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

Download

Page 1

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)

Page 2

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

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

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

Page 4

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.

Page 5

•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.

Page 6

•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice asrequired.

Page 7

SlopeChart7SafetyandInstructionalDecals

Page 8

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

Page 9

106-0699

104-8185

110-2067

104-8186

104-8569

110-2068

1.ReadtheOperator’sManual.

105-7798

106-0635

Page 10

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.

Page 11

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.

Page 12

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

Page 13

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.

Page 14

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).

Page 15

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.

Page 16

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.

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).

Page 17

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.

Page 18

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.

Page 19

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.

Page 20

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

Page 21

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

Page 22

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.

Page 23

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

Page 24

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).

Page 25

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.

Page 26

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).

Page 27

4.Installthereplacementoilltertothelteradapter,

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).

Page 28

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

Figure36

Page 29

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

Page 30

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

Page 31

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).

Page 32

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).

Page 33

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).

Page 34

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.

Page 35

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.

Page 36

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

Page 37

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.

Page 38

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

Page 39

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.

Page 40

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

3.Tires

AandB

Page 41

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

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.

Page 42

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.

Page 43

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.

Page 44

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

Page 45

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.

Page 46

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.

Page 47

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.

Page 48

Schematics

ElectricalSchematic(Rev.A)

Page 49

Notes:

Page 50

Notes:

Page 51

Notes:

Page 52

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)

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