Toro 78449 Operator's Manual

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48in Side Discharge Mower

for 5xi Garden Tractors

Model No. 78449—Serial No. 230000001 and Up

Form No. 3326-570

Operator ’s Manual

Original Instructions (GB)

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 3. . . . . . . . . . . . . . . . . . .

Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling the Mower 4. . . . . . . . . . . . . . . . . . . . .

Installing the Mower 5. . . . . . . . . . . . . . . . . . . . . .

Attaching the PTO Drive Belt 7. . . . . . . . . . . . . . .

Adjusting the Mower 8. . . . . . . . . . . . . . . . . . . . . .

Removing the Mower 11. . . . . . . . . . . . . . . . . . . . . .

Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Mower 13. . . . . . . . . . . . . . . . . . . . . .

Cutting Modes 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Front Wheels 13. . . . . . . . . . . . . . . . .

Check for Debris 13. . . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 13. . . . . . . . . . . . . . . . . . . . .

Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 14. . . . . . . . .

Servicing the Blades 15. . . . . . . . . . . . . . . . . . . . . . .

Greasing the Blade Spindles 16. . . . . . . . . . . . . . . . .

Checking PTO Drive Belt Tension 16. . . . . . . . . . . .

Extending PTO Drive Belt Life 17. . . . . . . . . . . . . .

Replacing the Blade Drive Belt 17. . . . . . . . . . . . . .

Washing the Mower 17. . . . . . . . . . . . . . . . . . . . . . .

Storage 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

Figure 1

1. Location of the model and serial numbers

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

Model No.

Serial No.

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

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

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

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

m-3520

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

Printed in the USA

Safety and Instruction Decals

This machine meets or exceeds the EN 836-1997 and ISO 5395-2001 specifications in effect at the time of production. However, 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. Refer to your tractor Operator’s Manual for additional safety instructions.

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

93-7282

1. Stop the engine and remove the ignition key before leaving the machine

2. Read the

Manual.

3. Wheel height

Operator’s

93-7316

1. Thrown object hazard—stay a safe distance from the machine.

2. Thrown object hazard, mower—keep the deflector in place.

3. Cutting/dismemberment of hand or foot—stay away from moving parts.

93-7317

1. Thrown object hazard—stay a safe distance from the machine.

2. Thrown object hazard, mower—keep the deflector in place.

3. Cutting/dismemberment of hand or foot—stay away from moving parts.

98-3480

98-3481

93-9367

1. Crushing hazard of hand—keep hands a safe distance from the hazard area.

Setup

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

Loose Parts

Note: Use the chart below to identify parts used for assembly.

Description Qty. Use

Discharge chute Nylon washer, 3/8 in. Spring Rubber bushing Flat washer, 1/2 in. Locknut, 3/8 in. Cotter pin, 3/4 in.

Pulley box PTO drive belt

Assembling the Mower

Installing the Discharge Chute

1. Place the short end of the spring into the small hole in

the discharge chute (Fig. 2).

1 2 1 1 1 1 1

1 1

Install the discharge chute

Install the PTO drive belt

4. Slide the rubber bushing and nylon washer over the stud

at the front of the mower.

5. Place the discharge chute over the stud and secure it

with a second nylon washer and a locknut (3/8 in.) (Fig. 2).

6. Tighten the locknut flush with the end of the stud.

Important The discharge chute must be spring loaded

in the down position. Lift the chute up and release it to test that it snaps to the full down position.

1. Discharge chute

2. Spring

3. Cotter pin, 3/4 in.

4. Washer, 1/2 in.

5. Rubber bushing

2. Position the spring and discharge chute over the post on

the rear of the mower and secure them with a washer (1/2 in.) and a cotter pin (3/4 in.) (Fig. 2).

3. Ensure that the loop in the spring slides over the stud on

the mower housing.

Figure 2

6. Plastic washer

7. Jam nut, 3/8 in.

8. Loop in spring

9. Post on mower housing

10. Stud on mower housing

m-3144

Danger

Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blades 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 the discharge area or mower

blades unless you move the power take off (PTO) to Off and rotate the ignition key to Off. Also remove the key and pull the wires off of the spark plugs.

Mower Belt Routing

Route the mower belt as shown in Fig. 3. Ensure that you install the belt on the lower mower deck pulley.

m-3525

Figure 3

Top View

1. Mower belt 2. Mower deck pulley

Installing the Mower

Preparing the Tractor

Install the mower on a level concrete surface. Rougher dirt or lawn surfaces make installation more difficult.

m–3433

Figure 4

1. Clevis pin 2. Hairpin cotter

4. Attach the pulley box if it is not already on the tractor (Fig. 5).

1. Position the tractor and mower side by side, with the

mower on the right side of the tractor.

2. Set the parking brake, raise the attachment lift, stop the

engine, and remove the ignition key.

3. If you have previously had a snowthrower, blade, or

tiller attached to the attachment lift, remove the two clevis pins on each side of the attachment lift (Fig. 4).

Figure 5

1. Attach-A-Matic latches

2. Pulley box

3. Idler pulley

4. Belt tension release arm

5. Belt tension adjustment knob

6. Belt tension indicators

7. Attach-A-Matic buttons (one on each side)

A. Ensure that the latches on the tractor’s front

Attach-A-Matic are open.

B. Slide the pulley box into the Attach-A-Matic

latches and seat it.

C. Close the latches.

m–5510

Attaching the Mower

1. Set the mower wheels for the lowest height of cut.

2. Move the attachment lift to the full up position.

3. From the right side of the tractor, slide the mower under

the tractor.

4. Position the mower so that the slots in the side of each

of the mower mounting brackets (Fig. 6) are aligned directly below the tractor attachment lift arm.

1. Slots in the side mounting brackets (2)

2. Belt guide

Figure 6

3. Front to rear adjustment rod

m–3519

m–3456

Figure 7

Left Side of Tractor Shown

1. J-pin 2. Mower slot in side mounting bracket.

7. On the left side, pull out the attachment lift J-pin and

slide it into the slot on the other mower mounting bracket.

8. After the two J-pins are seated through the mower

mounting brackets, using the attachment lift and your hand on the right front adjustable mower wheel bracket (Fig. 8), position the mower so its attachment bar fits into the mid Attach-A-Matic mount.

Caution

5. Start the tractor.

6. Lower the attachment lift arm fully and adjust the

mower position until you can pull out on the J-pin of the lift arm and slide it into the slot in the mounting bracket of the mower (Fig. 7).

Movement of the attachment lift between the mower mounting brackets and the attachment lift arms can injure a person when aligning the deck with the lift arms.

• Keep hands away from moving parts while

operating the attachment lift.

• Always position the mower with your hand on

the right front mower wheel bracket.

• Never try to position the mower with your

hands on the mower mounting brackets or below the mower housing.

Figure 8

1. Place hand here

9. Turn the lever of the Attach-A-Matic

counterclockwise to lock the mower to the tractor (Fig. 9).

Caution

Components under the hood will be hot if the tractor has been running. If you touch hot components you may be burned.

Allow the tractor to cool before performing maintenance or touching components under the hood.

2. Release the belt tension release arm on the pulley box

housing and swing it out toward you (Fig. 10).

m–35211

Figure 10

1. Belt tension release arm

2. Belt tension indicators

3. Belt tension adjustment knob

4. Seating position for tension arm

5. Belt tension released

m–5511

m–3611

Figure 9

1. Attach-A-Matic button

2. Attach-A-Matic lever

3. Lock

10.Set the parking brake, lower the attachment lift, stop the

engine, and remove the ignition key.

Attaching the PTO Drive Belt

1. Remove the tractor grill.

3. Extend the belt through the center of the pulley box,

between the two pulleys.

4. Position the belt into the groove of the PTO pulley

(Fig. 11), making sure it is also under the pulleys in the pulley box.

m–4231

Figure 11

1. Pulley box pulley

2. PTO pulley

3. PTO drive belt

5. Hang the belt over the mower, then thread it forward

through the belt guide (Fig. 12) on the mower.

D. Swing the tension release arm into the pulley box

and seat it by moving it into the position shown in Figure 10.

9. Loosen the belt guide bolt (Fig. 14).

m–3457

Figure 12

1. Belt 2. Belt guide

6. Loop the other end of the belt over the drive pulley of

the mower. Additional belt slack can be obtained (if needed) by turning the belt tension adjustment knob (Fig. 10).

7. Make certain that the wide side of the PTO drive belt is toward the outside diameter of all (four) pulleys (Fig.

13).

m–3465

Figure 14

1. Belt guide

2. Belt

3. Belt touches here

4. Belt guide bolt

10.Adjust the belt guide so that it just touches the belt on

the inside arm of the guide (toward the center of the mower) (Fig. 14).

11. Tighten the belt guide bolt.

12.Replace the front grill of the tractor.

Adjusting the Mower

Adjusting the Height of Cut

You can adjust the rear support wheels in different hole locations for 1-1/2 to 4-1/2 in. (4 to 11 cm) heights of cut.

1. Start the tractor, set the parking brake, and raise the

mower. Get off the tractor.

m–4230

Figure 13

1. Pulley outside diameter 2. Wide side of belt

8. Adjust the belt tension. A. Push the belt tension release arm toward the pulley

box to tension the belt.

B. Check the tension indicators on front of the pulley

box. The two arrow points on the indicators should line up (Fig. 10).

C. If the tension indicators do not line up, release the

belt tension, turn the adjustment knob and repeat steps A through C until the indicators line up (Fig. 10).

2. Pull the height-of-cut lever out to disengage it from the

quadrant (Fig. 15).

Front

m–3474

Figure 15

1. Height-of-cut lever

2. Quadrant

3. High

4. Low

3. Adjust the height-of-cut to the desired level (Fig. 15).

4. Release the lever inward to lock it into the quadrant

(Fig. 15).

5. Adjust the front wheels in the proper hole location for

the selected height-of-cut; refer to Adjusting the Two Front Wheels, page 13.

Checking the Mower Level

For optimum efficiency, check the level of the mower after installation and periodically, to ensure that the blades are 1/8 in. (3 mm) lower in the front than in the rear.

Check and adjust the mower on a flat, level surface, preferably concrete. Before checking the mower level, set the air pressure in the front and rear tires as specified in the tractor Operator’s Manual. Place the mower height-of-cut lever to the middle cut position. Ensure that the two adjustable front wheels are off of the ground.

m–3528

Figure 16

1. Blade oriented front to rear

2. Measure front blade tip

3. Rotate front tip to rear and measure

4. Measure here (side to side)

3. Measure the distance from the front tip of the blade

(Fig. 16) to the flat surface.

4. Carefully rotate the blade tip until it is in the rear

position and measure it in that position. When the blade tip is in the front position, it should be

1/8 in. (3 mm) lower than when it is in the rear position.

5. If an adjustment is required, turn the adjusting nut

(Fig. 17) on the back of the mower. To raise the front of the mower, turn the adjustment nut clockwise. To lower the front of the mower, turn the nut counterclockwise.

1. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

2. Carefully rotate one of the blades so it is oriented front

to rear (Fig. 16).

m–3519

Figure 17

1. Front to rear adjustment rod

Adjusting the Side-to-Side Blade Cut

This optional adjustment is available if necessary to compensate for uneven side-to-side cut.

Equalize side-to-side cut by adjusting the two carriage bolts (Fig. 18) on the mower. Check the height of the blade at outside blade tips (Fig. 16).

m–3459

Figure 18

1. Side-to-side adjustment bolts

Adjusting the Blade Slope for Transport

Because the attachment lift is used when the PTO drive is engaged, you must adjust the transport blade slope to extend the PTO drive belt life. This adjustment also provides adequate transport height.

m–3518

Figure 19

Right Side of Tractor Shown

1. Indicator

2. Adjustment cam

3. Lift arm

4. Pivot point

5. Lowers front of deck

6. Raises front of deck

2. If they are not, park the machine on a level surface, set

the parking brake, lower the attachment lift to take pressure off the cams, stop the engine, and remove the ignition key.

Important Failure to adjust for blade slope in transport

can result in drive belt failure and/or insufficient transport height.

1. Check to see that both adjustment cams are oriented

with the indicator toward the pivot point at the rear of the tractor (Fig. 19).

Caution

Movement of the attachment lift between the mower mounting brackets and the attachment lift arms can injure a person when aligning the deck with the lift arms.

• Keep hands away from moving parts while

operating the attachment lift.

• Set the parking brake, lower the attachment lift,

stop the engine, and remove the ignition key before making any adjustments.

3. Loosen the nuts on the cams, rotate the cams to the

proper position, then tighten the cam nuts.

4. Start the tractor and raise the attachment lift.

5. Stop the engine and remove the ignition key.

6. Check the slope of one of the blades (Fig. 16).

A. Measure the distance from the front tip of the blade

to the flat surface.

B. Carefully rotate the blade tip until it is in the rear

position and measure it there.

When the blade tip is in the front position, it should be approximately 1/4 in. (7 mm) lower than when it is in the rear position.

7. To adjust the blade slope, start the tractor, lower the

attachment lift to take pressure off the cams, stop the engine, and remove the ignition key.

8. Loosen the cam nuts and equally rotate the left and right

cams down to raise the front of the mower, or up to lower it. Tighten the nuts.

9. Repeat steps 4 through 8 until the slope of the blade is

approximately 1/4 in. (7 mm) lower in the front than it is in the rear.

Removing the Mower

Remove the mower on a level, concrete surface. Rougher dirt or lawn surfaces make removing the mower more difficult.

1. Set the parking brake, start the tractor, and raise the

attachment lift.

m–5511

Figure 20

1. Belt tension release arm

2. Belt tension adjustment knob

3. Belt tension released

7. Remove the belt from around the PTO pulley (Fig. 21). Additional belt slack can be obtained (if needed) by turning the belt tension adjustment knob.

2. Get off the tractor. Place the mower height-of-cut lever

in the lowest cut position.

3. Lower the mower until its weight is completely on its

wheels, not on the tractor.

4. Stop the engine and remove the ignition key.

5. Remove the grill.

Caution

Components under the hood will be hot if the tractor has been running. If you touch hot components you may be burned.

Allow the tractor to cool before performing maintenance or touching components under the hood.

6. Release the belt tension release arm on the pulley box to

release the tension on the drive belt (Fig. 20).

m–3454

Figure 21

1. PTO pulley

8. Replace the grill.

9. Press the button of the mid Attach-A-Matic and twist

the lever clockwise to release the mower (Fig. 22).

m–3457

Figure 22

1. Mid Attach-A-Matic button

2. Mid Attach-A-Matic lever

10.Pull the two spring loaded J-pins from the deck lift arms

and twist them slightly so that they stay disengaged (Fig. 23).

m–3456

Figure 23

1. J-pin

11. If you wish to remove the pulley box, push the latch

release buttons on the front Attach-A-Matic (Fig. 24) and raise the latch levers to open the latches holding the pulley box. Remove the pulley box.

m–5511

Figure 24

1. Front Attach–A–Matic button (one on each side)

2. Front Attach–A–Matic latches

3. Pulley box

12.Start the tractor and raise the attachment lift to provide ample clearance to slide out the mower.

13.Stop the engine and remove the ignition key.

14.Slide the mower out from the right side of the tractor.

Operation

Danger

• 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 the discharge area or mower

blades unless you move the PTO to Off and rotate the ignition key to Off. Also remove the key and pull the wires off of the spark plugs.

Operating the Mower

The power take off (PTO) engages and disengages power to the mower. The attachment lift lever raises and lowers the mower. For detailed information on operating your tractor’s controls, refer to the tractor Operator’s Manual.

Cutting Modes

Depending on what you install on your mower, you can use it to side discharge, mulch, or bag grass clippings.

Side Discharge Mode

All mower models have a hinged discharge chute that disperses clippings to the side and down toward the turf.

Bagging Mode

You can also purchase various grass baggers and catchers from your Authorized Toro Dealer that you can install on your mower and tractor. A grass bagger/catcher catches the grass clippings, allowing you to remove them completely from your lawn.

Adjusting the Front Wheels

The two front adjustable wheels must be adjusted in the proper hole location each time you change the height-of-cut.

1. After selecting a height of cut, make sure the front

adjustable wheels are approximately 3/8 in. (9.5 mm) off the ground.

2. To adjust the wheel height, remove the hairpin cotter

and pin to change hole location (Fig. 25).

1233

Figure 25

1. Wheel

2. Pin

3. Hairpin Cotter

Check for Debris

Each time you use the mower, be sure to check for debris build up on and inside the rear transaxle cover (Fig. 26). Remove any build up.

m–3436

Figure 26

1. Rear transaxle cover

3. Select a hole position so the wheel is approximately 3/8

in. (9.5 mm) off the ground for the height-of-cut position to be used (Fig. 25).

4. Insert the pin and secure it with a hairpin cotter.

5. Repeat this adjustment on the other wheel.

Tips for Mowing Grass

• For best mowing and maximum air circulation, operate

the engine at the fastest throttle position.

• When using the mower for the first time, cut grass

slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground.

• Cut only about 1/3 of the grass blade. Cutting more than

that is not recommended, unless grass is sparse or it is late fall when grass grows more slowly.

• Alternate mowing direction to keep the grass standing

straight. This also helps disperse clippings which enhances decomposition and fertilization.

• Avoid mowing in reverse.

• To improve cut quality, use slower ground speed. For

best results on average lawns, operate the engine at full throttle while controlling the ground speed with the transmission. Operate the tractor at 2 to 3.5 MPH (3.2 to 5.6 kms/hr) while mowing grass. Excessive ground speed may result in uneven cutting.

• Air is required to thoroughly cut grass clippings, so do

not set the height-of-cut so low as to totally surround the mower by uncut grass.

• Always try to have one side of the mower free from

uncut grass, which allows air to be drawn into the mower.

• To cut long or wet grass, raise the cutting height and cut the grass. Then, cut the grass again using the lower, normal setting.

• If you must stop while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously mowed area with the blades engaged and then raise the attachment to disperse the clippings evenly.

• Use the washout port to clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

• If the cutting width of the mower is wider than the

mower you previously used, raise the cutting height to ensure uneven turf is not cut too short. Average lawns are usually cut at a height between 2 and 3 inches (5 to

7.6 cm).

• Keep the blade sharp. A sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding slows growth and increases the chance of disease. Every 30 days, check the blades for sharpness and file down any nicks.

Maintenance

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

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use • Wash the underside of the mower.

5 hours

25 hours • Grease the mower spindles.

50 Hours • Check the belt tension.

Storage Service

Maintenance Procedure

• Inspect the blades.

• Check the belt tension (initial check only).

• Wash the underside of the mower.

• Inspect the blades.

• Grease the mower spindles.

• Check the belt tension.

• Check the belts for wear and cracks.

• Paint chipped surfaces.

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 wires from the spark plugs before you do any maintenance. Set the wires aside so that it does not accidentally contact the spark plugs.

Servicing the Blades

To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to have extra blades.

Note: A block of wood may be wedged between the blade and the mower to lock the blade when you are removing the nut.

3. Inspect all parts. If damage is noticed, install new parts.

Danger

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.

1. Remove the mower; refer to Removing the Mower,

page 11.

2. Carefully turn the mower over to expose the blades

Inspecting the Blades

1. Inspect the cutting edges (Fig. 27).

2. If the edges are not sharp or have nicks, remove the

blades and sharpen them.

3. Inspect the blades, especially the curved area (Fig. 27).

4. If you notice any damage, wear, or a slot forming in this

area (Fig. 27), immediately install a new blade.

m–3585

Figure 28

1. Nut

2. Flat washer—thin

3. Blade

4. Washer—thick

5. Spindle

Sharpening a Blade

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

blade (Fig. 29). Maintain the original angle. The blade retains its

balance if the same amount of material is removed from both cutting edges.

151

Figure 27

1. Cutting edge

2. Curved area

3. Wear/slot forming

Removing the Blades

Important There are two different sizes of blades. The

shorter blade goes into the center spindle. The two longer blades go on the outside spindles (Fig. 31).

1. Hold the blade end using a rag or thickly padded glove.

2. Remove the nut, two washers, and blade (Fig. 28).

Figure 29

1. Sharpen at original angle

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

balancer (Fig. 30). If the blade stays in a horizontal position, the blade is

balanced and can be used.

Figure 30

1. Blade 2. Balancer

3. If the blade is not balanced, file some metal off the back

side of the blade.

4. Repeat steps 2 and 3 until the blade is balanced.

Installing the Blades

Important There are two different sizes and shapes of

blades. The shorter blade goes into the center spindle. The two longer blades go on the outside spindles (Fig. 32). See figure 31 for the shape difference.

2. Clean the grease fittings (Fig. 33) with a rag.

m–5707

Figure 31

1. Outside blade

2. Center blade

Figure 32

1. Long blade, 16–11/32 in. 2. Short blade, 15–27/32 in.

1. Hold the blade end using a rag or thickly padded glove.

2. Install the thick washer, blade, thin flat washer, and the

nut (Fig. 28).

Important The sail (curved part of the blade) must be

pointing up toward the inside of the mower to ensure proper cutting.

3. Angle on sail of blade

Front

m–3519

Figure 33

3. Scrape any paint off the end of the fittings.

4. Connect a grease gun to each fitting (Fig. 33).

5. Pump grease into the fittings.

6. Wipe up any excess grease.

Checking PTO Drive Belt Tension

Check the PTO drive belt tension after 5 hours of operating with a new belt, then every 50 hours or once a year, whichever occurs first.

1. Check the tension indicators on the front of the pulley

box. If the tension indicators do not line up, release the belt tension and turn the adjustment knob. Push the belt tension release arm back toward the pulley box to tension the belt (Fig. 34).

3. Tighten the nut to 80 to 100 ft.-lb. (109 to 136 N⋅m).

Greasing the Blade Spindles

Grease the mower after every 25 operating hours or once a year, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose grease.

How to Grease

1. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

m–3458

Figure 34

1. Belt tension release arm

2. Belt tension indicators

3. Belt tension adjustment knob

4. Seating position for tension arm

5. Belt tension released

2. Repeat step 1 until the indicators move to the same

position.

2. Remove the pulley cover mounting screws and pulley

covers from the blade pulleys (Fig. 35).

m-3525

Figure 35

Top View

1. Pulley cover screw

2. Pulley cover

3. Belt guide

4. Mower belt

5. Spring

3. Swing the tension release arm into the pulley box by

moving it into the position shown in Figure 34.

Extending PTO Drive Belt Life

The PTO drive belt will provide a long service life if properly installed and operated. Check the following to help extend belt life.

• Maintain correct belt tension.

• Maintain correct mower level.

• Maintain correct blade slope in transport.

• Adjust the position of the mower belt guide.

• Replace damaged pulleys.

• Always operate engine-powered attachments at full

throttle.

• Avoid engaging the PTO when the mower is in tall

uncut grass or weeds.

• Cut tall grass and weeds with the mower in its highest

position, making a second pass cutting at desired height.

• Regularly clean the mower of any buildup of grass

clippings.

• Use low range or reduce ground speed when mowing in

heavy conditions or when mulching or bagging.

3. Release the spring (Fig. 35).

4. Remove the belt from the pulleys (Fig. 35).

Installing the Blade Drive Belt

1. Install the new belt around the blade pulleys and the

idler pulleys.

2. Attach the spring (Fig. 35).

3. Install the left and right pulley covers with the

mounting screws (Fig. 35).

4. Install the mower; refer to Installing the Mower,

page 5.

Washing the Mower

After each use, wash the underside of the mower to prevent grass build-up and improve performance.

1. Park the tractor on a hard level surface.

2. Apply the parking brake, start the tractor, and raise the

attachment lift.

3. Get off the tractor. Place the mower height-of-cut lever

in the lowest cut position.

4. Lower the attachment lift, stop the engine, and remove

the ignition key.

Replacing the Blade Drive Belt

Removing the Blade Drive Belt

1. Remove the mower; refer to Removing the Mower,

page 11.

5. Attach a hose coupling to the end of the washout fitting

and turn water on high (Fig. 36).

Note: Spread petroleum jelly on the washout fitting o-ring to help the coupling slide on easier and protect the o-ring.

9. Turn the water off and remove the hose coupling from

the washout fitting.

Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes. Then repeat the process.

10.Run the mower again for one to three minutes to

remove excess water.

Warning

m–3586

Figure 36

1. Washout fitting

2. Coupling

6. Sit on the seat and start the engine.

7. Engage the PTO and let the mower run for one to three

minutes.

8. Disengage the PTO, stop the engine, and remove the

ignition key. Wait for all moving parts to stop.

3. Hose

Storage

1. Clean dirt and chaff from the top of the mower.

2. Scrape heavy buildup of grass and dirt from the

underside of the mower.

3. Use the wash out port to wash the underside of the

mower; refer to Washing the Mower, page 17.

4. Wash the top side of the mower with a garden hose.

A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with the blade or thrown debris will cause injury or death.

• Replace a broken or missing washout fitting

immediately, before using the mower again.

• Plug any hole(s) in the mower with bolts and

locknuts.

• Never put your hands or feet under the mower

or through openings in the mower.

5. Check the condition of the blades.

6. Check the condition of the blade drive belt.

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

replace any part that is damaged.

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

available from you Authorized Service Dealer.

9. Store the mower in a clean, dry garage or storage area.

Cover the mower to protect it and keep it clean.

Troubleshooting

Problem Possible Causes Corrective Action

Abnormal vibration.

Blades do not rotate.

Uneven cutting height.

1. A blade is bent or unbalanced. 1. Install new blades.

2. A blade mounting bolt is loose. 2. Tighten the blade mounting bolts.

3. The engine mounting bolts are

loose.

4. A loose engine pulley, idler

pulley, or blade pulley.

5. The engine pulley is damaged. 5. Contact your Authorized

1. The blade drive belt is worn,

loose, or broken.

2. The blade drive belt is off the

pulley.

3. The PTO belt is worn, loose, or

broken.

1. The tire pressure is incorrect. 1. Set tire pressure.

2. The mower is not level. 2. Level the mower from

3. The underside of the mower is

dirty.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley .

Service Dealer.

1. Install a new blade drive belt.

2. Install the blade drive belt and check idler pulley and belt guides for correct position.

3. Install a new PTO belt.

side-to-side and front-to-rear.

3. Clean the underside of the mower.

Insufficient transport height. 1. The lift arm cams are

improperly adjusted.

1. Adjust lift arm cams.

Problem Corrective ActionPossible Causes

PTO drive belt comes off of pulleys,slips or fails.

1. The belt tension is incorrect. 1. Adjust the belt tension.

2. The mower level is incorrect. 2. Adjust the mower level.

3. The blade slope in transport is incorrect.

4. The mower belt guide is loose or incorrectly adjusted.

5. The belt is worn or damaged. 5. Install a new belt.

6. The Pulley is damaged. 6. Contact your Authorized

7. The engine is not at full throttle. 7. Always operate

8. The PTO is being engaged when the mower is in tall uncut grass or weeds.

9. The mower is overloaded because mulching or bagging requires more power.

10.The mower is overloaded because too much grass is being cut at a time.

3. Adjust the blade slope in transport.

4. Adjust and tighten the belt guide.

Service Dealer.

engine-powered attachments at full throttle.

8. Engage the PTO only in shorter or previously cut grass.

9. Reduce the ground speed when mulching or bagging.

10.Cut tall grass and weeds with the mower in its highest position, making a second pass cutting at height desired.

11.The mower is overloaded because deck is clogged with grass clippings.

12.The mower is overloaded because tractor is mowing too fast for conditions.

11.Clean the mower.

12.Reduce ground speed.

Toro 78449 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual