Toro 30494, 30496, 30498, 30499 Operator's Manual

Download

FormNo.3361-918RevA

CommercialWalk-BehindMower

withFloatingDeck,T-Bar,Hydrowith36in, 40in,48inor52inTURBOFORCE Unit

ModelNo.30494—SerialNo.280001101andUp

Cutting

ModelNo.30496—SerialNo.280001101andUp

ModelNo.30498—SerialNo.280001101andUp

ModelNo.30499—SerialNo.280001101andUp

Registeratwww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002.

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

Theenclosed

Engine Owner’ s Man ual

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

Introduction

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.

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

Figure1

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythefollowingwords:

•Dangersignalsanextremehazardthatwillcause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

•Warningsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.

•Cautionsignalsahazardthatmaycauseminor ormoderateinjuryifyoudonotfollowthe recommendedprecautions.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizesgeneral informationworthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready .Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

Contents

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

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

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

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

SlopeChart..........................................................7

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

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

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

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

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

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

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

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

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

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

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

OperatingtheMowerBladeControl

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GreasingthePTODriveBeltIdlerandMower

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ReplacingtheCasterWheelFork

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

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

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

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

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

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

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

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

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

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

AdjustingthePTODriveBeltIdlerSpring

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

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

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

AdjustingtheMotionControlHandle

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

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

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

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

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

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

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

CheckingtheMowerDeckFront-to-Rear

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

ChangingtheMowerDeckFront-to-Rear

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

CheckingtheMowerDeckSide-to-Side

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

ChangingtheMowerDeckSide-to-Side

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

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

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

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

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

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

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

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

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

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

Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.

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

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

–Useonlyanapprovedcontainer

,whichmeans

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

–Neverrefuelordrainthemachineindoors.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Onlystartengine fromtheoperator’sposition.

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

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

•Slowdownandusecautionwhenmakingturnsand whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

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

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

•Stoponlevelground,disengagedrives,engage parkingbrake(ifprovided),shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesure ofaclearpath.

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesifnot mowing.

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

•Usecarewhenloadingorunloadingthemachine intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

Maintenanceandstorage

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

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

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake. Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.

•UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

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

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.

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

•Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.

•Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.

•Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.

•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice asrequired.

SlopeChart7SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

98-0776

43-8480

98-5954

66-1340

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical

68-8340

burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe distancefromthebattery.

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

10.Containslead;donot discard.

95-2814

106-0699

104-8185

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

104-8186

110-2067

104-8569

110-2068

1.ReadtheOperator’sManual.

105-7798

106-0635

112-8720

115-4212

1.Hydraulicoillevel3.Warning—donottouch thehotsurface.

2.ReadtheOperator’s

Manual.

1.Interval

2.PowerT ake-off(PTO)

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

115-4186

115–4179

1.Movethemotioncontrollevertotheneutralposition,thenpull

outonPTO(PowerT akeOff)switchtoengagetheblades.

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

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

4.Warning—donotoperatethismachineunlessyouaretrained.

5.Warning—stoptheengineandremovethesparkplugwire

beforeperforminganymaintenanceonthemachine.

6.Warning—stoptheenginebeforeleavingthemachine.

themachine.

9.Cutting,dismembermenthazardofhandorfoot—stayaway frommovingparts;keepallguardsandshieldsinplace.

1.Fast2.Enginespeed

115–4189

3.Slow4.Choke

1.Tractioncontrol

2.Fast4.Neutral

ProductOverview

Figure2

1.Sidedischargechute

2.Engine6.Mowerdeck

3.Gastank

4.Controls

5.Parkingbrake

7.Frontcasterwheel

114-3424

3.Slow

1.Ignitionswitch

2.Leftmotioncontrollever7.Neutrallockpositionfor

3.Throttlecontrol8.Rightmotioncontrollever

4.Hourmeter

5.Fueltank

5.Reverse

6.DisengagethePTO(PowerT akeOff)

Figure3

6.Choke

rightmotioncontrollever

9.bladecontrolswitch(PTO)

10.Operatormanualtube

HourMeter

Controls

Becomefamiliarwithallthecontrols(Figure3)before youstarttheengineandoperatethemachine.

Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance (Figure4).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandindicatewith ablacktrianglethattheinterlockcomponentisinthe correctposition(Figure4).

BatteryIndicatorLight

WhentheignitionkeyisinitiallyturnedtotheOn position,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure4).

Figure4

1.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

ThrottleControl

Thethrottlecontrolhastwopositions:FastandSlow.

enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

36inchmowers:

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

Length

Height

Weight

78–1/2inches(199cm)

46inches(117cm)

667lb(303kg)

Choke

Usethechoketostartacoldengine.

BladeControlSwitch(PTO)

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

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

40inchmowers:

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

Length

Height

Weight

75–3/8inches(192cm)

46inches(117cm)

667lb(303kg)

48inchmowers:

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

Length

Height

Weight

77–3/4inches(198cm)

46inches(117cm)

682lb(309kg)

52inchmowers:

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

Length

Height

Weight

77–3/4inches(198cm)

46inches(117cm)

721lb(327kg)

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageanddisengagethemowerbladesand todetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(underthefueltank)when transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto

Operation

AddingFuel

UseUnleadedRegularGasolinesuitablefor automotiveuse(85pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.

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

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouand othersandcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupany gasolinethatspills.

•Neverllthefueltankinsideanenclosed trailer.

•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4 to1/2inch(6to13mm)belowthebottomof thellerneck.Thisemptyspaceinthetank allowsgasolinetoexpand.

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitethegasolinevapors.Are orexplosionfromgasolinecanburnyouand othersandcandamageproperty.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Important:Donotusefueladditives containingmethanolorethanol.

Addthecorrectamountofgas stabilizer/conditionertothegas.

Iftheparkingbrakedoesnotholdsecurely,adjustit. RefertoServicingtheParkingBrake.

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

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

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

3.Installfueltankcapsecurely.Wipeupanygasoline thatmayhavespilled.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelinEngineMaintenance.

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

SettingtheParkingBrake

Pulltheparkingbrakeleverrearward(Figure5).

Note:Determinetheleftandrightsidesofthe machinefromthenormaloperatingposition.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

OperatingtheParkingBrake

Figure5

1.Parkingbrakelever(inthe releasedposition)

2.Parkingbrakelever(inthe engagedposition)

ReleasingtheParkingBrake

Pushtheparkingbrakeleverforward.

StartingandStoppingthe Engine

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Settheparkingbrake.

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse,check theparkingbrakeforproperoperation.

4.Movethethrottlecontroltofastandmovethe chokelevertotheonpositionbeforestartingacold engine(Figure6).

Note:Awarmorhotenginemaynotrequire choking.Tostartawarmengine,movethrottle controlmidwaybetweenthefastandslow positions.

Figure6

1.Ignitionswitch

2.Throttlelever

3.Choke

OperatingtheMowerBlade Control(PTO)

Thebladecontrolswitch(PTO)isusedinconjunction withtherightsidemotioncontrollevertoengageand disengagethemowerblades.

