Toro 30338 Operator's Manual

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Form No. 3325–888

Mid–Size Mower

ProLine Hydro 15 HP with 44 in. Side Discharge Mower

Model No. 30338—210000001 and Up

Operator ’s Manual

English (EN)

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 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .

Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .

Set Up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Fuel Tank and Fuel Line 14. . . . . . . . . . .

Install Upper Handle 15. . . . . . . . . . . . . . . . . . . . . .

Install Control Rods 15. . . . . . . . . . . . . . . . . . . . . . .

Install Speed Control Rod 16. . . . . . . . . . . . . . . . . .

Hydro Linkage Set Up 16. . . . . . . . . . . . . . . . . . . . .

Checking the Hydraulic Fluid 17. . . . . . . . . . . . . . .

Install Hairpin Cotter Pins 17. . . . . . . . . . . . . . . . . .

Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 2001 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Page

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

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

Starting and Stopping the Engine 19. . . . . . . . . . . .

Operating Neutral Locks 19. . . . . . . . . . . . . . . . . . .

Operating Mower Blade Control (PTO) 20. . . . . . .

The Safety Interlock System 20. . . . . . . . . . . . . . . .

Driving Forward or Backward 21. . . . . . . . . . . . . . .

Bringing Machine to Neutral Position 21. . . . . . . . .

Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 21. . . . . . . . . . . . . . .

Transporting Machines 22. . . . . . . . . . . . . . . . . . . .

Side Discharge or Mulch Grass 22. . . . . . . . . . . . . .

Adjusting Height-of-Cut 22. . . . . . . . . . . . . . . . . . .

Adjusting Center Gage Wheels 23. . . . . . . . . . . . . .

Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 24. . . . . . . .

Air Cleaner Service 25. . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Service 26. . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Service 27. . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 28. . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 29. . . . . . . . . . . . . . .

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

Fuel Tank Service 30. . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter Service 30. . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Service 31. . . . . . . . . . . . . . . . . .

Adjusting By-pass Valve 32. . . . . . . . . . . . . . . . . . .

Hydro Linkage Adjustments 33. . . . . . . . . . . . . . . .

Adjust Speed Control Linkage 33. . . . . . . . . . . . . . .

Adjust Neutral Control Linkages 34. . . . . . . . . . . . .

Adjust Hydro Control Linkages 35. . . . . . . . . . . . . .

Control Rod Adjustment 36. . . . . . . . . . . . . . . . . . .

Tracking Adjustment 37. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 37. . . . . . . . . . . . . . .

Fuse Service 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Blade Service 38. . . . . . . . . . . . . . . . . . . . .

Correcting Cutting Unit Mismatch 40. . . . . . . . . . .

Frame Set Up 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Deck Front-to-Rear Pitch 41. . . . . . .

Changing the Deck Front-to-Rear Pitch 42. . . . . . .

Checking the Deck Side-to-Side Leveling 42. . . . .

Changing the Side-to-Side Leveling 42. . . . . . . . . .

Matching Height of Cut 42. . . . . . . . . . . . . . . . . . . .

Replacing the Traction Belt 43. . . . . . . . . . . . . . . . .

Replacing the Deck Belt 43. . . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 44. . . . . . . . . . . . . . .

Replacing the Caster Wheel Fork Bushings 44. . . .

Caster Wheel and Bearings Service 45. . . . . . . . . . .

Replacing the Grass Deflector 46. . . . . . . . . . . . . . .

Wiring Diagram 47. . . . . . . . . . . . . . . . . . . . . . . . . .

Printed in the USA

Hydraulic Diagram 48. . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 49. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .

Introduction

Page

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.

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.

m–5404

Figure 1

1. Location o f the model and serial numbers

Safety

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.

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

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

• 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 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.

• 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.

• 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 wheels are

chocked and blocked 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, chock or block

wheels, 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.

• 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, chock or block wheels, 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. Chock or block wheels

when it is parked. 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

• Keep hands and feet away from the cutting unit.

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

a clear path.

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.

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

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

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.

General Operation

• 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.

• 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.

• 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.

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.

• 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.

• Never tamper with safety devices. Check safety

systems for proper operation before each use.

• Use only Toro genuine replacement parts to ensure that

original standards are maintained.

• Hydraulic fluid escaping under pressure can penetrate

the skin and cause injury. Use cardboard or paper to find hydraulic leaks. Never use your hands.

• 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.

• 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.

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.

82–4590

67–5360

95–2814

63–8440

66–1340

43–8480

68–8340

54–9220

105–4146

1–523552

98–0776

104–8569

98–4387

95–1543

105–4144

104–8172

105–4109

105–0840

105–4110

104–8186

104–8171

105–4106

105–4108

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.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 in. to 1/2 in. (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.

• 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 below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.

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

that may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 26.

Set Up

Loose Parts

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

DESCRIPTION QTY. USE

Fuel tank Bolt 5/16 x 7/8 in. (22 mm) Lock washer 5/16 in. Washer 5/16 in. Stud Spring Hose clamp

Upper handle Flanged bolt 3/8 x 1 in. (26 mm) Flange nut 3/8 in.

Rod fitting E–ring Clevis pin Hairpin cotter

Hairpin cotter 2 Install hairpin cotter pins Operator’s Manual

Engine Operator’s Manual

1 2 2 4 2 2 1

1 4 4

2 2 2 2

1 1

Install fuel tank and fuel line

Install upper handle to frame

Install control rods

Read before operating machine

Parts Catalog Registration card

Installing Fuel Tank and Fuel Line

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

tank right side with 2 bolts (5/16 x 7/8 in. (22 mm)), 2 lock washers (5/16 in.) and 2 washers (5/16) (Fig. 2).

2. Secure fuel tank left side to frame with 2 studs (5/16

x 7/8 in. (22 mm)), 2 washers (5/16 in.), 2 springs and 2 locknuts (5/16 in.) (Fig. 2).

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

1 1

Fill out and return to Toro

5 6

m–5339

Figure 2

1. Bolt, 5/8 x 7/8 in. (22 mm)

2. Lock washer, 5/16 in.

3. Washer, 5/16 in.

4. Stud

5. Spring

6. Locknut

7. Hose clamp

8. Fuel tank connection

3. Slide the hose clamp onto the fuel line (Fig. 2).

4. Push the fuel line onto the fuel tank connection and

secure it with a hose clamp (Fig. 2).

Install Upper Handle

Important Install the flange bolts

(3/8 x 1 in. (26 mm)) with the bolt head on the inside of machine frame. Refer to figure 3.

1. Align upper handle with upper mounting holes in rear

frame (Fig. 3).

2. Secure each upper mounting hole with a flange bolt

(3/8 x 1 in. (26 mm)) and flange nut (Fig. 3).

3. Select medium or low position for the lower mounting

hole (Fig. 3). This allows the upper handle to be

adjusted to the user’s height preference.

m–5401

Figure 3

1. Upper handle

2. Rear frame

3. Flange bolt, 3/8 x 1 in. (26 mm)

4. Flange nut, 3/8 in.

5. Upper mounting hole

6. Lower mounting hole

7. Low position

8. Medium position

9. High position—Do not use

Install Control Rods

1. Install control rod to drive lever and neutral lock using a clevis pin (Fig. 4).

2. Install hairpin cotter between drive lever and neutral lock and into clevis pin (Fig. 4).

Note: Make sure the clevis pin is inserted into the neutral lock.

3. Repeat this procedure for the opposite side.

Note: Do not put in high position. Machine can not be

used in the high position.

4. Secure each lower mounting hole with a flange bolt

(3/8 x 1 in. (26 mm)) and flange nut (Fig. 3).

2. Thread yoke onto speed control rod approximately

3/4 in. (19 mm) (Fig. 5).

3. Install yoke to the speed control crank with a clevis

pin, washer and hairpin cotter (Fig. 5).

4 5

m–5400

Figure 4

1. Left handle shown

2. Neutral lock

3. Clevis pin

4. Drive lever

5. Control rod

6. Operator Presence Control lever (OPC)

7. Hairpin cotter

4. Thread rod fittings equal distance onto each control

rod. For a starting point, thread rod fittings onto control rod approximately 2–1/2 in. (63.5 mm) from the bottom (Fig. 5).

5. Install rod fittings to idler brackets with clevis pins and

e–ring (Fig. 5).

4. Secure yoke with jam nut (Fig. 5).

4 2

6 5

Figure 6

1. Speed control rod

2. Yoke

3. Jam nut

4. Speed control crank

5. Hair pin cotter

6. Washer

7. Clevis pin

1 3 7

m–5402

Figure 5

1. Control ro d

2. Idler bracket

3. Rod fitting

4. E–ring

5. 2–1/2 in. (63.5 mm) from bottom

Install Speed Control Rod

1. Place the speed control lever full forward (Fig. 5).

m–5400

Hydro Linkage Set Up

Perform the following adjustments when the machine is first set up and when any adjustment is needed. Do them in the order that they are listed here.

Adjust Speed Control Linkage

Refer to Adjusting Speed Control Linkages on page 33.

Adjust Neutral Control Linkages

Refer to Adjusting Neutral Control Linkages on page 34.

Adjust Hydro Control Linkages

Refer to Adjusting Hydro Control Linkages on page 35.

Adjust Control Rods

Refer to Adjusting Control Rods on page 36.

Adjust Tracking

Refer to Adjusting Tracking on page 37.

Checking the Hydraulic Fluid

Check the hydraulic fluid level before engine is first started.

Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important Use oil specified or equivalent. Other

fluids could cause system damage. Hydraulic System Oil Capacity: 67 oz. (2.0 l)

1. Position machine on a level surface and chock or block

tires.

2. Clean area around filler neck of hydraulic tank

(Fig. 7).

3. Remove cap from filler neck. Look inside to check if

there is fluid in the reservoir (Fig. 7).

4. If there is no fluid, add fluid to reservoir

approximately a 1/4 in. (6 mm) below the top of baffle.

5. Run the machine 15 minutes to allow any air to purge

out of the system and warm fluid.

6. Recheck level while fluid is warm. Add fluid to raise

level to top of the baffle, if required.

Warning

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it

must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Relieve all pressure in the hydraulic system

before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Install Hairpin Cotter Pins

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

1. On opposite side of muffler, install extra hairpin cotter

pins into front and rear height–of–cut pins (Fig. 8).

Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 7).

7. Install cap on filler neck.

M-4280

Figure 7

1. Cap

2. Baffle

3. Fluid level—full

m–5314

Figure 8

1. Hairpin cotter

2. Extra 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, your family, pets or bystanders avoid injury.

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

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 9

1. Caution 2. Wear hearing protection

Neutral lock – Squeeze drive levers back and move locks to the rear for neutral lock. Squeeze drive levers back and move locks to the front for parking brake lock.

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

Recoil Starter – Pull recoil starter handle to start engine. Fuel Shut–off Valve – (Under fuel tank) Close fuel

shut–off valve when transporting or storing mower. Hour Meter – Shows total hours that machine has been

operated. This operates only when the mower blades are operating.

The hour meter will flash 3 hours before and after a service interval.

The service intervals are set for the first 8 hours, every 100 hours there after and every 400 hours.

Perform any recommended maintenance at these intervals. Refer to Recommended Maintenance Schedule on page

24. Note: Make sure maintenance is done at all recommended

intervals shown in the Recommended Maintenance Schedule on page 24.

Controls

Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine.

Throttle control – The throttle control has three positions: CHOKE, FAST and SLOW.

Operator Presence Control (OPC) levers – OPC levers are used in conjunction with deck engagement switch (PTO) to release blade brake and engage clutch to drive mower blades. Release OPC levers to disengage mower blades.

Blade control switch (PTO) – Pull switch used in conjunction with OPC levers to release blade brake and engage clutch to drive mower blades.

Speed control lever – This machine has a variable speed control with a neutral position. This controls how fast the machine will travel.

Drive levers – Shift to desired gear and release drive levers to engage forward traction operation and squeeze to reverse. Squeeze right side of drive lever to turn right and left side to turn left.

1. Throttle control

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

4. Drive lever

Figure 10

5. Neutral lock

6. Ignition switch

7. Handle

8. Speed control lever

9. Hour meter

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 to “SLOW” (Fig. 11).

2. Move drive levers to neutral and set neutral locks.

3. Let engine idle for 30 to 60 seconds before turning the

ignition key “OFF.”

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4. Turn the ignition key to “OFF” (Fig. 11).

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Figure 11

1. Throttle lever 2. Ignition key

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 speed control lever to neutral, set the neutral locks and turn ignition key to RUN.

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 and allow rope to recoil slowly.

Important Make sure fuel shut off valve is closed

before transporting or storing machine, as fuel leakage may occur.

Before storing machine, pull wire off spark plug(s) to prevent possibility of accidental starting.

Operating Neutral Locks

Always set the neutral lock when you stop the machine. Chock or block wheels if it is left unattended.

Setting the Neutral Lock

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them back (Fig. 12).

Releasing the Neutral Lock

1. Squeeze the drive levers back.

2. Place thumbs on the upper part of of locks and move

them forward until in forward slot (Fig. 12).

Disengaging the Mower Blades (PTO)

The mower blades can be disengaged by one of the following steps.

1. Handle

2. Neutral lock

3. Neutral position

4 Figure 12

4. Drive lever

5. Full speed forward

6. Reverse position

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Operating Mower Blade Control (PTO)

The blade control switch (PTO) in conjunction with the Operator Presence Control (OPC) levers engage and disengage power to the electric clutch and mower blades.

1. Push the blade control switch (PTO) to off (Fig. 13).

2. Release Operator Presence Control (OPC) levers to

disengage blades (Fig. 13). This will also kill the engine.

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 from starting unless:

Engaging the Mower Blades (PTO)

1. To engage blade, squeeze the Operator Presence

Control (OPC) levers against handle grips (Fig. 13).

2. Pull blade switch (PTO) up. Hold the OPC levers

against handle grip.

Figure 13

1. Handle

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

4. Drive Lever

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• The blade control switch (PTO) is pushed off.

• The speed control lever is in neutral.

The safety interlock system is designed to kill the engine when:

• The Operator Presence Control (OPC) levers are

released.

• The speed control lever is shifted out of neutral

without holding OPC levers.

• The blade control switch (PTO) is pulled on without

holding the OPC levers.

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, have an Authorized Service Dealer repair the safety system immediately.

1. Set the neutral locks and place speed control lever in

neutral. Start the engine; refer to Starting and Stopping the Engine, page 19.

2. Without holding the Operator Presence Control (OPC) levers, pull the blade control switch (PTO) up. The

engine should kill.

3. Push the blade control switch off.

4. With engine running, hold down the OPC levers. Pull

the blade control switch (PTO) up. The clutch should engage and the mower blades begin rotating.

5. Release the OPC levers. The engine should kill.

6. With the engine running, move the speed control lever forward. Release the OPC levers. The engine should kill.

7. If all the above conditions are not met have an

Authorized Service Dealer repair the safety system immediately.

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 speed control lever to desired speed.

2. Release the neutral lock. Refer to Releasing the Neutral Lock on page 19.

3. Slowly release the drive levers to move forward (Fig. 14).

To go straight, release drive levers equally (Fig. 14). To turn, squeeze the drive lever on the side and direction

you want to turn (Fig. 14).

2. Release the neutral lock. Refer to Releasing the

Neutral Locks on page 19.

3. Slowly squeeze the drive levers back together to move

rearward (Fig. 14).

Bringing Machine to Neutral Position

Always set the neutral lock when you stop the machine. Chock or block wheels if it is left unattended.

1. Squeeze the drive levers back.

2. Set the neutral locks. Refer to Operating Neutral Locks

on page 19.

3. Move speed control lever to neutral position.

Stopping the Machine

1. To stop the machine, squeeze the drive levers all the

way back to engage neutral locks.

2. Move neutral locks into the neutral position. Refer to

Operating Neutral Locks on page 19.

3. Move speed control lever into neutral.

4. Turn the ignition key to “OFF” to stop the engine. Note: Remember to remove the key from the ignition

switch if you leave the machine.

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.

Figure 14

1. Drive lever 2. Speed control lever

Backward

1. To go backward, move the speed control lever to desired speed.

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Pushing the Machine by Hand

The by–pass valve also allows the machine to be pushed by hand with the engine not running for easier servicing. If the by–pass valve is opened to push the machine by hand, adjustment is required for operation.

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

To Push the Machine

1. Disengage the power take off (PTO) and turn the

ignition key to “OFF” to stop the engine.

2. Loosen jam nuts and rotate by-pass valves open 5 turns

to push. This allows hydraulic fluid to by-pass the pump and the wheels to turn (Fig. 15).

Important Rotate by-pass valve a maximum of 5 turns

so the valve does not come out of the body causing fluid to run out.

Side Discharge or Mulch Grass

This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

Danger

To Operate the Machine

If the by–pass valve is opened to push the machine by hand, adjustment is required for operation. Refer to Adjusting By-pass Valve on page 32.

Note: The machine will not drive unless by-pass valves are properly adjusted.

Figure 15

1. By-pass valve 2. Jam nut

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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:

• Chock 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.

Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• Never remove the grass deflector from the

mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

blades unless you release the bail and the power take off (PTO) is off. Rotate the ignition key to “OFF.” Also remove the key and pull the wire off the spark plug(s).

Adjusting Height-of-Cut

The height-of-cut can be adjusted from 1 to 4-1/2 in. (25 to 115 mm) in 1/4 in. (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers.

Note: Rear height–of–cut pins need at least one spacer or damage can occur to bushing if none are used.

1. To adjust, remove hairpin cotter from height-of-cut

post (Fig. 16).

2. Select hole in height-of-cut post corresponding to the

height-of-cut desired (Fig. 16).

3. Lift on side of deck and remove hairpin cotter

(Fig. 16).

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

and insert hairpin cotter (Fig. 16).

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.

1. Carrier Frame

2. Hairpin Cotter

3. Front height–of–cut post

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Figure 16

4. Spacers

5. Back height–of–cut post

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Figure 17

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1. Center Gage Wheels and Spacer

2. Nut

3. Bolt

4. Washer

Adjusting Center Gage Wheels

The gage wheels must be adjusted in the proper hole location for each height-of-cut position.

1. After adjusting height-of-cut remove bolt, washers and

nut (Fig. 17).

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

minimum of 3/8 in. (9.5 mm)off the ground for the height-of-cut to be used (Fig. 17).

3. Reinstall the bolt, washers and nut (Fig. 17).

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 5 hours • Engine Oil—change

After first 8 Hours • Hydraulic Oil—check

8 Hours

25 Hours

40 Hours

50 Hours • Belts—check for wear/cracks

100 Hours

Maintenance Procedure

• Engine Oil—check level

• Safety System—check

• Brake—check

• Engine—clean outside

• Mower Housing—clean

• Cutting Blades—check

• Mower Housing—clean

• Caster Wheels—grease

• Foam Air Cleaner—service

• Paper Air Cleaner—clean

• PTO Belt Idler Arm—grease

• Tires—check pressure

• Hydraulic Oil—check

• Engine Oil—change

• Spark Plug(s)—check

• Electric Clutch—adjust

• Engine—clean outside

• Paper Air Cleaner—replace

• Hydraulic lines—check

After first 200 Hours • Hydraulic oil filter—change

200 Hours

At storage or 400 Hours

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)

• Fuel Filter—replace

• Hydraulic oil filter—change

• 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 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.

Air Cleaner Service

Service Interval/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), 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. Pull out on retaining locks and remove the air cleaner cover (Fig. 18).

3. Unscrew nut and remove the air cleaner assembly

(Fig. 18).

4. Carefully pull the foam element off the paper element

(Fig. 18).

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1. Retaining lock

2. Cover

3. Nut

Figure 18

4. Foam element

5. Paper element

Cleaning the Foam

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 (59 ml) of oil on the element

(Fig. 19). Squeeze the element to distribute the oil.

Important Replace the foam element if it is torn or

worn.

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

(Fig. 18). Secure with nut.

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Figure 19

1. Foam element 2. Oil

Cleaning the Paper Element

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

dust and dirt (Fig. 20).

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.

3. Install the air cleaner cover and secure locks (Fig. 18).

Engine Oil Service

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 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

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Figure 20

1. Paper element 2. Rubber seal

Installing the Foam and Paper Elements

Important To prevent engine damage, always operate

the engine with the complete foam and paper air cleaner assembly installed.

1. Carefully place the foam element onto the paper air

cleaner element (Fig. 18).

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. 21) so dirt cannot

fall into the filler hole and damage the engine.

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

(Fig. 21).

4. Thread the oil dipstick fully onto the filler tube

(Fig. 21). 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.

5. Slowly pour approximately 80% of the specified oil, page 26, into the filler tube (Fig. 21). Now check the oil level; refer to Checking Oil Level, page 26. Slowly add additional oil to bring to “FULL” mark on dipstick.

Change Oil Filter Service Interval/Specification

Replace the oil filter every 200 hours or every other oil change.

Figure 21

1. Oil dipstick

2. Metal end

3. Filler tube

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 make sure 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. 22).

4. When oil has drained completely, install the oil drain

cap.

Note: Dispose of the used oil at a certified recycling center.

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 27.

2. Remove the old filter (Fig. 23).

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

the replacement filter (Fig. 23).

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Figure 23

1. Oil filter 2. Adapter

1. Oil drain cap

Figure 22

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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. 23).

5. Fill the crankcase with the proper type of new oil; refer to Engine Oil Service, page 26.

Spark Plug Service

Service Interval/Specification

Check the spark plug(s) after every 100 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: Champion RCJ8Y or NGK BPR4ES Air Gap: 0.030 in. (.75 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. 24). Now

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

0.030 in .

(.75 mm)

3. Remove the spark plug(s).

M-4294

Figure 24

1. Spark plug wire installe d 2. Spark plug

Checking the Spark Plug

1. Remove spark plug.

2. Look at the center of the spark plug(s) (Fig. 25). 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. 25). Bend the side electrode if the gap is not correct.

Figure 25

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

1. Install the spark plug(s). Make sure the air gap is set

correctly.

2. Tighten the spark plug(s) to 11 ft-lb (15 Nm).

3. Push the wire(s) onto the spark plug(s) (Fig. 24).

Greasing and Lubrication

Service Interval/Specification

Refer to the Check Service Reference Aid decal for location and interval of greasing and lubrication (Fig. 26).

Grease with No. 2 general purpose lithium base or molybdenum base grease.

How to Grease

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

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

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.

4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Figure 26).

Figure 26

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. 28).

Note: You’ll have to remove the carrier covers to access

the grease fitting for the deck.

3. Grease the idler pulley pivots (Fig. 28).

Lubricate the caster and wheel bearings

1. Lubricate the front and back wheel bearings and front

spindles until grease begins to ooze out of the bearings (Fig. 27).

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Figure 27

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Figure 28

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 ensure adequate cooling and correct engine speed and reduce the possibility of overheating and mechanical damage to the engine.

Checking 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. 29). Check the tires when they are cold to get the most accurate pressure reading.

Rear Tire Pressure: 12–14 psi (83–97 kPa) Caster Tire Pressure: 20–24 psi (138–165 kPa)

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

it up the fuel line away from valve (Fig. 30).

4. Pull the fuel line off the valve (Fig. 30). 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 30.

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

clamp close to the valve to secure the fuel line.

Figure 29

1. Rear Tire 2. Caster tire

Fuel Tank Service

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

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Figure 30

1. Fuel shut-off valve 2. Clamp

Fuel Filter Service

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 power take off (PTO), set the parking

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

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” to stop the engine. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 30). Note: Remove fuel line from fuel valve that is closest to

the engine.

2. Close fuel shut–off valve at fuel tank (Fig. 30).

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

them away from the filter (Fig. 31).

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. 30).

7. Check for fuel leaks and repair if needed (Fig. 30).

Figure 31

1. Hose clamp

2. Fuel line

3. Filter

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1. Cap

2. Baffle

M-4280

Figure 32

3. Fluid level—full

Warning

Hydraulic System Service

Checking the Hydraulic Fluid

Check the hydraulic fluid level:

• Before engine is first started.

• After first 8 operating hours.

• After 40 operating hours.

Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important Use oil specified or equivalent. Other

fluids could cause system damage. Hydraulic System Oil Capacity: 67 oz. (2.0 l)

1. Position machine on a level surface, stop the engine

and chock or block tires.

2. Clean area around filler neck of hydraulic tank

(Fig. 32).

3. Remove cap from filler neck. Look inside to check if

there is fluid in the reservoir. (Fig. 32).

4. If there is no fluid, add fluid to reservoir

approximately a 1/4 in. (6 mm) below the top of baffle.

5. Run the machine 15 minutes to allow any air to purge

out of the system and warm fluid.

6. Recheck level while fluid is warm. Add fluid to raise

level to top of the baffle, if required.

Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 32).

7. Install cap on filler neck.

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it

must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 200 operating hours.

• Yearly, before storage.

1. Position machine on a level surface, stop the engine, and remove key from ignition switch.

Important Do not substitute automotive oil filter or

severe hydraulic system damage may result.

2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out.

3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 33).

Bleeding Hydraulic System

The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system.

1. Raise rear of the machine so wheels are off the ground

and support with jack stands.

2. Start the engine and run at idle speed. Engage traction

on one side and spin the wheel by hand.

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Figure 33

1. Hydraulic filter

4. Apply a thin coat hydro fluid to the rubber gasket on

the replacement filter (Fig. 34).

5. Install replacement hydraulic filter onto the filter

adapter. Do not tighten.

6. Remove plastic bag from tank opening and allow filter

to fill with hydro fluid.

7. When fluid overflows filter turn the oil filter clockwise

until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 34).

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Figure 34

1. Hydraulic filter

2. Gasket

3. Adapter

8. If there is no fluid, add fluid to reservoir

approximately a 1/4 in. (6 mm) below the top of baffle.

3. When the wheel begins to spin on its own, keep it

engaged until wheel drives smoothly (minimum 2 minute).

4. Check hydraulic fluid level as it drops and add as

required to maintain proper level.

5. Repeat procedure on opposite wheel.

Check Hydraulic Lines

After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating.

Note: Keep areas around hydraulic system clean from grass and debris build up.

Warning

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it

must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

9. Start engine and let run for about two minutes to purge

air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 32.

10.Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Do not overfill.

Adjusting By-pass Valve

The by–pass valve is adjustable to ensure easy operation with a variety of deck sizes. If the front of the deck lifts off the ground when the upper control bar is quickly pushed forward or the machine is unable to drive up hills, an adjustment may be needed.

Test Procedure

1. Start engine and run for 5 minutes at 3/4 throttle, to

warm hydraulic fluid.

2. Drive the machine to a clear and level open area such

as a driveway.

Important There should be at least 10 feet of clear

area in front of the machine.

3. Loosen the quick release levers and push the reference

bar forward to the “FAST” position. Lock the quick release levers to secure the reference bar.

4. Move throttle control to 3/4 throttle.

5. Quickly push the upper control bar against the

reference bar. The front caster wheels should almost lift off the ground. If front caster wheels lift the off the ground , the machine is too aggressive and adjustment is required.

Important By–pass valve adjustment is very sensitive,

do not adjust more than 1/6 turn (one flat) at a time.

6. If the machine is too aggressive or tends to jump

forward, the valve needs to be opened further.

7. If the machine is slow to respond, the valve needs to

be closed further.

8. Repeat “Test Procedure” to check for proper operation.

Re-adjust the by–pass valves until proper performance is achieved.

6. Move the engine throttle to the “FAST” position.

7. Quickly push the upper control bar against the

reference bar. The front caster wheels should lift approximately 1 inch off the ground. If front caster wheels lift the off the ground more than 2 inches, the machine is too aggressive. Adjustment is required.

8. If the machine accelerates slowly, and the front caster

wheels do not lift off the ground, the machine is too un–responsive. Adjustment is required.

Adjustment Procedure

The by–pass valve should be adjusted to deliver best performance for the size (weight) mower you have.

The following values can be used as initial settings for different size mowers: 52 in. (132 cm) 1/2 turn out 44 in. (112 cm) 1 turn out 36 in. (91 cm) 1–1/6 turn out

1. Loosen large jam nut several turns (Fig. 35).

2. Gently close by–pass valve (Fig. 35).

Important Do not over–tighten valve or needle and

seat may be damaged. Do not exceed 50 inch pounds to close valve.

3. Open by–pass valve 1/2 turn (Fig. 35).

4. Tighten jam nut to lock the adjustment (Fig. 35).

5. Repeat “Test Procedure” to check for proper operation.

m–5209

Figure 35

1. By-pass valve 2. Jam nut

Hydro Linkage Adjustments

Perform the following linkage adjustments when the machine needs maintenance. Perform steps Adjust Speed Control Linkage through Adjust Tracking. If adjustment is needed, do them in the order that they are listed.

Adjust Speed Control Linkage

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

2. Move the speed control lever (located on the console)

to the full forward position.

3. Check the orientation of the tabs on the ends of the

speed control crank. These tabs should be pointing straight down at the 6 o’clock position approximately (Fig. 37).

4. Adjust the threaded yoke at the bottom of the speed

control linkage until the tabs are at the 6 o’clock position (Fig. 37).

Adjust Neutral Control Linkages

Figure 36

1. Speed control rod

2. Yoke

3. Speed control crank

5. Pull the speed control lever back to neutral.

6. Check to make sure the safety switch is depressed and

there is a 5/16 in. (8 mm) space between the actuating tab and the switch. (Fig. 37).

7. If needed, adjust switch location to create the 5/16 in. (8 mm) space (Fig. 37).

4. Tabs, 6 o’clock position

5. Jam nut

m–5398

Warning

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.

Warning

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

1. Raise the rear of the machine onto jack stands to raise

the drive wheels off the ground.

2. Start the engine and move the throttle ahead to the full

throttle position.

1. Actuating t a b

2. 5/16 in. (8 mm) space

Figure 37

3. Safety switch

3. Place the neutral locks in the full forward position and

move the speed control lever to the medium speed position.

4. Hold OPC levers down. Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

m–5394

Warning

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC)

levers are working when adjustment is completed.

• Never operate this unit with Operator Presence

Control (OPC) levers held in place.

5. Squeeze one drive lever until an increased resistance is

felt. This is where neutral should be.

Note: Make sure you have not reached the end of the neutral lock slot. If you have, shorten the control lever linkage. Refer to Control Rod Adjustment on page 36.

6. If the wheel turns while holding the drive lever in

neutral, the neutral control linkages need to be adjusted (Fig. 38). If wheel stops then go to step 12.

7. Loosen the nut against the neutral control linkage yoke

(Fig. 38).

8. Adjust the neutral control linkage until the respective

drive wheel stops while the drive lever is pulled against the neutral spring (neutral position) (Fig. 38).

Warning

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

9. Turn the adjusting bolt approximately 1/4 turn

clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counter–clockwise if the wheel is turning forward (Fig. 38).

10.Release the drive lever to the forward drive position

and squeeze back into the neutral position. Check to see if the wheel stops. If not, repeat the above adjustment procedure.

11. After adjustments are made, tighten the nuts against

the yokes.

12.Repeat this procedure for the opposite side.

Left Side Linkage Adjustment

1. Raise the rear of the machine onto jack stands high

enough to raise the drive wheels off of the ground.

2. Place the speed control lever in the neutral position.

3. Place the left drive lever in the full forward position.

4. Hold OPC levers down. Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

Warning

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC)

levers are working when adjustment is completed.

• Never operate this unit with Operator Presence

Control (OPC) levers held in place.

m–5394

Figure 38

1. Neutral control linkage

2. Yoke

3. Adjusting bolt

4. Nut

Adjust Hydro Control Linkages

Warning

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.

5. Loosen the front nut on left hydro control linkage as

shown in figure 39.

6. Turn the left rear adjusting nut counter–clockwise until

wheel rotates forward (Fig. 39).

7. Turn the rear adjusting nut clockwise 1/4 of a turn at a

time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Fig. 39).

8. Turn the rear nut an additional 1/2 turn and tighten the

front nut.

Note: Make sure flat part of linkage is perpendicular to pin part of swivel.

9. After adjusting the left hydro control linkage, move

the speed control lever forward and then back to the neutral position.

10. Make sure the speed control lever is in the neutral

position and the tire does not rotate.

11. Repeat adjustment if needed.

m–5394

Figure 39

1. Hydro control linkage

2. Front nut

3. Rear adjusting nut

Note: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring. Repeat above adjustments if necessary (Fig. 40).

5. Turn the knob clockwise 1/4 of a turn at a time. Then

move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Fig. 41).

6. The spring that keeps tension on the knob should

normally not need adjustment. However if adjustment is needed, adjust the length of spring to 1 in. (26 mm) between the washers (Fig. 41).

7. Adjust spring length by turning nut at front of spring

(Fig. 41).

3 2

m–5396

Figure 40

1. Speed control lever

2. Rear pivot spring

3. spring

Right Side Linkage Adjustment

1. Place the speed control lever in the neutral position.

2. Place the right drive lever in the full forward position.

3. Hold OPC levers down.

Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Fig. 41).

m–5403

Figure 41

1. Hydro control linkage

2. Quick track knob

3. Spring

4. 1 inch (26 mm)

Control Rod Adjustment

Checking Control Rod

1. With rear of machine still on jack stands and engine

running at full throttle, move the speed control lever to the medium speed position.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

2. Move the respective drive lever upward until it reaches

the neutral position and engage neutral locks.

3. If the tire rotates in either direction, the length of the

control rod will need to be adjusted.

Adjusting Control Rods

1. Adjust the rod length by releasing the drive lever and

removing clevis pin. Rotate the rod in the rod fitting (Fig. 42).

2. Lengthen the rod if the tire is turning in reverse and

shorten the rod if the tire is turning forward.

3. Rotate the rod several turns if the tire is rotating fast.

Then, adjust the rod in 1/2 turn increments.

4. Release and engage neutral lock checking that the tire

does not rotate. Continue this process until the tire does not rotate.

5. Place the hairpin back into clevis pin (Fig. 42).

6. Repeat this adjustment for opposite side.

Figure 42

1. Handle

2. Neutral lock

3. Neutral position

4. Drive lever

5. Full speed forward

6. Control rod

Tracking Adjustment

1. Remove machine from any jack stands.

2. Check the rear tire pressure. Refer to Tire Pressure

Service on page 30.

m–5388

m–5398

Figure 43

1. Quick track knob

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. 44).

2. Check adjustment by inserting feeler gauge through

slots next to studs (Fig. 44).

3. The proper disengaged clearance between the clutch

plates is .012–.024 in. (0.30-0.60 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

3. Run the unit and observe the tracking on a level,

smooth, hard surface such as concrete or asphalt.

4. If the unit tracks to one side or the other, turn the quick

track knob . Turn the knob right to steer right and turn the knob left to steer left (Fig. 43).

1. Adjusting n u t

2. Slot

m–2600

Figure 44

3. Feeler gauge

Fuse Service

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. 45) to remove or replace it.

Fuse: F1– 10 amp, blade-type

m–5390

m–5391

Figure 45

1. Fuse, 10 am p

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and chock or block tires. Turn the ignition key to “OFF” to stop the engine. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Fig 46). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 39.

2. Inspect the blades, especially the curved area (Fig. 46).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 46), immediately install a new blade.

1. Disengage the power take off (PTO), chock or block tires, and turn the ignition key to “OFF” to stop the engine. Remove the key.

Cutting Blade Service

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.

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Figure 46

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. 47). Measure from a level surface to the cutting edge, position “A”, of the blades (Fig. 48). Note this dimension.

m–151

Front

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. 49).

m–1078

Figure 47

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 48

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 in. (3 mm) If this dimension exceeds 1/8 in. (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 40.

m–5199

Figure 49

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

Warning

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

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

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.

m–1854

Figure 50

1. Sharpen a t original angle

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

balancer (Fig. 51). 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. 49). Repeat this procedure until the blade is balanced.

m–1855

Figure 51

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 49).

Important The sail part of the blade must be pointing

upward, toward the inside of the mower to ensure proper cutting (Fig. 49).

2. Install the washer, lock washer and blade bolt

(Fig. 49). Torque the blade bolt to 85–110 ft-lb

(115–140 Nm).

Correcting Cutting Unit

7. Tighten the carrier frame mounting bolts on both sides

of the machine.

Mismatch

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

2. Adjust the tire pressure in all tires to specifications on page 30.

3. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 38.

4. Set the height-of-cut to the 4 in. (102 mm) position. Refer to Adjusting the Height-Of-Cut in the Operation section.

5. 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

m–5315

Figure 52

1. Carrier Frame

2. T op of engine deck

3. Carrier frame mounting bolts

4. Location A, 2–13/16 in. (71 mm)±1/4 in. (6 mm)

5. Straight edge

6. Carrier frame cross tube

Checking Engine Deck Height

1. Stop the engine, remove the key and disconnect the

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

2. Adjust the tire pressure in all tires to specifications on

page 30.

3. Measure engine deck height at location “A” (Fig. 53).

4. Measure engine deck height at location “B” (Fig. 53).

5. If the height at location “A” and “B” are not the same,

change tire pressure slightly to make them the same.

1. Stop the engine, remove the key and disconnect the

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

2. Place a long straight edge on top of the engine deck as

shown in figure 52.

3. At the carrier frame cross tube, measure location “A”

height (Fig. 52). This measurement must be 2–13/16 in. (71 mm), plus or minus a 1/4 in. (6 mm).

4. If the height at location “A” is not correct, adjustment

is needed.

5. Loosen the carrier frame mounting bolts on both sides

of the machine (Fig. 52).

6. Align the carrier frame and engine deck to match

2–13/16 in. (71 mm), plus or minus a 1/4 in. (6 mm) at location “A” (Fig. 52).

1. Back view of machine

2. T op of engine deck

3. Tires

Figure 53

4. Same height at locations

444

A and B

m–5237

Checking Carrier Frame Front–to–Rear Pitch

The carrier frame must have a pitch of a 1/4 in. (6 mm) over the length of 24 inches (61 cm) on the carrier frame.

1. Measure out 24 inches on the carrier frame (Fig. 54).

2. Measure carrier frame height at location “A” (Fig. 54).

3. Measure carrier frame height at location “B” (Fig. 54).

4. The height at location “A” must be a 1/4–3/8 in.

(6 mm –10 mm) lower than location “B” (Fig. 54).

5. If the carrier frame is not correct, move caster spacers

to make it a 1/4–3/8 in. (6 mm –10 mm) pitch (Fig. 54). Move spacers from top or bottom to make the correct pitch.

6. The tire pressure may also be adjusted slightly to make

a 1/4–3/8 in. (6 mm –10 mm) pitch.

(6.1cm)

24 in.

m–5231

Figure 55

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Same height at locations A and B

5. Caster spacers

Checking the Deck Front-to-Rear Pitch

m–5242

Figure 54

1. Caster Wheel

2. Carrier Frame

3. 1/4–3/8 in. (6mm–10mm) pitch over 24 in. (6.1 cm) length

4. Height at locations A and B

5. Caster spacers

Checking Carrier Frame Side–to–Side

1. Stop the engine, remove the key and disconnect the

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

2. Adjust the tire pressure in all tires to specifications on

page 30.

3. Measure carrier frame height at location “A” (Fig. 55).

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

2. Position one blade front-to-rear (Fig. 56). Measure at

“C” and “D” locations (Fig. 56) from a level surface to the cutting edge of the blade tips (Fig. 57).

3. The mower blade should be 1/4 in. (6 mm) lower in front “C” than in the rear “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 56

4. Measure carrier frame height at location “B” (Fig. 55).

5. 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.

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

Figure 57

m–2539

Changing the Deck Front-to-Rear Pitch

Changing the front–to–rear pitch is done by adjusting the front height–of–cut posts.

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. 59). Measure at

“A” and “B” locations (Fig. 59) from a level surface to the cutting edge of blade tips (Fig. 60).

3. The difference between measurements “A” and “B”

should be no more than 1/4” (6 mm).

Front

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. 58).

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

rotate the front pin clockwise (Fig. 58).

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

rotate the front pin counter clockwise (Fig. 58).

3 4

m–5231

Figure 59

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

Figure 60

m–1078

m–2550

Changing the Side-to-Side Leveling

Changing the side–to–side leveling is done by adjusting tire pressure.

Figure 58

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Position the blades front-to-rear (Fig. 56). Measure at

“C” and “D” locations (Fig. 56) from a level surface to the cutting edge of the blades (Fig. 57).

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

4. Jam nut

5. Ball joint

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 in. (102 mm) position

following the height-of-cut decal.

3. With the machine on level surface, position one blade

front-to-rear (Fig. 61). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 62).

4. The measurement should be 4 in. (102 mm).

Front

7. Install new belt around clutch and drive pulleys.

8. Torque pivot bolt to 35-40 ft. lb. (47-54 N.m). Install

tension spring between idler arm and frame bracket (Fig. 63).

9. Install clutch retainer to the engine deck (Fig. 63).

10.Connect clutch wire connector to wire harness.

11. Install PTO drive belt.

m–1078

Figure 61

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

m–2550

Figure 62

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.

2 8

m–5340

Figure 63

1. Traction 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 Deck 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).

Replacing the Traction Belt

Check traction drive belt for wear after every 50 hours of operation.

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

stands.

2. Disconnect clutch wire connector from wire harness.

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

Drive Belt on page 44.

4. Remove clutch retainer from the engine deck (Fig. 63).

5. Unhook tension spring from side of frame (Fig. 63).

6. Loosen pivot bolt enough to remove traction belt from

the drive pulley and clutch.

2. Remove the knobs holding the carrier frame cover and

remove the carrier frame cover.

3. Remove the knobs 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 44.

5. Disconnect the idler arm spring to relieve tension on

the idler arm and idler pulley, then remove the worn deck belt (Fig. 64).

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. 64).

7. Connect the idler arm spring (Fig. 64).

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

PTO Drive Belt page 44.

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

(Fig. 64).

7. Install belt onto idler pulley and then install idler

spring (Fig. 65).

10.Reinstall the belt covers onto the cutting unit, then

reinstall and tighten the knobs.

11. Install the carrier frame cover onto the cutting unit,

then install and tighten the hand knobs.

m–5194

Figure 64

1. Deck belt

2. Idler arm spring

3. Outward pulley

4. PTO drive Belt

5. Center Spindle Pulley

6. Deck belt guide

8. Adjust PTO drive belt guides an 1/8 in. (3 mm) from

belt (Fig. 65).

9. Install the belt covers onto the cutting unit, then install

and tighten the knobs.

10.Install the carrier frame cover onto the cutting unit,

then install and tighten the hand knobs.

2 5

m–5194

Figure 65

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 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 holding the carrier frame cover and

remove the carrier frame cover.

3. Remove the knobs 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. 65).

5. Remove the worn drive belt (Fig. 65).

6. Install the new drive belt onto the PTO engagement

pulley and the top groove of the center spindle pulley (Fig. 65).

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. 66).

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-5198

Figure 66

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. 67). 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. 66).

7. Slide the caster wheel fork through the bushings in the

mounting tube. Replace the spacers(s) onto the fork and secure with the retaining ring (Fig 66).

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 in. (28.6mm).

m–5197

Figure 67

1. Carrier Frame Mounting Tube

2. Bushing

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. 68).

2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 68).

3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 68).

4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 68).

8. Grease the fitting on the carrier frame mounting tube

using No. 2 general purpose lithium base or molybdenum base grease.

3. Install bolt and nut. Place “J” hook end of spring

around grass deflector (Fig. 69).

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-5210

Figure 68

1. Locknut

2. Wheel Bolt

3. Bushing

4. Spanner Bushing

5. Roller Bearing

5. To assemble, place one (1) 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. 68).

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. 68).

7. Grease the fitting on the caster wheel.

Replacing the Grass Deflector

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

m-5037

Figure 69

6. Grass Deflector

7. “L” end of spring, place behind deck edge before installing bolt

8. “J” hook end of spring

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.

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

the deflector to the pivot brackets (Fig. 69). 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 69.

Wiring Diagram

WIRE COLOR CODES

Operator Presence Switch (No Operator)

Neutral Switch (In Neutral)

HOUR METER

PTO Switch (Off)

–+

TY Y

354

BK BN

Clutch

K1 Interlock

Relay

10A

KEY SWITCH

(OPEN = ON) (CLOSED = OFF)

GN GY OR

REG

MAG

BLACK BROWN BLUE GREEN GREY ORANGE

SPARK PLUG SPARK PLUG

PK R

T VIO W Y

IGNITION MODULES

PINK RED

TAN VIOLET WHITE

YELLOW

GND

Hydraulic Diagram

Motor Right Side

Motor Left side

Pump Right Side

Filter

Expansion Tank

Pump Left side

Charge Pump Inlet

Case Drain

m–5225

Cleaning and Storage

g,,

1. Disengage the power take off (PTO) and turn the

ignition key to “OFF” to stop the engine. 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 control panel, engine, hydraulic pumps and motors.

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

page 25.

4. Change the crankcase oil; refer to Engine Oil Service,

page 26.

5. Change the hydraulic filter; refer to Hydraulic System

Service on page 31.

6. Check the tire pressure; refer to Checking Tire

Pressure, page 30.

7. 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. 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.

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 30. 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.

8. Remove the spark plug(s) and check its condition;

refer to Spark Plug Service on page 27. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

9. Check and tighten all bolts, nuts, and screws. Repair or

replace any part that is damaged or defective.

10.Paint all scratched or bare metal surfaces. Paint is

available from your Authorized Service Dealer.

11. Store the machine in a clean, dry garage or storage

area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

Troubleshooting

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

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

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

2. PTO is on (Pulled up). 2. Turn PTO off (Push in).

3. Speed control lever is in gear. 3. Move speed control lever to neutral.

4. Choke is not ON. 4. Move choke lever to ON.

5. Air cleaner is dirty. 5. Clean or replace air cleaner element.

6. Spark plug wire is loose or

disconnected.

7. Spark plug is pitted, fouled, or

gap is incorrect.

8. Dirt in fuel filter. 8. Replace fuel filter.

9. Dirt, water, or stale fuel is in

fuel system.

6. Install wire on spark plug.

7. Install new, correctly gapped spark plug.

9. Contact Authorized Service Dealer.

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Engine loses power.

Engine overheats.

Machine does not drive.

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.

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. Neutral lock is in neutral position.

4. Remove obstruction from cooling fins and air passages.

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.

1. Move neutral lock to forward position.

2. Hydrostatic fluid level low. 2. Fill hydrostatic fluid tank.

3. Traction belt is worn, loose or broken.

4. Traction belt is off pulley. 4. Install Belt.

Machine does not drive up hills or inclines.

Machine moves slowly in neutral. 1. Neutral is mis-adjusted.

Machine drive is too aggressive. 1. By-pass valve is adjusted too

Machine tracks left or right.

1. By-pass valve is adjusted too far open.

2. Neutral control spring is broken or missing.

far closed.

1. Tire pressure is not correct. 1. Adjust tire pressure.

2. Tracking knob not adjusted correctly.

3. Change Belt.

1. Adjust by-pass valve.

1. Adjust hydro linkages.

2. Replace neutral control spring.

1. Adjust by-pass valve.

2. Adjust tracking knob.

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

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.

LCE

The Toro Total Coverage Guarantee

A One-Year 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 any Toro Product used for commercial, institutional, or rental purposes 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 Toro 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. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0037 Rev. B

Toro 30338 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual