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

FormNo.3391-863RevA

G017540

CommercialWalk-BehindMower

FixedDeck,PistolGrip,HydroDrivewith
36inand48inTURBOFORCE

ModelNo.30934—SerialNo.315000001andUp
ModelNo.30938—SerialNo.315000001andUp
ModelNo.39934—SerialNo.315000001andUp

®

CuttingUnit

ModelNo.39938—SerialNo.315000001andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3391-863*A

WARNING

Introduction

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002.

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

WARNING

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

Thisrotary-blade,lawnmowerisintendedtobeused
byresidentialhomeownersorprofessional,hired
operators.Itisdesignedprimarilyforcuttinggrasson
well-maintainedlawnsonresidentialorcommercial
properties.Itisnotdesignedforcuttingbrushorfor
agriculturaluses.

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .T oro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

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

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

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

Engine Owner's Man ual

issuppliedfor

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

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

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Contents

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

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

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

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

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

ProductOverview.........................................................13

Controls...............................................................13

Specications........................................................14

Attachments/Accessories........................................14

Operation....................................................................14

AddingFuel...........................................................14

CheckingtheEngine-OilLevel.................................15

PuttingSafetyFirst.................................................15

OperatingtheParkingBrake....................................16

StartingandStoppingtheEngine..............................16

OperatingtheNeutralLocks....................................17

OperatingtheMower-Blade-ControlKnob

(PTO)...............................................................18

TheSafety-InterlockSystem....................................18

DrivingtheMachineForwardandBackward..............19

BringingtheMachinetoNeutralPosition...................19

StoppingtheMachine.............................................19

PushingtheMachinebyHand..................................19

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

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

TransportingtheMachine........................................21

SideDischargingorMulchingtheGrass.....................21

AdjustingtheHeight-of-Cut....................................21

AdjustingtheCasterPosition...................................22

AdjustingtheHandleHeight....................................23

Height-of-CutChart...............................................24

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

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

Lubrication...............................................................26

LubricatingtheMachine..........................................26

LubricatingtheCasterandWheelBearings.................26

GreasingtheMower-BeltIdler.................................26

GreasingthePumpControlandtheBell

Crank................................................................26

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

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

ServicingtheEngineOil..........................................27

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

FuelSystemMaintenance...........................................30

ServicingtheFuelTank...........................................30

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

ServicingtheFuel-VentSystem................................31

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

AdjustingtheSpeed-ControlLinkage........................32

AdjustingtheNeutralControlLinkages.....................32

AdjustingtheHydroControlLinkages.......................33

AdjustingtheControlRod.......................................35

AdjustingtheTracking...........................................36

AdjustingtheSpringAnchorLinks...........................36

CheckingtheTirePressure......................................37

CoolingSystemMaintenance......................................37

3

CleaningtheAir-IntakeScreen.................................37

CleaningtheCoolingSystem....................................37

BrakeMaintenance....................................................38

ServicingtheBrake.................................................38

BeltMaintenance......................................................39

CheckingtheBelts..................................................39

ReplacingtheMowerBelt........................................39

AdjustingtheMowerBeltTension............................40

HydraulicSystemMaintenance....................................43

ServicingtheHydraulicSystem.................................43

MowerDeckMaintenance...........................................46

ServicingtheCuttingBlades.....................................46

AdjustingtheBladeBrake........................................48

ReplacingtheGrassDeector..................................48

Storage........................................................................49

CleaningandStorage..............................................49

Troubleshooting...........................................................51

Schematics...................................................................53

Safety

Note:Theadditionofattachmentsmadebyother

manufacturersthatdonotmeetAmericanNationalStandards
Institutecerticationwillcausenoncomplianceofthis
machine.

Improperlyusingormaintainingthemachinecanresult
ininjury.Toreducethepotentialforinjury,complywith
thesesafetyinstructionsandalwayspayattentiontothe
safetyalertsymbol,whichmeans

Danger

withtheinstructionmayresultinpersonalinjuryor
death.

Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

—personalsafetyinstruction.Failuretocomply

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI
B71.4-2012.

Caution, W ar ning ,

or

Training

•ReadtheOperator'sManualandothertrainingmaterial.If

theoperator(s)ormechanic(s)cannotreadorunderstand
theinformationitistheowner'sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof
theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtopeopleordamageto
property.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform
thejob.Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety

glasses,andhearingprotection.Longhair,looseclothing,
orjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeusedand

removeallobjectssuchasrocks,toys,andwirewhichcan
bethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches,

andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.

4

Operation

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholesand

hiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis

engagedbeforestartingtheengine.Onlystarttheengine
fromtheoperator'sposition.

•Besureofyourfootingwhileusingthismachine,

especiallywhenbackingup.Walk;donotrun.Never
operateonwetgrass.Reducedfootingcouldcause
slipping.

•Slowdownanduseextracareonhillsides.Besureto

travelsidetosideonhillsides.Turfconditionscanaffect
thestabilityofthemachine.Usecautionwhileoperating
neardrop-offs.

•Slowdownandusecautionwhenmakingturnsandwhen

changingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshieldorotherguardsnot

securelyinplace.Besureallinterlocksareattached,
adjustedproperly ,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingoroverspeed

theengine.

•Stoponlevelground,disengagedrives,engagethe

parkingbrake(ifprovided),andshutofftheenginebefore
leavingtheoperator'spositionforanyreason,including
emptyingthecatchersoruncloggingthechute.

•Stopequipmentandinspectbladesafterstrikingobjects

orifanabnormalvibrationoccurs.Makenecessary
repairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesureof

aclearpath.

•Nevercarrypassengersonthemachine.

•Keeppetsandbystandersaway .

•Slowdownandusecautionwhenmakingturnsand

crossingroadsandsidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwherethereis

anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete.

•Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

MaintenanceandStorage

•Disengagedrives,settheparkingbrake,stoptheengine

andremovethekeyordisconnectthespark-plugwire.
Waitforallmovementtostopbeforeadjusting,cleaning
orrepairingthemachine.

•Cleangrassanddebrisfromthecuttingunit,thedrives,

themufers,andtheenginetohelppreventres.Clean
upoilorfuelspillage.

•Lettheenginecoolbeforestoringanddonotstorenear

ame.

•Shutoffthefuelwhilestoringortransporting.Donot

storefuelnearamesordrainindoors.

•Parkthemachineonlevelground.Settheparkingbrake.

Neverallowuntrainedpersonneltoservicethemachine.

•Usejackstandstosupportcomponentswhenrequired.

•Carefullyreleasepressurefromcomponentswithstored

energy.

•Disconnectthebatteryorthespark-plugwirebefore

makinganyrepairs.Disconnectthenegativeterminal
rstandthepositivelast.Connectthepositiverstand
negativelast.

5

•Usecarewhencheckingtheblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only
replaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replaceallwornordamageddecals.

•Removeobstaclessuchasrocks,treelimbs,etc.fromthe

mowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide

obstacles.

•Usecautionneardrop-offs,ditches,orembankments.

Themachinecouldsuddenlyturnoverifawheelgoes
overtheedgeofaclifforditch,orifanedgecavesin.

•Tobestprotectyourinvestmentandmaintainoptimal

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

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro
productsandothersafetyinformationyoumustknow.

Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

•Useextracarewithgrasscatchersorotherattachments.

Thesecanchangethestabilityofthemachine.

•Keepallmovementonslopesslowandgradual.Donot

makesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinsidewhere

thereisanopename,suchasnearawaterheateror
furnace.

•Keepnutsandboltstight,especiallythebladeattachment

bolts.Keepequipmentingoodcondition.

•Nevertamperwithsafetydevices.Checksafetysystems

forproperoperationbeforeeachuse.

•Useonlygenuinereplacementpartstoensurethatoriginal

standardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandserviceas

required.

Thisproductisdesignedforcuttingandrecyclinggrassor,
whenequippedwithagrassbagger,forcatchingcutgrass.
Anyuseforpurposesotherthanthesecouldprovedangerous
touserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebeforemowing.

Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhichmay

behotfromoperation.Allowtocoolbeforeattempting
tomaintain,adjustorservice.

•UseonlyToroapprovedattachments.Warrantymaybe

voidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforeoperatingunderany
objectsanddonotcontactthem.

SlopeOperation

Allslopesandrampsrequireextracaution.Ifyoufeeluneasy
onaslope,donotmowit.

6

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

7

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

93-7010

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Thrownobjecthazard,mower—keepthedeectorinplace.

3.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts.

95-5852

1.Warning—engagetheparkingbrakeandchockorblockthe
wheelswhenparkingthemachineonaslope.

98-5130

1.Warning—readtheOperator'sManualforinstructionson
torquingthebladebolt/nutto102-106N⋅m(75-80ft-lb).

1.ReadtheOperator's
Manualforinstructionson
operatingthecuttingblade

2.Pushforwardtoengage

99-3943

1.Engine

95-5537

3.Pullbacktodisengage

8

106-2733

1.Fast

2.Continuousvariable
setting

1.Warning—donottouchthehotsurface.

3.Slow

106-5517

112-8760

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts.

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin
place.

9

115-1038

1.Forward

2.Neutral

3.Reverse

4.Toturnrightmovethelefthandleverintotheforwardpositionwhiletherighthandleverisintheneutralposition.

5.Toturnleftmovetherighthandleverintotheforwardpositionwhilethelefthandleverisintheneutralposition.

6.Engine—stop

7.Engine—run

8.Groundspeed

9.Fast

10.Continuousvariablesetting

11.Slow

12.Neutral

13.Warning—readtheOperator'sManual.

14.Warning—donotoperatethismachineunlessyouaretrained.

15.Warning—wearhearingprotection.

16.Warning—removetheignitionkeybeforeperformingmaintenanceonthemachine.

17.Cutting/dismembermenthazardofhandorfoot,mowerblade—stoptheenginebeforeleavingtheoperatingposition.

18.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.

19.Warning—stayawayfrommovingparts;keepallguardsinplace.

115-4212

1.Hydraulicoillevel3.Warning—donottouchthe

hotsurface.

2.ReadtheOperator's
Manual.

117-2718

10

130-8375

121-6049

1.Thrownobject
hazard—keepbystanders
awayfromthemachine.

2.Thrownobjecthazard,
mower—donotoperate
themowerwithguardsor
shieldsremoved.

3.Cutting/dismemberment
hazardofhandorfoot,
mowerblade—keephands
awayfrommovingparts.

126-1400

1.Warning-ReadtheOperator’smanual.UseonlyTororiding
attachments.Useofotherridingattachmentsmaycreatea
hazardousconditionresultingininjury.

1.ReadtheOperator's
Manual.

2.Increaseleft

3.Trackingadjustment

4.Increaseright

5.Trackingadjustmentknob

130-8376

1.Engagetheparkingbrake.2.Disengagetheparking

brake.

1.Neutrallock

130-8370

11

131-1180

1.ReadtheOperator's
Manual.

2.Short,lightgrass;dry
conditions;maximum
dispersion

3.Baggingsetting

4.Tall,densegrass;wet
conditions;maximum
groundspeed

12

ProductOverview

G017541

Figure4

1.Sidedischarge5.Controls

2.Mowerdeck6.Handle

3.Recoil-starthandle

4.Gastank

Controls

Becomefamiliarwithallthecontrols(Figure5)beforeyou
starttheengineandoperatethemachine.

7.Casterwheel

Figure5

1.Throttlecontrol6.Handle

2.Speed-controllever

3.Ignitionswitch

4.Neutrallock

5.Operator-presence-control
levers(OPC)

7.Drivelever

8.Blade-controlknob(PTO)

9.Choke

10.Fuel-shutoffvalve

ThrottleControl

Thethrottlecontrolhas2positions:FastandSlow.

Operator-Presence-Control(OPC)
Levers

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

Blade-ControlKnob(PTO)

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

IgnitionSwitch

Thisswitchisusedinconjunctionwithrecoilstarterandhas
2positions:RunandOff.

Speed-ControlLever

Thismachinehasavariable-speedcontrolwithaNeutral
position.Thiscontrolshowfastthemachinetravelsforward.

DriveLevers

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

NeutralLock

Squeezethedriveleversbackuntilanincreaseinforceisfelt,
andmovethelockstotherearforneutrallock.

Recoil-StartHandle

Pulltherecoil-starthandletostarttheengine(notshown
inFigure4).

13

Fuel-ShutoffValve

Closethefuel-shutoffvalvewhentransportingorstoringthe
machine.

Operation

AddingFuel

Choke

Usethechoketostartacoldengine.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

36-inchmowers:

Widthwithdeectordown118.4cm(46.6inches)

Length

Height

Weight

48-inchmowers:

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

Length

Height

Weight

203.2cm(80inches)

11 1.8cm(44inches)

241kg(532lb)

198.9cm(78-3/8inches)

11 1.8cm(44inches)

259kg(570lb)

•Forbestresults,useonlyclean,fresh(lessthan30days

old),unleadedgasolinewithanoctaneratingof87or
higher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol(gasohol)

or15%MTBE(methyltertiarybutylether)byvolume
isacceptable.EthanolandMTBEarenotthesame.
Gasolinewith15%ethanol(E15)byvolumeisnot
approvedforuse.Neverusegasolinethatcontainsmore
than10%ethanolbyvolume,suchasE15(contains15%
ethanol),E20(contains20%ethanol),orE85(contains
85%ethanol).Usingunapprovedgasolinemaycause
performanceproblemsand/orenginedamagewhichmay
notbecoveredunderwarranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuelcontainers

overthewinterunlessafuelstabilizerisused.

•Donotaddoiltogasoline.

DANGER

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

Attachments/Accessories

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

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanygasoline
thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis6to13
mm(1/4to1/2inch)belowthebottomofthe
llerneck.Thisemptyspaceinthetankallows
gasolinetoexpand.

•Neversmokewhenhandlinggasoline,andstay
awayfromanopenameorwheregasoline
fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Neverbuy
morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystemin
placeandinproperworkingcondition.

14

DANGER

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

•Alwaysplacegasolinecontainersontheground
awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor
onatruckortrailerbedbecauseinteriorcarpets
orplastictruckbedlinersmayinsulatethe
containerandslowthelossofanystaticcharge.

UsingFuelStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachinetokeepthe
fuelfreshduringstorageof90daysorless.Ifyouarestoring
themachineforlonger,drainthefueltank;refertoDraining

theFuelTank(page30).

Important:Donotusefueladditivescontaining
methanolorethanol.

Addthecorrectamountoffuelstabilizer/conditionertothe
fuel,andfollowthedirectionsofthemanufacturer.

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

•Whenpractical,removegas-poweredequipment
fromthetruckortrailerandrefueltheequipment
withitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromagasolinedispenser
nozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimofthe
fueltankorcontaineropeningatalltimesuntil
fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditionerbottleopening.

•Keepgasawayfromeyesandskin.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

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

3.Installthefuel-tankcapsecurely.Wipeupanygasoline
thatmayhavespilled.

CheckingtheEngine-OilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoCheckingthe

Engine-OilLevel(page28).

PuttingSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsinthe
safetysection.Knowingthisinformationcouldhelpyouor
anybystandersavoidinjury.

Theuseofprotectiveequipmentforeyes,hearing,feetand
headisrecommended.

CAUTION

Thismachineproducessoundlevelsinexcessof
85dBAattheoperator'searandcancausehearing
lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Figure6

1.Warning—wearhearingprotection.

15

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor
leaveitunattended.Beforeeachuse,checktheparkingbrake
forproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit.Referto
ServicingtheParkingBrake.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

SettingtheParkingBrake

Pulltheparking-brakeleverrearward(Figure7).

Figure7

1.Parking-brakelever(inthereleasedposition)

ReleasingtheParkingBrake

Pushtheparking-brakeleverforward.

StartingandStoppingthe Engine

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

Note:Acold-weatherstartingkithasbeen
incorporatedtoassistenginestartingincoldweather
orwhenthemachinehasnotbeenrunforaperiod
oftime.

Tousethecold-weatherstartingkit:

•Graspthesplitring(Figure8)ontherightsideof

themachine,pulltheringandchainstraightout
fromthesideofthemachine,andhookthering
overthecontrol-shieldbolt.

Figure8

1.Splitring2.Control-shieldbolt

•Aftertheengineisstarted,pullthechainstraight

outfromthesideofthemachineuntiltheringcan
beremovedfromshieldbolt.Slowlyreleasethe
tensiononthechain.

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

4.Movethedriveleverstotheneutralpositionandset
theneutrallocks.

5.Settheparkingbrake.

6.Turntheignitionkeytotherunposition(Figure5).

7.Tostartacoldengine,movethethrottlecontrol
midwaybetweenthefastandslowpositions.

8.Tostartawarmengine,movethethrottlecontrolto
thefastposition.

9.Pullthechokeknobiftheengineiscold(Figure5).

Note:Awarmorhotengineusuallydoesnotrequire
anychoking.

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

11.Pushthechoketotheoffpositionastheenginewarms
up(Figure9).

12.Iftheengineiscold,allowittowarmupandthen
movethethrottlecontroltothefastposition.

StoppingtheEngine

1.Movethethrottlelevertotheslowposition(Figure9).

2.Movethedriveleverstotheneutralpositionandset
theneutrallocks.

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

4.Lettheengineidlefor30to60secondsbeforeturning
theengineoff.

5.Tostoptheengine,turntheignitionkeytooff.

16

Figure9

ReleasingtheNeutralLock

1.Squeezethedriveleversbackuntilanincreaseinforce
isfelt.

2.Placeyourthumbsontheupperpartofthelocksand
movethemforwarduntilthepinsareintheforward
slot(Figure11).

1.Throttlelever

2.Ignitionswitch

3.Choke

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

OperatingtheNeutralLocks

Alwayssettheneutrallockwhenyoustopthemachine.Set
theparkingbrakeifitisleftunattended.

SettingtheNeutralLock

1.Squeezethedriveleversbackuntilanincreaseinforce
isfelt.

2.Placethumbsontheupperpartofthelocksandmove
themback(Figure10).

Figure11

1.Handle

2.Neutrallock5.Handle

3.Drivelever6.Forwardslot

4.Pininfullspeedforward

Figure10

1.Handle4.Drivelever

2.Neutrallock

3.Neutralposition6.Reverseposition

5.Fullspeedforward

17

Operatingthe

TheSafety-InterlockSystem
Mower-Blade-ControlKnob
(PTO)

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

EngagingtheMowerBlades(PTO)

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

12).

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

Note:TheenginewillstopiftheOPCleversare
releasedifthemowerisrunningandthespeed-control
leverisnotinneutral.

3.Starttheengineandrepeattheproceduretoengagethe
mowerbladesiftheoperatorpresencecontrol(OPC)
leversarereleased.

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

UnderstandingtheSafety-Interlock
System

Thesafetyinterlocksystemisdesignedtopreventthemower
fromstartingunless:

•Theblade-controlknob(PTO)ispushedoff.

•Thespeed-controlleverisintheNeutralposition.

Thesafetyinterlocksystemisdesignedtostoptheengine
when:

•Theoperator-presence-control(OPC)leversarereleased

withthemowerengagedand/orthespeedcontrolisout
ofneutral.

•Thespeed-controlleverisshiftedoutofneutralwithout

holdingOPCleversorwiththebrakeengaged.

•Theblade-controlknob(PTO)ispulledupwithout

holdingtheOPClevers.

Figure12

1.Throttlelever4.DriveLever

2.OperatorPresence
Controllevers(OPC)

3.Handle

5.Blade-controlknob(PTO)

DisengagingtheMowerBlades(PTO)

Themowerbladescanbedisengagedbyoneofthefollowing
steps.

1.Pushtheblade-controlknob(PTO)downtotheoff
position(Figure12).

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

TestingtheSafety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethemachine
eachtime.Ifthesafetysystemdoesnotoperateasdescribed,
haveanAuthorizedServiceDealerrepairthesafetysystem
immediately.

WARNING

Whiletestingthesafety-interlocksystem,the
machinemaymoveforwardandcausepersonal
injuryorpropertydamage.

•Performthesafety-interlocktestinanopenarea.

•Ensurethatnooneisstandinginfrontofthe
machinewhileperformingthesafety-interlock
test.

1.Settheneutrallocksandplacespeed-controlleverin
neutral.

2.Starttheengine;refertoStartingandStoppingthe
Engine.

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

18

4.Pushtheblade-controlknobdowntooff.

DrivingBackward

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

6.Withenginerunning,releasetheOPClevers.The
engineshouldstop.

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

8.Ifalltheaboveconditionsarenotmet,havean
AuthorizedServiceDealerrepairthesafetysystem
immediately.

DrivingtheMachineForward andBackward

Thethrottlecontrolregulatestheenginespeedasmeasured
inrpm(revolutionsperminute).Placethethrottlecontrolin
theFastpositionforbestmowingperformance.

DrivingForward

1.Releasetheparkingbrake.

2.Togoforward,movethespeed-controllevertothe
desiredspeed.

3.Releasetheneutrallock.RefertoReleasingtheNeutral

Lock(page17).

4.Slowlyreleasethedriveleverstomoveforward(Figure

13).

Togostraight,releasethedriveleversequally(Figure

13).

Toturn,squeezethedriveleveronthesideofthe
directionwhichyouwanttoturn(Figure13).

Fromneutral,slowlysqueezethedriveleverstomove
rearward(Figure13).

BringingtheMachineto NeutralPosition

Alwayssettheneutrallockandparkingbrakewhenyoustop
themachine.

1.Squeezethedriveleverstoneutralposition.

2.Settheneutrallocks.RefertoOperatingtheNeutral

Locks(page17).

3.Movespeed-controllevertoneutralposition.

Note:Thespeed-controllevercanalsobeusedto
bringthemowertoneutralpositionandthensetthe
neutrallocks.

StoppingtheMachine

1.Tostopthemachine,squeezethedriveleverstothe
neutralpositionandengageneutrallocks.

2.Movespeed-controlleverintoneutral.

3.Stoptheengine;refertoStoppingtheEngine.

4.Waitforallmovingpartstostopbeforeleavingthe
operatingposition.Settheparkingbrake.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

1.Drivelever

Figure13

2.Speed-controllever

PushingtheMachinebyHand

Thebypassvalvesallowthemachinetobepushedbyhand
withouttheenginerunning.

Important:Alwayspushthemachinebyhand.Never
towthemachinebecausehydraulicdamagemayoccur.

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.Openthebypassvalvesbyturningthemcounter
clockwise1to2turns.Thisallowshydraulicuidto
bypassthepumpsandthewheelstoturn(Figure14).

3.Releasetheparkingbrake.

4.Pushthemachinetothedesiredlocation.

5.Settheparkingbrake.

6.Closethebypassvalves,butdonotovertightenthem.

19

Note:Rotatethebypassvalvesamaximumof2turns

g012676

1 2

G012677

G012678

sothevalvedoesnotcomeoutofthebodycausing
uidtorunout.

Important:Donotstartoroperatethemachine
withthebypassvalvesopen.Damagetosystem
mayoccur.

Figure14

1.Bypassvalve

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse.
Adjustmentswillvarybygrasstype,moisturecontent,and
heightofgrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition(seeFigure16).Thesuggested
useforthispositionisafollows:

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthemower.

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferenttypes
ofmowingconditions.Positionthecamlockandbafeto
givethebestqualityofcut.

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Toadjustthebafe,loosenthenut(Figure15).

4.Adjustthebafeandnutintheslottothedesired
dischargeowandtightenthenut.

Figure16

PositionB

Usethispositionwhenbagging(Figure17).

Figure15

2.Nut

Figure17

20

1.Slot

PositionC

G012679

SideDischargingorMulching

Thisisthefullopenposition.Thesuggesteduseforthis
positionisasfollows(Figure18):

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

Figure18

theGrass

Thismowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

DANGER

Withoutthegrassdeector,dischargecover,or
completegrasscatcherassemblymountedin
place,youandothersareexposedtobladecontact
andthrowndebris.Contactwithrotatingmower
blade(s)andthrowndebriswillcauseinjuryor
death.

•Neverremovethegrassdeectorfromthemower
becausethegrassdeectorroutesmaterialdown
towardtheturf.Ifthegrassdeectorisever
damaged,replaceitimmediately .

•Neverputyourhandsorfeetunderthemower.

•Nevertrytocleardischargeareaormower
bladesunlessyoureleasethebailandthepower
takeoff(PTO)isoff.Rotatetheignitionkeyto
Off.Alsoremovethekeyandpullthewireoff
thesparkplug(s).

TransportingtheMachine

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

1.Stoptheengine,removethekey,setthebrake,and
closethefuelvalve.

2.Securelyfastenthemachinetothetrailerortruckwith
straps,chains,cable,orropes.

3.Secureatrailertotowingvehiclewithsafetychains.

4.Ifapplicable,connectthetrailerbrakes.

AdjustingtheHeight-of-Cut

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

AdjustingtheBladeHeight

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

1.DisengagethePTOandpullthethrottletotheslow
position.

2.Turntheignitionswitchtooff.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingposition.Settheparkingbrake.

4.Holdthebladeboltandremovethenut.Slidethebolt
downthroughthespindle,andchangethespacersas
needed(Figure19).

21

Figure20

1.Topaxlebolt2.Loweraxlebolt

7.Raiseorlowerthemountingbracketsothatyoucan
installthe2axleadjustmentboltsinthedesiredhole
location(Figure20).

Note:Useataperedpunchtohelpaligntheholes.

8.Tightenall4bolts.

9.Installthedrivewheelsandlowerthemachine.

Figure19

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

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

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

AdjustingtheAxleHeight

Adjusttheaxlepositiontotheselectedheight-of-cutsetting.

1.DisengagethePTOandpullthethrottletothestop
position.

2.Waitforallmovingpartstostopbeforeleavingthe
operatingposition,andthensettheparkingbrake.

3.Placeajackundertherearcenteroftheengineframe.
Raisethebackendoftheengineframeupenoughto
removethedrivewheels.

4.Removethedrivewheels.

5.Loosen,butdonotremove,the2topaxlebolts(Figure

20).

6.Removethe2loweraxlebolts(Figure20).

AdjustingtheCasterPosition

1.UsingtheHeight-of-CutChart(page24),adjustthe
casterspacerstomatchwiththeaxleholeselected
(Figure21).

Figure21

1.Latchpin

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

2.Removethelatchpin,slidethecasterfromthesupport,
andchangethespacers(Figure21).

3.Installthecasterinthesupportandinsertthelatchpin
(Figure21).

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

22

AdjustingtheHandleHeight

Thehandlepositioncanbeadjustedtomatchtheoperator's
heightpreference.

1.Removethehairpincotterpinsandclevispinsfrom
thedriveleversandneutrallocks(Figure22).

Figure23

Figure22

1.Controlrod5.Lefthandle

2.Clevispin

3.Drivelever7.Hairpincotter

4.Operator-presence-control
(OPC)lever

6.Neutrallock

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

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

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

1.Controlrodtting

2.Lowermountingholes7.Lowerposition

3.Rearframe

4.Lowerangebolt(3/8x1
inch)

5.Upperangebolt(3/8x
1-1/4inches)

6.Highposition

8.Uppermountinghole

9.Handle

10.Flangenut(3/8inch)

5.Adjustthecontrolrodlengthbyrotatingthecontrol
rodintherodtting(Figure23).

6.Installthehairpincotterbetweenthedriveleversand
theneutrallocksandintotheclevispins(Figure22).

Note:Makesurethattheclevispinsareinsertedinto
theneutrallocks.

7.Performthehydrauliclinkageadjustmentswhenthe
handleheightischanged;referHydraulicLinkage
Adjustments.

23

Height-of-CutChart

Numberofspacersbelow

Axle

position

A00

A01

A10

B01

B10

B11

B20

C

C

C

C

D21

D30

D31

D40

E31

E40

E41

thecaster

13mm

(1/2inch)

11

20

21

30

Numberof1/4inchbladespacersbelowthespindle

5mm

(3/16inch)

43210

26mm

(1inch)

29mm

(1-1/8inch)

35mm

(1-3/8inch)

35mm

(1-3/8inch)

41mm

(1-5/8inch)

45mm

(1-3/4inch)

51mm

(2inch)

48mm

(1-7/8inch)

55mm

(2-1/8inch)

57mm

(2-1/4inch)

64mm

(2-1/2inch)

61mm

(2-3/8inch)

64mm

(2-1/2inch)

70mm

(2-3/4inch)

76mm

(3inch)

73mm

(2-7/8inch)

79mm

(3-1/8inch)

82mm

(3-1/4inch)

32mm

(1-1/4inch)

35mm

(1-3/8inch)

41mm

(1-5/8inch)

41mm

(1-5/8inch)

48mm

(1-7/8inch)

51mm

(2inch)

57mm

(2-1/4inch)

54mm

(2-1/8inch)

60mm

(2-3/8inch)

64mm

(2-1/2inch)

70mm

(2-3/4inch)

67mm

(2-5/8inch)

70mm

(2-3/4inch)

76mm

(3inch)

82mm

(3-1/4inch)

79mm

(3-1/8inch)

86mm

(3-3/8inch)

89mm

(3-1/2inch)

38mm

(1-1/2inch)

41mm

(1-5/8inch)

48mm

(1-7/8inch)

48mm

(1-7/8inch)

54mm

(2-1/8inch)

57mm

(2-1/4inch)

64mm

(2-1/2inch)

60mm

(2-3/8inch)

67mm

(2-5/8inch)

70mm

(2-3/4inch)

76mm

(3inch)

73mm

(2-7/8inch)

76mm

(3inch)

82mm

(3-1/4inch)

89mm

(3-1/2inch)

86mm

(3-3/8inch)

92mm

(3-5/8inch)

95mm

(3-3/4inch)

45mm

(1-3/4inch)

48mm

(1-7/8inch)

54mm

(2-1/8inch)

54mm

(2-1/8inch)

60mm

(2-3/8inch)

64mm

(2-1/2inch)

70mm

(2-3/4inch)

67mm

(2-5/8inch)

73mm

(2-7/8inch)

76mm

(3inch)

83mm

(3-1/4inch)

79mm

(3-1/8inch)

82mm

(3-1/4inch)

89mm

(3-1/2inch)

95mm

(3-3/4inch)

92mm

(3-5/8inch)

98mm

(3-7/8inch)

102mm

(4inch)

51mm

(2inch)

54mm

(2-1/8inch)

60mm

(2-3/8inch)

60mm

(2-3/8inch)

67mm

(2-5/8inch)

70mm

(2-3/4inch)

76mm

(3inch)

73mm

(2-7/8inch)

79mm

(3-1/8inch)

83mm

(3-1/4inch)

89mm

(3-1/2inch)

86mm

(3-3/8inch)

89mm

(3-1/2inch)

95mm

(3-3/4inch)

102mm

(4inch)

98mm

(3-7/8inch)

105mm

(4-1/8inch)

108mm

(4-1/4inch)

24

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst25hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthemowerbelttension.

•Checkthehydraulicuidlevel.

•Changethehydrauliclter.

•Checkthemowerbelttension.

•Checkthesafetysystem.

•Greasethecasterwheelsandthecasterpivots.

•Checktheengineoillevel.

•Cleantheair-intakescreen.

•Inspecttheblades.

•Cleanthemowerdeck.

•Cleanthefoamair-cleanerelement.

•Checkthehydraulicuidlevel.

•Greasethemower-beltidler.

•Greasethepump-drive-idlerpivot.

•Greasethepumpcontrol.

•Checkthepaperair-cleanerelement.

•Checkthetirepressure.

•Checkthebelts.

•Checkthemowerbelttension.

•Greasethebladeengagementbellcrank.

•Changetheengineoil.

•Checkthesparkplugs.

•Checkandcleantheengine-coolingnsandshrouds.

•Checkthehydraulichoses.

•Replacethepaperair-cleanerelement.

•Changetheoillter.

Every200hours

Every400hours

Beforestorage

•Replacethefuellter.

•Replacethefuel-ventlter.

•Changethehydrauliclter.

•Lubricatethecamlockwithanti-seizecompound.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthesparkplugwirefromthesparkplug(s)beforeyoudo
anymaintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

25

Lubrication

GreasingthePumpControl

UseFigure24forlocatingthegreasepointsonthemachine.

GreaseType:#2general-purposelithium-basedor
molybdenum-basedgrease

LubricatingtheMachine

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Cleanthegreasettingswitharag.Makesuretoscrape
anypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease
intothettingsuntilgreasebeginstooozeoutofthe
bearings.

5.Wipeupanyexcessgrease.

LubricatingtheCasterand WheelBearings

ServiceInterval:Beforeeachuseordaily—Greasethecaster

wheelsandthecasterpivots.

andtheBellCrank

ServiceInterval:Every50hours—Greasethe

pump-drive-idlerpivot.

Every50hours—Greasethepumpcontrol.

Every100hours—Greasethebladeengagement
bellcrank.

Every400hours—Lubricatethecamlockwith
anti-seizecompound.

Greasethettingonthepumpdriveidlerpivotandthe
pumpcontrol.

Greasethebladeengagement(PTO)bellcrank(Figure24).

Lubricatethefrontwheelbearingsandthefrontspindles.

GreasingtheMower-BeltIdler

ServiceInterval:Every50hours—Greasethemower-belt

idler.

Greasethettingonthemower-belt-idlerarmpivot(Figure

24).

Note:Removethemower-deckcovertoaccessthegrease
ttingforthemower-belt-idlerarm.

Figure24

48-inchmowerdeckshown

1.Pump-drive-idlerarm4.Mower-belt-idlerarm

2.Pump-controlarm

3.Bellcrank

5.Caster-wheelbearing

6.Casterpivot

26

EngineMaintenance

ServicingtheAirCleaner

CleaningtheFoamAir-CleanerElement

1.Washthefoamelementinliquidsoapandwarmwater.
Whentheelementisclean,rinseitthoroughly .

2.Drytheelementbysqueezingitinacleancloth.

ServiceInterval/Specication

ServiceInterval:Every25hours—Cleanthefoam

air-cleanerelement.

Every50hours—Checkthepaperair-cleanerelement.

Every200hours—Replacethepaperair-cleaner
element.

Note:Servicetheaircleanermorefrequently(everyfew
operatinghours)iftheoperatingconditionsareextremely
dustyorsandy .

Important:Donotoilthefoamorpaperelement.

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Cleanaroundtheaircleanertopreventdirtfrom
gettingintotheengineandcausingdamage(Figure25).

4.Unscrewthecoverknobsandremovetheair-cleaner
cover(Figure25).

Important:Replacethefoamelementifitistorn
orworn.

ServicingthePaperAir-Cleaner
Element

1.Donotcleanthepaperlter,replaceit(Figure25).

2.Inspecttheelementfortears,anoilylm,ordamageto
therubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,alwaysoperate

theenginewiththecompletefoamandpaperaircleaner
assemblyinstalled.

1.Carefullyslidethefoamelementontothepaper
air-cleanerelement(Figure25).

2.Placetheaircleanerassemblyontotheaircleanerbase
andsecureitwiththe2wingnuts(Figure25).

3.Placetheair-cleanercoverintopositionandtighten
thecoverknob(Figure25).

5.Unscrewthehoseclampandremovetheaircleaner
assembly(Figure25).

6.Carefullypullthefoamelementoffthepaperelement
(Figure25).

Figure25

1.Cover

2.Hoseclamp4.Foamelement

3.Paperelement

ServicingtheEngineOil

ServiceInterval:Beforeeachuseordaily—Checktheengine

oillevel.

Aftertherst8hours—Changetheengineoil.

Every100hours—Changetheengineoil.

Every200hours—Changetheoillter.

Note:Changetheoilmorefrequentlywhentheoperating
conditionsareextremelydustyorsandy.

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

CrankcaseCapacity:1.7L(1.8USqt)withthelter

removed;1.5L(1.6USqt)withoutthelterremoved

Viscosity:Refertothetable(Figure26).

27

ChangingtheEngineOil

1.Parkthemachinesothatthedrainsideisslightlylower
thantheoppositesidetoensurethattheoildrains
completely.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Slidethedrainhoseovertheoildrainvalve.

5.Placeapanbelowthedrainhose.Rotateoildrainvalve
toallowoiltodrain(Figure28).

Figure26

CheckingtheEngine-OilLevel

1.Parkthemachineonalevelsurface.

2.DisengagethePTOandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Cleanaroundtheoildipstick(Figure27)sothatdirt
cannotfallintothellerholeanddamagetheengine.

6.Whenoilhasdrainedcompletely,closethedrainvalve.

7.Removethedrainhose(Figure28).

Note:Disposeoftheusedoilatarecyclingcenter.

Figure27

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean(Figure

27).

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

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

Important:Donotoverllthecrankcasewithoil
andruntheengine;enginedamagecanresult.

Figure28

1.Oil-drainvalve2.Oil-drainhose

8.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure27).

9.Checktheoillevel;refertoCheckingtheEngine-Oil

Level(page28).

10.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

Note:Changetheoilltermorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe

EngineOil(page28).

2.Removetheoldlter(Figure29).

28

Figure29

1

1.Oillter

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure29).

4.Installthereplacementoilltertothelteradapter,
turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure29).

5.Fillthecrankcasewiththepropertypeofnewoil;refer
toServicingtheEngineOil(page27).

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillteranddrain
valve.

7.Checktheengineoillevelandaddoilifneeded.

8.Wipeupanyspilledoil.

ServicingtheSparkPlugs

ServiceInterval:Every100hours—Checkthesparkplugs.

Ensurethattheairgapbetweenthecenterelectrodeandthe
sideelectrodeiscorrectbeforeinstallingeachsparkplug.Use
aspark-plugwrenchforremovingandinstallingthespark
plugsandagappingtoolorafeelergaugetocheckandadjust
theairgap.Installnewsparkplugsifnecessary.

Figure30

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausingdamage.

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

1.Lookatthecenterofthesparkplugs(Figure31).If
youseelightbrownorgrayontheinsulator,theengine
isoperatingproperly.Ablackcoatingontheinsulator
usuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Type:Champion®RCJ8Yorequivalent

AirGap:0.75mm(0.030inch)

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Disconnectthewiresfromthesparkplugs(Figure30).

Figure31

1.Centerelectrode;insulator3.Airgap(nottoscale)

2.Sideelectrode

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

3.Checkthegapbetweenthecenterelectrodeandthe
sideelectrode(Figure31).Bendthesideelectrode
(Figure31)ifthegapisnotcorrect.

29

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

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

3.Connectthewirestothesparkplugs(Figure31).

FuelSystem
Maintenance

ServicingtheFuelTank

DANGER

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

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopenarea.
Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,andstay
awayfromanopenameorwhereasparkmay
ignitethegasolinefumes.

DrainingtheFuelTank

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

2.Closethefuelshut-offvalveatthefueltank(Figure32).

3.Squeezetheendsofthehoseclamptogetherandslide
itupthefuellineawayfromfuellter(Figure32).

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

Note:Nowisthebesttimetoinstallanewfuellter
becausethefueltankisempty.RefertoReplacingthe
FuelFilter.

5.Installthefuellineontothefuellter.Slidethehose
clampclosetothevalvetosecurethefuelline.

1.Fuel-shutoffvalve2.Clamp

30

Figure32

ServicingtheFuelFilter

g014686

1 2

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

ReplacingtheFuelFilter

Neverinstalladirtylterifitisremovedfromthefuelline.

Note:Notehowthefuellterisinstalledinordertoinstall
thenewltercorrectly.

Note:Wipeupanyspilledfuel.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Closefuelshut-offvalveatthefueltank(Figure32).

4.Installanewlter.

4.Squeezetheendsofthehoseclampstogetherandslide
themawayfromthelter(Figure33).

Figure33

1.Hoseclamp3.Filter

2.Fuelline

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampscloseto
thelter.

Figure34

1.Fuel-ventlter2.Rightsideofmotor

7.Openfuelshut-offvalveatfueltank(Figure32).

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

ServicingtheFuel-Vent System

ServiceInterval:Every200hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Removetheexistingfuel-ventlter(Figure34).

31

DriveSystem
Maintenance

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

AdjustingtheSpeed-Control Linkage

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Movethespeed-controllever(locatedontheconsole)
tothefullforwardposition.

4.Checktheorientationofthetabsontheendsofthe
speed-controlcrank.Thesetabsshouldbepointing
straightdownatthe6o'clockpositionapproximately
(Figure35).

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

5.Adjustthethreadedyokeatthebottomofthespeed
controllinkageuntilthetabsareatthe6o'clock
position(Figure35).

Figure35

1.Speed-controlrod

2.Yoke5.Jamnut

3.Speed-controlcrank

4.Tabs,6o'clockposition

Figure36

1.Actuatingtab

2.8mm(5/16inch)space

3.Safetyswitch

AdjustingtheNeutralControl Linkages

WARNING

Enginemustberunningsothatcontrollinkage
adjustmentscanbeperformed.Contactwith
movingpartsorhotsurfacesmaycausepersonal
injury.

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

WARNING

Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.

6.Pullthespeed-controlleverbacktoneutral.

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

•Usejackstandswhensupportingmachine.

•Donotusehydraulicjacks.

1.DisengagethePTOandsettheparkingbrake.

32

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineontojackstandstoraise
thedrivewheelsofftheground.

4.Disengagetheparkingbrake.

5.Starttheengineandmovethethrottleaheadtothefull
throttleposition.

6.Placetheneutrallocksinthefullforwardpositionand
movethespeed-controllevertothemediumspeed
position.

7.HoldtheOPCleversdown.

Note:HoldtheOPCleversdownwheneverthe
speed-controlleverisoutoftheNeutralposition;
otherwise,theenginewillstop.

WARNING

Electricalsystemwillnotperformpropersafety
shutoffwiththeoperator-presence-control
(OPC)levershelddowninplace.

Figure37

1.Neutralcontrollinkage3.Adjustingbolt

2.Yoke4.Nut

AdjustingtheHydroControl

•MakesurethattheOPCleversareworking
whenadjustmentiscompleted.

•NeveroperatethismachinewiththeOPC
levershelddowninplace.

8.Squeezeonedriveleveruntilanincreasedresistanceis
felt.Thisiswhereneutralshouldbe.

Note:Makesureyouhavenotreachedtheendofthe
neutrallockslot.Ifyouhave,shortenthecontrollever
linkage.RefertoAdjustingtheControlRod(page35).

9.Ifthewheelturnswhileholdingthedriveleverin
neutral,theneutralcontrollinkagesneedtobeadjusted
(Figure37).Ifwheelstopsthengotostep12.

10.Loosenthenutagainsttheneutralcontrollinkageyoke
(Figure37).

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

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

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

Linkages

WARNING

Theenginemustberunningsothatthecontrol
linkageadjustmentscanbeperformed.Contact
withmovingpartsorhotsurfacesmaycause
personalinjury.

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

WARNING

Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.

•Usejackstandswhensupportingmachine.

•Donotusehydraulicjacks.

AdjustingtheLeftLinkage

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineontojackstandshigh
enoughtoraisethedrivewheelsofftheground.

14.Afteradjustmentsaremade,tightenthenutsagainst
theyokes.

15.Repeatthisprocedurefortheoppositeside.

4.Disengagetheparkingbrake.

5.Starttheengineandmovethethrottleaheadtothefull
throttleposition.

33

6.Placetheleftdriveleverinthefullforwardposition.

1

1

2

4

3

4

5

G024291

7.Placethespeed-controlleverintheNeutralposition.

Note:TheOPCleversmustbehelddownwhenever
thespeed-controlleverisoutoftheneutralpositionor
theenginewillstop.

WARNING

Electricalsystemwillnotperformproper
safetyshutoffwithOperatorPresenceControl
(OPC)leversheldinplace.

•MakesurethattheOPCleversareworking
whenadjustmentiscompleted.

•NeveroperatethismachinewiththeOPC
leversheldinplace.

8.Loosenthefrontadjustingnutonlefthydrocontrol
linkageasshowninFigure39.

9.Turntheleftrearadjustingnutcounterclockwiseuntil
thewheelrotatesforward(Figure39).

10.Turntherearadjustingnutclockwise1/4ofaturnata
time.Thenmovethespeed-controlleverforwardand
backtotheNeutralposition.Repeatthisuntiltheleft
wheelstopsrotatingforward(Figure39).

11.Turntherearnutanadditional1/2turnandtightenthe
frontadjustingnut.

Note:Makesurethattheatpartofthelinkageis
perpendiculartothepinpartoftheswivel.

14.Makesurethatthespeed-controlleverisintheneutral
positionandthetiredoesnotrotate.

15.Repeattheadjustmentifneeded.

Figure39

1.Hydrocontrollinkage3.Rearadjustingnut

2.Frontadjustingnut

4.Controlarm

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

1.Hydrocontrollinkage

2.Frontnut5.90degrees

3.Rearnut

12.Afteradjustingthelefthydrocontrollinkage,move

Figure38

4.Swivel

thespeed-controlleverforwardandthenbacktothe
neutralposition.

13.HoldtheOPCleversdown.

Figure40

1.Speed-controllever

2.Rearpivotspring

3.spring

AdjustingtheRightLinkage

1.Placethespeed-controlleverintheneutralposition.

2.Placetherightdriveleverinthefullforwardposition.

3.Adjusttherightlinkagebyturningthequicktrackknob
counterclockwiseuntilthetirebeginstorotateforward
(Figure41).

34

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

5.HoldtheOPCleversdown.

Note:TheOPCleversmustbehelddownwhenever
thespeed-controlleverisoutoftheNeutralposition
ortheenginewillstop.

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

7.Adjustthespringlengthbyturningthenutatthefront
ofspring(Figure41).

AdjustingtheControlRod

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

2.Lengthenthecontrolrodifthetireisturninginreverse
andshortentherodifthetireisturningforward.

3.Rotatetherodseveralturnsifthetireisrotatingfast.
Then,adjusttherodin1/2turnincrements.

4.Placetheclevispinintothedrivelever(Figure42).

Figure41

1.Hydrocontrollinkage

2.Quicktrackknob4.26mm(1inch)

3.Spring

AdjustingtheControlRod

CheckingtheControlRod

1.Withtherearofthemachinestillonjackstandsandthe
enginerunningatfullthrottle,movethespeed-control
levertothemediumspeedposition.

Note:TheOPCleversmustbehelddownwhenever
thespeed-controlleverisoutoftheneutralposition,or
theenginewillstop.

Figure42

1.Controlrod5.Lefthandleshown

2.Clevispin

3.Drivelever7.Hairpincotterpin

4.Operator-presence-control
lever(OPC)

6.Neutrallock

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

6.Installthehairpincotterpinbetweenthedrivelevers
andtheneutrallocksandintotheclevispins(Figure

42).

7.Repeatthisadjustmentfortheoppositeside.

2.Movetherespectivedriveleverupwarduntilitreaches
theneutralpositionandengagetheneutrallocks.

3.Ifthetirerotatesineitherdirection,thelengthofthe
controlrodwillneedtobeadjusted.

35

Figure43

1.Handle5.Neutralposition

2.Neutrallock6.Drivelever

3.Handle

4.Neutral-lockslot

7.Fullspeedforward

8.Controlrod

AdjustingtheTracking

1.Removethemachinefromanyjackstands.

2.Checkthereartirepressure.RefertoCheckingtheTire

Pressure(page37).

3.Runthemachineandobservethetrackingonalevel,
smooth,hardsurfacesuchasconcreteorasphalt.

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

Figure44

1.Quicktrackknob

AdjustingtheSpringAnchor Links

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

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

36

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

CoolingSystem
Maintenance

Note:Inthemedium-dutyorheavy-dutypositions,
thedriveleverforcesattheupperhandlewillalsobe
increased

Figure45

1.Springanchor

2.Standardsetting

3.Mediumsetting

4.Heavy-dutysetting

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthetirepressure.

CleaningtheAir-IntakeScreen

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

CleaningtheCoolingSystem

ServiceInterval:Every100hours/Yearly(whichevercomes

rst)

Cleantheairintakescreenfromgrassanddebrisbeforeeach
use.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

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

4.Cleanthedebrisandgrassfromtheengineparts.

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

Checkthepressureatthevalvestem(Figure46).

Maintaintheairpressureinthereartiresat83to97kPa(12
to14psi).Uneventirepressurecancauseanunevencut.

Note:Thefronttiresaresemi-pneumatictiresanddonot
requireairpressuremaintenance.

Figure46

Figure47

1.Air-intakescreen4.Bolt

2.Fanhousing5.Nut

3.Recoilstarter

37

BrakeMaintenance

yokecounterclockwiseoutoftheyokeouttoloosen
theparkingbrake(Figure48).

ServicingtheBrake

Beforeeachuse,checktheparkingbrakeforproperoperation.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnothold
securely,adjustit.

CheckingtheParkingBrake

1.Movethemachineontoalevelsurface.

2.Disengagethepowertake-off(PTO)andstopthe
engine.

3.Settheparkingbrake.

Note:Settingtheparkingbrakeshouldtakea
reasonableamountofforce.Ifitengagestoohardor
tooeasily,anadjustmentisrequired.RefertoAdjusting

theParkingBrake(page38).

AdjustingtheParkingBrake

Theparkingbrakeleverisontherightsideofthemachine
(Figure45).Iftheparkingbrakedoesnotholdsecurely,
adjustit.

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

5.Securethelowerlinktothelowerbrakeleverwiththe
hairpincotterandtheclevispin(Figure48).

6.Checkthebrakeoperationagain;refertoCheckingthe

ParkingBrake(page38).

1.Checktheparkingbrakebeforeyouadjustit;referto

CheckingtheParkingBrake(page38).

2.Releasetheparkingbrake;refertoReleasingthe

ParkingBrake(page16).

3.Removethespringclevispinfromthelowerbrakelink
(Figure48).

Figure48

1.Brakelinkageyoke4.Lowerbrakelink

2.Lowerbrakelever

3.Springclevispin

5.6mm(1/4inch)

6.Hairpincotter

4.Rotatethelowerbrakelinkyokeclockwiseintothe
yoketotightentheparkingbrake;rotatethebrakelink

38

BeltMaintenance

10.Removethehairpincotterpinandtheclevispinfrom
thebellcrank.

CheckingtheBelts

ServiceInterval:Every50hours/Monthly(whichever

comesrst)—Checkthebelts.

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

ReplacingtheMowerBelt

Important:Adjustthebrakewheneveryouadjustthe

belttensionorthebrakelinkage.

1.Disengagetheblade-control(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Removetheknobsandthebeltcoveronthemower.

4.Removetheidlerpulleyandthewornbelt.

5.Installthenewmowerbelt.

6.Installtheidlerpulley.

11.Rotatetheclevisclockwiseontherodtoincreasethe
clearance;rotateitcounterclockwisetodecreaseit
(Figure49).

12.Disengagetheblade-control(PTO)lever.

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

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

Tension(page40).

Note:Thepropermowerbelttensionis44to67N-m
(10to15ft-lb)withthebeltdeected13mm(1/2inch)
halfwaybetweenthepulleys(Figure50orFigure51).

8.Engagetheblade-control(PTO)lever.

9.Checktheclearancebetweenthebellcrankandthe
transmissionoutputshaft(Figure49).

Figure49

Figure50

36-inchmowerdeck

1.13mm(1/2inch)deection
here

2.Assistarm5.Turnbuckle

3.Frontstop

4.Locknut

1.2to3mm(1/16to1/8inch)

2.Bellcrank

3.Transmissionoutputshaft6.Clevis

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

4.Hairpincotter

5.Clevispin

39

1.Disengagetheblade-control(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Loosenthelocknutontheturnbuckle(Figure52).

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

Note:Theeyeboltthreadsonbothendsofthe
turnbuckleshouldbeengagedaminimumof8mm
(5/16inch).

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

Figure51

48-inchmowerdeck

1.13mm(1/2inch)deection
here

2.Assistarm5.Turnbuckle

3.Frontstop

13.Checkthebeltguideundertheengineframeforthe
properadjustment.

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

4.Locknut

AdjustingtheMowerBelt Tension

AdjustingtheTensionfor36-inch
MowerDecks

ServiceInterval:Aftertherst8hours—Checkthemower

belttension.

Aftertherst25hours—Checkthemowerbelt
tension.

Every50hours—Checkthemowerbelttension.

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

Figure52

36-inchmowerdeck

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

6.Tightenthelocknutontheturnbuckle.

7.Checkthebladebrakeadjustment;refertoAdjusting

theBladeBrake(page48).

2.Idlerpulley

Important:Thebrakeneedstobeadjustedwhenthe
belttensionorthebrakelinkageisadjusted.

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

Thebeltmustbetightenoughsothatitdoesnotslipduring
heavyloadswhilecuttinggrass,andover-tensioningwill
reducebeltandspindlebearinglife.

AdjustingtheTensionfor48-inch
MowerDecks

Important:Thebeltmustbetightenoughtonotslip

duringheavyloadswhilecuttinggrass.Over-tensioning
thebeltwillreducethespindlebearinglife,thebeltlife
andtheidlerpulleylife.

Important:Thebrakeneedstobeadjustedwhenthe
belttensionorthebrakelinkageisadjusted.

40

1.Disengagetheblade-control(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Loosenthelocknutontheturnbuckle(Figure54).

4.Rotatetheturnbuckletowardtherearofthemowerto
increasethetensiononthebelt.Rotatetheturnbuckle
towardthefrontofthemowertodecreasethetension
onthebelt(Figure54).

Note:Thepropermowerbelttensionis44to67N-m
(10to15ft-lb)withthebeltdeected13mm(1/2inch)
halfwaybetweenthepulleys(Figure53).

Figure54

Figure53

48-inchmowerdeck

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

Note:Theeyeboltthreadsonbothendsofthe
turnbuckleshouldbeengagedaminimumof8mm
(5/16inch).

1.13mm(1/2inch)deection
here

2.Assistarm5.Turnbuckle

3.Frontstop

4.Locknut

5.Engagetheblade-controllever(PTO)andcheckthe
belttension.

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

7.Whentheidlerpulleyismovedthebeltguidemust
bemoved.Movethebeltguidetothefrontposition
(Figure55).

Figure55

1.Rearidlerpulley4.Beltguideinbackposition

2.Middlehole5.Frontidlerpulley

3.Fronthole

8.Checkthebeltguideundertheengineframeforproper
adjustment(Figure56).

41

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

9.Checkthebladebrakeadjustment;refertoAdjusting

theBladeBrake(page48).

Figure56

Figure57

1.Bellcrank4.Yoke

2.Safetyswitchlocated
underenginedeck

3.Bellcrankjustclearsthe
gussetwiththePTO
engaged

5.Nut

6.Assistarmlink

1.Idlerpulleyinslot4.Beltguide

2.Tractionbelt

3.Mowerbelt6.Mowerbelt

5.19mm(3/4inch)

AdjustingthePTOEngagement
Linkage

ThePTOengagementlinkageadjustmentislocatedbeneath
thefrontleft-handcorneroftheenginedeck.

1.Disengagetheblade-control(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Engagetheblade-controllever(PTO).

4.Adjustthelinkagelengthtowherethelowerendofthe
bellcrankjustclearstheaxlesupportgusset(Figure57).

5.Makesuretheassistarmisagainsttherearassistarm
stoponthedeck(Figure58).

6.Pushtheblade-controllever(PTO)downtothe
disengagedposition.

7.Theassistarmshouldcontactthefrontassistarmstop
onthedeck.Ifitdoesnotcontact,adjustthebellcrank
sothatitisclosertothegusset(Figure58).

Figure58

1.Yoke5.Assistarmlink

2.Nut6.Assistarm

3.Rearassistarmstop7.Turnbuckle

4.Frontassistarmstop

8.Toadjusttheassistarmlink,removethehairpincotter
pinfromtheassistarm(Figure58).

42

9.Loosenthenutagainsttheyoke(Figure57).

10.Removetheassistarmlinkfromtheassistarmand
rotatethelinktoadjustthelength.

11.Installtheassistarmlinkintotheassistarmandsecure
itwiththehairpincotterpin(Figure58).

12.Checkiftheassistarmhitsagainstthestopscorrectly.

HydraulicSystem
Maintenance

ServicingtheHydraulic System

AdjustingthePTOSafetySwitch

1.Disengagetheblade-control(PTO)leverandsetthe
parkingbrakes.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

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

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

5.Movethemountingbracketuntilthebellcrankpresses
theplungerby6mm(1/4inch).

6.

Note:Makesurethatthebellcrankdoesnottouch
theswitchbody ,ordamagetotheswitchcouldoccur
(Figure59).
Tightentheswitchmountingbracket.

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every25hours

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

HydraulicSystemOilCapacity:2.3L(2.4USqt)

Important:Useoilspecied.Otheruidscouldcause
systemdamage.

Note:Therearetwowaysofcheckingthehydraulicoil.
Oneiswhentheoiliswarmandoneiswhentheoiliscold.
Thebafeinsidethetankhas2levelsdependingiftheoil
iswarmorcold.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andshutoffthe
engine.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthensettheparkingbrake.

4.Cleanareaaroundcapandllerneckofhydraulictank
(Figure60).

1.Bellcrank

2.Boltsandnuts

Figure59

3.Switchmountingbracket

4.Switchbody

Figure60

1.Cap3.Colduidlevel—full

2.Bafe4.Hotuidlevel—full

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

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

7.Runthemachineatlowidlefor15minutestoallow
anyairtopurgeoutofthesystemandwarmtheuid.
RefertoStartingandStoppingtheEngine(page16).

43

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

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

9.Installthecaponthellerneck.

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit
mustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistype
ofinjury.Gangrenemayresultifthisis
notdone.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesurethatallhydraulicuidhoses
andlinesareingoodconditionandall
hydraulicconnectionsandttingsare
tightbeforeapplyingpressuretohydraulic
system.

ReplacingtheHydraulicFilter

ServiceInterval:Aftertherst8hours

Every200hours

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

Figure61

1.Hydrauliclter

2.Gasket

6.Applyathincoathydraulicuidtotherubbergasket
onthereplacementlter.

7.Installthereplacementhydrauliclterontothelter
adapter.Donottighten.

8.Removetheplasticbagfromthereservoiropeningand
allowtheltertollwithhydraulicuid.

9.Whenthehydrauliclterisfull,turntheoillter
clockwiseuntiltherubbergasketcontactsthelter
adapter,thentightenthelteranadditional1/2turn
(Figure61).

10.Cleanupanyspilleduid.

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

Important:Useoilspeciedorequivalent.Other
uidscouldcausesystemdamage.

12.Starttheengineandletitrunforabout2minutesto
purgeairfromthesystem.Stoptheengineandcheck
forleaks.Ifoneorbothwheelswillnotdrive,referto

BleedingtheHydraulicSystem(page44).

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

3.Adapter

Important:Donotsubstituteanautomotiveoil
lter,orseverehydraulicsystemdamagemay
result.

3.Removethehydraulic-reservoircapandtemporarily
covertheopeningwithaplasticbagandarubberband
topreventallofthehydraulicuidfromdrainingout.

4.Locatethelterundertheenginebaseandplacea
drainpanunderthelter(Figure61).

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

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe
necessarytobleedthesystemiftheuidischangedorafter
workisperformedonthesystem.

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

1.DisengagethePTOandsettheparkingbrake.

44

2.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

3.Raisetherearofthemachineupontojackstandshigh
enoughtoraisethedrivewheelsofftheground.

4.Checkthehydraulicuidlevel.

5.Starttheengineandmovethethrottlecontroltothe
fullthrottleposition.Movethespeed-controlleverto
themiddlespeedpositionandplacethedrivelevers
intothedriveposition.

Ifeitherdrivewheeldoesnotrotate,itispossible
toassistthepurgingofthechargepumpbycarefully
rotatingthetireintheforwarddirection.

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

10.Checkthehydrauliccontrollinkageadjustment.Refer
toAdjustingtheHydroControlLinkages(page33).

CheckingtheHydraulicHoses

ServiceInterval:Every100hours

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

Note:Keeptheareasaroundthehydraulicsystemclean
fromgrassanddebrisbuildup.

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskinit
mustbesurgicallyremovedwithinafewhours
byadoctorfamiliarwiththistypeofinjury.
Gangrenemayresultifthisisnotdone.

•Keepbodyandhandsawayfrompin-holeleaks
ornozzlesthatejecthigh-pressurehydraulic
uid.

Figure62

1.Charge-pumpcap2.Socket-headscrew

6.Thoroughlycleantheareaaroundeachofthe
charge-pumphousings.

7.Toprimethechargepump,loosenthe2hex
socket-headcapscrews(Figure62)1-1/2turnsonly.
Makesurethattheengineisnotrunning.Liftthe
chargepumphousingupwardandwaitforasteady
owofoiltoowoutfromunderthehousing,then
tightenthecapscrews.

Note:Dothisforbothpumps.

Note:Thehydraulicreservoircanbepressurizedto

upto5psitospeedthisprocess.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.

•Makesurethatallhydraulic-uidhosesand
linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretothehydraulicsystem.

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

9.Allowthemachinetorunforseveralminutesafterthe
chargepumpsareprimedwiththedrivesysteminthe
full-speedposition.

45

MowerDeck Maintenance

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keepthebladessharp.
Forconvenientsharpeningandreplacement,youmaywant
tokeepextrabladesonhand.

WARNING

Awornordamagedbladecanbreak,andapiece
ofthebladecouldbethrownintotheoperator's
orbystander'sarea,resultinginseriouspersonal
injuryordeath.

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

PreparingtoInspectorServicethe
Blades

Parkthemachineonalevelsurface,disengagethe
blade-controlleverandsettheparkingbrake.Turnthe
ignitionkeytotheOffposition.Removethekeyand
disconnectthespark-plugwire(s)fromthesparkplug(s).

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure63).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades(page47).

Figure63

1.CuttingEdge3.Wear/slotformingin
curvedarea

2.Sail4.Crackinthecurvedarea

2.Inspecttheblades,especiallythecurvedarea(Figure

63).Ifyounoticeanydamage,wear,oraslotforming

inthisarea(item3.inFigure63),immediatelyinstall
anewblade.

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforwardand
backward(Figure64).

Figure64

Figure65

46

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

Figure66

1.Measurefromthecuttingedgetoalevelsurface

3.Rotatetheoppositeendsofthebladesforward.

4.Measurefromalevelsurfacetothecuttingedgeofthe
bladesatthesamepositionasinstep1.Thedifference
betweenthedimensionsobtainedinsteps1and2
mustnotexceed3mm(1/8inch).Ifthisdimension
exceeds3mm(1/8inch),thebladeisbentandmust
bereplaced.RefertoRemovingtheBlades(page47)
andInstallingtheBlades(page48).

WARNING

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedblade
withanewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Replacethebladesifyouhitasolidobjectorifthebladesare
outofbalanceorbent.Toensureoptimumperformanceand
continuedsafetyconformanceofthemachine,usegenuine
Tororeplacementblades.Replacementbladesmadebyother
manufacturersmayresultinnon-conformancewithsafety
standards.

1.Holdthebladeboltwithawrench.

2.Removethenut,bladebolt,curvedwasher,blade,
spacers,andthinwasherfromthespindle(Figure67).

Figure67

1.Blade

2.Bladebolt5.Thinwasher

3.Curvedwasher

4.Spacer

6.Nut

SharpeningtheBlades

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

Figure68

1.Sharpenatoriginalangle

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

47

Figure69

1.Blade2.Balancer

InstallingtheBlades

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

67).

Important:Thecurvedpartoftheblademust
pointupwardtowardtheinsideofthemowerto
ensurepropercutting.

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

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

Figure70

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

2.Bladebrakepad

ReplacingtheGrassDeector

AdjustingtheBladeBrake

1.DisengagethePTO,turntheignitionkeytooff,and
removethekey.

2.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthensettheparkingbrake.

3.Ifnecessary,adjustthespringmountingboltssothat
thebladebrakepadrubsagainstbothsidesofthe
pulleygroove(Figure70).

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

5.Engagetheblades.Ensurethebladebrakepadno
longercontactsthepulleygroove.

WARNING

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

Neveroperatethelawnmowerunlessyouinstall
acoverplate,amulchplate,oragrasschuteand
catcher.

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

48

g012749

Figure71

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.J-hookendofspring

5.Springinstalled

7.L-endofspring,place
behinddeckedgebefore
installingbolt

2.Placespacerandspringontograssdeector.Placethe
L-endofspringbehinddeckedge.

Note:MakesurethattheL-endofspringisinstalled
behinddeckedgebeforeinstallingtheboltasshown
inFigure71.

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

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

Storage

CleaningandStorage

1.Disengagethepowertake-off(PTO),settheparking
brake,andturntheignitionkeytotheoffposition.
Removethekey.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engine.Cleandirtandchafffromtheoutsideofthe
enginecylinder-headnsandtheblowerhousing.

Important:Youcanwashthemachinewithmild
detergentandwater.Donotpressurewashthe
machine.Avoidexcessiveuseofwater,especially
neartheshift-leverplateandtheengine.

3.Checkthebrake;refertoCheckingtheParkingBrake

(page38).

4.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page27).

5.Greasethemachine;refertoLubrication(page26).

6.Changethecrankcaseoil;refertoServicingtheEngine

Oil(page27).

7.Checkthetirepressure;refertoCheckingtheTire

Pressure(page37).

8.Forlong-termstorage:

A.Addstabilizer/conditioneradditivetofuelinthe

tank.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthefuel

tank;refertoServicingtheFuelTank(page30),
orruntheengineuntilitstops.

D.Starttheengineandrunituntilitstops.Repeat

theprocess,withthechokeon,untiltheengine
willnotstart.

E.Disposeoffuelproperly.Recycleitasperlocal

codes.

Note:Donotstorestabilizer/conditioned
gasolineover90days.

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

10.Checkandtightenallbolts,nuts,andscrews.Repairor
replaceanypartthatisdamagedorworn.

11.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

12.Storethemachineinaclean,drygarageorstoragearea.
Removethekeyfromtheignitionswitchandkeepit

49

inamemorableplace.Coverthemachinetoprotect
itandkeepitclean.

50

Troubleshooting

Problem

Theenginedoesnotstart,startshard,or
failstokeeprunning.

Theenginelosespower.

PossibleCauseCorrectiveAction

1.Thefueltankisempty.1.Fillthefueltankwithgasoline.

2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.

3.Thechokeisnotinthecorrectposition.

4.Theaircleanerisdirty.

5.Thespark-plugwireislooseor
disconnected.

6.Thesparkplugispittedorfouled,or
thegapisincorrect.

7.Thereisdirtinthefuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel
system.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandairpassages
undertheengineblowerhousingare
plugged.

5.Thesparkplugispittedorfouled,or
thegapisincorrect.

6.Theventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

7.Thereisdirtinthefuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel
system.

3.Closethechokeiftheengineiscold;
openthechokeiftheengineiswarm.

4.Cleanorreplacetheair-cleaner
element.

5.Installthewireonsparkplug.

6.Installanew,correctlygappedspark
plug.

8.ContactanAuthorizedServiceDealer.

2.Cleantheair-cleanerelement.

4.Removetheobstructionfromthe
coolingnsandairpassages.

5.Installanew,correctlygappedspark
plug.

8.ContactanAuthorizedServiceDealer.

Theengineoverheats.

Themachinedoesnotdrive.

Thereisabnormalvibration.

Themachineproducesanunevencutting
height.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandairpassages
undertheengineblowerhousingare
plugged.

1.Theshiftleverisinneutral.1.Movetheshiftlevertoadrivegear

2.Thetractionbeltisworn,loose,or
broken.

3.Thetractionbeltisoffapulley.3.Changethebelt.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.One/severalcuttingbladesis/arebent
orunbalanced.

2.Ablademountingboltisloose.2.Tightentheblademountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Theenginepulley,idlerpulley ,orblade
pulleyisloose.

5.Theenginepulleyisdamaged.

6.Thebladespindleisbent.

1.Theblade(s)is/arenotsharp.1.Sharpentheblade(s).

2.One/severalcuttingblade(s)is/are
bent.

3.Themowerisnotlevel.

4.Theundersideofthemowerisdirty.4.Cleantheundersideofthemower.

5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.

6.Abladespindleisbent.

3.Removetheobstructionfromthe
coolingnsandairpassages.

position.

2.Changethebelt.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

2.Installnewcuttingblade(s).

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

6.ContactanAuthorizedServiceDealer.

51

Problem

PossibleCauseCorrectiveAction

Thebladesdonotrotate.

1.Themowerdeckbeltiswornorloose.

2.Themowerdeckbeltisbroken.2.Installanewdeckbelt.

3.Themowerdeckbeltisoffpulley.3.Inspectthebeltandreplaceitifitis

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Checkthebelttension.

damaged.Checkthepulleysandidlers
andadjustthebelttension.

52

Schematics

ElectricalSchematic(Rev .-)

HydraulicSchematic(Rev .-)

53

Notes:

54

Notes:

55

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment
(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuanttoanagreement
betweenthem,jointlypromisetotheoriginalpurchasertorepairtheT oroProducts
listedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Mid-SizeWalk-BehindMowers

4

•Engines

GrandStand

4

•Engines

•Frame

®

ZMaster

•Engines

2000SeriesMowers

4

•Frame

®

ZMaster

•Engines

•Frame

ZMaster

•Engines

4

®

4

3000SeriesMowers

5000SeriesMowers

®

Mowers

Kawasaki–3years

2years

Kawasaki–3years

5yearsor1,200hours

3years

Lifetime(originalowneronly)

4yearsor500hours

3years

Lifetime(originalowneronly)

5yearsor1,200hours
3years
Lifetime(originalowneronly)
5yearsor1,200hours

KohlerCommand–2years

KohlerEFI–3years

•Frame

®

ZMaster

•Engines

6000SeriesMowers

4

•Frame

®

ZMaster

•Engines

7000SeriesMowers

4

•Frame

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

2years

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

1

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

2

Whicheveroccursrst.

3

LifetimeFrameW arranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforpartsand
labor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosion
arenotcovered.

4

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer .

1

1

2

3

2

3

2

3

2

3

2

3

2

3

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship,
followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir
dealership.T olocateadealerconvenienttoyou,refertotheY ellowPagesof
yourtelephonedirectory(lookunder“LawnMowers”)oraccessourwebsite
atwww.Toro.com.Youmayalsocallthenumberslistedinitem#3tousethe
24-hourT oroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService
Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered
underwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith
theassistanceprovided,contactusat:

RLCCustomerCareDepartment

ToroWarrantyCompany

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

888-865-5676(U.S.Customers)

888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures
describedintheOperator'sManual.Suchroutinemaintenance,whetherperformedby
adealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage
andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot
coverthefollowing:

•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil

changes,sparkplugs,airltersbladesharpeningorwornblades,cable/linkage
adjustments,orbrakeandclutchadjustments

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenalteredormisusedorneglectedandrequires

replacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult

Operator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan

10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro
ServiceDealerusingT oroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect,
incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro
Productscoveredbythiswarranty ,includinganycostorexpenseofproviding
substituteequipmentorserviceduringreasonableperiodsofmalfunctionor
non-usependingcompletionofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse)
andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto
thedurationoftheexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages,
orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions
andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry,
province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheToroimporter.Ifallother
remediesfail,youmaycontactusatT oroWarrantyCompany.

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer .

374-0252RevF