EngagingtheMowerBlades(PTO)

1.Toengagethemowerblades,movetherightside motioncontrollevertothecenter,un-locked position(Figure7).

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

5.Turntheignitionkeytothestartpositionto energizethestarter.Whentheenginestarts,release thekey .

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

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

StoppingtheEngine

1.Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.

2.Movethethrottlelevertoslow(Figure6).

3.Iftheenginehasbeenworkinghardorishot,let theengineidlefor30to60secondsbeforeturning theengineoff.

4.Tostoptheengine,turntheignitionkeytooff.

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

Figure7

1.Bladecontrolswitch(PTO)

2.Rightsidemotioncontrol leverpusheddownintothe center,un-lockedposition

3.Rightmotioncontrollever inneutrallockposition

4.Leftmotioncontrollever

DisengagingtheMowerBlades(PTO)

Thefollowingaretwooptionsfordisengagingthe mowerblades.

•Pushthebladecontrolswitch(PTO)downtothe offposition.

•Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.

TheSafetyInterlockSystem

1.Starttheengine;refertoStartingandStoppingthe Enginein,page.

2.Settheparkingbrake.

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe mowerbladesfromrotatingunless:

•Therightsidemotioncontrolleverismovedtothe center,un-lockedposition.

•Thebladecontrolswitch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostopthe mowerbladesifyoumoveorreleasetherightside motioncontrolleverintotheneutrallockposition.

Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglewilllightupinthecorrespondingsquare.

3.Movetherightsidemotioncontrollevertothe center,un-lockedposition.Thebladesshould

notrotate.

4.Movethemotioncontrolleversforward.The engineshouldkill.

5.Starttheengineandreleasetheparkingbrake.

6.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

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

8.Moveorreleasetherightsidemotioncontrollever intotheneutrallockposition.Thebladesshould

stoprotating.

9.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

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

11.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.

Figure8

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe machineeachtime.

Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately.

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

DrivingForwardorBackward

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

Machinecanspinveryrapidly .Operatormay losecontrolofmachineandcausepersonal injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakein,page.

2.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

StoppingtheMachine

Tostopthemachine,movethemotioncontrolleversto neutral,movetherightsidemotioncontrolleverinto theneutrallockposition,disengagethepowertakeoff (PTO),andturntheignitionkeytooff.

3.Togoforward,slowlypushthemotioncontrol leversforward(Figure9).

Note:Theenginewillkillifthetractioncontrol leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretobothmotion controllevers(Figure9).

Toturn,movethemotioncontrollevertoward neutralinthedirectionyouwanttoturn(Figure9).

Thefartheryoumovethetractioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.

Tostop,pullthemotioncontrolleversbacktothe neutralposition.

Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakein,page.Rememberto removethekeyfromtheignitionswitch.

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

PushingtheMachinebyHand

Theby-passvalvesallowthemachinetobepushedby handwithouttheenginerunning.

Important:Alwayspushthemachinebyhand. Nevertowthemachinebecausehydraulicdamage mayoccur.

Figure9

1.Forward2.Backward

DrivingBackward

1.Movetherightsidemotioncontrollevertothe center,un-lockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure9).

Togostraight,applyequalpressuretobothmotion controllevers(Figure9).

Toturn,releasepressureonthemotioncontrollever towardthedirectionyouwanttoturn(Figure9).

Tostop,pushthemotioncontrolleverstothe neutralposition.

ToPushtheMachine

1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.

2.Opentheby-passvalveonbothpumpsbyturning themcounterclockwise1to2turns.Thisallows hydraulicuidtoby-passthepumpsandthewheels toturn(Figure10).

Note:Rotatetheby-passvalvesamaximumof2 turnssothevalvedoesnotcomeoutofthebody causinguidtorunout.

1.Pumpby-passvalve

Figure11

1.Tractionunittiedownloop

Figure10

SideDischargingorMulching

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

6.Closetheby-passvalves,butdonotovertighten them.

Important:Donotstartoroperatethe machinewiththeby-passvalvesopen.Damage tosystemmayoccur.

TransportingMachines

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

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

theGrass

Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

Withoutthegrassdeector,dischargecover, orcompletegrasscatcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebriswill causeinjuryordeath.

•Neverremovethegrassdeectorfrom themowerbecausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthe powertakeoff(PTO)isoff.Rotatethe ignitionkeytoOff.Alsoremovethekeyand pullthewire(s)offthesparkplug(s).

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(Figure11).

6.Fastenthefrontofthemachinetothetraileror truckwithstraps,chains,cable,orropes.

AdjustingtheHeight-of-Cut

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

Note:Allheight-of-cutpinsneedatleastonespacer ordamagecanoccurtobushingifnoneareused.

Note:Allheight-of-cutpinscanusetwospacers maximum.

1.Selectholeinheight-of-cutpostandnumberof spacerscorrespondingtotheheight-of-cutdesired (Figure12).

2.Usingthelifthandle,raisesideofdeckandremove hairpincotter(Figure12).

3.Addorremovespacersifneededandthenalign holesandinserthairpincotter(Figure12).

Note:Spareheight-of-cutspacersmaybestored onpostsandretainedbyahairpincotter.

Important:Allfourhairpincotterpinsmustbe inthesameholelocationandwiththecorrect numberofspacersforalevelcut.

1.Afteradjustingheight-of-cut,checktheanti-scalp rollerssothatthereisaminimumof3/8inch (10mm)clearanceabovetheground(Figure13, Figure14,Figure15).

2.Ifadjustmentisneeded,removethebolt,washers andnut(Figure13,Figure14,Figure15).

3.Selectaholepositionsotheanti-scalprollersare aminimumof3/8inch(10mm)offtheground (Figure13,Figure14,Figure15).

4.Installtheboltandnut(Figure13,Figure14, Figure15).

Figure12

1.CarrierFrame4.Spacers

2.HairpinCotter5.Frontheight-of-cutpost

3.Backheight-of-cutpost

AdjustingtheAnti-Scalp Rollers

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

Figure13

40inch,48inch,and52inchMowerDecks

1.Mowerdeck

2.Bolt5.Nut

3.Spacer

4.Anti-ScalpRollers

Note:Iftheanti-scalprollersareadjustedtoolowit cancauseexcesswearoftherollers.

Figure14

40inch,48inch,and52inchMowerDecks

1.Mowerdeck4.Bushing

2.Bolt

3.Spacer

1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Toadjustthecamlock,swingtheleveruptoloosen thecamlock(Figure16).

4.Adjustthebafeandcamlockintheslottothe desireddischargeow .

5.Swingtheleverbackovertotightenthebafeand camlock(Figure16).

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

5.Anti-ScalpRollers

6.Nut

Figure15

36inchMowerDeck

1.Mowerdeck

2.Bolt5.Nut

3.Spacer

4.Anti-ScalpRollers

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

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlockand bafetogivethebestqualityofcut.

Figure16

1.Camlock

2.Lever

3.Rotatecamtoincreaseor decreaselockingpressure

4.Slot

PositioningtheFlowBafe

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

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure17).The suggesteduseforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe mower.

Figure17

PositionB

Usethispositionwhenbagging(Figure18).

Figure19

Figure18

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure19).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheToro SFSmower.

UsingtheMid-SizeWeight

Weightsareinstalledoncertainmowerstoimprove balanceandimproveperformance.Theweightscanbe movedorremovedtocreateoptimizedperformance underdifferentmowingconditionsandforoperator preference(Figure20orFigure21).

Thefollowingtableindicatesthepositionoftheweight asinstalledatthefactory.

MowerDeckSizeNumberofweights

36inches1Front

40inches1Front

48inches

52inches1Rear

install

nonenone

Positionofthe

•Anyrearweightmustberemovedwhena Tru–Track

•WhenaTru–Track

Sulkyisinstalled.

Sulkyisinstalledfrontweights areneeded.ContactanAuthorizedServiceDealer forthecorrectquantityofweightsandplacement.

Thefrontendofthemachinecanrapidlyrise upwhenthemowerisremoved.Thiscould causeseriousinjurytoyouorbystanders.

Supporttherearofthemachinewhenremoving themowerfromthecarrierframe.

weight

Figure20

Installingthefrontweight.

1.Bolt3.Weight

2.Washer4.Nut

Figure21

Installingtherearweight.

1.Nut3.Washer

2.Weight4.Bolt

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulicuidlevel.

•Changethehydrauliclter.

•Checkthesafetyinterlocksystem.

•Greasethefrontcasterpivotbearing.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrakes.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.

•Checkthebatteryelectrolytelevel.

•Checkthehydraulicuidlevel.

•Greasethesidebearings.

•GreasethePTObeltidler.

•Greasethemowerdeckbeltidler.

•Checkthepaperaircleanerelement.

•Checkthetirepressure.

•Checkthemowerbelt.

•CheckthePTOdrivebelt.

•Checkthepumpdrivebelt.

•Checkthesparkplugs.

•Adjusttheelectricclutch.

•Checkthehydrauliclines.

•Replacethepaperaircleanerelement.

Every200hours

Every400hours

Beforestorage

Important:Refertoyour

•Changetheoillter.

•Replacethefuellter.

•Changethehydrauliclter.

•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyou doanymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.

Lubrication

GreasingthePTODriveBelt

GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.

HowtoGrease

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

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

5.Wipeupanyexcessgrease.

LubricatingtheBearings

ServiceInterval:Beforeeachuseordaily

IdlerandMowerDeckBelt Idler

ServiceInterval:Every50hours

Every50hours

Greasetheidlerpulleypivots(Figure23orFigure24).

Note:Youwillhavetoremovethecarriercoversto accessthegreasettingforthemowerdeck.

Every400hours

Every50hours

Lubricatethefrontcasterwheelbearingsandfront pivots(Figure22).

Note:Makesuretherearwheelgreasecapsare removedbeforelubricatingrearwheels.

Figure23

40inch,48inch,and52inchMowerDeckshown

Figure22

Figure24

36inchMowerDeckshown

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval/Specication

Foamelement:Cleanitafterevery25operatinghours.

Paperelement:Checkitafterevery50operatinghours. Replaceitafterevery200operatinghoursoryearly, whichevercomesrst.

Inspectthefoamandpaperelementsandreplacethem iftheyaredamagedorexcessivelydirty.

Note:Servicetheaircleanermorefrequently(every fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy .

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Figure25

1.Engine4.Foamelement

2.Cover

3.Wingnut

5.Paperelement

6.Coverknob

3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage (Figure25).

4.Unscrewthecoverknobandremovetheaircleaner cover(Figure25).

5.Removethe2wingnutsandremovetheaircleaner assembly(Figure25).

6.Carefullypullthefoamelementoffthepaper element(Figure25).

CleaningtheFoamAirCleanerElement

ServiceInterval:Every25hours

1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis tornorworn.

ServicingthePaperAirCleaner Element

ServiceInterval:Every50hours

Every200hours

1.Donotcleanthepaperlter.Replaceitafter200 operatinghours(Figure25).

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure25).

2.Placetheaircleanerassemblyontotheaircleaner baseandsecureitwiththe2wingnuts(Figure25).

3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure25).

ServicingtheEngineOil

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Cleanaroundtheoildipstick(Figure27)sothatdirt cannotfallintothellerholeanddamagetheengine.

ServiceInterval/Specication

Checktheengineoilleveldaily.

Changetheengineoilasfollows:

•Aftertherst8operatinghours

•Afterevery100operatinghours

Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.

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

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

Viscosity:Refertothetable(Figure26).

Figure27

1.Oildipstick

5.Unscrewtheoildipstickandwipetheendclean (Figure27).

6.Slidetheoildipstickfullyintothellertube,butdo notthreadontotube(Figure27).

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

Important:Donotoverllthecrankcasewith oilandruntheengine;enginedamagecan result.

2.Fillertube

ChangingtheOil

ServiceInterval:Aftertherst8hours

1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.

Figure26

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain valvetoallowoiltodrain(Figure28).

7.Whenoilhasdrainedcompletely,closethedrain valve.

8.Removethedrainhose(Figure28).

Note:Disposeoftheusedoilatarecyclingcenter.

Figure28

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil intothellertube(Figure27).

10.Checktheoillevel;refertoCheckingtheEngineOil Level.

11.SlowlyaddtheadditionaloiltobringittotheFull mark.

3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure29).

4.Installthereplacementoilltertothelteradapter, turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional3/4turn(Figure29).

5.Fillthecrankcasewiththepropertypeofnewoil; refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine, andcheckforoilleaksaroundtheoillteranddrain valve.

7.Checktheengineoillevelandaddoilifneeded.

8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

Checkthesparkplugsafterevery100operatinghours.

Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstallingthe sparkplugsandagappingtool/feelergaugetocheckand adjusttheairgap.Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

ChangingtheOilFilter

ServiceInterval:Every200hours

Replacetheoillterevery200operatinghoursorevery otheroilchange.

Note:Changetheoilltermorefrequentlywhenthe operatingconditionsareextremelydustyorsandy .

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Removetheoldlter(Figure29).

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Disconnectthewiresfromthesparkplugs (Figure30).

1.Oillter

Figure29

Figure30

2.Adapter

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausing damage.

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

ServiceInterval:Every100hours

FuelSystem Maintenance

DrainingtheFuelTank

1.Lookatthecenterofthesparkplugs(Figure31). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto removecarbondeposits.

Figure31

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouand othersandcandamageproperty.

•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopen area.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.

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

2.Closethefuelshut-offvalveatthefueltank (Figure32).

3.Squeezetheendsofthehoseclamptogether andslideitupthefuellineawayfromfuellter (Figure32).

Important:Alwaysreplacethesparkplugs whenithaswornelectrodes,anoilylmonit, orhascracksintheporcelain.

3.Checkthegapbetweenthecenterandsideelectrodes (Figure31).Bendthesideelectrode(Figure31)if thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.

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

3.Connectthewirestothesparkplugs(Figure31).

4.Pullthefuellineoffthefuellter(Figure32).Open thefuelshut-offvalveandallowthegasolinetodrain intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter becausethefueltankisempty.RefertoReplacing theFuelFilter.

5.Installthefuellineontothefuellter.Slidethehose clampclosetothevalvetosecurethefuelline.

6.Wipeupanyspilledfuel.

Figure32

1.Fuelshut-offvalve2.Clamp

ServicingtheFuelFilter

Figure33

1.Hoseclamp3.Filter

2.Fuelline

Replacethefuellterafterevery200operatinghoursor yearly,whicheveroccursrst.

ReplacingtheFuelFilter

ServiceInterval:Every200hours

Neverinstalladirtylterifitisremovedfromthefuel line.

Note:Notehowthefuellterisinstalledinorderto installthenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Closefuelshut-offvalveatthefueltank(Figure32).

4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure33).

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose tothelter.

7.Openfuelshut-offvalveatfueltank(Figure32).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

ElectricalSystem Maintenance

ServicingtheBattery

Checktheelectrolytelevelinthebatteryevery25hours. Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof fourpartswaterandonepartbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.

Voltage:12V

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.

•AlwaysDisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.

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

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Lifttheblackrubbercoveronthenegativecable. Disconnectthenegativebatterycablefromthe negative(-)batteryterminal(Figure34).

4.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure34).

Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.

RemovingtheBattery

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,do notallowthebatteryterminalstotouchany metalpartsofthemachine.

5.Removethebatteryholddownplate(Figure34)and removethebattery.

InstallingtheBattery

1.Placethebatterontothemachine(Figure34).

2.Securethebatterywiththeholddownplate,j-bolts, andlocknuts.

3.First,installthepositive(red)batterycableto positive(+)batteryterminalwithanut,washerand bolt(Figure34).Slidetherubbercoveroverthepost.

4.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminalwithanut, washerandbolt(Figure34).Slidetherubbercover overthepost.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

Figure35

1.Ventcaps3.Lowerline

2.Upperline

2.Iftheelectrolyteislow ,addtherequiredamountof distilledwater;refertoAddingWatertotheBattery in,page.

AddingWatertotheBattery

Thebesttimetoadddistilledwatertothebatteryisjust beforeyouoperatethemachine.Thisletsthewatermix thoroughlywiththeelectrolytesolution.

1.Removethebatteryfromthemachine;referto RemovingtheBatteryin,page.

Figure34

1.Negativecable7.Positivecable

2.Nut(1/4in.)

3.Nut(5/16in.)

4.Bolt10.Batteryholddown

5.Rubbercover(red)

6.Rubbercover(black)

8.Batteryholddownplate

9.Washer

11.Battery

CheckingtheBatteryElectrolyteLevel

ServiceInterval:Every25hours

Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.

Important:Neverllthebatterywithdistilled waterwhilethebatteryisinstalledinthe machine.Electrolytecouldbespilledonother partsandcausecorrosion.

2.Cleanthetopofthebatterywithapapertowel.

3.Removetheventcapsfromthebattery(Figure35).

4.Slowlypourdistilledwaterintoeachbatterycell untiltheelectrolytelevelisuptotheUpperline (Figure35)onthebatterycase.

Important:Donotoverllthebatterybecause electrolyte(sulfuricacid)cancausesevere corrosionanddamagetothechassis.

5.Waitvetotenminutesafterllingthebatterycells. Adddistilledwater,ifnecessary,untiltheelectrolyte levelisuptotheUpperline(Figure35)onthe batterycase.

6.Reinstallthebatteryventcaps.

ChargingtheBattery

•Fillthebatterywherecleanwaterisalways availableforushingtheskin.

1.Lookatthesideofthebattery.Theelectrolytemust beuptotheupperline(Figure35).Donotallowthe electrolytetofallbelowtheLowerline(Figure35).

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.

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

1.Removethebatteryfromthechassis;referto RemovingtheBattery.

2.Checktheelectrolytelevel;refertoCheckingthe ElectrolyteLevel.

3.Makesurethellercapsareinstalledinbattery. Chargebatteryfor1hourat25to30ampsor6 hoursat4to6amps.

4.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure36).

5.Installthebatteryontothemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

Figure36

1.PositiveBatteryPost

2.NegativeBatteryPost

3.Red(+)ChargerLead

4.Black(-)ChargerLead

ServicingtheFuses

Figure37

1.Redwire3.Fuse,25amp,bladetype

2.Fuse,30amp,bladetype4.Violetwire

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance.Ifafuseblows,checkthecomponent orcircuitforamalfunctionorshort.

1.Removethecoverunderthecontrolpanel.

2.Pulloutonthefusetoremoveorreplaceit (Figure37).

3.Installthecoverunderthecontrolpanel.

Note:Ensurethecorrectsizefuseisinstallwiththe correctwirecolorasshowninFigure37.

DriveSystem Maintenance

AdjustingtheTracking

1.Ifthemachinedoesnottrackstraight,adjustment isrequired.

2.Checkthereartirepressure.RefertoCheckingthe TirePressure.

3.Loosenthewingnutsontherightcontrolrodand rotatetheturnbuckleinorouttoensuretheright sidecontrolleveriscenteredintheneutrallock position.Securetheturnbuckleinpositionwiththe wingnuts(Figure38).

4.Loosenthewingnutsontheleftcontrolrodand rotatetheturnbuckleinorouttochangethetracking. Securetheturnbuckleinpositionwiththewingnuts (Figure38).

5.Checkforpropertracking.Adjusttheleftcontrol rodifachangeisneeded.

Figure39

ReplacingtheCasterWheel ForkBushings

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

1.Raisethecuttingunitsothecasterwheelsareoff theoor,thensupportthefrontofthemowerwith jackstands.

2.Removethelockingpinandspacer(s)fromthetop ofthecasterwheelfork(Figure40).

Figure38

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand threaded)

CheckingtheTirePressure

ServiceInterval:Every50hours

Checkthepressureatthevalvestemafterevery 50operatinghoursormonthly,whicheveroccursrst (Figure39).

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

Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.

Figure40

1.LockingPin

2.Spacers4.Casterwheelfork

3.Pullthecasterwheelforkoutofthemountingtube, leavingthespacer(s)onthebottomofthefork. Rememberthelocationofthespacersoneachfork

3.Carrierframepivottube

toensurecorrectinstallation,andtomaintainalevel deck.

4.Insertapinpunchintothemountingtubeand carefullydriveoutthebushings(Figure41).Clean theinsideofthemountingtube.

Figure41

1.MountingTube2.Bushing

Figure42

1.Locknut

2.WheelBolt5.RollerBearing

3.Bushing

4.SpannerBushing

2.Removeonebushing,thenpullthespannerbushing androllerbearingoutofthewheelhub(Figure42).

5.Greasetheinsideandoutsideofthenewbushings. Useahammerandatplatetocarefullydrivethe bushingsintothepivottubes.

6.Inspectthecasterwheelforkforwearandreplace ifnecessary(Figure40).

7.Slidethecasterwheelforkthroughthebushingsin themountingtube.Replacethespacer(s)ontothe forkandsecurewiththeretainingring(Figure40).

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

8.Greasethettingonthecarrierframepivottubes usingNo.2generalpurposelithiumbaseor molybdenumbasegrease.

ServicingtheCasterWheel andBearings

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

1.Removethelocknutandwheelboltholdingthe casterwheeltothecasterfork(Figure42).

3.Removetheotherbushingfromthewheelhub andcleananygreaseanddirtfromthewheelhub (Figure42).

4.Inspecttherollerbearing,bushings,spannerbushing andinsideofthewheelhubforwear.Replaceany defectiveorwornparts(Figure42).

5.Toassemble,placeonebushingintothewheelhub. Greasetherollerbearingandspannerbushingand slidethemintothewheelhub.Placethesecond bushingintothewheelhub(Figure42).

6.Installthecasterwheelintothecasterforkand securewiththewheelboltandlocknut.Tightenthe locknutuntilthespannerbushingbottomsagainst theinsideofthecasterforks(Figure42).

7.Greasethettingonthecasterwheel.

AdjustingtheElectricClutch

ServiceInterval:Every100hours

Theclutchisadjustabletoensureproperengagement andproperbraking.Checkadjustmentafterevery100 hoursofoperation.

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

2.Tightenthelocknutsuntilthereisslightbindingon thefeelergaugebutitcanbemovedeasilywithinthe airgap(Figure43).

3.Repeatthisfortheremainingslots.

CoolingSystem Maintenance

4.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.

Figure43

1.Adjustingnut3.Feelergauge

2.Slot

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

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

BrakeMaintenance

ServicingtheBrake

Beforeeachuse,checkbrakesonbothalevelsurface andslope.

Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.

CheckingtheParkingBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengagethe PTO.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

Note:Whenthebrakeisengaged,thebrakehandle shouldbeinthe1o’clockposition(Figure44).

9.Tightenthetopandbottomjamnuts(Figure44).

10.Checkthebrakeoperationagain;refertoChecking theBrake.

Figure44

1.Parkingbrakelever (releasedposition)

2.1o’clockposition6.Yoke

3.Haripincotter7.JamNut

4.Lowerbrakelever8.Brakerod

5.Clevispin

AdjustingtheBrakes

Iftheparkingbrakedoesnotholdsecurely,an adjustmentisrequired.

1.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Checkthebrakebeforeyouadjustit;referto CheckingtheBrakes.

4.Releasetheparkingbrake;refertoReleasingthe ParkingBrakein,page.

5.Loosenthetopandbottomjamnuts(Figure44).

6.Toadjustthebrake,removethehairpincotterand clevispinfromthelowerbrakelever(Figure44).

7.Rotatethebrakerodintheyokes.Totightenthe brake,lengthentherodbetweentheyokes.To loosenthebrake,shortentherodbetweentheyokes (Figure44).

Note:Thebrakerodshouldbethreadedintoboth yokesthesamedistance.

8.Securetheyoketolowerbrakeleverwiththehairpin cotterandclevispin(Figure44).

BeltMaintenance

ReplacingtheMowerBelt

ServiceInterval:Every50hours

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

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Unlatchandremovethecarrierframecover.

4.Unlatchandremovethebeltcovers.

5.RemovethePTOdrivebelt.RefertoReplacingthe PTODriveBelt.

6.Disconnecttheidlerarmspringtorelievetensionon theidlerarmandidlerpulley,thenremovetheworn mowerbelt(Figure45orFigure46).

7.Installthenewmowerbeltaroundthetwooutside spindlepulleys,theidlerpulley,andinthelower grooveofthedoublespindlepulley(Figure45or Figure46).

8.Connecttheidlerarmspring(Figure45orFigure46).

9.InstallthePTOdrivebelt.RefertoReplacingthe PTODriveBelt.

10.Adjustthebeltguidean1/8inch(3mm)fromthe belt(Figure45orFigure46).

11.Installthebeltcoversontothecuttingunitand securethelatches.

Figure45

40inch,48inch,and52inchMowerDeckshown

1.Outsidepulley

2.PTODriveBelt

3.Idlerarmspring

4.Mowerdeckbelt

5.Beltguide

6.Centerspindlepulley

12.Installthecarrierframecoverontothecuttingunit andsecurethelatches.

Figure46

36inchMowerDeckshown

1.Mowerdeckbelt4.Idlerarmspring

2.PTODriveBelt

3.Drivebeltpulley

5.Drivebeltpulley

ReplacingthePTODriveBelt

ServiceInterval:Every50hours

Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks

aresignsofaworndrivebelt.Replacethedrivebeltif anyoftheseconditionsareevident.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Unlatchandremovethecarrierframecover.

4.Unlatchandremovethebeltcovers.

5.Removetheheatshieldfromtheenginedeckand carrierframe.

6.Rollthebeltoffofthecenterpulleyonthemower deck(Figure47).RefertoFigure48torollthebelt offleftpulleyfora36inchmowerdeck.Usecaution whenremovingthebeltastensionwillincrease becauseofthespringloadedidlerpulley.

7.Removethebeltfromtheenginepulleyandthe springloadedidlerpulley(Figure47).Referto Figure48toremovethebeltfromthe36inchmower deckpulleys.

Figure47

40inch,48inch,and52inchMowerDeckshown

1.PTOdrivebeltguide4.PTOengagementpulley

2.PTOdriveBelt5.PTOdrivebeltidlerpulley

3.Idlerspring

6.Centerspindlepulley

8.Installthenewbeltontotheenginepulleyandspring loadedidlerpulley(Figure47).

9.Rollthebeltontothecenterpulleyonthemower deck(Figure47).Usecautionwheninstallthebelt astensionwillincreasebecauseofthespringloaded idlerpulley.RefertoFigure48torollthenewbelt ontotheleftpulleyfora36inchmowerdeck.

10.Installtheheatshieldtotheenginedeckandcarrier frame.

11.Adjustthebeltguidean1/8inch(3mm)fromthe beltfor40,48and52inchmowerdecks(Figure47).

12.Installthebeltcoversontothecuttingunitand securethelatches.

13.Installthecarrierframecoverontothecarrierframe andsecurethelatches.

1.Mowerdeckbelt

2.PTODriveBelt

3.Idlerarmandspring

Figure48

36inchMowerDeckshown

4.Clutchpulley

5.Idlerpulley

AdjustingthePTODriveBelt IdlerSpringAnchor

ThepositionofthePTOidlercanbeadjustedto increaseordecreasebelttension.

UseFigure49fortheidlerpositionoptions.

Figure49

1.PTOdrivebeltidlerpulley4.Mosttensionforwornbelts

2.PTOdriveBelt5.Mediumtensionfornormal

3.Idlerspring

beltconditions

6.Leasttensionfornewbelts

Figure50

1.Hydraulicpumps

2.Idlerpulley6.Pivotbolt

3.Clutchretainer

4.Tensionspring8.Pumpdrivebelt

5.Clutchwireconnector

7.Drivepulley

7.Unhooktheidlerspringfromtheframe(Figure50).

ReplacingthePumpDriveBelt

ServiceInterval:Every50hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.RemovePTOdrivebelt.RefertoReplacingthe PTODriveBeltinthe,page.

4.Raisethemachineandsupportitwithjackstands.

5.Disconnecttheclutchwireconnectorfromthewire harness.

6.Disconnecttheclutchretainerfromtheenginedeck (Figure50).

8.Installthenewbeltaroundclutchandthetwodrive pulleys.

9.Installtheidlerspringbetweenidlerarmandframe bracket(Figure50).

10.Installtheclutchretainertotheenginedeck (Figure50).

11.Connecttheclutchwireconnectortothewire harness.

12.InstallthePTOdrivebelt.

ControlsSystem Maintenance

AdjustingtheMotionControl HandlePositions

AdjustingtheRightSideMotionControl Lever

Ifthemotioncontrolleversdonotalignhorizontally, adjusttherightsidemotioncontrollever.

Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.

1.DisengagethePTO,movetherightsidemotion controllevertotheneutralpositionandsetthe parkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pushtherightmotioncontrolleverdownoutof lockedneutralposition(Figure51).

4.Checkifitalignshorizontallywiththeleftmotion controllever(Figure51).

Figure51

1.Leftmotioncontrollever3.Checkthehorizontal

2.Rightmotioncontrollever inneutrallockedposition

alignmenthere

4.Rightmotioncontrollever

Figure52

1.Cam

2.Nutandbolt

3.Wingnut

4.Turnbuckle

5.Switchscrews

9.Afterthecamisadjusted,theleverswitchneedsto bechecked.

10.Checkthegapbetweenthecontrolleverandswitch asshowninFigure53.Thegapneedstobean1/8 inch(3mm).

11.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch.

12.Tightenthescrewsandinstallthecoverunderthe controlpanel.

5.Toadjusttherightmotioncontrolleverhorizontally, thecamneedstobeadjusted.

6.Removethecoverunderthecontrolpanel.

7.Loosenthenutandboltholdingthecam(Figure52).

8.Adjustthecamuntilitalignswiththeleftmotion controlleverandtightenthenutandboltforthe cam.

1.Rightsidemotioncontrol leverpivotshownunder controls

2.Rightsidemotioncontrol lever

Figure53

3.1/8inch(3mm)gap

4.Switch

neededbetweenswitch andcontrollever

Figure54

1.Leftmotioncontrollever

2.Rightmotioncontrollever4.Alignthecontrollevers

3.Neutrallockedposition

fronttobackhere

AdjustingtheNeutralPostionforthe MotionControlLevers

Important:Ensurethetrackingofthemoweris

correctafteradjustingthemotioncontrollevers. Afteradjustingthetracking,themotioncontrol leversmaynotaligntheexactlyfronttoback (Figure54).

Ifthemotioncontrolleversdonotalignfronttoback, ortherightsidecontrolleverdoesnotmoveeasilyinto theneutrallockposition,adjustmentisrequired.Adjust eachleverandcontrolrodseparately.

Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.

1.Afterthehorizontalalignmentisnished,checkthe fronttobackalignment(Figure54).

2.Loosenthewingnutsontherightcontrolrodand rotatetheturnbuckleinorouttoensuretheright sidecontrolleveriscenteredintheneutrallock position.Securetheturnbuckleinpositionwiththe wingnuts(Figure55).

3.Loosenthewingnutsontheleftcontrolrodand rotatetheturnbuckleinorouttochangethetracking. Securetheturnbuckleinpositionwiththewingnuts (Figure55).

Figure55

1.Turnbuckle

2.Bottomwingnut

3.Topwingnut(lefthand

4.Checkforpropertracking.Adjusttheleftcontrol rodifachangeisneeded.RefertoAdjustingthe TrackingintheOperationSection.

threaded)

HydraulicSystem Maintenance

5.Removecapfromllerneck.Lookinsidetocheck theuidlevelinthereservoir.(Figure56).

6.Adduidtothereservoiruntilitreachesthecold levelofthebafe.

ServicingtheHydraulic System

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every25hours

Checkthehydraulicuidlevelasfollows:

•Checkthehydraulicuidlevelbeforeengineisrst started.

•Checkthehydraulicuidlevelafterrst8operating hours.

•Checkthehydraulicuidlevelafterevery25 operatinghours.

FluidType:Mobil115W -50syntheticmotoroilor equivalentsyntheticoil.

Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.

HydraulicSystemOilCapacity:67oz.(2.0l)

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

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoff theengine.

3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulic tank(Figure56).

7.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmuid. RefertoStartingandStoppingtheEngine.

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

Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidiswarm(Figure56).

9.Installcaponllerneck.

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

Figure56

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

ReplacingtheHydraulicFilter

ServiceInterval:Aftertherst8hours

Every200hours

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbefore performinganymaintenancetothehydraulic system.

Changethehydrauliclterasfollows:

•Aftertherst8operatinghours.

•Afterevery200operatinghoursoryearlybefore storage.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.

3.Removehydraulicreservoircapandtemporarily coveropeningwithaplasticbagandrubberbandto preventallhydraulicuidfromdrainingout.

4.Locatethelterunderthefueltankandplacedrain panunderlter(Figure57).

Figure58

1.Hydrauliclter

2.Gasket

3.Adapter

10.Cleanupanyspilleduid.

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

Important:Useoilspeciedorequivalent. Otheruidscouldcausesystemdamage.

12.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.

13.Rechecklevelandadduid,ifrequired.Donot

overll.

Figure57

5.Removetheoldlterandwipethelteradapter gasketsurfaceclean(Figure58).

6.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.

7.Installreplacementhydrauliclterontothelter adapter.Donottighten.

8.Removeplasticbagfromreservoiropeningand allowltertollwithhydraulicuid.

9.Whenthehydrauliclterisfull,turntheoillter clockwiseuntiltherubbergasketcontactsthelter adapter,thentightenthelteranadditional1/2turn (Figure58).

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemifuidischangedorafter workisperformedonthesystem.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsofftheground.

4.Starttheengineandmovethethrottlecontroltoidle position.

Ifthedrivewheeldoesnotrotate,itispossibleto assistthepurgingofthesystembycarefullyrotating thetireintheforwarddirection.

5.Checkthehydraulicuidlevelasitdropsadduid asrequiredtomaintaintheproperlevel.

6.Repeatthisprocedurefortheoppositewheel.

7.Thoroughlycleantheareaaroundeachofthecharge pumphousings.

CheckingtheHydraulicLines

ServiceInterval:Every100hours

Afterevery100operatinghours,checkhydraulic linesandhosesforleaks,loosettings,kinkedlines, loosemountingsupports,wear,weatherandchemical deterioration.Makenecessaryrepairsbeforeoperating.

MowerDeck Maintenance

Note:Keepareasaroundhydraulicsystemcleanfrom grassanddebrisbuildup.

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.

Awornordamagedbladecanbreak,anda pieceofthebladecouldbethrownintothe operator’sorbystander’sarea,resultingin seriouspersonalinjuryordeath.

•Inspectthebladesperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagetheblades andsettheparkingbrake.Turntheignitionkeytooff. Removethekeyanddisconnectthesparkplugwires fromthesparkplugs.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

Inspectthebladesevery8hours.

1.Inspectthecuttingedges(Figure59).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

Figure60

40inch,48inch,and52inchMowerDeckshown

Figure59

1.CuttingEdge3.Wear/slotformingin curvedarea

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea (Figure59).Ifyounoticeanycracks,wear,ora slotforminginthisarea(item3inFigure59), immediatelyinstallanewblade.

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromalevelsurfacetothe cuttingedge,positionA,oftheblades(Figure60 ).Notethisdimension.For36inchmowerdecks useFigure61.

1.Measureherefromblade tohardsurface

36inchMowerDeckshown

2.PositionA

Figure61

4.Rotatetheoppositeendsofthebladesforward.

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

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

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

1.Holdthebladeendusingaragorthickly-padded glove.

2.For40and48inchmowerdecks,removetheblade bolt,curvedwasher,andbladefromthespindle shaft(Figure62).

Figure63

36inchand52inchMowerDecks

1.SailAreaofBlade4.Curvedwasher

2.Blade5.BladeBolt

3.Bladestiffener

Figure62

40inchand48inchMowerDecks

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

3.For36and52inchmowerdecks,removetheblade bolt,curvedwasher,bladestiffener,andbladefrom thespindleshaft(Figure63).

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure64).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

Figure64

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure65).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure62).Repeatthis procedureuntilthebladeisbalanced.

Figure65

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure62).

Important:Thesailpartoftheblademustbe pointingupward,towardtheinsideofthemower toensurepropercutting(Figure62).

2.For40inchand48inchmowerdecks,installthe blade,curvedwasher,andbladebolt(Figure62).

3.For36inchand52inchmowerdecks,installthe blade,stiffener,curvedwasher,andbladebolt (Figure63).

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

FrameSetUp

CheckingtheCarrierFrameandEngine DeckAlignment

Note:MisalignmentcancauseexcesswearonthePTO

drivebelt.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Placealongstraightedgeontopoftheenginedeck asshowninFigure66.

4.Atthecarrierframecrosschannel,measurethe heightatlocationA(Figure66).Thismeasurement mustbe1-5/16inch(33mm),plusorminusa1/4 inch(6mm).

5.IftheheightatlocationAisnotcorrect,adjustment isneeded.

6.Loosenthecarrierframemountingboltsonboth sidesofthemachine(Figure66).

CorrectingtheMowerQuality ofCut

Ifonedeckbladecutslowerthantheother,correctas follows.

Note:Tireairpressureiscriticalintheseprocedures. Makesurealltireshavecorrectpressure.

1.DisengagethePTOandsettheparkingbrake.

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

3.Adjustthetirepressureinthereartiresto specications;referto,page.

4.Checkthatthebladesandspindleshaftsarenot bent.RefertoCheckingforBentBlades.

5.Settheheight-of-cuttothe4inch(101.6mm) position.RefertoAdjustingtheHeight-Of-Cutin, page.

7.Alignthecarrierframeandenginedecktomatch 1-5/16inch(33mm),plusorminusa1/4inch(6 mm)atlocationA(Figure66).

8.Tightenthecarrierframemountingboltsonboth sidesofthemachine.

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

Figure66

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

2.Topofenginedeck5.Straightedge

3.Carrierframemounting bolts

(33mm)±1/4inch(6mm)

6.Carrierframecross channel

CheckingtheEngineDeckHeight

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Adjustthetirepressureinthereartiresto specications;referto,page.

4.MeasureenginedeckheightatlocationA(Figure67).

5.MeasureenginedeckheightatlocationB(Figure67).

6.IftheheightatlocationAandBarenotthesame, changetirepressureslightlytomakethemthesame.

Figure67

1.Backviewofmachine

2.Topofenginedeck4.Sameheightatlocations

3.Tires

AandB

CheckingtheCarrierFrame Front-to-RearPitch

Figure68

1.CarrierFrame

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

3.24inches(61cm)6.Casterspacers

4.HeightatlocationsAand

5.CasterWheel

2.MeasurecarrierframeheightatlocationA (Figure68).

3.MeasurecarrierframeheightatlocationB (Figure68).

4.TheheightatlocationAmustbean1/8-3/8inch(3 mm-10mm)lowerthanlocationB(Figure68).

5.Ifthecarrierframeisnotcorrect,movecaster spacerstomakeitan1/8-3/8inch(3-10mm)pitch (Figure68).Movespacersfromtoporbottomto makethecorrectpitch.

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

Thecarrierframemusthaveapitchbetween1/8inch (3mm)to3/8inch(9mm)overthelengthof24inches (61cm)onthecarrierframe(Figure68).

1.Measureout24inches(61cm)onthecarrierframe (Figure68).

CheckingtheCarrierFrame Side-to-SideHeight

Thecarrierframeneedstobeparallelside-to-sidefrom theground.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Adjustthetirepressureinthereartiresto specications;referto,page.

4.MeasurecarrierframeheightatlocationA (Figure69).

5.MeasurecarrierframeheightatlocationB (Figure69).

6.Ifthecarrierframeheightisnotthesamemove spacersfromtoporbottomofcasterwheel,to makeitlevel.Thetirepressuremayalsobeadjusted slightlytomakeitlevel.

Figure69

1.CasterWheel4.Sameheightatlocations AandB

2.CarrierFrame5.Casterspacers

3.Frontheight-of-cutpins

Figure71

36inchMowerDeckshown

ChangingtheMowerDeck

Front-to-RearPitch CheckingtheMowerDeck Front-to-RearPitch

1.Adjustthetirepressureinthereartiresto

specications;referto,page.

2.Positiononebladefront-to-rear.MeasureatAand

Blocationsfromalevelsurfacetothecuttingedge ofthebladetips(Figure70orFigure71).For36 inchmowerdecksuseFigure71.

3.Themowerbladeshouldbea1/4inch(6mm)lower

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

Changingthefront-to-rearpitchisdonebyadjustingthe

frontheight-of-cutposts.

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

Figure72

1.CasterWheel

2.CarrierFrame

3.Frontheight-of-cutpins

4.Jamnut

5.Balljoint

Figure70

40inch,48inch,and52inchMowerDeckshown

1.MeasurebladeatpointsA andB

2.Measurefromalevel

2.Toraisethefrontofthedeck,loosenjamnutand rotatethefrontpinclockwise(Figure72).

3.Tolowerthefrontofthedeck,loosenjamnutand rotatethefrontpincounterclockwise(Figure72).

4.Positionthebladesfront-to-rear.MeasureatCand Dlocations(Figure70)fromalevelsurfacetothe

surface

cuttingedgeoftheblades.

5.Checktheside-to-sidelevelingofthecuttingunit.

6.Tightenthejamnuts(Figure72).

CheckingtheMowerDeck Side-to-SideHeight

1.Adjustthereartirepressuretospecications;refer to,page.

2.Positionthebladesside-to-side.MeasureatCand Dlocationsfromalevelsurfacetothecuttingedge ofbladetips(Figure73).For36inchmowerdecks useFigure74.

2.Adjustthecasterspacer.

3.Recheckthefront-to-rearpitchandsidetoside levelingofthecuttingunit.

MatchingHeightofCut

1.Checkthereartirepressure.

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

3.Withthemachineonlevelsurface,positiononeblade front-to-rear.MeasureatAandfromlevelsurfaceto thecuttingedgeofthebladetips(Figure75).For36 inchmowerdecksuseFigure76.

Figure73

40inch,48inch,and52inchMowerDeckshown

1.Measurefromalevel surface

36inchMowerDeckshown

2.MeasurebladeatpointsC andD

Figure74

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

Figure75

40inch,48inch,and52inchMowerDeckshown

1.Measurefromalevel surface

2.MeasurebladeatpointA

ChangingtheMowerDeck Side-to-SideHeight

Changingtheside-to-sideheightisdonebyadjustingthe reartirepressureandcasterspacers.

1.Changethereartirepressure.Dothistothe correspondingsidethatneedsadjustment.

Figure76

36inchMowerDeckshown

4.Themeasurementshouldbe4inch(101.6mm).

5.Ifitdoesnotmeasurecorrectly:

A.Adjustthereartirepressure.

B.Adjustthecasterforkspacers.

C.Adjustthefrontmowerdecksupportpins.

6.Checkthecarrierframefront-to-rearpitch.

ReplacingtheGrassDeector

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.

Neveroperatethelawnmowerunlessyouinstall acoverplate,amulchplate,grassdeectoror bagger.

1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure77). Removedamagedorworngrassdeector.

Note:MakesuretheLendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown inFigure77.

3.Installboltandnut.PlacetheJhookendofspring aroundgrassdeector(Figure77).

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

Figure77

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place behinddeckedgebefore installingbolt

2.Placespacerandspringontograssdeector.Place theLendofspringbehinddeckedge.

Cleaning

Storage

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethefrontofthemachineandusejackstandsto supportthemower.

WasteDisposal

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

CleaningandStorage

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

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

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

3.Checkthebrake;refertoServicingtheBrakein, page.

4.Servicetheaircleaner;refertoServicingtheAir Cleanerin,page.

5.Greasethemachine;refertoGreasingand Lubricationin,page.

6.Changetheengineoil;refertoServicingtheEngine in,page.

7.Checkthetirepressure;refertoCheckingtheTire Pressurein,page.

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefuel

tank;refertoServicingtheFuelTankin,page, oroperateengineuntilitstops.

D.Restartengineandrununtilitstops.Repeat,on

Chokeuntilenginewillnotrestart.

E.Disposeoffuelproperly .Recycleasperlocal

codes.

Note:Donotstorestabilizer/conditioned gasolineover90days.

9.Removethesparkplug(s)andcheckitscondition; refertoServicingtheSparkPlugin,page.With thesparkplug(s)removedfromtheengine,pour twotablespoonsofengineoilintothesparkplug hole.Nowusethestartertocranktheengineand distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.

11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

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

Troubleshooting

Problem

Enginewillnotstart,startshard,orfails tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Fueltankisempty.

2.Chokeisnoton.

3.Aircleanerisdirty.

4.Sparkplugwireislooseor disconnected.

5.Sparkplugispitted,fouled,orthegap isincorrect.

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

7.Dirt,water,orstalefuelisinthefuel system.

8.Thegapbetweentheneutralswitch boltandtheswitchisnotcorrect.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesunder theengineblowerhousingareplugged.

5.Sparkplugispitted,fouled,orthegap isincorrect.

6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

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

8.Dirt,water,orstalefuelisinthefuel system.

1.Fillfueltankwithgasoline.

2.Movethechokelevertochokeposition.

3.Servicetheaircleanerelement.

4.Installwireonsparkplug.

5.Installanew,correctlygappedspark plug.

7.ContactanAuthorizedServiceDealer.

8.ContactanAuthorizedServiceDealer.

2.Servicetheaircleaner.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

5.Installanew,correctlygappedspark plug.

8.ContactanAuthorizedServiceDealer.

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesunder theengineblowerhousingareplugged.

1.Hydraulicoilreservoirlow.1.Addhydraulicoiltothereservoir.

2.Airinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.

3.Pumpdrivebeltslipping.3.Replacethepumpdrivebelt.

4.Pumpdrivebeltidlerspringmissing.4.Replacethepumpdrivebeltidler

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley ,or bladepulley .

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

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

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

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

4.Mowerpitchiswrong.

5.Undersideofmowerisdirty .5.Cleantheundersideofthemower.

6.Tirepressureisnotcorrect.6.Adjustthetirepressure.

7.Bladespindlebent.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

spring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

4.Adjustthefront-to-rearpitch.

7.ContactanAuthorizedServiceDealer.

Problem

PossibleCauseCorrectiveAction

Bladesdonotrotate.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.

5.Brokenormissingidlerspring.5.Replacethespring.

6.Electricclutchoutofadjustment.

7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer.

8.Damagedelectricclutch.

9.Safetyinterlocksystempreventsblade rotation.

10.PTOswitchisfaulty.10.ContactanAuthorizedServiceDealer .

1.Checkthebelttension.

2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.

4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.

6.Adjusttheclutchairgap.

8.ContactanAuthorizedServiceDealer.

9.ContactanAuthorizedServiceDealer.

Schematics

HydraulicSchematic(Rev.A)

ElectricalSchematic(Rev.A)

Notes:

The Toro Total Coverage Guarantee

A Limited Warranty (see warranty periods below)

Landscape

Contractor

Equipment (LCE)

The Toro Company and its afﬁliate, Toro Warranty Company, pursuant to an

Conditions and Products Covered

agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.

The following warranty time periods apply from the date of purchase by the original owner:

Product Warranty Period

Mid-Size Walk-Behind Mowers 2 years** GrandStand

•

Z Master

•

Z Master® G3 Mowers

•

Batteries (for above units)

Mowers Engine Frame

Z300, Z400, Z500 Mowers Engine Frames

Engine Frame

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

4 years or 1,200 hours* 2 years** Lifetime (original owner only)***

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

1 year

Attachments (for above units) 1 year

*Whichever occurs ﬁ rst. **Some engines used on Toro LCE Products are warranted by the engine manufacturer. ***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form the tractor structure that other components such as the engine are secured to, cracks or breaks in normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame failure due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.

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

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our web site at www.Toro.com. You may also call the numbers listed in item #3 to use the 24-hour Toro Dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. The dealer will diagnose the problem and determine if it is covered under warranty.

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

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-865-5676 (U.S. Customers) 888-865-5691 (Canada customers)

You must maintain your Toro Product by following the maintenance

Owner Responsibilities

procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system and engine warranty coverage on some products. This express warranty does not cover:

Cost of regular maintenance service or parts, such as ﬁ lters, fuel,

• lubricants, tune-up parts, blade sharpening, brake and clutch adjustments. Any product or part which has been altered or misused or required

• replacement or repair due to normal wear, accidents, or lack of proper maintenance. Repairs necessary due to improper fuel, contaminants in the fuel system,

• or failure to properly prepare the fuel system prior to any period of nonuse over three months.

Pickup and delivery charges.

•

General Conditions

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

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

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

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

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

Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee

Countries Other than the United States or Canada

policies for your country, province, or state. If for any reason you are dissatisﬁ ed with your Distributor’s service or have difﬁ culty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part Number 374-0037 Rev. H

Toro 30494, 30496, 30498, 30499 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual