Toro 30261TE Operator's Manual

Mid–Size Mower ProLine T-Bar Gear 12.5 HP with 92 cm Side Discharge Mower Model No. 30261TE—Serial No. 230000001 and Up

Printed in the USA � 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 This spark ignition system complies with Canadian ICES-002. Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada. Contents Page Introduction 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Lawn Mower Safety 3 . . . . . . . . . . . . . . . . Sound Pressure 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound Power 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slope Chart 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 9 . . . . . . . . . . . . . . . Gasoline and Oil 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Gasoline 12 . . . . . . . . . . . . . . . . . . . Using Stabilizer/Conditioner 12 . . . . . . . . . . . . . . . . Filling the Fuel Tank 12 . . . . . . . . . . . . . . . . . . . . . . Check Engine Oil Level 12 . . . . . . . . . . . . . . . . . . . . Set Up 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Upper Handle 14 . . . . . . . . . . . . . . . . . Installing the Shift Lever Plate and Fuel Tank 14 . . Adjusting the Shift Lever Plate 15 . . . . . . . . . . . . . . Installing the Control Rods 16 . . . . . . . . . . . . . . . . . Installing the Hairpin Cotter Pins and Washers 17 . . Operation 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First 18 . . . . . . . . . . . . . . . . . . . . . . . . Controls 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Parking Brake 18 . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine 19 . . . . . . . . . . . . Operating the Mower Blade Control (PTO) 19 . . . . The Safety Interlock System 20 . . . . . . . . . . . . . . . . Driving Forward or Backward 20 . . . . . . . . . . . . . . . Using the Lower Control Bar Operation 21 . . . . . . . Stopping the Machine 21 . . . . . . . . . . . . . . . . . . . . . Transporting Machines 22 . . . . . . . . . . . . . . . . . . . . Side Discharge or Mulch Grass 22 . . . . . . . . . . . . . . Adjusting the Height-of-Cut 22 . . . . . . . . . . . . . . . . Adjusting the Center Gage Wheels 23 . . . . . . . . . . . Adjusting the Handle Height 23 . . . . . . . . . . . . . . . . Using the Mid–Size Weight Kit 23 . . . . . . . . . . . . . . Page Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule 24 . . . . . . . . Servicing the Air Cleaner 25 . . . . . . . . . . . . . . . . . . Servicing the Engine Oil 26 . . . . . . . . . . . . . . . . . . . Servicing the Spark Plug 27 . . . . . . . . . . . . . . . . . . . Greasing and Lubrication 28 . . . . . . . . . . . . . . . . . . . Cleaning the Cooling System 29 . . . . . . . . . . . . . . . Checking the Tire Pressure 29 . . . . . . . . . . . . . . . . . Servicing the Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Brakes 29 . . . . . . . . . . . . . . . . . . . . . . Adjusting the Electric Clutch 30 . . . . . . . . . . . . . . . Servicing the Fuel Tank 31 . . . . . . . . . . . . . . . . . . . . Servicing the Fuel Filter 31 . . . . . . . . . . . . . . . . . . . Servicing the Cutting Blades 32 . . . . . . . . . . . . . . . . Correcting the Mower Quality of Cut 33 . . . . . . . . . Frame Set Up 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Deck Front-to-Rear Pitch 35 . . . . . . . Changing the Deck Front-to-Rear Pitch 35 . . . . . . . Checking the Deck Side-to-Side Leveling 36 . . . . . Changing the Side-to-Side Leveling 36 . . . . . . . . . . Matching Height of Cut 36 . . . . . . . . . . . . . . . . . . . . Replacing the Traction Drive Belt 37 . . . . . . . . . . . . Replacing the Transmission Belt 37 . . . . . . . . . . . . . Replacing the Mower Belt 38 . . . . . . . . . . . . . . . . . . Replacing the PTO Drive Belt 38 . . . . . . . . . . . . . . . Replacing the Caster Wheel Fork Bushings 39 . . . . Caster Wheel and Bearings Service 40 . . . . . . . . . . . Replacing the Grass Deflector 40 . . . . . . . . . . . . . . . Wiring Diagram 41 . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage 42 . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. 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 illustrates the location of the model and serial numbers on the product.

Write the product model and serial numbers in the space below: Model No. Serial No. This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions. Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Safety Improperly using or maintaining this lawn mower can result in injury. To reduce the potential for injury, comply with these safety instructions. Toro designed and tested this lawn 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 lawn mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the safety alert symbol 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 lawn 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 lawn 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.

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. • Stay alert for holes in the terrain and other hidden hazards. • Never direct discharge of material towards bystanders. • Avoid operating the equipment in wet grass, where feasible. • 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 blades 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 lead or turn off and remove 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.

battery compartment and gasoline storage are free of grass, leaves, or excessive grease. • Check the grass catcher frequently and replace if worn or deteriorated. • 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 at excessive speed can increase the hazard of 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 a maximum sound pressure level at the operator’s ear of 88 dBA, based on measurements of identical machines per Directive 98/37/EC. Sound Power This unit has a guaranteed sound power level of 100 dBA, based on measurements of identical machines per Directive 2000/14/EC. Vibration This unit does not exceed a hand/arm vibration level of 4.0 m/s2, based on measurements of identical machines per Directive 98/37/EC.

