Toro 36" Side Discharge Mower Attachment Operator's Manual
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Toro 36" Side Discharge Mower: Tackle your lawn care tasks efficiently with this robust and versatile mower. Equipped with a powerful cutting deck, this machine delivers clean and precise cuts, ensuring a well-manicured lawn. Its side discharge capability allows for effective grass dispersal, while the adjustable cutting height provides flexibility to suit your desired lawn length. Enhance your mowing experience with the easy-to-use controls and smooth maneuverability of the Toro 36" Side Discharge Mower.
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FORM NO. 3317–981AGB ProLine 36” Mower for Mid-Size Traction Unit Model No. 30138 – 690001 & Up Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product. Introduction We want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number plate located in a unique place on the product as shown below. The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed. WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed. CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed. Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention. 1 The left and right side of the machine is determined by sitting on the seat in the normal operator’s position. 1074 1. Model and Serial Number Plate For your convenience, write the product model and serial numbers in the space below. Model No: Serial No. Printed in USA Contents Safety and Instruction Decals . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Castor Wheels . . . . . . . . . . . Installing the Carrier Frame to the Traction Unit . . . . . . . . . . . . . . . . . . . . . . Installing the Deflector Guard . . . . . . . . . . Installing the Front Baffle . . . . . . . . . . . . . Installing the Cutting Deck . . . . . . . . . . . . Installing the Drive Belt . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge or Mulch Grass . . . . . . . . . Engaging the Mower Blades (PTO) . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . Tips for Mowing Grass . . . . . . . . . . . . . . . Page 2 3 3 4 4 5 5 6 6 8 8 8 9 10 Page Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Interval Chart . . . . . . . . . . . . . . . . Cutting Blades . . . . . . . . . . . . . . . . . . . . . . Correcting Cutting Unit Mismatch . . . . . . Greasing the Bearings and Bushings . . . . . Replacing the Deck Belt . . . . . . . . . . . . . . Replacing the Drive Belt . . . . . . . . . . . . . . Replacing the Castor Wheel Fork Bushings Servicing the Castor Wheels and Bearings Replacing the Grass Deflector . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 14 16 16 17 18 19 20 20 21 1 Safety 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. See Traction Unit Operator’s Manual for Glossary of Safety Symbols 2 !#$ " !#$ " !#$ " !#$ " !#$ " !#$ " Installation Loose Parts Note: Use the chart below to identify parts used for assembly. DESCRIPTION QTY. USE Castor Wheel Assembly 2 Thrust Washer 8 Spacer 2 Retaining Ring 2 Carrier Frame 1 Flange Screw, 1/2”-13 x 1” (25 mm) 6 Flange Nut, 1/2”-13 6 Adjusting Shaft 2 Jam Nut, 1/2”-13 4 Spacer, 1/2” (13 mm) 2 Spring 2 Bushing 2 Clevis Pin 4 Hairpin Cotter 4 Front Baffle 1 Bolt, 5/16” x 3/4” (19 mm) 6 Locknut, 5/16” 6 Deflector Guard 1 Bolt, 5/16” x 3/4” (19 mm) 2 Locknut, 5/16” 2 Operator’s Manual 1 Read before operating Parts Catalog 1 Ordering parts Install castor wheels to carrier frame Install carrier frame to traction unit Install adjusting shafts Install cutting unit to carrier frame Install front baffle Install deflector guard 3 Installation Installing the Castor Wheels 1. 2. 3. Place two (2) thrust washers onto the castor wheel fork (Fig. 1). Insert the castor wheel fork into the carrier frame mounting tube (Fig. 1). Install the spacer and two (2) thrust washers onto the castor wheel fork, then secure with a retaining ring (Fig. 1). Installing the Carrier Frame to the Traction Unit 1. Align the carrier frame holes with the mounting holes in the traction unit frame (Fig. 2). 2. Fasten each side of the carrier frame to the traction unit with three (3) 1/2” x 1” (25 mm) flange screws and locknuts. Torque the mounting screws to 60–80 ft-lb (81–109 Nm) (Fig. 2). 1 2 3 2 1 4 2 Figure 2 5 1. Carrier Frame Figure 1 1. Retaining Ring 2. Thrust Washer 3. Spacer 4 4. Carrier Frame Mounting Tube 5. Castor Wheel Fork 2. Traction Unit Frame Installation Installing the Deflector Guard Installing the Front Baffle 1. Measure 10 mm in from the rear outer corner of the grass deflector and mark a line to the inside corner (Fig. 3). Cut the grass deflector along the line. 1. 