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39484
Operator's Manual
60 pgs3.6 Mb0

Toro 30486, 30489, 39484 Operator's Manual

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Page 1
FormNo.3367-266RevA
CommercialWalk-BehindMower
FloatingDeck,SplitLever,HydroDrivewith 36in,40in,48inor52inTURBOFORCE CuttingUnit
ModelNo.30484—SerialNo.311000001andUp
®
ModelNo.30486—SerialNo.311000001andUp
ModelNo.30488—SerialNo.311000001andUp
ModelNo.30489—SerialNo.311000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.
Figure1
1.Modelandserialnumberlocation
Theenclosed
Engine Owner’ s Man ual
issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
Introduction
Thisrotary-blade,lawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional, hiredoperators.Itisdesignedprimarilyforcutting grassonwell-maintainedlawnsonresidential orcommercialproperties.Itisnotdesignedfor cuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready .
Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
©2010—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroMowerSafety...............................................5
SlopeIndicator.....................................................7
SafetyandInstructionalDecals.............................8
ProductOverview......................................................11
Controls.............................................................11
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
Specications.....................................................12
Operation...................................................................13
AddingFuel.......................................................13
CheckingtheEngineOilLevel............................14
ThinkSafetyFirst...............................................14
OperatingtheParkingBrake...............................14
StartingandStoppingtheEngine........................14
OperatingtheMowerBladeControl
(PTO)............................................................15
TheSafetyInterlockSystem................................16
DrivingForwardorBackward.............................16
StoppingtheMachine.........................................17
PushingtheMachinebyHand.............................17
TransportingMachines.......................................18
SideDischargingorMulchingtheGrass..............18
AdjustingtheHeight-of-Cut...............................18
AdjustingtheAnti-ScalpRollers.........................19
AdjustingtheFlowBafe...................................20
PositioningtheFlowBafe.................................20
UsingtheMid-SizeWeight..................................22
Maintenance...............................................................23
RecommendedMaintenanceSchedule(s)................23
Lubrication.............................................................24
HowtoGrease...................................................24
LubricatingtheBearings.....................................24
GreasingthePTODriveBeltIdlerandMower
DeckBeltIdler...............................................24
EngineMaintenance...............................................25
ServicingtheAirCleaner....................................25
ServicingtheEngineOil.....................................26
ServicingtheSparkPlugs....................................27
FuelSystemMaintenance.......................................28
DrainingtheFuelTank.......................................28
ServicingtheFuelFilter......................................29
ServicingtheFuelV entSystem...........................29
ElectricalSystemMaintenance................................30
ServicingtheBattery...........................................30
ServicingtheFuses.............................................32
DriveSystemMaintenance.....................................33
AdjustingtheTracking.......................................33
CheckingtheTirePressure.................................33
ReplacingtheCasterWheelFork
Bushings........................................................34
ServicingtheCasterWheelandBearings.............35
AdjustingtheElectricClutch..............................35
CoolingSystemMaintenance..................................36
CleaningtheAirIntakeScreen............................36
BrakeMaintenance.................................................36
ServicingtheBrake.............................................36
BeltMaintenance....................................................37
ReplacingtheMowerBelt...................................37
ReplacingthePTODriveBelt.............................38
AdjustingthePTODriveBeltIdlerSpring
Anchor...........................................................39
ReplacingthePumpDriveBelt...........................39
ControlsSystemMaintenance.................................40
AdjustingtheMotionControlHandle
Positions........................................................40
HydraulicSystemMaintenance...............................42
ServicingtheHydraulicSystem...........................42
MowerDeckMaintenance......................................45
ServicingtheCuttingBlades...............................45
CorrectingtheMowerQualityofCut..................47
FrameSetUp.....................................................48
CheckingtheMowerDeckFront-to-Rear
Pitch...............................................................49
ChangingtheMowerDeckFront-to-Rear
Pitch...............................................................50
CheckingtheMowerDeckSide-to-Side
Height............................................................50
ChangingtheMowerDeckSide-to-Side
Height............................................................51
MatchingHeightofCut......................................51
ReplacingtheGrassDeector.............................52
Cleaning.................................................................52
CleaningUndertheMower.................................52
WasteDisposal...................................................52
Storage.......................................................................53
CleaningandStorage..........................................53
Troubleshooting.........................................................54
Schematics.................................................................56
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Safety
Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol,whichmeans CAUTION,WARNING,orDANGER-“personalsafety instruction."Failuretocomplywiththeinstructionmay resultinpersonalinjuryordeath.
–Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling. Donotsmoke.
–Neverrefuelordrainthemachineindoors.
•Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
SafeOperatingPractices
ThefollowinginstructionsarefromANSIstandard B71.4-2004.
Training
•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner’sresponsibilitytoexplain thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Onlystartengine fromtheoperator’sposition.
•Besureofyourfootingwhileusingthismachine, especiallywhenbackingup.Walk,don’trun.Never operateonwetgrass.Reducedfootingcouldcause slipping.
•Slowdownanduseextracareonhillsides.Besure totravelsidetosideonhillsides.Turfconditions canaffectthemachine’ sstability.Usecautionwhile operatingneardrop-offs.
•Slowdownandusecautionwhenmakingturnsand whenchangingdirectionsonslopes.
•Neverraisedeckwiththebladesrunning.
•NeveroperatewiththePTOshield,orotherguards notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly .
Preparation
•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.
•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.
–Useonlyanapprovedcontainer
•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.
•Donotchangetheenginegovernorsettingor overspeedtheengine.
•Stoponlevelground,disengagedrives,engage parkingbrake,shutoffenginebeforeleavingthe operator’spositionforanyreasonincludingemptying thecatchersoruncloggingthechute.
•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunit.
•Lookbehindanddownbeforebackinguptobesure ofaclearpath.
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•Keeppetsandbystandersaway.
•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesifnot mowing.
•Beawareofthemowerdischargedirectionanddo notpointitatanyone.
•Donotoperatethemowerundertheinuenceof alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine intoorfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
Maintenanceandstorage
•Disengagedrives,setparkingbrake,stopengineand removekeyordisconnectsparkplugwire.Waitfor allmovementtostopbeforeadjusting,cleaningor repairing.
•Cleangrassanddebrisfromcuttingunit,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear ame.
•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.
•Parkmachineonlevelground.Setparkingbrake. Neverallowuntrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen required.
•Carefullyreleasepressurefromcomponentswith storedenergy.
•Disconnectthebatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthenegative terminalrstandthepositivelast.Reconnectthe positiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.
•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
GeneralOperation
•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.
•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.
•UseonlyToroapprovedattachments.W arrantymay bevoidedifusedwithunapprovedattachments.
•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)before operatingunderanyobjectsanddonotcontact them.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.
•Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.
•Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.
•Usecautionneardrop-offs,ditches,orembankments. Themachinecouldsuddenlyturnoverifawheel goesovertheedgeofaclifforditch,orifanedge cavesin.
•Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.
•Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.
•Mowslopessidetoside.
•Donotmowslopesgreaterthan20degrees.
Service
•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.
•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.
•Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.
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•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.
•Checkbrakeoperationfrequently.Adjustandservice asrequired.
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SlopeIndicator
G011841
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
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SafetyandInstructional Decals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
98-5954
43-8480
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard
2.Nore,opename,or smoking.
66-1340
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator’s
Manual.
6.Keepbystandersasafe distancefromthebattery.
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries
8.Batteryacidcancause blindnessorsevereburns.
withwaterandgetmedical helpfast.
10.Containslead;donot discard.
68-8340
104-8185
36inmowerdecks
98-0776
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104-8186
40inandlargermowerdecks
104-8569
Manufacturer’sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
110-2067
110-2068
105-7798
1.ReadtheOperator’sManual.
106-0635
112-8720
106-0699
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115-4212
1.Hydraulicoillevel3.Warning—donottouch thehotsurface.
2.ReadtheOperator’s
Manual.
1.Interval
2.PowerT ake-off(PTO)
3.Parkingbrake
4.Neutral
5.Operatorpresenceswitch
6.Battery
115-4186
115–4179
1.Movethemotioncontrollevertotheneutralposition,thenpull
outonPTO(PowerTakeOff)switchtoengagetheblades.
2.PushinonthePTO(PowerT akeOff)todisengagetheblades.7.Thrownobjecthazard—keepbystandersasafedistancefrom
3.Warning—readtheOperator’sManual.8.Thrownobjecthazard—keepdeectorinplace.
4.Warning—donotoperatethismachineunlessyouaretrained.
5.Warning—stoptheengineandremovethesparkplugwire
beforeperforminganymaintenanceonthemachine.
6.Warning—stoptheenginebeforeleavingthemachine.
themachine.
9.Cutting,dismembermenthazardofhandorfoot—stayaway frommovingparts;keepallguardsandshieldsinplace.
1.Fast2.Enginespeed
115–4189
3.Slow4.Choke
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1.Tractioncontrol
1
2
3
4
5
6
7
2.Fast4.Neutral
ProductOverview
Figure4
1.Sidedischargechute
2.Engine6.Mowerdeck
3.Gastank
4.Controls
5.Parkingbrake
7.Frontcasterwheel
114-3424
3.Slow
1.Ignitionswitch
2.Leftmotioncontrollever7.Neutrallockpositionfor
3.Throttlecontrol8.Rightmotioncontrollever
4.Hourmeter
5.Fueltank
5.Reverse
6.DisengagethePTO(PowerTakeOff)
Figure5
6.Choke
rightmotioncontrollever
9.bladecontrolswitch(PTO)
10.Operatormanualtube
HourMeter
Controls
Becomefamiliarwithallthecontrols(Figure5)before youstarttheengineandoperatethemachine.
Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance
Figure6).
(
SafetyInterlockIndicators
Therearesymbolsonthehourmeterandindicatewith ablacktrianglethattheinterlockcomponentisinthe correctposition(Figure6).
BatteryIndicatorLight
WhentheignitionkeyisinitiallyturnedtotheOn position,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(
Figure6).
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Figure6
1.Safetyinterlocksymbols
2.Batterylight
3.Hourmeter
ThrottleControl
Thethrottlecontrolhastwopositions:FastandSlow.
enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
36inchmowers:
Widthwithdeectordown51–1/8inches(130cm)
Length
Height
Weight
78–1/2inches(199cm)
46inches(117cm)
667lb(303kg)
Choke
Usethechoketostartacoldengine.
BladeControlSwitch(PTO)
Thebladecontrolswitch(PTO)isusedtoengage theelectricclutchtodrivethemowerbladeswiththe rightsidemotioncontrolleverinthecenter,un-locked position.Pulltheswitchuptoengagethebladesand release.Todisengagetheblades,pushthebladecontrol switch(PTO)downormoveorreleasetherightside motioncontrolleverintotheneutrallockposition.
IgnitionSwitch
Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.
MotionControlLevers
Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.
40inchmowers:
Widthwithdeectordown55–1/2inches(141cm)
Length
Height
Weight
75–3/8inches(192cm)
46inches(117cm)
667lb(303kg)
48inchmowers:
Widthwithdeectordown63–1/2inches(161cm)
Length
Height
Weight
77–3/4inches(198cm)
46inches(117cm)
682lb(309kg)
52inchmowers:
Widthwithdeectordown67–5/8inches(171.7cm)
Length
Height
Weight
77–3/4inches(198cm)
46inches(117cm)
721lb(327kg)
NeutralLockPosition
Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageanddisengagethemowerbladesand todetermineneutralposition.
FuelShut-offValve
Closethefuelshut-offvalve(underthefueltank)when transportingorstoringthemower.
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto
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Operation
AddingFuel
UseUnleadedRegularGasolinesuitablefor automotiveuse(85pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.
Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontainingmore than10%ethanolbecausethefuelsystemcouldbe damaged.Donotmixoilwithgasoline.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.
•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.
•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.
•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditioneropening .
•Keepgasawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting
Important:Donotusefueladditives containingmethanolorethanol.
Addthecorrectamountofgas stabilizer/conditionertothegas.
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Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasoline.To minimizethechanceofvarnishdepositsinthefuel system,usefuelstabilizeratalltimes.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileit isunattended.
FillingtheFuelT ank
1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundfueltankcapandremovethecap. Addunleadedregulargasolinetofueltank,untilthe levelis1/4to1/2inch(6to13mm)belowthe bottomofthellerneck.Thisspaceinthetank allowsgasolinetoexpand.Donotllthefueltank completelyfull.
3.Installfueltankcapsecurely.Wipeupanygasoline thatmayhavespilled.
CheckingtheEngineOilLevel
Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelinEngineMaintenance.
Note:Determinetheleftandrightsidesofthe machinefromthenormaloperatingposition.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
SettingtheParkingBrake
Pulltheparkingbrakeleverrearward(Figure7).
ThinkSafetyFirst
Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator’searandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
OperatingtheParkingBrake
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse,check theparkingbrakeforproperoperation.
Iftheparkingbrakedoesnotholdsecurely,adjustit. RefertoServicingtheParkingBrake.
Figure7
1.Parkingbrakelever(inthe releasedposition)
2.Parkingbrakelever(inthe engagedposition)
ReleasingtheParkingBrake
Pushtheparkingbrakeleverforward.
StartingandStoppingthe Engine
StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
3.Settheparkingbrake.
4.Movethethrottlecontroltofastandmovethe chokelevertotheonpositionbeforestartingacold engine(Figure8).
Note:Awarmorhotenginemaynotrequire choking.Tostartawarmengine,movethrottle controlmidwaybetweenthefastandslow positions.
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Figure8
1.Ignitionswitch
2.Throttlelever
3.Choke
5.Turntheignitionkeytothestartpositionto energizethestarter.Whentheenginestarts,release thekey .
Note:Donotengagethestarterformorethan 5secondsatatime.Iftheenginefailstostart, allowfora15secondcool-downperiodbetween attempts.Failuretofollowtheseinstructionscan burnoutthestartermotor.
OperatingtheMowerBlade Control(PTO)
Thebladecontrolswitch(PTO)isusedinconjunction withtherightsidemotioncontrollevertoengageand disengagethemowerblades.
EngagingtheMowerBlades(PTO)
1.Toengagethemowerblades,movetherightside motioncontrollevertothecenter,un-locked position(Figure9).
2.Pullthebladecontrolswitch(PTO)upandrelease itwhileholdingdowntherightsidemotioncontrol leverinthecenter,un-lockedposition.
6.Whenenginestarts,movethethrottlecontrol betweenthefastandslowpositionandmovethe chokelevertotheoffposition.Allowtheengine towarmupandthenmovethethrottlecontrolto thefastposition.
StoppingtheEngine
1.Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.
2.Movethethrottlelevertoslow(Figure8).
3.Iftheenginehasbeenworkinghardorishot,let theengineidlefor30to60secondsbeforeturning theengineoff.
4.Tostoptheengine,turntheignitionkeytooff.
Important:Makesurefuelshutoffvalve isclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.Before storingthemachine,pullwireoffsparkplug(s) topreventpossibilityofaccidentalstarting.
Figure9
1.Bladecontrolswitch(PTO)
2.Rightsidemotioncontrol leverpusheddownintothe center,un-lockedposition
3.Rightmotioncontrollever inneutrallockposition
4.Leftmotioncontrollever
DisengagingtheMowerBlades(PTO)
Thefollowingaretwooptionsfordisengagingthe mowerblades.
•Pushthebladecontrolswitch(PTO)downtothe offposition.
•Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.
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TheSafetyInterlockSystem
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
UnderstandingtheSafetyInterlock System
Thesafetyinterlocksystemisdesignedtopreventthe mowerbladesfromrotatingunless:
•Therightsidemotioncontrolleverismovedtothe center,un-lockedposition.
•Thebladecontrolswitch(PTO)ispulledon.
Thesafetyinterlocksystemisdesignedtostopthe mowerbladesifyoumoveorreleasetherightside motioncontrolleverintotheneutrallockposition.
Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglewilllightupinthecorrespondingsquare.
2.Settheparkingbrake.
3.Movetherightsidemotioncontrollevertothe center,un-lockedposition.Thebladesshould
notrotate.
4.Movethemotioncontrolleversforward.The engineshouldkill.
5.Starttheengineandreleasetheparkingbrake.
6.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
7.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.
8.Moveorreleasetherightsidemotioncontrollever intotheneutrallockposition.Thebladesshould
stoprotating.
9.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
10.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.
11.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.
12.Withtheenginerunning,pullupthebladecontrol switch(PTO)andreleasewithoutholdingright sidemotioncontrollevertothecenter,un-locked position.Thebladesshouldnotrotate.
Figure10
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
TestingtheSafetyInterlockSystem
ServiceInterval:Beforeeachuseordaily
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.
Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately .
1.Starttheengine;refertoStartingandStoppingthe Enginein
Operation(page13).
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
CAUTION
Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemakingsharp turns.
DrivingForward
1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation(page13).
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Page 17
2.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
theneutrallockposition,disengagethepowertakeoff (PTO),andturntheignitionkeytooff.
3.Togoforward,slowlypushthemotioncontrol leversforward(Figure11).
Note:Theenginewillkillifthetractioncontrol leversaremovedwiththeparkingbrakeengaged.
Togostraight,applyequalpressuretobothmotion controllevers(
Toturn,movethemotioncontrollevertoward neutralinthedirectionyouwanttoturn(Figure11).
Thefartheryoumovethetractioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.
Tostop,pullthemotioncontrolleversbacktothe neutralposition.
Figure11).
Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakein Remembertoremovethekeyfromtheignitionswitch.
Operation(page13).
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
PushingtheMachinebyHand
Theby-passvalvesallowthemachinetobepushedby handwithouttheenginerunning.
Important:Alwayspushthemachinebyhand. Nevertowthemachinebecausehydraulicdamage mayoccur.
Figure11
1.Forward2.Backward
DrivingBackward
1.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure11).
Togostraight,applyequalpressuretobothmotion controllevers(Figure11).
Toturn,releasepressureonthemotioncontrollever towardthedirectionyouwanttoturn(Figure11).
ToPushtheMachine
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
2.Opentheby-passvalveonbothpumpsbyturning themcounterclockwise1to2turns.Thisallows hydraulicuidtoby-passthepumpsandthewheels toturn(
Note:Rotatetheby-passvalvesamaximumof2 turnssothevalvedoesnotcomeoutofthebody causinguidtorunout.
Figure12).
Tostop,pushthemotioncontrolleverstothe neutralposition.
StoppingtheMachine
Tostopthemachine,movethemotioncontrolleversto neutral,movetherightsidemotioncontrolleverinto
17
Page 18
1.Pumpby-passvalve
Figure13
1.Tractionunittiedownloop
Figure12
SideDischargingorMulching
3.Releasetheparkingbrake.
4.Pushthemachinetothedesiredlocation.
5.Settheparkingbrake.
6.Closetheby-passvalves,butdonotovertighten them.
Important:Donotstartoroperatethe machinewiththeby-passvalvesopen.Damage tosystemmayoccur.
TransportingMachines
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby law .Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.
Totransportthemachine:
1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
2.Ifapplicable,connectthetrailerbrakes.
theGrass
Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
DANGER
Withoutthegrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.
•Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
•Neverputyourhandsorfeetunderthemower.
•Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthepower takeoff(PTO)isoff.Rotatetheignitionkeyto Off.Alsoremovethekeyandpullthewire(s) offthesparkplug(s).
3.Loadthemachineontothetrailerortruck.
4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.
5.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(
6.Fastenthefrontofthemachinetothetraileror truckwithstraps,chains,cable,orropes.
Figure13).
AdjustingtheHeight-of-Cut
Theheight-of-cutcanbeadjustedfrom1to4-1/2 inch(25to114mm)in1/4inch(6mm)increments. Adjustmentisdonebyrelocatingfourhairpincotter pinsindifferentholelocationandbyaddingor removingspacers.
Note:Allheight-of-cutpinsneedatleastonespacer ordamagecanoccurtobushingifnoneareused.
Note:Allheight-of-cutpinscanusetwospacers maximum.
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1.Selectholeinheight-of-cutpostandnumberof spacerscorrespondingtotheheight-of-cutdesired (Figure14).
2.Usingthelifthandle,raisesideofdeckandremove hairpincotter(
Figure14).
3.Addorremovespacersifneededandthenalign holesandinserthairpincotter(Figure14).
(10mm)clearanceabovetheground(Figure15, Figure16,Figure17).
2.Ifadjustmentisneeded,removethebolt,washers andnut(
Figure15,Figure16,Figure17).
3.Selectaholepositionsotheanti-scalprollersare aminimumof3/8inch(10mm)offtheground (Figure15,Figure16,Figure17).
Note:Spareheight-of-cutspacersmaybestored onpostsandretainedbyahairpincotter.
Important:Allfourhairpincotterpinsmustbe inthesameholelocationandwiththecorrect numberofspacersforalevelcut.
4.Installtheboltandnut(Figure15,Figure16, Figure17).
Figure15
40inch,48inch,and52inchMowerDecks
1.Mowerdeck
2.Bolt5.Nut
3.Spacer
4.Anti-ScalpRollers
Figure14
1.CarrierFrame4.Spacers
2.HairpinCotter5.Frontheight-of-cutpost
3.Backheight-of-cutpost
AdjustingtheAnti-Scalp Rollers
Theanti-scalprollersneedtobeadjustedintheproper holelocationforeachheight-of-cutposition.There needstobe3/8inch(10mm)minimumclearance abovetheground.
Note:Iftheanti-scalprollersareadjustedtoolowit cancauseexcesswearoftherollers.
1.Afteradjustingheight-of-cut,checktheanti-scalp rollerssothatthereisaminimumof3/8inch
19
Page 20
Figure16
40inch,48inch,and52inchMowerDecks
1.Mowerdeck4.Bushing
2.Bolt
3.Spacer
5.Anti-ScalpRollers
6.Nut
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthecamlock,swingtheleveruptoloosen thecamlock(
Figure18).
4.Adjustthebafeandcamlockintheslottothe desireddischargeow .
5.Swingtheleverbackovertotightenthebafeand camlock(
Figure18).
6.Ifthecamdoesnotlockthebafeintoplaceoritis tootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilthedesiredlocking pressureisachieved.
Figure17
36inchMowerDeck
1.Mowerdeck
2.Bolt5.Nut
3.Spacer
4.Anti-ScalpRollers
5.Incertainmowingconditionsandterrain,a mismatchofcuttingheightmaybeseen.Adjusting theoutsideanti-scalprollerstotheminimumsetting of3/8inch(10mm)willhelppreventthemower deckcuttingtoolowontheoutsideandminimize themismatch.
AdjustingtheFlowBafe
Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlockand bafetogivethebestqualityofcut.
Figure18
1.Camlock
2.Lever
3.Rotatecamtoincreaseor decreaselockingpressure
4.Slot
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition(seeFigure19).The suggesteduseforthispositionisafollows.
•Useforshort,lightgrassmowingconditions.
•Useindryconditions.
•Forsmallergrassclippings.
•Propelsgrassclippingsfartherawayfromthe mower.
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Page 21
Figure19
PositionB
Usethispositionwhenbagging(Figure20).
Figure21
Figure20
PositionC
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure21).
•Useintall,densegrassmowingconditions.
•Useinwetconditions.
•Lowerstheenginepowerconsumption.
•Allowsincreasedgroundspeedinheavyconditions.
•ThispositionissimilartothebenetsoftheToro SFSmower.
21
Page 22
UsingtheMid-SizeWeight
Weightsareinstalledoncertainmowerstoimprove balanceandimproveperformance.Theweightscanbe movedorremovedtocreateoptimizedperformance underdifferentmowingconditionsandforoperator preference(Figure22orFigure23).
Thefollowingtableindicatesthepositionoftheweight asinstalledatthefactory.
MowerDeckSizeNumberofweights
36inches1Front
40inches1Front
48inches
52inches1Rear
install
nonenone
•Anyrearweightmustberemovedwhena Tru–Track
•WhenaTru–Track
®
Sulkyisinstalled.
®
Sulkyisinstalledfrontweights areneeded.ContactanAuthorizedServiceDealer forthecorrectquantityofweightsandplacement.
Positionofthe
weight
Figure23
Installingtherearweight.
1.Nut3.Washer
2.Weight4.Bolt
WARNING
Thefrontendofthemachinecanrapidlyriseup whenthemowerisremoved.Thiscouldcause seriousinjurytoyouorbystanders.
Supporttherearofthemachinewhenremoving themowerfromthecarrierframe.
Figure22
Installingthefrontweight.
1.Bolt3.Weight
2.Washer4.Nut
22
Page 23
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Beforeeachuseordaily
Every25hours
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthehydraulicuidlevel.
•Changethehydrauliclter.
•Checkthesafetyinterlocksystem.
•Greasethefrontcasterpivotbearing.
•Checktheengineoillevel.
•Cleantheairintakescreen.
•Checkthebrakes.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanfoamaircleanerelement.
•Checkthebatteryelectrolytelevel.
•Checkthehydraulicuidlevel.
•Greasethesidebearings.
•GreasethePTObeltidler.
•Greasethemowerdeckbeltidler.
•Checkthepaperaircleanerelement.
•Checkthetirepressure.
•Checkthemowerbelt.
•CheckthePTOdrivebelt.
•Checkthepumpdrivebelt.
•Changetheengineoil.
•Checkthesparkplugs.
•Adjusttheelectricclutch.
•Checkthehydrauliclines.
•Replacethepaperaircleanerelement.
Every200hours
Every250hours
Every400hours
Every500hours
Beforestorage
Important:Refertoyour
•Changetheoillter.
•Replacethefuellter.
•Replacethefuelventlter.
•ChangethehydrauliclterandhydraulicoilwhenusingMobil®1oil.
•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).
•ChangethehydrauliclterandhydraulicoilwhenusingT oro®HYPR-OIL™500 hydraulicoil.
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
Engine Operator’ s Man ual
foradditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.
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Page 24
Lubrication
GreasingthePTODriveBelt
GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.
HowtoGrease
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.
5.Wipeupanyexcessgrease.
LubricatingtheBearings
ServiceInterval:Beforeeachuseordaily
IdlerandMowerDeckBelt Idler
ServiceInterval:Every50hours
Every50hours
Greasetheidlerpulleypivots(Figure25orFigure26).
Note:Youwillhavetoremovethecarriercoversto accessthegreasettingforthemowerdeck.
Every400hours
Every50hours
Lubricatethefrontcasterwheelbearingsandfront pivots(Figure24).
Note:Makesuretherearwheelgreasecapsare removedbeforelubricatingrearwheels.
Figure25
40inch,48inch,and52inchMowerDeckshown
Figure24
Figure26
36inchMowerDeckshown
24
Page 25
EngineMaintenance
ServicingtheAirCleaner
ServiceInterval/Specication
ServiceInterval:Every25hours—Cleanfoamair
cleanerelement.
Every50hours—Checkthepaperair cleanerelement.
Every200hours—Replacethepaper aircleanerelement.
Note:Servicetheaircleanermorefrequently(every fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy .
Important:Donotoilthefoamorpaperelement.
RemovingtheFoamandPaper Elements
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage
Figure27).
(
4.Unscrewthecoverknobsandremovetheaircleaner cover(
5.Unscrewthehoseclampandremovetheaircleaner assembly(Figure27).
6.Carefullypullthefoamelementoffthepaper element(Figure27).
Figure27).
Figure27
1.Cover
2.Hoseclamp4.Foamelement
3.Paperelement
CleaningtheFoamAirCleanerElement
1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifitis tornorworn.
ServicingthePaperAirCleaner Element
1.Donotcleanthepaperlter,replaceit(Figure27).
2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaperElements
Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.
1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure27).
2.Placetheaircleanerassemblyontotheaircleaner baseandsecureitwiththe2wingnuts(Figure27).
3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure27).
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Page 26
ServicingtheEngineOil
ServiceInterval/Specication
ServiceInterval:Beforeeachuseordaily—Checkthe
engineoillevel.
Aftertherst8hours—Changethe engineoil.
Every100hours—Changetheengine oil.
Every200hours—Changetheoil lter.
Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.
OilType:Detergentoil(APIserviceSF ,SG,SH,SJ orSL)
CrankcaseCapacity:58ounces(1.7liter)withthelter removed;51ounces(1.5liter)withoutthelterremoved
Figure29
1.Oildipstick
2.Fillertube
5.Unscrewtheoildipstickandwipetheendclean (Figure29).
6.Slidetheoildipstickfullyintothellertube,butdo notthreadontotube(Figure29).
7.Pullthedipstickoutandlookattheend.Iftheoil levelislow ,slowlypouronlyenoughoilintotheller tubetoraisetheleveltotheFullmark.
Viscosity:Refertothetable(
Figure28
Figure28).
CheckingtheEngineOilLevel
1.Parkthemachineonalevelsurface.
2.DisengagethePTOandsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Cleanaroundtheoildipstick( cannotfallintothellerholeanddamagetheengine.
Figure29)sothatdirt
Important:Donotoverllthecrankcasewith oilandruntheengine;enginedamagecan result.
ChangingtheEngineOil
1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.
3.DisengagethePTOandsettheparkingbrake.
4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
5.Slidethedrainhoseovertheoildrainvalve.
6.Placeapanbelowthedrainhose.Rotateoildrain valvetoallowoiltodrain(
7.Whenoilhasdrainedcompletely,closethedrain valve.
8.Removethedrainhose(Figure30).
Note:Disposeoftheusedoilatarecyclingcenter.
Figure30).
26
Page 27
Figure30
1
1.Oildrainvalve2.Oildrainhose
9.Slowlypourapproximately80%ofthespeciedoil intothellertube(Figure29).
10.Checktheoillevel;refertoCheckingtheEngineOil Level.
11.SlowlyaddtheadditionaloiltobringittotheFull mark.
ChangingtheOilFilter
Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.
4.Installthereplacementoilltertothelteradapter, turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional3/4turn(
Figure31).
5.Fillthecrankcasewiththepropertypeofnewoil; refertoServicingtheEngineOil.
6.Runtheengineforabout3minutes,stoptheengine, andcheckforoilleaksaroundtheoillteranddrain valve.
7.Checktheengineoillevelandaddoilifneeded.
8.Wipeupanyspilledoil.
ServicingtheSparkPlugs
ServiceInterval:Every100hours
Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstallingthe sparkplugsandagappingtool/feelergaugetocheckand adjusttheairgap.Installanewsparkplugsifnecessary.
Type:Champion®RCJ8YorequivalentAirGap:
0.030inch(0.75mm)
RemovingtheSparkPlugs
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Disconnectthewiresfromthesparkplugs (Figure32).
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Removetheoldlter(
1.Oillter
Figure31).
Figure31
2.Adapter
3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure31).
Figure32
1.Spark-plugwire/sparkplug
4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausing damage.
5.Removethesparkplugsandthemetalwashers.
27
Page 28
CheckingtheSparkPlugs
1.Lookatthecenterofthesparkplugs(Figure33). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.
2.Ifneeded,cleanthesparkplugwithawirebrushto removecarbondeposits.
Figure33
1.Centerelectrodeinsulator3.Airgap(nottoscale)
2.Sideelectrode
Important:Alwaysreplacethesparkplugs whenithaswornelectrodes,anoilylmonit, orhascracksintheporcelain.
3.Checkthegapbetweenthecenterandsideelectrodes
Figure33).Bendthesideelectrode(Figure33)if
( thegapisnotcorrect.
InstallingtheSparkPlugs
1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.
2.Tightenthesparkplugsto16ft-lb(22N-m).
3.Connectthewirestothesparkplugs(
Figure33).
FuelSystem Maintenance
DrainingtheFuelTank
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.
•Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.
1.Parkthemachineonalevelsurface,toassurefuel tankdrainscompletely.Thendisengagethepower takeoff(PTO),settheparkingbrake,andturnthe ignitionkeytooff.Removethekey.
2.Closethefuelshut-offvalveatthefueltank
Figure34).
(
3.Squeezetheendsofthehoseclamptogether andslideitupthefuellineawayfromfuellter
Figure34).
(
4.Pullthefuellineoffthefuellter(Figure34).Open thefuelshut-offvalveandallowthegasolinetodrain intoagascanordrainpan.
Note:Nowisthebesttimetoinstallanewfuellter becausethefueltankisempty.RefertoReplacing theFuelFilter.
5.Installthefuellineontothefuellter.Slidethehose clampclosetothevalvetosecurethefuelline.
6.Wipeupanyspilledfuel.
28
Page 29
Figure34
1.Fuellter3.Fuelshut-offvalve
2.Clamp
Figure35
1.Hoseclamp3.Filter
2.Fuelline
ServicingtheFuelFilter
ServiceInterval:Every200hours/Yearly(whichever
comesrst)
ReplacingtheFuelFilter
Neverinstalladirtylterifitisremovedfromthefuel line.
Note:Notehowthefuellterisinstalledinorderto installthenewltercorrectly.
Note:Wipeupanyspilledfuel.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Closefuelshut-offvalveatthefueltank(
4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure35).
Figure34).
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclampsclose tothelter.
7.Openfuelshut-offvalveatfueltank(
Figure34).
8.Checkforfuelleaksandrepairifneeded.
9.Wipeupanyspilledfuel.
ServicingtheFuelVentSystem
ServiceInterval:Every200hours/Yearly(whichever
comesrst)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removetheexistingfuelventlter(
4.Installanewlter.
Figure36).
29
Page 30
1 2
ElectricalSystem Maintenance
ServicingtheBattery
Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof fourpartswaterandonepartbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.
Voltage:12V
Figure36
1.Fuelventlter2.Rightsideofmotor
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
DANGER
Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.
•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
30
Page 31
WARNING
7 6
5
4 3 2
1
8 9
10
11
Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.
•AlwaysDisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.
•AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative(black) cable.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Lifttheblackrubbercoveronthenegativecable. Disconnectthenegativebatterycablefromthe negative(-)batteryterminal(
4.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure37).
5.Removethebatteryholddownplate( removethebattery.
Figure37).
Figure37)and
Figure37
1.J-bolt7.Wingnut
2.Positivecable8.Negativecable
3.Washer
4.Nut(5/16inch)
5.Rubbercover(red)
6.Batteryholddown
9.Rubbercover(black)
10.Bolt
11.Battery
InstallingtheBattery
1.Placethebatterontothemachine(Figure37).
2.Securethebatterywiththeholddownplate,j-bolts, andlocknuts.
3.First,installthepositive(red)batterycableto positive(+)batteryterminalwithanut,washerand
Figure37).Slidetherubbercoveroverthepost.
bolt(
4.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminalwithanut, washerandbolt( overthepost.
Figure37).Slidetherubbercover
CheckingtheBatteryElectrolyteLevel
ServiceInterval:Every25hours
DANGER
Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.
•Fillthebatterywherecleanwaterisalways availableforushingtheskin.
1.Lookatthesideofthebattery.Theelectrolytemust beuptotheupperline( electrolytetofallbelowtheLowerline(Figure38).
Figure38).Donotallowthe
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Page 32
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).
1.Removethebatteryfromthechassis;referto RemovingtheBattery.
Figure38
1.Ventcaps3.Lowerline
2.Upperline
2.Iftheelectrolyteislow,addtherequiredamountof distilledwater;refertoAddingW atertotheBattery inElectricalSystemMaintenance(page30).
AddingWatertotheBattery
Thebesttimetoadddistilledwatertothebatteryisjust beforeyouoperatethemachine.Thisletsthewatermix thoroughlywiththeelectrolytesolution.
1.Removethebatteryfromthemachine; refertoRemovingtheBatteryin ElectricalSystemMaintenance(page30).
Important:Neverllthebatterywithdistilled waterwhilethebatteryisinstalledinthe machine.Electrolytecouldbespilledonother partsandcausecorrosion.
2.Checktheelectrolytelevel;refertoCheckingthe ElectrolyteLevel.
3.Makesurethellercapsareinstalledinbattery. Chargebatteryfor1hourat25to30ampsor6 hoursat4to6amps.
4.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(
Figure39).
5.Installthebatteryontothemachineandconnectthe batterycables,refertoInstallingtheBattery.
Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.
2.Cleanthetopofthebatterywithapapertowel.
3.Removetheventcapsfromthebattery(
Figure38).
4.Slowlypourdistilledwaterintoeachbatterycell untiltheelectrolytelevelisuptotheUpperline
Figure38)onthebatterycase.
(
Important:Donotoverllthebatterybecause electrolyte(sulfuricacid)cancausesevere corrosionanddamagetothechassis.
5.Waitvetotenminutesafterllingthebatterycells. Adddistilledwater,ifnecessary,untiltheelectrolyte levelisuptotheUpperline(
Figure38)onthe
batterycase.
6.Reinstallthebatteryventcaps.
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthatcan explode.
Figure39
1.PositiveBatteryPost
2.NegativeBatteryPost
3.Red(+)ChargerLead
4.Black(-)ChargerLead
ServicingtheFuses
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance.Ifafuseblows,checkthecomponent orcircuitforamalfunctionorshort.
1.Removethecoverunderthecontrolpanel.
2.Pulloutonthefusetoremoveorreplaceit (Figure40).
3.Installthecoverunderthecontrolpanel.
Note:Ensurethecorrectsizefuseisinstallwiththe correctwirecolorasshowninFigure40.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
32
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Figure40
1.Redwire3.Fuse,25amp,bladetype
2.Fuse,30amp,bladetype4.Violetwire
DriveSystem Maintenance
AdjustingtheTracking
1.Ifthemachinedoesnottrackstraight,adjustment isrequired.
2.Checkthereartirepressure.RefertoCheckingthe TirePressure.
3.Loosenthewingnutsontherightcontrolrodand rotatetheturnbuckleinorouttoensuretheright sidecontrolleveriscenteredintheneutrallock position.Securetheturnbuckleinpositionwiththe wingnuts(
4.Loosenthewingnutsontheleftcontrolrodand rotatetheturnbuckleinorouttochangethetracking. Securetheturnbuckleinpositionwiththewingnuts (Figure41).
5.Checkforpropertracking.Adjusttheleftcontrol rodifachangeisneeded.
Figure41).
Figure41
1.Turnbuckle
2.Bottomwingnut
3.Topwingnut(lefthand threaded)
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Checkthepressureatthevalvestem(
33
Figure42).
Page 34
Maintaintheairpressureinthereartiresat12-14psi (83-97kPa).Uneventirepressurecancauseanuneven cut.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
Figure42
ReplacingtheCasterWheel ForkBushings
Thecasterwheelforksaremountedinbushingspressed intothetopandbottomofthecarrierframemounting pivottubes.Tocheckthebushings,movethecaster forksbackandforthandside-to-side.Ifacasterforkis loose,thebushingsarewornandmustbereplaced.
1.Raisethecuttingunitsothecasterwheelsareoff theoor,thensupportthefrontofthemowerwith jackstands.
2.Removethelockingpinandspacer(s)fromthetop ofthecasterwheelfork(
Figure43).
Figure43
1.LockingPin
2.Spacers4.Casterwheelfork
3.Carrierframepivottube
3.Pullthecasterwheelforkoutofthemountingtube, leavingthespacer(s)onthebottomofthefork. Rememberthelocationofthespacersoneachfork toensurecorrectinstallation,andtomaintainalevel deck.
4.Insertapinpunchintothemountingtubeand carefullydriveoutthebushings(
Figure44).Clean
theinsideofthemountingtube.
Figure44
1.MountingTube2.Bushing
5.Greasetheinsideandoutsideofthenewbushings. Useahammerandatplatetocarefullydrivethe bushingsintothepivottubes.
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Page 35
6.Inspectthecasterwheelforkforwearandreplace ifnecessary(Figure43).
7.Slidethecasterwheelforkthroughthebushingsin themountingtube.Replacethespacer(s)ontothe forkandsecurewiththeretainingring(Figure43).
Important:Theinsidediameterofthebushings maycollapseslightlywheninstalled.Ifthe casterwheelforkdoesnotslideintothenew bushings,reambothbushingstoaninside diameterof1.126inch(29mm).
8.Greasethettingonthecarrierframepivottubes usingNo.2generalpurposelithiumbaseor molybdenumbasegrease.
ServicingtheCasterWheel andBearings
Thecasterwheelsrotateonarollerbearingsupportedby aspannerbushing.Ifthebearingiskeptwelllubricated, wearwillbeminimal.Failuretokeepthebearingwell lubricatedwillcauserapidwear.Awobblycasterwheel usuallyindicatesawornbearing.
1.Removethelocknutandwheelboltholdingthe casterwheeltothecasterfork(
Figure45).
4.Inspecttherollerbearing,bushings,spannerbushing andinsideofthewheelhubforwear.Replaceany defectiveorwornparts(
Figure45).
5.Toassemble,placeonebushingintothewheelhub. Greasetherollerbearingandspannerbushingand slidethemintothewheelhub.Placethesecond bushingintothewheelhub(
Figure45).
6.Installthecasterwheelintothecasterforkand securewiththewheelboltandlocknut.Tightenthe locknutuntilthespannerbushingbottomsagainst theinsideofthecasterforks(
Figure45).
7.Greasethettingonthecasterwheel.
AdjustingtheElectricClutch
ServiceInterval:Every100hours
Theclutchisadjustabletoensureproperengagement andproperbraking.
1.Inserta0.015–0.021inch(0.381–0.533mm)feeler gaugethroughoneinspectionslotinthesideofthe assembly.Makesureitisbetweenthearmatureand therotorfrictionsurfaces.
2.Tightenthelocknutsuntilthereisslightbindingon thefeelergaugebutitcanbemovedeasilywithinthe airgap(
Figure46).
Figure45
1.Locknut
2.WheelBolt5.RollerBearing
3.Bushing
4.SpannerBushing
2.Removeonebushing,thenpullthespannerbushing androllerbearingoutofthewheelhub(Figure45).
3.Repeatthisfortheremainingslots.
4.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.
Figure46
1.Adjustingnut3.Feelergauge
2.Slot
3.Removetheotherbushingfromthewheelhub andcleananygreaseanddirtfromthewheelhub (Figure45).
35
Page 36
CoolingSystem
BrakeMaintenance
Maintenance
CleaningtheAirIntakeScreen
ServiceInterval:Beforeeachuseordaily
Beforeeachuseremoveanybuild-upofgrass,dirt orotherdebrisfromthecylinderandcylinderhead coolingns,airintakescreenonywheelend,and carburetor-governorleversandlinkage.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine.
ServicingtheBrake
Beforeeachuse,checkbrakesonbothalevelsurface andslope.
Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.
CheckingtheParkingBrake
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengagethe PTO.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Applytheparkingbrake.Settingtheparkingbrake shouldtakeareasonableamountofforce.Ifthe parkingbrakedoesnotholdsecurely,anadjustment isrequired.RefertoAdjustingtheParkingBrake.
Note:Whenthebrakeisengaged,thebrakehandle shouldbeinthe1o’clockposition(
Figure47).
AdjustingtheBrakes
Iftheparkingbrakedoesnotholdsecurely,an adjustmentisrequired.
1.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Checkthebrakebeforeyouadjustit;referto CheckingtheBrakes.
4.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation(page13).
5.Loosenthetopandbottomjamnuts(
6.Toadjustthebrake,removethehairpincotterand clevispinfromthelowerbrakelever(
7.Rotatethebrakerodintheyokes.T otightenthe brake,lengthentherodbetweentheyokes.To loosenthebrake,shortentherodbetweentheyokes (Figure47).
Figure47).
Figure47).
Note:Thebrakerodshouldbethreadedintoboth yokesthesamedistance.
8.Securetheyoketolowerbrakeleverwiththehairpin cotterandclevispin(Figure47).
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Page 37
9.Tightenthetopandbottomjamnuts(Figure47).
10.Checkthebrakeoperationagain;refertoChecking theBrake.
Figure47
1.Parkingbrakelever (releasedposition)
2.1o’clockposition6.Yoke
3.Haripincotter7.JamNut
4.Lowerbrakelever8.Brakerod
5.Clevispin
BeltMaintenance
ReplacingtheMowerBelt
ServiceInterval:Every50hours
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofaworndeckbelt.Replacethedeckbeltif anyoftheseconditionsareevident.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchandremovethecarrierframecover.
4.Unlatchandremovethebeltcovers.
5.RemovethePTOdrivebelt.RefertoReplacingthe PTODriveBelt.
6.Disconnecttheidlerarmspringtorelievetensionon theidlerarmandidlerpulley,thenremovetheworn mowerbelt(
7.Installthenewmowerbeltaroundthetwooutside spindlepulleys,theidlerpulley,andinthelower grooveofthedoublespindlepulley( Figure49).
Figure48orFigure49).
Figure48or
8.Connecttheidlerarmspring(Figure48orFigure49).
9.InstallthePTOdrivebelt.RefertoReplacingthe PTODriveBelt.
10.Adjustthebeltguidean1/8inch(3mm)fromthe
Figure48orFigure49).
belt(
11.Installthebeltcoversontothecuttingunitand securethelatches.
12.Installthecarrierframecoverontothecuttingunit andsecurethelatches.
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Figure48
40inch,48inch,and52inchMowerDeckshown
1.Outsidepulley
2.PTODriveBelt
3.Idlerarmspring
4.Mowerdeckbelt
5.Beltguide
6.Centerspindlepulley
aresignsofaworndrivebelt.Replacethedrivebeltif anyoftheseconditionsareevident.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchandremovethecarrierframecover.
4.Unlatchandremovethebeltcovers.
5.Removetheheatshieldfromtheenginedeckand carrierframe.
6.Rollthebeltoffofthecenterpulleyonthemower
Figure50).RefertoFigure51torollthebelt
deck( offleftpulleyfora36inchmowerdeck.Usecaution whenremovingthebeltastensionwillincrease becauseofthespringloadedidlerpulley .
7.Removethebeltfromtheenginepulleyandthe springloadedidlerpulley(
Figure50).Referto Figure51toremovethebeltfromthe36inchmower deckpulleys.
Figure49
36inchMowerDeckshown
1.Mowerdeckbelt4.Idlerarmspring
2.PTODriveBelt
3.Drivebeltpulley
5.Drivebeltpulley
8.Installthenewbeltontotheenginepulleyandspring loadedidlerpulley(
Figure50).
9.Rollthebeltontothecenterpulleyonthemower deck(Figure50).Usecautionwheninstallthebelt astensionwillincreasebecauseofthespringloaded idlerpulley.RefertoFigure51torollthenewbelt ontotheleftpulleyfora36inchmowerdeck.
10.Installtheheatshieldtotheenginedeckandcarrier frame.
11.Adjustthebeltguidean1/8inch(3mm)fromthe beltfor40,48and52inchmowerdecks(
Figure50).
12.Installthebeltcoversontothecuttingunitand securethelatches.
13.Installthecarrierframecoverontothecarrierframe andsecurethelatches.
ReplacingthePTODriveBelt
ServiceInterval:Every50hours
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks
38
Page 39
Figure50
40inch,48inch,and52inchMowerDeckshown
1.PTOdrivebeltguide4.PTOengagementpulley
2.PTOdriveBelt5.PTOdrivebeltidlerpulley
3.Idlerspring
6.Centerspindlepulley
UseFigure52fortheidlerpositionoptions.
Figure52
1.PTOdrivebeltidlerpulley4.Mosttensionforwornbelts
2.PTOdriveBelt5.Mediumtensionfornormal
3.Idlerspring
beltconditions
6.Leasttensionfornewbelts
1.Mowerdeckbelt
2.PTODriveBelt
3.Idlerarmandspring
Figure51
36inchMowerDeckshown
4.Clutchpulley
5.Idlerpulley
ReplacingthePumpDriveBelt
ServiceInterval:Every50hours
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.RemovePTOdrivebelt.RefertoReplacingthe PTODriveBeltinthe
4.Raisethemachineandsupportitwithjackstands.
5.Disconnecttheclutchwireconnectorfromthewire harness.
6.Disconnecttheclutchretainerfromtheenginedeck
Figure53).
(
BeltMaintenance(page37).
AdjustingthePTODriveBelt IdlerSpringAnchor
ThepositionofthePTOidlercanbeadjustedto increaseordecreasebelttension.
39
Page 40
Figure53
1.Hydraulicpumps
2.Idlerpulley6.Pivotbolt
3.Clutchretainer
4.Tensionspring8.Pumpdrivebelt
5.Clutchwireconnector
7.Drivepulley
7.Unhooktheidlerspringfromtheframe(Figure53).
8.Installthenewbeltaroundclutchandthetwodrive pulleys.
9.Installtheidlerspringbetweenidlerarmandframe bracket(
Figure53).
ControlsSystem Maintenance
AdjustingtheMotionControl HandlePositions
AdjustingtheRightSideMotionControl Lever
Ifthemotioncontrolleversdonotalignhorizontally, adjusttherightsidemotioncontrollever.
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
1.DisengagethePTO,movetherightsidemotion controllevertotheneutralpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Pushtherightmotioncontrolleverdownoutof lockedneutralposition(
4.Checkifitalignshorizontallywiththeleftmotion controllever(
Figure54).
Figure54).
10.Installtheclutchretainertotheenginedeck (Figure53).
11.Connecttheclutchwireconnectortothewire harness.
12.InstallthePTOdrivebelt.
Figure54
1.Leftmotioncontrollever3.Checkthehorizontal
2.Rightmotioncontrollever inneutrallockedposition
alignmenthere
4.Rightmotioncontrollever
5.Toadjusttherightmotioncontrolleverhorizontally, thecamneedstobeadjusted.
6.Removethecoverunderthecontrolpanel.
7.Loosenthenutandboltholdingthecam(
Figure55).
8.Adjustthecamuntilitalignswiththeleftmotion controlleverandtightenthenutandboltforthe cam.
40
Page 41
Figure55
1.Cam
2.Nutandbolt
3.Wingnut
4.Turnbuckle
5.Switchscrews
9.Afterthecamisadjusted,theleverswitchneedsto bechecked.
10.Checkthegapbetweenthecontrolleverandswitch asshownin
Figure56.Thegapneedstobebetween
a1/16inchto3/32inch(1.6mmto2.4mm).
11.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch.
12.Tightenthescrewsandinstallthecoverunderthe controlpanel.
Figure56
1.Rightsidemotioncontrol leverpivotshownunder controls
2.Rightsidemotioncontrol lever
3.1/16inchto3/32inch (1.6mmto2.4mm)gap neededbetweenswitch andcontrollever
4.Switch
AdjustingtheNeutralPostionforthe MotionControlLevers
Important:Ensurethetrackingofthemoweris
correctafteradjustingthemotioncontrollevers. Afteradjustingthetracking,themotioncontrol leversmaynotaligntheexactlyfronttoback
Figure57).
(
Ifthemotioncontrolleversdonotalignfronttoback, ortherightsidecontrolleverdoesnotmoveeasilyinto theneutrallockposition,adjustmentisrequired.Adjust eachleverandcontrolrodseparately.
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
1.Afterthehorizontalalignmentisnished,checkthe fronttobackalignment(
41
Figure57).
Page 42
Figure57
1.Leftmotioncontrollever
2.Rightmotioncontrollever4.Alignthecontrollevers
3.Neutrallockedposition
fronttobackhere
2.Loosenthewingnutsontherightcontrolrodand rotatetheturnbuckleinorouttoensuretheright sidecontrolleveriscenteredintheneutrallock position.Securetheturnbuckleinpositionwiththe wingnuts(Figure58).
HydraulicSystem Maintenance
ServicingtheHydraulic System
CheckingtheHydraulicFluid
ServiceInterval:Aftertherst8hours
Every25hours
Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoilis cold.Thebafeinsidethetankhastwolevelsdepending iftheoiliswarmorcold.
1.Positionmachineonalevelsurface.
2.Disengagethepowertakeoff(PTO)andshutoff theengine.
3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.
4.Cleanareaaroundcapandllerneckofhydraulic
Figure59).
tank(
3.Loosenthewingnutsontheleftcontrolrodand rotatetheturnbuckleinorouttochangethetracking. Securetheturnbuckleinpositionwiththewingnuts
Figure58).
(
Figure58
1.Turnbuckle
2.Bottomwingnut
3.Topwingnut(lefthand threaded)
4.Checkforpropertracking.Adjusttheleftcontrol rodifachangeisneeded.RefertoAdjustingthe TrackingintheOperationSection.
Figure59
1.Cap3.Colduidlevel-full
2.Bafe4.Hotuidlevel-full
5.Removecapfromllerneck.Lookinsidetocheck theuidlevelinthereservoir.(Figure59).
6.Adduidtothereservoiruntilitreachesthecold levelofthebafe.
7.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmuid. RefertoStartingandStoppingtheEngine.
8.Rechecktheuidlevelwhiletheuidiswarm.If required,adduidtothereservoiruntilitreaches thehotlevelofthebafe.
Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidiswarm(
Figure59).
9.Installcaponllerneck.
42
Page 43
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
•Usecardboardorpapertondhydraulic leaks.
Figure60
•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
ReplacingtheHydraulicFilterand HydraulicOil
ServiceInterval:Aftertherst8hours
Every250hours—Changethe hydrauliclterandhydraulicoilwhen usingMobil
®
1oil.
Every500hours—Changethe hydrauliclterandhydraulicoil whenusingToro
®
hydraulicoil.
WARNING
4.Removetheoldlter,allowtheoiltodrainandwipe thelteradaptergasketsurfaceclean(Figure61).
5.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.
6.Installreplacementhydrauliclterontothelter adapter.Donottighten.
7.Fillthehydraulictankwithhydraulicuiduntilthe uidoverowsthelterandthenturntheoillter clockwiseuntiltherubbergasketcontactsthelter adapter,thentightenthelteranadditional1/2turn
Figure61).
(
HYPR-OIL
™
500
Hothydraulicuidcancausesevereburns.
Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.
3.Locatethelterunderthefueltankandplacedrain panunderlter(Figure60).
Figure61
1.Hydrauliclter
2.Gasket
3.Adapter
8.Cleanupanyspilleduid.
9.Checktheuidinthereservoir,adduidtothetank untilitreachesthecoldbafeofthetank.
Important:Useoilspecied.Otheruids couldcausesystemdamage.
10.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand
43
Page 44
checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.
11.Rechecklevelandadduid,ifrequired.Donot
overll.
BleedingtheHydraulicSystem
Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemifuidischangedorafter workisperformedonthesystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsofftheground.
4.Starttheengineandmovethethrottlecontroltoidle position.
Ifthedrivewheeldoesnotrotate,itispossibleto assistthepurgingofthesystembycarefullyrotating thetireintheforwarddirection.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafewhours byadoctorfamiliarwiththistypeofinjury. Gangrenemayresultifthisisnotdone.
•Keepbodyandhandsawayfrompinholeleaks ornozzlesthatejecthighpressurehydraulic uid.
•Usecardboardorpapertondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.
•Makesureallhydraulicuidhosesandlinesare ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto hydraulicsystem.
5.Checkthehydraulicuidlevelasitdropsadduid asrequiredtomaintaintheproperlevel.
6.Repeatthisprocedurefortheoppositewheel.
7.Thoroughlycleantheareaaroundeachofthecharge pumphousings.
CheckingtheHydraulicLines
ServiceInterval:Every100hours
Checkhydrauliclinesandhosesforleaks,loosettings, kinkedlines,loosemountingsupports,wear,weather andchemicaldeterioration.Makenecessaryrepairs beforeoperating.
Note:Keepareasaroundhydraulicsystemcleanfrom grassanddebrisbuildup.
44
Page 45
MowerDeck Maintenance
ServicingtheCuttingBlades
Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
WARNING
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator’s orbystander’sarea,resultinginseriouspersonal injuryordeath.
•Inspectthebladesperiodicallyforwearor damage.
•Replaceawornordamagedblade.
BeforeInspectingorServicingthe Blades
Parkthemachineonalevelsurface,disengagetheblades andsettheparkingbrake.Turntheignitionkeytooff. Removethekeyanddisconnectthesparkplugwires fromthesparkplugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure62).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
Figure62
1.CuttingEdge3.Wear/slotformingin curvedarea
2.Sail4.Crackinthecurvedarea
2.Inspecttheblades,especiallythecurvedarea (Figure62).Ifyounoticeanycracks,wear,ora slotforminginthisarea(item3inFigure62), immediatelyinstallanewblade.
CheckingforBentBlades
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromalevelsurfacetothe cuttingedge,positionA,oftheblades(Figure63 ).Notethisdimension.For36inchmowerdecks useFigure64.
45
Page 46
Figure63
40inch,48inch,and52inchMowerDeckshown
1.Measureherefromblade tohardsurface
2.PositionA
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedbladewith anewblade.
•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
RemovingtheBlades
Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.T oensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineT ororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
1.Holdthebladeendusingaragorthickly-padded glove.
2.For40and48inchmowerdecks,removetheblade bolt,curvedwasher,andbladefromthespindle
Figure65).
shaft(
Figure64
36inchMowerDeckshown
4.Rotatetheoppositeendsofthebladesforward.
5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).If thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.
Figure65
40inchand48inchMowerDecks
1.SailAreaofBlade3.Curvedwasher
2.Blade4.BladeBolt
3.For36and52inchmowerdecks,removetheblade bolt,curvedwasher,bladestiffener,andbladefrom thespindleshaft(Figure66).
46
Page 47
Figure66
36inchand52inchMowerDecks
Figure68
1.Blade2.Balancer
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure65).
Important:Thesailpartoftheblademustbe pointingupward,towardtheinsideofthemower toensurepropercutting(Figure65).
2.For40inchand48inchmowerdecks,installthe blade,curvedwasher,andbladebolt(Figure65).
3.For36inchand52inchmowerdecks,installthe blade,stiffener,curvedwasher,andbladebolt
Figure66).
(
1.SailAreaofBlade4.Curvedwasher
2.Blade5.BladeBolt
3.Bladestiffener
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure67).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
Figure67
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure68).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure65).Repeatthis procedureuntilthebladeisbalanced.
4.Torquethebladeboltto85-110ft-lb(115-140N-m).
CorrectingtheMowerQuality ofCut
Ifonedeckbladecutslowerthantheother,correctas follows.
Note:Tireairpressureiscriticalintheseprocedures. Makesurealltireshavecorrectpressure.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.Disconnectthesparkplugwire(s)from thesparkplug(s).
3.Adjustthetirepressureinthe reartirestospecications;referto DriveSystemMaintenance(page33).
4.Checkthatthebladesandspindleshaftsarenot bent.RefertoCheckingforBentBlades.
5.Settheheight-of-cuttothe4inch(101.6mm) position.RefertoAdjustingtheHeight-Of-Cutin Operation(page13).
6.PerformthestepsinthefollowingsectionsFrame SetUp,CheckingFront-to-RearPitch,andChecking Side-to-SideLeveling.
47
Page 48
FrameSetUp
CheckingtheCarrierFrameandEngine DeckAlignment
Note:MisalignmentcancauseexcesswearonthePTO
drivebelt.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Placealongstraightedgeontopoftheenginedeck asshowninFigure69.
4.Atthecarrierframecrosschannel,measurethe heightatlocationA(Figure69).Thismeasurement mustbe1-5/16inch(33mm),plusorminusa1/4 inch(6mm).
5.IftheheightatlocationAisnotcorrect,adjustment isneeded.
6.Loosenthecarrierframemountingboltsonboth sidesofthemachine(Figure69).
CheckingtheEngineDeckHeight
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Adjustthetirepressureinthe reartirestospecications;referto DriveSystemMaintenance(page33).
4.MeasureenginedeckheightatlocationA(Figure70).
5.MeasureenginedeckheightatlocationB(Figure70).
6.IftheheightatlocationAandBarenotthesame, changetirepressureslightlytomakethemthesame.
7.Alignthecarrierframeandenginedecktomatch 1-5/16inch(33mm),plusorminusa1/4inch(6 mm)atlocationA(Figure69).
8.Tightenthecarrierframemountingboltsonboth sidesofthemachine.
Figure70
1.Backviewofmachine
2.Topofenginedeck4.Sameheightatlocations
3.Tires
AandB
CheckingtheCarrierFrame Front-to-RearPitch
Thecarrierframemusthaveapitchbetween1/8inch (3mm)to3/8inch(9mm)overthelengthof24inches (61cm)onthecarrierframe(Figure71).
1.Measureout24inches(61cm)onthecarrierframe (Figure71).
Figure69
1.CarrierFrame4.LocationA,1-5/16inch
2.Topofenginedeck5.Straightedge
3.Carrierframemounting bolts
(33mm)±1/4inch(6mm)
6.Carrierframecross channel
48
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Figure71
1.CarrierFrame
2.1/8inch-3/8inch(3-10 mm)pitchover24inch(61 cm)length
3.24inches(61cm)6.Casterspacers
4.HeightatlocationsAand
B
5.CasterWheel
2.MeasurecarrierframeheightatlocationA (Figure71).
makeitlevel.Thetirepressuremayalsobeadjusted slightlytomakeitlevel.
Figure72
1.CasterWheel4.Sameheightatlocations AandB
2.CarrierFrame5.Casterspacers
3.Frontheight-of-cutpins
3.MeasurecarrierframeheightatlocationB (Figure71).
4.TheheightatlocationAmustbean1/8-3/8inch(3 mm-10mm)lowerthanlocationB(Figure71).
5.Ifthecarrierframeisnotcorrect,movecaster spacerstomakeitan1/8-3/8inch(3-10mm)pitch
Figure71).Movespacersfromtoporbottomto
( makethecorrectpitch.
6.Thetirepressuremayalsobeadjustedslightlyto makean1/8-3/8inch(3-10mm)pitch.
CheckingtheCarrierFrame Side-to-SideHeight
Thecarrierframeneedstobeparallelside-to-sidefrom theground.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
CheckingtheMowerDeck Front-to-RearPitch
1.Adjustthetirepressureinthe reartirestospecications;referto DriveSystemMaintenance(page33).
2.Positiononebladefront-to-rear.MeasureatAand Blocationsfromalevelsurfacetothecuttingedge ofthebladetips(Figure73orFigure74).For36 inchmowerdecksuseFigure74.
3.Themowerbladeshouldbea1/4inch(6mm)lower infrontatAthanintherearatB.Rotatebladesand repeatforotherblades.Ifitisnotcorrect,proceed toChangingtheDeckFront-to-RearPitch.
3.Adjustthetirepressureinthe reartirestospecications;referto DriveSystemMaintenance(page33).
4.MeasurecarrierframeheightatlocationA (Figure72).
5.MeasurecarrierframeheightatlocationB (Figure72).
6.Ifthecarrierframeheightisnotthesamemove spacersfromtoporbottomofcasterwheel,to
49
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Figure73
40inch,48inch,and52inchMowerDeckshown
1.MeasurebladeatpointsA andB
2.Measurefromalevel
Figure75
1.CasterWheel
2.CarrierFrame
surface
3.Frontheight-of-cutpins
4.Jamnut
5.Balljoint
2.Toraisethefrontofthedeck,loosenjamnutand rotatethefrontpinclockwise(
Figure75).
3.Tolowerthefrontofthedeck,loosenjamnutand rotatethefrontpincounterclockwise(Figure75).
4.Positionthebladesfront-to-rear.MeasureatCand Dlocations(
Figure73)fromalevelsurfacetothe
cuttingedgeoftheblades.
5.Checktheside-to-sidelevelingofthecuttingunit.
Figure74
36inchMowerDeckshown
ChangingtheMowerDeck Front-to-RearPitch
Changingthefront-to-rearpitchisdonebyadjustingthe frontheight-of-cutposts.
1.Tochangethefront-to-rearpitch,thefront height-of-cutpostscanbeadjusted(
Figure75).
6.Tightenthejamnuts(Figure75).
CheckingtheMowerDeck Side-to-SideHeight
1.Adjustthereartirepressuretospecications;refer toDriveSystemMaintenance(page33).
2.Positionthebladesside-to-side.MeasureatCand Dlocationsfromalevelsurfacetothecuttingedge ofbladetips( useFigure77.
Figure76).For36inchmowerdecks
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Figure76
40inch,48inch,and52inchMowerDeckshown
3.Withthemachineonlevelsurface,positiononeblade front-to-rear.MeasureatAandfromlevelsurfaceto thecuttingedgeofthebladetips(Figure78).For36 inchmowerdecksuse
Figure79.
1.Measurefromalevel surface
36inchMowerDeckshown
2.MeasurebladeatpointsC andD
Figure77
3.ThedifferencebetweenmeasurementsCandD shouldbenomorethan1/4inch(6mm).
ChangingtheMowerDeck
Figure78
40inch,48inch,and52inchMowerDeckshown
1.Measurefromalevel surface
36inchMowerDeckshown
2.MeasurebladeatpointA
Figure79
Side-to-SideHeight
Changingtheside-to-sideheightisdonebyadjustingthe reartirepressureandcasterspacers.
1.Changethereartirepressure.Dothistothe correspondingsidethatneedsadjustment.
2.Adjustthecasterspacer.
3.Recheckthefront-to-rearpitchandsidetoside levelingofthecuttingunit.
MatchingHeightofCut
1.Checkthereartirepressure.
2.Settheheight-of-cuttothe4inch(101.6mm) positionfollowingtheheight-of-cutdecal.
4.Themeasurementshouldbe4inch(101.6mm).
5.Ifitdoesnotmeasurecorrectly:
A.Adjustthereartirepressure.
B.Adjustthecasterforkspacers.
C.Adjustthefrontmowerdecksupportpins.
6.Checkthecarrierframefront-to-rearpitch.
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ReplacingtheGrassDeector
Cleaning
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure80). Removedamagedorworngrassdeector.
CleaningUndertheMower
ServiceInterval:Beforeeachuseordaily
Removethegrassbuildupunderthemowerdaily.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethefrontofthemachineandusejackstandsto supportthemower.
WasteDisposal
Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.
Figure80
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring8.Jhookendofspring
2.Placespacerandspringontograssdeector.Place theLendofspringbehinddeckedge.
Note:MakesuretheLendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown inFigure80.
3.Installboltandnut.PlacetheJhookendofspring aroundgrassdeector(Figure80).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.
5.Springinstalled
7.Lendofspring,place behinddeckedgebefore installingbolt
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Storage
CleaningandStorage
1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytooff.Removethe key.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideofthe engine’scylinderheadnsandblowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotpressurewash themachine.Avoidexcessiveuseofwater, especiallynearthedrivesystemandengine. Pressurewashingcanforcedirtandwaterinto criticalparts,suchasspindlebearingsand electricalswitches.
3.Checkthebrake;refertoServicingtheBrakein BrakeMaintenance(page36).
4.Servicetheaircleaner;refertoServicingtheAir CleanerinEngineMaintenance(page25).
hole.Nowusethestartertocranktheengineand distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).
10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.
11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
12.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachineto protectitandkeepitclean.
5.Greasethemachine;refertoGreasingand Lubricationin
6.Changetheengineoil;refertoServicingtheEngine inEngineMaintenance(page25).
7.Checkthetirepressure;refertoCheckingtheTire PressureinDriveSystemMaintenance(page33).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelinthe
tank.
B.Runenginetodistributeconditionedfuelthrough
thefuelsystem(5minutes).
C.Stopengine,allowtocoolanddrainthefuel
tank;refertoServicingtheFuelTankin FuelSystemMaintenance(page28),oroperate engineuntilitstops.
D.Restartengineandrununtilitstops.Repeat,on
Chokeuntilenginewillnotrestart.
E.Disposeoffuelproperly .Recycleasperlocal
codes.
Lubrication(page24).
Note:Donotstorestabilizer/conditioned gasolineover90days.
9.Removethesparkplug(s)andcheckits condition;refertoServicingtheSparkPlugin EngineMaintenance(page25).Withthespark plug(s)removedfromtheengine,pourtwo tablespoonsofengineoilintothesparkplug
53
Page 54
Troubleshooting
Problem
Enginewillnotstart,startshard,orfails tokeeprunning.
Enginelosespower.
PossibleCauseCorrectiveAction
1.Fueltankisempty.
2.Chokeisnoton.
3.Aircleanerisdirty.
4.Sparkplugwireislooseor disconnected.
5.Sparkplugispitted,fouled,orthegap isincorrect.
6.Dirtinthefuellter.6.Replacethefuellter.
7.Dirt,water,orstalefuelisinthefuel system.
8.Thegapbetweentheneutralswitch boltandtheswitchisnotcorrect.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow .
4.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
5.Sparkplugispitted,fouled,orthegap isincorrect.
6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.
7.Dirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
1.Fillfueltankwithgasoline.
2.Movethechokelevertochokeposition.
3.Servicetheaircleanerelement.
4.Installwireonsparkplug.
5.Installanew,correctlygappedspark plug.
7.ContactanAuthorizedServiceDealer.
8.ContactanAuthorizedServiceDealer.
2.Servicetheaircleaner.
3.Addoiltothecrankcase.
4.Removetheobstructionfromthe coolingnsandairpassages.
5.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
Engineoverheats.
Machinedoesnotdrive.
Abnormalvibration.
Unevencuttingheight.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow .
3.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
1.Hydraulicoilreservoirlow.1.Addhydraulicoiltothereservoir.
2.Airinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.
3.Pumpdrivebeltslipping.3.Replacethepumpdrivebelt.
4.Pumpdrivebeltidlerspringmissing.4.Replacethepumpdrivebeltidler
1.Cuttingblade(s)is/arebentor unbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley,idlerpulley,or bladepulley .
5.Enginepulleyisdamaged.
6.Bladespindleisbent.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerisnotlevel.3.Levelthemowerside-to-sideposition.
4.Mowerpitchiswrong.
5.Undersideofmowerisdirty.5.Cleantheundersideofthemower.
6.Tirepressureisnotcorrect.6.Adjustthetirepressure.
7.Bladespindlebent.
2.Addoiltothecrankcase.
3.Removetheobstructionfromthe coolingnsandairpassages.
spring.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
4.Adjustthefront-to-rearpitch.
7.ContactanAuthorizedServiceDealer.
54
Page 55
Problem
PossibleCauseCorrectiveAction
Bladesdonotrotate.
1.Drivebeltisworn,looseorbroken.
2.Drivebeltisoffpulley.
3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.
4.Deckbeltisoffpulley.
5.Brokenormissingidlerspring.5.Replacethespring.
6.Electricclutchoutofadjustment.
7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer.
8.Damagedelectricclutch.
9.Safetyinterlocksystempreventsblade rotation.
10.PTOswitchisfaulty .10.ContactanAuthorizedServiceDealer.
1.Checkthebelttension.
2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.
4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.
6.Adjusttheclutchairgap.
8.ContactanAuthorizedServiceDealer.
9.ContactanAuthorizedServiceDealer.
55
Page 56
Schematics
HydraulicSchematic(Rev.A)
56
Page 57
ElectricalSchematic(Rev.A)
57
Page 58
Notes:
58
Page 59
Notes:
59
Page 60
TheToroT otalCoverageWarranty
ALimitedWarranty(seewarrantyperiodsbelow)
Landscape Contractor Equipment(LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:
ProductsWarrantyPeriod
AllMowers
•Engine
Seeenginemanufacturer’swarranty
•Battery90daysPartsandLabor 1yearPartsonly
•BeltsandTires90days
•Attachments1year
21in.HeavyDutyMowers
Mid-SizeWalk-BehindMowers GrandStand
TM
Mowers
•Frame
ZMaster
®
Z400,Z500Mowers4yearsor1,200hours
•Frame
ZMaster
®
G3Mowers
•Frame
1
SomeenginesusedonToroLCEProductsarewarrantedbytheenginemanufacturer .
2
Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone
locationisconsideredcommercialuseandthecommercialusewarrantywouldapply .
3
Whicheveroccursrst.
4
LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atToro’ soption,underwarrantyatnocostforparts
andlabor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor
corrosionarenotcovered.
1yearCommercialUse 2yearsResidentialUse 2years 5yearsor1,200hours Lifetime(originalowneronly)
Lifetime(originalowneronly) 5yearsor1,200hours Lifetime(originalowneronly)
2
3
4
3
4
3
4
Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:
1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,refertotheY ellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww.T oro.com.Youmayalsocallthenumbers listedinitem#3tousethe24-hourToroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:
RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)
1
OwnerResponsibilities
YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator’sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:
•Costofregularmaintenanceserviceorwearparts,suchaslters,
fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.
•Anyproductorpartwhichhasbeenalteredormisusedandrequires
replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.
•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel
system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.
•Pickupanddeliverycharges.
GeneralConditions
Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingToroapprovedreplacementparts.
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.
Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty
Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee information,contacttheT oroimporter.Ifallotherremediesfail,youmaycontactusatToroWarrantyCompany.
374-0252RevB
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