Toro 74408, 74408CP, 74409CP Operator's Manual

Download

FormNo.3362-127RevA

Z300ZMaster

witha34inor40in

7-GaugeSideDischargeMower

ModelNo.74408—SerialNo.290000001andUp

ModelNo.74408CP—SerialNo.290000001andUp

ModelNo.74409—SerialNo.290000001andUp

ModelNo.74409CP—SerialNo.290000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

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

ThissparkignitionsystemcomplieswithCanadian ICES-002.

Theenclosed

Engine Owner’ s Man ual

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

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Introduction

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .T oro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready .Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

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

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Contents

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

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

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

ToroRidingMowerSafety....................................5

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

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

ProductOverview......................................................10

Contactusatwww.T oro.com.

PrintedintheUSA.

AllRightsReserved

Controls.............................................................10

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

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

CheckingtheEngineOilLevel............................13

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

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

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

OperatingthePowerTakeOff(PTO).................15

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

DrivingForwardorBackward.............................16

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

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

UsingtheLiftAssistPedal..................................18

AdjustingtheAnti-ScalpRollers.........................18

PositioningtheSeat............................................19

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

UsingtheSideDischarge....................................20

TransportingMachines.......................................20

LoadingMachines..............................................21

OperatingTips...................................................21

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

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

Lubrication.............................................................23

GreasingandLubrication...................................23

LubricatingtheCasterWheelHubs.....................25

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

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

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

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

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

DrainingtheFuelTank.......................................30

ReplacingtheFuelFilter.....................................30

ElectricalSystemMaintenance................................31

ServicingtheBattery...........................................31

ServicingtheFuses.............................................33

DriveSystemMaintenance.....................................34

CheckingtheTirePressure.................................34

AdjustingtheCasterPivotBearing......................34

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

CleaningtheAirIntakeScreen............................35

CleaningtheEngineCoolingSystem...................35

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

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

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

InspectingtheBelts............................................36

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

CheckingandReplacingthePumpDrive

Belt................................................................36

ControlsSystemMaintenance.................................37

AdjustingtheControlHandleNeutral

Position..........................................................37

AdjustingtheTracking........................................38

HydraulicSystemMaintenance...............................39

ServicingtheHydraulicSystem...........................39

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

LevelingtheMower............................................41

ServicingtheCuttingBlades...............................42

ReplacingtheGrassDeector.............................45

Cleaning.................................................................46

CleaningUndertheMower.................................46

WasteDisposal...................................................46

Storage.......................................................................46

Troubleshooting.........................................................48

Schematics.................................................................50

Safety

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol,whichmeans CAUTION,WARNING,orDANGER-“personal safetyinstruction."Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator’sposition.Useseatbelts.

•Neverraisemowerwiththebladesrunning.

•NeveroperatewithoutthePTOshield,orother guardssecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly .

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

•Stoponlevelground,lowerimplements,disengage drives,engageparkingbrake,shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

•Nevercarrypassengersandkeeppetsandbystanders away.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.

•Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

•Donotmowneardrop-offs,ditches,steepbanks orwater.Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury,death ordrowning.

•Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

•Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater.

•Reducespeedanduseextremecautiononslopes.

•Removeormarkobstaclessuchasrocks,treelimbs, etc.fromthemowingarea.Tallgrasscanhide obstacles.

•Watchforditches,holes,rocks,dips,andrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing downhill.Weighttransfertothefrontwheelsmay causedrivewheelstoslipandcauselossofbraking andsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

Maintenanceandstorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

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

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwirebefore makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Reconnectpositiverst andnegativelast.

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

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.W ear protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

•UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

ToroRidingMowerSafety

•Engineexhaustcontainscarbonmonoxide,whichis anodorless,deadlypoisonthatcankillyou.Donot runengineindoorsorinanenclosedarea.

•Stoptheengine,disconnectsparkplugwire(s)and removekeybeforeperforminganyservice,repairs, maintenanceoradjustments.

•Keephands,feet,hair,andlooseclothingawayfrom attachmentdischargearea,undersideofmowerand anymovingpartswhileengineisrunning.

•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.

•Batteryacidispoisonousandcancauseburns.Avoid contactwithskin,eyes,andclothing.Protectyour face,eyes,andclothingwhenworkingwithabattery.

•Batterygasescanexplode.Keepcigarettes,sparks andamesawayfrombattery.

•Ifloadingthemachineontoatrailerortruck,usea single,full-widthramponly.Therampangleshould notexceed15degrees.

SafeHandlingofGasoline:

Toavoidpersonalinjuryorpropertydamage,useextra carewhenhandlinggasolineandotherfuels.Theyare ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipesandother sourcesofignition.

•Neverremovethegascaporaddfuelwhenthe engineisrunning.Allowtheenginetocoolbefore refueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.

•Neverllcontainersinsideavehicleoronatruckor trailerwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.

•Keepthenozzleincontactwiththerimofthefuel tankorcontaineropeningatalltimesuntilthefueling iscomplete.Donotuseanozzlelock-opendevice.

•Iffuelisspilledonclothing,changeclothing immediately.

•Neveroverllthefueltank.Replacegascapand tightensecurely .

•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.

•Checkforproperbrakeoperationfrequently.Adjust andserviceasrequired.

SlopeChart7SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

98-5954

1-403005

54-9220

68-8340

93-8069

1.Hotsurface/burnhazard—stayasafedistancefromthe hotsurface.

99-8936

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery.

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

109-2463

112-3854

1.Pulltowbypasslevers rearwardandthenoutto lockintoplace.

2.Pushthemachine.

112-3856

1.Warning—readtheOperator’sManualformoreinformation.

2.Poisonhazard;causticliquid/chemicalburnhazard—keep childrenawayfromthebattery.

3.Explosionhazard—nore,openames,orsmoking;avoid sparks.

112-3836

112-3850

1.Slidingandlossofcontrolhazardandtippinghazard, drop-offs—donotoperatethemachineneardrop-offs, slopesgreaterthan15degrees,orwater;keepasafe distancefromdrop-offs;donotturnsharplywhiletraveling fast,instead,slowdownandturngradually .

112-3857

1.Warning—readtheOperator’sManual.

2.Cutting/dismembermenthazard,fanandentanglement hazard,belt—stayawayfrommovingparts.

112-3858

1.ReadtheOperator’s Manual.

2.Readtheinstructions beforeservicingor performingmaintenance.

3.Removetheignitionkey beforeadjustingtheheight ofcut.

4.Heightofcutsettings.

ProductOverview

Figure3

1.Sidedischargechute5.Fuelcap(bothsides)

2.Height-of-cutselectionpin

3.Controls

4.Motioncontrollever8.Frontcasterwheel

6.Parkingbrakelever

7.Mowerdeck

114–3556

Figure4

1.Ignitionswitch

2.Hourmeter5.Throttlecontrol

3.PTOSwitch

4.Chokelever

BatteryIndicatorLight

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure3andFigure4).

WhentheignitionkeyisinitiallyturnedtotheOn positionforafewseconds,thebatteryvoltagewillbe displayedintheareawherethehoursarenormally displayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure5).

1.Safetyinterlocksymbols

2.Batterylight

Closethefuelshutoffvalvebeforetransportingor storingthemachine.

Figure5

3.Hourmeter

UsingtheHourMeter

Thehourmeter(@@@5)recordsthenumberofhours theenginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance.

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengage theelectricclutchtodrivethemowerbladeswiththe rightsidemotioncontrolleverinthecenter,un-locked position.Pulltheswitchuptoengagethebladesand release.Todisengagetheblades,pushthebladecontrol switch(PTO)downormoveorreleasetherightside motioncontrolleverintotheneutrallockposition.

Figure6

1.Fuelshutoffvalve

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Off,RunandStart.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

UsingtheFuelShutoffValve

Themachinehas2fueltanks,oneontheleftsideand theotherontherightside.Eachtankconnectstoa checkvalveandthentoatee.Fromthereacommon fuellineleadstotheengine(Figure6).

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

UseUnleadedRegularGasolinesuitablefor automotiveuse(85pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.

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

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupany gasolinethatspills.

•Neverllthefueltankinsideanenclosed trailer.

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.

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

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner tothegas.

Note:Afuelstabilizer/conditionerismosteffective whenmixedwithfreshgasoline.Tominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethecap.

3.Addunleadedregulargasolinetobothfueltanks, untilthelevelis1/4to1/2inch(6mmto13mm) belowthebottomofthellerneck.

Thisspaceinthetankallowsgasolinetoexpand. Donotllthefueltankscompletelyfull.

4.Installfueltankcapssecurely.

5.Wipeupanygasolinethatmayhavespilled.

Figure7

1.SafeZone-usetheZMasterhereonslopeslessthan 15degreesoratareas.

2.Usewalkbehindmowerand/orhandtrimmerneardrop-offs andwater.

3.Water

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelin,page

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Toavoidlossofcontrolandpossibilityof rollover:

Thismachineproducessoundlevelsinexcess of85dBAattheoperatorsearandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Useprotectiveequipmentforyoureyes,hearing,feet, andhead.

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan 15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure8

1.Warningwearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.

SettingtheParkingBrake

1.Movethemotioncontrollevers(Figure15)outto theneutrallockposition.

2.Pullupandbackontheparkingbrakelevertoset theparkingbrake(Figure9).Theparkingbrake levershouldstayrmlyintheengagedposition.

Parkingbrakemaynotholdmachineparked onaslopeandcouldcausepersonalinjuryor propertydamage.

Donotparkonslopesunlesswheelsare chockedorblocked

ReleasingtheParkingBrake

Pushforwardanddownontheparkingbrakeleverto releasetheparkingbrake(Figure9).

Figure9

1.Parkingbrake–Set/ON

2.Parkingbrake– Released/OFF

StartingandStoppingthe Engine

StartingtheEngine

1.Sitontheseatandmovethemotioncontrolsto neutrallockedposition.

2.Settheparkingbrake;refertoSettingtheParking Brake.

3.MovethePTO(powertakeoff)switchtotheOff position(Figure10).

Figure10

1.PTOon(knobout)2.PTOoff(knobin)

4.Movethechokecontroltotheonpositionbefore startingacoldengine(Figure11).

Note:Awarmorhotenginemaynotrequire choking.Afterenginestarts,movechokecontrolto Runposition.

5.Movethethrottlecontroltothefastpositionbefore startingacoldengine(Figure11).

Figure11

1.Chokeon

2.Chokeoff4.Throttlefast

3.Throttleslow

6.TurntheignitionkeytoStart.Whentheengines starts,releasethekey(Figure12).

Important:Donotengagestarterformore than10secondsatatime.Ifenginefailsto startallow30secondcool-downperiodbetween attempts.Failuretofollowtheseinstructions canburnoutstartermotor.

3.Lettheengineidlefor60seconds.

4.Turntheignitionkeytotheoffpositionandremove thekey(Figure12).

5.Closethefuelshutoffvalvebeforetransportingor storingthemachine(Figure6).

Important:Makesurethatthefuelshutoff valveisclosedbeforetransportingorstoring themachine,asfuelleakagemayoccur.Setthe parkingbrakebeforetransporting.Makesure toremovethekeyasthefuelpumpmayrun andcausethebatterytolosecharge.

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

OperatingthePowerTakeOff (PTO)

Thepowertakeoff(PTO)switchstartsandstopsthe mowerbladesandanypoweredattachments.

Figure12

1.Off3.Start

2.Run

7.Aftertheenginestarts,movethechoketooff (Figure11).Iftheenginestallsorhesitates,move thechokebacktoonforafewseconds,thenmove thethrottlelevertodesiredsetting.Repeatthisas required.

StoppingtheEngine

1.PushthePTOtotheoffposition(Figure10).

2.Movethethrottlelevermidwaybetweentheslow andfastpositions(Figure11).

EngagingthePTO

1.Iftheengineiscold,allowtheenginetowarmup5 to10minutesbeforeengagingthePTO.

2.Whileseatedintheseat,releasethepressureonthe tractioncontrolleversandplaceinneutral.

3.Placethethrottleinthefastposition.

Note:EngagingthePTOwiththethrottleatthe halforlesspositionwillcauseexcessiveweartothe drivebelts.

4.Pulloutonthepowertakeoff(PTO)switchto engageit(Figure13).

Figure13

1.PTO-On(knobout)2.PTO-Off(knobin)

Figure14

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

DisengagingthePTO

Todisengage,pushthePTOswitchtotheoffposition (Figure13).

TheSafetyInterlockSystem

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Theparkingbrakeisengaged.

•Thepowertakeoff(PTO)isoff.

•Themotioncontrolleversareintheneutrallocked position

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOswitchison.

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately .

1.Sittingontheseat,engagetheparkingbrakeand movethePTOtoon.Trystartingtheengine;the engineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeand movethePTOtooff.Moveeithermotioncontrol lever(outofneutrallockedposition).Trystarting theengine;theengineshouldnotcrank.Repeatfor othercontrollever.

3.Sittingontheseat,engagetheparkingbrake,move thePTOswitchtooffandmovethemotioncontrol leverstoneutrallockposition.Nowstartthe engine.Whiletheengineisrunning,releasethe parkingbrake,movethePTOtoonandriseslightly fromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move thePTOswitchtooffandmovethemotioncontrol leverstoneutrallockposition.Nowstarttheengine. Whiletheengineisrunning,centereithermotion controlandmove(forwardorreverse);theengine shouldstop.Repeatforothermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake, movethePTOswitchtooffandmovethemotion controlleverstoneutrallockposition.Trystarting theengine;theengineshouldnotcrank.

DrivingForwardorBackward

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.

Thethrottlecontrolregulatestheenginespeedas measuredinRPM(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.

Machinecanspinveryrapidly.Operatormay losecontrolofmachineandcausepersonal injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakein,page.

2.Movetheleverstothecenter,theun-locked position.

3.Togoforward,slowlypushthemotioncontrol leversforward(Figure15).

Note:Theenginewillkillifthetractioncontrol leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretobothmotion controllevers(Figure15).

Toturn,movethemotioncontrollevertoward neutralinthedirectionyouwanttoturn(Figure15).

Thefartheryoumovethetractioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.

Tostop,pullthemotioncontrolleverstothecenter position.

Figure15

1.Motioncontrol lever-neutrallockposition

2.Centerun-lockposition

3.Forward

4.Backward

DrivingBackward

1.Movetheleverstothecenter,un-lockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure15).

Togostraight,applyequalpressuretobothmotion controllevers(Figure15).

Toturn,releasepressureonthemotioncontrollever towardthedirectionyouwanttoturn(Figure15).

Tostop,pushthemotioncontrolleverstothe neutralposition.

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers tothecenterpositionandmovethemouttothelocked position,disengagethepowertakeoff(PTO),andturn theignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakein,page.Rememberto removethekeyfromtheignitionswitch.

UsingtheLiftAssistPedal

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

AdjustingtheHeight-of-Cut

Theheight-of-cutisadjustedfrom1to5inch (25to127mm)in1/4inch(6mm)incrementsby relocatingtheclevispinintodifferentholelocations.

1.Raisetheheight-of-cutlevertothetransport position(alsothe5inch(127mm)cuttingheight position)(Figure16).

2.Toadjust,removetheclevispinfromthe height-of-cutbracket(Figure16).

3.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, inserttheclevispin(Figure16).

4.Movethelevertotheselectedheight.

Theliftassistpedalisusedforraisingthemowerdeck. Thisallowsforeasierraisingofthemowerdeck.

1.Placeyourfootontoliftassistlever.

2.Pressontheliftassistleverwhilepullinguponthe height-of-cutlever(Figure17).

Figure17

1.LiftAssistpedal2.Height-of-cutlever

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,adjustthe heightoftheanti-scalprollers.

1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Afteradjustingtheheight-of-cut,adjusttherollers byremovingtheangenut,bushing,spacer,and bolt(Figure18).

4.Selectaholesotheanti-scalprollerispositionedto thenearestcorrespondingheight-of-cutdesired.

5.Installtheangenutbushing,spacer,andbolt. Torqueto40-45ft-lb(54-61N•m)(Figure18).

6.Repeatthisadjustmentontheotheranti-scalp rollers.

Figure16

1.Heightofcutholes2.ClevisPin

Figure18

1.Bolt4.Anti-scalproller

2.Anti-scalprollerbracket

3.FlangeNut6.Bushing

5.Spacer

PushingtheMachinebyHand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay occur.

ToPushtheMachine

1.Disengagethebladecontrolswitchandmovethe controlleverstotheneutrallockedpositionand applytheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pullthetwobypassleversrearwardandpushthem totheoutsideintotheslottolockthemintoplace. (Figure20).

Note:Makesurebothbypassleversaredisengaged beforepushingthemachine.

4.Disengagetheparkingbraketopushthemachine.

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.

1.Raisetheseatandloosentheadjustmentbolts (Figure19).

2.Movetheseattothedesiredpositionandtighten thebolts.

1.Adjustmentbolts

Figure19

2.Seat

G004250

21

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

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

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytoclearthedischargeareaor mowerbladesunlessyoumovethepower takeoff(PTO)totheoffposition,rotatethe ignitionkeytooffandremovethekey .

•Makesurethegrassdeectorisinthedown position.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall

Figure20

1.Bypasslever

2.Topviewofengine

3.Slot

ToOperatetheMachine

Pusheachbypasslevertotheinsideandpushthem forward(Figure20).

Note:Themachinewillnotdriveunlessthebypass leversarepushedforward.

UsingtheSideDischarge

necessarylightingandmarkingasrequiredbylaw . Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.

Totransportthemachine:

•Lockthebrakeandblockthewheels.

•Securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes.

•Secureatrailertothetowingvehiclewithsafety chains.

Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow movingvehicleemblemisdangerousandcan leadtoaccidentscausingpersonalinjury.

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

Donotdrivemachineonapublicstreetor roadway.

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure21). Thelowerrearsectionofthetractorframeextends backbetweentherearwheelsandservesasastopfor tippingbackward.Havingafullwidthrampprovides asurfacefortheframememberstocontactifthe unitstartstotipbackward.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.

Therampshouldbelongenoughsothattheangles donotexceed15degrees(Figure21).Asteeperangle maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.

Figure21

1.Trailer3.Notgreaterthan 15degrees

2.Fullwidthramp4.Fullwidthrampsideview

Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

Loadingaunitontoatrailerortruckincreases thepossibilityofbackwardtip-overandcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideofthe unit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbrokenramp surfacewiderthantheunit.

OperatingTips

FastThrottleSetting

Forbestmowingandmaximumaircirculation,operate theengineatthefastthrottleposition.Airisrequired tothoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower byuncutgrass.Alwaystrytohaveonesideofthe mowerfreefromuncutgrass,whichallowsairtobe drawnintothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethe cuttingheightofthemowerdoesnotscalpanyuneven ground.However,thecuttingheightusedinthepastis generallythebestonetouse.Whencuttinggrasslonger thansixinchestall,youmaywanttocutthelawntwice toensureanacceptablequalityofcut.

•Donotexceeda15degreeanglebetween rampandgroundorbetweenrampand trailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtippingbackward.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

MowatCorrectIntervals

Normally,moweveryfourdays.Butremember, grassgrowsatdifferentratesatdifferenttimes.So tomaintainthesamecuttingheight,whichisagood practice,mowmoreofteninearlyspring.Asthegrass growthrateslowsinmidsummer,mowlessfrequently. Ifyoucannotmowforanextendedperiod,rstmow atahighcuttingheight;thenmowagaintwodayslater atalowerheightsetting.

CuttingSpeed

Toimprovecutquality,useaslowergroundspeedin certainconditions.

AvoidCuttingTooLow

shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.Checkthecutterblades dailyforsharpness,andforanywearordamage.File downanynicksandsharpenthebladesasnecessary.If abladeisdamagedorworn,replaceitimmediatelywith agenuineTOROreplacementblade.

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raise thecuttingheighthigherthanusualandcutthegrassat thissetting.Thencutthegrassagainusingthelower, normalsetting.

WhenStopping

Ifthemachine’sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyour lawn.T oavoidthis,moveontoapreviouslycutarea withthebladesengaged.

KeeptheUndersideoftheMower Clean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst250hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Checkforanyloosefastenersandtightenthem.

•Changetheengineoil.

•Tightenthewheellugnuts.

•Checkthehydraulicuid.

•Changethehydraulicltersandoil.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrake.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.(moreoftenindirtyordustyconditions)

•Checkthepaperaircleanerelement.(moreoftenindirtyordustyconditions)

•Checkthetirepressure.

•Checkpumpdrivebelt.

•Checkthehydraulicuid.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Checkthesparkplugs.

•Checkandcleanenginecoolingnsandshrouds.

•Inspectallbeltsforcracksandwear.

Every150hours

Every200hours

Every500hours

Yearly

Important:Refertoyour

•Lubricatethemachinewithlightoil

•Replacethepaperaircleanerelement.

•Replacetheoillter

•Replacethefuellter .

•Adjustthecasterpivotbearing.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions)

•Lubricatethecasterwheelhubs.

•Changethehydraulicltersandoil.

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthewirefromthesparkplug(s)beforeyoudoany maintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

Lubrication

frequentlywhenoperatingconditionsareextremely dustyorsandy.

GreasingandLubrication

LubricatethemachinewhenshownontheCheck ServiceReferenceAiddecal(Figure22).Greasemore

GreaseType:General-purposegrease.

HowtoGrease

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

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

5.Wipeupanyexcessgrease.

GreasingtheFrontCasterPivots

Figure23

Brakehandlepivot

ServiceInterval:Yearly(moreoftenindirtyordusty

conditions)

1.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Refer toAdjustingtheCasterPivotBearingin,page.

2.Removethehexplug.Threadagreasezerkintothe hole.

3.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

4.Removethegreasezerkinthehole.Installthehex plugandcap.

WheretoAddGrease

LubricatethegreasettingsasshownontheCheck ServiceReferenceAiddecal(Figure22).

GreaseandoilthelinkagesasshowninFigure24and Figure25.

Figure22

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every150hours(Referto

Lubrication).

Lubricatethemachineinthefollowingareaswithspray typelubricantorlightoil.

•Seatswitchactuator.

•Brakecontrollinks.

•Motioncontrolpivots.

Figure24

Figure25

LubricatingtheCasterWheel Hubs

ServiceInterval:Yearly

Figure26

1.Casterfork4.Casterwheel

2.Bolt5.Nut

3.Sealguard

Note:Whenperformingthisprocedure,theoldseals willneedtobereplacedwithnewseals.Contactan AuthorizedServiceDealerforthecorrectseals.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethefrontofthemachineandsupportitwith jackstands.

4.Removethennutandboltholdingthecasterwheel tothefrontcasterfork(Figure26).

5.Removethesealguardfromthewheelhub (Figure26).

6.Removeoneofthespacernuts(withwrenchats) fromtheaxle(Figure28).

Note:Threadlockingadhesivehasbeenapplied tothespacernuts.

7.Removetheaxlewithoutremovingtheopposite spacernut(Figure28).

8.Removethesealsandinspectthebearingsforwear ordamage.Replacethebearingsifneeded.

9.Packthebearingswithgeneralpurposegrease.

10.Insertthebearingandanewsealintothewheel (Figure28).

Note:Donotinstallthenutallthewayontothe axle.

11.Ifbothspacernutswereremovedfromtheaxle, applythreadlockingadhesivetothespacernut. Installthespacernutsontotheaxleleavingan1/8 inch(3mm)ofthenutpasttheaxle(Figure27).

Figure27

1.1/8inch(3mm)ofthenutpasttheaxle

12.Installtheassemblednutandaxleintothewheelon thesidewiththebearingandanewseal(Figure28).

13.Placethewheelwiththeopenendfacingupandll theareainsidethewheelwithmulti-purposegrease.

14.Installthesecondbearingandanewsealintothe wheel(Figure28).

15.Applythreadlockingadhesivetothesecondspacer nutandinstallitontotheaxlewiththewrenchats facingoutward.

16.Torquethespacernutto75-80in-lb(8-9N⋅m)then loosenitandtorqueitto20–25in-lb(2-3N⋅m). Makesuretheaxledoesnotextendpasteithernut (Figure27).

Figure28

1.Spacernut4.Casterwheel

2.Bearingseal(newseals required)

3.Bearing

5.Nutandaxleassembled

17.Installthesealguardsoverthewheelhubsandinsert thewheelintothecasterfork(Figure26).

18.Installthecasterboltandtightenthenut(Figure26).

Important:Checkthebearingadjustmentoften topreventsealandbearingdamage.Spinthe castertire.Thetireshouldnotspinfreelymore than1to2revolutionsorhaveanyside-to-side playbetweenthecasterfork.Ifthewheelspins freely,adjustthetorqueonthespacernutuntil thereisaslightamountofdrag.

EngineMaintenance

ServicingtheAirCleaner

Important:Donotoilthefoamorpaperelement.

Note:Servicetheaircleanermorefrequently(every

fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy .

RemovingtheFoamandPaper Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage (Figure29).

4.Unscrewthecoverknobandremovetheaircleaner cover(Figure29).

5.Removethe2wingnutsandremovetheaircleaner assembly(Figure29).

6.Carefullypullthefoamelementoffthepaper element(Figure29).

Figure29

1.Engine4.Foamelement

2.Cover

3.Wingnut

5.Paperelement

6.Coverknob

CleaningtheFoamAirCleanerElement

ServiceInterval:Every25hours(moreoftenindirty

ordustyconditions)

1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis tornorworn.

ServicingthePaperAirCleaner Element

ServiceInterval:Every50hours(moreoftenindirty

ordustyconditions)

Every200hoursoryearly ,whichever occursrst.

1.Donotcleanthepaperlter,replaceit.(Figure29).

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure29).

2.Placetheaircleanerassemblyontotheaircleaner baseandsecureitwiththe2wingnuts(Figure29).

3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure29).

ServicingtheEngineOil

Note:Changetheoilmorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

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

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

Viscosity:Refertothetablebelow

Figure31

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean (Figure31).

6.Slidetheoildipstickfullyintothellertube,butdo notthreadontotube(Figure31).

7.Pullthedipstickoutandlookatthemetalend.Ifthe oillevelislow,slowlypouronlyenoughoilintothe llertubetoraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewith oilandruntheengine;enginedamagecan result.

ChangingtheOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirty ordustyconditions)

Figure30

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface.

2.DisengagethePTO,turntheignitionkeytooff,and removethekey.

3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthenchockorblocktires.

4.Cleanaroundtheoildipstick(Figure31)sothatdirt cannotfallintothellerholeanddamagetheengine.

1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain valvetoallowoiltodrain(Figure32).

7.Whenoilhasdrainedcompletely,closethedrain valve.

8.Removethedrainhose(Figure32).

Note:Disposeoftheusedoilatarecyclingcenter.

3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure33).

4.Installthereplacementoilltertothelteradapter, turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional3/4turn(Figure33).

5.Fillthecrankcasewiththepropertypeofnewoil; refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine, andcheckforoilleaksaroundtheoillter.

7.Checktheengineoillevelandaddoilifneeded.

ServicingtheSparkPlugs

ServiceInterval/Specication

Figure32

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil intothellertube(Figure31).

10.Checktheoillevel;refertoCheckingtheEngineOil Level.

11.SlowlyaddtheadditionaloiltobringittotheFull mark.

ChangingtheOilFilter

ServiceInterval:Every200hoursoreveryotheroil

change.

Note:Changetheoilltermorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Removetheoldlter(Figure33).

Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstallingthe sparkplugsandagappingtool/feelergaugetocheckand adjusttheairgap.Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Disconnectthewiresfromthesparkplugs (Figure34).

1.Oillter

Figure33

Figure34

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom fallingintotheengineandpotentiallycausing

2.Adapter

damage.

5.Removethesparkplugsandthemetalwashers.

CheckingtheSparkPlugs

ServiceInterval:Every100hours

1.Lookatthecenterofthesparkplugs(Figure35). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto removecarbondeposits.

FuelSystem Maintenance

DrainingtheFuelTank

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

•Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopen area.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.

Figure35

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

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

3.Checkthegapbetweenthecenterandsideelectrodes (Figure35).Bendthesideelectrode(Figure35)if thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure thattheairgapissetcorrectly.

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

3.Connectthewirestothesparkplugs(Figure35).

1.Parkthemachineonalevelsurface,toensurethat thefueltankdrainscompletely.

2.Disengagethebladecontrolswitchandmovethe controlleverstotheneutrallockedpositionand applytheparkingbrake.

3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Closethefuelshut-offvalvelocatedunderthefront ofthefueltank.

5.Loosenthehoseclampatthefuellterandslideit upthefuellineawayfromthefuellter(Figure36).

6.Pullthefuellineoffofthefuellter(Figure36).

7.Openthefuelshut-offvalve.Allowgasolinetodrain intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuel lterbecausethefueltankisempty.

ReplacingtheFuelFilter

ServiceInterval:Every200hoursoryearly ,whichever

occursrst.

Neverinstalladirtylterifitisremovedfromthefuel line.

1.Disengagethebladecontrolswitchandmovethe controlleverstotheneutrallockedpositionand applytheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Closethefuelshut-offvalvelocatedunderthefront ofthefueltank.

4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure36).

ElectricalSystem Maintenance

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose tothelter(Figure36).

Important:Installtheltersothedirectionof theowarrowisconsistentwiththeowoffuel; fromthegastanktotheengine.

7.Openthefuelshut-offvalve.

Figure36

1.Fuellter

2.Hoseclamp

3.Fuelline

ServicingtheBattery

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling .

Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.

RemovingtheBattery

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery ,do notallowthebatteryterminalstotouchany metalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.

•AlwaysDisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.

•AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative (black)cable.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Unlatchtheseatandtilttheseatup.

4.Firstdisconnectthenegativebatterycableand groundwirefromthenegative(-)batteryterminal (Figure37).

5.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure37).

Figure37

1.Battery7.J-bolts

2.Positivebatterypost

3.Negativebatterypost

4.Terminalboot10.Negativebatterycable

5.Batteryclamp

6.Wingnut(1/4inch)

8.Bolt(1/4x3/4inch)

9.Groundwire

11.Locknut(1/4inch)

12.Positivebatterycable

6.Removebothwingnuts(1/4inch)securingthe batteryclamp(Figure37).

7.Removethebattery.

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts towardtheengine(Figure37).

2.First,installthepositive(red)batterycableto positive(+)batteryterminal.

3.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminal.

4.Securethecableswith2bolts(1/4x3/4inch), 2washers(1/4inch),and2locknuts(1/4inch) (Figure37).

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.SecurebatterywithJ-bolts,holddownclampand 2washers(1/4inch),and2wingnuts(1/4inch) (Figure37).

ChargingtheBattery

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).

1.Chargebatteryfor10to15minutesat25to30amps or30minutesat4-6amps.

2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure38).

Figure39

1.Fuseblock

2.Clutch,10amp(F3)4.Main,30amp(F1)

3.Chargecircuit,25amp (F2)

Figure38

3.Installthebatteryinthemachineandconnectthe batterycables;refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheck component/circuitformalfunctionorshort.

1.Raisetheseattogainaccesstothefusesontheleft sideofthemachine(Figure39).

2.Toreplacethefuses,pulloutonthefusetoremove it.

3.Installanewfuse(Figure39).

DriveSystem Maintenance

CheckingtheTirePressure

ServiceInterval:Every50hoursormonthly ,whichever

occursrst.

Checkthepressureatthevalvestemafterevery 50operatinghoursormonthly,whicheveroccursrst (Figure40).

Maintaintheairpressureinthereartiresat13psi(90 kPa).Uneventirepressurecancauseunevencut.Check thetireswhentheyarecoldtogetthemostaccurate pressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.

Figure40

AdjustingtheCasterPivot

Figure41

1.SpringWashers3.DustCap

2.LockNut

Bearing

ServiceInterval:Every500hours

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethedustcapfromcasterandtightenlock nut(Figure41).

4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(Figure41).

Important:Makesurespringwashersare installedcorrectlyasshowninFigure41.

5.Installthedustcap(Figure41).

CoolingSystem Maintenance

BrakeMaintenance

ServicingtheBrakes

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

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

CleaningtheEngineCooling System

ServiceInterval:Every100hoursoryearly ,whichever

occursrst.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removetheengineguard,theengineairintake screen,andthefanhousing(Figure42).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installtheengineguard,theengineairintakescreen, andthefanhousing(Figure42).

Beforeeachuse,checkthebrakesonbothalevelsurface andslope.

Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely ,seeanAuthorizedServiceDealerfor maintenance.

CheckingtheBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengagethe bladecontrol(PTO).

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Applytheparkingbrake.Thewheelsmustlock whenyoutrytopushthemachineforward.

4.Ifthewheelsdonotlock,seeanAuthorizedService Dealerformaintenance.

5.Releasethebrakesandmovetheneutral/brake lockstotheneutralposition.Thewheelsshould rotate,ifnot;seeanAuthorizedServiceDealerfor maintenance.

Figure42

1.Engineguard4.Bolt

2.Engineairintakescreen

3.Fanhousing

5.Screw

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every100hours—Inspectallbelts

forcracksandwear.

Checkbeltsforcracks,frayededges,burnmarksorany otherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

Thesignsofawornmowerbeltaresquealingwhilethe beltisrotating,bladesslippingwhileyouarecutting grass,frayedbeltedges,burnmarks,andcracks.Replace themowerbeltifyoudetectanyofthesesigns.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Remove2boltsandwashersineachbeltcoverand removethebeltcoversovertheoutsidespindles (Figure45).

Figure44

40inchMower

1.Fixedidlerpulley3.Mowerbelt

2.Leftspindlepulley4.Spring-loadedidlerarm

8.Installthebeltcoversovertheoutsidespindles (Figure45).

Note:Non-commercialownerswillneedtoinstall thefrontwasherandboltthatholdsthebeltcover inplace.

4.Pullontheidlerarmtorelievethebelttensionon theleftspindlepulley(Figure43orFigure44).

5.Removetheoldbelt.

6.Installthenewbeltaroundthepulleys(Figure43 orFigure44).

7.Installthebeltontothespringloadedidlerpulley.

Figure43

34inchMower

1.Fixedidlerpulley3.Mowerbelt

2.Leftspindlepulley4.Spring-loadedidlerarm

Figure45

40inchmowershown

1.Leftbeltcover

2.Rightbeltcover4.Bolt

3.Washer

CheckingandReplacingthe PumpDriveBelt

ServiceInterval:Every50hours—Checkpumpdrive

belt.

1.Pushtheseatforwadandlocatethepumpdrivebelt.

Note:Non-commercialownerswillneedtoloosen theseatretainerclipthatholdstheseatinplace.

2.Checkthebeltforwearandreplaceitifneeded.

3.Toreplacethebelt,removetheboltfromtheclutch stopandunplugtheclutchelectricalwire(Figure46).

ControlsSystem Maintenance

AdjustingtheControlHandle

4.Pullontheidlerpulleytorelievethebelttensionon theidlerpulley(Figure46).

5.Removethepumpdrivebeltfromtheengineandthe hydraulicpumppulleys(Figure46).

6.Installthenewbeltaroundtheengineandthe hydraulicpumppulleys(Figure46).

7.Pullthespring-loadedidlertothesideandalignthe belt.

8.Releasethepressureonthespringloadedidler (Figure46).

NeutralPosition

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Loosentheboltsandcurvedwashersinstalledinthe levers(Figure47).

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslide themuntiltheyarealigned,thentightenthebolts (Figure48).

Figure46

1.Belt3.Enginepulley

2.Transmissionpump pulleys

4.Springloadedidlerpulley

Figure47

Figure48

5.Iftheendsofthelevershitagainsteachother,adjust theleversbyrotatingthemouttotheneutrallocked positionandcarefullybendthemoutward.Repeat thisstepasneeded.

AdjustingtheTracking

1.Ifthemachineturnsrightorleftwhenthehandles arepushedforwardtogether,adjustthestoponthe sideoppositethatthemachineturns.

2.Loosentheboltlocatedinfrontofthecontrollever.

3.Movethestopuntilthemachinedrivesstraight (Figure49).

4.Tightentheboltlocatedinfrontofthecontrollever (Figure49).

Figure49

1.Controllever3.Boltinfrontofthecontrol lever

2.Stop

HydraulicSystem Maintenance

ServicingtheHydraulic System

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every50hours

FluidType:Mobil115W -50syntheticmotoroilor equivalentsyntheticoil.

Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.

Note:Therearetwowaysofcheckingthehydraulic oil;whentheoiliswarmorwhentheoiliscold.The tankhastwolevelsdependingiftheoiliswarmorcold (Figure50).

1.Positionthemachineonalevelsurfaceandsetthe parkingbrake.

2.Cleantheareaaroundthehydraulictank(Figure50).

3.Ifthemachinehasnotbeenstartedandiscold, ensuretheuidisuptothecoldlineonthesideof thehydraulictank.

4.Ifthemachinehasbeenrunandisuptonormal operatingtemperature,ensuretheuidisuptothe hotlineonthesideofthehydraulictank.

5.Ifuidisneeded,removethecapfromtheller neck(Figure50).

6.Adduidtothereservoiruntilitreachesthecoldor hotlineofthetankdependingonthetemperature oftheuid.

7.Installthecaponllerneck.

Figure50

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

ReplacingtheHydraulicFiltersandOil

ServiceInterval:Aftertherst250hours

Yearly—Changethehydrauliclters andoil.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.

3.Locatethetwolters,oneundereachtransmission andremovethelterguards.

4.Carefullycleantheareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem(Figure51).

5.Unscrewtheltersandallowtheoiltodrainfrom thedrivesystem(Figure51).

Important:Beforereinstallingnewlters, applyathincoatofoilonthesurfaceofthe ltersrubberseal.

6.Installthenewltersclockwiseuntilrubberseal contactsthelteradapterandthentightenthelter anadditional3/4to1fullturn.

changinglter),unlessitisfelttheoilhasbeen contaminatedorbeenextremelyhot.Changing theoilunnecessarilycoulddamagethehydraulic systembyintroducingcontaminatesintothe system.

7.Removetheventplugoneachtransmissionandll throughthehydraulictank,whenoilcomesoutof ventreinstallplug.T orquetheplugsto180in-lb (244N⋅m).

8.Addoiluntilitreachesthecoldlineonthehydraulic tank(Figure50).

9.Raisetherearofmachineupjustenoughtoallow thedrivewheelstoturnfreelyandsupportitwith jackstands.

10.Starttheengineandmovethethrottlecontrolahead tothe1/2throttleposition.Disengagetheparking brake.

11.Withthebypassvalveopenandtheenginerunning, slowlymovethedirectionalcontrolinbothforward andreverse5or6times.

12.Withthebypassvalveclosedandtheengine running,slowlymovethedirectionalcontrolinboth forwardandreversedirections5to6times.Stop theengineandchecktheoillevel,andaddoilas requiredtothehotline.

13.Repeatitems11and12asnecessaryuntilalltheair iscompletelypurgedfromthesystem.Whenthe transaxleoperatesatnormalnoiselevelsandmoves smoothlyforwardandreverseatnormalspeeds,then thetransaxleispurged.

1.Leftreartire

2.Hydrauliclter

Figure51

3.Ventplug

Important:Donotchangehydraulicsystem oil(exceptforwhatcanbedrainedwhen

MowerDeck Maintenance

LevelingtheMower

Important:Thereareonlythreemeasuring

positionsneededtolevelthemower.

1.Positionmoweronaatsurface.

2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Checktirepressureofthereartires.Ifneeded,adjust to13psi(90kPa)

5.Placetwothickblocksunderrearleftandrightlower edgeofthemowerdecksotheweightofthedeck restsontheblocks.

6.Lowerthemowertothe3inch(76mm)height-of-cut position.

7.Loosentheboltsconnectingthetwochainsandthe tworearbracketstothemower(Figure53).

8.Adjustthetworearboltssotheyareinthemiddleof theslotlocatedinthepivotbracket(Figure53).

9.Adjusttheboltssotheendoftheboltisushwith thenut.Thiswillallowthebushingtorollintheslot inthemowerdeckbracket(Figure52).

10.Adjustthedischargesidefrontboltsoitisinthe middleoftheslotlocatedinthepivotbracket (Figure53).

11.Raisethemowerdeckandremovetheblocksholding upthemowerdeck.

12.Adjusttheleftfrontboltinthepivotbracketsothe chainhasnoslackinit.

13.Inspectthefourchains.Thechainsneedtohave tension.

Note:Themowerdeckcuttingheightcanbe adjusted.Loosentheheightofcutbracketandadjust itforwardorbackwardtogetthecorrectheight. Tightenthebracketaftertheadjustmentismade.

Figure52

1.Keeptheendofthebolt ushwiththenut

2.Rearpivotbracket4.Bolt

3.Nut

Note:Whenproperlyadjusted,thefrontbladetip willbea1/4inch(6mm)lowerfor34inchmowers and3/16(4mm)lowerfor40inchmowersthanthe rearbladetip.RefertoCheckingforBentBladesfor theproceduretomeasurethebladetipheight.

14.Therightbladeatthefrontposition(Figure55or Figure56)needstobethesameheightastheleft bladeatthefrontposition.

Ifthereismorethanan1/8inch(3mm)difference betweenleftandright,thenadjustthemounting boltsintheslottolevelthemowerdecklefttoright.

Figure53

Leftsideshown

1.Pivotbracket3.Rearpivotbracket

2.Boltinstalledinthemiddleoftheslot

4.Frontpivotbracket

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.

Checkthecutterbladesdailyforsharpness,andforany wearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn, replaceitimmediatelywithagenuineTororeplacement blade.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagetheblade control(PTO),andsettheparkingbrake.Turnthe ignitionkeytoOff.Removethekey .

InspectingtheBlades

G004621

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure54).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea (Figure54).Ifyounoticeanydamage,wear,oraslot forminginthisarea(Figure54),immediatelyinstalla newblade.

Figure55

34inchMower

Figure54

1.CuttingEdge3.Wear/slotForming

2.CurvedArea

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure55orFigure56).Measurefroma levelsurfacetothecuttingedgeatpositionA,ofthe blades(Figure55orFigure56).Notethisdimension.

1.Measureherefromblade tohardsurface

40inchMower

1.Measureherefromblade tohardsurface

2.PositionA

Figure56

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/16inch(1.5mm). Ifthisdimensionexceeds1/16inch(1.5mm), thebladeisbentandmustbereplaced;referto RemovingtheBladesandInstallingtheBlades.

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineT ororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnonconformancewithsafetystandards.

Contactwithasharpbladecancauseserious injury.

Wearglovesorwrapsharpedgesoftheblade witharag.

Figure57

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure58).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure59).Repeatthis procedureuntilthebladeisbalanced.

Figure58

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure59).

1.Holdthebladeendusingaragorthickly-padded glove.

2.Removethebladebolt,springdiskandbladefrom thespindleshaft(Figure59).

SharpeningtheBlades

Whensharpeningblade,piecesofbladecould bethrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpening blade.

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure57).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.

2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead (Figure59).Torquethebladeboltto85-110ft-lb (115-150N•m).

Figure59

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeTowardsBoltHead

ReplacingtheGrassDeector

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.

•Neveroperatethelawnmowerunlessyou installacoverplate,amulchplate,oragrass chuteandcatcher.

•Makesurethegrassdeectorisinthedown position.

Figure60

1.Bolt5.Locknut

2.GrassDeector6.Springinstalled

3.Spring

4.Spacer

7.Mowerdeck

1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure60). Removethedamagedorworngrassdeector.

2.Placethespacerandspringontograssdeector. Placeoneendofspringbehinddeckedge.

Note:Makesuretheendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure60.

3.Installtheboltandnut.Placetheendofthespring aroundthegrassdeector(Figure60).

Important:Thegrassdeectormustbeableto lowerdownintoposition.Liftthedeectorup totestthatitlowersintothefulldownposition.

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemowertothetransportposition.

4.Liftthefrontofthemachineandsupportthe machineusingjackstands.

WasteDisposal

Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.

Storage

1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytoOff.Removethe key.

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engineandhydraulicsystem.Cleandirtandchaff fromtheoutsideoftheenginecylinderheadnsand blowerhousing.

Important:Youcanwashthemachinewith milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuseof water,especiallynearthecontrolpanel,engine, hydraulicpumps,andmotors.

3.Servicetheaircleaner;refertoServicingtheAir Cleanerin,page.

4.Greasethemachine;refertoGreasingand Lubricationin,page.

5.Changethecrankcaseoil;refertoServicingthe EngineOilin,page.

6.Checkthetirepressure;refertoCheckingtheTire Pressurein,page.

7.Changethehydrauliclter;refertoServicingthe HydraulicSystemin,page.

8.Chargethebattery;refertoServicingtheBatteryin, page.

9.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:RunthemachinewiththePTOengaged andtheengineathighidlefor2to5minutesafter washing.

10.Checktheconditionoftheblades;refertoServicing theCuttingBladesin,page.

11.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachineforstorage asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandused atalltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankin, page.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Important:Donotstore stabilizer/conditionedfuelover90days.

12.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.

13.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

14.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitoutofreachofchildrenorotherunauthorized users.Coverthemachinetoprotectitandkeepit clean.

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Bladecontrol(PTO)isengaged.1.Movethebladecontrol(PTO)to

2.Parkingbrakeisnoton.

3.Operatorisnotseated.3.Sitontheseat.

4.Batteryisdead.

5.Electricalconnectionsarecorrodedor loose.

6.Fuseisblown.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.

2.Aircleanerisdirty.

3.Dirtinthefuellter.3.Replacethefuellter.

4.Dirt,water ,orstalefuelisinthefuel system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesabove theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

6.Dirtinthefuellter.6.Replacethefuellter.

7.Dirt,water ,orstalefuelisinthefuel system.

disengaged.

2.Settheparkingbrake.

4.Chargethebattery.

5.Checktheelectricalconnectionsfor goodcontact.

6.Replacethefuse.

1.Fillthefueltankwithfuel.

2.Cleanorreplacetheaircleaner element.

4.ContactanAuthorizedServiceDealer.

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesabove theengineareplugged.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or bladepulley .

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

Problem

PossibleCauseCorrectiveAction

Unevencuttingheight.

Bladesdonotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Mowerisnotlevel.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley .

3.Deckbeltisworn,looseorbroken.3.Installanewdeckbelt.

4.Deckbeltisoffpulley .

5.Brokenormissingidlerspring.5.Replacethespring.

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

6.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installthedrivebeltandcheck adjustingshaftsandbeltguidesfor correctposition.

4.Installthedeckpulleyandcheckthe idlerpulley,idlerarmandspringfor correctpositionandfunction.

Schematics

WireDiagram(Rev.A)

Notes:

The Toro Total Coverage Guarantee

A Limited Warranty (see warranty periods below)

Landscape

Contractor

Equipment (LCE)

The Toro Company and its afﬁliate, Toro Warranty Company, pursuant to an

Conditions and Products Covered

agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.

The following warranty time periods apply from the date of purchase by the original owner:

Product Warranty Period

Mid-Size Walk-Behind Mowers 2 years** GrandStand

•

Z Master

•

Z Master® G3 Mowers

•

Batteries (for above units)

Mowers Engine Frame

Z300, Z400, Z500 Mowers Engine Frames

Engine Frame

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

4 years or 1,200 hours* 2 years** Lifetime (original owner only)***

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

1 year

Attachments (for above units) 1 year

*Whichever occurs ﬁ rst. **Some engines used on Toro LCE Products are warranted by the engine manufacturer. ***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form the tractor structure that other components such as the engine are secured to, cracks or breaks in normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame failure due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.

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

Instructions for Obtaining Warranty Service

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

1. Contact any Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our web site at www.Toro.com. You may also call the numbers listed in item #3 to use the 24-hour Toro Dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. The dealer will diagnose the problem and determine if it is covered under warranty.

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

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-865-5676 (U.S. Customers) 888-865-5691 (Canada customers)

You must maintain your Toro Product by following the maintenance

Owner Responsibilities

procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

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

Cost of regular maintenance service or parts, such as ﬁ lters, fuel,

• lubricants, tune-up parts, blade sharpening, brake and clutch adjustments. Any product or part which has been altered or misused or required

• replacement or repair due to normal wear, accidents, or lack of proper maintenance. Repairs necessary due to improper fuel, contaminants in the fuel system,

• or failure to properly prepare the fuel system prior to any period of nonuse over three months.

Pickup and delivery charges.

•

General Conditions

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

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

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

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

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

Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee

Countries Other than the United States or Canada

policies for your country, province, or state. If for any reason you are dissatisﬁ ed with your Distributor’s service or have difﬁ culty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part Number 374-0037 Rev. H

Toro 74408, 74408CP, 74409CP Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual