Toro TimeCutter ZX440, TimeCutter ZX525 Operator's Manual

Download

Page 1

Form No. 3354-630 Rev A

TimeCutter® ZX440 and ZX525 Riding Mowers

Model No. 74406 —Serial No. 260000001 and Up Model No. 74407 —Serial No. 260000001 and Up

Page 2

F or models with stated engine horse po w er , the g ross horse po w er of the engine w as laborator y rated b y the engine man ufacturer in accordance with SAE J1940. As conﬁgured to meet safety , emission, and operating requirements , the actual engine horse po w er on this class of la wn mo w er will be signiﬁcantly lo w er .

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Figure 1

1. Model and serial number plate

Model No.

Serial No.

Figure 2

1. Safety alert symbol.

T his man ual uses tw o other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

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

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

Safe Operation Practices for

Ride-on (riding) R otar y La wnmo w er

Mac hines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Riding Mo w er Safety . . . . . . . . . . . . . . . . . . . 5

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sound P o w er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

R ecommended Gasoline . . . . . . . . . . . . . . . . . . . . 12

Chec king the Engine Oil Lev el . . . . . . . . . . . 14

Using the P arking Brak e . . . . . . . . . . . . . . . . . . . . . 14

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operating the Blades . . . . . . . . . . . . . . . . . . . . . . . . . 15

T he Safety Interloc k System . . . . . . . . . . . . . . . 15

Dri ving F orw ard or Bac kw ard . . . . . . . . . . . . 16

Stopping the Mac hine . . . . . . . . . . . . . . . . . . . . . . . . 17

Adjusting the Height of Cut . . . . . . . . . . . . . . . 17

Adjusting the Anti-Scalp

R ollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

P ositioning the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Page 3

Adjusting the Motion Control

Lev ers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pushing the Mac hine b y Hand . . . . . . . . . . . . 18

Con v er ting to Side Disc harg e . . . . . . . . . . . . . 19

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

Ho w to Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

W here to Add Grease . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 24

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 25

Cleaning the Cooling System . . . . . . . . . . . . . . 27

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Draining the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 28

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 28

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 31

Mo w er Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Cutting Blades . . . . . . . . . . . . . . . 32

Lev eling the Mo w er from

Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . 33

Adjusting the F ront-to-R ear Blade

Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

R emo ving the Mo w er . . . . . . . . . . . . . . . . . . . . . . . . 35

Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

R e placing the Mo w er Belt . . . . . . . . . . . . . . . . . . 36

Installing the Mo w er . . . . . . . . . . . . . . . . . . . . . . . . . . 37

R e placing the Grass Deﬂector . . . . . . . . . . . . 37

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

W ashing the Underside of the

Mo w er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Cleaning and Storag e . . . . . . . . . . . . . . . . . . . . . . . . . 39

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Page 4

Safety

Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines

T his mac hine meets or ex ceeds European Standards in effect at the time of production. Ho w ev er , improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means CA UTION , W ARNING , or D ANGER -“personal safety instr uction. ” F ailure to comply with the instr uction ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Training

• R ead the instr uctions carefully . Be familiar with the controls and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use the la wnmo w er . Local regulations can restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to other people or their proper ty .

• Do not car r y passeng ers .

• All dri v ers should seek and obtain professional

and practical instr uction. Suc h instr uction should emphasize:

◊ being dri v en too fast;

◊ inadequate braking;

◊ the type of mac hine is unsuitable for its

task;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear and long trousers . Do not operate the equipment when barefoot or w earing open sandals .

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning-Fuel is highly ﬂammable .

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers .

• Before using, alw a ys visually inspect to see that

the blades , blade bolts and cutter assembly are not w or n or damag ed. R e place w or n or damag ed blades and bolts in sets to preser v e balance .

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application of the brak e . T he main reasons for loss of control are:

◊ insufﬁcient wheel g rip;

• On m ulti-bladed mac hines , tak e care as rotating one blade can cause other blades to rotate .

Operation

• Be aler t, slo w do wn and use caution when making tur ns . Look behind and to the side before c hanging directions .

Page 5

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes and shift into neutral.

• Do not use on slopes of more than 12-1/2 deg rees .

• R emember there is no suc h thing as a safe slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– do not stop or star t suddenly when g oing

up or do wnhill;

– use lo w speeds on slopes and during tight

tur ns;

– sta y aler t for humps and hollo ws and other

hidden hazards;

• Use care when pulling loads .

– Use only appro v ed dra wbar hitc h points . – Limit loads to those y ou can safely control. – Do not tur n shar ply . Use care when

rev ersing .

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Nev er operate the mac hine with damag ed guards or without safety protecti v e devices in place .

• Do not c hang e the engine g o v er nor settings or o v erspeed the engine . Operating the engine at ex cessi v e speed can increase the hazard of personal injur y .

• Before lea ving the operator’ s position:

– diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments , stop the engine , and disconnect the spark plug wire(s) or remo v e the ignition k ey

– before clearing bloc kag es or unclog ging

c hute;

– before c hec king, cleaning or w orking on

the la wnmo w er;

– after striking a foreign object. Inspect

the la wnmo w er for damag e and mak e re pairs before restar ting and operating the equipment;

– if the mac hine star ts to vibrate abnor mally

(c hec k immediately).

• Diseng ag e dri v e to attac hments when transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to attac hment

– before refuelling;

– before remo ving the g rass catc her;

– before making height adjustment unless

adjustment can be made from the operator’ s position.

• R educe the throttle setting during engine r un-out and, if the engine is pro vided with a shut-off v alv e , tur n the fuel off at the conclusion of mo wing .

Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes can reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure .

• T o reduce the ﬁre hazard, k ee p the engine , silencer , batter y compar tment and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or deterioration.

• R e place w or n or damag ed par ts for safety .

• If the fuel tank has to be drained, this should

be done outdoors .

• W hen mac hine is to be park ed, stored or left unattended, lo w er the cutting means .

Toro Riding Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety

Page 6

infor mation that y ou m ust kno w that is not included in the CEN standard.

• A v oid sudden star ts when mo wing uphill because the mo w er ma y tip bac kw ards .

• Engine exhaust contains carbon mono xide , whic h is an odorless , deadly poison that can kill y ou. Do not r un engine indoors or in an enclosed area.

• K ee p hands , feet, hair and loose clothing a w a y from attac hment disc harg e area, underside of mo w er and any mo ving par ts while engine is r unning .

• Do not touc h equipment or attac hment par ts whic h ma y be hot from operation. Allo w to cool before attempting to maintain, adjust, or ser vice .

• Batter y acid is poisonous and can cause bur ns . A v oid contact with skin, eyes and clothing . Protect y our face , eyes , and clothing when w orking with a batter y .

• Batter y g ases can explode . K ee p cig arettes , sparks , and ﬂames a w a y from batter y .

• Use only g en uine T oro re placement par ts to ensure that original standards are maintained.

• Use only T oro-appro v ed attac hments .

Slope Operation

• Do not mo w slopes g reater than 12-1/2 deg rees .

• Do not mo w near drop-offs , ditc hes , stee p banks , or w ater . W heels dropping o v er edg es can cause rollo v ers , whic h ma y result in serious injur y , death, or dro wning .

• Do not mo w slopes when g rass is w et. Slipper y conditions reduce traction and could cause sliding and loss of control.

• Do not mak e sudden tur ns or rapid speed c hang es .

• Use a w alk behind mo w er and/or a hand trimmer near drop-offs , ditc hes , stee p banks , or w ater .

• Be a w are that loss of traction ma y occur g oing do wnhill. W eight transfer to the front wheels ma y cause dri v e wheels to slip and cause loss of braking and steering .

• Alw a ys a v oid sudden star ting or stopping on a slope . If tires lose traction, diseng ag e the blades and proceed slo wly off the slope .

• F ollo w the man ufacturer’ s recommendations for wheel w eights or counterw eights to impro v e stability .

• Use extreme care with g rass catc hers or other attac hments . T hese can c hang e the stability of the mac hine and cause loss of control.

Sound Pressure

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 90 dB A, based on measurements of identical mac hines per EN11094 and EN836.

Sound Power

T his unit has a guaranteed sound po w er lev el of 105 dB A, based on measurements of identical mac hines per EN11094.

Vibration

T his unit does not ex ceed a hand/ar m vibration lev el of 2.36 m/s2, based on measurements of identical mac hines per EN1033.

T his unit does not ex ceed a whole body vibration lev el of .295 m/s2, based on measurements of identical mac hines per EN1032.

• R educe speed and use extreme caution on slopes .

• R emo v e or mark obstacles suc h as roc ks , tree limbs , etc . from mo wing area. T all g rass can hide obstacles .

• W atc h for ditc hes , holes , roc ks dips , and rises that c hang e the operating angle , as rough ter rain could o v er tur n the mac hine .

Page 7

Slope Chart

Page 8

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

93-7009

1. Warning—don’t operate the mower with the deector up or removed; keep the deector in place.

2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.

99-3943

1. Engine

110-1868

1. Thrown object hazard, mower—keep the deector in place.

2. Thrown object hazard—Keep bystanders a safe distance from the machine; Do not operate the without grass collection system in place.

3. Cutting/dismemberment of hand or foot—stay away from moving parts.

93-7317

1. Thrown object hazard—keep bystanders a safe distance from the machine.

2. Thrown object hazard, mower—keep the deector in place.

3. Cutting/dismemberment of hand or foot—stay away from moving parts.

99-8936

1. Machine speed 4. Neutral

2. Fast

3. Slow

5. Reverse

Page 9

1. Read the Operator’s Manual .

2. Height of cut

1. Throttle 7. Headlights

2. Choke

3. Continuous variable setting

4. Slow

5. On

6. Off

99-8939

3. Remove the ignition key and read the instructions before servicing or performing maintenance.

1. Height of cut

104-8062

104-8009

8. Engine—stop

9. Engine—run

10. Engine—start

11. Ignition

1. Height of cut

104-8063

1. To ride the machine, pull the lever out.

2. Do not tow the machine.

104-8061

3. To push the machine, push the lever in.

1. Warning—do not touch the hot surface.

106-5517

Page 10

1. Read the instructions before servicing or performing maintenance.

2. Check the tire pressure every 25 operating hours.

Battery Symbols

Some or all of these symbols are on your battery

107-2474

3. Grease every 25 operating hours.

4. Engine

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

Manufacturer’s Mark

1. Indicates the blade is identied as a part from the original machine manufacturer.

107-2482

1. Engage

2. Disengage

3. Parking brake 7. Tipping hazard, slopes greater than

4. Warning—set the parking brake and remove the ignition key before leaving the machine and read the instructions before servicing or performing maintenance.

5. Warning—read the Operator’s Manual.

6. Thrown object hazard, mower—keep the deector in place.

12.5 degrees—do not drive the machine on a slope greater than 12.5 degrees.

8. Thrown object hazard—keep bystanders a safe distance from the machine and pick up debris before operating.

9. Crushing/dismemberment hazard of bystanders—do not carry passengers.

10. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.

Page 11

Product Overview

Figure 3

1. Seat

2. Control panel 5. Parking brake 8. Front castor wheel 11. Gas tank

3. Motion control levers 6. Mower deck

4. Height of cut lever 7. Anti-scalp wheel 10. Discharge chute

9. Footrest

12. Rear drive wheel

Controls

Become familiar with all of the controls ( Figure 4 and Figure 5 ) before y ou star t the engine and operate the mac hine .

Figure 4

1. Ignition switch 3. Blade control switch (power take-off)

2. Throttle/Choke 4. Headlights-optional

Figure 5

1. Motion control lever 3. Height-of-cut lever

2. Parking brake lever

Page 12

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Think Safety First

Please carefully read all of the safety instr uctions and decals in the safety section. Kno wing this infor mation could help y ou, y our family , pets or b ystanders a v oid injur y .

Mo wing on w et g rass or steep slopes can cause sliding and loss of contr ol.

W heels dr opping o v er edges can cause r ollo v er s, which may r esult in serious injur y , death or dr o wning .

T o a v oid loss of contr ol and possibility of r ollo v er :

1. Safe Zone-use the TimeCutter here

2. Use walk behind mower and/or hand trimmer near drop-offs and water.

Figure 6

3. Water

• Do not mo w near dr op-of fs or near w ater .

• Do not mo w slopes g r eater than

12.5 deg r ees.

• R educe speed and use extr eme caution on slopes.

• A v oid sudden tur ns or rapid speed changes.

Recommended Gasoline

Use UNLEADED R egular Gasoline suitable for automoti v e use (87 pump octane minim um). Leaded regular g asoline ma y be used if unleaded regular is not a v ailable .

Important: Nev er use methanol, gasoline containing methanol, or gasohol containing mor e than 10% ethanol because the fuel system could be dama ged. Do not mix oil with gasoline.

Page 13

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of gasoline.

• Do not operate without entir e exhaust system in place and in pr oper w or king condition.

In cer tain conditions during fueling , static electricity can be r eleased causing a spar k which can ignite the gasoline v apor s. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Gasoline is har mful or f atal if s w allo w ed. Long-ter m exposur e to v apor s can cause serious injur y and illness.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the mac hine to pro vide the follo wing beneﬁts:

• K ee ps g asoline fresh during storag e of 30 da ys or less . F or long er storag e it is recommended that the fuel tank be drained.

Page 14

• Cleans the engine while it r uns

• Eliminates gum-lik e v ar nish buildup in the fuel

system, whic h causes hard star ting

Important: Do not use fuel additi v es containing methanol or ethanol.

Add the cor rect amount of g as stabilizer/conditioner to the g as .

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline . T o minimize the c hance of v ar nish de posits in the fuel system, use fuel stabilizer at all times .

Filling the Fuel Tank

1. Shut the engine off and set the parking brak e .

2. Clean around the fuel tank cap and remo v e the cap . Add unleaded regular g asoline to the fuel tank until the lev el is 1/4 to 1/2 inc h (6 to 13 mm) belo w the bottom of the ﬁller nec k. T his space in the tank allo ws g asoline to expand. Do not ﬁll the fuel tank completely full.

3. Install the fuel tank cap securely . Wipe up any g asoline that ma y ha v e spilled.

Checking the Engine Oil Level

Before y ou star t the engine and use the mac hine , c hec k the oil lev el in the engine crankcase; refer to Chec king the Oil Lev el in Engine Maintenance , pag e 24 .

Figure 7

1. Parking brake-On 2. Parking brake-Off

Releasing the Parking Brake

Push forw ard and do wn on the parking brak e lev er to release the parking brak e ( Figure 7 ).

Starting and Stopping the Engine

Starting the Engine

1. Sit do wn on the seat and mo v e the motion controls to neutral loc k ed position.

2. Set the parking brak e; refer to Setting the P arking Brak e abo v e .

3. Diseng ag e the blades b y mo ving the blade control switc h to Off ( Figure 8 ).

Using the Parking Brake

Alw a ys set the parking brak e when y ou stop the mac hine or lea v e it unattended.

Setting the Parking Brake

1. Mo v e the motion control lev ers ( Figure 5 ) out to the neutral loc k position.

2. Pull bac k and up on the parking brak e lev er to set the parking brak e ( Figure 7 ). T he parking brak e lev er should sta y ﬁr mly in the Eng ag ed position.

Important: Do not enga ge the par king brak e while the machine is mo ving . Dama ge to the dri v e system may occur .

Figure 8

1. Blade control switch—On 2. Blade control switch—Off

4. Mo v e the throttle lev er to Chok e before star ting a cold engine .

Note: A w ar m or hot engine ma y require c hoking . After the engine star ts , mo v e the throttle lev er to F ast.

5. T ur n the ignition k ey to Star t to energize the star ter . W hen the engine star ts , release the k ey .

Page 15

Important: Do not enga ge the star ter f or mor e than 10 seconds at a time. If the engine f ails to star t, allo w a 60 second cool-do wn period betw een attempts. F ailur e to f ollo w these instr uctions can bur n out the star ter motor .

6. After the engine star ts , mo v e the throttle lev er to F ast ( Figure 9 ). If the engine stalls or hesitates , mo v e the throttle lev er bac k to Chok e for a few seconds . T hen mo v e the throttle lev er to the desired setting . R e peat this as required.

Figure 9

1. Engine

2. Choke 4. Slow

3. Fast

Operating the Blades

T he blade control switc h, re presented b y a po w er tak e-off (PTO) symbol, eng ag es and diseng ag es po w er to the mo w er blades . T his switc h controls po w er to any attac hments that dra w po w er from the engine , including the mo w er dec k and cutting blades .

Engaging the Blades

1. R elease pressure on the traction control lev ers and place the mac hine in neutral.

2. Mo v e the throttle to the F ast position.

3. Pull out on the blade control switc h to eng ag e blades ( Figure 11 ).

Figure 10

1. Off

2. Run

3. Start

4. Ignition

Stopping the Engine

1. Mo v e the throttle lev er to Slo w ( Figure 9 ).

2. Diseng ag e the blades b y mo ving the blade control switc h to Off ( Figure 8 ).

3. T ur n the ignition k ey to Off ( Figure 10 ).

4. Pull the wire off of the spark plug(s) to prev ent the possibility of someone accidentally star ting the mac hine before transpor ting or storing the mac hine .

5. Close the fuel shut-off v alv e under the front of the fuel tank before transpor ting or storing the mac hine .

Important: Mak e sur e the fuel shut-of f v alv e is closed bef or e transpor ting or storing machine, as fuel leaka ge may occur .

Figure 11

1. Blade control switch-On 2. Blade control switch-Off

Disengaging the Blades

Push the blade control switc h to Off to diseng ag e the blades ( Figure 11 ).

The Safety Interlock System

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

Understanding the Safety Interlock System

T he safety interloc k system is designed to prev ent the engine from star ting unless:

• T he parking brak e is eng ag ed.

Page 16

• T he blades are diseng ag ed.

• T he motion control lev ers are in the neutral

loc k ed position.

T he safety interloc k system also is designed to stop the engine when the traction controls are mo v ed with the parking brak e on or if y ou rise from the seat when the blades are eng ag ed.

Testing the Safety Interlock System

T est the safety interloc k system before y ou use the mac hine eac h time . If the safety system does not operate as described belo w , ha v e an A uthorized Ser vice Dealer re pair the safety system immediately .

1. W hile sitting on the seat, eng ag e the parking brak e and mo v e the blade control switc h to On. T r y star ting the engine; the engine should not crank.

2. W hile sitting on the seat, eng ag e the parking brak e and mo v e the blade control switc h to Off . Mo v e either motion control lev er (forw ard or rev erse). T r y star ting the engine; the engine should not crank. R e peat with the other motion control lev er .

T he machine can spin v er y rapidl y . T he operator may lose contr ol of the machine and cause per sonal injur y or dama ge to the machine.

• Use caution when making tur ns.

• Slo w the machine do wn bef or e making shar p tur ns.

Forward

1. R elease the parking brak e .

2. Mo v e the lev ers to the center , unloc k ed position.

3. T o g o forw ard, slo wly push the motion control lev ers forw ard ( Figure 12 ).

Note: T he engine will kill if the traction control lev ers are mo v ed with the parking brak e eng ag ed.

3. W hile sitting on the seat, eng ag e the parking brak e , mo v e the blade control switc h to Off , and loc k the motion control lev ers in neutral. Star t the engine . W hile the engine is r unning, release the parking brak e , eng ag e the blade control switc h, and rise slightly from the seat; the engine should stop .

4. W hile sitting on the seat, eng ag e the parking brak e , mo v e the blade control switc h to Off , and loc k the motion control lev ers in neutral. Star t the engine . W hile the engine is r unning, center the motion controls and mo v e (forw ard or rev erse); the engine should stop .

Driving Forward or Backward

T he throttle control regulates the engine speed as measured in r pm (rev olutions per min ute). Place the throttle control in the F ast position for best perfor mance . Alw a ys operate in the full throttle position.

Figure 12

1. Motion control lever-neutral lock position

2. Center unlock position 4. Backward

3. Forward

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 12 ).

T o tur n, release pressure on the motion control lev er to w ard the direction y ou w ant to tur n ( Figure 12 ).

T he far ther y ou mo v e the traction control lev ers in either direction, the faster the mac hine will mo v e in that direction.

T o stop , pull the motion control lev ers to neutral.

Page 17

Backward

1. Mo v e the lev ers to the center , unloc k ed position.

2. T o g o bac kw ard, slo wly pull the motion control lev ers rearw ard ( Figure 12 ).

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 12 ).

T o tur n, release the pressure on the motion control lev er to w ard the direction y ou w ant to tur n ( Figure 12 ).

T o stop , push the motion control lev ers to neutral.

4. Secure the clevis pin with the hair pin cotter ( Figure 13 ).

Stopping the Machine

T o stop the mac hine , mo v e the traction control lev ers to neutral and se parate to loc k, diseng ag e the blade control switc h, and tur n the ignition k ey to Off to stop the engine . Also set the parking brak e when y ou lea v e the mac hine; refer to Setting the P arking Brak e . R emember to remo v e the k ey from the ignition switc h.

Important: Do not enga ge the par king brak e while the machine is mo ving . Dama ge to the dri v e system may occur .

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the tractor while it is unattended.

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

Adjusting the Height of Cut

T he height of cut is adjusted from 1-1/2 to 4-1/2 inc h (38 to 114 mm) in 1/2 inc h (13 mm) increments b y relocating the clevis pin in different hole locations .

1. Raise the height-of-cut lev er to the transpor t position (also the 4-1/2 inc h (114 mm) cutting height position) ( Figure 13 ).

2. T o adjust, remo v e the hair pin cotter and clevis pin from the height-of-cut brac k et ( Figure 13 ).

3. Select the hole in the height-of-cut brac k et cor responding to the height-of-cut desired, and inser t the clevis pin ( Figure 13 ).

Figure 13

1. Height-of-cut lever

2. Clevis pin

5. Lo w er the height-of-cut lev er onto the clevis pin.

3. Hairpin cotter

Adjusting the Anti-Scalp Rollers

W henev er y ou c hang e the height-of-cut it is recommended to adjust the height of the anti-scalp rollers .

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

A. After adjusting the height-of-cut, remo v e

the n ut and w asher while holding the stud with a wrenc h ( Figure 14 ).

Note: Do not remo v e the wheel n ut and w asher ( Figure 14 ).

Page 18

Figure 14

1. Gage wheel

2. Stud 5. Wheel nut and washer.

3. Washer

4. Nut

Do not remove.

B . Select a hole so that the g ag e wheel is

positioned to the nearest cor responding height-of-cut desired ( Figure 14 ).

3. Install the stud n ut and w asher ( Figure 14 ).

4. R e peat the adjustment on the other g ag e wheels .

Adjusting the Motion Control Levers

T he motion control lev ers can be adjusted higher or lo w er for maxim um operator comfor t.

1. R emo v e the 2 screws and cur v ed w ashers holding the control lev er to the control ar m shaft ( Figure 16 ).

2. Mo v e the control lev er to the next set of holes . Secure the lev er with the 2 screws and cur v ed w ashers . T he cupped side of the w asher should be to w ard the control ar m shaft ( Figure 16 ).

3. R e peat the adjustment on the other control lev er .

Positioning the Seat

T he seat can mo v e forw ard and bac kw ard. P osition the seat where y ou ha v e the best control of the mac hine and are most comfor table .

1. Raise the seat and loosen the adjustment knobs ( Figure 15 ).

2. Mo v e the seat to the desired position and tighten the knobs .

Figure 15

1. Adjustment knobs

Figure 16

1. Control lever 3. Curved washer

2. Screw

4. Control arm shaft

Pushing the Machine by Hand

Important: Al w ays push the machine

by hand. Nev er to w the machine because dama ge may occur .

To Push the Machine

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Pull the tw o b ypass lev ers up and push them until the w asher on the rod passes through the slot. Push the lev ers do wn to loc k them in place ( Figure 17 ).

4. Diseng ag e the parking brak e to push the mac hine .

Page 19

Figure 17

1. Position for pushing the machine

2. Position for operating the machine

To Operate the Machine

Pull eac h b ypass lev er up and pull them completely out. Push the lev ers do wn ( Figure 17 ).

Note: T he mac hine will not dri v e unless the b ypass lev ers are pulled out.

Converting to Side

W ithout the g rass deﬂector , discharge co v er , or complete g rass catcher assembl y mounted in place, y ou and other s ar e exposed to blade contact and thr o wn de bris. Contact with r otating mo w er blade(s) and thr o wn de bris will cause injur y or death.

• Nev er r emo v e the g rass deﬂector fr om the mo w er because the g rass deﬂector r outes material do wn to w ard the turf. If the g rass deﬂector is ev er dama ged, r eplace it immediatel y .

• Nev er put y our hands or feet under the mo w er .

• Nev er tr y to clear discharge ar ea or mo w er blades unless y ou mo v e the blade contr ol s witch to Of f and r otate the ignition k ey to Of f. Also r emo v e the k ey and pull the wir e of f the spar k plug(s).

Removing the Recycler® Bafe On 44 inch Mowers

Discharge

T he mo w er has a hing ed g rass deﬂector that disperses clippings to the side and do wn to w ard the turf .

Open holes in the mo w er expose y ou and other s to thr o wn de bris which can cause sev er e injur y .

• Nev er operate the mo w er without hard w ar e mounted in all holes in the mo w er housing .

• Install the hard w ar e in the mounting holes when y ou r emo v e the r ecy cling baf ﬂe.

Note: Only the right side bafﬂe needs to be remo v ed for side disc harg e mo wing .

1. T horoughly clean the mo w er .

2. R emo v e the knobs and cur v ed w ashers from the right side bafﬂe ( Figure 18 ).

Page 20

2. R emo v e the car riag e bolts and loc kn uts securing the front bafﬂe to the dec k ( Figure 19 ). R emo v e the front bafﬂe to g ain access to the right side R ecycler® bafﬂe .

Figure 18

1. Right side bafe 4. Knob

2. Bolt (5/16 x 1-1/4 inches)

3. Locknut (5/16 inch)

5. Curved washer

6. Left side bafe

Note: Sa v e the hardw are for use when installing the bafﬂe .

3. Lift the bafﬂe and slide it out of the interloc k with the left side bafﬂe .

4. F or safety , install the knobs , w ashers and loc kn uts into the open holes of the mo w er , wherev er the hardw are w as remo v ed in 2 .

Installing the Recycler® Bafe on 44 Inch Mowers

Install the right bafﬂe when con v er ting from side disc harg e mode to m ulc hing .

1. T horoughly clean the mo w er .

2. R emo v e knobs , w ashers and loc kn uts in the holes needed to install the right side bafﬂe .

3. Install the bafﬂe into the interloc k with the left side bafﬂe .

4. Install the right side bafﬂe to the mo w er with knobs and cur v ed w ashers ( Figure 18 ) remo v ed in Ste p 2 .

Figure 19

Operating the mo w er without the fr ont baf ﬂe in place, can expose y ou and other s to blade contact and thr o wn de bris. Contact with r otating blade(s) and thr o wn de bris will cause serious injur y .

Nev er operate the mo w er without the fr ont baf ﬂe installed.

3. R emo v e the loc k n uts from the top and center of the right side bafﬂe ( Figure 20 ).

4. Lo w er the bafﬂe and slide it out of disc harg e opening to remo v e it ( Figure 20 ).

Note: Only the right side bafﬂe needs be remo v ed for side disc harg e mo wing .

5. Install the bolts (5/16 x 5/8 inc h) and loc kn uts (5/16 inc h) remo v ed in Ste p 3 in the open holes of the mo w er for safety ( Figure 20 ).

Removing the Recycler® Bafe On 52 inch Mowers

R emo v e the right side bafﬂe to con v er t from m ulc hing to the side disc harg e mode .

1. T horoughly clean the mo w er .

Page 21

3. R emo v e the bolts and n uts in the dec k holes needed to secure the bafﬂe to the dec k ( Figure 20 ).

4. Install the bafﬂe b y sliding it into the disc harg e opening ( Figure 20 ).

5. Secure the bafﬂe with the n uts and bolts ( Figure 20 ) remo v ed in Ste p 3 .

6. R e place the front bafﬂe and secure it to the dec k ( Figure 19 ) using the fasteners remo v ed previously .

Figure 20

1. Bafe left side 3. Lock nut, 5/16 inch

2. Bolt, 5/16 x 5/8 inch

Open holes in the mo w er expose y ou and other s to thr o wn de bris which can cause sev er e injur y .

• Nev er operate the mo w er without hard w ar e mounted in all holes in the mo w er housing .

• Install the hard w ar e in the mounting holes when y ou r emo v e the r ecy cling baf ﬂe.

6. R e place the front bafﬂe and secure it to the dec k ( Figure 19 ) using the fasteners remo v ed previously .

Important: Do Not operate the machine without the fr ont baf ﬂe in place.

Nev er operate the mo w er without the fr ont baf ﬂe installed.

Operating Tips

Fast Throttle Setting

F or best mo wing and maxim um air circulation, operate the engine at F ast. Air is required to thoroughly cut g rass clippings , so do not set the height-of-cut so lo w as to totally sur round the mo w er b y uncut g rass . Alw a ys tr y to ha v e one side of the mo w er free from uncut g rass , whic h allo ws air to be dra wn into the mo w er .

Cutting a Lawn for the First Time

Installing the Recycler® Bafe on 52 Inch Mowers

Install the right side bafﬂe to con v er t from side disc harg e mode to m ulc hing .

1. T horoughly clean the mo w er .

2. R emo v e the car riag e bolts and loc kn uts securing the front bafﬂe to the dec k ( Figure 19 ). R emo v e the front bafﬂe to install the right side R ecycler® bafﬂe .

Important: Do Not operate the machine without the fr ont baf ﬂe in place.

Cut g rass slightly long er than nor mal to ensure that the cutting height of the mo w er does not scalp any unev en g round. Ho w ev er , the cutting height used in the past is g enerally the best one to use . W hen cutting g rass long er than six inc hes tall, y ou ma y w ant to cut the la wn twice to ensure an acce ptable quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the g rass blade . Cutting more than that is not recommended unless g rass is sparse , or it is late fall when g rass g ro ws more slo wly .

Page 22

Mowing Direction

Alter nate mo wing direction to k ee p the g rass standing straight. T his also helps disperse clippings whic h enhances decomposition and fer tilization.

Mow at Correct Intervals

Nor mally , mo w ev er y four da ys . But remember , g rass g ro ws at different rates at different times . So to maintain the same cutting height, whic h is a g ood practice , mo w more often in early spring . As the g rass g ro wth rate slo ws in mid summer , mo w less frequently . If y ou cannot mo w for an extended period, ﬁrst mo w at a high cutting height; then mo w ag ain tw o da ys later at a lo w er height setting .

Cutting Speed

T o impro v e cut quality , use a slo w er g round speed.

Avoid Cutting Too Low

If the cutting width of the mo w er is wider than the mo w er y ou previously used, raise the cutting height to ensure that unev en turf is not cut too shor t.

tearing or shredding the g rass blades . T earing and shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease . Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a g en uine T oro re placement blade .

Long Grass

If the g rass is ev er allo w ed to g ro w slightly long er than nor mal, or if it contains a high deg ree of moisture , raise the cutting height higher than usual and cut the g rass at this setting . T hen cut the g rass ag ain using the lo w er , nor mal setting .

When Stopping

If the mac hine’ s forw ard motion m ust be stopped while mo wing, a clump of g rass clippings ma y drop onto y our la wn. T o a v oid this , mo v e onto a previously cut area with the blades eng ag ed.

Keep the Underside of the Mower Clean

Clean clippings and dir t from the underside of the mo w er after eac h use . If g rass and dir t build up inside the mo w er , cutting quality will ev entually become unsatisfactor y .

Blade Maintenance

Maintain a shar p blade throughout the cutting season because a shar p blade cuts cleanly without

Page 23

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 200 hours

Every 300 hours

Maintenance Procedure

• Change the engine oil.

• Check the safety system.

• Check the engine oil level (more often in dirty or dusty conditions).

• Clean the air intake screen.

• Check the cutting blades.

• Clean the mower housing.

• Grease all lubrication points (more often in dusty, dirty conditions).

• Service the foam air cleaner (more often in dusty, dirty conditions).

• Check the battery electrolyte.

• Check the tire pressure.

• Check belts for wear/cracks.

• Service the paper air cleaner (more often in dusty, dirty conditions).

• Change the engine oil (more often in dusty, dirty conditions).

• Check the spark plug(s).

• Change the oil lter.

• Replace the paper air cleaner (more often in dusty, dirty conditions).

• Replace the fuel lter.

• Clean the engine shrouds and cooling ns (more often in dusty, dirty conditions).

• Perform all maintenance procedures listed above before storage.

Before storage

• Drain the fuel tank.

• Charge the battery and disconnect the battery cables.

• Paint any chipped surfaces.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the wir e fr om the spar k plug(s) bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

Lubrication

Lubricate the mac hine when sho wn on the Chec k Ser vice R eference Aid decal ( Figure 21 ) located beneath the seat. Grease more frequently when operating conditions are extremely dusty or sandy .

Grease with No . 2 g eneral pur pose lithium base or molybden um base g rease .

How to Grease

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Page 24

3. Clean the g rease ﬁttings with a rag . Mak e sure to scrape any paint off of the front of the ﬁtting(s).

4. Connect a g rease gun to the ﬁtting . Pump g rease into the ﬁttings until g rease begins to ooze out of the bearings .

5. Wipe up any ex cess g rease .

Where to Add Grease

Lubricate the g rease ﬁttings as sho wn on the Chec k Ser vice R eference Aid decal ( Figure 21 ) located beneath the seat and the mo w er ( Figure 22 ).

Figure 21

Oil T ype: Deterg ent oil (API ser vice SF , SG , SH or SJ)

Crankcase Capacity: with ﬁlter , 51 ounces (1.5 l)

Viscosity: See the table belo w .

Figure 23

Checking the Oil Level

1. P ark the mac hine on a lev el surface , diseng ag e the blade control switc h, stop the engine , and remo v e the k ey .

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

3. Clean around the oil dipstic k ( Figure 24 ) so that dir t cannot fall into the ﬁll hole and damag e the engine .

4. Unscrew the oil dipstic k and wipe the metal end clean ( Figure 24 ).

Figure 22

Top View

Engine Maintenance

Servicing the Engine Oil

Chang e the oil after the ﬁrst 8 operating hours and ev er y 100 operating hours thereafter .

Figure 24

1. Oil dipstick 3. Metal end, dipstick

2. Filler tube

5. Screw the oil dipstic k fully onto the ﬁll hole . Unscrew the dipstic k, pull it out, and look at the metal end. If the oil lev el is lo w , slo wly

Page 25

pour only enough oil into the ﬁll hole to raise the lev el to , but not o v er , the Full mark on the dipstic k.

Important: Do not o v erﬁll the crankcase with oil because the engine may be dama ged.

Changing and Draining the Oil

1. Star t the engine and let it r un until w ar m. T his w ar ms the oil so it drains better .

2. P ark the mac hine so that the drain side is slightly lo w er than the opposite side to ensure that the oil drains completely .

3. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

4. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

5. Slide the drain hose o v er the oil drain v alv e ( Figure 25 ).

6. Place a pan belo w the oil drain hose . Use either a ﬂat screw dri v er , 3/8 inc h (10 mm) wrenc h to open v alv e ( Figure 25 ).

7. R otate v alv e end countercloc kwise to open v alv e ( Figure 25 ).

8. W hen oil has drained completely , rotate v alv e end cloc kwise to close the v alv e ( Figure 25 ).

9. R emo v e the drain hose .

11. Slo wly pour appro ximately 80% of the speciﬁed oil into the ﬁller cap ( Figure 25 ). R efer to Ser vicing the Engine Oil, in Engine Maintenance , pag e 24 .

12. Chec k the oil lev el; refer to Chec king the Oil Lev el.

13. Slo wly add additional oil to bring it to the full mark.

Changing the Oil Filter

R e place the oil ﬁlter ev er y 200 hours or ev er y other oil c hang e .

Note: Chang e the oil ﬁlter more frequently when operating conditions are extremely dusty or sandy .

1. Drain the oil from the engine; refer to Changing and Draining the Oil.

2. R emo v e the old ﬁlter ( Figure 26 ).

3. Apply a thin coat of new oil to the r ubber g ask et on the re placement ﬁlter .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

Figure 25

1. Oil drain

10. Clean around the oil dipstic k and unscrew the cap ( Figure 25 ).

Figure 26

1. Oil lter 2. Adapter

4. Install the re placement oil ﬁlter to the adapter . T ur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 3/4 tur n ( Figure 26 ).

5. Fill the crankcase with the proper type of new oil; refer to Changing and Draining the Oil.

Servicing the Air Cleaner

F oam Element: Clean and oil after ev er y 25 operating hours .

P aper Element: Clean after ev er y 100 operating hours . R e place after ev er y 200 operating hours or yearly , whic hev er comes ﬁrst.

Page 26

Note: Ser vice the air cleaner more frequently (ev er y few hours) if operating conditions are extremely dusty or sandy .

C . Soak the element in new engine oil.

( Figure 28 ). Squeeze the element to remo v e ex cess oil.

Removing the Foam and Paper Elements

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean around the air cleaner to prev ent dir t from g etting into the engine and causing damag e . Unlatc h the tw o side latc hes and remo v e the air cleaner co v er ( Figure 27 ).

4. Carefully remo v e the foam element from the paper element ( Figure 27 ).

5. Unscrew the wing n ut and remo v e the paper element ( Figure 27 ).

Important: R eplace the f oam element if it is tor n or w or n.

Figure 28

1. Foam element 2. Oil

2. P aper Element

A. Lightly tap the element on a ﬂat surface to

remo v e dust and dir t ( Figure 29 ).

B . Inspect the element for tears , an oily ﬁlm,

and damag e to the r ubber seal.

Important: Nev er clean the paper element with pr essuriz ed air or liquids, such as solv ent, gas, or k er osene. R eplace the paper element if it is dama ged or cannot be cleaned thor oughl y .

Figure 27

1. Cover

2. Foam element 5. Air cleaner base

3. Paper element 6. Latches

4. Wing nut

Cleaning the Foam and Paper Elements

1. F oam Element

A. W ash the foam element in liquid soap and

w ar m w ater . W hen the element is clean, rinse it thoroughly .

B . Dr y the element b y squeezing it in a clean

cloth (do not wring). Allo w the element to air dr y .

Figure 29

1. Paper element 2. Rubber seal

Installing the Foam and Paper Elements

Important: T o pr ev ent engine dama ge,

al w ays operate the engine with the complete f oam and paper air cleaner assembl y installed.

1. Carefully slide the foam element onto the paper air cleaner element ( Figure 27 ).

Page 27

2. Place the air cleaner assembly onto the air cleaner base and install the wing n ut ( Figure 27 ).

3. Install the air cleaner co v er and secure the latc hes ( Figure 27 ).

installing the spark plug . Use a spark plug wrenc h for remo ving and installing the spark plug(s) and a g apping tool/feeler g aug e to c hec k and adjust the air g ap . Install a new spark plug(s) if necessar y .

T ype: Champion R C12Y C (or equi v alent)

Cleaning the Cooling System

Clean the air intak e screen from g rass and debris before eac h use .

Clean the cooling ﬁns and engine shrouds ev er y 300 hours or yearly , whic hev er comes ﬁrst.

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the air intak e screen, cylinder co v ers , and fan housing .

4. Clean debris and g rass from the par ts .

5. Install the air intak e screen, cylinder co v ers , and fan housing .

Air Gap: 0.030 inc h (0.76 mm)

Removing the Spark Plug(s)

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Pull the wire(s) off of the spark plug(s) ( Figure 31 ). Clean around the spark plug(s) to prev ent dir t from falling into the engine and potentially causing damag e .

4. R emo v e the spark plug(s) and metal w asher .

Figure 30

1. Air intake screen 3. Cylinder cover

2. Fan housing 4. Cylinder cover

Spark Plug

Chec k the spark plug(s) after ev er y 200 operating hours . Mak e sure that the air g ap betw een the center and side electrodes is cor rect before

Figure 31

1. Spark plug wire installed 2. Spark plug

Checking the Spark Plug

1. Look at the center of the spark plug(s) ( Figure 32 ). If y ou see light bro wn or g ra y on the insulator , the engine is operating properly . A blac k coating on the insulator usually means the air cleaner is dir ty .

Important: Nev er clean the spar k plug(s). Al w ays r eplace the spar k plug(s) when it has a black coating , w or n electr odes, an oil y ﬁlm, or cracks.

2. Chec k the g ap betw een the center and side electrodes ( Figure 32 ). Bend the side electrode ( Figure 32 ) if the g ap is not cor rect.

Page 28

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Close the fuel shut-off v alv e located under the front of the fuel tank.

5. Loosen the hose clamp at the fuel ﬁlter and slide it up the fuel line a w a y from the fuel ﬁlter ( Figure 33 ).

Figure 32

1. Center electrode insulator

2. Side electrode

Installing the Spark Plug(s)

1. Install the spark plug(s). Mak e sure that the air g ap is set cor rectly .

2. Tighten the spark plug(s) to 11 ft.-lb . (15 N·m).

3. Push the wire(s) onto the spark plug(s) ( Figure 31 ).

3. Air gap (not to scale)

Fuel System Maintenance

Draining the Fuel Tank

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Drain gasoline fr om the fuel tank when the engine is cold. Do this outdoor s in an open ar ea. W ipe up an y gasoline that spills.

• Nev er smok e when draining gasoline, and stay a w ay fr om an open ﬂame or wher e a spar k may ignite the gasoline fumes.

6. Pull the fuel line off of the fuel ﬁlter ( Figure 33 ).

7. Open the fuel shut-off v alv e . Allo w g asoline to drain into a g as can or drain pan.

Note: No w is the best time to install a new fuel ﬁlter because the fuel tank is empty .

Replacing the Fuel Filter

R e place the fuel ﬁlter after ev er y 200 operating hours or yearly , whic hev er occurs ﬁrst.

Nev er install a dir ty ﬁlter if it is remo v ed from the fuel line .

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Close the fuel shut-off v alv e located under the front of the fuel tank.

4. Squeeze the ends of the hose clamps tog ether and slide them a w a y from the ﬁlter ( Figure 33 ).

5. R emo v e the ﬁlter from the fuel lines .

6. Install a new ﬁlter and mo v e the hose clamps close to the ﬁlter ( Figure 33 ).

Important: Install the ﬁlter so the dir ection of the ﬂo w ar r o w is consistent with the ﬂo w of fuel; fr om the gas tank to the engine.

7. Open the fuel shut-off v alv e .

1. P ark the mac hine on a lev el surface , to ensure that the fuel tank drains completely .

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

Page 29

Figure 33

1. Fuel lter 3. Fuel line

2. Hose clamp

Electrical System Maintenance

Servicing the Battery

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Tip the seat forw ard to see the batter y .

4. Disconnect the neg ati v e (blac k) g round cable from the batter y post ( Figure 34 ).

Incor r ect batter y ca ble r outing could dama ge the tractor and ca bles causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays connect the positi v e (r ed) batter y ca ble bef or e connecting the negati v e (black) ca ble.

Chec k the electrolyte lev el in the batter y ev er y 25 hours . Alw a ys k ee p the batter y clean and fully c harg ed. Use a paper to w el to clean the batter y case . If the batter y ter minals are cor roded, clean them with a solution of four par ts w ater and one par t baking soda. Apply a light coating of g rease to the batter y ter minals to prev ent cor rosion.

V oltag e: 12 v

Removing the Battery

Batter y ter minals or metal tools could shor t a gainst metal tractor components causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the tractor .

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the tractor .

5. Slide the r ubber co v er up the positi v e (red) cable . Disconnect the positi v e (red) cable from the batter y post ( Figure 34 ).

6. R emo v e the batter y hold-do wn ( Figure 34 ) and lift the batter y from the batter y tra y .

Figure 34

1. Battery

2. Terminal boot 6. Bolt and washer

3. Positive battery cable

4. Negative battery cable

5. Battery hold-down

7. Nut

Installing the Battery

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

1. P osition the batter y in the tra y with the ter minal posts a w a y from the control panel ( Figure 34 ).

Page 30

2. Install the positi v e (red) batter y cable to the positi v e (+) batter y ter minal.

3. Install the neg ati v e batter y cable to the neg ati v e (-) batter y ter minal.

Adding Water to the Battery

T he best time to add distilled w ater to the batter y is just before y ou operate the mac hine . T his lets the w ater mix thoroughly with the electrolyte solution.

4. Secure the cables with 2 bolts (1/4 x 3/4 inc h), w ashers (1/4 inc h), and n uts (1/4 inc h) ( Figure 34 ).

5. Slide the red ter minal boot onto the positi v e (red) batter y post.

6. Secure the batter y with the hold-do wn ( Figure 34 ).

Checking the Electrolyte Level

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

1. R emo v e the batter y from the tractor; refer to R emo ving the Batter y .

Important: Nev er ﬁll the batter y with distilled w ater while the batter y installed in the tractor . Electr ol yte could be spilled on other par ts and cause cor r osion.

2. Clean the top of the batter y with a paper to w el.

3. R emo v e the v ent caps from the batter y ( Figure 35 ).

4. Slo wly pour distilled w ater into eac h batter y cell until the electrolyte lev el is up to the Upper line ( Figure 35 ) on the batter y case .

Important: Do not o v erﬁll the batter y because electr ol yte (sulfuric acid) can cause sev er e cor r osion and dama ge to the chassis.

5. W ait ﬁv e to ten min utes after ﬁlling the batter y cells . Add distilled w ater , if necessar y , until the electrolyte lev el is up to the Upper line ( Figure 35 ) on the batter y case .

1. Tip the seat forw ard to see the batter y .

2. Look at the side of the batter y . T he electrolyte m ust be up to the Upper line ( Figure 35 ). Do not allo w the electrolyte to fall belo w the Lo w er line ( Figure 35 ).

Figure 35

1. Vent caps

2. Upper line

3. Lower line

3. If the electrolyte is lo w , add the required amount of distilled w ater; refer to Adding W ater to the Batter y .

6. R einstall the batter y v ent caps .

Charging the Battery Important: Al w ays k eep the batter y

full y charged (1.260 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32°F (0°C).

1. R emo v e the batter y from the c hassis; refer to R emo ving the Batter y .

2. Chec k the electrolyte lev el; refer to Chec king the Electrolyte Lev el.

3. Mak e sure that the v ent caps are installed in the batter y . Charg e the batter y for 1 hour at 25 to 30 amps or 6 hours at 4-6 amps . Do not o v erc harg e the batter y .

4. W hen the batter y is fully c harg ed, unplug the c harg er from the electrical outlet, then disconnect the c harg er leads from the batter y posts ( Figure 36 ).

Page 31

Figure 36

1. Positive battery post

2. Negative battery post

3. Red (+) charger lead

4. Black (-) charger lead

5. Install the batter y in the tractor and connect the batter y cables; refer to Installing the Batter y .

Note: Do not r un the tractor with the batter y disconnected, electrical damag e ma y occur .

Servicing the Fuses

Ser vice Inter v al/Speciﬁcation

T he electrical system is protected b y fuses . It requires no maintenance; ho w ev er , if a fuse blo ws , c hec k the component/circuit for a malfunction or shor t.

Fuse:

• Main F1–30 amp , blade-type

• Charg e Circuit F2–25 amp , blade-type

• Optional Headlight Kit–10 amp , blade type

1. Raise the seat to g ain access to the fuse holder ( Figure 37 ).

Figure 37

1. Main–30 amp

2. Charge circuit–25 amp

3. For optional Headlight Kit–10 amp

Drive System Maintenance

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as speciﬁed. Unev en tire pressure can cause unev en cut. Chec k the pressure at the v alv e stem after ev er y 50 operating hours or monthly , whic hev er occurs ﬁrst ( Figure 38 ). Chec k the tires when they are cold to g et the most accurate pressure reading .

R ear Tires: 13 psi (90 kP a)

2. T o re place a fuse , pull out on the fuse to remo v e it ( Figure 37 ).

F ront Tires (castor wheels): 35 psi (139 kP a)

Figure 38

1. Valve stem

Page 32

Mower Maintenance

Servicing the Cutting Blades

Maintain shar p blades throughout the cutting season because shar p blades cut cleanly without tearing or shredding the g rass blades . T earing and shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease .

Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a g en uine T oro re placement blade . F or con v enient shar pening and re placement, y ou ma y w ant to k ee p extra blades on hand.

A w or n or dama ged blade can br eak, and a piece of the blade could be thr o wn into the operator’ s or bystander’ s ar ea, r esulting in serious per sonal injur y or death.

• Inspect the blade periodicall y f or w ear or dama ge.

Figure 39

1. Cutting edge 3. Wear/slot forming

2. Curved area

Checking for Bent Blades

1. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R otate the blades until the ends face forw ard and bac kw ard ( Figure 40 ). Measure from a lev el surface to the cutting edg e of the blades ( Figure 41 ). Note this dimension.

• R eplace a w or n or dama ged blade.

Before Inspecting or Servicing the Blades

P ark the mac hine on a lev el surface , diseng ag e the blade control switc h, and set the parking brak e . Stop the engine , remo v e the k ey , and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edg es ( Figure 39 ). If the edg es are not shar p or ha v e nic ks , remo v e and shar pen the blades; refer to Shar pening the Blades .

2. Inspect the blades , especially the cur v ed area ( Figure 39 ). If y ou notice any damag e , w ear , or a slot for ming in this area (item 3 in Figure 39 ), immediately install a new blade .

Figure 40

Figure 41

4. R otate the opposite ends of the blades forw ard.

5. Measure from a lev el surface to the cutting edg e of the blades at the same position as in ste p 3 abo v e . T he difference betw een the

Page 33

dimensions obtained in ste ps 3 and 4 m ust not ex ceed 1/8 inc h (3 mm). If this dimension ex ceeds 1/8 inc h (3 mm), the blade is bent and m ust be re placed; refer to R emo ving the Blades and Installing the Blades .

the same amount of material is remo v ed from both cutting edg es .

A blade that is bent or dama ged could br eak apar t and could seriousl y injur e or kill y ou or bystander s.

• Al w ays r eplace bent or dama ged blade with a new blade.

• Nev er ﬁle or cr eate shar p notches in the edges or surf aces of blade.

Removing the Blades

T he blades m ust be re placed if a solid object is hit, if the blade is out of balance , or the blade is bent. T o ensure optim um perfor mance and contin ued safety confor mance of the mac hine , use g en uine T oro re placement blades . R e placement blades made b y other man ufacturers ma y result in non-confor mance with safety standards .

Hold the blade end using a rag or thic kly-padded glo v e . R emo v e the blade bolt, cur v ed w asher , stiffener (52 inc h dec ks only) and blade from the spindle shaft ( Figure 42 ).

Figure 43

1. Sharpen at original angle

2. Chec k the balance of the blade b y putting it on a blade balancer ( Figure 44 ). If the blade sta ys in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, re peat the shar pening procedure on the hea vier side until the blade is balanced.

Figure 44

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft with the stiffener (52 inc h dec ks only) as sho wn in Figure 42 .

Figure 42

1. Sail area of blade 4. Blade bolt

2. Blade

3. Curved washer

5. Stiffener (52 inch decks only)

Sharpening the Blades

1. Use a ﬁle to shar pen the cutting edg e at both ends of the blade ( Figure 43 ). Maintain the original angle . T he blade retains its balance if

Important: T he cur v ed par t of the blade must be pointing up w ard to w ard the inside of the mo w er to ensur e pr oper cutting .

2. Install the cur v ed w asher (cupped side to w ard the blade) and blade bolt ( Figure 42 ). T or que the blade bolt to 35-65 ft-lb (47-88 N ⋅ m).

Leveling the Mower from Side-to-Side

T he mo w er blades m ust be lev el from side to side . Chec k the side-to-side lev el any time y ou install the mo w er or when y ou see an unev en cut on y our la wn.

1. P osition the mo w er on a ﬂat surface . Diseng ag e the blade control switc h, set the parking brak e , stop the engine , and remo v e the k ey . Disconnect the spark plug wire(s) from the spark plug(s).

Page 34

2. Chec k the air pressure of all four tires . If needed, adjust to the recommended inﬂation; refer to Tire Press .

3. Set the height-of-cut at 3 inc h (76 mm).

4. Carefully rotate the blade(s) from side to side ( Figure 45 ). Measure betw een the outside cutting edg es and the ﬂat surface ( Figure 45 ). If both measurements are not within 3/16 inc h (4.75 mm), an adjustment is required; refer to ste ps 5 and 6.

Adjusting the Front-to-Rear Blade Slope

Chec k the front-to-rear blade lev el any time y ou install the mo w er . If the front of the mo w er is more than 5/16 inc h (7.9 mm) lo w er than the rear of the mo w er , adjust the blade lev el using the follo wing instr uctions:

1. P osition the mo w er on a ﬂat surface .

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Chec k the air pressure of all four tires . If needed, adjust to the recommended inﬂation; refer to Tire Pressure .

5. Chec k and adjust the side-to-side blade lev el if y ou ha v e not c hec k ed the setting; refer to Lev eling the Mo w er from Side-to-Side .

Figure 45

1. Blades side to side 3. Measure here

2. Outside cutting edges

5. R emo v e the hair pin cotter and w asher from the lev eling brac k et ( Figure 46 ). T o lev el the blade(s), re position the lev eling brac k et(s) in a different hole and install the w asher and hair pin cotter . ( Figure 46 ). A front hole lo w ers the blade height and a rear hole raises its height. Adjust both sides as required.

6. Measure the length of the rear tr union rod ( Figure 47 ). If the rod length is not 11-1/2 inc h (29.2 cm), remo v e the clevis pin and cotter pin from the end of the rod ( Figure 47 ), loosen the jam n ut, and tur n the y ok e until the 11-1/2 inc h (29.3 cm) dimension is obtained.

7. T hen secure the y ok e with the clevis pin and cotter pin. R e peat this procedure on the opposite side of the mo w er .

Figure 47

1. Rear trunion rod

2. Clevis pin and cotter pin 4. Yoke

3. Jam nut

Figure 46

1. Hairpin cotter and washer 3. Front hole

2. Leveling bracket 4. Rear hole

6. Chec k the front-to-rear blade slope; refer to Adjusting the F ront-to-R ear Blade Slope .

8. Set the height-of-cut at 3 inc h (76 mm) and carefully rotate the blades so they are facing front to rear ( Figure 48 ).

9. Measure betw een the tip of the front blade ( Figure 48 ) and the tip of the rear blade to

Page 35

the ﬂat surface . If the front blade tip is not 1/16-5/16 inc h (1.6-7.9 mm) lo w er than the rear blade tip , adjust the front tr union rods .

13. W hen the front-to-rear blade slope is cor rect, tighten the jam n uts ( Figure 47 and Figure 49 ).

14. R ec hec k the side-to-side lev el of the mo w er; refer to Lev eling the Mo w er from Side-to-Side .

15. Chec k the height of the anti-scalp rollers; refer to Adjusting the Anti-Scalp R ollers .

Removing the Mower

1. P ark the mac hine on a lev el surface .

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Figure 48

1. Blade front to rear 3. Measure rear blade tip

2. Measure front blade tip 4. Measure here

10. T o adjust the front-to-rear blade slope , remo v e the hair pin cotter from the front tr union y ok es and loosen the jam n uts ( Figure 49 ).

Figure 49

1. Front trunion rod yoke

2. Hairpin cotter

3. Jam nut

11. R otate the y ok es on the rods to c hang e the adjustment ( Figure 49 ). T o raise the front of the mo w er , tighten the y ok es (shor ten the rods). T o lo w er the front of the mo w er , loosen the y ok es (lengthen the rods).

4. Lo w er the height-of-cut lev er to the lo w est position.

5. R emo v e the hair pin cotter and clevis pin from the front tr union y ok es ( Figure 50 ).

Figure 50

1. Hairpin cotter and clevis pin

2. Front trunion

6. R emo v e the hair pin cotter and clevis pin from the rear tr union rod ( Figure 51 ) on eac h side of the mo w er .

7. R emo v e the hair pin cotter and w asher at the mo w er lev eling brac k ets ( Figure 51 ) on eac h side of the mo w er . Note whic h hole the lev eling brac k et is mounted in for future installation. Slide the brac k ets off of the mounting pin.

12. After adjusting both tr union rod y ok es ev enly , secure the y ok es with the hair pin cotters . Chec k the front-to-rear lev el ag ain. Contin ue adjusting the y ok es until the front blade tip is 1/16-5/16 inc h (1.6-7.9 mm) lo w er than the rear blade tip ( Figure 48 ).

Page 36

Figure 51

1. Hairpin cotter and clevis pin

2. Rear trunion rod 4. Leveling bracket

3. Hairpin cotter and washer

8. Slide the mo w er rearw ard to remo v e the mo w er belt from the engine pulley .

9. Slide the mo w er out from under neath the tractor .

T he spring is under tension when installed and can cause per sonal injur y .

Do not r emo v e the spring fr om the spring ey e bolt.

5. R oute the new belt through the idler ar m and around the idler pulley ( Figure 52 ).

Figure 52

Note: R etain all par ts for future installation.

Inspecting the Belts

Inspect all belts ev er y 100 hours .

Chec k the belts for crac ks , fra yed edg es , bur n marks , or any other damag e . R e place damag ed belts .

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks , and crac ks are signs of a w or n mo w er belt. R e place the mo w er belt if any of these conditions are evident.

Replacing the Mower Belt

1. Stop the engine , set the parking brak e , remo v e the k ey , and disconnect the spark plug wire(s) from the spark plug(s).

2. Set the height-of-cut at 1-1/2 inc h (38 mm).

Top View

1. Outer nut

2. Idler pulley

3. Idler arm 7. Mower belt

4. Spring eye bolt

5. Spring

6. 1/8 inch (3 mm)

6. Pull the idler pulley in the direction sho wn in Figure 52 and route the belt onto the other pulleys ( Figure 53 ).

Note: Chec k to ensure that the length of exposed thread on the spring eye bolt is 1/8 in. (3 mm) ( Figure 52 ).

7. Install the belt co v ers o v er the outside spindles .

3. R emo v e the belt co v ers o v er the outside spindles .

4. Pull the idler pulley in the direction sho wn in Figure 52 and roll the belt off of the pulleys .

Note: Do not remo v e the spring .

1. Mower belt

2. Idler arm 5. Idler pulley

3. Outside pulley

Figure 53

Top View

4. Spring

Page 37

Installing the Mower

1. P ark the mac hine on a lev el surface .

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Slide the mo w er under the tractor .

5. Lo w er the height-of-cut lev er to the lo w est position.

6. Attac h the rear tr union rod to the tractor with the clevis pin and hair pin cotter ( Figure 51 ) on eac h side of the mo w er .

7. Slide the lev eling brac k ets onto the mounting pins and secure them with the w ashers and hair pin cotters ( Figure 51 ).

8. Attac h the front tr union rods to the tractor with the clevis pins and hair pin cotters ( Figure 50 ).

9. Install the mo w er belt onto the engine pulley; refer to R e placing the Mo w er Belt.

Replacing the Grass Deector

An unco v er ed discharge opening could allo w the la wn mo w er to thr o w objects in the operator’ s or bystander’ s dir ection and r esult in serious injur y . Also, contact with the blade could occur .

Nev er operate the la wn mo w er unless y ou install a co v er plate, a mulch plate, or a g rass chute and catcher .

1. R emo v e the loc kn ut, bolt, and spring holding the deﬂector to the mo w er brac k ets ( Figure 54 ). R emo v e the damag ed or w or n g rass deﬂector .

Figure 54

1. Mower bracket 4. Grass deector

2. Spring hook end 5. Bolt

3. Space for spring 6. Locknut

2. Place the springs into the brac k ets on the mo w er with the hook ed ends o v er the raised bac k ( Figure 54 ).

3. Align the g rass deﬂector with the holes in the brac k ets and the spring straight ends in the space under the hing e and abo v e the deﬂector ( Figure 54 ).

4. Secure the deﬂector to the mo w er brac k et with the bolts . T he bolts should pass through the g rass deﬂector , springs , and brac k ets .

Note: It ma y be helpful to press do wn near the end of the bolt with a 9/16 inc h open end wrenc h to align the bolts with the second holes on the mo w er brac k et and g rass deﬂector .

5. Lift the g rass deﬂector and c hec k that it is spring loaded and pi v ots freely to the full do wn position.

Important: T he g rass deﬂector must be spring loaded in the do wn position. Lift the deﬂector up to test that it snaps to the full do wn position.

Cleaning

Washing the Underside of the Mower

After eac h use , w ash the underside of the mo w er to prev ent g rass buildup , for impro v ed m ulc h action, and clipping dispersal.

1. P ark the mac hine on a hard lev el surface .

Page 38

2. Diseng ag e the blade control switc h and mo v e the control lev ers to the neutral loc k ed position and apply the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Attac h the hose coupling to the end of the mo w er w ashout ﬁtting, and tur n the w ater on high ( Figure 55 ).

Note: Spread petroleum jelly on the w ashout ﬁtting O-ring to mak e the coupling slide on easier and protect the O-ring .

A br ok en or missing w ashout ﬁtting could expose y ou and other s to thr o wn objects or blade contact. Contact with blade or thr o wn de bris contact will cause injur y or death.

• R eplace br ok en or missing w ashout ﬁtting immediatel y , bef or e using mo w er a gain.

• Plug an y hole(s) in mo w er with bolts and lockn uts.

• Nev er put y our hands or feet under the mo w er or thr ough openings in the mo w er .

Figure 55

1. Washout tting

2. Coupling

3. Hose

4. O-ring

5. Lo w er the mo w er to the lo w est height-of-cut.

6. Sit on the seat and star t the engine . Eng ag e the blade control switc h and let the mo w er r un for one to three min utes .

7. Diseng ag e the blade control switc h, stop the engine , and remo v e the ignition k ey . W ait for all mo ving par ts to stop .

8. T ur n the w ater off and remo v e the coupling from the w ashout ﬁtting .

Note: If the mo w er is not clean after one w ashing, soak it and let it stand for 30 min utes . T hen re peat the process .

9. R un the mo w er ag ain for one to three min utes to remo v e ex cess w ater .

Page 39

Storage

Cleaning and Storage

1. Diseng ag e the blade control switc h, set the parking brak e , stop the engine , and remo v e the k ey .

2. R emo v e g rass clippings , dir t, and g rime from the exter nal par ts of the entire mac hine , especially the engine . Clean dir t and c haff from the outside of the engine cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not pr essur e w ash the machine. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, h y draulic pumps, and motor s.

3. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner , Engine Maintenance , pag e 24 .

4. Grease and oil the mac hine; refer to Greasing and Lubrication, Lubrication , pag e 23 .

C . R estar t the engine and r un it until it stops .

D . Chok e or prime the engine . Star t and r un

the engine until it will not star t. Operate the primer , if equipped, sev eral times to ensure no fuel remains in the primer system.

E. Dispose of fuel properly . R ecycle as per

local codes .

Important: Do not stor e sta biliz er/conditioned gasoline o v er 30 days.

11. R emo v e the spark plug(s) and c hec k its condition; refer to Spark Plug, Electrical System Maintenance , pag e 29 . With the spark plug(s) remo v ed from the engine , pour tw o tablespoons of engine oil into the spark plug hole . Use the star ter to crank the engine and distribute the oil inside the cylinder . Install the spark plug(s). Do not install the wire on the spark plug(s).

12. Clean any dir t and c haff from the top of the mo w er .

5. Chang e the crankcase oil and ﬁlter; refer to Engine Oil, Engine Maintenance , pag e 24 .

6. Chec k the tire pressure; refer to Tire Pressure , Dri v e System Maintenance , pag e 31 .

7. Charg e the batter y; refer to Ser vicing the Batter y , Electrical System Maintenance , pag e 29 .

8. Chec k the condition of the blades; refer to Cutting Blades , Mo w er Maintenance , pag e 32 .

9. Pre pare the mac hine for storag e when non-use occurs o v er 30 da ys . Pre pare the mac hine for storag e as follo ws .

10. Add a petroleum based stabilizer/conditioner to the fuel in the tank. F ollo w the mixing instr uctions from the stabilizer man ufacturer . Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline and used at all times .

13. Scrape any hea vy buildup of g rass and dir t from the underside of the mo w er , then w ash the mo w er with a g arden hose .

14. Chec k the condition of the dri v e and mo w er belts .

15. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is w or n or damag ed.

16. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

17. Store the mac hine in a clean, dr y g arag e or storag e area. R emo v e the k ey from the ignition switc h and k ee p it in a memorable place . Co v er the mac hine to protect it and k ee p it clean.

A. R un the engine to distribute the conditioned

fuel through the fuel system (5 min utes).

B . Stop the engine , allo w it to cool, and drain

the fuel tank; refer to Draining the Fuel T ank, Fuel System Maintenance , pag e 28 .

Page 40

Troubleshooting

Problem

The engine overheats.

The starter does not crank

Possible Cause Corrective Action

1. The engine load is excessive.

2. The oil level in the crankcase is low.

3. The cooling ns and air passages under the engine blower housing are plugged.

4. The air cleaner is dirty. 4. Clean or replace the air

5. Dirt, water, or stale fuel is in fuel system.

1. The blade control switch (PTO) is engaged.

2. The parking brake is not on.

3. The operator is not seated.

4. The battery is dead. 4. Charge the battery.

5. The electrical connections are corroded or loose.

6. A fuse is blown. 6. Replace the fuse.

7. A relay or switch is damaged.

1. Reduce ground speed.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling ns and air passages.

cleaner element.

5. Contact an Authorized Service Dealer

1. Move the blade control switch to Off.

2. Move the motion control levers to the brake position.

3. Sit on the seat.

5. Check the electrical connections for good contact.

7. Contact an Authorized Service Dealer.

Page 41

Problem

Possible Cause Corrective Action

The engine will not start, starts hard, or fails to keep running.

The engine loses power.

1. The fuel tank is empty. 1. Fill the fuel tank.

2. The fuel valve turned off. 2. Open the fuel valve.

3. The choke is not on. 3. Move the choke lever to On.

4. The air cleaner is dirty. 4. Clean or replace the air cleaner element.

5. The spark plug wire(s) is

loose or disconnected.

6. The spark plug(s) is

pitted, fouled, or the gap

5. Install the wire(s) on the spark plug.

6. Install a new, correctly gapped spark plug(s).

is incorrect.

7. There is dirt in fuel lter. 7. Replace the fuel lter.

8. Dirt, water, or stale fuel is in fuel system.

9. There is incorrect fuel in the fuel tank.

8. Contact an Authorized Service Dealer.

9. Drain the tank and replace the fuel with the proper type.

10. The oil level in the

10. Add oil to the crankcase.

crankcase is low.

1. The engine load is

1. Reduce ground speed.

excessive.

The machine does not drive.

2. The air cleaner is dirty. 2. Clean the air cleaner element.

3. The oil level in the

3. Add oil to the crankcase.

crankcase is low.

4. The cooling ns and

air passages under the engine blower housing

4. Remove the obstruction from the cooling ns and air passages.

are plugged.

5. The spark plug(s) is pitted, fouled, or the gap

5. Install a new, correctly gapped spark plug(s).

is incorrect.

6. The vent in the fuel cap is closed.

7. There is dirt in the fuel

6. Open the vent in the fuel cap.

7. Replace the fuel lter.

lter.

8. Dirt, water, or stale fuel is in the fuel system.

9. There is incorrect fuel in the fuel tank.

8. Contact an Authorized Service Dealer.

9. Drain the tank and replace the fuel with the proper type.

1. The traction belts are worn, loose, or broken.

1. Contact an Authorized Service Dealer.

2. The traction belts are off of the pulleys.

2. Contact an Authorized Service Dealer.

Page 42

Problem

Possible Cause Corrective Action

There is abnormal vibration.

Uneven cutting height.

1. The engine mounting bolts are loose.

2. The engine pulley, idler pulley, or blade pulley is

1. Tighten the engine mounting bolts.

2. Tighten the appropriate pulley.

loose.

3. The engine pulley is damaged.

4. The cutting blade(s) is/are bent or

3. Contact an Authorized Service Dealer.

4. Install a new cutting blade(s).

unbalanced.

5. A blade mounting bolt is loose.

5. Tighten the blade mounting bolt.

6. A blade spindle is bent. 6. Contact an Authorized Service Dealer.

1. The blade(s) is not sharp. 1. Sharpen the blade(s).

2. A cutting blade(s) is/are

bent.

2. Install a new cutting blade(s).

3. The mower is not level. 3. Level the mower from side-to-side and front-to-rear.

4. An anti-scalp wheel is

not set correctly.

5. The underside of the

mower is dirty.

6. The tire pressure is

4. Adjust the anti-scalp wheel height.

5. Clean the underside of the mower.

6. Adjust the tire pressure.

incorrect.

7. A blade spindle is bent. 7. Contact an Authorized Service Dealer.

The blades do not rotate.

1. The drive belt is worn,

loose or broken.

2. The drive belt is off of the

pulley.

3. The mower belt is worn,

loose, or broken.

1. Install a new drive belt.

2. Install the drive belt and check the adjusting shafts and belt guides for the correct position.

3. Install a new mower belt.

Page 43

Schematics

Electrical Schematic (Rev. B)

Page 44