Toro 30686 Operator's Manual

FormNo.3353-992RevC

CommercialWalk-BehindMower

FixedDeck,PistolGrip,Gear-Drive,witha
40inor48inTURBOFORCE®CuttingUnit

ModelNo.30686—SerialNo.260000001andUp

ModelNo.30688—SerialNo.260000001andUp

Registeratwww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

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

Theenclosed

Engine Owner’ s Man ual

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

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

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

Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready .
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

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

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

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

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

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

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

Setup..........................................................................11

1CheckingtheFluidsandTirePressure..............11

2ReadingtheManualandViewingtheSafety

Video.............................................................11

ProductOverview......................................................12

Controls.............................................................12

Specications.....................................................13

Attachments/Accessories...................................13

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

©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

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

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

OperatingtheParkingBrakeandNeutral

Locks.............................................................14

StartingandStoppingtheEngine........................15

OperatingtheBladeControl(PTO)

Lever..............................................................16

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

DrivingForwardorBackward.............................17

StoppingtheMower...........................................17

TransportingMachines.......................................17

SideDischargingorMulchingtheGrass..............17

AdjustingtheWheelDriveTension.....................18

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

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

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

AdjustingtheHandleHeight..............................22

HeightofCutChart............................................24

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

RecommendedMaintenanceSchedule(s)................25

Lubrication.............................................................25

HowtoGrease...................................................25

LubricatingtheCasterandWheel

Bearings.........................................................26

GreasingtheTransmissionCouplers...................26

GreasingtheMowerBeltIdler............................26

EngineMaintenance...............................................27

ServicingtheAirCleaner....................................27

ServicingtheEngineOil.....................................28

ServicingtheSparkPlugs....................................29

FuelSystemMaintenance.......................................31

ServicingtheFuelTank......................................31

ServicingtheFuelFilter......................................31

DriveSystemMaintenance.....................................32

CheckingtheTirePressure.................................32

AdjustingtheControlRods................................32

CoolingSystemMaintenance..................................34

CleaningtheAirIntakeScreen............................34

CleaningtheCoolingSystem...............................34

BrakeMaintenance.................................................35

ServicingtheBrakes...........................................35

BeltMaintenance....................................................36

CheckingtheBelts..............................................36

ReplacingtheTractionDriveBelt........................36

ReplacingtheDriveBelt.....................................36

ReplacingtheMowerBelt...................................36

AdjustingtheMowerBeltTension......................37

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

AdjustingtheControlRods................................40

MowerDeckMaintenance......................................41

ServicingtheCuttingBlades...............................41

AdjustingtheBladeBrake...................................43

ReplacingtheGrassDeector.............................43

Storage.......................................................................44

Troubleshooting.........................................................46

Schematics.................................................................48

3

Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

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

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

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

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

–Useonlyanapprovedcontainer

,whichmeans

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

–Neverrefuelordrainthemachineindoors.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator’sposition.

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

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

•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

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

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

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

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopbladesifnot
mowing.

4

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

•Usecarewhenloadingorunloadingthemachine
intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

Maintenanceandstorage

•Disengagedrives,setparkingbrake,stopengineand
removekeyanddisconnectsparkplugwire.Wait
forallmovementtostopbeforeadjusting,cleaning
orrepairing.

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

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.
Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore
mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowtocoolbefore
attemptingtomaintain,adjustorservice.

•UseonlyToro-approvedattachments.Warrantymay
bevoidedifusedwithunapprovedattachments.

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

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeel
uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from
themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide
obstacles.

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

•Useextracarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machine.

•Keepallmovementonslopesslowandgradual.Do
notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan15degrees.

Service

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyoumust
know .

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade
attachmentboltsandnuts.Keepequipmentingood
condition.

•Nevertamperwithsafetydevices.Checksafety
systemsforproperoperationbeforeeachuse.

5

•Useonlygenuinereplacementpartstoensurethat
originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice
asrequired.

6

SlopeChart7SafetyandInstructional
Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

43-8480

95-5537

1.ReadtheOperator’s
Manualforinstructionson

operatingthecuttingblade

2.Pushforwardtoengage

3.Pullbacktodisengage

66-1340

98-0776

95-2814

99-3943

1.Engine

8

98-5130

1.Warning—readtheOperator’sManualforinstructionson
torquingthebladebolt/nutto75-80ft-lb(102-106N⋅m).

98-5954

104-8569

105-4104

1.Reverse3.Transmissionspeeds

2.Neutral

1.Fast

2.Continuousvariable
setting

106-2733

3.Slow

105-4111

106-0699

9

106-2737

1.Park3.Neutral5.Engine—run

2.Drive4.Engine—stop6.Warning—wearearprotection.

110-2067

110-2068

1.ReadtheOperator’sManual.

10

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Nopartsrequired

Operator’sManual
EngineOperator’sManual
PartsCatalog
SafetyVideo
RegistrationCard
Oildrainhose

1

CheckingtheFluidsandTire
Pressure

NoPartsRequired

ReadingtheManualand
ViewingtheSafetyVideo

Partsneededforthisprocedure:

Qty.

–

1
1
1
1
1
1

2

Use

Checktheuidsandtirepressure.

ReadtheOperator’sManualandwatch
thevideobeforeoperatingthemachine.

Procedure

•Beforeyoustarttheengineandusethemachine,
checktheoillevelintheenginecrankcase;referto
CheckingtheEngineOilLevel.

•Checkthegreaseforthemowerandmowerdeck.
RefertotheLubricationSection.

•Checkthetirepressure;refertoCheckingtheTire
Pressure.

1

Operator’sManual

1

EngineOperator’sManual

1

PartsCatalog

1

SafetyVideo

1

RegistrationCard

1

Oildrainhose

Procedure

•ReadtheOperator’sManual.

•Viewthesafetyvideo.

•Fillouttheregistrationcardandmailitinorregister
onlineatwww .Toro.com.

•Usetheoildrainhosewhenchangingtheengineoil.

Note:Thecuttingbladesaresettoa3inch(76mm)
height-of-cutatinitialpurchase.TheaxlepositionisD,
with4spacersbelowboththespindleandthecaster.

11

ProductOverview

1.Sidedischarge5.Controls

2.Mowerdeck6.Handle

3.Recoilstarter

4.Gastank

Figure3

ThrottleControl

Thethrottlecontrolhastwopositions:FastandSlow.

OperatorPresenceControl(OPC)
Levers

WhenyousqueezetheOPCleversagainstthehandles,
theOPCsystemsensesthattheoperatorisinthenormal
operatingposition.WhenyoureleasetheOPClevers,
theOPCsystemsensesthattheoperatorhasleftthe
normaloperatingposition,andthesystemwillstopthe
engineifeitherthegearshiftleverisnotintheneutral
positionorthebladecontrol(PTO)leverisengaged.

DriveLevers

Releasedriveleverstoengageforwardtraction
operation.Squeezerightsideofdrivelevertoturnright
andleftsidetoturnleft.

GearShiftLever

7.Casterwheel

Thetransmissionhasveforwardspeeds,neutraland
reverse,andhasanin-lineshiftpattern.

Controls

Becomefamiliarwithallthecontrols(Figure4)before
youstarttheengineandoperatethemachine.

Figure4

1.Throttlecontrol6.Drivelever

2.Ignitionswitch

3.Neutral/parkingbrakelock8.Choke

4.OperatorPresence
Control(OPC)lever

5.Handle

7.Gearshiftlever

9.Powertakeofflever(PTO)

Important:Donotshiftwhileunitismoving,as
transmissiondamagemayoccur.

Neutral/ParkingBrakeLock

Squeezedriveleversandmovethelocksrearwardfor
neutrallock.Squeezedriveleversandmovethelocks
forwardtosettheparkingbrake.

BladeControlLever(PTO)

ThisleverisusedinconjunctionwiththeOPClevers
toengageordisengagethemowerdeckbeltanddrive
themowerblades.

RecoilStarter

Pulltherecoilstarterhandletostartengine(notshown
in).

FuelShut-offValve

Closethefuelshut-offvalvewhentransportingor
storingmower.

IgnitionSwitch

Thisswitchisusedinconjunctionwithrecoilstarterand
hastwopositions:RunandOff.

Choke

Usethechoketostartacoldengine.

12

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Operation

AddingFuel

40inchmowers:

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

Length

Height

Weight

75–3/8inches(191.3cm)

41inches(104.1cm)

477lb(216kg)

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.

UseUnleadedRegularGasolinesuitablefor
automotiveuse(85pumpoctaneminimum).Leaded
regulargasolinemaybeusedifunleadedregularisnot
available.

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

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

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

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

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Never
buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

13

Important:Donotusefueladditives
containingmethanolorethanol.

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

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

Addthecorrectamountofgas
stabilizer/conditionertothegas.

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.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin
thesafetysection.Knowingthisinformationcould
helpyouoranybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feet
andheadisrecommended.

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditionerbottleopening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

Figure5

1.Warning—wearhearingprotection.

OperatingtheParkingBrake
andNeutralLocks

Alwayssettheparkingbrakeswhenyoustopthe
machineorleaveitunattended.

14

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwayssettheparkingbrakewhenleaving
themachineunattended,evenifjustforafew
minutes.

ReleasingtheNeutralLocks

1.Squeezethedriveleversback.

2.Placeyourthumbsontheupperpartofthelocks
andmovethemforwarduntiltheyareinthedrive
position(Figure6).

StartingandStoppingthe
Engine

SettingtheParkingBrakes

1.Squeezethedrivelevers(Figure6).

Figure6

1.Handle

2.Neutral/parkingbrakelock

3.Parkposition6.Neutralposition

2.Placeyourthumbsontheupperpartofthelocks
andmovethemforwardinintotheparkposition
(Figure6).

3.Releasethedrivelevers.

4.Fullspeedforward

5.Drivelever

ReleasingtheParkingBrakes

1.Squeezethedrivelevers(Figure6).

2.Placeyourthumbsontheupperpartofthelocks
andmovethemrearwarduntiltheyareinthedrive
position(Figure6).

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Disengagethebladecontrol(PTO)leverandmove
theshiftlevertotheneutralposition.

4.Settheparkingbrakes.

5.Turntheignitionkeytotherunposition(Figure7).

6.Tostartacoldengine,movethethrottlecontrol
midwaybetweenthefastandslowpositions.

7.Tostartawarmengine,movethethrottlecontrol
tothefastposition.

8.Pullthechokeknobiftheengineiscold(Figure7).

Note:Awarmorhotengineusuallydoesnot
requireanychoking.

9.Grasptherecoilstarterhandlermlyandpullit
outuntilpositiveengagementresults;thenpullthe
handlevigorouslytostarttheengine.Allowthe
ropetorecoilslowly .

Important:Donotpulltherecoilropetoits
limitorreleasethestarterhandlewhenyoupull
outtheropebecausetheropemaybreakorthe
recoilassemblymaybedamaged.

10.Pushthechoketooffastheenginewarmsup.

11.Iftheengineiscold,allowittowarmupandthen
movethethrottlecontroltothefastposition.

StoppingtheEngine

SettingtheNeutralLocks

1.Squeezethedrivelevers(Figure6).

2.Placeyourthumbsontheupperpartofthelocks
andmovethemrearwardintotheneutrallock
position(Figure6).

Important:Inanemergency ,youcanstopthe
engineimmediatelybyturningtheignitionkeyto
the

of f

position.

1.Movethethrottlelevertotheslowposition.

2.Letengineidlefor30to60secondsbeforeturning
theignitionkeytooff.

3.Turntheignitionkeytotheoffposition.

4.Settheparkingbrakesandremovethekey .

15

5.Disconnectthewirefromthesparkplugtoprevent
someonefromaccidentallystartingthemachine
whiletransportingorperformingmaintenanceonit.

6.Closethefuelshut-offvalvebeforetransporting
orstoringthemachine.

Important:Closethefuelshut-offvalvebefore
transportingorthestoringthemachineto
preventfuelleakage.

1.OperatorPresence
Control(OPC)lever

TheSafetyInterlockSystem

Figure8

2.Bladecontrollever(PTO)

Figure7

1.Throttlecontrol

2.Ignitionswitch

3.Choke

OperatingtheBladeControl
(PTO)Lever

Thebladecontrol(PTO)leverengagesanddisengages
thepowertothemowerblades.

EngagingtheMowerBlades(PTO)

1.Squeezetheoperatorpresencecontrol(OPC)levers
againstthehandles(Figure8).

2.Pushthebladecontrol(PTO)leverrmlyforward
untilitlatchesoverthecenter(Figure8).

3.Restarttheengineandrepeattheprocedureto
engagethemowerbladesiftheoperatorpresence
control(OPC)leversarereleased.

DisengagingtheMowerBlades(PTO)

Todisengagetheblades,pullthebladecontrollever
rearwardalltheway(Figure8).Theenginewillkill
whentheOPCleversarereleasedwiththebladecontrol
leverengaged.

Ifsafetyinterlockswitchesaredisconnected
ordamagedthemachinecouldoperate
unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventthe
enginefromstartingunless:

•Thebladecontrol(PTO)leverisdisengaged.

•ThemachineisshiftedintotheNeutralposition.

•TheignitionkeyisintheRunposition.

Thesafetyinterlocksystemisalsodesignedtostopthe
enginewhen:

•TheignitionkeyisturnedtotheOffposition.

•Themachineisshiftedintogearwithoutholding
theOPClevers.

Note:Itisnecessarytofullyandmanuallydisengage
thebladecontrollever.

•Thebladecontrol(PTO)leverisengagedwithout
holdingtheOPClevers.

16

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe
machineeachtime.Ifthesafetysystemdoesnot
operateasdescribed,haveanAuthorizedService
Dealerrepairthesafetysystemimmediately .

1.Settheparkingbrakes,movetheshiftleverintothe
Neutralposition,disengagethebladecontrol(PTO)
leverandplacethethrottleforward.

2.Starttheengine;refertoStartingtheEngine.

3.WithoutholdingtheOperatorPresenceControl
(OPC)levers,engagethebladecontrol(PTO)lever.
Theengineshouldstop.

4.Disengagethebladecontrol(PTO)lever.

5.Withtheenginerunning,holddowntheOPC
leversandengagethebladecontrol(PTO)lever.
Thedrivebeltshouldengageandthemowerblades
beginrotating.

6.ReleasetheOPClevers.Theengineshouldstop.

7.Withtheenginerunning,movetheshiftleverinto
gearandreleasetheOPClevers.Theengineshould
stop.

8.Withtheenginerunning,turntheignitionkeyto
theoffposition.Theengineshouldstop.

9.Ifalltheaboveconditionsarenotmet,havean
AuthorizedServiceDealerrepairthesafetysystem
immediately.

2.SqueezetheOPCleversagainstthehandles.

3.Movetheshiftleverintothereversegear.

4.Releasetheparkingbrakes;refertoReleasingthe
ParkingBrakesandNeutralLocks.

5.Slowlyreleasethedrivelevers.

Note:Youmustpullthemowerbackwardtoassist
itsrearwardmovement.

StoppingtheMower

1.Squeezethedriveleversallthewaybacktoengage
thebrakes.

2.Settheparkingbrakes.RefertoSettingtheParking
Brakes.

3.ShifttransmissionintotheNeutralposition.

4.MovethethrottletotheStopposition,andwaitfor
allmovingpartstostopbeforeleavingtheoperating
position.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas
measuredinRPM(revolutionsperminute).Placethe
throttlecontrolinthefastpositionforbestmowing
performance.

DrivingForward

1.Ensurethattheparkingbrakesareengaged.

2.Movetheshiftleverintoaforwardgear.

3.SqueezetheOPCleversagainstthehandles.

4.Releasetheparkingbrakes;refertoReleasingthe
ParkingBrakesandNeutralLocks.

5.Slowlyreleasethedrivelevers.

Note:Togostraight,releasethedrivelevers
equally.Toturn,squeezethedriveleveronthesame
sideasthedirectionyouwanttoturn.

DrivingBackward

1.Ensurethattheparkingbrakesareengaged.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
necessarylightingandmarkingasrequiredbylaw .
Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily ,
petsorbystandersavoidinjury.

Totransportthemachine:

•Stoptheengine,removethekey ,setthebrake,and
closethefuelvalve.

•Securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes.

•Secureatrailertothetowingvehiclewithsafety
chains.

SideDischargingorMulching
theGrass

Thismowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

17

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

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

•Neverputyourhandsorfeetunderthe
mower.

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

Figure9

1.PositionA4.Drivespring

2.PositionB

3.PositionC

5.Adjustmentbolt(In
positionA)

6.Drivepulleyshield

5.Removethelocknutthatsecurestheadjustment
bolttothedrivepulleyshield(Figure9).

6.Locateboltassemblyinthedesiredtensionposition
asfollows:

AdjustingtheWheelDrive
Tension

Youmayneedtoincreasethewheeldrivebelttension
undercertainoperatingconditions,suchasmowerover
hillyterrainorwhilepullingasulky.

1.Stoptheengine,removethekey ,andwaitforall
movingpartstostop.

2.Disconnectthewiresfromthesparkplugs.

3.Disengagetheneutral/parkingbrakelocks,and
releasethedriveleverstoreducethespringforce.

4.Removethedrivespringfromtheadjustmentbolt
(Figure9).

•PositionAfornormalconditions

•PositionBformoresevereconditions

•PositionCforthemostsevereconditions

Note:Thewheeldrivetensionislowestwhen
theboltassemblyisinPositionA.Thetension
increasesinPositionsBandC(Figure9).

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.

18

2.Stoptheengineandwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Holdthebladeboltandremovethenut(Figure10).

Figure11

1.Axlepivotbolt2.Axleadjustmentbolt

4.Placeajackundertherearcenteroftheengine
frame.Raisethebackendoftheengineframeup
enoughtoremovethefront2axleadjustmentbolts
(Figure11).

Note:Usejackstandstosupportthemachine.

5.Raiseorlowertheengineframewiththejackso
thatyoucaninstallthefront2axleadjustmentbolts
inthedesiredholelocation(Figure11).

Figure10

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

4.Slidetheboltdownthroughthespindle,andchange
thespacersasneeded(Figure10).

5.Installtheboltandcurvedwasher,addextra
spacer(s),andsecurethemwithathinwasheranda
nut(Figure10).

6.Torquethebladeboltto75-80ft-lb(101-108N•m).

AdjustingtheAxleHeight

Adjusttheaxlepositiontotheselectedheight-of-cut
setting.RefertotheHeight-of-CutChart.

Note:Useataperedpunchtohelpaligntheholes.

6.Tightenall4boltsandlowerthemower.

7.Adjustthecontrolrodsandthebrakelinkages
asrequired.RefertoServicingtheBrakesand
AdjustingtheControlRods.

Important:Youmustadjustthecontrolrods
andthebrakelinkagewhenyouchangethe
axlepositionsforpropertractionandbrake
function.

AdjustingtheCasterPosition

1.UsingtheHeight-of-CutChart,adjustthecaster
spacerstomatchwiththeaxleholeselected
(Figure12).

1.Disengagethebladecontrol(PTO)leverandset
theparkingbrakes.

2.Stoptheengineandwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Loosen,butdonotremove,the2axlepivotbolts
andthe2axleadjustmentbolts(Figure11).

19

Figure12

1.Latchpin

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

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

2.Removethelatchpin,slidethecasterfromthe
support,andchangethespacers(Figure12).

1.Camlock

2.Lever

Figure13

3.Rotatecamtoincreaseor
decreaselockingpressure

4.Slot

3.Installthecasterinthesupportandinsertthelatch
pin(Figure12).

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent
typesofmowingconditions.Positionthecamlockand
bafetogivethebestqualityofcut.

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Toadjustthecamlock,swingtheleveruptoloosen
thecamlock(Figure13).

4.Adjustthebafeandcamlockintheslottothe
desireddischargeow .

5.Swingtheleverbackovertotightenthebafeand
camlock(Figure13).

PositioningtheFlowBafe

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

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

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

20

PositionA

Thisisthefullrearposition.Thesuggesteduseforthis
positionisafollows(Figure14).

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe
mower.

Figure14

PositionB

Usethispositionwhenbagging(Figure15).

Figure15

PositionC

Thisisthefullopenposition.Thesuggestedusefor
thispositionisasfollows(Figure16).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheToro
SFSmower.

21

Figure16

AdjustingtheHandleHeight

Thehandlepositioncanbeadjustedtomatchthe
operator’sheightpreference.

1.Removethehairpincotterpinsandclevispinsfrom
thedriveleversandneutrallocks(Figure17).

Figure17

1.Controlrod

2.Clevispin

3.OperatorPresence
Controllever(OPC)

4.Handle8.Drivelever

5.Neutrallock

6.Hairpincotterpin

7.Lefthandleshown

2.Loosentheupperbolts(3/8x1-1/4inch)and
angenutsecuringhandletorearframe(Figure18).

3.Removethelowerbolts(3/8x1inch)andange
nutssecuringhandletorearframe(Figure18).

4.Pivothandletodesiredoperatingpositionand
installlowerangebolts(3/8x1inch)andange
nutsintomountingholes.Tightenallangebolts.

Figure18

1.Upperhandle6.Lowermountingholes

2.Rearframe

3.Flangebolt(3/8x1inch)

4.Locknut(3/8inch)

5.Uppermountinghole

22

7.Lowposition

8.Middleposition

9.Highposition

5.Adjustthecontrolrodlengthbyrotatingthecontrol
rodintherodtting(Fig.8).

6.Installhairpincotterbetweendriveleversand
neutrallocksandintoclevispins(Fig.25).

Note:Makesuretheclevispinsareinsertedinto
theneutrallocks.

7.Checktheparkingbrakeadjustment.Referto
CheckingtheBrakesinBrakeMaintenance,
page35.

23

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)

24

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst25hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

Every200hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthemowerbelttension.

•Checkthemowerbelttension.

•Checkthesafetysystem.

•Greasethecasterwheelsandcasterpivot.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrakes.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.

•Greasethemowerbeltidler .

•Checkthepaperaircleanerelement.

•Checkthetirepressure.

•Checkthebelts.

•Checkthemowerbelttension.

•Changetheengineoil.

•Checkthesparkplugs.

•Checkandcleanenginecoolingnsandshrouds.

•Replacethepaperaircleanerelement.

•Replacetheoillter.

•Replacethefuellter.

Every250hours

Every400hours

Beforestorage

•Greasethetransmissioncouplers(moreoftenindirtyordustyconditions).

•Greasethewheelbearings(moreoftenindirtyordustyconditions).

•LubricatecamlockwithNever-Seez®.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator’smanualforadditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously
injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwirefromthesparkplug(s)beforeyou
doanymaintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

Lubrication

GreasewithNo.2generalpurposelithiumbaseor

HowtoGrease

1.DisengagethePTOandsettheparkingbrake.

molybdenumbasegrease.

25

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

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

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

5.Wipeupanyexcessgrease.

LubricatingtheCasterand
WheelBearings

ServiceInterval:Beforeeachuseordaily

Every400hours

Figure20

GreasingtheMowerBeltIdler

ServiceInterval:Every50hours

Every400hours

1.Lubricatethefrontwheelbearingsandfrontspindles

Figure19).

(

2.Lubricatethedrivewheelbearings.

Figure19

GreasingtheTransmission

Greasethettingonthemowerbeltidlerarmpivot
(Figure21).

Note:Removethemowerdeckcovertoaccessthe
greasettingforthemowerbeltidlerarm.

Figure21

Couplers

ServiceInterval:Every250hours

Lubricatethetransmissioncouplerslocatedintheback
ofthemachine(Figure20).

26

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval/Specication

Foamelement:Cleanitafterevery25operatinghours.

Paperelement:Checkitafterevery50operatinghours.
Replaceitafterevery200operatinghoursoryearly,
whichevercomesrst.

Inspectthefoamandpaperelementsandreplacethem
iftheyaredamagedorexcessivelydirty.

Note:Servicetheaircleanermorefrequently(every
fewoperatinghours)iftheoperatingconditionsare
extremelydustyorsandy .

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanaroundtheaircleanertopreventdirt
fromgettingintotheengineandcausingdamage
(Figure22).

4.Unscrewthecoverknobandremovetheaircleaner
cover(Figure22).

5.Removethe2wingnutsandremovetheaircleaner
assembly(Figure22).

6.Carefullypullthefoamelementoffthepaper
element(Figure22).

Figure22

1.Engine4.Foamelement

2.Cover

3.Wingnut

5.Paperelement

6.Coverknob

CleaningtheFoamAirCleanerElement

ServiceInterval:Every25hours

1.Washthefoamelementinliquidsoapandwarm
water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis
tornorworn.

ServicingthePaperAirCleaner
Element

ServiceInterval:Every50hours

Every200hours

1.Donotcleanthepaperlter.Replaceitafter200
operatinghours(Figure22).

2.Inspecttheelementfortears,anoilylm,ordamage
totherubberseal.

3.Replacethepaperelementifitisdamaged.

27

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand
paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair
cleanerelement(Figure22).

2.Placetheaircleanerassemblyontotheaircleaner
baseandsecureitwiththe2wingnuts(Figure22).

3.Placetheaircleanercoverintopositionandtighten
thecoverknob(Figure22).

4.Cleanaroundtheoildipstick(Figure24)sothatdirt
cannotfallintothellerholeanddamagetheengine.

ServicingtheEngineOil

ServiceInterval/Specication

Changetheengineoilasfollows:

•Aftertherst8operatinghours

•Afterevery100operatinghours

Note:Changetheoilmorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.

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

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

Viscosity:Refertothefollowingtable(Figure23).

Figure24

1.Oildipstick

5.Unscrewtheoildipstickandwipetheendclean
(Figure24).

6.Slidetheoildipstickfullyintothellertube,butdo
notthreadontotube(Figure24).

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

Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagecan
result.

2.Fillertube

ChangingtheOil

ServiceInterval:Aftertherst8hours

Every100hours

1.Starttheengineandletitrunveminutes.This
warmstheoilsoitdrainsbetter.

Figure23

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface.

2.DisengagethePTO,turntheignitionkeytooff,and
removethekey.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthensettheparkingbrake.

2.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoildrains
completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain
valvetoallowoiltodrain(Figure25).

7.Whenoilhasdrainedcompletely,closethedrain
valve.

8.Removethedrainhose(Figure25).

Note:Disposeoftheusedoilatarecyclingcenter.

28

Figure25

1.Oildrainvalve2.Oildrainhose

Figure26

1.Oillter

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure26).

4.Installthereplacementoilltertothelteradapter,
turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure26).

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure24).

10.Checktheoillevel;refertoCheckingtheEngineOil
Level.

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

ServiceInterval:Every200hours

Replacetheoillterevery200operatinghoursorevery
otheroilchange.

Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy .

1.Draintheoilfromtheengine;refertoChangingthe
EngineOil.

2.Removetheoldlter(Figure26).

5.Fillthecrankcasewiththepropertypeofnewoil;
refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillteranddrain
valve.

7.Checktheengineoillevelandaddoilifneeded.

ServicingtheSparkPlugs

ServiceInterval/Specication

Checkthesparkplugsafterevery100operatinghours.

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
(Figure27).

29

Figure27

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausing
damage.

Important:Alwaysreplacethesparkplugs
whenithasablackcoating,wornelectrodes,
anoilylm,orcracks.

3.Checkthegapbetweenthecenterandsideelectrodes
(Figure28).Bendthesideelectrode(Figure28)if
thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

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

3.Connectthewirestothesparkplugs(Figure28).

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

ServiceInterval:Every100hours

1.Lookatthecenterofthesparkplugs(Figure28).
Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly .Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Figure28

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

30

FuelSystem
Maintenance

ServicingtheFuelTank

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

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopen
area.Wipeupanygasolinethatspills.

Figure29

1.Fuelshut-offvalve2.Clamp

•Neversmokewhendraininggasoline,and
stayawayfromanopenameorwherea
sparkmayignitethegasolinefumes.

DrainingtheFuelTank

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

2.Closethefuelshut-offvalveatthefueltank
(Figure29).

3.Squeezetheendsofthehoseclamptogether
andslideitupthefuellineawayfromfuellter
(Figure29).

4.Pullthefuellineoffthefuellter(Figure29).Open
thefuelshut-offvalveandallowthegasolinetodrain
intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter
becausethefueltankisempty.RefertoReplacing
theFuelFilter.

5.Installthefuellineontothefuellter.Slidethehose
clampclosetothevalvetosecurethefuelline.

ServicingtheFuelFilter

Replacethefuellterafterevery200operatinghoursor
yearly,whicheveroccursrst.

ReplacingtheFuelFilter

ServiceInterval:Every200hours

Neverinstalladirtylterifitisremovedfromthefuel
line.

Note:Notehowthefuellterisinstalledinorderto
installthenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Closefuelshut-offvalveatthefueltank(Figure29).

4.Squeezetheendsofthehoseclampstogetherand
slidethemawayfromthelter(Figure30).

31

DriveSystem
Maintenance

CheckingtheTirePressure

ServiceInterval:Every50hours

Maintaintheairpressureinthefrontandreartiresas
specied.Checkthepressureatthevalvestemafter
every50operatinghoursormonthly,whicheveroccurs
rst(Figure31).

RearTirePressure:15psi(103kPa)

Figure30

1.Hoseclamp3.Filter

2.Fuelline

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose
tothelter.

7.Openfuelshut-offvalveatfueltank(Figure29).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

CasterTirePressure:25-30psi(172-207kPa)

Figure31

1.RearTire

2.Castertire

AdjustingtheControlRods

1.Removethehairpincotterpinsandclevispinsfrom
thedriveleversandneutrallocks(Fig.25).

