Toro 30031 Operator's Manual

Commercial Walk-Behind Mower For Floating Deck, T-Bar, Gear with 91cm TURBO FORCE® Cutting Unit Model No. 30031—Serial No. 270000001 and Up Register your product at www.Toro.com Original Instructions (EN)

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. This spark ignition system complies with Canadian ICES-002 Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. The enclosed Engine Owner’s Manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer. Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. Figure 1 1. Model and serial number location Model No. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Figure 2 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Contents Introduction .......................................................2 Safety ..................................................................4 General Lawn Mower Safety ................4 Sound Pressure....................................6 Sound Power.......................................6 Vibration, Hand/arm ..........................6 Slope Chart .........................................7 © 2006—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 2 Contact us at www.Toro.com. Printed in the USA. All Rights Reserved

Product Overview............................................. 11 Controls ........................................... 11 Specifications ................................... 12 Operation.......................................................... 13 Adding Fuel ...................................... 13 Checking the Engine Oil Level........... 14 Think Safety First .............................. 14 Using the Parking Brake..................... 14 Starting and Stopping the Engine .............................. 15 Operating the Mower Power Take Off (PTO)......................... 15 The Safety Interlock System............... 16 Driving Forward or Backward............ 16 Using the Lower Control Bar ............. 17 Stopping the Machine........................ 18 Transporting Machines...................... 18 Side Discharging or Mulching the Grass................................. 18 Adjusting the Height-of-Cut .............. 18 Adjusting the Anti-Scalp Rollers............................... 19 Adjusting the Handle Height.............. 19 Adjusting the Flow Baffle................... 20 Positioning the Flow Baffle................ 21 Using the Mid-Size Weight................. 22 Maintenance...................................................... 23 Recommended Maintenance Schedule(s) ............................... 23 Lubrication................................................ 23 How to Grease .................................. 23 Lubricating the Caster and Wheel Bearings ............................ 24 Greasing the Transmission Couplers............................ 24 Greasing the PTO Drive Belt Idler and Mower Deck Belt Idler .................................. 24 Engine Maintenance.................................. 25 Servicing the Air Cleaner ................... 25 Servicing the Engine Oil .................... 26 Servicing the Spark Plugs................... 27 Fuel System Maintenance .......................... 28 Draining the Fuel Tank...................... 28 Replacing the Fuel Filter .................... 29 Electrical System Maintenance................... 29 Servicing the Fuse ............................. 29 Drive System Maintenance......................... 30 Adjusting the Control Bar.................. 30 Checking the Tire Pressure................. 31 Replacing the Caster Wheel Fork Bushings ........................... 31 Servicing the Caster Wheel and Bearings ............................ 32 Adjusting the Electric Clutch ............. 32 Cooling System Maintenance..................... 33 Cleaning the Air Intake Screen ........... 33 Brake Maintenance.................................... 33 Servicing the Brakes .......................... 33 Belt Maintenance....................................... 34 Replacing the Traction Drive Belt ................................... 34 Replacing the Transmission Belt ................................... 34 Replacing the Mower Belt .................. 35 Replacing the PTO Drive Belt............ 35 Adjusting the PTO Drive Belt Idler Spring Anchor................... 36 Mower Deck Maintenance......................... 36 Servicing the Cutting Blades............... 36 Correcting the Mower Quality of Cut.................................... 38 Frame Set Up .................................... 39 Checking the Mower Deck Front-to-Rear Pitch ........... 41 Changing the Mower Deck Front-to-Rear Pitch ........... 41 Checking the Mower Deck Side-to-Side Height ........... 41 Changing the Mower Deck Side-to-Side Height ........... 42 Matching Height of Cut ..................... 42 Replacing the Grass Deflector............ 42 Storage.............................................................. 44 Cleaning and Storage ......................... 44 Troubleshooting................................................ 45 Schematics ........................................................ 48 3

can result in injury. To reduce the potential for injury, comply with these safety instructions. Toro designed and tested this mower for reasonably safe service; however, failure to comply with the following instructions may result in personal injury. To ensure maximum safety, best performance, and to gain knowledge of the product, it is essential that you and any other operator of the mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the safety alert symbol (Figure 2) which means Caution, Warning, or Danger—“personal safety instruction.” Read and understand the instruction because it has to do with safety. Failure to comply with the instruction may result in personal injury. General Lawn Mower Safety The following instructions have been adapted from the ISO standard 5395. This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. Training • Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. • Never allow children or people unfamiliar with these instructions to use the mower. Local regulations can restrict the age of the operator. • Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property. • Understand explanations for all pictograms used on the mower or in the instructions. Gasoline WARNING-Gasoline is highly flammable. Take the following precautions. • Store fuel in containers specifically designed for this purpose. • Refuel outdoors only and do not smoke while refueling. • Add fuel before starting the engine. Never remove the cap of the fuel tank or ad gasoline while the engine is running or when the engine is hot. • If gasoline is spilled, do not attempt to start the engine but move the mower away from the area of spillage and avoid creating any source of ignition until gasoline vapors have dissipated. • Replace all fuel tank and container caps securely. Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones and other foreign objects. • Before using, always visually inspect to see that guards, and safety devices, such as deflectors and/or grass catchers, are in place and working correctly. • Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance. Starting • Disengage all blade and drive clutches and shift into neutral before starting the engine. • Do not tilt mower when starting the engine or switching on the motor, unless the mower has to be tilted for starting. In this case, do not tilt it more than absolutely necessary and lift only the part, which is away from the operator. • Start the engine or switch on the motor carefully according to instructions and with feet well away from the blade(s) and not in front of the discharge chute. Operation • Never mow while people, especially children, or pets are nearby. • Mow only in daylight or in good artificial light. 4

where feasible. • Stay alert for holes in the terrain and other hidden hazards. • Never direct discharge of material towards bystanders. • Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. • Never pick up or carry a lawn mower while the engine is running. • Use extreme caution when reversing or pulling a pedestrian controlled lawn mower towards you. • Walk, never run. • Slopes: – Do not mow excessively steep slopes. – Exercise extreme caution when on slopes. – Mow across the face of slopes, never up and down and exercise extreme caution when changing direction on slopes. – Always be sure of your footing on slopes. • Use low throttle settings when engaging the traction-clutch, especially in high gears. Reduce speed on slopes and in sharp turns to prevent overturning or loss of control. • Stop the blade if the lawn mower has to be tilted for transportation when crossing surfaces other than grass and when transporting the lawn mower to and from the area to be mowed. • Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect. • Stop the engine – whenever you leave the lawn mower. – before refueling. – before removing the grass catcher. – before making height adjustment unless adjustment can be made from the operator’s position. • Stop the engine and disconnect the spark-plug wire or turn off and remove the key. – before clearing blockages or unclogging chute. – before checking, cleaning or working on the lawn mower. – after striking a foreign object, inspect the lawn mower for damage and make repairs before restarting and operating the lawn mower. – if lawn mower starts to vibrate abnormally (check immediately). • Use care when using sulkies, and – use only approved drawbar hitch points. – limit loads to those you can safely control. – do not turn sharply: use care when reversing. – do not carry passengers. • Watch out for traffic when crossing or near roadways. • Before leaving the operator’s position – disengage the power take-off and lower the attachments. – change into neutral and set the parking brake. – stop the engine and remove the key. Maintenance and Storage • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • Do not use pressure cleaning equipment on machine. • Never store the equipment with gasoline in the tank and inside a building where fumes can reach an open flame or spark. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, silencer, battery compartment and gasoline storage are free of grass, leaves, or excessive grease. • Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts, when necessary. • Replace worn or damaged parts for safety. • Replace faulty silencers. • If the fuel tank has to be drained, do this out-doors. • Do not change the engine governor settings or overspeed the engine. Operating an engine 5

personal injury. • On multibladed lawn mowers, take care as rotating one blade may cause others to rotate. • Be careful during adjustment of the lawn mower to prevent entrapment of the fingers between moving blades and fixed parts of the lawn mower. • To ensure the best performance and safety, purchase only genuine Toro replacement parts and accessories. Do not use will fit parts and accessories; they may cause a safety hazard. Sound Pressure This unit has an equivalent continuous A-weighted sound pressure level at the operator ear of 87 dBA, based on measurements of identical machines per EN 11094 and EN 836. Sound Power This unit has an equivalent continuous A-weighted sound power level of 100 dBA, based on measurements of identical machines per EN 11094. Vibration, Hand/arm This unit does not exceed a hand/arm vibration level of 2.0 m/s2, based on measurements of identical machines per EN 1033. 6

Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-9353 1. Shut off fuel valve before transporting, rotate knob clockwise until it stops. 93-7010 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. 93-7298 1. Traction drive—forward 2. Pull to brake 93-7299 1. Traction drive—reverse 93-7442 1. Parking brake 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115-149 N•m (85-110 ft-lb). 93-7824 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. 8

2. Cutting/dismemberment of hand or foot—stay away from moving parts. 98-1977 1. Entanglement hazard, belt—stay away from moving parts. 98-3264 1. Read the Operator’s Manual. 98-4387 1. Warning—wear hearing protection. 99-8939 1. Read the Operator’s Manual. 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. Height of cut Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer. 104-8185 106-0636 1. Height-of-cut 3. Read the Operator’s Manual for more information. 2. Warning—power 106-5517 1. Warning—do not touch the hot surface. 110-2067 9

110-4972 1. Fast 3. Slow 5. Engine—Start 7. Choke 2. Continuous variable setting 4. Engine—stop 6. Engage bale then pull out on the PTO to engage the blade. 10

5. Controls 2. Mower deck 6. Handle 3. Recoil starter 7. Caster wheel 4. Gas tank Controls Become familiar with all the controls (Figure 4) before you start the engine and operate the machine. Figure 4 1. Gear shift lever 7. Blade control bail 2. Power take off switch (PTO) 8. Upper control bar 3. Choke control 9. Upper handle 4. Lower handle 10. Throttle control 5. Lower control bar 11. Ignition switch 6. Parking brake lever-released position 12. Fuel shut-off valve Throttle Control The throttle control has two positions: Fast and Slow. Choke Use the choke to start a cold engine. Blade Control Bail The bail is used in conjunction with the power take off switch (PTO) to engage the clutch to drive the mower blades. Release the mower control bail to disengage the mower blades. Power Take Off Switch (PTO) This pull switch is used in conjunction with the blade control bail to engage the clutch to drive the mower blades. Gear Shift Lever The transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. Important: Do not shift while unit is moving, as transmission damage may occur. 11

Shift to the desired gear and push forward on the upper control bar to engage forward traction operation and pull back to brake forward movement. Pull back on right side of upper control bar to turn right and left side to turn left. Lower Control Bar Shift transmission to reverse and squeeze the lower control bar and handle together to engage rearward traction assist operation. Parking Brake Lever Pull back on upper control bar and swing brake lever up against the upper handle (Figure 4). Ignition Switch This switch is used in conjunction with recoil starter and has two positions: Run and Off. Recoil Starter Pull recoil starter handle to start engine (not shown in Figure 4). Fuel Shut-off Valve Close the fuel shut-off valve when transporting or storing mower. Specications Note: Specifications and design are subject to change without notice. Width with deector down 51–1/8 inches (130 cm) Length 82–3/4 inches (210 cm) Height with handle in lowest position 41–3/16 inches (105 cm) Weight 598 lb (271 kg) Attachments/Accessories A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. 12

machine from the normal operating position. Adding Fuel Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand. • Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark. • Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline. • Do not operate without entire exhaust system in place and in proper working condition. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Always place gasoline containers on the ground away from your vehicle before filling. • Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. • When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. • If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle. • If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin. Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained. 13

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. Filling the Fuel Tank 1. Shut the engine off and set the parking brake. 2. Clean around each fuel tank cap and remove the cap. 3. Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tanks completely full. 4. Install fuel tank caps securely. 5. Wipe up any gasoline that may have spilled. Checking the Engine Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level in Engine Maintenance, page 25 Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you or any bystanders avoid injury. The use of protective equipment for eyes, hearing, feet and head is recommended. This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Figure 5 1. Warning—wear hearing protection. Using the Parking Brake Stop on level ground, disengage drives, engage parking brake, shut off engine and remove key. Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 1. Pull the upper control bar (Figure 6) rearward and hold it in this position. 2. Lift the parking brake lock (Figure 6) up and gradually release the upper control bar. The brake lock should stay in the set (locked) position. Figure 6 1. Upper control bar 3. Fixed bar 2. Parking brake lever-set position 14

1. Pull rearward on the upper control bar. Lower the parking brake lock to the released position. 2. Gradually release the upper control bar. Starting and Stopping the Engine Starting the Engine 1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open. 2. Move the shift lever to neutral, set the parking brake and turn ignition key to run. 3. Move the throttle control to fast and move the choke lever to the on position before starting a cold engine. Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to the fast position. 4. Grasp recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly. Important: Do not pull recoil rope to its limit or let go of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged. Stopping the Engine 1. Move the throttle lever to the slow position (Figure 7). 2. Let engine idle for 30 to 60 seconds before turning the ignition key to off. 3. Turn the ignition key to off (Figure 7). Figure 7 1. Throttle lever 2. Ignition key 4. Set the parking brake and remove key. 5. Pull wire off spark plug(s) to prevent possibility of accidental starting before storing machine. 6. Close the fuel shut off valve before storing machine. Important: Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. Operating the Mower Power Take Off (PTO) The power take off switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades. Engaging the Mower Blades (PTO) 1. Release the upper control bar to stop the machine (Figure 8). 2. To engage blade, squeeze blade control bail against the upper control bar (Figure 8). 3. Pull the power take off switch (PTO) up and release. Hold the blade control bail against the upper control bar while operating. 4. Repeat the procedure to engage the mower blades if the blade control bail is released. 15

3. Power take off switch (PTO) 2. Blade control bail Disengaging the Mower Blades (PTO) Release the blade control bail to disengage the blades (Figure 8). The Safety Interlock System If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Understanding the Safety Interlock System The safety interlock system is designed to prevent the mower blades from rotating unless: • The control bail is depressed. • The power take off switch (PTO) is pulled on. The safety interlock system is designed to stop the mower blades if you release the blade control bail. Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. Note: If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Set the parking brake and start the engine; refer to Starting and Stopping the Engine. 2. Squeeze the blade control bail against upper control bar. The blades should not rotate. 3. Then continue holding the blade control bail and pull up on the blade control switch and release. The clutch should engage and the mower blades begin rotating. 4. Release the blade control bail. The blades should stop rotating. 5. With the engine running, pull up the power take off switch (PTO) and release without holding the blade control bail. The blades should not rotate. Driving Forward or Backward The throttle control regulates the engine speed as measured in RPM (revolutions per minute). Place the throttle control in the fast position for best mowing performance. Driving Forward 1. To go forward, move the shift lever to a forward gear (Figure 9). 2. Release the parking brake; refer to Releasing the Parking Brake in Brake Maintenance, page 33. 3. Slowly press on the upper control bar to move forward (Figure 9). To go straight, apply equal pressure to both ends of the upper control bar (Figure 9). To turn, release pressure on the upper control bar side in the direction you want to turn (Figure 9). 16

3. Shift lever 2. Lower control bar Driving Backward 1. To go backward, move the shift lever to reverse gear. 2. Release the parking brake; refer to Releasing the Parking Brake. 3. Slowly squeeze the lower control bar and lower handle together to move rearward (Figure 9). Using the Lower Control Bar This procedure is for driving up a curb. This can be performed while driving forward or backward. Note: Some curbs do not allow the rear drive tires to contact the curb. If this happens, drive the machine up the curb at an angle. A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders. Do not run blades while driving up a curb forward or backward. Driving Forward Up a Curb 1. Disengage the mower blades. 2. Select first gear to drive the machine. 3. Drive machine until the castor wheels contact curb (Figure 10). 4. Lift the front of the machine by pushing down on the lower handle (Figure 10). 5. Drive the machine until drive wheels contact the curb (Figure 10). 6. Lower the front of the machine (Figure 10). Note: Both drive wheels should contact the curb and caster wheels straight. 7. At the same time engage the lower control bar and lift up on the lower handle to drive over the curb (Figure 9 and Figure 10). Note: Lifting up on the lower handle will assist driving the machine up a curb and not spin the drive wheels. Figure 10 1. Lower Control Bar engaged and mower in reverse. 3. Lower Control Bar engaged and mower going forward. 2. Pull up to assist machine Driving Backward Up a Curb 1. Disengage the mower blades. 2. Select reverse to drive machine. 3. Drive the machine until drive wheels contact curb (Figure 10). Note: Both drive wheels should contact the curb and caster wheels straight. 4. At the same time engage lower control bar and lift up on the lower handle (Figure 9 and Figure 10). 17

assist driving the machine up a curb and not spin the drive wheels. Stopping the Machine To stop the machine, pull back on the upper control bar, release the blade control bail, and turn the ignition key to off. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake in Operation, page 13. Remember to remove the key from the ignition switch. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Transporting Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. To transport the machine: 1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes. 3. Load the machine onto the trailer or truck. 4. Stop the engine, remove the key, set the brake, and close the fuel valve. 5. Use the metal tie down loops on the machine to securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes (Figure 11). Figure 11 1. Traction unit tie down loop Side Discharging or Mulching the Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower. • Never try to clear discharge area or mower blades unless you release the bail and the power take off (PTO) is off. Rotate the ignition key to Off. Also remove the key and pull the wire(s) off the spark plug(s). Adjusting the Height-of-Cut The height-of-cut can be adjusted from 1 to 4-1/2 inch (25 to 114 mm) in 1/4 inch (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers. 18

spacer or damage can occur to bushing if none are used. Note: All height-of-cut pins can use two spacers maximum. 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Figure 12). 2. Using the lift handle, raise side of deck and remove hairpin cotter (Figure 12). 3. Add or remove spacers if needed and then align holes and insert hairpin cotter (Figure 12). Note: Spare height-of-cut spacers may be stored on posts and retained by a hairpin cotter. Important: All four hairpin cotter pins must be in the same hole location and with the correct number of spacers for a level cut. Figure 12 1. Carrier Frame 4. Spacers 2. Hairpin Cotter 5. Front height-of-cut post 3. Back height-of-cut post Adjusting the Anti-Scalp Rollers The anti-scalp rollers need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground. Note: If the anit-scalp rollers are adjusted too low can cause excess wear of the rollers. 1. After adjusting height-of-cut, check the anti-scalp rollers so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figure 13). 2. If adjustment is needed, remove the bolt, washers and nut (Figure 13). 3. Select a hole position so the anti-scalp rollers are a minimum of 3/8 inch (10 mm) off the ground (Figure 13). 4. Install the bolt and nut (Figure 13). Figure 13 1. Mower deck 4. Anti-Scalp Rollers 2. Bolt 5. Nut 3. Spacer Adjusting the Handle Height The handle position can be adjusted to match the operator’s height preference. 1. Remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket (Figure 14). 19

4. Washer 2. Idler bracket 5. Hairpin cotter pin 3. Clevis pin 6. Rod tting 2. Loosen the upper flange bolts (3/8 x 1 inch) and flange nut securing handle to rear frame (Figure 15). Figure 15 1. Upper handle 5. Upper mounting hole 2. Rear frame 6. Lower mounting holes 3. Flange nut, (3/8 inch) 7. Low position 4. Flange bolt, (3/8 x 1 inch) 8. High position 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 15). 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. Tighten all flange bolts. 5. Check the control bar for correct adjustment. Refer to Adjusting the Control Bar in the maintenance section. 6. Check the parking brake adjustment. Refer to Checking the Brakes in the maintenance section. Adjusting the Flow Bafe The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. To adjust the cam lock, swing the lever up to loosen the cam lock (Figure 16). 4. Adjust the baffle and cam lock in the slot to the desired discharge flow. 5. Swing the lever back over to tighten the baffle and cam lock (Figure 16). 6. If the cam does not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 16 1. Cam lock 4. Slot 2. Lever 5. Rotate the lever to release or lock the cam 3. Rotate cam to increase or decrease locking pressure 20

The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position A This is the full rear position (see Figure 17). The suggested use for this position is a follows. • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 17 Position B Use this position when bagging (Figure 18). Figure 18 Position C This is the full open position. The suggested use for this position is as follows (Figure 19). • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. 21

• Any rear weight must be removed when a Tru–Track® Sulky is installed. • When a Tru–Track® Sulky is installed front weights are needed. Contact an Authorized Service Dealer for the correct quantity of weights and placement. The front end of the machine can rapidly rise up when the mower is removed. This could cause serious injury to you or bystanders. Support the rear of the machine when removing the mower form the carrier frame. 22

Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. Before each use or daily • Check the safety interlock system. • Grease the caster wheels and caster pivot. • Check the engine oil level. • Clean the air intake screen. • Check the brakes. • Inspect the blades. Every 25 hours • Clean foam air cleaner element. Every 50 hours • Grease the PTO belt idler. • Grease the mower deck belt idler. • Check the paper air cleaner element. • Check the tire pressure. • Check the traction drive belt. • Check the transmission belt. • Check the mower belt. • Check the PTO drive belt. Every 100 hours • Change the engine oil. • Check the spark plugs. • Adjust the electric clutch. Every 200 hours • Replace the paper air cleaner element. • Change the oil lter. • Replace the fuel lter. Every 250 hours • Grease the transmission couplers (more often in dirty or dusty conditions). Every 400 hours • Grease the front wheel bearings (more often in dirty or dusty conditions). Before storage • Paint chipped surfaces. • Perform all maintenance procedures listed above before storage. Important: Refer to your engine operator’s manual for additional maintenance procedures. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the spark plug wires from the spark plugs before you do any maintenance. Set the wires aside so that they do not accidentally contact the spark plugs. Lubrication Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 1. Disengage the PTO and set the parking brake. 23

all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. Lubricating the Caster and Wheel Bearings 1. Lubricate the front caster wheel bearings and front pivots (Figure 20). 2. Raise the rear of the machine and use jack stands to support the machine. 3. Remove the rear wheel and tire assemblies. 4. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Figure 20). 5. Install the grease cap. 6. Install the rear wheel and tire assembly. Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. Figure 20 Greasing the Transmission Couplers Lubricate the transmission couplers located in the back of the machine (Figure 21). Figure 21 Greasing the PTO Drive Belt Idler and Mower Deck Belt Idler Grease the idler pulley pivot(Figure 22). Figure 22 24

Service Interval/Specication Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. Inspect the foam and paper elements and replace them if they are damaged or excessively dirty. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage (Figure 23). 4. Unscrew the cover knob and remove the air cleaner cover (Figure 23). 5. Remove the 2 wing nuts and remove the air cleaner assembly (Figure 23). 6. Carefully pull the foam element off the paper element (Figure 23). Figure 23 1. Engine 4. Foam element 2. Cover 5. Paper element 3. Wing nut 6. Cover knob Cleaning the Foam Air Cleaner Element 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. Servicing the Paper Air Cleaner Element 1. Do not clean the paper filter. Replace it after 200 operating hours (Figure 23). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 3. Replace the paper element if it is damaged. 25

Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 23). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 23). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 23). Servicing the Engine Oil Service Interval/Specication Check the engine oil level daily. Change the engine oil as follows: • After the first 8 operating hours • After every 100 operating hours Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF, SG, SH, or SJ) Crankcase Capacity: 58 ounces (1.7 liter) with the filter removed; 51 ounces (1.5 liter) without the filter removed Viscosity: Refer to the table (Figure 24). Figure 24 Checking the Engine Oil Level 1. Park the machine on a level surface. 2. Disengage the PTO and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Clean around the oil dipstick (Figure 25) so that dirt cannot fall into the filler hole and damage the engine. Figure 25 1. Oil dipstick 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 25). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 25). 7. Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. Important: Do not overfill the crankcase with oil and run the engine; engine damage can result. Changing the Oil 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 3. Disengage the PTO and set the parking brake. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Slide the drain hose over the oil drain valve. 6. Place a pan below the drain hose. Rotate oil drain valve to allow oil to drain (Figure 26). 26

drain valve. 8. Remove the drain hose (Figure 26). Note: Dispose of the used oil at a recycling center. Figure 26 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 25). 10. Check the oil level; refer to Checking the Engine Oil Level. 11. Slowly add the additional oil to bring it to the Full mark. Changing the Oil Filter Replace the oil filter every 200 operating hours or every other oil change. Note: Change the oil filter more frequently when the operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing the Engine Oil. 2. Remove the old filter (Figure 27). Figure 27 1. Oil lter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 27). 4. Install the replacement oil filter to the filter adapter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Figure 27). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter and drain valve. 7. Check the engine oil level and add oil if needed. 8. Wipe up any spilled oil. Servicing the Spark Plugs Check the spark plugs after every 100 operating hours. Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plugs if necessary. Type: Champion® RCJ8Y or equivalent Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plugs 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 27

(Figure 28). Figure 28 1. Spark-plug wire/spark plug 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 29). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. 2. If needed, clean the spark plug with a wire brush to remove carbon deposits. Figure 29 1. Center electrode insulator 3. Air gap (not to scale) 2. Side electrode Important: Always replace the spark plugs when it has worn electrodes, an oily film on it, or has cracks in the porcelain. 3. Check the gap between the center and side electrodes (Figure 29). Bend the side electrode (Figure 29) if the gap is not correct. Installing the Spark Plugs 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 16 ft-lb (22 N⋅m). 3. Connect the wires to the spark plugs (Figure 29). Fuel System Maintenance Draining the Fuel Tank In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 1. Park the machine on a level surface, to assure fuel tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Close the fuel shut-off valve at the fuel tank (Figure 30). 3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from fuel filter (Figure 30). 4. Pull the fuel line off the fuel filter (Figure 30). Open the fuel shut-off valve and allow the gasoline to drain into a gas can or drain pan. 28

fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter. 5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the valve to secure the fuel line. Figure 30 1. Fuel shut-off valve 2. Clamp Replacing the Fuel Filter Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line. Note: Note how the fuel filter is installed. Note: Wipe up any spilled fuel. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Close fuel shut-off valve at fuel tank (Figure 30). Note: Remove the fuel line from the fuel valve that is closest to the engine. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 31). Figure 31 1. Hose clamp 3. Filter 2. Fuel line 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Figure 30). 8. Check for fuel leaks and repair if needed. Electrical System Maintenance Servicing the Fuse The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows check component or circuit for malfunction or short. To replace fuse pull out on the fuse (Figure 32) to remove or replace it. 29

Drive System Maintenance Adjusting the Control Bar 1. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. The gap should be approximately 1 to 1-1/4 inch (25-32 mm) (Figure 33). Note: The upper control bar and fixed bar must be parallel when the upper control bar is in the engaged, drive, neutral, or brake positions. Figure 33 1. Upper control bar 4. Handle 2. Parking brake lever 5. 1 to 1-1/4 inch (25-32mm) gap 3. Fixed control bar 2. Check the operation. If adjustment is required, remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket (Figure 34). 3. Thread the rod fitting up or down on the rod until the proper position is attained and install the rod fitting to the idler bracket with the clevis pin, washer and hairpin cotter. Figure 34 1. Control rod and tting 5. Washer 2. 3-1/2 inch (89 mm) 6. Hairpin cotter pin 3. Idler bracket 7. Rod tting 4. Clevis pin 8. Hole F 30

Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 35). Maintain the air pressure in the rear tires at 12-14 psi (83-97 kPa). Uneven tire pressure can cause an uneven cut. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance. Figure 35 Replacing the Caster Wheel Fork Bushings The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting pivot tubes. To check the bushings, move the caster forks back and forth and side-to-side. If a caster fork is loose, the bushings are worn and must be replaced. 1. Raise the cutting unit so the caster wheels are off the floor, then support the front of the mower with jack stands. 2. Remove the locking pin and spacer(s) from the top of the caster wheel fork (Figure 36). Figure 36 1. Locking Pin 3. Carrier frame pivot tube 2. Spacers 4. Caster wheel 3. Pull the caster wheel fork out of the mounting tube, leaving the spacer(s) on the bottom of the fork. Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck. 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Figure 37). Clean the inside of the mounting tube. Figure 37 1. Mounting Tube 2. Bushing 5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to 31

tubes. 6. Inspect the caster wheel fork for wear and replace if necessary (Figure 36). 7. Slide the caster wheel fork through the bushings in the mounting tube. Replace the spacer(s) onto the fork and secure with the retaining ring (Figure 36). Important: The inside diameter of the bushings may collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 inch (29 mm). 8. Grease the fitting on the carrier frame pivot tubes using No. 2 general purpose lithium base or molybdenum base grease. Servicing the Caster Wheel and Bearings The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly caster wheel usually indicates a worn bearing. 1. Remove the locknut and wheel bolt holding the caster wheel to the caster fork (Figure 38). Figure 38 1. Locknut 4. Spanner Bushing 2. Cap 5. Wheel 3. Roller Bearing 6. Bushing 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 38). 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Figure 38). 4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Figure 38). 5. To assemble, place one bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Figure 38). 6. Install the caster wheel into the caster fork and secure with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the caster forks (Figure 38). 7. Grease the fitting on the caster wheel. Adjusting the Electric Clutch The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation. 1. Insert a 0.015–0.021 inch (0.381–0.533 mm) feeler gauge through one inspection slot in the side of the assembly. Make sure it is between the armature and the rotor friction surfaces. 2. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Figure 39). 3. Repeat this for the remaining slots. 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. 32

Screen Before each use remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor-governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine. Brake Maintenance Servicing the Brakes Before each use, check brakes on both a level surface and slope. Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. Checking the Brakes 1. Park the machine on a level surface, disengage the PTO. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Apply the parking brake. The wheels must lock when you try to push the machine forward. 4. If the wheels do not lock, adjust the brakes. Refer to Adjusting the Brakes. 5. Release the brake and press upper control bar very lightly, approximately 1/2 inch (13 mm). The wheels should rotate freely, if not; refer to Adjusting the Brakes. Adjusting the Brakes The brake lever is on the upper control bar. If the parking brake does not hold securely, an adjustment is required. Note: For the initial adjustment, adjust the wing nut until it is 1-1/4 inches from the top of the rod (Figure 40). 1. Park the machine on a level surface, disengage the PTO, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the brake before you adjust it; refer to Checking the Brakes. 4. Release the parking brake; refer to Releasing the Parking Brake in Operation, page 13. 5. To adjust the brake remove the hair pin cotter and washer from the brake lever and trunnion (Figure 40). 33

5. Hole F 2. Trunnion 6. Initial adjustment- 1-1/4 inch (32 mm) 3. Brake lever 7. Rod 4. Wing nut 6. Rotate the wing nut clockwise to increase the braking pressure. 7. Rotate the wing nut counterclockwise to decrease the braking pressure. 8. Install the trunnion into hole F (Figure 40). Tighten the wing nut. 9. Secure trunnion to brake lever with washer and hair pin cotter (Figure 40). 10. Check the brake operation again; refer to Checking the Brakes. Important: With the parking brake released, the rear wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately. Belt Maintenance Replacing the Traction Drive Belt Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for cracks, wear, and signs of overheating. 1. Remove the plastic cover over the idler bracket. 2. Remove the top capscrew securing idler support and idler bracket to rear frame (Figure 41). Figure 41 1. Top capscrew 4. Bottom capscrew 2. Idler bracket 5. Traction drive belt 3. Idler support 3. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Figure 41). 4. Raise the wheel off the ground, to allow the belt to be removed, and remove the belt. 5. Install a new belt. 6. Install the top bolt securing the idler support and idler bracket to the rear frame (Figure 41). 7. Tighten the bottom two mounting screws enough to allow the belt to pass between the drive pulley and idler support (Figure 41). 8. Install the plastic cover over the idler bracket. Replacing the Transmission Belt 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the panel from the bottom of the machine. 4. Remove PTO drive belt. Refer to Replacing the PTO Drive Belt in the Belt Maintenance, page 34. 34

jack stands. 6. Disconnect clutch wire connector from wire harness. 7. Disconnect clutch retainer from the engine deck (Figure 42). Figure 42 1. Transmission belt 5. Clutch wire connector 2. Idler pulley 6. Pivot bolt 3. Clutch retainer 7. Drive pulley 4. Tension spring 8. Engine deck 8. Unhook tension spring from side of frame (Figure 42). 9. Loosen pivot bolt enough to remove traction belt from the drive pulley and clutch. 10. Install new belt around clutch and drive pulley. 11. Torque pivot bolt to 35-40 ft-lb (47-54 N·m). Install tension spring between idler arm and frame bracket (Figure 42). 12. Install clutch retainer to the engine deck (Figure 42). 13. Connect clutch wire connector to wire harness. 14. Install PTO drive belt. 15. Install the panel to the bottom of the machine. Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the carrier frame cover. 4. Unlatch and remove the belt covers. 5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 43). 7. Install the new mower belt around the two outside spindle pulleys, the idler pulley, and in the lower groove of the double spindle pulley (Figure 43). 8. Connect the idler arm spring (Figure 43). 9. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt. 10. Adjust the belt guide an 1/8 inch (3 mm) from the belt (Figure 43). 11. Install the belt covers onto the cutting unit and screw in the bolts. 12. Install the carrier frame cover onto the cutting unit. Figure 43 1. Mower deck belt 4. Idler arm spring 2. PTO Drive Belt 5. Drive belt pulley 3. Drive belt pulley Replacing the PTO Drive Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the drive belt if any of these conditions are evident. 35

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the carrier frame cover. 4. Remove the belt covers. 5. Remove the heat shield from the engine deck and carrier frame. 6. Roll the belt off of the center pulley on the mower deck (Figure 44). Use caution when removing the belt as tension will increase because of the spring loaded idler pulley. 7. Remove the belt from the engine pulley and the spring loaded idler pulley (Figure 44). 8. Install the new belt onto the engine pulley and spring loaded idler pulley (Figure 44). 9. Roll the belt onto the center pulley on the mower deck (Figure 44). Use caution when install the belt as tension will increase because of the spring loaded idler pulley. 10. Install the heat shield to the engine deck and carrier frame. 11. Install the belt covers onto the cutting unit and screw in the bolts. 12. Install the carrier frame cover onto the carrier frame. Figure 44 1. Mower deck belt 4. Clutch pulley 2. PTO Drive Belt 5. Idler pulley 3. Idler arm and spring Adjusting the PTO Drive Belt Idler Spring Anchor The position of the PTO idler can be adjusted to increase or decrease belt tension. Use Figure 45 for the idler position options. Figure 45 1. PTO drive belt idler pulley 4. Most tension for worn belts 2. PTO drive Belt 5. Medium tension for normal belt conditions 3. Idler spring 6. Least tension for new belts Mower Deck Maintenance Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. A worn or damaged blade can break, and 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 blades periodically for wear or damage. • Replace a worn or damaged blade. 36

Blades Park the machine on a level surface, disengage the blades and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wires from the spark plugs. Inspecting the Blades Inspect the blades every 8 hours. 1. Inspect the cutting edges (Figure 46). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. Figure 46 1. Cutting Edge 3. Wear/slot forming in curved area 2. Sail 4. Crack in the curved area 2. Inspect the blades, especially the curved area (Figure 46). If you notice any cracks, wear, or a slot forming in this area (item 3 in Figure 46), immediately install a new blade. Checking for Bent Blades 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Rotate the blades until the ends face forward and backward. Measure from a level surface to the cutting edge, position A, of the blades (Figure 47 ). Note this dimension. Figure 47 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. 37

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, curved washer, blade stiffener, and blade from the spindle shaft (Figure 48). Figure 48 1. Sail Area of Blade 4. Curved washer 2. Blade 5. Blade Bolt 3. Blade stiffener Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 49). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Figure 49 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 50). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 46). Repeat this procedure until the blade is balanced. Figure 50 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 48). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 48). 2. Install the blade, stiffener, curved washer, and blade bolt (Figure 48). 3. Torque the blade bolt to 85-110 ft-lb (115-140 N•m). Correcting the Mower Quality of Cut If one deck blade cuts lower than the other, correct as follows. Note: Tire air pressure is critical in these procedures. Make sure all tires have correct pressure. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the 38

wire(s) from the spark plug(s). 3. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance, page 30 . 4. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades. 5. Set the height-of-cut to the 4 inch (101.6 mm) position. Refer to Adjusting the Height-Of-Cut in Operation, page 13. 6. Perform the steps in the following sections Frame Set Up, Checking Front-to-Rear Pitch, and Checking Side-to-Side Leveling. Frame Set Up Checking the Carrier Frame and Engine Deck Alignment Note: Misalignment can cause excess wear on the PTO drive belt. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Place a long straight edge on top of the engine deck as shown in Figure 51. 4. At the carrier frame cross channel, measure the height at location A (Figure 51). This measurement must be 1-5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm). 5. If the height at location A is not correct, adjustment is needed. 6. Loosen the carrier frame mounting bolts on both sides of the machine (Figure 51). 7. Align the carrier frame and engine deck to match 1-5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm) at location A (Figure 51). 8. Tighten the carrier frame mounting bolts on both sides of the machine. Figure 51 1. Carrier Frame 4. Location A, 1-5/16 inch (33 mm) ±1/4 inch (6 mm) 2. Top of engine deck 5. Straight edge 3. Carrier frame mounting bolts 6. Carrier frame cross channel Checking the Engine Deck Height 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance, page 30 . 4. Measure engine deck height at location A (Figure 52). 39

3. Tires 2. Top of engine deck 4. Same height at locations A and B 5. Measure engine deck height at location B (Figure 52). 6. If the height at location A and B are not the same, change tire pressure slightly to make them the same. Checking the Carrier Frame Front-to-Rear Pitch The carrier frame must have a pitch between 1/8 inch (3 mm) to 3/8 inch (9 mm) over the length of 24 inches (61 cm) on the carrier frame (Figure 53). 1. Measure out 24 inches (61 cm) on the carrier frame (Figure 53). Figure 53 1. Carrier Frame 4. Height at locations A and B 2. 1/4-3/8 inch (6-10 mm) pitch over 24 inch (61 cm) length 5. Caster Wheel 3. 24 inches (61 cm) 6. Caster spacers 2. Measure carrier frame height at location A (Figure 53). 3. Measure carrier frame height at location B (Figure 53). 4. The height at location A must be a 1/4-3/8 inch (6 mm -10 mm) lower than location B (Figure 53). 5. If the carrier frame is not correct, move caster spacers to make it a 1/4-3/8 inch (6 -10 mm) pitch (Figure 53). Move spacers from top or bottom to make the correct pitch. 6. The tire pressure may also be adjusted slightly to make a 1/4 inch (6 mm) pitch. Checking the Carrier Frame Side-to-Side Height The carrier frame needs to be parallel side-to-side from the ground. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance, page 30 . 4. Measure carrier frame height at location A (Figure 54). 5. Measure carrier frame height at location B (Figure 54). 6. If the carrier frame height is not the same move spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level. Figure 54 1. Caster Wheel 4. Same height at locations A and B 2. Carrier Frame 5. Caster spacers 3. Front height-of-cut pins 40

Front-to-Rear Pitch 1. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance, page 30 . 2. Position one blade front-to-rear. Measure at A and B locations from a level surface to the cutting edge of the blade tips (Figure 55). 3. The mower blade should be a 1/4 inch (6 mm) lower in front at A than in the rear at B. Rotate blades and repeat for other blades. If it is not correct, proceed to Changing the Deck Front-to-Rear Pitch. Figure 55 Changing the Mower Deck Front-to-Rear Pitch Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1. To change the front-to-rear pitch, the front height-of-cut posts can be adjusted (Figure 56). Figure 56 1. Caster Wheel 4. Jam nut 2. Carrier Frame 5. Ball joint 3. Front height-of-cut pins 2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Figure 56). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 56). 4. Position the blades front-to-rear. Check the front-to-rear pitch and adjust if needed. 5. Check the side-to-side leveling of the cutting unit. 6. Tighten the jam nuts (Figure 56). Checking the Mower Deck Side-to-Side Height 1. Adjust the rear tire pressure to specifications; refer to Drive System Maintenance, page 30 . 2. Position the blades side-to-side. Measure at C and D locations from a level surface to the cutting edge of blade tips (Figure 57). 41

D should be no more than 1/4 inch (6 mm). Changing the Mower Deck Side-to-Side Height Changing the side-to-side height is done by adjusting the rear tire pressure and caster spacers. 1. Change the rear tire pressure. Do this to the corresponding side that needs adjustment. 2. Adjust the caster spacer. 3. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. Matching Height of Cut 1. Check the rear tire pressure. 2. Set the height-of-cut to the 4 inch (101.6 mm) position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear. Measure at A and from level surface to the cutting edge of the blade tips (Figure 58). Figure 58 4. The measurement should be 4 inch (101.6 mm). 5. If it does not measure correctly: A. Adjust the rear tire pressure. B. Adjust the caster fork spacers. C. Adjust the front mower deck support pins. 6. Check the carrier frame front-to-rear pitch. Replacing the Grass Deector An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Never operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or bagger. 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 59). Remove damaged or worn grass deflector. 42

behind deck edge before installing bolt 4. Spring 8. J hook end of spring 2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in Figure 59. 3. Install bolt and nut. Place the J hook end of spring around grass deflector (Figure 59). Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position. 43

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate, and engine. 3. Check the brake; refer to Servicing the Brake in Brake Maintenance, page 33. 4. Service the air cleaner; refer to Servicing the Air Cleaner in Engine Maintenance, page 25. 5. Grease the machine; refer to Greasing and Lubrication in Lubrication, page 23. 6. Change the engine oil; refer to Servicing the Engine in Engine Maintenance, page 25. 7. Check the tire pressure; refer to Checking the Tire Pressure in Drive System Maintenance, page 30. 8. For long-term storage: A. Add stabilizer/conditioner additive to fuel in the tank. B. Run engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance, page 28, or operate engine until it stops. D. Restart engine and run until it stops. Repeat, on Choke until engine will not restart. E. Dispose of fuel properly. Recycle as per local codes. Note: Do not store stabilizer/conditioned gasoline over 90 days. 9. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in Engine Maintenance, page 25. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter 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). 10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 12. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean. 44

1. Fill fuel tank with gasoline. 2. Choke is not on. 2. Move the choke lever to choke position. 3. Air cleaner is dirty. 3. Clean or replace the air cleaner element. 4. Spark plug wire is loose or disconnected. 4. Install wire on spark plug. 5. Spark plug is pitted, fouled, or the gap is incorrect. 5. Install a new, correctly gapped spark plug. 6. Dirt in the fuel lter. 6. Replace the fuel lter. Engine will not start, starts hard, or fails to keep running. 7. Dirt, water, or stale fuel is in the fuel system. 7. Contact an Authorized Service Dealer. 1. Engine load is excessive. 1. Reduce the ground speed. 2. Air cleaner is dirty. 2. Service the air cleaner. 3. Oil level in the crankcase is low. 3. Add oil to the crankcase. 4. Cooling ns and air passages under the engine blower housing are plugged. 4. Remove the obstruction from the cooling ns and air passages. 5. Spark plug is pitted, fouled, or the gap is incorrect. 5. Install a new, correctly gapped spark plug. 6. Vent hole in the fuel cap is plugged. 6. Clean or replace the fuel cap. 7. Dirt in the fuel lter. 7. Replace the fuel lter. Engine loses power. 8. Dirt, water, or stale fuel is in the fuel system. 8. Contact an Authorized Service Dealer. 1. Engine load is excessive. 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 2. Add oil to the crankcase. Engine overheats. 3. Cooling ns and air passages under the engine blower housing are plugged. 3. Remove the obstruction from the cooling ns and air passages. 45

1. Move shift lever to a drive gear position. 2. Traction belt is worn, loose or broken. 2. Change the belt. 3. Traction belt is off a pulley. 3. Change the belt. Machine does not drive. 4. Broken or missing idler spring. 4. Replace the spring. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten the blade mounting bolt. 3. Engine mounting bolts are loose. 3. Tighten the engine mounting bolts. 4. Loose engine pulley, idler pulley, or blade pulley. 4. Tighten the appropriate pulley. 5. Engine pulley is damaged. 5. Contact an Authorized Service Dealer. Abnormal vibration. 6. Blade spindle is bent. 6. Contact an Authorized Service Dealer. 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s). 3. Mower is not level. 3. Level the mower side-to-side position. 4. Mower pitch is wrong. 4. Adjust the front-to-rear pitch. 5. Underside of mower is dirty. 5. Clean the underside of the mower. 6. Tire pressure is not correct. 6. Adjust the tire pressure. Uneven cutting height. 7. Blade spindle bent. 7. Contact an Authorized Service Dealer. 46

or broken. 1. Check the belt tension. 2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Deck belt is worn, loose or broken. 3. Install new deck belt. 4. Deck belt is off pulley. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Broken or missing idler spring. 5. Replace the spring. 6. Electric clutch out of adjustment. 6. Adjust the clutch air gap. 7. Clutch connector or wire damaged. 7. Contact an Authorized Service Dealer. 8. Damaged electric clutch. 8. Contact an Authorized Service Dealer. 9. Safety interlock system prevents blade rotation. 9. Contact an Authorized Service Dealer. Blades do not rotate. 10.PTO switch is faulty. 10.Contact an Authorized Service Dealer. 47