Toro 30488, 30489 Operator's Manual

FormNo.3392-453RevA

CommercialWalk-BehindMower

FloatingDeck,SplitLever,HydroDrivewith
48inand52inTURBOFORCE

ModelNo.30488—SerialNo.315000001andUp
ModelNo.30489—SerialNo.315000001andUp

®

CuttingUnit

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3392-453*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orotherreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002.

Important:Thisengineisnotequippedwithaspark
arrestermufer.ItisaviolationofCaliforniaPublic
ResourceCodeSection4442touseoroperatetheengine
onanyforest-covered,brush-covered,orgrass-covered
land.Otherstatesorfederalareasmayhavesimilarlaws.

Figure1

1.Modelandserialnumberlocation

Theenclosed

Engine Owner's Man ual

issuppliedfor
informationregardingtheUSEnvironmentalProtection
Agency(EPA)andtheCaliforniaEmissionControl
Regulationofemissionsystems,maintenance,and
warranty.Replacementsmaybeorderedthroughthe
enginemanufacturer.

Introduction

Thisrotary-blade,lawnmowerisintendedtobe
usedbyprofessional,hiredoperatorsorresidential
homeowners.Itisdesignedprimarilyforcuttinggrass
onwell-maintainedlawnsonresidentialorcommercial
properties.Itisnotdesignedforcuttingbrushorfor
agriculturaluses.

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .T oro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Contents

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

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

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

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

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

ProductOverview.........................................................13

Controls...............................................................13

Specications........................................................14

Operation....................................................................15

AddingFuel...........................................................15

CheckingtheEngine-OilLevel.................................16

PuttingSafetyFirst.................................................16

OperatingtheParkingBrake....................................16

StartingandStoppingtheEngine..............................16

OperatingtheMower-BladeControl(PTO)...............17

UsingtheSafety-InterlockSystem.............................18

DrivingForwardorBackward..................................18

StoppingtheMachine.............................................19

PushingtheMachinebyHand..................................19

TransportingtheMachine........................................20

SideDischargingorMulchingtheGrass.....................20

AdjustingtheHeight-of-Cut....................................20

AdjustingtheAnti-ScalpRollers...............................21

AdjustingtheFlowBafe........................................22

PositioningtheFlowBafe......................................22

UsingtheMid-SizeWeight.......................................23

Maintenance.................................................................24

RecommendedMaintenanceSchedule(s)......................24

Lubrication...............................................................25

LubricatingtheBearings..........................................25

GreasingthePTODrive-BeltIdlerandthe

Mower-Deck-BeltIdler........................................25

EngineMaintenance..................................................26

ServicingtheAirCleaner.........................................26

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

ServicingtheSparkPlugs.........................................28

FuelSystemMaintenance...........................................29

DrainingtheFuelTank...........................................29

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

ServicingtheFuel-VentSystem................................30

ElectricalSystemMaintenance....................................31

ServicingtheBattery...............................................31

ServicingtheFuses.................................................33

DriveSystemMaintenance.........................................34

AdjustingtheTracking...........................................34

CheckingtheTirePressure......................................34

ReplacingtheCaster-Wheel-ForkBushings................34

ServicingtheCasterWheelandBearings....................35

AdjustingtheElectricClutch....................................36

CoolingSystemMaintenance......................................36

CleaningtheAir-IntakeScreen.................................36

BrakeMaintenance....................................................37

ServicingtheBrake.................................................37

BeltMaintenance......................................................38

ReplacingtheMowerBelt........................................38

ReplacingthePTO-DriveBelt..................................39

AdjustingthePTO-driveBeltIdler-Spring

Anchor..............................................................40

ReplacingthePump-DriveBelt................................40

ControlsSystemMaintenance.....................................41

AdjustingtheMotion-ControlHandle.......................41

HydraulicSystemMaintenance....................................43

ServicingtheHydraulicSystem.................................43

MowerDeckMaintenance...........................................45

ServicingtheCuttingBlades.....................................45

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

SettinguptheFrame...............................................48

CheckingtheMowerDeckFront-to-Rear

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

ChangingtheMowerDeckFront-to-Rear

Pitch.................................................................50

CheckingtheMowerDeckSide-to-Side

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

ChangingtheMowerDeckSide-to-Side

Height...............................................................51

MatchingtheHeightofCut......................................51

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

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

CleaningundertheMower.......................................52

DisposingofWaste.................................................52

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

CleaningandStoringtheMachine.............................52

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

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

3

Safety

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,

complywiththesesafetyinstructions,andpayattentionto
thesafetyalertsymbol,whichmeansCaution,Warning,or

Danger—“personalsafetyinstruction.”Failuretocomply
withtheinstructionsmayresultinpersonalinjuryor
death.

Important:Thismachinewasmanufacturedaccording
totheappropriateregulatorystandardsineffectatthe
timeofmanufacture.Modifyingthismachineinany
waymaycauseittobeoutofcompliancewiththose
standardsandwiththeinstructionsinthisOperator’s
Manual.Modicationstothismachineshouldonlybe
madebyeitherthemanufactureroranAuthorizedT oro
Dealer.

Thisproductiscapableofamputatinghandsandfeet.Follow
allsafetyinstructionstoavoidseriousinjuryordeath.

Theowner/usercanpreventandisresponsibleforaccidents
orinjuriesoccurringtopeople,ordamagetoproperty.

Important:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSIstandard
B71.4-2012.

Training

•ReadtheOperator'sManualandothertrainingmaterial.

Note:Iftheoperator(s)ormechanic(s)cannotreadthe
manuallanguage,itistheowner'sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof
theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtopeople,ordamageto
property.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform
thejob.

Note:Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.

•Wearappropriateclothingincluding:ahardhat,safety

glasses,andhearingprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentisused,andremove

allobjectsthatcanbethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches

andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.

Operation

•Lightningcancausesevereinjuryordeath.Iflightning

isseen,orthunderisheardinthearea,donotoperate
themachine;seekshelter.

•Donotrunanengineinanenclosedarea.

•Onlyoperateinwell-litareas,keepingawayfromholes

andhiddenhazards.

•Ensurethatalldrivesareinneutralandthattheparking

brakeisengagedbeforestartingengine.Onlystartthe
enginefromtheoperator’ sposition.

•Makesurethatyouhavegoodfootingwhileusingthis

machine,especiallywhenbackingup.

Note:Reducedfootingcouldcauseslipping.

•Slowdownanduseextracareonhillsides.Besureto

travelsidetosideonhillsides.Turfconditionscanaffect
thestabilityofthemachine.Usecautionwhileoperating
neardrop-offs.

•Slowdownandusecautionwhenmakingturnsandwhen

changingdirectionsonslopes.

•Donotraisethemowerdeckwiththebladesrunning.

•DonotoperatethemachinewithoutthePTOshieldor

otherguardssecurelyinplace.Besureallinterlocksare
attached,adjustedproperly ,andfunctioningproperly .

•Donotoperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingoroverspeed

theengine.

•Stoponlevelground,disengagedrives,engagethe

parkingbrake(ifprovided),shutofftheenginebefore
leavingtheoperator'spositionforanyreason,including
emptyingthecatchersoruncloggingthechute.

•Stopequipmentandinspectthebladesafterstriking

objectsorifanabnormalvibrationoccurs.Makethe
necessaryrepairsbeforeresumingoperations.

•Keepyourhandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptoensurea

clearpath.

4

•Keeppetsandbystandersawayfromanoperating

machine.

•Slowdownandusecautionwhenmakingturnsand

crossingroadsandsidewalks.Stopthebladesifyouare
notmowing.

MaintenanceandStorage

•Disengagedrives,settheparkingbrake,stoptheengine,

andremovethekeyordisconnectspark-plugwire.W ait
forallmovementtostopbeforeadjusting,cleaning,or
repairing.

•Beawareofthemower-dischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporaddfuelwiththeengine

running.

•Allowtheenginetocoolbeforefueling.

•Donotrefuelthemachineindoors.

•Donotstorethemachineorfuelcontainerwherethere

isanopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.

•Donotllcontainersinsideavehicle,onatruck,orona

trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandfuelit

ontheground.Ifthisisnotpossible,thenaddfuelwith
suchequipmentasaportablecontainer,ratherthanfrom
afueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete.

•Parkthemachineonalevelsurface.

•Cleangrassanddebrisfromthecuttingunit,drives,

mufers,andenginetohelppreventres.

•Cleanupoilorfuelspillage.

•Lettheenginecoolbeforestoring.

•Donotstorefuelnearamesordrainindoors.

•Donotallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhenrequired.

•Carefullyreleasepressurefromcomponentswithstored

energy.

•Disconnectthebatteryorremovethespark-plugwire

beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositiveterminallast.Reconnect
thepositiverstandnegativelast.

•Usecarewhencheckingtheblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only
replaceblades;donotstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replaceallwornordamageddecals.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

traileroratruck.

•Usefull-widthrampsforloadingmachineintoatrailer

oratruck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.

•Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeyourclothing

immediately.

•Donotoverllfueltank.Replacefuelcapandtighten

securely.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro
productsandothersafetyinformationyoumustknow.

Thisproductiscapableofamputatinghandsandfeet,and
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass,or,
whenequippedwithagrassbagger,forcatchingcutgrass.
Anyuseforpurposesotherthanthesecouldprovedangerous
totheuserandbystanders.

5

GeneralOperation

Service

•Besurethattheareaisclearofbystandersbeforemowing.

Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhichmay

behotfromoperation.Allowallofthepartstocool
beforeattemptingtomaintain,adjust,orservicethe
machine.

•UseonlyToro-approvedattachments.Warrantymaybe

voidedifusedwithanyunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires,etc.)beforeoperatingunder
anyobjects,anddonotcontactthem.

•Slowdownbeforemakingturnsanduseextracaution.

•Usecautionwhenridingtheplatformovercurbs,rocks,

roots,orotherobstructions.

•Lookbehindanddownbeforebackinguptoensurea

clearpath.Useextracarewhenoperatinginreverse.

•Donotjerkthecontrols;useasteadymotion.

•Whenloadingorunloadingthemachine,useone

full-widthrampthatiswideenoughtoextendbeyond
thewidthofthemachine.

•Donotstorethemachineorafuelcontainerinsidewhere

thereisanopename,suchasnearawaterheateror
furnace.

•Keepthenutsandboltstight,especiallythe

blade-attachmentbolts.

•Neverinterferewiththeintendedfunctionofasafety

deviceorreducetheprotectionprovidedbyasafety
device.Checktheirproperoperationregularly.

•Tobestprotectyourinvestmentandmaintainoptimal

performanceofyourToroequipment,countonT oro
genuineparts.Whenitcomestoreliability,Torodelivers
replacementpartsdesignedtotheexactengineering
specicationsofourequipment.Forpeaceofmind,insist
onTorogenuineparts.

•Checkbrakeoperationfrequently.Adjustandserviceas

required.

•Donotcarrypassengers.

•Donotcarryequipmentonthemachine.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeeluneasy
onaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.fromthe

mowingarea.

•Watchforholes,rutsorbumps.

Note:Tallgrasscanhideobstacles.

•Usecautionneardrop-offs,ditches,orembankments.

Note:Themachinecouldsuddenlyturnoverifawheel
goesovertheedgeofaclifforditch,orifanedgecavesin.

•Useextracarewithgrasscatchersorotherattachments.

Note:Thesecanchangethestabilityofthemachine.

•Keepallmovementonslopesslowandgradual.

•Donotmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

6

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

7

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

93-7010

104-8186

48inchmower

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Thrownobjecthazard,mower—keepthedeectorinplace.

3.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts.

93-7818

1.Warning—readtheOperator'sManualforinstructionson
torquingthebladebolt/nutto115-149N-m(85-110ft-lb).

93-7828

1.Thrownobjecthazard,mower—keepthedeectorinplace.

2.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts.

1.Warning—donottouchthehotsurface.

1.Parkingbrake—off

106-5517

112-8721

2.Parkingbrake—on

8

112-8760

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts.

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin
place.

114-3424

1.Tractioncontrol

2.Fast4.Neutral

3.Slow

5.Reverse

6.DisengagethePTO(PowerTakeOff)

115–4179

1.Movethemotioncontrollevertotheneutralposition,thenpull
outonPTO(PowerTakeOff)switchtoengagetheblades.

2.PulloutonthePTO(PowerTakeOff)toengagetheblades.7.Warning—stoptheenginebeforeleavingthemachine.

3.PushinonthePTO(PowerT akeOff)todisengagetheblades.8.Thrownobjecthazard—keepbystandersasafedistancefrom

4.Warning—readtheOperator’sManual.9.Thrownobjecthazard—keepdeectorinplace.

5.Warning—donotoperatethismachineunlessyouaretrained.

6.Warning—stoptheengineandremovethesparkplugwire
beforeperforminganymaintenanceonthemachine.

themachine.

10.Cutting,dismembermenthazardofhandorfoot—stayaway
frommovingparts;keepallguardsandshieldsinplace.

9

1.Interval

2.PowerTake-off(PTO)

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

115-4186

115–4189

1.Fast2.Enginespeed

115-4212

1.Hydraulicoillevel3.Warning—donottouchthe
hotsurface.

2.ReadtheOperator's

Manual.

117–2718

3.Slow4.Choke

126-1400

1.Warning-ReadtheOperator’smanual.UseonlyTororiding
attachments.Useofotherridingattachmentsmaycreatea
hazardousconditionresultingininjury.

10

130-0765

1.ReadtheOperator's
Manual.

2.Height-of-cutselection

3.Removethekeyfrom
theignitionandreadthe
Operator'sManualbefore
performingmaintenance.

130-8372

1.Height-of-cut3.Turnoffpowerbeforechangingheight-of-cut.

2.Hairpincotter

4.ReadtheOperator'sManual.

11

131-1180

12

ProductOverview

g014654

1

2

3

4

5

6

7

HourMeter

Thehourmeterrecordsthenumberofhourstheenginehas
operated.Itoperateswhentheengineisrunning.Usethese
timesforschedulingregularmaintenance(Figure6).

Safety-InterlockIndicators

Therearesymbolsonthehourmeterandindicatewitha
blacktrianglethattheinterlockcomponentisinthecorrect
position(Figure6).

Battery-IndicatorLight

WhentheignitionkeyisinitiallyturnedtotheOnposition,
thebatteryvoltagewillbedisplayedintheareawherethe
hoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturnedonand
whenthechargeisbelowthecorrectoperatinglevel(Figure

6).

Figure4

1.Side-dischargechute

2.Engine6.Mowerdeck

3.Gastank

4.Controls

5.Parkingbrake

7.Frontcasterwheel

Controls

Becomefamiliarwithallthecontrols(Figure5)beforeyou
starttheengineandoperatethemachine.

Figure5

1.Ignitionswitch

2.Leftmotion-controllever7.Neutral-lockpositionfor

3.Throttlecontrol8.Rightmotion-controllever

4.Hourmeter9.Blade-controlswitch

5.Fueltank

6.Choke

rightmotion-controllever

(PTO)

10.OperatorManualtube

Figure6

1.Safety-interlocksymbols

2.Batterylight

3.Hourmeter

ThrottleControl

Thethrottlecontrolhas2positions:FastandSlow .

Choke

Usethechoketostartacoldengine.

Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)isusedtoengagethe
electricclutchtodrivethemowerbladeswiththerightside
motion-controlleverinthecenter,unlockedposition.Pull
theswitchuptoengagethebladesandrelease.Todisengage
theblades,pushtheblade-controlswitch(PTO)downor
moveorreleasetherightsidemotion-controlleverintothe
Neutral-Lockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas3
positions:Start,Run,andOff.

13

Motion-ControlLevers

Specications

Themotion-controlleversareusedtodrivethemachine
forward,reverse,andturneitherdirection.

Neutral-LockPosition

Theneutral-lockpositionisusedwiththesafety-interlock
systemtoengageanddisengagethemowerbladesandto
determinetheneutralposition.

Fuel-ShutoffValve

Closethefuel-shutoffvalve(underthefueltank)when
transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesis
availableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealeror
Distributororgotowww .Toro.comforalistofallapproved
attachmentsandaccessories.

Note:Specicationsanddesignaresubjecttochange
withoutnotice.

48-inchmowers:

Widthwithdeectordown161cm(63.5inches)

Length

Height

Weight

198cm(77.7inches)

117cm(46inches)

309kg(682lb)

52-inchmowers:

Widthwithdeectordown172cm(67.6inches)

Length

Height

Weight

198cm(77.7inches)

117cm(46inches)

327kg(721lb)

14

Operation

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan30days

old),unleadedgasolinewithanoctaneratingof87or
higher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol(gasohol)

or15%MTBE(methyltertiarybutylether)byvolume
isacceptable.EthanolandMTBEarenotthesame.
Gasolinewith15%ethanol(E15)byvolumeisnot
approvedforuse.Neverusegasolinethatcontains
morethan10%ethanolbyvolume,suchasE15
(contains15%ethanol),E20(contains20%ethanol),or
E85(containsupto85%ethanol).Usingunapproved
gasolinemaycauseperformanceproblemsand/orengine
damagewhichmaynotbecoveredunderwarranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuelcontainers

overthewinterunlessafuelstabilizerisused.

•Donotaddoiltogasoline.

DANGER

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

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanygasoline
thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis6to13
mm(1/4to1/2inch)belowthebottomofthe
llerneck.Thisemptyspaceinthetankallows
gasolinetoexpand.

DANGER

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

•Alwaysplacegasolinecontainersontheground
awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor
onatruckortrailerbedbecauseinteriorcarpets
orplastictruckbedlinersmayinsulatethe
containerandslowthelossofanystaticcharge.

•Whenpractical,removegas-poweredequipment
fromthetruckortrailerandrefueltheequipment
withitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromagasolinedispenser
nozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimofthe
fueltankorcontaineropeningatalltimesuntil
fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditionerbottleopening.

•Avoidcontactwithskin;washoffspillagewith
soapandwater.

UsingStabilizer/Conditioner

•Neversmokewhenhandlinggasoline,andstay
awayfromanopenameorwheregasoline
fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Neverbuy
morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystemin
placeandinproperworkingcondition.

Useafuelstabilizer/conditionerinthemachinetoprovide
thefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysorless.

Forlongerstorageitisrecommendedthatthefueltank
bedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuelsystem,

whichcauseshardstarting

Important:Donotusefueladditivescontaining
methanolorethanol.

Addthecorrectamountofgasstabilizer/conditionerto
thegas.

Note:Afuelstabilizer/conditionerismosteffective
whenmixedwithfreshgasoline.Tominimizethechance

15

ofvarnishdepositsinthefuelsystem,usefuelstabilizer

G009027

1

2

atalltimes.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundthefueltankcapandremovethecap.
Addunleadedregulargasolinetothefueltank,untilthe
levelis6to13mm(1/4to1/2inch)belowthebottom
ofthellerneck.Thisspaceinthetankallowsthe
gasolinetoexpand.Donotllthefueltankcompletely
full.

3.Installthefueltankcapsecurely.Wipeupanygasoline
thatmayhavespilled.

CheckingtheEngine-OilLevel

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor
leaveitunattended.Beforeeachuse,checktheparkingbrake
forproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit;referto

SettingtheParkingBrake(page16).

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoCheckingthe

Engine-OilLevel(page27).

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

PuttingSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsinthe
safetysection.Knowingthisinformationcouldhelpyouor
anybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feetand
headisrecommended.

CAUTION

Thismachineproducessoundlevelsinexcessof
85dBAattheoperator'searandcancausehearing
lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

SettingtheParkingBrake

Pulltheparking-brakeleverrearward(Figure8).

Figure8

1.Parking-brakelever(inthe
releasedposition)

2.Parking-brakelever(inthe
engagedposition)

Theuseofprotectiveequipmentforeyes,ears,feet,andhead
isrecommended.

ReleasingtheParkingBrake

Pushtheparking-brakeleverforward.

StartingandStoppingthe Engine

Figure7

1.Wearsafetyglasses

2.Wearhearingprotection

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Settheparkingbrake.

16

4.MovethethrottlecontroltoFast,andmovethechoke
levertotheOnpositionbeforestartingacoldengine
(Figure9).

OperatingtheMower-Blade Control(PTO)

Note:Awarmorhotenginemaynotrequirechoking.

Tostartawarmengine,movethrottlecontrolmidway
betweentheFastandSlowpositions.

Figure9

1.Ignitionswitch

2.Throttlelever

5.Turntheignitionkeytothestartpositiontoenergize
thestarter.

3.Choke

Theblade-controlswitch(PTO)isusedinconjunctionwith
therightsidemotion-controllevertoengageanddisengage
themowerblades.

EngagingtheMowerBlades(PTO)

1.Toengagethemowerblades,movetherightside
motion-controllevertothecenter,unlockedposition
(Figure10).

2.Pulltheblade-controlswitch(PTO)upandreleaseit
whileholdingdowntherightsidemotion-controllever
inthecenter,unlockedposition.

Note:Whentheenginestarts,releasethekey .

Note:Donotengagethestarterformorethan5

secondsatatime.Iftheenginefailstostart,allow
fora15-secondcool-downperiodbetweenattempts.
Failuretofollowtheseinstructionscanburnoutthe
startermotor.

6.Whenenginestarts,movethethrottlecontrolbetween
theFastandSlowposition,andmovethechokelever
totheOffposition.

7.Allowtheenginetowarmupandthenmovethe
throttlecontroltotheFastposition.

StoppingtheEngine

1.Movethemotion-controlleverstoneutralandmove
therightsidemotion-controlleverintotheneutral-lock
position.

2.MovethethrottlelevertoSlow(Figure9).

3.Iftheenginehasbeenworkinghardorishot,letthe
engineidlefor30to60secondsbeforeturningthe
engineoff.

4.Tostoptheengine,turntheignitionkeytooff.

Important:Ensurethatthefuel-shutoffvalveis
closedbeforetransportingorstoringthemachine,
asfuelleakagemayoccur.Beforestoringthe
machine,pullwireoffsparkplug(s)toprevent
possibilityofaccidentalstarting.

Figure10

1.Blade-controlswitch
(PTO)

2.Rightsidemotion-control
leverpusheddownintothe
center,unlockedposition

3.Rightmotion-controllever
inneutral-lockposition

4.Leftmotion-controllever

DisengagingtheMowerBlades(PTO)

Thefollowingare2optionsfordisengagingthemowerblades.

•Pushtheblade-controlswitch(PTO)downtotheOff

position.

•Movethemotion-controlleverstoneutral,andmove

therightsidemotion-controlleverintotheneutral-lock
position.

17

UsingtheSafety-Interlock System

2.Settheparkingbrake.

3.Movetherightsidemotion-controllevertothecenter,
unlockedposition.

CAUTION

Ifsafety-interlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

UnderstandingtheSafety-Interlock
System

Thesafety-interlocksystemisdesignedtopreventthemower
bladesfromrotatingunless:

•Therightsidemotion-controlleverismovedtothe

center,unlockedposition.

•Theblade-controlswitch(PTO)ispulledtotheOn

position.

Thesafety-interlocksystemisdesignedtostopthemower
bladesifyoumoveorreleasetherightsidemotion-control
leverintotheneutral-lockposition.

Thehourmeterhassymbolstonotifytheuserwhenthe
interlockcomponentisinthecorrectposition.Whenthe
componentisinthecorrectposition,atrianglewilllight
upinthecorrespondingsquare.

Note:Thebladesshouldnotrotate.

4.Movethemotion-controlleversforward.

Note:Theengineshouldstop.

5.Starttheengineandreleasetheparkingbrake.

6.Movetherightsidemotion-controllevertothecenter,
unlockedposition.

7.Continueholdingtherightsidemotion-controllever
inthecenter,unlockedposition,andpulluponthe
blade-controlswitch(PTO)andrelease.

Note:Theclutchshouldengageandthemower
bladesshouldbegintorotate.

8.Moveorreleasetherightsidemotion-controlleverinto
theneutral-lockposition.

Note:Thebladesshouldstoprotating.

9.Movetherightsidemotion-controllevertothecenter,
unlockedposition.

10.Continueholdingtherightsidemotion-controllever
inthecenter,unlockedposition,andpulluponthe
blade-controlswitch(PTO)andrelease.

Note:Theclutchshouldengageandthemower
bladesshouldbegintorotate.

11.Pushtheblade-controlswitch(PTO)downtotheOff
position.

Figure11

1.Triangleslightupwhentheinterlockcomponentsareinthe
correctposition

TestingtheSafety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethemachine
eachtime.

Note:Ifthesafetysystemdoesnotoperateasdescribed
below,haveanAuthorizedServiceDealerrepairthesafety
systemimmediately.

1.Starttheengine;refertoStartingtheEngine(page16).

Note:Thebladesshouldstoprotating.

12.Withtheenginerunning,pulluptheblade-control
switch(PTO),andreleaseitwithoutholdingrightside
motion-controllevertothecenter,unlockedposition.

Note:Thebladesshouldnotrotate.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedasmeasured
inrpm(revolutionsperminute).Placethethrottlecontrolin
theFastpositionforbestperformance.Alwaysoperateinthe
full-throttlepositionwhenmowing.

CAUTION

Themachinecanspinveryrapidly,causingthe
operatortolosecontrolofmachine,whichcould
causepersonalinjuryordamagetothemachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp
turns.

18

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe

ParkingBrake(page16).

2.Movetherightsidemotion-controllevertothecenter,
unlockedposition.

3.Togoforward,slowlypushthemotion-controllevers
forward(Figure12).

Note:Theenginewillstopifthetraction-control
leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretoboth
motion-controllevers(Figure12).

Toturn,movethemotion-controllevertowardneutral
inthedirectionyouwanttoturn(Figure12).

Thefartheryoumovethetraction-controlleversin
eitherdirection,thefasterthemachinewillmovein
thatdirection.

StoppingtheMachine

Tostopthemachine,movethemotion-controlleversto
neutral,movetherightsidemotion-controlleverintothe
neutral-lockposition,disengagethepowertakeoff(PTO),
andturntheignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;referto

SettingtheParkingBrake(page16).Remembertoremove

thekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

Tostop,pullthemotion-controlleversbacktothe
neutralposition.

Figure12

1.Forward2.Backward

DrivingBackward

1.Movetherightsidemotion-controllevertothecenter,
unlockedposition.

PushingtheMachinebyHand

Thebypassvalvesallowthemachinetobepushedbyhand
withouttheenginerunning.

Important:Alwayspushthemachinebyhand.Never
towthemachinebecausehydraulicdamagemayoccur.

1.DisengagethePTO ,movethemotion-controlleversto
theneutral-lockedposition,andsettheparkingbrake.

2.Openthebypassvalveonbothpumpsbyturningthem
counterclockwise1to2turns(Figure13).

Note:Thisallowshydraulicuidtobypassthepumps
andthewheelstoturn.

Note:Rotatethebypassvalvesamaximumof2turns,
sothevalvedoesnotcomeoutofthebodycausing
uidtorunout.

2.Togobackward,slowlypullthemotion-controllevers
rearward(Figure12).

Togostraight,applyequalpressuretoboth
motion-controllevers(Figure12).

Toturn,releasepressureonthemotion-controllever
towardthedirectionyouwanttoturn(Figure12).

Tostop,pushthemotion-controlleverstotheneutral
position.

Figure13

1.Pumpbypassvalve

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

19

6.Closethebypassvalves,butdonotovertightenthem.

Important:Donotstartoroperatethemachine
withthebypassvalvesopen.Damagetothe
systemmayoccur.

SideDischargingorMulching theGrass

Thismowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthemachine.
Ensurethatthetrailerortruckhasallnecessarybrakes,
lighting,andmarkingasrequiredbylaw .Pleasecarefullyread
allthesafetyinstructions.Knowingthisinformationcould
helpyou,yourfamily,pets,orbystanderstoavoidinjury.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle,and
connectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,and
closethefuelvalve.

5.Usethemetaltie-downloopsonthemachineto
securelyfastenthemachinetothetrailerortruckwith
straps,chains,cable,orropes(Figure14).

6.Fastenthefrontofthemachinetothetrailerortruck
withstraps,chains,cable,orropes.

DANGER

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

•Neverremovethegrassdeectorfromthemower
becausethegrassdeectorroutesmaterialdown
towardtheturf.Ifthegrassdeectorisever
damaged,replaceitimmediately .

•Neverputyourhandsorfeetunderthemower.

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

AdjustingtheHeight-of-Cut

1.Tractionunittie-downloop

Figure14

Theheight-of-cutcanbeadjustedfrom25to114mm(1to
4-1/2inches)in6mm(1/4inch)increments.Adjustment
isdonebyrelocatingthe4hairpincottersindifferenthole
locationsandbyaddingorremovingspacers.

Note:Allheight-of-cutpinsneedatleastonespacer,or
damagecanoccurtothebushingifnoneareused.

Note:Allheight-of-cutpinscanuse2spacersmaximum.

1.Selecttheholeheight-of-cutpostandnumberof
spacerscorrespondingtotheheight-of-cutdesired
(Figure15).

2.Usingthelifthandle,raisesideofdeck,andremovethe
hairpincotter(Figure15).

3.Addorremovespacersifneeded,aligntheholes,and
insertthehairpincotter(Figure15).

Note:Spareheight-of-cutspacersmaybestoredon
postsandretainedbyahairpincotter.

Important:All4hairpincottersmustbeinthe
sameholelocationandwiththecorrectnumberof
spacersforalevelcut.

20

Figure15

1.Carrierframe4.Spacers

2.Hairpincotter

3.Backoftheheight-of-cut
post

5.Frontoftheheight-of-cut
post

AdjustingtheAnti-Scalp Rollers

Theanti-scalprollersneedtobeadjustedintheproperhole
locationforeachheight-of-cutposition.Thereneedstobe10
mm(3/8inch)minimumclearanceabovetheground.

Note:Iftheanti-scalprollersareadjustedtoolow ,itcan
causeexcesswearoftherollers.

1.Afteradjustingheight-of-cut,checktheanti-scalp
rollerssothatthereisaminimumof10mm(3/8
inch)clearanceabovetheground(Figure16,Figure

17,Figure18).

2.Ifadjustmentisneeded,removethebolt,washers,and
nut(Figure16,Figure17,Figure18).

Figure16

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Anti-scalprollers

2.Bolt5.Nut

3.Spacer

Figure17

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Bushing

2.Bolt5.Anti-scalprollers

3.Spacer

6.Nut

3.Selectaholeposition,sotheanti-scalprollersarea
minimumof10mm(3/8inch)offtheground(Figure

16,Figure17,Figure18).

4.Installtheboltandnut(Figure16,Figure17,Figure

18).

21

Figure18

g012676

1 2

G012677

G012678

36inchMowerDeck

1.Mowerdeck4.Anti-scalprollers

2.Bolt5.Nut

3.Spacer

5.Incertainmowingconditionsandterrain,amismatch
ofcuttingheightmaybeseen.Adjustingtheoutside
anti-scalprollerstotheminimumsettingof10mm
(3/8inch)willhelppreventthemowerdeckcutting
toolowontheoutsideandminimizethemismatch.