32

Figure32

1.Controlrod

2.Clevispin

3.OperatorPresence
Controllever(OPC)

4.Handle8.Drivelever

5.Neutrallock

6.Hairpincotterpin

7.Lefthandleshown

4.Checktheoperationofthecontrolrod.Ifyouneed
toadjustit,removethehairpincotterandtheclevis
pinthatsecurethecontrolrodtothedrivelevers.

5.Adjustthecontrolrodlengthbyrepeatingthe
previoussteps.

2.Adjustthecontrolrodlengthbythreadingtherodin
oroutoftherodttinguntilthereisa3/16to1/4
inches(5to6mm)clearancebetweenthecontrol
rodandthebottomoftheneutral/parkingbrake
lock(Figure33).

Figure33

1.Handle4.Drivelever

2.Neutral/parkingbrakelock

3.3/16to1/4inch(5to6
mm)clearance

5.Forwardspeed

6.Controlrod

3.Installthecontrolrodtothedriveleverandthe
neutral/parkingbrakelock.Securethecontrolrod
withaclevispinandahairpincotter(Figure33).

33

CoolingSystem
Maintenance

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

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

CleaningtheCoolingSystem

ServiceInterval:Every100hours

Cleantheairintakescreenfromgrassanddebrisbefore
eachuse.

Checkandcleancoolingnsandengineshroudsevery
100hoursoryearly,whichevercomesrst.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removetheairintakescreen,recoilstarterandfan
housing(Figure34).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing
(Figure34).

Figure34

1.Airintakescreen4.Bolt

2.Fanhousing5.Nut

3.Recoilstarter

34

BrakeMaintenance

ServicingtheBrakes

Beforeeachuse,checkbrakesonbothalevelsurface
andslope.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnot
holdsecurely,anadjustmentisrequired.

CheckingtheBrakes

ServiceInterval:Beforeeachuseordaily

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.

Figure35

1.Brakerod2.Wingnut

4.Positionthewingnutssothatthebrakesengage
whenyousqueezethedriveleversenoughtoplace
theneutral/parkingbrakelocksforward,andthen
setthebrakes.

5.Checktheoperationofthebrakesagain;referto
CheckingtheBrakes.

Important:Whenyoureleasetheparking
brakes,therearwheelsshouldrotatefreelywhen
youpushthemower.Iftheydonot,contactan
AuthorizedServiceDealerimmediately.

6.Checkthecontrolrodlength,refertoAdjustingthe
ControlRods.

2.Releasetheparkingbrakes;refertoReleasingthe
ParkingBrakes.

3.Toadjustthebrakes,rotatethewingnutson
thebrakerods(Figure35).Rotatethewing
nutsclockwisetotightenthebrakes;rotatethem
counterclockwisetoloosenthem.

35

BeltMaintenance

CheckingtheBelts

ServiceInterval:Every50hours

Checkallbeltsafterevery50operatinghoursor
monthly,whicheveroccursrst.

Lookfordirt,wear,cracksandsignsofoverheating.

ReplacingtheTractionDrive
Belt

1.Removehairpincottersecuringbrakerodtobrake
armtorelaxbeltidlertension(Figure36).

2.Removebottomandloosentopboltsofshieldto
rotateforbeltclearance(Figure36).

3.Liftthebeltpastidlerandoffthedrivepulley
(Figure36).

4.Raisethewheeloffgroundenoughtoallowbelt
removal.

5.Replacethetractiondrivebelt.

6.Secureshieldwithpreviouslyremovedboltand
tightenbolts(Figure36).

7.Securebrakerodtobrakearmwithhairpincotter
(Figure36).

4.Removethemowerbelt(Figure37).

Figure37

1.Idlerpulleyinslot4.Beltguide

2.Tractionbelt

3.Mowerbelt6.Mowerbelt

5.Loosenthepivotboltenoughtoslidetheidlerpulley
intheslotandremovethetractionbeltfromthe
engineandthedrivepulleys(Figure37).

6.Installthenewdrivebeltaroundtheengineandthe
drivepulleys(Figure37).

7.Slidetheidlerpulleyintheengineframetotension
thetractionbelt(Figure37).

8.Installthemowerbelt(Figure37).

5.3/4inch(19mm)

Figure36

1.Drivebelt3.Tire

2.Drivespring4.Adjustmentbolt

ReplacingtheDriveBelt

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineandholditupwith
jackstands.

9.Checkthebeltguideundertheengineframeforthe
properadjustment(Figure37).

Note:Thedistancebetweenthebeltguideand
mowerbeltshouldbe3/4inch(19mm)whenthe
mowerbeltisengaged.Adjustthebeltifnecessary.
Thedisengagedbeltshouldnotdragorfalloffthe
pulleywhentheguidesareproperlyadjusted.

ReplacingtheMowerBelt

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Removetheknobsandthebeltcoveronthemower.

4.Removetheidlerpulleyandthewornbelt(Figure38).

5.Installthenewmowerbelt.

6.Installtheidlerpulley.

7.Engagethebladecontrol(PTO)leverandcheck
thebelttension.RefertoAdjustingtheMowerBelt
Tension.

36

Note:Thepropermowerbelttensionis10-15lbf.
(44-67N)withthebeltdeected1/2inch(13mm)
halfwaybetweenthepulleys(Figure38).

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Loosenthelocknutontheturnbuckle(Figure39).

4.Rotatetheturnbuckletowardtherearofthe
mowertoincreasethetensiononthebelt.Rotate
theturnbuckletowardthefrontofthemowerto
decreasethetensiononthebelt(Figure39).

Note:Theeyeboltthreadsonbothendsofthe
turnbuckleshouldbeengagedaminimumof
5/16inch(8mm).

Figure38

1.Mowerbeltwith1/2inch
(13mm)deection

2.Idlerpulley

AdjustingtheMowerBelt
Tension

AdjustingtheTension

ServiceInterval:Aftertherst8hours

Aftertherst25hours

Every50hours

Adjustthemowerbelttensionasfollows:

•Aftertherst8operatinghours.

•Aftertherst25operatinghours.

•Afterevery50operatinghours.

Checkthebelttensionaftertherst8operatinghours
and25operatinghoursthereafter.Checkthebelt
tensionafterevery50operatinghours.

Figure39

1.1/2inch(13mm)deection
here

2.Assistarm5.Turnbuckle

3.Frontstop

4.Locknut

5.Engagethebladedcontrollever(PTO)andcheck
thebelttension.

6.Ifthereisnoadjustmentleftintheturnbuckleand
thebeltisstillloose,therearidlerpulleyneedstobe
positionedtothemiddleorfronthole(Figure40).
Usetheholethatwillgivethecorrectadjustment.

7.Whentheidlerpulleyismovedthebeltguidemust
bemoved.Movethebeltguidetothefrontposition
(Figure40).

Important:Thebeltmustbetightenoughtonot
slipduringheavyloadswhilecuttinggrass.Over
tensioningthebeltwillreducethespindlebearing
life,thebeltlifeandtheidlerpulleylife.

Important:Thebrakeneedstobeadjustedwhen
thebelttensionorthebrakelinkageisadjusted.

37

Figure40

1.Rearidlerpulley4.Beltguideinbackposition

2.Middlehole5.Frontidlerpulley

3.Fronthole

8.Checkthebeltguideundertheengineframefor
properadjustment(Figure41).

Note:Thedistancebetweenthebeltguideand
themowerbeltshouldbe3/4inch(19mm)when
youengagethemowerbelt(Figure41).Adjustthe
mowerbeltasnecessary.Thedisengagedbeltshould
notdragorfalloffthepulleywhentheguidesand
belttensionareproperlyadjusted.

ThePTOengagementlinkageadjustmentislocated
beneaththefrontlefthandcorneroftheenginedeck.

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Engagethebladecontrollever(PTO).

4.Adjustthelinkagelengthtowherethelowerend
ofthebellcrankjustclearstheaxlesupportgusset
(Figure42).

9.Checkthebladebrakeadjustment;refertoAdjusting
theBladeBrake.

Figure41

1.Beltguide

AdjustingthePTOEngagement
Linkage

Figure42

1.Bellcrank4.Yoke

2.Safetyswitchlocated
underenginedeck

3.Bellcrankjustclearsthe
gussetwiththePTO
engageded

5.Nut

6.Assistarmlink

5.Makesuretheassistarmisagainsttherearassistarm
stoponthedeck(Figure43).

6.Pushthebladecontrollever(PTO)downtothe
disengagedposition.

7.Theassistarmshouldcontactthefrontassistarm
stoponthedeck.Ifitdoesnotcontact,adjustthe
bellcranksoitisclosertothegusset(Figure43).

Important:Thebrakeneedstobeadjustedwhen
thebelttensionorthebrakelinkageisadjusted.

38

Figure43

1.Assistarm3.Rearassistarmstop

2.Frontassistarmstop4.Turnbuckle

8.Toadjusttheassistarmlink,removethehairpin
cotterpinfromtheassistarm(Figure43).

9.Loosenthenutagainsttheyoke(Figure42).

10.Removetheassistarmlinkfromtheassistarmand
rotatethelinktoadjustthelength.

11.Installtheassistarmlinkintotheassistarmand
secureitwiththehairpincotterpin(Figure43).

12.Checkiftheassistarmhitsagainstthestops
correctly.

AdjustingthePTOSafetySwitch

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

1.Bellcrank

2.Boltsandnuts

Figure44

3.Switchmountingbracket

4.Switchbody

3.Disengagethebladecontrollever(PTO).Makesure
theassistarmisagainstthefrontassiststoparm.

4.Ifneeded,adjustthebladesafetyswitchbyloosening
theboltsholdingtheswitchbracket(Figure44).

5.Movethemountingbracketuntilthebellcrank
depressestheplungerbya1/4inch(6mm).

6.

Note:Makesurethebellcrankdoesnottouchthe
switchbodyordamagetotheswitchcouldoccur
(Figure44).
Tightentheswitchmountingbracket.

39

ControlsSystem
Maintenance

AdjustingtheControlRods

1.Removethehairpincotterpinsandclevispinsfrom
thedriveleversandneutrallocks(Figure45).

Figure45

1.Controlrod

2.Clevispin

3.OperatorPresence
Controllever(OPC)

4.Handle8.Drivelever

5.Neutrallock

6.Hairpincotterpin

7.Lefthandleshown

Figure46

1.Handle4.Drivelever

2.Neutral/parkingbrakelock

3.3/16to1/4inch(5to6
mm)clearance

5.Forwardspeed

6.Controlrod

3.Installthecontrolrodtothedriveleverandthe
neutral/parkingbrakelock.Securethecontrolrod
withaclevispinandahairpincotter(Figure33).

4.Checktheoperationofthecontrolrod.Ifyouneed
toadjustit,removethehairpincotterandtheclevis
pinthatsecurethecontrolrodtothedrivelevers.

5.Adjustthecontrolrodlengthbyrepeatingthe
previoussteps.

2.Adjustthecontrolrodlengthbythreadingtherodin
oroutoftherodttinguntilthereisa3/16to1/4
inches(5to6mm)clearancebetweenthecontrol
rodandthebottomoftheneutral/parkingbrake
lock(Figure46).

40

MowerDeck
Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keeptheblades
sharp.Forconvenientsharpeningandreplacement,you
maywanttokeepextrabladesonhand.

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

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagetheblade
controlbailandsettheparkingbrake.Turntheignition
keytooff.Removethekeyanddisconnectthespark
plugwire(s)fromthesparkplug(s).

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

Inspectthebladesevery8hours.

Figure47

1.CuttingEdge3.Wear/slotForming

2.CurvedArea

2.Inspecttheblades,especiallythecurvedarea
(Figure47).Ifyounoticeanydamage,wear,or
aslotforminginthisarea(item3inFigure47),
immediatelyinstallanewblade.

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforwardand
backward(Figure48).

1.Inspectthecuttingedges(Figure47).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades.

Figure48

Figure49

1.Measurefromcuttingedgetoalevelsurface

2.Measurefromalevelsurfacetothecuttingedge,
positionA,oftheblades(Figure49).Notethis
dimension.

41

3.Rotatetheoppositeendsofthebladesforward.

4.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep1.The
differencebetweenthedimensionsobtainedinsteps
1and2mustnotexceed1/8inch(3mm).Ifthis
dimensionexceeds1/8inch(3mm),thebladeis
bentandmustbereplaced.RefertoRemovingthe
BladesandInstallingtheBlades.

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedbladewith
anewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Replacethebladesifyouhitasolidobjectorifthe
bladesareoutofbalanceorbent.T oensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineT ororeplacementblades.
Replacementbladesmadebyothermanufacturersmay
resultinnon-conformancewithsafetystandards.

1.Holdthebladeboltwithawrench.

2.Removethenut,bladebolt,curvedwasher,blade,
spacers,andthinwasherfromthespindle(Figure50).

Figure50

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends
oftheblade(Figure51).Maintaintheoriginalangle.
Thebladeretainsitsbalanceifthesameamountof
materialisremovedfrombothcuttingedges.

Figure51

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure52).Ifthebladestaysina
horizontalposition,thebladeisbalancedandcanbe
used.Ifthebladeisnotbalanced,lesomemetaloff

42

theendofthesailareaonly(Figure52).Repeatthis
procedureuntilthebladeisbalanced.

Figure52

1.Blade2.Balancer

InstallingtheBlades

1.Placethebladeontotheboltandoverthecone
washer.Selectthepropernumberofspacer(s)for
theheight-of-cut,andslidetheboltintothespindle
(Figure50).

Important:Thecurvedpartoftheblademust
pointupwardtowardtheinsideofthemowerto
ensurepropercutting.

2.Installtheremainingspacer(s)andsecurethemwith
athinwasherandanut(Fig.Figure50).

Figure53

1.Springmountingbolts3.1/8-3/16inch(3mm-5mm)

2.Bladebrakepad

ReplacingtheGrassDeector

3.Torquethebladeboltto75-80ft-lb(101-108N•m).

AdjustingtheBladeBrake

1.Disengagethebladecontrol(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Ifnecessary,adjustthespringmountingboltssothat
thebladebrakepadrubsagainstbothsidesofthe
pulleygroove(Figure53).

4.Adjustthenutattheendofthebladebrakeroduntil
thereis1/8-3/16inch(3mm-5mm)betweenthe
nutandspacer(Figure53).

5.Engagetheblades.Ensurethebladebrakepadno
longercontactsthepulleygroove.

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresultin
seriousinjuryordeath.Also,contactwiththe
bladecouldoccur.

Neveroperatethelawnmowerwiththegrass
deectorremovedunlessyouinstallacover
plate,amulchplate,oragrasschuteand
catcher.

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure54).
Removedamagedorworngrassdeector.

43

Figure54

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore
installingbolt

Storage

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,page35.

4.Servicetheaircleaner;refertoServicingtheAir
Cleaner.

5.Greasethemachine;refertoGreasingand
LubricationinLubrication,page25.

6.Changethecrankcaseoil;refertoServicingthe
Enginein.

7.Checkthetirepressure;refertoCheckingtheTire
PressureinDriveSystemMaintenance,page32.

2.Placespacerandspringontograssdeector.Place
theLendofspringbehinddeckedge.

Note:MakesuretheLendofspringisinstalled
behinddeckedgebeforeinstallingtheboltasshown
inFigure54.

3.Installboltandnut.PlacetheJhookendofspring
aroundgrassdeector(Figure54).

Important:Thegrassdeectormustbefree
torotate.Liftthedeectoruptothefullopen
positionandensurethatitrotatesfreelywithout
bindingintothefulldownposition.

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runenginetodistributeconditionedfuelthrough

thefuelsystem(5minutes).

C.Stopengine,allowtocoolanddrainthefuel

tank;refertoServicingtheFuelTankinFuel
SystemMaintenance,page31,oroperateengine
untilitstops.

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.

44

11.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

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

45

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.Movetheshiftlevertoadrivegear

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.

position.

2.Changethebelt.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

3.Levelthemowerfromside-to-sideand
front-to-rear.

6.ContactanAuthorizedServiceDealer.

46

Problem

PossibleCauseCorrectiveAction

Bladesdonotrotate.

1.Mowerdeckbeltiswornorloose.

2.Mowerdeckbeltisbroken.2.Installnewdeckbelt.

3.Mowerdeckbeltisoffpulley .3.Inspectthebeltandreplaceifdamaged.

4.Brokenormissingidlerspring.4.Replacethespring.

1.Checkthebelttension.

Checkthepulleysandidlersandadjust
thebelttension.

47

Schematics

ElectricalSchematic(Rev.-)

48

Landscape
Contractor

Equipment (LCE)

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

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

This warranty applies to:

•

ProLine Mid-Size Mowers and Attachments

•

Z Master Mid-Mount ZRTs and Attachments

Components

Traction Unit Frame and Carrier Frame
All Spindles

Engines* and /Hydraulic System
Deck Shells (34 ″ -72 ″ )
Z500 Series Electric Clutch
Remaining Components

* S o m e e n g i n e s u s e d o n T o r o L C E P r o d u c t s a r e w a r r a n t e d b y t h e e n g i n e m a n u f a c t u r e r .

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

Warranty Period

1 year
1 year

2 year

3 years Parts

2 years Labor

2 years
2 years
2 years

1 year

Instructions for Obtaining Warranty Service

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

1. Contact any Toro Authorized or Master Service Dealer to arrange service at
their dealership. To locate a dealer convenient to you, access our website at
www.Toro.com. You may also call our Toro Customer Care Department
toll free at 888–865–5676 (U.S. Customers) or 888–865–5691 (Canada
customers).

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

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

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Owner Responsibilities

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

Items and Conditions Not Covered

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

• Cost of regular maintenance service or parts, such as lters, fuel, lubricants,

tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required

replacement or repair due to normal wear, accidents, or lack of proper
maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or

failure to properly prepare the fuel system prior to any period of non-use
over three months.

• Pickup and delivery charges.

General Conditions

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

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

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

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

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

Countries Other than the United States or Canada

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

374-0037 Rev F