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. 93-7010 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7298 1. Traction drive—forward 2. Brake 93-7299 1. Traction drive—reverse 106-5533 1. Read the Operator’s Manual. 2. Height of cut 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 93-7316 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7442 1. Parking brake

torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-lb.). 93-7828 1. Thrown object hazard, mower—do not operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-9353 1. Shut off the fuel by turning the fuel shutoff valve clockwise before transporting the machine. 98-1977 1. Entanglement hazard, belt—stay away from moving parts. 98-4387 1. Warning—wear hearing protection. 104-8185 106-0636 1. To set the height of cut, install the hairpin cotter in the hole for the desired setting. 2. Turn off the power. 3. Read the Operator’s Manual. 106-5517 1. Warning—do not touch the hot surface. 106-5495 1. Read the Operator’s Manual. 2. Reverse 3. Neutral 4. Forward speeds

4. Slow 5. Engine—stop 6. Engine—start 7. Move the control bar to the handle, then pull the knob. 106-5519 1. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 2. Warning—stop the engine before leaving the machine. 3. Warning—read the Operator’s Manual. 4. Thrown object hazard—keep bystanders a safe distance from the machine. 5. Thrown object hazard, mower—keep the deflector in place.

Recommended Gasoline 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. Danger 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 in. (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. • 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. Warning 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. • Cleans the engine while it runs • 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 fuel tank cap and remove the cap. Add unleaded regular gasoline to fuel tank, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. 3. Install fuel tank cap securely. Wipe up any gasoline that may have spilled. Check 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, page 26.

from the normal operating position. Loose Parts Note: Use the chart below to verify all parts have been shipped. Step Description Qty. Use 1 Upper handle Flanged bolt 3/8 x 1 inch Flange nut 3/8 inch 1 4 4 Installing the upper handle 2 Fuel tank with studs installed Shift lever plate Bolt, 5/16 x 7/8 inch Lock washer, 5/16 inch Washer, 5/16 inch Spring Hose clamp 1 1 2 2 4 2 1 Installing shift lever plate and fuel tank 3 No parts needed Adjusting the shift lever plate 4 Clevis pin Washer Hairpin cotter pin 2 2 2 Installing the control rods 5 Hairpin cotter pin 2 Installing the hairpin cotter pins and washers 6 Operator’s Manual Engine Operator’s Manual Parts Catalog Registration card 1 1 1 1 Read before operating machine Read before operating machine Fill out and return to Toro

• 1 Upper handle • 4 Flange bolts, 3/8 x 1 inch • 4 Flange nuts, 3/8 inch Installing the Upper Handle 1. Align upper handle with upper mounting holes in rear frame (Fig. 2). 2. Secure the handle at each upper mounting hole with a flange bolt (3/8 x 1 inch) and flange nut (Fig. 2). 3. Select the low position for the lower mounting hole (Fig. 2). 4. Secure the handle at each lower mounting hole with a flange bolt (3/8 x 1 inch) and flange nut (Fig. 2). Note: The handle position can be adjusted to match the operator’s height preference. 1 2 3 4 8 7 5 6 m–6402 Figure 2 1. Upper handle 2. Rear frame 3. Flange bolt, 3/8 x 1 inch 4. Flange nut, 3/8 inch 5. Upper mounting hole 6. Lower mounting holes 7. Low position 8. High position � ���� Parts needed for this step: • 1 Fuel tank • 1 Shift lever plate • 2 Bolts, 5/16 x 7/8 inch • 2 Lock washers, 5/16 inch • 2 Flat washers, 5/16 inch • 2 Springs • 1 Hose clamp Installing the Shift Lever Plate and Fuel Tank 1. Remove the bolts and nuts holding the shift lever plate to the rear frame. Discard these nuts and bolts. 2. Slide the shift lever plate over the shift lever and under the bottom of the rear frame (Fig. 3). m–5221 3 1 2 Figure 3 1. Rear frame 2. Shift lever plate 3. Fuel tank 3. Align fuel tank with the top of the rear frame (Fig. 3). 4. Push the fuel line onto the fuel tank connection and secure it with the hose clamp that is on the fuel line (Fig. 5). Note: Make sure the fuel line and clamp are on as shown in Figure 4.

5. Secure the right side shift lever plate and fuel tank to the rear frame (Fig. 5) with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 5). 6. Secure the left side shift lever plate and fuel tank to the rear frame (Fig. 5) with washers (5/16 inch), springs and locknuts (5/16 inch) (Fig. 5). Note: Tighten left side of shift lever plate until it is completely tight and then unscrew locknut one full turn. This will allow the spring to work. 3 8 7 3 6 2 1 5 4 10 9 m–6465 Figure 5 1. Bolt, 5/16 x 7/8 inch 2. Lock washers, 5/16 inch 3. Washer, 5/16 inch 4. Fuel line 5. Hose clamp 6. Stud 7. Spring 8. Locknut 9. Shift lever plate 10. Fuel tank connection � ���� No parts needed for this step. Adjusting the Shift Lever Plate 1. Shift lever to second gear and check alignment of lever in slot of shifter lever plate. The clearance between top and bottom of the shift lever should be equal (Fig. 7). 2. If clearance is not correct, remove lever and bend it slightly to adjust (Fig. 6). m–5250 1 2 6 5 4 3 Figure 6 1. Shift lever 2. Shift lever plate 3. Rubber seal washer 4. Square hole washer 5. Spring washer 6. Locknut, 3/8 inch Note: Do not bend lever while attached to transmission shaft or damage may occur. 3. Shift lever to neutral and check alignment of lever in slot of shifter lever plate. The clearance on the sides of shift lever should be equal (Fig. 7). 4. If clearance is not correct, loosen shift lever plate and adjust it side–to–side. Tighten the shift lever plate.

completely tight and then unscrew the locknut one full turn. This will allow the spring to work. 4 Rear View 1 m–5458 4 3 2 2 Figure 7 1. Shift lever, 2nd gear 2. Shift lever plate 3. Shift lever, neutral 4. Equal distance � ���� Parts needed for this step: • 2 Clevis pins • 2 Washers • 2 Hairpin cotter pins Installing the Control Rods 1. Make sure the rod fittings are equal distance onto each control rod. The rod fittings should be approximately 3–1/2 inch (89 mm) from the start of the threads (Fig. 8). 2. Slide clevis pins through rod fittings and mounting holes in idler brackets (from outside) (Fig. 8). Secure with washers and hairpin cotters (Fig. 8). 1 3 2 4 4 m–5329 5 6 Figure 8 1. Control rod and fitting 2. 1–3/4inch (44 mm) 3. Idler bracket 4. Clevis pin, washer and hairpin cotter 5. Rod fitting 6. Hole F 3. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 inch (25–32 mm) (Fig. 9). Note: The upper control bar and fixed bar must be parallel when in engaged, drive, relaxed and brake positions. 4. Check operation. If adjustment is required, remove hairpin cotter securing rod to upper control bar. Thread rod in or out of fitting for proper position and install into upper control bar with hairpin cotter.

3. Parking brake lever 4. Upper control bar 5. 1 to 1–1/4 inch (25–32mm) gap 6. Fitting 5. Check the parking brake adjustment (Fig. 10). Refer to Checking the Brakes, page 30. Note: Make sure brake rod is installed in front (F) mounting hole in idler bracket. 1 2 m–5233 3 Figure 10 1. Upper control bar 2. Parking brake lever 3. Fixed bar � ���� Parts needed for this step: • 2 Hairpin cotter pins Installing the Hairpin Cotter Pins and Washers Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter. 1. On the opposite side of the muffler, install extra washers and hairpin cotter pins into front and rear height–of–cut pins (Fig. 11). m-6505 3 2 1 Figure 11 1. Hairpin cotter 2. Extra spacers 3. Height–of–cut post

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, your family, pets or bystanders avoid injury. The use of protective equipment for eyes, hearing, feet and head is recommended. This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Caution 1 2 Figure 12 1. Caution 2. Wear hearing protection Controls Become familiar with all the controls (Fig. 13) before you start the engine and operate the machine. Throttle Control – The throttle control has three positions: Choke, Fast and Slow. Deck Engagement Control Bail – Control bail used in conjunction with deck engagement switch (PTO) to release blade brake and engage clutch to drive mower blades. Release bail to disengage mower blades. Blade Control Switch (PTO) – Pull switch used in conjunction with control bail to release blade brake and engage clutch to drive mower blades. Gear Shift Lever – Transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. Do not shift while unit is moving, as transmission damage may occur. Upper Control Bar – Shift to desired gear and push forward on control bar to engage forward traction operation and pull back to brake. Pull right side of 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 operation. Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle. Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: Run and Off. Recoil Starter – Pull recoil starter handle to start engine. Fuel Shut–off Valve – (Under fuel tank) Close fuel shut–off valve when transporting or storing mower. 2 3 4 8 1 6 5 7 9 m–6443 Figure 13 1. Throttle control 2. Blade control bail 3. Blade control switch (PTO) 4. Gear shift lever 5. Upper control bar 6. Lower control bar 7. Parking brake lever 8. Ignition switch 9. Handle Using the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 1. Pull the upper control bar (Fig. 14) rearward and hold it in this position.

release the upper control bar. The brake lock should stay in the set (locked) position. Releasing the Parking Brake 1. Pull rearward on the upper control bar (Fig. 14). Lower the parking brake lock to the released position. 2. Gradually release the upper control bar. 1 2 m–5233 3 Figure 14 1. Upper control bar 2. Parking brake lever (set position) 3. Fixed 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 the choke 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 slow (Fig. 15). 2. Let engine idle for 30 to 60 seconds before turning the ignition key to off. 3. Turn the ignition key to off (Fig. 15). 1 2 m–6443 Figure 15 1. Throttle lever 2. Ignition key 4. Set the parking brake. 5. Pull wire off spark plug(s) to prevent possibility of accidental starting before storing machine. 6. Close 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 Blade Control (PTO) The blade control 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 (Fig. 16). 2. To engage blade, squeeze blade control bail against upper control bar (Fig. 16). 3. Pull blade switch (PTO) up and release. Hold blade control bail against control bar while operating. 4. Repeat procedure to engage mower blades if blade control bail is released.

2. Blade control bail 3. Blade control switch (PTO) Disengaging the Mower Blades (PTO) 1. Release blade control bail to disengage blades (Fig. 16). 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. Caution 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 blade control 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, page 19. 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 blade control 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 (Fig. 17). 2. Release the parking brake; refer to Releasing the Parking Brake, page 19. 3. Slowly press on the upper control bar to move forward (Fig. 17). To go straight, apply equal pressure to both ends of the upper control bar (Fig. 17). To turn, release pressure on the upper control bar side in the direction you want to turn (Fig. 17).

2. Lower control bar 3. Shift lever Driving Backward 1. To go backward, move the shift lever to reverse gear. 2. Release the parking brake; refer to Releasing the Parking Brake, page 19. 3. Slowly squeeze the lower control bar and handle together to move rearward (Fig. 17). Using the Lower Control Bar Operation 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. Warning 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 (Fig. 18). 4. Lift the front of the machine by pushing down on the handle (Fig. 18). 5. Drive machine until drive wheels contact curb (Fig. 18). 6. Lower the front of the machine (Fig. 18). Note: Both drive wheels should contact the curb and caster wheels straight. 7. At the same time engage lower control bar and lift up on handle to drive over the curb (Fig. 17 and 18). Note: Lifting up on handle will assist driving the machine up a curb and not spin the drive wheels. m–4185 3 2 1 2 Figure 18 1. Lower Control Bar engaged and mower in reverse. 2. Pull up to assist machine 3. Lower Control Bar engaged and mower going forward. 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 (Fig. 18). 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 handle (Fig. 17 and 18). Note: Lifting up on handle will 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 (PTO), and turn the ignition key to off. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 18. Remember to remove the key from the ignition switch.

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. Caution Transporting Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary 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: • Lock brake and block wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. • Secure a trailer to towing vehicle with safety chains. Side Discharge or Mulch Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Danger 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 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. Note: All height–of–cut pins need at least one spacer or damage can occur to bushing if none are used. Note: All height–of–cut pins can use only two spacers maximum. 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Fig. NO TAG). 2. Lift on side of deck and remove hairpin cotter (Fig. NO TAG). 3. Add or remove spacers if needed and then align holes and insert hairpin cotter (Fig. NO TAG). 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. 2 1 3 4 2 4 1 5 m–6365 Figure 19 1. Carrier Frame 2. Hairpin Cotter 3. Front height–of–cut post 4. Spacers 5. Back height–of–cut post

Wheels The gage wheels need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) clearance above the ground. 1. After adjusting height-of-cut, check the gage wheels so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Fig. 20). 2. If adjustment is needed, remove the bolt, washers and nut (Fig. 20). 3. Select a hole position so the gage wheels are a minimum of 3/8 inch (10 mm) off the ground (Fig. 20). 4. Install the bolt, washers and nut (Fig. 20). 1 2 3 4 4 m–6366 Figure 20 1. Center Gage Wheels and Spacer 2. Nut 3. Bolt 4. Washer 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 (Fig. 8). 2. Loosen the upper flange bolts (3/8 x 1 inch) and flange nut securing handle to rear frame (Fig. 21). 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Fig. 21). 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. 1 2 3 4 8 7 5 6 m–6403 Figure 21 1. Upper handle 2. Rear frame 3. Flange nut, 3/8 inch 4. Flange bolt, 3/8 x 1 inch 5. Upper mounting hole 6. Lower mounting holes 7. Low position 8. High position 5. Thread rod fitting up or down on rod until proper position is attained and install into fitting to idler bracket with clevis pin, washer and hairpin cotter. Refer to Installing the Control Rod on page 16. 6. Check the parking brake adjustment (Fig. 10). Refer to Checking the Brakes, page 30. Using the Mid–Size Weight Kit A weight kit is available for this machine. This kit is optional and can be obtain from an Authorized Service Dealer. Installing this weight kit can improve performance on slopes. Note: For this machine install the weight kit only in the front position.

Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Each Use • Oil—check level • Safety System—check • Brake—check • Engine—clean outside • Mower Housing—clean After first 8 hours • Oil—change 8 Hours • Mower Housing—clean • Caster Wheels—grease • Caster Pivot—grease 25 Hours • Foam Air Cleaner—clean1 40 Hours • Tires—check pressure • PTO Belt Idler Arm—grease 50 Hours • Oil—change1 • Belts—check 100 Hours • Spark Plug(s)—check • Electric Clutch—adjust • Engine—clean outside • Oil Filter—change (100 hours or every other oil change) • Paper Air Cleaner—clean1 200 Hours • Fuel Filter—replace 250 Hours • Transmission Couplings—grease1 300 Hours • Paper Air Cleaner—replace1 400 Hours • Wheel Bearings—grease1 At storage • Chipped Surfaces—paint • Perform all maintenance procedures listed above before storage 1More often in dusty, dirty conditions. Important Refer to your engine operator’s manual for additional maintenance procedures. Caution 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 wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Service Interval/Specification Foam Element: Clean and re-oil after every 25 operating hours. Paper Element: Clean after every 100 operating hours. Replace after every 300 operating hours. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Unscrew the cover nuts and remove the air cleaner cover (Fig. 22). 3. Remove the air cleaner assembly (Fig. 22). 4. Carefully slide the foam element off the paper element (Fig. 22). ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓ ÓÓÓÓ 1 2 2072 3 4 5 Figure 22 1. Cover nut 2. Air cleaner cover 3. Foam element 4. Paper element 5. Air cleaner base Cleaning the Foam 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. 3. Put one or two ounces (30 to 60 ml) of oil on the element (Fig. 23). Squeeze the element to distribute the oil. Important Replace the foam element if it is torn or worn. 2 m–1213 1 ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ Figure 23 1. Foam element 2. Oil Cleaning the Paper Element 1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 24). 2. Inspect the element for tears, an oily film, and damage to the rubber seal. 3. Replace the paper element if it is damaged, torn, oily, or cannot be cleaned thoroughly Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. 1 m–1213 2 Figure 24 1. Paper element 2. Rubber seal Installing the Foam and Paper 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 (Fig. 22). 2. Place the air cleaner assembly onto the air cleaner base (Fig. 22). 3. Install the air cleaner cover and secure with cover nuts (Fig. 22).

Service Interval/Specification Change oil: • After the first 8 operating hours. • After every 50 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF, SE/CC, CD or SE) Crankcase Capacity: with filter change, 54 oz. (1.6 l) without filter change, 47 oz. (1.4 l) Viscosity: See table below USE THESE SAE VISCOSITY OILS Checking the Oil Level 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 oil dipstick (Fig. 25) so dirt cannot fall into the filler hole and damage the engine. 4. Unscrew the oil dipstick and wipe the metal end clean (Fig. 25). 5. Slide the oil dipstick fully into the filler tube, do not thread onto tube (Fig. 25). Pull the dipstick out and look at the metal end. If 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 because the engine may be damaged. 1 2 3 Figure 25 1. Oil dipstick 2. Metal end 3. Filler tube Changing the Engine 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 (Fig. 26). 7. When oil has drained completely, close the drain valve. 8. Remove the drain hose (Fig. 26). Note: Dispose of the used oil at a recycling center. m–6401 2 1 Figure 26 1. Oil drain valve 2. Drain hose

page 26, into the filler tube (Fig. 25). 10. Check the oil level; refer to Checking Oil Level, page 26. 11. If needed, slowly add additional oil to bring to the full mark on dipstick. Changing the Engine Oil Filter Service Interval/Specification Replace the oil filter every 100 hours or every other oil change. Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 26. 2. Remove the old filter and wipe the filter adapter (Fig. 27) gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 27). m–1256 1 2 3 Figure 27 1. Oil filter 2. Gasket 3. Adapter 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 (Fig. 27). 5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 26. Servicing the Spark Plug Service Interval/Specification Check the spark plug(s) after every 100 operating hours. Make sure 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 plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. Type: NGK BMR-4A, Champion RCJ–8 or equivalent Air Gap: 0.025 inch (0.65 mm) Removing the Spark Plug(s) 1. Park the machine on a level surface and disengage the blade control (PTO). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Pull the wire(s) off the spark plug(s) (Fig. 28). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 4. Remove the spark plug(s) and metal washer. 2 1 m–5328 Figure 28 1. Spark plug wire 2. Spark plug Checking the Spark Plug 1. Look at the center of the spark plug(s) (Fig. 29). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. Important Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Fig. 29). Bend the side electrode (Fig. 29) if the gap is not correct.

2. Side electrode 3. Air gap (not to scale) Installing the Spark Plug(s) 1. Install the spark plug(s). Make sure the air gap is set correctly. 2. Tighten the spark plug(s) to 20 ft-lb (27 N�m). 3. Push the wire(s) onto the spark plug(s) (Fig. 28). Greasing and Lubrication Service Interval/Specification Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 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 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 wheel bearings and front spindles until grease begins to ooze out of the bearings (Fig. 30). 2. Raise the rear of the machine and use jack stands to support the machine. 3. Remove the rear wheel and tire assembly. 4. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Fig. 30). 5. Install the rear wheel and tire assembly. Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. m–6367 Figure 30 Lubricating the Transmission Couplers 1. Lubricate the transmission couplers located in the back of the machine (Fig. 31). m–5191 Figure 31

1. Grease the fitting on the PTO belt idler arm pivot (Fig. 32). m–5247 Figure 32 Cleaning the Cooling System Service Interval/Specification Before each use, check and clean engine cooling system. 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. Checking the Tire Pressure Service Interval/Specification Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 40 operating hours or monthly, whichever occurs first (Fig. 33). Check the tires when they are cold to get the most accurate pressure reading. Rear Tire Pressure: 12–14 psi (83–97 kPa) Caster Tire Pressure: 20–24 psi (138–165 kPa) 2 1 m–6367 Figure 33 1. Rear Tire 2. Caster tire Servicing the Fuse Service Interval/Specification 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 the fuse, pull out the old the fuse (Fig. 34) and push in new fuse. Fuse: F1–7.5 amp, blade-type m–5206 1 Figure 34 1. Fuse 7.5 amp Servicing the Brakes Service Interval/Specification 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.

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 on page 30. 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 Brake, page 30. Adjusting the Brakes The brake lever is on the upper control bar (Fig. 13). If the parking brake does not hold securely, an adjustment is required. 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, page 30. 4. Release the parking brake; refer to Releasing the Parking Brake, page 19. 5. To adjust the brake remove the cotter pin and washer from the brake lever and trunnion (Fig. 35). 6. Rotate the wingnut clockwise to increase the braking pressure. 7. Rotate the wingnut counterclockwise to decrease the braking pressure. 8. Install the trunnion into hole F (Fig. 35). Tighten the wing nut. 9. Secure trunnion to brake lever with washer and cotter pin (Fig. 35). 10. Check the brake operation again; refer to Checking the Brake, page 30. 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. 3 2 1 4 5 m–5329 6 Figure 35 1. Hairpin cotter and washer 2. Trunnion 3. Brake lever 4. Wing nut 5. Hole F 6. Drive belt shroud Adjusting the Electric Clutch The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation. 1. To adjust clutch, tighten or loosen lock nuts on flange studs (Fig. 36). 2. Check adjustment by inserting feeler gauge thru slots next to studs (Fig. 36). 3. The proper disengaged clearance between the clutch plates is 0.012–.018 inch (0.30-0.45 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

Danger 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. Draining the Fuel Tank 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 fuel shut–off valve at fuel tank (Fig. 37). Note: Remove fuel line from fuel valve that is closest to the engine. 3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from valve (Fig. 37). 4. Pull the fuel line off the valve (Fig. 37). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 31. 5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line. 1 2 m–5185 Figure 37 1. Fuel shut-off valve 2. Clamp Servicing the Fuel Filter Service Interval/Specification Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. Note: Note how the fuel filter is installed. 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 (Fig. 37). 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 38). 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 (Fig. 37).

3 2 1 m–5234 3 1 Figure 38 1. Hose clamp 2. Fuel line 3. Filter 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 blade periodically for wear or damage. • Replace a worn or damaged blade. Warning Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s). Inspecting the Blades 1. Inspect the cutting edges (Fig 39). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 33. 2. Inspect the blades, especially the curved area (Fig. 39). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 39), immediately install a new blade. 1 2 3 m–151 Figure 39 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Fig. 40). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 41). Note this dimension. m–1078 Front A A Figure 40 MEASURE FROM CUT- TING EDGE TO A LEV- EL SURFACE m–1087 Figure 41 2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds

replaced. Refer to Removing the Blades, and Installing the Blades on page 33. 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. Warning Removing the Blades 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. Remove the blade bolt, blade stiffener, washer, and blade from the spindle shaft (Fig. 42). 1 3 2 4 5 m–6368 6 Figure 42 1. Sail Area of Blade 2. Blade 3. Blade spindle 4. Blade Bolt 5. Blade stiffener 6. Flat washer Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 43). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 1 m–1854 Figure 43 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Fig. 44). 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 (Fig. 42). Repeat this procedure until the blade is balanced. 1 2 m–1855 Figure 44 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Fig. 42). Important The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Fig. 42). 2. Install the lock washer and blade bolt (Fig. 42). 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 operating position. Disconnect the spark plug wire(s) from the spark plug(s). 3. Adjust the tire pressure in all tires to specifications on page 29. 4. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 32.

position. Refer to Adjusting the Height-Of-Cut in the Operation section. 6. Perform steps in the following sections Frame Set Up, Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling. Frame Set Up Checking Carrier Frame and Deck Alignment 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 45. 4. At the carrier frame cross tube, measure location A height (Fig. 45). 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 (Fig. 45). 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 (Fig. 45). 8. Tighten the carrier frame mounting bolts on both sides of the machine. 1 A 3 5 4 2 6 m–6369 Figure 45 1. Carrier Frame 2. Top of engine deck 3. Carrier frame mounting bolts 4. Location A, 1–5/16 inch (33 mm) ±1/4 inch (6 mm) 5. Straight edge 6. Carrier frame cross tube Checking 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 all tires to specifications on page 29. 4. Measure engine deck height at location A (Fig. 46). 5. Measure engine deck height at location B (Fig. 46). 6. If the height at location A and B are not the same, change tire pressure slightly to make them the same. 3 2 m–5237 A B 1 3 4 4 Figure 46 1. Back view of machine 2. Top of engine deck 3. Tires 4. Same height at locations A and B Checking Carrier Frame Front–to–Rear Pitch The carrier frame must have a pitch of a 1/4 inch (6 mm) over the length of 24 inches (61 cm) on the carrier frame (Fig. 47). 1. Measure out 24 inches (61cm) on the carrier frame (Fig. 47). 2. Measure carrier frame height at location A (Fig. 47). 3. Measure carrier frame height at location B (Fig. 47). 4. The height at location A must be a 1/4–3/8 inch (6 mm –10 mm) lower than location B (Fig. 47). 5. If the carrier frame is not correct, move caster spacers to make it a 1/4–3/8 inch (6 –10 mm) pitch (Fig. 47). 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.

24 inch (61 cm) length 4. Height at locations A and B 5. Caster spacers Checking Carrier Frame Side–to–Side 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 all tires to specifications on page 29. 4. Measure carrier frame height at location A (Fig. 48). 5. Measure carrier frame height at location B (Fig. 48). 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. 5 1 A B 2 4 4 1 2 3 5 m–6371 Figure 48 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins 4. Same height at locations A and B 5. Caster spacers Checking the Deck Front-to-Rear Pitch 1. Check the tire pressure on both deck and traction unit. 2. Position one blade front-to-rear (Fig. 49). Measure at C and D locations (Fig. 49) from a level surface to the cutting edge of the blade tips (Fig. 50). 3. The mower blade should be 1/4 inch (6 mm) lower in front at C than in the rear at D. Rotate blades and repeat for other blades. If it is not correct, proceed to Changing the Deck Front–to–Rear Pitch. m–1078 Front C C D D Figure 49 MEASURE FROM CUT- TING EDGE TO A LEV- EL SURFACE m–1087 Figure 50 Changing the Deck Front-to-Rear Pitch Changing the front–to–rear pitch is done by adjusting the front height–of–cut posts. Changing the Deck Front–to–Rear Pitch by Adjusting Front Height–of–Cut Posts 1. To change the front-to-rear pitch, the front height–of–cut posts can be adjusted (Fig. 51). 2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Fig. 51). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Fig. 51).

4. Jam nut 5. Ball joint 4. Position the blades front-to-rear (Fig. 49). Measure at C and D locations (Fig. 49) from a level surface to the cutting edge of the blades (Fig. 50). 5. Check the side-to-side leveling of the cutting unit. Checking the Deck Side-to-Side Leveling 1. Check the tire pressure on both deck and traction unit. 2. Position the blades side-to-side (Fig. 52). Measure at A and B locations (Fig. 52) from a level surface to the cutting edge of blade tips (Fig. 53). 3. The difference between measurements A and B should be no more than 1/4 inch (6 mm). m–1078 Front A B Figure 52 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2550 Figure 53 Changing the Side-to-Side Leveling Changing the side–to–side leveling is done by adjusting tire pressure. Changing the Side–to–Side Leveling with Tire Pressure 1. Change the tire pressure on both deck and traction unit. Do this to the corresponding side that needs adjustment. 2. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. Matching Height of Cut 1. Check the tire pressure on both deck and traction unit. 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 (Fig. 54). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 55). 4. The measurement should be 4 inch (101.6 mm).

A LEVEL SURFACE m–2550 Figure 55 5. If it does not measure correctly, add air pressure in rear tires to raise height–of–cut 6. If it does not measure correctly, decrease air pressure in rear tires to lower height–of–cut. 7. Check carrier frame front–to–rear pitch. Replacing the Traction Drive Belt Service Interval/Specification Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for cracks, wear, and signs of overheating. 1. Remove belt guard, not shown for clarity. 2. Remove the top capscrew securing idler support and idler bracket to rear frame (Fig. 56). 3. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Fig. 56). 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 capscrew securing the idler support and idler bracket to the rear frame (Fig. 56). 7. Tighten the bottom two mounting screws enough to allow the belt to pass between the drive pulley and idler support (Fig. 56). 8. Install belt guard, not shown for clarity. 2 m–1722 1 4 3 5 Figure 56 1. Top capscrew 2. Idler bracket 3. Idler support 4. Bottom capscrew 5. Traction drive belt 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. Raise the front of the machine and hold with jack stands. Remove lower shield. 4. Disconnect clutch wire connector from wire harness. 5. Remove PTO drive belt. Refer to Replacing the PTO Drive Belt on page 38. 6. Remove clutch retainer from the engine deck (Fig. 57). 7. Unhook tension spring from side of frame (Fig. 57). 8. Loosen pivot bolt enough to remove traction belt from the drive pulley and clutch. 9. Install new belt around clutch and drive pulley. 10. Torque pivot bolt to 35-40 ft–lb (47-54 N�m). Install tension spring between idler arm and frame bracket (Fig. 57). 11. Install clutch retainer to the engine deck (Fig. 57). 12. Connect clutch wire connector to wire harness. 13. Install PTO drive belt and install lower shield.

6. Pivot bolt 7. Drive pulley 8. Engine deck 9. Lower shield 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 screws holding the carrier frame cover and remove the carrier frame cover. 4. Remove the screws holding the belt cover to the cutting unit and remove the belt cover. 5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt on page 38. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Fig. 58). 7. Install the new mower belt around the outward spindle pulley, the idler pulley, and in the lower groove of the double spindle pulley (Fig. 58). 8. Reconnect the idler arm spring (Fig. 58). 9. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt on page 38. 10. Reinstall the belt cover onto the cutting unit, then reinstall and tighten the screws. 11. Install the carrier frame cover onto the cutting unit, then install and tighten the screws. 1 5 m–5247 4 2 3 Figure 58 1. Mower belt 2. Idler arm spring 3. Outward pulley 4. PTO Drive Belt 5. Double Spindle 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. 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 screws holding the carrier frame cover and remove the carrier frame cover. 4. Remove the screws holding the belt covers to the top of the cutting unit and remove the belt covers. 5. Remove the heat shield from the the engine deck and carrier frame. 6. Remove the idler spring from idler arm. Remove the drive belt from the PTO engagement pulley and the center spindle pulley (Fig. 59). 7. Remove the worn drive belt (Fig. 59). 8. Install the new drive belt onto the PTO engagement pulley and the top groove of the center spindle pulley (Fig. 59). 9. Install belt onto idler pulley and then install idler spring (Fig. 59). 10. Install the heat shield to the engine deck and carrier frame.

reinstall and tighten the screws. 12. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the hand screws. 3 1 2 4 m–5247 Figure 59 1. PTO engagement pulley 2. Drive belt idler 3. Drive Belt 4. Double Spindle Pulley 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 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 block up the front of the mower with jack stands. 2. Remove the locking pin and spacer(s) from the top of the caster wheel fork (Fig. 60). 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 2 1 3 2 m–6372 Figure 60 1. Locking Pin 2. Spacers (locate as required) 3. Carrier frame mounting tube 4. Caster wheel fork 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 61). Clean the inside of the mounting tube. 5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the mounting tube. 6. Inspect the caster wheel fork for wear and replace if necessary (Fig. 60). 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 (Fig 60). 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 mounting tube using No. 2 general purpose lithium base or molybdenum base grease. 2 2 1 m–6373 Figure 61 1. Mounting Tube 2. Bushing

Service 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 (Fig. 62). 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 62). 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 62). 4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 62). 1 2 3 4 5 3 m–5210 Figure 62 1. Locknut 2. Wheel Bolt 3. Bushing 4. Spanner Bushing 5. Roller Bearing 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 (Fig. 62). 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 (Fig. 62). 7. Grease the fitting on the caster wheel. Replacing the Grass Deflector 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, or a grass chute and catcher. Warning 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Fig. 63). Remove damaged or worn grass deflector. 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 63. 3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 63). Important The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 6 1 5 m–5037 4 2 3 7 8 Figure 63 1. Bolt 2. Spacer 3. Locknut 4. Spring 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8. J hook end of spring

BROWN BLUE WHITE VIOLET YELLOW ORANGE GREY GREEN BN W VIO GN GY OR Y BU BN PK R T BK KEY SW. G M KEY SWITCH P/N 29–5560 NONE G+M OFF ON W PK J8–1 SPARK PLUG ENGINE IGNITION MODULE MAG AC W BK BU PK BU BU + – BRIDGE RECTIFIER R4 R3 D5 C2 D6 PK HOURMETER (OPTIONAL)

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 Brake Service, page 29. 4. Service the air cleaner; refer to Air Cleaner Service, page 25. 5. Grease the machine; refer to Greasing and Lubrication, page 28. 6. Change the crankcase oil; refer to Engine Oil Service, page 26. 7. Check the tire pressure; refer to Tire Pressure, page 29. 8. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank. A. Run engine to distribute conditioned fuel through the fuel system (5 minutes). B. Stop engine, allow to cool and drain the fuel tank; refer to Fuel Tank, page 31, or operate engine until it stops. C. Restart engine and run until it stops. Repeat, on Choke until engine will not restart. D. 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 Spark Plug Service, page 27. 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. Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Engine will not start, starts hard, or 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. g , , fails to keep running. 2. Choke is not ON. 2. Move throttle lever to choke position. 3. Air cleaner is dirty. 3. Clean or replace air cleaner element. 4. Spark plug wire is loose or disconnected. 4. Install wire on spark plug. 5. Spark plug is pitted, fouled, or gap is incorrect. 5. Install new, correctly gapped spark plug. 6. Dirt in fuel filter. 6. Replace fuel filter. 7. Dirt, water, or stale fuel is in fuel system. 7. Contact Authorized Service Dealer.

1. Engine load is excessive. 1. Reduce ground speed. g 2. Air cleaner is dirty. 2. Clean air cleaner element. 3. Oil level in crankcase is low. 3. Add oil to crankcase. 4. Cooling fins and air passages under engine blower housing are plugged. 4. Remove obstruction from cooling fins and air passages. 5. Spark plug is pitted, fouled, or gap is incorrect. 5. Install new, correctly gapped spark plug. 6. Vent hole in fuel cap is plugged. 6. Clean or replace the fuel cap. 7. Dirt in fuel filter. 7. Replace fuel filter. 8. Dirt, water, or stale fuel is in fuel system. 8. Contact Authorized Service Dealer. Engine overheats. 1. Engine load is excessive. 1. Reduce ground speed. g 2. Oil level in crankcase is low. 2. Add oil to crankcase. 3. Cooling fins and air passages under engine blower housing are plugged. 3. Remove obstruction from cooling fins and air passages. Machine does not drive. 1. Shift lever is in NEUTRAL. 1. Move shift lever to a drive gear position. 2. Traction belt is worn, loose or broken. 2. Change Belt. 3. Traction belt is off pulley. 3. Change Belt. Abnormal vibration. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Engine mounting bolts are loose. 3. Tighten engine mounting bolts. 4. Loose engine pulley, idler pulley, or blade pulley. 4. Tighten the appropriate pulley. 5. Engine pulley is damaged. 5. Contact Authorized Service Dealer. 6. Blade spindle bent. 6. Contact Authorized Service Dealer.

1. Blade(s) not sharp. 1. Sharpen blade(s). g g 2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s). 3. Mower is not level. 3. Level mower from side-to-side and front-to-rear. 4. Underside of mower is dirty. 4. Clean the underside of the mower. 5. Tire pressure is incorrect. 5. Adjust tire pressure. 6. Blade spindle bent. 6. Contact Authorized Service Dealer. Blades do not rotate. 1. PTO Drive belt is worn, loose or broken. 1. Install new drive belt. 2. PTO 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.