Toro 30484, 30486 Operator's Manual

FormNo.3364-522RevB

CommercialWalk-BehindMower

FloatingDeck,SplitLever,HydroDrivewith
36in,40in,48inor52inTURBOFORCE
CuttingUnit

ModelNo.30484—SerialNo.310000001andUp

®

ModelNo.30486—SerialNo.310000001andUp

ModelNo.30488—SerialNo.310000001andUp

ModelNo.30489—SerialNo.310000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

Figure1

1.Modelandserialnumberlocation

Theenclosed

Engine Owner’ s Man ual

issupplied
forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCalifornia
EmissionControlRegulationofemissionsystems,
maintenance,andwarranty.Replacementsmaybe
orderedthroughtheenginemanufacturer.

Introduction

Thisrotary-blade,lawnmowerisintendedtobe
usedbyresidentialhomeownersorprofessional,
hiredoperators.Itisdesignedprimarilyforcutting
grassonwell-maintainedlawnsonresidential
orcommercialproperties.Itisnotdesignedfor
cuttingbrushorforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .

Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

©2010—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contents

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

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

SafeOperatingPractices.......................................4

ToroMowerSafety...............................................5

SlopeIndicator.....................................................7

SafetyandInstructionalDecals.............................8

ProductOverview......................................................11

Controls.............................................................11

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Specications.....................................................12

Operation...................................................................13

AddingFuel.......................................................13

CheckingtheEngineOilLevel............................14

ThinkSafetyFirst...............................................14

OperatingtheParkingBrake...............................14

StartingandStoppingtheEngine........................14

OperatingtheMowerBladeControl

(PTO)............................................................15

TheSafetyInterlockSystem................................16

DrivingForwardorBackward.............................16

StoppingtheMachine.........................................17

PushingtheMachinebyHand.............................17

TransportingMachines.......................................18

SideDischargingorMulchingtheGrass..............18

AdjustingtheHeight-of-Cut...............................18

AdjustingtheAnti-ScalpRollers.........................19

AdjustingtheFlowBafe...................................20

PositioningtheFlowBafe.................................20

UsingtheMid-SizeWeight..................................22

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

RecommendedMaintenanceSchedule(s)................23

Lubrication.............................................................24

HowtoGrease...................................................24

LubricatingtheBearings.....................................24

GreasingthePTODriveBeltIdlerandMower

DeckBeltIdler...............................................24

EngineMaintenance...............................................25

ServicingtheAirCleaner....................................25

ServicingtheEngineOil.....................................26

ServicingtheSparkPlugs....................................27

FuelSystemMaintenance.......................................28

DrainingtheFuelTank.......................................28

ServicingtheFuelFilter......................................29

ElectricalSystemMaintenance................................30

ServicingtheBattery...........................................30

ServicingtheFuses.............................................32

DriveSystemMaintenance.....................................33

AdjustingtheTracking.......................................33

CheckingtheTirePressure.................................33

ReplacingtheCasterWheelFork

Bushings........................................................33

ServicingtheCasterWheelandBearings.............34

AdjustingtheElectricClutch..............................34

CoolingSystemMaintenance..................................35

CleaningtheAirIntakeScreen............................35

BrakeMaintenance.................................................36

ServicingtheBrake.............................................36

BeltMaintenance....................................................37

ReplacingtheMowerBelt...................................37

ReplacingthePTODriveBelt.............................37

AdjustingthePTODriveBeltIdlerSpring

Anchor...........................................................38

ReplacingthePumpDriveBelt...........................39

ControlsSystemMaintenance.................................40

AdjustingtheMotionControlHandle

Positions........................................................40

HydraulicSystemMaintenance...............................42

ServicingtheHydraulicSystem...........................42

MowerDeckMaintenance......................................44

ServicingtheCuttingBlades...............................44

CorrectingtheMowerQualityofCut..................47

FrameSetUp.....................................................47

CheckingtheMowerDeckFront-to-Rear

Pitch...............................................................49

ChangingtheMowerDeckFront-to-Rear

Pitch...............................................................49

CheckingtheMowerDeckSide-to-Side

Height............................................................50

ChangingtheMowerDeckSide-to-Side

Height............................................................50

MatchingHeightofCut......................................50

ReplacingtheGrassDeector.............................51

Cleaning.................................................................52

CleaningUndertheMower.................................52

WasteDisposal...................................................52

Storage.......................................................................52

CleaningandStorage..........................................52

Troubleshooting.........................................................54

Schematics.................................................................56

3

Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
CAUTION,WARNING,orDANGER-“personalsafety
instruction."Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

–Neverrefuelordrainthemachineindoors.

•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator’sposition.

•Besureofyourfootingwhileusingthismachine,
especiallywhenbackingup.Walk,don’trun.Never
operateonwetgrass.Reducedfootingcouldcause
slipping.

•Slowdownanduseextracareonhillsides.Besure
totravelsidetosideonhillsides.Turfconditions
canaffectthemachine’ sstability.Usecautionwhile
operatingneardrop-offs.

•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguards
notsecurelyinplace.Besureallinterlocksare
attached,adjustedproperly,andfunctioningproperly .

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

–Useonlyanapprovedcontainer

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Stoponlevelground,disengagedrives,engage
parkingbrake,shutoffenginebeforeleavingthe
operator’spositionforanyreasonincludingemptying
thecatchersoruncloggingthechute.

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

4

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopbladesifnot
mowing.

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Usecarewhenloadingorunloadingthemachine
intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

Maintenanceandstorage

•Disengagedrives,setparkingbrake,stopengineand
removekeyordisconnectsparkplugwire.Waitfor
allmovementtostopbeforeadjusting,cleaningor
repairing.

•Cleangrassanddebrisfromcuttingunit,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.
Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectthebatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositivelast.Reconnectthe
positiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyoumust
know .

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore
mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowtocoolbefore
attemptingtomaintain,adjustorservice.

•UseonlyToroapprovedattachments.W arrantymay
bevoidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)before
operatingunderanyobjectsanddonotcontact
them.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeel
uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from
themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide
obstacles.

•Usecautionneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifawheel
goesovertheedgeofaclifforditch,orifanedge
cavesin.

•Useextracarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machine.

•Keepallmovementonslopesslowandgradual.Do
notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade
attachmentbolts.Keepequipmentingood
condition.

•Nevertamperwithsafetydevices.Checksafety
systemsforproperoperationbeforeeachuse.

5

•Useonlygenuinereplacementpartstoensurethat
originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice
asrequired.

6

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope
ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline
tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

7

SafetyandInstructional
Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

98-5954

43-8480

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

66-1340

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe
distancefromthebattery.

7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries

8.Batteryacidcancause
blindnessorsevereburns.

withwaterandgetmedical
helpfast.

10.Containslead;donot
discard.

68-8340

104-8185

36inmowerdecks

98-0776

8

104-8186

40inandlargermowerdecks

104-8569

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

110-2067

110-2068

105-7798

1.ReadtheOperator’sManual.

106-0635

112-8720

106-0699

9

115-4212

1.Hydraulicoillevel3.Warning—donottouch
thehotsurface.

2.ReadtheOperator’s

Manual.

1.Interval

2.PowerT ake-off(PTO)

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

115-4186

115–4179

1.Movethemotioncontrollevertotheneutralposition,thenpull

outonPTO(PowerTakeOff)switchtoengagetheblades.

2.PushinonthePTO(PowerT akeOff)todisengagetheblades.7.Thrownobjecthazard—keepbystandersasafedistancefrom

3.Warning—readtheOperator’sManual.8.Thrownobjecthazard—keepdeectorinplace.

4.Warning—donotoperatethismachineunlessyouaretrained.

5.Warning—stoptheengineandremovethesparkplugwire

beforeperforminganymaintenanceonthemachine.

6.Warning—stoptheenginebeforeleavingthemachine.

themachine.

9.Cutting,dismembermenthazardofhandorfoot—stayaway
frommovingparts;keepallguardsandshieldsinplace.

1.Fast2.Enginespeed

115–4189

3.Slow4.Choke

10

1.Tractioncontrol

2.Fast4.Neutral

ProductOverview

Figure4

1.Sidedischargechute

2.Engine6.Mowerdeck

3.Gastank

4.Controls

5.Parkingbrake

7.Frontcasterwheel

114-3424

3.Slow

1.Ignitionswitch

2.Leftmotioncontrollever7.Neutrallockpositionfor

3.Throttlecontrol8.Rightmotioncontrollever

4.Hourmeter

5.Fueltank

5.Reverse

6.DisengagethePTO(PowerTakeOff)

Figure5

6.Choke

rightmotioncontrollever

9.bladecontrolswitch(PTO)

10.Operatormanualtube

HourMeter

Controls

Becomefamiliarwithallthecontrols(Figure5)before
youstarttheengineandoperatethemachine.

Thehourmeterrecordsthenumberofhourstheengine
hasoperated.Itoperateswhentheengineisrunning.
Usethesetimesforschedulingregularmaintenance

Figure6).

(

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandindicatewith
ablacktrianglethattheinterlockcomponentisinthe
correctposition(Figure6).

BatteryIndicatorLight

WhentheignitionkeyisinitiallyturnedtotheOn
position,thebatteryvoltagewillbedisplayedinthearea
wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned
onandwhenthechargeisbelowthecorrectoperating
level(

Figure6).

11

Figure6

1.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

ThrottleControl

Thethrottlecontrolhastwopositions:FastandSlow.

enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.Toro.comforalistofallapprovedattachments
andaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

36inchmowers:

Widthwithdeectordown51–1/8inches(130cm)

Length

Height

Weight

78–1/2inches(199cm)

46inches(117cm)

667lb(303kg)

Choke

Usethechoketostartacoldengine.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengage
theelectricclutchtodrivethemowerbladeswiththe
rightsidemotioncontrolleverinthecenter,un-locked
position.Pulltheswitchuptoengagethebladesand
release.Todisengagetheblades,pushthebladecontrol
switch(PTO)downormoveorreleasetherightside
motioncontrolleverintotheneutrallockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas
threepositions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine
forward,reverse,andturneitherdirection.

40inchmowers:

Widthwithdeectordown55–1/2inches(141cm)

Length

Height

Weight

75–3/8inches(192cm)

46inches(117cm)

667lb(303kg)

48inchmowers:

Widthwithdeectordown63–1/2inches(161cm)

Length

Height

Weight

77–3/4inches(198cm)

46inches(117cm)

682lb(309kg)

52inchmowers:

Widthwithdeectordown67–5/8inches(171.7cm)

Length

Height

Weight

77–3/4inches(198cm)

46inches(117cm)

721lb(327kg)

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock
systemtoengageanddisengagethemowerbladesand
todetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(underthefueltank)when
transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesareavailableforusewiththemachineto

12

Operation

AddingFuel

UseUnleadedRegularGasolinesuitablefor
automotiveuse(85pumpoctaneminimum).Leaded
regulargasolinemaybeusedifunleadedregularisnot
available.

Important:Neverusemethanol,gasoline
containingmethanol,orgasoholcontainingmore
than10%ethanolbecausethefuelsystemcouldbe
damaged.Donotmixoilwithgasoline.

DANGER

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areorexplosion
fromgasolinecanburnyouandothersandcan
damageproperty.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanygasoline
thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4to
1/2inch(6to13mm)belowthebottomofthe
llerneck.Thisemptyspaceinthetankallows
gasolinetoexpand.

•Neversmokewhenhandlinggasoline,andstay
awayfromanopenameorwheregasoline
fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Neverbuy
morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystem
inplaceandinproperworkingcondition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingasparkwhich
canignitethegasolinevapors.Areorexplosion
fromgasolinecanburnyouandothersandcan
damageproperty.

•Alwaysplacegasolinecontainersontheground
awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicle
oronatruckortrailerbedbecauseinterior
carpetsorplastictruckbedlinersmayinsulate
thecontainerandslowthelossofanystatic
charge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerandrefuel
theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromagasolinedispenser
nozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimofthe
fueltankorcontaineropeningatalltimesuntil
fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening .

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

Important:Donotusefueladditives
containingmethanolorethanol.

Addthecorrectamountofgas
stabilizer/conditionertothegas.

13

Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshgasoline.To
minimizethechanceofvarnishdepositsinthefuel
system,usefuelstabilizeratalltimes.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileit
isunattended.

FillingtheFuelT ank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundfueltankcapandremovethecap.
Addunleadedregulargasolinetofueltank,untilthe
levelis1/4to1/2inch(6to13mm)belowthe
bottomofthellerneck.Thisspaceinthetank
allowsgasolinetoexpand.Donotllthefueltank
completelyfull.

3.Installfueltankcapsecurely.Wipeupanygasoline
thatmayhavespilled.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoChecking
OilLevelinEngineMaintenance.

Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

SettingtheParkingBrake

Pulltheparkingbrakeleverrearward(Figure7).

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin
thesafetysection.Knowingthisinformationcould
helpyouoranybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feet
andheadisrecommended.

CAUTION

Thismachineproducessoundlevelsinexcessof
85dBAattheoperator’searandcancausehearing
lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe
machineorleaveitunattended.Beforeeachuse,check
theparkingbrakeforproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit.
RefertoServicingtheParkingBrake.

Figure7

1.Parkingbrakelever(inthe
releasedposition)

2.Parkingbrakelever(inthe
engagedposition)

ReleasingtheParkingBrake

Pushtheparkingbrakeleverforward.

StartingandStoppingthe
Engine

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Settheparkingbrake.

4.Movethethrottlecontroltofastandmovethe
chokelevertotheonpositionbeforestartingacold
engine(Figure8).

Note:Awarmorhotenginemaynotrequire
choking.Tostartawarmengine,movethrottle
controlmidwaybetweenthefastandslow
positions.

14

Figure8

1.Ignitionswitch

2.Throttlelever

3.Choke

5.Turntheignitionkeytothestartpositionto
energizethestarter.Whentheenginestarts,release
thekey .

Note:Donotengagethestarterformorethan
5secondsatatime.Iftheenginefailstostart,
allowfora15secondcool-downperiodbetween
attempts.Failuretofollowtheseinstructionscan
burnoutthestartermotor.

OperatingtheMowerBlade
Control(PTO)

Thebladecontrolswitch(PTO)isusedinconjunction
withtherightsidemotioncontrollevertoengageand
disengagethemowerblades.

EngagingtheMowerBlades(PTO)

1.Toengagethemowerblades,movetherightside
motioncontrollevertothecenter,un-locked
position(Figure9).

2.Pullthebladecontrolswitch(PTO)upandrelease
itwhileholdingdowntherightsidemotioncontrol
leverinthecenter,un-lockedposition.

6.Whenenginestarts,movethethrottlecontrol
betweenthefastandslowpositionandmovethe
chokelevertotheoffposition.Allowtheengine
towarmupandthenmovethethrottlecontrolto
thefastposition.

StoppingtheEngine

1.Movethemotioncontrolleverstoneutralandmove
therightsidemotioncontrolleverintotheneutral
lockposition.

2.Movethethrottlelevertoslow(Figure8).

3.Iftheenginehasbeenworkinghardorishot,let
theengineidlefor30to60secondsbeforeturning
theengineoff.

4.Tostoptheengine,turntheignitionkeytooff.

Important:Makesurefuelshutoffvalve
isclosedbeforetransportingorstoringthe
machine,asfuelleakagemayoccur.Before
storingthemachine,pullwireoffsparkplug(s)
topreventpossibilityofaccidentalstarting.

Figure9

1.Bladecontrolswitch(PTO)

2.Rightsidemotioncontrol
leverpusheddownintothe
center,un-lockedposition

3.Rightmotioncontrollever
inneutrallockposition

4.Leftmotioncontrollever

DisengagingtheMowerBlades(PTO)

Thefollowingaretwooptionsfordisengagingthe
mowerblades.

•Pushthebladecontrolswitch(PTO)downtothe
offposition.

•Movethemotioncontrolleverstoneutralandmove
therightsidemotioncontrolleverintotheneutral
lockposition.

15

TheSafetyInterlockSystem

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventthe
mowerbladesfromrotatingunless:

•Therightsidemotioncontrolleverismovedtothe
center,un-lockedposition.

•Thebladecontrolswitch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostopthe
mowerbladesifyoumoveorreleasetherightside
motioncontrolleverintotheneutrallockposition.

Thehourmeterhassymbolstonotifytheuserwhen
theinterlockcomponentisinthecorrectposition.
Whenthecomponentisinthecorrectposition,a
trianglewilllightupinthecorrespondingsquare.

2.Settheparkingbrake.

3.Movetherightsidemotioncontrollevertothe
center,un-lockedposition.Thebladesshould

notrotate.

4.Movethemotioncontrolleversforward.The
engineshouldkill.

5.Starttheengineandreleasetheparkingbrake.

6.Movetherightsidemotioncontrollevertothe
center,un-lockedposition.

7.Continueholdingtherightsidemotioncontrollever
inthecenter,un-lockedpositionandpulluponthe
bladecontrolswitch(PTO)andrelease.Theclutch
shouldengageandthemowerbladesbeginrotating.

8.Moveorreleasetherightsidemotioncontrollever
intotheneutrallockposition.Thebladesshould

stoprotating.

9.Movetherightsidemotioncontrollevertothe
center,un-lockedposition.

10.Continueholdingtherightsidemotioncontrollever
inthecenter,un-lockedpositionandpulluponthe
bladecontrolswitch(PTO)andrelease.Theclutch
shouldengageandthemowerbladesbeginrotating.

11.Pushthebladecontrolswitch(PTO)downtothe
offposition.Thebladesshouldstoprotating.

12.Withtheenginerunning,pullupthebladecontrol
switch(PTO)andreleasewithoutholdingright
sidemotioncontrollevertothecenter,un-locked
position.Thebladesshouldnotrotate.

Figure10

1.Triangleslightupwhentheinterlockcomponentsareinthe
correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe
machineeachtime.

Note:Ifthesafetysystemdoesnotoperateas
describedbelow,haveanAuthorizedServiceDealer
repairthesafetysystemimmediately .

1.Starttheengine;refertoStartingandStoppingthe
Enginein

Operation(page13).

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas
measuredinrpm(revolutionsperminute).Place
thethrottlecontrolinthefastpositionforbest
performance.Alwaysoperateinthefullthrottle
positionwhenmowing.

CAUTION

Machinecanspinveryrapidly.Operatormaylose
controlofmachineandcausepersonalinjuryor
damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp
turns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakeinOperation(page13).

16

2.Movetherightsidemotioncontrollevertothe
center,un-lockedposition.

theneutrallockposition,disengagethepowertakeoff
(PTO),andturntheignitionkeytooff.

3.Togoforward,slowlypushthemotioncontrol
leversforward(Figure11).

Note:Theenginewillkillifthetractioncontrol
leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretobothmotion
controllevers(

Toturn,movethemotioncontrollevertoward
neutralinthedirectionyouwanttoturn(Figure11).

Thefartheryoumovethetractioncontrolleversin
eitherdirection,thefasterthemachinewillmovein
thatdirection.

Tostop,pullthemotioncontrolleversbacktothe
neutralposition.

Figure11).

Settheparkingbrakewhenyouleavethemachine;refer
toSettingtheParkingBrakein
Remembertoremovethekeyfromtheignitionswitch.

Operation(page13).

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

PushingtheMachinebyHand

Theby-passvalvesallowthemachinetobepushedby
handwithouttheenginerunning.

Important:Alwayspushthemachinebyhand.
Nevertowthemachinebecausehydraulicdamage
mayoccur.

Figure11

1.Forward2.Backward

DrivingBackward

1.Movetherightsidemotioncontrollevertothe
center,un-lockedposition.

2.Togobackward,slowlypullthemotioncontrol
leversrearward(Figure11).

Togostraight,applyequalpressuretobothmotion
controllevers(Figure11).

Toturn,releasepressureonthemotioncontrollever
towardthedirectionyouwanttoturn(Figure11).

ToPushtheMachine

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Opentheby-passvalveonbothpumpsbyturning
themcounterclockwise1to2turns.Thisallows
hydraulicuidtoby-passthepumpsandthewheels
toturn(

Note:Rotatetheby-passvalvesamaximumof2
turnssothevalvedoesnotcomeoutofthebody
causinguidtorunout.

Figure12).

Tostop,pushthemotioncontrolleverstothe
neutralposition.

StoppingtheMachine

Tostopthemachine,movethemotioncontrolleversto
neutral,movetherightsidemotioncontrolleverinto

17

1.Pumpby-passvalve

Figure13

1.Tractionunittiedownloop

Figure12

SideDischargingorMulching

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

6.Closetheby-passvalves,butdonotovertighten
them.

Important:Donotstartoroperatethe
machinewiththeby-passvalvesopen.Damage
tosystemmayoccur.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
necessarybrakes,lighting,andmarkingasrequiredby
law .Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily,
petsorbystandersavoidinjury.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle
andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

theGrass

Thismowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

DANGER

Withoutthegrassdeector,dischargecover,or
completegrasscatcherassemblymountedin
place,youandothersareexposedtobladecontact
andthrowndebris.Contactwithrotatingmower
blade(s)andthrowndebriswillcauseinjuryor
death.

•Neverremovethegrassdeectorfromthe
mowerbecausethegrassdeectorroutes
materialdowntowardtheturf.Ifthe
grassdeectoriseverdamaged,replaceit
immediately.

•Neverputyourhandsorfeetunderthemower.

•Nevertrytocleardischargeareaormower
bladesunlessyoureleasethebailandthepower
takeoff(PTO)isoff.Rotatetheignitionkeyto
Off.Alsoremovethekeyandpullthewire(s)
offthesparkplug(s).

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,and
closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto
securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes(

6.Fastenthefrontofthemachinetothetraileror
truckwithstraps,chains,cable,orropes.

Figure13).

AdjustingtheHeight-of-Cut

Theheight-of-cutcanbeadjustedfrom1to4-1/2
inch(25to114mm)in1/4inch(6mm)increments.
Adjustmentisdonebyrelocatingfourhairpincotter
pinsindifferentholelocationandbyaddingor
removingspacers.

Note:Allheight-of-cutpinsneedatleastonespacer
ordamagecanoccurtobushingifnoneareused.

Note:Allheight-of-cutpinscanusetwospacers
maximum.

18

1.Selectholeinheight-of-cutpostandnumberof
spacerscorrespondingtotheheight-of-cutdesired
(Figure14).

2.Usingthelifthandle,raisesideofdeckandremove
hairpincotter(

Figure14).

3.Addorremovespacersifneededandthenalign
holesandinserthairpincotter(Figure14).

(10mm)clearanceabovetheground(Figure15,
Figure16,Figure17).

2.Ifadjustmentisneeded,removethebolt,washers
andnut(

Figure15,Figure16,Figure17).

3.Selectaholepositionsotheanti-scalprollersare
aminimumof3/8inch(10mm)offtheground
(Figure15,Figure16,Figure17).

Note:Spareheight-of-cutspacersmaybestored
onpostsandretainedbyahairpincotter.

Important:Allfourhairpincotterpinsmustbe
inthesameholelocationandwiththecorrect
numberofspacersforalevelcut.

4.Installtheboltandnut(Figure15,Figure16,
Figure17).

Figure15

40inch,48inch,and52inchMowerDecks

1.Mowerdeck

2.Bolt5.Nut

3.Spacer

4.Anti-ScalpRollers

Figure14

1.CarrierFrame4.Spacers

2.HairpinCotter5.Frontheight-of-cutpost

3.Backheight-of-cutpost

AdjustingtheAnti-Scalp
Rollers

Theanti-scalprollersneedtobeadjustedintheproper
holelocationforeachheight-of-cutposition.There
needstobe3/8inch(10mm)minimumclearance
abovetheground.

Note:Iftheanti-scalprollersareadjustedtoolowit
cancauseexcesswearoftherollers.

1.Afteradjustingheight-of-cut,checktheanti-scalp
rollerssothatthereisaminimumof3/8inch

19

Figure16

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Bushing

2.Bolt

3.Spacer

5.Anti-ScalpRollers

6.Nut

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Toadjustthecamlock,swingtheleveruptoloosen
thecamlock(

Figure18).

4.Adjustthebafeandcamlockintheslottothe
desireddischargeow .

5.Swingtheleverbackovertotightenthebafeand
camlock(

Figure18).

6.Ifthecamdoesnotlockthebafeintoplaceoritis
tootight,loosentheleverandthenrotatethecam
lock.Adjustthecamlockuntilthedesiredlocking
pressureisachieved.

Figure17

36inchMowerDeck

1.Mowerdeck

2.Bolt5.Nut

3.Spacer

4.Anti-ScalpRollers

5.Incertainmowingconditionsandterrain,a
mismatchofcuttingheightmaybeseen.Adjusting
theoutsideanti-scalprollerstotheminimumsetting
of3/8inch(10mm)willhelppreventthemower
deckcuttingtoolowontheoutsideandminimize
themismatch.

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent
typesofmowingconditions.Positionthecamlockand
bafetogivethebestqualityofcut.

Figure18

1.Camlock

2.Lever

3.Rotatecamtoincreaseor
decreaselockingpressure

4.Slot

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsfor
use.Adjustmentswillvarybygrasstype,moisture
content,andheightofgrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure19).The
suggesteduseforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe
mower.

20

Figure19

PositionB

Usethispositionwhenbagging(Figure20).

Figure21

Figure20

PositionC

Thisisthefullopenposition.Thesuggestedusefor
thispositionisasfollows(Figure21).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheT oro
SFSmower.

21

UsingtheMid-SizeWeight

Weightsareinstalledoncertainmowerstoimprove
balanceandimproveperformance.Theweightscanbe
movedorremovedtocreateoptimizedperformance
underdifferentmowingconditionsandforoperator
preference(Figure22orFigure23).

Thefollowingtableindicatesthepositionoftheweight
asinstalledatthefactory.

MowerDeckSizeNumberofweights

36inches1Front

40inches1Front

48inches

52inches1Rear

install

nonenone

•Anyrearweightmustberemovedwhena
Tru–Track

•WhenaTru–Track

®

Sulkyisinstalled.

®

Sulkyisinstalledfrontweights
areneeded.ContactanAuthorizedServiceDealer
forthecorrectquantityofweightsandplacement.

Positionofthe

weight

Figure23

Installingtherearweight.

1.Nut3.Washer

2.Weight4.Bolt

WARNING

Thefrontendofthemachinecanrapidlyriseup
whenthemowerisremoved.Thiscouldcause
seriousinjurytoyouorbystanders.

Supporttherearofthemachinewhenremoving
themowerfromthecarrierframe.

Figure22

Installingthefrontweight.

1.Bolt3.Weight

2.Washer4.Nut

22

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulicuidlevel.

•Changethehydrauliclter.

•Checkthesafetyinterlocksystem.

•Greasethefrontcasterpivotbearing.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrakes.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.

•Checkthebatteryelectrolytelevel.

•Checkthehydraulicuidlevel.

•Greasethesidebearings.

•GreasethePTObeltidler.

•Greasethemowerdeckbeltidler.

•Checkthepaperaircleanerelement.

•Checkthetirepressure.

•Checkthemowerbelt.

•CheckthePTOdrivebelt.

•Checkthepumpdrivebelt.

•Changetheengineoil.

•Checkthesparkplugs.

•Adjusttheelectricclutch.

•Checkthehydrauliclines.

•Replacethepaperaircleanerelement.

Every200hours

Every250hours

Every400hours

Every500hours

Beforestorage

Important:Refertoyour

•Changetheoillter.

•Replacethefuellter.

•ChangethehydrauliclterandhydraulicoilwhenusingMobil®1oil.

•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).

•ChangethehydrauliclterandhydraulicoilwhenusingT oro®HYPR-OIL™500
hydraulicoil.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo
anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.

23

Lubrication

GreasingthePTODriveBelt

GreasewithNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

HowtoGrease

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanthegreasettingswitharag.Makesureto
scrapeanypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease
intothettingsuntilgreasebeginstooozeoutof
thebearings.

5.Wipeupanyexcessgrease.

LubricatingtheBearings

ServiceInterval:Beforeeachuseordaily

IdlerandMowerDeckBelt
Idler

ServiceInterval:Every50hours

Every50hours

Greasetheidlerpulleypivots(Figure25orFigure26).

Note:Youwillhavetoremovethecarriercoversto
accessthegreasettingforthemowerdeck.

Every400hours

Every50hours

Lubricatethefrontcasterwheelbearingsandfront
pivots(Figure24).

Note:Makesuretherearwheelgreasecapsare
removedbeforelubricatingrearwheels.

Figure25

40inch,48inch,and52inchMowerDeckshown

Figure24

Figure26

36inchMowerDeckshown

24

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval/Specication

ServiceInterval:Every25hours—Cleanfoamair

cleanerelement.

Every50hours—Checkthepaperair
cleanerelement.

Every200hours—Replacethepaper
aircleanerelement.

Note:Servicetheaircleanermorefrequently(every
fewoperatinghours)iftheoperatingconditionsare
extremelydustyorsandy .

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanaroundtheaircleanertopreventdirt
fromgettingintotheengineandcausingdamage

Figure27).

(

4.Unscrewthecoverknobsandremovetheaircleaner
cover(

5.Unscrewthehoseclampandremovetheaircleaner
assembly(Figure27).

6.Carefullypullthefoamelementoffthepaper
element(Figure27).

Figure27).

Figure27

1.Cover

2.Hoseclamp4.Foamelement

3.Paperelement

CleaningtheFoamAirCleanerElement

1.Washthefoamelementinliquidsoapandwarm
water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis
tornorworn.

ServicingthePaperAirCleaner
Element

1.Donotcleanthepaperlter,replaceit(Figure27).

2.Inspecttheelementfortears,anoilylm,ordamage
totherubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand
paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair
cleanerelement(Figure27).

2.Placetheaircleanerassemblyontotheaircleaner
baseandsecureitwiththe2wingnuts(Figure27).

3.Placetheaircleanercoverintopositionandtighten
thecoverknob(Figure27).

25

ServicingtheEngineOil

ServiceInterval/Specication

ServiceInterval:Beforeeachuseordaily—Checkthe

engineoillevel.

Aftertherst8hours—Changethe
engineoil.

Every100hours—Changetheengine
oil.

Every200hours—Changetheoil
lter.

Note:Changetheoilmorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.

OilType:Detergentoil(APIserviceSF ,SG,SH,SJ
orSL)

CrankcaseCapacity:58ounces(1.7liter)withthelter
removed;51ounces(1.5liter)withoutthelterremoved

Figure29

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean
(Figure29).

6.Slidetheoildipstickfullyintothellertube,butdo
notthreadontotube(Figure29).

7.Pullthedipstickoutandlookattheend.Iftheoil
levelislow ,slowlypouronlyenoughoilintotheller
tubetoraisetheleveltotheFullmark.

Viscosity:Refertothetable(

Figure28

Figure28).

CheckingtheEngineOilLevel

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

4.Cleanaroundtheoildipstick(
cannotfallintothellerholeanddamagetheengine.

Figure29)sothatdirt

Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagecan
result.

ChangingtheEngineOil

1.Starttheengineandletitrunveminutes.This
warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoildrains
completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain
valvetoallowoiltodrain(

7.Whenoilhasdrainedcompletely,closethedrain
valve.

8.Removethedrainhose(Figure30).

Note:Disposeoftheusedoilatarecyclingcenter.

Figure30).

26

Figure30

1

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure29).

10.Checktheoillevel;refertoCheckingtheEngineOil
Level.

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

Note:Changetheoilltermorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

4.Installthereplacementoilltertothelteradapter,
turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(

Figure31).

5.Fillthecrankcasewiththepropertypeofnewoil;
refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillteranddrain
valve.

7.Checktheengineoillevelandaddoilifneeded.

8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

ServiceInterval:Every100hours

Ensurethattheairgapbetweenthecenterandside
electrodesiscorrectbeforeinstallingthesparkplug.
Useasparkplugwrenchforremovingandinstallingthe
sparkplugsandagappingtool/feelergaugetocheckand
adjusttheairgap.Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Disconnectthewiresfromthesparkplugs
(Figure32).

1.Draintheoilfromtheengine;refertoChangingthe
EngineOil.

2.Removetheoldlter(

1.Oillter

Figure31).

Figure31

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure31).

Figure32

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausing
damage.

5.Removethesparkplugsandthemetalwashers.

27

CheckingtheSparkPlugs

1.Lookatthecenterofthesparkplugs(Figure33).
Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly .Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Figure33

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

Important:Alwaysreplacethesparkplugs
whenithaswornelectrodes,anoilylmonit,
orhascracksintheporcelain.

3.Checkthegapbetweenthecenterandsideelectrodes

Figure33).Bendthesideelectrode(Figure33)if

(
thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

2.Tightenthesparkplugsto16ft-lb(22N-m).

3.Connectthewirestothesparkplugs(

Figure33).

FuelSystem
Maintenance

DrainingtheFuelTank

DANGER

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areorexplosion
fromgasolinecanburnyouandothersandcan
damageproperty.

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopenarea.
Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,andstay
awayfromanopenameorwhereasparkmay
ignitethegasolinefumes.

1.Parkthemachineonalevelsurface,toassurefuel
tankdrainscompletely.Thendisengagethepower
takeoff(PTO),settheparkingbrake,andturnthe
ignitionkeytooff.Removethekey.

2.Closethefuelshut-offvalveatthefueltank

Figure34).

(

3.Squeezetheendsofthehoseclamptogether
andslideitupthefuellineawayfromfuellter

Figure34).

(

4.Pullthefuellineoffthefuellter(Figure34).Open
thefuelshut-offvalveandallowthegasolinetodrain
intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter
becausethefueltankisempty.RefertoReplacing
theFuelFilter.

5.Installthefuellineontothefuellter.Slidethehose
clampclosetothevalvetosecurethefuelline.

6.Wipeupanyspilledfuel.

28

Figure34

1.Fuellter3.Fuelshut-offvalve

2.Clamp

Figure35

1.Hoseclamp3.Filter

2.Fuelline

ServicingtheFuelFilter

ServiceInterval:Every200hours/Yearly(whichever

comesrst)

ReplacingtheFuelFilter

Neverinstalladirtylterifitisremovedfromthefuel
line.

Note:Notehowthefuellterisinstalledinorderto
installthenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Closefuelshut-offvalveatthefueltank(

4.Squeezetheendsofthehoseclampstogetherand
slidethemawayfromthelter(Figure35).

Figure34).

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose
tothelter.

7.Openfuelshut-offvalveatfueltank(

Figure34).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

29

ElectricalSystem
Maintenance

ServicingtheBattery

Alwayskeepthebatterycleanandfullycharged.Use
apapertoweltocleanthebatterycase.Ifthebattery
terminalsarecorroded,cleanthemwithasolutionof
fourpartswaterandonepartbakingsoda.Applyalight
coatingofgreasetothebatteryterminalstoprevent
corrosion.

WARNING

Incorrectbatterycableroutingcoulddamagethe
machineandcablescausingsparks.Sparkscan
causethebatterygassestoexplode,resultingin
personalinjury.

•AlwaysDisconnectthenegative(black)battery
cablebeforedisconnectingthepositive(red)
cable.

•AlwaysReconnectthepositive(red)battery
cablebeforereconnectingthenegative(black)
cable.

Voltage:12V

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassestoshield
youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Lifttheblackrubbercoveronthenegativecable.
Disconnectthenegativebatterycablefromthe
negative(-)batteryterminal(

4.Slidetheredterminalbootoffthepositive(red)
batteryterminal.Thenremovethepositive(red)
batterycable(Figure36).

5.Removethebatteryholddownplate(
removethebattery.

Figure36).

Figure36)and

InstallingtheBattery

1.Placethebatterontothemachine(Figure36).

2.Securethebatterywiththeholddownplate,j-bolts,
andlocknuts.

3.First,installthepositive(red)batterycableto
positive(+)batteryterminalwithanut,washerand

Figure36).Slidetherubbercoveroverthepost.

bolt(

WARNING

Batteryterminalsormetaltoolscouldshortagainst
metalmachinecomponentscausingsparks.Sparks
cancausethebatterygassestoexplode,resulting
inpersonalinjury.

•Whenremovingorinstallingthebattery,donot
allowthebatteryterminalstotouchanymetal
partsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

4.Theninstallthenegativebatterycableandground
wiretothenegative(-)batteryterminalwithanut,
washerandbolt(
overthepost.

30

Figure36).Slidetherubbercover

g012916

7
6

5

4
3
2

1

8
9

10

11

Figure36

1.J-bolt7.Wingnut

2.Positivecable8.Negativecable

3.Washer

4.Nut(5/16inch)

5.Rubbercover(red)

6.Batteryholddown

9.Rubbercover(black)

10.Bolt

11.Battery

Figure37

1.Ventcaps3.Lowerline

2.Upperline

2.Iftheelectrolyteislow,addtherequiredamountof
distilledwater;refertoAddingW atertotheBattery
inElectricalSystemMaintenance(page30).

AddingWatertotheBattery

Thebesttimetoadddistilledwatertothebatteryisjust
beforeyouoperatethemachine.Thisletsthewatermix
thoroughlywiththeelectrolytesolution.

1.Removethebatteryfromthemachine;
refertoRemovingtheBatteryin
ElectricalSystemMaintenance(page30).

Important:Neverllthebatterywithdistilled
waterwhilethebatteryisinstalledinthe
machine.Electrolytecouldbespilledonother
partsandcausecorrosion.

CheckingtheBatteryElectrolyteLevel

2.Cleanthetopofthebatterywithapapertowel.

3.Removetheventcapsfromthebattery(

Figure37).

ServiceInterval:Every25hours

4.Slowlypourdistilledwaterintoeachbatterycell

DANGER

untiltheelectrolytelevelisuptotheUpperline

Figure37)onthebatterycase.

(

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

Important:Donotoverllthebatterybecause
electrolyte(sulfuricacid)cancausesevere

•Donotdrinkelectrolyteandavoidcontactwith

corrosionanddamagetothechassis.

skin,eyesorclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.

5.Waitvetotenminutesafterllingthebatterycells.
Adddistilledwater,ifnecessary,untiltheelectrolyte
levelisuptotheUpperline(

Figure37)onthe

batterycase.

6.Reinstallthebatteryventcaps.

1.Lookatthesideofthebattery.Theelectrolytemust
beuptotheupperline(
electrolytetofallbelowtheLowerline(Figure37).

Figure37).Donotallowthe

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparksand
amesawayfrombattery.

31

Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespeciallyimportant
topreventbatterydamagewhenthetemperatureis
below32°F(0°C).

1.Removethebatteryfromthechassis;referto
RemovingtheBattery.

2.Checktheelectrolytelevel;refertoCheckingthe
ElectrolyteLevel.

3.Makesurethellercapsareinstalledinbattery.
Chargebatteryfor1hourat25to30ampsor6
hoursat4to6amps.

4.Whenthebatteryisfullycharged,unplugthecharger
fromtheelectricaloutlet,thendisconnectthe
chargerleadsfromthebatteryposts(

Figure38).

5.Installthebatteryontothemachineandconnectthe
batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery
disconnected,electricaldamagemayoccur.

Figure38

1.PositiveBatteryPost

2.NegativeBatteryPost

3.Red(+)ChargerLead

4.Black(-)ChargerLead

ServicingtheFuses

Figure39

1.Redwire3.Fuse,25amp,bladetype

2.Fuse,30amp,bladetype4.Violetwire

Theelectricalsystemisprotectedbyfuses.Itrequires
nomaintenance.Ifafuseblows,checkthecomponent
orcircuitforamalfunctionorshort.

1.Removethecoverunderthecontrolpanel.

2.Pulloutonthefusetoremoveorreplaceit
(Figure39).

3.Installthecoverunderthecontrolpanel.

Note:Ensurethecorrectsizefuseisinstallwiththe
correctwirecolorasshowninFigure39.

32

DriveSystem
Maintenance

AdjustingtheTracking

1.Ifthemachinedoesnottrackstraight,adjustment
isrequired.

2.Checkthereartirepressure.RefertoCheckingthe
TirePressure.

3.Loosenthewingnutsontherightcontrolrodand
rotatetheturnbuckleinorouttoensuretheright
sidecontrolleveriscenteredintheneutrallock
position.Securetheturnbuckleinpositionwiththe
wingnuts(

Figure40).

Figure41

ReplacingtheCasterWheel

4.Loosenthewingnutsontheleftcontrolrodand
rotatetheturnbuckleinorouttochangethetracking.
Securetheturnbuckleinpositionwiththewingnuts

Figure40).

(

5.Checkforpropertracking.Adjusttheleftcontrol
rodifachangeisneeded.

Figure40

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand
threaded)

ForkBushings

Thecasterwheelforksaremountedinbushingspressed
intothetopandbottomofthecarrierframemounting
pivottubes.Tocheckthebushings,movethecaster
forksbackandforthandside-to-side.Ifacasterforkis
loose,thebushingsarewornandmustbereplaced.

1.Raisethecuttingunitsothecasterwheelsareoff
theoor,thensupportthefrontofthemowerwith
jackstands.

2.Removethelockingpinandspacer(s)fromthetop
ofthecasterwheelfork(

Figure42).

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Checkthepressureatthevalvestem(Figure41).

Maintaintheairpressureinthereartiresat12-14psi
(83-97kPa).Uneventirepressurecancauseanuneven
cut.

Note:Thefronttiresaresemi-pneumatictiresanddo
notrequireairpressuremaintenance.

Figure42

1.LockingPin

2.Spacers4.Casterwheelfork

3.Pullthecasterwheelforkoutofthemountingtube,
leavingthespacer(s)onthebottomofthefork.

33

3.Carrierframepivottube

Rememberthelocationofthespacersoneachfork
toensurecorrectinstallation,andtomaintainalevel
deck.

4.Insertapinpunchintothemountingtubeand
carefullydriveoutthebushings(

Figure43).Clean

theinsideofthemountingtube.

Figure43

1.MountingTube2.Bushing

5.Greasetheinsideandoutsideofthenewbushings.
Useahammerandatplatetocarefullydrivethe
bushingsintothepivottubes.

6.Inspectthecasterwheelforkforwearandreplace
ifnecessary(

Figure42).

7.Slidethecasterwheelforkthroughthebushingsin
themountingtube.Replacethespacer(s)ontothe
forkandsecurewiththeretainingring(Figure42).

Important:Theinsidediameterofthebushings
maycollapseslightlywheninstalled.Ifthe
casterwheelforkdoesnotslideintothenew
bushings,reambothbushingstoaninside
diameterof1.126inch(29mm).

8.Greasethettingonthecarrierframepivottubes
usingNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

1.Removethelocknutandwheelboltholdingthe
casterwheeltothecasterfork(Figure44).

Figure44

1.Locknut

2.WheelBolt5.RollerBearing

3.Bushing

4.SpannerBushing

2.Removeonebushing,thenpullthespannerbushing
androllerbearingoutofthewheelhub(

Figure44).

3.Removetheotherbushingfromthewheelhub
andcleananygreaseanddirtfromthewheelhub
(Figure44).

4.Inspecttherollerbearing,bushings,spannerbushing
andinsideofthewheelhubforwear.Replaceany
defectiveorwornparts(

Figure44).

5.Toassemble,placeonebushingintothewheelhub.
Greasetherollerbearingandspannerbushingand
slidethemintothewheelhub.Placethesecond
bushingintothewheelhub(Figure44).

6.Installthecasterwheelintothecasterforkand
securewiththewheelboltandlocknut.Tightenthe
locknutuntilthespannerbushingbottomsagainst
theinsideofthecasterforks(

Figure44).

7.Greasethettingonthecasterwheel.

ServicingtheCasterWheel
andBearings

Thecasterwheelsrotateonarollerbearingsupportedby
aspannerbushing.Ifthebearingiskeptwelllubricated,
wearwillbeminimal.Failuretokeepthebearingwell
lubricatedwillcauserapidwear.Awobblycasterwheel
usuallyindicatesawornbearing.

AdjustingtheElectricClutch

ServiceInterval:Every100hours

Theclutchisadjustabletoensureproperengagement
andproperbraking.

1.Inserta0.015–0.021inch(0.381–0.533mm)feeler
gaugethroughoneinspectionslotinthesideofthe

34

assembly.Makesureitisbetweenthearmatureand
therotorfrictionsurfaces.

2.Tightenthelocknutsuntilthereisslightbindingon
thefeelergaugebutitcanbemovedeasilywithinthe
airgap(

3.Repeatthisfortheremainingslots.

4.Checkeachslotagainandmakeslightadjustments
untilthefeelergaugebetweentherotorandarmature
withveryslightcontactbetweenthem.

Figure45).

CoolingSystem
Maintenance

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

Beforeeachuseremoveanybuild-upofgrass,dirt
orotherdebrisfromthecylinderandcylinderhead
coolingns,airintakescreenonywheelend,and
carburetor-governorleversandlinkage.Thiswillhelp
insureadequatecoolingandcorrectenginespeedand
willreducethepossibilityofoverheatingandmechanical
damagetotheengine.

Figure45

1.Adjustingnut3.Feelergauge

2.Slot

35

BrakeMaintenance

ServicingtheBrake

Beforeeachuse,checkbrakesonbothalevelsurface
andslope.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnot
holdsecurely,anadjustmentisrequired.

CheckingtheParkingBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengagethe
PTO.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Applytheparkingbrake.Settingtheparkingbrake
shouldtakeareasonableamountofforce.Ifthe
parkingbrakedoesnotholdsecurely,anadjustment
isrequired.RefertoAdjustingtheParkingBrake.

Note:Whenthebrakeisengaged,thebrakehandle
shouldbeinthe1o’clockposition(

Figure46).

9.Tightenthetopandbottomjamnuts(Figure46).

10.Checkthebrakeoperationagain;refertoChecking
theBrake.

Figure46

1.Parkingbrakelever
(releasedposition)

2.1o’clockposition6.Yoke

3.Haripincotter7.JamNut

4.Lowerbrakelever8.Brakerod

5.Clevispin

AdjustingtheBrakes

Iftheparkingbrakedoesnotholdsecurely,an
adjustmentisrequired.

1.Parkthemachineonalevelsurface,disengagethe
PTO,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Checkthebrakebeforeyouadjustit;referto
CheckingtheBrakes.

4.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakeinOperation(page13).

5.Loosenthetopandbottomjamnuts(

6.Toadjustthebrake,removethehairpincotterand
clevispinfromthelowerbrakelever(

7.Rotatethebrakerodintheyokes.T otightenthe
brake,lengthentherodbetweentheyokes.To
loosenthebrake,shortentherodbetweentheyokes
(Figure46).

Figure46).

Figure46).

Note:Thebrakerodshouldbethreadedintoboth
yokesthesamedistance.

8.Securetheyoketolowerbrakeleverwiththehairpin
cotterandclevispin(Figure46).

36

BeltMaintenance

ReplacingtheMowerBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracks
aresignsofaworndeckbelt.Replacethedeckbeltif
anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchandremovethecarrierframecover.

4.Unlatchandremovethebeltcovers.

5.RemovethePTOdrivebelt.RefertoReplacingthe
PTODriveBelt.

6.Disconnecttheidlerarmspringtorelievetensionon
theidlerarmandidlerpulley,thenremovetheworn
mowerbelt(

Figure47orFigure48).

7.Installthenewmowerbeltaroundthetwooutside
spindlepulleys,theidlerpulley,andinthelower
grooveofthedoublespindlepulley(

Figure47or

Figure48).

8.Connecttheidlerarmspring(Figure47orFigure48).

9.InstallthePTOdrivebelt.RefertoReplacingthe
PTODriveBelt.

10.Adjustthebeltguidean1/8inch(3mm)fromthe

Figure47orFigure48).

belt(

11.Installthebeltcoversontothecuttingunitand
securethelatches.

Figure47

40inch,48inch,and52inchMowerDeckshown

1.Outsidepulley

2.PTODriveBelt

3.Idlerarmspring

4.Mowerdeckbelt

5.Beltguide

6.Centerspindlepulley

12.Installthecarrierframecoverontothecuttingunit
andsecurethelatches.

Figure48

36inchMowerDeckshown

1.Mowerdeckbelt4.Idlerarmspring

2.PTODriveBelt

3.Drivebeltpulley

5.Drivebeltpulley

ReplacingthePTODriveBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracks

37

aresignsofaworndrivebelt.Replacethedrivebeltif
anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchandremovethecarrierframecover.

4.Unlatchandremovethebeltcovers.

5.Removetheheatshieldfromtheenginedeckand
carrierframe.

6.Rollthebeltoffofthecenterpulleyonthemower

Figure49).RefertoFigure50torollthebelt

deck(
offleftpulleyfora36inchmowerdeck.Usecaution
whenremovingthebeltastensionwillincrease
becauseofthespringloadedidlerpulley .

7.Removethebeltfromtheenginepulleyandthe
springloadedidlerpulley(

Figure49).Referto
Figure50toremovethebeltfromthe36inchmower
deckpulleys.

