Toro 30934, 30938, 39934, 39938 Operator's Manual

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Page 1

FormNo.3379-930RevA

G017540

CommercialWalk-BehindMower

FixedDeck,PistolGrip,HydroDrivewith 36inor48inTURBOFORCE

ModelNo.30934—SerialNo.314000001andUp

ModelNo.30938—SerialNo.314000001andUp

CuttingUnit

ModelNo.39934—SerialNo.314000001andUp

ModelNo.39938—SerialNo.314000001andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3379-930*A

Page 2

WARNING

Introduction

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002.

Important:Thisengineisnotequippedwithaspark arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperatetheengine onanyforest-covered,brush-covered,orgrass-covered land.Otherstatesorfederalareasmayhavesimilarlaws.

WARNING

Removingstandardoriginalequipmentpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.FailuretouseoriginalToro partscouldcauseseriousinjuryordeath.Making unauthorizedchangestotheengine,fuelorventing system,mayviolateEPAandCARBregulations.

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,genuineT oroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready.Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.

Replaceallpartsincluding,butnotlimitedto,tires, belts,blades,andfuelsystemcomponentswith originalToroparts.

Theenclosed informationregardingtheUSEnvironmentalProtection Agency(EPA)andtheCaliforniaEmissionControl Regulationofemissionsystems,maintenance,and warranty.Replacementsmaybeorderedthroughthe enginemanufacturer.

Engine Owner's Man ual

issuppliedfor

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.

Contents

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

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

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

ToroMowerSafety..................................................6

SlopeIndicator.......................................................7

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

ProductOverview.........................................................11

Controls...............................................................11

Specications........................................................12

Attachments/Accessories........................................12

Operation....................................................................12

AddingFuel...........................................................12

CheckingtheEngine-oilLevel..................................13

ThinkSafetyFirst...................................................13

OperatingtheParkingBrake....................................14

StartingandStoppingtheEngine..............................14

OperatingtheNeutralLocks....................................15

OperatingtheMower-blade-controlKnob

(PTO)...............................................................16

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

DrivingtheMachineForwardandBackward..............17

BringingtheMachinetoNeutralPosition...................17

StoppingtheMachine.............................................17

PushingtheMachinebyHand..................................17

AdjustingtheFlowBafe........................................18

PositioningtheFlowBafe......................................18

TransportingMachines............................................19

SideDischargingorMulchingtheGrass.....................19

AdjustingtheHeight-of-Cut....................................19

AdjustingtheCasterPosition...................................20

AdjustingtheHandleHeight....................................21

Height-of-cutChart................................................22

Maintenance.................................................................23

RecommendedMaintenanceSchedule(s)......................23

Lubrication...............................................................24

LubricatingtheMachine..........................................24

LubricatingtheCasterandWheelBearings.................24

GreasingtheMowerBeltIdler..................................24

GreasingthePumpControlandtheBell

Crank................................................................24

EngineMaintenance..................................................25

ServicingtheAirCleaner.........................................25

ServicingtheEngineOil..........................................25

ServicingtheSparkPlugs.........................................27

FuelSystemMaintenance...........................................28

ServicingtheFuelTank...........................................28

ServicingtheFuelFilter...........................................29

ServicingtheFuelVentSystem.................................29

DriveSystemMaintenance.........................................30

AdjustingtheSpeedControlLinkage........................30

AdjustingtheNeutralControlLinkages.....................30

AdjustingtheHydroControlLinkages.......................31

AdjustingtheControlRod.......................................33

AdjustingtheTracking...........................................34

AdjustingtheSpringAnchorLinks...........................34

CheckingtheTirePressure......................................35

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CoolingSystemMaintenance......................................35

CleaningtheAir-intakeScreen..................................35

CleaningtheCoolingSystem....................................35

BrakeMaintenance....................................................36

ServicingtheBrake.................................................36

BeltMaintenance......................................................37

CheckingtheBelts..................................................37

ReplacingtheMowerBelt........................................37

AdjustingtheMowerBeltTension............................38

HydraulicSystemMaintenance....................................41

ServicingtheHydraulicSystem.................................41

MowerDeckMaintenance...........................................44

ServicingtheCuttingBlades.....................................44

AdjustingtheBladeBrake........................................46

ReplacingtheGrassDeector..................................46

Storage........................................................................47

CleaningandStorage..............................................47

Troubleshooting...........................................................49

Schematics...................................................................51

Safety

Note:Theadditionofattachmentsmadebyother

manufacturersthatdonotmeetAmericanNationalStandards Institutecerticationwillcausenoncomplianceofthis machine.

Improperlyusingormaintainingthemachinecanresult ininjury.Toreducethepotentialforinjury,complywith thesesafetyinstructionsandalwayspayattentiontothe safetyalertsymbol,whichmeans

Danger

withtheinstructionmayresultinpersonalinjuryor death.

Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.

—personalsafetyinstruction.Failuretocomply

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI B71.4-2012.

Caution, W ar ning ,

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.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety

glasses,andhearingprotection.Longhair,looseclothing, orjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeusedand

removeallobjectssuchasrocks,toys,andwirewhichcan bethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches,

andshieldsareattachedandfunctioningproperly.Donot operateunlesstheyarefunctioningproperly.

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Operation

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.

•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.

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•Usecarewhencheckingtheblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only replaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replaceallwornordamageddecals.

•Removeobstaclessuchasrocks,treelimbs,etc.fromthe

mowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide

obstacles.

•Usecautionneardrop-offs,ditches,orembankments.

Themachinecouldsuddenlyturnoverifawheelgoes overtheedgeofaclifforditch,orifanedgecavesin.

•Tobestprotectyourinvestmentandmaintainoptimal

performanceofyourToroequipment,countonToro genuineparts.Whenitcomestoreliability,T orodelivers replacementpartsdesignedtotheexactengineering specicationsofourequipment.Forpeaceofmind,insist onTorogenuineparts.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected downandoutwardfromthemachine.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro productsandothersafetyinformationyoumustknow.

Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.

•Useextracarewithgrasscatchersorotherattachments.

Thesecanchangethestabilityofthemachine.

•Keepallmovementonslopesslowandgradual.Donot

makesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinsidewhere

thereisanopename,suchasnearawaterheateror furnace.

•Keepnutsandboltstight,especiallythebladeattachment

bolts.Keepequipmentingoodcondition.

•Nevertamperwithsafetydevices.Checksafetysystems

forproperoperationbeforeeachuse.

•Useonlygenuinereplacementpartstoensurethatoriginal

standardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandserviceas

required.

Thisproductisdesignedforcuttingandrecyclinggrassor, whenequippedwithagrassbagger,forcatchingcutgrass. Anyuseforpurposesotherthanthesecouldprovedangerous touserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebeforemowing.

Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhichmay

behotfromoperation.Allowtocoolbeforeattempting tomaintain,adjustorservice.

•UseonlyToroapprovedattachments.Warrantymaybe

voidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforeoperatingunderany objectsanddonotcontactthem.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeeluneasy onaslope,donotmowit.

Page 7

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

Page 8

SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.

98-0776

1-403005

1.ReadtheOperator's Manualforinstructionson

operatingthecuttingblade

2.Pushforwardtoengage

66-1340

ForModelswith2BladeMowerDecks

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

95-5537

3.Pullbacktodisengage

98-3296

98-5130

98-5954

Page 9

BatterySymbols

Someorallofthesesymbolsareonyourbattery

103–2076

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery.

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

104-8569

105-4109

105-4110

99-3943

1.Engine

106-2733

1.Fast

2.Continuousvariable setting

3.Slow

103-2103

Page 10

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

110-2067

106-2743

110-2068

1.ReadtheOperator'sManual.

115-4212

1.Hydraulicoillevel3.Warning—donottouchthe

2.ReadtheOperator's Manual.

106-2738

1.Park4.Engine—stop7.Fast10.Neutral

2.Drive5.Engine—run

3.Neutral6.Warning—wearear protection.

8.Continuousvariablesetting

9.Slow

hotsurface.

Page 11

ProductOverview

G017541

Figure4

1.Sidedischarge5.Controls

2.Mowerdeck6.Handle

3.Recoil-starthandle

4.Gastank

Controls

Becomefamiliarwithallthecontrols(Figure5)beforeyou starttheengineandoperatethemachine.

7.Casterwheel

Figure5

1.Throttlecontrol6.Handle

2.Speed-controllever

3.Ignitionswitch

4.Neutrallock

5.OperatorPresence Controllevers(OPC)

7.Drivelever

8.Blade-controlknob(PTO)

9.Choke

10.Fuel-shutoffvalve

ThrottleControl

Thethrottlecontrolhas2positions:FastandSlow.

OperatorPresenceControl(OPC) Levers

WhenyousqueezetheOPCleversagainstthehandles, theOPCsystemsensesthattheoperatorisinthenormal operatingposition.WhenyoureleasetheOPClevers,the OPCsystemsensesthattheoperatorhasleftthenormal operatingposition,andthesystemwillstoptheengineif eitherthespeed-controlleverisnotintheneutralpositionor theblade-control(PTO)knobisengaged.

Blade-controlKnob(PTO)

Theblade-controlknob(PTO)isusedtoengageand disengagethedrivebelttodrivethemowerbladeswiththe OPCleverspressedagainstthehandles.Pulltheknobupto engagethebladesanddowntodisengagetheblades.

IgnitionSwitch

Thisswitchisusedinconjunctionwithrecoilstarterandhas 2positions:RunandOff.

Speed-controlLever

Thismachinehasavariable-speedcontrolwithaneutral position.Thiscontrolshowfastthemachinetravelsforward.

DriveLevers

Releasethedriveleverstoengageforwardtractionoperation andsqueezetheleversuntilanincreaseinforceisfeltto gointoneutralpositionandcontinuetosqueezetogoin reverse.Squeezetheright-sidedrivelevertoturnrightand theleft-sidedrivelevertoturnleft.

NeutralLock

Squeezethedriveleversbackuntilanincreaseinforceisfelt, andmovethelockstotherearforneutrallock.

RecoilStarter

Pulltherecoil-starthandletostarttheengine(notshown inFigure4).

Page 12

Fuel-shutoffValve

Closethefuel-shutoffvalvewhentransportingorstoringthe machine.

Operation

AddingFuel

Choke

Usethechoketostartacoldengine.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

36-inchmowers:

Widthwithdeectordown118.4cm(46.6inches)

Length

Height

Weight

48-inchmowers:

Widthwithdeectordown161.3cm(63-1/2inches)

Length

Height

Weight

203.2cm(80inches)

11 1.8cm(44inches)

241kg(532lb)

198.9cm(78-3/8inches)

11 1.8cm(44inches)

259kg(570lb)

•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,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

Attachments/Accessories

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystemin placeandinproperworkingcondition.

Page 13

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor onatruckortrailerbedbecauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.

UsingFuelStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachinetokeepthe fuelfreshduringstorageof90daysorless.Ifyouarestoring themachineforlonger,drainthefueltank;refertoStorage (page47).

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountoffuelstabilizer/conditionertothe fuel,andfollowthedirectionsofthemanufacturer.

Note:Fuelstabilizer/conditionerismosteffectivewhen mixedwithfreshgasoline.Tominimizethechanceofvarnish depositsinthefuelsystem,usefuelstabilizeratalltimes.

•Whenpractical,removegas-poweredequipment fromthetruckortrailerandrefueltheequipment withitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditionerbottleopening.

•Keepgasawayfromeyesandskin.

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.

CAUTION

Thismachineproducessoundlevelsinexcessof 85dBAattheoperator'searandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Figure6

1.Warning—wearhearingprotection.

Page 14

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor leaveitunattended.Beforeeachuse,checktheparkingbrake forproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit.Referto ServicingtheParkingBrake.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

SettingtheParkingBrake

Pulltheparking-brakeleverrearward(Figure7).

Figure7

1.Parking-brakelever(inthereleasedposition)

ReleasingtheParkingBrake

Pushtheparking-brakeleverforward.

StartingandStoppingthe Engine

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

Note:Acold-weatherstartingkithasbeen incorporatedtoassistenginestartingincoldweather orwhenthemachinehasnotbeenrunforaperiod oftime.

Tousethecold-weatherstartingkit:

•Graspthesplitring(

themachine,pulltheringandchainstraightout fromthesideofthemachine,andhookthering overthecontrol-shieldbolt.

Figure8)ontherightsideof

Figure8

1.Splitring2.Control-shieldbolt

•Aftertheengineisstarted,pullthechainstraight

outfromthesideofthemachineuntiltheringcan beremovedfromshieldbolt.Slowlyreleasethe tensiononthechain.

3.Disengagetheblade-controlknob(PTO)andmove thespeed-controllevertotheneutralposition.

4.Movethedriveleverstotheneutralpositionandset theneutrallocks.

5.Settheparkingbrake.

6.Turntheignitionkeytotherunposition(

7.Tostartacoldengine,movethethrottlecontrol midwaybetweenthefastandslowpositions.

8.Tostartawarmengine,movethethrottlecontrolto thefastposition.

9.Pullthechokeknobiftheengineiscold(Figure5).

Note:Awarmorhotengineusuallydoesnotrequire anychoking.

10.Grasptherecoil-starthandlermlyandpullitout untilpositiveengagementresults;thenpullthehandle vigorouslytostarttheengine.Allowtheropetorecoil slowly.

11.Pushthechoketotheoffpositionastheenginewarms up(Figure9).

12.Iftheengineiscold,allowittowarmupandthen movethethrottlecontroltothefastposition.

Figure5).

StoppingtheEngine

1.Movethethrottlelevertotheslowposition(Figure9).

2.Movethedriveleverstotheneutralpositionandset theneutrallocks.

3.Disengagetheblade-controlknob(PTO)andmove thespeed-controllevertotheneutralposition.

4.Lettheengineidlefor30to60secondsbeforeturning theengineoff.

5.Tostoptheengine,turntheignitionkeytooff.

Page 15

Figure9

ReleasingtheNeutralLock

1.Squeezethedriveleversbackuntilanincreaseinforce isfelt.

2.Placeyourthumbsontheupperpartofthelocksand movethemforwarduntilthepinsareintheforward slot(Figure11).

1.Throttlelever

2.Ignitionswitch

3.Choke

Important:Makesurethatthefuel-shutoff valveisclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.Beforestoring themachine,disconnectthewiresfromthespark plugstopreventthepossibilityofaccidentally startingtheengine.

OperatingtheNeutralLocks

Alwayssettheneutrallockwhenyoustopthemachine.Set theparkingbrakeifitisleftunattended.

SettingtheNeutralLock

1.Squeezethedriveleversbackuntilanincreaseinforce isfelt.

2.Placethumbsontheupperpartofthelocksandmove themback(

Figure10).

Figure11

1.Handle

2.Neutrallock5.Handle

3.Drivelever6.Forwardslot

4.Pininfullspeedforward

Figure10

1.Handle4.Drivelever

2.Neutrallock

3.Neutralposition6.Reverseposition

5.Fullspeedforward

Page 16

Operatingthe

TheSafetyInterlockSystem Mower-blade-controlKnob (PTO)

Theblade-controlknob(PTO)isusedinconjunctionwith theOperatorPresenceControl(OPC)leverstoengageand disengagethemowerblades.

EngagingtheMowerBlades(PTO)

1.Toengagetheblades,squeezetheOperatorPresence Control(OPC)leversagainstthehandlegrips(Figure

12).

2.Pulltheblade-controlknob(PTO)up.HoldtheOPC leversagainstthehandlegrip.

Note:TheenginewillstopiftheOPCleversare releasedifthemowerisrunningandthespeed-control leverisnotinneutral.

3.Starttheengineandrepeattheproceduretoengagethe mowerbladesiftheoperatorpresencecontrol(OPC) leversarereleased.

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthemower fromstartingunless:

•Theblade-controlknob(PTO)ispushedoff.

•Thespeed-controlleverisinneutral.

Thesafetyinterlocksystemisdesignedtostoptheengine when:

•TheOperatorPresenceControl(OPC)leversarereleased

withthemowerengagedand/orthespeedcontrolisout ofneutral.

•Thespeed-controlleverisshiftedoutofneutralwithout

holdingOPCleversorwiththebrakeengaged.

•Theblade-controlknob(PTO)ispulledupwithout

holdingtheOPClevers.

Figure12

1.Throttlelever4.DriveLever

2.OperatorPresence Controllevers(OPC)

3.Handle

5.Blade-controlknob(PTO)

DisengagingtheMowerBlades(PTO)

Themowerbladescanbedisengagedbyoneofthefollowing steps.

1.Pushtheblade-controlknob(PTO)downtotheoff position(

2.ReleasingtheOperatorPresenceControl(OPC)levers willstoptheengineandstoptheblades(Figure12) withtheblade-controlleverengaged.

Figure12).

TestingtheSafety-interlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethemachine eachtime.Ifthesafetysystemdoesnotoperateasdescribed, haveanAuthorizedServiceDealerrepairthesafetysystem immediately.

WARNING

Whiletestingthesafety-interlocksystem,the machinemaymoveforwardandcausepersonal injuryorpropertydamage.

•Performthesafety-interlocktestinanopenarea.

•Ensurethatnooneisstandinginfrontofthe machinewhileperformingthesafety-interlock test.

1.Settheneutrallocksandplacespeed-controlleverin neutral.

2.Starttheengine;refertoStartingandStoppingthe Engine.

3.WithoutholdingtheOperatorPresenceControl(OPC) levers,pulltheblade-controlknob(PTO)up.The engineshouldstop.

Page 17

4.Pushtheblade-controlknobdowntooff.

DrivingBackward

5.Withenginerunning,holddowntheOPClevers. Pulltheblade-controlknob(PTO)up.Thedrivebelt shouldengageandthemowerbladesshouldbegin rotating.

6.Withenginerunning,releasetheOPClevers.The engineshouldstop.

7.Withtheenginerunning,movethespeed-controllever forwardslightly.ReleasetheOPClevers.Theengine shouldstop.

8.Ifalltheaboveconditionsarenotmet,havean AuthorizedServiceDealerrepairthesafetysystem immediately.

DrivingtheMachineForward andBackward

Thethrottlecontrolregulatestheenginespeedasmeasured inrpm(revolutionsperminute).Placethethrottlecontrolin thefastpositionforbestmowingperformance.

DrivingForward

1.Releasetheparkingbrake.

2.Togoforward,movethespeed-controllevertothe desiredspeed.

3.Releasetheneutrallock.RefertoReleasingtheNeutral Lock.

4.Slowlyreleasethedriveleverstomoveforward(

13).

Togostraight,releasethedriveleversequally(Figure

13).

Toturn,squeezethedriveleveronthesideofthe directionwhichyouwanttoturn(Figure13).

Figure

Fromneutral,slowlysqueezethedriveleverstomove rearward(Figure13).

BringingtheMachineto NeutralPosition

Alwayssettheneutrallockandparkingbrakewhenyoustop themachine.

1.Squeezethedriveleverstoneutralposition.

2.Settheneutrallocks.RefertoOperatingNeutralLocks.

3.Movespeed-controllevertoneutralposition.

Note:Thespeed-controllevercanalsobeusedto bringthemowertoneutralpositionandthensetthe neutrallocks.

StoppingtheMachine

1.Tostopthemachine,squeezethedriveleverstothe neutralpositionandengageneutrallocks.

2.Movespeed-controlleverintoneutral.

3.Stoptheengine;refertoStoppingtheEngine.

4.Waitforallmovingpartstostopbeforeleavingthe operatingposition.Settheparkingbrake.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

PushingtheMachinebyHand

1.Drivelever

Figure13

2.Speed-controllever

Thebypassvalvesallowthemachinetobepushedbyhand withouttheenginerunning.

Important:Alwayspushthemachinebyhand.Never towthemachinebecausehydraulicdamagemayoccur.

ToPushtheMachine

1.DisengagethePTO ,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Openthebypassvalvesbyturningthemcounter clockwise1to2turns.Thisallowshydraulicuidto bypassthepumpsandthewheelstoturn(

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

6.Closethebypassvalves,butdonotovertightenthem.

Figure14).

Page 18

Note:Rotatethebypassvalvesamaximumof2turns

g012676

1 2

G012677

G012678

sothevalvedoesnotcomeoutofthebodycausing uidtorunout.

Important:Donotstartoroperatethemachine withthebypassvalvesopen.Damagetosystem mayoccur.

Figure14

1.Bypassvalve

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse. Adjustmentswillvarybygrasstype,moisturecontent,and heightofgrass.

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure16).Thesuggested useforthispositionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthemower.

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferenttypes ofmowingconditions.Positionthecamlockandbafeto givethebestqualityofcut.

1.DisengagethePTO ,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Toadjustthebafe,loosenthenut(Figure15).

4.Adjustthebafeandnutintheslottothedesired dischargeowandtightenthenut.

Figure16

PositionB

Usethispositionwhenbagging(Figure17).

Figure15

2.Nut

Figure17

1.Slot

Page 19

PositionC

G012679

SideDischargingorMulching

Thisisthefullopenposition.Thesuggesteduseforthis positionisasfollows(Figure18).

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

Figure18

theGrass

Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

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.Alsoremovethekeyandpullthewireoff thesparkplug(s).

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthemachine. Ensurethatthetrailerortruckhasallnecessarylightingand markingasrequiredbylaw.Pleasecarefullyreadallthesafety instructions.Knowingthisinformationcouldhelpyou,your family,petsorbystandersavoidinjury.

Totransportthemachine:

1.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

2.Securelyfastenthemachinetothetrailerortruckwith straps,chains,cable,orropes.

3.Secureatrailertotowingvehiclewithsafetychains.

4.Ifapplicable,connectthetrailerbrakes.

AdjustingtheHeight-of-Cut

Thismachinehasa26to108mm(1to4-1/4inch)rangefor theheightofcut.Thiscanbeachievedbyadjustingblade spacers,rearaxleheight,andfrontcasterspacers.Usethe Height-of-CutCharttoselectthecombinationofadjustments required.

AdjustingtheBladeHeight

Adjustthebladesbyusingthe4spacers(6mm)(1/4inch) onthebladespindlebolts.Thisallowsfora25mm(1inch) adjustmentrange,in6mm(1/4inch)increments,ofcutting heightinanyaxleposition.Usethesamenumberofblade spacersonallbladestoachievealevelcut(2aboveand 2below ,1aboveand3below,etc.).

1.DisengagethePTOandpullthethrottletotheslow position.

2.Turntheignitionswitchtooff.

3.Waitforallmovingpartstostopbeforeleavingthe operatingposition.Settheparkingbrake.

4.Holdthebladeboltandremovethenut.Slidethebolt downthroughthespindle,andchangethespacersas needed(

Figure19).

Page 20

Figure20

1.Topaxlebolt2.Loweraxlebolt

7.Raiseorlowerthemountingbracketsothatyoucan installthe2axleadjustmentboltsinthedesiredhole location(Figure20).

Note:Useataperedpunchtohelpaligntheholes.

8.Tightenall4bolts.

9.Installthedrivewheelsandlowerthemachine.

Figure19

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

5.Installthebolt,thecurvedwasher,andtheblade;add extraspacers,andsecurethemwithathinwasheranda nut(Figure19).

6.Torquethebladeboltto101to108N-m(75to 80ft-lb).

AdjustingtheAxleHeight

Adjusttheaxlepositiontotheselectedheight-of-cutsetting.

1.DisengagethePTOandpullthethrottletothestop position.

2.Waitforallmovingpartstostopbeforeleavingthe operatingposition,andthensettheparkingbrake.

3.Placeajackundertherearcenteroftheengineframe. Raisethebackendoftheengineframeupenoughto removethedrivewheels.

4.Removethedrivewheels.

5.Loosen,butdonotremove,the2topaxlebolts(

20).

Figure

AdjustingtheCasterPosition

1.UsingtheHeight-of-CutChart,adjustthecaster spacerstomatchwiththeaxleholeselected(Figure21).

Figure21

1.Latchpin

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

2.Removethelatchpin,slidethecasterfromthesupport, andchangethespacers(Figure21).

3.Installthecasterinthesupportandinsertthelatchpin (

Figure21).

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

6.Removethe2loweraxlebolts(Figure20).

Page 21

AdjustingtheHandleHeight

Thehandlepositioncanbeadjustedtomatchtheoperator's heightpreference.

1.Removethehairpincotterpinsandclevispinsfrom thedriveleversandneutrallocks(Figure22).

Figure23

Figure22

1.Controlrod5.Lefthandleshown

2.Clevispin

3.Drivelever7.Hairpincotterpin

4.OperatorPresence Controllever(OPC)

6.Neutrallock

2.Loosentheupperangebolts(3/8x1-1/4inch)and angenutsecuringhandletorearframe(Figure23).

3.Removethelowerangebolts(3/8x1inch)andange nutssecuringhandletorearframe(Figure23).

4.Pivotthehandletothedesiredoperatingpositionand installthelowerangebolts(3/8x1inch)andange nutsintothemountingholes.Tightenalltheange bolts.

1.Controlrodtting

2.Lowermountingholes7.Lowerposition

3.Rearframe

4.Lowerangebolt(3/8x1 inch)

5.Upperangebolt(3/8x 1-1/4inches)

6.Highposition

8.Uppermountinghole

9.Handle

10.Flangenut(3/8inch)

5.Adjustthecontrolrodlengthbyrotatingthecontrol rodintherodtting(Figure23).

6.Installthehairpincotterbetweenthedriveleversand theneutrallocksandintotheclevispins(Figure22).

Note:Makesurethattheclevispinsareinsertedinto theneutrallocks.

7.Performthehydrauliclinkageadjustmentswhenthe handleheightischanged;referHydraulicLinkage Adjustments.

Page 22

Height-of-cutChart

Numberofspacers

13mm

Axleposition

A00

A01

A10

B01

B10

B11

B20

D21

D30

D31

D40

E31

E40

E41

(1/2inch)

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)

Page 23

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst25hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthemowerbelttension.

•Checkthehydraulicuidlevel.

•Changethehydrauliclter.

•Checkthemowerbelttension.

•Checkthesafetysystem.

•Greasethecasterwheelsandthecasterpivots.

•Checktheengineoillevel.

•Cleantheair-intakescreen.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanthefoamair-cleanerelement.

•Checkthehydraulicuidlevel.

•Greasethemowerbeltidler.

•Greasethepumpdriveidlerpivot.

•Greasethepumpcontrol.

•Checkthepaperair-cleanerelement.

•Checkthetirepressure.

•Checkthebelts.

•Checkthemowerbelttension.

•Greasethebladeengagementbellcrank.

•Changetheengineoil.

•Checkthesparkplugs.

•Checkandcleantheengine-coolingnsandshrouds.

•Checkthehydraulichoses.

•Replacethepaperair-cleanerelement.

•Changetheoillter.

Every200hours

Every400hours

Beforestorage

•Replacethefuellter.

•Replacethefuelventlter.

•Changethehydrauliclter.

•Lubricatethecamlockwithanti-seizecompound.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwirefromthesparkplug(s)beforeyoudo anymaintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

Page 24

Lubrication

GreasingthePumpControl

UseFigure24forlocatingthegreasepointsonthemachine.

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.

LubricatingtheCasterand WheelBearings

ServiceInterval:Beforeeachuseordaily—Greasethecaster

wheelsandthecasterpivots.

andtheBellCrank

ServiceInterval:Every50hours—Greasethepumpdrive

idlerpivot.

Every50hours—Greasethepumpcontrol.

Every100hours—Greasethebladeengagement bellcrank.

Every400hours—Lubricatethecamlockwith anti-seizecompound.

Greasethettingonthepumpdriveidlerpivotandthe pumpcontrol.

Greasethebladeengagement(PTO)bellcrank(Figure24).

Lubricatethefrontwheelbearingsandthefrontspindles.

GreasingtheMowerBeltIdler

ServiceInterval:Every50hours—Greasethemowerbelt

idler.

Greasethettingonthemowerbeltidlerarmpivot(Figure

24).

Note:Removethemowerdeckcovertoaccessthegrease ttingforthemowerbeltidlerarm.

Figure24

48-inchmowerdeckshown

1.Pumpdriveidlerarm4.Mowerbeltidlerarm

2.Pumpcontrolarm

3.Bellcrank

5.Casterwheelbearing

6.Casterpivot

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(Figure25).

4.Unscrewthecoverknobsandremovetheair-cleaner cover(Figure25).

5.Unscrewthehoseclampandremovetheaircleaner assembly(Figure25).

6.Carefullypullthefoamelementoffthepaperelement (Figure25).

Important:Replacethefoamelementifitistorn orworn.

ServicingthePaperAir-cleanerElement

1.Donotcleanthepaperlter,replaceit(Figure25).

2.Inspecttheelementfortears,anoilylm,ordamageto therubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,alwaysoperate

theenginewiththecompletefoamandpaperaircleaner assemblyinstalled.

1.Carefullyslidethefoamelementontothepaper air-cleanerelement(Figure25).

2.Placetheaircleanerassemblyontotheaircleanerbase andsecureitwiththe2wingnuts(

3.Placetheair-cleanercoverintopositionandtighten thecoverknob(Figure25).

Figure25).

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Checktheengine

oillevel.

Aftertherst8hours—Changetheengineoil.

Every100hours—Changetheengineoil.

Figure25

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(Figure26).

Page 26

ChangingtheEngineOil

1.Parkthemachinesothatthedrainsideisslightlylower thantheoppositesidetoensurethattheoildrains completely.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

4.Slidethedrainhoseovertheoildrainvalve.

5.Placeapanbelowthedrainhose.Rotateoildrainvalve toallowoiltodrain(Figure28).

Figure26

CheckingtheEngine-oilLevel

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

4.Cleanaroundtheoildipstick(Figure27)sothatdirt cannotfallintothellerholeanddamagetheengine.

6.Whenoilhasdrainedcompletely,closethedrainvalve.

7.Removethedrainhose(

Figure28).

Note:Disposeoftheusedoilatarecyclingcenter.

Figure27

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean(Figure

27).

6.Slidetheoildipstickfullyintothellertube,butdonot threaditontothetube(Figure27).

7.Pullthedipstickoutandlookattheend.Iftheoillevel islow,slowlypouronlyenoughoilintothellertube toraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewithoil andruntheengine;enginedamagecanresult.

Figure28

1.Oildrainvalve2.Oildrainhose

8.Slowlypourapproximately80%ofthespeciedoil intothellertube(

Figure27).

9.Checktheoillevel;refertoCheckingtheEngineOil Level.

10.SlowlyaddtheadditionaloiltobringittotheFull mark.

ChangingtheOilFilter

Note:Changetheoilltermorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Removetheoldlter(

Figure29).

Page 27

Figure29

1.Oillter

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure29).

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

Figure29).

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.

Figure30

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausingdamage.

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

1.Lookatthecenterofthesparkplugs(Figure31).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(

Figure30).

Figure31

1.Centerelectrode;insulator3.Airgap(nottoscale)

2.Sideelectrode

Important:Alwaysreplacethesparkplugswhen theyhavewornelectrodes,anoilylm,ora crackedinsulator.

3.Checkthegapbetweenthecenterelectrodeandthe sideelectrode(

Figure31).Bendthesideelectrode

(Figure31)ifthegapisnotcorrect.

Page 28

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.

2.Tightenthesparkplugsto22N-m(16ft-lb).

FuelSystem Maintenance

3.Connectthewirestothesparkplugs(Figure31).

ServicingtheFuelTank

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.

DrainingtheFuelTank

1.Parkthemachineonalevelsurface,toassurefueltank drainscompletely .Thendisengagethepowertakeoff (PTO),settheparkingbrake,andturntheignitionkey tooff.Removethekey .

2.Closethefuelshut-offvalveatthefueltank(Figure32).

3.Squeezetheendsofthehoseclamptogetherandslide itupthefuellineawayfromfuellter(Figure32).

4.Pullthefuellineoffthefuellter(Figure32).Open thefuelshut-offvalveandallowthegasolinetodrain intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuellter becausethefueltankisempty.RefertoReplacingthe FuelFilter.

5.Installthefuellineontothefuellter.Slidethehose clampclosetothevalvetosecurethefuelline.

1.Fuelshut-offvalve2.Clamp

Figure32

Page 29

ServicingtheFuelFilter

g014686

1 2

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

ReplacingtheFuelFilter

Neverinstalladirtylterifitisremovedfromthefuelline.

Note:Notehowthefuellterisinstalledinordertoinstall thenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Closefuelshut-offvalveatthefueltank(

4.Squeezetheendsofthehoseclampstogetherandslide themawayfromthelter(

Figure33

1.Hoseclamp3.Filter

2.Fuelline

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampscloseto thelter.

Figure33).

Figure32).

Figure34

1.Fuelventlter2.Rightsideofmotor

7.Openfuelshut-offvalveatfueltank(Figure32).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

ServicingtheFuelVentSystem

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removetheexistingfuelventlter(

4.Installanewlter.

Figure34).

Page 30

DriveSystem Maintenance

Performthefollowinglinkageadjustmentswhenthemachine needsmaintenance.PerformthestepsAdjusttheSpeed ControlLinkagethroughAdjustingtheTracking.Ifany adjustmentsareneeded,dothemintheorderthattheyare listed.

AdjustingtheSpeedControl Linkage

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Movethespeed-controllever(locatedontheconsole) tothefullforwardposition.

4.Checktheorientationofthetabsontheendsofthe speed-controlcrank.Thesetabsshouldbepointing straightdownatthe6o'clockpositionapproximately

Figure35).

(

8.Ifneeded,adjusttheswitchlocationtocreatethe8mm (5/16inch)space(Figure36).

5.Adjustthethreadedyokeatthebottomofthespeed controllinkageuntilthetabsareatthe6o'clock position(Figure35).

Figure35

1.Speed-controlrod

2.Yoke5.Jamnut

3.Speed-controlcrank

4.Tabs,6o'clockposition

Figure36

1.Actuatingtab

2.8mm(5/16inch)space

3.Safetyswitch

AdjustingtheNeutralControl Linkages

WARNING

Enginemustberunningsothatcontrollinkage adjustmentscanbeperformed.Contactwith movingpartsorhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothing,andotherbody partsawayfromrotatingparts,themufer,and otherhotsurfaces.

WARNING

Mechanicalorhydraulicjacksmayfailtosupport machineandcauseaseriousinjury.

6.Pullthespeed-controlleverbacktoneutral.

7.Checktomakesurethatthesafetyswitchispressed andthereisa8mm(5/16inch)spacebetweenthe actuatingtabandtheswitch.(Figure36).

•Usejackstandswhensupportingmachine.

•Donotusehydraulicjacks.

1.DisengagethePTOandsettheparkingbrake.

Page 31

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Raisetherearofthemachineontojackstandstoraise thedrivewheelsofftheground.

4.Disengagetheparkingbrake.

5.Starttheengineandmovethethrottleaheadtothefull throttleposition.

6.Placetheneutrallocksinthefullforwardpositionand movethespeed-controllevertothemediumspeed position.

7.HoldOPCleversdown.

Note:TheOPCleversmustbehelddownwhenever thespeed-controlleverisoutoftheneutralpositionor theenginewillstop.

WARNING

Electricalsystemwillnotperformproper safetyshutoffwithOperatorPresenceControl (OPC)levershelddowninplace.

•MakesureOperatorPresenceControl (OPC)leversareworkingwhenadjustment iscompleted.

•NeveroperatethisunitwithOperator PresenceControl(OPC)levershelddown inplace.

8.Squeezeonedriveleveruntilanincreasedresistanceis felt.Thisiswhereneutralshouldbe.

Note:Makesureyouhavenotreachedtheendofthe neutrallockslot.Ifyouhave,shortenthecontrollever linkage.RefertoAdjustingtheControlRod.

Figure37

1.Neutralcontrollinkage3.Adjustingbolt

2.Yoke4.Nut

AdjustingtheHydroControl Linkages

WARNING

Theenginemustberunningsothatthecontrol linkageadjustmentscanbeperformed.Contact withmovingpartsorhotsurfacesmaycause personalinjury.

Keephands,feet,face,clothingandotherbody partsawayfromrotatingparts,mufer,andother hotsurfaces.

9.Ifthewheelturnswhileholdingthedriveleverin neutral,theneutralcontrollinkagesneedtobeadjusted

Figure37).Ifwheelstopsthengotostep12.

(

10.Loosenthenutagainsttheneutralcontrollinkageyoke (Figure37).

11.Adjusttheneutralcontrollinkageuntiltherespective drivewheelstopswhilethedriveleverispulledagainst theneutralspring(neutralposition)(Figure37).

12.Turntheadjustingboltapproximately1/4turn clockwiseifthewheelisturninginreverseorturnthe boltapproximately1/4turncounter-clockwiseifthe wheelisturningforward(Figure37).

13.Releasethedrivelevertotheforwarddriveposition andsqueezebackintotheneutralposition.Check toseeifthewheelstops.Ifnot,repeattheabove adjustmentprocedure.

14.Afteradjustmentsaremade,tightenthenutsagainst theyokes.

15.Repeatthisprocedurefortheoppositeside.

WARNING

Mechanicalorhydraulicjacksmayfailtosupport machineandcauseaseriousinjury.

•Usejackstandswhensupportingmachine.

•Donotusehydraulicjacks.

AdjustingtheLeftSideLinkage

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Raisetherearofthemachineontojackstandshigh enoughtoraisethedrivewheelsofftheground.

4.Disengagetheparkingbrake.

5.Starttheengineandmovethethrottleaheadtothefull throttleposition.

6.Placetheleftdriveleverinthefullforwardposition.

Page 32

7.Placethespeed-controlleverintheneutralposition.

G024291

WARNING

Electricalsystemwillnotperformproper safetyshutoffwithOperatorPresenceControl (OPC)leversheldinplace.

•MakesureOperatorPresenceControl (OPC)leversareworkingwhenadjustment iscompleted.

•NeveroperatethisunitwithOperator PresenceControl(OPC)leversheldin place.

8.Loosenthefrontadjustingnutonlefthydrocontrol linkageasshowninFigure39.

9.Turntheleftrearadjustingnutcounterclockwiseuntil thewheelrotatesforward(Figure39).

10.Turntherearadjustingnutclockwise1/4ofaturnata time.Thenmovethespeed-controlleverforwardand backtoneutral.Repeatthisuntiltheleftwheelstops rotatingforward(Figure39).

11.Turntherearnutanadditional1/2turnandtightenthe frontadjustingnut.

Note:TheOPCleversmustbehelddownwhenever thespeed-controlleverisoutoftheneutralpositionor theenginewillstop.

14.Makesurethatthespeed–controlleverisintheneutral positionandthetiredoesnotrotate.

15.Repeattheadjustmentifneeded.

Figure39

1.Hydrocontrollinkage3.Rearadjustingnut

2.Frontadjustingnut

4.Controlarm

Note:Makesurethattheatpartofthelinkageis perpendiculartothepinpartoftheswivel.

1.Hydrocontrollinkage

2.Frontnut5.90degrees

3.Rearnut

12.Afteradjustingthelefthydrocontrollinkage,move thespeed-controlleverforwardandthenbacktothe neutralposition.

Figure38

4.Swivel

13.HoldtheOPCleversdown.

Note:Ifinconsistentneutraloccurs,checktobe surethatbothspringsareproperlytightenedonthe speed-controlleverundertheconsole,especiallythe rearpivotspring.Repeattheaboveadjustmentsif necessary(Figure40).

Figure40

1.Speed-controllever

2.Rearpivotspring

3.spring

AdjustingtheRightSideLinkage

1.Placethespeed-controlleverintheneutralposition.

2.Placetherightdriveleverinthefullforwardposition.

3.Adjusttherightsidelinkagebyturningthequicktrack knobcounterclockwiseuntilthetirebeginstorotate forward(

Figure41).

Page 33

4.Turntheknobclockwise1/4ofaturnatatime.Then movethespeed-controlforwardandbacktoneutral. Repeatthisuntiltherightwheelstopsrotatingforward (Figure41).

5.HoldtheOPCleversdown.

Note:TheOPCleversmustbehelddownwhenever thespeed-controlleverisoutoftheneutralpositionor theenginewillstop.

6.Thespringthatkeepstensionontheknobshould normallynotneedadjustment.Howeverifan adjustmentisneeded,adjustthelengthofthespringto 26mm(1inch)betweenthewashers(Figure41).

7.Adjustthespringlengthbyturningthenutatthefront ofspring(Figure41).

AdjustingtheControlRod

1.Adjusttherodlengthbyreleasingthedriveleverand removingthehairpincotterpinandclevispin.Rotate therodintherodtting(Figure42).

2.Lengthenthecontrolrodifthetireisturninginreverse andshortentherodifthetireisturningforward.

3.Rotatetherodseveralturnsifthetireisrotatingfast. Then,adjusttherodin1/2turnincrements.

4.Placetheclevispinintothedrivelever(Figure42).

Figure41

1.Hydrocontrollinkage

2.Quicktrackknob4.26mm(1inch)

3.Spring

AdjustingtheControlRod

CheckingtheControlRod

1.Withtherearofthemachinestillonjackstandsandthe enginerunningatfullthrottle,movethespeed-control levertothemediumspeedposition.

Note:TheOPCleversmustbehelddownwhenever thespeed-controlleverisoutoftheneutralposition,or theenginewillstop.

Figure42

1.Controlrod5.Lefthandleshown

2.Clevispin

3.Drivelever7.Hairpincotterpin

4.OperatorPresence Controllever(OPC)

6.Neutrallock

5.Releaseandengagetheneutrallock,checkingthatthe tiredoesnotrotate(Figure43).Continuethisprocess untilthetiredoesnotrotate.

6.Installthehairpincotterpinbetweenthedrivelevers andtheneutrallocksandintotheclevispins( 42

7.Repeatthisadjustmentfortheoppositeside.

Figure

2.Movetherespectivedriveleverupwarduntilitreaches theneutralpositionandengagetheneutrallocks.

3.Ifthetirerotatesineitherdirection,thelengthofthe controlrodwillneedtobeadjusted.

Page 34

Figure43

1.Handle5.Neutralposition

2.Neutrallock6.Drivelever

3.Handle

4.Neutrallockslot

7.Fullspeedforward

8.Controlrod

AdjustingtheTracking

1.Removethemachinefromanyjackstands.

2.Checkthereartirepressure.RefertoCheckingthe TirePressure.

3.Runthemachineandobservethetrackingonalevel, smooth,hardsurfacesuchasconcreteorasphalt.

4.Ifthemachinetrackstoonesideortheother,turnthe quicktrackknob.Turntheknobrighttosteerright andturntheknoblefttosteerleft(Figure44).

Figure44

1.Quicktrackknob

AdjustingtheSpringAnchor Links

Formedium-dutyorheavy-dutydriveconditions,suchas operatingwithasulkyonsteepslopes,ahigherspringforce mayberequiredonthehydropumpcontrolarmstoprevent thedrivesystemfromstalling.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

Page 35

3.Foraheavierdrivesetting,relocatethespringanchor linkstoeitherthemediumorheavydutypositions (Figure45).Thespringanchorlinksareattachedtothe upperrearcornerofthehydrodriveshieldsontheleft andrightsidesofthemachine.

CoolingSystem Maintenance

Note:Inthemedium-dutyorheavy-dutypositions, thedriveleverforcesattheupperhandlewillalsobe increased

Figure45

1.Springanchor

2.Standardsetting

3.Mediumsetting

4.Heavy-dutysetting

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthetirepressure.

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.

3.Removetheair-intakescreen,therecoilstarter,and thefanhousing(Figure47).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installtheair-intakescreen,therecoilstarter,andthe fanhousing(Figure47).

Checkthepressureatthevalvestem(Figure46).

Maintaintheairpressureinthereartiresat83to97kPa(12 to14psi).Uneventirepressurecancauseanunevencut.

Note:Thefronttiresaresemi-pneumatictiresanddonot requireairpressuremaintenance.

Figure46

Figure47

1.Air-intakescreen4.Bolt

2.Fanhousing5.Nut

3.Recoilstarter

Page 36

BrakeMaintenance

yokecounterclockwiseoutoftheyokeouttoloosen theparkingbrake(

Figure48).

ServicingtheBrake

Beforeeachuse,checktheparkingbrakeforproperoperation.

Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnothold securely,adjustit.

CheckingtheParkingBrake

1.Movethemachineontoalevelsurface.

2.Disengagethepowertake-off(PTO)andstopthe engine.

3.Settheparkingbrake.

Note:Settingtheparkingbrakeshouldtakea reasonableamountofforce.Ifitengagestoohardor tooeasily,anadjustmentisrequired.RefertoAdjusting theParkingBrake.

AdjustingtheParkingBrake

Theparkingbrakeleverisontherightsideofthemachine (Figure45).Iftheparkingbrakedoesnotholdsecurely, adjustit.

Note:Thereshouldbeapproximately6mm(1/4inch) clearancebetweenthetireandtheatbarwiththe parkingbrakeinthereleasedposition(Figure48).

5.Securethelowerlinktothelowerbrakeleverwiththe hairpincotterandtheclevispin(Figure48).

6.Checkthebrakeoperationagain;refertoCheckingthe ParkingBrake.

1.Checktheparkingbrakebeforeyouadjustit;referto CheckingtheParkingBrake.

2.Releasetheparkingbrake;refertoReleasingthe ParkingBrake.

3.Removethespringclevispinfromthelowerbrakelink

Figure48).

(

Figure48

1.Brakelinkageyoke4.Lowerbrakelink

2.Lowerbrakelever

3.Springclevispin

5.6mm(1/4inch)

6.Hairpincotter

4.Rotatethelowerbrakelinkyokeclockwiseintothe yoketotightentheparkingbrake;rotatethebrakelink

Page 37

BeltMaintenance

10.Removethehairpincotterpinandtheclevispinfrom thebellcrank.

CheckingtheBelts

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthebelts.

Checkthebeltsforcracks,frayededges,burnmarks,wear, signsofoverheating,oranyotherdamage.Replaceany damagedbelts.

ReplacingtheMowerBelt

Important:Thebrakeneedstobeadjustedwhenthe

belttensionorthebrakelinkageisadjusted.

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Removetheknobsandthebeltcoveronthemower.

4.Removetheidlerpulleyandthewornbelt.

5.Installthenewmowerbelt.

6.Installtheidlerpulley.

11.Rotatetheclevisclockwiseontherodtoincreasethe clearance;rotateitcounterclockwisetodecreaseit (Figure49).

12.Disengagetheblade-control(PTO)lever.

Note:Iftheassistarmdoesnotcontactthefrontstop onthemowerdeck(Figure50orFigure51),adjustthe clevistobringthebellcrankclosertothetransmission outputshaft(Figure49).

7.Engagetheblade-control(PTO)leverandcheck thebelttension.RefertoAdjustingtheMowerBelt Tension.

Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(

8.Engagetheblade-control(PTO)lever.

9.Checktheclearancebetweenthebellcrankandthe transmissionoutputshaft(Figure49).

Figure49

Figure50orFigure51).

Figure50

36-inchmowerdeck

1.13mm(1/2inch)deection here

2.Assistarm5.Turnbuckle

3.Frontstop

4.Locknut

1.2to3mm(1/16to1/8inch)

2.Bellcrank

3.Transmissionoutputshaft6.Clevis

Note:Theclearanceshouldbe2to3mm(1/16to 1/8inch).

4.Hairpincotter

5.Clevispin

Page 38

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

Figure51

48-inchmowerdeck

1.13mm(1/2inch)deection here

2.Assistarm5.Turnbuckle

3.Frontstop

13.Checkthebeltguideundertheengineframeforthe properadjustment.

Note:Thedistancebetweenthebeltguideandthe mowerbeltshouldbe32mm(1-1/4inch)whenyou engagethemowerbelt.Adjustthemowerbeltas necessary.Thedisengagedbeltshouldnotdragorfall offthepulleywhentheguidesareproperlyadjusted.

4.Locknut

3.Loosenthelocknutontheturnbuckle(

4.Rotatetheturnbuckletowardtherearofthemowerto increasethetensiononthebelt.Rotatetheturnbuckle towardthefrontofthemowertodecreasethetension onthebelt(Figure52).

Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof8mm (5/16inch).

5.Engagetheblade-controllever(PTO)andcheckthe belttension.Adjustthetensionuntilitiscorrect.

Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(Figure52).

Figure52).

AdjustingtheMowerBelt Tension

AdjustingtheTensionfor36-inch MowerDecks

ServiceInterval:Aftertherst8hours—Checkthemower

belttension.

Aftertherst25hours—Checkthemowerbelt tension.

Every50hours—Checkthemowerbelttension.

Important:Thebrakeneedstobeadjustedwhenthe belttensionorthebrakelinkageisadjusted.

Important:Thebeltmustbetightenoughtonotslip duringheavyloadswhilecuttinggrass.Over-tensioning thebeltwillreducethespindlebearinglife,thebeltlife, andtheidlerpulleylife.

Thebeltmustbetightenoughsothatitdoesnotslipduring heavyloadswhilecuttinggrass,andover-tensioningwill reducebeltandspindlebearinglife.

Figure52

36-inchmowerdeck

1.Mowerbeltwith13mm (1/2inch)deection

6.Tightenthelocknutontheturnbuckle.

7.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.

2.Idlerpulley

AdjustingtheTensionfor48-inch MowerDecks

Important:Thebeltmustbetightenoughtonotslip

duringheavyloadswhilecuttinggrass.Over-tensioning thebeltwillreducethespindlebearinglife,thebeltlife andtheidlerpulleylife.

Important:Thebrakeneedstobeadjustedwhenthe belttensionorthebrakelinkageisadjusted.

Page 39

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Loosenthelocknutontheturnbuckle(Figure54).

4.Rotatetheturnbuckletowardtherearofthemowerto increasethetensiononthebelt.Rotatetheturnbuckle towardthefrontofthemowertodecreasethetension onthebelt(

Figure54).

Note:Thepropermowerbelttensionis44to67N-m (10to15ft-lb)withthebeltdeected13mm(1/2inch) halfwaybetweenthepulleys(

Figure53).

Figure54

Figure53

48-inchmowerdeck

1.Idlerpulley2.Mowerbeltwith13mm (1/2inch)deection

Note:Theeyeboltthreadsonbothendsofthe turnbuckleshouldbeengagedaminimumof8mm (5/16inch).

1.13mm(1/2inch)deection here

2.Assistarm5.Turnbuckle

3.Frontstop

4.Locknut

5.Engagetheblade-controllever(PTO)andcheckthe belttension.

6.Ifthereisnoadjustmentleftintheturnbuckleand thebeltisstillloose,therearidlerpulleyneedstobe positionedtothemiddleorfronthole(Figure55).Use theholethatwillgivethecorrectadjustment.

7.Whentheidlerpulleyismovedthebeltguidemust bemoved.Movethebeltguidetothefrontposition (Figure55).

Figure55

1.Rearidlerpulley4.Beltguideinbackposition

2.Middlehole5.Frontidlerpulley

3.Fronthole

8.Checkthebeltguideundertheengineframeforproper adjustment(Figure56).

Page 40

Note:Thedistancebetweenthebeltguideandthe mowerbeltshouldbe19mm(3/4inch)whenyou engagethemowerbelt(Figure56).Adjustthemower beltasnecessary.Thedisengagedbeltshouldnotdrag orfalloffthepulleywhentheguidesandbelttension areproperlyadjusted.

9.Checkthebladebrakeadjustment;refertoAdjusting theBladeBrake.

Figure56

1.Idlerpulleyinslot4.Beltguide

2.Tractionbelt

3.Mowerbelt6.Mowerbelt

5.19mm(3/4inch)

Figure57

1.Bellcrank4.Yoke

2.Safetyswitchlocated underenginedeck

3.Bellcrankjustclearsthe gussetwiththePTO engaged

5.Nut

6.Assistarmlink

5.Makesuretheassistarmisagainsttherearassistarm stoponthedeck(Figure58).

AdjustingthePTOEngagement Linkage

ThePTOengagementlinkageadjustmentislocatedbeneath thefrontleft-handcorneroftheenginedeck.

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Engagetheblade-controllever(PTO).

4.Adjustthelinkagelengthtowherethelowerendofthe bellcrankjustclearstheaxlesupportgusset(

Figure57).

6.Pushtheblade-controllever(PTO)downtothe disengagedposition.

7.Theassistarmshouldcontactthefrontassistarmstop onthedeck.Ifitdoesnotcontact,adjustthebellcrank sothatitisclosertothegusset(

Figure58

1.Yoke5.Assistarmlink

2.Nut6.Assistarm

3.Rearassistarmstop7.Turnbuckle

4.Frontassistarmstop

Figure58).

8.Toadjusttheassistarmlink,removethehairpincotter pinfromtheassistarm(Figure58).

Page 41

9.Loosenthenutagainsttheyoke(Figure57).

10.Removetheassistarmlinkfromtheassistarmand rotatethelinktoadjustthelength.

11.Installtheassistarmlinkintotheassistarmandsecure itwiththehairpincotterpin(Figure58).

12.Checkiftheassistarmhitsagainstthestopscorrectly.

HydraulicSystem Maintenance

ServicingtheHydraulic System

AdjustingthePTOSafetySwitch

1.Disengagetheblade-control(PTO)leverandsetthe parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Disengagetheblade-controllever(PTO).Makesure thattheassistarmisagainstthefrontassistarmstop.

4.Ifneeded,adjusttheblade-safetyswitchbyloosening theboltsholdingtheswitchbracket(Figure59).

5.Movethemountingbracketuntilthebellcrankpresses theplungerby6mm(1/4inch).

Note:Makesurethatthebellcrankdoesnottouch theswitchbody ,ordamagetotheswitchcouldoccur

Figure59).

( Tightentheswitchmountingbracket.

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every25hours

HydraulicOilType:Toro®HYPR-OIL™500hydraulic oilorMobil®115W -50

HydraulicSystemOilCapacity:2.3L(2.4USqt)

Important:Useoilspecied.Otheruidscouldcause systemdamage.

Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoiliscold. Thebafeinsidethetankhastwolevelsdependingiftheoil iswarmorcold.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoffthe engine.

3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulictank

Figure60).

(

1.Bellcrank

2.Boltsandnuts

Figure59

3.Switchmountingbracket

4.Switchbody

Figure60

1.Cap3.Colduidlevel—full

2.Bafe4.Hotuidlevel—full

5.Removethecapfromthellerneck.Lookinsideto checkifthereisuidinthereservoir(Figure60).

6.Ifthereisnouid,adduidtothereservoiruntilit reachesthecoldlevelofthebafe.

7.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmtheuid. RefertoStartingandStoppingtheEngine.

Page 42

8.Rechecktheuidlevelwhiletheuidiswarm.If required,adduidtothereservoiruntilitreachesthe hotlevelofthebafe.

Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidiswarm(Figure60).

9.Installthecaponthellerneck.

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistype ofinjury.Gangrenemayresultifthisis notdone.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesurethatallhydraulicuidhoses andlinesareingoodconditionandall hydraulicconnectionsandttingsare tightbeforeapplyingpressuretohydraulic system.

ReplacingtheHydraulicFilter

ServiceInterval:Aftertherst8hours

Every200hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

Figure61

1.Hydrauliclter

2.Gasket

6.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.

7.Installthereplacementhydrauliclterontothelter adapter.Donottighten.

8.Removetheplasticbagfromthereservoiropeningand allowtheltertollwithhydraulicuid.

9.Whenthehydrauliclterisfull,turntheoillter clockwiseuntiltherubbergasketcontactsthelter adapter,thentightenthelteranadditional1/2turn (

Figure61).

10.Cleanupanyspilleduid.

11.Ifthereisnouid,addMobil115W-50syntheticmotor oiloranequivalentsyntheticoiltoapproximately6mm (1/4inch)belowthetopofthereservoirbafe.

Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.

12.Starttheengineandletitrunforabout2minutesto purgeairfromthesystem.Stoptheengineandcheck forleaks.Ifoneorbothwheelswillnotdrive,referto BleedingHydraulicSystem.

13.Checkthelevelandadduid,ifrequired.Donot overll.

3.Adapter

Important:Donotsubstituteanautomotiveoil lter,orseverehydraulicsystemdamagemay result.

3.Removethehydraulic-reservoircapandtemporarily covertheopeningwithaplasticbagandarubberband topreventallofthehydraulicuidfromdrainingout.

4.Locatethelterundertheenginebaseandplacea drainpanunderthelter(

5.Removetheoldlterandwipethelter-adaptergasket surfaceclean(Figure61).

Figure61).

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemiftheuidischangedorafter workisperformedonthesystem.

Airmustbepurgedfromthehydraulicsystemwhenany hydrauliccomponents,includingtheoillter,areremoved oranyofthehydrauliclinesaredisconnected.Thecritical areaforpurgingairfromthehydraulicsystemisbetweenthe oilreservoirandeachchargepumplocatedonthetopof eachvariabledisplacementpump.Airinotherpartsofthe hydraulicsystemwillbepurgedthroughnormaloperation oncethechargepumpisprimed.

1.DisengagethePTOandsettheparkingbrake.

Page 43

2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstandshigh enoughtoraisethedrivewheelsofftheground.

4.Checkthehydraulicuidlevel.

5.Starttheengineandmovethethrottlecontroltothe fullthrottleposition.Movethespeed-controlleverto themiddlespeedpositionandplacethedrivelevers intothedriveposition.

Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpbycarefully rotatingthetireintheforwarddirection.

CheckingtheHydraulicHoses

ServiceInterval:Every100hours

Checkhydraulichosesforleaks,loosettings,kinkedlines, loosemountingsupports,wear,andweatherandchemical deterioration.Makenecessaryrepairsbeforeoperating.

Note:Keeptheareasaroundthehydraulicsystemclean fromgrassanddebrisbuildup.

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

Note:Itisnecessarytolightlytouchthecharge-pump capwithyourhandtocheckthepumptemperature.If thecapistoohottotouch,turnofftheengine.The pumpsmaybedamagedifthepumpbecomestoohot. Ifeitherdrivewheelstilldoesnotrotatecontinueto thenextstep.

Figure62

1.Charge-pumpcap2.Socket-headscrew

6.Thoroughlycleantheareaaroundeachofthe charge-pumphousings.

•Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafewhours byadoctorfamiliarwiththistypeofinjury. Gangrenemayresultifthisisnotdone.

•Keepbodyandhandsawayfrompin-holeleaks ornozzlesthatejecthigh-pressurehydraulic uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.

•Makesurethatallhydraulic-uidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretothehydraulicsystem.

7.Toprimethechargepump,loosenthe2hex socket-headcapscrews(Figure62)1-1/2turnsonly. Makesureengineisnotrunning.Liftchargepump housingupwardandwaitforasteadyowofoiltoow outfromunderthehousing.Tightenthecapscrews. Dothisforbothpumps.

Note:Thehydraulicreservoircanbepressurizedto upto5psitospeedthisprocess.

8.Ifeitherdrivewheelstilldoesnotrotate,stopand repeatsteps4and5ontherespectivepump.Ifthe wheelsrotateslowly ,thesystemmayprimeafter additionalrunning.Checkthehydraulicuidlevel.

9.Allowthemachinetorunforseveralminutesafterthe chargepumpsareprimedwiththedrivesysteminthe full-speedposition.

10.Checkthehydrauliccontrollinkageadjustment.Refer toAdjustingtheHydroControlLinkages.

Page 44

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-controlleverandsettheparkingbrake.Turnthe ignitionkeytotheoffposition.Removethekeyand disconnectthespark-plugwire(s)fromthesparkplug(s).

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges( arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

Figure63

1.CuttingEdge3.Wear/slotformingin

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea(Figure

63).Ifyounoticeanydamage,wear,oraslotforming inthisarea(item3.inFigure63),immediatelyinstall anewblade.

Figure63).Iftheedges

curvedarea

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforwardand backward(Figure64).

Figure64

Figure65

Page 45

2.Measurefromalevelsurfacetothecuttingedge, positionA,oftheblades(Figure66).Notethis dimension.

Figure66

1.Measurefromthecuttingedgetoalevelsurface

3.Rotatetheoppositeendsofthebladesforward.

4.Measurefromalevelsurfacetothecuttingedgeofthe bladesatthesamepositionasinstep1.Thedifference betweenthedimensionsobtainedinsteps1and2 mustnotexceed3mm(1/8inch).Ifthisdimension exceeds3mm(1/8inch),thebladeisbentandmustbe replaced.RefertoRemovingtheBladesandInstalling theBlades.

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(Figure67).

Figure67

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothendsof theblade(Figure68).Maintaintheoriginalangle.The bladeretainsitsbalanceifthesameamountofmaterial isremovedfrombothcuttingedges.

Figure68

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitonablade balancer(Figure69).Ifthebladestaysinahorizontal position,thebladeisbalancedandcanbeused.Ifthe bladeisnotbalanced,lesomemetalofftheendof thesailareaonly(Figure69).Repeatthisprocedure untilthebladeisbalanced.

Page 46

Figure69

1.Blade2.Balancer

InstallingtheBlades

1.Installthecurvedwasherandthenthebladeontothe bolt.Selectthepropernumberofspacer(s)forthe heightofcut,andslidetheboltintothespindle(Figure

67).

Important:Thecurvedpartoftheblademust pointupwardtowardtheinsideofthemowerto ensurepropercutting .

2.Installtheremainingspacer(s)andsecurethemwitha thinwasherandanut(Fig.Figure67).

3.Torquethebladeboltto101to108N-m(75to 80ft-lb).

Figure70

1.Springmountingbolts3.3mmto5mm(1/8to 3/16inch)

2.Bladebrakepad

ReplacingtheGrassDeector

AdjustingtheBladeBrake

1.DisengagethePTO,turntheignitionkeytooff,and removethekey.

2.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.

3.Ifnecessary,adjustthespringmountingboltssothat thebladebrakepadrubsagainstbothsidesofthe pulleygroove(Figure70).

4.Adjustthenutattheendofthebladebrakeroduntil thereis3mmto5mm(1/8to3/16inch)betweenthe nutandspacer(Figure70).

5.Engagetheblades.Ensurethebladebrakepadno longercontactsthepulleygroove.

WARNING

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator'sor bystander'sdirectionandresultinseriousinjuryor death.Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstall acoverplate,amulchplate,oragrasschuteand catcher.

1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure71).Remove damagedorworngrassdeector.

Page 47

g012749

Figure71

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore installingbolt

2.Placespacerandspringontograssdeector.Placethe Lendofspringbehinddeckedge.

Note:MakesuretheLendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown inFigure71.

3.Installboltandnut.PlacetheJhookendofspring aroundgrassdeector(Figure71).

Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.

Storage

CleaningandStorage

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.Checkthebrake;refertoCheckingtheParkingBrake (page36).

4.Servicetheaircleaner;refertoServicingtheAir Cleaner.

5.Greasethemachine;refertoLubrication(page24).

6.Changethecrankcaseoil;refertoServicingtheEngine Oil(page25).

7.Checkthetirepressure;refertoCheckingtheTire Pressure(page35).

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTank(page

28),orruntheengineuntilitstops.

D.Starttheengineandrunituntilitstops.Repeat

theprocess,withthechokeon,untiltheengine willnotstart.

E.Disposeoffuelproperly.Recycleitasperlocal

codes.

Note:Donotstorestabilizer/conditioned gasolineover90days.

9.Removethesparkplug(s)andcheckthecondition; refertoServicingtheSparkPlug.Withthespark plug(s)removedfromtheengine,pour2tablespoons ofengineoilintothespark-plughole.Nowusethe startertocranktheengineanddistributetheoilinside thecylinder.Installthesparkplug(s).Donotinstallthe wireonthesparkplug(s).

10.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamagedorworn.

11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

12.Storethemachineinaclean,drygarageorstoragearea. Removethekeyfromtheignitionswitchandkeepit

Page 48

inamemorableplace.Coverthemachinetoprotect itandkeepitclean.

Page 49

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.

Page 50

Problem

PossibleCauseCorrectiveAction

Thebladesdonotrotate.

1.Themowerdeckbeltiswornorloose.

2.Themowerdeckbeltisbroken.2.Installanewdeckbelt.

3.Themowerdeckbeltisoffpulley.3.Inspectthebeltandreplaceitifitis

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Checkthebelttension.

damaged.Checkthepulleysandidlers andadjustthebelttension.

Page 51

Schematics

ElectricalSchematic(Rev .-)

HydraulicSchematic(Rev .-)

Page 52

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment(LCE)

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuanttoan agreementbetweenthem,jointlypromisetotheoriginalpurchasertorepairtheToro Productslistedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

•Engines

Mid-SizeWalk-BehindMowers

•Engines

GrandStand

•Engines

•Frame

ZMaster

•Engines

2000SeriesMowers

•Frame

ZMaster

•Engines

•Frame

ZMaster

•Engines

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

•Frame

ZMaster

•Engines

7000SeriesMowers

•Frame

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

2years

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforparts andlabor .Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor corrosionarenotcovered.

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer .

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

Toro 30934, 30938, 39934, 39938 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SafeOperatingPractices

ToroMowerSafety

AddingFuel

Attachments/Accessories

CheckingtheEngine-oilLevel

ThinkSafetyFirst

OperatingtheParkingBrake

StartingandStoppingthe Engine

OperatingtheNeutralLocks

DrivingtheMachineForward andBackward

BringingtheMachineto NeutralPosition

StoppingtheMachine

PushingtheMachinebyHand

TransportingMachines

AdjustingtheHeight-of-Cut

AdjustingtheCasterPosition

AdjustingtheHandleHeight

Height-of-cutChart

LubricatingtheMachine

LubricatingtheCasterand WheelBearings

GreasingtheMowerBeltIdler

ServicingtheAirCleaner

ServicingtheEngineOil

ServicingtheSparkPlugs

ServicingtheFuelTank

ServicingtheFuelFilter

ServicingtheFuelVentSystem

AdjustingtheSpeedControl Linkage

AdjustingtheNeutralControl Linkages

AdjustingtheHydroControl Linkages

AdjustingtheControlRod

AdjustingtheTracking

AdjustingtheSpringAnchor Links

CheckingtheTirePressure

CleaningtheAir-intakeScreen

CleaningtheCoolingSystem

ServicingtheBrake

CheckingtheBelts

ReplacingtheMowerBelt

AdjustingtheMowerBelt Tension

ServicingtheHydraulic System

MowerDeck Maintenance

ServicingtheCuttingBlades

AdjustingtheBladeBrake

CleaningandStorage