Page 1
ProLine
13hp–92cm Mid–Size Mower
30184—200000001 & Up
Form No. 3324–377
Operator’s Manual
English (GB)
Page 2
Introduction
Thank you for purchasing a Toro product.
All of us at Toro want you to be completely satisfied
with your new product, so feel free to contact your
local Authorized Service Dealer for help with service,
genuine replacement parts, or other information you
may require.
Whenever you contact your Authorized Service
Dealer or the factory, always know the model and
serial numbers of your product. These numbers will
help the Service Dealer or Service Representative
provide exact information about your specific
product. You will find the model and serial number
plate located in a unique place on the product as
shown below
.
1
The warning system in this manual identifies
potential hazards and has special safety messages that
help you and others avoid personal injury, even death.
DANGER, WARNING and CAUTION are signal
words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
DANGER signals an extreme hazard that will cause
serious injury or death if the recommended
precautions are not followed.
WARNING signals a hazard that may cause serious
injury or death if the recommended precautions are
not followed.
CAUTION signals a hazard that may cause minor or
moderate injury if the recommended precautions are
not followed.
Two other words are also used to highlight
information. “Important” calls attention to special
mechanical information and “Note” emphasizes
general information worthy of special attention.
m–3775
1. Model
For your convenience, write the product model and
serial numbers in the space below.
Model No:
Serial No.
Read this manual carefully to learn how to operate
and maintain your product correctly. Reading this
manual will help you and others avoid personal injury
and damage to the product. Although we design,
produce and market safe, state-of-the-art products,
you are responsible for using the product properly
and safely. You are also responsible for training
persons, who you allow to use the product, about safe
operation.
and Serial Number Plate
The left and right side of the machine is determined
from the normal operator’s position.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
IMPORTANT: This engine is not equipped
with a spark arrester muffler. It is a violation
of California Public Resource Code Section
4442 to use or operate this engine on any
forest–covered, brush–covered or
grass–covered land. Other states or federal
areas may have similar laws.
The Toro Company – 1998
All Rights Reserved
Page 3
Contents
Safety 2.
Gasoline and Oil 8. . . . . . . . . . . . . . . . . . . . . . . .
Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 4. . . . . . . . . . . . . . . . . . . . . . . . .
Symbols Glossary
Symbols Glossary
Symbols Glossary
Recommended Gasoline
Stabilizer/Conditioner 9. . . . . . . . . . . . . . . .
Filling the Fuel Tank 9. . . . . . . . . . . . . . . . .
Check Engine Oil Level 9. . . . . . . . . . . . . . .
Loose Parts 10. . . . . . . . . . . . . . . . . . . . . . . . .
Install Front Castors 11. . . . . . . . . . . . . . . . . .
Install Upper Handle 11. . . . . . . . . . . . . . . . .
Connect Throttle Cable 13. . . . . . . . . . . . . . .
Install Blade Control (PTO) Rod 14. . . . . . . .
Install Shift Lever 14. . . . . . . . . . . . . . . . . . .
Mount Fuel Tank 15. . . . . . . . . . . . . . . . . . . .
Think Safety First 16. . . . . . . . . . . . . . . . . . .
Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake 17. . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping
the Engine 18. . . . . . . . . . . . . . . . . . . . . . . .
Operating Blade Control (PTO) 19. . . . . . . . .
The Safety Interlock System 19. . . . . . . . . . .
Page
Driving Forward or Backward 20. . . . . . . . . .
Lower Control Bar Operation 21. . . . . . . . . .
5. . . . . . . . . . . . . . . . . . .
6. . . . . . . . . . . . . . . . . . .
7. . . . . . . . . . . . . . . . . . .
8. . . . . . . . . . . . . .
Stopping the Machine 21. . . . . . . . . . . . . . . .
Adjusting Height-of-Cut 22. . . . . . . . . . . . . .
Height-of-Cut Chart 23. . . . . . . . . . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart 24. . . . . . . . . . . . . . . .
Air Cleaner 25. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 26. . . . . . . . . . . . . . . . . . . . . . . . .
Tire Pressure 28. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 28. . . . . . . . . . .
Spark Plug 29. . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Blades
Adjusting Blade Brake
Greasing and Lubrication 33. . . . . . . . . . . . . .
Brake 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 35. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 36. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Wheel Belt 36. . . . . . . . . . . . .
Replacing the Traction Belt 37. . . . . . . . . . . .
Replacing the Mower Belts
Adjusting Grass\Mud Scraper 38. . . . . . . . . .
Replacing the Grass Deflector 38. . . . . . . . . .
Wiring Diagram 39. . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 40. . . . . . . . . . . . . . . . .
Troubleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . .
Page
30. . . . . . . . . . . . . . . . . . . . . .
32. . . . . . . . . . . . . . . .
37. . . . . . . . . . . .
! % ! # ! !# "
$ " "" &
" !! " #" !! !&!"!
" % "&
"! % ! # %" &# #" # "!
% ! #
"& "! & " # "
#"#
1
Page 4
Safety
Toro designed this lawn mower for cutting and
mulching grass, or, when equipped with a grass bag,
for catching cut grass. Any use for purposes other
than these could prove dangerous to the operator or to
bystanders.
Note: This engine is not equipped with a spark
arrester muffler. Operating this mower on any
forest-covered, brush-covered, or unimproved
grass-covered land without an approved spark arrester
muffler may violate your state law.
POTENTIAL HAZARD
• Engine exhaust contains carbon monoxide,
which is an odorless, deadly poison.
WHAT CAN HAPPEN
• Carbon monoxide can kill you and is also
known to the State of California to cause
birth defects.
HOW TO AV
• Do not run engine indoors or in an enclosed
area.
OID THE HAZARD
Training
• Read the instructions carefully. Be familiar with
the controls and the proper use of the equipment
before starting.
• See manufacturer’s instructions for proper
operation and installation of accessories. Only use
accessories approved by the manufacturer.
• Never allow children or people unfamiliar with
these instructions to use the mower. Local
regulations may restrict the age of the operator.
• Never mow while people, especially children, or
pets are nearby. Stop mower if anyone enters the
area.
Tragic accidents can occur if the operator is not alert
to the presence of children. Children are often
attracted to the mower and the mowing activity.
Never assume that children will remain where you
last saw them.
• Keep children out of the mowing area and under
the watchful care of a responsible adult.
• Be alert and turn mower off if children enter the
area.
• Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
To ensure maximum safety, best performance, and
to gain knowledge of the product, it is essential
that you and any other operator of the lawn
mower read and understand the contents of this
manual before the motor is ever started. Pay
particular attention to the safety alert symbol
which means CAUTION, WARNING, OR
DANGER — “personal safety instruction.” Read
and understand the instruction because it has to
do with safety. Failure to comply with instruction
may result in personal injury.
General
The following instructions have been adapted from
the ANSI/OPEI standard B71.1—1998 and ISO
standard 5395:1990(E). Information or terminology
specific to Toro lawn mowers is enclosed in
parenthesis.
This cutting machine is capable of amputating hands
and feet and throwing objects. Failure to observe the
following safety instructions could result in serious
injury or death.
Lawn Mower Safety
• Keep in mind that the operator or user is
responsible for accidents or hazards occurring to
other people or their property.
Preparation
• While mowing, always wear substantial footwear
and long trousers.
• Do not operate the equipment when barefoot or
wearing open sandals.
• Always wear safety goggles or safety glasses with
side shields when operating mower.
• Thoroughly inspect the area where the equipment
is to be used and remove all stones, sticks, wires,
bones, and other foreign objects.
• Warning: Gasoline is highly flammable. Take
the following precautions:
– Store fuel in containers specifically
designed for this purpose.
2
Page 5
Safety
– Refuel outdoors only and do not smoke
while refuelling.
– Add fuel before starting the engine. Never
remove the cap of the fuel tank or add
gasoline while the engine is running or
when the engine is hot.
– If gasoline is spilled, do not attempt to start
the engine but move the machine away
from the area of spillage and avoid creating
any source of ignition until gasoline vapors
have dissipated.
– Replace all fuel tank and container caps
securely.
– If the fuel tank has to be drained, do this
outdoors.
• Replace faulty mufflers.
• Before using, always visually inspect to see that
the blades, blade bolts, and cutter assembly are not
worn or damaged. Replace worn or damaged
blades and bolts in sets to preserve balance.
• On multibladed machines, take care as rotating
one blade can cause other blades to rotate.
• Stop the blade(s) if the mower has to be tilted for
transportation when crossing surfaces other than
grass and when transporting the mower to and
from the area to be mowed.
• Never operate the mower with damaged or
missing guards or shields, or without safety
devices; for example, deflectors and/or grass
catchers in place.
• Do not change the engine governor settings or
overspeed the engine.
• Disengage all blade and drive clutches before
starting the engine.
• Start the engine or switch on the motor carefully
according to instructions and with feet well away
from the blade(s).
• Do not tilt when starting the engine or switching
on the motor, unless the mower has to be tilted for
starting. In this case, do not tilt it more than
absolutely necessary and lift only the part which is
away from the operator.
• Do not start the engine when standing in front of
the discharge chute.
• Do not put hands or feet near or under rotating
parts. Keep clear of the discharge opening at all
times.
Operation
• Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can
collect.
• Mow only in daylight or in good artificial light.
• Always be sure of your footing on slopes.
• Walk; never run.
• Keep a firm hold on the handle.
• For wheeled rotary machines, mow across the face
of slopes, never up and down.
• Exercise extreme caution when changing direction
on slopes.
• Do not mow excessively steep slopes.
• Use extreme caution when reversing or pulling the
mower towards you.
• Before and while moving backwards, look behind
and down for small children.
• Never pick up or carry a mower while the engine
is running.
• Stop the engine and disconnect the spark plug lead
– before clearing blockages or unclogging
chute;
– before checking, cleaning, or working on
the mower;
– after striking a foreign object. Inspect the
mower for damage and make repairs before
restarting and operating the mower;
– if mower starts to vibrate abnormally (check
immediately).
• Stop the engine
– whenever you leave the mower;
– before refuelling.
3
Page 6
Safety
• Reduce the throttle setting during engine run-out
and, if the engine is provided with a shut-off
valve, turn the fuel off at the conclusion of
mowing.
• Stop the blade(s) when crossing gravel drives,
walks, or roads.
• Shut the engine (motor) off and wait until the
blade comes to complete stop before removing
grass catcher
.
• Do not operate the mower while under the
influence of alcohol or drugs.
• If the equipment should start to vibrate
abnormally, stop the engine (motor) and check
immediately for the cause. Vibration is generally a
warning of trouble.
Slopes are a major factor related to slip and fall
accidents which can result in a severe injury. If you
feel uneasy on a slope, do not mow it.
• Watch for holes, ruts, or bumps. Tall grass can
hide obstacles.
• Do not mow near drop-offs, ditches, or
embankments. The operator could lose footing or
balance.
• Do not mow on wet grass. Reduced footing could
cause slipping.
• tamper with safety devices. Check their proper
operation regularly.
• Keep the mower free of grass, leaves, or other
debris build-up. Clean up oil or fuel spillage.
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
• Never attempt to make wheel height adjustments
while the engine (motor) is running.
• Always disconnect electric mowers (live operated)
before cleaning, repairing, or adjusting.
• Grass catcher components are subject to wear,
damage, and deterioration, which could expose
moving parts or allow objects to be thrown.
Frequently check components and replace with
manufacturer’s recommended parts when
necessary.
• Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves, and use extra caution
when servicing them.
• Do not change the engine governor setting or
overspeed the engine.
• To ensure the best performance and safety,
purchase only genuine Toro replacement parts and
accessories.
Do not use “will fit” parts and
accessories; they may cause a safety hazard.
Maintenance and Storage
• Keep all nuts, bolts (especially blade attachment
bolts), and screws tight to be sure the equipment is
in safe working condition.
• Never store the equipment with gasoline in the
tank inside a building where fumes may reach an
open flame or spark.
• Allow the engine to cool before storing in any
enclosure.
• To reduce the fire hazard, keep the engine,
muffler, battery compartment, and gasoline storage
area free of grass, leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Replace worn or damaged parts for safety.
• Use extra care when handling gasoline; vapors are
explosive.
4
Page 7
Safety
Slope
Read all safety instructions on pages 2–9.
Chart
5
Page 8
6
Page 9
Safety
Symbols
Safety alert triangle–
symbol within triangle
indicates a hazard
Safety alert symbol
Read operator’s manual
Caustic liquids, chemical
burns to fingers or hand
Glossary
Fire, open light & smoking
prohibited
Fire or open flame
Explosion
Do not dispose of lead
battery in garbage
Caution, toxic risk
Eye protection must
be worn
First aid, flush with water
Stay a safe distance
from the machine
Stay safe distance
from machine
Stay safe distance
from machine
Keep children away
from battery
7
Page 10
Safety
w
w
m
Symbols Glossary
Do not open or
remove safety shields
Cutting of foot
hile engine is running
Thrown or flying objects,
hole body exposure
Thrown or flying objects,
whole body exposure
Do not operate without safety
Hot surface, burns to
fingers or hands
Stop engine before
leaving operator position
Machine being transported
shield in place
Keep guards and safety
sheilds in place
Severing of toes & fingers,
rotary mower blade
Severing of fingers or hand,
mower blade
Severing of toes or foot,
mower blade
Blade cutting elementheight adjustment
Fuel shut off
control operation
Blade retaining bolts must be
T
orqued to 101–108 N.m
Finger & hand engagement,
belt drive
(mm)
101–108 N.
8
Page 11
Symbols Glossary
Safety
Fast
Slow
Decreasing/Increasing
Stop Engine
Choke
Fuel
STOP
Parking brake
T
raction drive
Reverse
Neutral
First gear
Power take off (PT
Engage
Disengage
Parking brake
O)
Second gear
Third gear
Fourth gear
Fifth gear
Forward
F
9
Page 12
Gasoline and Oil
Recommended
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is
not available.
IMPORTANT: Never use methanol, gasoline
containing methanol, or gasohol containing
more than 10% ethanol because the fuel
system could be damaged. Do not mix oil with
gasoline.
POTENTIAL HAZARD
Gasoline
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AV
OID THE HAZARD
• Use a funnel and fill the fuel tank outdoors,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Do not fill the fuel tank completely full.
Add gasoline to the fuel tank until the level
is 1/4” to 1/2” (6 mm to 13 mm) below the
bottom of the filler neck. This empty space
in the tank allows gasoline to expand.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by a spark.
• Store gasoline in an approved container
and keep it out of the reach of children.
Never buy more than a 30-day supply of
gasoline.
POTENTIAL HAZARD
• When fueling, under certain circumstances,
a static charge can develop, igniting the
gasoline.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you and others and cause property damage.
HOW TO AV
OID THE HAZARD
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Do not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• When practical, r
equipment from the truck or trailer and
refuel the equipment with its wheels on the
round.
emove gas–power
ed
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of
the fuel tank or container opening at all
times until fueling is complete.
10
Page 13
Gasoline and Oil
POTENTIAL HAZARD
• Gasoline is harmful or fatal if swallowed.
Long–term eposure to vapors has caused
cancer to laboratory animals.
WHAT CAN HAPPEN
• Failure to use caution may result in serious
injury or illness
HOW TO AV
OID THE HAZARD
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank
or conditioner opening.
• Keep gas away from eyes and skin.
Using
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
Stabilizer/Conditioner
Filling
1. Shut the engine off.
2. Clean around the fuel tank cap and remove the
3. Install the fuel tank cap securely. Wipe up any
Check
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer to
Checking Oil Level, page 30.
the Fuel T
cap. Use a funnel and add unleaded regular
gasoline to the fuel tank, until the level is 1/4 to
1/2 inch (6 mm to 13 mm) below the bottom of
the filler neck. This space in the tank allows
gasoline to expand. Do not fill the fuel tank
completely full.
gasoline that may have spilled.
ank
Engine Oil Level
• Keeps gasoline fresh during storage of 90 days
or less. For longer storage, drain the fuel tank.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
IMPORTANT: Do not use fuel additives
containing methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner
to the gas.
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh
gasoline. To minimize the chance of
varnish deposits in the fuel system, use
fuel stabilizer at all times.
11
Page 14
Assembly
Loose
Parts
Note: Use the chart below to verify all parts have been shipped.