Figure49

40inch,48inch,and52inchMowerDeckshown

1.PTOdrivebeltguide4.PTOengagementpulley

2.PTOdriveBelt5.PTOdrivebeltidlerpulley

3.Idlerspring

6.Centerspindlepulley

8.Installthenewbeltontotheenginepulleyandspring
loadedidlerpulley(

Figure49).

9.Rollthebeltontothecenterpulleyonthemower
deck(Figure49).Usecautionwheninstallthebelt
astensionwillincreasebecauseofthespringloaded
idlerpulley.RefertoFigure50torollthenewbelt
ontotheleftpulleyfora36inchmowerdeck.

10.Installtheheatshieldtotheenginedeckandcarrier
frame.

11.Adjustthebeltguidean1/8inch(3mm)fromthe
beltfor40,48and52inchmowerdecks(

Figure49).

12.Installthebeltcoversontothecuttingunitand
securethelatches.

13.Installthecarrierframecoverontothecarrierframe
andsecurethelatches.

1.Mowerdeckbelt

2.PTODriveBelt

3.Idlerarmandspring

Figure50

36inchMowerDeckshown

4.Clutchpulley

5.Idlerpulley

AdjustingthePTODriveBelt
IdlerSpringAnchor

ThepositionofthePTOidlercanbeadjustedto
increaseordecreasebelttension.

38

UseFigure51fortheidlerpositionoptions.

Figure51

1.PTOdrivebeltidlerpulley4.Mosttensionforwornbelts

2.PTOdriveBelt5.Mediumtensionfornormal

3.Idlerspring

beltconditions

6.Leasttensionfornewbelts

Figure52

1.Hydraulicpumps

2.Idlerpulley6.Pivotbolt

3.Clutchretainer

4.Tensionspring8.Pumpdrivebelt

5.Clutchwireconnector

7.Drivepulley

7.Unhooktheidlerspringfromtheframe(Figure52).

ReplacingthePumpDriveBelt

ServiceInterval:Every50hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.RemovePTOdrivebelt.RefertoReplacingthe
PTODriveBeltinthe

4.Raisethemachineandsupportitwithjackstands.

5.Disconnecttheclutchwireconnectorfromthewire
harness.

6.Disconnecttheclutchretainerfromtheenginedeck

Figure52).

(

BeltMaintenance(page37).

8.Installthenewbeltaroundclutchandthetwodrive
pulleys.

9.Installtheidlerspringbetweenidlerarmandframe
bracket(

Figure52).

10.Installtheclutchretainertotheenginedeck
(Figure52).

11.Connecttheclutchwireconnectortothewire
harness.

12.InstallthePTOdrivebelt.

39

ControlsSystem
Maintenance

AdjustingtheMotionControl
HandlePositions

AdjustingtheRightSideMotionControl
Lever

Ifthemotioncontrolleversdonotalignhorizontally,
adjusttherightsidemotioncontrollever.

Note:Adjustthehorizontalalignmentbeforethefront
tobackalignment.

1.DisengagethePTO,movetherightsidemotion
controllevertotheneutralpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Pushtherightmotioncontrolleverdownoutof
lockedneutralposition(

Figure53).

4.Checkifitalignshorizontallywiththeleftmotion
controllever(

1.Leftmotioncontrollever3.Checkthehorizontal

2.Rightmotioncontrollever
inneutrallockedposition

Figure53).

Figure53

alignmenthere

4.Rightmotioncontrollever

Figure54

1.Cam

2.Nutandbolt

3.Wingnut

4.Turnbuckle

5.Switchscrews

9.Afterthecamisadjusted,theleverswitchneedsto
bechecked.

10.Checkthegapbetweenthecontrolleverandswitch
asshownin

Figure55.Thegapneedstobean1/8

inch(3mm).

11.Ifneeded,loosenthescrewsholdingtheswitchand
adjusttheswitch.

12.Tightenthescrewsandinstallthecoverunderthe
controlpanel.

5.Toadjusttherightmotioncontrolleverhorizontally,
thecamneedstobeadjusted.

6.Removethecoverunderthecontrolpanel.

7.Loosenthenutandboltholdingthecam(

Figure54).

8.Adjustthecamuntilitalignswiththeleftmotion
controlleverandtightenthenutandboltforthe
cam.

40

1.Rightsidemotioncontrol
leverpivotshownunder
controls

2.Rightsidemotioncontrol
lever

Figure55

3.1/8inch(3mm)gap

4.Switch

neededbetweenswitch
andcontrollever

Figure56

1.Leftmotioncontrollever

2.Rightmotioncontrollever4.Alignthecontrollevers

3.Neutrallockedposition

fronttobackhere

AdjustingtheNeutralPostionforthe
MotionControlLevers

Important:Ensurethetrackingofthemoweris

correctafteradjustingthemotioncontrollevers.
Afteradjustingthetracking,themotioncontrol
leversmaynotaligntheexactlyfronttoback

Figure56).

(

Ifthemotioncontrolleversdonotalignfronttoback,
ortherightsidecontrolleverdoesnotmoveeasilyinto
theneutrallockposition,adjustmentisrequired.Adjust
eachleverandcontrolrodseparately.

Note:Adjustthehorizontalalignmentbeforethefront
tobackalignment.

1.Afterthehorizontalalignmentisnished,checkthe
fronttobackalignment(

Figure56).

2.Loosenthewingnutsontherightcontrolrodand
rotatetheturnbuckleinorouttoensuretheright
sidecontrolleveriscenteredintheneutrallock
position.Securetheturnbuckleinpositionwiththe
wingnuts(Figure57).

3.Loosenthewingnutsontheleftcontrolrodand
rotatetheturnbuckleinorouttochangethetracking.
Securetheturnbuckleinpositionwiththewingnuts

Figure57).

(

Figure57

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand

4.Checkforpropertracking.Adjusttheleftcontrol
rodifachangeisneeded.RefertoAdjustingthe
TrackingintheOperationSection.

41

threaded)

HydraulicSystem
Maintenance

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

ServicingtheHydraulic
System

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every25hours

Note:Therearetwowaysofcheckingthehydraulicoil.
Oneiswhentheoiliswarmandoneiswhentheoilis
cold.Thebafeinsidethetankhastwolevelsdepending
iftheoiliswarmorcold.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoff
theengine.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulic

Figure58).

tank(

•Ifhydraulicuidisinjectedintotheskin
itmustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistypeof
injury.Gangrenemayresultifthisisnot
done.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesureallhydraulicuidhosesand
linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretohydraulicsystem.

ReplacingtheHydraulicFilterand
HydraulicOil

Figure58

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

5.Removecapfromllerneck.Lookinsidetocheck
theuidlevelinthereservoir.(Figure58).

6.Adduidtothereservoiruntilitreachesthecold
levelofthebafe.

7.Runthemachineatlowidlefor15minutestoallow
anyairtopurgeoutofthesystemandwarmuid.
RefertoStartingandStoppingtheEngine.

8.Rechecktheuidlevelwhiletheuidiswarm.If
required,adduidtothereservoiruntilitreaches
thehotlevelofthebafe.

Note:Theuidlevelshouldbetothetopofthehot
levelofthebafe,whentheuidiswarm(

9.Installcaponllerneck.

Figure58).

ServiceInterval:Aftertherst8hours

Every250hours—Changethe
hydrauliclterandhydraulicoilwhen
usingMobil

Every500hours—Changethe
hydrauliclterandhydraulicoil
whenusingToro
hydraulicoil.

®

1oil.

®

HYPR-OIL

WARNING

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbeforeperforming
anymaintenancetothehydraulicsystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

Important:Donotsubstituteautomotiveoil
lterorseverehydraulicsystemdamagemay
result.

3.Locatethelterunderthefueltankandplacedrain
panunderlter(Figure59).

™

500

42

checkforleaks.Ifoneorbothwheelswillnotdrive,
refertoBleedingHydraulicSystem.

11.Rechecklevelandadduid,ifrequired.Donot

overll.

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe
necessarytobleedthesystemifuidischangedorafter
workisperformedonthesystem.

1.DisengagethePTOandsettheparkingbrake.

Figure59

4.Removetheoldlter,allowtheoiltodrainandwipe
thelteradaptergasketsurfaceclean(Figure60).

5.Applyathincoathydraulicuidtotherubbergasket
onthereplacementlter.

6.Installreplacementhydrauliclterontothelter
adapter.Donottighten.

7.Fillthehydraulictankwithhydraulicuiduntilthe
uidoverowsthelterandthenturntheoillter
clockwiseuntiltherubbergasketcontactsthelter
adapter,thentightenthelteranadditional1/2turn

Figure60).

(

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsofftheground.

4.Starttheengineandmovethethrottlecontroltoidle
position.

Ifthedrivewheeldoesnotrotate,itispossibleto
assistthepurgingofthesystembycarefullyrotating
thetireintheforwarddirection.

5.Checkthehydraulicuidlevelasitdropsadduid
asrequiredtomaintaintheproperlevel.

6.Repeatthisprocedurefortheoppositewheel.

7.Thoroughlycleantheareaaroundeachofthecharge
pumphousings.

CheckingtheHydraulicLines

ServiceInterval:Every100hours

Checkhydrauliclinesandhosesforleaks,loosettings,
kinkedlines,loosemountingsupports,wear,weather
andchemicaldeterioration.Makenecessaryrepairs
beforeoperating.

Figure60

1.Hydrauliclter

2.Gasket

3.Adapter

8.Cleanupanyspilleduid.

9.Checktheuidinthereservoir,adduidtothetank
untilitreachesthecoldbafeofthetank.

Important:Useoilspecied.Otheruids
couldcausesystemdamage.

10.Startengineandletrunforabouttwominutesto
purgeairfromthesystem.Stoptheengineand

Note:Keepareasaroundhydraulicsystemcleanfrom
grassanddebrisbuildup.

43

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit
mustbesurgicallyremovedwithinafewhours
byadoctorfamiliarwiththistypeofinjury.
Gangrenemayresultifthisisnotdone.

•Keepbodyandhandsawayfrompinholeleaks
ornozzlesthatejecthighpressurehydraulic
uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.

•Makesureallhydraulicuidhosesandlinesare
ingoodconditionandallhydraulicconnections
andttingsaretightbeforeapplyingpressureto
hydraulicsystem.

MowerDeck
Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keeptheblades
sharp.Forconvenientsharpeningandreplacement,you
maywanttokeepextrabladesonhand.

WARNING

Awornordamagedbladecanbreak,andapiece
ofthebladecouldbethrownintotheoperator’s
orbystander’sarea,resultinginseriouspersonal
injuryordeath.

•Inspectthebladesperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagetheblades
andsettheparkingbrake.Turntheignitionkeytooff.
Removethekeyanddisconnectthesparkplugwires
fromthesparkplugs.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure61).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades.

44

Figure62

40inch,48inch,and52inchMowerDeckshown

Figure61

1.CuttingEdge3.Wear/slotformingin
curvedarea

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea
(Figure61).Ifyounoticeanycracks,wear,ora
slotforminginthisarea(item3inFigure61),
immediatelyinstallanewblade.

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Rotatethebladesuntiltheendsfaceforwardand
backward.Measurefromalevelsurfacetothe
cuttingedge,positionA,oftheblades(Figure62
).Notethisdimension.For36inchmowerdecks
useFigure63.

1.Measureherefromblade
tohardsurface

36inchMowerDeckshown

2.PositionA

Figure63

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep3above.
Thedifferencebetweenthedimensionsobtainedin
steps3and4mustnotexceed1/8inch(3mm).If
thisdimensionexceeds1/8inch(3mm),theblade
isbentandmustbereplaced;refertoRemovingthe
BladesandInstallingtheBlades.

45

WARNING

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedbladewith
anewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe
bladeisoutofbalanceorisbent.T oensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineT ororeplacementblades.
Replacementbladesmadebyothermanufacturersmay
resultinnon-conformancewithsafetystandards.

1.Holdthebladeendusingaragorthickly-padded
glove.

2.For40and48inchmowerdecks,removetheblade
bolt,curvedwasher,andbladefromthespindle

Figure64).

shaft(

Figure65

36inchand52inchMowerDecks

1.SailAreaofBlade4.Curvedwasher

2.Blade5.BladeBolt

3.Bladestiffener

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends
oftheblade(Figure66).Maintaintheoriginalangle.
Thebladeretainsitsbalanceifthesameamountof
materialisremovedfrombothcuttingedges.

Figure66

1.Sharpenatoriginalangle

Figure64

40inchand48inchMowerDecks

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

3.For36and52inchmowerdecks,removetheblade
bolt,curvedwasher,bladestiffener,andbladefrom
thespindleshaft(Figure65).

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure67).Ifthebladestaysina
horizontalposition,thebladeisbalancedandcanbe
used.Ifthebladeisnotbalanced,lesomemetaloff
theendofthesailareaonly(Figure64).Repeatthis
procedureuntilthebladeisbalanced.

46

Figure67

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure64).

Important:Thesailpartoftheblademustbe
pointingupward,towardtheinsideofthemower
toensurepropercutting(Figure64).

2.For40inchand48inchmowerdecks,installthe
blade,curvedwasher,andbladebolt(Figure64).

3.For36inchand52inchmowerdecks,installthe
blade,stiffener,curvedwasher,andbladebolt

Figure65).

(

4.Torquethebladeboltto85-110ft-lb(115-140N-m).

FrameSetUp

CheckingtheCarrierFrameandEngine
DeckAlignment

Note:MisalignmentcancauseexcesswearonthePTO

drivebelt.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Placealongstraightedgeontopoftheenginedeck
asshowninFigure68.

4.Atthecarrierframecrosschannel,measurethe
heightatlocationA(Figure68).Thismeasurement
mustbe1-5/16inch(33mm),plusorminusa1/4
inch(6mm).

5.IftheheightatlocationAisnotcorrect,adjustment
isneeded.

6.Loosenthecarrierframemountingboltsonboth
sidesofthemachine(Figure68).

CorrectingtheMowerQuality
ofCut

Ifonedeckbladecutslowerthantheother,correctas
follows.

Note:Tireairpressureiscriticalintheseprocedures.
Makesurealltireshavecorrectpressure.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.Disconnectthesparkplugwire(s)from
thesparkplug(s).

3.Adjustthetirepressureinthe
reartirestospecications;referto
DriveSystemMaintenance(page33).

4.Checkthatthebladesandspindleshaftsarenot
bent.RefertoCheckingforBentBlades.

5.Settheheight-of-cuttothe4inch(101.6mm)
position.RefertoAdjustingtheHeight-Of-Cutin
Operation(page13).

7.Alignthecarrierframeandenginedecktomatch
1-5/16inch(33mm),plusorminusa1/4inch(6
mm)atlocationA(Figure68).

8.Tightenthecarrierframemountingboltsonboth
sidesofthemachine.

6.PerformthestepsinthefollowingsectionsFrame
SetUp,CheckingFront-to-RearPitch,andChecking
Side-to-SideLeveling.

Figure68

1.CarrierFrame4.LocationA,1-5/16inch

2.Topofenginedeck5.Straightedge

3.Carrierframemounting
bolts

47

(33mm)±1/4inch(6mm)

6.Carrierframecross
channel

CheckingtheEngineDeckHeight

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Adjustthetirepressureinthe
reartirestospecications;referto
DriveSystemMaintenance(page33).

4.MeasureenginedeckheightatlocationA(Figure69).

5.MeasureenginedeckheightatlocationB(Figure69).

6.IftheheightatlocationAandBarenotthesame,
changetirepressureslightlytomakethemthesame.

Figure69

1.Backviewofmachine

2.Topofenginedeck4.Sameheightatlocations

3.Tires

AandB

CheckingtheCarrierFrame
Front-to-RearPitch

Thecarrierframemusthaveapitchbetween1/8inch
(3mm)to3/8inch(9mm)overthelengthof24inches
(61cm)onthecarrierframe(Figure70).

1.Measureout24inches(61cm)onthecarrierframe
(Figure70).

Figure70

1.CarrierFrame

2.1/8inch-3/8inch(3-10
mm)pitchover24inch(61
cm)length

3.24inches(61cm)6.Casterspacers

4.HeightatlocationsAand

B

5.CasterWheel

2.MeasurecarrierframeheightatlocationA
Figure70).

(

3.MeasurecarrierframeheightatlocationB

(Figure70).

4.TheheightatlocationAmustbean1/8-3/8inch(3

mm-10mm)lowerthanlocationB(Figure70).

5.Ifthecarrierframeisnotcorrect,movecaster

spacerstomakeitan1/8-3/8inch(3-10mm)pitch
(Figure70).Movespacersfromtoporbottomto
makethecorrectpitch.

6.Thetirepressuremayalsobeadjustedslightlyto

makean1/8-3/8inch(3-10mm)pitch.

CheckingtheCarrierFrame
Side-to-SideHeight

Thecarrierframeneedstobeparallelside-to-sidefrom
theground.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating
position.

3.Adjustthetirepressureinthe

reartirestospecications;referto
DriveSystemMaintenance(page33).

4.MeasurecarrierframeheightatlocationA

(

Figure71).

5.MeasurecarrierframeheightatlocationB

(Figure71).

6.Ifthecarrierframeheightisnotthesamemove

spacersfromtoporbottomofcasterwheel,to
makeitlevel.Thetirepressuremayalsobeadjusted
slightlytomakeitlevel.

48

Figure71

1.CasterWheel4.Sameheightatlocations
AandB

2.CarrierFrame5.Casterspacers

3.Frontheight-of-cutpins

Figure73

36inchMowerDeckshown

ChangingtheMowerDeck

Front-to-RearPitch
CheckingtheMowerDeck
Front-to-RearPitch

1.Adjustthetirepressureinthe

reartirestospecications;referto
DriveSystemMaintenance(page33).

2.Positiononebladefront-to-rear.MeasureatAand

Blocationsfromalevelsurfacetothecuttingedge
ofthebladetips(Figure72orFigure73).For36
inchmowerdecksuseFigure73.

3.Themowerbladeshouldbea1/4inch(6mm)lower

infrontatAthanintherearatB.Rotatebladesand
repeatforotherblades.Ifitisnotcorrect,proceed
toChangingtheDeckFront-to-RearPitch.

Changingthefront-to-rearpitchisdonebyadjustingthe

frontheight-of-cutposts.

1.Tochangethefront-to-rearpitch,thefront
height-of-cutpostscanbeadjusted(Figure74).

Figure74

1.CasterWheel

2.CarrierFrame

3.Frontheight-of-cutpins

4.Jamnut

5.Balljoint

Figure72

40inch,48inch,and52inchMowerDeckshown

1.MeasurebladeatpointsA
andB

2.Measurefromalevel

2.Toraisethefrontofthedeck,loosenjamnutand
rotatethefrontpinclockwise(Figure74).

3.Tolowerthefrontofthedeck,loosenjamnutand
rotatethefrontpincounterclockwise(Figure74).

4.Positionthebladesfront-to-rear.MeasureatCand
Dlocations(

Figure72)fromalevelsurfacetothe

cuttingedgeoftheblades.

surface

5.Checktheside-to-sidelevelingofthecuttingunit.

6.Tightenthejamnuts(Figure74).

49

CheckingtheMowerDeck
Side-to-SideHeight

1.Adjustthereartirepressuretospecications;refer
toDriveSystemMaintenance(page33).

2.Positionthebladesside-to-side.MeasureatCand
Dlocationsfromalevelsurfacetothecuttingedge
ofbladetips(Figure75).For36inchmowerdecks
useFigure76.

2.Adjustthecasterspacer.

3.Recheckthefront-to-rearpitchandsidetoside
levelingofthecuttingunit.

MatchingHeightofCut

1.Checkthereartirepressure.

2.Settheheight-of-cuttothe4inch(101.6mm)
positionfollowingtheheight-of-cutdecal.

3.Withthemachineonlevelsurface,positiononeblade
front-to-rear.MeasureatAandfromlevelsurfaceto
thecuttingedgeofthebladetips(Figure77).For36
inchmowerdecksuseFigure78.

Figure75

40inch,48inch,and52inchMowerDeckshown

1.Measurefromalevel
surface

36inchMowerDeckshown

2.MeasurebladeatpointsC
andD

Figure76

3.ThedifferencebetweenmeasurementsCandD
shouldbenomorethan1/4inch(6mm).

Figure77

40inch,48inch,and52inchMowerDeckshown

1.Measurefromalevel
surface

2.MeasurebladeatpointA

ChangingtheMowerDeck
Side-to-SideHeight

Changingtheside-to-sideheightisdonebyadjustingthe
reartirepressureandcasterspacers.

1.Changethereartirepressure.Dothistothe
correspondingsidethatneedsadjustment.

Figure78

36inchMowerDeckshown

4.Themeasurementshouldbe4inch(101.6mm).

5.Ifitdoesnotmeasurecorrectly:

A.Adjustthereartirepressure.

50

B.Adjustthecasterforkspacers.

C.Adjustthefrontmowerdecksupportpins.

6.Checkthecarrierframefront-to-rearpitch.

ReplacingtheGrassDeector

WARNING

Anuncovereddischargeopeningcouldallowthe
lawnmowertothrowobjectsintheoperator’sor
bystander’sdirectionandresultinseriousinjury.
Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstalla
coverplate,amulchplate,grassdeectororbagger.

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure79).
Removedamagedorworngrassdeector.

Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefullopen
positionandensurethatitrotatesintothefull
downposition.

Figure79

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place
behinddeckedgebefore
installingbolt

2.Placespacerandspringontograssdeector.Place
theLendofspringbehinddeckedge.

Note:MakesuretheLendofspringisinstalled
behinddeckedgebeforeinstallingtheboltasshown
inFigure79.

3.Installboltandnut.PlacetheJhookendofspring
aroundgrassdeector(Figure79).

51

Cleaning

Storage

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Raisethefrontofthemachineandusejackstandsto
supportthemower.

WasteDisposal

Engineoil,batteries,hydraulicoil,andenginecoolant
arepollutantstotheenvironment.Disposeofthese
accordingtoyourstateandlocalregulations.

CleaningandStorage

1.Disengagethepowertakeoff(PTO),settheparking
brake,andturntheignitionkeytooff.Removethe
key.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engine.Cleandirtandchafffromtheoutsideofthe
engine’scylinderheadnsandblowerhousing.

Important:Youcanwashthemachinewith
milddetergentandwater.Donotpressurewash
themachine.Avoidexcessiveuseofwater,
especiallynearthedrivesystemandengine.
Pressurewashingcanforcedirtandwaterinto
criticalparts,suchasspindlebearingsand
electricalswitches.

3.Checkthebrake;refertoServicingtheBrakein
BrakeMaintenance(page36).

4.Servicetheaircleaner;refertoServicingtheAir
Cleanerin

5.Greasethemachine;refertoGreasingand
LubricationinLubrication(page24).

EngineMaintenance(page25).

6.Changetheengineoil;refertoServicingtheEngine

EngineMaintenance(page25).

in

7.Checkthetirepressure;refertoCheckingtheTire
Pressurein

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefuel

tank;refertoServicingtheFuelTankin
FuelSystemMaintenance(page28),oroperate
engineuntilitstops.

D.Restartengineandrununtilitstops.Repeat,on

Chokeuntilenginewillnotrestart.

E.Disposeoffuelproperly .Recycleasperlocal

codes.

Note:Donotstorestabilizer/conditioned
gasolineover90days.

9.Removethesparkplug(s)andcheckits
condition;refertoServicingtheSparkPlugin
EngineMaintenance(page25).Withthespark
plug(s)removedfromtheengine,pourtwo
tablespoonsofengineoilintothesparkplug
hole.Nowusethestartertocranktheengineand

DriveSystemMaintenance(page33).

52

distributetheoilinsidethecylinder.Installthespark
plug(s).Donotinstallthewireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repair
orreplaceanypartthatisdamagedordefective.

11.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

12.Storethemachineinaclean,drygarageorstorage
area.Removethekeyfromtheignitionswitchand
keepitinamemorableplace.Coverthemachineto
protectitandkeepitclean.

53

Troubleshooting

Problem

Enginewillnotstart,startshard,orfails
tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Fueltankisempty.

2.Chokeisnoton.

3.Aircleanerisdirty.

4.Sparkplugwireislooseor
disconnected.

5.Sparkplugispitted,fouled,orthegap
isincorrect.

6.Dirtinthefuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel
system.

8.Thegapbetweentheneutralswitch
boltandtheswitchisnotcorrect.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesunder
theengineblowerhousingareplugged.

5.Sparkplugispitted,fouled,orthegap
isincorrect.

6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

7.Dirtinthefuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel
system.

1.Fillfueltankwithgasoline.

2.Movethechokelevertochokeposition.

3.Servicetheaircleanerelement.

4.Installwireonsparkplug.

5.Installanew,correctlygappedspark
plug.

7.ContactanAuthorizedServiceDealer.

8.ContactanAuthorizedServiceDealer.

2.Servicetheaircleaner.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe
coolingnsandairpassages.

5.Installanew,correctlygappedspark
plug.

8.ContactanAuthorizedServiceDealer.

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesunder
theengineblowerhousingareplugged.

1.Hydraulicoilreservoirlow.1.Addhydraulicoiltothereservoir.

2.Airinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.

3.Pumpdrivebeltslipping.3.Replacethepumpdrivebelt.

4.Pumpdrivebeltidlerspringmissing.4.Replacethepumpdrivebeltidler

1.Cuttingblade(s)is/arebentor
unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or
bladepulley .

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Mowerisnotlevel.3.Levelthemowerside-to-sideposition.

4.Mowerpitchiswrong.

5.Undersideofmowerisdirty.5.Cleantheundersideofthemower.

6.Tirepressureisnotcorrect.6.Adjustthetirepressure.

7.Bladespindlebent.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe
coolingnsandairpassages.

spring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

4.Adjustthefront-to-rearpitch.

7.ContactanAuthorizedServiceDealer.

54

Problem

PossibleCauseCorrectiveAction

Bladesdonotrotate.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.

5.Brokenormissingidlerspring.5.Replacethespring.

6.Electricclutchoutofadjustment.

7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer.

8.Damagedelectricclutch.

9.Safetyinterlocksystempreventsblade
rotation.

10.PTOswitchisfaulty .10.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installdrivebeltandcheckadjusting
shaftsandbeltguidesforcorrect
position.

4.Installdeckpulleyandchecktheidler
pulley,idlerarmandspringforcorrect
positionandfunction.

6.Adjusttheclutchairgap.

8.ContactanAuthorizedServiceDealer.

9.ContactanAuthorizedServiceDealer.

55

Schematics

HydraulicSchematic(Rev.A)

56

ElectricalSchematic(Rev.A)

57

Notes:

58

Notes:

59

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)

Landscape
Contractor
Equipment(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto
anagreementbetweenthem,jointlypromisetotheoriginalpurchaser
torepairtheToroProductslistedbelowifdefectiveinmaterialsor
workmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal
owner:

ProductsWarrantyPeriod

AllMowers

•Engine**

•Battery1year

•Attachments1year

Mid-SizeWalk-BehindMowers
GrandStand

•Frame
ZMaster

•Engine

•Frame

ZMaster

•Frame

*Whicheveroccursrst.

**SomeenginesusedonToroLCEProductsarewarrantedbytheenginemanufacturer.Kawasaki

FXengineshavea3yearwarrantytermforresidentialuse.Residentialusemeansuseofthe

productonthesamelotasyourhome.

***LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe

tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin

normaluse,itwillberepairedorreplaced,atToro’ soption,underwarrantyatnocostforparts

andlabor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor

corrosionarenotcovered.

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay
transportationcosts.

TM

Mowers5yearsor1,200hours*

®

Z400,Z500Mowers

®

G3Mowers5yearsor1,200hours*

2years

2years

Lifetime(originalowneronly)***
4yearsor1,200hours*
2years**
Lifetime(originalowneronly)***

Lifetime(originalowneronly)***

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor
workmanship,followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir
dealership.Tolocateadealerconvenienttoyou,refertotheY ellow
Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or
accessourwebsiteatwww.T oro.com.Youmayalsocallthenumbers
listedinitem#3tousethe24-hourToroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe
ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine
ifitiscoveredunderwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s
analysisorwiththeassistanceprovided,contactusat:

RLCCustomerCareDepartment
ToroWarrantyCompany
811 1LyndaleAvenueSouth
Bloomington,MN55420-1196
888-865-5676(U.S.Customers)
888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenance
proceduresdescribedintheOperator’sManual.Suchroutine
maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemission
systemandenginewarrantycoverageonsomeproducts.
Thisexpresswarrantydoesnotcoverthefollowing:

•Costofregularmaintenanceserviceorwearparts,suchaslters,

fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch
adjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear,accidents,orlackof
propermaintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel

system,orfailuretoproperlypreparethefuelsystempriortoany
periodofnon-useoverthreemonths.

•Pickupanddeliverycharges.

GeneralConditions

Allrepairscoveredbythesewarrantiesmustbeperformedbyan
AuthorizedToroServiceDealerusingToroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor
indirect,incidentalorconsequentialdamagesinconnectionwiththe
useoftheT oroProductscoveredbythiswarranty,includingany
costorexpenseofprovidingsubstituteequipmentorserviceduring
reasonableperiodsofmalfunctionornon-usependingcompletion
ofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistfor
ordinaryuse)andtnessforuse(thattheproductistforaparticular
purpose)arelimitedtothedurationoftheexpresswarranty

Somestatesdonotallowexclusionsofincidentalorconsequential
damages,orlimitationsonhowlonganimpliedwarrantylasts,so
theaboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother
rightswhichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee
policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee
information,contacttheT oroimporter.Ifallotherremediesfail,youmaycontactusatToroWarrantyCompany.

374-0252RevA