Toro 30326, 30327 Operator's Manual

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Page 1

Form No. 3354-442 Rev A

Mid-Size, T-bar, Gear, 15hp or 17hp with 44in Side Discharge Mower

Model No. 30326 —Serial No. 260000001 and Up Model No. 30327 —Serial No. 260000001 and Up

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Warning

CALIFORNIA

Pr oposition 65 W ar ning

T he engine exhaust fr om this pr oduct contains chemicals kno wn to the State of Calif or nia to cause cancer , bir th defects, or other r epr oducti v e har m.

T his spark ignition system complies with Canadian ICES-002

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

T he enclosed Engine Owner’ s Man ual is supplied f or inf or mation r egarding the US En vir onmental Pr otection Agency (EP A) and the Calif or nia Emission Contr ol R egulation of emission systems, maintenance, and w ar ranty . R eplacements may be order ed thr ough the engine man uf actur er .

Introduction

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

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

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

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Mo w er Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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1 R emo ving the Shipping

Brac k et and Shipping

W ashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Installing the Handle

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Installing the Fuel T ank . . . . . . . . . . . . . . . . . . . 13

4 Chec king and Adjusting the Shift

Lev er Plate . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Installing the Control R ods . . . . . . . . . . . . . . 14

6 Installing the Hair pin Cotter Pins

and Spacers . . . . . . . . . . . . . . . . . . . . . . . 15

7 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 16

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

R ecommended Gasoline . . . . . . . . . . . . . . . . . . . . 19

Chec king the Engine Oil Lev el . . . . . . . . . . . 20

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Using the P arking Brak e . . . . . . . . . . . . . . . . . . . . . 20

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operating the Mo w er P o w er T ak e

Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . 21

T he Safety Interloc k System . . . . . . . . . . . . . . . 22

Dri ving F orw ard or Bac kw ard . . . . . . . . . . . . 22

Using the Lo w er Control Bar . . . . . . . . . . . . . 23

Stopping the Mac hine . . . . . . . . . . . . . . . . . . . . . . . . 24

T ranspor ting Mac hines . . . . . . . . . . . . . . . . . . . . . . 24

Side Disc harging or Mulc hing the

Grass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Adjusting the Height-of-Cut . . . . . . . . . . . . . . 24

Adjusting the Gag e W heels . . . . . . . . . . . . . . . . 25

Adjusting the Handle Height . . . . . . . . . . . . . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Ho w to Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Lubricating the Caster and W heel

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Greasing the T ransmission

Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Greasing the PTO Dri v e Belt Idler

and Dec k Belt Idler . . . . . . . . . . . . 28

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 28

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 30

Ser vicing the Spark Plugs . . . . . . . . . . . . . . . . . . . 31

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Draining the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 32

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 33

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 34

R e placing the Caster W heel F ork

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Ser vicing the Caster W heel and

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting the Electric Clutc h . . . . . . . . . . . . . 35

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 36

Cleaning the Air Intak e Screen . . . . . . . . . . . 36

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Ser vicing the Brak es . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

R e placing the T raction Dri v e

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

R e placing the T ransmission

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

R e placing the Mo w er Belt . . . . . . . . . . . . . . . . . . 38

R e placing the PTO Dri v e Belt . . . . . . . . . . . . 38

Mo w er Dec k Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ser vicing the Cutting Blades . . . . . . . . . . . . . . . 39

Cor recting the Mo w er Quality of

Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the F rame . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chec king the Mo w er Dec k

F ront-to-R ear Pitc h . . . . . . . . . . . 43

Changing the Dec k F ront-to-R ear

Pitc h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chec king the Dec k Side-to-Side

Lev eling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Changing the Side-to-Side

Lev eling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Matc hing Height of Cut . . . . . . . . . . . . . . . . . . . . . 45

R e placing the Grass Deﬂector . . . . . . . . . . . . 45

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cleaning and Storag e . . . . . . . . . . . . . . . . . . . . . . . . . 47

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Safety

Note: T he addition of attac hments made b y

other man ufacturers that do not meet American National Standards Institute cer tiﬁcation will cause noncompliance of this mac hine .

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol

, whic h means CA UTION , W ARNING , or D ANGER-“personal safety instr uction." F ailure to comply with the instr uction ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from ANSI standard B71.4-2004.

• Use extra care when handling g asoline and other fuels . T hey are ﬂammable and v apors are explosi v e .

– Use only an appro v ed container

– Nev er remo v e g as cap or add fuel with

engine r unning . Allo w engine to cool before refueling . Do not smok e .

– Nev er refuel or drain the mac hine indoors .

• Chec k that operator’ s presence controls , safety switc hes and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

Operation

• Nev er r un an engine in an enclosed area.

• Only operate in g ood light, k ee ping a w a y from

holes and hidden hazards .

Training

• R ead the Operator’ s Man ual and other training material. If the operator(s) or mec hanic(s) can not read English it is the o wner’ s responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls , and safety signs .

• All operators and mec hanics should be trained. T he o wner is responsible for training the users .

• Nev er let c hildren or untrained people operate or ser vice the equipment. Local regulations ma y restrict the ag e of the operator .

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people or proper ty .

Preparation

• Ev aluate the ter rain to deter mine what accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• W ear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair , loose clothing or jew elr y ma y g et tangled in mo ving par ts .

• Inspect the area where the equipment is to be used and remo v e all objects suc h as roc ks , to ys and wire whic h can be thro wn b y the mac hine .

• Be sure all dri v es are in neutral and parking brak e is eng ag ed before star ting engine . Only star t engine from the operator’ s position.

• Be sure of y our footing while using this mac hine , especially when bac king up . W alk, don ’ t r un. Nev er operate on w et g rass . R educed footing could cause slipping .

• Slo w do wn and use extra care on hillsides . Be sure to tra v el side to side on hillsides . T urf conditions can affect the mac hine’ s stability . Use caution while operating near drop-offs .

• Slo w do wn and use caution when making tur ns and when c hanging directions on slopes .

• Nev er raise dec k with the blades r unning .

• Nev er operate with the PTO shield, or other

guards not securely in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning properly .

• Nev er operate with the disc harg e deﬂector raised, remo v ed or altered, unless using a g rass catc her .

• Do not c hang e the engine g o v er nor setting or o v erspeed the engine .

• Stop on lev el g round, diseng ag e dri v es , eng ag e parking brak e (if pro vided), shut off engine before lea ving the operator’ s position for any reason including emptying the catc hers or unclog ging the c hute .

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• Stop equipment and inspect blades after striking objects or if an abnor mal vibration occurs . Mak e necessar y re pairs before resuming operations .

• K ee p hands and feet a w a y from the cutting unit.

• Look behind and do wn before bac king up to be sure of a clear path.

• K ee p pets and b ystanders a w a y .

• Slo w do wn and use caution when making tur ns

and crossing roads and sidew alks . Stop blades if not mo wing .

• Be a w are of the mo w er disc harg e direction and do not point it at any one .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into or from a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

ser vicing them. Only re place blades . Nev er straighten or w eld them.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• K ee p all par ts in g ood w orking condition and all hardw are tightened. R e place all w or n or damag ed decals .

Toro Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products and other safety infor mation y ou m ust kno w .

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

T his product is designed for cutting and recycling g rass or , when equipped with a g rass bag g er , for catc hing cut g rass . Any use for pur poses other than these could pro v e dang erous to user and b ystanders .

Maintenance and storage

• Diseng ag e dri v es , set parking brak e , stop engine and remo v e k ey or disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting unit, dri v es , m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• Let engine cool before storing and do not store near ﬂame .

• Shut off fuel while storing or transpor ting . Do not store fuel near ﬂames or drain indoors .

• P ark mac hine on lev el g round. Set parking brak e . Nev er allo w untrained personnel to ser vice mac hine .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect the batter y or remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect the positi v e ﬁrst and neg ati v e last.

General Operation

• Be sure the area is clear of other people before mo wing . Stop the mac hine if any one enters the area.

• Do not touc h equipment or attac hment par ts whic h ma y be hot from operation. Allo w to cool before attempting to maintain, adjust or ser vice .

• Use only T oro appro v ed attac hments . W ar ranty ma y be v oided if used with unappro v ed attac hments .

• Chec k carefully for o v erhead clearances (i.e . branc hes , doorw a ys , electrical wires) before operating under any objects and do not contact them.

Slope Operation

All slopes and ramps require extra caution. If y ou feel uneasy on a slope , do not mo w it.

• R emo v e obstacles suc h as roc ks , tree limbs , etc . from the mo wing area.

• W atc h for holes , r uts or bumps . T all g rass can hide obstacles .

• Use care when c hec king blades . W rap the blade(s) or w ear glo v es , and use caution when

• Use caution near drop-offs , ditc hes , or embankments . T he mac hine could suddenly

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tur n o v er if a wheel g oes o v er the edg e of a cliff or ditc h, or if an edg e ca v es in.

• Use extra care with g rass catc hers or other attac hments . T hese can c hang e the stability of the mac hine .

• K ee p all mo v ement on slopes slo w and g radual. Do not mak e sudden c hang es in speed or direction.

• Mo w slopes side to side .

• Do not mo w slopes g reater than 15 deg rees .

Service

• Nev er store the mac hine or fuel container inside where there is an open ﬂame , suc h as near a w ater heater or fur nace .

• K ee p n uts and bolts tight, especially the blade attac hment bolts . K ee p equipment in g ood condition.

• Nev er tamper with safety devices . Chec k safety systems for proper operation before eac h use .

• Use only g en uine re placement par ts to ensure that original standards are maintained.

• Chec k brak e operation frequently . Adjust and ser vice as required.

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Slope Chart

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Safety and Instructional Decals

82- 2280

REVERSE  TRACTION DRIVE

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

43-8480

66-1340

67-5360

68-8340

82-2280

52-2010

82-2290

Page 9

104-8186

93-1122

95-2814

106-0699

98-0776

1. Warning—wear hearing protection.

98-3256

98-4387

106-5505

Page 10

106-5532

105-0884

106-0635

106-5499

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Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

1 2

No parts required

Handle assembly Flanged bolt, (3/8 x 1 inch) Flange nut, (3/8 inch) Fuel tank with studs installed Bolt, (5/16 x 7/8 inch) Lock nut, (5/16 inch) Washer, (5/16 inch) Hose clamp Lock washer, (5/16 inch) Spring

No parts required

Control rods Cotter pin Clevis Pin Washer Hairpin cotter pin Hairpin cotter pin Spacers 6 Operator’s Manual Engine Operator’s Manual Parts Catalog Safety Video Registration Card Oil drain hose

Description

Qty.

