Toro 30518, 30519 Operator's Manual

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Page 1

Form No. 3352–525 Rev B

Mid–Size Mower

ProLine Gear 13hp with 32in or 36in Side Discharge Mower

Model No. 30518—Serial No. 250000001 and Up Model No. 30519—Serial No. 250000001 and Up

Operator’s Manual

Original Instructions (EN)

Page 2

Warning

CALIFORNIA

Proposition 65 Warning

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

Important This engine is not equipped with a spark

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

This spark ignition system complies with Canadian ICES-002.

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

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

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

Contents

Page

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

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

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

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

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

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

Gasoline and Oil 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 11. . . . . . . . . . . . . . . . . . . . .

Using Fuel Stabilizer/Conditioner 11. . . . . . . . . . . . .

Filling the Fuel Tank 11. . . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 11. . . . . . . . . . . . . . .

Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Front Casters 12. . . . . . . . . . . . . . . . . .

Installing the Upper Handle and Wire Harness 13. . .

Installing the Control Rods 14. . . . . . . . . . . . . . . . . .

Adjusting the Parking Brakes 14. . . . . . . . . . . . . . . . .

Connecting the Throttle Cable 15. . . . . . . . . . . . . . . .

Connecting the Choke Cable 15. . . . . . . . . . . . . . . . .

Installing the Blade Control (PTO) Rod 15. . . . . . . .

Installing the Shift Lever 15. . . . . . . . . . . . . . . . . . . .

Mounting the Fuel Tank 16. . . . . . . . . . . . . . . . . . . . .

Installing the Muffler 17. . . . . . . . . . . . . . . . . . . . . . .

Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating the Parking Brake and Neutral Locks 18. .

Starting the Engine 19. . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Engine 19. . . . . . . . . . . . . . . . . . . . . . . .

Operating the Blade Control (PTO) Lever 19. . . . . . .

Understanding the Safety Interlock System 19. . . . . .

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

Stopping the Mower 20. . . . . . . . . . . . . . . . . . . . . . . .

Transporting the Mower 21. . . . . . . . . . . . . . . . . . . . .

Side Discharging or Mulching the Grass 21. . . . . . . .

Adjusting the Wheel Drive Tension 21. . . . . . . . . . . .

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

Height-of-Cut Chart 24. . . . . . . . . . . . . . . . . . . . . . . .

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

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

Servicing the Cutting Blades 26. . . . . . . . . . . . . . . . .

Servicing the Air Cleaner 27. . . . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 28. . . . . . . . . . . . . . . . . . . .

Servicing the Spark Plugs 30. . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 31. . . . . . . . . . . . . . . . .

Checking the Tire Pressure 31. . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 31. . . . . . . . . . . . . . . . .

Greasing and Lubrication 31. . . . . . . . . . . . . . . . . . . .

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

Draining the Fuel Tank 33

Servicing the Fuel Filter 33. . . . . . . . . . . . . . . . . . . . .

Checking the Belts 33. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Drive Belt 33. . . . . . . . . . . . . . . . . . . .

Replacing the Traction Belt 34. . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 34. . . . . . . . . . . . . . . . . . .

Adjusting the Mower Belt Tension 35. . . . . . . . . . . .

Adjusting the Blade Brake 36. . . . . . . . . . . . . . . . . . .

Adjusting the Grass/Mud Scraper 36. . . . . . . . . . . . .

Replacing the Grass Deflector 36. . . . . . . . . . . . . . . .

Wiring Diagram 38. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 39. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Page

W 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Page 3

Introduction

Safety

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

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

m-3775

Figure 1

1. Location of the model and serial numbers

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

Model No.

Serial No.

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

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

Note: The addition of attachments made by other

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

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

symbol, which means

Safe Operating Practices

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

Training

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

If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

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

• The owner/user can prevent and is responsible for

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

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

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

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

This manual uses two other words to highlight information.

Important calls attention to special mechanical

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

Preparation

• Evaluate the terrain to determine what accessories and

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

• Wear appropriate clothing including hard hat, safety

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

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

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

Page 4

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use only an approved container.

• Never remove gas cap or add fuel with engine

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

• Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety switches

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

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

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

engaged before starting engine.

• Be sure of your footing while using pedestrian

controlled equipment, especially when backing up. Walk, don’t run. Never operate on wet grass. Reduced footing could cause slipping.

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

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

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not

mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs.

• Use care when loading or unloading the machine into or

from a trailer or truck.

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

or other objects that may obscure vision.

Maintenance and storage

• Disengage drives, set parking brake, stop engine and

disconnect spark plug wire. Wait for all movement to

stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting unit, drives,

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

or fuel spillage.

• Let engine cool before storing and do not store near

flame.

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

fuel near flames or drain indoors.

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

allow untrained personnel to service machine.

• Slow down and use caution when making turns and

when changing directions on slopes.

• Never raise deck with the blades running.

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

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

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed

the engine.

• Stop on level ground, disengage drives, engage parking

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

• Stop equipment and inspect blades after striking objects

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

• Keep hands and feet away from the cutting unit.

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

a clear path.

• Keep pets and bystanders away.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored

energy.

• Remove spark plug wire before making any repairs.

• Use care when checking blades. Wrap the blades or

wear gloves, and use caution when servicing them.

Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine

running.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged

decals.

Toro Mower Safety

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

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

Page 5

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

General Operation

• Allow only responsible adults who are familiar with the

instructions to operate the machine.

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

Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing.

• Be aware of the mower discharge direction and do not

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

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Turn off blades when not mowing.

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

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

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts which may

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

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

traction, disengage the blades.

• Mow slopes side-to-side.

DO NOT

• Do not mow slopes greater than 15 degrees.

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

and gradually downhill, if possible.

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

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

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

sliding.

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

bags could cause loss of control of the machine.

• Do not mow up and down slopes.

Service

• Never store the machine or fuel container inside where

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

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check safety systems

for proper operation before each use.

• Use only genuine replacement parts to ensure that

original standards are maintained.

• Check brake operation frequently. Adjust and service as

required.

• Use only Toro-approved attachments. Warranty may be

voided if used with unapproved attachments.

Slope Operation

All slopes and ramps require extra caution. If you feel uneasy on a slope, do not mow it.

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

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

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

on the slope.

• Use extra care with grass catchers or other attachments.

These can change the stability of the machine.

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

make sudden changes in speed or direction.

Page 6

Page 7

Slope Chart

Example: Compare

slope with folded

edge.

Fold along appropriate line

Align this edge with a vertical surface

(Tree, Building, Fence post, pole, etc.)

Page 8

Page 9

Safety and Instruction Decals

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

1-403005

66-1340

1. Hot surface

95-2814

93-1122

63-8440

95-5537

1. Read the Operator’s Manual for instructions on operating the cutting blade

2. Push forward to engage

3. Pull back to disengage

Page 10

98-0776

98-3296

1. Reverse

2. Neutral

105-4104

3. Transmission speeds

105-4111

98-5130

1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 75–80 ft.-lb.(102–106 N⋅m).

1. Park

2. Drive

3. Neutral

4. Engine—stop

106-2733

1. Fast

2. Continuous variable setting

3. Slow

106-2737

5. Engine—run 6. Warning—wear hearing protection.

Page 11

Gasoline and Oil

Warning

Recommended Gasoline

Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Use leaded regular gasoline if unleaded regular is not available.

Important Never use methanol, gasoline containing

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

Danger

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

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

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

• Never fill the fuel tank inside an enclosed trailer.

• Do not fill the fuel tank completely full. Add

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

• Never smoke when handling gasoline, and stay

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

• Store gasoline in an approved container and

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

• Always place gasoline containers on the ground

and away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

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

• When practical, remove gas-powered equipment

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

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used, keep

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

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

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and fuel tank or

conditioner opening.

• Keep gasoline away from eyes and skin.

Using Fuel Stabilizer/Conditioner

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

• Keeps gasoline fresh during storage of 90 days or less

(For longer storage, drain the fuel tank.)

• Cleans the engine while it runs

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

which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol.

Add the correct amount of fuel stabilizer/conditioner to the gasoline.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

1. Stop the engine, wait for all moving parts to stop, and set the parking brakes.

2. Clean around the fuel tank cap and remove the cap. Add unleaded regular gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows the gasoline to expand. Do not fill the fuel tank completely full.

3. Install the fuel tank cap securely. Wipe up any spilled gasoline.

Checking the Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 29.

Page 12

Setup

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

Loose Parts

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

DESCRIPTION

Caster assemblies

Bolt, 3/8 x 3/4 inch

Flange nut, 3/8 inch

Upper handle

Flanged bolt, 3/8 x 1 inch

Flanged nut, 3/8 inch

Wire tie

Clevis pin

Washer

Hairpin cotter

Fuel tank

Bolt, 5/16 x 3/4 inch

Lock washer, 5/16 inch

Locknut

Washer, 5/16 inch

Stud

QTY. USE

Installing the front casters

Installing the upper handle and wire harness

Installing the control rods

Installing the fuel tank

Spring

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Video

Registration card 1 Fill out and return to Toro

Review before operating machine

Installing the Front Casters

1. Align the casters with the holes on the top and front of the mower, and insert 8 bolts (3/8 x 3/4 inch) through the mower. Secure the casters with 8 flange nuts (3/8 inch) below the mower (Fig. 2).

Page 13

1. Front caster

2. Bolt, 3/8 x 3/4 inch

Figure 2

3. Select the low, middle, or high position for the lower mounting hole according to the operator’s height (Fig. 3).

4. Secure each side of the handle to the rear frame (using the lower mounting hole) with a flange bolt (3/8 in. x 1 in.) and a flange nut (Fig. 3).

Note: If you change the handle position, you must readjust the control rods and brakes.

5. Route the wire harness along the inside of the left handle and under the control panel (Fig. 16).

m–3777

6. Connect the right-angled insulated terminals to the switch (Fig. 4).

3. Flange nut, 3/8 inch

Note: Tighten the lower bolts first to pull each caster against the front, then tighten the top bolts.

2. Torque the bolts to 30–35 ft.-lb. (40–47 NSm).

Installing the Upper Handle and Wire Harness

1. Align the upper handle mounting holes with the mounting holes in the rear frame (Fig. 3).

Figure 3

1. Handle

2. Rear frame

3. Flange bolt, 3/8 x 1 inch

4. Flange nut, 3/8 inch

5. Upper mounting hole

m-5382

6. Lower mounting holes

7. Low position

8. Middle position

9. High position

m–5906

Figure 4

1. Switch 2. Right-angled insulated terminals

7. Install the harness connector to the ignition switch

(Fig. 4).

m–8247

2. Secure each side of the handle to the rear frame (using the upper mounting hole) with a flange bolt (3/8 in. x 1 in.) and a flange nut (Fig. 3).

1. Ignition switch

2. Harness connector

Figure 5

3. Handle

Page 14

8. Use the wire ties to secure the wire harness and the throttle cable to the left handle and away from the blade control (PTO) lever (Fig. 16).

Installing the Control Rods

1. Thread the rod fittings an equal distance onto each control rod (Fig. 6).

m-5385

Figure 6

1. Control rod

2. Idler bracket

3. Hairpin cotter

4. Clevis pin

5. Washer

6. Rod fitting

2. Install the rod fittings with clevis pins into the holes in the idler brackets (Fig. 6). Secure the rod fittings with washers and hairpin cotters (Fig. 6).

Note: Install each rod fitting so that the clevis pin is above the control rod as shown in Figure 6.

3. Place the clevis pin into the upper part of the control rods, drive lever and neutral/parking brake locks (Fig. 7).

4. Install the hairpin cotter pins between the drive levers and neutral/parking brake locks and into the clevis pins (Fig. 7).

m–7669

Figure 7

1. Control rod

2. Drive lever

3. Hairpin cotter

4. Clevis pin

5. Handle

6. Neutral/parking brake lock

5. Adjust the control rod length by threading the rod in or out of the rod fitting until there is a 3/16 to 1/4 inch (5 to 6 mm) clearance between the control rod and the bottom of the neutral/parking brake lock (Fig. 8).

m-5387

Figure 8

1. Handle

2. Neutral/ parking brake lock

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

4. Drive lever

5. Forward speed

6. Control rod

6. Install the control rod to the drive lever and the neutral/parking brake lock. Secure the control rod with a clevis pin and a hairpin cotter.

7. Check the operation of the control rod. If you need to adjust it, remove the hairpin cotter and the clevis pin that secure the control rod to the drive levers.

8. Adjust the control rod length by repeating steps 3 and 4 (Fig. 8).

Adjusting the Parking Brakes

Refer to Servicing the Brakes, page 32 for checking the brakes and adjusting them.

Page 15

Connecting the Throttle Cable

1. Hook the throttle cable inner wire into the hole of the speed control lever (Fig. 9).

2. Move the throttle control lever to the Fast position (Fig. 9).

3. Loosen the throttle cable clamp screw (Fig. 9).

4. Pull the throttle cable slightly to remove any slack in

the inner wire (Fig. 9).

5. Tighten the cable clamp screw to lock the adjustment in place (Fig. 9).

6. Move the choke control to make sure the carburetor choke valve moves.

Installing the Blade Control (PTO) Rod

1. Rotate the blade control (PTO) lever vertically away from the left handle so that the blade control (PTO) rod drops down (Fig. 10).

6. Move the throttle lever to make sure the carburetor valve moves.

1. Throttle cable

2. Throttle cable inner wire

3. Speed control lever

4. Cable clamp screw

Figure 9

5. Choke cable

6. Choke control lever

7. Choke cable inner wire

m–7537

Connecting the Choke Cable

1. Move the choke control to the Open position (Fig. 9).

2. Hook the choke cable inner wire into the hole of the

choke control lever (Fig. 9).

3. Loosen the choke cable clamp screw (Fig. 9).

4. Pull the choke cable slightly to remove any slack in the

inner wire (Fig. 9).

5. Tighten the cable clamp screw to lock the adjustment in place (Fig. 9).

Figure 10

1. Blade control lever

2. Blade control (PTO) rod

2. Remove the hairpin cotter from the bottom end of the blade control (PTO) rod (Fig. 10).

3. Secure the blade control (PTO) rod through the hole in the bell crank with the hairpin cotters (Fig. 10).

3. Bell crank

4. Hairpin cotter

m–3783

Installing the Shift Lever

1. Remove the locknut (3/8 inch) and spring washer from the stud on top of the transmission (Fig. 11).

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

2. Slide the shift lever through the control panel and align the mounting hole in lever with square on transmission shaft (Fig. 11).

3. Secure lever to transmission with previously removed spring washer and locknut (Fig. 11).

4. Replace the spring washer, dish down, and locknut (Fig. 11).

Page 16

5. Torque the nut to 35 ft–lb (47 NSm).

m–3772

Figure 11

1. Shift lever

2. Control panel

3. Rubber seal washer

4. Square hole washer

5. Spring washer

6. Locknut 3/8

Adjusting the Shift Lever Plate

1. Shift lever to second gear and check alignment of lever in slot of shifter lever plate. The clearance between top and bottom of the shift lever should be equal (Fig. 12).

2. If clearance is not correct, remove lever and bend it slightly to adjust (Fig. 12).

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

3. Shift lever to neutral and check alignment of lever in slot of shifter lever plate. The clearance on the sides of shift lever should be equal (Fig. 12).

4. If clearance is not correct, loosen shift lever plate and adjust it side–to–side. Tighten the shift lever plate.

Rear View

m–7454

Figure 12

1. Shift lever, 2nd gear

2. Shift lever plate

3. Shift lever, neutral

4. Equal distance

Mounting the Fuel Tank

1. Align fuel tank with the top of the rear frame (Fig. 13).

2. Secure the right side of the fuel tank to the rear frame

with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 13).

3. Secure the left side of the fuel tank to the rear frame with 2 studs, washers (5/16 inch), springs and locknuts (5/16 inch) (Fig. 13).

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

m–3771

Figure 13

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

2. Lock washer, 5/16 inch

3. Washer, 5/16 inch

4. Stud

5. Spring

6. Locknut

4. Slide the hose clamp onto the fuel line (Fig. 14).

Page 17

5. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 14).

Operation

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

Figure 14

1. Fuel line

2. Hose clamp

3. Fuel fitting

Installing the Muffler

1. Loosen the clamp (Fig. 15).

m–6442

Think Safety First

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

Caution

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

Wear hearing protection when operating this machine.

Use protective equipment for eyes, hearing, feet, and head.

m–5941

Figure 15

1. Muffler

2. Clamp

2. Rotate the muffler forward into the position shown in Figure 15.

3. Secure the muffler bracket (Fig. 15) to the engine bracket with the hardware provided.

4. Tighten the clamp.

3. Muffler bracket

Page 18

Controls

Become familiar with all the controls (Fig. 16) before you start the engine and operate the machine.

m–5907

respectively. The sharpness of the turn depends on how much you squeeze the drive lever. To move the mower straight forward (or backward), smoothly release both drive levers simultaneously.

Neutral/parking brake locks—Squeeze the drive levers back and move the locks rearward to activate the neutral lock. Squeeze the drive levers back and move the locks forward to activate the parking brake locks.

Choke—Use the choke to start a cold engine.

Blade control (PTO) lever—The blade control (PTO)

lever engages and disengages power to the mower blades. Move the PTO lever forward to engage the blades. Pull the lever rearward to stop driving the mower blades.

Ignition switch—The ignition switch is used in conjunction with the recoil starter. The switch has two positions: Run and Off.

Recoil starter (On the engine)—Pull the recoil starter handle to start the engine.

Fuel shut-off valve (In the fuel line)—Close the fuel shut-off valve when transporting or storing the mower.

Operating the Parking Brake

Figure 16

1. Throttle control

2. Operator Presence Control (OPC) lever (2)

3. Gear shift lever

4. Drive lever (2)

5. Neutral/parking brake lock (2)

6. Handle

7. Blade control (PTO) lever

8. Control panel

9. Throttle cable

10. Ignition switch

11. Choke

12. Left side

Throttle control—The throttle control has two positions: Fast and Slow.

Operator presence control (OPC) levers—When you squeeze the OPC levers against the handles, the OPC system senses that the operator is in the normal operating position. When you release the OPC levers, the OPC system senses that the operator has left the normal operating position, and the system will stop the engine if either the gear shift lever is not in the Neutral position or the blade control (PTO) lever is engaged.

Gear shift lever—The transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern.

Do not shift the lever while the mower is moving to prevent transmission damage.

Drive levers—The drive levers control the wheel traction.

Release the drive levers to engage the wheel traction, or squeeze them to disengage the traction. Fully squeezing the drive levers engages the parking brakes. Gradually squeezing the left or right drive lever disengages the traction on that side, causing the left or right wheel to slow down. This causes the mower to turn left or right,

and Neutral Locks

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

Setting the Parking Brakes

1. Squeeze the drive levers back (Fig. 17).

Figure 17

1. Handle

2. Neutral/parking brake lock

3. Park position

4. Neutral position

5. Drive lever

6. Full speed forward

2. Place your thumbs on the upper part of the locks and move them forward in into the Park position (Fig. 17).

3. Release the drive levers.

Releasing the Parking Brakes

1. Squeeze the drive levers back (Fig. 17).

m-5386

Page 19

2. Place your thumbs on the upper part of the locks and move them rearward until they are in the Drive position (Fig. 17).

Note: If the engine has been working hard or is hot, let it idle for a minute before stopping it to help cool it.

2. Turn the ignition key to the Off position.

Setting the Neutral Locks

1. Squeeze the drive levers back (Fig. 17).

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

move them rearward into the Neutral Lock position (Fig. 17).

Releasing the Neutral Locks

1. Squeeze the drive levers back.

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

move them forward until they are in the Drive position (Fig. 17).

Starting the Engine

1. Connect the wires to the spark plugs.

2. Open the fuel valve.

3. Disengage the blade control (PTO) lever and move the shift lever to the Neutral position.

4. Set the parking brakes.

5. Turn the ignition key to the Run position.

3. Set the parking brakes.

4. Disconnect the wire from the spark plug to prevent

someone from accidentally starting the machine while transporting or storing it.

5. Close the fuel shut-off valve before transporting or storing the machine.

Important Close the fuel shut-off valve before

transporting or the storing the machine to prevent fuel leakage.

Operating the Blade Control (PTO) Lever

The blade control (PTO) lever engages and disengages the power to the mower blades.

Engaging the Mower Blades (PTO)

1. Squeeze the operator presence control (OPC) levers against the handles (Fig. 16).

2. Push the blade control (PTO) lever firmly forward until it latches over the center (Fig. 16).

6. Move the throttle control midway between the Fast and Slow positions before starting a cold engine.

Note: A warm or hot engine usually does not require

any choking. To start a warm engine, move the throttle control to the Fast position.

7. Pull the choke knob.

8. Grasp the recoil starter handle firmly and pull it out

until positive engagement results; then pull the handle vigorously to start the engine. Allow the rope to recoil slowly.

Important Do not pull the recoil rope to its limit or

release the starter handle when you pull out the rope because the rope may break or the recoil assembly may be damaged.

9. If the engine is cold, allow it to warm up and then move the throttle control to the Fast position.

Stopping the Engine

Important In an emergency, you can stop the engine

immediately by turning the ignition key to the Off position.

1. Move the throttle lever to the Slow position (Fig. 16).

Disengaging the Mower Blades (PTO)

Pull the blade control (PTO) lever fully rearward (Fig. 16).

Understanding the Safety Interlock System

Caution

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

Page 20

• The throttle is out of the Stop position.

• The blade control (PTO) lever is disengaged.

• The machine is shifted into the Neutral position.

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

• the Operator Presence Control (OPC) levers are

released when the transmission or the blades are engaged;

• the machine is shifted into gear without holding the

OPC levers; or

• the blade control (PTO) lever is engaged without

holding the OPC levers.

Testing the Safety Interlock System

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

1. Set the parking brakes and move the shift lever into the Neutral position.

2. Start the engine; refer to Starting the Engine, page 19.

3. Without holding the Operator Presence Control (OPC) levers, engage the blade control (PTO) lever. The engine should stop.

4. Disengage the blade control (PTO) lever.

5. With engine running, hold down the OPC levers and

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

6. Release the OPC levers. The engine should stop.

7. With the engine running, move the shift lever into gear and release the OPC levers. The engine should stop.

8. Move the throttle to the Stop position. The engine should stop.

Driving Forward

1. Ensure that the parking brakes are engaged.

2. Squeeze the OPC levers against the handles.

3. Move the shift lever into a forward gear.

4. Release the parking brakes; refer to Releasing the

Parking Brakes, page 18.

5. Slowly release the drive levers.

Note: To go straight, release the drive levers equally. To

turn, squeeze the drive lever on the same side as the direction you want to turn.

Driving Backward

1. Ensure that the parking brakes are engaged.

2. Squeeze the OPC levers against the handles.

3. Move the shift lever into the reverse gear.

4. Release the parking brakes; refer to Releasing the

Parking Brakes, page 18.

5. Slowly release the drive levers.

Note: You must pull the mower backward to assist its

rearward movement.

Stopping the Mower

1. Squeeze the drive levers all the way back to engage the brakes.

2. Set the parking brakes. Refer to Setting the Parking Brakes, page 18.

3. Shift transmission into the Neutral position.

4. Move the throttle to the Stop position, and wait for all

moving parts to stop before leaving the operating position.

9. If all the above conditions are not met, have an Authorized Service Dealer repair the safety system immediately.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Move the throttle control into the Fast position for the best mowing performance.

Caution

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

Always set the parking brakes when you leave the machine unattended, even for a few minutes.

Page 21

Transporting the Mower

Adjusting the Wheel Drive

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

To transport the mower:

• Lock the brakes and block the wheels.

• Securely fasten the mower to the trailer or truck with

straps, chains, cable, or ropes.

• Secure the trailer to the towing vehicle with safety

chains.

Side Discharging or Mulching the Grass

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

Danger

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

• Never remove the grass deflector from the

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

• Never put your hands or feet under the mower.

• Never try to clear the discharge area or the

mower blades unless you disengage the power take-off (PTO), stop the engine and wait for all moving parts to stop, and disconnect the wire from the spark plug.

Tension

You may need to increase the wheel drive belt tension under certain operating conditions, such as mowing over hilly terrain or while pulling a sulky.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Disengage the neutral/parking brake locks, and release

the drive levers to reduce the spring force.

4. Remove the drive spring from the adjustment bolt (Fig. 18).

Figure 18

1. Position A

2. Position B

3. Position C

4. Drive spring

5. Remove the locknut that secures the adjustment bolt to the drive pulley shield (Fig. 18).

6. Locate bolt assembly in the desired tension position as follows:

• Position A for normal conditions

• Position B for more severe conditions

• Position C for the most severe conditions

Note: The wheel drive tension is lowest when the bolt assembly is in Position A. The tension increases in Positions B and C (Fig. 18).

5. Adjustment bolt ( In position A)

6. Drive pulley shield

m–5372

7. Install the adjustment bolt and the drive spring.

8. Repeat steps 4 through 7 for the opposite side.

Page 22

Adjusting the Height-of-Cut

This machine has a 1 to 4-1/4 inch (26 to 108 mm) range for the height-of-cut. This can be achieved by adjusting blade spacers, rear axle height, and front caster spacers. Use the Height-of-Cut Chart on page 24 to select the combination required.

Adjusting the Axle Height

You can obtain the desired height-of-cut range by adjusting the rear axle and placing the caster spacers above or below the caster arm (refer to the Height-of-Cut Chart, page ).

1. Disengage the blade control (PTO) lever and set the parking brakes.

Adjusting the Blade Height

Adjust the blades by using the 4 spacers (1/4 inch) on the blade spindle bolts. This allows a range, in 1/4 inch (6 mm) increments, of cutting height in any axle position. Use the same number of blade spacers on all blades to achieve a level cut (2 above and 2 below, 1 above and 3 below, etc.).

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Hold the blade bolt and remove the nut (Fig. 19).

1. Blade

2. Blade bolt

3. Cone washer

4. Slide the bolt down through the spindle, and change the spacers as needed (Fig. 19).

5. Insert a bolt, add extra spacer(s), and secure them with a thin washer and a nut (Fig. 19).

m–3779

Figure 19

4. Spacer

5. Thin washer

6. Nut

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Loosen, but do not remove, the 2 axle pivot bolts and the 2 axle adjustment bolts (Fig. 20).

m–3789

5 4

1. Axle pivot bolt 2. Axle adjustment bolt

Figure 20

4. Place a jack under the rear center of the engine frame. Raise the back end of the engine frame up enough to remove the front 2 axle adjustment bolts (Fig. 20).

5. Raise or lower the engine frame with the jack so that you can install the front 2 axle adjustment bolts in the desired hole location (Fig. 20).

Note: Use a tapered punch to help align the holes.

6. Tighten all 4 bolts and lower the mower.

7. Adjust the control rods and the brake linkages as

required. Refer to Servicing the Brakes, page 32 and Installing the Control Rods, page 14.

Important You must adjust the control rods and the

brake linkage when you change the axle positions for proper traction and brake function.

6. Torque the blade bolt to 75–80 ft-lb (101–108 NSm).

Page 23

Adjusting the Caster Position

1. Using the Height-of-Cut Chart (on page ), adjust the caster spacers to match with the axle hole selected (Fig. 21).

m–3791

Figure 21

1. Clevis pin

2. Spacer, 3/16 inch (5 mm)

3. Spacer, 1/2 inch (13 mm)

2. Remove the clevis pin, slide the caster from the support, and change the spacers (Fig. 21).

3. Install the caster in the support and insert the clevis pin (Fig. 21).

Page 24

Height-of-Cut Chart

No. of Spacers Below

Caster

Number of 1/4 inch Blade Spacers Below Spindle

Axle

Position

A 0 0

A 0 1

A 1 0

B 0 1

B 1 0

B 1 1

B 2 0

C 1 1

C 2 0

1/2 inch

(13mm)

3/16 inch

(5 mm)

1 inch

(26 mm)

1–1/8 inch

(29 mm)

1–3/8 inch

(35 mm)

1–3/8 inch

(35 mm)

1–5/8 inch

(41 mm)

1–3/4 inch

(45 mm)

2 inch

(45 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

3210

1–1/4 inch

(32 mm)

1–3/8 inch

(35 mm)

1–5/8 inch

(41 mm)

1–5/8 inch

(41 mm)

1–7/8 inch

(48 mm)

2 inch

(52 mm)

2–1/4 inch

(58 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(61 mm)

1–1/2 inch

(38 mm)

1–5/8 inch

(41 mm)

1–7/8 inch

(48 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

2–1/4 inch

(58 mm)

2–1/2 inch

(64 mm)

2–3/8 inch

(61 mm)

2–5/8 inch

(67 mm)

1–3/4 inch

(45 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(61 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

2–5/8 inch

(67 mm)

2–7/8 inch

(73 mm)

2 inch

(45 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(55 mm)

2–3/8 inch

(61 mm)

2–5/8 inch

(67 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3–1/8 inch

(79 mm)

C 2 1

C 3 0

D 2 1

D 3 0

D 3 1

D 4 0

E 3 1

E 4 0

E 4 1

2–1/4 inch

(58 mm)

2–1/2 inch

(64 mm)

2–3/8 inch

(61 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3–1/8 inch

(79 mm)

3–1/4 inch

(82 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

2–5/8 inch

(67 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/8 inch

(79 mm)

3–3/8 inch

(86 mm)

3–1/2 inch

(89 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/8 inch

(86 mm)

3–5/8 inch

(92 mm)

3–3/4 inch

(96 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/8 inch

(79 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/4 inch

(96 mm)

3–5/8 inch

(92 mm)

3–7/8 inch

(99 mm)

4 inch

(102 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/8 inch

(86 mm)

3–1/2 inch

(89 mm)

3–3/4 inch

(96 mm)

4 inch

(102 mm)

3–7/8 inch

(99 mm)

4–1/8 inch

(105 mm)

4–1/4 inch

(108 mm)

Page 25

Maintenance

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

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

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

After first 8 Hours

8 Hours

After first 25 Hours • Mower Belt—check tension

25 Hours • Foam Air Cleaner—clean

50 Hours

100 Hours

Maintenance Procedure

• Engine Oil—check the level

• Safety System—check

• Brakes—check

• Engine—clean engine screen

• Idler Pivots—grease

• Engine Oil—change

• Mower Belt—check the tension

• Cutting Blades—check

• Mower Housing—clean

• Caster Wheels—grease

• Wheel Bearings—grease

• Belts—check for wear/cracks

• Paper Air Cleaner—clean

• Mower Belt—check the tension

• Mower Belt Idler Pivots—grease

• Tires—check pressure

• Engine Oil—change

• Engine—clean cooling system

• Transmission Couplings—grease

• Spark Plug—check

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

200 Hours

At storage

More often in dusty, dirty conditions.

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

• Fuel Filter—replace

• Paper Air Cleaner—replace

• Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storing the mower

Page 26

Caution

Someone could accidently start the engine and seriously injure you or other bystanders.

Disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Servicing the Cutting Blades

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

Warning

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

• Inspect the blades periodically for wear or

damage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) lever, and set the parking brakes.

Inspecting the Blades

1. Inspect the cutting edges (Fig 22). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades, page 27.

2. Inspect the blades, especially the curved area (Fig. 22). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 22), immediately install a new blade.

Checking for Bent Blades

1. Rotate the blades until the ends face forward and backward (Fig. 23).

Front

1666

Figure 23

2. Measure from a level surface to the cutting edge of the blades (Fig. 24). Note this dimension.

1. Cutting edge

2. Curved area

Figure 22

3. Wear/slot forming

MEASURE FROM CUTTING

EDGE TO A LEVEL SURFACE

Figure 24

m–2558

3. Rotate the opposite ends of the blades forward.

m–151

4. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm).

Note: If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, page 27 and Installing the Blades, page 27.

Page 27

Warning

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

m–1854

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of the blade.

Removing the Blades

Replace the blades if you hit a solid object or if the blades are out of balance or bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

1. Hold the blade bolt with a wrench.

2. Remove the nut, blade bolt, cone washer, blade,

spacers, and thin washer from the spindle (Fig. 25).

1. Blade

2. Blade bolt

3. Cone washer

m–3779

Figure 25

4. Spacer

5. Thin washer

6. Nut

Figure 26

1. Sharpen at original angle 2. Sail

2. Check the balance of the blade by putting it on a blade balancer (Fig. 27). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 26). Repeat this step until the blade is balanced.

m–1855

Figure 27

1. Blade 2. Balancer

5 4

Installing the Blades

1. Place the blade onto the bolt and over the cone washer. Select the proper number of spacer(s) for the height-ofcut, and slide the bolt into the spindle (Fig. 25).

Important The curved part of the blade must point

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

2. Install the remaining spacer(s) and secure them with a thin washer and a nut (Fig. 25).

3. Torque the blade bolt to 75–80 ft-lb (101–108 NSm).

Servicing the Air Cleaner

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 26). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

Service Interval/Specification

Foam element: Clean it after every 25 operating hours.

Paper element: Replace it after every 200 operating hours

or yearly, which ever comes first.

Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty.

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

Important Do not oil the foam or paper element.

Page 28

Removing the Foam and Paper Elements

Cleaning the Paper Element

1. Disengage the PTO and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage (Fig. 28).

4. Unscrew the cover knob and remove the air cleaner cover (Fig. 28).

5. Unscrew the 2 wing nuts and remove the air cleaner assembly (Fig. 28).

6. Carefully pull the foam element off the paper element (Fig. 28).

Note: Never try to brush dirt off the paper element; brushing forces the dirt into the fibers.

Important Never clean the paper element with

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

1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 28).

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

3. Replace the paper element if it is damaged or dirty.

Installing the Foam and Paper Elements

Important To prevent engine damage, always operate

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

1. Carefully slide the foam element onto the paper air cleaner element (Fig. 28).

2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Fig. 28).

m–7452

Figure 28

1. Engine

2. Cover

3. Wing nut

4. Foam element

5. Paper element

6. Cover knob

Cleaning the Foam Element

1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.

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

3. Place the air cleaner cover into position and tighten the

cover knob (Fig. 28).

Servicing the Engine Oil

Service Interval/Specification

Change the engine oil:

• After the first 8 operating hours

• After every 100 operating hours

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

Important Replace the foam element if it is torn or

worn.

Page 29

Oil Type: Detergent oil (API service SE/CC, SF, SG, SH, or SJ)

Crankcase Capacity: 58 ounces (1.7 liter) with the filter removed; 51 ounces (1.5 liter) without the filter removed

Viscosity: Refer to the table below

USE THESE SAE VISCOSITY OILS

Checking the Engine Oil Level

1. Park the machine on a level surface.

2. Disengage the PTO, turn the ignition key to off, and

remove the key.

Changing the Oil

1. Start the engine and let it run five minutes. This warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.

3. Disengage the PTO, turn the ignition key to off, and remove the key.

4. Wait for all moving parts to stop before leaving the operating position and then chock or block tires.

5. Place a pan under the oil drain hole in the engine frame (Fig. 30).

6. Open the oil drain (Fig. 30).

3. Wait for all moving parts to stop before leaving the

operating position and then chock or block tires.

4. Clean around the oil dipstick (Fig. 29) so that dirt cannot fall into the filler hole and damage the engine.

m–7449

Figure 29

1. Oil dipstick 2. Filler tube

5. Unscrew the oil dipstick and wipe the end clean (Fig. 29).

6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Fig. 29).

7. Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark.

Important Do not overfill the crankcase with oil and

run the engine; engine damage can result.

m–7453

Figure 30

1. Oil drain plug

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

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

8. Slowly pour approximately 80% of the specified oil

(refer to Service Interval/Specification, page 28) into the filler cap (Fig. 29).

9. Check the oil level; refer to Checking the Engine Oil Level, page 29.

10. Slowly add the additional oil to bring it to the Full mark.

Changing the Oil Filter

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

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

1. Drain the oil from the engine; refer to Changing the Oil, page 29.

2. Remove the old filter (Fig. 31).

Page 30

m–7451

Figure 31

1. Oil filter 2. Adapter

3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 31).

4. Install the replacement oil filter to the filter adapter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 31).

5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 28.

Servicing the Spark Plugs

Service Interval/Specification

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

Type: Champion Air Gap: 0.030 inch (0.75 mm)

RCJ-8Y or equivalent

m–7453

Figure 32

1. Spark-plug (2)

4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage.

5. Remove the spark plugs and the metal washers.

Checking the Spark Plugs

1. Look at the center of the spark plugs (Fig. 33). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty.

0.030 inch (0.75 mm)

Removing the Spark Plugs

1. Disengage the PTO, turn the ignition key to off, and remove the key.

2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires.

3. Disconnect the wires from the spark plugs (Fig. 32).

Figure 33

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Important Never clean the spark plugs. Always replace

the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side electrodes (Fig. 33). Bend the side electrode (Fig. 33) if the gap is not correct.

Installing the Spark Plugs

1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly.

Page 31

2. Tighten the spark plugs to 11 ft-lb (15 NSm).

3. Connect the wires to the spark plugs (Fig. 32).

Pressure: 15 psi (103 kPa) rear tires

25–30 psi (172–207 kPa) caster tires

Cleaning the Cooling System

Clean the air intake screen from grass and debris before each use.

Clean cooling fins and engine shrouds every 100 hours or yearly, which ever comes first.

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the air intake screen, recoil starter and fan housing.

4. Clean the debris and grass from the engine parts.

5. Install air intake screen, recoil starter and fan housing.

Figure 35

1. Valve stem

Cleaning the Cooling System

Service Interval/Specification

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

Greasing and Lubrication

m–7450

Figure 34

1. Air intake screen

2. Fan housing

3. Recoil starter

4. Bolt

5. Nut

Checking the Tire Pressure

Service Interval/Specification

Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 35). Check the tires when they are cold to get the most accurate pressure reading.

Service Interval/Specification

Grease the areas shown at the intervals given in the Locating Where to Add Grease section below. Grease them more frequently when operating conditions are extremely dusty or sandy.

Grease with No. 2 general-purpose lithium-base or molybdenum-base grease.

Applying the Grease

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Clean the grease fittings with a rag and scrape any paint from the front of the fitting(s).

3. Connect a grease gun to the fitting and pump grease into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Locating Where to Apply Grease

1. Lubricate the drive and caster wheel bearings and front spindles (Fig. 36) after every 8 operating hours.

Page 32

Figure 36

Servicing the Brakes

Service Interval/Specification

Before each use, check the brakes for proper operation.

Always set the parking brakes when you stop the machine or leave it unattended. If the parking brakes do not hold securely, adjust them.

Checking the Brakes

m–3780

1. Park the machine on a level surface, disengage the blade control (PTO) lever, and push the neutral/parking brake locks forward to set the brakes.

2. Lubricate the transmission couplers after every 100 operating hours and the idler bracket pivots after every 8 operating hours (Fig 37).

m–5389

Figure 37

3. Lubricate the blade belt idler arm pivot (Fig. 38) after every 50 operating hours.

2. The rear wheels should lock when you try to push the machine forward or backward. Adjust the brakes if the wheels turn and do not lock. Refer to Adjusting the Brakes, page 32.

3. Release the brakes and move the neutral/brake locks to the Neutral position. Move the machine slightly, approximately 1/2 in. (13 mm). The wheels should rotate freely.

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

Adjusting the Brakes

If the parking brakes do not hold securely, adjust them.

1. Check the brakes before you adjust them; refer to Checking the Brakes, page 32.

2. Release the parking brakes; refer to Releasing the Parking Brakes, page 18.

3. To adjust the brakes, rotate the wing nuts on the brake rods (Fig. 39). Rotate the wing nuts clockwise to tighten the brakes; rotate them counterclockwise to loosen them.

Figure 38

m-4749

m–5372

Figure 39

1. Brake rod 2. Wing nut

Page 33

4. Position the wing nuts so that the brakes engage when you squeeze the drive levers enough to place the neutral/parking brake locks forward, and then set the brakes.

5. Check the operation of the brakes again; refer to Checking the Brakes, page 32.

Important When you release the parking brakes, the

rear wheels should rotate freely when you push the mower. If they do not, contact an Authorized Service Dealer immediately.

Draining the Fuel Tank

Danger

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

• Drain gasoline from the fuel tank when the

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

• Never smoke when draining gasoline, and stay

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

1. Park the machine on a level surface, to ensure that the

fuel tank drains completely.

6. Open the fuel shut-off valve and allow the gasoline to drain into a fuel container or drain pan.

Note: Install a new fuel filter while the fuel tank is empty. Refer to Replacing the Fuel Filter, page 33.

7. Install the fuel line onto the fuel filter, and slide the hose clamp close to the filter to secure the fuel line.

Servicing the Fuel Filter

Service Interval/Specification

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

Replacing the Fuel Filter

Important Never install a dirty filter if it is removed

from the fuel line.

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Close the fuel shut-off valve (Fig. 40).

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

them away from the filter (Fig. 40).

5. Remove the filter from the fuel lines.

2. Disengage the blade control (PTO) lever and set the

parking brakes.

3. Close the fuel shut-off valve in fuel line (Fig. 40).

Figure 40

1. Fuel shut-off valve

2. Fuel filter

4. Squeeze the ends of the hose clamp together, and slide it up the fuel line away from fuel filter (Fig. 40).

5. Pull the fuel line off the fuel filter (Fig. 40).

m–3778

3. Clamp

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

7. Open the fuel shut-off valve at the fuel tank (Fig. 40).

8. Check for fuel leaks and make any needed repairs.

Checking the Belts

Service Interval/Specification

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

Replacing the Drive Belt

Service Interval/Specification

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

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop.

Page 34

3. Remove the drive spring from the adjustment bolt (Fig. 41).

Replacing the Traction Belt

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Raise the rear of the machine and hold it up with jack stands.

4. Remove the mower belt (Fig. 42).

m–5372

Figure 41

1. Drive belt

2. Drive spring

3. Tire

4. Adjustment bolt

4. Remove the drive belt from the pulleys and over the tire.

5. Install the new belt and the drive spring.

m–4726

Figure 42

1. Idler pulley in slot

2. Traction belt

3. Mower belt

4. Belt guide

5. 1-1/4 inch (32 mm)

6. Mower belt

5. Loosen the pivot bolt enough to slide the idler pulley in the slot and remove the traction belt from the engine and the drive pulleys (Fig. 42).

6. Install the new traction belt around the engine and the drive pulleys (Fig. 42).

7. Slide the idler pulley in the engine frame to tension the traction belt (Fig. 42).

8. Install the mower belt (Fig. 42).

9. Check the belt guide under the engine frame for the proper adjustment (Fig. 42).

Note: The distance between the belt guide and mower belt should be 1-1/4 inch (32 mm) when the mower belt is engaged. Adjust the belt if necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted.

Replacing the Mower Belt

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Remove the knobs and the belt cover on the mower.

Page 35

4. Remove the idler pulley and the worn belt (Fig. 42).

5. Install the new mower belt.

6. Install the idler pulley.

7. Engage the blade control (PTO) lever and check the belt

tension. Refer to Adjusting the Mower Belt Tension, page 35.

Note: The proper mower belt tension is 10–15 lbf. (44–67 N) with the belt deflected 1/2 inch (13 mm) halfway between the pulleys (Fig. 43).

10. Remove the hairpin cotter and the clevis pin from the bell crank.

11. Rotate the clevis clockwise on the rod to increase the clearance; rotate it counterclockwise to decrease it (Fig. 44).

12. Disengage the blade control (PTO) lever.

Note: If the assist arm does not contact the front stop on

the mower deck (Fig. 45), adjust the clevis to bring the bell crank closer to the transmission output shaft (Fig. 44).

1/2 in.

(13 mm)

m-4750

Figure 43

1. Mower belt with 1/2 inch (13mm) deflection

2. Idler pulley

8. Engage the blade control (PTO) lever.

9. Check the clearance between the bell crank and the

transmission output shaft (Fig. 44).

Figure 45

1. 1/2 inch (13 mm) deflection here

2. Assist arm

3. Front stop

4. Locknut

5. Turnbuckle

13. Check the belt guide under the engine frame for the proper adjustment (Fig. 42).

Note: The distance between the belt guide and the mower belt should be 1-1/4 inch (32 mm) when you engage the mower belt. Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted.

m–4739

Figure 44

1. 1/16–1/8 inch (2–3 mm)

2. Bell crank

3. Transmission output shaft

4. Hairpin cotter

5. Clevis pin

6. Clevis

Note: The clearance should be 1/16–1/8 inch (2–3 mm).

m–3860

Adjusting the Mower Belt Tension

Service Interval/Specification

Check the belt tension after the first 8 operating hours and 25 operating hours thereafter. Check the belt tension after every 50 operating hours.

Important The belt must be tight enough to not slip

during heavy loads while cutting grass. Over tensioning the belt will reduce the bearing life of the belt and the spindle.

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

Page 36

3. Loosen the locknut on the turnbuckle (Fig. 45).

4. Rotate the turnbuckle toward the rear of the mower to

increase the tension on the belt. Rotate the turnbuckle toward the front of the mower to decrease the tension on the belt (Fig. 45).

Adjusting the Grass/Mud Scraper

1. Loosen the locknut that holds the scraper to the engine frame (Fig. 47).

Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16 inch (8 mm).

Adjusting the Blade Brake

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. If necessary, adjust the spring mounting bolts so that the blade brake pad rubs against the pulley edges (Fig. 46).

m–47271

Figure 46

1. Spring mounting bolts

2. Blade brake pad

3. 1/8–3/16 inch (3–5mm)

Figure 47

1. Scraper

2. Locknut

2. Rotate the scraper until it aligns with the center of the pulley grooves (Fig. 47).

3. Tighten the locknut (Fig. 47).

Note: The scraper must not contact the pulley on the sides

or bottom of the grooves. Adjust it if necessary.

1. Remove the locknut, bolt, spring, and spacer that hold the deflector to the mounts (Fig. NO TAG).

3. Pulley

m-3776

Replacing the Grass Deflector

Warning

4. Adjust the nut at the end of the blade brake rod until there is 1/8–3/16 inch (3–5 mm) between the nut and the spacer (Fig. 46).

5. Engage the blades, and ensure that the blade brake pad no longer contacts the pulley edges.

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

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

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

deflector to the pivot brackets (Fig. 48). Remove damaged or worn grass deflector.

2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge.

Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in figure 48.

Page 37

3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 48).

Important The grass deflector must be able to lower

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

m–7868

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

Figure 48

6. Grass Deflector

7. L end of spring, place

behind deck edge before installing bolt

8. J hook end of spring

Page 38

Wiring Diagram

RED

YELLOW

ORANGE

IGNITION

SPARK PLUG

MODULE

WIRE COLOR CODES

BLACK

SW2

BLUE

BROWN

NEUTRAL SWITCH

GREEN

(NEUTRAL SWITCH CLOSES

MAG

WHEN IN NEUTRAL)

WHEN THROTTLE

SWITCH CLOSES

GND

PULLED BACK

YGN

SW1

BLADE SWITCH

WHEN BLADE IS ENGAGED)

(BLADE SWITCH OPENS

INTERLOCK MODULE

OPERATOR IS PRESENT)

SW3

DELTA MODULE (2001)

(SWITCH CLOSED WHEN

OPERATOR PRESENCE SWITCH

Page 39

Cleaning and Storage

1. Disengage the blade control (PTO) lever and set the parking brakes.

2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and the blower housing.

Important Wash the machine with a mild detergent and

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

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

4. Service the air cleaner; refer to Servicing the Air Cleaner, page 27.

5. Grease the machine; refer to Greasing and Lubrication, page 31.

6. Change the crankcase oil; refer to Servicing the Engine Oil, page 28.

9. Empty the fuel tank using the following steps:

A. Run the engine to distribute conditioned fuel

through the fuel system (5 minutes).

B. Stop engine and wait for all moving parts to stop

before leaving the operating position.

C. Allow the engine to cool and drain the fuel tank;

refer to Servicing the Fuel Tank, page 33, or operate engine until it stops.

D. Start the engine and run it until it stops. Repeat this

step with the Choke on until engine will not start.

E. Dispose of fuel properly. Recycle per local codes.

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

10. Remove and inspect the spark plug; refer to Servicing the Spark Plug, page 30.

11. With the spark plug removed from the engine, pour two tablespoons of engine oil into the spark plug hole, then use the starter to crank the engine and distribute the oil inside the cylinder.

7. Check the tire pressure; refer to Checking the Tire Pressure, page 31.

8. For long-term storage (more than 90 days) add a stabilizer/conditioner additive to the fuel in the tank.

Troubleshooting

Problem Possible Causes Corrective Action

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

1. The fuel tank is empty. 1. Fill the fuel tank with gasoline.

2. The choke is not on. 2. Set the Choke to the on

3. The blade control (PTO) lever is engaged.

4. The air cleaner is dirty. 4. Clean or replace the air

12. Install the spark plug. Do not connect the wire to the spark plug.

13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is worn or damaged.

14. Paint all scratched or bare metal surfaces with paint available from an Authorized Service Dealer.

15. Store the machine in a clean, dry garage or storage area, and cover it to protect it and keep it clean.

position.

3. Disengage the blade control (PTO) lever.

cleaner element.

5. The spark plug wire is loose or disconnected.

6. The spark plugs are pitted, fouled, or gap is incorrect.

7. There is dirt in the fuel filter. 7. Replace the fuel filter.

8. There is dirt, water, or stale fuel in the fuel system.

5. Connect the wire to the spark plug.

6. Install new, correctly gapped spark plugs.

8. Contact an Authorized Service Dealer.

Page 40

Problem Corrective ActionPossible Causes

The engine loses power.

The engine overheats.

1. The engine load is excessive. 1. Reduce the ground speed.

2. The air cleaner is dirty. 2. Clean the air cleaner element.

3. The engine oil level in the crankcase is low.

4. The cooling fins and air passages under the engine blower housing are plugged.

5. The spark plug is pitted, fouled, or the gap is incorrect.

6. The vent hole in the fuel cap is plugged.

7. There is dirt in fuel filter. 7. Replace the fuel filter.

8. There is dirt, water, or stale fuel is in fuel system.

1. The engine load is excessive. 1. Reduce the ground speed.

2. The engine oil level in the crankcase is low.

3. The cooling fins and air passages under the engine blower housing are plugged.

3. Add engine oil to the crankcase.

4. Remove the obstruction(s) from the cooling fins and air passages.

5. Install a new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact an Authorized Service Dealer.

2. Add oil to the crankcase.

3. Remove the obstruction(s) from cooling fins and air passages.

The machine does not drive.

There is abnormal vibration.

1. The shift lever is in the

Neutral position.

2. The traction belt is worn, loose, or broken.

3. The traction belt is off the pulley.

1. The cutting blades are bent or unbalanced.

2. The blade mounting bolt is loose.

3. The engine mounting bolts are loose.

4. The engine pulley, idler pulley, or blade pulley is loose.

5. The engine pulley is damaged.

6. The blade spindle is bent. 6. Contact an Authorized

1. Move the shift lever to a drive gear position.

2. Change the belt.

3. Change the belt.

1. Install new cutting blades.

2. Tighten the blade mounting bolt.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

5. Contact an Authorized Service Dealer.

Service Dealer.

Page 41

Problem Corrective ActionPossible Causes

The cutting height is uneven.

The blades do not rotate.

1. The blades are not sharp. 1. Sharpen the blades.

2. The blades are bent. 2. Install new blades.

3. The mower is not level. 3. Level the mower from side-to-side and front-to-rear.

4. The underside of the mower

is dirty.

5. The tire pressure is incorrect. 5. Adjust the tire pressure.

6. The blade spindle is bent. 6. Contact an Authorized

1. The drive belt is worn, loose,

or broken.

2. The drive belt is off the pulley. 2. Install the drive belt and

3. The mower belt is worn,

loose, or broken.

4. The mower belt is off the

pulley.

4. Clean the underside of the mower.

Service Dealer.

1. Check the belt tension.

check the adjusting shafts and the belt guides for the correct position.

3. Install the new mower belt.

4. Install the deck pulley and check the idler pulley, idler arm, and spring for the correct position and function.

The blades do not stop when they are disengaged.

1. The blade brake is not adjusted properly.

2. The belt guide is not set properly.

1. Adjust the blade brake.

2. Adjust the belt guide.

Page 42

Page 43

Page 44

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

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

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

ProLine Mid-Size Mowers Mid-Mount Z’s

• Electric Clutch on 500 Series Mid-Mount Z’s

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

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

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

engine manufacturer.

Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

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

1. Contact any Toro Authorized or Master Service Dealer to

arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. U.S. Customers may also call 800-348-2424.

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

the Service Dealer.

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

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

You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

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

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

• Pickup and delivery charges.

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

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

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

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

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

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

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0037 Rev. D