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse.
Adjustmentswillvarybygrasstype,moisturecontent,and
theheightofthegrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure20).Thesuggested
useforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthemower.

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferenttypes
ofmowingconditions.Positionthecamlockandbafeto
givethebestqualityofcut.

1.DisengagethePTO ,movethemotion-controlleversto
theneutral-lockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Toadjustthebafe,loosenthenut(Figure19).

4.Adjustthebafeandnutintheslottothedesired
dischargeow,andtightenthenut.

Figure20

PositionB

Usethispositionwhenbagging(Figure21).

Figure19

Figure21

2.Nut

22

1.Slot

PositionC

G012679

Thisisthefullopenposition.Thesuggesteduseforthis
positionisasfollows(Figure22).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

Figure23

Installingthefrontweight

1.Bolt3.Weight

2.Washer4.Nut

Figure22

UsingtheMid-SizeWeight

Weightsareinstalledoncertainmowerstoimprovebalance
andimproveperformance.Theweightscanbemovedor
removedtocreateoptimizedperformanceunderdifferent
mowingconditionsandforoperatorpreference(Figure23
orFigure24).

Thefollowingtableindicatesthepositionoftheweightas
installedatthefactory.

MowerDeckSizeNumberof

48inches

52inches1Rear

weightsinstall

nonenone

•AnyrearweightmustberemovedwhenaTru–Track

Sulkyisinstalled.

•WhenaTru-Track

needed.ContactanAuthorizedServiceDealerforthe
correctquantityofweightsandplacement.

®

Sulkyisinstalled,frontweightsare

Positionofthe

weight

Figure24

Installingtherearweight

1.Nut3.Washer

2.Weight4.Bolt

®

WARNING

Thefrontendofthemachinecanrapidlyriseup
whenthemowerisremoved.Thiscouldcause
seriousinjurytoyouorbystanders.

Supporttherearofthemachinewhenremovingthe
mowerfromthecarrierframe.

23

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulic-uidlevel.

•Changethehydrauliclter.

•Checkthesafety-interlocksystem.

•Greasethefrontcaster-pivotbearing.

•Checktheengine-oillevel.

•Cleantheair-intakescreen.

•Checkthebrakes.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanthefoamair-cleanerelement.

•Checkthebattery-electrolytelevel.

•Checkthehydraulic-uidlevel.

•Greasethesidebearings.

•GreasethePTObeltidler .

•Greasethemower-deck-beltidler.

•Checkthepaperair-cleanerelement.

•Checkthetirepressure.

•Checkthemowerbelt.

•CheckthePTO-drivebelt.

•Checkthepump-drivebelt.

•Changetheengineoil.

•Checkthesparkplugs.

•Adjusttheelectricclutch.

•Checkthehydrauliclines.

•Replacethepaperair-cleanerelement.

Every200hours

Every250hours

Every400hours

Every500hours

Beforestorage

•Changetheoillter.

•Replacethefuellter.

•Replacethefuel-ventlter.

•ChangethehydrauliclterandthehydraulicoilwhenusingMobil®1oil.

•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).

•ChangethehydrauliclterandthehydraulicoilwhenusingToro®HYPR-OIL™
500hydraulicoil.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineowner’smanualforadditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo
anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.

24

Lubrication

g014655

g014675

GreasingthePTODrive-Belt

GreasewithNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Cleanthegreasettingswitharag.

Note:Makesuretoscrapeanypaintoffthefrontof
thetting(s).

4.Connectagreaseguntothetting.

5.Pumpgreaseintothettingsuntilgreasebeginsto
oozeoutofthebearings.

6.Wipeupanyexcessgrease.

LubricatingtheBearings

ServiceInterval:Beforeeachuseordaily

Every400hours

Every50hours

IdlerandtheMower-Deck-Belt
Idler

ServiceInterval:Every50hours

Every50hours

Greasetheidler-pulleypivots(Figure26orFigure27).

Note:Youwillhavetoremovethecarriercoverstoaccess
thegreasettingforthemowerdeck.

Lubricatethefrontcaster-wheelbearingsandthefrontpivots
(Figure25).

Note:Makesuretherearwheelgreasecapsareremoved
beforelubricatingrearwheels.

Figure25

Figure26

40-inch,48-inch,and52-inchmowerdeckshown

Figure27

36-inchmowerdeckshown

25

EngineMaintenance

ServicingtheAirCleaner

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitistorn
orworn.

ServiceInterval:Every25hours—Cleanthefoam

air-cleanerelement.

Every50hours—Checkthepaperair-cleanerelement.

Every200hours—Replacethepaperair-cleaner
element.

Note:Servicetheaircleanermorefrequently(everyfew
operatinghours)iftheoperatingconditionsareextremely
dustyorsandy .

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Cleanaroundtheaircleanertopreventdirtfrom
gettingintotheengineandcausingdamage(Figure28).

4.Unscrewthecoverknobsandremovetheair-cleaner
cover(Figure28).

5.Unscrewthehoseclampandremovetheair-cleaner
assembly(Figure28).

6.Carefullypullthefoamelementoffthepaperelement
(Figure28).

ServicingthePaperAir-Cleaner
Element

1.Donotcleanthepaperlter,replaceit(Figure28).

2.Inspecttheelementfortears,anoilylm,ordamageto
therubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:T opreventenginedamage,alwaysoperate

theenginewiththecompletefoamandpaperaircleaner
assemblyinstalled.

1.Carefullyslidethefoamelementontothepaper
air-cleanerelement(Figure28).

2.Placetheair-cleanerassemblyontotheair-cleanerbase,
andsecureitwiththe2wingnuts(Figure28).

3.Placetheair-cleanercoverintopositionandtighten
thecoverknob(Figure28).

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Checkthe

engine-oillevel.

Aftertherst8hours—Changetheengineoil.

Every100hours—Changetheengineoil.

Every200hours—Changetheoillter.

Figure28

1.Cover

2.Hoseclamp4.Foamelement

3.Paperelement

CleaningtheFoamAir-CleanerElement

1.Washthefoamelementinliquidsoapandwarmwater.
Whentheelementisclean,rinseitthoroughly .

Note:Changetheoilmorefrequentlywhentheoperating
conditionsareextremelydustyorsandy.

OilType:Detergentoil(APIserviceSF,SG,SH,SJorSL)

CrankcaseCapacity:1.7L(58oz)withthelterremoved;

1.5L(51oz)withoutthelterremoved

Viscosity:Refertothetable(Figure29).

Figure29

26

CheckingtheEngine-OilLevel

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Cleanaroundtheoildipstick(Figure30)sothatdirt
cannotfallintothellerholeanddamagetheengine.

Figure30

1.Oildipstick

5.Unscrewtheoildipstickandwipetheendclean(Figure

30).

6.Slidetheoildipstickfullyintothellertube,butdonot
threaditontothetube(Figure30).

7.Pullthedipstickoutandlookattheend.Iftheoillevel
islow,slowlypouronlyenoughoilintothellertube
toraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewithoil
andruntheengine;enginedamagecanresult.

2.Fillertube

Figure31

1.Oil-drainvalve2.Oil-drainhose

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure30).

10.Checktheoillevel;refertoCheckingtheEngine-Oil

Level(page27).

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheEngine-OilFilter

Note:Changetheoilltermorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

ChangingtheEngineOil

1.Parkthemachine,sothatthedrainsideisslightlylower
thantheoppositeside,toensurethattheoildrains
completely.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Slidethedrainhoseovertheoil-drainvalve.

5.Placeadrainpanbelowthedrainhose.

6.Rotatetheoil-drainvalvetoallowtheoiltodrain
(Figure31).

7.Whenoilhasdrainedcompletely,closethedrainvalve.

8.Removethedrainhose(Figure31).

Note:Disposeoftheusedoilatarecyclingcenter.

1.Draintheoilfromtheengine;refertoChangingthe

EngineOil(page27).

2.Removetheoldlter(Figure32).

Figure32

1.Oillter

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure32).

27

4.Installthereplacementoilltertothelteradapter,

1

turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure32).

5.Fillthecrankcasewiththepropertypeofnewoil;refer
toServicingtheEngineOil(page26).

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillterandthe
drainvalve.

7.Checktheengine-oillevelandaddoilifneeded.

8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

ServiceInterval:Every100hours

Ensurethattheairgapbetweenthecenterandsideelectrodes
iscorrectbeforeinstallingthesparkplug.Useasparkplug
wrenchforremovingandinstallingthesparkplugsanda
gappingtool/feelergaugetocheckandadjusttheairgap.
Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:0.75mm
(0.03inch)

CheckingtheSparkPlugs

1.Lookatthecenterofthesparkplugs(Figure34).

Note:Ifyouseelightbrownorgrayontheinsulator,
theengineisoperatingproperly .Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Figure34

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Disconnectthewiresfromthesparkplugs(Figure33).

Figure33

1.Spark-plugwire/sparkplug

Important:Alwaysreplacethesparkplugswhen
ithaswornelectrodes,anoilylmonit,orhas
cracksintheporcelain.

3.Checkthegapbetweenthecenterandsideelectrodes
(Figure34).Bendthesideelectrode(Figure34)ifthe
gapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

2.Tightenthesparkplugsto22N-m(16ft-lb).

3.Connectthewirestothesparkplugs(Figure34).

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausingdamage.

5.Removethesparkplugsandthemetalwashers.

28

FuelSystem
Maintenance

DrainingtheFuelTank

DANGER

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

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopenarea.
Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,andstay
awayfromanopenameorwhereasparkmay
ignitethegasolinefumes.

1.Parkthemachineonalevelsurface,toassurefueltank
drainscompletely.

2.Disengagethepowertakeoff(PTO),settheparking
brake,turntheignitionkeytooff,andremovethekey.

3.Closethefuel-shutoffvalveatthefueltank(Figure35).

4.Squeezetheendsofthehoseclamptogetherandslide
itupthefuellineawayfromfuellter(Figure35).

5.Pullthefuellineoffthefuellter(Figure35).

6.Openthefuel-shutoffvalveandallowthegasolineto
drainintoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter
becausethefueltankisempty;refertoReplacingthe

FuelFilter(page29)

Figure35

1.Fuellter3.Fuel-shutoffvalve

2.Clamp

ServicingtheFuelFilter

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

ReplacingtheFuelFilter

Neverinstalladirtylterifitisremovedfromthefuelline.

Note:Notehowthefuellterisinstalledinordertoinstall
thenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Closefuel-shutoffvalveatthefueltank(Figure35).

7.Installthefuellineontothefuellter.

8.Slidethehoseclampclosetothevalvetosecurethe
fuelline.

9.Wipeupanyspilledfuel.

4.Squeezetheendsofthehoseclampstogetherandslide
themawayfromthelter(Figure36).

29

Figure36

g014686

1 2

1.Hoseclamp3.Filter

2.Fuelline

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampscloseto
thelter.

ServicingtheFuel-Vent System

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Removetheexistingfuel-ventlter(Figure37).

4.Installanewlter.

7.Openfuel-shutoffvalveatthefueltank(Figure35).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

Figure37

1.Fuel-ventlter2.Rightsideofmotor

30

ElectricalSystem
Maintenance

ServicingtheBattery

Alwayskeepthebatterycleanandfullycharged.Useapaper
toweltocleanthebatterycase.Ifthebatteryterminalsare
corroded,cleanthemwithasolutionof4partswaterand
onepartbakingsoda.Applyalightcoatingofgreasetothe
batteryterminalstopreventcorrosion.

Voltage:12V

WARNING

Incorrectbatterycableroutingcoulddamagethe
machineandcablescausingsparks.Sparkscan
causethebatterygassestoexplode,resultingin
personalinjury.

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

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

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassestoshield
youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst
metalmachinecomponentscausingsparks.Sparks
cancausethebatterygassestoexplode,resulting
inpersonalinjury.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Lifttheblackrubbercoveronthenegativecable,and
disconnectthenegativebatterycablefromthenegative
(-)batteryterminal(Figure38).

4.Slidetheredterminalbootoffthepositive(red)battery
terminal,andremovethepositive(red)batterycable
(Figure38).

5.Removethebatteryhold-downplate(Figure38)and
removethebattery.

InstallingtheBattery

1.Placethebatteryontothemachine(Figure38).

2.Securethebatterywiththehold-downplate,j-bolts,
andlocknuts.

3.Installthepositive(red)batterycabletopositive(+)
batteryterminalwithanut,awasher,andabolt(Figure

38).

4.Slidetherubbercoveroverthepost.

5.Theninstallthenegativebatterycableandgroundwire
tothenegative(-)batteryterminalwithanut,awasher,
andabolt(Figure38).

6.Slidetherubbercoveroverthepost.

•Whenremovingorinstallingthebattery,donot
allowthebatteryterminalstotouchanymetal
partsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

31

g012916

7
6

5

4
3
2

1

8
9

10

11

Figure38

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

Figure39

1.Ventcaps3.Lowerline

2.Upperline

2.Iftheelectrolyteislow ,addtherequiredamountof
distilledwater;refertoAddingWatertotheBattery

(page32).

AddingWatertotheBattery

Thebesttimetoadddistilledwatertothebatteryisjust
beforeyouoperatethemachine.Thisletsthewatermix
thoroughlywiththeelectrolytesolution.

1.Removethebatteryfromthemachine;referto

RemovingtheBattery(page31).

Important:Neverllthebatterywithdistilled
waterwhilethebatteryisinstalledinthemachine.
Electrolytecouldbespilledonotherpartsand
causecorrosion.

2.Cleanthetopofthebatterywithapapertowel.

3.Removetheventcapsfromthebattery(Figure39).

CheckingtheBattery-ElectrolyteLevel

ServiceInterval:Every25hours

4.Slowlypourdistilledwaterintoeachbatterycelluntil
theelectrolytelevelisuptotheUpperline(Figure39)
onthebatterycase.

Important:Donotoverllthebatterybecause

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

•Fillthebatterywherecleanwaterisalways

electrolyte(sulfuricacid)cancausesevere
corrosionanddamagetothechassis.

5.Waitfor5to10minutesafterllingthebatterycells.

6.Adddistilledwater,ifnecessary,untiltheelectrolyte
levelisuptotheUpperline(Figure39)onthebattery
case.

7.Installthebattery-ventcaps.

availableforushingtheskin.

1.Lookatthesideofthebattery.Theelectrolytemust
beuptotheupperline(Figure39).Donotallowthe
electrolytetofallbelowtheLowerline(Figure39).

32

ChargingtheBattery

ServicingtheFuses

WARNING

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparksand
amesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespeciallyimportantto
preventbatterydamagewhenthetemperatureisbelow
0°C(32°F).

1.Removethebatteryfromthechassis;refertoRemoving

theBattery(page31).

2.Checktheelectrolytelevel;refertoCheckingthe

Battery-ElectrolyteLevel(page32).

3.Makesurethatthellercapsareinstalledinbattery.

4.Chargethebatteryfor1hourat25to30ampsor6
hoursat4to6amps.

5.Whenthebatteryisfullycharged,unplugthecharger
fromtheelectricaloutlet,thendisconnectthecharger
leadsfromthebatteryposts(Figure40).

Theelectricalsystemisprotectedbyfuses.Itrequiresno
maintenance.Ifafuseblows,checkthecomponentorcircuit
foramalfunctionorshort.

1.Removethecoverunderthecontrolpanel.

2.Pulloutonthefusetoremoveorreplaceit(Figure41).

3.Installthecoverunderthecontrolpanel.

Note:Ensurethatthecorrect-sizefuseisinstallwith
thecorrectwirecolorasshowninFigure41.

6.Installthebatteryontothemachineandconnectthe
batterycables.

Note:Donotrunthemachinewiththebattery
disconnected,electricaldamagemayoccur.

Figure40

1.Positivebatterypost

2.Negativebatterypost

3.Red(+)chargerlead

4.Black(-)chargerlead

Figure41

1.Redwire3.Fuse—25amp,bladetype

2.Fuse—30amp,bladetype4.Violetwire

33

DriveSystem
Maintenance

AdjustingtheTracking

Ifthemachinedoesnottrackstraight,adjustmentisrequired.

1.Checkthereartirepressure;refertoCheckingtheTire

Pressure(page34).

2.Loosenthewingnutsontherightcontrolrod,and
rotatetheturnbuckleinorouttoensurethatthe
rightsidecontrolleveriscenteredintheneutral-lock
position.

3.Securetheturnbuckleinpositionwiththewingnuts
(Figure42).

Figure43

Replacingthe

4.Loosenthewingnutsontheleftcontrolrodandrotate
theturnbuckleinorouttochangethetracking.

5.Securetheturnbuckleinpositionwiththewingnuts
(Figure42).

6.Checkforpropertracking.

7.Adjusttheleftcontrolrodifachangeisneeded.

Figure42

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand
threaded)

Caster-Wheel-ForkBushings

Thecaster-wheelforksaremountedinbushingspressedinto
thetopandbottomofthecarrierframemounting-pivot
tubes.Tocheckthebushings,movethecasterforksbackand
forthandside-to-side.Ifacasterforkisloose,thebushings
arewornandmustbereplaced.

1.Raisethecuttingunitsothecasterwheelsareoffthe
oor,thensupportthefrontofthemowerwithjack
stands.

2.Removethelockingpinandspacer(s)fromthetopof
thecaster-wheelfork(Figure44).

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Checkthepressureatthevalvestem(Figure43).

Maintaintheairpressureinthereartiresat83to97kPa(12
to14psi).Uneventirepressurecancauseanunevencut.

Note:Thefronttiresaresemi-pneumatictiresanddonot
requireair-pressuremaintenance.

Figure44

1.Lockingpin

2.Spacers4.Caster-wheelfork

3.Pullthecaster-wheelforkoutofthemountingtube,
leavingthespacer(s)onthebottomofthefork.

34

3.Carrierframepivottube

Note:Rememberthelocationofthespacersoneach
forktoensurecorrectinstallation,andtomaintaina
leveldeck.

ServicingtheCasterWheel andBearings

4.Insertapinpunchintothemountingtubeandcarefully
driveoutthebushings(Figure45).

5.Cleantheinsideofthemountingtube.

Figure45

1.Mountingtube2.Bushing

Thecasterwheelsrotateonarollerbearingsupportedbya
spannerbushing.Ifthebearingiskeptwelllubricated,wear
willbeminimal.Failuretokeepthebearingwelllubricated
willcauserapidwear.Awobblycasterwheelusuallyindicates
awornbearing.

1.Removethelocknutandwheelboltholdingthecaster
wheeltothecasterfork(Figure46).

6.Greasetheinsideandoutsideofthenewbushings.

Note:Useahammerandatplatetocarefullydrive
thebushingsintothepivottubes.

7.Inspectthecaster-wheelforkforwear,andreplaceif
necessary(Figure44).

8.Slidethecaster-wheelforkthroughthebushingsinthe
mountingtube.

9.Replacethespacer(s)ontotheforkandsecurewiththe
retainingring(Figure44).

Important:Theinsidediameterofthebushings
maycollapseslightlywheninstalled.Ifthe
caster-wheelforkdoesnotslideintothenew
bushings,reambothbushingstoaninside
diameterof29mm(1.1inches).

10.Greasethettingonthecarrierframepivottubes
usingNo.2generalpurposelithiumbaseor
molybdenum-basegrease.

Figure46

1.Locknut

2.Wheelbolt5.Rollerbearing

3.Bushing

2.Removeonebushing,thenpullthespannerbushing
andtherollerbearingoutofthewheelhub(Figure46).

3.Removetheotherbushingfromthewheelhuband
cleananygreaseanddirtfromthewheelhub(Figure

46).

4.Inspecttherollerbearing,bushings,spannerbushing
andtheinsideofthewheelhubforwear.Replaceany
defectiveorwornparts(Figure46).

5.Toassemble,placeonebushingintothewheelhub.

6.Greasetherollerbearingandspannerbushingandslide
themintothewheelhub.

7.Placethesecondbushingintothewheelhub(Figure

46).

8.Installthecasterwheelintothecasterfork,andsecure
withthewheelboltandlocknut.

4.Spannerbushing

9.Tightenthelocknutuntilthespannerbushingbottoms
againsttheinsideofthecasterforks(Figure46).

10.Greasethettingonthecasterwheel.

35

AdjustingtheElectricClutch

CoolingSystem

ServiceInterval:Every100hours

Theclutchisadjustabletoensureproperengagementand
properbraking.

1.Inserta0.381to0.533mm(0.015to0.021inch)feeler
gaugethroughoneinspectionslotinthesideofthe
assembly.

Note:Makesureitisbetweenthearmatureandthe
rotorfrictionsurfaces.

2.Tightenthelocknutsuntilthereisslightbindingon
thefeelergaugebutitcanbemovedeasilywithinthe
airgap(Figure47).

3.Repeatthisfortheremainingslots.

4.Checkeachslotagainandmakeslightadjustmentsuntil
thefeelergaugebetweentherotorandarmaturewith
veryslightcontactbetweenthem.

Maintenance

CleaningtheAir-IntakeScreen

ServiceInterval:Beforeeachuseordaily

Beforeeachuse,removeanybuildupofgrass,dirt,orother
debrisfromthecylinderandcylinderheadcoolingns,
air-intakescreenontheywheelend,andcarburetor-governor
leversandlinkage.Thiswillhelpinsureadequatecooling
andcorrectenginespeedandwillreducethepossibilityof
overheatingandmechanicaldamagetotheengine.

Figure47

1.Adjustingnut3.Feelergauge

2.Slot

36

BrakeMaintenance

ServicingtheBrake

Beforeeachuse,checkthebrakesonbothalevelsurfaceand
slope.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnothold
securely,anadjustmentisrequired.

CheckingtheParkingBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurfaceanddisengagethe
PTO.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Applytheparkingbrake.Settingtheparkingbrake
shouldtakeareasonableamountofforce.Ifthe
parkingbrakedoesnotholdsecurely,anadjustmentis
required;refertoAdjustingtheParkingBrake(page

37).

Note:Whenthebrakeisengaged,thebrakehandle
shouldbeinthe1o'clockposition(Figure48).

10.Checkthebrakeoperationagain;refertoCheckingthe

ParkingBrake(page37).

Figure48

1.Parking-brakelever
(releasedposition)

2.1o'clockposition6.Yoke

3.Hairpincotter7.Jamnut

4.Lowerbrakelever8.Brakerod

5.Clevispin

AdjustingtheParkingBrake

Iftheparkingbrakedoesnotholdsecurely ,anadjustment
isrequired.

1.Parkthemachineonalevelsurface,disengagethe
PTO,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Checkthebrakebeforeyouadjustit;refertoChecking

theParkingBrake(page37).

4.Releasetheparkingbrake;refertoReleasingthe

ParkingBrake(page16).

5.Loosenthetopandbottomjamnuts(Figure48).

6.Toadjustthebrake,removethehairpincotterand
clevispinfromthelowerbrakelever(Figure48).

7.Rotatethebrakerodintheyokes(Figure48).

Note:T otightenthebrake,lengthentherodbetween
theyokes.Toloosenthebrake,shortentherod
betweentheyokes.

Note:Thebrakerodshouldbethreadedintoboth
yokesatthesamedistance.

8.Securetheyoketothelowerbrakeleverwiththe
hairpincotterandtheclevispin(Figure48).

9.Tightenthetopandbottomjamnuts(Figure48).

37

BeltMaintenance

g014676

ReplacingtheMowerBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracksare
signsofaworndeckbelt.Replacethedeckbeltifanyof
theseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Unlatchandremovethecarrier-framecover.

4.Unlatchandremovethebeltcovers.

5.RemovethePTOdrivebelt;refertoReplacingthe

PTO-DriveBelt(page39)

6.Disconnecttheidlerarmspringtorelievetensionon
theidlerarmandidlerpulley,thenremovetheworn
mowerbelt(Figure49).

7.Installthenewmowerbeltaroundthe2outsidespindle
pulleys,theidlerpulley,andinthelowergrooveofthe
double-spindlepulley(Figure49).

8.Connecttheidler-armspring(Figure49).

9.InstallthePTO-drivebelt;refertoReplacingthe

PTO-DriveBelt(page39).

10.Adjustthebeltguide3mm(1/8inch)fromthebelt
(Figure49).

11.Installthebeltcoversontothecuttingunitandsecure
thelatches.

12.Installthecarrier-framecoverontothecuttingunitand
securethelatches.

1.Outsidepulley

2.PTO-drivebelt

3.Idler-armspring

Figure49

4.Mower-deckbelt

5.Beltguide

6.Centerspindlepulley

38

ReplacingthePTO-DriveBelt

g014677

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracksare
signsofaworndrivebelt.Replacethedrivebeltifanyof
theseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Unlatchandremovethecarrier-framecover.

4.Unlatchandremovethebeltcovers.

5.Removetheheatshieldfromtheenginedeckand
carrierframe.

6.Rollthebeltoffofthecenterpulleyonthemower
deck(Figure50).

Note:Usecautionwhenremovingthebelt,astension
willincreasebecauseofthespring-loadedidlerpulley.

7.Removethebeltfromtheenginepulleyandthe
spring-loadedidlerpulley(Figure50).

8.Installthenewbeltontotheenginepulleyandthe
spring-loadedidlerpulley(Figure50).

9.Rollthebeltontothecenterpulleyonthemowerdeck
(Figure50).

10.Installtheheatshieldtotheenginedeckandcarrier
frame.

11.Adjustthebeltguide3mm(1/8inch)fromthebelt
(Figure50).

12.Installthebeltcoversontothecuttingunitandsecure
thelatches.

13.Installthecarrierframecoverontothecarrierframe
andsecurethelatches.

Figure50

1.PTOdrivebeltguide4.PTOengagementpulley

2.PTOdriveBelt5.PTOdrivebeltidlerpulley

3.Idlerspring

6.Centerspindlepulley

39

AdjustingthePTO-driveBelt Idler-SpringAnchor

ThepositionofthePTOidlercanbeadjustedtoincreaseor
decreasebelttension.

UseFigure51fortheidlerpositionoptions.

Figure52

Figure51

1.PTO-drivebeltidlerpulley4.Maximumtensionforworn

2.PTO-drivebelt5.Mediumtensionfornormal

3.Idlerspring

belts

beltconditions

6.Leasttensionfornewbelts

ReplacingthePump-DriveBelt

ServiceInterval:Every50hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.RemovePTO-drivebelt;refertoReplacingthe

PTO-DriveBelt(page39).

1.Hydraulicpumps

2.Idlerpulley6.Pivotbolt

3.Clutchretainer

4.Tensionspring8.Pump-drivebelt

5.Clutchwireconnector

7.Drivepulley

7.Unhooktheidlerspringfromtheframe(Figure52).

8.Installthenewbeltaroundclutchandthe2drive
pulleys.

9.Installtheidlerspringbetweentheidlerarmandthe
framebracket(Figure52).

10.Installtheclutchretainertotheenginedeck(Figure52).

11.Connecttheclutchwireconnectortothewireharness.

12.InstallthePTO-drivebelt.

4.Raisethemachineandsupportitwithjackstands.

5.Disconnecttheclutchwireconnectorfromthewire
harness.

6.Disconnecttheclutchretainerfromtheenginedeck
(Figure52).

40

ControlsSystem
Maintenance

AdjustingtheMotion-Control Handle

AdjustingtheRightMotion-Control
Lever

Ifthemotion-controlleversdonotalignhorizontally ,adjust
therightmotion-controllever.

Note:Adjustthehorizontalalignmentbeforethe
front-to-backalignment.

1.DisengagethePTO,movetherightmotion-control
levertotheneutralposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Pushtherightmotion-controlleverdownoutofthe
Neutral-Lockposition(Figure53).

4.Checkifitalignshorizontallywiththeleft
motion-controllever(Figure53).

1.Cam

2.Nutandbolt

3.Wingnut

Figure54

4.Turnbuckle

5.Switchscrews

Figure53

1.Leftmotion-controllever3.Checkthehorizontal

2.Rightmotion-control
leverintheNeutral-Lock
position

5.Toadjusttherightmotion-controlleverhorizontally,
thecamneedstobeadjusted.

6.Removethecoverunderthecontrolpanel.

alignmenthere

4.Rightmotion-controllever

9.Afterthecamisadjusted,theleverswitchneedstobe
checked.

10.Checkthegapbetweenthecontrolleverandtheswitch
asshowninFigure55.Thegapneedstobebetween

1.6to2.4mm(1/16to3/32inch).

11.Ifneeded,loosenthescrewsholdingtheswitchand
adjusttheswitch.

12.Tightenthescrewsandinstallthecoverunderthe
controlpanel.

7.Loosenthenutandboltholdingthecam(Figure54).

8.Adjustthecamuntilitalignswiththeleft
motion-controlleverandtightenthenutandboltfor
thecam.

41

Figure55

1.Rightside
motion-control-leverpivot
shownundercontrols

2.Rightsidemotion-control
lever

3.1.6to2.4mm(1/16to3/32
inch)gapneededbetween
switchandcontrollever

4.Switch

AdjustingtheNeutralPositionforthe
Motion-ControlLevers

Important:Ensurethatthetrackingofthemoweris

correctafteradjustingthemotion-controllevers.After
adjustingthetracking,themotion-controlleversmay
notalignexactlyfromfronttoback(Figure56).

Ifthemotion-controlleversdonotalignfronttoback,or
therightsidecontrolleverdoesnotmoveeasilyintothe
neutral-lockposition,adjustmentisrequired.Adjusteach
leverandcontrolrodseparately.

Note:Adjustthehorizontalalignmentbeforethe
front-to-backalignment.

1.Afterthehorizontalalignmentisnished,checkthe
front-to-backalignment(Figure56).

Figure56

1.Leftmotion-controllever

2.Rightmotion-controllever4.Alignthecontrollevers

3.Neutral-lockedposition

fromfronttobackhere

2.Loosenthewingnutsontherightcontrolrodand
rotatetheturnbuckleinorouttoensurethatthe
rightsidecontrolleveriscenteredintheneutral-lock
position.

3.Securetheturnbuckleintopositionwiththewingnuts
(Figure57).

4.Loosenthewingnutsontheleftcontrolrodandrotate
theturnbuckleinorouttochangethetracking.

5.Securetheturnbuckleinpositionwiththewingnuts
(Figure57).

Figure57

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand
threaded)

6.Checkforpropertracking.

7.Adjusttheleftcontrolrodifachangeisneeded;refer
toAdjustingtheTracking(page34).

42

HydraulicSystem

10.Installthecapontothellerneck.

Maintenance

ServicingtheHydraulic System

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every25hours

Note:Thereare2waysofcheckingthehydraulicoil.One
iswhentheoiliswarmandoneiswhentheoiliscold.The
bafeinsidethetankhas2levelsdependingiftheoiliswarm
orcold.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoffthe
engine.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulictank
(Figure58).

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit
mustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistype
ofinjury.Gangrenemayresultifthisis
notdone.

•Keepyourbodyandhandsawayfrom
pin-holeleaksornozzlesthateject
high-pressurehydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesurethatallhydraulic-uidhoses
andlinesareingoodconditionandall
hydraulicconnectionsandttingsare
tightbeforeapplyingpressuretohydraulic
system.

Figure58

1.Cap3.Colduidlevel—full

2.Bafe4.Hotuidlevel—full

5.Removethecapfromthellerneck.

6.Lookinsidetochecktheuidlevelinthereservoir.
(Figure58).

7.Adduidtothereservoiruntilitreachesthecoldlevel
ofthebafe.

8.Runthemachineatlowidlefor15minutestoallow
anyairtopurgeoutofthesystemandwarmuid;refer
toStartingandStoppingtheEngine(page16).

9.Checktheuidlevelwhiletheuidiswarm.

Note:Ifrequired,adduidtothereservoiruntilit
reachesthehotlevelofthebafe.

Note:Theuidlevelshouldbetothetopofthehot
levelofthebafe,whentheuidiswarm(Figure58).

ReplacingtheHydraulicFilterand
HydraulicOil

ServiceInterval:Aftertherst8hours

Every250hours—Changethehydrauliclterandthe
hydraulicoilwhenusingMobil

Every500hours—Changethehydrauliclterandthe
hydraulicoilwhenusingToro
hydraulicoil.

®

1oil.

®

HYPR-OIL

WARNING

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbeforeperforming
anymaintenancetothehydraulicsystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

Important:Donotsubstituteanautomotiveoil
lter,orseverehydraulic-systemdamagemay
result.

3.Locatethelterunderthefueltankandplaceadrain
panunderthelter(Figure59).

™

500

43

Figure59

11.Checkthelevelandadduid,ifrequired.Donot
overll.

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe
necessarytobleedthesystemiftheuidischangedorafter
workisperformedonthesystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstandshigh
enoughtoraisethedrivewheelsofftheground.

1.Filter

4.Removetheoldlter,allowtheoiltodrain,andwipe
thelter-adaptergasketsurfaceclean(Figure60).

5.Applyathincoatofhydraulicuidtotherubbergasket
onthereplacementlter.

6.Installthereplacementhydrauliclterontothelter
adapter.

Note:Donottightenthelterontotheadapter.

7.Fillthehydraulictankwithhydraulicuiduntiltheuid
overowsthelterandthenturntheoillterclockwise
untiltherubbergasketcontactsthelteradapter,then
tightenthelteranadditional1/2turn(Figure60).

4.Starttheengineandmovethethrottlecontroltothe
idleposition.

Note:Ifthedrivewheeldoesnotrotate,itispossible
toassistthepurgingofthesystembycarefullyrotating
thetireintheforwarddirection.

5.Checkthehydraulic-uidlevelasitdrops,andadduid
asrequiredtomaintaintheproperlevel.

6.Repeatthisprocedurefortheoppositewheel.

7.Thoroughlycleantheareaaroundeachofthe
charge-pumphousings.

CheckingtheHydraulicLines

ServiceInterval:Every100hours

Checkhydrauliclinesandhosesforleaks,loosettings,kinked
lines,loosemountingsupports,wear,weather,andchemical
deterioration.Makenecessaryrepairsbeforeoperating.

Note:Keepareasaroundhydraulicsystemcleanfromgrass
anddebrisbuildup.

Figure60

1.Hydrauliclter

2.Gasket

3.Adapter

8.Cleanupanyspilleduid.

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

Important:Usetheoilspecied,asotheruids
couldcausesystemdamage.

10.Starttheengineandletitrunforabout2minutesto
purgeairfromthesystem.Stoptheengineandcheck
forleaks.Ifoneorbothwheelswillnotdrive,referto

BleedingtheHydraulicSystem(page44).

44

MowerDeck Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keepthebladessharp.
Forconvenientsharpeningandreplacement,youmaywant
tokeepextrabladesonhand.

WARNING

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

•Inspectthebladesperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagethebladesand
settheparkingbrake.Turntheignitionkeytooff.Remove
thekeyanddisconnectthesparkplugwiresfromthespark
plugs.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure61).

Note:Iftheedgesarenotsharporhavenicks,remove
andsharpentheblades;refertoSharpeningtheBlades

(page47).

Figure61

1.Cuttingedge3.Wear/slotforminginthe
curvedarea

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea(Figure

61).

Note:Ifyounoticeanycracks,wear,oraslotforming
inthisarea(Figure61),immediatelyinstallanewblade.

CheckingforBentBlades

1.DisengagethePTO ,movethemotion-controlleversto
theneutral-lockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Rotatethebladesuntiltheendsfaceforwardand
backward.Measurefromalevelsurfacetothecutting
edge,positionA,oftheblades(Figure62).

45

Figure62

1.Measureherefromblade
tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep3above.
Thedifferencebetweenthedimensionsobtainedin
steps3and4mustnotexceed3mm(1/8inch).Ifthis
dimensionexceeds3mm(1/8inch),thebladeisbent
andmustbereplaced;refertoRemovingtheBlades

(page46)andInstallingtheBlades(page47).

WARNING

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedblade
withanewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

Figure63

48-inchmowerdecks

1.Sailareaoftheblade3.Curvedwasher

2.Blade4.Bladebolt

3.For52-inchmowerdecks,removethebladebolt,
curvedwasher,bladestiffener,andthebladefromthe
spindleshaft(Figure64).

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthebladeis
outofbalanceorisbent.Toensureoptimumperformance
andcontinuedsafetyconformanceofthemachine,use
genuineT ororeplacementblades.Replacementbladesmade
byothermanufacturersmayresultinnon-conformancewith
safetystandards.

1.Holdthebladeendusingaragorthickly-paddedglove.

2.For48-inchmowerdecks,removethebladebolt,
curvedwasher,andbladefromthespindleshaft(Figure

63).

Figure64

52-inchmowerdecks

1.Sailareaoftheblade4.Curvedwasher

2.Blade5.Bladebolt

3.Bladestiffener

46

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothendsof
theblade(Figure65).Maintaintheoriginalangle.The
bladeretainsitsbalanceifthesameamountofmaterial
isremovedfrombothcuttingedges.

Figure65

1.Sharpenattheoriginalangle

2.Checkthebalanceofthebladebyputtingitonablade
balancer(Figure66).

Note:Ifthebladestaysinahorizontalposition,the
bladeisbalancedandcanbeused.Ifthebladeisnot
balanced,lesomemetalofftheendofthesailarea
only(Figure63).

CorrectingtheMowerQuality ofCut

Ifonedeckbladecutslowerthantheother,correctasfollows.

Note:Tireairpressureiscriticalintheseprocedures.Make
surealltireshavethecorrectpressure.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Disconnectthesparkplugwire(s)fromthespark
plug(s).

4.Adjustthetirepressureinthereartirestospecications.

5.Checkthatthebladesandspindleshaftsarenotbent;
refertoCheckingforBentBlades(page45).

6.Settheheight-of-cuttothe101.6mm(4inches)
position;refertoAdjustingtheHeight-of-Cut(page

20).

7.PerformthestepsinSettinguptheFrame(page48).

3.Repeatthisprocedureuntilthebladeisbalanced.

Figure66

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure63).

Important:Thesailpartoftheblademustbe
pointingupward,towardtheinsideofthemower
toensurepropercutting(Figure63).

2.For48–inchmowerdecks,installtheblade,curved
washer,andthebladebolt(Figure63).

3.For52-nchmowerdecks,installtheblade,stiffener,
curvedwasher,andthebolt(Figure64).

4.Torquethebladeboltto115to140N-m(85to110
ft-lb).

47

SettinguptheFrame

CheckingtheCarrierFrameandthe
Engine-DeckAlignment

Note:MisalignmentcancauseexcesswearonthePTO-drive

belt.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Placealongstraightedgeontopoftheenginedeckas
showninFigure67.

4.Atthecarrierframecrosschannel,measuretheheight
atlocationA(Figure67).Thismeasurementmustbe
33mm(1-5/16inches),plusorminus6mm(1/4inch).

5.IftheheightatlocationAisnotcorrect,adjustment
isneeded.

6.Loosenthecarrierframemountingboltsonbothsides
ofthemachine(Figure67).

7.Alignthecarrierframeandenginedecktomatch33
mm(1-5/16inches),plusorminus6mm(1/4inch)
atlocationA(Figure67).

8.Tightenthecarrierframemountingboltsonbothsides
ofthemachine.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Adjustthetirepressureinthereartirestospecications;
refertoCheckingtheTirePressure(page34).

4.Measureengine-deckheightatlocationA(Figure68).

5.Measureengine-deckheightatlocationB(Figure68).

6.IftheheightatlocationAandBarenotthesame,
changetirepressureslightlytomakethemthesame.

Figure68

1.Backviewofthemachine

2.Topoftheenginedeck4.Sameheightatlocations

3.Tires

AandB

Figure67

1.Carrierframe

2.Topoftheenginedeck5.Straightedge

3.Carrierframemounting
bolts

4.LocationA—33mm
(1-5/16inches)±6mm
(1/4inch)

6.Carrierframecross
channel

CheckingtheEngine-DeckHeight

1.DisengagethePTOandsettheparkingbrake.

CheckingtheCarrierFrame
Front-to-RearPitch

Thecarrierframemusthaveapitchbetween3mm(1/8inch)
to9mm(3/8inch)overthelengthof61cm(24inches)on
thecarrierframe(Figure69).

1.Measureout61cm(24inches)onthecarrierframe
(Figure69).

Figure69

1.Carrierframe

2.3to10mm(1/8inchto3/8
inch)pitchover61cm(24
inches)length

3.61cm(24inches)6.Casterspacers

2.Measurecarrier-frameheightatlocationA(Figure69).

4.HeightatlocationsAand
B

5.Casterwheel

48

3.Measurecarrier-frameheightatlocationB(Figure69).

4.TheheightatlocationAmustbe3to10mm(1/8inch
to3/8inch)lowerthanlocationB(Figure69).

5.Ifthecarrierframeisnotcorrect,movecasterspacers
tomakeitan3to10mm(1/8inchto3/8inch)pitch
(Figure69).

6.Movespacersfromthetoporbottomtomakethe
correctpitch.

7.Thetirepressuremayalsobeadjustedslightlytomake
an3to10mm(1/8inchto3/8inch)pitch.

CheckingtheCarrierFrame
Side-to-SideHeight

Thecarrierframeneedstobeparallelside-to-sidefromthe
ground.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Adjustthetirepressureinthereartirestospecications;
refertoCheckingtheTirePressure(page34).

CheckingtheMowerDeck Front-to-RearPitch

1.Adjustthetirepressureinthereartirestospecications;
refertoCheckingtheTirePressure(page34).

2.Positiononebladefront-to-rear.MeasureatAandB
locationsfromalevelsurfacetothecuttingedgeof
thebladetips(Figure71).

3.Themowerbladeshouldbea6mm(1/4inch)lower
inthefrontatAthanintherearatB.

4.Rotatebladesandrepeatforotherblades.Ifitis
notcorrect,proceedtoChangingtheMowerDeck

Front-to-RearPitch(page50).

4.Measurecarrier-frameheightatlocationA(Figure70).

5.Measurecarrier-frameheightatlocationB(Figure70).

6.Ifthecarrier-frameheightisnotthesamemovespacers
fromthetoporbottomofcasterwheel,tomakeit
level.Thetirepressuremayalsobeadjustedslightly
tomakeitlevel.

Figure70

1.Casterwheel4.Sameheightatlocations
AandB

2.Carrierframe5.Casterspacers

3.Frontheight-of-cutpins

1.MeasurebladeatpointsA
andB

Figure71

2.Measurefromalevel
surface

49

ChangingtheMowerDeck

CheckingtheMowerDeck

Front-to-RearPitch

Changingthefront-to-rearpitchisdonebyadjustingthe
frontheight-of-cutposts.

1.Tochangethefront-to-rearpitch,thefront
height-of-cutpostscanbeadjusted(Figure72).

Figure72

1.Casterwheel

2.Carrierframe

3.Frontheight-of-cutpins

4.Jamnut

5.Balljoint

Side-to-SideHeight

1.Adjustthereartirepressuretospecications;referto

CheckingtheTirePressure(page34).

2.Positionthebladesside-to-side.

3.MeasureatCandDlocationsfromalevelsurfaceto
thecuttingedgeofbladetips(Figure73).

Figure73

1.Measurefromalevel
surface

2.MeasurebladeatpointsC
andD

2.Toraisethefrontofthedeck,loosenthejamnutand
rotatethefrontpinclockwise(Figure72).

3.Tolowerthefrontofthedeck,loosenthejamnutand
rotatethefrontpincounterclockwise(Figure72).

4.Positionthebladesfront-to-rear.

5.MeasureattheCandDlocations(Figure71)froma
levelsurfacetothecuttingedgeoftheblades.

6.Checktheside-to-sidelevelingofthecuttingunit.

7.Tightenthejamnuts(Figure72).

4.ThedifferencebetweenmeasurementsCandDshould
benomorethan6mm(1/4inch).

50

ChangingtheMowerDeck

ReplacingtheGrassDeector

Side-to-SideHeight

Changingtheside-to-sideheightisdonebyadjustingtherear
tirepressureandthecasterspacers.

1.Changethereartirepressure.Dothistothe
correspondingsidethatneedsadjustment.

2.Adjustthecasterspacer.

3.Checkthefront-to-rearpitchandside-to-sideleveling
ofthecuttingunit.

MatchingtheHeightofCut

1.Checkthereartirepressure;refertoCheckingtheTire

Pressure(page34).

2.Settheheight-of-cuttothe101.6mm(4inches)
positionfollowingtheheight-of-cutdecal.

3.Withthemachineonlevelsurface,positiononeblade
front-to-rear.MeasureatAandfromlevelsurfaceto
thecuttingedgeofthebladetips(Figure74).

Note:Themeasurementshouldbe101.6mm(4
inches).

WARNING

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

Neveroperatethelawnmowerunlessyouinstalla
coverplate,amulchplate,grassdeectororbagger.

1.Removethelocknut,bolt,spring,andspacerholding
thedeectortothepivotbrackets(Figure75).

2.Removethedamagedorworngrassdeector.

Figure74

1.Measurefromalevel
surface

4.Ifitdoesnotmeasurecorrectly:

A.Adjustthereartirepressure.

B.Adjustthecaster-forkspacers.

C.Adjustthefrontmowerdecksupportpins.

5.Checkthecarrierframefront-to-rearpitch.

2.MeasurebladeatpointA

Figure75

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring

3.Placethespacerandspringontothegrassdeector.
PlaceoneJendofthespringbehindthedeckedge.

Note:MakesureoneJendofthespringisinstalled
behindthedeckedgebeforeinstallingtheboltas
showninFigure75.

4.Installtheboltandnut.PlaceoneJ-hookendofthe
springaroundthegrassdeector(Figure75).

Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefull,open
positionandensurethatitrotatesintothefull,
downposition.

5.Springinstalled

7.J–hookendofspring

51

Cleaning

Storage

CleaningundertheMower

ServiceInterval:Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.DisengagethePTO ,movethemotion-controlleversto
theneutral-lockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Raisethefrontofthemachineandusejackstandsto
supportthemower.

DisposingofWaste

Engineoil,batteries,hydraulicoil,andenginecoolantare
pollutantstotheenvironment.Disposeoftheseaccordingto
yourstateandlocalregulations.

CleaningandStoringthe Machine

1.Disengagethepowertakeoff(PTO),settheparking
brake,turntheignitionkeytooff,andremovethekey.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engine.Cleanthedirtandchafffromtheoutsideofthe
engine'scylinder-headnsandtheblowerhousing.

Important:Y oucanwashthemachinewithmild
detergentandwater.Donotpressurewashthe
machine.Avoidexcessiveuseofwater,especially
nearthedrivesystemandengine.Pressure
washingcanforcedirtandwaterintocriticalparts,
suchasspindlebearingsandelectricalswitches.

3.Checkthebrake;refertoServicingtheBrake(page37).

4.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page26).

5.Greasethemachine;refertoLubrication(page25).

6.Changetheengineoil;refertoChangingtheEngine

Oil(page27).

7.Checkthetirepressure;refertoCheckingtheTire

Pressure(page34).

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefueltank;

refertoDrainingtheFuelTank(page29),or
operateengineuntilitstops.

D.Restartengineandrununtilitstops.Repeat,on

Chokeuntilenginewillnotrestart.

E.Disposeoffuelproperly .Recycleasperlocal

codes.

Note:Donotstorestabilizer/conditioned
gasolineover90days.

9.Removethesparkplug(s)andcheckitscondition;refer
toServicingtheSparkPlugs(page28).Withthespark
plug(s)removedfromtheengine,pourtwotablespoons
ofengineoilintothesparkplughole.Nowusethe
startertocranktheengineanddistributetheoilinside
thecylinder.Installthesparkplug(s).Donotinstallthe
wireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repairor
replaceanypartthatisdamagedordefective.

11.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

52

12.Storethemachineinaclean,drygarageorstoragearea.
Removethekeyfromtheignitionswitchandkeepit
inamemorableplace.Coverthemachinetoprotect
itandkeepitclean.

53

Troubleshooting

Problem

Theenginewillnotstart,startshard,or
failstokeeprunning.

Theenginelosespower.

PossibleCauseCorrectiveAction

1.Fueltankisempty.

2.Chokeisnoton.

3.Aircleanerisdirty.

4.Spark-plugwireislooseor
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.Fillthefueltankwithgasoline.

2.Movethechokelevertochokeposition.

3.Servicetheair-cleanerelement.

4.Installthewireonthesparkplug.

5.Installanew,correctlygappedspark
plug.

7.ContactanAuthorizedServiceDealer.

8.ContactanAuthorizedServiceDealer.

2.Servicetheaircleaner.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe
coolingnsandairpassages.

5.Installanew,correctlygappedspark
plug.

8.ContactanAuthorizedServiceDealer.

Theengineoverheats.

Themachinedoesnotdrive.

Thereisanabnormalvibration.

Thecuttingheightisuneven.

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

Thebladesdonotrotate.

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

TheToroT otalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment
(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuanttoanagreement
betweenthem,jointlypromisetotheoriginalpurchasertorepairtheT oroProducts
listedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Mid-SizeWalk-BehindMowers

4

•Engines

GrandStand

4

•Engines

•Frame

®

ZMaster

•Engines

2000SeriesMowers

4

•Frame

®

ZMaster

•Engines

•Frame

ZMaster

•Engines

®

3000SeriesMowers

4

5000SeriesMowers

4

®

Mowers

Kawasaki–3years

2years

Kawasaki–3years

5yearsor1,200hours

3years

Lifetime(originalowneronly)

4yearsor500hours

3years

Lifetime(originalowneronly)

5yearsor1,200hours
3years
Lifetime(originalowneronly)
5yearsor1,200hours

KohlerCommand–2years

KohlerEFI–3years

•Frame

®

ZMaster

•Engines

6000SeriesMowers

4

•Frame

®

ZMaster

•Engines

7000SeriesMowers

4

•Frame

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

2years

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

1

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

2

Whicheveroccursrst.

3

LifetimeFrameW arranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforpartsand
labor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosion
arenotcovered.

4

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer.

1

1

2

3

2

3

2

3

2

3

2

3

2

3

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship,
followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir
dealership.T olocateadealerconvenienttoyou,refertotheY ellowPagesof
yourtelephonedirectory(lookunder“LawnMowers”)oraccessourwebsite
atwww.Toro.com.Youmayalsocallthenumberslistedinitem#3tousethe
24-hourT oroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService
Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered
underwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith
theassistanceprovided,contactusat:

RLCCustomerCareDepartment

ToroWarrantyCompany

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

888-865-5676(U.S.Customers)

888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures
describedintheOperator'sManual.Suchroutinemaintenance,whetherperformedby
adealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage
andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot
coverthefollowing:

•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil

changes,sparkplugs,airltersbladesharpeningorwornblades,cable/linkage
adjustments,orbrakeandclutchadjustments

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenalteredormisusedorneglectedandrequires

replacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult

Operator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan

10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro
ServiceDealerusingT oroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect,
incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro
Productscoveredbythiswarranty ,includinganycostorexpenseofproviding
substituteequipmentorserviceduringreasonableperiodsofmalfunctionor
non-usependingcompletionofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse)
andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto
thedurationoftheexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages,
orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions
andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry,
province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheToroimporter.Ifallother
remediesfail,youmaycontactusatT oroWarrantyCompany.

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer .

374-0252RevF