–

1 4 4 1 2 2 4 1 2 2

–

2 2 2 2 2 2

1 1 1 1 1 1

Remove the shipping bracket and shipping washers.

Install the handle assembly.

Install the fuel tank.

Check and adjust the shift lever plate.

Install the control rods.

Install the hairpin cotter pins and spacers.

Read the Operator’s Manual and watch the video before operating the machine.

Use

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

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Step

Removing the Shipping Bracket and Shipping Washers

No Parts Required

Procedure

1. R emo v e the center g ag e wheel n ut, 2 larg e w ashers , angle brac k et and 1 small w asher ( Figure 3 ). Discard the 2 larg e w ashers and the angle brac k et.

1. Center Gage Wheels and Spacer

2. Nut 5. Spacer

3. Bolt

Step

Installing the Handle

Figure 4

4. Washer

Figure 3

1. Center Gage Wheels and Spacer

2. Nut

3. Large washer-discard

2. Install the center g ag e wheels with the previously remo v ed bolt, spacer , small w asher , and n ut ( Figure 4 ).

4. Angle bracket-discard

5. Small washer

Assembly

Parts needed for this step:

Handle assembly

Flanged bolt, (3/8 x 1 inch)

Flange nut, (3/8 inch)

Procedure

1. Align handle with upper mounting holes in rear frame ( Figure 5 ).

2. Secure the handle at eac h upper mounting hole with a ﬂang e bolt (3/8 x 1 inc h) and ﬂang e n ut ( Figure 5 ).

3. Select the lo w position for the lo w er mounting hole ( Figure 5 ).

4. Secure the handle at eac h lo w er mounting hole with a ﬂang e bolt (3/8 x 1 inc h) and ﬂang e n ut ( Figure 5 ).

Note: T he handle position can be adjusted to matc h the operator’ s height preference .

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Figure 5

1. Upper handle 5. Upper mounting hole

2. Rear frame 6. Lower mounting holes

3. Flange nut, (3/8 inch)

4. Flange bolt, (3/8 x 1 inch)

7. Low position

8. High position

Note: Handle assembly m ust be installed before fuel tank is installed.

Step

Installing the Fuel Tank

Note: Tighten left side of the fuel tank until

it is completely tight and then unscrew loc kn ut one full tur n. T his will allo w the spring to w ork.

Figure 6

1. Bolt, 5/16 x 7/8 inch 4. Stud

2. Lock washer, (5/16 inch)

3. Washer, (5/16 inch)

5. Spring

6. Locknut

Note: R emo v e the plastic cap from the fuel ﬁtting before installing the fuel line .

4. Slide the hose clamp onto the fuel line ( Figure 7 ).

5. Push the fuel line onto the fuel tank connection and secure it with a hose clamp ( Figure 7 ).

Parts needed for this step:

Fuel tank with studs installed

Bolt, (5/16 x 7/8 inch)

Lock nut, (5/16 inch)

Washer, (5/16 inch)

Hose clamp

Lock washer, (5/16 inch)

Spring

Procedure

1. Align fuel tank with the top of the rear frame ( Figure 6 ).

2. Secure the right side of the fuel tank to the rear frame with 2 bolts (5/16 x 7/8 inc h), loc k w ashers (5/16 inc h) and w ashers (5/16 inc h) ( Figure 6 ).

3. Secure the left side of the fuel tank to the rear frame with 2 studs , w ashers (5/16 inc h), springs and loc kn uts (5/16 inc h) ( Figure 6 ).

Figure 7

1. Fuel line 3. Fuel tting

2. Hose clamp

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Step

Checking and Adjusting the Shift Lever Plate

No Parts Required

Procedure

1. Shift lev er to second g ear and c hec k alignment of lev er in slot of shift lev er plate . T he clearance betw een top and bottom of the shift lev er should be equal ( Figure 8 ).

Figure 9

1. Shift lever in 2nd gear 3. Shift lever in neutral position

2. Shift lever plate 4. Equal distance

Figure 8

1. Shift lever 4. Square hole washer

2. Shift lever plate 5. Spring washer

3. Rubber seal washer 6. Locknut, 3/8 inch

2. If clearance is not cor rect, remo v e lev er and bend it slightly to adjust ( Figure 8 ).

Note: Do not bend lev er while it is attac hed to the transmission shaft or damag e ma y occur .

3. Shift lev er to neutral and c hec k alignment of lev er in slot of shift lev er plate . T he clearance on the sides of shift lev er should be equal ( Figure 8 ).

4. If clearance is not cor rect, loosen shift lev er plate and adjust it side-to-side . Tighten the shift lev er plate .

Step

Installing the Control Rods

Parts needed for this step:

Control rods

Cotter pin

Clevis Pin

Washer

Hairpin cotter pin

Procedure

1. Install the control rods into the upper control bar and the blade control bail. Secure the control rods with 2 cotter pins ( Figure 10 ).

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Figure 10

1. Control rod 3. Blade control bail

2. Upper control bar

4. Cotter pin

2. Mak e sure the rod ﬁttings are equal distance onto eac h control rod. T he rod ﬁttings should be appro ximately 3-1/2 inc h (89 mm) from the star t of the threads for the handles lo w est position ( Figure 11 ).

3. Slide clevis pins through rod ﬁttings and mounting holes in idler brac k ets (from outside) ( Figure 11 ). Secure with w ashers and hair pin cotters ( Figure 11 ).

Note: T he upper control bar and ﬁx ed bar m ust be parallel when the upper control bar is in the eng ag ed, dri v e , neutral, or brak e positions .

5. Chec k the operation. If adjustment is required, remo v e hair pin cotter , w asher and clevis pin securing control rod ﬁtting to idler brac k et.

6. T hread ﬁtting up or do wn on rod until proper position is attained and install the ﬁtting into the idler brac k et with clevis pin, w asher and hair pin cotter .

Note: Mak e sure brak e rod is installed in front (F) mounting hole in idler brac k et.

Figure 11

1. Control rod and tting 5. Washer

2. 3-1/2 inch (89 mm)

3. Idler bracket 7. Rod tting

4. Clevis pin 8. Hole F

6. Hairpin cotter pin

4. Chec k the g ap betw een upper control bar and ﬁx ed bar with wheel dri v e fully eng ag ed. Gap should be appro ximately 1 to 1-1/4 inc h (25-32 mm) ( Figure 12 ).

Figure 12

1. Control rod 4. Upper control bar

2. Fixed control bar

3. Parking brake lever

5. 1 to 1-1/4 inch (25-32mm) gap

6. Fitting

7. Chec k the parking brak e adjustment. R efer to Chec king the Brak es in the Brak e Maintenance , pag e 36 .

Page 16

Step

Installing the Hairpin Cotter Pins and Spacers

Parts needed for this step:

Hairpin cotter pin

6 Spacers

Procedure

Un used height-of-cut spacers ma y be stored on posts and retained b y a hair pin cotter .

Note: Mak e sure there is at least one spacer used on eac h height-of-cut post.

1. Hairpin cotter

2. Unused spacers

Step

Figure 14

3. Height-of-cut post (front shown)

1. R emo v e the existing rear hair pin cotter pins from the rear height-of-cut posts ( Figure 13 ).

2. Install a spacer onto both rear height-of-cut posts and install the hair pin cotter pins ( Figure 13 ).

Figure 13

1. Hairpin cotter

2. Spacer

3. Install a spacer onto both front height-of-cut posts and install the hair pin cotter pins .

3. Height-of-cut post (rear shown)

Reading the Manual and Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Oil drain hose

Procedure

• R ead the Operator’ s Man ual.

• View the safety video .

• Fill out the registration card and mail it in or

• Use the oil drain hose when c hanging the engine oil.

4. On the opposite side of the m ufﬂer , install un used spacers onto front and rear height-of-cut pins and inser t the hair pin cotter pins ( Figure 14 ).

Page 17

Product Overview

Figure 15

1. Side discharge chute 5. Controls

2. Mower deck 6. Handle

3. Recoil starter 7. Caster wheel

4. Gas tank

Controls

Become familiar with all the controls ( Figure 16 ) before y ou star t the engine and operate the mac hine .

Figure 16

1. Power take off switch (PTO)

2. Parking brake lever-released position

3. Upper handle 9. Throttle control

4. Blade control bail 10. Gear shift lever

5. Upper control bar 11. Fuel shut-off valve

6. Lower handle

7. Lower control bar

8. Ignition switch

Throttle Control

T he throttle control has three positions: Chok e , F ast and Slo w .

Blade Control Bail

T he bail is used in conjunction with the po w er tak e off switc h (PTO) to eng ag e the clutc h to dri v e the mo w er blades . R elease the mo w er control bail to diseng ag e the mo w er blades .

Power Take Off Switch (PTO)

T his pull switc h is used in conjunction with the blade control bail to eng ag e the clutc h to dri v e the mo w er blades .

Gear Shift Lever

T he transmission has ﬁv e forw ard speeds , neutral and rev erse , and has an in-line shift patter n.

Page 18

Important: Do not shift while unit is mo ving , as transmission dama ge may occur .

Upper Control Bar

Shift to the desired g ear and push forw ard on the upper control bar to eng ag e forw ard traction operation and pull bac k to brak e forw ard mo v ement. Pull bac k on right side of upper control bar to tur n right and left side to tur n left.

Lower Control Bar

Shift transmission to rev erse and squeeze the lo w er control bar and handle tog ether to eng ag e rearw ard traction assist operation.

Parking Brake Lever

Pull bac k on upper control bar and swing brak e lev er up ag ainst the upper handle ( Figure 16 ).

Ignition Switch

T his switc h is used in conjunction with recoil star ter and has tw o positions: R un and Of f .

Recoil Starter

Pull recoil star ter handle to star t engine (not sho wn in Figure 16 ).

Fuel Shut-off Valve

Close the fuel shut-off v alv e when transpor ting or storing mo w er .

Page 19

Operation

Recommended Gasoline

Use UNLEADED R egular Gasoline suitable for automoti v e use (85 pump octane minim um). Leaded regular g asoline ma y be used if unleaded regular is not a v ailable .

Important: Nev er use methanol, gasoline containing methanol, or gasohol containing mor e than 10% ethanol because the fuel system could be dama ged. Do not mix oil with gasoline.

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30 day suppl y of gasoline.

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Page 20

Gasoline is har mful or f atal if s w allo w ed. Long-ter m exposur e to v apor s can cause serious injur y and illness.

to Chec king Oil Lev el in Engine Maintenance , pag e 28

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the mac hine to pro vide the follo wing beneﬁts:

• K ee ps g asoline fresh during storag e of 90 da ys or less . F or long er storag e it is recommended that the fuel tank be drained.

• Cleans the engine while it r uns

• Eliminates gum-lik e v ar nish buildup in the fuel

system, whic h causes hard star ting

Important: Do not use fuel additi v es containing methanol or ethanol.

Add the cor rect amount of g as stabilizer/conditioner to the g as .

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline . T o minimize the c hance of v ar nish de posits in the fuel system, use fuel stabilizer at all times .

Think Safety First

Carefully read all the safety instr uctions and decals in the safety section. Kno wing this infor mation could help y ou or any b ystanders a v oid injur y .

T he use of protecti v e equipment for eyes , hearing, feet and head is recommended.

T his machine pr oduces sound lev els in ex cess of 85 dB A at the operator’ s ear and can cause hearing loss thr ough extended periods of exposur e.

W ear hearing pr otection when operating this machine.

Figure 17

1. Warning—wear hearing protection.

Using the Parking Brake

Filling the Fuel Tank

1. Shut the engine off and set the parking brak e .

2. Clean around fuel tank cap and remo v e the cap . Add unleaded regular g asoline to fuel tank, until the lev el is 1/4 to 1/2 inc h (6 to 13 mm) belo w the bottom of the ﬁller nec k. T his space in the tank allo ws g asoline to expand. Do not ﬁll the fuel tank completely full.

3. Install fuel tank cap securely . Wipe up any g asoline that ma y ha v e spilled.

Checking the Engine Oil Level

Before y ou star t the engine and use the mac hine , c hec k the oil lev el in the engine crankcase; refer

Stop on lev el g round, diseng ag e dri v es , eng ag e parking brak e , shut off engine and remo v e k ey . Alw a ys set the parking brak e when y ou stop the mac hine or lea v e it unattended.

Setting the Parking Brake

1. Pull the upper control bar ( Figure 18 ) rearw ard and hold it in this position.

2. Lift the parking brak e loc k ( Figure 18 ) up and g radually release the upper control bar . T he brak e loc k should sta y in the set (loc k ed) position.

Page 21

Figure 18

1. Upper control bar 3. Fixed bar

2. Parking brake lever-set position

Releasing the Parking Brake

2. Let engine idle for 30 to 60 seconds before tur ning the ignition k ey to of f .

3. T ur n the ignition k ey to of f ( Figure 19 ).

Figure 19

1. Throttle lever 2. Ignition key

1. Pull rearw ard on the upper control bar . Lo w er the parking brak e loc k to the released position.

2. Gradually release the upper control bar .

Starting and Stopping the Engine

Starting the Engine

1. Mak e sure spark plug wire(s) are installed on spark plug(s) and fuel v alv e is open.

2. Mo v e the shift lev er to neutral, set the parking brak e and tur n ignition k ey to r un.

3. Mo v e the throttle control to the c hok e position before star ting a cold engine .

Note: A w ar m or hot engine usually does not require any c hoking . T o star t a w ar m engine , mo v e throttle control to the fast position.

4. Grasp recoil star ter handle ﬁr mly and pull out until positi v e eng ag ement results; then pull handle vig orously to star t engine and allo w rope to recoil slo wly .

Important: Do not pull r ecoil r ope to its limit or let go of the star ter handle when r ope is pulled out because r ope may br eak or r ecoil assembl y may be dama ged.

Stopping the Engine

4. Set the parking brak e and remo v e k ey .

5. Pull wire off spark plug(s) to prev ent possibility of accidental star ting before storing mac hine .

6. Close the fuel shut off v alv e before storing mac hine .

Important: Mak e sur e fuel shut of f v alv e is closed bef or e transpor ting or storing machine, as fuel leaka ge may occur .

Operating the Mower Power Take Off (PTO)

T he po w er tak e off switc h (PTO) in conjunction with the blade control bail eng ag es and diseng ag es po w er to the electric clutc h and mo w er blades .

Engaging the Mower Blades (PTO)

1. R elease the upper control bar to stop the mac hine ( Figure 20 ).

2. T o eng ag e blade , squeeze blade control bail ag ainst the upper control bar ( Figure 20 ).

3. Pull the po w er tak e off switc h (PTO) up and release . Hold the blade control bail ag ainst the upper control bar while operating .

4. R e peat the procedure to eng ag e the mo w er blades if the blade control bail is released.

1. Mo v e the throttle lev er to the slo w position ( Figure 19 ).

Page 22

1. Upper control bar

2. Blade control bail

Figure 20

3. Power take off switch (PTO)

Testing the Safety Interlock System

T est the safety interloc k system before y ou use the mac hine eac h time .

Note: If the safety system does not operate as described belo w , ha v e an A uthorized Ser vice Dealer re pair the safety system immediately .

1. Set the parking brak e and star t the engine; refer to Star ting and Stopping the Engine in Operation , pag e 19 .

2. Squeeze the blade control bail ag ainst upper control bar . T he blades should not r otate.

3. T hen contin ue holding the blade control bail and pull up on the blade control switc h and release . T he clutc h should eng ag e and the mo w er blades begin rotating .

4. R elease the blade control bail. T he blades

should stop r otating .

Disengaging the Mower Blades (PTO)

R elease the blade control bail to diseng ag e the blades ( Figure 20 ).

The Safety Interlock System

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

Understanding the Safety Interlock System

T he safety interloc k system is designed to prev ent the mo w er blades from rotating unless:

• T he control bail is de pressed.

• T he po w er tak e off switc h (PTO) is pulled on .

T he safety interloc k system is designed to stop the mo w er blades if y ou release the blade control bail.

5. With the engine r unning, pull up the po w er tak e off switc h (PTO) and release without holding the blade control bail. T he blades

should not r otate.

Driving Forward or Backward

T he throttle control regulates the engine speed as measured in RPM (rev olutions per min ute). Place the throttle control in the f ast position for best mo wing perfor mance .

Driving Forward

1. T o g o forw ard, mo v e the shift lev er to a forw ard g ear ( Figure 21 ).

2. R elease the parking brak e; refer to R eleasing the P arking Brak e in Brak e Maintenance , pag e 36 .

3. Slo wly press on the upper control bar to mo v e forw ard ( Figure 21 ).

T o g o straight, apply equal pressure to both ends of the upper control bar ( Figure 21 ).

T o tur n, release pressure on the upper control bar side in the direction y ou w ant to tur n ( Figure 21 ).

Page 23

Figure 21

1. Upper control bar 3. Shift lever

2. Lower control bar

Driving Backward

1. T o g o bac kw ard, mo v e the shift lev er to rev erse g ear .

4. Lift the front of the mac hine b y pushing do wn on the lo w er handle ( Figure 22 ).

5. Dri v e the mac hine until dri v e wheels contact the curb ( Figure 22 ).

6. Lo w er the front of the mac hine ( Figure 22 ). Note: Both dri v e wheels should contact the

curb and caster wheels straight.

7. At the same time eng ag e the lo w er control bar and lift up on the lo w er handle to dri v e o v er the curb ( Figure 21 and Figure 22 ).

Note: Lifting up on the lo w er handle will assist dri ving the mac hine up a curb and not spin the dri v e wheels .

2. R elease the parking brak e; refer to R eleasing the P arking Brak e in Operation , pag e 19 .

3. Slo wly squeeze the lo w er control bar and lo w er handle tog ether to mo v e rearw ard ( Figure 21 ).

Using the Lower Control Bar

T his procedure is for dri ving up a curb . T his can be perfor med while dri ving forw ard or bac kw ard.

Note: Some curbs do not allo w the rear dri v e tires to contact the curb . If this happens , dri v e the mac hine up the curb at an angle .

A blade can be bent or dama ged when dri ving up a curb . Pieces of blade that may be thr o wn could seriousl y injur e or kill y ou or bystander s.

Do not r un blades while dri ving up a curb f orw ard or backw ard.

Figure 22

1. Lower Control Bar engaged and mower in reverse.

2. Pull up to assist machine

3. Lower Control Bar engaged and mower going forward.

Driving Backward Up a Curb

1. Diseng ag e the mo w er blades .

2. Select rev erse to dri v e mac hine .

3. Dri v e the mac hine until dri v e wheels contact curb ( Figure 22 ).

Driving Forward Up a Curb

1. Diseng ag e the mo w er blades .

2. Select ﬁrst g ear to dri v e the mac hine .

3. Dri v e mac hine until the castor wheels contact curb ( Figure 22 ).

Note: Both dri v e wheels should contact the curb and caster wheels straight.

4. At the same time eng ag e lo w er control bar and lift up on the lo w er handle ( Figure 21 and Figure 22 ).

Page 24

Note: Lifting up on the lo w er handle will assist dri ving the mac hine up a curb and not spin the dri v e wheels .

Stopping the Machine

T o stop the mac hine , pull bac k on the upper control bar , release the blade control bail, and tur n the ignition k ey to off . Also set the parking brak e if y ou lea v e the mac hine unattended; refer to Setting the P arking Brak e in Operation , pag e 19 . R emember to remo v e the k ey from the ignition switc h.

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the machine while it is unattended.

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

W ithout the g rass deﬂector , discharge co v er , or complete g rass catcher assembl y mounted in place, y ou and other s ar e exposed to blade contact and thr o wn de bris. Contact with r otating mo w er blade(s) and thr o wn de bris will cause injur y or death.

• Nev er r emo v e the g rass deﬂector fr om the mo w er because the g rass deﬂector r outes material do wn to w ard the turf. If the g rass deﬂector is ev er dama ged, r eplace it immediatel y .

• Nev er put y our hands or feet under the mo w er .

• Nev er tr y to clear discharge ar ea or mo w er blades unless y ou r elease the bail and the po w er tak e of f (PT O) is of f. R otate the ignition k ey to Of f. Also r emo v e the k ey and pull the wir e of f the spar k plug(s).

Transporting Machines

Use a hea vy-duty trailer or tr uc k to transpor t the mac hine . Ensure that the trailer or tr uc k has all necessar y lighting and marking as required b y la w . Please carefully read all the safety instr uctions . Kno wing this infor mation could help y ou, y our family , pets or b ystanders a v oid injur y .

T o transpor t the mac hine:

1. If using a trailer , connect it to the to wing v ehicle and connect the safety c hains .

2. Load the mac hine onto the trailer or tr uc k.

3. Stop the engine , remo v e the k ey , set the brak e , and close the fuel v alv e .

4. Securely fasten the mac hine to the trailer or tr uc k with straps , c hains , cable , or ropes .

Side Discharging or Mulching the Grass

T his mo w er has a hing ed g rass deﬂector that disperses clippings to the side and do wn to w ard the turf .

Adjusting the Height-of-Cut

T he height-of-cut can be adjusted from 1 to 4-1/2 inc h (25 to 114 mm) in 1/4 inc h (6 mm) increments . Adjustment is done b y relocating four hair pin cotter pins in different hole location and b y adding or remo ving spacers .

Note: All height-of-cut pins need at least one spacer or damag e can occur to bushing if none are used.

Note: All height-of-cut pins can use only tw o spacers maxim um.

1. Select hole in height-of-cut post and n umber of spacers cor responding to the height-of-cut desired ( Figure 23 ).

2. Using the lift handle , raise side of dec k and remo v e hair pin cotter ( Figure 23 ).

3. Add or remo v e spacers if needed and then align holes and inser t hair pin cotter ( Figure 23 ).

Note: Spare height-of-cut spacers ma y be stored on posts and retained b y a hair pin cotter .

Important: All f our hair pin cotter pins must be in the same hole location and with the cor r ect n umber of spacer s f or a lev el cut.

Page 25

Figure 23

1. Carrier Frame

2. Hairpin Cotter

3. Front height-of-cut post

4. Spacers

5. Back height-of-cut post

Adjusting the Gage Wheels

T he g ag e wheels need to be adjusted in the proper hole location for eac h height-of-cut position. T here needs to be 3/8 inc h (10 mm) minim um clearance abo v e the g round.

1. After adjusting height-of-cut, c hec k the g ag e wheels so that there is a minim um of 3/8 inc h (10 mm) clearance abo v e the g round ( Figure 24 and Figure 25 ).

2. If adjustment is needed, remo v e the bolt, w ashers and n ut ( Figure 24 and Figure 25 ).

3. Select a hole position so the g ag e wheels are a minim um of 3/8 inc h (10 mm) off the g round ( Figure 24 and Figure 25 ).

4. Install the bolt, w ashers and n ut ( Figure 24 and Figure 25 ).

Figure 24

1. Gage Wheels 4. Washer

2. Nut 5. Spacer

3. Bolt

Figure 25

1. Center Gage Wheels and spacer

2. Nut

3. Bolt

4. Washer

Adjusting the Handle Height

T he handle position can be adjusted to matc h the operator’ s height preference .

1. R emo v e hair pin cotter , w asher and clevis pin securing control rod ﬁtting to idler brac k et ( Figure 26 ).

Page 26

Figure 26

1. Control rod and tting 4. Washer

2. Idler bracket

3. Clevis pin 6. Rod tting

5. Hairpin cotter pin

2. Loosen the upper ﬂang e bolts (3/8 x 1 inc h) and ﬂang e n ut securing handle to rear frame ( Figure 27 ).

and hair pin cotter . R efer to Installing the Control R ods in Setup , pag e 11 .

6. Chec k the parking brak e adjustment. R efer to Chec king the Brak es in Brak e Maintenance , pag e 36 .

Figure 27

1. Upper handle 5. Upper mounting hole

2. Rear frame 6. Lower mounting holes

3. Flange nut, (3/8 inch)

4. Flange bolt, (3/8 x 1 inch)

7. Low position

8. High position

3. R emo v e the lo w er ﬂang e bolts (3/8 x 1 inc h) and ﬂang e n uts securing handle to rear frame ( Figure 25 ).

4. Pi v ot handle to desired operating position and install lo w er ﬂang e bolts (3/8 x 1 inc h) and ﬂang e n uts into mounting holes . Tighten all ﬂang e bolts .

5. T hread rod ﬁtting up or do wn on rod until proper position is attained and install into ﬁtting to idler brac k et with clevis pin, w asher

Page 27

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 200 hours

Maintenance Procedure

• Change the engine oil.

• Check the safety interlock system.

• Grease the caster wheels and caster pivot.

• Check the engine oil level.

• Clean the air intake screen.

• Check the brakes.

• Inspect the blades.

• Clean foam air cleaner element.

• Grease the PTO belt idler.

• Grease the mower deck belt idler.

• Check the paper air cleaner element.

• Check the tire pressure.

• Check the traction drive belt.

• Check the transmission belt.

• Check the mower belt.

• Change the engine oil.

• Check the spark plugs.

• Adjust the electric clutch.

• Replace the paper air cleaner element.

• Replace the oil lter.

• Replace the fuel lter.

Every 250 hours

Every 400 hours

Before storage

• Grease the transmission couplers (more often in dirty or dusty conditions).

• Grease the wheel bearings (more often in dirty or dusty conditions).

• Paint chipped surfaces.

• Perform all maintenance procedures listed above before storage.

Important: R efer to y our engine operator’ s man ual f or additional maintenance pr ocedur es.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the spar k plug wir e fr om the spar k plug(s) bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

Lubrication

Grease with No . 2 g eneral pur pose lithium base or

How to Grease

1. Diseng ag e the PTO and set the parking brak e .

molybden um base g rease .

Page 28

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean the g rease ﬁttings with a rag . Mak e sure to scrape any paint off the front of the ﬁtting(s).

4. Connect a g rease gun to the ﬁtting . Pump g rease into the ﬁttings until g rease begins to ooze out of the bearings .

5. Wipe up any ex cess g rease .

Lubricating the Caster and Wheel Bearings

1. Lubricate the front wheel bearings and front spindles ( Figure 28 ).

2. Raise the rear of the mac hine and use jac k stands to suppor t the mac hine .

3. R emo v e the rear wheel and tire assembly .

4. R emo v e rear wheel g rease cap . Lubricate the rear wheel bearing ( Figure 28 ).

5. Install the g rease cap .

6. Install the rear wheel and tire assembly . Note: Mak e sure the rear wheel g rease caps

are remo v ed before lubricating rear wheels .

Figure 29

Greasing the PTO Drive Belt Idler and Deck Belt Idler

Grease the ﬁtting on the PTO belt idler ar m pi v ot ( Figure 30 ).

Note: Y ou will ha v e to remo v e the car rier co v ers to access the g rease ﬁtting for the dec k.

Figure 28

Greasing the Transmission Couplers

Lubricate the transmission couplers located in the bac k of the mac hine ( Figure 29 ).

Figure 30

Engine Maintenance

Servicing the Air Cleaner

F oam element: Clean it after ev er y 25 operating hours .

Page 29

P aper element: Chec k it after ev er y 50 operating hours . R e place it after ev er y 200 operating hours or yearly , whic h ev er comes ﬁrst.

Inspect the foam and paper elements and re place them if they are damag ed or ex cessi v ely dir ty .

Note: Ser vice the air cleaner more frequently (ev er y few operating hours) if the operating conditions are extremely dusty or sandy .

Important: Do not oil the f oam or paper element.

Removing the Foam and Paper Elements

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean around the air cleaner to prev ent dir t from g etting into the engine and causing damag e ( Figure 31 ).

4. Unscrew the co v er knob and remo v e the air cleaner co v er ( Figure 31 ).

5. R emo v e the 2 wing n uts and remo v e the air cleaner assembly ( Figure 31 ).

6. Carefully pull the foam element off the paper element ( Figure 31 ).

Figure 31

1. Engine

2. Cover

3. Wing nut

4. Foam element

5. Paper element

6. Cover knob

Cleaning the Foam Air Cleaner Element

1. W ash the foam element in liquid soap and w ar m w ater . W hen the element is clean, rinse it thoroughly .

2. Dr y the element b y squeezing it in a clean cloth.

Important: R eplace the f oam element if it is tor n or w or n.

Servicing the Paper Air Cleaner Element

1. Do not clean the paper ﬁlter . R e place it after 200 operating hours ( Figure 31 ).

2. Inspect the element for tears , an oily ﬁlm, or damag e to the r ubber seal.

3. R e place the paper element if it is damag ed.

Page 30

Installing the Foam and Paper Elements

Important: T o pr ev ent engine dama ge,

al w ays operate the engine with the complete f oam and paper air cleaner assembl y installed.

1. Carefully slide the foam element onto the paper air cleaner element ( Figure 31 ).

2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing n uts ( Figure 31 ).

3. Place the air cleaner co v er into position and tighten the co v er knob ( Figure 31 ).

Servicing the Engine Oil

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Clean around the oil dipstic k ( Figure 33 ) so that dir t cannot fall into the ﬁller hole and damag e the engine .

Chang e the engine oil as follo ws:

• After the ﬁrst 8 operating hours

• After ev er y 100 operating hours

Note: Chang e the oil more frequently when the operating conditions are extremely dusty or sandy .

Oil T ype: Deterg ent oil (API ser vice SF , SG , SH, or SJ)

Crankcase Capacity: 58 ounces (1.7 liter) with the ﬁlter remo v ed; 51 ounces (1.5 liter) without the ﬁlter remo v ed

Viscosity: R efer to the table ( Figure 32 ).

Figure 33

1. Oil dipstick 2. Filler tube

5. Unscrew the oil dipstic k and wipe the end clean ( Figure 33 ).

6. Slide the oil dipstic k fully into the ﬁller tube , but do not thread onto tube ( Figure 33 ).

7. Pull the dipstic k out and look at the metal end. If the oil lev el is lo w , slo wly pour only enough oil into the ﬁller tube to raise the lev el to the Full mark.

Important: Do not o v erﬁll the crankcase with oil and r un the engine; engine dama ge can r esult.

Changing the Oil

1. Star t the engine and let it r un ﬁv e min utes . T his w ar ms the oil so it drains better .

Figure 32

Checking the Engine Oil Level

1. P ark the mac hine on a lev el surface .

2. Diseng ag e the PTO and set the parking brak e .

2. P ark the mac hine so that the drain side is slightly lo w er than the opposite side to assure the oil drains completely .

3. Diseng ag e the PTO and set the parking brak e .

4. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

5. Slide the drain hose o v er the oil drain v alv e .

6. Place a pan belo w the drain hose . R otate oil drain v alv e to allo w oil to drain ( Figure 34 ).

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7. W hen oil has drained completely , close the drain v alv e .

8. R emo v e the drain hose ( Figure 34 ). Note: Dispose of the used oil at a recycling

center .

Figure 35

1. Oil lter 2. Adapter

3. Apply a thin coat of new oil to the r ubber g ask et on the re placement ﬁlter ( Figure 35 ).

4. Install the re placement oil ﬁlter to the ﬁlter adapter , tur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 3/4 tur n ( Figure 35 ).

Figure 34

1. Oil drain valve 2. Oil drain hose

9. Slo wly pour appro ximately 80% of the speciﬁed oil into the ﬁller tube ( Figure 33 ).

10. Chec k the oil lev el; refer to Chec king the Engine Oil Lev el.

11. Slo wly add the additional oil to bring it to the Full mark.

Changing the Oil Filter

R e place the oil ﬁlter ev er y 200 operating hours or ev er y other oil c hang e .

Note: Chang e the oil ﬁlter more frequently when the operating conditions are extremely dusty or sandy .

1. Drain the oil from the engine; refer to Changing the Engine Oil.

2. R emo v e the old ﬁlter ( Figure 35 ).

5. Fill the crankcase with the proper type of new oil; refer to Ser vicing the Engine Oil.

6. R un the engine for about 3 min utes , stop the engine , and c hec k for oil leaks around the oil ﬁlter and drain v alv e .

7. Chec k the engine oil lev el and add oil if needed.

Servicing the Spark Plugs

Chec k the spark plugs after ev er y 100 operating hours .

Ensure that the air g ap betw een the center and side electrodes is cor rect before installing the spark plug . Use a spark plug wrenc h for remo ving and installing the spark plugs and a g apping tool/feeler g aug e to c hec k and adjust the air g ap . Install a new spark plugs if necessar y .

T ype: Champion® R CJ8Y or equi v alent Air Gap:

0.030 inc h (0.75 mm)

Removing the Spark Plugs

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Disconnect the wires from the spark plugs ( Figure 36 ).

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Important: Al w ays r eplace the spar k plugs when it has a black coating , w or n electr odes, an oil y ﬁlm, or cracks.

3. Chec k the g ap betw een the center and side electrodes ( Figure 37 ). Bend the side electrode ( Figure 37 ) if the g ap is not cor rect.

Installing the Spark Plugs

1. Install the spark plugs and the metal w asher . Ensure that the air g ap is set cor rectly .

2. Tighten the spark plugs to 16 ft-lb (22 N ⋅ m).

3. Connect the wires to the spark plugs ( Figure 37 ).

Figure 36

1. Spark-plug wire/spark plug

4. Clean around the spark plugs to prev ent dir t from falling into the engine and potentially causing damag e .

5. R emo v e the spark plugs and the metal w ashers .

Checking the Spark Plugs

1. Look at the center of the spark plugs ( Figure 37 ). If y ou see light bro wn or g ra y on the insulator , the engine is operating properly . A blac k coating on the insulator usually means that the air cleaner is dir ty .

2. If needed, clean the spark plug with a wire br ush to remo v e carbon de posits .

Fuel System Maintenance

Draining the Fuel Tank

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Drain gasoline fr om the fuel tank when the engine is cold. Do this outdoor s in an open ar ea. W ipe up an y gasoline that spills.

• Nev er smok e when draining gasoline, and stay a w ay fr om an open ﬂame or wher e a spar k may ignite the gasoline fumes.

1. P ark the mac hine on a lev el surface , to assure fuel tank drains completely . T hen diseng ag e the po w er tak e off (PTO), set the parking brak e , and tur n the ignition k ey to of f . R emo v e the k ey .

1. Center electrode insulator

2. Side electrode

Figure 37

3. Air gap (not to scale)

2. Close the fuel shut-off v alv e at the fuel tank ( Figure 38 ).

3. Squeeze the ends of the hose clamp tog ether and slide it up the fuel line a w a y from fuel ﬁlter ( Figure 38 ).

4. Pull the fuel line off the fuel ﬁlter ( Figure 38 ). Open the fuel shut-off v alv e and allo w the g asoline to drain into a g as can or drain pan.

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Note: No w is the best time to install a new fuel ﬁlter because the fuel tank is empty . R efer to R e placing the Fuel Filter .

5. Install the fuel line onto the fuel ﬁlter . Slide the hose clamp close to the v alv e to secure the fuel line .

Figure 39

1. Hose clamp 3. Filter

2. Fuel line

5. R emo v e the ﬁlter from the fuel lines .

Figure 38

1. Fuel shut-off valve 2. Clamp

Replacing the Fuel Filter

R e place the fuel ﬁlter after ev er y 200 operating hours or yearly , whic hev er occurs ﬁrst.

Nev er install a dir ty ﬁlter if it is remo v ed from the fuel line .

Note: Note ho w the fuel ﬁlter is installed. Note: Wipe up any spilled fuel.

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Close fuel shut-off v alv e at fuel tank ( Figure 38 ).

6. Install a new ﬁlter and mo v e the hose clamps close to the ﬁlter .

7. Open fuel shut-off v alv e at fuel tank ( Figure 38 ).

8. Chec k for fuel leaks and re pair if needed.

Electrical System Maintenance

Servicing the Fuse

T he electrical system is protected b y a fuse . It requires no maintenance . If the fuse blo ws c hec k component or circuit for malfunction or shor t. T o re place fuse pull out on the fuse ( Figure 40 ) to remo v e or re place it.

Note: R emo v e the fuel line from the fuel v alv e that is closest to the engine .

4. Squeeze the ends of the hose clamps tog ether and slide them a w a y from the ﬁlter ( Figure 39 ).

Page 34

Replacing the Caster Wheel Fork Bushings

T he caster wheel forks are mounted in bushings pressed into the top and bottom of the car rier frame mounting tubes . T o c hec k the bushings , mo v e the caster forks bac k and for th and side-to-side . If a caster fork is loose , the bushings are w or n and m ust be re placed.

1. Raise the cutting unit so the caster wheels are off the ﬂoor , then bloc k up the front of the mo w er with jac k stands .

Figure 40

1. Fuse, 7.5 amp, blade type

Drive System Maintenance

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as speciﬁed. Chec k the pressure at the v alv e stem after ev er y 50 operating hours or monthly , whic hev er occurs ﬁrst ( Figure 41 ). Chec k the tires when they are cold to g et the most accurate pressure reading .

R ear Tire Pressure: 12-14 psi (83-97 kP a)

Caster Tire Pressure: 25-30 psi (172-207 kP a)

2. R emo v e the loc king pin and spacer(s) from the top of the caster wheel fork ( Figure 42 ).

Figure 41

1. Rear Tire 2. Caster tire

Figure 42

1. Locking Pin 3. Carrier frame mounting

2. Spacers (locate as required)

tube

4. Caster wheel fork

3. Pull the caster wheel fork out of the mounting tube , lea ving the spacer(s) on the bottom of the fork. R emember the location of the spacers on eac h fork to ensure cor rect installation, and to maintain a lev el dec k.

4. Inser t a pin punc h into the mounting tube and carefully dri v e out the bushings ( Figure 43 ). Clean the inside of the mounting tube .

Page 35

Figure 43

1. Mounting Tube 2. Bushing

5. Grease the inside and outside of the new bushings . Use a hammer and ﬂat plate to carefully dri v e the bushings into the mounting tube .

6. Inspect the caster wheel fork for w ear and re place if necessar y ( Figure 42 ).

7. Slide the caster wheel fork through the bushings in the mounting tube . R e place the spacer(s) onto the fork and secure with the retaining ring ( Figure 42 ).

Important: T he inside diameter of the bushings may collapse slightl y when installed. If the caster wheel f or k does not slide into the new bushings, r eam both bushings to an inside diameter of 1.126 inch (29 mm).

8. Grease the ﬁtting on the car rier frame mounting tube using No . 2 g eneral pur pose lithium base or molybden um base g rease .

Servicing the Caster Wheel and Bearings

T he caster wheels rotate on a roller bearing suppor ted b y a spanner bushing . If the bearing is k e pt w ell lubricated, w ear will be minimal. F ailure to k ee p the bearing w ell lubricated will cause rapid w ear . A w obbly caster wheel usually indicates a w or n bearing .

1. R emo v e the loc kn ut and wheel bolt holding the caster wheel to the caster fork ( Figure 44 ).

Figure 44

1. Locknut 4. Spanner Bushing

2. Wheel Bolt 5. Roller Bearing

3. Bushing

2. R emo v e one bushing, then pull the spanner bushing and roller bearing out of the wheel hub ( Figure 44 ).

3. R emo v e the other bushing from the wheel hub and clean any g rease and dir t from the wheel hub ( Figure 44 ).

4. Inspect the roller bearing, bushings , spanner bushing and inside of the wheel hub for w ear . R e place any defecti v e or w or n par ts ( Figure 44 ).

5. T o assemble , place one bushing into the wheel hub . Grease the roller bearing and spanner bushing and slide them into the wheel hub . Place the second bushing into the wheel hub ( Figure 44 ).

6. Install the caster wheel into the caster fork and secure with the wheel bolt and loc kn ut. Tighten the loc kn ut until the spanner bushing bottoms ag ainst the inside of the caster forks ( Figure 44 ).

7. Grease the ﬁtting on the caster wheel.

Adjusting the Electric Clutch

T he clutc h is adjustable to ensure proper eng ag ement and proper braking . Chec k adjustment after ev er y 100 hours of operation.

1. T o adjust the clutc h, tighten or loosen the loc k n uts on the ﬂang e studs ( Figure 45 ).

Page 36

Figure 45

1. Adjusting nut 3. Feeler gauge

2. Slot

2. Chec k adjustment b y inser ting a feeler g aug e through the slots next to the studs ( Figure 45 ).

3. T he proper diseng ag ed clearance betw een the clutc h plates is 0.012-0.024 inc h (0.30-0.60 mm). It will be necessar y to c hec k this clearance at eac h of the three slots to ensure the plates are parallel to eac h other .

Cooling System

brak e does not hold securely , an adjustment is required.

Checking the Brakes

1. P ark the mac hine on a lev el surface , diseng ag e the PTO .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Apply the parking brak e . T he wheels m ust loc k when y ou tr y to push the mac hine forw ard.

4. If the wheels do not loc k, adjust the brak es . R efer to Adjusting the Brak es .

5. R elease the brak e and press upper control bar v er y lightly , appro ximately 1/2 inc h (13 mm). T he wheels should rotate freely , if not; refer to Adjusting the Brak es .

Adjusting the Brakes

T he brak e lev er is on the upper control bar . If the parking brak e does not hold securely , an adjustment is required.

Note: F or the initial adjustment, adjust the wing n ut until it is 1-1/4 inc hes from the top of the rod ( Figure 46 ).

Maintenance

Cleaning the Air Intake Screen

Before eac h use remo v e any build-up of g rass , dir t or other debris from the cylinder and cylinder head cooling ﬁns , air intak e screen on ﬂywheel end, and carburetor -g o v er nor lev ers and linkag e . T his will help insure adequate cooling and cor rect engine speed and will reduce the possibility of o v erheating and mec hanical damag e to the engine .

Brake Maintenance

Servicing the Brakes

Before eac h use , c hec k brak es on both a lev el surface and slope .

Alw a ys set the parking brak e when y ou stop the mac hine or lea v e it unattended. If the parking

1. P ark the mac hine on a lev el surface , diseng ag e the PTO , and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Chec k the brak e before y ou adjust it; refer to Chec king the Brak es .

4. R elease the parking brak e; refer to R eleasing the P arking Brak e in Operation , pag e 19 .

5. T o adjust the brak e remo v e the hair pin cotter and w asher from the brak e lev er and tr unnion ( Figure 46 ).

Page 37

1. R emo v e the top capscrew securing idler suppor t and idler brac k et to rear frame ( Figure 47 ).

Figure 46

1. Hairpin cotter and washer 5. Hole F

2. Trunnion

3. Brake lever 7. Rod

4. Wing nut

6. Initial adjustment- 1-1/4 inch (32 mm)

6. R otate the wing n ut cloc kwise to increase the braking pressure .

7. R otate the wing n ut countercloc kwise to decrease the braking pressure .

8. Install the tr unnion into hole F ( Figure 46 ). Tighten the wing n ut.

9. Secure tr unnion to brak e lev er with w asher and hair pin cotter ( Figure 46 ).

10. Chec k the brak e operation ag ain; refer to Chec king the Brak es .

Important: W ith the par king brak e r eleased, the r ear wheels must r otate fr eel y when y ou push the mo w er . If brak e action and fr ee wheel r otation cannot be achiev ed contact y our ser vice dealer immediatel y .

Figure 47

1. Top capscrew 4. Bottom capscrew

2. Idler bracket 5. Traction drive belt

3. Idler support

2. Loosen bottom tw o mounting screws enough to allo w belt to pass betw een dri v e pulley and idler suppor t ( Figure 47 ).

3. Raise the wheel off the g round, to allo w the belt to be remo v ed, and remo v e the belt.

4. Install a new belt.

5. Install the top capscrew securing the idler suppor t and idler brac k et to the rear frame ( Figure 47 ).

6. Tighten the bottom tw o mounting screws enough to allo w the belt to pass betw een the dri v e pulley and idler suppor t ( Figure 47 ).

Replacing the Transmission Belt

1. Diseng ag e the PTO and set the parking brak e .

Belt Maintenance

Replacing the Traction Drive Belt

Chec k all belts after ev er y 50 operating hours or monthly , whic hev er occurs ﬁrst. Look for crac ks , w ear , and signs of o v erheating .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e PTO dri v e belt. R efer to R e placing the PTO Dri v e Belt in the Belt Maintenance , pag e 37 .

4. Raise the front of the mac hine and hold with jac k stands .

Page 38

5. Disconnect clutc h wire connector from wire har ness .

6. Disconnect clutc h retainer from the engine dec k ( Figure 48 ).

Figure 48

1. Transmission belt 5. Clutch wire connector

2. Idler pulley 6. Pivot bolt

3. Clutch retainer 7. Drive pulley

4. Tension spring

8. Engine deck

7. Unhook tension spring from side of frame ( Figure 48 ).

8. Loosen pi v ot bolt enough to remo v e traction belt from the dri v e pulley and clutc h.

9. Install new belt around clutc h and dri v e pulley .

10. T or que pi v ot bolt to 35-40 ft-lb (47-54 N·m). Install tension spring betw een idler ar m and frame brac k et ( Figure 48 ).

11. Install clutc h retainer to the engine dec k ( Figure 48 ).

12. Connect clutc h wire connector to wire har ness .

13. Install PTO dri v e belt.

4. R emo v e the knobs/r ubber w ashers holding the belt co v er to the cutting unit and remo v e the belt co v er .

5. R emo v e the PTO dri v e belt. R efer to R e placing the PTO Dri v e Belt in Belt Maintenance , pag e 37 .

6. Disconnect the idler ar m spring to reliev e tension on the idler ar m and idler pulley , then remo v e the w or n mo w er dec k belt ( Figure 49 ).

7. Install the new mo w er dec k belt around the tw o outside spindle pulleys , the idler pulley , and in the lo w er g roo v e of the double spindle pulley ( Figure 49 ).

8. Connect the idler ar m spring ( Figure 49 ).

9. Install the PTO dri v e belt. R efer to R e placing the PTO Dri v e Belt in the Belt Maintenance , pag e 37 .

10. Adjust the belt guide an 1/8 inc h (3 mm) from the belt ( Figure 49 ).

11. Install the belt co v er onto the cutting unit, then install and tighten the knobs/r ubber w ashers .

12. Install the car rier frame co v er onto the cutting unit, then install and tighten the knobs/r ubber w ashers .

Replacing the Mower Belt

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks and crac ks are signs of a w or n dec k belt. R e place the dec k belt if any of these conditions are evident.

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the knobs/r ubber w ashers holding the car rier frame co v er and remo v e the car rier frame co v er .

Figure 49

1. Mower deck belt 4. PTO Drive Belt

2. Idler arm spring 5. Center spindle pulley

3. Outside pulley 6. Belt guide

Replacing the PTO Drive Belt

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks and crac ks are signs of a w or n dri v e belt. R e place the dri v e belt if any of these conditions are evident.

Page 39

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the knobs/r ubber w ashers holding the car rier frame co v er and remo v e the car rier frame co v er .

4. R emo v e the knobs/r ubber w ashers holding the belt co v ers to the top of the cutting unit and remo v e the belt co v ers .

5. R emo v e the heat shield from the engine dec k and car rier frame .

6. R emo v e the idler spring from idler ar m. R emo v e the dri v e belt from the PTO clutc h pulley , idler pulleys and the left spindle pulley ( Figure 50 ).

7. Install the new dri v e belt onto the PTO eng ag ement pulley and the top g roo v e of the center spindle pulley ( Figure 50 ).

8. Install the belt onto idler pulleys and then install idler spring ( Figure 50 ).

9. Install the heat shield to the engine dec k and car rier frame .

10. Adjust the belt guide an 1/8 inc h (3 mm) from the belt ( Figure 50 ).

11. Install the belt co v ers onto the cutting unit, then reinstall and tighten the knobs/r ubber w ashers .

12. Install the car rier frame co v er onto the cutting unit, then reinstall and tighten the knobs/r ubber w ashers .

Figure 50

1. PTO engagement pulley 4. Center sprindle pulley

2. PTO drive belt idler pulley 5. PTO drive belt guide

3. PTO drive Belt 6. Idler spring

Mower Deck Maintenance

Servicing the Cutting Blades

T o ensure a superior quality of cut, k ee p the blades shar p . F or con v enient shar pening and re placement, y ou ma y w ant to k ee p extra blades on hand.

A w or n or dama ged blade can br eak, and a piece of the blade could be thr o wn into the operator’ s or bystander’ s ar ea, r esulting in serious per sonal injur y or death.

• Inspect the blade periodicall y f or w ear or dama ge.

• R eplace a w or n or dama ged blade.

Before Inspecting or Servicing the Blades

P ark the mac hine on a lev el surface , diseng ag e the blade control bail and set the parking brak e . T ur n the ignition k ey to off . R emo v e the k ey and disconnect the spark plug wire(s) from the spark plug(s).

Page 40

Inspecting the Blades

Inspect the blades ev er y 8 hours .

1. Inspect the cutting edg es ( Figure 51 ). If the edg es are not shar p or ha v e nic ks , remo v e and shar pen the blades . R efer to Shar pening the Blades .

1. Measure here from blade to hard surface

Figure 52

2. Position A

Figure 51

1. Cutting Edge 3. Wear/slot Forming

2. Curved Area

2. Inspect the blades , especially the cur v ed area ( Figure 51 ). If y ou notice any damag e , w ear , or a slot for ming in this area (item 3 in Figure 51 ), immediately install a new blade .

Checking for Bent Blades

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R otate the blades until the ends face forw ard and bac kw ard ( Figure 52 ). Measure from a lev el surface to the cutting edg e , position A , of the blades ( Figure 52 ). Note this dimension.

4. R otate the opposite ends of the blades forw ard.

5. Measure from a lev el surface to the cutting edg e of the blades at the same position as in ste p 3 abo v e . T he difference betw een the dimensions obtained in ste ps 3 and 4 m ust not ex ceed 1/8 inc h (3 mm). If this dimension ex ceeds 1/8 inc h (3 mm), the blade is bent and m ust be re placed; refer to R emo ving the Blades and Installing the Blades .

A blade that is bent or dama ged could br eak apar t and could seriousl y injur e or kill y ou or bystander s.

• Al w ays r eplace bent or dama ged blade with a new blade.

• Nev er ﬁle or cr eate shar p notches in the edges or surf aces of blade.

Removing the Blades

Blades m ust be re placed if a solid object is hit, if the blade is out of balance or is bent. T o ensure optim um perfor mance and contin ued safety confor mance of the mac hine , use g en uine T oro re placement blades . R e placement blades made b y other man ufacturers ma y result in non-confor mance with safety standards . 1. Hold the blade end using a rag or thic kly-padded glo v e . (Fig . 48).

Page 41

1. Hold the blade end using a rag or thic kly-padded glo v e .

Figure 54

1. Sharpen at original angle

2. R emo v e the blade bolt, blade stiffener , w asher , and blade from the spindle shaft ( Figure 53 ).

Figure 53

1. Sail Area of Blade 4. Blade stiffener

2. Blade spindle 5. Flat washer

3. Blade 6. Blade Bolt

Sharpening the Blades

1. Use a ﬁle to shar pen the cutting edg e at both ends of the blade ( Figure 54 ). Maintain the original angle . T he blade retains its balance if the same amount of material is remo v ed from both cutting edg es .

2. Chec k the balance of the blade b y putting it on a blade balancer ( Figure 55 ). If the blade sta ys 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 ( Figure 53 ). R e peat this procedure until the blade is balanced.

Figure 55

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft ( Figure 53 ).

Important: T he sail par t of the blade must be pointing up w ard, to w ard the inside of the mo w er to ensur e pr oper cutting ( Figur e 53 ).

2. Install the blade stiffener , ﬂat w asher and blade bolt ( Figure 53 ).

3. T or que the blade bolt to 85-110 ft-lb (115-140 N•m).

Correcting the Mower Quality of Cut

If one dec k blade cuts lo w er than the other , cor rect as follo ws .

Note: Tire air pressure is critical in these procedures . Mak e sure all tires ha v e cor rect pressure .

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the

Page 42

operating position. Disconnect the spark plug wire(s) from the spark plug(s).

3. Adjust the tire pressure in all tires to speciﬁcations on pag e .

4. Chec k that the blades and spindle shafts are not bent. R efer to Chec king for Bent Blades .

5. Set the height-of-cut to the 4 inc h (101.6 mm) position. R efer to Adjusting the Height-Of-Cut in Operation , pag e 19 .

6. P erfor m the ste ps in the follo wing sections F rame Set Up , Chec king F ront-to-R ear Pitc h, and Chec king Side-to-Side Lev eling .

Adjusting the Frame

Checking the Carrier Frame and Deck Alignment

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

7. Align the car rier frame and engine dec k to matc h 1-5/16 inc h (33 mm), plus or min us a 1/4 inc h (6 mm) at location A ( Figure 56 ).

8. Tighten the car rier frame mounting bolts on both sides of the mac hine .

Checking the Engine Deck Height

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Adjust the tire pressure in all tires to speciﬁcations on pag e .

4. Measure engine dec k height at location A ( Figure 57 ).

3. Place a long straight edg e on top of the engine dec k as sho wn in Figure 56 .

Figure 56

1. Carrier Frame

2. Top of engine deck 5. Straight edge

3. Carrier frame mounting bolts

4. Location A, 1-5/16 inch (33 mm) ±1/4 inch (6 mm)

6. Carrier frame cross tube

4. At the car rier frame cross tube , measure the height at location A ( Figure 56 ). T his measurement m ust be 1-5/16 inc h (33 mm), plus or min us a 1/4 inc h (6 mm).

5. If the height at location A is not cor rect, adjustment is needed.

6. Loosen the car rier frame mounting bolts on both sides of the mac hine ( Figure 56 ).

Figure 57

1. Back view of machine

2. Top of engine deck 4. Same height at locations A

3. Tires

and B

5. Measure engine dec k height at location B ( Figure 57 ).

6. If the height at location A and B are not the same , c hang e tire pressure slightly to mak e them the same .

Checking Carrier Frame Front-to-Rear Pitch

T he car rier frame m ust ha v e a pitc h of a 1/4 inc h (6 mm) o v er the length of 24 inc hes (61 cm) on the car rier frame ( Figure 58 ).

1. Measure out 24 inc hes (61cm) on the car rier frame ( Figure 58 ).

Page 43

Figure 58

1. Caster Wheel 4. Height at locations A and B

2. Carrier Frame

3. 1/4-3/8 inch (6-10 mm) pitch over 24 inch (61 cm) length

5. Caster spacers

2. Measure car rier frame height at location A ( Figure 58 ).

3. Measure car rier frame height at location B ( Figure 58 ).

4. T he height at location A m ust be a 1/4-3/8 inc h (6 mm -10 mm) lo w er than location B ( Figure 58 ).

5. If the car rier frame is not cor rect, mo v e caster spacers to mak e it a 1/4-3/8 inc h (6 -10 mm) pitc h ( Figure 58 ). Mo v e spacers from top or bottom to mak e the cor rect pitc h.

6. T he tire pressure ma y also be adjusted slightly to mak e a 1/4 inc h (6 mm) pitc h.

Checking Carrier Frame Side-to-Side

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Figure 59

1. Caster Wheel 4. Same height at locations A

2. Carrier Frame

3. Front height-of-cut pins

and B

5. Caster spacers

5. Measure car rier frame height at location B ( Figure 59 ).

6. If the car rier frame height is not the same mo v e spacers from top or bottom of caster wheel, to mak e it lev el. T he tire pressure ma y also be adjusted slightly to mak e it lev el.

Checking the Mower Deck Front-to-Rear Pitch

1. Chec k the tire pressure on both dec k and traction unit.

2. P osition one blade front-to-rear ( Figure 60 ). Measure at A and B locations ( Figure 60 ) from a lev el surface to the cutting edg e of the blade tips ( Figure 60 ).

3. T he mo w er blade should be 1/4 inc h (6 mm) lo w er in front at A than in the rear at B . R otate blades and re peat for other blades . If it is not cor rect, proceed to Changing the Dec k F ront-to-R ear Pitc h.

3. Adjust the tire pressure in all tires to speciﬁcations; refer to Dri v e System Maintenance , pag e 34 .

4. Measure car rier frame height at location A ( Figure 59 ).

Page 44

3. T o lo w er the front of the dec k, loosen jam n ut and rotate the front pin counter cloc kwise ( Figure 61 ).

4. P osition the blades front-to-rear . Measure at C and D locations ( Figure 60 ) from a lev el surface to the cutting edg e of the blades .

5. Chec k the side-to-side lev eling of the cutting unit.

6. Tighten the jam n uts ( Figure 61 ).

Checking the Deck Side-to-Side Leveling

Figure 60

1. Measure blade at points A and B

2. Measure from a level surface

Changing the Deck Front-to-Rear Pitch

Changing the front-to-rear pitc h is done b y adjusting the front height-of-cut posts .

1. T o c hang e the front-to-rear pitc h, the front height-of-cut posts can be adjusted ( Figure 61 ).

1. Chec k the tire pressure on both dec k and traction unit.

2. P osition the blades side-to-side ( Figure 62 ). Measure at B and C locations ( Figure 62 ) from a lev el surface to the cutting edg e of blade tips ( Figure 62 ).

Figure 62

1. Measure from a level surface

2. Measure blade at points B and C

Figure 61

1. Caster Wheel

2. Carrier Frame

3. Front height-of-cut pins

4. Jam nut

5. Ball joint

2. T o raise the front of the dec k, loosen jam n ut and rotate the front pin cloc kwise ( Figure 61 ).

3. T he difference betw een measurements B and C should be no more than 1/4 inc h (6 mm).

Changing the Side-to-Side Leveling

Changing the side-to-side lev eling is done b y adjusting tire pressure .

Page 45

1. Chang e the tire pressure on both dec k and traction unit. Do this to the cor responding side that needs adjustment.

2. R ec hec k the front-to-rear pitc h and side to side lev eling of the cutting unit.

Matching Height of Cut

1. Chec k the tire pressure on both dec k and traction unit.

2. Set the height-of-cut to the 4 inc h (101.6 mm) position follo wing the height-of-cut decal.

3. With the mac hine on lev el surface , position one blade front-to-rear ( Figure 63 ). Measure at A and from lev el surface to the cutting edg e of the blade tips ( Figure 63 ).

Replacing the Grass Deector

An unco v er ed discharge opening could allo w the la wn mo w er to thr o w objects in the operator’ s or bystander’ s dir ection and r esult in serious injur y . Also, contact with the blade could occur .

Nev er operate the la wn mo w er unless y ou install a co v er plate, a mulch plate, or a g rass chute and catcher .

1. R emo v e the loc kn ut, bolt, spring and spacer holding the deﬂector to the pi v ot brac k ets ( Figure 64 ). R emo v e damag ed or w or n g rass deﬂector .

Figure 63

1. Measure from a level surface

2. Measure blade at point A

4. T he measurement should be 4 inc h (101.6 mm).

5. If it does not measure cor rectly , add air pressure in the rear tires to raise the height-of-cut.

6. If it does not measure cor rectly , decrease air pressure in rear tires to lo w er the height-of-cut.

7. Chec k the car rier frame front-to-rear pitc h.

Figure 64

1. Bolt 5. Spring installed

2. Spacer

3. Locknut 7. L end of spring, place

4. Spring

6. Grass Deector

behind deck edge before installing bolt

8. J hook end of spring

2. Place spacer and spring onto g rass deﬂector . Place the L end of spring behind dec k edg e .

Page 46

Note: Mak e sure the L end of spring is installed behind dec k edg e before installing the bolt as sho wn in Figure 64 .

3. Install bolt and n ut. Place the J hook end of spring around g rass deﬂector ( Figure 64 ).

Important: T he g rass deﬂector must be a ble to r otate. Lift the deﬂector up to the full open position and ensur e that it r otates into the full do wn position.

Page 47

Storage

Cleaning and Storage

1. Diseng ag e the po w er tak e off (PTO), set the parking brak e , and tur n the ignition k ey to off . R emo v e the k ey .

Engine Maintenance , pag e 28 . With the spark plug(s) remo v ed from the engine , pour tw o tablespoons of engine oil into the spark plug hole . No w use the star ter 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).

2. R emo v e g rass clippings , dir t, and g rime from the exter nal par ts of the entire mac hine , especially the engine . Clean dir t and c haff from the outside of the engine’ s cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not pr essur e w ash the machine. A v oid ex cessi v e use of w ater , especiall y near the shift lev er plate, and engine.

3. Chec k the brak e; refer to Ser vicing the Brak e in Brak e Maintenance , pag e 36 .

4. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner in Engine Maintenance , pag e 28 .

5. Grease the mac hine; refer to Greasing and Lubrication in Lubrication , pag e 27 .

6. Chang e the crankcase oil; refer to Ser vicing the Engine in Engine Maintenance , pag e 28 .

7. Chec k the tire pressure; refer to Chec king the Tire Pressure in Dri v e System Maintenance , pag e 34 .

10. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed or defecti v e .

11. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

12. Store the mac hine in a clean, dr y g arag e or storag e area. R emo v e the k ey from the ignition switc h and k ee p it in a memorable place . Co v er the mac hine to protect it and k ee p it clean.

8. F or long-ter m storag e:

A. Add stabilizer/conditioner additi v e to fuel

in the tank.

B . R un engine to distribute conditioned fuel

through the fuel system (5 min utes).

C . Stop engine , allo w to cool and drain the

fuel tank; refer to Ser vicing the Fuel T ank in Fuel System Maintenance , pag e 32 , or operate engine until it stops .

D . R estar t engine and r un until it stops .

R e peat, on Chok e until engine will not restar t.

E. Dispose of fuel properly . R ecycle as per

local codes . Note: Do not store stabilizer/conditioned

g asoline o v er 90 da ys .

9. R emo v e the spark plug(s) and c hec k its condition; refer to Ser vicing the Spark Plug in

Page 48

Troubleshooting

Problem

Engine will not start, starts hard, or fails to keep running.

Engine loses power.

Possible Cause Corrective Action

1. Fuel tank is empty. 1. Fill fuel tank with gasoline.

2. Choke is not on. 2. Move the throttle lever to choke position.

3. Air cleaner is dirty. 3. Clean or replace the air cleaner element.

4. Spark plug wire is loose

or disconnected.

5. Spark plug is pitted,

fouled, or the gap is incorrect.

6. Dirt in the fuel lter. 6. Replace the fuel lter.

7. Dirt, water, or stale fuel

is in the fuel system.

1. Engine load is excessive. 1. Reduce the ground

2. Air cleaner is dirty. 2. Clean the air cleaner

3. Oil level in the crankcase

is low.

4. Cooling ns and air

passages under the engine blower housing are plugged.

5. Spark plug is pitted,

fouled, or the gap is incorrect.

6. Vent hole in the fuel cap

is plugged.

7. Dirt in the fuel lter. 7. Replace the fuel lter.

8. Dirt, water, or stale fuel

is in the fuel system.

4. Install wire on spark plug.

5. Install a new, correctly gapped spark plug.

7. Contact an Authorized Service Dealer.

speed.

element.

3. Add oil to the crankcase.

4. Remove the obstruction from the cooling ns and air passages.

5. Install a new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact an Authorized Service Dealer.

Engine overheats.

1. Engine load is excessive. 1. Reduce the ground speed.

2. Oil level in the crankcase

is low.

3. Cooling ns and air

passages under the engine blower housing are plugged.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling ns and air passages.

Page 49

Problem

Possible Cause Corrective Action

Machine does not drive.

Abnormal vibration.

1. Shift lever is in neutral. 1. Move shift lever to a drive gear position.

2. Traction belt is worn,

2. Change the belt.

loose or broken.

3. Traction belt is off a

3. Change the belt.

pulley.

4. Broken or missing idler

4. Replace the spring.

spring.

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,

idler pulley, or blade

1. Install new cutting blade(s).

2. Tighten the blade mounting bolt.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

pulley.

5. Engine pulley is damaged.

5. Contact an Authorized Service Dealer.

6. Blade spindle is bent. 6. Contact an Authorized Service Dealer.

Uneven cutting height.

1. Blade(s) not sharp. 1. Sharpen the blade(s).

2. Cutting blade(s) is/are

bent.

2. Install new cutting blade(s).

3. Mower is not level. 3. Level mower from side-to-side and front-to-rear.

4. Underside of mower is

dirty.

5. Tire pressure is not

4. Clean the underside of the mower.

5. Adjust the tire pressure.

correct.

6. Blade spindle bent. 6. Contact an Authorized Service Dealer.

Page 50

Problem

Possible Cause Corrective Action

Blades do not rotate.

1. Drive belt is worn, loose

1. Check the belt tension.

or broken.

2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position.

3. Deck belt is worn, loose

3. Install new deck belt.

or broken.

4. Deck belt is off pulley. 4. Inspect the belt and replace if damaged. Check the pulleys and idler pulleys.

5. Broken or missing idler

5. Replace the spring.

spring.

Page 51

Schematics

Electrical Schematic (Rev. A)

Page 52

Page 53

Page 54

Page 55

Evaporative Emission Control Warranty Statement

California Evaporative Emission Control Warranty Statement

Your Warranty Rights and Obligations

Introduction

The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. The Toro® Company must warrant the evaporative emission control system on your equipment for two years provided there has been no abuse, neglect or improper maintenance of your equipment.

Your evaporative emission control system may include parts such as: fuel lines, fuel line ttings, and clamps.

Manufacturer’s Warranty Coverage:

This evaporative emission control system is warranted for two years. If any evaporative emission-related part on your equipment is defective, the part will be repaired or replaced by The Toro® Company.

Owner’s Warranty Responsibilities:

• As the equipment owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual.

The Toro® Company recommends that you retain all receipts covering maintenance on your equipment, but The Toro® Company cannot deny warranty solely for the lack of receipts.

• As the equipment owner, you should however be aware that The Toro® Company may deny you warranty coverage if your emission

warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modications.

• You are responsible for presenting your equipment to an Authorized Service Dealer as soon as the problem exists. The warranty

repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact The Toro® Company at 1-952–948–4027 or call us toll free at the number listed in your Toro Warranty statement.

Defects Warranty Requirements:

1. The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.

2. General Evaporative Emissions Warranty Coverage. The emission warranty parts must be warranted to the ultimate purchaser and any subsequent owner that the evaporative emission control system when installed was:

A. Designed, built, and equipped so as to conform with all applicable regulations; and B. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.

3. The warranty on evaporative emissions-related parts will be interpreted as follows: A. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions must be

warranted for the warranty period of two years. If any such part fails during the period of warranty coverage, it must be repaired or replaced by The Toro® Company. Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period.

B. Any warranted part that is scheduled only for regular inspection in the written instructions must be warranted for the warranty

period of two years. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for a time not less than the remaining warranty period.

C. Any warranted part that is scheduled for replacement as required maintenance in the written instructions must be warranted

for the period of time prior to the rst scheduled replacement point for that part. If the part fails prior to the rst scheduled replacement, the part must be repaired or replaced by The Toro® Company. Any such part repaired or replaced under warranty must be warranted for a time not less than the remainder of the period prior to the rst scheduled replacement point for the part.

D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to

the owner at an Authorized Service Dealer.

E. Notwithstanding the provisions of subsection (D) above, warranty services or repairs must be provided at an Authorized

Service Dealer.

F. The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective,

provided that such diagnostic work is performed at an Authorized Service Dealer.

G. Throughout the evaporative emission control system’s two year warranty period, The Toro® Company must maintain a supply

of warranted parts sufcient to meet the expected demand for such parts.

H. Manufacturer approved replacement parts must be used in the performance of any warranty maintenance or repairs and must

be provided without charge to the owner. Such use will not reduce the warranty obligations of The Toro® Company.

I. The use of any add-on or modied parts will be grounds for disallowing a warranty claim made in accordance with this

article. The Toro® Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an add-on or modied part.

J. The Toro® Company shall provide any documents that describe the warranty procedures or policies within ve working

days of request by the Air Resources Board.

The following lists includes the parts covered under this warranty:

• Fuel Lines

• Fuel Line Fittings

• Clamps

Emission Warranty Parts List:

374-0092 Rev A

Page 56

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

All Products All Spindles

Engines/Hydraulic Systems* on the following:

Outfront and Mid-Mount Z’s ProLine Mid-Size Mowers Groundsmaster[Symbol_registersans] Riding Mowers Backpack Blowers

Deck Shells (32 ″ -72 ″ ) on the following:

ProLine Mid-Size Mowers

Mid-Mount Z’s Electric Clutch on 500 Series Mid-Mount Z’s

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

This warranty applies to:

Warranty Period

2 years

t h i r d y e a r , p a r t s o n l y )

1 year

( p a r t s a n d l a b o r ;

2 years

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

S o m e e n g i n e s u s e d o n T o r o L C E P r o d u c t s a r e w a r r a n t e d b y t h e e n g i n e m a n u f a c t u r e r .

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 Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com . You may also call our Toro Customer Care Department toll free at 888–577–7466 (U.S. Customers) or 877–484–9255 (Canada customers).

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

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

Owner Responsibilities

You must maintain your Toro Product by following the maintenance 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 coverage on some products. This express warranty does not cover the following:

• Cost of regular maintenance service or parts, such as 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 non-use over three months.

• Pickup and delivery charges.

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

General Conditions

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

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.

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.

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

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

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0037 Rev D