DESCRIPTION QTY. USE
Castor assemblies
Bolt 3/8–16 x 19 mm ( 3/4”)
Flange nut 3/8–16
Upper handle
Bolt 3/8–16 x 26 mm (1”)
Locknut 3/8–16
Plastic terminal
Wire tie
Rod fitting
Clevis pin
Washer 1/4”
Hairpin cotter
PT
O rod
Hairpin cotter
2
8
8
1
4
4
1
1
2
2
2
4
1
2
Install front castors to mower
Install upper handle to frame
Install wire harness to handle
Install traction control rods
Install PT
O rod
Shift lever
Rubber seal
Square hole washer
Spring washer
Locknut
1
1
1
1
1
Install shift lever to transmission
12
Page 15
DESCRIPTION USEQTY.
Assembly
Fuel tank
Bolt 5/16–1/ x 22.5 mm (7/8”)
Lock washer 5/16”
W
asher 5/16”
Stud
Spring
Hose clamp
Operator’
Engine Operator
s Manual
’
s Manual
Parts Catalog
Registration card
Install
Front Castors
1. Align castors with holes on top and front of
mower and insert (8) 3/8–16 x 19 mm (3/4”)
bolts through mower. Secure with (8) 3/8–16
flange nuts below mower (Fig. 1).
1
2
2
4
Install fuel tank
2
2
1
1
Read before operating machine
1
1
Fill out and return to T
oro
1
Install
Upper Handle
1. Position handle outside frame and align
mounting holes. Select desired lower mounting
holes for high, medium or low position
according to operators height (Fig. 2).
Note: Tighten lower bolts first to pull castor
against front, then top bolts last.
2. Torque bolts to 40–47 NSm (30–35 ft. lb.).
Figure 1
1. Front
2. Bolt
castor
3/8–16 x
3/4” (19 mm)
3. Flange
nut 3/8–16
m–3777
2. Secure each side with (2) 3/8–16 x 26mm (1”)
bolts and (2) 3/8–16 locknuts (Fig. 2).
3. Torque bolts to 34 NSm (25 ft. lbs.).
1. Upper
2.
Rear frame
3.
Bolt 3/8–16 x 1” (26mm)
handle
Figure 2
4.
Locknut 3/8
5. Low
6. High
m–4213
13
Page 16
Assembly
Connect Wire Harness
1. Route wire harness inside of frame, along left
handle and over throttle cable. Compress wire
harness covering and press into lower and upper
holes in rear of control panel (Fig. 3).
2. Thread harness up through rear tube of traction
handle (Fig. 3).
M-4211
Figure 3
1. Wire
2.
3. Insert terminals into plastic plug until the clips
harness
Control panel
3. Tube
Wire tie
4.
snap into position (Fig. 4). If they do not snap
turn around.
Install Traction Control Rods
1. Thread trunnions equal distance onto each
control rod. For a starting point thread on
approximately 51 mm (2 in.) (Fig. 5).
2. With trunnion rod up, slide clevis pins through
rod fittings and mounting holes in idler brackets
(from outside) (Fig. 5). Secure with 6 mm (1/4”)
washers and hairpin cotters (Fig. 5).
1. Control
2. Trunnion
3.
Idler bracket
rod
Figure 5
4.
5. W
6.
Clevis pin
asher 6 mm (1/4” )
Hairpin cotter
m–3785
4. Push plug onto switch to latch interlock (Fig. 4).
5. Secure wire harness and throttle cable to left
handle, away from PTO lever, with wire tie
(Fig. 3).
1. Terminal
2. Clip
Figure 4
3. Plastic
4. Switch
m–3782
plug
14
Page 17
Assembly
3. Check the gap between upper control bar and
fixed bar with wheel drive fully engaged. Gap
should be approximately 25–32 mm (1 to 1-1/4
in.) (Fig. 6).
Note: The upper control bar and fixed bar
must be parallel in the engaged,
relaxed and brake positions.
4. After completing assembly check operation. If
adjustment is required, remove hairpin cotter
securing rod to upper control bar. Thread rod in
or out of fitting for proper position and install
into upper control bar with hairpin cotter.
5. After adjusting control rods, check parking brake
adjustment, refer to: Brake page 37 for
instructions.
Connect
Throttle Cable
1. Place throttle control lever in FAST detent
position.(Fig. 7).
2. Route cable along left handle, under fuel tank
mount and up to engine throttle base plate.
3. Hook wire Z–bend into hole of speed control
lever (Fig. 7).
4. Loosen cable clamp screw allowing cable
installation, but do not tighten (Fig. 7).
5. Move control cable casing and wire until hole in
speed control lever is aligned with hole in base
plate. Insert a 6.35 mm (1/4 in.) diameter pin or
bolt into aligned holes to hold adjustment.
6. Pull throttle cable slightly to remove any slack
and tighten cable clamp screw to lock
adjustment in place.
1. Control
2.
Fixed control bar
rod
Figure 6
3.
Parking brake lever
4.
Upper control bar
7. Remove alignment pin and check control
operation.
m-4194
1. Wire
2.
3.
Z-bend
Speed control lever
Base plate
Figure 7
4.
Alignment holes 6.35mm
(1/4 in.)
5.
Cable clamp
m–3787
15
Page 18
Assembly
Install
Blade Control (PT
O)
Rod
1. Rotate blade control lever (PTO) away from left
handle so rod drops down.
2. Remove hairpin cotter from bottom end of blade
control rod (PTO) (Fig. 8).
3. Slide blade control (PTO) rod through hole in
bellcrank and secure with hairpin cotter (Fig. 8).
1. Blade
2.
control lever
Blade control rod
Figure 8
3. Bellcrank
4.
Hairpin cotter
m–3783
3. Replace the spring washer,dish down, and
locknut (Fig. 8).
4. Torque nut to 47 NSm (35 ft. lbs.).
5. Shift lever to second gear and check alignment
of lever in slot of shifter plate. Clearance
between top of lever and the top of the slot
should be about equal to the clearance between
bottom of the lever and the bottom of the slot.
6. If clearance is not correct, remove lever and bend
it slightly to adjust.
Note: Do not bend lever while attached to
transmission shaft or damage may
occur.
7. Shift lever to neutral and check alignment of
lever in slot of shifter plate. Clearance between
left and right of slot should be about equal. If not
move control panel to adjust (Fig. 9).
Install
Shift Lever
1. Remove the 3/8” locknut and spring disk washer
from the stud on top of the transmission.
Note: Do not remove rubber seal washer and
square hole washer from transmission
shaft.
2. Slide shift lever through control panel and align
mounting hole in lever with square on
transmission shaft. Secure lever to transmission
with previously removed spring washer and
locknut (Fig. 9).
1. Shift
2.
3.
lever
Control panel
Rubber seal washer
Figure 9
4.
Square hole washer
5.
Spring washer
6.
Locknut 3/8
m–3772
16
Page 19
Assembly
Mount
Fuel T
ank
1. Align fuel tank to top of rear frame and secure
fuel tank right side with (2) 5/16–18 x 22.5 mm
(7/8 in.) bolts, (2) 5/16 lock washers and (2)
5/16 washers (Fig. 10).
2. Torque bolts to 13 NSm (10 ft. lbs.).
3. Secure fuel tank left side to frame with (2)
5/16–18 x 22.5 mm (7/8 in.) studs, (2) 5/16
washers and (2) 5/16 locknuts (Fig. 10).
4. Tighten nuts until stud threads appear just below
nut.
3
2
5. Push fuel line onto fuel tank fitting and secure
with hose clamp (Fig. 11).
1
23
1. Fuel
2.
Hose clamp
Figure 1
line
1
3.
Fuel fitting
4
3
5
6
m–3778
1. Bolt
5/8–18 x 7/8”
(22.5 mm)
2.
Lock washer 5/16
3. W
asher 5/16
m–37711
Figure 10
4. Stud
5. Spring
6. Locknut
17
Page 20
Operation
Think
Safety First
Please carefully read all the safety instructions and
symbols in the safety section. Knowing this
information could help you, pets or bystanders avoid
injury.
Controls
Become familiar with all the controls (Fig. 12) before
you start the engine and operate the machine.
Throttle Control – The throttle control has CHOKE,
FAST, SLOW and STOP positions.
Bail – The bail, in conjunction with the PTO switch,
allows the engine to be started with the PTO
disengaged. With the bail compressed the blade
control (PTO) can be engaged. Release the bail with
the PTO engaged and the engine stops.
Blade Control (PTO) – The blade control lever
(PTO) engages and disengages power to the mower
blades. Move the PTO lever forward to engage the
blades. Pull rearward,all the way, to stop driving
mower blades
Gear Shift Lever – Transmission has five forward
speeds, neutral and reverse, and has an in-line shift
pattern. Do not shift while unit is moving, as
transmission damage may occur.
Recoil Starter – Pull recoil starter handle to start
engine.
Fuel Shut–off Valve – (In fuel line) Close fuel
shut–off valve when transporting or storing mower.
2
7
3
1
4
m–4194
Figure 12
1. Throttle
2. Bail
3.
4.
control
Blade control (PT
Gear shift lever
O)
5.
Upper control bar
6.
Lower control bar
7.
Parking brake lever
5
6
Upper Control Bar – Shift to desired gear and push
forward on control bar to engage forward traction
operation and pull back to brake. Pull right side of
control bar to turn right and left side to turn left.
Lower Control Bar – Shift transmission to reverse
and squeeze the lower control bar and handle together
to engage rearward traction operation.
Parking Brake Lever – Pull back on upper control
bar and swing brake lever up against the upper handle
to keep brake engaged.
18
Page 21
Parking Brake
Always set the parking brake when you stop the
machine or leave it unattended.
Setting the Parking Brake
1. Pull the upper control bar rearward and hold it in
this position (Fig. 13).
2. Lift the parking brake lock up and gradually
release the upper control bar (Fig. 13). The brake
lock should stay in the set (locked) position.
Releasing the Parking Brake
1. Pull rearward on the upper control bar (Fig. 13).
Lower the parking brake lock to the released
position.
Operation
2. Gradually release the upper control bar.
2
Figure 13
1. Upper
control bar
2.
Parking brake lock
1
m–4212
19
Page 22
Operation
Starting
and Stopping
the Engine
Starting
1. Make sure spark plug wire(s) are installed on
spark plug(s) and fuel valve is open.
2. Move the blade control to off, the shift lever to
neutral and set the parking brake.
3. Move the throttle control to CHOKE position
before starting a cold engine.
Note: A warm or hot engine usually does not
require any choking. To start a warm
engine, move throttle control to FAST
position.
4. Grasp recoil starter handle firmly and pull out
until positive engagement results; then pull
handle vigorously to start engine. Allow rope to
recoil slowly.
IMPORTANT: Do not pull recoil rope to its
limit or let go of the starter handle when rope
is pulled out because rope may break or recoil
assembly may be damaged.
Stopping
1. Move the throttle lever to “SLOW” (Fig. 14).
Note: If the engine has been working hard or
is hot, let it idle for a minute before
stopping. This helps cool the engine.
In an emergency, the engine may be
stopped by pulling the throttle all the
way back, past SLOW.
2. To stop the engine pull the throttle all the way
back, past SLOW(Fig. 14).
1
m–4194
Figure 14
1. Blade
control (PT
O) 2.
Throttle lever
2
3. Set the parking brake.
4. Pull wire off spark plug(s) to prevent possibility
of accidental starting before storing machine.
5. Close fuel shut off valve before storing machine.
IMPORTANT: Make sure fuel shut off valve
is closed before transporting or storing
machine, or fuel leakage may occur.
20
Page 23
Operation
Operating
The blade control (PTO) lever engages and
disengages power to the mower blades.
Blade Control (PT
O)
Engaging the Mower Blades (PTO)
1. Pull on the upper control bar to stop the machine
(Fig. 15).
2. Hold the bail against the upper control bar
(Fig. 15).
3. To engage blade(s), push the blade control lever
firmly forward, until it latches going over-center
(Fig. 15).
1
3
2
The
Safety Interlock System
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting if:
• The throttle lever is all the way back, past
SLOW
• The blade control lever (PTO) is engaged
The safety interlock system is also designed to stop
the engine if you released the bail with the PTO
engaged or move the throttle all the way back, past
SLOW.
Testing the Safety Interlock System
Test the safety interlock system before you use the
machine each time. If the safety system does not
operate as described below, have an Authorized
Service Dealer repair the safety system immediately.
Figure 15
1. Upper
2. Bail
control bar
Blade control (PT
3.
O)
Disengaging the Mower Blades (PTO)
1. To disengage the blade(s), pull blade control
lever rearward, all the way (Fig. 15).
Note: It is necessary to fully and manually
disengage mower
.
m–4194
1. Set the parking brake, disengage the PTO and
place the throttle forward. Start the engine. With
the engine running squeeze the bail against upper
control bar and push the mower blade control
lever forward. The mower blades begin rotating.
2. With the engine running, release the bail. The
engine should stop.
3. Start the engine again.
4. With the engine running, move the throttle lever
all the way back, past SLOW. The engine should
stop.
21
Page 24
Operation
Driving
Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place the
throttle control in the “FAST” position for best
performance.
Forward
1. To go forward, move the shift lever to a forward
gear.
2. Release the parking brake: refer to Releasing the
Parking Brake, page 19.
3. Slowly press on the upper control bar to move
forward (Fig. 16).
To go straight, apply equal pressure to both ends of
the upper control bar (Fig. 16).
To turn, release pressure on the upper control bar side
toward the direction you want to turn (Fig. 16).
Backward
1. To go backward, move the shift lever to reverse
gear.
2. Release the parking brake: refer to Releasing the
Parking Brake, page 19.
3. Slowly squeeze on the lower control bar and
handle together to move rearward (Fig. 16).
1. Upper
control bar
Figure 16
2.
1
2
m–4194
Lower control bar
22
Page 25
Operation
Lower
Control Bar Operation
This procedure is for driving up a curb. This can be
performed while driving forward or backward.
1. Disengage the mower blades.
POTENTIAL HAZARD
• A blade can be bent or damaged when
driving up a curb. Blades could break
apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
• Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AV
OID THE HAZARD
• Do not run blades while driving up a curb
forward or backward.
2. Select first gear or reverse to drive machine.
1
2
m–4185
1. Lower
Control Bar
engaged and mower in
reverse.
Stopping
Figure
the Machine
18
2.
Pull up to assist machine
To stop the machine apply the brakes, pull back on
the upper control bar, release the bail and set the
parking brake; refer to Setting the Parking Brake,
page 19.
3. Drive machine until drive wheels contact curb
(Fig. 18).
Note: Both drive wheels should contact the
curb and castor wheels straight.
4. At the same time engage lower control bar and
lift up on handle (Fig. 17 and 18).
Note: Lifting up on handle will assist driving
the machine up a curb and not spin the
drive wheels.
1
1. Lower
(Engaged)
Control Bar
2
Figure 17
2. Handle
m–4192
23
Page 26
Operation
Adjusting
Height-of-Cut
A 25mm to 108mm (1” to 4-1/4”) range for
height-of-cut can be achieved by adjusting blade
spacers, rear axle height and front castor spacers. Use
the Height-of-Cut chart on page 26 to select the
combination required
Adjust Blade Height
Blades are adjusted by using the four, 6.35mm (1/4”)
spacers found on the blade spindle bolts. This allows
a range, in 6.35mm (1/4”) increments, of cutting
height in any axle position. The same number of
blade spacers must be used on all blades to achieve a
level cut (two above and two below, one above and
three below, etc.).
1. Stop engine and remove spark plug wire(s).
2. Hold blade bolt and remove nut. Slide bolt
down, through spindle, and change spacers as
required (Fig. 19).
3. Insert bolt, add extra spacer(s), and secure with
thin washer and nut (Fig. 19).
4. Torque blade bolt to 101–108 NSm
(75–80 ft. lb.).
4
1
3
Adjust Axle Height
Desired height-of-cut range can be obtained by
adjusting the rear axle and placing caster spacers
above or below the caster arm (see chart).
1. Stop engine, remove spark plug wire(s) and belt
guard (Fig. 20).
2. Loosen but do not remove the (2) axle pivot
bolts and the (2) axle adjustment bolts (Fig. 20).
3. Place a jack under the rear center of the engine
frame. Raise the back end of the engine frame up
enough to remove front (2) axle adjustment bolts
(Fig. 20).
4. Raise or lower the engine frame with the jack,so
that front (2) axle adjustment bolts can be
installed in the desired hole location (Fig. 20). A
tapered punch can be used to help align the
holes.
5. Tighten all (4) bolts and lower the unit.
6. Adjust control rods and brake linkages as
required, refer to: Assembly and Brake.
IMPORTANT: It will be necessary to adjust
control rods and brake linkage when
changing axle positions for proper traction
and brake function.
6
5
4
1
2
A
B
C
D
E
2
1. Blade
2. Blade
3.
Cone washer
24
bolt
Figure 19
4. Spacer
5.
6. Nut
Thin washer
m–3779
1. Axle
pivot bolt
Figure 20
2.
m–3825
Axle adjustment bolt
Page 27
Operation
Adjust Caster Position
1. Using the height-of-cut chart, adjust the caster
spacers to match with the axle hole selected
(Fig. 21).
2. Remove clevis pin, slide castor from support and
change spacers(Fig. 21).
3. Install castor in support and insert clevis
pin(Fig. 21).
1. Clevis
2.
pin
5 mm (3/16”) spacer
2
Figure 21
3.
1
3
m–3791
13 mm (1/2”) spacer
25
Page 28
Operation
Height-of-Cut
Axle
Position
A 0 0 26mm (1”)
A 0 1
A 1 0
B 0 1
B 1 0
B 1 1
B 2 0
13mm
(1/2″)
Chart
No.
of Spacers
Below Caster
5 mm
(3/16″)
Number of 6mm (1/4″)Blade Spacers Below Spindle
4 3210
29mm
(1–1/8”)
35mm
(1–3/8”)
35mm
(1–3/8”)
42mm
(1–5/8”)
45mm
(1–3/4”)
51mm
(2”)
32mm
(1–1/4”)
35mm
(1–3/8”)
42mm
(1–5/8”)
42mm
(1–5/8”)
48mm
(1–7/8”)
51mm
(2”)
57mm
(2–1/4”)
39mm
(1–1/2”)
42mm
(1–5/8”)
48mm
(1–7/8”)
48mm
(1–7/8”)
54mm
(2–1/8”)
57mm
(2–1/4”)
64mm
(2–1/2”)
45mm
(1–3/4”)
48mm
(1–7/8”)
54mm
(2–1/8”)
54mm
(2–1/8”)
61mm
(2–3/8”)
64mm
(2–1/2”)
70mm
(2–3/4”)
51mm
(2”)
54mm
(2–1/8”)
61mm
(2–3/8”)
61mm
(2–3/8”)
67mm
(2–5/8”)
70mm
(2–3/4”)
76mm
(3”)
C 1 1
C 2 0
C 2 1
C 3 0
D 2 1
D 3 0
D 3 1
D 4 0
E 3 1
E 4 0
48mm
(1–7/8”)
54mm
(2–1/8”)
57mm
(2–1/4”)
64mm
(2–1/2”)
61mm
(2–3/8”)
64mm
(2–1/2”)
70mm
(2–3/4”)
76mm
(3”)
73mm
(2–7/8”)
79mm
(3–1/8”)
54mm
(2–1/8”)
61mm
(2–3/8”)
64mm
(2–1/2”)
70mm
(2–3/4”)
67mm
(2–5/8”)
70mm
(2–3/4”)
76mm
(3”)
82mm
(3–1/4”)
79mm
(3–1/8”)
86mm
(3–3/8”
61mm
(2–3/8”)
67mm
(2–5/8”)
70mm
(2–3/4”)
76mm
(3”)
73mm
(2–7/8”)
76mm
(3”)
82mm
(3–1/4”)
89mm
(3–1/2”)
86mm
(3–3/8”)
92mm
(3–5/8”)
67mm
(2–5/8”)
73mm
(2–7/8”)
76mm
(3”)
82mm
(3–1/4”)
79mm
(3–1/8”)
82mm
(3–1/4”)
89mm
(3–1/2”)
95mm
(3–3/4”)
92mm
(3–5/8”)
98mm
(3–7/8”)
73mm
(2–7/8”)
79mm
(3–1/8”)
82mm
(3–1/4”)
89mm
(3–1/2”)
86mm
(3–3/8”)
89mm
(3–1/2”)
95mm
(3–3/4”)
102mm
(4”)
98mm
(3–7/8”)
105mm
(4–1/8”)
E 4 1
26
82mm
(3–1/4”)
89mm
(3–1/2”)
95mm
(3–3/4”)
102mm
(4”)
108mm
(4–1/4”)
Page 29
Maintenance
Service
Service Operation
Oil—check level
Oil—change* Initial X X
Oil Filter–change (200 hours or every
other oil change)
Safety System—check
Brakes—check X X
Cutting Blades – check
Wheel Bearings—grease*
T
ransmission Couplers – grease*
Idler Pivots – grease*
Blade Belt Idler Pivot – grease*
Foam Air Cleaner—service*
Paper Air Cleaner—replace*
Spark Plug(s)—check
Belts—check for wear/cracks
PT
O Belt—check tension
Gasoline—drain X
Engine—clean cooling system
Fuel Filter—replace
T
ires—check pressure
Chipped Surfaces—paint
Interval Chart
Each
Use8Hours25Hours50Hours
X X
X X
X X X
X X
X X
X X
X X
X X
X X
Initial X X
X X X
X X
100
Hours
X X
200
Hours
X X
X X
X X
Storage
Service
X
*
More often in dusty
, dirty conditions
27
Page 30
Maintenance
Air
Cleaner
Service Interval/Specification
Foam Element: Clean and re-oil after every 25
operating hours.
Paper Element: Replace after every 100 operating
hours.
Note: Service the air cleaner more frequently
(every few hours) if operating
conditions are extremely dusty or
sandy.
Removing the Foam and Paper Elements
1. Disengage the blade control (PTO) and set the
parking brake.
2. Clean around the air cleaner to prevent dirt from
getting into the engine and causing damage.
Unscrew the cover nut and remove the air
cleaner cover (Fig. 22).
3. Remove the air cleaner assembly (Fig. 22).
4. Carefully slide the foam element off the paper
element (Fig. 22).
Cleaning the Foam and Paper Elements
1. Foam Element
A. Wash the foam element in liquid soap and
warm water. When the element is clean,
rinse it thoroughly.
B. Dry the element by squeezing it in a clean
cloth.
C. Put one or two ounces of oil on the element
(Fig. 23). Squeeze the element to distribute
the oil.
IMPORTANT: Replace the foam element if it
is torn or worn.
2
1
m–1213
Figure 23
1. Foam
element
2. Oil
1. Cover
2.
Wing nut
3.
Foam element
28
1
4
5
and nut
Figure 22
4. W
5.
6.
2
3
6
m–2595
asher and grommet
Paper element
Air cleaner base
Page 31
Maintenance
2. Paper Element
A. Lightly tap the element on a flat surface to
remove dust and dirt (Fig. 24).
B. Inspect the element for tears, an oily film,
and damage to the rubber seal.
IMPORTANT: Never clean the paper element
with pressurized air or liquids, such as
solvent, gas, or kerosene. Replace the paper
element if it is damaged, defective, or cannot
be cleaned thoroughly.
Engine
Oil
Service Interval/Specification
Change oil:
• After the first 8 operating hours.
• After every 100 operating hours.
Note: Change oil more frequently when
operating conditions are extremely
dusty or sandy.
Oil Type: Detergent oil (API service SF, SG or SH)
Crankcase Capacity: w/filter, 2 qt. (1.9 l)
Viscosity: See table below
1
USE THESE SAE VISCOSITY OILS
2
m–1213
Figure 24
1. Paper
element
2.
Rubber seal
Installing the Foam and Paper Elements
1. Installing the Foam and Paper Elements
IMPORTANT: To prevent engine damage,
always operate the engine with the complete
foam and paper air cleaner assembly
installed.
1. Carefully slide the foam element onto the paper
air cleaner element (Fig. 22).
2. Place the air cleaner assembly onto the air
cleaner base (Fig. 22).
5W–20, 5W–30
–20 0 20
°
F
–30°–20 –10
C
10W–30, 10W–40
40 60
32
01020
80 100
30 40
3. Install the air cleaner cover and secure with
cover nuts (Fig. 22).
29
Page 32
Maintenance
Checking Oil Level
1. Park the machine on a level surface, disengage
the blade control (PTO) and set the parking.
2. Clean around the oil dipstick (Fig. 25) so dirt
cannot fall into the filler hole and damage the
engine.
3. Unscrew the oil dipstick and wipe the metal end
clean (Fig. 25).
4. Slide the oil dipstick fully into the filler tube, do
not thread onto tube (Fig. 25). Pull the dipstick
out and look at the metal end. If oil level is low,
slowly pour only enough oil into the filler tube
to raise the level to the “FULL” mark.
IMPORTANT: Do not overfill the crankcase
with oil because the engine may be damaged.
1
2
Changing/Draining Oil
1. Start the engine and let it run five minutes. This
warms the oil so it drains better.
2. Park the machine so that the drain side is slightly
lower than the opposite side to assure the oil
drains completely. Then disengage the blade
control (PTO), set the parking brake, and turn
the ignition key to “OFF” to stop the engine.
Remove the key.
3. Place a pan below the oil drain. Remove the oil
drain plug (Fig. 26).
4. When oil has drained completely, install the oil
drain plug.
Note: Dispose of the used oil at a certified
recycling center.
1. Oil
2.
Metal end
3
dipstick
Figure 25
3.
Filler tube
1
m–3816
Figure 26
1. Oil
drain cap
5. Slowly pour approximately 80% of the specified
amount of oil specified, page 29, into the filler
tube (Fig. 25). Now check the oil level; refer to
Checking Oil Level, page 30. Slowly add
additional oil to bring to “FULL” mark on
dipstick.
30
Page 33
Maintenance
Change Oil Filter
Service Interval/Specification
Replace the oil filter every 200 hours or every other
oil change.
Note: Change oil filter more frequently when
operating conditions are extremely
dusty or sandy.
1. Drain the oil from the engine; refer to
Changing/Draining Oil, page 30.
2. Remove the old filter and wipe the filter adapter
(Fig. 27) gasket surface.
3. Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 27).
2
Tire
Pressure
Service Interval/Specification
Maintain the air pressure in the front and rear tires as
specified. Check the pressure at the valve stem after
every 50 operating hours or monthly, whichever
occurs first (Fig. 28). Check the tires when they are
cold to get the most accurate pressure reading.
Pressure: 103 kPa (15 psi) rear tires
172–207 kPa (25–30 psi) castor tires
1
3
1. Oil
filter
2. Gasket
Figure 27
3. Adapter
1
m–1256
4. Install the replacement oil filter to the filter
adapter. Turn the oil filter clockwise until the
rubber gasket contacts the filter adapter, then
tighten the filter an additional 3/4 turn (Fig. 27).
5. Fill the crankcase with the proper type of new
oil; refer to Changing/Draining Oil, page 30.
Figure 28
Cleaning
1. Valve
the Cooling System
stem
Service Interval/Specification
Before each use, check and clean engine cooling
system. Remove any build–up of grass, dirt or other
debris from the cylinder and cylinder head cooling
fins, air intake screen on flywheel end, and
carburetor–governor levers and linkage. This will
help insure adequate cooling and correct engine speed
and will reduce the possibility of overheating and
mechanical damage to the engine.
31
Page 34
Maintenance
Spark
Plug
Service Interval/Specification
Check the spark plug(s) after every 200 operating
hours. Make sure the air gap between the center and
side electrodes is correct before installing the spark
plug. Use a spark plug wrench for removing and
installing the spark plug(s) and a gapping tool/feeler
gauge to check and adjust the air gap. Install a new
spark plug(s) if necessary.
Type: Champion RC12YC (or equivalent) Air Gap:
1.02 mm (0.040 in.).
Removing the Spark Plug(s)
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
2. Pull the wire(s) off the spark plug(s) (Fig. 29).
Now clean around the spark plug(s) to prevent
dirt from falling into the engine and potentially
causing damage.
Checking the Spark Plug
1. Look at the center of the spark plug(s) (Fig. 30).
If you see light brown or gray on the insulator,
the engine is operating properly. A black coating
on the insulator usually means the air cleaner is
dirty.
IMPORTANT: Never clean the spark plug(s).
Always r
a black coating, worn electrodes, an oily film,
or cracks.
2. Check the gap between the center and side
electrodes (Fig. 30). Bend the side electrode
(Fig. 30) if the gap is not correct.
2
eplace the spark plug(s) when it has:
3
1
1.02
mm
(0.040 in.)
3. Remove the spark plug(s) and metal washer.
1
Figure 29
1. Spark
plug wire
2.
Spark plug
m–3817
1. Center
2.
Side electrode
Figure
electrode insulator
30
3.
Air gap (not to scale)
Installing the Spark Plug(s)
2
1. Install the spark plug(s) and metal washer. Make
sure the air gap is set correctly.
2. Tighten the spark plug(s) to 27 NSm (20 ft-lb).
3. Push the wire(s) onto the spark plug(s) (Fig. 29).
32
Page 35
Maintenance
Cutting
Blades
To ensure a superior quality of cut, keep the blades
sharp. For convenient sharpening and replacement,
you may want to keep extra blades on hand.
POTENTIAL HAZARD
• A blade that is worn or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
• Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AV
OID THE HAZARD
• Periodically inspect the blade for wear and
damage. Immediately install a new blade if
it is worn or damaged.
Inspecting the Blades
1. Inspect the cutting edges (Fig 31). If the edges
are not sharp or have nicks, remove and sharpen
the blades. Refer to Sharpening the Blades on
page 35.
2. Inspect the blades, especially the curved area
(Fig. 31). If you notice any damage, wear, or a
slot forming in this area (item 3 in Fig. 31),
immediately install a new blade.
2
1
3
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the
blade control (PTO) and set the parking brake.
1. Cutting
2.
Curved Area
Edge
Figure 31
3. W
m–151
ear/slot Forming
33
Page 36
Maintenance
Checking for Bent Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 32). Measure from a level
surface to the cutting edge of the blades
(Fig. 33). Note this dimension.
Front
POTENTIAL HAZARD
• A blade that is bent or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
• Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
A
B
1666
Figure 32
Figure
33
m–2558
2. Rotate the opposite ends of the blades forward.
Measure from a level surface to the cutting edge
of the blades at the same position as in step 1
above. The difference between the dimensions
obtained in steps 1 and 2 must not exceed 3 mm
(1/8”). If this dimension exceeds 3 mm (1/8”),
the blade is bent and must be replaced. Refer to
Removing the Blades, and Installing the Blades
on page 35.
HOW TO AV
•
Always r
OID THE HAZARD
eplace bent or damaged blade with
a new blade.
• Never file or create sharp notches in the
edges or surfaces of blade.
Removing the Blades
Blades must be replaced if a solid object is hit, if the
blade is out of balance or is bent. To ensure optimum
performance and continued safety conformance of the
machine, use genuine TORO replacement blades.
Replacement blades made by other manufacturers
may result in non-conformance with safety standards.
Hold the blade bolt with a wrench. Remove the nut,
blade bolt, cone washer, blade, spacers and thin
washer from the spindle (Fig. 34).
4
1
3
6
5
4
34
2
1. Blade
2. Blade
3.
Cone washer
bolt
Figure 34
4. Spacer
5.
6. Nut
m–3779
Thin washer
Page 37
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both
ends of the blade (Fig. 35). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
2
1
m–1854
Figure 35
1. Sharpen
2. Check the balance of the blade by putting it on a
at original angle
2. Sail
blade balancer (Fig. 36). If the blade stays in a
horizontal position, the blade is balanced and can
be used. If the blade is not balanced, file some
metal off the end of the sail area only (Fig. 35).
Repeat this procedure until the blade is balanced.
Maintenance
2
1
Figure 36
1. Blade 2. Balancer
m–1855
Installing the Blades
1. Place the blade onto the bolt, over cone washer.
Select proper number of spacer(s) for
height-of-cut and slide bolt into spindle
(Fig. 34).
IMPORTANT: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.
2. Install remaining spacer(s) and secure with thin
washer and nut (Fig. 34).
3. Torque the blade bolt to 101–108 NSm
(75–80 ft. lb.).
35
Page 38
Maintenance
Greasing
and Lubrication
Service Interval/Specification
Grease the areas shown and at intervals in Where to
Add Grease section below. Grease more frequently
when operating conditions are extremely dusty or
sandy.
Grease Type: General-purpose grease.
How to Grease
1. Disengage the blade control (PTO) and set the
parking brake.
2. Clean the grease fittings with a rag. Make sure to
scrape any paint off the front of the fitting(s).
3. Connect a grease gun to the fitting. Pump grease
into the fittings until grease begins to ooze out of
the bearings.
2. Lubricate the transmission couplers every 50
hours and idler arm pivots every 8 hours
(Fig 38).
1
2
Figure 38
1. Idler
Arm Pivots
(Lubricate after 8 hours)
2. T
ransmission Couplers
(Lubricate after 50 hours)
3. Lubricate the blade belt idler arm pivot.
(Fig. 39). Lubricate every 50 hours.
m–3797
4. Wipe up any excess grease.
Where to Add Grease
1. Lubricate the drive and castor wheel bearings
and front spindles (Fig. 37). Lubricate every 8
hours.
m–3780
Figure 37
m–4749
Figure 39
36
Page 39
Maintenance
Brake
Service Interval/Specification
Before each use, check brakes for proper operation.
Always set the parking brake when you stop the
machine or leave it unattended. If the parking brake
does not hold securely, an adjustment is required.
Checking the Brake
1. Park the machine on a level surface, disengage
the blade control (PTO) and set the parking
brake.
2. Rear wheels must lock when you try to push the
machine forward or backward. Adjustment is
required if the wheels turn and do not lock; refer
to Adjusting the Brake, page 37.
3. Release the brake and press upper control bar
very lightly, approximately 13 mm (1/2 in.),
wheels should rotate freely.
4. If both conditions are met, no adjustment is
required.
Adjusting the Brake
The brake lever is on the upper control bar (Fig. 12).
If the parking brake does not hold securely, an
adjustment is required.
1. Remove belt guard.
2. Check the brake before you adjust it; refer to
Checking the Brake, page 37.
3. Release the parking brake; refer to Releasing the
Parking Brake, page 19.
4. To adjust brake set the parking brake latch, and
rotate the wing nuts on the brake rods (Fig. 40).
Clockwise to tighten the brake and
counterclockwise to loosen the brake.
Note: Control bar should be parallel with
reference bar when properly adjusted.
5. Check the brake operation again; refer to
Checking the Brake, page 37.
IMPORTANT: With the parking brake
released, the rear wheels must rotate freely
when you push the mower. If brake action
and free wheel rotation cannot be achieved
contact your service dealer immediately.
1. Brake
2
rod
Figure 40
2.
1
m–3820
Wing nut
37
Page 40
Maintenance
Fuel Tank
Draining The Fuel Tank
POTENTIAL
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AV
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open
area. Wipe up any gasoline that spills.
• Never drain gasoline near an open flame or
where gasoline fumes may be ignited by a
spark.
• Never smoke a cigarette, cigar or pipe.
HAZARD
OID THE HAZARD
4. Pull the fuel line off the fuel filter (Fig. 41).
Open fuel shut-off valve and allow gasoline to
drain into a gas can or drain pan.
Note: Now is the best time to install a new
fuel filter because the fuel tank is
empty. Refer to Replacing the Fuel
Filter; page 39.
5. Install the fuel line onto the fuel filter. Slide the
hose clamp close to the filter to secure the fuel
line.
3
2
1
1. Park the machine on a level surface, to assure
fuel tank drains completely. Then disengage the
blade control (PTO) and set the parking brake.
2. Close the fuel shut–off valve in fuel line
(Fig. 41).
3. Squeeze the ends of the hose clamp together and
slide it up the fuel line away from fuel filter
(Fig. 41).
1. Fuel
2.
Fuel filter
shut-of
f valve
m–3778
Figure 41
3. Clamp
38
Page 41
Maintenance
Fuel
Filter
Service Interval/Specification
Replace the fuel filter after every 200 operating hours
or yearly, whichever occurs first.
Replacing the Fuel Filter
Never install a dirty filter if it is removed from the
fuel line.
1. Disengage the blade control (PTO) and set the
parking brake. Stop engine.
2. Close fuel shut–off valve (Fig. 41).
3. Squeeze the ends of the hose clamps together
and slide them away from the filter (Fig. 42).
4. Remove the filter from the fuel lines.
5. Install a new filter and move the hose clamps
close to the filter.
6. Open fuel shut-off valve at fuel tank (Fig. 41).
Replacing
the Wheel Belt
Service Interval/Specification
Check all belts after every 50 operating hours or
monthly, whichever occurs first. Look for dirt, wear,
cracks and signs of overheating.
1. Remove belt guard.
2. Remove hairpin cotter securing brake rod to
brake arm to relax belt idler tension (Fig. 43).
3. Remove bottom and loosen top bolts of shield to
rotate for belt clearance (Fig. 43).
4. Lift belt past idler and off drive pulley (Fig. 43).
5. Raise wheel off ground enough to allow belt
removal.
Note: Ensure that the mud and grass scraper
is adjusted properly and centered in the
pulley grooves (see page 43). The
pointed part of the scraper should be
centered and as deep in the pulley
groove as possible, without rubbing at
any point.
2
1. Hose
1
clamp
Figure 42
2. Filter
m–3778
6. Replace drive belt.
7. Secure shield with previously removed bolts and
tighten bolts (Fig. 43).
8. Secure brake rod to brake arm with hairpin cotter
(Fig. 43).
1
2
3
4
m–3820
Figure 43
1. Hairpin
2.
cotter
Brake rod
3. Shield
4.
Drive belt
39
Page 42
Maintenance
Replacing
the T
raction Belt
1. Stop the engine, set the parking brake and
remove the spark plug wire(s).
2. Raise the rear of the machine and hold with jack
stands.
3. Remove mower belt (Fig. 47).
4. Loosen pivot bolt enough to slide idler pulley in
slot and remove traction belt from the engine and
drive pulleys.
5. Install new belt around engine and drive pulleys
(Fig. 44).
6. Slide idler pulley in engine frame to tension
traction belt (Fig. 44).
7. Install the mower belt (Fig. 47).
8. Check the belt guides under the engine frame for
proper adjustment (Fig. 44). The distance
between the belt guide and mower belt should be
32mm (1-1/4”) when mower belt is engaged.
Adjust as necessary
. The disengaged belt should
not drag or fall off pulley when guides are
properly adjusted.
1. Idler
2.
Belt guide
4
in slot
1
3
2
m-4726
2
Figure 44
3.
32 mm (1-1/4” )
4.
Mower belt
40
Page 43
Maintenance
Replacing
the Mower Belt
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key and
spark plug wire.
2. Remove the knobs and belt cover on mower.
3. Remove idler pulley and then remove worn belt
(Fig. 45).
4. Install new belt.
5. Install idler pulley.
6. Engage PTO and check belt tension. See
Adjusting Mower Belt Tension, page 42.
Note: Proper belt tension is 4.54–6.8 Kg
(10–15 lbs.) with the belt deflected a
13mm (1/2”) halfway between pulleys
(Fig. 45).
3
2
1
4
5
6
m–3860
Figure 46
1. 2mm–3mm
2. Bellcrank
ransmission output shaft
3. T
(1/16” –1/8”)
4.
Hairpin cotter
5.
Clevis pin
6. Clevis
9. Disengage the PTO. If the assist arm does not
contact the front stop on the mower deck
(Fig. 47), readjust the clevis to bring the
bellcrank closer to the transmission output shaft
(Fig. 46).
(1/2”)
2
13mm
1
Figure 45
1. Belt
(1/2” (13mm)
Deflection)
2.
Idler Pulley
7. Engage PTO lever and check the clearance
between the bellcrank and the transmission
output shaft (Fig. 46). Space should be 2–3mm
(1/16”–1/8”).
8. Remove hairpin cotter and clevis pin from
bellcrank. Rotate clevis clockwise on rod to
increase or counterclockwise to decrease
clearance (Fig. 46).
M-4750
4
5
3
2
1
m-4739
Figure 47
1. 1/2”
(13 mm) deflection
here
2.
Assist arm
3.
Front stop
4. Locknut
5. Turnbuckle
10. Check the belt guide under the engine frame for
proper adjustment (Fig. 44). The distance
between the belt guide and mower belt should be
32mm (1-1/4”) when mower belt is engaged.
Adjust as necessary
. The disengaged belt should
not drag or fall off pulley when guides are
properly adjusted.
41
Page 44
Maintenance
Adjusting
Mower Belt T
ension
Service Interval/Specification
Check belt tension after the first hour of operation
and at least twice during the first 24 hours of
operation.
IMPORTANT: Belt must be tight enough to not
slip during heavy loads while cutting grass. Over
tensioning will reduce belt and spindle bearing
life.
1. Set the parking brake, and turn the ignition key
to “OFF” to stop the engine. Remove the key
and spark plug wire.
2. Loosen locknut on turnbuckle (Fig. 47).
3. Rotate turnbuckle toward rear of mower to
increase tension on belt. Rotate turnbuckle
toward front of mower to decrease tension on
belt (Fig. 47).
Adjusting
the Blade Brake
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key and
spark plug wire.
2. If necessary, adjust the spring mounting bolts so
that the blade brake pad rubs against the pulley
edges (Fig. 48).
3. Adjust the nut at the end of the blade brake rod
until there is 3mm–5mm (1/8”– 3/16”) between
the nut and spacer (Fig. 48).
4. Engage the blades. Ensure the blade brake pad
no longer contacts the pulley edges.
3
Note: The eyebolt threads on both ends of the
turnbuckle should be engaged a
minimum of 8mm (5/16”).
1. Spring
2.
Blade brake pad
mounting bolts
2
Figure 48
3.
3mm–5mm (1/8”–3/16”)
m–47271
42
Page 45
Maintenance
Adjusting
Grass\Mud Scraper
1. Remove belt guard.
2. Loosen the locknut holding scraper to the engine
frame (Fig. 49).
3. Rotate scraper until they align with center of
pulley grooves (Fig. 49).
4. Tighten the locknut (Fig. 49).
Note: The scraper must not contact the pulley
on the sides or bottom of grooves.
Re-adjust if necessary
2
.
3
Replacing
the Grass Deflector
1. Remove the locknut, bolt, spring and spacer
holding deflector to the mounts (Fig. 50).
2. Straighten deflector mounts if they are bent
(Fig. 50).
3. Install new deflector between mounts with
spacer and spring. Place spacer through spring
and hook the front end of the spring around the
front deflector mount. Insert bolt through mounts
and spacer
. Secure with locknut. Confirm there
is downward spring force on deflector (Fig. 50).
4. Tighten the bolt and locknut until they lightly
contact the pivot brackets (Fig. 50).
IMPORTANT: The grass deflector must be
spring-loaded in the down position. Lift the
deflector up to test that it snaps to the full
down position.
6
3
1. Scraper
2. Locknut
1
m–3821
Figure 49
3. Pulley
5
4
1. Deflector
2. Bolt
3. Deflector
mount
1
Figure 50
4. Spring
5. Spacer
6. Locknut
2
m–3781
43
Page 46
Maintenance
Wiring
J3
J4
WIRE LIST
DESIG. AWG COLOR ROUTE
W1 16 WHITE J3 J1
W2 16 BLUE P1-1 J4
W3 16 BLACK P1-2 J2
Diagram
W2
W1
1
P1 PTO
J1
KILL
W3
2
J2
GND
44
Page 47
Maintenance
Cleaning and Storage
1. Disengage the blade control (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially
the engine. Clean dirt and chaff from the outside
of the engine’s cylinder head fins and blower
housing.
IMPORTANT: You can wash the machine
with mild detergent and water. Do not
pressure wash the machine. A
use of water, especially near the control panel,
and engine.
3. Check the brake; refer to Brake, page 37.
4. Service the air cleaner; refer to Air Cleaner,
page 28.
5. Grease the machine; refer to Greasing and
Lubrication, page 36.
6. Change the crankcase oil; refer to Engine Oil,
page 29.
void excessive
9. For storage over 30 days, prepare the traction
unit as follows.
A. Add a petroleum based
stabilizer/conditioner to fuel in the tank.
Follow mixing instructions from stabilizer
manufacturer. (1 oz. per gallon). Do not use
an alcohol based stabilizer (ethanol or
methanol).
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh
gasoline and used at all times.
B. Run the engine to distribute conditioned
fuel through the fuel system (5 minutes).
C. Stop the engine, allow it to cool and drain
the fuel tank; refer to Draining Fuel Tank,
page 38.
D. Restart the engine and run it until it stops.
E. Choke or prime the engine.
F. Start and run the engine until it will not
start again. Use the primer, if equipped on
machine, several times to ensure no fuel
remains in primer system.
7. Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 32. With the
spark plug(s) removed from the engine, pour two
tablespoons of engine oil into the spark plug
hole. Now use the starter to crank the engine and
distribute the oil inside the cylinder. Install the
spark plug(s). Do not install the wire on the
spark plug(s).
8. Check the tire pressure; refer to Tire Pressure,
page 31.
G. Dispose of fuel properly. Recycle as per
local codes.
IMPORTANT: Do not store
stabilizer/conditioned gasoline over 90 days.
10. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged or
defective.
11. Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service
Dealer.
12. Store the machine in a clean, dry garage or
storage area. Remove the key from the ignition
switch and keep it in a memorable place. Cover
the machine to protect it and keep it clean.
45
Page 48
Troubleshooting
g
g
g
PROBLEM
Engine will not start, starts hard, or
fails to keep running.
Engine loses power
.
POSSIBLE CAUSES
1.
Fuel tank is empty
2.
Choke is not ON.
3.
Air cleaner is dirty
4.
Spark plug wire is loose or
disconnected.
5.
Spark plug is pitted, fouled, or
gap is incorrect.
6.
Dirt in fuel filter
7.
Dirt, water
fuel system.
1.
Engine load is excessive.
2.
Air cleaner is dirty
3.
Oil level in crankcase is low
4.
Cooling fins and air passages
under engine blower housing
are plugged.
5.
Spark plug is pitted, fouled, or
gap is incorrect.
, or stale fuel is in
. 1.
. 3.
. 6.
. 2.
2.
4.
5.
7.
1.
. 3.
4.
5.
CORRECTIVE ACTION
Fill fuel tank with gasoline.
Move choke lever to ON.
Clean or replace air cleaner
element.
Install wire on spark plug.
Install new
spark plug.
Replace fuel filter
Contact Authorized Service
Dealer.
Reduce ground speed.
Clean air cleaner element.
Add oil to crankcase.
Remove obstruction from
cooling fins and air passages.
Install new
spark plug.
, correctly gapped
.
, correctly gapped
Engine overheats.
Abnormal vibration.
6. V
ent hole in fuel cap is
plugged.
7.
Dirt in fuel filter
8.
Dirt, water
fuel system.
1.
Engine load is excessive.
2.
Oil level in crankcase is low
3.
Cooling fins and air passages
under engine blower housing
are plugged.
1.
Engine mounting bolts are
loose.
2.
Loose engine pulley
pulley
, or blade pulley
3.
Engine pulley is damaged.
. 7.
, or stale fuel is in
, idler
.
6.
8.
1.
. 2.
3.
1. T
2. T
3.
Clean or replace the fuel cap.
Replace fuel filter
Contact Authorized Service
Dealer.
Reduce ground speed.
Add oil to crankcase.
Remove obstruction from
cooling fins and air passages.
ighten engine mounting
bolts.
ighten the appropriate
pulley.
Contact Authorized Service
Dealer.
.
46
Page 49
Troubleshooting
gg
gg
PROBLEM
Machine does not drive.
Abnormal vibration.
Uneven cutting height.
POSSIBLE CAUSES
1.
Shift lever is in NEUTRAL.
2. T
raction belt is worn, loose or
broken.
3. T
raction belt is of
1.
Cutting blade(s) is/are bent or
unbalanced.
2.
Blade mounting bolt is loose.
3.
Engine mounting bolts are
loose.
4.
Loose engine pulley
pulley
, or blade pulley
5.
Engine pulley is damaged.
6.
Blade spindle bent.
1.
Blade(s) not sharp.
2.
Cutting blade(s) is/are bent.
f pulley
. 3.
, idler
.
CORRECTIVE ACTION
1.
Move shift lever to a drive
gear position.
2.
Change Belt.
Change Belt.
1.
Install new cutting blade(s).
2. T
ighten blade mounting bolt.
3. T
ighten engine mounting
bolts.
4. T
ighten the appropriate
pulley.
5.
Contact Authorized Service
Dealer.
6.
Contact Authorized Service
Dealer.
1.
Sharpen blade(s).
2.
Install new cutting blade(s).
Blades do not rotate.
Blades do not stop when
disengaged.
3.
Mower is not level.
4.
Underside of mower is dirty
5. T
ire pressure is incorrect.
6.
Blade spindle bent.
1.
Drive belt is worn, loose or
broken.
2.
Drive belt is of
3.
Deck belt is worn, loose or
broken.
4.
Deck belt is of
1.
Blade brake is not adjusted
properly.
f pulley
f pulley
3.
. 4.
5.
6.
1.
. 2.
3.
. 4.
1.
Level mower from
side-to-side and front-to-rear.
Clean the underside of the
mower.
Adjust tire pressure.
Contact Authorized Service
Dealer.
Check belt tension.
Install drive belt and check
adjusting shafts and belt
guides for correct position.
Install new deck belt.
Install deck pulley and check
the idler pulley
spring for correct position and
function.
Adjust blade brake.
, idler arm and
2.
Belt guide is not set properly
. 2.
Adjust belt guide.
47
Page 50
Page 51
Page 52
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