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30632
Operator's Manual
48 pgs13.65 Mb0
Operator's Manual
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Operator's Manual
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Operator's Manual [es]
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Operator's Manual [es]
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Operator's Manual [fr]
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Toro 30632, 30634, 30638, 39634, 39638 Operator's Manual

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Page 1
FormNo.3391-556RevB
G017536
CommercialWalk-BehindMower
FixedDeck,PistolGrip,GearDrivewith32in, 36inor48inCuttingUnit
ModelNo.30632—SerialNo.315000001andUp ModelNo.30634—SerialNo.315000001andUp ModelNo.30638—SerialNo.315000001andUp ModelNo.39634—SerialNo.315000001andUp ModelNo.39638—SerialNo.315000001andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
*3391-556*B
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Thisengineisnotequippedwith
asparkarrestermufer.Itisaviolationof CaliforniaPublicResourceCodeSection4442to useoroperatetheengineonanyforest-covered, brush-covered,orgrass-coveredland.Other statesorfederalareasmayhavesimilarlaws.
WARNING
Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty, traction,andsafetyofthemachine.Failureto useoriginalT oropartscouldcauseserious injuryordeath.Makingunauthorizedchanges totheengine,fuelorventingsystem,may violateEPAandCARBregulations.
Replaceallpartsincluding,butnotlimited to,tires,belts,blades,andfuelsystem componentswithoriginalToroparts.
Theenclosedengineowner’smanualissupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCaliforniaEmission ControlRegulationofemissionsystems,maintenance, andwarranty.Replacementsmaybeorderedthrough theenginemanufacturer.
YoumaycontactT orodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
g001487
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
g000502
Figure2
1.Safetyalertsymbol
Introduction
Thisrotary-blade,lawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional, hiredoperators.Itisdesignedprimarilyforcutting grassonwell-maintainedlawnsonresidential orcommercialproperties.Itisnotdesignedfor cuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Y ouareresponsiblefor operatingtheproductproperlyandsafely .
©2017—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
2
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved
Page 3
Contents
Safety.......................................................................4
SafeOperatingPractices....................................4
ToroMowerSafety..............................................5
SlopeIndicator...................................................7
SafetyandInstructionalDecals..........................8
ProductOverview....................................................11
Controls............................................................11
Specications..................................................12
Attachments/Accessories.................................12
Operation................................................................12
AddingFuel......................................................12
UsingFuelStabilizer/Conditioner.....................13
CheckingtheEngine-OilLevel..........................13
FillingtheFuelTank..........................................13
PuttingSafetyFirst...........................................13
OperatingtheParkingBrakeandNeutral
Locks............................................................14
StartingandStoppingtheEngine......................14
OperatingtheBlade-Control(PTO)
Lever.............................................................15
TheSafety-InterlockSystem.............................15
DrivingForwardorBackward............................16
StoppingtheMower..........................................16
TransportingtheMachine.................................17
SideDischargingorMulchingthe
Grass............................................................17
AdjustingtheWheel-Drive-BeltT ension............17
AdjustingtheHeightofCut...............................18
AdjustingtheFlowBafe..................................19
PositioningtheFlowBafe................................19
AdjustingtheHandleHeight.............................20
Height-of-CutChart..........................................22
Maintenance...........................................................23
RecommendedMaintenanceSchedule(s)...........23
Lubrication..........................................................24
LubricatingtheMachine....................................24
LubricatingtheCasterandWheel
Bearings........................................................24
GreasingtheTransmissionCouplers................24
GreasingtheMower-BeltIdler..........................24
EngineMaintenance...........................................25
ServicingtheAirCleaner..................................25
ServicingtheEngineOil....................................25
ServicingtheSparkPlugs.................................27
FuelSystemMaintenance...................................28
ServicingtheFuelSystem................................28
DriveSystemMaintenance..................................30
CheckingtheTirePressure...............................30
CoolingSystemMaintenance..............................31
CleaningtheAir-intakeScreen.........................31
CleaningtheCoolingSystem............................31
BrakeMaintenance.............................................32
ServicingtheBrakes.........................................32
BeltMaintenance................................................33
CheckingtheBelts............................................33
ReplacingtheTractionDriveBelt......................33
ReplacingtheDriveBelt...................................33
ReplacingtheMowerBelt.................................33
AdjustingtheMowerBeltT ension.....................35
ControlsSystemMaintenance.............................38
AdjustingtheControlRods...............................38
MowerDeckMaintenance....................................39
ServicingtheCuttingBlades.............................39
AdjustingtheBladeBrake.................................41
ReplacingtheGrassDeector..........................42
Storage...................................................................43
CleaningandStorage.......................................43
Troubleshooting......................................................44
Schematics.............................................................46
3
Page 4
Safety
Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.
Improperlyusingormaintainingthemachinecan resultininjury.Toreducethepotentialforinjury , complywiththesesafetyinstructionsandalways payattentiontothesafetyalertsymbol,which meansCaution,Warning,orDanger—personal safetyinstruction.Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.
Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI B71.4-2012.
Training
•ReadtheOperator'sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot readorunderstandtheinformationitistheowner's responsibilitytoexplainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmay restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtopeopleor damagetoproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand safelyperformthejob.Useonlyaccessoriesand attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,
substantial,slip-resistantfootwear,safetyglasses, andhearingprotection.Longhair,looseclothing, orjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobe
usedandremoveallobjectssuchasrocks,toys, andwire,whichcanbethrownbythemachine.
•Checkthatoperator'spresencecontrols,safety
switches,andshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyare functioningproperly.
Operation
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
•Neverrunanengineinanenclosedarea.
•Operatethemachineonlyingoodlight,keeping
awayfromholesandhiddenhazards.
•Besurethatalldrivesareinneutralandthe
parkingbrakeisengagedbeforestartingthe engine.Starttheengineonlyfromtheoperator's position.
•Besureofyourfootingwhileusingthismachine,
especiallywhenbackingup.Walk;donotrun. Neveroperateonwetgrass.Reducedfooting couldcauseslipping.
•Slowdownanduseextracareonhillsides.Be
suretotravelsidetosideonhillsides.Turf conditionscanaffectthestabilityofthemachine. Usecautionwhileoperatingneardrop-offs.
•Slowdownandusecautionwhenmakingturns
andwhenchangingdirectiononslopes.
•Neverraisethedeckwiththebladesrunning.
•NeveroperatewiththePTOshieldorotherguards
notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioning properly.
•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessyouareusingagrass catcher.
•Donotchangetheenginegovernorsettingor
overspeedtheengine.
•Stoponlevelground,disengagedrives,engage
theparkingbrake(ifprovided),andshutoffthe enginebeforeleavingtheoperator'spositionfor anyreason,includingemptyingthecatchersor uncloggingthechute.
•Stoptheequipmentandinspecttheblades
afterstrikingobjectsorifanabnormalvibration occurs.Makenecessaryrepairsbeforeresuming operation.
•Keephandsandfeetawayfromthecuttingunit.
•Lookbehindanddownbeforebackinguptobe
sureofaclearpath.
•Nevercarrypassengersonthemachine.
•Keeppetsandbystandersaway .
•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.Stopthe bladesifyouarenotmowing.
4
Page 5
•Beawareofthemowerdischargedirectionand
donotpointitatanyone.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Usecarewhenloadingorunloadingthemachine
intoorfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
•Usefull-widthrampsforloadingmachineinto
trailerortruck.
•Tiethemachinedownsecurelyusingstraps,
chains,cable,orropes.Bothfrontandrearstraps shouldbedirecteddownandoutwardfromthe machine.

ToroMowerSafety

MaintenanceandStorage
•Disengagedrives,settheparkingbrake,stop
theengineandremovethekeyordisconnect thespark-plugwire.Waitforallmovementto stopbeforeadjusting,cleaning,orrepairingthe machine.
•Cleangrassanddebrisfromthecuttingunit,the
drives,themufers,andtheenginetohelpprevent res.Cleanupoilorfuelspills.
•Lettheenginecoolbeforestoring,anddonot
storeitnearaame.
•Shutoffthefuelwhilestoringortransportingthe
machine.Donotstorefuelnearamesordrainit indoors.
•Parkthemachineonlevelground.Settheparking
brake.Neverallowuntrainedpersonneltoservice themachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectthebatteryorthespark-plugwire
beforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositivelast. Connectthepositiverstandnegativelast.
•Usecarewhencheckingtheblades.Wrapthe
blade(s)orweargloves,andusecautionwhen servicingthem.Onlyreplaceblades.Never straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine running.
•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged decals.
•Tobestprotectyourinvestmentandmaintain
optimalperformanceofyourToroequipment,count onT orogenuineparts.Whenitcomestoreliability , Torodeliversreplacementpartsdesignedtothe exactengineeringspecicationsofourequipment. Forpeaceofmind,insistonT orogenuineparts.
Hauling
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyou mustknow.
Thisproductisdesignedforcuttingandrecycling grassor,whenequippedwithagrassbagger,for catchingcutgrass.Anyuseforpurposesotherthan thesecouldprovedangeroustoyouandbystanders.
GeneralOperation
•Besurethattheareaisclearofotherpeople
beforemowing.Stopthemachineifanyoneenters thearea.
•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowthemtocool beforeattemptingtomaintain,adjust,orservice them.
•UseonlyT oroapprovedattachments.The
warrantymaybevoidedifyouusethemachine withunapprovedattachments.
•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)before operatingthemachineunderanyobjects,anddo notcontactthem.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.
•Removeobstaclessuchasrocks,treelimbs,etc.
fromthemowingarea.
•Watchforholes,ruts,orbumps.Tallgrasscan
hideobstacles.
•Usecautionneardrop-offs,ditches,or
embankments.Themachinecouldsuddenlyturn overifawheelgoesovertheedgeofacliffor ditch,orifanedgecavesin.
•Useextracarewithgrasscatchersorother
attachments.Thesecanchangethestabilityof themachine.
•Keepallmovementonslopesslowandgradual.
Donotmakesuddenchangesinspeedor direction.
•Mowslopessidetoside.
•Donotmowslopesgreaterthan20degrees.
5
Page 6
Service
•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasneara waterheaterorfurnace.
•Keepnutsandboltstight,especiallytheblade
attachmentbolts.Keepequipmentingood condition.
•Nevertamperwithsafetydevices.Checksafety
systemsforproperoperationbeforeeachuse.
•Useonlygenuinereplacementpartstoensurethat
originalstandardsaremaintained.
•Checkbrakeoperationfrequently.Adjustand
serviceasrequired.
6
Page 7
SlopeIndicator
G011841
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
7
g011841
Page 8
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedorlost.
Manufacturer'sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
93-7010
decaloemmarkt
decal98-5130
98-5130
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto75-80ft-lb(102-106N⋅m).
decal93-7010
1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.
2.Thrownobjecthazard,mower—keepthedeectorinplace.
3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts.
95-5537
1.ReadtheOperator's Manualforinstructionson
operatingthecuttingblade
2.Pushforwardtoengage
3.Pullbacktodisengage
decal99-3943
99-3943
1.Engine
decal105-4104
105-4104
1.Reverse3.Transmissionspeeds
2.Neutral
decal95-5537(gear)
8
Page 9
decal112-9028
112-9028
1.Warning—stayawayfrommovingparts;keepallguardsin place.
1.Fast
2.Continuousvariable setting
1.Warning—donottouchthehotsurface.
decal106-2733
106-2733
117–2718
decal117-2718
3.Slow
decal106-5517
106-5517
decal121-6049
121-6049
1.Thrownobject hazard—keepbystanders awayfromthemachine.
2.Thrownobjecthazard, mower—donotoperate themowerwithguardsor shieldsremoved.
3.Cutting/dismemberment hazardofhandorfoot, mowerblade—keephands awayfrommovingparts.
112-8760
1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.
2.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts.
decal112-8760
decal126-1400
126-1400
1.Warning-ReadtheOperator’smanual.UseonlyTororiding attachments.Useofotherridingattachmentsmaycreatea hazardousconditionresultingininjury.
9
Page 10
130-8371
1.Parkingbrake3.Neutrallock
2.Tractiondrive
decal130-8371
decal131-1180
131-1180
1.ReadtheOperator'sManual.(A)Short,lightgrass;dry conditions;maximumdispersion;(B)Baggingsetting;(C) Tall,densegrass;wetconditions;maximumgroundspeed
decal130-8373
130-8373
1.Parkingposition5.Engine—run9.Thrownobject hazard—keepbystanders awayfromthemachine.
2.Driveposition6.Warning—readthe
Operator'sManual.
3.Neutralposition7.Warning—donotoperate
themachinewithout receivingpropertraining.
10.Warning—wearhearing protection.
11.Warning—stoptheengine, removethekeyfromthe ignition,andreadthe Operator'sManualbefore servicingorperforming maintenance.
4.Engine—stop8.Thrownobject hazard—stoptheengine andpickupanydebrisin theareabeforeoperating
12.Warning,releasethebar andensuretheenginehas stoppedbeforewalking awayfromthemachine.
themachine.
10
13.Warning—stayawayfrom movingparts;keepall guardsandshieldsinplace.
Page 11
ProductOverview
g012616
1
2
3
4
5
6
7
1.Sidedischarge5.Controls
2.Mowerdeck6.Handle
3.Recoil-starthandle
4.Fueltank
Figure4
7.Casterwheel
ThrottleControl
Thethrottlecontrolhas2positions:FastandSlow.
Operator-Presence-Control(OPC) Levers
WhenyousqueezetheOPCleversagainstthe handles,theOPCsystemsensesthattheoperatoris inthenormaloperatingposition.Whenyourelease theOPClevers,theOPCsystemsensesthatthe operatorhasleftthenormaloperatingposition,and thesystemwillstoptheengineifeitherthegear-shift leverisnotintheNeutralpositionortheblade-control (PTO)leverisengaged.
Gear-ShiftLever
g012616
Thetransmissionhas5forwardspeeds,neutral,and reverse,andhasanin-lineshiftpattern.
Important:Donotshiftwhilethemachineis
moving,astransmissiondamagemayoccur.
DriveLevers
Controls
Becomefamiliarwithallthecontrols(Figure5)before youstarttheengineandoperatethemachine.
1.Throttlecontrol6.Drivelever
2.Ignitionswitch
3.Neutral/parkingbrakelock8.Choke
4.Operator-presence-control (OPC)lever
5.Handle
Figure5
7.Gear-shiftlever
9.Power-take-offlever(PTO)
Releasethedriveleverstoengagetheforward tractionoperation.Squeezetheright-handdrivelever toturnrightandtheleft-handdrivelevertoturnleft.
Neutral/Parking-BrakeLock
Squeezethedriveleversandmovethelocksrearward forneutrallock.Squeezethedriveleversandmove thelocksforwardtosettheparkingbrake.
Blade-ControlLever(PTO)
ThisleverisusedinconjunctionwiththeOPClevers toengageordisengagethemowerdeckbeltand drivethemowerblades.
Recoil-StartHandle
Pulltherecoil-starthandletostarttheengine(not showninFigure5).
g001496
Fuel-ShutoffValve
Closethefuel-shutoffvalvewhentransportingor storingthemachine.
IgnitionSwitch
Thisswitchisusedinconjunctionwiththerecoil starterandhas2positions:RunandOff.
11
Page 12
Choke
Usethechoketostartacoldengine.
Operation

AddingFuel

Specications
Note:Specicationsanddesignaresubjectto
changewithoutnotice.
32-inchmowers:
Widthwithdeectordown116cm(46inches)
Length
Height
Weight
36-inchmowers:
Widthwithdeectordown118cm(47inches)
Length
Height
Weight
48-inchmowers:
Widthwithdeectordown161cm(63-1/2inches)
Length
Height
Weight
198cm(78inches)
104cm(41inches)
182kg(402lb)
203cm(80inches)
104cm(41inches)
210kg(462lb)
199cm(78inches)
104cm(41inches)
227kg(500lb)
•Forbestresults,useonlyclean,fresh(lessthan
30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol
(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.EthanolandMTBE arenotthesame.Gasolinewith15%ethanol (E15)byvolumeisnotapprovedforuse.Never usegasolinethatcontainsmorethan10%ethanol byvolume,suchasE15(contains15%ethanol), E20(contains20%ethanol),orE85(contains85% ethanol).Usingunapprovedgasolinemaycause performanceproblemsand/orenginedamage whichmaynotbecoveredunderwarranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuel
containersoverthewinterunlessafuelstabilizer isused.
•Donotaddoiltogasoline.
DANGER
Incertainconditions,fuelisextremely ammableandhighlyexplosive.Areor explosionfromfuelcanburnyouandothers andcandamageproperty .

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesisavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.T oro.comforalistofallapprovedattachments andaccessories.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanyfuel thatspills.
•Neverllthefueltankinsideanenclosed trailer.
•Donotllthefueltankcompletelyfull. Addfueltothefueltankuntilthelevelis25 mm(1inch)belowthebottomoftheller neck.Thisemptyspaceinthetankallows thefueltoexpand.
•Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
•Storefuelinanapprovedcontainerand keepitoutofthereachofchildren.Donot buymorethana30-daysupplyoffuel.
•Donotoperatewithouttheentireexhaust systeminplaceandinproperworking condition.
12
Page 13
DANGER
CheckingtheEngine-Oil
Incertainconditionsduringfueling,static electricitycancauseaspark,whichcanignite thefuelvapors.Areorexplosionfromfuel canburnyouandothersandcandamage property.
•Alwaysplacefuelcontainersontheground awayfromyourvehiclebeforelling.
•Donotllfuelcontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruck-bedlinersmay insulatethecontainerandslowthelossof anystaticcharge.
•Whenpractical,removefuel-powered equipmentfromthetruckortrailerand fueltheequipmentwithitswheelsonthe ground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma fuel-dispensernozzle.
•Ifafueldispensermustbeused,keepthe nozzleincontactwiththerimofthefuel tankorcontaineropeningatalltimesuntil fuelingiscomplete.
Level
Beforeyoustarttheengineandusethemachine, checktheoillevelintheenginecrankcase;referto CheckingtheEngine-oilLevel.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundthefuel-tankcapandremovethe cap.Addunleadedregulargasolinetothefuel tank,untilthelevelis6to13mm(1/4to1/2 inch)belowthebottomofthellerneck.This spaceinthetankallowsgasolinetoexpand.Do notllthefueltankcompletelyfull.
3.Installthefuel-tankcapsecurely.Wipeupany gasolinethatmayhavespilled.

PuttingSafetyFirst

Carefullyreadallthesafetyinstructionsanddecals inthesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing, feetandheadisrecommended.
WARNING
Fuelisharmfulorfatalifswallowed. Long-termexposuretovaporscancause seriousinjuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepyourfaceawayfromthenozzleand fueltankorconditioneropening.
•Keepfuelawayfromeyesandskin.

