Toro 30716TE Operator's Manual

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FORM NO. 3318-414 GB Rev A

MODEL NO. 30716—60001 & UP MODEL NO. 30716TE—60001 & UP

GUARDIAN

72” RECYCLER

OPERATOR’S

MANUAL

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FOREWORD

The Guardian® 72” Recycler®Cutting Deck has advanced concepts in engineering, design and safety; and if maintained properly, will give excellent service.

Since this is a high-quality product, Toro is concerned about the future use of the machine and the safety of the user. Therefore, read this manual to familiarize yourself with proper operation and maintenance instructions. The major sections of the manual are:

Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety related information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read this directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies general information worthy of special attention.

Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a complete line of accessories and professional turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep your machine operating properly. Keep your TORO all TORO. Buy genuine TORO parts and accessories.

Table of Contents

SAFETY INSTRUCTIONS 3-5 SYMBOL GLOSSARY 6-8 SPECIFICATIONS 9 BEFORE OPERATING 10

Check Lubricant in Gear Box 10 Adjusting Height-of-Cut 12 Adjusting Skids 13 Grease Cutting Unit 13

OPERATING INSTRUCTIONS 13

Operating Tips 13

LUBRICATION 14

Grease Bearings, Bushings and Gear Box 14

MAINTENANCE 15-19

Trouble Shooting 15 Separating The cutting Unit from Traction Unit 16 Mounting The cutting Unit to Traction Unit 16 Replacing Drive Belt 16 Servicing Front Bushings in The castor Arms 17 Servicing The castor Wheels and Bearings 17 Removing Cutter Blades 18 Inspecting and Sharpening Blades 18

Correcting The cutting Unit Mismatch 19

IDENTIFICA TION AND ORDERING 20

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Safety

Training

1. Read the instructions carefully. Be familiar with the

controls and the proper use of the equipment.

2. Never allow children or people unfamiliar with these

instructions to use the lawnmower. Local regulations may restrict the age of the operator.

3. Never mow while people, especially children, or pets

are nearby.

4. Keep in mind that the operator or user is responsible

for accidents or hazards occurring to other people or their property.

5. Do not carry passengers.

6. All drivers should seek and obtain professional and

practical instruction. Such instruction should emphasize:

• the need for care and concentration when working with ride-on machines;

• control of a ride on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

– insufficient wheel grip; – being driven too fast;

3. WARNING—Petrol is highly flammable.

• Store fuel in containers specifically designed for this purpose.

• Refuel outdoors only and do not smoke while refueling.

• Add fuel before starting the engine. Never remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.

• If petrol is spilled, do not attempt to start the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated.

• Replace all fuel tanks and container caps securely.

4. Replace faulty silencers.

5. Before using, always visually inspect to see that the

blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

6. On multi-bladed machines, take care as rotating one

blade can cause other blades to rotate.

Operation

– inadequate braking; – the type of machine is unsuitable for its task; – lack of awareness of the effects of ground

conditions, especially slopes;

Preparation

1. While mowing, always wear substantial footwear

and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

2. Thoroughly inspect the area where the equipment is

to be used and remove all objects which may be thrown by the machine.

1. Do not operate the engine in a confined space where

dangerous carbon monoxide fumes can collect.

2. Mow only in daylight or in good artificial light.

3. Before attempting to start the engine, disengage all

blade attachment clutches and shift into neutral.

4. Do not use on slopes of more than:

• Never mow side hills over 5°

• Never mow uphill over 10°

• Never mow downhill over 15°

5. Remember there is no such thing as a “safe” slope.

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Travel on grass slopes requires particular care. To guard against overturning:

• do not stop or start suddenly when going up or downhill;

13. Disengage drive to attachments, stop the engine, and

disconnect the spark plug wire(s)or remove the ignition key

• before cleaning blockages or unclogging chute;

• engage clutch slowly, always keep machine in gear, especially when travailing downhill;

• machine speeds should be kept low on slopes and during tight turns;

• stay alert for bumps and hollows and other hidden hazards;

• never mow across the face of the slope, unless the lawnmower is designed for this purpose.

6. Use care when pulling loads or using heavy equip-

ment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely control.

• Do not turn sharply. Use care when reversing.

• Use counterweight(s) or wheel weights when suggested in the instruction handbook .

7. Watch out for traffic when crossing or near road-

ways.

• before checking, cleaning or working on the lawnmower;

• after striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the equipment;

• if the machine starts to vibrate abnormally (check immediately).

14. Disengage drive to attachments when transporting or

not in use.

15. Stop the engine and disengage drive to attachment

• before refueling;

• before removing the grass catcher;

• before making height adjustment unless adjustment can be made from the operator's position.

16. Reduce the throttle setting during engine runout and,

if the engine is provided with a shutoff valve, turn the fuel off at the conclusion of mowing.

8. Stop the blades rotating before crossing surfaces

other than grass.

9. When using any attachments, never direct discharge

of material toward bystanders nor allow anyone near the machine while in operation .

10. Never operate the lawnmower with defective guards,

shields or without safety protective devices in place.

11. Do not change the engine governor settings or over-

speed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury.

12. Before leaving the operator's position:

• disengage the power take-off and lower the attachments;

• change into neutral and set the parking brake;

• stop the engine and remove the key.

Maintenance and Storage

1. Keep all nuts, bolts and screws tight to be sure the

equipment is in safe working condition.

2. Never store the equipment with petrol in the tank

inside a building where fumes may reach an open flame or spark.

3. Allow the engine to cool before storing in any enclo-

sure.

4. To reduce the fire hazard, keep the engine, silencer,

battery compartment and petrol storage area free of grass, leaves, or excessive grease.

5. Check the grass catcher frequently for wear or dete-

rioration.

6. Replace worn or damaged parts for safety.

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7. If the fuel tank has to be drained, this should be

done outdoors

Sound & Vibration Levels

8. On multi-bladed machines, take care as rotating one

blade can cause other blades to rotate.

9. When machine is to be parked, stored or left unat-

tended, lower the cutting means unless a positive mechanical lock is used.

Sound Levels

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 90 dB(A), based on measurements of identical machines per 84/538/EEC.

This unit has a sound power level of 106 dB(A)/1pW, based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments

Vibration Levels

This unit has a vibration level of 5.5 m/s2at the posterior, based on measurements of identical machines per ISO 2631 procedures.

This unit does not exceed a vibration level of 0.5 m/s the posterior based on measurements of identical machines per ISO 2631 procedures.

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Symbol Glossary

Caustic liquids, chemical burns to fingers or hand

Crushing of whole body, applied from above

Severing of fingers or hand, mower blade

Poisonous fumes or toxic gases, asphyxiation

Crushing of torso, force applied from side

Severing of toes or foot, mower blade

Electrical shock, electrocution

Crushing of fingers or hand/, force applied from side

Severing of toes or fingers, rotary mower blade

High pressure fluid, injection into body

force applied from side

Cutting or entanglement of foot, rotating auger

High pressure spray, erosion of flesh

Crushing of whole body

Severing of foot, rotating knives

Crushing of head, torso and arms

Severing of fingers or hand, impeller blade

High pressure spray, erosion of flesh

Crushing of fingers force above

Dismemberment, front engine mower in forward motion

or hand,

applied from

Cutting of fingers or hand

Crushing of toes or foot, force applied from above

Cutting of footCrushing of leg,

Dismemberment, front engine mower in rearward motion

Severing of fingers or hand, engine fan

Runover/backover, vehicle

Stay a safe distance from the machine

Whole body entanglement, implement input drive line

Machine tipping, riding mower

Stay clear of articulation area while engine is running

Machine rollover, ROPS (rear engine mower)

Do not open or remove safety shields while engine is running

Fingers or hand entanglement, chain drive

Stored energy hazard, kickback or upward motion

Do not step on loading platform if PTO is connected to tractor & engine is running

Hand & arm entanglement, belt drive

Hot surfaces, burns to fingers or hands

Do not step Wait until all

Thrown or flying objects, whole body exposure

Explosion Fire or open

machine components have completely stopped before touching them

Thrown or flying objects, face exposure

flame

Shut off engine & remove key before performing maintenance or repair work

Thrown or flying objects, rotary mover

Secure lifting cylinder with locking device before getting in hazardous area

Riding on this machine is allowed only on a passenger seat & only if the driver’s view is not hindered

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Consult technical manual for proper service procedures

Fasten seat belts

Safety alert triangle

Outline safety alert symbol

Read operator’s manual

Fire, open light and smoking prohibited

Eye protection must be worn

Head protection must be worn

Brake system

Filter Temperature Failure/

Plus/increase/ positive polarity

Hearing protection must be worn

Oil Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level

Minus/decrease/ negative polarity

Caution, toxic risk

Malfunction

Horn

Flush with water Engine Transmission Hydraulic systemFirst aid

Start switch/ mechanism

Battery charging condition

Hourmeter/ elapsed operating hours

On/start Off/stop Engage

Fast Slow Continuous

Disengage

variable, linear

Volume empty Volume full Machine travel

Oil lubrication point

Engine lubricating oil temperature

Lift point Jack or

Engine coolant

direction, forward/ rearward

support point

Engine coolant pressure

Control lever operating direction, dual direction

Draining/ emptying

Engine coolant filter

Control lever operating direction, multiple direction

Engine lubricating oil

Engine coolant temperature

Clockwise rotation

Engine lubricating oil pressure

Engine intake/ combustion air

Counter-clockwise rotation

Engine lubricating oil level

Engine intake/combustion air pressure

Grease lubrication point

Engine lubricating oil filter

Engine intake/air filter

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Engine start Engine stop Engine failure/

Transmission oil pressure

Transmission oil temperature

malfunction

Transmission failure/malfunction

RP 231

Reverse

Park First gear

n/min

Engine rotational speed/frequency

Choke Primer (start aid) Electrical preheat

(low temperature start aid)

Transmission oil

NHLF

Clutch Neutral High Low Forward

Second gear

Third gear (other #'s may be used until the maximum # of forward gears is reached.)

Hydraulic oil

Hydraulic oil pressure

Hydraulic oil level

Hydraulic oil filter

Power Take-Off, rotational speed

Cutting unit, transport position

Hydraulic oil temperature

Blade cutting element

Cutting unit, raise to transport position

Hydraulic oil failure/malfunction

Blade cutting element, height adjustment

Parking brake Fuel

Lock Unlock Differential lock 4-Wheel drive Power Take-OffDiesel fuel Unleaded fuel Headlights

Cutting unit Cutting unit,

Cutting unit, lower to transport position

Attachment lower

raise

Attachment raise

Fuel level

Cutting unit, lower

Spacing distance Snow thrower,

Fuel filter Fuel system

Cutting unit, hold

collector auger

failure/malfunction

Cutting unit, float

Traction

Above working temperature range

Drilling Manual metal

arc welding

Manual Water pump Keep dry Weight Do not dispose

in the garbage

CE logo

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Specifications

Width of Cut: 72 inches (183 cm)

Height of Cut: Adjustable from 5–12.7 cm in 1.25 cm increments.

Cutter Housing: 12-gauge steel and reinforced with 2-1/2" x 10

gauge channel.

Cutting Unit Drive: Power is transmitted to the blades by one hex B section belt. Spindle shafts are 3.2 cm diameter and supported by two externally-sealed, greaseable, tapered roller bearings.

Cutting Unit: The cutting unit has front and rear castor wheels, and three heat-treated steel blades 63.5 cm long and 6.3 mm thick.

Castor Wheels: The two front castor wheels have roller bearings with 10.25 in x 3.25 in. hard rubber tires. The rear wheels have roller bearings and 8 in. x 3.50 in. hard rubber tires.

Blade Tip Speed: At 3200 engine rpm, blade tip speed is 15,800 ft/min.

Cutting Unit Lift: The cutting unit is lifted by a hydraulic cylinder that has a 6.3 cm bore and 8.3 cm stroke.

Dimensions and Weights:

Width: 190.5 cm Weight: 172 kg

Specifications and design are subject to change without notice.

Before Operating

CHECK THE GEAR BOX LUBRICANT (Fig. 1)

The gear box in designed to operate on SAE 80-90 weight gear lubrication. Although the gear box is shipped from the factory with lubricant, check the level before operating the cutting unit.

1. Position the machine and cutting unit on a level surface.

2. Remove the check plug from the side of the gear box and make

sure the lubricant level is up to the bottom of the hole. If the level of lubricant is low, remove the fill plug on top of the gear

1. Filler plug 2. Check plug

Figure 1

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case and add enough lubricant to bring it up to the bottom of the hole in side.

ADJUSTING HEIGHT-OF-CUT (Fig. 2–3)

The height-of-cut is adjustable from 5 to 12.7 inches in 1.3 cm increments, by adding or removing an equal number of spacers from the front and rear castor forks. The height-of-cut chart below gives the combinations of spacers to use for all height-of-cut settings.

Height of Cut Spacers Below Castor Arm Setting Front Rear

5 cm 0 0

6.3 cm 1 1

7.6 cm 2 2

8.9 cm 3 3

10.1 cm 4 4

11.4 cm 5 5

12.7 cm 6 6

1. Start the engine and raise the cutting unit so the height-of-cut

can be changed. Stop the engine after you raise the cutting unit.

FRONT CASTOR WHEELS

1. Remove the lynch pin from the spindle shaft and slide the spin-

dle out of the front castor arm. Remove the washer from the spindle shaft. Slide spacers onto the spindle shaft to the get desired height-of-cut, then slide the washer onto the shaft.

2. Push the castor spindle through the front castor arm. Install the

other thrust washer and the remaining spacers onto the spindle and install the lynch pin to secure the assembly.

1. Front castor wheel

Figure 2

2. Lynch pin

3. Spacers

4. Thrust washers

Figure 3

1. Rear castor wheel

2. Lynch pin

3. Spacers

4. Thrust washers

REAR CASTOR WHEELS

1. Remove the lynch pin from spindle shaft.

Note: You don’t need to remove the rear castor fork assembly

from the castor arm to change height-of-cut.

2. Remove or add "C" shaped spacers at the narrow portion of the

spindle shaft, below the castor arm, to get the desired heightof-cut. Make sure thrust washers —not the spacers—contact the top and bottom of the castor arm.

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Operating Instructions

3. Install the lynch pin to secure the assembly .

4. Assure all four castor wheels are set at same height-of-cut.

ADJUSTING SKIDS (Fig. 4)

1. Adjust skids by loosening flange nuts, positioning as desired

and re-tightening the flange nuts.

OPERA TING TIPS

1. MOW WHEN GRASS IS DRY—Mow either in the late morn-

ing to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.

2. SELECT THE PROPER HEIGHT-OF-CUT SETTING TO

SUIT CONDITIONS—Remove approximately one inch or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to raise your height-ofcut setting another notch.

3. MOWING IN EXTREME CONDITIONS—Air is required to

cut and recut grass clippings in the mower housing, so do not set the height-of-cut too low or totally surround the housing by uncut grass. Always try to have one side of the mower housing free from uncut grass, thus allowing air to be drawn into housing. When making an initial cut through the center of an uncut area, operate the machine slower and back up if the mower starts to clog.

1. Skid

Figure 4

4. MOW AT PROPER INTERVALS—Under most normal condi-

tions you'll need to mow every 4–5 days. Remember, grass grows at different rates at different times. To maintain the same height-of-cut—which is a good practice—you'll need to cut more frequently in early spring. When the grass growth rate slows in mid summer, cut only every 8–10 days. If you are unable to mow for an extended period, mow first with the height-of-cut at a high level; then mow again 2–3 days later with a lower height setting.

5. ALWAYS MOW WITH SHARP BLADES—A sharp blade

cuts cleanly and without tearing or shredding the grass. Tearing and shredding causes the grass to turn brown at the

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edges, which impairs growth and increases susceptibility to diseases.

CAUTION: This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of permanent hearing damage.

6. STOPPING—If you stop while cutting, a clump of grass clip-

pings may be deposited on lawn. Follow this procedure for stopping while cutting:

A. With the deck engaged, move onto a previously cut area. B. Shift to neutral, move the throttle control lever to SLOW

and rotate ignition key to OFF.

7. AFTER OPERATING —For optimum performance, clean the

underside of the mower housing. If you let residue build up in the mower housing, cutting performance will decrease.

Maintenance

LUBRICATION

GREASE BEARINGS, BUSHINGS AND GEAR BOX (Fig. 5–8)

Lubricate the cutting unit regularly. If you operate the machine under normal conditions, lubricate the castor bearings and bushings with No. 2 general purpose lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, whichever comes first.

1. The cutting unit has bearings and bushings that must be lubri-

cated, and these lubrication points are: front castor spindle bushings (Fig. 5); castor wheel bearings (Fig. 5 & 6); blade spindle bearings (Fig. 7); idler arm pivot (Fig. 7) and right and left push-arm ball joints (Fig. 7).

Also, remove the rear castor spindle shaft from the castor arm and coat the shaft with No. 2 general purpose lithium base grease or molybdenum base grease every 50 hours (Fig. 6).

2. Position the machine and cutting unit on a level surface and

lower the cutting unit. Remove the check plug from the side of gear box (Fig. 8) and make sure the lubricant level is up to the

Figure 5

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bottom of the hole. If the level is low, remove the fill plug on top of the gear case and add SAE 80-90 weight gear lubrication until the level is up to the bottom of the hole in side.

Figure 6

1. Filler plug

2. Check plug

3. Drain plug

Figure 7

Figure 8

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TROUBLESHOO TING

Box Shafts

Inspect Gear

Broken

Box Pulley

Inspect Gear

Loose or

Deck Belts

Inspect Cutter

Loose or

Broken

Replace

Tighten or

Replace

Tighten or

Inspect P.T.O.

Belt

Pulley

Broken

Loose or

Broken

Loose or

Replace

Tighten or

Replace

Tighten or

UNIT WILL NOT CUT OR CUTS POORLY

Bolts

Loose

Inspect Spindle

Blades

Inspect Cutter

Dull or Bent

Retorque

115–149 Nm

Replace

Sharpen or

Shaft

Broken

Inspect P.T.O.

on Engine

Inspect Pulley

Loose or

Output Shaft

Broken

Replace

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CAUTION

To prevent accidental starting of the engine while performing maintenance, shut of the engine and remove the key from the ignition switch.

SEPARATING THE CUTTING UNIT FROM THE TRACTION UNIT (Fig 9–11)

1. Position the machine on level surface, lower the cutting unit to

the floor, shut the engine off and engage the parking brake.

2. Remove the self-tapping screws securing the shield to the top

of the cutting unit and set the shield aside.

3. Drive out the roll pin securing the drive shaft yoke to the input

shaft of the gear box. Loosen the capscrews and locknuts and slide the yoke off the input shaft. If the traction unit will be used without the cutting unit, drive the roll pin out of the yoke at the traction unit PTO shaft and remove the entire drive shaft from the traction unit.

1. Drive shaft yokes

Figure 9

2. Yokes in phase

3. Roll pin & capscrews

DANGER

Do not start the engine and engage the PTO lever when the PTO shaft is not connected to the gear box on the cutting unit. If the engine is started and the PTO shaft is allowed to rotate, serious injury could result.

4. Disconnect the cotter pins and clevis pins securing the lift

chains to the lift arms.

WARNING

Since the right-hand push arm is spring loaded and the lefthand push arm is spring loaded, a helper is needed to push the arm down. Sudden release of the push arm could cause injury.

5. Have a helper push down on the right push arm while you

remove the capscrews, flatwashers and locknuts securing the ball joint mount to the castor arm on the cutting unit. Now the helper can carefully allow the push arm to move upward, which will gradually release the spring load.

6. Have a helper push down on the left push arm while you

1. R. H. Push arm 4. Capscrews & washers

Figure 10

2. Castor arm 5. Ball joint

3. Ball joint mount 6. Jam nut

Figure 11

1. L. H. Push arm 4. Capscrews & washers

2. Castor arm 5. Ball joint

3. Ball joint mount 6. Jam nut

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7. Roll the cutting unit away from the traction unit.

MOUNTING THE CUTTING UNIT TO THE TRACTION UNIT (Fig 9–11)

1. Position the machine on a level surface and shut the engine off.

2. Move the cutting unit into position in front of the traction unit.

WARNING

Since the right-hand push arm is spring loaded and the lefthand push arm is spring loaded, a helper is needed to push the arm down. Sudden release of the push arm could cause injury.

3. Have a helper carefully push down on the right push arm until

the holes in the ball joint mount line up with the holes in the castor arm.

4, Secure the ball joint mount to the castor arm with capscrews,

flatwashers and flange nuts. Position flatwashers outside of the castor arm.

5. Have a helper carefully push down on the left push arm until

the holes in the ball joint mount line up with the holes in the castor arm. Immediately slide a 10 x 10 cm block of wood between the top of the push arm and the underside of the chassis.

1. Spring

Figure 12

2. Idler arm

3. Idler arm bracket

Figure 13

1. Gear box plate

2. Capscrews & nuts

WARNING

Make sure the wooden block does not slip out accidentally. Sudden release of the push arm could cause injury

6. Secure the ball joint mount and chain bracket to the castor arm

with capscrews, flatwashers and flange nuts. Position the flatwashers to the outside of the castor arm. Position the chain bracket in the forward set of holes.

7. Carefully remove the wood block holding the push arm down.

Figure 14

Belt Routing

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8. Line up the holes in the yoke and the input shaft of the gear

box. Slide the yoke onto the shaft and secure together with a

roll pin and two locknuts.

⁄16-18 x 1-3⁄4 inch long capscrews and 5⁄16-18

REPLACING THE DRIVE BELT (Fig 12–14)

The blade drive belt, tensioned by the spring-loaded idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are: squealing when the belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Replace the belt if any of these conditions are evident.

1. Lower the cutting unit to the shop floor. Remove the belt cov-

ers from the top of the cutting unit and set the covers aside.

2. Unhook the spring from the idler arm bracket to release belt

tension. Remove the cotter pin and clevis pin securing the idler arm bracket to the idler arm.

3. Remove the capscrews and flange nuts securing the gear box

plate to the deck channels. Lift the gear box plate and the gear box off the deck channels and lay them on top of the deck.

4. Remove the old belt from around the spindle pulleys and

through the idler pulley assembly.

5. Route the new belt around the spindle pulleys and through the

idler pulley assembly, as shown in Figure 13.

6. Reposition the gear box plate on the deck while routing the

belt around the gear box pulley. Mount the gear box plate to the deck with the capscrews and nuts you previously removed.

7. Reinstall the idler arm bracket to the idler arm with a cotter pin

and clevis pin. Hook the spring onto the idler arm bracket. To assure proper tension on the drive belt, extend the spring to a length of 17.8 cm. If the spring is not extended to this length, relocate the spring rod to a new mounting hole further away from the belt.

8. Reinstall the belt covers.

SERVICING THE FRONT BUSHINGS IN THE CASTOR ARMS (Fig 15)

1. Front castor arm tube

Figure 15

2. Bushings

The castor arms have bushings pressed into the top and bottom of

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the tube and after many hours of operation, the bushings will wear. To check the bushings, move the castor fork back and forth and from side to side. If the castor spindle is loose inside the bushings, bushings are worn and must be replaced.

1. Raise the cutting unit so its wheels are off the floor and block

it so that it cannot fall accidentally.

2. Remove the lynch pin, spacer(s) and thrust washer from top

of the castor spindle.

3. Pull the castor spindle out of the mounting tube. Allow the

thrust washer and spacer(s) to remain on bottom of the spindle.

4. Insert a pin punch into the top or bottom of the mounting tube

and drive the bushing out of the tube. Also drive the other bushing out of the tube. Clean inside the tubes to remove dirt.

5. Apply grease to the inside and outside of the new bushings.

Using a hammer and flat plate, drive the bushings into the mounting tube.

6. Inspect the castor spindle for wear and replace it if damaged.

7. Push the castor spindle through the bushings and mounting

tube. Slide the thrust washer and spacer(s) onto the spindle. Install the tensioning cap on the castor spindle to retain all parts in place.

SERVICING THE CASTOR WHEELS AND BEARINGS (Fig. 16)

The castor wheel rotates on a high-quality roller bearing and is supported by a spanner bushing. Even after many hours of use, provided that the bearing was kept well-lubricated, bearing wear will be minimal. However, failure to keep the bearing lubricated will cause rapid wear. A wobbly castor wheel usually indicates a worn bearing.

1. Remove the locknut from the capscrew holding the castor

wheel assembly between the castor fork. Grasp the castor wheel and slide the capscrew out of the fork.

1. Castor wheel

Figure 16

2. Capscrew & locknut

3. Bushing (2)

4. Spanner bushing

5. Roller bearing

2. Pull the spanner bushing out of the wheel hub.

3. Remove the bushing from the wheel hub and allow the bear-

ing to fall out. Remove the bushing from the opposite side of the wheel hub.

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4. Check the bearing, spanner and inside of the wheel hub for

wear. Replace defective parts.

5. To assemble the castor wheel, push the bushing into wheel hub.

Slide the bearing into the wheel hub. Push the other bushing into the open end of the wheel hub to captivate the bearing inside the wheel hub.

6. Carefully slide the spanner through the bushings and the wheel

hub.

7. Install the castor wheel assembly between the castor fork and

secure in place with a capscrew and locknut.

8. Lubricate the castor wheel bearing through the grease fitting,

using No. 2 general purpose lithium base grease.

REMOVING THE CUTTER BLADE (Fig. 17)

The blade must be replaced if a solid object is hit, the blade is outof-balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous.

1. Blade bolt

Figure 17

2. Lockwasher

3. Anti-scalp cup

1. Raise the cutting unit to its highest position, shut the engine off

and engage the parking brake. Block the cutting unit to prevent it from falling accidentally.

2. Grasp the end of blade using a rag or thickly padded glove.

Remove the blade bolt, lockwasher, cup and blade from the spindle shaft.

WARNING

• Trying to straighten a blade that is bent or welding a broken or cracked blade may result in serious personal injury and/or discontinued safety certification of the product

• Do not try to straighten a blade that is bent, and never weld a broken or cracked blade.

• Always replace a damaged blade

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3. Install blade–sail facing toward the cutting unit with the cup,

lockwasher and blade bolt. Tighten the blade bolt to 85-110 ftlb.

INSPECTING AND SHARPENING BLADE (Fig. 18–19)

1. Raise the cutting unit to the highest position, shut the engine

off and engage the parking brake. Block the cutting unit to prevent it from falling accidentally.

2. Examine the cutting ends of the blade carefully, especially

where the flat and curved parts of the blade meet (Fig. 26-A). Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine. If you notice wear (Fig. 26-B), replace the blade: refer to Removing Cutter Blade.

WARNING

If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Fig. 26-C). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to yourself or bystander.s.

1. Sail

Figure 18

2. Wear

3. Slot formed

3. Inspect the cutting edges of all blades. Sharpen the cutting

edges if they are dull or nicked. Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure of sharpness (Fig. 27). The blade will remain balanced if the same amount of metal is removed from both cutting edges.

4. To check the blade for being straight and parallel, lay it on a

level surface and check its ends. Ends of blade must be slightly lower than the center, and the cutting edge must be lower than the heel of the blade. This blade will produce a good quality of cut and require minimal power from the engine. By contrast, a blade that is higher at the ends than the center, with a cutting edge higher than the heel, must be replaced.

5. Install the blade-sail facing toward the cutting unit with the

cup, lockwasher and blade bolt. Tighten the blade bolt to 115–149Nm

1. Sharpen at this angle only

Figure 19

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CORRECTING CUTTING UNIT MISMATCH

If there is mismatch between the blades, the grass will appear streaked when it is cut. Correct this by making sure the blades are straight and all blades cut on the same plane.

1. Using a 1-meter long carpenters level, find a level

surface on the shop floor.

2. Raise the height of cut to the highest position.

3. Lower the cutting unit onto a flat surface. Remove

the covers from the top of the cutting unit.

4. Unhook the spring from the idler arm bracket to

release belt tension.

the belt covers.

IDENTIFICATION AND ORDERING

MODEL AND SERIAL NUMBERS

The cutting deck has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate on rear of the mower deck, under cover. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained.

To order replacement parts from an authorized TORO Distributor, supply the following information:

1. Model and serial numbers of the machine.

5. Rotate the blades until the ends face forward and

backward. Measure from the floor to the front tip of the cutting edge and remember this dimension. Then rotate the same blade so that its opposite end is forward and measure again. The difference between dimensions must not exceed 32 mm. If it does, replace the blade because it is bent. Make sure to measure all blades.

6. Compare measurements of the outer blades with the

center blade. The center blade must not be more than 94mm lower than the outer blades. If the center blade is more than 94mm lower than the outer blades, go to step 7 and add shims between the spindle housing and the bottom of the cutting unit.

7. Remove the capscrews, flatwashers, lockwashers and

nuts from the outer spindle in the area where shims must be added. To raise or lower the blade, add a shim, Part No. 3256-24, between the spindle housing and the bottom of cutting unit. Continue to check alignment of blades and add shims until the tips of the blades are within the required dimension.

2. Part number, description and quantity of parts

desired.

Note: Do not order by reference number if a parts catalog is being used; use the part number.

IMPORTANT: Do not use more than three shims at any one hole location. Use decreasing numbers of shims in adjacent holes if more than one shim is added to any one hole location.

8. Hook the spring onto the idler arm bracket. Reinstall

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