Toro 30320 Operator's Manual

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Form No. 3327–378

Mid–Size Mower

ProLine T–Bar Gear 15 HP with 44 in. Side Discharge Mower

Model No. 30320—Serial No. 230000001 and Up

Operator ’s Manual

Domestic English (EN)

Warning

CALIFORNIA

Proposition 65 Warning

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.

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.

The enclosed Engine Owner ’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner ’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .

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

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 Handle Assembly 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. .

Page

Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . .

Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Parking Brake 19. . . . . . . . . . . . . . . . . . .

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 Gage Wheels 23. . . . . . . . . . . . . . . . .

Adjusting the Handle Height 23. . . . . . . . . . . . . . . .

Using the Mid–Size Weight Kit 24. . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 25. . . . . . . .

Servicing the Air Cleaner 26. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 27. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 28. . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 29. . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 30. . . . . . . . . . . . . . .

Checking the Tire Pressure 30. . . . . . . . . . . . . . . . .

Servicing the Fuse 30. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Brakes 30. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 31. . . . . . . . . . . . . . .

Servicing the Fuel Tank 32. . . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 32. . . . . . . . . . . . . . . . . . .

Servicing the Cutting Blades 33. . . . . . . . . . . . . . . .

Correcting the Mower Quality of Cut 34. . . . . . . . .

Frame Set Up 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Deck Front-to-Rear Pitch 36. . . . . . .

Changing the Deck Front-to-Rear Pitch 36. . . . . . .

Checking the Deck Side-to-Side Leveling 37. . . . .

Changing the Side-to-Side Leveling 37. . . . . . . . . .

Matching Height of Cut 37. . . . . . . . . . . . . . . . . . . .

Replacing the Traction Drive Belt 38. . . . . . . . . . . .

Replacing the Transmission Belt 38. . . . . . . . . . . . .

Replacing the Mower Belt 39. . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 39. . . . . . . . . . . . . . .

Replacing the Caster Wheel Fork Bushings 40. . . .

Caster Wheel and Bearings Service 41. . . . . . . . . . .

Replacing the Grass Deflector 41. . . . . . . . . . . . . . .

Wiring Diagram 42. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 43. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 48. . . . . . . . . . . . .

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Introduction

Safety

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.

Figure 1

1. Location o f the model and serial numbers

Write the product model and serial numbers in the space below:

m–5191

Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance 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 Operating Practices

The following instructions are from ANSI standard B71.4—1999.

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’s responsibility 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.

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.

• 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.

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 hearing 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.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not

mowing.

• 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.

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.

• Be sure of your footing while using this machine,

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 side to side on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and

when changing directions on slopes.

• 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 properly.

• 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, 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.

• Keep hands and feet away from the cutting unit.

• Look behind and down before backing up to be sure of

a clear path.

• Keep pets and bystanders away.

• 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

or from a trailer or truck.

• Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure vision.

Maintenance and storage

• Disengage drives, 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 unit, 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. Set parking brake.

Never allow untrained personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with

stored energy.

• Remove spark plug wire before making any repairs.

• 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.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged

decals.

Toro Mower Safety

The following list contains safety information specific to Toro products and other safety information you must know.

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

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.

• 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.

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.

• 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.

• Do not touch equipment or attachment parts which

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

• Use only Toro-approved attachments. Warranty may

be voided if used with unapproved attachments.

• Check carefully for overhead clearances (i.e. branches,

doorways, electrical wires) before driving under any objects and do not contact them.

• Mow slopes side to side.

DO NOT

• Do not mow slopes greater than 15 degrees.

• 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 use a grass catcher on steep slopes. Heavy

grass bags could cause loss of control of the machine.

• Do not mow up and down slopes.

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.

• Use only genuine replacement parts to ensure that

original standards are maintained.

Slope Operation

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

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

the mowing area.

• Watch for holes, ruts or bumps. Tall grass can hide

obstacles.

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

on the slope.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Check brake operation frequently. Adjust and service

as required.

Slope 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.

43-8480

68-8340

82-2280

52-2010

66-1340

82-2290

93-1122

95-2814

67-5360

98-0776

104-8569

98-4387

1. Warning—wear hearing protection.

104-8186

106-5532

106-0699

105-0884

106-0635

106-5494

106-5499

1. Engine—stop 2. Engine—start 3. Move the control bar to the handle, then pull the knob.

106-5505

Gasoline and Oil

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.

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage it is recommended that the fuel tank be drained.

• 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 27.

Set Up

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

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

Step Description Qty. Use

1 2

3 4 5

Handle assembly Flanged bolt 3/8 x 1 inch Flange nut 3/8 inch

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

No parts needed Adjusting the shift lever plate

Clevis pin Washer Hairpin cotter pin

Hairpin cotter pin 2

1 4 4

1 1 2 2 4 2 1

2 2 2

Installing the handle assembly

Installing shift lever plate and fuel tank

Installing the control rods

Installing the hairpin cotter pins and washers

6 7

Oil drain hose 1 Use for draining engine oil

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

Step

Parts needed for this step:

• 1 Handle assembly

• 4 Flange bolts, 3/8 x 1 inch

• 4 Flange nuts, 3/8 inch

Installing the Handle Assembly

1. Align 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.

Parts needed for this step:

• 1 Fuel tank with studs installed

• 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).

1 3

Figure 2

1. Upper handle

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

Note: Handle assembly must be installed before fuel tank is installed.

m–6403

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. High position

m–5221

Figure 3

1. Rear frame

2. Shift lever plate

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: To ease assembly of the fuel line to fuel tank connection, apply a light lubricant, such as WD 40, to the end of the fuel line.

Note: Make sure the fuel line and clamp are on as shown in Figure 4.

3. Fuel tank

Step

Figure 4

1. Fuel line

2. Clamp

5. Secure the right side of 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. 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).

6 5

4 3

6 3

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

Figure 5

3 2

6. Stud

7. Spring

8. Locknut

9. Shift lever plate

10. Fuel tank connection

m–6465

m–5250

Figure 6

1. Shift lever

2. Shift lever plate

3. Rubber seal washer

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.

Note: Tighten the left side of the shift lever plate until it is completely tight and then unscrew the locknut one full turn. This will allow the spring to work.

4. Square hole washer

5. Spring washer

6. Locknut, 3/8 inch

1. Shift lever, 2nd gear

2. Shift lever plate

Step

Figure 7

Rear View

3. Shift lever, neutral

4. Equal distance

m–5458

Figure 8

1. Control rod and fitting

2. 3–1/2inch (89 mm)

3. Idler bracket

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, washer and clevis pin securing control rod fitting to idler bracket. Thread 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.

4. Clevis pin, washer and hairpin cotter

5. Rod fitting

6. Hole F

m–5316

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. Control ro d

2. Fixed control bar

3. Parking brake lever

4. Upper control bar

m–6443

Figure 9

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 31.

Note: Make sure brake rod is installed in front (F) mounting hole in idler bracket.

Step

1. Upper control bar

2. Parking brake lever

Figure 10

3. Fixed bar

m–5233

Parts needed for this step:

• 2 Hairpin cotter pins

Installing the Hairpin Cotter Pins and Washers

Unused height–of–cut spacers may be stored on posts and retained by a hairpin cotter.

1. On the opposite side of the muffler, install unused

washers and hairpin cotter pins into front and rear height–of–cut pins (Fig. 11).

m-6505

Figure 11

1. Hairpin cotter

2. Unused spacers

3. Height–of–cut post

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Think Safety First

Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you or any bystanders avoid injury.

The use of protective equipment for eyes, hearing, feet and head is recommended.

Upper Control Bar – Shift to desired gear and push forward on control bar to engage forward traction operation and pull back to brake forward movement. Pull back on 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 assist operation.

Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle (Fig. 10).

Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: Run and Off.

Caution

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.

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.

Recoil Starter – Pull recoil starter handle to start engine. Fuel Shut–off Valve – Close fuel shut–off valve when

transporting or storing mower.

Throttle Control – The throttle control has three positions: Choke, Fast and Slow.

Deck Engagement Control Bail – Control bail is used in conjunction with deck engagement switch (PTO) to release clutch 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 clutch 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.

Important Do not shift while unit is moving, as

transmission damage may occur.

1. Throttle control

2. Blade control bail

3. Blade control switch (PTO)

4. Gear shift lever

5. Upper control bar

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Figure 13

6. Lower control bar

7. Parking brake lever

8. Ignition switch

9. Handle

10. Fuel shut–off valve

Using the Parking Brake

Stop on level ground, disengage drives, engage parking brake, shut off engine and remove key. Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

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.

1. Pull the upper control bar (Fig. 14) rearward and hold

it in this position.

2. Lift the parking brake lock (Fig. 14) up and gradually

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.

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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).

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Figure 15

1. Throttle lever 2. Ignition key

4. Set the parking brake and remove key.

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.

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.

• 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.

1. Upper control bar

2. Blade control bail

Figure 16

3. Blade control switch (PTO)

Disengaging the Mower Blades (PTO)

1. Release blade control bail to disengage blades

(Fig. 16).

The Safety Interlock System

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the mower blades from rotating unless:

• The control bail is depressed.

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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).

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).

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Figure 17

1. Upper control bar

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.

Note: Lifting up on handle will assist driving the machine up a curb and not spin the drive wheels.

2 1

2 3

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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.

Warning

A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders.

• Do not run blades while driving up a curb

forward or backward.

Driving Forward Up a Curb

1. Disengage the mower blades.

2. Select first gear to drive the machine.

3. Drive machine until the castor wheels contact curb

(Fig. 18).

4. Lift the front of the machine by pushing down on the

handle (Fig. 18).

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 19. Remember to remove the key from the ignition switch.

Caution

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Transporting Machines

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary 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:

• Stop engine, remove key, lock brake, shut –off fuel

valve 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.

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. 19).

2. Using lift handle,raise side of deck and remove hairpin

cotter (Fig. 19).

3. Add or remove spacers if needed and then align holes

and insert hairpin cotter (Fig. 19).

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.

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).

1. Carrier Frame

2. Hairpin Cotter

3. Front height–of–cut post

Figure 19

4. Spacers

5. Back height–of–cut post

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Adjusting the Gage Wheels

Adjusting the Handle Height

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) minimum 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 (Figures 20 and 21).

2. If adjustment is needed, remove the bolt, washer(s)

and nut (Figures 20 and 21).

3. Select a hole position so the gage wheels are a

minimum of 3/8 inch (10 mm) off the ground (Figures 20 and 21).

4. Install the bolt, washer(s) and nut (Figures 20 and 21).

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. 22).

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Figure 22

1. Control rod and fitting

2. 3–1/2inch (89 mm)

3. Idler bracket

4. Clevis pin, washer and hairpin cotter

5. Rod fitting

6. Hole F

2. Loosen the upper flange bolts (3/8 x 1 inch) and flange

nut securing handle to rear frame (Fig. 23).

1. Gage wheel

2. Nut

3. Bolt

1. Center Gage Wheels and Spacer

2. Nut

Figure 20

4. Washer

5. Spacer

Figure 21

3. Bolt

4. Washer

m–6470

m–6403

Figure 23

1. Upper handle

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

m–6510

3. Loosen the upper flange bolts (3/8 x 1 inch) and flange

nut securing handle to rear frame (Fig. 23).

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. High position

4. Remove the lower flange bolts (3/8 x 1 inch) and

flange nuts securing handle to rear frame (Fig. 23).

5. 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.

6. 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 Rods, page 16.

7. Check the parking brake adjustment (Fig. 10). Refer to

Checking the Brakes, page 31.

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

• The weight kit mounted in the front position is

required when a Tru–Trak Sulky is installed.

• The weight kit mounted in the back position is

optional when a Tru–Trak Sulky is not installed

(Fig. 24).

• Installing this weight kit can improve performance on

slopes without the Tru–Trak Sulky.

1. Weight mounted in rear position

2. Capscrew

Figure 24

3. Washer

4. Nut

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

After first 8 Hours • Engine Oil—change

8 Hours

25 Hours • Foam Air Cleaner—clean

40 Hours

50 Hours

100 Hours

Maintenance Procedure

• Oil—check level

• Safety System—check

• Brake—check

• Engine—clean outside

• Mower Housing—clean

• Caster Wheels—grease

• Caster Pivot—grease

• Cutting Blades—check

• Tires—check pressure

• PTO Belt Idler Arm—grease

• Belts—check

• Paper Air Cleaner—clean

• Oil—change

• Spark Plug(s)—check

• Electric Clutch—adjust

• Engine—clean outside

• Fuel Filter—replace

200 Hours

250 Hours • Transmission Couplings—grease 400 Hours • Wheel Bearings—grease

At storage

More often in dusty, dirty conditions.

Important Refer to your engine operator’s manual for additional maintenance procedures.

• Oil Filter—change (200 hours or every other oil change)

• Paper Air Cleaner—replace

• Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

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.

Servicing the Air Cleaner

Service Interval and Specification

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

Paper Element: Clean after every 50 operating hours.

Replace after every 200 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), chock or block tires, and turn the ignition key to off. Remove the key.

Important Replace the foam element if it is torn or

worn.

m–4694

Figure 26

1. Foam element 2. Oil

Cleaning the Paper Element

2. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Pull out on retaining latches and remove the air cleaner cover (Fig. 25).

3. Unscrew nut and remove the air cleaner assembly (Fig. 25).

4. Carefully pull the foam element off the paper element (Fig. 25).

m–4689

Figure 25

1. Retaining latch

2. Cover

3. Nut

4. Foam element

5. Paper element

1. Lightly tap the element on a flat surface to remove

dust and dirt (Fig. 27).

2. 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.

m–4695

Figure 27

1. Paper element 2. Rubber seal

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 of oil on the element (Fig. 26).

Squeeze the element to distribute the oil.

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 place the foam element onto the paper air

cleaner element (Fig. 25).

2. Place the air cleaner assembly onto the air cleaner base

(Fig. 25). Secure with nut.

3. Install the air cleaner cover and secure latches

(Fig. 25).

Servicing the Engine Oil

Service Interval and 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 SE, SF or SG) Crankcase Capacity: with new filter, 57–1/2 oz. (1.7 l)

without new filter, 51 oz. (1.5 l)

Viscosity: See table below

Checking Oil Level

1. Park the machine on a level surface, disengage the

power take off (PTO), chock or block tires, and turn the ignition key to off. Remove the key.

2. Clean around the oil dipstick (Fig. 28) so dirt cannot

fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean

(Fig. 28).

Figure 28

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. 29).

7. When oil has drained completely, close the drain

valve.

8. Remove the drain hose (Fig. 29). Note: Dispose of the used oil at a recycling center.

4. Thread the oil dipstick fully onto the filler tube

(Fig. 28). 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.

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. 30).

5. Fill the crankcase with the proper type of new oil;

refer to Engine Oil Service, page 27.

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Figure 29

1. Oil drain valve 2. Drain hose

9. Slowly pour approximately 80% of the specified oil, page 27, into the filler tube (Fig. 28).

10.Check the oil level; refer to Checking Oil Level, page 27.

11. If needed, slowly add additional oil to bring to the full mark on dipstick.

Changing the Oil Filter Service Interval and 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.

Servicing the Spark Plug

Service Interval and 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: Champion RCJ8Y or NGK BPR4ES Air Gap: 0.030 in. (.75 mm)

Removing the Spark Plug(s)

1. Disengage the power take off (PTO), chock or block

tires, and turn the ignition key to off. Remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 31). Now

clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

3. Remove the spark plug(s).

1. Drain the oil from the engine; refer to

Changing/Draining Oil, page NO TAG.

2. Remove the old filter (Fig. 30).

3. Apply a thin coat of new oil to the rubber gasket on

the replacement filter (Fig. 30).

M-4288

Figure 30

1. Oil filter 2. Adapter

M-429

Figure 31

1. Spark plug wire installed 2. Spark plug

Checking the Spark Plug

1. Remove spark plug.

2. Look at the center of the spark plug(s) (Fig. 32). 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.

3. Check the gap between the center and side electrodes

(Fig. 32). Bend the side electrode (Fig. 32) if the gap is not correct.

0.030 in .

(.75 mm)

Figure 32

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

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. 33).

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. 33).

5. Install the grease cap.

6. Install the rear wheel and tire assembly. Note: Make sure the rear wheel grease caps are removed

before lubricating rear wheels.

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 11 ft-lb (15 Nm).

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

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).

m–636

Figure 33

Lubricating the Transmission Couplers

1. Lubricate the transmission couplers located in the back

of the machine (Fig. 34).

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.

m–5191

Figure 34

Greasing the PTO Drive Belt Idler and Deck Belt Idler

1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Grease the idler pulley pivots (Fig. 35).

Note: You will have to remove the carrier covers to access

the grease fitting for the deck.

m–6529

Figure 35

m–6367

Figure 36

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 fuse pull out on the fuse (Fig. 37) and push in new fuse.

Fuse: F1–7.5 amp, blade-type

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. 36). 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: 25–30 psi (172–207 kPa)

m–5206

Figure 37

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.

Checking the Brakes

1. Park the machine on a level surface, disengage the

PTO.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Apply the parking brake. The wheels must lock when

you try to push the machine forward.

4. If the wheels do not lock, adjust the brakes. Refer to

Adjusting the Brakes on page 31.

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 31.

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.

Note: For the initial adjustment, adjust the wing nut until it is 1–1/4 inches from the top of the rod (Fig. 38).

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 31.

4. Release the parking brake; refer to Releasing the

Parking Brake, page 19.

5. To adjust the brake remove the hair pin cotter and

washer from the brake lever and trunnion (Fig. 38).

6. Rotate the wing nut clockwise to increase the braking

pressure.

7. Rotate the wing nut counterclockwise to decrease the

braking pressure.

4 2

m–65121

Figure 38

1. Hairpin cotter and washer

2. Trunnion

3. Brake lever

4. Wing nut

5. Hole F

6. Initial adjustment— 1–1/4 inch (32 mm)

7. Rod

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. 39).

2. Check adjustment by inserting feeler gauge thru slots

next to studs (Fig. 39).

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.

8. Install the trunnion into hole F (Fig. 38). Tighten the

wing nut.

9. Secure trunnion to brake lever with washer and hair

pin cotter (Fig. 38).

10.Check the brake operation again; refer to Checking the

Brake, page 31.

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.

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 32.

5. Install the fuel line onto the valve. Slide the hose

clamp close to the valve to secure the fuel line.

1. Adjusting n u t

2. Slot

Figure 39

3. Feeler gauge

m–2600

Servicing the Fuel Tank

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. 40).

3. Squeeze the ends of the hose clamp together and slide

it up the fuel line away from valve (Fig. 40).

Note: Remove fuel line from fuel valve that is closest to the engine.

m–5185

Figure 40

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. 40).

4. Squeeze the ends of the hose clamps together and slide

them away from the filter (Fig. 41).

5. Remove the filter from the fuel lines.

4. Pull the fuel line off the valve (Fig. 40). Open fuel

shut-off valve and allow gasoline to drain into a gas can or drain pan.

6. Install a new filter and move the hose clamps close to

the filter.

7. Open fuel shut-off valve at fuel tank (Fig. 40).

8. Check for fuel leaks and repair if needed (Fig. 40).

m–5234

Figure 41

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.

Warning

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.

Figure 42

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. 43). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 44). Note this dimension.

Front

m–151

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

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 42). 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. 42).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 42), immediately install a new blade.

m–1078

Figure 43

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 44

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

1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 34.

Warning

A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

m–1854

Figure 46

1. Sharpen a t original angle

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

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, washer, lock washer and blade from the spindle shaft (Fig. 45).

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

balancer (Fig. 47). 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. 45). Repeat this procedure until the blade is balanced.

m–1855

Figure 47

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 45).

Important The sail part of the blade must be pointing

upward, toward the inside of the mower to ensure proper cutting (Fig. 45).

2. Install the lock washer and blade bolt (Fig. 45).

Torque the blade bolt to 85–110 ft-lb (115–140 Nm).

m–5199

Figure 45

1. Sail Area of Blade

2. Blade

3. Blade spindle

4. Washer

5. Blade bolt

6. Lock washer

Sharpening the Blades

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

the blade (Fig. 46). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

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 30.

4. Check that the blades and spindle shafts are not bent.

Refer to Checking for Bent Blades on page 33.

5. Set the height-of-cut to the 4 inch (101.6 mm)

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 48.

4. At the carrier frame cross tube, measure location A

height (Fig. 48). 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.

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 30.

4. Measure engine deck height at location A (Fig. 49).

5. Measure engine deck height at location B (Fig. 49).

6. If the height at location A and B are not the same,

change tire pressure slightly to make them the same.

6. Loosen the carrier frame mounting bolts on both sides

of the machine (Fig. 48).

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. 48).

8. Tighten the carrier frame mounting bolts on both sides

of the machine.

m–6369

Figure 48

1. Carrier Frame

2. T op 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

444

m–5237

Figure 49

1. Back view of machine

2. T op of engine deck

3. Tires

Checking Carrier Frame Front–to–Rear

4. Same height at locations A and B

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. 50).

1. Measure out 24 inches (61cm) on the carrier frame

(Fig. 50).

2. Measure carrier frame height at location A (Fig. 50).

3. Measure carrier frame height at location B (Fig. 50).

4. The height at location A must be a 1/4–3/8 inch (6 mm –10 mm) lower than location B (Fig. 50).

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. 50). 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 in.

(61cm)

Checking the Deck Front-to-Rear Pitch

1. Check the tire pressure on both deck and traction unit.

m–6370

Figure 50

1. Caster Wheel

2. Carrier Frame

3. 1/4–3/8 inch (6 mm–10 mm) pitch over 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 30.

2. Position one blade front-to-rear (Fig. 52). Measure at C and D locations (Fig. 52) from a level surface to the

cutting edge of the blade tips (Fig. 53).

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.

Front

m–1078

Figure 52

4. Measure carrier frame height at location A (Fig. 51).

5. Measure carrier frame height at location B (Fig. 51).

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.

4 4

m–6371

Figure 51

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Same height at locations A and B

5. Caster spacers

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 53

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. 54).

2. To raise the front of the deck, loosen jam nut and

rotate the front pin clockwise (Fig. 54).

3. To lower the front of the deck, loosen jam nut and

rotate the front pin counter clockwise (Fig. 54).

3 4

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

Figure 56

m–2550

Figure 54

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Position the blades front-to-rear (Fig. 52). Measure at C and D locations (Fig. 52) from a level surface to the

cutting edge of the blades (Fig. 53).

5. Check the side-to-side leveling of the cutting unit.

4. Jam nut

5. Ball joint

m–6371

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. 55). Measure at A

and B locations (Fig. 55) from a level surface to the cutting edge of blade tips (Fig. 56).

3. The difference between measurements A and B should be no more than 1/4 inch (6 mm).

Front

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. 57). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 58).

4. The measurement should be 4 inch (101.6 mm).

Figure 55

m–1078

Front

6. Tighten the bottom two mounting screws enough to

allow the belt to pass between the drive pulley and

idler support (Fig. 59).

m–1078

Figure 57

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

m–2550

Figure 58

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.

Figure 59

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.

m–1722

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 the top capscrew securing idler support and

idler bracket to rear frame (Fig. 59).

2. Loosen bottom two mounting screws enough to allow

belt to pass between drive pulley and idler support (Fig. 59).

3. Raise the wheel off the ground, to allow the belt to be

removed, and remove the belt.

4. Install a new belt.

5. Install the top capscrew securing the idler support and

idler bracket to the rear frame (Fig. 59).

3. Remove PTO drive belt. Refer to Replacing the PTO

Drive Belt on page 39.

4. Raise the front of the machine and hold with jack

stands.

5. Disconnect clutch wire connector from wire harness.

6. Disconnect clutch retainer from the engine deck

(Fig. 60).

7. Unhook tension spring from side of frame (Fig. 60).

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. 60).

11. Install clutch retainer to the engine deck (Fig. 60).

12.Connect clutch wire connector to wire harness.

13.Install PTO drive belt.

2 8

m–5321

Figure 60

1. Transmission belt

2. Idler pulley

3. Clutch retainer

4. T ension spring

5. Clutch wire connector

6. Pivot bolt

7. Drive pulley

8. Engine deck

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. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Remove the knobs and rubber washers holding the

carrier frame cover and remove the carrier frame cover.

3. Remove the knobs and rubber washers holding the belt

covers to the cutting unit and remove the belt covers.

4. Remove the PTO drive belt. Refer to Replacing the

PTO Drive Belt on page 39.

5. Disconnect the idler arm spring to relieve tension on

the idler arm and idler pulley, then remove the worn deck belt (Fig. 61).

6. Install the new deck belt around the two outside

spindle pulleys, the idler pulley, and in the lower groove of the center spindle pulley (Fig. 61).

7. Connect the idler arm spring (Fig. 61).

8. Reinstall the PTO drive belt. Refer to Replacing the

PTO Drive Belt page 39.

9. Adjust deck belt guide an 1/8 inch (3 mm) from belt

(Fig. 61).

10.Reinstall the deck covers and rubber washers onto the

cutting unit, then reinstall and tighten the knobs.

11. Install the carrier frame cover and rubber washers onto

the cutting unit, then install and tighten the hand knobs.

m–6529

Figure 61

1. Deck belt

2. Idler arm spring

3. Outside pulley

4. PTO drive Belt

5. Center Spindle Pulley

6. Deck belt guide

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. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove the knobs and rubber washers holding the carrier frame cover and remove the carrier frame cover.

3. Remove the knobs and rubber washers holding the belt covers to the top of the cutting unit and remove the belt covers.

4. Remove the idler spring from idler arm. Remove the drive belt from the PTO engagement pulley and the center spindle pulley (Fig. 62).

5. Remove the worn drive belt (Fig. 62).

6. Install the new drive belt onto the PTO engagement

pulley and the top groove of the center spindle pulley (Fig. 62).

7. Install belt onto idler pulley and then install idler spring (Fig. 62).

8. Adjust PTO drive belt guides an 1/8 inch (3 mm) from belt (Fig. 62).

9. Install the belt covers and rubber washers onto the cutting unit, then install and tighten the knobs.

10.Install the carrier frame cover and rubber washers onto the cutting unit, then install and tighten the hand knobs.

m–6529

Figure 62

1. PTO engagement pulley

2. PTO drive belt idler

3. PTO drive Belt

4. Center Spindle Pulley

5. PTO Drive belt guide

6. Idler Spring

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. 63).

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.

m–6372

Figure 63

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. 64). 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. 63).

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 63).

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.

Figure 64

1. Mounting Tube 2. Bushing

m–6373

Caster Wheel and Bearings 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. 65).

2. Remove one bushing, then pull the spanner bushing

and roller bearing out of the wheel hub (Fig. 65).

Replacing the Grass Deflector

Warning

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.

3. Remove the other bushing from the wheel hub and

clean any grease and dirt from the wheel hub (Fig. 65).

4. Inspect the roller bearing, bushings, spanner bushing

and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 65).

m–5210

Figure 65

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. 65).

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. 65).

1. Remove the locknut, bolt, spring and spacer holding

the deflector to the pivot brackets (Fig. 66). 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 66.

3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 66).

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.

m–5037

Figure 66

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

7. Grease the fitting on the caster wheel.

Wiring Diagram

S1 IGNITION

KEY SWITCH

M G

KEY SW.

G+MOFF NONE

WIRE COLOR CODES

BLACK BROWN

BLUE

GREEN

GN VIO

GREY

ORANGE

PK R

W YOR

PINK RED

TAN VIOLET WHITE

YELLOW

J2–1

GND

HOUR METER (OPTIONAL)

PTO

CLUTCH

DELAY MODULE

354

7.5A

S2 CLUTCH SW. (MOMENTARY)

D3 D1 D4

S3 BAIL SW. (NORMALLY OPEN)

SPARK PLUG

IGNITION MODULE

{Value}

R4R3

HOUR METER (OPTIONAL)

REG

MAG

Cleaning and Storage

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 30.

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

page 26.

5. Grease the machine; refer to Greasing and Lubrication, page 29.

6. Change the crankcase oil; refer to Engine Oil Service, page 27.

7. Check the tire pressure; refer to Tire Pressure, page 30.

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 32, 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 28. 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

g,, g

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

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

Engine loses power.

1. Fuel tank is empty. 1. Fill fuel tank with gasoline.

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.

5. Spark plug is pitted, fouled, or

gap is incorrect.

6. Dirt in fuel filter. 6. Replace fuel filter.

7. Dirt, water, or stale fuel is in

fuel system.

8. Shift lever plate out of

adjustment.

1. Engine load is excessive. 1. Reduce ground speed.

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. Install wire on spark plug.

5. Install new, correctly gapped spark plug.

7. Contact Authorized Service Dealer.

8. Adjust shift lever plate to match shift lever neutral position.

4. Remove obstruction from cooling fins and air passages.

Engine overheats.

Machine does not drive.

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

6. Vent hole in fuel cap is plugged.

7. Dirt in fuel filter. 7. Replace fuel filter.

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

1. Engine load is excessive. 1. Reduce ground speed.

2. Oil level in crankcase is low. 2. Add oil to crankcase.

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

1. Shift lever is in NEUTRAL. 1. Move shift lever to a drive

2. Traction belt is worn, loose or broken.

3. Traction belt is off pulley.

4. Broken or missing idler spring.

5. Install new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

gear position.

2. Change Belt.

3. Change Belt.

4. Replace spring

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Abnormal vibration.

Uneven cutting height.

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

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Engine mounting bolts are loose.

4. Loose engine pulley, idler pulley, or blade pulley.

5. Engine pulley is damaged. 5. Contact Authorized Service

6. Blade spindle bent. 6. Contact Authorized Service

1. Blade(s) not sharp. 1. Sharpen blade(s).

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

4. Underside of mower is dirty. 4. Clean the underside of the

5. Tire pressure is incorrect. 5. Adjust tire pressure.

6. Blade spindle bent. 6. Contact Authorized Service

1. Install new cutting blade(s).

3. Tighten engine mounting bolts.

4. Tighten the appropriate pulley.

Dealer.

and front-to-rear.

mower.

Dealer.

Blades do not rotate.

1. PTO Drive belt is worn, loose or broken.

2. PTO Drive belt is off pulley. 2. Install drive belt and check

3. Deck belt is worn, loose or broken.

4. Deck belt is off pulley. 4. Install deck pulley and check

5. Broken or missing idler

spring.

1. Install new drive belt.

adjusting shafts and belt guides for correct position.

3. Install new deck belt.

the idler pulley, idler arm and spring for correct position and function.

5. Replace idler spring

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

Outfront and Mid-Mount Z’s ProLine Mid-Size Mowers Groundsmaster Backpack Blowers

• Deck Shells (36″–72″) on the following:

ProLine Mid-Size Mowers Mid-Mount Z’s

• Electric Clutch on 200 Series Mid-Mount Z’s

This warranty includes the cost of parts and labor, but you must pay transportation costs.

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

* Some engines used on Toro LCE Products are warranted by the

engine manufacturer.



Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. U.S. Customers may also call 800-348-2424.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-577-7466 (U.S. customers) 877-484-9255 (Canada customers)

Y ou must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover the following:

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

• Pickup and delivery charges.

All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts.

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states d o n o t a l l o w exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

All implied warranties of merchantability (that the product is fit for ordinary use) and fitness for use (that the product is fit for a particular purpose) are limited to the duration of the express warranty.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (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. I f all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0037 Rev. C

Toro 30320 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual