Commercial 30

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark 4–Cycle Premium Engine Oil

• RPM: 3500 RPM (No Load)

• Capacity: 1 gallon (3.8 L)

• Fuel Recommendations:

  • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable.

  • Do Not use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty.

  • Do Not use gasoline containing methanol.

  • Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do Not add oil to gasoline.

• Fuel Filter: Replaceable In-line

• Fuel Shut-Off Valve: 1/4 turn

Equipped with Blade Brake Clutch (BBC).

Variable

Speed Range: 0–4.0 mph (6.4 km/hr)

• Cutting Width: 30 inches (76 cm)

• Blade Brake: When the blade engagement control is moved to the disengaged position a friction brake pad stops the rotation of the blades.

• Blade Size: (2 ea.): 15.40 inches (39.1 cm)

• Deck: 30 inches rigid. Deck design allows for bagging, mulching or side discharge.

• Cutting Height Adjustment:

  Adjusts from 1 1/2 inch (3.8 cm) to 5 inches (12.7 cm) in 1/2 inch (1.3 cm) increments.

• Mulching Kit: High performance mulch kit optional

170 lb (77 kg)

31.9 inches (81 cm)

Located on the upper handle as shown in Figure 4.

When the blade control bail is depressed, the system senses that the operator is in the normal operator's position.

When the blade control bail is released, the system senses that the operator has moved from the normal operating position and will stop the blade.

Figure 4

1. Blade control lock lever
2. Blade control bail
3. Handle
4. Drive bail

Located on the upper handle as shown in Figure 4.

When the self-propel drive bail is squeezed against the handle, the unit ground speed will change based on the distance between the bail and the handle. When this bail is released the unit will stop moving.

The throttle-choke-engine stop control is located on the left side of the engine as shown in Figure 5 and Figure 9.

Figure 5

1. Throttle-Choke-Engine stop control
2. Fuel valve

The lever is used to control engine speed. Moving the lever to the full forward (Choke) position will place the lever in the choke position. The choke aids in starting a cold engine. Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed.

The throttle-choke-engine stop control also includes an engine shutdown position. Moving the lever into the full rearward (Off) position will shutdown the engine.

The blade control lock lever is located on the right side of the handle next to the Blade Control Bail as shown in Figure 4.

Moving the blade control lock lever into the full forward position releases the blade control bail. Squeezing the blade control bail against the handle engages the blade. Releasing the blade control bail automatically disengages the blade. The blade control lock lever will reset to lock the blade control bail.

Located on the upper handle of models with Kohler engines only.

Engage the parking brake by pulling the brake lever up towards the handle.

Figure 6

Disengage the parking brake by pushing the brake lever down away from the handle.

Figure 7

The fuel shut off valve is located between the carburetor and the fuel tank. The fuel shut off valve shuts off the flow of fuel when the machine will not be used for a few days, when parking inside a building, and during transport to and from the job.

Rotate the valve 1/4 turn clockwise to shut off fuel. Rotate the valve 1/4 turn counterclockwise to turn on fuel.

Figure 8

1. Rotate clockwise to close
2. Rotate counterclockwise to open

The height of the handle can be adjusted for comfortable operation. Stand behind the handle to determine the height. To adjust the handle height, position the hardware into one of the three holes in the handle bracket.

Rotate the valve 1/4 turn counterclockwise to turn the fuel on.

1. Connect the wire to the spark plug.

   

   Figure 9

   1. Muffler
   2. Oil fill/dipstick
   3. Recoil starter handle
   4. Fuel tank cap
   5. Throttle-choke-engine stop control
   6. Oil filter
   7. Air cleaner
   8. Primer bulb
   9. Spark plug

2. Open the fuel valve.

3. Move the throttle-choke-engine stop control to the full forward (Choke) position.

   Note: Do Not use the choke when the engine is warm.

4. Pull the starter handle lightly until you feel resistance, then pull it sharply. Allow the rope to return slowly.

5. When the engine starts, move the throttle-choke-engine stop control to the Fast position.

1. Bring the unit to a full stop.

2. Release the blade control bail. The blade should stop within three seconds; the engine will continue to run. Move the throttle-choke-engine stop control to the Stop position to kill the engine.

   Note: If the blade does not stop within 3 seconds after releasing the blade control bail, contact an Authorized Service Dealer.

3. Close the fuel shut-off valve, if equipped, when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building.

The lawn mower is variable speed, the more you squeeze the drive bail against the handle the faster the machine travels.

1. Start the engine.

2. Squeeze the drive bail against the handle (see Figure 4).

   Note: You can vary the ground speed by increasing or decreasing the distance between the ground speed control bail and the handle. Lower the control bail to decrease the ground speed when you are making a turn or if the lawn mower is moving too fast for you. If you lower the control bail too far the lawn mower stops self-propelling. Squeeze the ground speed control bail closer to the handle to increase the ground speed. When you hold the ground speed control bail tight against the handle, the lawn mower self-propels at the maximum ground speed. Release the drive bail to stop moving when you use the lawn mower for trimming or whenever you leave the lawn mower.

3. To disengage the self-propel drive, release the drive bail.

1. Start the engine.

2. Push and hold the blade control lock lever forward to release the blade control bail (Figure 10).

   

   Figure 10

   1. Blade control lock lever
   2. Locked position
   3. Blade control bail
   4. Push
   5. Unlocked position
   6. Squeeze against handle

3. Squeeze the blade control bail against the handle and release the blade control lock lever; the blade should engage.

4. Release the blade control bail to disengage the blade. The blade control lock lever will reset to lock the blade control bail.

Check the Blade Brake Clutch (BBC) system before each use to ensure that it is operating properly.

Normal Test:

1. Stop the engine and wait for all moving parts to stop.

2. Move the lawn mower onto a paved surface in a non-windy area.

3. Set all four wheels to the 2 1/2 inches (6.4 cm) cutting height (see Figure 12 and Figure 14).

4. Take a half sheet of newspaper and crumple it into ball small enough to go under the deck (about 3 inches or 7.6 cm in diameter) as shown in Figure 11.

   

   Figure 11

   1. Crumpled newspaper
   2. 5 inches (12.7 cm)

5. Place the ball of newspaper 5 inches (12.7 cm) in front of the lawn mower.

6. Start the engine.

7. Push the blade control lock lever forward to release the blade control bail (Figure 4).

8. Squeeze the blade control bail against the handle; the blade should engage.

9. Release the blade control bail. You should hear a “bang.” The blade should stop in three seconds. The blade control lock lever should reset to lock the blade control bail.

10. Immediately push the lawn mower over the newspaper ball.

11. Stop the engine and wait for all moving parts to stop.

12. Walk around the lawn mower to check for the newspaper ball. If the ball did not go under the deck, repeat steps 6 through 11.

13. Pull the lawn mower away from the newspaper. If the newspaper ball unravels or is shredded, the blade has not properly stopped, resulting in an unsafe operating condition. Contact an Authorized Service Dealer.

    Danger

    If the blade brake clutch system is inoperative, the blade will continue to rotate when you release the blade control bail. Contact with the blade could occur, causing serious injury.

    • Check the BBC operation before each use.

    • Never use the BBC-equipped lawn mower with an inoperative safety system.

    • Take your lawn mower to an Authorized Service Dealer for repair if the safety system fails to operate properly.

1. If the mulch plug is installed on the mower, remove it (refer to Removing the Mulch Plug). If the side discharge deflector is on, remove it and install the side discharge door (refer to Using the Side Discharge Deflector).

2. Install the empty grass bag on the rear of the mower (refer to Installing the Grass Bag).

3. Start the engine.

4. Push the blade control lock lever forward to release the blade control bail (Figure 4).

5. Squeeze the blade control bail against the handle.

6. The bag should begin to inflate, indicating that the blade is engaged and rotating.

7. Release the blade control bail. If the bag does not immediately deflate, it indicates that the blade is still rotating. The blade brake clutch mechanism may be deteriorating, and, if ignored could result in an unsafe operating condition. Have the lawn mower inspected and serviced by an Authorized Service Dealer.

8. Stop the engine and wait for all moving parts to stop.

The rear wheels are adjusted together with a height adjustment rod located on the mower housing by the left rear wheel. The front wheels are adjusted separately by removing the front wheel shaft assemblies, adjusting the height, and then replacing the shaft assemblies. The cutting height can be adjusted from 1 1/2 inches (38 mm) to 5 inches (127 mm) in 1/2 inch (12.7 mm) increments.

• Rear Wheel Adjustment:

  1. Pull the wheel height adjustment rod upward to release the pin from the notch in the adjustment bracket (Figure 12).

     

     Figure 12

     1. Pull upward
     2. Wheel height adjustment rod
     3. Indicator
     4. Pin
     5. Rotate to desired setting

  2. Apply downward pressure or lift the housing to rotate the height adjustment bracket to the desired setting.

  3. Release the wheel height adjustment rod to set the pin securely in the desired notch.

     

     Figure 13

• Front Wheel Adjustment

  1. Pull up on the height lock and pull the front wheel shaft assembly outward as shown in Figure 14.

     

     Figure 14

     1. Front wheel shaft assembly
     2. Pull up
     3. Height lock
     4. Front quadrant block cut heights
     5. Pull outward
     6. Shaft groove

  2. Insert the front wheel shaft assembly into the desired cut height setting in the front quadrant block. Lower the height lock into the groove on the front wheel shaft. Pull and push the wheel shaft assembly to make sure it has locked into place.

     

     Figure 15

     1. Front quadrant block
     2. Cutting heights

• Installing the Grass Bag

  1. Release the blade control lock lever and wait for the blade and all moving parts to stop.

  2. If the mulch plug is installed on the mower, remove it (refer to Removing the Mulch Plug). If the side discharge deflector is on, remove it and install the side discharge door (refer to Using the Side Discharge Deflector).

  3. Open the rear discharge door.

  4. Grasp the handle on the bag and set the rear of the bag frame onto the handle bracket notch (Figure 16).

     

     Figure 16

     1. Bag
     2. Handle
     3. Bag frame
     4. Handle bracket notch
     5. Rear door
     6. Lower

  5. Once the bag is seated, lower the rear discharge door onto the bag.

• Mowing with the Grass Bag

  Warning

  A worn grass bag could allow small stones and other similar debris to be thrown in the operator’s or bystander’s direction. Thrown objects can result in serious personal injury or death to the operator or bystanders.

  Check the grass bag frequently. If it is damaged, install a new Exmark replacement bag.

  Cut the grass until the bag is full. To see if the grass bag is full, release the blade control lock lever and wait for the blade to stop. Feel the bag to determine whether the bag needs to be emptied.

  Note: Do Not overfill the bag.

• Removing the Grass Bag

  1. Release the blade control lock lever and wait for the blade and all moving parts to stop.

  2. Raise the rear discharge door and grasp the handle on the bag.

  3. Lift the bag off of the lawn mower and lower the rear discharge door.

  4. Gradually tip the bag forward to empty the clippings.

  5. To install the bag, refer to the section on Installing the Grass Bag.

     Danger

     If the rear discharge door does not close completely, the lawn mower could throw objects. Thrown objects can result in serious personal injury or death to the operator or bystanders.

     • Never open the door to the rear discharge opening when the blades are still moving.

     • If you cannot close the door because the grass clippings clog the discharge area, stop the engine and gently move the discharge door handle back and forth until you can close the door completely. If you still cannot close the door, remove the obstruction with a stick, not your hand.

Occasionally you may wish to use the mulch plug to mulch the grass and leaf clippings back into the lawn.

• Installing the Mulch Plug:

  1. Stop the engine and wait for all moving parts to stop.

  2. If the grass bag is on the mower, remove it (refer to Removing the Grass Bag). If the side discharge deflector is on, remove it and lower the side discharge door (refer to Using the Side Discharge Deflector).

  3. Raise the rear discharge door and insert the mulch plug into the discharge opening. The plug will snap into the mower housing.

     

     Figure 17

     1. Mulch plug
     2. Rear discharge door

  4. Lower the discharge door.

• Removing the Mulch Plug:

  Note: When grass is thick and lush, clippings may collect on and around the discharge tunnel plug. This may make it difficult to remove the plug. Clean the plug thoroughly after each use.

  1. Stop the engine and wait for all moving parts to stop.

  2. Raise the rear discharge door and pull the mulch plug out of the discharge tunnel.

  3. Lower the discharge door.

Use the side discharge for cutting very tall grass.

• Installing the Side Discharge Deflector:

  1. Stop the engine and wait for all moving parts to stop.

  2. Remove the grass bag if it is installed on the mower (refer to Removing the Grass Bag).

  3. Install the mulch plug (refer to Installing the Mulch Plug).

  4. Lift and hold the side discharge spring in the “up” position and pull outward on the discharge door to remove (see Figure 18).

     

     Figure 18

     1. Side discharge spring
     2. Lift and hold in “up” position
     3. Pull outward
     4. Side discharge door

  5. With the side discharge spring held in the “up” position, place the discharge deflector onto the mower housing over the opening. Allow the spring to lower over the tabs on the discharge deflector. Make sure the discharge deflector is securely in place (see Figure 19).

     

     Figure 19

     1. Discharge deflector tabs
     2. Lower side discharge spring
     3. Secured position

     Important: Make sure the mulch plug is in place before using the side discharge deflector (see Figure 17).

     Danger

     An uncovered discharge opening will allow objects to be thrown in an operator's or bystander's direction. Also, contact with the blade could occur. Thrown objects or blade contact can cause serious injury or death.

     Never operate the mower with the side discharge door raised, removed, or altered unless there is a discharge deflector and mulch plug in place and working properly.

• Removing Side Discharge Deflector:

  1. Stop the engine and wait for all moving parts to stop.

  2. Lift and hold the side discharge spring in the “up” position and pull outward on the discharge deflector to remove it (reference Figure 18).

  3. With the side discharge spring held in the “up” position, place the discharge door onto the mower housing over the opening. Allow the spring to lower over the tabs on the discharge door. Make sure the discharge door is securely in place.

• Use extreme care when loading and unloading the machine into a trailer or truck.

• Use full width ramps for loading the machine into a trailer or truck.

• Tie the machine down securely using straps, chains, cable or ropes. If possible both front and rear straps should be directed down and outward from the machine.

• Be sure the fuel shut-off valve is closed during transport.

Important: Refer to the Engine Owner’s Manual for additional maintenance procedures.

1. Stop engine and wait for all moving parts to stop. Make sure the machine is on a level surface.

2. Check with engine cold.

3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick and push it all the way down into the tube. Do Not screw into place. Remove the dipstick and read the oil level.

   

   Figure 20

   1. Dipstick
   2. Full
   3. Add

4. If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for appropriate API rating and viscosity. Do Not overfill.

Important: Do Not operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

Always mow with a sharp blade. A sharp blade cuts cleanly and without tearing or shredding the grass blade.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug (Figure 9).

3. Drain the gasoline from the fuel tank. Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter section.

4. Remove the bagger from the machine. Tip the machine backwards until the upper handle rests on the ground and place a jack stand under the machine.

   Caution

   Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

   Do Not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

5. Inspect the blades for sharpness and wear, especially where the flat and the curved parts meet (see Figure 21). Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the lawn mower. If you notice a slot or wear (Figure 21B and Figure 21C), replace the blade.

   

   Figure 21

   1. Sail
   2. Flat
   3. Wear
   4. Slot

   Danger

   A worn or damaged blade can break. A piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death.

   • Inspect the blade periodically for wear or damage.

   • Replace a worn or damaged blade.

   • Removing Mower Blades:

     1. To remove the blade, use a block of wood to hold the blade steady. Make sure to grasp the end of the blade using a rag or thickly padded glove.

     2. Remove the blade bolt, blade driver, and blade.

     3. Inspect blades and sharpen or replace as required.

     4. Inspect the pins on the blade driver for wear and damage or replace as required.

   • Installing Mower Blades:

     1. Install the blade driver by inserting the raised area into the recess on the cutter housing.

     2. Make sure to grasp the end of the blade using a rag or a thickly padded glove. Align the two holes on the blade with the two holes on the blade driver and install a sharp, balanced Exmark blade and blade bolt as shown in Figure 22. The sail of the blade must point toward the top of the lawn mower housing for proper installation.

        

        Figure 22

        1. Blade bolt
        2. Blade-vertical position
        3. Blade driver
        4. Blade-horizontal position

     3. Torque the blade bolt to 60 ft-lb (82 N-m).

     4. Make sure the installed blade is vertical before installing the second blade. The second blade must be installed perpendicular to the first using steps 1 through 3. The two blades will form a sideways “T” as shown in Figure 23.

        

        Figure 23

        1. Blades form sideways “T”

     5. Rotate the blades by hand a full 360 degree turn to ensure they Do Not touch.

        Warning

        Incorrect installation of the blade or components used to retain the blade can be dangerous. Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death.

        Always install the original Exmark blades, blade drivers, and blade bolts as shown.

     6. If they touch, the blades are not mounted correctly. Repeat steps 1 through 5. If the blades still touch after repeating the steps, contact an Authorized Service Dealer.

6. Return the lawn mower to its upright position.

7. Connect the wire to the spark plug.

Refer to Checking the Blade Brake Clutch in Operation.

1. Stop engine, wait for all moving parts to stop.

2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating.

1. Stop engine, wait for all moving parts to stop.

2. Disconnect the wire from the spark plug (Figure 9).

3. Remove the cover and clean it thoroughly.

4. Check the paper element and foam cleaner. If cleaning is required, see Service Air Filter.

5. Reinstall the cover.

Note: Do Not operate the engine without the air filter assembly; extreme engine damage will occur.

1. Stop engine, wait for all moving parts to stop.

2. Disconnect the wire from the spark plug (Figure 9).

3. Remove the cover and clean it thoroughly.

   

   Figure 24

   1. Cover
   2. Foam element
   3. Paper air filter
   4. Air filter base

4. Remove the paper air filter and discard it as required.

   Note: Do Not try to clean a paper air filter.

5. Remove the foam element and wash it with a mild detergent and water, then blot it dry.

6. Saturate the element with clean engine oil, then squeeze it (Do Not twist) to remove the excess oil.

7. Install the foam element.

8. Install the new paper air filter.

9. Reinstall the cover.

1. Run the engine to warm the engine oil.

   Note: Warm oil flows better and carries more contaminates.

   Warning

   Oil may be hot after engine has been run. Contact with hot oil can cause severe personal injury.

   Avoid contacting the hot engine oil when you drain it.

2. Stop engine, wait for all moving parts to stop.

3. Disconnect the wire from the spark plug.

4. Drain the gasoline from the fuel tank. Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter section.

5. Place a suitable drain pan under the dipstick/oil drain.

6. Clean around the dipstick.

7. Remove the dipstick by rotating the cap counterclockwise and pulling it out.

8. Raise the left side of the lawn mower to drain the oil from the dipstick fill tube into the drain pan.

9. After draining the oil, return the lawn mower to the operating position.

10. Fill the crankcase with fresh oil to the upper limit mark on the dipstick. Use oil recommended in the Check Engine Oil Level section. Do Not overfill

11. Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight.

12. Wipe up any spilled oil.

13. Connect the wire to the spark plug.

14. Recycle the used oil according to local codes.

1. Run the engine to warm the oil.

2. Stop the engine and wait for all moving parts to stop.

3. Disconnect the wire from the spark plug.

4. Drain the engine oil.

5. Place a rag under the oil filter to catch any oil that may leak out as you remove the filter.

6. Remove the oil filter.

7. Use your finger to coat the gasket on the new filter with clean Exmark 4–Cycle Premium Engine oil (see Figure 25).

   

   Figure 25

   1. Gasket

8. Install the new filter and hand tighten it 2/3 turn only.

9. Fill the crankcase as stated in Check Engine Oil Level section. Exmark 4–Cycle Premium Engine oil is recommended. Refer to the Engine Owner's Manual for an acceptable alternative.

10. Connect the wire to the spark plug.

11. Run the engine for about 3 minutes.

12. Stop the engine, wait for all moving parts to stop, and check for oil leakage around the filter.

13. Add oil to compensate for the oil in the oil filter.

14. Recycle the used oil filter according to local codes.

1. Stop engine, wait for all moving parts to stop.

2. Remove the belt cover to the lawn mower housing.

3. Check the belt for cracks, frayed edges, burn marks or any other damage.

4. Replace the damaged belt(s).

   If the blade drive belt is replaced or needs adjustment, see Adjusting the Blade Drive Belt in Adjustments.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove and retain the belt access panel by rotating the screws a quarter-turn.

   

   Figure 26

   1. Belt access panel

4. Brush out all the debris around the belt area.

5. Use a feeler gauge, a piece of paper, or a note card against the frame and slide it down behind the belt tension spring.

   Note: The gap between the gauge and the spring should be .005-.030 inch (.13-.76 mm), tighten the adjusting bolt and nut until the paper barely slides freely in and out of the gap.

   

   Figure 27

   1. Belt tension spring
   2. Adjusting bolt
   3. Gap
   4. Adjusting nut
   5. Frame

   Important: Do Not overtighten the adjusting bolt. This could damage the blade drive belt.

6. Reinstall the belt access panel and rotate the screws a quarter-turn to lock into place.

7. Connect the wire to the spark plug.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove and retain the front belt cover and its four bolts. Remove any debris under the cover.

4. Remove and retain the BBC bracket and its mounting hardware.

5. Loosen the cable clamp screw on the BBC cable and remove the old belt (refer to Figure 36).

6. Install the new belt.

7. Reinstall the BBC bracket.

8. Adjust the BBC cable as described in Adjusting the Blade Brake Cable in the Adjustments section.

9. Reinstall the front belt cover.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove and retain the front belt cover and its four bolts. Remove any debris under the cover.

4. Remove and retain the BBC bracket and its mounting hardware. Remove the BBC belt from the front LH pulley.

5. Loosen the blade drive adjusting bolt (refer to Figure 27).

6. Remove and retain the fixed idler pulley and its hardware (see Figure 28).

   

   Figure 28

   1. Hole in deck
   2. RH sprocket hole
   3. Fixed idler
   4. LH sprocket hole (BBC idler removed for clarity)

7. Remove the blade drive belt.

8. Align the holes in the RH and LH sprockets with the holes in the deck as shown in Figure 28. Hold the sprockets in place with a rod or screwdriver.

9. Once the sprockets are locked into place, reinstall the blade drive belt and the fixed idler pulley.

   Note: Make sure the teeth are engaged in the sprockets.

10. Tighten the belt tension to the recommended settings; refer to Check the Blade Drive System.

11. Remove the rod or screwdrivers from the sprockets.

12. Check the blades under the deck to make sure they are properly aligned; refer to Check the Mower Blade section.

13. Reinstall the BBC belt and the BBC bracket.

14. Reinstall the belt cover using the four bolts.

15. Connect the wire to the spark plug.

16. Check the operation of the blade control lever and the blade brake clutch.

1. Shut off the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove the four bolts that hold the belt cover to the machine housing.

   Note: Save the bolts for installing the belt cover to the machine housing.

4. Remove the belt cover.

5. Remove any debris from under the belt cover.

6. If the grass bag is on the machine, remove and retain it.

7. Raise and hold up the rear door.

8. Remove and retain the rear panel and its mounting hardware (machines with a Kohler engine).

   

   Figure 29

   1. Rear panel
   2. Hardware
   3. Dust shield

9. Remove and retain the dust shield and its mounting hardware (machines with a Kawasaki engine).

10. Remove the transmission belt.

    • For machines with Kawasaki engines:

      1. Loosen the bracket and allow the bracket to drop (Figure 30).

         Note: The bracket prevents the transmission from tipping to the point where the transmission belt comes off.

         

         Figure 30

         1. Transmission tension spring
         2. Bracket
         3. Transmission
         4. BBC belt
         5. Transmission belt

      2. Remove the transmission tension spring.

      3. Remove the transmission belt from the transmission pulley.

      4. Remove the transmission belt.

      5. To install a new transmission belt, reverse the steps above.

    • For machines with Kohler engines:

      1. Rotate the idler pulley over the access hole on the transmission by using a socket wrench to turn the idler pulley nut.

         

         Figure 31

         1. Socket wrench
         2. Idler pulley nut
         3. Idler pulley nut
         4. Screwdriver

      2. While you are holding the idler pulley over the access hole on the transmission, insert a screwdriver through the access hole to catch a rib on the idler pulley.

         

         Figure 32

         1. Screwdriver through access hole
         2. Access hole
         3. Idler pulley
         4. Transmission belt

      3. Use the screwdriver to hold the idler pulley out of the way until you are done installing the new transmission belt.

      4. From the front of the machine, remove the belt from the engine pulley and then remove from the transmission pulley.

      5. While the idler pulley is pulled out of the way, install the new transmission belt placing the belt over the transmission pulley first and then over the engine pulley.

      6. Using a socket wrench to hold the idler pulley in position, remove the screwdriver from the access hole in the transmission and return the idler pulley to its tensioned position.

11. Ensure that the new transmission belt is positioned correctly.

12. Reinstall the dust shield using the hardware retained in step 9 (machines with a Kawasaki engine).

13. Reinstall the rear panel and secure with its mounting hardware retained in step 8 (machines with a Kohler engine).

14. Adjust the bracket to contact the transmission (see Adjusting the Transmission section).

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug (see Figure 9).

3. Clean around the spark plug.

4. Remove the spark plug from the cylinder head.

   Note: Replace a cracked, fouled, or dirty spark plug. Do Not clean the electrodes because grit entering the cylinder can damage the engine.

5. Set the gap on the plug to 0.030 inch (0.76 mm) (Figure 33).

   

   Figure 33

   1. Side electrode
   2. Center electrode insulator
   3. Air gap—0.030 inch (0.76 mm)

6. Install the spark plug and the gasket seal.

7. Torque the plug to 17 ft-lb (23 N-m).

8. Connect the wire to the spark plug.

The fuel filter (screen) element is located inside the fuel tank (if applicable).

1. Stop the engine and wait for it to cool down.

   Note: Drain gasoline for a cold engine only.

2. Disconnect the wire from the spark plug.

3. Close the fuel valve.

4. Disconnect the fuel line by loosening the tube clamp at the carburetor.

5. Open the fuel valve by turning the lever to the open position.

6. Drain the gasoline completely from the tank and fuel line into an approved fuel container.

7. Remove the fuel tank from the mower.

8. Close the fuel valve.

9. Pour a small amount of fuel in the fuel tank, move the fuel around in the tank, and pour it out into an approved fuel container.

10. Install the fuel tank and fuel line.

A fuel filter is installed between the fuel tank and the engine. Replace when necessary.

If the lawn mower does not self-propel or has a tendency to creep forward when the control bail is released, adjust the drive cable.

1. Stop the engine and wait for all moving parts to stop.

2. Loosen the cable support nut (Figure 34).

   

   Figure 34

3. Pull down the cable jacket (toward the mower) until there is no slack in the cable (Figure 35).

   

   Figure 35

4. Tighten the nut on the cable support.

5. Check the operation for desired drive control.

   Note: If the unit creeps forward without the bail engaged or if the wheels spin when you lift the rear wheels off the ground, the cable is too tight; repeat steps 1 and 2.

   Note: Adjustment to obtain desired ground speed at full bail travel may be made in order to accommodate slower speeds.

Adjust whenever a new blade brake cable assembly is installed or if the blade control lock lever does not operate properly or the BBC belt is replaced.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove and retain the front belt cover and its four bolts. Remove any debris under the cover.

4. Pull the cable until there is approximately 1/8 inch in slack. Do Not put tension on the spring.

   

   Figure 36

   1. Cable clamp screw
   2. Blade brake cable

5. Tighten the screw to lock the adjustment in place.

6. Reinstall the belt cover using the four bolts.

7. Connect the wire to the spark plug.

8. Check the operation of the blade control lock lever (see Figure 10). The lever must reset itself to lock out the blade control bail. If it does not, repeat steps 4 through 7.

9. Perform the Checking the Blade Brake Clutch procedure in Operation.

If the machine starts to lose traction, check and adjust the transmission.

1. Shut off the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Loosen the bolt and nut holding the bracket into place (see Figure 30).

4. Adjust the bracket so that it is in contact with the transmission.

   Note: The bracket prevents the transmission from tipping to the point where the transmission belt comes off.

5. Tighten the bolt and nut to secure the bracket into place.

Whenever you install a new parking-brake cable or if the parking brake is out of adjustment, adjust the parking-brake cable.

1. Disengage the parking brake.

2. Turn the adjustment nut counterclockwise to loosen the cable adjustment (Figure 37).

   

   Figure 37

   1. Parking-brake cable
   2. Adjustment nut
   3. Handle (right side)
   4. Turn the nut clockwise to tighten the adjustment.
   5. Turn the nut counterclockwise to loosen the adjustment.

3. Adjust the tension on the cable (Figure 37) by pulling or pushing the cable jacket and holding that position.

   Note: Pull the cable jacket toward the engine to increase tension (also increases brake clamp load); push the cable jacket away from the engine to decrease tension (also decreases brake clamp load).

   Important: Adjust the cable jacket in small increments to avoid over tensioning. Over tensioning may cause the machine to not roll free even when the parking brake is disengaged. Correct tensioning allows the machine to roll free when the parking brake is disengaged and to hold position when the parking brake is engaged.

4. Turn the adjustment nut clockwise to tighten the cable adjustment.

   Note: Tighten the nut firmly with a socket or wrench.

1. Stop engine, wait for all moving parts to stop, and remove spark plug wire.

2. Clean all debris from rotating engine air intake screen, around engine shrouding, and exhaust system area.

3. Wipe up any excessive grease or oil around the engine and exhaust system area.

1. Stop engine, wait for all moving parts to stop, and remove spark plug wire.

2. To ensure the best performance, keep the underside of the lawn mower housing clean.

   Caution

   The mower may dislodge material from under the mower housing.

   • Wear eye protection.

   • Stay in the operating position (behind the handle).

   • Do Not allow bystanders in the area.

Washing Method

1. Position the lawn mower on a flat concrete or asphalt surface near a garden hose.

2. Start the engine.

3. Hold the running garden hose at handle level and direct the water to flow on the ground just in front of the right rear tire (Figure 38).

   

   Figure 38

4. Engage the blade.

   Note: The blade will draw in water and wash out clippings. Let the water run until you no longer see clippings being washed out from under the housing.

5. Disengage the blade, stop the engine and wait for all moving parts to stop.

6. Turn off the water.

7. Start the lawn mower, engage the blade, and let the lawn mower run for a few minutes to dry out its components.

Scraping Method

If washing does not remove all debris from under the lawn mower, scrape it clean.

1. Disconnect the wire from the spark plug.

2. Drain the fuel from the fuel tank. Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter section.

3. Tip the lawn mower onto its right side.

4. Remove the dirt and grass clippings with a hardwood scraper. Avoid burrs and sharp edges.

5. Turn the lawn mower upright.

6. Fill the fuel tank.

7. Connect the wire to the spark plug.

Always be sure that the discharge tunnel door closes securely when you release the handle. If the debris prevents the discharge door from closing securely, clean the inside of the discharge tunnel and the door thoroughly.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove and retain the belt access panel by rotating the screws a quarter-turn.

4. Brush out all the debris around the belt area.

5. Reinstall the belt access panel and rotate the screws a quarter-turn to lock into place.

6. Connect the wire to the spark plug.

1. Stop the engine and wait for all moving parts to stop.

2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.