

Weight

82inches(208cm)

41–3/16inches(105cm)

684lb(310kg)

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesareavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.T oro.comforalistofallapprovedattachments
andaccessories.

11

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

Useunleadedregulargasolinesuitableforautomotive
use(85pumpoctaneminimum).Leadedregular
gasolinemaybeusedifunleadedregularisnotavailable.

Important:Neverusemethanol,gasoline
containingmethanol,orgasoholcontainingmore
than10%ethanolbecausethefuelsystemcouldbe
damaged.Donotmixoilwithgasoline.

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4
to1/2inch(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsgasolinetoexpand.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Never
buymorethana30-daysupplyofgasoline.

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitethegasolinevapors.Are
orexplosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepgasawayfromeyesandskin.

•Donotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

12

Important:Donotusefueladditivescontaining
methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner
tothegas.

Note:Afuelstabilizer/conditionerismosteffective
whenmixedwithfreshgasoline.Tominimizethe
chanceofvarnishdepositsinthefuelsystem,usefuel
stabilizeratalltimes.

Figure5

1.Warning—wearhearingprotection.

UsingtheParkingBrake

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethecap.

3.Addunleadedregulargasolinetobothfueltanks,
untilthelevelis1/4to1/2inch(6mmto13mm)
belowthebottomofthellerneck.

Thisspaceinthetankallowsgasolinetoexpand.
Donotllthefueltankscompletelyfull.

4.Installfueltankcapssecurely.

5.Wipeupanygasolinethatmayhavespilled.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoChecking
OilLevelin,page

Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.

Stoponlevelground,disengagedrives,engageparking
brake,shutoffengineandremovekey.Alwayssetthe
parkingbrakewhenyoustopthemachineorleaveit
unattended.

SettingtheParkingBrake

1.Pulltheuppercontrolbar(Figure6)rearwardand
holditinthisposition.

2.Lifttheparkingbrakelock(Figure6)upand
graduallyreleasetheuppercontrolbar.Thebrake
lockshouldstayintheset(locked)position.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin
thesafetysection.Knowingthisinformationcould
helpyouoranybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feet
andheadisrecommended.

Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

Figure6

1.Uppercontrolbar3.Fixedbar

2.Parkingbrakelever-set
position

ReleasingtheParkingBrake

1.Pullrearwardontheuppercontrolbar.Lowerthe
parkingbrakelocktothereleasedposition.

2.Graduallyreleasetheuppercontrolbar.

StartingandStoppingthe
Engine

StartingtheEngine

1.Makesuresparkplugwire(s)areinstalledonspark
plug(s)andfuelvalveisopen.

13

2.Movetheshiftlevertoneutral,settheparkingbrake
andturnignitionkeytorun.

3.Movethethrottlecontroltofastandmovethe
chokelevertotheonpositionbeforestartingacold
engine.

Note:Awarmorhotengineusuallydoesnot
requireanychoking.Tostartawarmengine,move
throttlecontroltothefastposition.

OperatingtheMowerPower
TakeOff(PTO)

Thepowertakeoffswitch(PTO)inconjunctionwith
thebladecontrolbailengagesanddisengagespowerto
theelectricclutchandmowerblades.

EngagingtheMowerBlades(PTO)

4.Grasprecoilstarterhandlermlyandpullout
untilpositiveengagementresults;thenpullhandle
vigorouslytostartengineandallowropetorecoil
slowly.

Important:Donotpullrecoilropetoitslimit
orletgoofthestarterhandlewhenropeis
pulledoutbecauseropemaybreakorrecoil
assemblymaybedamaged.

StoppingtheEngine

1.Movethethrottlelevertotheslowposition
(Figure7).

2.Letengineidlefor30to60secondsbeforeturning
theignitionkeytooff.

3.Turntheignitionkeytooff(Figure7).

1.Releasetheuppercontrolbartostopthemachine
(Figure8).

2.Toengagetheblades,squeezebladecontrolbail
againsttheuppercontrolbar(Figure8).

3.Pullthepowertakeoffswitch(PTO)upand
release.Holdthebladecontrolbailagainstthe
uppercontrolbarwhileoperating.

4.Repeattheproceduretoengagethemowerbladesif
thebladecontrolbailisreleased.

Figure7

1.Throttlelever2.Ignitionkey

4.Settheparkingbrakeandremovekey.

5.Pullthewireoffsparkplug(s)topreventpossibility
ofaccidentalstartingbeforestoringmachine.

6.Closethefuelshutoffvalvebeforestoringmachine.

Important:Makesurethefuelshutoffvalveis
closedbeforetransportingorstoringmachine,
asfuelleakagemayoccur.

Figure8

1.Uppercontrolbar

2.Bladecontrolbail

3.Powertakeoffswitch
(PTO)

DisengagingtheMowerBlades(PTO)

Releasethebladecontrolbailtodisengagetheblades
(Figure8).

14

TheSafetyInterlockSystem

Ifthesafetyinterlockswitchesaredisconnected
ordamagedthemachinecouldoperate
unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

throttlecontrolinthefastpositionforbestmowing
performance.

DrivingForward

1.Togoforward,movetheshiftlevertoaforward
gear(Figure9).

2.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakeinOperation.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventthe
mowerbladesfromrotatingunless:

•Thecontrolbailispressedagainsttheuppercontrol
bar.

•Thepowertakeoffswitch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostopthe
mowerbladesifyoureleasethebladecontrolbail.

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe
machineeachtime.

3.Slowlypressontheuppercontrolbartomove
forward(Figure9).

Togostraight,applyequalpressuretobothendsof
theuppercontrolbar(Figure9).

Toturn,releasepressureontheuppercontrolbar
sideinthedirectionyouwanttoturn(Figure9).

Note:Ifthesafetysystemdoesnotoperateas
describedbelow ,haveanAuthorizedServiceDealer
repairthesafetysystemimmediately.

1.Settheparkingbrakeandstarttheengine;referto
StartingandStoppingtheEngine.

2.Squeezethebladecontrolbailagainstuppercontrol
bar.Thebladesshouldnotrotate.

3.Thencontinueholdingthebladecontrolbailand
pulluponthebladecontrolswitchandrelease.The
clutchshouldengageandthemowerbladesbegin
rotating.

4.Releasethebladecontrolbail.Thebladesshould

stoprotating.

5.Withtheenginerunning,pullupthepowertakeoff
switch(PTO)andreleasewithoutholdingtheblade
controlbail.Thebladesshouldnotrotate.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas
measuredinRPM(revolutionsperminute).Placethe

Figure9

1.Uppercontrolbar

2.Lowercontrolbar

3.Shiftlever

DrivingBackward

1.Togobackward,movetheshiftlevertoreversegear.

2.Releasetheparkingbrake;refertoReleasingthe
ParkingBrake.

3.Slowlysqueezethelowercontrolbarandlower
handletogethertomoverearward(Figure9).

UsingtheLowerControlBar

Thisprocedureisfordrivingupacurb.Thiscanbe
performedwhiledrivingforwardorbackward.

Note:Somecurbsdonotallowthereardrivetiresto
contactthecurb.Ifthishappens,drivethemachineup
thecurbatanangle.

15

Abladecanbebentordamagedwhendriving
upacurb.Piecesofbladethatmaybethrown
couldseriouslyinjureorkillyouorbystanders.

Donotrunbladeswhiledrivingupacurb
forwardorbackward.

DrivingForwardUpaCurb

DrivingBackwardUpaCurb

1.Disengagethemowerblades.

2.Selectreversetodrivemachine.

3.Drivethemachineuntildrivewheelscontactcurb
(Figure10).

Note:Bothdrivewheelsshouldcontactthecurb
andcasterwheelsstraight.

4.Atthesametimeengagelowercontrolbarandlift
uponthelowerhandle(Figure9andFigure10).

1.Disengagethemowerblades.

2.Selectrstgeartodrivethemachine.

3.Drivemachineuntilthecastorwheelscontactthe
curb(Figure10).

4.Liftthefrontofthemachinebypushingdownon
thelowerhandle(Figure10).

5.Drivethemachineuntildrivewheelscontactthe
curb(Figure10).

6.Lowerthefrontofthemachine(Figure10).

Note:Bothdrivewheelsshouldcontactthecurb
andcasterwheelsstraight.

7.Atthesametime,engagethelowercontrolbarand
liftuponthelowerhandletodriveoverthecurb
(Figure9andFigure10).

Note:Liftinguponthelowerhandlewillassist
drivingthemachineupacurbandnotspinthe
drivewheels.

Note:Liftinguponthelowerhandlewillassist
drivingthemachineupacurbandnotspinthe
drivewheels.

StoppingtheMachine

Tostopthemachine,pullbackontheuppercontrol
bar,releasethebladecontrolbail,andturntheignition
keytooff.Alsosettheparkingbrakeifyouleavethe
machineunattended;refertoSettingtheParkingBrake
in,page.Remembertoremovethekeyfromthe
ignitionswitch.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

1.LowerControlBar
engagedandmower
inreverse.

2.Pulluptoassistmachine

Figure10

3.LowerControlBar
engagedandmower
goingforward.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
necessarybrakes,lighting,andmarkingasrequiredby
law .Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily,
petsorbystandersavoidinjury.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle
andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey ,setthebrake,and
closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto
securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes(Figure11).

16

Figure11

1.Tractionunittiedownloop

SideDischargingorMulching
theGrass

Thismowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

Note:Allheight-of-cutpinscanusetwospacers
maximum.

1.Selectholeinheight-of-cutpostandnumberof
spacerscorrespondingtotheheight-of-cutdesired
(Figure12).

2.Usingthelifthandle,raisesideofdeckandremove
hairpincotter(Figure12).

3.Addorremovespacersifneededandthenalignthe
holesandinsertthehairpincotter(Figure12).

Note:Spareheight-of-cutspacersmaybestored
onpostsandretainedbyahairpincotter.

Important:Allfourhairpincotterpinsmustbe
inthesameholelocationandwiththecorrect
numberofspacersforalevelcut.

Withoutthegrassdeector,dischargecover,
orcompletegrasscatcherassemblymounted
inplace,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebriswill
causeinjuryordeath.

•Neverremovethegrassdeectorfrom
themowerbecausethegrassdeector
routesmaterialdowntowardtheturf.Ifthe
grassdeectoriseverdamaged,replaceit
immediately.

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytocleardischargeareaormower
bladesunlessyoureleasethebailandthe
powertakeoff(PTO)isoff.Rotatethe
ignitionkeytoOff.Alsoremovethekeyand
pullthewire(s)offthesparkplug(s).

AdjustingtheHeight-of-Cut

Theheight-of-cutcanbeadjustedfrom1to4-1/2
inches(25to114mm)in1/4inch(6mm)increments.
Adjustmentisdonebyrelocatingfourhairpincotter
pinsindifferentholelocationsandbyaddingor
removingspacers.

Figure12

1.CarrierFrame4.Spacers

2.HairpinCotter5.Frontheight-of-cutpost

3.Backheight-of-cutpost

AdjustingtheAnti-Scalp
Rollers

Theanti-scalprollersneedtobeadjustedintheproper
holelocationforeachheight-of-cutposition.There
needstobe3/8inch(10mm)minimumclearance
abovetheground.

Note:Allheight-of-cutpinsneedatleastonespacer
ordamagecanoccurtothebushingifnoneareused.

Note:Iftheanit-scalprollersareadjustedtoolow,it
cancauseexcesswearoftherollers.

17

1.Afteradjustingtheheight-of-cut,checkthe
anti-scalprollerssothatthereisaminimumof
3/8inch(10mm)clearanceabovetheground
(Figure13,Figure14,Figure15).

2.Ifadjustmentisneeded,removethebolt,washers
andnut(Figure13,Figure14,Figure15).

3.Selectaholepositionsotheanti-scalprollersare
aminimumof3/8inch(10mm)offtheground
(Figure13,Figure14,Figure15).

4.Installtheboltandnut(Figure13,Figure14,
Figure15).

Figure14

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Bushing

2.Bolt5.Anti-scalprollers

3.Spacer

6.Nut

Figure13

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Anti-scalprollers

2.Bolt5.Nut

3.Spacer

Figure15

36inchMowerDeck

1.Mowerdeck4.Anti-scalprollers

2.Bolt5.Nut

3.Spacer

5.Incertainmowingconditionsandterrain,a
mismatchofcuttingheightmaybeseen.Adjusting
theoutsideanti-scalprollerstotheminimumsetting
of3/8inch(10mm)willhelppreventthemower
deckcuttingtoolowontheoutsideandminimize
themismatch.

AdjustingtheHandleHeight

Thehandlepositioncanbeadjustedtomatchthe
operator’sheightpreference.

18

1.Removethehairpincotter,washerandclevispin
securingcontrolrodttingtotheidlerbracket
(Figure16).

Figure16

1.Controlrodandtting

2.Idlerbracket5.Hairpincotter

3.Clevispin6.Rodtting

4.Washer

5.Checkthecontrolbarforcorrectadjustment.Refer
toAdjustingtheControlBarinthemaintenance
section.

6.Checktheparkingbrakeadjustment.Referto
CheckingtheBrakesinthemaintenancesection.

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent
typesofmowingconditions.Positionthecamlockand
bafetogivethebestqualityofcut.

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Toadjustthecamlock,swingtheleveruptoloosen
thecamlock(Figure18).

2.Loosentheupperangebolts(3/8x1inch)and
theangenutsecuringthehandletotherearframe
(Figure17).

Figure17

1.Upperhandle5.Uppermountinghole

2.Rearframe

3.Flangenut,(3/8inch)

4.Flangebolt,(3/8x1inch)

6.Lowermountingholes

7.Lowposition

8.Highposition

3.Removethelowerangebolts(3/8x1inch)and
angenutssecuringthehandletotherearframe
(Figure17).

4.Adjustthebafeandcamlockintheslottothe
desireddischargeow.

5.Swingtheleverbackovertotightenthebafeand
camlock(Figure18).

6.Ifthecamdoesnotlockthebafeintoplaceoritis
tootight,loosentheleverandthenrotatethecam
lock.Adjustthecamlockuntilthedesiredlocking
pressureisachieved.

Figure18

1.Camlock4.Slot

2.Lever5.Rotatethelevertorelease
orlockthecam

3.Rotatecamtoincreaseor

decreaselockingpressure

4.Pivotthehandletothedesiredoperatingposition
andinstallthelowerangebolts(3/8x1inch)and
theangenutsintothemountingholes.Tighten
allangebolts.

19

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsfor
use.Adjustmentswillvarybygrasstype,moisture
content,andheightofgrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure19).The
suggesteduseforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe
mower.

Figure20

PositionC

Figure19

PositionB

Usethispositionwhenbagging(Figure20).

Thisisthefullopenposition.Thesuggestedusefor
thispositionisasfollows(Figure21).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheToro
SFSmower.

Figure21

20

UsingtheMid-SizeWeight

Weightsareinstalledoncertainmowerstoimprove
balanceandimproveperformance.Theweightscanbe
movedorremovedtocreateoptimizedperformance
underdifferentmowingconditionsandforoperator
preference(Figure22orFigure23).

Thefollowingtableindicatesthepositionoftheweight
asinstalledatthefactory.

MowerDeckSizeNumberofweights

36inches

40inches1Front

48inches2Rear

52inches3Rear

install

nonenone

Positionofthe

•Anyrearweightmustberemovedwhena
Tru-Track

•WhenaTru-Track

®

Sulkyisinstalled.

®

Sulkyisinstalledfrontweights
areneeded.ContactanAuthorizedServiceDealer
forthecorrectquantityofweightsandplacement.

Thefrontendofthemachinecanrapidlyrise
upwhenthemowerisremoved.Thiscould
causeseriousinjurytoyouorbystanders.

Supporttherearofthemachinewhenremoving
themowerformthecarrierframe.

weight

Figure22

Installingthefrontweight.

1.Bolt3.Weight

2.Washer4.Nut

Figure23

Installingtherearweight.

1.Nut3.Washer

2.Weight4.Bolt

21

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

Every200hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthesafetyinterlocksystem.

•Greasethecasterwheelsandcasterpivot.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrakesonbothalevelsurfaceandslope.

•Inspecttheblades.

•Cleanfoamaircleanerelement.

•GreasethePTObeltidler.

•Greasethemowerdeckbeltidler.

•Checkthepaperaircleanerelement.

•Checkthetirepressure

•Checkthetractiondrivebelt

•Checkthetransmissionbelt.

•Checkthemowerbelt.

•CheckthePTOdrivebelt.

•Changetheengineoil.

•Checkthesparkplugs.

•Adjusttheelectricclutch.

•Replacethepaperaircleanerelement.

•Changetheoillter.

•Replacethefuellter.

Every250hours

Every400hours

Beforestorage

•Greasethetransmissioncouplers(moreoftenindirtyordustyconditions).

•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator’smanualforadditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously
injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyou
doanymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.

Lubrication

GreasewithNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

HowtoGrease

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

22

3.Cleanthegreasettingswitharag.Makesureto
scrapeanypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease
intothettingsuntilgreasebeginstooozeoutof
thebearings.

5.Wipeupanyexcessgrease.

LubricatingtheCasterand
WheelBearings

ServiceInterval:Beforeeachuseordaily

Every400hours

1.Lubricatethefrontcasterwheelbearingsandfront
pivots(Figure24).

2.Raisetherearofthemachineandusejackstands
tosupportthemachine.

Figure25

3.Removetherearwheelandtireassemblies.

4.Removetherearwheelgreasecap.Lubricatetherear
wheelbearing(Figure24).

5.Installthegreasecap.

6.Installtherearwheelandtireassembly.

Note:Makesuretherearwheelgreasecapsare
removedbeforelubricatingrearwheels.

GreasingthePTODriveBelt
IdlerandMowerDeckBelt
Idler

ServiceInterval:Every50hours—GreasethePTO

beltidler.

Every50hours—Greasethemower
deckbeltidler.

Greasetheidlerpulleypivots(Figure26orFigure27).

Note:Youwillhavetoremovethecarriercoversto
accessthegreasettingforthemowerdeck.

Figure24

GreasingtheTransmission
Couplers

ServiceInterval:Every250hours

Lubricatethetransmissioncouplerslocatedintheback
ofthemachine(Figure25).

Figure26

40inch,48inch,and52inchMowerDeckshown

23

Figure27

36inchMowerDeckshown

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval/Specication

ServiceInterval:Every25hours—Cleanfoamair

cleanerelement.

Every50hours—Checkthepaperair
cleanerelement.

Every200hours—Replacethepaper
aircleanerelement.

Note:Servicetheaircleanermorefrequently(every
fewoperatinghours)iftheoperatingconditionsare
extremelydustyorsandy.

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanaroundtheaircleanertopreventdirt
fromgettingintotheengineandcausingdamage
(Figure28).

4.Unscrewthecoverknobandremovetheaircleaner
cover(Figure28).

5.Removethe2wingnutsandremovetheaircleaner
assembly(Figure28).

6.Carefullypullthefoamelementoffthepaper
element(Figure28).

24

2.Placetheaircleanerassemblyontotheaircleaner
baseandsecureitwiththe2wingnuts(Figure28).

3.Placetheaircleanercoverintopositionandtighten
thecoverknob(Figure28).

ServicingtheEngineOil

ServiceInterval/Specication

ServiceInterval:Beforeeachuseordaily—Checkthe

engineoillevel.

Aftertherst8hours—Changethe
engineoil.

Every100hours—Changetheengine
oil.

Every200hours—Changetheoil
lter.

Note:Changetheoilmorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.

Figure28

1.Engine4.Foamelement

2.Cover

3.Wingnut

5.Paperelement

6.Coverknob

CleaningtheFoamAirCleanerElement

1.Washthefoamelementinliquidsoapandwarm
water.Whentheelementisclean,rinseitthoroughly .

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis
tornorworn.

ServicingthePaperAirCleaner
Element

1.Donotcleanthepaperlter,replaceit(Figure28).

2.Inspecttheelementfortears,anoilylm,ordamage
totherubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

OilType:Detergentoil(APIserviceSF,SG,SH,orSJ)

CrankcaseCapacity:58ounces(1.7liter)withthelter

removed;51ounces(1.5liter)withoutthelterremoved

Viscosity:Refertothetable(Figure29).

Figure29

CheckingtheEngineOilLevel

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand
paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair
cleanerelement(Figure28).

3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

4.Cleanaroundtheoildipstick(Figure30)sothatdirt
cannotfallintothellerholeanddamagetheengine.

25

Figure30

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean
(Figure30).

6.Slidetheoildipstickfullyintothellertube,butdo
notthreadontotube(Figure30).

7.Pullthedipstickoutandlookattheend.Iftheoil
levelislow ,slowlypouronlyenoughoilintotheller
tubetoraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagecan
result.

Figure31

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure30).

10.Checktheoillevel;refertoCheckingtheEngineOil
Level.

ChangingtheEngineOil

1.Starttheengineandletitrunveminutes.This
warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoildrains
completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain
valvetoallowoiltodrain(Figure31).

7.Whenoilhasdrainedcompletely,closethedrain
valve.

8.Removethedrainhose(Figure31).

Note:Disposeoftheusedoilatarecyclingcenter.

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

Note:Changetheoilltermorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe
EngineOil.

2.Removetheoldlter(Figure32).

Figure32

1.Oillter

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure32).

26

4.Installthereplacementoilltertothelteradapter,

1

turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure32).

5.Fillthecrankcasewiththepropertypeofnewoil;
refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillteranddrain
valve.

7.Checktheengineoillevelandaddoilifneeded.

8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

ServiceInterval/Specication

ServiceInterval:Every100hours—Checkthespark

plugs.

Ensurethattheairgapbetweenthecenterandside
electrodesiscorrectbeforeinstallingthesparkplug.
Useasparkplugwrenchforremovingandinstallingthe
sparkplugsandagappingtool/feelergaugetocheckand
adjusttheairgap.Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausing
damage.

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

1.Lookatthecenterofthesparkplugs(Figure34).
Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly.Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Figure34

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Disconnectthewiresfromthesparkplugs
(Figure33).

Figure33

1.Spark-plugwire/sparkplug

Important:Alwaysreplacethesparkplugs
whenithaswornelectrodes,anoilylmonit,
orhascracksintheporcelain.

3.Checkthegapbetweenthecenterandsideelectrodes
(Figure34).Bendthesideelectrode(Figure34)if
thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

2.Tightenthesparkplugsto16ft-lb(22N-m).

3.Connectthewirestothesparkplugs(Figure34).

27

FuelSystem
Maintenance

DrainingtheFuelTank

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopen
area.Wipeupanygasolinethatspills.

Figure35

1.Fuelshut-offvalve2.Clamp

•Neversmokewhendraininggasoline,and
stayawayfromanopenameorwherea
sparkmayignitethegasolinefumes.

1.Parkthemachineonalevelsurface,toensurethe
fueltankdrainscompletely .Thendisengagethe
powertakeoff(PTO),settheparkingbrake,and
turntheignitionkeytooff.Removethekey .

2.Closethefuelshut-offvalveatthefueltank
(Figure35).

3.Squeezetheendsofthehoseclamptogether
andslideitupthefuellineawayfromfuellter
(Figure35).

4.Pullthefuellineoffthefuellter(Figure35).Open
thefuelshut-offvalveandallowthegasolinetodrain
intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter
becausethefueltankisempty.RefertoReplacing
theFuelFilter.

5.Installthefuellineontothefuellter.Slidethehose
clampclosetothevalvetosecurethefuelline.

ReplacingtheFuelFilter

ServiceInterval:Every200hours

Neverinstalladirtylterifitisremovedfromthefuel
line.

Note:Notehowthefuellterisinstalled.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Closefuelshut-offvalveatfueltank(Figure35).

Note:Removethefuellinefromthefuelvalvethat
isclosesttotheengine.

4.Squeezetheendsofthehoseclampstogetherand
slidethemawayfromthelter(Figure36).

1.Hoseclamp3.Filter

2.Fuelline

28

Figure36

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose
tothelter.

7.Openfuelshut-offvalveatfueltank(Figure35).

8.Checkforfuelleaksandrepairifneeded.

ElectricalSystem
Maintenance

ServicingtheFuse

Theelectricalsystemisprotectedbyafuse.Itrequires
nomaintenance.Ifthefuseblows,checkthecomponent
orcircuitformalfunctionorashort.Toreplacethefuse,
pulloutonthefuse(Figure37)toremoveorreplaceit.

1.Fuse,7.5amp,bladetype

Figure37

29

DriveSystem
Maintenance

AdjustingtheControlBar

1.Checkthegapbetweenuppercontrolbarand
xedbarwithwheeldrivefullyengaged.Thegap
shouldbeapproximately1to1-1/4inch(25-32mm)
(Figure38).

Note:Theuppercontrolbarandxedbarmustbe
parallelwhentheuppercontrolbarisintheengaged,
drive,neutral,orbrakepositions.

Figure39

1.Controlrodandtting

2.3-1/2inch(89mm)

3.Idlerbracket

4.Clevispin

5.Washer

6.Hairpincotterpin

7.Rodtting

8.HoleF

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthetirepressure

Figure38

1.Uppercontrolbar4.Handle

2.Parkingbrakelever

3.Fixedcontrolbar

5.1to1-1/4inch(25-32mm)
gap

2.Checktheoperation.Ifadjustmentisrequired,
removehairpincotter,washerandclevispinsecuring
controlrodttingtoidlerbracket(Figure39).

3.Threadtherodttingupordownontheroduntil
theproperpositionisattainedandinstalltherod
ttingtotheidlerbracketwiththeclevispin,washer
andhairpincotter.

Checkthepressureatthevalvestem(Figure40).

Maintaintheairpressureinthereartiresat12-14psi
(83-97kPa).Uneventirepressurecancauseanuneven
cut.

Note:Thefronttiresaresemi-pneumatictiresanddo
notrequireairpressuremaintenance.

Figure40

30

ReplacingtheCasterWheel
ForkBushings

Thecasterwheelforksaremountedinbushingspressed
intothetopandbottomofthecarrierframemounting
pivottubes.Tocheckthebushings,movethecaster
forksbackandforthandside-to-side.Ifacasterforkis
loose,thebushingsarewornandmustbereplaced.

1.Raisethecuttingunitsothecasterwheelsareoff
theoor,thensupportthefrontofthemowerwith
jackstands.

2.Removethelockingpinandspacer(s)fromthetop
ofthecasterwheelfork(Figure41).

Figure42

1.MountingTube2.Bushing

5.Greasetheinsideandoutsideofthenewbushings.
Useahammerandatplatetocarefullydrivethe
bushingsintothepivottubes.

Figure41

1.LockingPin

2.Spacers4.Casterwheel

3.Pullthecasterwheelforkoutofthemountingtube,
leavingthespacer(s)onthebottomofthefork.
Rememberthelocationofthespacersoneachfork
toensurecorrectinstallation,andtomaintainalevel
deck.

4.Insertapinpunchintothemountingtubeand
carefullydriveoutthebushings(Figure42).Clean
theinsideofthemountingtube.

3.Carrierframepivottube

6.Inspectthecasterwheelforkforwearandreplace
ifnecessary(Figure41).

7.Slidethecasterwheelforkthroughthebushingsin
themountingtube.Replacethespacer(s)ontothe
forkandsecurewiththeretainingring(Figure41).

Important:Theinsidediameterofthebushings
maycollapseslightlywheninstalled.Ifthe
casterwheelforkdoesnotslideintothenew
bushings,reambothbushingstoaninside
diameterof1.126inch(29mm).

8.Greasethettingonthecarrierframepivottubes
usingNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

ServicingtheCasterWheel
andBearings

Thecasterwheelsrotateonarollerbearingsupportedby
aspannerbushing.Ifthebearingiskeptwelllubricated,
wearwillbeminimal.Failuretokeepthebearingwell
lubricatedwillcauserapidwear.Awobblycasterwheel
usuallyindicatesawornbearing.

1.Removethelocknutandwheelboltholdingthe
casterwheeltothecasterfork(Figure43).

31

3.Repeatthisfortheremainingslots.

4.Checkeachslotagainandmakeslightadjustments
untilthefeelergaugebetweentherotorandarmature
withveryslightcontactbetweenthem.

Figure43

1.Locknut

2.Cap

3.RollerBearing6.Bushing

4.SpannerBushing

5.Wheel

2.Removeonebushing,thenpullthespannerbushing
androllerbearingoutofthewheelhub(Figure43).

3.Removetheotherbushingfromthewheelhub
andcleananygreaseanddirtfromthewheelhub
(Figure43).

4.Inspecttherollerbearing,bushings,spannerbushing
andinsideofthewheelhubforwear.Replaceany
defectiveorwornparts(Figure43).

5.Toassemble,placeonebushingintothewheelhub.
Greasetherollerbearingandspannerbushingand
slidethemintothewheelhub.Placethesecond
bushingintothewheelhub(Figure43).

6.Installthecasterwheelintothecasterforkand
securewiththewheelboltandlocknut.Tightenthe
locknutuntilthespannerbushingbottomsagainst
theinsideofthecasterforks(Figure43).

7.Greasethettingonthecasterwheel.

Figure44

1.Adjustingnut3.Feelergauge

2.Slot

AdjustingtheElectricClutch

ServiceInterval:Every100hours

Theclutchisadjustabletoensureproperengagement
andproperbraking.

1.Inserta0.015–0.021inch(0.381–0.533mm)feeler
gaugethroughoneinspectionslotinthesideofthe
assembly.Makesureitisbetweenthearmatureand
therotorfrictionsurfaces.

2.Tightenthelocknutsuntilthereisslightbindingon
thefeelergaugebutitcanbemovedeasilywithinthe
airgap(Figure44).

32

CoolingSystem
Maintenance

BrakeMaintenance

ServicingtheBrakes

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

Removeanybuild-upofgrass,dirtorotherdebrisfrom
thecylinderandcylinderheadcoolingns,airintake
screenonywheelend,andcarburetor-governorlevers
andlinkage.Thiswillhelpinsureadequatecoolingand
correctenginespeedandwillreducethepossibilityof
overheatingandmechanicaldamagetotheengine.

ServiceInterval:Beforeeachuseordaily—Checkthe

brakesonbothalevelsurfaceand
slope.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnot
holdsecurely ,anadjustmentisrequired.

CheckingtheBrakes

1.Parkthemachineonalevelsurface,disengagethe
PTO.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Applytheparkingbrake.Thewheelsmustlock
whenyoutrytopushthemachineforward.

4.Ifthewheelsdonotlock,adjustthebrakes.Refer
toAdjustingtheBrakes.

5.Releasethebrakeandpressuppercontrolbarvery
lightly,approximately1/2inch(13mm).Thewheels
shouldrotatefreely ,ifnot;refertoAdjustingthe
Brakes.

AdjustingtheBrakes

Thebrakeleverisontheuppercontrolbar.Ifthe
parkingbrakedoesnotholdsecurely,anadjustmentis
required.

Note:Fortheinitialadjustment,adjustthewing
nutuntilitis1-1/4inchesfromthetopoftherod
(Figure45).

1.Parkthemachineonalevelsurface,disengagethe
PTO,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Checkthebrakebeforeyouadjustit;referto
CheckingtheBrakes.

4.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakein,page.

5.Toadjustthebrakeremovethehairpincotter
andwasherfromthebrakeleverandtrunnion
(Figure45).

33

Figure45

1.Hairpincotterandwasher5.HoleF

2.Trunnion

3.Brakelever7.Rod

4.Wingnut

6.Initialadjustment-1-1/4
inch(32mm)

BeltMaintenance

ReplacingtheTractionDrive
Belt

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthetraction
drivebelt

Lookforcracks,wear,andsignsofoverheating.

1.Removethetopboltsecuringidlersupportandidler
brackettorearframe(Figure46).

6.Rotatethewingnutclockwisetoincreasethebraking
pressure.

7.Rotatethewingnutcounterclockwisetodecrease
thebrakingpressure.

8.InstallthetrunnionintoholeF(Figure45).Tighten
thewingnut.

9.Securetrunniontobrakeleverwithwasherandhair
pincotter(Figure45).

10.Checkthebrakeoperationagain;refertoChecking
theBrakes.

Important:Withtheparkingbrakereleased,
therearwheelsmustrotatefreelywhenyou
pushthemower.Ifbrakeactionandfreewheel
rotationcannotbeachievedcontactyourservice
dealerimmediately.

Figure46

1.Topbolt4.Bottombolt

2.Idlerbracket5.Tractiondrivebelt

3.Idlersupport

2.Loosenbottomtwomountingscrewsenoughto
allowbelttopassbetweendrivepulleyandidler
support(Figure46).

3.Raisethewheelofftheground,toallowthebeltto
beremoved,andremovethebelt.

4.Installanewbelt.

5.Installthetopboltsecuringtheidlersupportand
idlerbrackettotherearframe(Figure46).

6.Tightenthebottomtwomountingscrewsenoughto
allowthebelttopassbetweenthedrivepulleyand
idlersupport(Figure46).

ReplacingtheTransmission
Belt

ServiceInterval:Every50hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.RemovePTOdrivebelt.RefertoReplacingthe
PTODriveBeltinthe,page.

34

4.Raisethefrontofthemachineandholdwithjack
stands.

5.Disconnectclutchwireconnectorfromwireharness.

4.Unlatchandremovethebeltcovers.

5.RemovethePTOdrivebelt.RefertoReplacingthe
PTODriveBelt.

6.Disconnectclutchretainerfromtheenginedeck
(Figure47).

Figure47

1.Transmissionbelt

2.Idlerpulley6.Pivotbolt

3.Clutchretainer

4.Tensionspring8.Enginedeck

5.Clutchwireconnector

7.Drivepulley

7.Unhooktensionspringfromsideofframe
(Figure47).

6.Disconnecttheidlerarmspringtorelievetensionon
theidlerarmandidlerpulley,thenremovetheworn
mowerbelt(Figure48orFigure49).

7.Installthenewmowerbeltaroundthetwooutside
spindlepulleys,theidlerpulley,andinthelower
grooveofthedoublespindlepulley(Figure48or
Figure49).

8.Connecttheidlerarmspring(Figure48orFigure49).

9.InstallthePTOdrivebelt.RefertoReplacingthe
PTODriveBelt.

10.Adjustthebeltguidean1/8inch(3mm)fromthe
belt(Figure48orFigure49).

11.Installthebeltcoversontothecuttingunitand
securethelatches.

12.Installthecarrierframecoverontothecuttingunit
andsecurethelatches.

8.Loosenpivotboltenoughtoremovetractionbelt
fromthedrivepulleyandclutch.

9.Installnewbeltaroundclutchanddrivepulley.

10.T orquepivotboltto35-40ft-lb(47-54N-m).Install
tensionspringbetweenidlerarmandframebracket
(Figure47).

11.Installclutchretainertotheenginedeck(Figure47).

12.Connectclutchwireconnectortowireharness.

13.InstallPTOdrivebelt.

ReplacingtheMowerBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracks
aresignsofaworndeckbelt.Replacethedeckbeltif
anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

Figure48

40inch,48inch,and52inchMowerDeckshown

1.Outsidepulley

2.PTOdrivebelt

3.Idlerarmspring

4.Mowerdeckbelt

5.Beltguide

6.Centerspindlepulley

3.Unlatchandremovethecarrierframecover.

35

Figure49

36inchMowerDeckshown

1.Mowerdeckbelt4.Idlerarmspring

2.PTOdrivebelt

3.Drivebeltpulley

5.Drivebeltpulley

9.Rollthebeltontothecenterpulleyonthemower
deck(Figure50).Usecautionwheninstallthebelt
astensionwillincreasebecauseofthespringloaded
idlerpulley.RefertoFigure51torollthenewbelt
ontotheleftpulleyfora36inchmowerdeck.

10.Installtheheatshieldtotheenginedeckandcarrier
frame.

11.Adjustthebeltguidean1/8inch(3mm)fromthe
beltfor40,48and52inchmowerdecks(Figure50).

12.Installthebeltcoversontothecuttingunitand
securethelatches.

13.Installthecarrierframecoverontothecarrierframe
andsecurethelatches.

ReplacingthePTODriveBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracks
aresignsofaworndrivebelt.Replacethedrivebeltif
anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchandremovethecarrierframecover.

4.Unlatchandremovethebeltcovers.

5.Removetheheatshieldfromtheenginedeckand
carrierframe.

6.Rollthebeltoffofthecenterpulleyonthemower
deck(Figure50).RefertoFigure51torollthebelt
offleftpulleyfora36inchmowerdeck.Usecaution
whenremovingthebeltastensionwillincrease
becauseofthespringloadedidlerpulley.

7.Removethebeltfromtheenginepulleyandthe
springloadedidlerpulley(Figure50).Referto
Figure51toremovethebeltfromthe36inchmower
deckpulleys.

8.Installthenewbeltontotheenginepulleyandspring
loadedidlerpulley(Figure50).

Figure50

40inch,48inch,and52inchMowerDeckshown

1.PTOdrivebeltguide4.PTOengagementpulley

2.PTOdriveBelt5.PTOdrivebeltidlerpulley

3.Idlerspring

6.Centerspindlepulley

36

MowerDeck
Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keeptheblades
sharp.Forconvenientsharpeningandreplacement,you
maywanttokeepextrabladesonhand.

Awornordamagedbladecanbreak,anda
pieceofthebladecouldbethrownintothe
operator’sorbystander’sarea,resultingin
seriouspersonalinjuryordeath.

Figure51

36inchMowerDeckshown

1.Mowerdeckbelt

2.PTODriveBelt

3.Idlerarmandspring

4.Clutchpulley

5.Idlerpulley

AdjustingthePTODriveBelt
IdlerSpringAnchor

ThepositionofthePTOidlercanbeadjustedto
increaseordecreasebelttension.

UseFigure52fortheidlerpositionoptions.

•Inspectthebladesperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagetheblades
andsettheparkingbrake.Turntheignitionkeytooff.
Removethekeyanddisconnectthesparkplugwires
fromthesparkplugs.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure53).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades.

Figure52

1.PTOdrivebeltidlerpulley4.Mosttensionforwornbelts

2.PTOdriveBelt5.Mediumtensionfornormal

3.Idlerspring

beltconditions

6.Leasttensionfornewbelts

Figure53

1.CuttingEdge3.Wear/slotformingin
curvedarea

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea
(Figure53).Ifyounoticeanycracks,wear,ora
slotforminginthisarea(item3inFigure53),
immediatelyinstallanewblade.

37

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Rotatethebladesuntiltheendsfaceforwardand
backward.Measurefromalevelsurfacetothe
cuttingedge,positionA,oftheblades(Figure54
).Notethisdimension.For36inchmowerdecks
useFigure55.

steps3and4mustnotexceed1/8inch(3mm).If
thisdimensionexceeds1/8inch(3mm),theblade
isbentandmustbereplaced;refertoRemovingthe
BladesandInstallingtheBlades.

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedbladewith
anewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe
bladeisoutofbalanceorisbent.Toensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineTororeplacementblades.
Replacementbladesmadebyothermanufacturersmay
resultinnon-conformancewithsafetystandards.

Figure54

40inch,48inch,and52inchMowerDeckshown

1.Measureherefromblade
tohardsurface

36inchMowerDeckshown

2.PositionA

Figure55

1.Holdthebladeendusingaragorthickly-padded
glove.

2.For40and48inchmowerdecks,removetheblade
bolt,curvedwasher,andbladefromthespindle
shaft(Figure56).

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep3above.
Thedifferencebetweenthedimensionsobtainedin

38

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends
oftheblade(Figure58).Maintaintheoriginalangle.
Thebladeretainsitsbalanceifthesameamountof
materialisremovedfrombothcuttingedges.

Figure58

1.Sharpenatoriginalangle

Figure56

40inchand48inchMowerDecks

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

3.For36and52inchmowerdecks,removetheblade
bolt,curvedwasher,bladestiffener,andbladefrom
thespindleshaft(Figure57).

Figure57

36inchand52inchMowerDecks

1.SailAreaofBlade4.Curvedwasher

2.Blade5.BladeBolt

3.Bladestiffener

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure59).

3.Ifthebladestaysinahorizontalposition,theblade
isbalancedandcanbeused.Ifthebladeisnot
balanced,lesomemetalofftheendofthesailarea
only(Figure56)

4..Repeatthisprocedureuntilthebladeisbalanced.

Figure59

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure56).

Important:Thesailpartoftheblademustbe
pointingupward,towardtheinsideofthemower
toensurepropercutting(Figure56).

2.For40inchand48inchmowerdecks,installthe
blade,curvedwasher,andbladebolt(Figure56).

3.For36inchand52inchmowerdecks,installthe
blade,stiffener,curvedwasher,andbladebolt
(Figure57).

4.Torquethebladeboltto85-110ft-lb(115-140N-m).

CorrectingtheMowerQuality
ofCut

Ifonedeckbladecutslowerthantheother,correctas
follows.

Note:Tireairpressureiscriticalintheseprocedures.
Makesurealltireshavecorrectpressure.

39

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.Disconnectthesparkplugwire(s)from
thesparkplug(s).

3.Adjustthetirepressureinthereartiresto
specications;referto,page.

4.Checkthatthebladesandspindleshaftsarenot
bent.RefertoCheckingforBentBlades.

5.Settheheight-of-cuttothe4inch(101.6mm)
position.RefertoAdjustingtheHeight-Of-Cutin,
page.

6.PerformthestepsinthefollowingsectionsFrame
SetUp,CheckingFront-to-RearPitch,andChecking
Side-to-SideLeveling.

FrameSetUp

CheckingtheCarrierFrameandEngine
DeckAlignment

Figure60

1.CarrierFrame4.LocationA,1-5/16inch

2.Topofenginedeck5.Straightedge

3.Carrierframemounting
bolts

(33mm)±1/4inch(6mm)

6.Carrierframecross
channel

Note:MisalignmentcancauseexcesswearonthePTO
drivebelt.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Placealongstraightedgeontopoftheenginedeck
asshowninFigure60.

4.Atthecarrierframecrosschannel,measurethe
heightatlocationA(Figure60).Thismeasurement
mustbe1-5/16inch(33mm),plusorminusa1/4
inch(6mm).

5.IftheheightatlocationAisnotcorrect,adjustment
isneeded.

6.Loosenthecarrierframemountingboltsonboth
sidesofthemachine(Figure60).

7.Alignthecarrierframeandenginedecktomatch
1-5/16inch(33mm),plusorminusa1/4inch(6
mm)atlocationA(Figure60).

CheckingtheEngineDeckHeight

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Adjustthetirepressureinthereartiresto
specications;referto,page.

4.MeasureenginedeckheightatlocationA(Figure61).

8.Tightenthecarrierframemountingboltsonboth
sidesofthemachine.

Figure61

1.Backviewofmachine

2.Topofenginedeck4.Sameheightatlocations

40

3.Tires

AandB

5.MeasureenginedeckheightatlocationB(Figure61).

6.IftheheightatlocationAandBarenotthesame,
changetirepressureslightlytomakethemthesame.

CheckingtheCarrierFrame
Front-to-RearPitch

Thecarrierframemusthaveapitchbetween1/8inch
(3mm)to3/8inch(9mm)overthelengthof24inches
(61cm)onthecarrierframe(Figure62).

1.Measureout24inches(61cm)onthecarrierframe
(Figure62).

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Adjustthetirepressureinthereartiresto
specications;referto,page.

4.MeasurecarrierframeheightatlocationA
(Figure63).

5.MeasurecarrierframeheightatlocationB
(Figure63).

6.Ifthecarrierframeheightisnotthesamemove
spacersfromtoporbottomofcasterwheel,to
makeitlevel.Thetirepressuremayalsobeadjusted
slightlytomakeitlevel.

Figure62

1.CarrierFrame

2.1/4-3/8inch(6-10mm)
pitchover24inch(61cm)
length

3.24inches(61cm)6.Casterspacers

4.HeightatlocationsAand

B

5.CasterWheel

2.MeasurecarrierframeheightatlocationA
(Figure62).

3.MeasurecarrierframeheightatlocationB
(Figure62).

4.TheheightatlocationAmustbea1/4-3/8inch(6
mm-10mm)lowerthanlocationB(Figure62).

5.Ifthecarrierframeisnotcorrect,movecaster
spacerstomakeita1/4-3/8inch(6-10mm)pitch
(Figure62).Movespacersfromtoporbottomto
makethecorrectpitch.

6.Thetirepressuremayalsobeadjustedslightlyto
makea1/4inch(6mm)pitch.

CheckingtheCarrierFrame
Side-to-SideHeight

Figure63

1.CasterWheel4.Sameheightatlocations
AandB

2.CarrierFrame5.Casterspacers

3.Frontheight-of-cutpins

CheckingtheMowerDeck
Front-to-RearPitch

1.Adjustthetirepressureinthereartiresto
specications;referto,page.

2.Positiononebladefront-to-rear.MeasureatAand
Blocationsfromalevelsurfacetothecuttingedge
ofthebladetips(Figure64orFigure65).For36
inchmowerdecksuseFigure65.

3.Themowerbladeshouldbea1/4inch(6mm)lower
infrontatAthanintherearatB.Rotatebladesand
repeatforotherblades.Ifitisnotcorrect,proceed
toChangingtheDeckFront-to-RearPitch.

Thecarrierframeneedstobeparallelside-to-sidefrom
theground.

1.DisengagethePTOandsettheparkingbrake.

41

Figure64

40inch,48inch,and52inchMowerDeckshown

1.MeasurebladeatpointsA
andB

2.Measurefromalevel

Figure66

1.CasterWheel

2.CarrierFrame

surface

3.Frontheight-of-cutpins

4.Jamnut

5.Balljoint

2.Toraisethefrontofthedeck,loosenjamnutand
rotatethefrontpinclockwise(Figure66).

3.Tolowerthefrontofthedeck,loosenjamnutand
rotatethefrontpincounterclockwise(Figure66).

4.Positionthebladesfront-to-rear.MeasureatCand
Dlocations(Figure64)fromalevelsurfacetothe
cuttingedgeoftheblades.

5.Checktheside-to-sidelevelingofthecuttingunit.

Figure65

36inchMowerDeckshown

ChangingtheMowerDeck
Front-to-RearPitch

Changingthefront-to-rearpitchisdonebyadjustingthe
frontheight-of-cutposts.

1.Tochangethefront-to-rearpitch,thefront
height-of-cutpostscanbeadjusted(Figure66).

6.Tightenthejamnuts(Figure66).

CheckingtheMowerDeck
Side-to-SideHeight

1.Adjustthereartirepressuretospecications;refer
to,page.

2.Positionthebladesside-to-side.MeasureatCand
Dlocationsfromalevelsurfacetothecuttingedge
ofbladetips(Figure67).For36inchmowerdecks
useFigure68.

42

Figure67

40inch,48inch,and52inchMowerDeckshown

3.Withthemachineonlevelsurface,positiononeblade
front-to-rear.MeasureatAandfromlevelsurfaceto
thecuttingedgeofthebladetips(Figure69).For36
inchmowerdecksuseFigure70.

1.Measurefromalevel
surface

36inchMowerDeckshown

2.MeasurebladeatpointsC
andD

Figure68

3.ThedifferencebetweenmeasurementsCandD
shouldbenomorethan1/4inch(6mm).

ChangingtheMowerDeck

Figure69

40inch,48inch,and52inchMowerDeckshown

1.Measurefromalevel
surface

36inchMowerDeckshown

2.MeasurebladeatpointA

Figure70

Side-to-SideHeight

Changingtheside-to-sideheightisdonebyadjustingthe
reartirepressureandcasterspacers.

1.Changethereartirepressure.Dothistothe
correspondingsidethatneedsadjustment.

2.Adjustthecasterspacer.

3.Recheckthefront-to-rearpitchandsidetoside
levelingofthecuttingunit.

MatchingHeightofCut

1.Checkthereartirepressure.

2.Settheheight-of-cuttothe4inch(101.6mm)
positionfollowingtheheight-of-cutdecal.

4.Themeasurementshouldbe4inch(101.6mm).

5.Ifitdoesnotmeasurecorrectly:

A.Adjustthereartirepressure.

B.Adjustthecasterforkspacers.

C.Adjustthefrontmowerdecksupportpins.

6.Checkthecarrierframefront-to-rearpitch.

43

ReplacingtheGrassDeector

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

Neveroperatethelawnmowerunlessyouinstall
acoverplate,amulchplate,grassdeectoror
bagger.

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure71).
Removedamagedorworngrassdeector.

positionandensurethatitrotatesintothefull
downposition.

Figure71

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place
behinddeckedgebefore
installingbolt

2.Placespacerandspringontograssdeector.Place
theLendofspringbehinddeckedge.

Note:MakesuretheLendofspringisinstalled
behinddeckedgebeforeinstallingtheboltasshown
inFigure71.

3.Installboltandnut.PlacetheJhookendofspring
aroundgrassdeector(Figure71).

Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefullopen

44

Storage

11.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

CleaningandStorage

1.Disengagethepowertakeoff(PTO),settheparking
brake,andturntheignitionkeytooff.Removethe
key.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engine.Cleandirtandchafffromtheoutsideofthe
engine’scylinderheadnsandblowerhousing.

Important:Youcanwashthemachinewith
milddetergentandwater.Donotpressurewash
themachine.Avoidexcessiveuseofwater,
especiallyneartheshiftleverplate,andengine.

3.Checkthebrake;refertoServicingtheBrakein,
page.

4.Servicetheaircleaner;refertoServicingtheAir
Cleanerin,page.

5.Greasethemachine;refertoGreasingand
Lubricationin,page.

6.Changetheengineoil;refertoServicingtheEngine
in,page.

12.Storethemachineinaclean,drygarageorstorage
area.Removethekeyfromtheignitionswitchand
keepitinamemorableplace.Coverthemachineto
protectitandkeepitclean.

7.Checkthetirepressure;refertoCheckingtheTire
Pressurein,page.

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefuel

tank;refertoServicingtheFuelTankin,page,
oroperateengineuntilitstops.

D.Restartengineandrununtilitstops.Repeat,on

Chokeuntilenginewillnotrestart.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Note:Donotstorestabilizer/conditioned
gasolineover90days.

9.Removethesparkplug(s)andcheckitscondition;
refertoServicingtheSparkPlugin,page.With
thesparkplug(s)removedfromtheengine,pour
twotablespoonsofengineoilintothesparkplug
hole.Nowusethestartertocranktheengineand
distributetheoilinsidethecylinder.Installthespark
plug(s).Donotinstallthewireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repair
orreplaceanypartthatisdamagedordefective.

45

Troubleshooting

Problem

Enginewillnotstart,startshard,orfails
tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Fueltankisempty .

2.Chokeisnoton.

3.Aircleanerisdirty .

4.Sparkplugwireislooseor
disconnected.

5.Sparkplugispitted,fouled,orthegap
isincorrect.

6.Dirtinthefuellter .6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel
system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty .

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesunder
theengineblowerhousingareplugged.

5.Sparkplugispitted,fouled,orthegap
isincorrect.

6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

7.Dirtinthefuellter .7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel
system.

1.Fillfueltankwithgasoline.

2.Movethechokelevertochokeposition.

3.Cleanorreplacetheaircleaner
element.

4.Installwireonsparkplug.

5.Installanew,correctlygappedspark
plug.

7.ContactanAuthorizedServiceDealer.

2.Servicetheaircleaner .

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe
coolingnsandairpassages.

5.Installanew,correctlygappedspark
plug.

8.ContactanAuthorizedServiceDealer.

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesunder
theengineblowerhousingareplugged.

1.Shiftleverisinneutral.1.Moveshiftlevertoadrivegearposition.

2.Tractionbeltisworn,looseorbroken.

3.Tractionbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

1.Cuttingblade(s)is/arebentor
unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley ,or
bladepulley.

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Mowerisnotlevel.3.Levelthemowerside-to-sideposition.

4.Mowerpitchiswrong.

5.Undersideofmowerisdirty.5.Cleantheundersideofthemower.

6.Tirepressureisnotcorrect.6.Adjustthetirepressure.

7.Bladespindlebent.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe
coolingnsandairpassages.

2.Changethebelt.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

4.Adjustthefront-to-rearpitch.

7.ContactanAuthorizedServiceDealer.

46

Problem

PossibleCauseCorrectiveAction

Bladesdonotrotate.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.

5.Brokenormissingidlerspring.5.Replacethespring.

6.Electricclutchoutofadjustment.

7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer.

8.Damagedelectricclutch.

9.Safetyinterlocksystempreventsblade
rotation.

10.PTOswitchisfaulty .10.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installdrivebeltandcheckadjusting
shaftsandbeltguidesforcorrect
position.

4.Installdeckpulleyandchecktheidler
pulley,idlerarmandspringforcorrect
positionandfunction.

6.Adjusttheclutchairgap.

8.ContactanAuthorizedServiceDealer.

9.ContactanAuthorizedServiceDealer.

47

Schematics

ElectricalSchematic(Rev.A)

48

Notes:

49

Notes:

50

Notes:

51

The Toro Total Coverage Guarantee

A Limited Warranty (see warranty periods below)

Landscape

Contractor

Equipment (LCE)

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an

Conditions and Products Covered

agreement between them, jointly promise to repair the listed Toro Products
if defective in materials or workmanship.

The following warranty time periods apply from the date of purchase by the
original owner:

Product Warranty Period

Mid-Size Walk-Behind Mowers 2 years**
GrandStand

•

•

Z Master

•

•

Z Master® G3 Mowers

•

•

Batteries (for above units)

TM

Mowers
Engine
Frame

®

Z300, Z400, Z500 Mowers
Engine
Frames

Engine
Frame

5 years or 1,200 hours*
2 years**
Lifetime (original owner only)***

4 years or 1,200 hours*
2 years**
Lifetime (original owner only)***

5 years or 1,200 hours*
2 years**
Lifetime (original owner only)***

1 year

Attachments (for above units) 1 year

*Whichever occurs fi rst.
**Some engines used on Toro LCE Products are warranted by the engine manufacturer.
***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form
the tractor structure that other components such as the engine are secured to, cracks or breaks in
normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame failure
due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.

This warranty includes the cost of parts and labor, but you must pay
transportation costs.

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:

1. Contact any Authorized Toro Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, refer to the Yellow
Pages of your telephone directory (look under “Lawn Mowers”) or access
our web site at www.Toro.com. You may also call the numbers listed in
item #3 to use the 24-hour Toro Dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the
Service Dealer. The dealer will diagnose the problem and determine if it
is covered under warranty.

3. If for any reason you are dissatisfi ed with the Service Dealer’s analysis
or with the assistance provided, contact us at:

LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-865-5676 (U.S. Customers)
888-865-5691 (Canada customers)

You must maintain your Toro Product by following the maintenance

Owner Responsibilities

procedures described in the Operator’s Manual. Such routine maintenance,
whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system and
engine warranty coverage on some products.
This express warranty does not cover:

Cost of regular maintenance service or parts, such as fi lters, fuel,

•
lubricants, tune-up parts, blade sharpening, brake and clutch
adjustments.
Any product or part which has been altered or misused or required

•
replacement or repair due to normal wear, accidents, or lack of proper
maintenance.
Repairs necessary due to improper fuel, contaminants in the fuel system,

•
or failure to properly prepare the fuel system prior to any period of non­use over three months.

Pickup and delivery charges.

•

General Conditions

All repairs covered by this warranty must be performed by an Authorized
Toro Service Dealer using Toro approved replacement parts.

Neither The Toro Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with
the use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion of
repairs under this warranty.

All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a particular
purpose) are limited to the duration of the express warranty.

Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the
above exclusions and limitations may not apply to you.

This warranty gives you specifi c legal rights, and you may also have other
rights which vary from state to state.

Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee

Countries Other than the United States or Canada

policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi culty obtaining guarantee
information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part Number 374-0037 Rev. H