Toro 30432 Operator's Manual

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Page 1

Form No. 3327–400

Mid–Size Mower

ProLine Gear 17 HP with 52 in. Side Discharge Mower

Model No. 30432—Serial No. 230000001 and Up

Operator’s Manual

English (EN)

Page 2

Warning

CALIFORNIA

Proposition 65 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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installing the Handle Assembly 14. . . . . . . . . . . . . . .

Installing the Shift Lever Plate and Fuel Tank 14. . . .

Adjusting the Shift Lever Plate 15. . . . . . . . . . . . . . .

Installing the Control Rods 16. . . . . . . . . . . . . . . . . .

Installing the Hairpin Cotter Pins and Washers 17. . .

Checking the Tire Pressure 17. . . . . . . . . . . . . . . . . .

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Page

Installing the Mid Size Weight 17. . . . . . . . . . . . . . . .

Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . . . .

Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake and Neutral Lock 19. . . . . . . . . . . . . .

Starting and Stopping the Engine 19. . . . . . . . . . . . . .

Operating Mower Blade Control (PTO) 20. . . . . . . .

The Safety Interlock System 20. . . . . . . . . . . . . . . . .

Driving Forward or Backward 20. . . . . . . . . . . . . . . .

Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . . .

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

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

Adjusting the Height-of-Cut 22. . . . . . . . . . . . . . . . .

Adjusting the Gage Wheels 22. . . . . . . . . . . . . . . . . .

Adjusting the Handle Height 23. . . . . . . . . . . . . . . . .

Using the Mid–Size Weight 23. . . . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 25. . . . . . . . .

Air Cleaner Service 26. . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Service 27. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Service 28. . . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 29. . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 30. . . . . . . . . . . . . . . . .

Checking the Tire Pressure 30. . . . . . . . . . . . . . . . . .

Fuel Tank Service 31. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter Service 31. . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Service 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 32. . . . . . . . . . . . . . . . .

Servicing the Brakes 32. . . . . . . . . . . . . . . . . . . . . . .

Servicing the Cutting Blades 33. . . . . . . . . . . . . . . . .

Correcting the Mower Quality of Cut 35. . . . . . . . . .

Frame Set Up 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Deck Front-to-Rear Pitch 37. . . . . . . . .

Changing the Deck Front-to-Rear Pitch 37. . . . . . . . .

Checking the Deck Side-to-Side Leveling 38. . . . . . .

Changing the Side-to-Side Leveling 38. . . . . . . . . . .

Matching Height of Cut 38. . . . . . . . . . . . . . . . . . . . .

Adjusting the Traction Drive Belt Tension 39. . . . . .

Replacing the Traction Drive Belt 39. . . . . . . . . . . . .

Replacing the Transmission Belt 40. . . . . . . . . . . . . .

Replacing the Mower Belt 40. . . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 41. . . . . . . . . . . . . . . .

Replacing the Caster Wheel Fork Bushings 41. . . . . .

Caster Wheel and Bearings Service 42. . . . . . . . . . . .

Replacing the Grass Deflector 43. . . . . . . . . . . . . . . .

Wiring Diagram 44. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 45. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 48. . . . . . . . . . . . . .

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.

Figure 1

1. Location of the model and serial numbers

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

m–6594

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.

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.

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.

• 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.

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.

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use only an approved container

Page 4

• 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.

• 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.

• Slow down and use caution when making turns and

when changing directions on slopes.

• 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.

• Use jack stands to support components when required.

• 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

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs

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

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

Page 5

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.

• 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.

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 slow speed so that you will not have to stop while

on the slope.

• 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.

• 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.

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.

43-8480

93-1122

66-1340

67-5360

68-8340

95-2814

98-0776

98-4387

1. Warning—wear hearing protection.

Page 10

104-8186

104-8569

105-4111

106-5532

106-0699

105-4146

106-5511

106-0635

Page 11

106-5496

1. Reverse 2. Neutral 3. Forward speeds

106-5501

1. Choke 2. Fast 3. Continuous variable setting 4. Slow

1. Keep bystanders a safe distance from the machine.

2. Do not allow bystanders to be hit by thrown objects.

3. Do not operate the mower with the deflector up or removed.

106-5514

4. Stop the engine and pick up debris before operating.

5. Cutting of hand or foot, mower.

6. Engine—stop

7. Engine—run

8. Hour meter

9. To park, move the controls as illustrated.

10. To drive, move the controls as illustrated.

11. To place the machine in neutral, move the controls as illustrated.

12. Power take-off (PTO)

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 inch to 1/2 inch (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 27.

Page 13

Setup

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.

Step Description Qty. Use

1 2

3 4 5

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

No parts needed Adjusting the shift lever plate

Clevis pin Washer Hairpin cotter pin

Hairpin cotter pin 2

1 4 4 1 1 2 2 4 2 1

2 2 2

Installing the handle assembly

Installing shift lever plate and fuel tank

Installing the control rods

Installing the hairpin cotter pins and washers

6 7

No parts needed Checking the tire pressure

Rear weight Screw, 5/16 x 1–1/2 inch Washer, 5/16 inch Nut, 5/16 inch

Oil drain hose Operator’s Manual Engine Operator’s Manual Parts Catalog Registration card

1 2 2 2

1 1 1 1 1

Installing the rear weight

Use for draining engine oil Read before operating machine Read before operating machine

Fill out and return to Toro

Page 14

Step

Parts needed for this step:

• 1 Handle assembly

• 4 Flange bolts, 3/8 x 1 inch

• 4 Flange nuts, 3/8 inch

Installing the Handle Assembly

1. Align handle with upper mounting holes in rear frame

(Fig. 2).

2. Secure the handle at each upper mounting hole with a

flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).

3. Select the low position for the lower mounting hole

(Fig. 2).

4. Secure the handle at each lower mounting hole with a

flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).

Note: The handle position can be adjusted to match the operator’s height preference.

Parts needed for this step:

• 1 Fuel tank with studs installed

• 1 Shift lever plate

• 2 Bolts, 5/16 x 7/8 inch

• 2 Lock washers, 5/16 inch

• 2 Flat washers, 5/16 inch

• 2 Springs

• 1 Hose clamp

Installing the Shift Lever Plate and Fuel Tank

1. Remove the bolts and nuts holding the shift lever plate

to the rear frame. Discard these nuts and bolts.

2. Slide the shift lever plate over the shift lever and under

the bottom of the rear frame (Fig. 3).

2 4 5

Figure 2

1. Upper handle

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

Note: Handle assembly must be installed before fuel tank is installed.

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. High position

m–6591

m–5221

Figure 3

1. Rear frame

2. Shift lever plate

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

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

secure it with the hose clamp that is on the fuel line (Fig. 5).

Note: To ease assembly of the fuel line to fuel tank connection, apply a light lubricant, such as WD 40, to the end of the fuel line.

Note: Make sure the fuel line and clamp are on as shown in Figure 4.

3. Fuel tank

Page 15

Step

Figure 4

1. Fuel line

2. Clamp

5. Slide the shift lever plate over the shift lever (Fig. 6).

6. Secure the right side of shift lever plate and fuel tank to

the rear frame (Fig. 5) with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 5).

7. Secure the left side shift lever plate and fuel tank to the

rear frame (Fig. 5) with washers (5/16 inch), springs and locknuts (5/16 inch) (Fig. 5).

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

3. Fuel tank connection

m–6504

No parts needed for this step.

Adjusting the Shift Lever Plate

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

in slot of shifter lever plate. The clearance between top and bottom of the shift lever should be equal (Fig. 7).

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

slightly to adjust (Fig. 6).

6 5

4 3

6 3

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

2. Lock washers, 5/16 inch

3. Washer, 5/16 inch

4. Fuel line

5. Hose clamp

Figure 5

3 2

6. Stud

7. Spring

8. Locknut

9. Shift lever plate

10. Fuel tank connection

m–6465

m–5250

Figure 6

1. Shift lever

2. Shift lever plate

3. Rubber seal washer

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

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

slot of shifter lever plate. The clearance on the sides of shift lever should be equal (Fig. 7).

4. If clearance is not correct, loosen shift lever plate and

adjust it side–to–side. Tighten the shift lever plate.

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

4. Square hole washer

5. Spring washer

6. Locknut, 3/8 inch

Page 16

1. Shift lever, 2nd gear

2. Shift lever plate

Step

Figure 7

Rear View

3. Shift lever, neutral

4. Equal distance

m–5458

m–6592

Figure 8

1. Control rod

2. Bell crank

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

rod fitting until there is a 3/16 to 1/4 inch (5 mm to 6 mm) clearance between the control rod and bottom of neutral/brake lock (Fig. 9).

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

Secure with clevis pin and hairpin cotter.

4. Check operation. If adjustment is required, remove

hairpin cotter and clevis pin securing rod to drive levers.

5. Adjust the control rod length by repeating steps 3 and 4

(Fig. 9).

6. Check the parking brake. Refer to Servicing the Brakes

on page 32.

3. Hairpin cotter

Parts needed for this step:

• 2 Clevis pins

• 2 Washers

• 2 Hairpin cotter pins

Installing the Control Rods

1. Install control rods into the bell cranks and secure with

hairpin cotters (Fig. 8).

Note: Install rod fittings so the clevis pin is above the control rod, as shown in Figure 8.

1. Handle

2. Neutral/Parking brake lock

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

m–658

Figure 9

4. Drive lever

5. Forward speed

6. Control Rod

Page 17

Step

Parts needed for this step:

• 2 Hairpin cotter pins

Installing the Hairpin Cotter Pins and Washers

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

1. On the opposite side of the muffler, install unused

washers and hairpin cotter pins into front and rear height–of–cut pins (Fig. 10).

Parts needed for this step:

• 1 Rear weight

• 2 Capscrews

• 2 Washers

• 2 Nuts

Installing the Mid Size Weight

1. Remove lag screws securing weight to the shipping

crate. Remove the weight and discard the screws.

2. Secure the weight to rear of the frame with

2 capscrews, washers and nuts (Fig. 23).

Note: The weight mounted in the rear position is recommended, except when a Tru–Trak

installed.



Sulky is

Figure 10

1. Hairpin cotter

2. Unused spacers

3. Height–of–cut post

Step

No parts needed for this step.

Checking the Tire Pressure

Refer to Page 30 for the correct correct tire pressure.

m-6505

1. Weight

2. Capscrew

Figure 11

3. Washer

4. Nut

Warning

With the weight installed in the rear position, the front end of the machine can rapidly raise up when the mower is removed. This could cause serious injury to you or bystanders.

• Support the rear of the machine when removing

the mower from the carrier frame.

Page 18

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.

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.

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.

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 12

1. Caution 2. Wear hearing protection

Controls

Become familiar with all the controls (Fig. 13) 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.

1. Throttle control

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

4. Gear shift lever

Figure 13

5. Drive levers

6. Neutral lock and Parking

7. Ignition switch

8. Handle

9. Fuel shut–off valve

brake locks

m–6581

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.

Page 19

Parking Brake and Neutral

Starting and Stopping the

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 to the grip (Fig. 14).

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

them forward (Fig. 14).

3. Release the drive levers.

Releasing the Parking Brake

1. Squeeze the drive levers back to the grip (Fig. 14).

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

them rearward until in forward speed slot (Fig. 14).

1. Handle

2. Neutral/Parking brake lock

3. Park position

4. Neutral position

Figure 14

5. Drive lever

6. Full speed forward position

7. Grip

8. Forward speed slot

m–6580

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, set the parking brake,

and turn ignition key to the Run position.

3. Move the throttle control to the 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 the 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.

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 the Slow position (Fig. 15).

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

ignition key to off.

3. Set the parking brake.

4. Turn the ignition key to the Off position (Fig. 15).

Setting the Neutral Lock

1. Squeeze the drive levers back to the grip (Fig. 14).

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

them rearward (Fig. 14).

Releasing the Neutral Lock

1. Squeeze the drive levers back to the grip (Fig. 14).

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

them forward until in forward speed slot (Fig. 14).

m–6581

Figure 15

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

Page 20

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. 16).

2. Pull blade switch (PTO) up and release. Hold the

Operator Presence Control (OPC) levers against handle grip.

3. Repeat procedure to engage mower blades if OPC

levers are released.

Understanding the Safety Interlock System

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

• The blade control switch (PTO) is off.

• The machine is shifted into neutral.

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

• The Operator Presence Control (OPC) levers are

released while the machine is in gear and/or the mower is engaged.

• The machine is shifted into gear without holding OPC

levers.

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

holding the OPC levers.

Figure 16

1. Handle

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

Disengaging the Mower Blades (PTO)

1. Release Operator Presence Control (OPC) levers to

disengage blades (Fig. 16). This will also kill the engine.

The Safety Interlock System

Caution

m–658

Testing the Safety Interlock System

Test the safety interlock system before each use of the machine. 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 19.

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

engine should kill.

3. Release the blade control switch (PTO).

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

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

rotating.

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

6. With the engine is running and holding the OPC levers

down, 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.

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.

Driving Forward

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

Page 21

2. Release the parking brake; refer to Releasing the

Parking Brake, page 19.

Caution

3. Slowly release the drive levers to move forward

(Fig. 17). To go straight, release drive levers equally (Fig. 17). To turn, squeeze the drive lever on the side and direction

you want to turn (Fig. 17).

m–6581

Figure 17

1. Drive lever 2. Gear shift lever

Driving Backward

Note: To drive backward, the machine may need to be assisted by pulling the machine backwards.

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

gear.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 19.

3. Slowly release the drive levers together to move

rearward (Fig. 17).

Stopping the Machine

1. To stop the machine, squeeze the drive levers back to

the grips to engage brakes.

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

to Setting the Parking Brake on page 19.

3. Shift transmission into neutral.

4. Turn the ignition key to Off. Note: Remember to remove the key from the ignition

switch if you leave the machine.

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.

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:

• Set the 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).

Page 22

Adjusting the Height-of-Cut

Adjusting the Gage Wheels

The height-of-cut can be adjusted from 1 to 4-1/2 inch (25 to 114 mm) in 1/4 inch (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers.

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

Note: All height–of–cut pins can use only two spacers maximum.

1. Select hole in height-of-cut post and number of spacers

corresponding to the height-of-cut desired (Fig. 18).

2. Using lift handle,raise side of deck and remove hairpin

cotter (Fig. 18).

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

and insert hairpin cotter (Fig. 18).

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

Important All four hairpin cotter pins must be in the

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

The gage wheels need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground.

1. After adjusting height-of-cut, check the gage wheels so

that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figures 19, 20, and 21).

2. If adjustment is needed, remove the bolt, washer(s) and

nut (Figures 19, 20, and 21).

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

minimum of 3/8 inch (10 mm) off the ground (Figures 19, 20, and 21).

4. Install the bolt, washer(s) and nut (Figures 19, 20,

and 21).

1. Carrier Frame

2. Hairpin Cotter

3. Front height–of–cut post

Figure 18

4. Spacers

5. Back height–of–cut post

m–6471

Figure 19

1. Gage wheel

2. Nut

3. Washer

m–6365

Page 23

4 5

1. Gage wheel

2. Nut

3. Bolt

Figure 20

4. Washer

5. Spacer

m–6470

1. Upper handle

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

Figure 22

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. High position

m–6591

2. Loosen the upper flange bolts (3/8 x 1 inch) and flange

nut securing handle to rear frame (Fig. 22).

3. Remove the lower flange bolts (3/8 x 1 inch) and flange

nuts securing handle to rear frame (Fig. 22).

4. Pivot handle to desired operating position and install

lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. Tighten all flange bolts.

5. Thread rod fitting up or down on rod until proper

position is attained and install into fitting to idler bracket with clevis pin, washer and hairpin cotter.

6. Check the parking brake adjustment; refer to Checking

m–6510

the Brakes, page 32.

Figure 21

1. Center Gage Wheels and

Spacer

2. Nut

3. Bolt

4. Washer

Adjusting the Handle Height

The handle position can be adjusted to match the operator’s height preference.

1. Remove hairpin cotter, washer and clevis pin securing

control rod fitting to idler bracket (Fig. 22).

Using the Mid–Size Weight

This machine includes a weight installed in the rear position (Fig. 23).

• The weight mounted in the rear position is

recommended, except when a Tru–Trak Sulky is

installed.

• The weight mounted in the back position, must be

removed when the when a Tru–T rak installed.



Sulky is

Page 24

Warning

With the weight installed in the rear position, the front end of the machine can rapidly raise up when the mower is removed. This could cause serious injury to you or bystanders.

• Support the rear of the machine when removing

the mower from the carrier frame.

1. Weight mounted in rear position

2. Capscrew

Figure 23

3. Washer

4. Nut

Page 25

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 26

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. Remove the key.

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. 24).

3. Unscrew nut and remove the air cleaner assembly (Fig. 24).

4. Carefully pull the foam element off the paper element (Fig. 24).

m–4694

Figure 25

1. Foam element 2. Oil

Cleaning the Paper Element

1. Lightly tap the element on a flat surface to remove dust

and dirt (Fig. 26).

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–4689

Figure 24

1. Retaining latch

2. Cover

3. Nut

4. Foam element

5. Paper element

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.

m–4695

Figure 26

1. Paper element 2. Rubber seal

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. 24).

3. Put one or two ounces of oil on the element (Fig. 25). Squeeze the element to distribute the oil.

Important Replace the foam element if it is torn or

worn.

2. Place the air cleaner assembly onto the air cleaner base

(Fig. 24). Secure with nut.

3. Install the air cleaner cover and secure latches (Fig. 24).

Page 27

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

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. Remove the key.

2. Clean around the oil dipstick (Fig. 27) so dirt cannot

fall into the filler hole and damage the engine.

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

(Fig. 27).

4. Thread the oil dipstick fully onto the filler tube

(Fig. 27). 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.

Figure 27

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 assure the oil drains completely.

3. Disengage the PTO and set the parking brake.

4. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

5. Slide the drain hose over the oil drain valve.

6. Place a pan below the drain hose. Rotate oil drain valve

to allow oil to drain (Fig. 28).

7. When oil has drained completely, close the drain valve.

8. Remove the drain hose (Fig. 28). Note: Dispose of the used oil at a recycling center.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

m–6574

Figure 28

1. Oil drain valve 2. Drain hose

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

page 27, into the filler tube (Fig. 27).

Page 28

10.Check the oil level; refer to Checking Oil Level,

page 27.

11. If needed, slowly add additional oil to bring to the full mark on dipstick.

Change Oil Filter Service Interval/Specification

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

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

1. Drain the oil from the engine; refer to Changing/Draining Oil, page 27.

2. Remove the old filter (Fig. 29).

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

replacement filter (Fig. 29).

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 inch (.75 mm)

Removing the Spark Plug(s)

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

tires, and turn the ignition key to Off. Remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 30). 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-4288

Figure 29

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. 29).

5. Fill the crankcase with the proper type of new oil; refer to Engine Oil Service, page 27.

M-429

Figure 30

1. Spark plug wire installed 2. Spark plug

Checking the Spark Plug

1. Remove spark plug.

2. Look at the center of the spark plug(s) (Fig. 31). 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.

Page 29

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. 31). Bend the side electrode (Fig. 31) if the gap is not correct.

Figure 31

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

0.030 inch (.75 mm)

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

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

4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decals (Fig. 32).

Installing the Spark Plug(s)

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. 30).

Greasing and Lubrication

Service Interval/Specification

Refer to the Check Service Reference Aid decal for location and interval of greasing and lubrication (Figure 32).

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. Remove the key.

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

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

Figure 32

Lubricating the Caster and Wheel Bearings

1. Lubricate the front wheel bearings and front spindles

until grease begins to ooze out of the bearings (Fig. 33).

2. Raise the rear of the machine and use jack stands to

support the machine.

3. Remove the rear wheel and tire assembly.

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

bearing (Fig. 33).

5. Install the grease cap.

6. Install the rear wheel and tire assembly. Note: Make sure the rear wheel grease caps are removed

before lubricating rear wheels.

Page 30

Figure 33

Lubricate the Transmission and Idler Bracket

m–636

m–5196

Figure 35

1. Lubricate the transmission couplers located in the back

of the machine (Fig. 34).

m–6594

Figure 34

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. 35).

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.

Checking the 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. 36). 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: 25–30 psi (172–207 kPa)

Page 31

Figure 36

1. Rear Tire 2. Caster tire

Fuel Tank Service

m–6367

Figure 37

1. Fuel line

2. Hose clamp

Fuel Filter Service

m–523

3. Fuel shut off valve

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.

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. Remove the key.

2. Close fuel shut–off valve (Fig. 37). Note: Remove fuel line from fuel valve that is closest to

the engine.

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

away from valve (Fig. 37).

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. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 38).

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

them away from the filter (Fig. 38).

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. 38).

7. Check for fuel leaks and repair if needed (Fig. 38).

4. Pull the fuel line off the valve (Fig. 37). 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 31.

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

close to the valve to secure the fuel line.

Page 32

Figure 38

1. Hose clamp

2. Fuel line

3. Filter

Fuse Service

Service Interval/Specification

M-4294

3. The proper disengaged clearance between the clutch

plates is 0.012–0.018 inch (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.

m–2600

Figure 40

1. Adjusting nut

2. Slot

3. Feeler gauge

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. 39) and push in new fuse.

Fuse: F1–10 amp, blade-type

m–5391

Figure 39

1. Fuse 10 amp

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. 40).

Servicing the Brakes

Service Interval/Specification

Before each use, check brakes on both a level surface and slope.

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 PTO.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Push the neutral/brake lock forward to set the brake.

4. 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 33.

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

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

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

2. Check adjustment by inserting feeler gauge thru slots

next to studs (Fig. 40).

Page 33

Adjusting the Brakes

The brake lever is on the upper control bar (Fig. 13). If the parking brake does not hold securely, an adjustment is required.

Note: For the initial adjustment, adjust the wing nut until it is 1–1/4 inches from the top of the rod (Fig. 41).

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

and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Check the brake before you adjust it; refer to Checking

the Brakes, page 32.

4. Release the parking brake; refer to Releasing the

Parking Brake, page 19.

5. To adjust the brake remove the hair pin cotter and

washer from the bell crank and trunnion (Fig. 41).

6. Rotate the wing nut clockwise to increase the braking

pressure.

7. Rotate the wing nut counterclockwise to decrease the

braking pressure.

8. Install the trunnion into the hole for the brake rod

(Fig. 41). Tighten the wing nut.

1 2

1. Hairpin cotter

2. Washer

3. Trunnion

4. Bell crank

Figure 41

m–6596

6. Hole for brake rod

7. Initial adjustment— 1–1/4 inch (32 mm)

8. Rod

9. Secure trunnion to brake lever with washer and hair pin

cotter (Fig. 41).

10.Check the brake operation again; refer to Checking the

Brake, page 32.

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.

Servicing the Cutting Blades

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

Warning

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.

Page 34

Before Inspecting or Servicing the Blades

Front

Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Fig 42). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 35.

2. Inspect the blades, especially the curved area (Fig. 42).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 42), immediately install a new blade.

m–151

1. Cutting Edge

2. Curved Area

Figure 42

3. Wear/slot Forming

m–1078

Figure 43

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 44

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 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 35.

Warning

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 43). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 44). Note this dimension.

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

or surfaces of blade.

Page 35

Removing the Blades

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

1. Hold the blade end using a rag or thickly-padded glove.

Remove the blade bolt, blade stiffener, washer, and blade from the spindle shaft (Fig. 45).

5 6 4

1. Sail Area of Blade

2. Blade

3. Blade spindle

Figure 45

4. Blade Bolt

5. Blade stiffener

6. Flat washer

m–6368

Figure 47

1. Blade 2. Balancer

m–1855

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 45).

Important The sail part of the blade must be pointing

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

(Fig. 45).

2. Install the lock washer and blade bolt (Fig. 45). Torque

the blade bolt to 85–110 ft-lb (115–140 Nm).

Correcting the Mower Quality of Cut

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. Disengage the PTO and set the parking brake.

Sharpening the Blades

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

blade (Fig. 46). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 46

1. Sharpen at original angle

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

balancer (Fig. 47). 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 blade is balanced.

(Fig. 45). Repeat this procedure until the

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position. Disconnect the spark plug wire(s) from the spark plug(s).

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

page 30.

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

Refer to Checking for Bent Blades on page 34.

5. Set the height-of-cut to the 4 inch (101.6 mm) position.

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

6. 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. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

Page 36

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

shown in figure 48.

4. At the carrier frame cross tube, measure location A

height (Fig. 48). This measurement must be 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm).

4. Measure engine deck height at location A (Fig. 49).

5. Measure engine deck height at location B (Fig. 49).

6. If the height at location A and B are not the same,

change tire pressure slightly to make them the same.

5. If the height at location A is not correct, adjustment is

needed.

6. Loosen the carrier frame mounting bolts on both sides

of the machine (Fig. 48).

7. Align the carrier frame and engine deck to match

1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm) at location A (Fig. 48).

8. Tighten the carrier frame mounting bolts on both sides

of the machine.

m–6369

Figure 48

1. Carrier Frame

2. Top of engine deck

3. Carrier frame mounting bolts

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

5. Straight edge

6. Carrier frame cross tube

444

m–5237

Figure 49

1. Back view of machine

2. Top of engine deck

3. Tires

4. Same height at locations A and B

Checking Carrier Frame Front–to–Rear Pitch

The carrier frame must have a pitch of a 1/4 inch (6 mm) over the length of 24 inches (61 cm) on the carrier frame (Fig. 50).

1. Measure out 24 inches (61cm) on the carrier frame

(Fig. 50).

2. Measure carrier frame height at location A (Fig. 50).

Checking Engine Deck Height

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

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

page 30.

3. Measure carrier frame height at location B (Fig. 50).

4. The height at location A must be a 1/4–3/8 inch (6 mm –10 mm) lower than location B (Fig. 50).

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

to make it a 1/4–3/8 inch (6 –10 mm) pitch (Fig. 50). 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 inch (6 mm) pitch.

Page 37

24 in.

(61cm)

Checking the Deck Front-to-Rear Pitch

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

m–6370

Figure 50

1. Caster Wheel

2. Carrier Frame

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

4. Height at locations A and B

5. Caster spacers

Checking Carrier Frame Side–to–Side

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

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

page 30.

2. Position one blade front-to-rear (Fig. 52). Measure at C and D locations (Fig. 52) from a level surface to the cutting edge of the blade tips (Fig. 53).

3. The mower blade should be 1/4 inch (6 mm) lower in front at C than in the rear at 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 52

4. Measure carrier frame height at location A (Fig. 51).

5. Measure carrier frame height at location B (Fig. 51).

6. 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.

4 4

m–6371

Figure 51

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Same height at locations A and B

5. Caster spacers

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 53

Changing the Deck Front-to-Rear Pitch

Changing the front–to–rear pitch is done by adjusting the 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. 54).

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

the front pin clockwise (Fig. 54).

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

the front pin counter clockwise (Fig. 54).

Page 38

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

m–2550

Figure 56

m–6371

Figure 54

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. 52). Measure at C and D locations (Fig. 52) from a level surface to the cutting edge of the blades (Fig. 53).

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. 55). Measure at A

and B locations (Fig. 55) from a level surface to the cutting edge of blade tips (Fig. 56).

3. The difference between measurements A and B should be no more than 1/4 inch (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 inch (101.6 mm) position

following the height-of-cut decal.

3. With the machine on level surface, position one blade front-to-rear (Fig. 57). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 58).

4. The measurement should be 4 inch (101.6 mm).

Front

Figure 55

m–1078

Figure 57

Page 39

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

m–2550

Figure 58

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.

Adjusting the Traction Drive Belt Tension

It may be necessary to increase the drive belt tension as the belt wears.

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 assembly

(Fig. 59).

4. Remove the adjustment bolt assembly (Fig. 59).

3 2 1

m–6595

Figure 59

1. Position A, New belt

2. Position B, Low belt wear

3. Position C, Medium belt wear

4. Position D, Most severe belt wear

5. Spring

6. Adjustment bolt, In position A

Replacing the Traction Drive Belt

Service Interval/Specification

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

1. Remove the top capscrew securing idler support and

idler bracket to rear frame (Fig. 60).

5. Locate the adjustment bolt assembly into the desired

tension position as follows.

• Position A – New belt

• Position B – Low belt wear

• Position C – Medium belt wear

• Position D – Most severe belt wear

Note: Do not over extend the spring. The spring length should not exceed 7–5/8 inches with the paring brake engaged (Fig. 59).

6. Install adjustment bolt assembly and spring.

7. Repeat for opposite side.

2. Loosen bottom two mounting screws enough to allow

belt to pass between drive pulley and idler support (Fig. 60).

3. Raise the wheel off the ground, to allow the belt to be

removed, and remove the belt.

4. Install a new belt.

5. Install the top capscrew securing the idler support and

idler bracket to the rear frame (Fig. 60).

6. Tighten the bottom two mounting screws enough to

allow the belt to pass between the drive pulley and idler support (Fig. 60).

Page 40

m–6597

Figure 60

1. Top capscrew

2. Idler bracket

3. Idler support

4. Bottom capscrew

5. Traction drive belt

Replacing the Transmission Belt

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

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

Drive Belt on page 41.

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

stands.

5. Disconnect clutch wire connector from wire harness.

2 8

m–5321

Figure 61

1. Transmission 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 Mower 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 and rubber washers holding the

carrier frame cover and remove the carrier frame cover.

3. Remove the knobs and rubber washers holding the belt

covers to the cutting unit and remove the belt covers.

6. Disconnect clutch retainer from the engine deck

(Fig. 61).

7. Unhook tension spring from side of frame (Fig. 61).

8. Loosen pivot bolt enough to remove traction belt from

the drive pulley and clutch.

9. Install new belt around clutch and drive pulley.

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

tension spring between idler arm and frame bracket (Fig. 61).

11. Install clutch retainer to the engine deck (Fig. 61).

12.Connect clutch wire connector to wire harness.

13.Install PTO drive belt.

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

PTO Drive Belt on page 41.

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

idler arm and idler pulley, then remove the worn deck belt (Fig. 62).

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. 62).

7. Connect the idler arm spring (Fig. 62).

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

PTO Drive Belt page 41.

9. Adjust deck belt guide an 1/8 inch (3 mm) from belt

(Fig. 62).

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

reinstall and tighten the knobs.

Page 41

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

install and tighten the hand knobs.

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

(Fig. 63).

m–6530

Figure 62

1. Deck belt

2. Idler arm spring

3. Outside pulley

4. PTO drive Belt

5. Center Spindle Pulley

6. Deck belt guide

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.

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

belt (Fig. 63).

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

and tighten the knobs.

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

install and tighten the hand knobs.

2 5

m–6530

Figure 63

1. PTO engagement pulley

2. PTO drive belt idler

3. PTO drive Belt

4. Center Spindle Pulley

5. PTO Drive belt guide

6. Idler Spring

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 and rubber washers holding the belt

covers to the top of the cutting unit and remove the belt covers.

4. Remove the idler spring from idler arm. Remove the

drive belt from the PTO engagement pulley and the center spindle pulley (Fig. 63).

5. Remove the worn drive belt (Fig. 63).

6. Install the new drive belt onto the PTO engagement

pulley and the top groove of the center spindle pulley (Fig. 63).

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.

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. 64).

Page 42

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.

m–6372

Figure 64

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. 65). 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. 64).

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

mounting tube. Replace the spacer(s) onto the fork and secure with the retaining ring (Fig 64).

m–6373

Figure 65

1. 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. 66).

2. Remove one bushing, then pull the spanner bushing and

roller bearing out of the wheel hub (Fig. 66).

3. Remove the other bushing from the wheel hub and

clean any grease and dirt from the wheel hub (Fig. 66).

4. Inspect the roller bearing, bushings, spanner bushing

and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 66).

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 inch (29 mm).

8. Grease the fitting on the carrier frame mounting tube

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

1. Locknut

2. Wheel Bolt

3. Bushing

m–5210

Figure 66

4. Spanner Bushing

5. Roller Bearing

Page 43

5. To 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 (Fig. 66).

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. 66).

7. Grease the fitting on the caster wheel.

Replacing the Grass Deflector

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. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

m–5037

Figure 67

6. Grass Deflector

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

8. J hook end of spring

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

deflector to the pivot brackets (Fig. 67). 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 67.

3. Install bolt and nut. Place the J hook end of spring

around grass deflector (Fig. 67).

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.

Page 44

Wiring Diagram

WIRE COLOR CODES

Operator Presence Switch

o Operator)

Neutral Switch (In Neutral)

HR MTR (OPTIONAL)

PTO Switch (Off)

BK BN

TY Y

354

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 45

Cleaning and Storage

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

brake, and turn the ignition key to Off. Remove the key.

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

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

Important You can wash the machine with mild

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

3. Check the brake; refer to Servicing the Brakes, page 32.

4. Service the air cleaner; refer to Servicing the Air

Cleaner, page 26.

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

page 29.

6. Change the crankcase oil; refer to Servicing the Engine

Oil, page 27.

7. Check the tire pressure; refer to Checking the Tire

Pressure, page 30.

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

stabilizer/conditioner additive to fuel in the tank.

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 Servicing the Fuel Tank, page 31, 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.

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

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

to Servicing the Spark Plug, page 28. 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.

Troubleshooting

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

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

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

2. Fuel valve is closed. 2. Open the fuel valve.

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

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

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

6. Spark plug wire is loose or

7. Spark plug is pitted, fouled, or

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

9. Dirt, water, or stale fuel is in

disconnected.

gap is incorrect.

fuel system.

position.

element.

6. Install wire on spark plug.

7. Install new, correctly gapped spark plug.

9. Contact Authorized Service Dealer.

Page 46

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 47

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 48

LCE

The Toro Total Coverage Guarantee

A 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 the listed Toro Products 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

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. U.S. Customers may also call 800-348-2424.

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

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

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-577-7466 (U.S. customers) 877-484-9255 (Canada customers)

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 d o n o t a l l o w 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. C