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30672
Operator's Manual
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Toro 30672 Operator's Manual

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Page 1
FormNo.3379-923RevA
G017538
CommercialWalk-BehindMower
FixedDeck,T-Bar,GearDrivewith32in,36in, or48inCuttingUnit
ModelNo.30672—SerialNo.314000001andUp
ModelNo.30674—SerialNo.314000001andUp
ModelNo.30678—SerialNo.314000001andUp
ModelNo.39674—SerialNo.314000001andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
*3379-923*A
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadianICES-002.
•ForModels30672,30674.and30678:
Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareasmay havesimilarlaws.
•ForModel39674:
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisincorporated withthemuferassembly .
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Agency(EPA)andtheCaliforniaEmissionControl Regulationofemissionsystems,maintenance,and warranty.Replacementsmaybeorderedthroughthe enginemanufacturer.
Introduction
Thisrotary-blade,lawnmowerisintendedtobeused byresidentialhomeownersorprofessional,hired operators.Itisdesignedprimarilyforcuttinggrasson well-maintainedlawnsonresidentialorcommercial properties.Itisnotdesignedforcuttingbrushorfor agriculturaluses.
Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely .
YoumaycontactTorodirectlyatwww .T oro.comforproduct andaccessoryinformation,helpndingadealer,ortoregister yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional information,contactanAuthorizedServiceDealerorT oro CustomerServiceandhavethemodelandserialnumbersof yourproductready.Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.
Important:Thisengineisequippedwithaspark arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered, orgrass-coveredlandwithoutasparkarrester mufermaintainedinworkingorder,ortheengine constricted,equipped,andmaintainedforthe preventionofre.Otherstatesorfederalareasmay havesimilarlaws.
WARNING
Removingstandardoriginalequipmentpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.FailuretouseoriginalToro partscouldcauseseriousinjuryordeath.Making unauthorizedchangestotheengine,fuelorventing system,mayviolateEP AandCARBregulations.
Replaceallpartsincluding,butnotlimitedto,tires, belts,blades,andfuelsystemcomponentswith originalToroparts.
Theenclosed informationregardingtheUSEnvironmentalProtection
Engine Owner's Man ual
issuppliedfor
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.
©2013—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.T oro.com.
2
PrintedintheUSA
AllRightsReserved
Page 3
Contents
Figure2
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.
Introduction..................................................................2
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................6
SlopeIndicator.......................................................7
SafetyandInstructionalDecals.................................8
ProductOverview.........................................................11
Controls...............................................................11
Specications........................................................12
Attachments/Accessories........................................12
Operation....................................................................13
AddingFuel...........................................................13
UsingFuelStabilizer/Conditioner............................13
FillingtheFuelTank...............................................14
CheckingtheEngine-oilLevel..................................14
ThinkSafetyFirst...................................................14
OperatingtheParkingBrake....................................14
StartingandStoppingtheEngine..............................14
OperatingtheBlade-controlLever(PTO)..................15
TheSafety-interlockSystem.....................................16
DrivingForwardorBackward..................................16
UsingtheLowerControlBar...................................16
StoppingtheMachine.............................................17
TransportingtheMachine........................................17
AdjustingtheFlowBafe........................................18
PositioningtheFlowBafe......................................18
SideDischargingorMulchingtheGrass.....................19
AdjustingtheHeightofCut.....................................19
AdjustingtheHandleHeight....................................20
AdjustingtheControlRods......................................21
Height-of-cutChart................................................22
Maintenance.................................................................23
RecommendedMaintenanceSchedule(s)......................23
Lubrication...............................................................24
LubricatingtheMachine..........................................24
LubricatingtheCasterandWheelBearings.................24
GreasingtheTransmissionCouplers.........................24
GreasingtheMowerBeltIdler..................................24
EngineMaintenance..................................................25
ServicingtheAirCleaner.........................................25
ServicingtheEngineOil..........................................25
ServicingtheSparkPlugs.........................................27
FuelSystemMaintenance...........................................28
ServicingtheFuelSystem........................................28
DriveSystemMaintenance.........................................30
CheckingtheTirePressure......................................30
CoolingSystemMaintenance......................................30
CleaningtheAir-intakeScreen..................................30
CleaningtheCoolingSystem....................................30
BrakeMaintenance....................................................31
ServicingtheBrakes................................................31
BeltMaintenance......................................................32
CheckingtheBelts..................................................32
ReplacingtheTractionDriveBelt.............................32
ReplacingtheDriveBelt..........................................32
ReplacingtheMowerBelt........................................32
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AdjustingtheMowerBeltTension............................34
MowerDeckMaintenance...........................................37
ServicingtheCuttingBlades.....................................37
AdjustingtheBladeBrake........................................40
ReplacingtheGrassDeector..................................41
Storage........................................................................41
Troubleshooting...........................................................43
Schematics...................................................................45
Safety
Note:Theadditionofattachmentsmadebyother
manufacturersthatdonotmeetAmericanNationalStandards Institutecerticationwillcausenoncomplianceofthis machine.
Improperlyusingormaintainingthemachinecanresult ininjury.Toreducethepotentialforinjury,complywith thesesafetyinstructionsandalwayspayattentiontothe safetyalertsymbol,whichmeans
Danger
withtheinstructionmayresultinpersonalinjuryor death.
—personalsafetyinstruction.Failuretocomply

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI B71.4-2012.
Training
•ReadtheOperator'sManualandothertrainingmaterial.If
theoperator(s)ormechanic(s)cannotreadorunderstand theinformationitistheowner'sresponsibilitytoexplain thismaterialtothem.
•Becomefamiliarwiththesafeoperationoftheequipment,
operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateorservice
theequipment.Localregulationsmayrestricttheageof theoperator.
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtopeopleordamageto property.
Caution, W ar ning ,
or
Preparation
•Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety
glasses,andhearingprotection.Longhair,looseclothing, orjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeusedand
removeallobjectssuchasrocks,toys,andwirewhichcan bethrownbythemachine.
•Checkthatoperator'spresencecontrols,safetyswitches,
andshieldsareattachedandfunctioningproperly .Donot operateunlesstheyarefunctioningproperly.
Operation
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.
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Page 5
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholesand
hiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingtheengine.Onlystarttheengine fromtheoperator'sposition.
•Besureofyourfootingwhileusingthismachine,
especiallywhenbackingup.Walk;donotrun.Never operateonwetgrass.Reducedfootingcouldcause slipping.
•Slowdownanduseextracareonhillsides.Besureto
travelsidetosideonhillsides.Turfconditionscanaffect thestabilityofthemachine.Usecautionwhileoperating neardrop-offs.
•Slowdownandusecautionwhenmakingturnsandwhen
changingdirectionsonslopes.
•Neverraisedeckwiththebladesrunning.
•NeveroperatewiththePTOshieldorotherguardsnot
securelyinplace.Besureallinterlocksareattached, adjustedproperly,andfunctioningproperly.
•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.
•Donotchangetheenginegovernorsettingoroverspeed
theengine.
•Stoponlevelground,disengagedrives,engagethe
parkingbrake(ifprovided),andshutofftheenginebefore leavingtheoperator'spositionforanyreason,including emptyingthecatchersoruncloggingthechute.
•Stopequipmentandinspectbladesafterstrikingobjects
orifanabnormalvibrationoccurs.Makenecessary repairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunit.
•Lookbehindanddownbeforebackinguptobesureof
aclearpath.
•Nevercarrypassengersonthemachine.
•Keeppetsandbystandersaway.
•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopbladesifnotmowing.
•Beawareofthemowerdischargedirectionanddonot
pointitatanyone.
•Donotoperatethemowerundertheinuenceofalcohol
ordrugs.
•Usecarewhenloadingorunloadingthemachineinto
orfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlinggasoline.Gasolineisextremely ammableandthevaporsareexplosive.
•Extinguishallcigarettes,cigars,pipes,andothersources
ofignition.
•Useonlyanapprovedfuelcontainer.
•Neverremovefuelcaporaddfuelwiththeengine
running.
•Allowenginetocoolbeforerefueling.
•Neverrefuelthemachineindoors.
•Neverstorethemachineorfuelcontainerwherethereis
anopename,spark,orpilotlightsuchasonawater heateroronotherappliances.
•Neverllcontainersinsideavehicleoronatruckor
trailerbedwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.
•Removeequipmentfromthetruckortrailerandrefuelit
ontheground.Ifthisisnotpossible,thenrefuelsuch equipmentwithaportablecontainer,ratherthanfroma fueldispensernozzle.
•Keepthenozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingiscomplete.
•Donotuseanozzlelockopendevice.
•Iffuelisspilledonclothing,changeclothingimmediately.
•Neveroverllfueltank.Replacefuelcapandtighten
securely.
MaintenanceandStorage
•Disengagedrives,settheparkingbrake,stoptheengine
andremovethekeyordisconnectthespark-plugwire. Waitforallmovementtostopbeforeadjusting,cleaning orrepairingthemachine.
•Cleangrassanddebrisfromthecuttingunit,thedrives,
themufers,andtheenginetohelppreventres.Clean upoilorfuelspillage.
•Lettheenginecoolbeforestoringanddonotstorenear
ame.
•Shutoffthefuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.
•Parkthemachineonlevelground.Settheparkingbrake.
Neverallowuntrainedpersonneltoservicethemachine.
•Usejackstandstosupportcomponentswhenrequired.
•Carefullyreleasepressurefromcomponentswithstored
energy.
•Disconnectthebatteryorthespark-plugwirebefore
makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Connectthepositiverstand negativelast.
•Usecarewhencheckingtheblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.Only replaceblades.Neverstraightenorweldthem.
•Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
•Keepallpartsingoodworkingconditionandallhardware
tightened.Replaceallwornordamageddecals.
•Tobestprotectyourinvestmentandmaintainoptimal
performanceofyourToroequipment,countonToro genuineparts.Whenitcomestoreliability,Torodelivers
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replacementpartsdesignedtotheexactengineering specicationsofourequipment.Forpeaceofmind,insist onT orogenuineparts.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usefullwidthrampsforloadingmachineintotraileror
truck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected downandoutwardfromthemachine.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro productsandothersafetyinformationyoumustknow.
Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrassor, whenequippedwithagrassbagger,forcatchingcutgrass. Anyuseforpurposesotherthanthesecouldprovedangerous touserandbystanders.
Service
•Neverstorethemachineorfuelcontainerinsidewhere
thereisanopename,suchasnearawaterheateror furnace.
•Keepnutsandboltstight,especiallythebladeattachment
bolts.Keepequipmentingoodcondition.
•Nevertamperwithsafetydevices.Checksafetysystems
forproperoperationbeforeeachuse.
•Useonlygenuinereplacementpartstoensurethatoriginal
standardsaremaintained.
•Checkbrakeoperationfrequently.Adjustandserviceas
required.
GeneralOperation
•Besuretheareaisclearofotherpeoplebeforemowing.
Stopthemachineifanyoneentersthearea.
•Donottouchequipmentorattachmentpartswhichmay
behotfromoperation.Allowtocoolbeforeattempting tomaintain,adjustorservice.
•UseonlyToroapprovedattachments.Warrantymaybe
voidedifusedwithunapprovedattachments.
•Checkcarefullyforoverheadclearances(i.e.branches,
doorways,electricalwires)beforeoperatingunderany objectsanddonotcontactthem.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeeluneasy onaslope,donotmowit.
•Removeobstaclessuchasrocks,treelimbs,etc.fromthe
mowingarea.
•Watchforholes,rutsorbumps.Tallgrasscanhide
obstacles.
•Usecautionneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifawheelgoes overtheedgeofaclifforditch,orifanedgecavesin.
•Useextracarewithgrasscatchersorotherattachments.
Thesecanchangethestabilityofthemachine.
•Keepallmovementonslopesslowandgradual.Donot
makesuddenchangesinspeedordirection.
•Mowslopessidetoside.
•Donotmowslopesgreaterthan20degrees.
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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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SafetyandInstructionalDecals
82- 2280
REV E R S E  TRACT ION DR I V E
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.
1-403005
95-5537
1.ReadtheOperator's Manualforinstructionson
operatingthecuttingblade
66-1340
82-2280
82-2290
2.Pushforwardtoengage
3.Pullbacktodisengage
98-0776
98-3256
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98-3266
98-4387
1.Warning—wearhearingprotection.
98-5130
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto75-80ft-lb(102-106N⋅m).
99-3943
ForModelwith3–BladeMowerDecks
1.Engine
104-8569
106-0699
98-5954
98-3296
ForModelswith2–BladeMowerDecks
103–2076
110-2067
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110-2068
1.ReadtheOperator'sManual.
Manufacturer'sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
117–2718
(Model39674only)
105-0884
110-6916
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ProductOverview
G017539
Controls
Becomefamiliarwithallthecontrols(Figure5)beforeyou starttheengineandoperatethemachine.
Figure4
1.Sidedischarge
2.Mowerdeck6.Handle
3.Recoil-starthandle7.Frontcasterwheel
4.Gastank
5.T-barcontrol
Figure5
1.Throttlecontrol7.Parkingbrake
2.Blade-controlbail
3.Powertake-offlever(PTO)
4.Gear-shiftlever
5.Uppercontrolbar11.Lowerhandle
6.Lowercontrolbar
lever—releasedposition
8.Choke
9.Ignitionswitch
10.Upperhandle
ThrottleControl
Thethrottlecontrolhas2positions:FastandSlow.
Blade-controlBail
Thebailisusedinconjunctionwiththeblade-controllever (PTO)toengagetheclutchanddrivethemowerblades. Releasingthebladecontrolbailwillstoptheenginewiththe PTOengaged.
Blade-controlLever(PTO)
Thisleverisusedinconjunctionwiththeblade-controlbail toengageanddisengagethemowerdeckbeltanddrivethe mowerblades.
Gear-shiftLever
Thetransmissionhas5forwardspeeds,neutral,andreverse, andhasanin-lineshiftpattern.
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Important:Donotshiftwhilethemachineismoving, astransmissiondamagemayoccur.
UpperControlBar
Shifttothedesiredgearandpushforwardontheupper controlbarandbladecontrolbailtoengageforwardtraction operationandpullbacktobrakeforwardmovement.Pull backonrightsideofuppercontrolbartoturnrightandleft sidetoturnleft.
LowerControlBar
Shifttransmissiontoreverseandsqueezethelowercontrol barandhandletogethertoengagetherearwardtractionassist.
Parking-brakeLever
Pullbackonuppercontrolbarandswingbrakeleverup againsttheupperhandletosettheparkingbrake(Figure5).
IgnitionSwitch
Thisswitchisusedinconjunctionwithrecoilstarterandhas twopositions:RunandOff.
RecoilStarter
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
32-inchmowers:
Widthwithdeectordown116.3cm(45.8inches)
Length
Height
Weight
36-inchmowers:
Widthwithdeectordown118.4cm(46.6inches)
Length
Height
Weight
48-inchmowers:
Widthwithdeectordown161.3cm(63-1/2inches)
Length
Height
Weight
183cm(72inches)
104.1cm(41inches)
181kg(400lb)
188cm(74inches)
104.1cm(41inches)
209kg(460lb)
183.6cm(72-3/8inches)
104.1cm(41inches)
226kg(598lb)
Pulltherecoil-starthandletostarttheengine(notshown inFigure4).
Fuel-shutoffValve
Closethefuel-shutoffvalvewhentransportingorstoringthe machine.
Choke
Usethechoketostartacoldengine.

Attachments/Accessories

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

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan30days
old),unleadedgasolinewithanoctaneratingof87or higher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol(gasohol)
or15%MTBE(methyltertiarybutylether)byvolume isacceptable.EthanolandMTBEarenotthesame. Gasolinewith15%ethanol(E15)byvolumeisnot approvedforuse.Neverusegasolinethatcontainsmore than10%ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85(contains 85%ethanol).Usingunapprovedgasolinemaycause performanceproblemsand/orenginedamagewhichmay notbecoveredunderwarranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuelcontainers
overthewinterunlessafuelstabilizerisused.
•Donotaddoiltogasoline.
DANGER
Incertainconditions,fuelisextremelyammable andhighlyexplosive.Areorexplosionfromfuel canburnyouandothersandcandamageproperty.
•Fillthefueltankoutdoors,inanopenarea,when theengineiscold.Wipeupanyfuelthatspills.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Addfuel tothefueltankuntilthelevelis25mm(1inch) belowthebottomofthellerneck.Thisempty spaceinthetankallowsthefueltoexpand.
•Neversmokewhenhandlingfuel,andstayaway fromanopenameorwherefuelfumesmaybe ignitedbyaspark.
•Storefuelinanapprovedcontainerandkeepit outofthereachofchildren.Donotbuymore thana30-daysupplyoffuel.
•Donotoperatewithouttheentireexhaust systeminplaceandinproperworkingcondition.
DANGER
Incertainconditionsduringfueling,static electricitycancauseaspark,whichcanignitethe fuelvapors.Areorexplosionfromfuelcanburn youandothersandcandamageproperty.
•Alwaysplacefuelcontainersonthegroundaway fromyourvehiclebeforelling.
•Donotllfuelcontainersinsideavehicleoron atruckortrailerbedbecauseinteriorcarpets orplastictruck-bedlinersmayinsulatethe containerandslowthelossofanystaticcharge.
•Whenpractical,removefuel-poweredequipment fromthetruckortrailerandfueltheequipment withitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromafuel-dispenser nozzle.
•Ifafueldispensermustbeused,keepthe nozzleincontactwiththerimofthefueltank orcontaineropeningatalltimesuntilfuelingis complete.
WARNING
Gasolineisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditioneropening.
•Keepgasawayfromeyesandskin.

UsingFuel Stabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachinetokeepthe fuelfreshduringstorageof90daysorless.Ifyouarestoring themachineforlonger,drainthefueltank;referto (page41).
Storage
Important:Donotusefueladditivescontaining methanolorethanol.
Addthecorrectamountoffuelstabilizer/conditionertothe fuel,andfollowthedirectionsofthemanufacturer.
Note:Fuelstabilizer/conditionerismosteffectivewhen mixedwithfreshgasoline.Tominimizethechanceofvarnish depositsinthefuelsystem,usefuelstabilizeratalltimes.
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Page 14

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundthefuel-tankcapandremovethecap. Addunleadedregulargasolinetothefueltank,untilthe levelis6to13mm(1/4to1/2inch)belowthebottom ofthellerneck.Thisspaceinthetankallowsgasoline toexpand.Donotllthefueltankcompletelyfull.
3.Installthefuel-tankcapsecurely .Wipeupanygasoline thatmayhavespilled.

CheckingtheEngine-oilLevel

Beforeyoustarttheengineandusethemachine,checktheoil levelintheenginecrankcase;refertoCheckingtheEngine-oil Level.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsinthe safetysection.Knowingthisinformationcouldhelpyouor anybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing,feetand headisrecommended.
SettingtheParkingBrake
1.Pulltheuppercontrolbarrearwardandholditinthis position(Figure7).
2.Lifttheparking-brakelockupandgraduallyreleasethe uppercontrolbar.Thebrakelockshouldstayintheset (locked)position(Figure7).
Figure7
1.Uppercontrolbar3.Fixedbar
2.Parking-brakelever—set position
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator'searandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Figure6
1.Warning—wearhearingprotection.

OperatingtheParkingBrake

Stoponlevelground,disengagedrives,engagetheparking brake,stoptheengine,andremovethekey.Alwaysset theparkingbrakewhenyoustopthemachineorleaveit unattended.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
ReleasingtheParkingBrake
1.Pullrearwardontheuppercontrolbar.Lowerthe parking-brakelocktothereleasedposition.
2.Graduallyreleasetheuppercontrolbar.

StartingandStoppingthe Engine

StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
3.Disengagetheblade-control(PTO)leverandmovethe shiftlevertotheneutralposition.
4.Settheparkingbrake.
5.Turntheignitionkeytotherunposition(
6.Tostartacoldengine,movethethrottlecontrol midwaybetweenthefastandslowpositions.
7.Tostartawarmengine,movethethrottlecontrolto thefastposition.
8.Pullthechokeknobtotheonpositioniftheengineis cold(Figure8).
Note:Awarmorhotengineusuallydoesnotrequire usingthechoke.
9.Grasptherecoilstarterhandlermlyandpullitout untilpositiveengagementresults;thenpullthehandle vigorouslytostarttheengine.Allowtheropetorecoil slowly.
Figure8).
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Page 15
Important:Donotpulltherecoilropetoitslimit orreleasethestarterhandlewhenyoupullout theropebecausetheropemaybreakortherecoil assemblymaybedamaged.
10.Pushthechoketotheoffpositionastheenginewarms up.

OperatingtheBlade-control Lever(PTO)

Theblade-controllever(PTO)engagesanddisengagespower tothemowerblades.
11.Iftheengineiscold,allowittowarmupandthen movethethrottlecontroltothefastposition.
StoppingtheEngine
Important:Inanemergency,youcanstoptheengine
immediatelybyturningtheignitionkeytothe position.
1.Movethethrottlelevertotheslowposition(
2.Lettheengineidlefor30to60secondsbeforeturning theignitionkeytotheoffposition.
3.Turntheignitionkeytotheoffposition(Figure8).
of f
Figure8).
EngagingtheMowerBlades
1.Toengagetheblades,squeezetheblade-controlbail againsttheuppercontrolbar(Figure9).
2.Pushtheblade-controllever(PTO)rmlyforward, untilitlatchesover-center.
3.Starttheengineandrepeattheproceduretoengagethe mowerbladesiftheblade-controlbailisreleased.
Figure8
1.Blade-controllever(PTO)
2.Throttlelever
4.Settheparkingbrakeandremovethekey.
5.Disconnectthewiresfromthesparkplugstoprevent thepossibilityofaccidentallystartingbeforestoringor performingmaintenanceonthemachine.
6.Closethefuel-shutoffvalvebeforestoringor transportingthemachine.
Important:Makesurethatthefuel-shutoff valveisclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.
3.Ignitionkey
Figure9
1.Uppercontrolbar
2.Blade-controlbail
3.Blade-controllever(PTO)
DisengagingtheMowerBlades(PTO)
Todisengagetheblades,pulltheblade-controllever(PTO) rearwardalltheway(Figure9).Theenginewillstopwhen theblade-controlbailisreleasedwiththeblade-controllever engaged.
Note:Itisnecessarytofullyandmanuallydisengagethe blade-controllever.
15
Page 16

TheSafety-interlockSystem

3.Slowlypressontheuppercontrolbartomoveforward (
Figure10).
CAUTION
Ifsafety-interlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly, causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlockswitches daily,andreplaceanydamagedswitchesbefore operatingthemachine.
Thesafety-interlocksystemisdesignedtopreventtheengine fromstartingwhen:
•Theblade-controllever(PTO)isengaged.
•Theignitionkeyisintheoffposition.
Thesafety-interlocksystemisalsodesignedtostopthe enginewhen:
•The-bladecontrolbailisreleasedwiththeblade-control
lever(PTO)engaged.
•Theignitionswitchisturnedtotheoffposition.
TestingtheSafety-interlockSystem
Testthesafety-interlocksystembeforeyouusethemachine eachtime.Ifthesafetysystemdoesnotoperateasdescribed below,haveanAuthorizedServiceDealerrepairthesafety systemimmediately .
1.Settheparkingbrake,disengagethePTO,andplace thethrottleforward.
2.Starttheengine.
3.Withtheenginerunningsqueezetheblade-control bailagainstuppercontrolbarandpushthe mower-blade-controlleverforward.Themowerblades shouldbeginrotating.
4.Withtheenginerunning,releasetheblade-controlbail. Theengineshouldstop.
5.Starttheengineagain.
6.Withtheenginerunning,turntheignitionkeytothe offposition.Theengineshouldstop.
Togostraight,applyequalpressuretobothendsofthe uppercontrolbar(Figure10).
Toturn,releasepressureontheuppercontrolbarside inthedirectionyouwanttoturn(Figure10).
Figure10
1.Uppercontrolbar
2.Lowercontrolbar4.Lowerhandle
3.Shiftlever
DrivingBackward
1.Togobackward,movetheshiftlevertothereverse gear.
2.Releasetheparkingbrake;refertoReleasingthe ParkingBrake.
3.Slowlysqueezethelowercontrolbarandlowerhandle togethertomoverearward(
Figure10).

UsingtheLowerControlBar

Thisprocedureisfordrivingupacurb.Thiscanbe performedwhiledrivingforwardorbackward.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedasmeasured inrpm(revolutionsperminute).Placethethrottlecontrolin thefastpositionforbestmowingperformance.
DrivingForward
1.Togoforward,movetheshiftlevertoaforwardgear (Figure10).
2.Releasetheparkingbrake;refertoReleasingthe ParkingBrake.
Note:Somecurbsdonotallowthereardrivetirestocontact thecurb.Ifthishappens,drivethemachineupthecurbatan angle.
WARNING
Abladecanbebentordamagedwhendrivingup acurb.Piecesofbladethatmaybethrowncould seriouslyinjureorkillyouorbystanders.
Donotrunbladeswhiledrivingupacurbforward orbackward.
16
Page 17
DrivingForwardupaCurb
1.Disengagethemowerblades.
2.Selecttherstgeartodrivethemachine.
3.Drivemachineuntilthecasterwheelscontactthecurb (Figure11).
4.Liftthefrontofthemachinebypushingdownonthe lowerhandle(
5.Drivethemachineuntilthedrivewheelscontactthe curb(Figure11).
6.Lowerthefrontofthemachine(Figure11).
Note:Bothdrivewheelsshouldcontactthecurband casterwheelsstraight.
7.Atthesametimeengagethelowercontrolbarandlift uponthelowerhandletodriveoverthecurb(Figure 10andFigure11).
Figure11).
Note:Liftinguponthelowerhandlewillassistdriving themachineupacurbandnotspinthedrivewheels.
Figure12
Note:Liftinguponthelowerhandlewillassistdriving
themachineupacurbandnotspinthedrivewheels.
Figure11
1.Lowercontrolbarengaged andmowerinreverse
2.Pulluptoassistmachine
3.Lowercontrolbarengaged andmowergoingforward
DrivingBackwardupaCurb
1.Disengagethemowerblades.
2.Selectreversetodrivethemachine.
3.Drivethemachineuntildrivewheelscontactcurb (Figure11).
Note:Bothdrivewheelsshouldcontactthecurband casterwheelsstraight.
4.Atthesametimeengagelowercontrolbarandliftup onthelowerhandle(Figure10andFigure12).
1.Lowercontrolbar (engaged)
2.Handle

StoppingtheMachine

Tostopthemachine,pullbackontheuppercontrolbar, releasetheblade-controlbail,turntheignitionkeytotheoff position,andsettheparkingbrake;referto ParkingBrake(page14) theignitionswitch.
.Remembertoremovethekeyfrom
Operatingthe
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthemachine. Ensurethatthetrailerortruckhasallnecessarylightingand markingasrequiredbylaw .Pleasecarefullyreadallthesafety instructions.Knowingthisinformationcouldhelpyou,your family,petsorbystandersavoidinjury.
Totransportthemachine:
1.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.
2.Securelyfastenthemachinetothetrailerortruckwith straps,chains,cable,orropes.
3.Ifusingatrailer,securethetrailertothetowingvehicle andinstallthesafetychains.
17
Page 18
AdjustingtheFlowBafe
g012676
1 2
G012677
G012678
Themowerdischargeowcanbeadjustedfordifferenttypes ofmowingconditions.Positionthebafetogivethebest qualityofcut.
1.DisengagethePTO ,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Toadjustthebafe,loosenthenut(
4.Adjustthebafeandnutintheslottothedesired dischargeowandtightenthenut.
Figure13
1.Slot
2.Nut
PositioningtheFlowBafe
Figure13).
Figure14
PositionB
Usethispositionwhenbagging(Figure15).
Thefollowingguresareonlyrecommendationsforuse. Adjustmentswillvarybygrasstype,moisturecontent,and heightofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition(seeFigure14).Thesuggested useforthispositionisafollows.
•Useforshort,lightgrassmowingconditions.
•Useindryconditions.
•Forsmallergrassclippings.
•Propelsgrassclippingsfartherawayfromthemower.
Figure15
PositionC
Thisisthefullopenposition.Thesuggesteduseforthis positionisasfollows(Figure16).
•Useintall,densegrassmowingconditions.
•Useinwetconditions.
•Lowerstheenginepowerconsumption.
•Allowsincreasedgroundspeedinheavyconditions.
18
Page 19
G012679
Figure16

SideDischargingorMulching theGrass

Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
adjustmentrange,in6mm(1/4inch)increments,ofcutting heightinanyaxleposition.Usethesamenumberofblade spacersonallbladestoachievealevelcut(2aboveand 2below,1aboveand3below ,etc.).
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Holdthebladeboltandremovethenut(Figure17).
DANGER
Withoutthegrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.
•Neverremovethegrassdeectorfromthemower becausethegrassdeectorroutesmaterialdown towardtheturf.Ifthegrassdeectorisever damaged,replaceitimmediately.
•Neverputyourhandsorfeetunderthemower.
•Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthepower takeoff(PTO)isoff.Rotatetheignitionkeyto Off.Alsoremovethekeyandpullthewiresoff thesparkplug(s).

AdjustingtheHeightofCut

Thismachinehasa26to108mm(1to4-1/4inch)range fortheheightofcut.Thiscanbeachievedbyadjusting thebladespacers,rearaxleheight,andfrontcasterspacers. UsetheHeight-of-CutCharttoselectthecombinationof adjustmentsrequired.
Figure17
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
4.Slidetheboltdownthroughthespindle,andchange thespacersasneeded(Figure17).
5.Installtheboltandcurvedwasher,addextraspacer(s), andsecurethemwithathinwasherandanut(Figure
17).
6.Torquethebladeboltto75-80ft-lb(101-108N-m).
4.Spacer
6.Nut
AdjustingtheBladeHeight
Adjustthebladesbyusingthe4spacers(6mm)(1/4inch), onthebladespindlebolts.Thisallowsfora25mm(1-inch)
19
Page 20
AdjustingtheAxleHeight
Adjusttheaxlepositiontotheselectedheight-of-cutsetting. RefertotheHeight-of-CutChart.
1.Disengagethebladecontrol(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Loosen,butdonotremove,the2axlepivotboltsand the2axleadjustmentbolts(Figure18).
Figure19
Figure18
1.Axlepivotbolt2.Axleadjustmentbolt
4.Placeajackundertherearcenteroftheengineframe. Raisethebackendoftheengineframeupenoughto removethefront2axleadjustmentbolts(Figure18).
Note:Usejackstandstosupportthemachine.
5.Raiseorlowertheengineframewiththejacksothat youcaninstallthefront2axleadjustmentboltsinthe desiredholelocation(Figure18).
Note:Useataperedpunchtohelpaligntheholes.
6.Tightenall4boltsandlowerthemower.
7.Adjustthecontrolrodsandthebrakelinkagesas required.RefertoServicingtheBrakesandAdjusting theControlRods.
1.Latchpin
2.Spacer,5mm(3/16inch)
3.Spacer,13mm(1/2inch)
2.Removethelatchpin,slidethecasterfromthesupport, andchangethespacers(Figure19).
3.Installthecasterinthesupportandinsertthevpin (Figure19).

AdjustingtheHandleHeight

Thehandlepositioncanbeadjustedtomatchtheoperator's heightpreference.
1.Removehairpincotter,washerandclevispinsecuring controlrodttingtoidlerbracket(
Figure20).
Important:Y oumustadjustthecontrolrods andthebrakelinkagewhenyouchangetheaxle positionsforpropertractionandbrakefunction.
AdjustingtheCasterPosition
1.UsingtheHeight-of-CutChart,adjustthecaster spacerstomatchwiththeaxleholeselected(Figure19).
Figure20
1.Controlrod4.Clevispin
2.Controlrodtting
3.Idlerbracket6.Hairpincotterpin
5.Washer
2.Loosentheupperangebolts(3/8x1inch)andange nutsecuringhandletorearframe(Figure21).
20
Page 21
Figure21
g018809
1
2
3
4
5
1.Upperhandle
2.Rearframe
3.Flangebolt(3/8x1inch)
4.Locknut(3/8inch)
5.Uppermountinghole
6.Lowermountinghole
3.Removethelowerangebolts(3/8x1inch)andange nutssecuringhandletorearframe(Figure21).
4.Pivothandletodesiredoperatingpositionandinstall lowerangebolts(3/8x1inch)andangenutsinto mountingholes.Tightenallangebolts.
5.Threadrodttingupordownonroduntilproper positionisattainedandinstallintottingtoidler bracketwithclevispin,washerandhairpincotter.
6.Checktheparkingbrakeadjustment.RefertoChecking theBrakesinBrakeMaintenance(page31).

AdjustingtheControlRods

1.Checkthegapbetweentheuppercontrolbarandthe xedbarwiththewheeldrivefullyengaged.Thegap willneedtobeapproximately25to32mm(1to1-1/4 inches);refertoFigure22.
Figure22
1.25to32mm(1to1-1/4 inches)gap
2.Fixedcontrolbar
3.Parking-brakelever
4.Uppercontrolbar
5.Controlrod
Note:Theuppercontrolbarandthexedbarmust beparallelintheengaged,relaxedandbrakepositions.
2.Checktheoperation.Ifadjustmentisrequired,remove thehairpincotterpinsecuringtherodtotheupper controlbar.Threadtherodinoroutofthecontrolrod ttingforproperpositionandinstallthecontrolrod intotheuppercontrolbarwiththehairpincotterpin.
3.Afteradjustingthecontrolrods,checktheparking brakeadjustment;refertoServicingtheBrakeinBrake Maintenance(page31).
21
Page 22

Height-of-cutChart

Numberofspacers
13mm
Axleposition
A00
A01
A10
B01
B10
B11
B20
C
C
C
C
D21
D30
D31
D40
E31
E40
E41
(1/2inch)
11
20
21
30
belowcaster
5mm
(3/16inch)
26mm
29mm
(1-1/8inch)
35mm
(1-3/8inch)
35mm
(1-3/8inch)
41mm
(1-5/8inch)
45mm
(1-3/4inch)
51mm
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
73mm
(2-7/8inch)
79mm
(3-1/8inch)
82mm
(3-1/4inch)
Numberof1/4inchbladespacersbelowspindle
43210
(1inch)
(2inch)
(3inch)
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
Every200hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthemowerbelttension.
•Checkthemowerbelttension.
•Checkthesafetysystem.
•Greasethecasterwheelsandcasterpivot.
•Checktheengine-oillevel.
•Cleantheair-intakescreen.
•Checkthebrakes.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanthefoamair-cleanerelement.
•Greasethemowerbeltidler.
•Checkthepaperair-cleanerelement.
•Checkthetirepressure.
•Checkthebelts.
•Checkthemowerbelttension.
•Changetheengineoil.
•Checkthesparkplugs.
•Checkandcleantheengine-coolingnsandshrouds.
•Replacethepaperair-cleanerelement.
•Changetheoillter.
•Replacethefuellter.
•Replacethefuelventlter.
Every250hours
Every400hours
Beforestorage
•Greasethetransmissioncouplers(moreoftenindirtyordustyconditions).
•Greasethewheelbearings(moreoftenindirtyordustyconditions).
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthespark-plugwire(s)fromthesparkplug(s)beforeyou doanymaintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.
23
Page 24
Lubrication
GreaseType:#2general-purposelithium-basedor molybdenum-basedgrease

LubricatingtheMachine

1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Cleanthegreasettingswitharag.Makesuretoscrape anypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutofthe bearings.
5.Wipeupanyexcessgrease.
Figure24

GreasingtheMowerBeltIdler

Greasethettingonthemowerbelt-idlerarmpivot(Figure
25).

LubricatingtheCasterand WheelBearings

1.Lubricatethefrontwheelbearingsandfrontspindles (Figure23).
2.Lubricatethedrivewheelbearings(Figure23).
Figure23
Note:Removethemowerdeckcovertoaccessthegrease
ttingforthemowerbelt-idlerarm.
Figure25
32-inchand36-inchmowerdeck

GreasingtheTransmission Couplers

Lubricatethetransmissioncouplersandidlerarmpivots locatedinthebackofthemachine(Figure24).
Figure26
48-inchmowerdeck
24
Page 25
EngineMaintenance

ServicingtheAirCleaner

CleaningtheFoamAir-cleanerElement
1.Washthefoamelementinliquidsoapandwarmwater. Whentheelementisclean,rinseitthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
ServiceInterval/Specication
ServiceInterval:Every25hours—Cleanthefoam
air-cleanerelement.
Every50hours—Checkthepaperair-cleanerelement.
Every200hours—Replacethepaperair-cleaner element.
Note:Servicetheaircleanermorefrequently(everyfew operatinghours)iftheoperatingconditionsareextremely dustyorsandy.
Important:Donotoilthefoamorpaperelement.
RemovingtheFoamandPaper Elements
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Cleanaroundtheaircleanertopreventdirtfrom gettingintotheengineandcausingdamage(Figure27).
4.Unscrewthecoverknobsandremovetheair-cleaner cover(Figure27).
5.Unscrewthehoseclampandremovetheaircleaner assembly(Figure27).
6.Carefullypullthefoamelementoffthepaperelement (Figure27).
Important:Replacethefoamelementifitistorn orworn.
ServicingthePaperAir-cleanerElement
1.Donotcleanthepaperlter,replaceit(Figure27).
2.Inspecttheelementfortears,anoilylm,ordamageto therubberseal.
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaperElements
Important:Topreventenginedamage,alwaysoperate
theenginewiththecompletefoamandpaperaircleaner assemblyinstalled.
1.Carefullyslidethefoamelementontothepaper air-cleanerelement(Figure27).
2.Placetheaircleanerassemblyontotheaircleanerbase andsecureitwiththe2wingnuts(
3.Placetheair-cleanercoverintopositionandtighten thecoverknob(Figure27).
Figure27).

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Checkthe
engine-oillevel.
Aftertherst8hours—Changetheengineoil.
Every100hours—Changetheengineoil.
Figure27
1.Cover
2.Hoseclamp4.Foamelement
3.Paperelement
Every200hours—Changetheoillter.
Note:Changetheoilmorefrequentlywhentheoperating conditionsareextremelydustyorsandy.
OilType:Detergentoil(APIserviceSF ,SG,SH,SJorSL)
CrankcaseCapacity:1.7L(1.8USqt)withthelter
removed;1.5L(1.6USqt)withoutthelterremoved
Viscosity:Refertothetable(Figure28).
25
Page 26
ChangingtheEngineOil
1.Parkthemachinesothatthedrainsideisslightlylower thantheoppositesidetoensurethattheoildrains completely.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
4.Slidethedrainhoseovertheoildrainvalve.
5.Placeapanbelowthedrainhose.Rotateoildrainvalve toallowoiltodrain(Figure30).
Figure28
CheckingtheEngine-oilLevel
1.Parkthemachineonalevelsurface.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
4.Cleanaroundtheoildipstick(Figure29)sothatdirt cannotfallintothellerholeanddamagetheengine.
6.Whenoilhasdrainedcompletely ,closethedrainvalve.
7.Removethedrainhose(
Figure30).
Note:Disposeoftheusedoilatarecyclingcenter.
Figure29
1.Oildipstick
2.Fillertube
5.Unscrewtheoildipstickandwipetheendclean(Figure
29).
6.Slidetheoildipstickfullyintothellertube,butdonot threaditontothetube(Figure29).
7.Pullthedipstickoutandlookattheend.Iftheoillevel islow,slowlypouronlyenoughoilintothellertube toraisetheleveltotheFullmark.
Important:Donotoverllthecrankcasewithoil andruntheengine;enginedamagecanresult.
Figure30
1.Oildrainvalve2.Oildrainhose
8.Slowlypourapproximately80%ofthespeciedoil intothellertube(
Figure29).
9.Checktheoillevel;refertoCheckingtheEngineOil Level.
10.SlowlyaddtheadditionaloiltobringittotheFull mark.
ChangingtheOilFilter
Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Removetheoldlter(
26
Figure31).
Page 27
Figure31
1
1.Oillter
2.Adapter
3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure31).
4.Installthereplacementoilltertothelteradapter, turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional3/4turn(
Figure31).
5.Fillthecrankcasewiththepropertypeofnewoil;refer toServicingtheEngineOil.
6.Runtheengineforabout3minutes,stoptheengine, andcheckforoilleaksaroundtheoillteranddrain valve.
7.Checktheengineoillevelandaddoilifneeded.
8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

ServiceInterval:Every100hours—Checkthesparkplugs.
Ensurethattheairgapbetweenthecenterelectrodeandthe sideelectrodeiscorrectbeforeinstallingeachsparkplug.Use aspark-plugwrenchforremovingandinstallingthespark plugsandagappingtoolorafeelergaugetocheckandadjust theairgap.Installnewsparkplugsifnecessary.
Figure32
1.Spark-plugwire/sparkplug
4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausingdamage.
5.Removethesparkplugsandthemetalwashers.
CheckingtheSparkPlugs
1.Lookatthecenterofthesparkplugs(Figure33).If youseelightbrownorgrayontheinsulator,theengine isoperatingproperly.Ablackcoatingontheinsulator usuallymeansthattheaircleanerisdirty.
2.Ifneeded,cleanthesparkplugwithawirebrushto removecarbondeposits.
Type:Champion®RCJ8Yorequivalent
AirGap:0.75mm(0.030inch)
RemovingtheSparkPlugs
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Disconnectthewiresfromthesparkplugs(
Figure32).
Figure33
1.Centerelectrode;insulator3.Airgap(nottoscale)
2.Sideelectrode
Important:Alwaysreplacethesparkplugswhen theyhavewornelectrodes,anoilylm,ora crackedinsulator.
3.Checkthegapbetweenthecenterelectrodeandthe sideelectrode(
Figure33).Bendthesideelectrode
(Figure33)ifthegapisnotcorrect.
27
Page 28
InstallingtheSparkPlugs
1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.
2.Tightenthesparkplugsto22N-m(16ft-lb).
FuelSystem Maintenance
3.Connectthewirestothesparkplugs(Figure33).

ServicingtheFuelSystem

DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.
•Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.
DrainingtheFuelTank
1.Parkthemachineonalevelsurfacetoensurethatthe fueltankdrainscompletely;thendisengagethepower take-off(PTO),settheparkingbrake,andturnthe ignitionkeytotheoffposition.Removethekey .
2.Closethefuel-shutoffvalveatthefueltank(Figure34).
3.Squeezetheendsofthehoseclamptogetherandslide itupthefuellineawayfromfuellter(Figure34).
4.Pullthefuellineoffthefuellter(Figure34).Open thefuel-shutoffvalveandallowthegasolinetodrain intoagascanordrainpan.
Note:Nowisthebesttimetoinstallanewfuellter becausethefueltankisempty.RefertoReplacingthe FuelFilter.
5.Installthefuellineontothefuellter.Slidethehose clampclosetothevalvetosecurethefuelline.
1.Fuel-shutoffvalve2.Clamp
28
Figure34
Page 29
ReplacingtheFuelFilter
g014686
1 2
ServiceInterval:Every200hours/Yearly(whichevercomes
rst)
Neverinstalladirtylterifitisremovedfromthefuelline.
Note:Notehowthefuellterisinstalledinordertoinstall thenewltercorrectly.
Note:Wipeupanyspilledfuel.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Closethefuel-shutoffvalveatthefueltank(
4.Squeezetheendsofthehoseclampstogetherandslide themawayfromthelter(Figure35).
Figure35
1.Hoseclamp3.Filter
2.Fuelline
Figure34).
Figure36
1.Fuelventlter2.Rightsideofengine
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclampscloseto thelter.
7.Openthefuel-shutoffvalveatthefueltank(Figure34).
8.Checkforfuelleaks,andrepairifneeded.
9.Wipeupanyfuelthatspilled.
ServicingtheFuelVentSystem
ServiceInterval:Every200hours/Yearly(whichevercomes
rst)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Removetheexistingfuelventlter(
4.Installanewlter.
Figure36).
29
Page 30
DriveSystem
CoolingSystem
Maintenance

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat83to97kPa(12 to14psi).Uneventirepressurecancauseanunevencut.
Note:Thefronttiresaresemi-pneumatictiresanddonot requireairpressuremaintenance.
Maintenance

CleaningtheAir-intakeScreen

Beforeeachuse,removeanybuildupofgrass,dirt,or otherdebrisfromthecylinderandcylinder-headcooling ns,theair-intakescreenontheywheelend,andthe carburetor-governorleversandlinkage.Thiswillhelpensure adequatecoolingandcorrectenginespeedandwillreduce thepossibilityofoverheatingandmechanicaldamagetothe engine.

CleaningtheCoolingSystem

ServiceInterval:Every100hours/Yearly(whichevercomes
rst)
Cleantheairintakescreenfromgrassanddebrisbeforeeach use.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
Figure37
3.Removetheair-intakescreen,therecoilstarter,and thefanhousing(Figure38).
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installtheair-intakescreen,therecoilstarter,andthe fanhousing(Figure38).
1.Air-intakescreen4.Bolt
2.Fanhousing5.Nut
3.Recoilstarter
30
Figure38
Page 31
BrakeMaintenance

ServicingtheBrakes

3.Checkthebrakebeforeyouadjustit;refertoChecking theBrakes.
4.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
Beforeeachuse,checkbrakesonbothalevelsurfaceand slope.
Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnothold securely,anadjustmentisrequired.
CheckingtheBrakes
1.Parkthemachineonalevelsurface,disengagethe bladecontrol(PTO).
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Applytheparkingbrake.Thewheelsmustlockwhen youtrytopushthemachineforward.
4.Ifthewheelsdonotlock,adjustthebrakes.Referto AdjustingtheBrakes.
5.Releasethebrakeandpressuppercontrolbarvery lightly,approximately13mm(1/2inch).Thewheels shouldrotatefreely;ifnot,refertoAdjustingthe Brakes.
5.Toadjustthebrake,rotatethewingnutsonthebrake Figure39).Turnthewingnutsclockwiseto
rods( tightenthebrakeandcounterclockwisetoloosenthe brake.
Figure39
1.Brakerod2.Wingnut
Note:Controlbarshouldbeparallelwiththe referencebarwhenproperlyadjusted.
AdjustingtheBrakes
Thebrakeleverisontheuppercontrolbar.Iftheparking brakedoesnotholdsecurely,anadjustmentisrequired.
1.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
6.Checkthebrakeoperationagain;refertoChecking theBrakes.
Important:Withtheparkingbrakereleased,the rearwheelsmustrotatefreelywhenyoupushthe mower.Ifbrakeactionandfreewheelrotation cannotbeachievedcontactyourservicedealer immediately.
31
Page 32
BeltMaintenance

CheckingtheBelts

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

ReplacingtheTractionDrive Belt

1.Removethehairpincottersecuringthebrakerodto thebrakearmtorelaxthebeltidlertension(Figure40).
2.Removethebottomboltandloosenthetopboltofthe shieldtorotateitforbeltclearance(Figure40).
3.Liftthebeltpasttheidlerandoffthedrivepulley (Figure40).
4.Raisethewheeloffthegroundenoughtoallowfor beltremoval.
5.Replacethetractiondrivebelt.
6.Securetheshieldwiththepreviouslyremovedboltand tightenthebolts(Figure40).
7.Securethebrakerodtothebrakearmwiththehairpin cotter(Figure40).
4.Removethemowerbelt(Figure41).
Figure41
1.Idlerpulleyinslot4.Beltguide
2.Tractionbelt
3.Mowerbelt6.Mowerbelt
5.Loosenthepivotboltenoughtoslidetheidlerpulleyin theslotandremovethetractionbeltfromtheengine andthedrivepulleys(Figure41).
6.Installthenewdrivebeltaroundtheengineandthe drivepulleys(Figure41).
7.Slidetheidlerpulleyintheengineframetotensionthe tractionbelt(Figure41).
8.Installthemowerbelt(Figure41).
9.Checkthebeltguideundertheengineframeforthe properadjustment(Figure41).
5.19mm(3/4inch)
Figure40
1.Hairpincotter
2.Brakerod4.Drivebelt
3.Shield

ReplacingtheDriveBelt

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Raisetherearofthemachineandholditupwithjack stands.
Note:Thedistancebetweenthebeltguideandmower beltshouldbe19mm(3/4inch)whenthemower beltisengaged.Adjustthebeltifnecessary.The disengagedbeltshouldnotdragorfalloffthepulley whentheguidesareproperlyadjusted.

ReplacingtheMowerBelt

Important:Thebrakeneedstobeadjustedwhenthe
belttensionorthebrakelinkageisadjusted.
1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Removetheknobsandthebeltcoveronthemower.
4.Removetheidlerpulleyandthewornbelt.
5.Installthenewmowerbelt.
6.Installtheidlerpulley.
7.Engagetheblade-control(PTO)leverandcheck thebelttension.RefertoAdjustingtheMowerBelt Tension.
32
Page 33
Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(Figure45orFigure46).
8.Engagetheblade-control(PTO)lever.
9.Checktheclearancebetweenthebellcrankandthe transmissionoutputshaft(Figure42).
Figure42
1.2to3mm(1/16to1/8inch)
2.Bellcrank
3.Transmissionoutputshaft6.Clevis
4.Hairpincotter
5.Clevispin
Figure43
32-inchand36-inchmowerdeck
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
Note:Theclearanceshouldbe2to3mm(1/16to 1/8inch).
10.Removethehairpincotterpinandtheclevispinfrom thebellcrank.
11.Rotatetheclevisclockwiseontherodtoincreasethe clearance;rotateitcounterclockwisetodecreaseit
Figure42).
(
12.Disengagetheblade-control(PTO)lever.
Note:Iftheassistarmdoesnotcontactthefrontstop onthemowerdeck(Figure43orFigure44),adjustthe clevistobringthebellcrankclosertothetransmission outputshaft(Figure42).
Figure44
48-inchmowerdeck
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
13.Checkthebeltguideundertheengineframeforthe properadjustment(Figure41).
Note:Thedistancebetweenthebeltguideandthe mowerbeltshouldbe32mm(1-1/4inch)whenyou engagethemowerbelt.Adjustthemowerbeltas
33
Page 34
necessary.Thedisengagedbeltshouldnotdragorfall offthepulleywhentheguidesareproperlyadjusted.

AdjustingtheMowerBelt Tension

AdjustingtheTensionfor32-inchand 36-inchMowerDecks
ServiceInterval:Aftertherst8hours—Checkthemower
belttension.
Aftertherst25hours—Checkthemowerbelt tension.
Every50hours—Checkthemowerbelttension.
Important:Thebrakeneedstobeadjustedwhenthe belttensionorthebrakelinkageisadjusted.
Important:Thebeltmustbetightenoughtonotslip duringheavyloadswhilecuttinggrass.Over-tensioning thebeltwillreducethespindlebearinglife,thebeltlife, andtheidlerpulleylife.
Figure45
32-inchand36-inchmowerdeck
1.Mowerbeltwith13mm (1/2inch)deection
6.Tightenthelocknutontheturnbuckle.
2.Idlerpulley
Thebeltmustbetightenoughsothatitdoesnotslipduring heavyloadswhilecuttinggrass,andover-tensioningwill reducebeltandspindlebearinglife.
1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Loosenthelocknutontheturnbuckle(Figure45).
4.Rotatetheturnbuckletowardtherearofthemowerto increasethetensiononthebelt.Rotatetheturnbuckle towardthefrontofthemowertodecreasethetension onthebelt(Figure45).
Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof8mm (5/16inch).
5.Engagetheblade-controllever(PTO)andcheckthe belttension.Adjustthetensionuntilitiscorrect.
Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(Figure45).
7.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.
AdjustingtheTensionfor48-inch MowerDecks
Important:Thebeltmustbetightenoughtonotslip
duringheavyloadswhilecuttinggrass.Over-tensioning thebeltwillreducethespindlebearinglife,thebeltlife andtheidlerpulleylife.
Important:Thebrakeneedstobeadjustedwhenthe belttensionorthebrakelinkageisadjusted.
1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Loosenthelocknutontheturnbuckle(Figure47).
4.Rotatetheturnbuckletowardtherearofthemowerto increasethetensiononthebelt.Rotatetheturnbuckle towardthefrontofthemowertodecreasethetension onthebelt(Figure47).
Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(Figure46).
34
Page 35
positionedtothemiddleorfronthole(Figure48).Use
g017651
theholethatwillgivethecorrectadjustment.
7.Whentheidlerpulleyismovedthebeltguidemust bemoved.Movethebeltguidetothefrontposition (Figure48).
Figure46
48-inchmowerdeck
1.Idlerpulley2.Mowerbeltwith13mm (1/2inch)deection
Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof8mm (5/16inch).
Figure48
1.Rearidlerpulley4.Beltguideinbackposition
2.Middlehole5.Frontidlerpulley
3.Fronthole
8.Checkthebeltguideundertheengineframeforproper adjustment(Figure49).
Note:Thedistancebetweenthebeltguideandthe mowerbeltshouldbe19mm(3/4inch)whenyou engagethemowerbelt(Figure49).Adjustthemower beltasnecessary.Thedisengagedbeltshouldnotdrag orfalloffthepulleywhentheguidesandbelttension areproperlyadjusted.
9.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.
Figure47
1.13mm(1/2inch)deection here
2.Assistarm5.Turnbuckle
3.Frontstop
4.Locknut
5.Engagetheblade-controllever(PTO)andcheckthe belttension.
6.Ifthereisnoadjustmentleftintheturnbuckleand thebeltisstillloose,therearidlerpulleyneedstobe
Figure49
1.Idlerpulleyinslot4.Beltguide
2.Tractionbelt
3.Mowerbelt6.Mowerbelt
35
5.19mm(3/4inch)
Page 36
AdjustingthePTOEngagement
g017648
1
2
3
4
g017649
Linkage
ThePTOengagementlinkageadjustmentislocatedbeneath thefrontleft-handcorneroftheenginedeck.
1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Engagetheblade-controllever(PTO).
4.Adjustthelinkagelengthtowherethelowerendofthe bellcrankjustclearstheaxlesupportgusset(Figure50).
Figure51
1.Yoke5.Assistarmlink
2.Nut6.Assistarm
3.Rearassistarmstop7.Turnbuckle
4.Frontassistarmstop
8.Toadjusttheassistarmlink,removethehairpincotter pinfromtheassistarm(Figure51).
9.Loosenthenutagainsttheyoke(Figure50).
10.Removetheassistarmlinkfromtheassistarmand
Figure50
1.Bellcrank4.Yoke
2.Safetyswitchlocated underenginedeck
3.Bellcrankjustclearsthe gussetwiththePTO engaged
5.Nut
6.Assistarmlink
rotatethelinktoadjustthelength.
11.Installtheassistarmlinkintotheassistarmandsecure itwiththehairpincotterpin(Figure51).
12.Checkiftheassistarmhitsagainstthestopscorrectly.
AdjustingthePTOSafetySwitch
1.Disengagetheblade-control(PTO)leverandsetthe
5.Makesuretheassistarmisagainsttherearassistarm stoponthedeck(Figure51).
6.Pushtheblade-controllever(PTO)downtothe disengagedposition.
7.Theassistarmshouldcontactthefrontassistarmstop onthedeck.Ifitdoesnotcontact,adjustthebellcrank sothatitisclosertothegusset(
Figure51).
parkingbrakes.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Disengagetheblade-controllever(PTO).Makesure thattheassistarmisagainstthefrontassistarmstop.
4.Ifneeded,adjusttheblade-safetyswitchbyloosening theboltsholdingtheswitchbracket(Figure52).
5.Movethemountingbracketuntilthebellcrankpresses theplungerby6mm(1/4inch);referto(Figure52).
Note:Makesurethatthebellcrankdoesnottouch theswitchbody,ordamagetotheswitchcouldoccur.
6.Tightentheswitchmountingbracket.
36
Page 37
2
3
g017650
1
1.Bellcrank
2.Boltsandnuts
Figure52
3.Switchmountingbracket
4.Switchbody

MowerDeck Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keepthebladessharp. Forconvenientsharpeningandreplacement,youmaywant tokeepextrabladesonhand.
WARNING
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator's orbystander'sarea,resultinginseriouspersonal injuryordeath.
•Inspectthebladeperiodicallyforwearor damage.
•Replaceawornordamagedblade.
PreparingtoInspectorServicethe Blades
Parkthemachineonalevelsurface,disengagethe blade-controlbail,andsettheparkingbrake.Turntheignition keytotheoffposition.Removethekeyanddisconnectthe spark-plugwiresfromthesparkplugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure53).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
Figure53
1.CuttingEdge3.Wear/slotformingin
2.Sail4.Crackinthecurvedarea
curvedarea
2.Inspecttheblades,especiallythecurvedarea(Figure
53).Ifyounoticeanydamage,wear,oraslotforming inthisarea(item3.inFigure53),immediatelyinstall
37
anewblade.
Page 38
CheckingforBentBlades
1
G024247
1.Disengagetheblade-controlswitch(PTO)andsetthe parkingbrake.
inch).Ifthisdimensionexceeds3mm(1/8inch),the bladeisbentandmustbereplaced.RefertoRemoving theBladesandInstallingtheBlades.
2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.
3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure54).
Figure54
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedblade withanewblade.
•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
RemovingtheBlades
Replacethebladesifyouhitasolidobjectorifthebladesare outofbalanceorbent.T oensureoptimumperformanceand continuedsafetyconformanceofthemachine,usegenuine Tororeplacementblades.Replacementbladesmadebyother manufacturersmayresultinnon-conformancewithsafety standards.
1.Holdthebladeboltwithawrench.
2.Removethenut,bladebolt,curvedwasher,blade, spacers,andthinwasherfromthespindle(Figure57).
Figure55
4.Measurefromalevelsurfacetothecuttingedge, positionA,oftheblades(
Note:Notethisdimension.
Figure56
1.Measurefromthecuttingedgetoalevelsurface
5.Rotatetheoppositeendsofthebladesforward.
6.Measurefromalevelsurfacetothecuttingedgeofthe bladesatthesamepositionasinstep3.
Note:Thedifferencebetweenthedimensions obtainedinsteps3and4mustnotexceed3mm(1/8
Figure56).
38
Page 39
balanced,lesomemetalofftheendofthesailarea only(
Figure59).Repeatthisprocedureuntiltheblade
isbalanced.
Figure59
1.Blade2.Balancer
InstallingtheBlades
1.Installthecurvedwasherandthenthebladeontothe bolt.Selectthepropernumberofspacer(s)forthe heightofcut,andslidetheboltintothespindle(Figure
57).
Important:Thecurvedpartoftheblademust pointupwardtowardtheinsideofthemowerto ensurepropercutting.
2.Installtheremainingspacer(s)andsecurethemwitha thinwasherandanut(Fig.Figure57).
Figure57
1.Blade
2.Bladebolt5.Thinwasher
3.Curvedwasher
4.Spacer
6.Nut
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatbothendsof theblade(Figure58).
Note:Maintaintheoriginalangle.Thebladeremains balancedifthesameamountofmaterialisremoved frombothcuttingedges.
3.Torquethebladeboltto101to108N-m(75to 80ft-lb).
Figure58
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitonablade balancer(Figure59).
Note:Ifthebladestaysinahorizontalposition,the bladeisbalancedandcanbeused.Ifthebladeisnot
39
Page 40

AdjustingtheBladeBrake

1.DisengagethePTO,turntheignitionkeytotheoff position,andremovethekey .
2.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.
3.Ifnecessary,adjustthespringmountingboltssothat thebladebrakepadrubsagainstbothsidesofthe pulleygroove(Figure60).
4.Adjustthenutattheendofthebladebrakeroduntil thereis3mmto5mm(1/8to3/16inch)betweenthe nutandthespacer(Figure60).
5.Engagetheblades.Ensurethatthebladebrakepadno longercontactsthepulleygroove.
Figure60
1.Springmountingbolts3.3mmto5mm(1/8to
2.Bladebrakepad
3/16inch)
40
Page 41
ReplacingtheGrassDeector
g015594
1
6 2
4
7
3
5
Storage
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator'sor bystander'sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure61).Remove thedamagedorworngrassdeector.
Figure61
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring
2.Placethespacerandspringontothegrassdeector. PlaceoneJendofthespringbehindthedeckedge.
Note:MakesureoneJendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure61.
3.Installtheboltandnut.PlaceoneJhookendofthe springaroundthegrassdeector(Figure61).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.
5.Springinstalled
7.Jhookendofspring
1.Disengagethepowertake-off(PTO),settheparking brake,andturntheignitionkeytotheoffposition. Removethekey .
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideofthe enginecylinder-headnsandtheblowerhousing.
Important:Youcanwashthemachinewithmild detergentandwater.Donotpressurewashthe machine.Avoidexcessiveuseofwater,especially neartheshift-leverplateandtheengine.
3.Checkthebrakes;refertoCheckingtheBrakes(page
31).
4.Servicetheaircleaner;refertoServicingtheAir Cleaner(page25).
5.Greaseandlubricatethemachine;referto (page24).
6.Changethecrankcaseoil;refertoServicingtheEngine Oil(page25).
7.Checkthetirepressure;refertoCheckingtheTire Pressure(page30).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelinthe
tank.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
C.Stoptheengine,allowittocool,anddrainthe
fueltank;refertoServicingtheFuelTankin SystemMaintenance(page28),oroperateengine untilitstops.
D.Starttheengineandrunituntilitstops.Repeat
theprocess,withthechokeon,untiltheengine willnotstart.
E.Disposeoffuelproperly.Recycleitasperlocal
codes.
Note:Donotstorestabilizer/conditioned gasolineover90days.
9.Conditiontheengineforstorageasfollows:
A.Removethesparkplug(s)andcheckthecondition;
refertoServicingtheSparkPlugs(page27).
B.Pour2tablespoonsofengineoilintotheengine
througheachspark-plughole.
C.Rotatetheengineusingthestarterofthemachine.
Lubrication
Fuel
Note:Rotatingtheenginedistributestheoil insidethecylinder.
D.Installthesparkplug(s).
Note:Donotconnectthespark-plugwiresto thesparkplugs.
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10.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamagedorworn.
11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
12.Storethemachineinaclean,drygarageorstoragearea. Removethekeyfromtheignitionswitchandkeepit inamemorableplace.Coverthemachinetoprotect itandkeepitclean.
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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.
Themachineproducesanunevencutting height.
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.
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.
3.Removetheobstructionfromthe coolingnsandairpassages.
position.
2.Changethebelt.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer .
6.ContactanAuthorizedServiceDealer .
2.Installnewcuttingblade(s).
3.Levelthemowerfromside-to-sideand front-to-rear.
6.ContactanAuthorizedServiceDealer .
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Problem
PossibleCauseCorrectiveAction
Thebladesdonotrotate.
1.Themowerdeckbeltiswornorloose.
2.Themowerdeckbeltisbroken.2.Installanewdeckbelt.
3.Themowerdeckbeltisoffpulley.3.Inspectthebeltandreplaceitifitis
4.Theidlerspringisbrokenormissing.4.Replacethespring.
1.Checkthebelttension.
damaged.Checkthepulleysandidlers andadjustthebelttension.
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Page 45
Schematics
ElectricalSchematic(Rev.-A)
45
Page 46
Notes:
46
Page 47
Notes:
47
Page 48
TheToroTotalCoverageWarranty
ALimitedWarranty(seewarrantyperiodsbelow)Contractor
Landscape
Equipment(LCE)
ConditionsandProductsCovered
TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuanttoan agreementbetweenthem,jointlypromisetotheoriginalpurchasertorepairtheToro Productslistedbelowifdefectiveinmaterialsorworkmanship.
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
®
4
4
3000SeriesMowers
5000SeriesMowers
®
Mowers
Kawasaki–3years
2years
Kawasaki–3years
5yearsor1,200hours
3years
Lifetime(originalowneronly)
4yearsor500hours
3years
Lifetime(originalowneronly)
5yearsor1,200hours 3years Lifetime(originalowneronly) 5yearsor1,200hours
KohlerCommand–2years
KohlerEFI–3years
•Frame
®
ZMaster
•Engines
6000SeriesMowers
4
•Frame
®
ZMaster
•Engines
7000SeriesMowers
4
•Frame
Lifetime(originalowneronly)
5yearsor1,200hours
Kawasaki–3years
Lifetime(originalowneronly)
5yearsor1,200hours
2years
Lifetime(originalowneronly)
AllMowers
•Battery90daysPartsandLabor
1yearPartsonly
•BeltsandTires90days
•Attachments1year
1
Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone
locationisconsideredcommercialuseandthecommercialwarrantywouldapply.
2
Whicheveroccursrst.
3
LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforparts andlabor .Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor corrosionarenotcovered.
4
SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer .
1
1
2
3
2
3
2
3
2
3
2
3
2
3
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,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,MN55420-1196
888-865-5676(U.S.Customers)
888-865-5691(Canadacustomers)
OwnerResponsibilities
YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures describedintheOperator'sManual.Suchroutinemaintenance,whetherperformed byadealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot coverthefollowing:
•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil
changes,sparkplugs,airltersbladesharpeningorwornblades,cable/linkage adjustments,orbrakeandclutchadjustments
•Componentsfailingduetonormalwear
•Anyproductorpartwhichhasbeenalteredormisusedorneglectedand
requiresreplacementorrepairduetoaccidentsorlackofpropermaintenance
•Pickupanddeliverycharges
•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService
Dealer
•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure
(consultOperator'sManualformoredetails)
–Removingcontaminantsfromthefuelsystemisnotcovered
–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmore
than10%ethanolormorethat15%MTBE
–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone
month
GeneralConditions
AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro ServiceDealerusingT oroapprovedreplacementparts.
NeitherTheToroCompanynorT oroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro Productscoveredbythiswarranty ,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty.
Allimpliedwarrantiesofmerchantability(thattheproductistforordinary use)andtnessforuse(thattheproductistforaparticularpurpose)are limitedtothedurationoftheexpresswarranty.
Somestatesdonotallowexclusionsofincidentalorconsequentialdamages, orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions andlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry, province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheToroimporter.Ifallother remediesfail,youmaycontactusatT oroWarrantyCompany.
AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer .
374-0252RevF
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