UsingFuel Stabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto keepthefuelfreshduringstorageof90daysorless. Ifyouarestoringthemachineforlonger,drainthefuel tank;refertoDrainingtheFuelT ank(page28).
Important:Donotusefueladditivescontaining
methanolorethanol.
Addthecorrectamountoffuelstabilizer/conditionerto thefuel,andfollowthedirectionsofthemanufacturer.
Note:Fuelstabilizer/conditionerismosteffective
whenmixedwithfreshgasoline.T ominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.
CAUTION
Thismachineproducessoundlevelsin excessof85dBAattheoperator'searand cancausehearinglossthroughextended periodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
decal98-4387
Figure6
1.Warning—wearhearingprotection.
13
Page 14

OperatingtheParking BrakeandNeutralLocks

Alwayssettheparkingbrakeswhenyoustopthe machineorleaveitunattended.
ReleasingtheNeutralLocks
1.Squeezethedriveleversback.
2.Placeyourthumbsontheupperpartofthelocks andmovethemforwarduntiltheyareinthe Driveposition(Figure7).
WARNING
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.
Alwayssettheparkingbrakewhenleaving themachineunattended,evenifjustforafew minutes.
SettingtheParkingBrakes
1.Squeezethedrivelevers(Figure7).
Figure7
1.Handle
2.Neutral/parkingbrakelock
3.Parkposition6.Neutralposition
2.Placeyourthumbsontheupperpartofthelocks
andmovethemforwardinintotheparkposition (Figure7).
3.Releasethedrivelevers.
4.Fullspeedforward
5.Drivelever
ReleasingtheParkingBrakes
1.Squeezethedriveleversback(Figure7).
2.Placeyourthumbsontheupperpartofthelocks andmovethemrearwarduntiltheyareinthe Driveposition(Figure7).
SettingtheNeutralLocks
1.Squeezethedriveleversback(Figure7).
2.Placeyourthumbsontheupperpartofthelocks andmovethemrearwardintotheNeutralLock position(Figure7).

StartingandStoppingthe Engine

StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
3.Disengagetheblade-control(PTO)leverand movetheshiftlevertotheNeutralposition.
4.Settheparkingbrakes.
5.TurntheignitionkeytotheRunposition(Figure
8).
6.T ostartacoldengine,movethethrottlecontrol midwaybetweentheFastandSlowpositions.
7.T ostartawarmengine,movethethrottlecontrol totheFastposition.
8.Pullthechokeknobiftheengineiscold(Figure
8).
Note:Awarmorhotengineusuallydoesnot
requireanychoking.
g001497
9.Grasptherecoil-starthandlermlyandpullitout untilpositiveengagementresults;thenpullthe handlevigorouslytostarttheengine.
Note:Allowtheropetorecoilslowly.
Important:Donotpulltherecoilropetoits
limitorreleasethestarterhandlewhenyou pullouttheropebecausetheropemaybreak ortherecoilassemblymaybedamaged.
10.PushthechoketotheOffpositionastheengine warmsup.
11.Iftheengineiscold,allowittowarmupandthen movethethrottlecontroltotheFastposition.
StoppingtheEngine
Important:Inanemergency,youcanstopthe
engineimmediatelybyturningtheignitionkeyto theOffposition.
1.Movethethrottlelevertotheslowposition (Figure8).
Note:Iftheenginehasbeenworkinghardor
ishot,letitidleforaminutebeforestoppingit tohelpcoolit.
2.TurntheignitionkeytotheOffposition.
14
Page 15
3.Settheparkingbrakesandremovethekey.
4.Disconnectthewirefromthesparkplugto preventsomeonefromaccidentallystartingthe machinewhiletransportingorstoringit.
5.Closethefuel-shutoffvalvebeforetransporting orstoringthemachine.
Important:Closethefuel-shutoffvalve
beforetransportingorthestoringthe machine,topreventfuelleakage.
g001756
Figure9
Figure8
1.Throttlecontrol
2.Ignitionswitch
3.Choke

Operatingthe Blade-Control(PTO)Lever

Theblade-control(PTO)leverengagesand disengagesthepowertothemowerblades.
EngagingtheMowerBlades(PTO)
1.Squeezetheoperatorpresencecontrol(OPC) leversagainstthehandles(Figure9).
2.Pushtheblade-control(PTO)leverrmly forwarduntilitlatchesoverthecenter(Figure9).
3.Starttheengineandrepeattheprocedure toengagethemowerbladesiftheoperator presencecontrol(OPC)leversarereleased.
DisengagingtheMowerBlades (PTO)
Todisengagetheblades,pulltheblade-controllever rearwardalltheway(Figure9).Theenginewill stopwhentheOPCleversarereleasedwiththe blade-controlleverengaged.
1.OperatorPresence Control(OPC)lever
2.Powertake-offlever(PTO)

TheSafety-Interlock System

g001755
CAUTION
Ifsafety-interlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedly,causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlock switchesdaily,andreplaceanydamaged switchesbeforeoperatingthemachine.
Understandingthe Safety-InterlockSystem
Thesafety-interlocksystemisdesignedtopreventthe enginefromstartingunless:
•Theblade-control(PTO)leverisdisengaged.
•ThemachineisshiftedintotheNeutralposition.
•TheignitionkeyisintheRunposition.
Thesafety-interlocksystemisdesignedtostop theenginewhen:
•Theoperator-presence-control(OPC)leversare
releasedwhenthetransmissionorthebladesare engaged.
•TheignitionkeyisturnedtotheOffposition.
15
Page 16
•Themachineisshiftedintogearwithoutholding
theOPClevers.
•Theblade-control(PTO)leverisengagedwithout
holdingtheOPClevers.
TestingtheSafety-Interlock System

DrivingForwardor Backward

Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Move thethrottlecontrolintotheFastpositionforthebest mowingperformance.
Testthesafety-interlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribed,haveanAuthorizedService Dealerrepairthesafetysystemimmediately.
1.Settheparkingbrakes,movetheshiftleverinto theNeutralposition,disengagetheblade-control (PTO)leverandplacethethrottleforward.
2.Starttheengine;refertoStartingtheEngine
(page14).
3.Withoutholdingtheoperator-presence-control (OPC)levers,engagetheblade-control(PTO) lever.
Note:Theengineshouldstop.
4.Disengagetheblade-control(PTO)lever.
5.Withtheenginerunning,holddowntheOPC leversandengagetheblade-control(PTO)lever.
Note:Themowerbeltshouldengageandthe
mowerbladesshouldbeginrotating.
6.ReleasetheOPClevers.
Note:Theengineshouldstop.
7.Withtheenginerunning,movetheshiftlever intogearandreleasetheOPClevers.
DrivingForward
1.Ensurethattheparkingbrakesareengaged.
2.SqueezetheOPCleversagainstthehandles.
3.Movetheshiftleverintoaforwardgear.
4.Releasetheparkingbrakes;refertoReleasing
theParkingBrakes(page14).
5.Slowlyreleasethedrivelevers.
Note:T ogostraight,releasethedrivelevers
equally.T oturn,squeezethedriveleveronthe samesideasthedirectionyouwanttoturn.
DrivingBackward
1.Ensurethattheparkingbrakesareengaged.
2.SqueezetheOPCleversagainstthehandles.
3.Movetheshiftleverintothereversegear.
4.Releasetheparkingbrakes;refertoReleasing
theParkingBrakes(page14).
5.Slowlyreleasethedrivelevers.
Note:Youmustpullthemowerbackwardto
assistitsrearwardmovement.
Note:Theengineshouldstop.
8.Withtheenginerunning,turntheignitionkey totheOffposition.
Note:Theengineshouldstop.
9.Ifalltheaboveconditionsarenotmet,have anAuthorizedServiceDealerrepairthesafety systemimmediately.

StoppingtheMower

1.Squeezethedriveleversallthewaybackto engagethebrakes.
2.Settheparkingbrakes.RefertoSettingthe
ParkingBrakes(page14).
3.ShifttransmissionintotheNeutralposition.
4.MovethethrottletotheStopposition,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
CAUTION
Childrenorbystandersmaybeinjured iftheymoveorattempttooperatethe machinewhileitisunattended.
Alwaysremovetheignitionkeyand settheparkingbrakewhenleavingthe machineunattended,evenifjustfora fewminutes.
16
Page 17

TransportingtheMachine

Adjustingthe
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarylightingandmarkingasrequiredbylaw. Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, pets,orbystandersavoidinjury.
Totransportthemachine:
1.Stoptheengine,removethekey,setthebrake, andclosethefuelvalve.
2.Securelyfastenthemachinetothetraileror truckwithstraps,chains,cable,orropes.
3.Secureatrailertotowingvehiclewithsafety chains.
4.Ifapplicable,connectthetrailerbrakes.

SideDischargingor MulchingtheGrass

Thismowerhasahingedgrassdeectorthat dispersesclippingstothesideanddowntowardthe turf.
Wheel-Drive-BeltTension
Youmayneedtoincreasethewheel-drive-belttension undercertainoperatingconditions,suchasmowing overhillyterrainorwhilepullingasulky.
1.Stoptheengine,removethekey ,andwaitforall movingpartstostop.
2.Disconnectthewiresfromthesparkplugs.
3.Disengagetheneutral/parkingbrakelocks,and releasethedriveleverstoreducethespring force.
4.Removethedrivespringfromtheadjustment bolt(Figure10).
DANGER
Withoutthegrassdeector,dischargecover, orcompletegrasscatcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris willcauseinjuryordeath.
•Neverremovethegrassdeectorfrom themower,becausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
•Neverputyourhandsorfeetunderthe mower.
•Nevertrytocleardischargeareaormower bladesunlessyoureleasetheOPClevers andthepowertake-off(PTO)isoff.Rotate theignitionkeytotheOffposition.Also removethekeyandpullthewireoffthe sparkplug(s).
Figure10
1.PositionA4.Drivespring
2.PositionB
3.PositionC
5.Removethelocknutthatsecurestheadjustment bolttothedrive-pulleyshield(Figure10).
6.Locateboltassemblyinthedesiredtension positionasfollows:
5.Adjustmentbolt(inposition
A)
6.Drive-pulleyshield
•PositionAfornormalconditions
•PositionBformoresevereconditions
•PositionCforthemostsevereconditions
Note:Thewheeldrivetensionislowest
whentheboltassemblyisinPositionA. ThetensionincreasesinPositionsBandC (Figure10).
g001498
7.Installtheadjustmentboltandthedrivespring.
8.Repeatstepsthroughfortheoppositeside.
17
Page 18

AdjustingtheHeightofCut

Thismachinehasa26to108mm(1to4-1/4inch) rangefortheheightofcut.Thiscanbeachievedby adjustingbladespacers,rearaxleheight,andfront casterspacers.UsetheHeight-of-CutChart(page
22)toselectthecombinationofadjustmentsrequired.
AdjustingtheBladeHeight
4.Slidetheboltdownthroughthespindle,and changethespacersasneeded(Figure11).
5.Installtheboltandcurvedwasher,addextra spacer(s),andsecurethemwithathinwasher andanut(Figure11).
6.T orquethebladeboltto101to108N-m(75to 80ft-lb).
Adjustthebladesbyusingthe4spacers(6mm) (1/4inch)onthebladespindlebolts.Thisallowsfora 25mm(1inch)adjustmentrange,in6mm(1/4inch) increments,ofcuttingheightinanyaxleposition.Use thesamenumberofbladespacersonallbladesto achievealevelcut(2aboveand2below,1above and3below,etc.).
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Holdthebladeboltandremovethenut(Figure
11).
AdjustingtheAxleHeight
Adjusttheaxlepositiontotheselectedheight-of-cut setting.RefertotheHeight-of-CutChart(page22).
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Loosen,butdonotremove,the2axlepivotbolts andthe2axleadjustmentbolts(Figure12).
g001455
Figure12
Figure11
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
1.Axlepivotbolt2.Axleadjustmentbolt
4.Placeajackundertherearcenteroftheengine frame.Raisethebackendoftheengineframe upenoughtoremovethefront2axleadjustment bolts(Figure12).
Note:Usejackstandstosupportthemachine.
5.Raiseorlowertheengineframewiththejackso thatyoucaninstallthefront2axleadjustment boltsinthedesiredholelocation(Figure12).
Note:Useataperedpunchtohelpalignthe
holes.
6.Tightenall4boltsandlowerthemower.
7.Adjustthecontrolrodsandthebrakelinkages asrequired.RefertoAdjustingtheControlRods
g001454
(page38)andAdjustingtheBrakes(page32).
Important:Youmustadjustthecontrolrods
4.Spacer
6.Nut
andthebrakelinkagewhenyouchangethe axlepositionsforpropertractionandbrake function.
18
Page 19
AdjustingtheCasterPosition
g012676
1 2
G012677
1.UsingtheHeight-of-CutChart(page22),adjust thecasterspacerstomatchwiththeaxlehole selected(Figure13).
g012676
Figure14
Figure13
1.Latchpin
2.Spacer,5mm(3/16inch)
3.Spacer,13mm(1/2inch)
2.Removethelatchpin,slidethecasterfromthe support,andchangethespacers(Figure13).
3.Installthecasterinthesupportandinsertthe latchpin(Figure13).
AdjustingtheFlowBafe
Youcanadjustthemowerdischargeowfordifferent typesofmowingconditions.Positionthecamlock andbafetogivethebestqualityofcut.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
1.Slot
g001456
2.Nut
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
Note:Iftheenginepowerdrawsdownandthe
mowergroundspeedisthesame,openupthebafe.
PositionA
Thisisthefull-rearposition(seeFigure15).The suggesteduseforthispositionisafollows:
•Useforshort,lightgrassmowingconditions.
•Useindryconditions.
•Useforsmallergrassclippings.
•Usetopropelgrassclippingsfartherawayfrom
themower.
3.Loosenthenut(Figure14).
4.Adjustthebafeandnutintheslottothedesired dischargeow,andtightenthenut.
g012677
Figure15
19
Page 20
PositionB
G012678
G012679
g012931
AdjustingtheHandle
Usethispositionwhenbagging(Figure16).
Figure16
PositionC
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure17):
•Useintall,densegrassmowingconditions.
•Useinwetconditions.
•Usetolowertheenginepowerconsumption.
•Useatanincreasedgroundspeedinheavy
conditions.
Height
Youcanadjustthehandlepositiontomatchyour heightpreference.
1.Removethehairpincotterpinsandclevispins fromthedriveleversandneutrallocks(Figure
18).
g012678
g012931
Figure18
1.Controlrod
2.Clevispin
3.OperatorPresence Controllever(OPC)
4.Handle
5.Neutrallock
6.Hairpincotterpin
7.Drivelever
Figure17
2.Loosentheupperbolts(3/8x1-1/4inches)and angenutsecuringhandletorearframe(Figure
19).
3.Removethelowerbolts(3/8x1inch)andange nutssecuringthehandletotherearframe (Figure19).
4.Pivotthehandletothedesiredoperatingposition andinstallthelowerangebolts(3/8x1inch) andangenutsintothemountingholes.
Note:Tightenallangebolts.
g012679
20
Page 21
Figure19
1.Upperhandle6.Lowermountingholes
2.Rearframe
3.Flangebolt(3/8x1inch)
4.Locknut(3/8inch)
5.Uppermountinghole
7.Lowposition
8.Middleposition
9.Highposition
5.Adjustthecontrolrodlengthbyrotatingthe controlrodintherodtting(Figure18).
6.Installahairpincotterbetweenthedrivelevers andtheneutrallocksandintotheclevispins (Figure18).
Note:Makesurethattheclevispinsare
insertedintotheneutrallocks.
7.Checktheparkingbrakeadjustment.Refer toCheckingtheBrakesinBrakeMaintenance
(page32).
g001493
21
Page 22

Height-of-CutChart

Numberofspacersbelow
Axle
position
A00
A01
A10
B01
B10
B11
B20
C
C
C
C
D21
D30
D31
D40
E31
E40
E41
thecaster
13mm
(1/2inch)
11
20
21
30
Numberof1/4inchbladespacersbelowthespindle
5mm
(3/16inch)
43210
26mm
(1inch)
29mm
(1-1/8inch)
35mm
(1-3/8inch)
35mm
(1-3/8inch)
41mm
(1-5/8inch)
45mm
(1-3/4inch)
51mm
(2inch)
48mm
(1-7/8inch)
55mm
(2-1/8inch)
57mm
(2-1/4inch)
64mm
(2-1/2inch)
61mm
(2-3/8inch)
64mm
(2-1/2inch)
70mm
(2-3/4inch)
76mm
(3inch)
73mm
(2-7/8inch)
79mm
(3-1/8inch)
82mm
(3-1/4inch)
32mm
(1-1/4inch)
35mm
(1-3/8inch)
41mm
(1-5/8inch)
41mm
(1-5/8inch)
48mm
(1-7/8inch)
51mm
(2inch)
57mm
(2-1/4inch)
54mm
(2-1/8inch)
60mm
(2-3/8inch)
64mm
(2-1/2inch)
70mm
(2-3/4inch)
67mm
(2-5/8inch)
70mm
(2-3/4inch)
76mm
(3inch)
82mm
(3-1/4inch)
79mm
(3-1/8inch)
86mm
(3-3/8inch)
89mm
(3-1/2inch)
38mm
(1-1/2inch)
41mm
(1-5/8inch)
48mm
(1-7/8inch)
48mm
(1-7/8inch)
54mm
(2-1/8inch)
57mm
(2-1/4inch)
64mm
(2-1/2inch)
60mm
(2-3/8inch)
67mm
(2-5/8inch)
70mm
(2-3/4inch)
76mm
(3inch)
73mm
(2-7/8inch)
76mm
(3inch)
82mm
(3-1/4inch)
89mm
(3-1/2inch)
86mm
(3-3/8inch)
92mm
(3-5/8inch)
95mm
(3-3/4inch)
45mm
(1-3/4inch)
48mm
(1-7/8inch)
54mm
(2-1/8inch)
54mm
(2-1/8inch)
60mm
(2-3/8inch)
64mm
(2-1/2inch)
70mm
(2-3/4inch)
67mm
(2-5/8inch)
73mm
(2-7/8inch)
76mm
(3inch)
83mm
(3-1/4inch)
79mm
(3-1/8inch)
82mm
(3-1/4inch)
89mm
(3-1/2inch)
95mm
(3-3/4inch)
92mm
(3-5/8inch)
98mm
(3-7/8inch)
102mm
(4inch)
51mm
(2inch)
54mm
(2-1/8inch)
60mm
(2-3/8inch)
60mm
(2-3/8inch)
67mm
(2-5/8inch)
70mm
(2-3/4inch)
76mm
(3inch)
73mm
(2-7/8inch)
79mm
(3-1/8inch)
83mm
(3-1/4inch)
89mm
(3-1/2inch)
86mm
(3-3/8inch)
89mm
(3-1/2inch)
95mm
(3-3/4inch)
102mm
(4inch)
98mm
(3-7/8inch)
105mm
(4-1/8inch)
108mm
(4-1/4inch)
22
Page 23
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst25hours
Beforeeachuseordaily
Every25hours
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthemowerbelttension.
•Checkthemowerbelttension.
•Checkthesafetysystem.
•Greasethecasterwheelsandcasterpivot.
•Checktheengine-oillevel.
•Cleantheair-intakescreen.
•Cleantheairintakescreenfromgrassanddebrisbeforeeachuse.
•Checkthebrakes.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanthefoamair-cleanerelement.
•Greasethemower-beltidler.
•Checkthepaperair-cleanerelement.
•Checkthetirepressure.
•Checkthebelts.
•Checkthemowerbelttension.
•Changetheengineoil.
•Checkthesparkplugs.
•Checkandcleantheengine-coolingnsandshrouds.
•Replacethepaperair-cleanerelement.
Every200hours
Every250hours
Every400hours
Beforestorage
•Changetheoillter .
•Replacethefuellter.
•Replacethefuel-ventlter.
•Greasethetransmissioncouplers(moreoftenindirtyordustyconditions).
•Greasethewheelbearings(moreoftenindirtyordustyconditions).
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineowner’smanualforadditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionanddisconnectthespark-plugwire(s)fromthesparkplug(s) beforeyoudoanymaintenance.Setthewireasidesothatitdoesnotaccidentallycontact thesparkplug.
23
Page 24
Lubrication
GreaseType:#2general-purposelithium-basedor molybdenum-basedgrease

LubricatingtheMachine

1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleanthegreasettingswitharag.Makesure toscrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pump greaseintothettingsuntilgreasebeginsto oozeoutofthebearings.
5.Wipeupanyexcessgrease.

LubricatingtheCasterand WheelBearings

g001458
Figure21

GreasingtheMower-Belt Idler

Greasethettingonthemower-belt-idler-armpivot (Figure22).
Note:Removethemower-deckcovertoaccessthe
greasettingforthemower-belt-idlerarm.
1.Lubricatethefront-wheelbearingsandfront spindles(Figure20).
2.Lubricatethedrive-wheelbearings.
Figure20

GreasingtheTransmission Couplers

g001459
Figure22
g001457
32-inchand36-inchmowerdeck
Lubricatethetransmissioncouplersandidlerarm pivotslocatedinthebackofthemachine(Figure21).
g001781
Figure23
48-inchmowerdeck
24
Page 25
EngineMaintenance
CleaningtheFoamAir-Cleaner Element

ServicingtheAirCleaner

ServiceInterval:Every25hours—Cleanthefoam
air-cleanerelement.
Every50hours—Checkthepaperair-cleaner element.
Every200hours—Replacethepaperair-cleaner element.
Note:Servicetheaircleanermorefrequently(every
fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy.
Important:Donotoilthefoamorpaperelement.
RemovingtheFoamandPaper Elements
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleanaroundtheaircleanertopreventdirtfrom gettingintotheengineandcausingdamage (Figure24).
4.Unscrewthecoverknobsandremovethe air-cleanercover(Figure24).
5.Unscrewthehoseclampandremovetheair cleanerassembly(Figure24).
6.Carefullypullthefoamelementoffthepaper element(Figure24).
1.Washthefoamelementinliquidsoapand warmwater.Whentheelementisclean,rinse itthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifit
istornorworn.
ServicingthePaperAir-Cleaner Element
1.Donotcleanthepaperlter,replaceit(Figure
24).
2.Inspecttheelementfortears,anoilylm,or damagetotherubberseal.
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaper Elements
Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.
1.Carefullyslidethefoamelementontothepaper air-cleanerelement(Figure24).
2.Placetheaircleanerassemblyontotheair cleanerbaseandsecureitwiththe2wingnuts (Figure24).
3.Placetheair-cleanercoverintopositionand tightenthecoverknob(Figure24).
Figure24
1.Cover
2.Hoseclamp4.Foamelement
3.Paperelement

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Check
theengine-oillevel.
Aftertherst8hours—Changetheengineoil.
Every100hours—Changetheengineoil.
Every200hours—Changetheoillter.
Note:Changetheoilmorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy .
OilType:Detergentoil(APIserviceSF,SG,SH,SJ orSL)
g012619
CrankcaseCapacity:1.7L(1.8USqt)withthelter removed;1.5L(1.6USqt)withoutthelterremoved
Viscosity:Refertothetable(Figure25).
25
Page 26
ChangingtheEngineOil
1.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoensurethatthe oildrainscompletely.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
4.Slidethedrainhoseovertheoildrainvalve.
5.Placeapanbelowthedrainhose.
Figure25
CheckingtheEngine-OilLevel
1.Parkthemachineonalevelsurface.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
4.Cleanaroundtheoildipstick(Figure26)sothat dirtcannotfallintothellerholeanddamage theengine.
g004216
Note:Rotateoildrainvalvetoallowoiltodrain
(Figure27).
6.Whenoilhasdrainedcompletely,closethedrain valve.
7.Removethedrainhose(Figure27).
Note:Disposeoftheusedoilatarecycling
center.
Figure26
1.Oildipstick
2.Fillertube
5.Unscrewtheoildipstickandwipetheendclean (Figure26).
6.Slidetheoildipstickfullyintothellertube,but donotthreaditontothetube(Figure26).
7.Pullthedipstickoutandlookattheend.Ifthe oillevelislow,slowlypouronlyenoughoilinto thellertubetoraisetheleveltotheFullmark.
Important:Donotoverllthecrankcase
withoilandruntheengine;enginedamage canresult.
g001464
g001466
Figure27
1.Oildrainvalve2.Oildrainhose
8.Slowlypourapproximately80%ofthespecied oilintothellertube(Figure26).
9.Checktheoillevel;refertoCheckingthe
Engine-OilLevel(page13)
10.Slowlyaddtheadditionaloiltobringittothe
Fullmark.
26
Page 27
ChangingtheOilFilter
1

ServicingtheSparkPlugs

Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy .
1.Draintheoilfromtheengine;refertoChanging
theEngineOil(page26).
2.Removetheoldlter(Figure28).
Figure28
1.Oillter
3.Applyathincoatofnewoiltotherubbergasket onthereplacementlter(Figure28).
2.Adapter
ServiceInterval:Every100hours—Checkthespark
plugs.
Ensurethattheairgapbetweenthecenterelectrode andthesideelectrodeiscorrectbeforeinstallingeach sparkplug.Useaspark-plugwrenchforremoving andinstallingthesparkplugsandagappingtoolora feelergaugetocheckandadjusttheairgap.Install newsparkplugsifnecessary.
Type:Champion®RCJ8Yorequivalent
AirGap:0.75mm(0.030inch)
RemovingtheSparkPlugs
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait
g001465
forallmovingpartstostopbeforeleavingthe operatingposition.
3.Disconnectthewiresfromthesparkplugs (Figure29).
4.Installthereplacementoilltertothelter adapter,turntheoillterclockwiseuntilthe rubbergasketcontactsthelteradapter,then tightenthelteranadditional3/4turn(Figure
28).
5.Fillthecrankcasewiththepropertypeofnew oil;refertoServicingtheEngineOil(page25).
6.Runtheengineforabout3minutes,stopthe engine,andcheckforoilleaksaroundtheoil lteranddrainvalve.
7.Checktheengineoillevelandaddoilifneeded.
8.Wipeupanyspilledoil.
g001469
Figure29
1.Spark-plugwire/sparkplug
4.Cleanaroundthesparkplugstopreventdirt fromfallingintotheengineandpotentially causingdamage.
5.Removethesparkplugsandthemetalwashers.
CheckingtheSparkPlugs
1.Lookatthecenterofthesparkplugs(Figure30).
Note:Ifyouseelightbrownorgrayonthe
insulator,theengineisoperatingproperly .A blackcoatingontheinsulatorusuallymeans thattheaircleanerisdirty.
2.Ifneeded,cleanthesparkplugwithawirebrush toremovecarbondeposits.
27
Page 28
Figure30
1.Centerelectrode;insulator3.Airgap(nottoscale)
2.Sideelectrode
Important:Alwaysreplacethesparkplugs
whentheyhavewornelectrodes,anoilylm, oracrackedinsulator.
3.Checkthegapbetweenthecenterelectrode andthesideelectrode(Figure30).
Note:Bendthesideelectrode(Figure30)ifthe
gapisnotcorrect.
InstallingtheSparkPlugs
1.Installthesparkplugsandthemetalwasher. Ensurethattheairgapissetcorrectly.
2.Tightenthesparkplugsto22N-m(16ft-lb).
3.Connectthewirestothesparkplugs(Figure30).
FuelSystem Maintenance

ServicingtheFuelSystem

DANGER
Incertainconditions,gasolineisextremely
g001470
ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouand othersandcandamageproperty.
•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopen area.Wipeupanygasolinethatspills.
•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.
DrainingtheFuelTank
1.Parkthemachineonalevelsurfacetoensure thatthefueltankdrainscompletely;then disengagethepowertake-off(PTO),setthe parkingbrake,andturntheignitionkeytothe Offposition.Removethekey.
2.Closethefuel-shutoffvalveatthefueltank (Figure31).
3.Squeezetheendsofthehoseclamptogether andslideitupthefuellineawayfromfuellter (Figure31).
4.Pullthefuellineoffthefuellter(Figure31).
Note:Openthefuel-shutoffvalveandallowthe
gasolinetodrainintoafuelcontaineroradrain pan.
Note:Nowisthebesttimetoinstallanewfuel
lterbecausethefueltankisempty .Referto
ReplacingtheFuelFilter(page29).
5.Installthefuellineontothefuellter.Slidethe hoseclampclosetothevalvetosecurethefuel line.
28
Page 29
Figure31
g001467
1.Fuel-shutoffvalve2.Clamp
ReplacingtheFuelFilter
ServiceInterval:Every200hours/Yearly(whichever
comesrst)
Neverinstalladirtylterifitisremovedfromthefuel line.
Note:Notehowthefuellterisinstalledinorderto
installthenewltercorrectly.
Note:Wipeupanyspilledfuel.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Closethefuel-shutoffvalveatthefueltank (Figure31).
4.Squeezetheendsofthehoseclampstogether andslidethemawayfromthelter(Figure32).
g001468
Figure32
1.Hoseclamp3.Filter
2.Fuelline
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclamps closetothelter.
7.Openthefuel-shutoffvalveatthefueltank (Figure31).
8.Checkforfuelleaks,andrepairifneeded.
9.Wipeupanyfuelthatspilled.
29
Page 30
ServicingtheFuel-VentSystem
g014686
1 2
ServiceInterval:Every200hours/Yearly(whichever
comesrst)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removetheexistingfuel-ventlter(Figure33).
4.Installanewlter.
DriveSystem Maintenance

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat83to97 kPa(12to14psi).Uneventirepressurecancause anunevencut.
Note:Thefronttiresaresemi-pneumatictiresanddo
notrequireairpressuremaintenance.
Figure33
1.Fuel-ventlter2.Rightsideoftheengine
g001055
g014686
Figure34
30
Page 31
CoolingSystem Maintenance

CleaningtheAir-intake Screen

Beforeeachuse,removeanybuildupofgrass,dirt, orotherdebrisfromthecylinderandcylinder-head coolingns,theair-intakescreenontheywheelend, andthecarburetor-governorleversandlinkage.This willhelpensureadequatecoolingandcorrectengine speedandwillreducethepossibilityofoverheating andmechanicaldamagetotheengine.

CleaningtheCooling System

ServiceInterval:Beforeeachuseordaily
Every100hours/Yearly(whichevercomesrst)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removetheair-intakescreen,therecoilstarter, andthefanhousing(Figure35).
4.Cleanthedebrisandgrassfromtheengine parts.
5.Installtheair-intakescreen,therecoilstarter, andthefanhousing(Figure35).
g001472
Figure35
1.Air-intakescreen4.Bolt
2.Fanhousing5.Nut
3.Recoilstarter
31
Page 32
BrakeMaintenance

ServicingtheBrakes

Beforeeachuse,checkthebrakesonbothalevel surfaceandaslope.
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Iftheparkingbrake doesnotholdthemachinesecurely,adjustit.
CheckingtheBrakes
1.Parkthemachineonalevelsurface,disengage theblade-control(PTO)lever.
2.Stoptheengine,removethekey,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Applytheparkingbrakes.
Note:Thewheelsmustlockwhenyoutryto
pushthemachineforward.
4.Ifthewheelsdonotlock,adjustthebrakes;refer toAdjustingtheBrakes(page32).
5.Releasethebrakesandmovetheneutral/brake lockstotheNeutralposition.
Note:Thewheelsshouldrotatefreely;ifthey
donot,refertoAdjustingtheBrakes(page32).
AdjustingtheBrakes
Iftheparkingbrakesdonotholdsecurely,adjustthem.
1.Checkthebrakesbeforeyouadjustthem;refer toCheckingtheBrakes(page32).
g001561
Figure36
1.Brakerod2.Wingnut
4.Positionthewingnutssothatthebrakesengage whenyousqueezethedriveleversenoughto placetheneutral/parkingbrakelocksforward, andthensetthebrakes.
5.Checktheoperationofthebrakesagain;referto
CheckingtheBrakes(page32).
Important:Whenyoureleasetheparking
brakes,therearwheelsshouldrotatefreely whenyoupushthemower.Iftheydo not,contactanAuthorizedServiceDealer immediately.
6.Checkthecontrolrodlength,refertoAdjusting
theBrakes(page32).
2.Releasetheparkingbrakes;refertoReleasing
theParkingBrakes(page14).
3.T oadjustthebrakes,rotatethewingnutsonthe brakerods(Figure36).
Note:Rotatethewingnutsclockwisetotighten
thebrakes;rotatethemcounterclockwiseto loosenthem.
32
Page 33
BeltMaintenance

CheckingtheBelts

ServiceInterval:Every50hours/Monthly(whichever
comesrst)—Checkthebelts.
Checkthebeltsforcracks,frayededges,burnmarks, wear,signsofoverheating,oranyotherdamage. Replaceanydamagedbelts.

ReplacingtheTraction DriveBelt

1.Removethehairpincottersecuringthebrake rodtothebrakearmtorelaxthetensiononthe beltidler(Figure37).
2.Removethebottomboltandloosenthetopbolt oftheshieldtorotateitforbeltclearance(Figure
37).
3.Liftthebeltpasttheidlerandoffthedrivepulley (Figure37).
4.Raisethewheeloffthegroundenoughto removethebelt.
5.Replacethetraction-drivebelt.
6.Securetheshieldwiththepreviouslyremoved bolt,andtightenthebolts(Figure37).
7.Securethebrakerodtothebrakearmwiththe hairpincotter(Figure37).
3.Raisetherearofthemachineandholditupwith jackstands.
4.Removethemowerbelt(Figure38).
Figure38
1.Idlerpulleyinslot4.Beltguide
2.Tractionbelt
3.Mowerbelt6.Mowerbelt
5.Loosenthepivotboltenoughtoslidetheidler pulleyintheslot,andremovethetractionbelt fromtheengineandthedrivepulleys(Figure
38).
6.Installthenewdrivebeltaroundtheengineand thedrivepulleys(Figure38).
7.Slidetheidlerpulleyintheengineframeto tensionthetractionbelt(Figure38).
8.Installthemowerbelt(Figure38).
5.19mm(3/4inch)
g001475
Figure37
1.Drivebelt3.Tire
2.Drivespring4.Adjustmentbolt

ReplacingtheDriveBelt

1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
9.Checkthebeltguideundertheengineframefor theproperadjustment(Figure38).
Note:Thedistancebetweenthebeltguideand
mowerbeltshouldbe19mm(3/4inch)when youengagethemowerbelt.Adjustthebeltif necessary.Thedisengagedbeltshouldnotdrag orfalloffthepulleywhentheguidesareproperly adjusted.
g001562

ReplacingtheMowerBelt

Important:Thebrakeneedstobeadjustedwhen
thebelttensionorthebrakelinkageisadjusted.
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Removetheknobsandthebeltcoveronthe mower.
4.Removetheidlerpulleyandthewornbelt.
5.Installthenewmowerbelt.
33
Page 34
6.Installtheidlerpulley.
7.Engagetheblade-control(PTO)leverandcheck thebelttension.RefertoCheckingtheBelts
(page33).
Note:Thepropermowerbelttensionis44to
67N-m(10to15ft-lb)withthebeltdeected 13mm(1/2inch)halfwaybetweenthepulleys (Figure42orFigure43).
8.Engagetheblade-control(PTO)lever.
9.Checktheclearancebetweenthebellcrankand thetransmissionoutputshaft(Figure39).
g001478
Figure40
32-inchand36-inchmowerdeck
Figure39
1.2to3mm(1/16to1/8inch)
2.Bellcrank
3.Transmissionoutputshaft6.Clevis
4.Hairpincotter
5.Clevispin
Note:Theclearanceshouldbe2to3mm(1/16
to1/8inch).
10.Removethehairpincotterpinandtheclevispin fromthebellcrank.
11.Rotatetheclevisclockwiseontherodtoincrease theclearance;rotateitcounterclockwiseto decreaseit(Figure39).
12.Disengagetheblade-control(PTO)lever.
Note:Iftheassistarmdoesnotcontactthe
frontstoponthemowerdeck(Figure40or
Figure41),adjusttheclevistobringthebell
crankclosertothetransmissionoutputshaft (Figure39).
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
g001477
48-inchmowerdeck
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
g001566
Figure41
4.Locknut
13.Checkthebeltguideundertheengineframefor theproperadjustment(Figure38).
Note:Thedistancebetweenthebeltguideand
themowerbeltshouldbe32mm(1-1/4inch) whenyouengagethemowerbelt.Adjustthe
34
Page 35
mowerbeltasnecessary.Thedisengagedbelt shouldnotdragorfalloffthepulleywhenthe guidesareproperlyadjusted.

AdjustingtheMowerBelt Tension

AdjustingtheTensionfor32-inch and36-inchMowerDecks
ServiceInterval:Aftertherst8hours—Checkthe
mowerbelttension.
Aftertherst25hours—Checkthemowerbelt tension.
Every50hours—Checkthemowerbelttension.
Important:Adjustthebrakewheneveryouadjust
thebelttensionorthebrakelinkage.
Important:Thebeltmustbetightenoughto
notslipduringheavyloadswhilecuttinggrass. Over-tensioningthebeltwillreducethelifeofthe spindlebearing,thebelt,andtheidlerpulley.
Thebeltmustbetightenoughsothatitdoesnot slipduringheavyloadswhilecuttinggrass,and over-tensioningwillreducebeltandspindlebearing life.
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Loosenthelocknutontheturnbuckle(Figure
42).
4.Rotatetheturnbuckletowardtherearofthe mowertoincreasethetensiononthebelt. Rotatetheturnbuckletowardthefrontofthe mowertodecreasethetensiononthebelt (Figure42).
Figure42
32-inchand36-inchmowerdeck
1.Mowerbeltwith13mm (1/2inch)deection
6.Tightenthelocknutontheturnbuckle.
7.Checktheadjustmentofthebladebrake;refer toAdjustingtheBladeBrake(page41).
2.Idlerpulley
AdjustingtheTensionfor48-inch MowerDecks
Important:Thebeltmustbetightenoughto
notslipduringheavyloadswhilecuttinggrass. Over-tensioningthebeltwillreducethespindle bearinglife,thebeltlifeandtheidlerpulleylife.
Important:Thebrakeneedstobeadjustedwhen
thebelttensionorthebrakelinkageisadjusted.
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
g001476
Note:Theeyeboltthreadsonbothendsofthe
turnbuckleshouldbeengagedaminimumof8 mm(5/16inch).
5.Engagetheblade-controllever(PTO)andcheck thebelttension.Adjustthetensionuntilitis correct.
Note:Thepropermowerbelttensionis44to
67N-m(10to15ft-lb)withthebeltdeected 13mm(1/2inch)halfwaybetweenthepulleys (Figure42).
3.Loosenthelocknutontheturnbuckle(Figure
44).
4.Adjustthetensionofthebelt.
•Rotatetheturnbuckletowardtherearofthe
mowertoincreasethetensiononthebelt.
•Rotatetheturnbuckletowardthefrontofthe
mowertodecreasethetensiononthebelt (Figure44).
Note:Thepropermowerbelttensionis44to
67N-m(10to15ft-lb)withthebeltdeected 13mm(1/2inch)halfwaybetweenthepulleys (Figure43).
35
Page 36
Figure43
48-inchmowerdeck
1.Idlerpulley2.Mowerbeltwith13mm (1/2inch)deection
Note:Theeyeboltthreadsonbothendsofthe
turnbuckleshouldbeengagedaminimumof8 mm(5/16inch).
6.Ifthereisnoadjustmentleftintheturnbuckle andthebeltisstillloose,therearidlerpulley needstobepositionedtothemiddleorfront hole(Figure45).Usetheholethatwillgivethe correctadjustment.
7.Whenyoumovetheidlerpulley,youmustmove thebeltguide.Movethebeltguidetothefront position(Figure45).
g001565
r:\g001848
Figure45
1.Rearidlerpulley4.Beltguideinbackposition
2.Middlehole5.Frontidlerpulley
3.Fronthole
8.Checkthebeltguideundertheengineframefor properadjustment(Figure46).
Figure44
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
5.Engagetheblade-controllever(PTO)andcheck thebelttension.
Note:Thedistancebetweenthebeltguideand
themowerbeltshouldbe19mm(3/4inch)when youengagethemowerbelt(Figure46).Adjust themowerbeltasnecessary.Thedisengaged beltshouldnotdragorfalloffthepulleywhenthe guidesandbelttensionareproperlyadjusted.
9.Checktheadjustmentofthebladebrake;refer toAdjustingtheBladeBrake(page41).
r:\g001566
36
Page 37
Figure46
1.Idlerpulleyinslot4.Beltguide
2.Tractionbelt
3.Mowerbelt6.Mowerbelt
5.19mm(3/4inch)
AdjustingthePTO-Engagement Linkage
TheadjustmentforthePTO-engagementlinkage islocatedbeneaththefrontleft-handcornerofthe enginedeck.
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Engagetheblade-controllever(PTO).
4.Adjustthelinkagelengthtowherethelower endofthebellcrankjustclearstheaxlesupport gusset(Figure47).
g001475
g001847
Figure47
1.Bellcrank4.Yoke
2.Safetyswitchlocated underenginedeck
3.Bellcrankjustclearsthe gussetwiththePTO engaged
5.Nut
6.Assistarmlink
5.Makesurethattheassistarmisagainstthe rear-assist-armstoponthedeck(Figure48).
6.Pushtheblade-controllever(PTO)downtothe disengagedposition.
7.Theassistarmshouldcontactthe front-assist-armstoponthedeck.Ifit doesnotcontact,adjustthebellcranksothatit isclosertothegusset(Figure48).
Figure48
1.Yoke5.Assistarmlink
2.Nut6.Assistarm
3.Rearassistarmstop7.Turnbuckle
4.Frontassistarmstop
37
g001849
Page 38
8.T oadjusttheassistarmlink,removethehairpin
g012931
cotterpinfromtheassistarm(Figure48).
ControlsSystem
9.Loosenthenutagainsttheyoke(Figure47).
10.Removetheassistarmlinkfromtheassistarm androtatethelinktoadjustthelength.
11.Installtheassistarmlinkintotheassistarmand secureitwiththehairpincotterpin(Figure48).
12.Checkiftheassistarmhitsagainstthestops correctly.
AdjustingthePTOSafetySwitch
1.Disengagetheblade-control(PTO)leverand settheparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Disengagetheblade-controllever(PTO). Makesurethattheassistarmisagainstthe front-assist-armstop.
4.Ifneeded,adjusttheblade-safetyswitchby looseningtheboltsholdingtheswitchbracket (Figure49).
5.Movethemountingbracketuntilthebellcrank pressestheplungerby6mm(1/4inch).
Note:Makesurethatthebellcrankdoesnot
touchtheswitchbody;otherwise,damagetothe switchcouldoccur(Figure49).
Maintenance

AdjustingtheControlRods

1.Removethehairpincotterpinsandclevispins fromthedriveleversandneutrallocks(Figure
50).
Figure50
1.Controlrod
2.Clevispin
3.Operator-presence-control lever(OPC)
4.Handle8.Drivelever
5.Neutrallock
6.Hairpincotter
7.Lefthandleshown
g012931
Figure49
1.Bellcrank
2.Boltsandnuts
6.Tightentheswitchmountingbracket.
2.Adjustthecontrolrodlengthbythreadingthe rodinoroutoftherodttinguntilthereisa5to6 mm(3/16to1/4inches)clearancebetweenthe controlrodandthebottomoftheneutral/parking brakelock(Figure51).
g001855
3.Switchmountingbracket
4.Switchbody
38
Page 39
Figure51
1.Handle4.Drivelever
2.Neutral/parkingbrakelock
3.5to6mm(3/16to1/4 inch)clearance
5.Forwardspeed
6.Controlrod

MowerDeck Maintenance

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement, youmaywanttokeepextrabladesonhand.
g001495
WARNING
Awornordamagedbladecanbreak,anda pieceofthebladecouldbethrownintothe operator'sorbystander'sarea,resultingin seriouspersonalinjuryordeath.
3.Installthecontrolrodtothedriveleverandthe neutral/parkingbrakelock.Securethecontrol rodwithaclevispinandahairpincotter(Figure
51).
4.Checktheoperationofthecontrolrod.
Note:Ifyouneedtoadjustit,removethe
hairpincotterandtheclevispinthatsecurethe controlrodtothedrivelevers.
5.Adjustthecontrolrodlengthbyrepeatingthe previoussteps.
•Inspectthebladeperiodicallyforwearor damage.
•Replaceawornordamagedblade.
PreparingtoInspectorService theBlades
1.Parkthemachineonalevelsurface,disengage theblade-controllever,andsettheparking brake.
2.TurntheignitionkeytotheOffposition.
3.Removethekeyanddisconnectthespark-plug wire(s)fromthesparkplug(s).
39
Page 40
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure52).Ifthe edgesarenotsharporhavenicks,removeand sharpentheblades.RefertoSharpeningthe
Blades(page41).
g001564
Figure54
2.Measurefromalevelsurfacetothecutting edge,positionA,oftheblades(Figure55).
Figure52
1.CuttingEdge3.Wear/slotformingin curvedarea
2.Sail4.Crackinthecurvedarea
2.Inspecttheblades,especiallythecurvedarea (Figure52).Ifyounoticeanydamage,wear,or aslotforminginthisarea(item3.inFigure52), immediatelyinstallanewblade.
CheckingforBentBlades
1.Rotatethebladesuntiltheendsfaceforward andbackward(Figure53).
g006530
Note:Notethisdimension.
g001563
Figure55
1.Measurefromthecuttingedgetoalevelsurface
3.Rotatetheoppositeendsofthebladesforward.
4.Measurefromalevelsurfacetothecuttingedge ofthebladesatthesamepositionasinstep1.
Note:Thedifferencebetweenthedimensions
obtainedinsteps1and2mustnotexceed3mm (1/8inch).Ifthisdimensionexceeds3mm(1/8 inch),thebladeisbentandmustbereplaced. RefertoRemovingtheBlades(page41)and
InstallingtheBlades(page41).
WARNING
Figure53
Abladethatisbentordamagedcould breakapartandcouldseriouslyinjureor killyouorbystanders.
g001481
•Alwaysreplacebentordamaged bladewithanewblade.
•Neverleorcreatesharpnotchesin theedgesorsurfacesofblade.
40
Page 41
RemovingtheBlades
Replacethebladesifyouhitasolidobjectorifthe bladesareoutofbalanceorbent.T oensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturers mayresultinnon-conformancewithsafetystandards.
1.Holdthebladeboltwithawrench.
2.Removethenut,bladebolt,curvedwasher, blade,spacers,andthinwasherfromthespindle (Figure56).
g000276
Figure57
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure58).
Note:Ifthebladestaysinahorizontalposition,
thebladeisbalancedandcanbeused.Ifthe bladeisnotbalanced,lesomemetaloffthe endofthesailareaonly(Figure58).Repeatthis procedureuntilthebladeisbalanced.
g000277
Figure58
Figure56
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
4.Spacer
6.Nut
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatboth endsoftheblade(Figure57).
Note:Maintaintheoriginalangle.Theblade
retainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
1.Blade2.Balancer
InstallingtheBlades
1.Installthecurvedwasherandthentheblade ontothebolt.Selectthepropernumberof spacer(s)fortheheightofcut,andslidethebolt intothespindle(Figure56).
Important:Thecurvedpartoftheblade
mustpointupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installtheremainingspacer(s)andsecurethem withathinwasherandanut(Fig.Figure56).
g001454
3.T orquethebladeboltto101to108N-m(75to 80ft-lb).

AdjustingtheBladeBrake

1.DisengagethePTO,turntheignitionkeytooff, andremovethekey.
2.Waitforallmovingpartstostopbeforeleaving theoperatingpositionandsettingtheparking brake.
3.Ifnecessary,adjustthespringmountingboltsso thattheblade-brakepadrubsagainstbothsides ofthepulleygroove(Figure59).
4.Adjustthenutattheendoftheblade-brakerod untilthereis3mmto5mm(1/8to3/16inch) betweenthenutandspacer(Figure59).
41
Page 42
5.Engagetheblades.
g012749
Note:Ensurethebladebrakepadnolonger
contactsthepulleygroove.
g012749
Figure60
Figure59
1.Springmountingbolts3.3mmto5mm(1/8to 3/16inch)
2.Blade-brakepad
ReplacingtheGrass Deector
WARNING
Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsatyouor bystanders,resultinginseriousinjuryor death.Also,contactwiththebladecould occur.
Neveroperatethelawnmowerunlessyou installacoverplate,amulchplate,oragrass chuteandcatcher.
1.Bolt
2.Spacer6.GrassDeector
g001485
3.Locknut
4.Spring8.Jhookendofspring
5.Springinstalled
7.Lendofspring,place
behinddeckedgebefore installingbolt
2.Placethespacerandthespringontothegrass deector,andplacetheL-endofspringbehind deckedge.
Note:MakesurethattheL-endofthespringis
installedbehinddeckedgebeforeinstallingthe boltasshowninFigure60.
3.Installtheboltandthenut.PlacetheJ-hookend ofthespringaroundthegrassdeector(Figure
60).
Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefully openpositionandensurethatitrotatesinto thefullydownposition.
1.Removethelocknut,bolt,springandspacer holdingthedeectortothepivotbrackets (Figure60).
Note:Removedamagedorworngrass
deector.
42
Page 43
Storage

CleaningandStorage

1.Disengagethepowertake-off(PTO),setthe parkingbrake,turntheignitionkeytotheOff position,andremovethekey.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especially theengine.Cleandirtandchafffromtheoutside oftheenginecylinder-headnsandtheblower housing.
Important:Youcanwashthemachine
withmilddetergentandwater.Donot pressure-washthemachine.Avoid excessiveuseofwater,especiallynearthe shift-leverplateandtheengine.
3.Checkthebrake;refertoCheckingtheBrakes
(page32).
4.Servicetheaircleaner;refertoServicingtheAir
Cleaner(page25).
12.Installthesparkplug(s),butdonotinstallthe wireonthesparkplug(s).
13.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamagedor worn.
14.Paintallscratchedorbaremetalsurfaceswith paintavailablefromyourAuthorizedService Dealer.
15.Storethemachineinaclean,drygarageor storagearea.Removethekeyfromtheignition switchandkeepitinamemorableplace.Cover themachinetoprotectitandkeepitclean.
5.Greasethemachine;refertoLubricatingthe
Machine(page24).
6.Changethecrankcaseoil;refertoChangingthe
EngineOil(page26).
7.Checkthetirepressure;refertoCheckingthe
TirePressure(page30).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelin
thetank.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
C.Stoptheengine,allowittocool,anddrain
thefueltank;refertoDrainingtheFuelTank
(page28),orruntheengineuntilitstops.
D.Starttheengineandrunituntilitstops.
Repeattheprocess,withthechokeon,until theenginewillnotstart.
E.Disposeoffuelproperly.Recycleit
accordingtolocalcodes.
Note:Donotstorestabilizer/conditioned
gasolineover90days.
9.Removeandchecktheconditionofthespark plug(s);refertoServicingtheSparkPlugs(page
27).
10.Withthesparkplug(s)removedfromthe engine,pour2tablespoonsofengineoilintothe spark-plughole.
11.Usethestartertocranktheengineanddistribute theoilinsidethecylinder.
43
Page 44
Troubleshooting
Problem
Theenginewillnotstart,startshard,or failstokeeprunning.
Theenginelosespower.
PossibleCauseCorrectiveAction
1.Thefueltankisempty.1.Fillthefueltankwithgasoline.
2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.
3.Thechokeisnotinthecorrectposition.
4.Theaircleanerisdirty.
5.Thespark-plugwireislooseor disconnected.
6.Thesparkplugispittedorfouled,or thegapisincorrect.
7.Thereisdirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theaircleanerisdirty.
3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.
4.Thecoolingnsandairpassages undertheengineblowerhousingare plugged.
5.Thesparkplugispittedorfouled,or thegapisincorrect.
6.Theventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.
7.Thereisdirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
3.Closethechokeiftheengineiscold; openthechokeiftheengineiswarm.
4.Cleanorreplacetheair-cleaner element.
5.Installthewireonsparkplug.
6.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
2.Cleantheair-cleanerelement.
4.Removetheobstructionfromthe coolingnsandairpassages.
5.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
Theengineoverheats.
Themachinedoesnotdrive.
Thereisabnormalvibration.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.
3.Thecoolingnsandairpassages undertheengineblowerhousingare plugged.
1.Theshiftleverisinneutral.1.Movetheshiftlevertoadrivegear
2.Thetractionbeltisworn,loose,or broken.
3.Thetractionbeltisoffapulley .3.Changethebelt.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
1.One/severalcuttingbladesis/arebent orunbalanced.
2.Ablademountingboltisloose.2.Tightentheblademountingbolt.
3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Theenginepulley ,idlerpulley,orblade pulleyisloose.
5.Theenginepulleyisdamaged.
6.Thebladespindleisbent.
3.Removetheobstructionfromthe coolingnsandairpassages.
position.
2.Changethebelt.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
44
Page 45
Problem
PossibleCauseCorrectiveAction
Themachineproducesanunevencutting height.
Thebladesdonotrotate.
1.Theblade(s)is/arenotsharp.1.Sharpentheblade(s).
2.One/severalcuttingblade(s)is/are bent.
3.Themowerisnotlevel.
4.Theundersideofthemowerisdirty.4.Cleantheundersideofthemower.
5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.
6.Abladespindleisbent.
1.Themowerdeckbeltiswornorloose.
2.Themowerdeckbeltisbroken.2.Installanewdeckbelt.
3.Themowerdeckbeltisoffpulley.3.Inspectthebeltandreplaceitifitis
4.Theidlerspringisbrokenormissing.4.Replacethespring.
2.Installnewcuttingblade(s).
3.Levelthemowerfromside-to-sideand front-to-rear.
6.ContactanAuthorizedServiceDealer.
1.Checkthebelttension.
damaged.Checkthepulleysandidlers andadjustthebelttension.
45
Page 46
Schematics
g001639
ElectricalSchematic(Rev .A)
46
Page 47
Notes:
Page 48
TheToroT otalCoverageWarranty
ALimitedWarranty(seewarrantyperiodsbelow)Contractor
Landscape
Equipment (LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuanttoanagreement betweenthem,jointlypromisetotheoriginalpurchasertorepairtheToroProducts listedbelowifdefectiveinmaterialsorworkmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:
ProductsWarrantyPeriod
21in.Mowers2yearsResidentialUse
1yearCommercialUse
4
•Engines
Honda–2years
Kawasaki–3years
30in.Mowers2yearsResidentialUse
1yearCommercialUse
4
•Engines
Mid-SizeWalk-BehindMowers
4
•Engines
GrandStand
4
•Engines
•Frame
®
ZMaster
•Engines
2000SeriesMowers
4
•Frame
®
ZMaster
•Engines
•Frame
ZMaster
•Engines
®
3000SeriesMowers
4
5000SeriesMowers
4
®
Mowers
Kawasaki–3years
2years
Kawasaki–3years
5yearsor1,200hours
3years
Lifetime(originalowneronly)
4yearsor500hours
3years
Lifetime(originalowneronly)
5yearsor1,200hours 3years Lifetime(originalowneronly) 5yearsor1,200hours
KohlerCommand–2years
KohlerEFI–3years
•Frame
®
ZMaster
•Engines
6000SeriesMowers
4
•Frame
®
ZMaster
•Engines
7000SeriesMowers
4
•Frame
®
ZMaster
•Engines
8000SeriesMowers
4
•Frame
Lifetime(originalowneronly)
5yearsor1,200hours
Kawasaki–3years
Lifetime(originalowneronly)
5yearsor1,200hours
2years
Lifetime(originalowneronly)
2yearsor1,200hours
2years
Lifetime(originalowneronly)
AllMowers
•Battery90daysPartsandLabor
1yearPartsonly
•BeltsandTires90days
•Attachments1year
1
Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone
locationisconsideredcommercialuseandthecommercialwarrantywouldapply.
2
Whicheveroccursrst.
3
LifetimeFrameW arranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforpartsand labor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosion arenotcovered.
4
SomeenginesusedonT oroProductsarewarrantedbytheenginemanufacturer.
1
1
2
3
2
3
2
3
2
3
2
3
2
3
2
3
InstructionsforObtainingWarrantyService
IfyouthinkthatyourToroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.T olocateadealerconvenienttoyou,refertotheY ellowPagesof yourtelephonedirectory(lookunder“LawnMowers”)oraccessourwebsite atwww.Toro.com.Y oumayalsocallthenumberslistedinitem#3tousethe 24-hourT oroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered underwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith theassistanceprovided,contactusat:
RLCCustomerCareDepartment
ToroWarrantyCompany
811 1LyndaleAvenueSouth
Bloomington,MN55420-1 196
888-865-5676(U.S.Customers)
888-865-5691(Canadacustomers)
OwnerResponsibilities
YoumustmaintainyourToroProductbyfollowingthemaintenanceprocedures describedintheOperator'sManual.Suchroutinemaintenance,whetherperformedby adealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot coverthefollowing:
•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil
changes,sparkplugs,airltersbladesharpeningorwornblades,cable/linkage adjustments,orbrakeandclutchadjustments
•Componentsfailingduetonormalwear
•Anyproductorpartwhichhasbeenalteredormisusedorneglectedandrequires
replacementorrepairduetoaccidentsorlackofpropermaintenance
•Pickupanddeliverycharges
•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService
Dealer
•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult
Operator'sManualformoredetails)
–Removingcontaminantsfromthefuelsystemisnotcovered
–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan
10%ethanolormorethat15%MTBE
–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone
month
GeneralConditions
AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedToro ServiceDealerusingT oroapprovedreplacementparts.
NeitherTheToroCompanynorT oroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheToro Productscoveredbythiswarranty,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty .
Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse) andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto thedurationoftheexpresswarranty .
Somestatesdonotallowexclusionsofincidentalorconsequentialdamages, orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions andlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry, province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheT oroimporter.Ifallother remediesfail,youmaycontactusatToroWarrantyCompany.
AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalToroDealer.
374-0252RevG
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