Toro 30197 Operator's Manual

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ProLine

15 HP – 48I Mid-Size Mower

30197—200000001 & Up

Form No. 3323–736

Operator’s Manual

Domestic English (EN)

Introduction

Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied

with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require.

Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number plate located in a unique place on the product as shown below

The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, 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 the recommended precautions are not followed.

WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed.

CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.

Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.

m–3775

1. Model

For your convenience, write the product model and serial numbers in the space below.

Model No:

Serial No.

Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although we design, produce and market safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons, who you allow to use the product, about safe operation.

and Serial Number Plate

The left and right side of the machine is determined from the normal operator’s position.

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

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 this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

The Toro Company – 1998

Contents

Safety 2.

Gasoline and Oil 11. . . . . . . . . . . . . . . . . . . . . . . .

Assembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 2. . . . . . . . . . . . . .

Toro Mower Safety 4. . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . .

Recommended Gasoline

Using Stabilizer/Conditioner 12. . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . .

Check Engine Oil Level 12. . . . . . . . . . . . . . .

Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . .

Install Front Castors 14. . . . . . . . . . . . . . . . . .

Install Upper Handle 14. . . . . . . . . . . . . . . . .

Connect Throttle Cable 16. . . . . . . . . . . . . . .

Install Blade Control (PTO) Rod 17. . . . . . . .

Install Shift Lever 17. . . . . . . . . . . . . . . . . . .

Mount Fuel Tank 18. . . . . . . . . . . . . . . . . . . .

Think Safety First 19. . . . . . . . . . . . . . . . . . .

Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake 20. . . . . . . . . . . . . . . . . . . . . . .

Starting and Stoppingthe Engine 21. . . . . . . .

Operating Blade Control (PTO) 22. . . . . . . . .

The Safety Interlock System 22. . . . . . . . . . .

Driving Forward or Backward 23. . . . . . . . . .

Lower Control Bar Operation 24. . . . . . . . . .

Page

11. . . . . . . . . . . . . .

Stopping the Machine 24. . . . . . . . . . . . . . . .

Adjusting Height-of-Cut 25. . . . . . . . . . . . . .

Height-of-Cut Chart 26. . . . . . . . . . . . . . . . . .

Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 27. . . . . . . . . . . . . . . .

Air Cleaner 28. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 29. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug 31. . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Blades

Tire Pressure 35. . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 35. . . . . . . . . . .

Greasing and Lubrication 35. . . . . . . . . . . . . .

Brake 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 37. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 38. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Wheel Belt 39. . . . . . . . . . . . .

Replacing the Traction Belt 39. . . . . . . . . . . .

Replacing the Mower Belt 40. . . . . . . . . . . . .

Adjusting Mower Belt Tension 41. . . . . . . . .

Adjusting the Blade Brake 41. . . . . . . . . . . . .

Adjusting Grass\Mud Scraper 42. . . . . . . . . .

Replacing the Grass Deflector 42. . . . . . . . . .

Wiring Diagram 43. . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 44. . . . . . . . . . . . . . . . .

Troubleshooting 45. . . . . . . . . . . . . . . . . . . . . . . . .

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover

Page

32. . . . . . . . . . . . . . . . . . . . . .

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Safety

This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of certain attachments

that do not meet American National Standards Institute certification will cause noncertification of this machine.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

Safe

The B71.4—1999.

Operating Practices

following instructions are from ANSI standard

Preparation

• Evaluate the terrain to determine what

accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat,

safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be

used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Use extra care when handling gasoline and other

fuels. They are flammable and vapors are explosive.

• Use only an approved container

• Never remove gas cap or add fuel with

engine running. Allow engine to cool before refueling. Do not smoke.

Training

• Read the Operator’s Manual and other training

material. If the operator(s) or mechanic(s) can not read English it is the owner’ to explain this material to them.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained.

The owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible

for accidents or injuries occurring to himself or herself, other people or property.

s responsibility

• Never refuel or drain the machine

indoors.

• Check that operator’s presence controls, safety

switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Safety

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from

holes and hidden hazards.

• Be sure all drives are in neutral and parking

brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided.

• Be sure of your footing while using pedestrian

controlled equipment, especially when backing up. Walk, don’t run. Never operate on wet grass. Reduced footing could cause slipping.

• Slow down and use extra care on hillsides. Be

sure to travel in the recommended direction on hillsides. Turf conditions can affect the machine’ near drop–offs.

• Slow down and use caution when making turns

and when changing directions on slopes.

s stability

. Use caution while operating

• Look behind and down before backing up to be

sure of a clear path.

• Never carry passengers and keep pets and

bystanders away

• Slow down and use caution when making turns

and crossing roads and sidewalks. Stop blades if

not mowing.

• Be aware of the mower discharge direction and

do not point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs

• Use care when loading or unloading the machine

into a trailer or truck

• Use care when approaching blind corners,

shrubs, trees, or other objects that may obscure

vision.

Maintenance and Storage

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other

guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property.

• Never operate with the discharge deflector

raised, removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or

overspeed the engine.

• Stop on level ground, lower implements,

disengage drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking

objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Disengage drives, lower implement, set parking

brake, stop engine and remove key or disconnect

spark plug wire. Wait for all movement to stop

before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

mufflers, and engine to help prevent fires. Clean

up oil or fuel spillage.

• Let engine cool before storing and do not store

near flame.

• Shut off fuel while storing or transporting. Do

not store fuel near flames or drain indoors.

• Park machine on level ground. Never allow

untrained personnel to service machine.

• Use jack stands to support components when

required.

• Carefully release pressure from components with

stored energy.

• Keep hands and feet away from the cutting units.

Safety

• Disconnect battery or remove spark plug wire

before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the

blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area,

away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

Note: 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 this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

General Operation

• Allow only responsible adults who are familiar

with the instructions to operate the machine.

• Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

Toro

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Mower Safety

POTENTIAL HAZARD

• Engine exhaust contains carbon monoxide,

which is an odorless, deadly poison.

WHAT CAN HAPPEN

• Carbon monoxide can kill you and is also

known to the State of California to cause birth defects.

HOW TO AV

OID THE HAZARD

• Do not run engine indoors or in an enclosed

area.

• Do not mow in reverse unless absolutely

necessary. Always look down and behind before and while backing.

• Be aware of the mower discharge direction and

do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any

terrain may cause loss of control.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away

from attachment discharge area, underside of mower and any moving parts while engine is running.

• Stop the engine before removing the grass

catcher or unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

Safety

• Do not touch equipment or attachment parts

which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Before operating a machine with ROPS (roll

over protection) be certain the seat belts are attached to prevent the seat from pivoting forward.

Slope Operation

Slopes and ramps are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• Mow up and down slopes greater than 5°, not

across.

• Mow downhill only on slopes above 10°, never

mow uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear.

• Remove obstacles such as rocks, tree limbs, etc.

from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Use slow speed so that you will not have to stop

while on the slope.

• Follow the manufacturer’s recommendations for

wheel weights or counterweights to improve stability.

• When operating machine on slopes, banks or

near drop offs, always have ROPS (roll over

protection) installed.

• When operating a machine with ROPS (roll over

protection) always use seat belt.

• Be certain that the seat belt can be released

quickly if the machine is driven or rolls into

ponds or water.

• Check carefully for overhead clearances (i.e.

branches, doorways, electrical wires) before

driving under any objects and do not contact

them.

DO NOT

• Do not operate machine on hillsides or slopes

exceeding 15°.

• Avoid turning on slopes. If you must turn, turn

slowly and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or

embankments. The machine could suddenly turn

over if a wheel goes over the edge of a cliff or

ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction

could cause sliding.

• Do not try to stabilize the machine by putting

your foot on the ground.

• Do not use a grass catcher on steep slopes.

Heavy grass bags could cause loss of control or

overturn the machine.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual.

Do not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires

lose traction, disengage the blades and proceed slowly straight down the slope.

Service

• Never store the machine or fuel container inside

where there is an open flame, such as near a

water heater or furnace.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good

condition.

• Never tamper with safety devices. Check safety

systems for proper operation before each use.

Safety

• Use only genuine replacement parts to ensure

that original standards are maintained.

• Check brake operation frequently. Adjust and

service as required.

• Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes,

sparks and flames away from battery.

• Hydraulic fluid escaping under pressure can

penetrate the skin and cause injury. Use cardboard or paper to find hydraulic leaks.

• Never modify ROPS (roll over protection)

frames or structures because they are specifically designed, sized, located and tested for injury reduction. If a rollover occurs, a modified ROPS will not provide adequate protection.

Safety

Slope

Read all safety instructions on pages 2–9.

Chart

Safety

and Instruction 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.

ON UPPER CONTROL BAR

(Part No. 82-2290)

ON TOP-FRONT OF MOWER

(Part No. 66-1340)

ON LOWER CONTROL BAR

(Part No. 82-2280)

ON CONTROL PANEL

(Part No. E323564)

ABOVE MUFFLER

(Part No. 63-8440)

ON TOP-LEFT SIDE OF MOWER

(Part No. 43-8480)

ON THE GEAR SELECTION PANEL

(Part No. E323560)

ABOVE GRASS DEFLECTOR

(Part No. 67-5360)

ON GRASS DEFLECTOR

(Part No. 54-9220)

Safety

ON REAR OF MOWER

(Part No. 99-3943)

99–3943

ON LEFT SIDE OF HANDLE FRAME

(Part No. E323563)

ON PARKING BRAKE

(Part No. E323558)

ALONG LEFT SIDE OF FUEL TANK

(Part No. 95-2814)

ON REAR FRAME

(Part No. E323562)

ON REAR-LEFT CORNER OF MOWER

(Part No. 98-5130)

Gasoline and Oil

Recommended

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.

POTENTIAL HAZARD

Gasoline

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.

Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm 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.

POTENTIAL HAZARD

• When fueling, under certain circumstances,

a static charge can develop, igniting the gasoline.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you and others and cause property damage.

HOW TO AV

OID THE HAZARD

• 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, r

equipment from the truck or trailer and refuel the equipment with its wheels on the round.

emove gas–power

• 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 and Oil

POTENTIAL HAZARD

• Gasoline is harmful or fatal if swallowed.

Long–term eposure to vapors has caused cancer to laboratory animals.

WHAT CAN HAPPEN

• Failure to use caution may result in serious

injury or illness

HOW TO AV

OID THE HAZARD

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank

or conditioner opening.

• Keep gas away from eyes and skin.

Using

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

Stabilizer/Conditioner

Filling

1. Shut the engine off.

2. Clean around the fuel tank cap and remove the

3. Install the fuel tank cap securely. Wipe up any

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page NO TAG.

the Fuel T

cap. Use a funnel and add unleaded regular gasoline to the fuel tank, 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 tank completely full.

gasoline that may have spilled.

ank

Engine Oil Level

• Keeps gasoline fresh during storage of 90 days

or less. For longer storage, drain the fuel tank.

• 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.

Assembly

Loose

Parts

Note: Use the chart below to verify all parts have been shipped.

DESCRIPTION QTY. USE

Castor assemblies Bolt 3/8–16 x 3/4” (19 mm) Flange nut 3/8–16

Upper handle Bolt 3/8–16 x 1” (26 mm) Locknut 3/8–16 Plastic terminal Wire tie

Rod fitting Clevis pin Washer 1/4” Hairpin cotter

O rod

Hairpin cotter

2 8 8

1 4 4 1 1

2 2 2 4

1 2

Install front castors to mower

Install upper handle to frame

Install wire harness to handle

Install traction control rods

Install PT

O rod

Shift lever Rubber seal Square hole washer Spring washer Locknut

1 1 1 1 1

Install shift lever to transmission

Assembly

DESCRIPTION USEQTY.

Fuel tank Bolt 5/16–1/ x 7/8” (22.5 mm) Lock washer 5/16” W

asher 5/16” Stud Spring Hose clamp

Operator’ Engine Operator

s Manual

’

s Manual Parts Catalog Registration card

Install

Front Castors

1. Align castors with holes on top and front of

mower and insert (8) 3/8–16 x 3/4” (19 mm) bolts through mower. Secure with (8) 3/8–16 flange nuts below mower (Fig. 1).

1 2 2 4

Install fuel tank 2 2 1

Read before operating machine 1

Fill out and return to T

oro

Install

Upper Handle

1. Position handle outside frame and align upper

handle mounting holes with desired mounting holes in rear frame. High, medium or low according to operators height (Fig. 2).

Note: Tighten lower bolts first to pull castor

against front, then top bolts last.

2. Torque bolts to 30–35 ft. lb. (40–47 NSm).





Figure 1

1. Front

2. Bolt

castor

3/8–16 x

3/4” (19 mm)

3. Flange

nut 3/8–16

m–3777

2. Secure each side with (2) 3/8–16 x 1” (26mm)

bolts and (2) 3/8–16 locknuts (Fig. 2).

3. Torque bolts to 25 ft. lbs. (34 NSm).





1. Upper

Rear frame

Bolt 3/8–16 x 1” (26mm)



handle



Figure 2



Locknut 3/8

5. Low

6. High





m–4213

Assembly

Connect Wire Harness

4. Route wire harness inside of frame, along left

handle and over throttle cable. Compress wire harness covering and press into lower and upper holes in rear of control panel (Fig. 3).

5. Thread harness up through rear tube of traction

handle (Fig. 3).









m–3774

Figure 3

1. Wire

6. Insert terminals into plastic plug until the clips

harness

Control panel

3. Tube Wire tie

snap into position (Fig. 3). If they do not snap turn around and try again.

Install Traction Control Rods

1. Thread trunnions equal distance onto each

control rod. For a starting point thread on approximately 2 in. (51 mm) (Fig. 5).

2. With trunnion rod up, slide clevis pins through

rod fittings and mounting holes in idler brackets (from outside) (Fig. 5). Secure with 1/4” (6 mm) washers and hairpin cotters (Fig. 5).





1. Control

2. Trunnion

Idler bracket



rod

Figure 5

5. W





Clevis pin

asher 1/4” (6 mm)

Hairpin cotter



m–3785

7. Push plug onto switch so latches interlock (Fig.

3).

8. Secure wire harness and throttle cable to left

handle, away from PTO lever, with wire tie (Fig. 3).





1. Terminal

2. Clip

Figure 4

3. Plastic

4. Switch



m–3782

plug

Assembly

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 in. (25–32 mm) (Fig. 6).

Note: The upper control bar and fixed bar

must be parallel in the engaged, 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.

5. After adjusting control rods, check parking brake

adjustment, refer to: Brake page 36 for instructions.







Connect

Throttle Cable

1. Place throttle control lever in FAST

position.(Fig. 7).

2. Hook wire Z–bend into hole of speed control

lever (Fig. 7).

3. Loosen cable clamp screw allowing cable

installation, but do not tighten (Fig. 7).

4. Move control cable casing and wire until hole in

speed control lever is aligned with hole in base plate. Insert a 1/4 in. (6.35 mm) diameter pin or bolt into aligned holes to hold adjustment.

5. Pull throttle cable slightly to remove any slack

and tighten cable clamp screw to lock adjustment in place.

6. Remove alignment pin and check control

operation.

1. Control

Fixed control bar

rod

Figure 6

Parking brake lever

Upper control bar







m–3770







m–2596

Figure 7

1. Wire

Z-bend Speed control lever Base plate

Alignment holes 1/4 in. (6.35mm)

Cable clamp

Assembly

Install

Blade Control (PT

Rod

1. Rotate blade control lever (PTO) vertical away

from left handle so rod drops down.

2. Remove hairpin cotters from bottom end of

blade control rod (PTO) (Fig. 8).

3. Secure blade control (PTO) rod through hole in

bellcrank with hairpin cotters (Fig. 8).





1. Blade

control lever

Blade control rod



Figure 8

3. Bellcrank

Hairpin cotter

m–3783



Install

Shift Lever

1. Remove the 3/8” locknut and spring disk washer

from the stud on top of the transmission. Note: Do not remove rubber seal washer and

square hole washer from transmission shaft.

2. Slide shift lever through control panel and align

mounting hole in lever with square on transmission shaft. Secure lever to transmission with previously removed spring washer and locknut (Fig. 9).

3. Replace the spring washer,dish down, and

locknut (Fig. 8).

4. Torque nut to 35 ft. lbs. (47 NSm).

5. Shift lever to second gear and check alignment

of lever in slot of shifter plate. Clearance between top of lever and the top of the slot should be about equal to the clearance between bottom of the lever and the bottom of the slot.

6. If clearance is not correct, remove lever and bend

it slightly to adjust. Note: Do not bend lever while attached to

transmission shaft or damage may occur.





Figure 9

1. Shift

lever Control panel Rubber seal washer

Square hole washer

Spring washer

Locknut 3/8









m–3772

Assembly

Mount

Fuel T

ank

1. Align fuel tank to top of rear frame and secure

fuel tank right side with (2) 5/16–18 x 7/8 in. (22.5 mm) bolts, (2) 5/16 lock washers and (2) 5/16 washers (Fig. 10).

2. Secure fuel tank left side to frame with (2)

5/16–18 x 7/8 in. (22.5 mm) studs, (2) 5/16 washers and (2) 5/16 locknuts (Fig. 10).

3 2

m–37711

3. Push fuel line onto fuel tank fitting and secure

with hose clamp (Fig. 11).

1. Fuel

Hose clamp

Figure 1

line

Fuel fitting

3 5 6

m–3778

1. Bolt

5/8–18 x 7/8”

(22.5 mm)

Lock washer 5/16

3. W

asher 5/16

Figure 10

4. Stud

5. Spring

6. Locknut

Operation

Think

Safety First

Please carefully read all the safety instructions and symbols in the safety section. Knowing this information could help you, pets or bystanders avoid injury.

Controls

Become familiar with all the controls (Fig. 12) before you start the engine and operate the machine.

Throttle Control – The throttle control has CHOKE, FAST, SLOW and STOP positions.

Bail – The bail, in conjunction with the PTO switch, allows the engine to be started with the PTO disengaged. With the bail compressed the blade control (PTO) can be engaged. Release the bail with the PTO engaged and the engine stops.

Blade Control (PTO) – The blade control lever (PTO) engages and disengages power to the mower blades. Move the PTO lever forward to engage the blades. Pull rearward to stop driving 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.

Recoil Starter – Pull recoil starter handle to start engine.

Fuel Shut–off Valve – (In fuel line) Close fuel shut–off valve when transporting or storing mower.

m–4194

Figure 12

1. Throttle

2. Bail

control

Blade control (PT Gear shift lever

Upper control bar

Lower control bar

Parking brake lever

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 pull rearward on lower control bar to engage rearward traction operation.

Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle to keep brake engaged.

Operation

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 rearward and hold it in

this position (Fig. 13).

2. Lift the parking brake lock up and gradually

release the upper control bar (Fig. 13). The brake lock should stay in the set (locked) position.

Releasing the Parking Brake

1. Pull rearward on the upper control bar (Fig. 13).

Lower the parking brake lock to the released position.

2. Gradually release the upper control bar.

Figure 13

1. Upper

control bar

Parking brake lock

m–4212

Operation

Starting

and Stopping

the Engine

Starting

1. Make sure spark plug wire(s) are installed on

spark plug(s) and fuel valve is open.

2. Move the blade control to off, the shift lever to

neutral and set the parking.

3. Move the throttle control to 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 FAST position.

4. Grasp recoil starter handle firmly and pull out

until positive engagement results; then pull handle vigorously to start engine. 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

1. Move the throttle lever midway between FAST

and SLOW (Fig. 14). Note: Allow the engine to run a minimum of

15 seconds and then stop the engine.

2. To stop the engine pull the throttle all the way

back, past SLOW(Fig. 14).

m–4194

Figure 14

1. Blade

3. Set the parking brake.

4. Pull wire off spark plug(s) to prevent possibility

control (PT

O) 2.

Throttle lever

of accidental starting before storing machine.

5. Close fuel shut off valve before storing machine. IMPORTANT: Make sure fuel shut off valve

is closed before transporting or storing machine, or fuel leakage may occur.

Operation

Operating

The blade control (PTO) lever engages and disengages power to the mower blades.

Blade Control (PT

Engaging the Mower Blades (PTO)

1. Pull on the upper control bar to stop the machine

(Fig. 15).

2. Hold the bail against the upper control bar

(Fig. 15).

3. To engage blade(s), push the blade control lever

firmly forward, until it latches over-center (Fig. 15).

The

Safety Interlock System

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the engine from starting if:

• The throttle lever is all the way back, past

SLOW

• The blade control lever (PTO) is engaged The safety interlock system is also designed to stop

the engine if you released the bail with the PTO engaged or move the throttle all the way back, past SLOW.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

Figure 15

1. Upper

2. Bail

control bar

Blade control (PT

Disengaging the Mower Blades (PTO)

1. To disengage the blade(s), pull blade control

lever rearward, all the way (Fig. 15). Note: It is necessary to fully and manually

disengage mower

m–4194

1. Set the parking brake, disengage the PTO and

place the throttle forward. Start the engine. With the engine running squeeze the bail against upper control bar and push the mower blade control lever forward. The mower blades begin rotating.

2. With the engine running, release the bail. The

engine should stop.

3. Start the engine again.

4. With the engine running, move the throttle lever

all the way back, past SLOW. The engine should stop.

Operation

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 performance.

Forward

1. To go forward, move the shift lever to a forward

gear.

2. Release the parking brake: refer to Releasing the

Parking Brake, page 20.

3. Slowly press on the upper control bar to move

forward (Fig. 16).

To go straight, apply equal pressure to both ends of the upper control bar (Fig. 16).

To turn, release pressure on the upper control bar side toward the direction you want to turn (Fig. 16).

Backward

1. To go backward, move the shift lever to reverse gear.

2. Release the parking brake: refer to Releasing the Parking Brake, page 20.

3. Slowly squeeze on the lower control bar and handle together to move rearward (Fig. 16).

1. Upper

control bar

Figure 16

m–4194

Lower control bar

Operation

Lower

Control Bar Operation

This procedure is for driving up a curb. This can be performed while driving forward or backward.

1. Disengage the mower blades.

POTENTIAL HAZARD

• A blade can be bent or damaged when

driving up a curb. Blades could break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

OID THE HAZARD

• Do not run blades while driving up a curb

forward or backward.

2. Select first gear or reverse to drive machine.

m–4185

1. Lower

Control Bar engaged and mower in reverse.

Stopping

Figure

the Machine

Pull up to assist machine

To stop the machine apply the brakes, pull back on the upper control bar, release the bail and set the parking brake; refer to Setting the Parking Brake, page 20.

3. Drive machine until drive wheels contact curb

(Fig. 18). Note: Both drive wheels should contact the

curb and castor 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.

1. Lower (Engaged)

Control Bar

Figure 17

2. Handle

m–4192

Operation

Adjusting

Height-of-Cut

A 1” to 4-1/4” range for height-of-cut can be achieved by adjusting blade spacers, rear axle height and front castor spacers. Use the Height-of-Cut chart on page 26 to select the combination required

Adjust Blade Height

Blades are adjusted by using the four, 1/4” spacers found on the blade spindle bolts. This allows a range, in 1/4” increments, of cutting height in any axle position. The same number of blade spacers must be used on all blades to achieve a level cut (two above and two below, one above and three below, etc.).

1. Stop engine and remove spark plug wire(s).

2. Hold blade bolt and remove nut. Slide bolt

down, through spindle, and change spacers as required (Fig. 19).

Adjust Axle Height

Desired height-of-cut range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm (see chart).

1. Stop engine and remove spark plug wire(s).

2. Loosen but do not remove the (2) axle pivot

bolts and the (2) axle adjustment bolts (Fig. 20).

3. Place a jack under the rear center of the engine

frame. Raise the back end of the engine frame up enough to remove front (2) axle adjustment bolts (Fig. 20).

4. Raise or lower the engine frame with the jack,so

that front (2) axle adjustment bolts can be installed in the desired hole location (Fig. 20). A tapered punch can be used to help align the holes.

5. Tighten all (4) bolts and lower the unit.

3. Insert bolt, add extra spacer(s), and secure with

thin washer and nut (Fig. 19).

4. Torque blade bolt to 75–80 ft. lb.

(101–108 NSm).

1. Blade

2. Blade

Cone washer

4. Spacer

bolt

Figure 19

5. Tube

7. Nut

m–3779

Thin washer

6. Adjust control rods and brake linkages as

required, refer to: Assembly and Brake.

IMPORTANT: It will be necessary to adjust control rods and brake linkage when changing axle positions for proper traction

7 6

and brake function.

1. Axle

pivot bolt

Figure 20

m–3789

Axle adjustment bolt

Operation

Axl

Adjust Caster Position

1. Using the height-of-cut chart, adjust the caster

spacers to match with the axle hole selected (Fig. 21).

2. Remove clevis pin, slide castor from support and

change spacers(Fig. 21).

3. Install castor in support and insert clevis

pin(Fig. 21).

Height-of-Cut

No.

Position

Below Caster

1/2″ 3/16″ 4 3210

Chart

of Spacers

Number of 1/4

1. Clevis

3/16” (5 mm) spacer

″ Blade

Figure 21

1/2” (13 mm) spacer

Spacers Below Spindle

m–3791

A 0 0 1” 1–1/4” 1–1/2” 1–3/4” 2” A 0 1 1–1/8” 1–3/8” 1–5/8” 1–7/8” 2–1/8” A 1 0 1–3/8” 1–5/8” 1–7/8” 2–1/8” 2–3/8” B 0 1 1–3/8” 1–5/8” 1–7/8” 2–1/8” 2–3/8” B 1 0 1–5/8” 1–7/8” 2–1/8” 2–3/8” 2–5/8” B 1 1 1–3/4” 2” 2–1/4” 2–1/2” 2–3/4” B 2 0 2” 2–1/4” 2–1/2” 2–3/4” 3” C 1 1 1–7/8” 2–1/8” 2–3/8” 2–5/8” 2–7/8” C 2 0 2–1/8” 2–3/8” 2–5/8” 2–7/8” 3–1/8” C 2 1 2–1/4” 2–1/2” 2–3/4” 3” 3–1/4” C 3 0 2–1/2” 2–3/4” 3” 3–1/4” 3–1/2” D 2 1 2–3/8” 2–5/8” 2–7/8” 3–1/8” 3–3/8” D 3 0 2–1/2” 2–3/4” 3” 3–1/4” 3–1/2” D 3 1 2–3/4” 3” 3–1/4” 3–1/2” 3–3/4” D 4 0 3” 3–1/4” 3–1/2” 3–3/4” 4” E 3 1 2–7/8” 3–1/8” 3–3/8” 3–5/8” 3–7/8” E 4 0 3–1/8” 3–3/8” 3–5/8” 3–7/8” 4–1/8” E 4 1 3–1/4” 3–1/2” 3–3/4” 4” 4–1/4”

Maintenance

Service

Service Operation

Oil—check level Oil—change* Initial X X Oil Filter–change (200 hours or every

other oil change) Safety System—check Brakes—check X X Cutting Blades – check Wheel Bearings—grease* T

ransmission Couplers – grease* Idler Pivots – grease* Belt Blade Idler Pivots – grease* Foam Air Cleaner—service* Paper Air Cleaner—replace* Spark Plug(s)—check Belts—check for wear/cracks PT

O Belt—check tension Gasoline—drain X Engine—clean cooling system Fuel Filter—replace T

ires—check pressure

Chipped Surfaces—paint

Interval Chart

Each

Use8Hours25Hours50Hours

X X

X X X

X X

Initial X X

X X X

X X

100

Hours

X X

200

Hours

X X

Storage Service

More often in dusty

, dirty conditions

Maintenance

Air

Cleaner

Service Interval/Specification

Foam Element: Clean and re-oil after every 25 operating hours.

Paper Element: Replace after every 100 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” to stop the engine. Remove the key.

2. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unscrew the cover nut and remove the air cleaner cover (Fig. 22).

3. Remove the air cleaner assembly (Fig. 22).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and

warm water. When the element is clean, rinse it thoroughly.

B. Dry the element by squeezing it in a clean

cloth.

C. Put one or two ounces 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.

m–1213

Figure 23

1. Foam

element

2. Oil

4. Carefully slide the foam element off the paper

element (Fig. 22).

m–2595

Figure 22

1. Cover

and nut Wing nut Foam element

4. W

asher and grommet

Paper element

Air cleaner base

Maintenance

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 24).

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

and damage to the rubber seal.

IMPORTANT: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly.

Engine

Oil

Service Interval/Specification

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when

operating conditions are extremely

dusty or sandy. Oil Type: Detergent oil (API service SF, SG or SH) Crankcase Capacity: w/filter, 2 qt. (1.9 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

m–1213

Figure 24

1. Paper

element

Rubber seal

Installing the Foam and Paper Elements

1. 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).

5W–20, 5W–30

–20 0 20

–30°–20 –10

10W–30, 10W–40

40 60

01020

80 100

30 40

3. Install the air cleaner cover and secure with cover nuts (Fig. 22).

Maintenance

Checking Oil Level

1. Park the machine on a level surface, disengage

the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Clean around the oil dipstick (Fig. 25) so dirt

cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end

clean (Fig. 25).

4. 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.

Changing/Draining 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. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Place a pan below the oil drain. Remove the oil

drain cap (Fig. 26).

4. When oil has drained completely, install the oil

drain cap. Note: Dispose of the used oil at a certified

recycling center.

1. Oil

Metal end

dipstick

Figure 25

Filler tube

m-4758

Figure 26

1. Oil

drain cap

5. Slowly pour approximately 80% of the specified

amount of oil specified, page 29, into the filler tube (Fig. 25). Now check the oil level; refer to Checking Oil Level, page 30. Slowly add additional oil to bring to “FULL” mark on dipstick.

Maintenance

Change Oil Filter Service Interval/Specification

Replace the oil filter every 200 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 30.

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).

Spark

Plug

Service Interval/Specification

Check the spark plug(s) after every 200 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: Champion RC12YC (or equivalent) Air Gap:

0.040 in. (1.02 mm)

Removing the Spark Plug(s)

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. 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.

m–1256

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 1/2 turn (Fig. 27).

5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 30.

3. Remove the spark plug(s) and metal washer.

Figure 28

1. Spark

plug wire

Spark plug

     

m–4757

Maintenance

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 r 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.

eplace the spark plug(s) when it has:

0.040

in.

(1.02 mm)

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.

POTENTIAL HAZARD

• A blade that is worn or damaged could

break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

OID THE HAZARD

• Periodically inspect the blade for wear and

damage. Immediately install a new blade if it is worn or damaged.

Air gap (not to scale)

1. Center

Side electrode

Figure

electrode insulator

Installing the Spark Plug(s)

1. Install the spark plug(s) and metal washer. 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).

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake.

Inspecting the Blades

1. Inspect the cutting edges (Fig 30). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 34.

2. Inspect the blades, especially the curved area (Fig. 30). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 30), immediately install a new blade.

Maintenance

 

   

 

Figure

m–2539

2. Rotate the opposite ends of the blades forward.

Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8” (3 mm). If this dimension exceeds 1/8” (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 34.

m–151

Figure 30

1. Cutting

Edge

Curved Area

3. W

ear/slot Forming

Checking for Bent Blades

1. Rotate the blades until the ends face forward and backward (Fig. 31). Measure from a level surface to the cutting edge of the blades (Fig. 32). Note this dimension.



POTENTIAL HAZARD

• A blade that is bent or damaged could

break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

•

Always r

OID THE HAZARD

eplace bent or damaged blade with

a new blade.

• Never file or create sharp notches in the

edges or surfaces of blade.

Figure 31

m–1078

Maintenance

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.

Hold the blade bolt with a wrench. Remove the nut, blade bolt, cone washer, blade, spacers and thin washer from the spindle (Fig. 33).

1. Blade

2. Blade

Cone washer

4. Spacer

bolt

Figure 33

5. Tube

7. Nut

m–3779

Thin washer

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both

ends of the blade (Fig. 34). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

7 6

1. Sharpen

at original angle

2. Check the balance of the blade by putting it on a

blade balancer (Fig. 35). 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. 34). Repeat this procedure until the blade is balanced.

1. Blade 2. Balancer

Figure 34

2. Sail

m–1855

Figure 35

Installing the Blades

1. Place the blade onto the bolt, over cone washer.

Select proper number of spacer(s) for height-of-cut and slide bolt into spindle (Fig.

33).

IMPORTANT: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

2. Install remaining spacer(s) and secure with thin

washer and nut (Fig. 33).

3. Torque the blade bolt to 75–80 ft. lb.

(101–108 NSm).

Tire

Pressure

Greasing

Maintenance

and Lubrication

Service Interval/Specification

Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 36). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 15 psi (103 kPa) rear tires

25–30 psi (172–207 kPa) castor tires

Figure 36

1. Valve

stem

Service Interval/Specification

Grease the areas shown and at intervals in Where to Add Grease section below. Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose grease.

How to Grease

1. Disengage the blade control (PTO) and set the

parking brake.

2. Clean the grease fittings with a rag. Make sure to

scrape any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease

into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Where to Add Grease

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.

1. Lubricate the drive and castor wheel bearings

and front spindles (Fig. 37). Lubricate every 8 hours.

m–3780

Figure 37

Maintenance

2. Lubricate the transmission couplers every 50

hours and idler arm pivots every 8 hours (Fig 38).

Figure 38

1. Idler

Arm Pivots

(Lubricate after 8 hours)

2. T

ransmission Couplers

(Lubricate after 50 hours)

3. Lubricate the blade belt idler arm pivot.

(Fig. 39). Lubricate every 50 hours.

m–3797

Brake

Service Interval/Specification

Before each use, check brakes for proper operation. 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 Brake

1. Park the machine on a level surface, disengage

the blade control (PTO) and set the parking brake.

2. Rear wheels must lock when you try to push the

machine forward or backward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 37.

3. Release the brake and press upper control bar

very lightly, approximately 1/2 in. (13 mm), wheels should rotate freely.

Figure 39

4. If both conditions are met, no adjustment is

required.

m–4731

Maintenance

Adjusting the Brake

The brake lever is on the upper control bar (Fig. 12). If the parking brake does not hold securely, an adjustment is required.

1. Check the brake before you adjust it; refer to Checking the Brake, page 36.

2. Release the parking brake; refer to Releasing the Parking Brake, page 20.

3. To adjust brake set the parking brake latch, and rotate the wing nuts on the brake rods (Fig. 40). Clockwise to tighten the brake and counterclockwise to loosen the brake.

Note: Control bar should be parallel with

reference bar when properly adjusted.

4. Check the brake operation again; refer to Checking the Brake, page 36.

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.

Fuel Tank

Draining The Fuel Tank

POTENTIAL

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

• 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 drain gasoline near an open flame or

where gasoline fumes may be ignited by a spark.

• Never smoke a cigarette, cigar or pipe.

1. Park the machine on a level surface, to assure

fuel tank drains completely. Disengage the blade control (PTO) and set the parking brake. Stop engine.

HAZARD

OID THE HAZARD

1. Brake

rod

Figure 40

Wing nut

2. Close the fuel shut–off valve in fuel line

(Fig. 41).

3. Squeeze the ends of the hose clamp together and

slide it up the fuel line away from fuel filter (Fig. 41).

m–3773

Maintenance

4. Pull the fuel line off the fuel filter (Fig. 41).

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 38.

5. Install the fuel line onto the fuel filter. Slide the

hose clamp close to the filter to secure the fuel line.

1. Fuel

Fuel filter

shut-of

Figure 41

f valve

m–3778

3. Clamp

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.

1. Disengage the blade control (PTO) and set the

parking brake. Stop engine.

2. Close fuel shut–off valve (Fig. 41).

3. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 42).

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps

close to the filter.

6. Open fuel shut-off valve at fuel tank (Fig. 41).

1. Hose

clamp

m–3778

Figure 42

2. Filter

Maintenance

Replacing

the Wheel Belt

Service Interval/Specification

Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating.

1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Fig. 43).

2. Remove bottom and loosen top bolts of shield to rotate for belt clearance (Fig. 43).

3. Lift belt past idler and off drive pulley (Fig. 43).

4. Raise wheel off ground enough to allow belt

removal. Note: Ensure that the mud and grass scraper

is adjusted properly and centered in the pulley grooves (see page 42). The pointed part of the scraper should be centered and as deep in the pulley groove as possible, without rubbing at any point.

5. Replace drive belt.

Replacing

the T

raction Belt

1. Stop the engine, set the parking brake and

remove the spark plug wire(s).

2. Raise the rear of the machine and hold with jack

stands.

3. Remove mower belt (Fig. 45).

4. Loosen pivot bolt enough to slide idler pulley in

slot and remove traction belt from the engine and drive pulleys.

5. Install new belt around engine and drive pulleys

(Fig. 44).

6. Slide idler pulley in engine frame to tension

traction belt (Fig. 44).

7. Install the mower belt (Fig. 45).

8. Check the belt guide under the engine frame for

proper adjustment (Fig. 44). The distance between the belt guide and mower belt should be 1-3/8” (35mm). Adjust as necessary. The disengaged belt should not drag or fall off pulley when guides are properly adjusted.

6. Secure shield with previously removed bolt and tighten bolts (Fig. 43).

7. Secure brake rod to brake arm with haripin cotter (Fig. 43).

Figure 43

1. Hairpin

cotter

Brake rod

3. Shield

Drive belt

1. Idler

Belt guide

in slot

m-4726

Figure 44

1-3/8” (35 mm)

Mower belt

Maintenance

Replacing

the Mower Belt

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key and spark plug wire.

2. Remove the knobs and belt cover on mower.

3. Remove idler pulley and then remove worn belt

(Fig. 45).

4. Install new belt.

5. Install idler pulley.

6. Engage PTO and check belt tension. See

Adjusting Mower Belt Tension, page 41. Note: Proper belt tension is 10–15 lbs. with

the belt deflected a 1/2” (13mm) halfway between pulleys (Fig. 45).

m–3860

Figure 46

1. 1/16”

2. Bellcrank

3. T

(2mm)–1/8” (3mm)

ransmission output shaft

Hairpin cotter

Clevis pin

6. Clevis

9. Disengage the PTO. If the assist arm does not

contact the front stop on the mower deck (Fig. 45), readjust the clevis to bring the bellcrank closer to the transmission output shaft (Fig. 46).

10. Check the belt guide under the engine frame for

Figure 45

1. Idler

pulley

1/2” (13 mm) deflection here

Assist arm

Front stop

7. Engage PTO lever and check the clearance

between the bellcrank and the transmission output shaft (Fig. 46). Space should be 1/16” (2mm)–1/8” (3mm).

8. Remove hairpin cotter and clevis pin from

bellcrank. Rotate clevis clockwise on rod to increase or counterclockwise to decrease clearance (Fig. 46).

m–4731

Maintenance

Adjusting

Mower Belt T

ension

Service Interval/Specification

Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation.

IMPORTANT: Belt must be tight enough to not slip during heavy loads while cutting grass. Over tensioning will reduce belt and spindle bearing life.

1. Set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key and spark plug wire.

2. Loosen locknut on turnbuckle (Fig. 47).

3. Rotate turnbuckle toward rear of mower to

increase tension on belt. Rotate turnbuckle toward front of mower to decrease tension on belt (Fig. 47).

4. If the belt is still loose after making adjustments

to the turnbuckle, reposition the rear idler pulley to the front hole. The belt guide next to the pulley must also be moved to the front hole (Fig. 47).

5. Readjust the turnbuckle.

Adjusting

the Blade Brake

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key and spark plug wire.

2. If necessary, adjust the spring mounting bolts so

that the blade brake pad rubs against the pulley edges (Fig. 48).

3. Adjust the nut at the end of the blade brake rod

until there is 1/8” (3mm)–3/16” (5mm) between the nut and spacer (Fig. 48).

Note: The eyebolt threads on both ends of the

turnbuckle should be engaged a minimum of 5/16” (8mm).

1. Locknut

2. Turnbuckle

3. Rear

idler pulley

Figure 47

Front position for idler pulley

Belt guide

m–4731

4. Engage the blades. Ensure the blade brake pad

no longer contacts the pulley edges.

m–47271

Figure 48

1. Spring

mounting bolts

Blade brake pad

1/8” (3mm)–3/16” (5mm)

Maintenance

Adjusting

Grass\Mud Scraper

1. Loosen the locknut holding scraper to the engine

frame (Fig. 49).

2. Rotate scraper until they align with center of

pulley grooves (Fig. 49).

3. Tighten the locknut (Fig. 49). Note: The scraper must not contact the pulley

on the sides or bottom of grooves. Re-adjust if necessary

Replacing

the Grass Deflector

1. Remove the locknut, bolt, spring and spacer

holding deflector to the mounts (Fig. 50).

2. Straighten deflector mounts if they are bent

(Fig. 50).

3. Install new deflector between mounts with

spacer and spring. Hook the front end of the spring around the front deflector mount. Insert bolt through spacer and secure with locknut. Confirm there is downward spring force on deflector (Fig. 50).

4. Tighten the bolt and locknut until they lightly

contact the pivot brackets (Fig. 50).

IMPORTANT: The grass deflector must be spring-loaded in the down position. Lift the deflector up to test that it snaps to the full down position.

1. Scraper

2. Locknut

Figure 49

3. Pulley

m–3776

1. Deflector

2. Bolt

3. Deflector

mount

Figure 50

4. Spring

5. Spacer

6. Locknut



Maintenance

Wiring

Diagram

WIRE LIST DESIG. AWG COLOR ROUTE W1 16 WHITE J2 J4 W2 16 WHITE J2 J3 W3 16 BLUE P1-1 J5 W4 16 BLACK P1-2 J1

P1 PTO

KILL

MAG

GND

Maintenance

Cleaning and Storage

1. Disengage the blade control (PTO), set the parking brake and turn the machine “OFF”.

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. A use of water, especially near the control panel, and engine. When done washing, start engine and engage PTO and run for five minutes. This will dry machine before storing.

3. Check the brake; refer to Brake, page 36.

4. Service the air cleaner; refer to Air Cleaner,

page 28.

5. Grease the machine; refer to Greasing and Lubrication, page 35.

6. Change the crankcase oil; refer to Engine Oil, page 29.

7. Check the tire pressure; refer to Tire Pressure, page 35.

void excessive

B. Run the engine to distribute conditioned

fuel through the fuel system (5 minutes).

C. Stop the engine, allow it to cool and drain

the fuel tank; refer to Draining Fuel Tank,

page 37. D. Restart the engine and run it until it stops. E. Choke or prime the engine. F. Start and run the engine until it will not

start again. Use the primer, if equipped on

machine, several times to ensure no fuel

remains in primer system. G. Dispose of fuel properly. Recycle as per

local codes.

IMPORTANT: Do not store stabilizer/conditioned gasoline over 90 days.

9. Remove the spark plug(s) and check its

condition; refer to Spark Plug, page NO TAG. 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.

8. For storage over 30 days, prepare the traction

unit as follows. A. Add a petroleum based

stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacturer. (1 oz. per gallon). Do not use

an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most

effective when mixed with fresh gasoline and used at all times.

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. Cover the machine to protect it and keep it clean.

Troubleshooting

PROBLEM

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

Engine loses power

POSSIBLE CAUSES

Fuel tank is empty

Choke is not ON.

Air cleaner is dirty

Spark plug wire is loose or disconnected.

Spark plug is pitted, fouled, or gap is incorrect.

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Air cleaner is dirty

Oil level in crankcase is low

Cooling fins and air passages under engine blower housing are plugged.

Spark plug is pitted, fouled, or gap is incorrect.

, or stale fuel is in

. 1.

. 3.

. 6.

. 2.

. 3.

CORRECTIVE ACTION

Fill fuel tank with gasoline. Move choke lever to ON. Clean or replace air cleaner

element. Install wire on spark plug.

Install new spark plug.

Replace fuel filter Contact Authorized Service

Dealer. Reduce ground speed. Clean air cleaner element. Add oil to crankcase. Remove obstruction from

cooling fins and air passages.

Install new spark plug.

, correctly gapped

Engine overheats.

Abnormal vibration.

6. V

ent hole in fuel cap is

plugged.

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Oil level in crankcase is low

Cooling fins and air passages under engine blower housing are plugged.

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

. 7.

, or stale fuel is in

, idler

. 2.

1. T

2. T

Clean or replace the fuel cap.

Replace fuel filter Contact Authorized Service

Dealer. Reduce ground speed. Add oil to crankcase. Remove obstruction from

cooling fins and air passages.

ighten engine mounting

bolts.

ighten the appropriate

pulley. Contact Authorized Service

Dealer.

Troubleshooting

PROBLEM

Machine does not drive.

Abnormal vibration.

Uneven cutting height.

POSSIBLE CAUSES

Shift lever is in NEUTRAL.

2. T

raction belt is worn, loose or

broken.

3. T

raction belt is of

Cutting blade(s) is/are bent or unbalanced.

Blade mounting bolt is loose.

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

Blade spindle bent.

Blade(s) not sharp.

Cutting blade(s) is/are bent.

f pulley

. 3.

, idler

CORRECTIVE ACTION

Move shift lever to a drive gear position.

Change Belt.

Install new cutting blade(s).

2. T

ighten blade mounting bolt.

3. T

ighten engine mounting

bolts.

4. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Sharpen blade(s).

Install new cutting blade(s).

Blades do not rotate.

Blades do not stop when disengaged.

Mower is not level.

Underside of mower is dirty

5. T

ire pressure is incorrect.

Blade spindle bent.

Drive belt is worn, loose or broken.

Drive belt is of

Deck belt is worn, loose or broken.

Deck belt is of

Blade brake is not adjusted properly.

f pulley

. 4.

. 2.

. 4.

Level mower from side-to-side and front-to-rear.

Clean the underside of the mower.

Adjust tire pressure. Contact Authorized Service

Dealer. Check belt tension.

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

Install new deck belt.

Install deck pulley and check the idler pulley spring for correct position and function.

Adjust blade brake.

, idler arm and

Belt guide is not set properly

. 2.

Adjust belt guide.

LCE

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

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Customers who have purchased TORO products exported from the United States or Canada should contact their TORO DisĆ tributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining guarantee information, contact the TORO importer. If all other remedies fail, you may contact us at The Toro Company.

Rev

9/30/98

ur-

Toro 30197 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual