Toro 30334 Operator's Manual

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Page 1

Form No. 3325–880

Mid–Size Mower

ProLine Gear 17 HP with 52 in. Side Discharge Mower

30334—210000001 and Up

Operator’s Manual

English (EN)

Page 2

Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important This engine is not equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . . . .

Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 12. . . . . . . . . . . . . . . . . . . . .

Set Up 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Control Panel and Fuel Tank 13. . . . . .

Install Shift Lever 14. . . . . . . . . . . . . . . . . . . . . . . . . .

Install Handles 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Control Rods 15. . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Adjustment 16. . . . . . . . . . . . . . . . . . .

Install Hairpin Cotter Pins 16. . . . . . . . . . . . . . . . . . .

Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 16. . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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

Parking Brake and Neutral Lock 17. . . . . . . . . . . . . .

Starting and Stopping the Engine 18. . . . . . . . . . . . . .

Operating Mower Blade Control (PTO) 18. . . . . . . .

The Safety Interlock System 19. . . . . . . . . . . . . . . . .

Driving Forward or Backward 19. . . . . . . . . . . . . . . .

Adjusting Wheel Drive Tension 20. . . . . . . . . . . . . . .

Stopping the Machine 20. . . . . . . . . . . . . . . . . . . . . .

Transporting Machines 21. . . . . . . . . . . . . . . . . . . . . .

Side Discharge or Mulch Grass 21. . . . . . . . . . . . . . .

Adjusting Height-of-Cut 21. . . . . . . . . . . . . . . . . . . .

Adjusting Gage Wheels 21. . . . . . . . . . . . . . . . . . . . .

Adjusting Center Gage Wheels 22. . . . . . . . . . . . . . .

Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 23. . . . . . . . .

Air Cleaner Service 24. . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Service 25. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Service 26. . . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 27. . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 28. . . . . . . . . . . . . . . . .

Checking Tire Pressure 28. . . . . . . . . . . . . . . . . . . . .

Fuel Tank Service 28. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter Service 29. . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Service 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 29. . . . . . . . . . . . . . . . .

Brake Service 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Blade Service 31. . . . . . . . . . . . . . . . . . . . . .

Correcting Cutting Unit Mismatch 32. . . . . . . . . . . .

Frame Set Up 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Deck Front-to-Rear Pitch 34. . . . . . . . .

Changing the Deck Front-to-Rear Pitch 34. . . . . . . . .

Checking the Deck Side-to-Side Leveling 35. . . . . . .

Changing the Side-to-Side Leveling 35. . . . . . . . . . .

Matching Height of Cut 35. . . . . . . . . . . . . . . . . . . . .

Replacing the Drive Belt 36. . . . . . . . . . . . . . . . . . . .

Replacing the Traction Belt 36. . . . . . . . . . . . . . . . . .

Replacing the Deck Belt 36. . . . . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 37. . . . . . . . . . . . . . . .

Replacing the Caster Wheel Fork Bushings 37. . . . . .

Caster Wheel and Bearings Service 38. . . . . . . . . . . .

Replacing the Grass Deflector 39. . . . . . . . . . . . . . . .

Wiring Diagram 40. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 41. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 44. . . . . . . . . . . . . .

 2000 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Page 3

Introduction

Safety

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

m–5372

Figure 1

1. Location of the model and serial numbers

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

This machine meets or exceeds the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of attachments made by other

manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

symbol, which means

Safe Operating Practices

The following instructions are from ANSI standard B71.4—1999.

Training

• Read the Operator’s Manual and other training material.

If the operator(s) or mechanic(s) can not read English it is the owner’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 mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people or property.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

Preparation

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety

glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and

remove all objects such as rocks, toys and wire which can be thrown by the machine.

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• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Use only an approved container

• Never remove gas cap or add fuel with engine

running. Allow engine to cool before refueling. Do not smoke.

• Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety switches

and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is

engaged before starting engine. Only start engine from the operator’s position.

• Slow down and use extra care on hillsides. Be sure to

travel side–to–side on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop–offs.

• Slow down and use caution when making turns and

when changing directions on slopes.

• Do not operate the mower under the influence of

alcohol or drugs

• Use care when loading or unloading the machine into or

from a trailer or truck

• Use care when approaching blind corners, shrubs, trees,

or other objects that may obscure vision.

Maintenance and storage

• Disengage drives, set parking brake, stop engine and

remove key or disconnect spark plug wire. Wait for all

movement to stop before adjusting, cleaning or

repairing.

• Clean grass and debris from cutting unit, drives,

mufflers, and engine to help prevent fires. Clean up oil

or fuel spillage.

• Let engine cool before storing and do not store near

flame.

• Shut off fuel while storing or transporting. Do not store

fuel near flames or drain indoors.

• Park machine on level ground. Set parking brake. Never

allow untrained personnel to service machine.

• Use jack stands to support components when required.

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other guards not

securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed

the engine.

• Stop on level ground, disengage drives, engage parking

brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking objects

or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Keep hands and feet away from the cutting unit.

• Look behind and down before backing up to be sure of

a clear path.

• Keep pets and bystanders away.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not mowing.

• Carefully release pressure from components with stored

energy.

• Disconnect battery or remove spark plug wire before

making any repairs. Disconnect the negative terminal

first and the positive last. Reconnect positive first and

negative last.

• Use care when checking blades. Wrap the blade(s) or

wear gloves, and use caution when servicing them.

Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine

running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before

connecting or disconnecting from battery. Wear

protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged

decals.

Toro Mower Safety

The following list contains safety information specific to Toro products and other safety information you must know.

Page 5

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

General Operation

• Allow only responsible adults who are familiar with the

instructions to operate the machine.

• Be sure the area is clear of other people before mowing.

Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing.

• Be aware of the mower discharge direction and do not

point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away from

attachment discharge area, underside of mower and any moving parts while engine is running.

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts which may

be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Use only Toro-approved attachments. Warranty may be

voided if used with unapproved attachments.

Slope Operation

Slopes and ramps are a major factor related to loss-of-control and accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you feel uneasy on a slope, do not mow it.

• Remove obstacles such as rocks, tree limbs, etc. from

the mowing area. Watch for holes, ruts or bumps. Tall grass can hide obstacles.

• Use extra care with grass catchers or other attachments.

These can change the stability of the machine.

• Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose

traction, disengage the blades.

• Check carefully for overhead clearances (i.e. branches,

doorways, electrical wires) before driving under any objects and do not contact them.

• Mow slopes side–to–side.

DO NOT

• Do not mow slopes greater than 15 degrees.

• Avoid turning on slopes. If you must turn, turn slowly

and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or embankments.

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause

sliding.

• Do not use a grass catcher on steep slopes. Heavy grass

bags could cause loss of control of the machine.

• Do not mow up and down slopes.

Service

• Never store the machine or fuel container inside where

there is an open flame, such as near a water heater or furnace.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check safety systems

for proper operation before each use.

• Use only genuine replacement parts to ensure that

original standards are maintained.

• Check brake operation frequently. Adjust and service as

required.

• Battery acid is poisonous and can cause burns. Avoid

contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks and

flames away from battery.

• Hydraulic fluid escaping under pressure can penetrate

the skin and cause injury. Use cardboard or paper to find hydraulic leaks. Never use your hands.

• Use slow speed so that you will not have to stop while

on the slope.

Page 6

Page 7

Slope Chart

Page 8

Page 9

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

67–5360

66–1340

63–8440

68–8340

43–8480

95–2814

54–9220

105–4146

Page 10

104–8186

105–0840

105–4142

98–0776

105–4111

98–4387

104–8569

Page 11

104–8171

105–4104

105–4105

105–4108

Page 12

Gasoline and Oil

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

Important Never use methanol, gasoline containing

methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Fill the fuel tank outdoors, in an open area,

when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 in. to 1/2 in. (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay

away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas–powered

equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep

the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage it is recommended that the fuel tank

be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system,

which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the

gas. Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

1. Shut the engine off and set the parking brake.

2. Clean around fuel tank cap and remove the cap. Add

unleaded regular gasoline to fuel tank, until the level is

1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of

the filler neck. This space in the tank allows gasoline to

expand. Do not fill the fuel tank completely full.

3. Install fuel tank cap securely. Wipe up any gasoline that

may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 25.

Page 13

Set Up

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

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

DESCRIPTION QTY. USE

Fuel tank Control panel Bolt, 5/16 x 7/8 in. (22.5 mm) Lock washer, 5/16 in. Washer, 5/16 Spring Stud Hose clamp

Shift lever Rubber seal Square hole washer Spring washer Locknut, 3/8 in.

Upper handle Flanged bolt, 3/8 x 1 in. (26 mm) Flange nut, 3/8 in. Clevis pin Washer

1 1 2 2 4 2 2 1

1 1 1 1 1

1 4 4 2 2

Install fuel tank and control panel

Install shift lever

Install upper handle to frame

Install control rods Hairpin cotter pin Hairpin cotter pin 2 Install hairpin cotter pins

Operator’s Manual Engine Operator’s Manual Parts Catalog Registration card

Installing the Control Panel and Fuel Tank

Note: Hardware to install control panel and fuel tank is installed in the bottom of fuel tank.

1 1 1 1

Read before operating machine

Fill out and return to Toro

1. Remove the bolts and nuts holding the control panel to

the rear frame. Discard these nuts and bolts.

2. Slide the control panel under the bottom of the rear

frame (Fig. 2).

Page 14

Install Shift Lever

1. Remove the locknut (3/8 in.) and spring washer from

the stud on top of the transmission.

m–5221

Figure 2

1. Rear frame

2. Control panel

3. Fuel tank

3. Align fuel tank with the top of the rear frame (Fig. 2).

4. Secure the right side control panel and fuel tank to the

rear frame with 2 bolts (5/16 x 7/8 in. (22 mm)), lock washers (5/16 in.) and washers (5/16 in.) (Fig. 3).

5. Secure the left side control panel and fuel tank to the

rear frame with 2 studs, washers (5/16 in.), springs and locknuts (5/16 in.) (Fig. 3).

Note: Tighten left side until it is completely tight and then unscrew locknut one full turn. This will allow the spring to work.

Note: Do not remove rubber seal washer and square hole washer from transmission shaft.

2. Slide shift lever through control panel and align

mounting hole in lever with square on transmission shaft. Secure lever to transmission with previously removed spring washer and locknut (Fig. 4).

3. Install the spring washer, dish down, and locknut

(Fig. 4).

4. Torque nut to 35 ft. lbs. (47 Nm).

m–5250

Figure 4

1. Shift lever

2. Control panel

3. Rubber seal washer

4. Square hole washer

5. Spring washer

6. Locknut, 3/8 in.

4 3

Figure 3

1. Bolt, 5/16 x 7/8 in. (22 mm)

2. Lock washers, 5/16 in.

3. Washer, 5/16 in.

4. Fuel line

5. Hose clamp

6. Stud

7. Spring

8. Locknut

9. Control panel

10. Fuel tank connection

6. Slide the hose clamp onto the fuel line (Fig. 3).

7. Push the fuel line onto the fuel tank connection and

secure it with a hose clamp (Fig. 3).

m–5220

5. Shift lever to second gear and check alignment of lever

in slot of shifter plate. The clearance between top and bottom of the shift lever should be equal (Fig. 5).

6. If clearance is not correct, remove lever and bend it

slightly to adjust.

Note: Do not bend lever while attached to transmission shaft or damage may occur.

7. Shift lever to neutral and check alignment of lever in

slot of shifter plate. The clearance on the sides of shift lever should be equal (Fig. 5).

8. If clearance is not correct, loosen control panel and

adjust it side–to–side. Tighten control panel.

Note: Tighten left side of control panel until it is completely tight and then unscrew locknuts one full turn. This will allow the spring to work.

Page 15

Rear View

m–5458

Figure 5

1. Shift lever, 2nd gear

2. Control panel

3. Shift lever, neutral

4. Equal distance

Install Handles

1. Align handle with upper mounting hole in rear frame

(Fig. 6).

2. Secure each upper mounting hole with a flange bolt

(3/8 x 1 in. (26 mm)) and flange nut (Fig. 6).

3. Select low, middle or high position for the lower

mounting hole (Fig. 6). This allows the upper handle to be adjusted to the user’s height preference.

7 8 9

m–5382

Figure 6

1. Handle

2. Rear frame

3. Flange bolt, 3/8 x 1 in. (26 mm)

4. Flange nut, 3/8 in.

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. Middle position

9. High position

Install Control Rods

1. Thread rod fittings equal distance onto each control rod (Fig. 7).

2. Install rod fittings with clevis pins into holes in idler brackets (Fig. 7). Secure with washers and hairpin cotters (Fig. 7).

Note: Install rod fittings so the clevis pin is above the control rod, as shown in figure 7.

4. Secure each lower mounting hole with a flange bolt

(3/8 x 1 in. (26 mm)) and flange nut (Fig. 6).

5. Repeat procedures for opposite handle. Note: If handle position is ever changed, the control rods

and brakes will need to be readjusted.

1. Control rod

2. Idler bracket

3. Hairpin cotter

3 5

m–5385

Figure 7

4. Clevis pin

5. Washer

6. Rod fitting

Page 16

3. Adjust control rod length by threading rod in or out of

rod fitting until there is a 3/16 to 1/4 in. (5 mm to 6 mm) clearance between the control rod and bottom of neutral/brake lock (Fig. 8).

4. Install control rod to drive lever and neutral/brake lock.

Secure with clevis pin and hairpin cotter.

5. Check operation. If adjustment is required, remove

hairpin cotter and clevis pin securing rod to drive levers.

6. Adjust control rod length by repeating steps 3 and 4

(Fig. 8).

1. Handle

2. Neutral/Parking brake lock

3. 3/16 in. to 1/4 in. (5 mm to 6 mm) clearance

Figure 8

4. Drive lever

5. Forward speed

6. Control Rod

m–5387

m–5314

Figure 9

1. Hairpin cotter

2. Extra spacers

3. Height–of–cut post

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Think Safety First

Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

The use of protective equipment for eyes, hearing, feet and head is recommended.

Parking Brake Adjustment

1. Refer to Brake Service on page 30 for checking brakes and adjusting them.

Install Hairpin Cotter Pins

Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter.

1. On opposite side of muffler, install extra hairpin cotter pins into front and rear height–of–cut pins (Fig. 9).

Caution

This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

Figure 10

1. Caution 2. Wear hearing protection

Page 17

Controls

Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine.

Throttle control – The throttle control has three positions: CHOKE, FAST and SLOW.

Operator Presence Control (OPC) levers – OPC levers are used in conjunction with deck engagement switch (PTO) to release blade brake and engage clutch to drive mower blades. Release OPC levers to disengage mower blades.

Blade control switch (PTO) – Pull switch used in conjunction with OPC levers to release blade brake and engage clutch to drive mower blades.

Gear shift lever – Transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. Do not shift while unit is moving, as transmission damage may occur.

Drive levers – Shift to desired gear and release drive levers to engage forward traction operation and squeeze to reverse. Squeeze right side of drive lever to turn right and left side to turn left.

Neutral lock and Parking brake locks – Squeeze drive levers back and move locks to the rear for neutral lock. Squeeze drive levers back and move locks to the front for parking brake lock.

1. Throttle control

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

4. Gear shift lever

Figure 11

5. Drive levers

6. Neutral lock and Parking

7. Ignition switch

8. Handle

brake locks

m–5379

Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: RUN and OFF.

Recoil Starter – Pull recoil Starter handle to start engine. Fuel Shut–off Valve – (Under fuel tank) Close fuel

shut–off valve when transporting or storing mower.

Parking Brake and Neutral Lock

Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them ahead (Fig. 12).

3. Release the drive levers.

Releasing the Parking Brake

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them back until in forward speed slot (Fig. 12).

Page 18

3 6

Figure 12

1. Handle

2. Neutral/Parking brake lock

3. Park position

Setting the Neutral Lock

4. Neutral position

5. Drive lever

6. Full speed forward

m–5386

Important Do not pull recoil rope to its limit or let go

of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged.

Stopping

1. Move the throttle lever to “SLOW” (Fig. 13).

2. Let engine idle for 30 to 60 seconds before turning the

ignition key “OFF.”

3. Set the parking brake.

4. Turn the ignition key to “OFF” (Fig. 13).

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them back (Fig. 12).

Releasing the Neutral Lock

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them forward until in forward slot (Fig. 12).

Starting and Stopping the Engine

Starting

1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open.

2. Move the shift lever to neutral, move PTO switch to off, set the parking brake and turn ignition key to RUN.

3. Move the throttle control to CHOKE position before starting a cold engine.

Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to FAST position.

4. Grasp recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly.

m–5379

Figure 13

1. Throttle lever 2. Ignition key

Important Make sure fuel shut off valve is closed

before transporting or storing machine, as fuel leakage may occur.

Before storing machine, pull wire off spark plug(s) to prevent possibility of accidental starting.

Operating Mower Blade Control (PTO)

The blade control switch (PTO) in conjunction with the Operator Presence Control (OPC) levers engage and disengage power to the electric clutch and mower blades.

Engaging the Mower Blades (PTO)

1. To engage blade, squeeze the Operator Presence

Control (OPC) levers against handle grips (Fig. 14).

2. Pull blade switch (PTO) up. Hold the Operator Presence

Control (OPC) levers against handle grip.

3. Repeat procedure to engage mower blades if OPC

levers are released.

Page 19

3 2

m–5379

Figure 14

1. Handle

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

Disengaging the Mower Blades (PTO)

The mower blades can be disengaged by one of the following steps.

1. Push the blade control switch (PTO) to off (Fig. 14).

2. Release Operator Presence Control (OPC) levers to

disengage blades (Fig. 14). This will also kill the engine.

The Safety Interlock System

Caution

• The Operator Presence Control (OPC) levers are

released.

• The machine is shifted into gear without holding OPC

levers.

• The blade control switch (PTO) is pulled on without

holding the OPC levers.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately.

1. Set the parking brake and place shift lever in neutral.

Start the engine; refer to Starting and Stopping the Engine, page 18.

2. Without holding the Operator Presence Control (OPC) levers, pull the blade control switch (PTO) up. The

engine should kill.

3. Push the blade control switch off.

4. With engine running, hold down the OPC levers. Pull

the blade control switch (PTO) up. The clutch should engage and the mower blades begin rotating.

5. Release the OPC levers. The engine should kill.

6. With the engine running, move shift lever into a gear. Release the OPC levers. The engine should kill.

7. If all the above conditions are not met have an

Authorized Service Dealer repair the safety system immediately.

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the mower from starting unless:

• The blade control switch (PTO) is pushed off.

• The machine is shifted into neutral.

The safety interlock system is designed to kill the engine when:

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the “FAST” position for best performance.

Forward

1. To go forward, move the shift lever to a forward gear.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 17.

3. Slowly release the drive levers to move forward (Fig. 15).

To go straight, release drive levers equally (Fig. 15). To turn, squeeze the drive lever on the side and direction

you want to turn (Fig. 15).

Page 20

m–5379

Figure 15

1. Drive lever 2. Gear shift lever

Backward

1. To go backward, move the shift lever to reverse gear.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 17.

3. Slowly squeeze the drive levers together to move

rearward (Fig. 15).

Adjusting Wheel Drive Tension

m–5372

Figure 16

1. Position A, Normal Conditions

2. Position B, More Severe

3. Position C, Most Severe

4. Drive spring

5. Adjustment bolt, In position A

6. Drive pulley shield

Stopping the Machine

1. To stop the machine, squeeze the drive levers all the

way back to engage brakes.

2. Move neutral/brake locks into the park position. Refer

to Setting the Parking Brake on page 17.

3. Shift transmission into neutral.

It may be necessary to increase wheel drive belt tension under certain operating conditions such as, wet grass, hilly terrain, or while pulling a sulky.

1. Stop engine and remove spark plug wire(s).

2. Disengage neutral/brake locks and release drive levers

to lower spring force.

3. Remove drive spring from adjustment bolt (Fig. 16).

4. Remove the lock nut securing the adjustment bolt to the

drive pulley shield (Fig. 16).

5. Locate bolt assembly in the desired tension position as

follows. Position A – Normal Conditions Position B – More Severe Position C – Most Severe

Note: Wheel drive tension is lowest with bolt assembly in Position A. It will increase in Positions B and C (Fig. 16).

6. Install adjustment bolt and drive spring.

7. Repeat for opposite side.

4. Turn the ignition key to “OFF” to stop the engine. Note: Remember to remove the key from the ignition

switch if you leave the machine.

Caution

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Page 21

Transporting Machines

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury.

To transport the machine:

2. Select hole in height-of-cut post corresponding to the

height-of-cut desired (Fig. 17).

3. Lift on side of deck and remove hairpin cotter (Fig. 17).

4. Add or remove spacers if needed and then align holes

and insert hairpin cotter (Fig. 17).

Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter.

• Lock brake and block wheels.

• Securely fasten the machine to the trailer or truck with

straps, chains, cable, or ropes.

• Secure a trailer to towing vehicle with safety chains.

Side Discharge or Mulch Grass

This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

Danger

Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• Never remove the grass deflector from the

mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

blades unless you release the bail and the power take off (PTO) is off. Rotate the ignition key to “OFF.” Also remove the key and pull the wire off the spark plug(s).

Important All four hairpin cotter pins must be in the

same hole location and with the correct number of spacers for a level cut.

1. Carrier Frame

2. Hairpin Cotter

3. Front height–of–cut post

m-4856

m–5230

Figure 17

4. Spacers

5. Back height–of–cut post

Adjusting Height-of-Cut

The height-of-cut can be adjusted from 1 to 4-1/2 in. (25 to 115 mm) in 1/4 in. (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers.

Note: Rear height–of–cut pins need at least one spacer or damage can occur to bushing if none are used.

1. To adjust, remove hairpin cotter from height-of-cut post

(Fig. 17).

Adjusting Gage Wheels

The gage wheels must be adjusted in the proper hole location for each height-of-cut position.

1. After adjusting height-of-cut, remove nut and washer

while holding stud with wrench (Fig. 18).

Note: Do not remove the wheel nut and washer (Fig. 18).

Page 22

2. Select a hole position so the gage wheels are a

minimum of 3/8 in. (9.5 mm) off the ground for the height-of-cut to be used (Fig. 18).

3. Reinstall the stud nut and washer (Fig. 18).

4. Repeat adjustment on other gage wheels.

Figure 18

1. Gage Wheel

2. Stud

3. Washer

4. Nut

5. Wheel nut and washer. Do Not Remove.

m–5201

1. Center Gage Wheels and Spacer

2. Nut

Figure 19

3. Bolt

4. Washer

m–5200

Adjusting Center Gage Wheels

The gage wheels must be adjusted in the proper hole location for each height-of-cut position.

1. After adjusting height-of-cut remove bolt, washers and

nut (Fig. 19).

2. Select a hole position so the gage wheels are a

minimum of 3/8 in. (9.5 mm) off the ground for the height-of-cut to be used (Fig. 19).

3. Reinstall the bolt, washers and nut (Fig. 19).

Page 23

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

After first 8 Hours • Oil—change

8 Hours

25 Hours • Foam Air Cleaner—service

40 Hours

50 Hours

100 Hours

Maintenance Procedure

• Oil—check level

• Safety System—check

• Brake—check

• Engine—clean outside

• Mower Housing—clean

• Cutting Blades—check

• Mower Housing—clean

• Caster Wheels—grease

• PTO Belt Idler Arm—grease

• Tires—check pressure

• Belts—check for wear/cracks

• Paper Air Cleaner—clean

• Oil—change

• Spark Plug(s)—check

• Electric Clutch—adjust

• Engine—clean outside

• Oil Filter—change (200 hours or every other oil change)

200 Hours

250 Hours • Transmission Couplings—grease 400 Hours • Wheel Bearings—grease

At storage

More often in dusty, dirty conditions.

Important Refer to your engine operator’s manual for additional maintenance procedures.

• Fuel Filter—replace

• Paper Air Cleaner—replace

• Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.

Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Page 24

Air Cleaner Service

Service Interval/Specification

Foam Element: Clean and re-oil after every 25 operating hours.

Paper Element: Clean after every 50 operating hours.

Replace after every 200 operating hours.

Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper Elements

1. Disengage the power take off (PTO), chock or block

tires, and turn the ignition key to “OFF” to stop the engine. Remove the key.

Important Replace the foam element if it is torn or

worn.

m–4694

Figure 21

1. Foam element 2. Oil

Cleaning the Paper Element

2. Clean around the air cleaner to prevent dirt from getting

into the engine and causing damage. Pull out on retaining latches and remove the air cleaner cover (Fig. 20).

3. Unscrew nut and remove the air cleaner assembly

(Fig. 20).

4. Carefully pull the foam element off the paper element

(Fig. 20).

m–4689

Figure 20

1. Retaining latch

2. Cover

3. Nut

4. Foam element

5. Paper element

1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 22).

2. Inspect the element for tears, an oily film, and damage to the rubber seal.

Important Never clean the paper element with

pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly.

m–4695

Figure 22

1. Paper element 2. Rubber seal

Cleaning the Foam

1. Wash the foam element in liquid soap and warm water.

When the element is clean, rinse it thoroughly.

2. Dry the element by squeezing it in a clean cloth.

3. Put one or two ounces of oil on the element (Fig. 21).

Squeeze the element to distribute the oil.

Installing the Foam and Paper Elements

Important T o prevent engine damage, always operate

the engine with the complete foam and paper air cleaner assembly installed.

1. Carefully place the foam element onto the paper air cleaner element (Fig. 20).

2. Place the air cleaner assembly onto the air cleaner base (Fig. 20). Secure with nut.

Page 25

3. Install the air cleaner cover and secure latches (Fig. 20).

Engine Oil Service

Service Interval/Specification

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SE, SF or SG) Crankcase Capacity: with new filter, 57–1/2 oz. (1.7 l)

without new filter, 51 oz. (1.5 l)

Viscosity: See table below

Figure 23

1. Oil dipstick

2. Metal end

3. Filler tube

Changing/Draining Oil

1. Start the engine and let it run five minutes. This warms

the oil so it drains better.

2. Park the machine so that the drain side is slightly lower

than the opposite side to make sure the oil drains completely. Then disengage the power take off (PTO), chock or block tires, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Place a pan below the oil drain. Remove the oil drain

cap (Fig. 24).

Checking Oil Level

1. Park the machine on a level surface, disengage the

power take off (PTO), chock or block tires, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Clean around the oil dipstick (Fig. 23) so dirt cannot

fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean

(Fig. 23).

4. Thread the oil dipstick fully onto the filler tube

(Fig. 23). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

4. When oil has drained completely, install the oil drain

cap.

Note: Dispose of the used oil at a certified recycling center.

m–5207

Figure 24

1. Oil drain cap

5. Slowly pour approximately 80% of the specified oil,

page 25, into the filler tube (Fig. 23). Now check the oil level; refer to Checking Oil Level, page 25. Slowly add additional oil to bring to “FULL” mark on dipstick.

Page 26

Change Oil Filter

Removing the Spark Plug(s)

Service Interval/Specification

Replace the oil filter every 200 hours or every other oil change.

Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to

Changing/Draining Oil, page 25.

2. Remove the old filter (Fig. 25).

3. Apply a thin coat of new oil to the rubber gasket on the

replacement filter (Fig. 25).

1. Disengage the power take off (PTO), chock or block tires, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 26). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

3. Remove the spark plug(s).

M-429

Figure 26

1. Spark plug wire installed 2. Spark plug

M-4288

Figure 25

1. Oil filter 2. Adapter

4. Install the replacement oil filter to the filter adapter.

Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 25).

5. Fill the crankcase with the proper type of new oil; refer

to Engine Oil Service, page 25.

Spark Plug Service

Service Interval/Specification

Check the spark plug(s) after every 100 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: Champion RCJ8Y or NGK BPR4ES Air Gap: 0.030 in. (.75 mm)

Checking the Spark Plug

1. Remove spark plug.

2. Look at the center of the spark plug(s) (Fig. 27). If you

see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Important Never clean the spark plug(s). Always

replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks.

3. Check the gap between the center and side electrodes (Fig. 27). Bend the side electrode (Fig. 27) if the gap is not correct.

Page 27

Figure 27

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

0.030 in.

(.75 mm)

1. Install the spark plug(s). Make sure the air gap is set

correctly.

2. Tighten the spark plug(s) to 11 ft-lb (15 Nm).

3. Push the wire(s) onto the spark plug(s) (Fig. 26).

Greasing and Lubrication

Service Interval/Specification

Refer to the CHECK SERVICE REFERENCE AID decal for location and interval of greasing and lubrication (Figure

28). Grease with No. 2 general purpose lithium base or

molybdenum base grease.

How to Grease

1. Disengage the power take off (PTO), set the parking

brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Clean the grease fittings with a rag. Make sure to scrape

any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease into

the fittings until grease begins to ooze out of the bearings.

Figure 28

Lubricate the castor and wheel bearings

1. Lubricate the front wheel bearings and front spindles

until grease begins to ooze out of the bearings (Fig. 29).

2. Remove rear wheel grease cap. Lubricate the rear wheel

bearing (Fig. 29).

Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels.

m–2147

Figure 29

4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decals (Fig. 28).

Lubricate the Transmission and Idler Bracket

1. Lubricate the transmission couplers located in the back

of the machine (Fig. 29).

Page 28

2. Lubricate the idler bracket pivots located in the back of

the machine (Fig. 29).

m–5389

Figure 30

Checking Tire Pressure

Service Interval/Specification

Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 40 operating hours or monthly, whichever occurs first (Fig. 32). Check the tires when they are cold to get the most accurate pressure reading.

Rear Tire Pressure: 12–14 psi (83–97 kPa) Caster Tire Pressure: 20–24 psi (138–165 kPa)

Greasing the PTO Drive Belt Idler

1. Stop the engine, chock or block tires, remove the key

and disconnect the spark plug wire(s) from the spark plug(s).

2. Grease the idler pulley pivot for the deck (Fig. 31).

m–5196

Figure 31

m–2147

Figure 32

1. Rear Tire 2. Caster tire

Fuel Tank Service

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Drain gasoline from the fuel tank when the

engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

Cleaning the Cooling System

Service Interval/Specification

Before each use, check and clean engine cooling system. Remove any build–up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor–governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.

Draining The Fuel Tank

1. Park the machine on a level surface, to assure fuel tank drains completely. Then disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut–off valve (Fig. 33).

Note: Remove fuel line from fuel valve that is closest to

the engine.

Page 29

3. Squeeze the ends of the hose clamp together and slide it

away from valve (Fig. 33).

4. Pull the fuel line off the valve (Fig. 33). Open fuel

shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 29.

5. Install the fuel line onto the valve. Slide the hose clamp

close to the valve to secure the fuel line.

1. Hose clamp

2. Fuel line

M-4294

Figure 34

3. Filter

m–523

Figure 33

1. Fuel line

2. Hose clamp

3. Fuel shut off valve

Fuel Filter Service

Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first.

Replacing the Fuel Filter

Never install a dirty filter if it is removed from the fuel line.

Note: Note how the fuel filter is installed.

1. Disengage the power take off (PTO) and turn the

ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 34).

3. Squeeze the ends of the hose clamps together and slide

them away from the filter (Fig. 34).

Fuse Service

Service Interval/Specification

The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows check component or circuit for malfunction or short.

To replace fuse pull out on the fuse (Fig. 35) to remove and push in to install it.

Fuse: F1–10 amp, blade-type

m–5391

Figure 35

1. Fuse 10 amp

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps close to

the filter.

6. Open fuel shut-off valve at fuel tank (Fig. 34).

7. Check for fuel leaks and repair if needed (Fig. 34).

Adjusting the Electric Clutch

The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation.

1. To adjust clutch, tighten or loosen lock nuts on flange

studs (Fig. 36).

Page 30

2. Check adjustment by inserting feeler gauge thru slots

next to studs (Fig. 36).

3. The proper disengaged clearance between the clutch

plates is .012–.018 in. (0.30-0.45 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

Adjusting the Brake

If the parking brake does not hold securely, an adjustment is required.

1. Check the brake before you adjust it; refer to Checking the Brake, page 30.

2. Release the parking brake; refer to Releasing the Parking Brake, page 17.

m–2600

Figure 36

1. Adjusting nut

2. Slot

3. Feeler gauge

Brake Service

Service Interval/Specification

Before each use, check brakes for proper operation. Always set the parking brake when you stop the machine or

leave it unattended. If the parking brake does not hold securely, an adjustment is required.

Checking the Brake

1. Park the machine on a level surface, disengage the

blade control (PTO) and push the neutral/brake lock forward to set the brake.

3. To adjust brake, rotate the wing nuts on the brake rods (Fig. 37). Rotate clockwise to tighten the brake and counterclockwise to loosen the brake.

4. Position wingnut so the brakes will engage when the drive levers are squeezed enough to place neutral/brake lock forward and set the brake.

5. Check the brake operation again; refer to Checking the Brake, page 30.

Important With the parking brake released, the rear

wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately.

m–5372

Figure 37

1. Brake rod 2. Wing nut

2. Rear wheels must lock when you try to push the

machine forward or backward. Adjustment is required if the wheels turn and do not lock. Refer to Adjusting the Brake on page 30.

3. Release the brake and move neutral/brake lock to

neutral. Move the machine lightly, approximately 1/2 in. (13 mm). Wheels should rotate freely.

4. If both conditions are met, no adjustment is required.

Page 31

Cutting Blade Service

To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand.

Danger

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 39). Measure from a level surface to the cutting edge, position “A”, of the blades (Fig. 40). Note this dimension.

Front

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and chock or block tires. Turn the ignition key to “OFF” to stop the engine. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Fig 38). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 32.

2. Inspect the blades, especially the curved area (Fig. 38).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 38), immediately install a new blade.

m–1078

Figure 39

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 40

2. Rotate the opposite ends of the blades forward.

3. Measure from a level surface to the cutting edge of the

blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 in. (3 mm). If this dimension exceeds 1/8 in. (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 32.

1. Cutting Edge

2. Curved Area

Figure 38

3. Wear/slot Forming

Warning

A blade that is bent or damaged could break apart and could seriously injure or kill you or

bystanders.

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

m–151

or surfaces of blade.

Removing the Blades

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the

Page 32

machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

Hold the blade end using a rag or thickly-padded

glove. Remove the blade bolt, blade stiffener and blade from the spindle shaft (Fig. 41).

Figure 43

1. Blade 2. Balancer

m–1855

5 4

1. Sail Area of Blade

2. Blade

3. Blade spindle

Figure 41

4. Blade Bolt

5. Blade stiffener

m–5227

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of the

blade (Fig. 42). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 41).

Important The sail part of the blade must be pointing

upward, toward the inside of the mower to ensure proper cutting

(Fig. 41).

2. Install the blade stiffener and blade bolt (Fig. 41). Torque the blade bolt to 85–110 ft-lb (115–140 Nm).

Correcting Cutting Unit Mismatch

If one deck blade cuts lower than the other, correct as follows.

Note: Tire air pressure is critical in these procedures.

Make sure all tires have correct pressure.

1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications on page 28.

m–1854

Figure 42

1. Sharpen at original angle

2. Check the balance of the blade by putting it on a blade

balancer (Fig. 43). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 41). Repeat this procedure until the blade is balanced.

3. Check that the blades and spindle shafts are not bent.

Refer to Checking for Bent Blades on page 31.

4. Set the height-of-cut to the 4 in. (102 mm) position.

Refer to Adjusting the Height-Of-Cut in the Operation section.

5. Perform steps in the following sections Frame Set Up,

Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling.

Frame Set Up

Checking Carrier Frame and Deck Alignment

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Place a long straight edge on top of the engine deck as

shown in figure 44.

3. At the carrier frame cross tube, measure location “A”

height (Fig. 44). This measurement must be 2–13/16 in. (71 mm), plus or minus a 1/4 in. (6 mm).

Page 33

4. If the height at location “A” is not correct, adjustment is

needed.

5. Loosen the carrier frame mounting bolts on both sides

of the machine (Fig. 44).

6. Align the carrier frame and engine deck to match

2–13/16 in. (71 mm), plus or minus a 1/4 in. (6 mm) at location “A” (Fig. 44).

7. Tighten the carrier frame mounting bolts on both sides

of the machine.

1. Back view of machine

2. Top of engine deck

3. Tires

Figure 45

444

4. Same height at locations A and B

m–5237

m–5315

Figure 44

1. Carrier Frame

2. Top of engine deck

3. Carrier frame mounting bolts

4. Location A, 2–13/16 in. (71 mm)±1/4 in. (6 mm)

5. Straight edge

6. Carrier frame cross tube

Checking Engine Deck Height

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications on

page 28.

3. Measure engine deck height at location “A” (Fig. 45).

4. Measure engine deck height at location “B” (Fig. 45).

5. If the height at location “A” and “B” are not the same,

change tire pressure slightly to make them the same.

Checking Carrier Frame Front–to–Rear Pitch

The carrier frame must have a pitch of a 1/4 in. (6 mm) over the length of 24 (6.1 cm) inches on the carrier frame (Fig. 46).

1. Measure out 24 inches (6.1 cm) on the carrier frame

(Fig. 46).

2. Measure carrier frame height at location “A” (Fig. 46).

3. Measure carrier frame height at location “B” (Fig. 46).

4. The height at location “A” must be a 1/4–3/8 in.

(6 mm – 10 mm) lower than location “B” (Fig. 46).

5. If the carrier frame is not correct, move caster spacers

to make it a 1/4–3/8 in. (6 mm – 10 mm) pitch (Fig. 46). Move spacers from top or bottom to make the correct pitch.

6. The tire pressure may also be adjusted slightly to make

a 1/4 in. (6 mm) pitch.

Page 34

(6.1cm)

24 in.

Checking the Deck Front-to-Rear Pitch

1. Check the tire pressure on both deck and traction unit.

m–5242

Figure 46

1. Caster Wheel

2. Carrier Frame

3. 1/4–3/8 in. (6 mm–10 mm) pitch over 24 in. (6.1 cm) length

4. Height at locations A and B

5. Caster spacers

Checking Carrier Frame Side–to–Side

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications on

page 28.

3. Measure carrier frame height at location “A” (Fig. 47).

2. Position one blade front-to-rear (Fig. 48). Measure at

“C” and “D” locations (Fig. 48) from a level surface to the cutting edge of the blade tips (Fig. 49).

3. The mower blade should be 1/4 in. (6 mm) lower in front “C” than in the rear “D”. Rotate blades and

repeat for other blades. If it is not correct, proceed to Changing the Deck Front–to–Rear Pitch.

Front

m–1078

Figure 48

4. Measure carrier frame height at location “B” (Fig. 47).

5. If the carrier frame height is not the same move spacers

from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level.

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

Figure 49

Changing the Deck Front-to-Rear Pitch

Changing the front–to–rear pitch is done by adjusting the

m–5231

Figure 47

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Same height at locations A and B

5. Caster spacers

front height–of–cut posts.

Changing the Deck Front–to–Rear Pitch by Adjusting Front Height–of–Cut Posts

1. To change the front-to-rear pitch, the front

height–of–cut posts can be adjusted (Fig. 50).

2. To raise the front of the deck, loosen jam nut and rotate

the front pin clockwise (Fig. 50).

3. To lower the front of the deck, loosen jam nut and rotate

the front pin counter clockwise (Fig. 50).

m–2539

Page 35

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

m–2550

Figure 52

m–5231

Figure 50

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Jam nut

5. Ball joint

4. Position the blades front-to-rear (Fig. 48). Measure at

“C” and “D” locations (Fig. 48) from a level surface to the cutting edge of the blades (Fig. 49).

5. Check the side-to-side leveling of the cutting unit.

Checking the Deck Side-to-Side Leveling

1. Check the tire pressure on both deck and traction unit.

2. Position the blades side-to-side (Fig. 51). Measure at

“A” and “B” locations (Fig. 51) from a level surface to the cutting edge of blade tips (Fig. 52).

3. The difference between measurements “A” and “B”

should be no more than 1/4 in. (6 mm).

Front

Changing the Side-to-Side Leveling

Changing the side–to–side leveling is done by adjusting tire pressure.

Changing the Side–to–Side Leveling with Tire Pressure

1. Change the tire pressure on both deck and traction unit.

Do this to the corresponding side that needs adjustment.

2. Recheck the front-to-rear pitch and side to side leveling

of the cutting unit.

Matching Height of Cut

1. Check the tire pressure on both deck and traction unit.

2. Set the height-of-cut to the 4 in. (102 mm) position

following the height-of-cut decal.

3. With the machine on level surface, position one blade

front-to-rear (Fig. 53). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 54).

4. The measurement should be 4 in. (102 mm)

Front

Figure 51

m–1078

Figure 53

Page 36

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

m–2550

Figure 54

5. If it does not measure correctly, add air pressure in rear

tires to raise height–of–cut

6. If it does not measure correctly, decrease air pressure in

rear tires to lower height–of–cut.

7. Check carrier frame front–to–rear pitch.

Replacing the Drive Belt

Service Interval/Specification

Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating.

2. Disconnect clutch wire connector from wire harness.

3. Remove PTO drive belt. Refer to Replacing the PTO

Drive Belt on page 37.

4. Remove clutch retainer from the engine deck (Fig. 56).

5. Unhook tension spring from side of frame (Fig. 56).

6. Loosen pivot bolt enough to remove traction belt from

the drive pulley and clutch.

7. Install new belt around clutch and drive pulley.

8. Torque pivot bolt to 35-40 ft. lb. (47-54 N.m). Install

tension spring between idler arm and frame bracket (Fig. 56).

9. Install clutch retainer to the engine deck (Fig. 56).

10.Connect clutch wire connector to wire harness.

11. Install PTO drive belt.

1. Disengage the power take off (PTO), set the parking

brake and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Remove the drive spring from adjustment bolt (Fig. 55).

3. Remove belt from pulleys and over tire.

4. Install new belt and install drive spring.

2 3

m–5372

Figure 55

1. Drive belt

2. Drive spring

3. Tire

4. Adjustment bolt

2 8

m–5321

Figure 56

1. Traction belt

2. Idler pulley

3. Clutch retainer

4. Tension spring

5. Clutch wire connector

6. Pivot bolt

7. Drive pulley

8. Engine deck

Replacing the Deck Belt

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident.

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Remove the knobs holding the carrier frame cover and

remove the carrier frame cover.

Replacing the Traction Belt

1. Raise the front of the machine and hold with jack

stands.

3. Remove the knobs holding the belt covers to the cutting

unit and remove the belt covers.

4. Remove the PTO drive belt. Refer to Replacing the

PTO Drive Belt on page 37.

Page 37

5. Disconnect the idler arm spring to relieve tension on the

idler arm and idler pulley, then remove the worn deck belt (Fig. 57).

6. Install the new deck belt around the two outside spindle

pulleys, the idler pulley, and in the lower groove of the center spindle pulley (Fig. 57).

7. Connect the idler arm spring (Fig. 57).

8. Reinstall the PTO drive belt. Refer to Replacing the

PTO Drive Belt page 37.

4. Remove the heat shield from the the engine deck and

carrier frame.

5. Remove the idler spring from idler arm. Remove the

drive belt from the PTO engagement pulley and the center spindle pulley (Fig. 58).

6. Remove the worn drive belt (Fig. 58).

7. Install the new drive belt onto the PTO engagement

pulley and the top groove of the center spindle pulley (Fig. 58).

9. Reinstall the deck covers onto the cutting unit, then

reinstall and tighten the knobs.

10.Install the carrier frame cover onto the cutting unit, then

install and tighten the hand knobs.

11. Adjust deck belt guide an 1/8 in. (3 mm) from belt

(Fig. 57).

m–5196

Figure 57

1. Deck belt

2. Idler arm spring

3. Outside pulley

4. PTO Drive belt

5. Center spindle pulley

6. Belt guide

8. Install belt onto idler pulley and then install idler spring

(Fig. 58).

9. Adjust PTO drive belt guides an 1/8 in. (3 mm) from

belt (Fig. 58).

10.Install the heat shield to the the engine deck and carrier

frame.

11. Install the belt covers onto the cutting unit, then install

and tighten the knobs.

12.Install the carrier frame cover onto the cutting unit, then

install and tighten the hand knobs.

2 5

m–5196

Replacing the PTO Drive Belt

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the drive belt if any of these conditions are evident.

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Remove the knobs holding the carrier frame cover and

remove the carrier frame cover.

3. Remove the knobs holding the belt covers to the top of

the cutting unit and remove the belt covers.

Figure 58

1. PTO engagement pulley

2. Drive belt idler

3. PTO drive Belt

4. Center Spindle Pulley

5. PTO Drive belt guide

6. Idler Spring

Replacing the Caster Wheel Fork Bushings

The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the caster forks back and forth and side-to-side. If a caster fork is loose, the bushings are worn and must be replaced.

Page 38

1. Raise the cutting unit so the caster wheels are off the

floor, then block up the front of the mower with jack stands.

2. Remove the locking pin and spacer(s) from the top of

the caster wheel fork (Fig. 59).

3. Pull the caster wheel fork out of the mounting tube,

leaving the spacer(s) on the bottom of the fork. Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck.

Important The inside diameter of the bushings may

collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 in. (28.6mm).

8. Grease the fitting on the carrier frame mounting tube

using No. 2 general purpose lithium base or molybdenum base grease.

m-5198

Figure 59

1. Locking Pin

2. Spacers (locate as required)

3. Carrier Frame Mounting Tube

4. Caster Wheel Fork

4. Insert a pin punch into the mounting tube and carefully

drive out the bushings (Fig. 60). Clean the inside of the mounting tube.

5. Grease the inside and outside of the new bushings. Use

a hammer and flat plate to carefully drive the bushings into the mounting tube.

6. Inspect the caster wheel fork for wear and replace if

necessary (Fig. 59).

7. Slide the caster wheel fork through the bushings in the

mounting tube. Replace the spacers(s) onto the fork and secure with the retaining ring (Fig 59).

m–5197

Figure 60

1. Carrier Frame Mounting Tube

2. Bushing

Caster Wheel and Bearings Service

The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly caster wheel usually indicates a worn bearing.

1. Remove the locknut and wheel bolt holding the caster wheel to the caster fork (Fig. 61).

2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 61).

3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 61).

4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 61).

Page 39

3. Install bolt and nut. Place “J” hook end of spring around

grass deflector (Fig. 62).

Important The grass deflector must be able to lower

down into position. Lift the deflector up to test that it lowers into the full down position.

m-5210

Figure 61

1. Locknut

2. Wheel Bolt

3. Bushing

4. Spanner Bushing

5. Roller Bearing

5. To assemble, place one (1) 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 (Fig. 61).

6. Install the caster wheel into the caster fork and secure

with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the caster forks (Fig. 61).

7. Grease the fitting on the caster wheel.

Replacing the Grass Deflector

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

m-5037

Figure 62

6. Grass Deflector

7. “L” end of spring, place behind deck edge before installing bolt

8. “J” hook end of spring

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Remove the locknut, bolt, spring and spacer holding the

deflector to the pivot brackets (Fig. 62). Remove damaged or worn grass deflector.

2. Place spacer and spring onto grass deflector. Place the

“L” end of spring behind deck edge.

Note: Make sure the “L” end of spring is installed behind deck edge before installing the bolt as shown in figure 62.

Page 40

Wiring Diagram

WIRE COLOR CODES

Operator Presence Switch

No Operator)

Neutral Switch (In Neutral)

PTO Switch (Off)

OPT HR MTR

YY T

354

BK BN

OPT

HR MTR

Clutch

K1 Interlock

Relay

10A

KEY SWITCH

(OPEN = ON) (CLOSED = OFF)

GN GY OR

REG

MAG

BLACK BROWN BLUE GREEN GREY ORANGE

SPARK PLUG

PK R

T VIO W Y

IGNITION MODULES

PINK RED

TAN VIOLET WHITE

YELLOW

SPARK PLUG

GND

Page 41

Cleaning and Storage

1. Disengage the power take off (PTO), set the parking

brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Remove grass clippings, dirt, and grime from the

external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing.

A. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

B. Stop engine, allow to cool and drain the fuel tank;

refer to Fuel Tank Service, page 28, or operate engine until it stops.

C. Restart engine and run until it stops. Repeat, on

“CHOKE” until engine will not restart.

D. Dispose of fuel properly. Recycle as per local codes.

Important You can wash the machine with mild

detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, and engine.

3. Check the brake; refer to Brake, page 30.

4. Service the air cleaner; refer to Air Cleaner Service,

page 24.

5. Grease the machine; refer to Greasing and Lubrication,

page 27.

6. Change the crankcase oil; refer to Engine Oil Service,

page 25.

7. Check the tire pressure; refer to Tire Pressure Service,

page 28.

8. For long-term storage (more than 90 days) add

stabilizer/conditioner additive to fuel in the tank.

Troubleshooting

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Note: Do not store stabilizer/conditioned gasoline over 90 days.

9. Remove the spark plug(s) and check its condition; refer

to Spark Plug Service, page 26. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

10.Check and tighten all bolts, nuts, and screws. Repair or

replace any part that is damaged or defective.

11. Paint all scratched or bare metal surfaces. Paint is

available from your Authorized Service Dealer.

12.Store the machine in a clean, dry garage or storage area.

Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

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

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

2. PTO is on (Pulled up). 2. Turn PTO off (Push in).

3. Shift lever is in gear. 3. Move shift lever to neutral.

4. Choke is not ON. 4. Move throttle lever to choke position.

5. Air cleaner is dirty. 5. Clean or replace air cleaner element.

6. Spark plug wire is loose or

disconnected.

7. Spark plug is pitted, fouled, or

gap is incorrect.

8. Dirt in fuel filter. 8. Replace fuel filter.

9. Dirt, water, or stale fuel is in

fuel system.

6. Install wire on spark plug.

7. Install new, correctly gapped spark plug.

9. Contact Authorized Service Dealer.

Page 42

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Engine loses power.

Engine overheats.

Machine does not drive.

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

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

3. Oil level in crankcase is low. 3. Add oil to crankcase.

4. Cooling fins and air passages under engine blower housing are plugged.

5. Spark plug is pitted, fouled, or gap is incorrect.

6. Vent hole in fuel cap is plugged.

7. Dirt in fuel filter. 7. Replace fuel filter.

8. Dirt, water, or stale fuel is in fuel system.

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

2. Oil level in crankcase is low. 2. Add oil to crankcase.

3. Cooling fins and air passages under engine blower housing are plugged.

1. Shift lever is in NEUTRAL. 1. Move shift lever to a drive

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

gear position.

Abnormal vibration.

2. Traction belt is worn, loose or broken.

3. Traction belt is off pulley. 3. Change Belt.

4. Neutral/Parking brake lock is in neutral or park position.

1. Cutting blade(s) is/are bent or

unbalanced.

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Engine mounting bolts are

loose.

4. Loose engine pulley, idler

pulley, or blade pulley.

5. Engine pulley is damaged. 5. Contact Authorized Service

6. Blade spindle bent. 6. Contact Authorized Service

2. Change Belt.

4. Move Neutral/Parking brake lock to forward position.

1. Install new cutting blade(s).

3. Tighten engine mounting bolts.

4. Tighten the appropriate pulley.

Dealer.

Page 43

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Uneven cutting height.

Blades do not rotate.

1. Blade(s) not sharp. 1. Sharpen 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. 4. Clean the underside of the mower.

5. Tire pressure is incorrect. 5. Adjust tire pressure.

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

1. PTO Drive belt is worn, loose

or broken.

2. PTO Drive belt is off pulley. 2. Install drive belt and check

3. Deck belt is worn, loose or

broken.

4. Deck belt is off pulley. 4. Install deck pulley and check

1. Install new drive belt.

adjusting shafts and belt guides for correct position.

3. Install new deck belt.

the idler pulley, idler arm and spring for correct position and function.

Page 44

LCE

The Toro Total Coverage Guarantee

A One-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

Outfront and Mid-Mount Z’s ProLine Mid-Size Mowers Groundsmaster Backpack Blowers

• Deck Shells (36″–72″) on the following:

ProLine Mid-Size Mowers Mid-Mount Z’s

• Electric Clutch on 200 Series Mid-Mount Z’s

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

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

* Some engines used on Toro LCE Products are warranted by the

engine manufacturer.



Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

Should you feel your Toro Product contains a defect in materials or workmanship, contact the dealer who sold you the product or any Authorized Service Dealer or Master Service Dealer. The Yellow Pages of your telephone directory is a good reference source. The dealer will either arrange service at his/her dealership or recommend another Authorized Service Dealer who may be more convenient. You may need proof of purchase (copy of registration card, sales receipt, etc.) for warranty validation.

If for any reason you are dissatisfied with the Service Dealer’s analysis of the defect in materials or workmanship or if you need a referral to a Toro Service Dealer, please feel free to contact us at:

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 888-577-7466

Y ou 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.

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 filters, 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.

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

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

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (Dealer) to obtain guarantee policies for your country , province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. I f all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0037 Rev. A