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30634
Operator's Manual
48 pgs13.65 Mb0
Operator's Manual
44 pgs9.14 Mb0
Operator's Manual [es]
52 pgs2.76 Mb0
Operator's Manual [fr]
52 pgs2.76 Mb0
Parts Catalogue
20 pgs652.51 Kb0
Setup Instructions
12 pgs16.5 Mb0

Toro 30632, 30634, 30638 Operator's Manual

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Page 1
FormNo.3364-486RevB
g012615
CommercialWalk-BehindMower
FixedDeck,PistolGrip,GearDrivewitha 32in,36inor48inCuttingUnit
ModelNo.30632—SerialNo.310000001andUp
ModelNo.30634—SerialNo.310000001andUp
ModelNo.30638—SerialNo.310000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)
Page 2
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Figure1
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.
Theenclosed
Engine Owner's Man ual
issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
Introduction
Thisrotary-blade,lawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional, hiredoperators.Itisdesignedprimarilyforcutting grassonwell-maintainedlawnsonresidential orcommercialproperties.Itisnotdesignedfor cuttingbrushorforagriculturaluses.
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjury ordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndingadealer, ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts, oradditionalinformation,contactanAuthorized ServiceDealerorToroCustomerServiceandhave themodelandserialnumbersofyourproductready . Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.
©2012—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contents
Introduction.................................................................2
Safety...........................................................................3
SafeOperatingPractices.......................................3
ToroMowerSafety...............................................4
SlopeIndicator.....................................................6
SafetyandInstructionalDecals.............................7
ProductOverview........................................................9
Controls...............................................................9
Specications.....................................................10
Attachments/Accessories...................................10
Operation...................................................................11
AddingFuel.......................................................11
ThinkSafetyFirst...............................................12
OperatingtheParkingBrakeandNeutral
Locks.............................................................12
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
StartingandStoppingtheEngine........................12
OperatingtheBladeControl(PTO)
Lever..............................................................13
TheSafetyInterlockSystem................................14
DrivingForwardorBackward.............................14
StoppingtheMower...........................................15
TransportingMachines.......................................15
SideDischargingorMulchingtheGrass..............15
AdjustingtheWheelDriveTension.....................15
AdjustingtheHeight-of-Cut...............................16
AdjustingtheHandleHeight..............................17
HeightofCutChart............................................19
Maintenance...............................................................20
RecommendedMaintenanceSchedule(s)................20
Lubrication.............................................................21
HowtoGrease...................................................21
LubricatingtheCasterandWheel
Bearings.........................................................21
GreasingtheTransmissionCouplers...................21
GreasingtheMowerBeltIdler............................21
EngineMaintenance...............................................22
ServicingtheAirCleaner....................................22
ServicingtheEngineOil.....................................23
ServicingtheSparkPlugs....................................24
FuelSystemMaintenance.......................................25
DrainingtheFuelTank.......................................25
ReplacingtheFuelFilter.....................................26
DriveSystemMaintenance.....................................27
CheckingtheTirePressure.................................27
CoolingSystemMaintenance..................................27
CleaningtheAirIntakeScreen............................27
CleaningtheCoolingSystem...............................27
BrakeMaintenance.................................................28
ServicingtheBrakes...........................................28
BeltMaintenance....................................................29
CheckingtheBelts..............................................29
ReplacingtheTractionDriveBelt........................29
ReplacingtheDriveBelt.....................................29
ReplacingtheMowerBelt...................................30
AdjustingtheMowerBeltTension......................31
ControlsSystemMaintenance.................................35
AdjustingtheControlRods................................35
MowerDeckMaintenance......................................36
ServicingtheCuttingBlades...............................36
AdjustingtheBladeBrake...................................38
ReplacingtheGrassDeector.............................38
Storage.......................................................................39
CleaningandStorage..........................................39
Troubleshooting.........................................................41
Schematics.................................................................43
Safety
Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol CAUTION,WARNING,orDANGER-“personalsafety instruction."Failuretocomplywiththeinstructionmay resultinpersonalinjuryordeath.
SafeOperatingPractices
ThefollowinginstructionsarefromANSIstandard B71.4-2004.
Training
•ReadtheOperator'sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner'sresponsibilitytoexplain thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.
,whichmeans
•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.
–Useonlyanapprovedcontainer
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–Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling. Donotsmoke.
–Neverrefuelordrainthemachineindoors.
•Checkthatoperator'spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Onlystartengine fromtheoperator'sposition.
•Besureofyourfootingwhileusingthismachine, especiallywhenbackingup.W alk,don'trun.Never operateonwetgrass.Reducedfootingcouldcause slipping.
•Slowdownanduseextracareonhillsides.Besure totravelsidetosideonhillsides.Turfconditions canaffectthemachine'sstability.Usecautionwhile operatingneardrop-offs.
•Slowdownandusecautionwhenmakingturnsand whenchangingdirectionsonslopes.
•Neverraisedeckwiththebladesrunning.
•NeveroperatewiththePTOshield,orotherguards notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly.
•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.
•Donotchangetheenginegovernorsettingor overspeedtheengine.
•Stoponlevelground,disengagedrives,engage parkingbrake(ifprovided),shutoffenginebefore leavingtheoperator'spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.
•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunit.
•Lookbehindanddownbeforebackinguptobesure ofaclearpath.
•Keeppetsandbystandersaway.
•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesifnot mowing.
•Beawareofthemowerdischargedirectionanddo notpointitatanyone.
•Donotoperatethemowerundertheinuenceof alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine intoorfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
Maintenanceandstorage
•Disengagedrives,setparkingbrake,stopengineand removekeyordisconnectsparkplugwire.Waitfor allmovementtostopbeforeadjusting,cleaningor repairing.
•Cleangrassanddebrisfromcuttingunit,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear ame.
•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.
•Parkmachineonlevelground.Setparkingbrake. Neverallowuntrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen required.
•Carefullyreleasepressurefromcomponentswith storedenergy.
•Disconnectthebatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthenegative terminalrstandthepositivelast.Reconnectthe positiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.
•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .
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Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatchingcut grass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
GeneralOperation
•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.
•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.
•UseonlyT oro-approvedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.
•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforeoperating underanyobjectsanddonotcontactthem.
•Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.
•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.
•Checkbrakeoperationfrequently.Adjustandservice asrequired.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.
•Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.
•Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.
•Usecautionneardrop-offs,ditches,orembankments. Themachinecouldsuddenlyturnoverifawheel goesovertheedgeofaclifforditch,orifanedge cavesin.
•Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.
•Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.
•Mowslopessidetoside.
•Donotmowslopesgreaterthan20degrees.
Service
•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.
•Keepnutsandboltstight,especiallytheblade attachmentboltsandnuts.Keepequipmentingood condition.
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SlopeIndicator
G011841
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
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SafetyandInstructional Decals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
98-0776
43-8480
98-5130
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto75-80ft-lb(102-106N⋅m).
66-1340
98-5954
1.ReadtheOperator's Manualforinstructionson
operatingthecuttingblade
2.Pushforwardtoengage
95-5537
3.Pullbacktodisengage
1.Engine
7
99-3943
Page 8
104-8569
105-4104
1.Reverse3.Transmissionspeeds
2.Neutral
105-4111
1.Fast
2.Continuousvariable setting
106-0699
106-2733
3.Slow
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106-2737
g012616
1
2
3
4
5
6
7
1.Park3.Neutral5.Engine—run
2.Drive4.Engine—stop6.Warning—wearearprotection.
ProductOverview
Figure5
1.Throttlecontrol6.Drivelever
Figure4
1.Sidedischarge5.Controls
2.Mowerdeck6.Handle
3.Recoilstarter
4.Gastank
7.Casterwheel
2.Ignitionswitch
3.Neutral/parkingbrakelock8.Choke
4.OperatorPresence Control(OPC)lever
5.Handle
7.Gearshiftlever
9.Powertakeofflever(PTO)
Controls
Becomefamiliarwithallthecontrols(Figure5)before youstarttheengineandoperatethemachine.
ThrottleControl
Thethrottlecontrolhastwopositions:FastandSlow.
OperatorPresenceControl(OPC) Levers
WhenyousqueezetheOPCleversagainstthehandles, theOPCsystemsensesthattheoperatorisinthenormal operatingposition.WhenyoureleasetheOPClevers, theOPCsystemsensesthattheoperatorhasleftthe normaloperatingposition,andthesystemwillstopthe engineifeitherthegearshiftleverisnotintheneutral positionorthebladecontrol(PTO)leverisengaged.
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GearShiftLever
36inchmowers:
Thetransmissionhasveforwardspeeds,neutraland reverse,andhasanin-lineshiftpattern.
Important:Donotshiftwhileunitismoving,as transmissiondamagemayoccur.
DriveLevers
Releasedriveleverstoengageforwardtractionoperation. Squeezerightsideofdrivelevertoturnrightandleft sidetoturnleft.
Neutral/ParkingBrakeLock
Squeezedriveleversandmovethelocksrearwardfor neutrallock.Squeezedriveleversandmovethelocks forwardtosettheparkingbrake.
BladeControlLever(PTO)
ThisleverisusedinconjunctionwiththeOPClevers toengageordisengagethemowerdeckbeltanddrive themowerblades.
Widthwithdeectordown46.6inches(1 18.4cm)
Length
Height
Weight
80inches(203.2cm)
41inches(104.1cm)
462lb(210kg)
48inchmowers:
Widthwithdeectordown63–1/2inches(161.3cm)
Length
Height
Weight
78–3/8inches(198.9cm)
41inches(104.1cm)
500lb(227kg)
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
RecoilStarter
Pulltherecoilstarterhandletostartengine(notshown in).
FuelShut-offValve
Closethefuelshut-offvalvewhentransportingor storingmower.
IgnitionSwitch
Thisswitchisusedinconjunctionwithrecoilstarterand hastwopositions:RunandOff.
Choke
Usethechoketostartacoldengine.
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
32inchmowers:
Widthwithdeectordown45.8inches(1 16.3cm)
Length
Height
Weight
78inches(198.1cm)
41inches(104.1cm)
402lb(182kg)
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Operation
AddingFuel
UseUnleadedRegularGasolinesuitablefor automotiveuse(87pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.
Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontainingmore than10%ethanolbecausethefuelsystemcouldbe damaged.Donotmixoilwithgasoline.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.
•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.
•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.
•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditionerbottleopening.
•Keepgasawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting
Important:Donotusefueladditives containingmethanolorethanol.
Addthecorrectamountofgasstabilizer/conditioner tothegas.
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Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasoline.To minimizethechanceofvarnishdepositsinthefuel system,usefuelstabilizeratalltimes.
FillingtheFuelTank
1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundfueltankcapandremovethecap. Addunleadedregulargasolinetofueltank,untilthe levelis1/4to1/2inch(6to13mm)belowthe bottomofthellerneck.Thisspaceinthetank allowsgasolinetoexpand.Donotllthefueltank completelyfull.
3.Installfueltankcapsecurely.Wipeupanygasoline thatmayhavespilled.
SettingtheParkingBrakes
1.Squeezethedrivelevers(Figure7).
Figure7
ThinkSafetyFirst
Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator'searandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Figure6
1.Warning—wearhearingprotection.
1.Handle
2.Neutral/parkingbrakelock
3.Parkposition6.Neutralposition
2.Placeyourthumbsontheupperpartofthelocks andmovethemforwardinintotheparkposition (Figure7).
3.Releasethedrivelevers.
4.Fullspeedforward
5.Drivelever
ReleasingtheParkingBrakes
1.Squeezethedriveleversback(Figure7).
2.Placeyourthumbsontheupperpartofthelocks andmovethemrearwarduntiltheyareinthedrive position(Figure7).
SettingtheNeutralLocks
1.Squeezethedriveleversback(Figure7).
2.Placeyourthumbsontheupperpartofthelocks andmovethemrearwardintotheneutrallock position(
Figure7).
OperatingtheParkingBrake andNeutralLocks
Alwayssettheparkingbrakeswhenyoustopthe machineorleaveitunattended.
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileit isunattended.
Alwayssettheparkingbrakewhenleavingthe machineunattended,evenifjustforafewminutes.
ReleasingtheNeutralLocks
1.Squeezethedriveleversback.
2.Placeyourthumbsontheupperpartofthelocks andmovethemforwarduntiltheyareinthedrive position(
Figure7).
StartingandStoppingthe Engine
StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
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3.Disengagethebladecontrol(PTO)leverandmove theshiftlevertotheneutralposition.
4.Settheparkingbrakes.
5.Turntheignitionkeytotherunposition(
6.Tostartacoldengine,movethethrottlecontrol midwaybetweenthefastandslowpositions.
7.Tostartawarmengine,movethethrottlecontrol tothefastposition.
8.Pullthechokeknobiftheengineiscold(
Note:Awarmorhotengineusuallydoesnot requireanychoking.
9.Grasptherecoilstarterhandlermlyandpullit outuntilpositiveengagementresults;thenpullthe handlevigorouslytostarttheengine.Allowthe ropetorecoilslowly .
Important:Donotpulltherecoilropetoits limitorreleasethestarterhandlewhenyoupull outtheropebecausetheropemaybreakorthe recoilassemblymaybedamaged.
10.Pushthechoketooffastheenginewarmsup.
11.Iftheengineiscold,allowittowarmupandthen movethethrottlecontroltothefastposition.
Figure8).
Figure8).
Figure8
1.Throttlecontrol
2.Ignitionswitch
3.Choke
OperatingtheBladeControl (PTO)Lever
Thebladecontrol(PTO)leverengagesanddisengages thepowertothemowerblades.
StoppingtheEngine
Important:Inanemergency,youcanstopthe
engineimmediatelybyturningtheignitionkeyto the
of f
position.
1.Movethethrottlelevertotheslowposition
Figure8).
(
Note:Iftheenginehasbeenworkinghardoris hot,letitidleforaminutebeforestoppingitto helpcoolit.
2.Turntheignitionkeytotheoffposition.
3.Settheparkingbrakesandremovethekey.
4.Disconnectthewirefromthesparkplugtoprevent someonefromaccidentallystartingthemachine whiletransportingorstoringit.
5.Closethefuelshut-offvalvebeforetransporting orstoringthemachine.
Important:Closethefuelshut-offvalvebefore transportingorthestoringthemachineto preventfuelleakage.
EngagingtheMowerBlades(PTO)
1.Squeezetheoperatorpresencecontrol(OPC)levers againstthehandles(Figure9).
2.Pushthebladecontrol(PTO)leverrmlyforward untilitlatchesoverthecenter(
3.Restarttheengineandrepeattheprocedureto engagethemowerbladesiftheoperatorpresence control(OPC)leversarereleased.
Figure9).
DisengagingtheMowerBlades(PTO)
Todisengagetheblades,pullthebladecontrollever rearwardalltheway(Figure9).Theenginewillkill whentheOPCleversarereleasedwiththebladecontrol leverengaged.
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Figure9
1.OperatorPresence Control(OPC)lever
2.Powertakeofflever(PTO)
TheSafetyInterlockSystem
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
TestingtheSafetyInterlockSystem
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribed,haveanAuthorizedServiceDealer repairthesafetysystemimmediately .
1.Settheparkingbrakes,movetheshiftleverintothe Neutralposition,disengagethebladecontrol(PTO) leverandplacethethrottleforward.
2.Starttheengine;refertoStartingtheEngine.
3.WithoutholdingtheOperatorPresenceControl (OPC)levers,engagethebladecontrol(PTO)lever. Theengineshouldstop.
4.Disengagethebladecontrol(PTO)lever.
5.Withtheenginerunning,holddowntheOPClevers andengagethebladecontrol(PTO)lever.The mowerbeltshouldengageandthemowerblades beginrotating.
6.ReleasetheOPClevers.Theengineshouldstop.
7.Withtheenginerunning,movetheshiftleverinto gearandreleasetheOPClevers.Theengineshould stop.
8.Withtheenginerunning,turntheignitionkeyto theoffposition.Theengineshouldstop.
9.Ifalltheaboveconditionsarenotmet,havean AuthorizedServiceDealerrepairthesafetysystem immediately.
•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
UnderstandingtheSafetyInterlock System
Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:
•Thebladecontrol(PTO)leverisdisengaged.
•ThemachineisshiftedintotheNeutralposition.
•TheignitionkeyisintheRunposition.
Thesafetyinterlocksystemisdesignedtostopthe enginewhen:
•TheOperatorPresenceControl(OPC)leversare releasedwhenthetransmissionorthebladesare engaged;
•TheignitionkeyisturnedtotheOffposition.
•Themachineisshiftedintogearwithoutholding theOPClevers.
•Thebladecontrol(PTO)leverisengagedwithout holdingtheOPClevers.
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinRPM(revolutionsperminute).Move thethrottlecontrolintotheFastpositionforthebest mowingperformance.
DrivingForward
1.Ensurethattheparkingbrakesareengaged.
2.SqueezetheOPCleversagainstthehandles.
3.Movetheshiftleverintoaforwardgear.
4.Releasetheparkingbrakes;refertoReleasingthe ParkingBrakesandNeutralLocks.
5.Slowlyreleasethedrivelevers.
Note:Togostraight,releasethedrivelevers equally.Toturn,squeezethedriveleveronthesame sideasthedirectionyouwanttoturn.
DrivingBackward
1.Ensurethattheparkingbrakesareengaged.
2.SqueezetheOPCleversagainstthehandles.
3.Movetheshiftleverintothereversegear.
14
Page 15
4.Releasetheparkingbrakes;refertoReleasingthe ParkingBrakesandNeutralLocks.
5.Slowlyreleasethedrivelevers.
Note:Youmustpullthemowerbackwardtoassist itsrearwardmovement.
StoppingtheMower
1.Squeezethedriveleversallthewaybacktoengage thebrakes.
2.Settheparkingbrakes.RefertoSettingtheParking Brakes.
3.ShifttransmissionintotheNeutralposition.
4.MovethethrottletotheStopposition,andwaitfor allmovingpartstostopbeforeleavingtheoperating position.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.
Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.
TransportingMachines
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarylightingandmarkingasrequiredbylaw . Pleasecarefullyreadallthesafetyinstructions.Knowing thisinformationcouldhelpyou,yourfamily ,petsor bystandersavoidinjury.
DANGER
Withoutthegrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.
•Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
•Neverputyourhandsorfeetunderthemower.
•Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthepower takeoff(PTO)isoff.Rotatetheignitionkeyto Off.Alsoremovethekeyandpullthewireoff thesparkplug(s).
AdjustingtheWheelDrive Tension
Youmayneedtoincreasethewheeldrivebelttension undercertainoperatingconditions,suchasmowerover hillyterrainorwhilepullingasulky.
1.Stoptheengine,removethekey ,andwaitforall movingpartstostop.
2.Disconnectthewiresfromthesparkplugs.
3.Disengagetheneutral/parkingbrakelocks,and releasethedriveleverstoreducethespringforce.
4.Removethedrivespringfromtheadjustmentbolt
Figure10).
(
Totransportthemachine:
1.Stoptheengine,removethekey ,setthebrake,and closethefuelvalve.
2.Securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes.
3.Secureatrailertotowingvehiclewithsafetychains.
4.Ifapplicable,connectthetrailerbrakes.
SideDischargingorMulching theGrass
Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
1.PositionA4.Drivespring
2.PositionB
3.PositionC
15
Figure10
5.Adjustmentbolt(In
positionA)
6.Drivepulleyshield
Page 16
5.Removethelocknutthatsecurestheadjustment bolttothedrivepulleyshield(Figure10).
6.Locateboltassemblyinthedesiredtensionposition asfollows:
•PositionAfornormalconditions
•PositionBformoresevereconditions
•PositionCforthemostsevereconditions
Note:Thewheeldrivetensionislowestwhen theboltassemblyisinPositionA.Thetension increasesinPositionsBandC(
Figure10).
7.Installtheadjustmentboltandthedrivespring.
8.Repeatstepsthroughfortheoppositeside.
AdjustingtheHeight-of-Cut
Thismachinehasa1to4-1/4inch(26to108mm) rangefortheheight-of-cut.Thiscanbeachievedby adjustingbladespacers,rearaxleheight,andfront casterspacers.UsetheHeight-of-CutCharttoselect thecombinationofadjustmentsrequired.
AdjustingtheBladeHeight
Adjustthebladesbyusingthe4spacers(1/4inch) (6mm)onthebladespindlebolts.Thisallowsfora 1-inch(25mm)adjustmentrange,in1/4inch(6mm) increments,ofcuttingheightinanyaxleposition.Use thesamenumberofbladespacersonallbladesto achievealevelcut(2aboveand2below,1aboveand3 below,etc.).
1.Disengagethebladecontrol(PTO)leverandset theparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Holdthebladeboltandremovethenut(
Figure11).
Figure11
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
4.Spacer
6.Nut
4.Slidetheboltdownthroughthespindle,andchange thespacersasneeded(
Figure11).
5.Installtheboltandcurvedwasher,addextra spacer(s),andsecurethemwithathinwasheranda nut(Figure11).
6.Torquethebladeboltto75-80ft-lb(101-108N-m).
AdjustingtheAxleHeight
Adjusttheaxlepositiontotheselectedheight-of-cut setting.RefertotheHeight-of-CutChart.
1.Disengagethebladecontrol(PTO)leverandset theparkingbrakes.
2.Stoptheengineandwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.
3.Loosen,butdonotremove,the2axlepivotbolts andthe2axleadjustmentbolts(
16
Figure12).
Page 17
Figure12
g012931
1.Axlepivotbolt2.Axleadjustmentbolt
4.Placeajackundertherearcenteroftheengine frame.Raisethebackendoftheengineframeup enoughtoremovethefront2axleadjustmentbolts
Figure12).
(
Note:Usejackstandstosupportthemachine.
5.Raiseorlowertheengineframewiththejacksothat youcaninstallthefront2axleadjustmentboltsin thedesiredholelocation(Figure12).
2.Removethelatchpin,slidethecasterfromthe support,andchangethespacers(Figure13).
3.Installthecasterinthesupportandinsertthelatch
Figure13).
pin(
AdjustingtheHandleHeight
Thehandlepositioncanbeadjustedtomatchthe operator'sheightpreference.
1.Removethehairpincotterpinsandclevispinsfrom thedriveleversandneutrallocks(
Figure14).
Note:Useataperedpunchtohelpaligntheholes.
6.Tightenall4boltsandlowerthemower.
7.Adjustthecontrolrodsandthebrakelinkages asrequired.RefertoServicingtheBrakesand AdjustingtheControlRods.
Important:Y oumustadjustthecontrolrods andthebrakelinkagewhenyouchangetheaxle positionsforpropertractionandbrakefunction.
AdjustingtheCasterPosition
1.UsingtheHeight-of-CutChart,adjustthecaster spacerstomatchwiththeaxleholeselected
Figure13).
(
Figure14
1.Controlrod
2.Clevispin
3.OperatorPresence Controllever(OPC)
4.Handle
5.Neutrallock
6.Hairpincotterpin
7.Drivelever
2.Loosentheupperbolts(3/8x1-1/4inches)and angenutsecuringhandletorearframe(
Figure15).
3.Removethelowerbolts(3/8x1inch)andange nutssecuringhandletorearframe(Figure15).
4.Pivotthehandletothedesiredoperatingposition andinstallthelowerangebolts(3/8x1inch)and angenutsintothemountingholes.Tightenall angebolts.
1.Latchpin
2.Spacer,3/16inch(5mm)
Figure13
3.Spacer,1/2inch(13mm)
17
Page 18
Figure15
1.Upperhandle6.Lowermountingholes
2.Rearframe
3.Flangebolt(3/8x1inch)
4.Locknut(3/8inch)
5.Uppermountinghole
7.Lowposition
8.Middleposition
9.Highposition
5.Adjustthecontrolrodlengthbyrotatingthecontrol rodintherodtting(
Figure14).
6.Installahairpincotterbetweenthedriveleversand neutrallocksandintotheclevispins(Figure14).
Note:Makesuretheclevispinsareinsertedinto theneutrallocks.
7.Checktheparkingbrakeadjustment.Referto CheckingtheBrakesin
BrakeMaintenance(page28).
18
Page 19
HeightofCutChart
Numberofspacers
1/2inch
AxlePosition
A00
A01
A10
B01
B10
B11
B20
C
C
C
C
D21
D30
D31
D40
E31
E40
E41
(13mm)
11
20
21
30
belowcaster
3/16inch(5
mm)
1inch(26
1–1/8inch
(29mm)
1–3/8inch
(35mm)
1–3/8inch
(35mm)
1–5/8inch
(41mm)
1–3/4inch
(45mm)
2inch(51
1–7/8inch
(48mm)
2–1/8inch
(55mm)
2–1/4inch
(57mm)
2–1/2inch
(64mm)
2–3/8inch
(61mm)
2–1/2inch
(64mm)
2–3/4inch
(70mm)
3inch(76
2–7/8inch
(73mm)
3–1/8inch
(79mm)
3–1/4inch
(82mm)
Numberof1/4inchbladespacersbelowspindle
43210
mm)
mm)
mm)
1–1/4inch
(32mm)
1–3/8inch
(35mm)
1–5/8inch
(41mm)
1–5/8inch
(41mm)
1–7/8inch
(48mm)
2inch(51
mm)
2–1/4inch
(57mm)
2–1/8inch
(54mm)
2–3/8inch
(60mm)
2–1/2inch
(64mm)
2–3/4inch
(70mm)
2–5/8inch
(67mm)
2–3/4inch
(70mm)
3inch(76
mm)
3–1/4inch
(82mm)
3–1/8inch
(79mm)
3–3/8inch
(86mm)
3–1/2inch
(89mm)
1–1/2inch
(38mm)
1–5/8inch
(41mm)
1–7/8inch
(48mm)
1–7/8inch
(48mm)
2–1/8inch
(54mm)
2–1/4inch
(57mm)
2–1/2inch
(64mm)
2–3/8inch
(60mm)
2–5/8inch
(67mm)
2–3/4inch
(70mm)
3inch(76
2–7/8inch
(73mm)
3inch(76
3–1/4inch
(82mm)
3–1/2inch
(89mm)
3–3/8inch
(86mm)
3–5/8inch
(92mm)
3–3/4inch
(95mm)
1–3/4inch
(45mm)
1–7/8inch
(48mm)
2–1/8inch
(54mm)
2–1/8inch
(54mm)
2–3/8inch
(60mm)
2–1/2inch
(64mm)
2–3/4inch
(70mm)
2–5/8inch
(67mm)
2–7/8inch
(73mm)
3inch(76
mm)
mm)
mm)
3–1/4inch
(83mm)
3–1/8inch
(79mm)
3–1/4inch
(82mm)
3–1/2inch
(89mm)
3–3/4inch
(95mm)
3–5/8inch
(92mm)
3–7/8inch
(98mm)
4inch(102
mm)
2inch(51
mm)
2–1/8inch
(54mm)
2–3/8inch
(60mm)
2–3/8inch
(60mm)
2–5/8inch
(67mm)
2–3/4inch
(70mm)
3inch(76
mm)
2–7/8inch
(73mm)
3–1/8inch
(79mm)
3–1/4inch
(83mm)
3–1/2inch
(89mm)
3–3/8inch
(86mm)
3–1/2inch
(89mm)
3–3/4inch
(95mm)
4inch(102
mm)
3–7/8inch
(98mm)
4–1/8inch
(105mm)
4–1/4inch
(108mm)
19
Page 20
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst25hours
Beforeeachuseordaily
Every25hours
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthemowerbelttension.
•Checkthemowerbelttension.
•Checkthesafetysystem.
•Greasethecasterwheelsandcasterpivot.
•Checktheengineoillevel.
•Cleantheairintakescreen.
•Cleantheairintakescreen.
•Checkthebrakes.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanfoamaircleanerelement.
•Greasethemowerbeltidler.
•Checkthepaperaircleanerelement.
•Checkthetirepressure.
•Checkthebelts.
•Checkthemowerbelttension.
•Changetheengineoil.
•Checkthesparkplugs.
•Checkandcleanenginecoolingnsandshrouds.
•Replacethepaperaircleanerelement.
Every200hours
Every250hours
Every400hours
Beforestorage
•Changetheoillter.
•Replacethefuellter.
•Greasethetransmissioncouplers(moreoftenindirtyordustyconditions).
•Greasethewheelbearings(moreoftenindirtyordustyconditions).
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthesparkplugwirefromthesparkplug(s)beforeyoudo anymaintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.
20
Page 21
Lubrication
GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.
HowtoGrease
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.
5.Wipeupanyexcessgrease.
LubricatingtheCasterand WheelBearings
Figure17
GreasingtheMowerBeltIdler
Greasethettingonthemowerbeltidlerarmpivot (Figure18).
Note:Removethemowerdeckcovertoaccessthe greasettingforthemowerbeltidlerarm.
1.Lubricatethefrontwheelbearingsandfrontspindles (Figure16).
2.Lubricatethedrivewheelbearings.
Figure16
GreasingtheTransmission Couplers
Figure18
Lubricatethetransmissioncouplerslocatedintheback ofthemachine(
Figure17).
21
Page 22
EngineMaintenance
ServicingtheAirCleaner
ServiceInterval/Specication
ServiceInterval:Every25hours—Cleanfoamair
cleanerelement.
Every50hours—Checkthepaperair cleanerelement.
Every200hours—Replacethepaper aircleanerelement.
Note:Servicetheaircleanermorefrequently(every fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy .
Important:Donotoilthefoamorpaperelement.
RemovingtheFoamandPaper Elements
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage
Figure19).
(
4.Unscrewthecoverknobsandremovetheaircleaner cover(Figure19).
5.Unscrewthehoseclampandremovetheaircleaner assembly(
6.Carefullypullthefoamelementoffthepaper element(
Figure19).
Figure19).
Figure19
1.Cover
2.Hoseclamp4.Foamelement
3.Paperelement
CleaningtheFoamAirCleanerElement
1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly .
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifitis tornorworn.
ServicingthePaperAirCleaner Element
1.Donotcleanthepaperlter,replaceit(Figure19).
2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaperElements
Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.
1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure19).
2.Placetheaircleanerassemblyontotheaircleaner baseandsecureitwiththe2wingnuts(Figure19).
3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure19).
22
Page 23
ServicingtheEngineOil
ServiceInterval/Specication
ServiceInterval:Beforeeachuseordaily—Checkthe
engineoillevel.
Aftertherst8hours—Changethe engineoil.
Every100hours—Changetheengine oil.
Every200hours—Changetheoil lter.
Figure21
1.Oildipstick
2.Fillertube
Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.
OilType:Detergentoil(APIserviceSF ,SG,SH,SJ orSL)
CrankcaseCapacity:58ounces(1.7liter)withthelter removed;51ounces(1.5liter)withoutthelterremoved
Viscosity:Refertothetable(
Figure20
Figure20).
5.Unscrewtheoildipstickandwipetheendclean (Figure21).
6.Slidetheoildipstickfullyintothellertube,butdo notthreadontotube(
Figure21).
7.Pullthedipstickoutandlookattheend.Iftheoil levelislow ,slowlypouronlyenoughoilintotheller tubetoraisetheleveltotheFullmark.
Important:Donotoverllthecrankcasewith oilandruntheengine;enginedamagecan result.
ChangingtheEngineOil
1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.
3.DisengagethePTOandsettheparkingbrake.
4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
CheckingtheEngineOilLevel
1.Parkthemachineonalevelsurface.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Cleanaroundtheoildipstick(Figure21)sothatdirt cannotfallintothellerholeanddamagetheengine.
5.Slidethedrainhoseovertheoildrainvalve.
6.Placeapanbelowthedrainhose.Rotateoildrain valvetoallowoiltodrain(
Figure22).
7.Whenoilhasdrainedcompletely,closethedrain valve.
8.Removethedrainhose(Figure22).
Note:Disposeoftheusedoilatarecyclingcenter.
23
Page 24
4.Installthereplacementoilltertothelteradapter,
1
turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional3/4turn(
Figure23).
5.Fillthecrankcasewiththepropertypeofnewoil; refertoServicingtheEngineOil.
6.Runtheengineforabout3minutes,stoptheengine, andcheckforoilleaksaroundtheoillteranddrain valve.
7.Checktheengineoillevelandaddoilifneeded.
8.Wipeupanyspilledoil.
ServicingtheSparkPlugs
ServiceInterval/Specication
Figure22
1.Oildrainvalve2.Oildrainhose
9.Slowlypourapproximately80%ofthespeciedoil intothellertube(Figure21).
10.Checktheoillevel;refertoCheckingtheEngineOil Level.
11.SlowlyaddtheadditionaloiltobringittotheFull mark.
ChangingtheOilFilter
Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Removetheoldlter(Figure23).
ServiceInterval:Every100hours—Checkthespark
plugs.
Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstallingthe sparkplugsandagappingtool/feelergaugetocheckand adjusttheairgap.Installanewsparkplugsifnecessary.
Type:Champion®RCJ8YorequivalentAirGap:
0.030inch(0.75mm)
RemovingtheSparkPlugs
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Disconnectthewiresfromthesparkplugs
Figure24).
(
Figure23
1.Oillter
2.Adapter
3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure23).
Figure24
1.Spark-plugwire/sparkplug
24
Page 25
4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausing damage.
5.Removethesparkplugsandthemetalwashers.
CheckingtheSparkPlugs
FuelSystem Maintenance
DrainingtheFuelTank
1.Lookatthecenterofthesparkplugs(Figure25). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.
2.Ifneeded,cleanthesparkplugwithawirebrushto removecarbondeposits.
Figure25
1.Centerelectrodeinsulator3.Airgap(nottoscale)
2.Sideelectrode
Important:Alwaysreplacethesparkplugs whenithaswornelectrodes,anoilylmonit, orhascracksintheporcelain.
3.Checkthegapbetweenthecenterandsideelectrodes
Figure25).Bendthesideelectrode(Figure25)if
( thegapisnotcorrect.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.
•Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.
1.Parkthemachineonalevelsurface,toassurefuel tankdrainscompletely.Thendisengagethepower takeoff(PTO),settheparkingbrake,andturnthe ignitionkeytooff.Removethekey.
2.Closethefuelshut-offvalveatthefueltank
Figure26).
(
3.Squeezetheendsofthehoseclamptogether andslideitupthefuellineawayfromfuellter (Figure26).
4.Pullthefuellineoffthefuellter( thefuelshut-offvalveandallowthegasolinetodrain intoagascanordrainpan.
Note:Nowisthebesttimetoinstallanewfuellter becausethefueltankisempty.RefertoReplacing theFuelFilter.
Figure26).Open
InstallingtheSparkPlugs
1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.
2.Tightenthesparkplugsto16ft-lb(22N-m).
3.Connectthewirestothesparkplugs(Figure25).
5.Installthefuellineontothefuellter.Slidethehose clampclosetothevalvetosecurethefuelline.
25
Page 26
Figure26
1.Fuelshut-offvalve2.Fuellter
6.Wipeupanyspilledfuel.
ReplacingtheFuelFilter
ServiceInterval:Every200hours/Yearly(whichever
comesrst)
Neverinstalladirtylterifitisremovedfromthefuel line.
Note:Notehowthefuellterisinstalledinorderto installthenewltercorrectly.
Note:Wipeupanyspilledfuel.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
Figure27
1.Hoseclamp3.Filter
2.Fuelline
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclampsclose tothelter.
7.Openfuelshut-offvalveatfueltank(Figure26).
8.Checkforfuelleaksandrepairifneeded.
9.Wipeupanyspilledfuel.
3.Closefuelshut-offvalveatthefueltank(
4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure27).
Figure26).
26
Page 27
DriveSystem
CoolingSystem
Maintenance
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat12-14psi (83-97kPa).Uneventirepressurecancauseanuneven cut.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
Maintenance
CleaningtheAirIntakeScreen
Beforeeachuseremoveanybuild-upofgrass,dirt orotherdebrisfromthecylinderandcylinderhead coolingns,airintakescreenonywheelend,and carburetor-governorleversandlinkage.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine.
CleaningtheCoolingSystem
ServiceInterval:Every100hours/Yearly(whichever
comesrst)
Beforeeachuseordaily
Cleantheairintakescreenfromgrassanddebrisbefore eachuse.
1.DisengagethePTOandsettheparkingbrake.
Figure28
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removetheairintakescreen,recoilstarterandfan housing(
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installairintakescreen,recoilstarterandfanhousing
Figure29).
(
Figure29).
27
Page 28
Figure29
1.Airintakescreen4.Bolt
2.Fanhousing5.Nut
3.Recoilstarter
BrakeMaintenance
ServicingtheBrakes
Beforeeachuse,checkbrakesonbothalevelsurface andslope.
Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.
CheckingtheBrakes
1.Parkthemachineonalevelsurface,disengagethe bladecontrol(PTO).
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Applytheparkingbrakes.Thewheelsmustlock whenyoutrytopushthemachineforward.
4.Ifthewheelsdonotlock,adjustthebrakes.Refer toAdjustingtheBrakes.
5.Releasethebrakesandmovetheneutral/brakelocks totheneutralposition..Thewheelsshouldrotate freely,ifnot;refertoAdjustingtheBrakes.
AdjustingtheBrakes
Iftheparkingbrakesdonotholdsecurely,adjustthem.
1.Checkthebrakesbeforeyouadjustthem;referto CheckingtheBrakes.
2.Releasetheparkingbrakes;refertoReleasingthe ParkingBrakes.
3.Toadjustthebrakes,rotatethewingnutson thebrakerods( nutsclockwisetotightenthebrakes;rotatethem counterclockwisetoloosenthem.
Figure30).Rotatethewing
Figure30
1.Brakerod2.Wingnut
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4.Positionthewingnutssothatthebrakesengage whenyousqueezethedriveleversenoughtoplace theneutral/parkingbrakelocksforward,andthen setthebrakes.
BeltMaintenance
CheckingtheBelts
5.Checktheoperationofthebrakesagain;referto CheckingtheBrakes.
Important:Whenyoureleasetheparking brakes,therearwheelsshouldrotatefreelywhen youpushthemower.Iftheydonot,contactan AuthorizedServiceDealerimmediately.
6.Checkthecontrolrodlength,refertoAdjustingthe ControlRods.
ServiceInterval:Every50hours/Monthly(whichever
comesrst)—Checkthebelts.
Checkbeltsforcracks,frayededges,burnmarks,wear, signsofoverheatingoranyotherdamage.Replace damagedbelts.
ReplacingtheTractionDrive Belt
1.Removehairpincottersecuringbrakerodtobrake armtorelaxbeltidlertension(Figure31).
2.Removebottomandloosentopboltsofshieldto rotateforbeltclearance(Figure31).
3.Liftthebeltpastidlerandoffthedrivepulley (Figure31).
4.Raisethewheeloffgroundenoughtoallowbelt removal.
5.Replacethetractiondrivebelt.
6.Secureshieldwithpreviouslyremovedboltand tightenbolts(
7.Securebrakerodtobrakearmwithhairpincotter (Figure31).
Figure31).
Figure31
1.Drivebelt3.Tire
2.Drivespring4.Adjustmentbolt
ReplacingtheDriveBelt
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Raisetherearofthemachineandholditupwith jackstands.
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Page 30
4.Removethemowerbelt(Figure32).
Figure32
1.Idlerpulleyinslot4.Beltguide
2.Tractionbelt
3.Mowerbelt6.Mowerbelt
5.3/4inch(19mm)
Note:Thepropermowerbelttensionis10-15lbf. (44-67N)withthebeltdeected1/2inch(13mm) halfwaybetweenthepulleys(
Figure36orFigure37).
8.Engagethebladecontrol(PTO)lever.
9.Checktheclearancebetweenthebellcrankandthe transmissionoutputshaft(
Figure33).
5.Loosenthepivotboltenoughtoslidetheidlerpulley intheslotandremovethetractionbeltfromthe engineandthedrivepulleys(
Figure32).
6.Installthenewdrivebeltaroundtheengineandthe drivepulleys(Figure32).
7.Slidetheidlerpulleyintheengineframetotension thetractionbelt(
Figure32).
8.Installthemowerbelt(Figure32).
9.Checkthebeltguideundertheengineframeforthe properadjustment(Figure32).
Note:Thedistancebetweenthebeltguideand mowerbeltshouldbe3/4inch(19mm)whenthe mowerbeltisengaged.Adjustthebeltifnecessary. Thedisengagedbeltshouldnotdragorfalloffthe pulleywhentheguidesareproperlyadjusted.
ReplacingtheMowerBelt
Important:Thebrakeneedstobeadjustedwhen
thebelttensionorthebrakelinkageisadjusted.
Figure33
1.1/16-1/8inch(2-3mm)
2.Bellcrank
3.Transmissionoutputshaft6.Clevis
4.Hairpincotter
5.Clevispin
Note:Theclearanceshouldbe1/16-1/8inch (2-3mm).
10.Removethehairpincotterpinandtheclevispin fromthebellcrank.
11.Rotatetheclevisclockwiseontherodtoincrease theclearance;rotateitcounterclockwisetodecrease
Figure33).
it(
12.Disengagethebladecontrol(PTO)lever.
Note:Iftheassistarmdoesnotcontactthefront stoponthemowerdeck(Figure34orFigure35), adjusttheclevistobringthebellcrankclosertothe transmissionoutputshaft(
Figure33).
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Removetheknobsandthebeltcoveronthemower.
4.Removetheidlerpulleyandthewornbelt.
5.Installthenewmowerbelt.
6.Installtheidlerpulley.
7.Engagethebladecontrol(PTO)leverandcheck thebelttension.RefertoAdjustingtheMowerBelt Tension.
30
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Figure34
32inand36inMowerDeck
1.1/2inch(13mm)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
AdjustingtheMowerBelt Tension
AdjustingtheTensionfor32inand36in MowerDecks
ServiceInterval:Aftertherst8hours—Checkthe
mowerbelttension.
Aftertherst25hours—Checkthe mowerbelttension.
Every50hours—Checkthemower belttension.
Important:Thebrakeneedstobeadjustedwhen thebelttensionorthebrakelinkageisadjusted.
Important:Thebeltmustbetightenoughtonot slipduringheavyloadswhilecuttinggrass.Over
4.Locknut
tensioningthebeltwillreducethespindlebearing life,thebeltlifeandtheidlerpulleylife.
Thebeltmustbetightenoughsoitdoesnotslipduring heavyloadswhilecuttinggrassandover-tensioningwill reducebeltandspindlebearinglife.
Figure35
48inMowerDeck
13.Checkthebeltguideundertheengineframeforthe properadjustment(Figure32).
Note:Thedistancebetweenthebeltguideandthe mowerbeltshouldbe1-1/4inch(32mm)when youengagethemowerbelt.Adjustthemowerbelt asnecessary.Thedisengagedbeltshouldnotdrag orfalloffthepulleywhentheguidesareproperly adjusted.
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Loosenthelocknutontheturnbuckle(
Figure36).
4.Rotatetheturnbuckletowardtherearofthe mowertoincreasethetensiononthebelt.Rotate theturnbuckletowardthefrontofthemowerto decreasethetensiononthebelt(
Figure36).
Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof 5/16inch(8mm).
5.Engagethebladedcontrollever(PTO)andcheck thebelttension.Adjusttensionuntilitiscorrect.
Note:Thepropermowerbelttensionis10-15lbf. (44-67N)withthebeltdeected1/2inch(13mm) halfwaybetweenthepulleys(
Figure36).
31
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Figure36
32inand36inMowerDeck
1.Mowerbeltwith1/2inch (13mm)deection
2.Idlerpulley
6.Tightenthelocknutontheturnbuckle.
7.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.
AdjustingtheTensionfor48inMower Decks
Important:Thebeltmustbetightenoughtonot
slipduringheavyloadswhilecuttinggrass.Over tensioningthebeltwillreducethespindlebearing life,thebeltlifeandtheidlerpulleylife.
Important:Thebrakeneedstobeadjustedwhen thebelttensionorthebrakelinkageisadjusted.
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
Figure37
48inMowerDeck
1.Mowerbeltwith1/2inch (13mm)deection
2.Idlerpulley
Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof 5/16inch(8mm).
3.Loosenthelocknutontheturnbuckle(
Figure38).
4.Rotatetheturnbuckletowardtherearofthe mowertoincreasethetensiononthebelt.Rotate theturnbuckletowardthefrontofthemowerto decreasethetensiononthebelt(Figure38).
Note:Thepropermowerbelttensionis10-15lbf. (44-67N)withthebeltdeected1/2inch(13mm) halfwaybetweenthepulleys(
Figure37).
Figure38
1.1/2inch(13mm)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
5.Engagethebladedcontrollever(PTO)andcheck thebelttension.
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6.Ifthereisnoadjustmentleftintheturnbuckleand thebeltisstillloose,therearidlerpulleyneedstobe positionedtothemiddleorfronthole(Figure39). Usetheholethatwillgivethecorrectadjustment.
7.Whentheidlerpulleyismovedthebeltguidemust bemoved.Movethebeltguidetothefrontposition
Figure39).
(
Figure39
AdjustingthePTOEngagement Linkage
ThePTOengagementlinkageadjustmentislocated beneaththefrontlefthandcorneroftheenginedeck.
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Engagethebladecontrollever(PTO).
4.Adjustthelinkagelengthtowherethelowerend ofthebellcrankjustclearstheaxlesupportgusset
Figure41).
(
1.Rearidlerpulley4.Beltguideinbackposition
2.Middlehole5.Frontidlerpulley
3.Fronthole
8.Checkthebeltguideundertheengineframefor properadjustment(Figure40).
Note:Thedistancebetweenthebeltguideand themowerbeltshouldbe3/4inch(19mm)when youengagethemowerbelt(Figure40).Adjustthe mowerbeltasnecessary.Thedisengagedbeltshould notdragorfalloffthepulleywhentheguidesand belttensionareproperlyadjusted.
9.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.
Figure41
1.Bellcrank4.Yoke
2.Safetyswitchlocated underenginedeck
3.Bellcrankjustclearsthe gussetwiththePTO engageded
5.Nut
6.Assistarmlink
5.Makesuretheassistarmisagainsttherearassistarm stoponthedeck(Figure42).
6.Pushthebladecontrollever(PTO)downtothe disengagedposition.
7.Theassistarmshouldcontactthefrontassistarm stoponthedeck.Ifitdoesnotcontact,adjustthe bellcranksoitisclosertothegusset(Figure42).
1.Beltguide
Figure40
33
Page 34
Figure42
1.Yoke5.Assistarmlink
2.Nut6.Assistarm
3.Rearassistarmstop7.Turnbuckle
4.Frontassistarmstop
8.Toadjusttheassistarmlink,removethehairpin cotterpinfromtheassistarm(Figure42).
9.Loosenthenutagainsttheyoke(
Figure41).
10.Removetheassistarmlinkfromtheassistarmand rotatethelinktoadjustthelength.
11.Installtheassistarmlinkintotheassistarmand secureitwiththehairpincotterpin(
Figure42).
12.Checkiftheassistarmhitsagainstthestopscorrectly.
AdjustingthePTOSafetySwitch
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
1.Bellcrank
2.Boltsandnuts
Figure43
3.Switchmountingbracket
4.Switchbody
3.Disengagethebladecontrollever(PTO).Makesure theassistarmisagainstthefrontassiststoparm.
4.Ifneeded,adjustthebladesafetyswitchbyloosening theboltsholdingtheswitchbracket(
Figure43).
5.Movethemountingbracketuntilthebellcrank depressestheplungerbya1/4inch(6mm).
6.
Note:Makesurethebellcrankdoesnottouchthe switchbodyordamagetotheswitchcouldoccur (Figure43). Tightentheswitchmountingbracket.
34
Page 35
ControlsSystem
g012931
Maintenance
AdjustingtheControlRods
1.Removethehairpincotterpinsandclevispinsfrom thedriveleversandneutrallocks(Figure44).
Figure44
1.Controlrod
2.Clevispin
3.OperatorPresence Controllever(OPC)
4.Handle8.Drivelever
5.Neutrallock
6.Hairpincotterpin
7.Lefthandleshown
Figure45
1.Handle4.Drivelever
2.Neutral/parkingbrakelock
3.3/16to1/4inch(5to6 mm)clearance
5.Forwardspeed
6.Controlrod
3.Installthecontrolrodtothedriveleverandthe neutral/parkingbrakelock.Securethecontrolrod withaclevispinandahairpincotter(Figure45).
4.Checktheoperationofthecontrolrod.Ifyouneed toadjustit,removethehairpincotterandtheclevis pinthatsecurethecontrolrodtothedrivelevers.
5.Adjustthecontrolrodlengthbyrepeatingthe previoussteps.
2.Adjustthecontrolrodlengthbythreadingtherodin oroutoftherodttinguntilthereisa3/16to1/4 inches(5to6mm)clearancebetweenthecontrol rodandthebottomoftheneutral/parkingbrake
Figure45).
lock(
35
Page 36
MowerDeck Maintenance
ServicingtheCuttingBlades
Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator's orbystander'sarea,resultinginseriouspersonal injuryordeath.
•Inspectthebladeperiodicallyforwearor damage.
•Replaceawornordamagedblade.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure46).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
Figure46
1.CuttingEdge3.Wear/slotformingin curvedarea
2.Sail4.Crackinthecurvedarea
BeforeInspectingorServicingthe Blades
Parkthemachineonalevelsurface,disengagetheblade controlbailandsettheparkingbrake.Turntheignition keytooff.Removethekeyanddisconnectthespark plugwire(s)fromthesparkplug(s).
2.Inspecttheblades,especiallythecurvedarea (Figure46).Ifyounoticeanydamage,wear,or aslotforminginthisarea(item immediatelyinstallanewblade.
3.inFigure46),
CheckingforBentBlades
1.Rotatethebladesuntiltheendsfaceforwardand backward(
Figure47).
Figure47
36
Page 37
Figure48
2.Measurefromalevelsurfacetothecuttingedge, positionA,oftheblades(Figure49).Notethis dimension.
Figure49
1.Measurefromthecuttingedgetoalevelsurface
3.Rotatetheoppositeendsofthebladesforward.
4.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep
1.The differencebetweenthedimensionsobtainedinsteps 1and2mustnotexceed1/8inch(3mm).Ifthis dimensionexceeds1/8inch(3mm),thebladeis bentandmustbereplaced.RefertoRemovingthe BladesandInstallingtheBlades.
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedbladewith anewblade.
•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
Figure50
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
4.Spacer
6.Nut
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatbothends oftheblade( Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
Figure51).Maintaintheoriginalangle.
RemovingtheBlades
Replacethebladesifyouhitasolidobjectorifthe bladesareoutofbalanceorbent.T oensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineT ororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
1.Holdthebladeboltwithawrench.
2.Removethenut,bladebolt,curvedwasher,blade, spacers,andthinwasherfromthespindle(
Figure50).
Figure51
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure52).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff
37
Page 38
theendofthesailareaonly(Figure52).Repeatthis procedureuntilthebladeisbalanced.
Figure52
1.Blade2.Balancer
InstallingtheBlades
1.Placethebladeontotheboltandoverthecurved washer.Selectthepropernumberofspacer(s)for theheight-of-cut,andslidetheboltintothespindle (Figure50).
Important:Thecurvedpartoftheblademust pointupwardtowardtheinsideofthemowerto ensurepropercutting.
2.Installtheremainingspacer(s)andsecurethemwith athinwasherandanut(Fig.
3.Torquethebladeboltto75-80ft-lb(101-108N-m).
Figure50).
AdjustingtheBladeBrake
1.DisengagethePTO ,turntheignitionkeytooff,and removethekey.
2.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.
3.Ifnecessary,adjustthespringmountingboltssothat thebladebrakepadrubsagainstbothsidesofthe pulleygroove(
Figure53).
Figure53
1.Springmountingbolts3.1/8-3/16inch(3mm-5mm)
2.Bladebrakepad
ReplacingtheGrassDeector
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator'sor bystander'sdirectionandresultinseriousinjuryor death.Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstall acoverplate,amulchplate,oragrasschuteand catcher.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure54). Removedamagedorworngrassdeector.
4.Adjustthenutattheendofthebladebrakeroduntil thereis1/8-3/16inch(3mm-5mm)betweenthe nutandspacer(Figure53).
5.Engagetheblades.Ensurethebladebrakepadno longercontactsthepulleygroove.
38
Page 39
Figure54
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring8.Jhookendofspring
5.Springinstalled
7.Lendofspring,place
behinddeckedgebefore installingbolt
2.Placespacerandspringontograssdeector.Place theLendofspringbehinddeckedge.
Note:MakesuretheLendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown
Figure54.
in
3.Installboltandnut.PlacetheJhookendofspring aroundgrassdeector(Figure54).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.
Storage
CleaningandStorage
1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytooff.Removethe key.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideofthe engine'scylinderheadnsandblowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotpressurewash themachine.Avoidexcessiveuseofwater, especiallyneartheshiftleverplate,andengine.
3.Checkthebrake;refertoServicingtheBrakein BrakeMaintenance(page28).
4.Servicetheaircleaner;refertoServicingtheAir Cleaner.
5.Greasethemachine;refertoGreasingand LubricationinLubrication(page21).
6.Changethecrankcaseoil;refertoServicingthe Enginein.
7.Checkthetirepressure;refertoCheckingtheTire PressureinDriveSystemMaintenance(page27).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelinthe
tank.
B.Runenginetodistributeconditionedfuelthrough
thefuelsystem(5minutes).
C.Stopengine,allowtocoolanddrainthefuel
tank;refertoServicingtheFuelTankin FuelSystemMaintenance(page25),oroperate engineuntilitstops.
D.Restartengineandrununtilitstops.Repeat,on
Chokeuntilenginewillnotrestart.
E.Disposeoffuelproperly.Recycleasperlocal
codes.
Note:Donotstorestabilizer/conditioned gasolineover90days.
9.Removethesparkplug(s)andcheckitscondition; refertoServicingtheSparkPlug.Withthe sparkplug(s)removedfromtheengine,pour twotablespoonsofengineoilintothesparkplug hole.Nowusethestartertocranktheengineand distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).
10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.
39
Page 40
11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
12.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachineto protectitandkeepitclean.
40
Page 41
Troubleshooting
Problem
Enginewillnotstart,startshard,orfails tokeeprunning.
Enginelosespower.
PossibleCauseCorrectiveAction
1.Fueltankisempty.
2.Fuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.
3.Chokeisnoton.
4.Aircleanerisdirty.
5.Sparkplugwireislooseor disconnected.
6.Sparkplugispitted,fouled,orthegap isincorrect.
7.Dirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
5.Sparkplugispitted,fouled,orthegap isincorrect.
6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.
7.Dirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
1.Fillthefueltankwithgasoline.
3.Movethethrottlelevertochoke position.
4.Cleanorreplacetheaircleaner element.
5.Installthewireonsparkplug.
6.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
2.Cleantheaircleanerelement.
3.Addoiltothecrankcase.
4.Removetheobstructionfromthe coolingnsandairpassages.
5.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
Engineoverheats.
Machinedoesnotdrive.
Abnormalvibration.
Unevencuttingheight.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
1.Shiftleverisinneutral.1.Moveshiftlevertoadrivegearposition.
2.Tractionbeltisworn,looseorbroken.
3.Tractionbeltisoffapulley.3.Changethebelt.
4.Brokenormissingidlerspring.4.Replacethespring.
1.Cuttingblade(s)is/arebentor unbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley ,idlerpulley,or bladepulley .
5.Enginepulleyisdamaged.
6.Bladespindleisbent.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerisnotlevel.
4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.
5.Tirepressureisnotcorrect.5.Adjustthetirepressure.
6.Bladespindlebent.
2.Addoiltothecrankcase.
3.Removetheobstructionfromthe coolingnsandairpassages.
2.Changethebelt.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
3.Levelthemowerfromside-to-sideand front-to-rear.
6.ContactanAuthorizedServiceDealer.
41
Page 42
Problem
PossibleCauseCorrectiveAction
Bladesdonotrotate.
1.Mowerdeckbeltiswornorloose.
2.Mowerdeckbeltisbroken.2.Installanewdeckbelt.
3.Mowerdeckbeltisoffpulley.3.Inspectthebeltandreplaceifdamaged.
4.Brokenormissingidlerspring.4.Replacethespring.
1.Checkthebelttension.
Checkthepulleysandidlersandadjust thebelttension.
42
Page 43
Schematics
ElectricalSchematic(Rev.A)
43
Page 44
TheToroTotalCoverageWarranty
ALimitedW arranty(seewarrantyperiodsbelow)
Landscape Contractor Equipment(LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:
ProductsWarrantyPeriod
AllMowers
•Engine**
•Battery1year
•Attachments1year
Mid-SizeWalk-BehindMowers GrandStand
•Frame ZMaster
•Engine
•Frame
ZMaster
•Frame
*Whicheveroccursrst.
**SomeenginesusedonToroLCEProductsarewarrantedbytheenginemanufacturer .
***LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplacedunderwarrantyatnocostforpartsandlabor .Frame
failureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosionarenotcovered.
Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.
TM
Mowers5yearsor1,200hours*
®
Z400,Z500Mowers
®
G3Mowers5yearsor1,200hours*
2years
2years
Lifetime(originalowneronly)*** 4yearsor1,200hours* 2years** Lifetime(originalowneronly)***
Lifetime(originalowneronly)***
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.T olocateadealerconvenienttoyou,refertotheY ellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww.Toro.com.Y oumayalsocallthenumbers listedinitem#3tousethe24-hourToroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:
RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)
OwnerResponsibilities
YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator'sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:
•Costofregularmaintenanceserviceorwearparts,suchaslters,
fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.
•Anyproductorpartwhichhasbeenalteredormisusedandrequires
replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.
•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel
system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.
•Pickupanddeliverycharges.
GeneralConditions
Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingToroapprovedreplacementparts.
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.
Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty
Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguarantee information,contacttheToroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany .
374-0252RevA
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