2. Mark and drill a 9 mm hole 13 mm up from the lower edge, and 6.5 mm in from the end of the grass deflector (Fig. 3). Locate the front baffle inside the front of the mower so the left end fits into the angle, and the top fits up against the top front edge. Using the baffle as a guide, mark and drill six (6) 9 mm holes in the front of the mower as shown (Fig. 4). 2. Install the front baffle inside the mower with 5/16” bolts from the inside, and secure with 5/16” thin locknuts (Fig. 4). 3. Hold the deflector guard in a level position along the rear of the deflector. 4. Mark and drill a second 9 mm hole in the grass deflector (Fig. 3). 4 1 3 5 5. Secure the deflector guard to the grass deflector with two (2) 5/16” bolts from the inside, and secure with 5/16” thin locknuts (Fig. 3). 1 2 10 mm 3 ÇÇ ÇÇ ÇÇ 5 2 Figure 4 6.5 mm 13 mm 4 6 1. 36” Mower 2. Front Baffle 3. Drill 9 mm Hole (6) 4. Bolt, 5/16”-18 x 3/4” (19mm) (6) 5. Locknut, 5/16” Thin (6) 2043 Figure 3 1. Grass Deflector 2. Cut off Grass Deflector 3. Mark and drill 9 mm hole (2) 4. Deflector Guard 5. Bolt, 5/16”-18 x 3/4” (19 mm) 6. Locknut, 5/16” Thin 5 Installation Installing the Cutting Deck Installing the Drive Belt 1. Position the cutting deck under the carrier frame. 1. 2. Mount the cutting deck to the carrier frame with four (4) clevis pins and hairpin cotters (Fig. 5). Remove the hand knobs holding the deck cover to the top of the cutting unit and remove the deck cover. 2. Install the drive belt around the drive pulley on the traction unit and the upper groove of the left spindle pulley. The belt must be between the belt guides (Fig. 6). 3. Reinstall the deck cover onto the cutting unit, then reinstall and tighten the hand knobs. Note: All four pins must be in the same hole locations to prevent uneven cutting. 8 1 2 3 9 4 5 1 6 2 7 3 10 4 11 Figure 5 1. 2. 3. 4. 5. 6. 6 1” (25 mm) Cut Height 1-1/2” (38 mm) Cut Height 2” (51 mm) Cut Height 2-1/2” (64 mm) Cut Height 3” (76 mm) Cut Height 3-1/2” (89 mm) Cut Height 7. 8. 9. 10. 11. 4” (102 mm) Cut Height Clevis Pin Carrier Frame Cutting Deck Hairpin Cotter Figure 6 1. Traction Unit Drive Pulley 2. Drive Belt 3. Belt Guide (2) 4. Left Spindle Pulley Installation 4. 5. Thread two (2) 1/2” jam nuts approximately 9” (22.8 cm) up on each adjusting shaft (Fig. 7). 3 4 Slide a 1/2” spacer, spring and bushing onto each adjusting shaft. Make sure to install the bushing with the flange end against the spring (Fig. 7). 1 2 1 3 5 6 4 5 m–2541 2 Figure 8 m–2542 Figure 7 1. 2. 3. 4. 6. 1/2” Jam Nut (2) 1/2” Spacer Spring Bushing 5. Adjusting Shaft 6. Locknut (already installed on Adjusting Shaft) Insert the spring end of the adjusting shaft into the hole in the deck mounting bracket. Note that the small end of the bushing fits into the hole in the deck bracket. Insert the locknut end of the adjusting shaft into the carrier frame mounting tab (Fig. 8). 7. To tension the belt, tighten the front jam nut on each adjusting shaft until the springs are compressed to 5” (12.7 cm). Measure the spring compression between the spacer and the bushing (Fig. 8). 8. Tighten the rear jam nuts (Fig. 8). 1. 5” between the Spacer and Bushing 2. Deck Mounting Bracket 3. Front Jam Nut 9. 4. Rear Jam Nut 5. Carrier Frame Mounting Tab Check the position of the belt guides. The guides should be positioned about 1/8” (3 mm) away from the belt (Fig. 9). Adjust the belt guides as necessary. 1 2 2 Figure 9 1. Drive Belt 2. Belt Guide 10. Check the front-to-rear blade pitch. Refer to Setting the Front-to-Rear Pitch in the Maintenance section. 7 Operation Side Discharge or Mulch Grass Engaging the Mower Blades (PTO) The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. The blade control switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades. POTENTIAL HAZARD • Without the grass deflector or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. 1. Pull on the upper control bar to stop the machine (Fig. 10). 2. To engage the blades, squeeze the blade control bail against the upper control bar. 3. Press the blade control rocker switch forward to “ON”. Hold the blade control bail against the control bar while operating. WHAT CAN HAPPEN • Contact with rotating mower blade(s) and Note: thrown debris will cause injury or death. HOW TO AVOID THE HAZARD • 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 move the power take-off (PTO) to “OFF” and rotate the ignition key to “OFF.” Also remove the key and pull the wire(s) off the spark plug(s). 4. Repeat the procedure to engage the mower blades if the blade control bail is released. To disengage the blades, release the blade control bail, or push the blade control switch to the “OFF” position. 2 1 3 m–2130 Figure 10 1. Upper Control Bar 2. Blade Control Bail 8 3. Blade Control Switch (PTO) Operation Adjusting the Height-of-Cut 1 8 2 3 The height-of-cut is adjustable from 1” to 4” (25 to 102 mm) in 1/2-inch (13 mm) increments by relocating the clevis pins in different hole locations in brackets at each corner of the cutting unit (Fig. 11). 4 5 6 7 Stop the engine before adjusting the height-of-cut. Note: All four pins must be in the same hole location for even cutting. 9 Figure 11 1. 2. 3. 4. 5. 1” (25 mm) Cut Height 1-1/2” (38 mm) Cut Height 2” (51 mm) Cut Height 2-1/2” (64 mm) Cut Height 3” (76 mm) Cut Height 6. 7. 8. 9. 3-1/2” (89 mm) Cut Height 4” (102 mm) Cut Height Clevis Pin Hairpin Cotter 9 Operation Tips for Mowing Grass Fast Throttle Setting Cutting Speed To improve cut quality, use a slower ground speed. For best mowing and maximum air circulation, operate the engine at “FAST.” 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. Avoid Cutting Too Low Cutting a Lawn for the First Time If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut. Cut 1/3 of the Grass Blade It is best to 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. Mowing Direction Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. Mow at Correct Intervals Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting. 10 If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short. Long Grass When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades “ENGAGED”. Keep the Underside of the Mower Clean 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. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine TORO replacement blade. Maintenance Service Interval Chart Service Operation Each Use Cutting Blades – check 8 Hours 25 Storage Hours Service X X Belts – check for wear/cracks X Blade Spindle Bearings – grease X Castor Wheels – grease Mower Housing – clean Notes X X Chipped Surfaces – paint Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. X X X Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to “OFF” to stop the engine. Remove the key and disconnect the spark plug wire(s) from the spark plug(s). POTENTIAL HAZARD • A blade that is worn or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders. HOW TO AVOID THE HAZARD • Periodically inspect the blade for wear and damage. Immediately install a new blade if it is worn or damaged. 11 Maintenance Inspecting the Blades Checking for Bent Blades 1. Inspect the cutting edges (Fig 12). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 13. 1. 2. Inspect the blades, especially the curved area (Fig. 12). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 12), immediately install a new blade. Rotate the blades until the ends face forward and backward (Fig. 13). Measure from a level surface to the cutting edge of the blades (Fig. 14). Note this dimension. m–2466 2 1 Figure 13 3 m–151 Figure 12 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming Figure 14 2. 12 m–1087 Rotate the opposite ends of the blades forward. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8” (3 mm). If this dimension exceeds 1/8” (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 13. Maintenance Sharpening the Blades 1. POTENTIAL HAZARD • A blade that is bent or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 16). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders. 1 HOW TO AVOID THE HAZARD • Always replace bent or damaged blade with m–1854 a new blade. • Never file or create sharp notches in the edges or surfaces of blade. Figure 16 1. Sharpen at original angle 2. Removing the Blades Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, lock washer, anti–scalp cup and blade from the spindle shaft (Fig. 15). 2 2 1 m–1855 Figure 17 1. Blade 2. Balancer Installing the Blades 1. 3 1 2. 5 1082 Figure 15 Install the blade onto the spindle shaft (Fig. 15). IMPORTANT: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 4 1. Sail Area of Blade 2. Blade 3. Anti–scalp Cup Check the balance of the blade by putting it on a blade balancer (Fig. 17). 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. 15). Repeat this procedure until the blade is balanced. Install the anti–scalp cup, lock washer and blade bolt (Fig. 15). Torque the blade bolt to 85–110 ft-lb (115–149 Nm). 4. Lock Washer 5. Blade Bolt 13 Maintenance Correcting Cutting Unit Mismatch Setting the Front-to-Rear Pitch 1. Check the tire pressure. If one cutter blade cuts lower than the other, correct as follows: 2. Position the blades front-to-rear (Fig. 18). Measure at “C” and “D” locations (Fig. 18) from a level surface to the cutting edge of the blades (Fig. 19). 3. The mower should be 1/8”–5/8” (3–16 mm) lower in front “C” than in the rear “D”. 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 and check that the blades are not bent. Refer to Checking for Bent Blades on page 12. 3. Set the height-of-cut to the 2-1/2” (64 mm) position. Refer to Adjusting the Height-Of-Cut in the Operation section. Make sure the clevis pins are resting on the frame cushions. 4. Rotate the blades so the tips line up with one another. The tips of both blades must be within 1/8” (3 mm) of each other. If the blade tips are not within 1/8” (3 mm) of each other, add shim washers (Part No. 3256-24) between the appropriate spindle housing and the bottom of the cutting unit to align the blades. Figure 18 Figure 19 14 m–1078 m–1087 Maintenance 4. 5. To change the front-to-rear pitch, move an equal number of thrust washers on both castor wheel forks. Move the thrust washers from the top of the carrier frame mounting tube to the bottom to raise the front of the mower. Move the thrust washers from the bottom of the mounting tube to the top to lower the front of the mower. (Fig. 20). Setting the Side-to-Side Leveling Check the side-to-side leveling of the cutting unit. 1. Check the tire pressure. 2. Position the blades side-to-side (Fig. 21). Measure at “A” and “B” locations (Fig. 21) from a level surface to the cutting edge of blades (Fig. 22). 3. The difference between measurements “A” and “B” should be no more than 1/4” (6 mm). 1 1666 Figure 21 2 1 3 m–2558 Figure 22 4. To change the side-to-side leveling, move the thrust washers on one castor wheel fork only. Move the thrust washers from the top of the carrier frame mounting tube to the bottom to raise the corresponding side of the mower. Move the thrust washers from the bottom of the mounting tube to the top to lower the corresponding side of the mower. (Fig. 20). 5. Recheck the front-to-rear pitch of the cutting unit. Figure 20 1. Thrust Washer (locate as required) 2. Carrier Frame Mounting Tube 3. Castor Wheel Fork 15 Maintenance Greasing the Bearings and Bushings The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 11. Grease with No. 2 general purpose lithium base or molybdenum base grease. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Grease the fittings on both spindle bearings (Fig. 24). Note: 3. You can access the spindle grease fittings through the holes in the mower deck cover. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Remove the hand knobs holding the deck cover to the top of the cutting unit and remove the deck cover. 3. Remove the drive belt. Refer to Replacing the Drive Belt, steps 3 and 4 on page 17. 4. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn deck belt (Fig. 24). 5. Install the new deck belt around the right spindle pulley, idler pulley, and in the lower groove of the left spindle pulley (Fig. 24). 6. Reconnect the idler arm spring (Fig. 24). Grease the fittings on the carrier frame mounting tubes and castor wheels (Fig. 23). 1 1 2 3 2 4 5 Figure 24 1. Deck Belt 2. Right Spindle Pulley 3. Idler Arm Spring 4. Idler Pulley 5. Left Spindle Pulley Figure 23 1. Carrier Frame Mounting Tube Grease Fitting 2. Castor Wheel Grease Fitting 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. 16 7. Reinstall the drive belt. Refer to Replacing the Drive Belt, steps 5 and 6 on page 17. 8. Reinstall the deck cover onto the cutting unit, then reinstall and tighten the hand knobs. Maintenance Replacing the Drive Belt 1 2 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 hand knobs holding the deck cover to the top of the cutting unit and remove the deck cover. 3. Loosen the jam nuts on each adjusting shaft to loosen the tension on the drive belt (Fig 25). 3 4 Figure 26 1. Traction Unit Drive Pulley 2. Drive Belt 6. 3. Belt Guide (2) 4. Left Spindle Pulley Tighten the jam nuts on the adjusting shafts until the springs are compressed to a length of 5” (12.7 cm) (Fig 27). 2 2 1 m–2541 Figure 25 1. Jam Nuts 2. Adjusting Shaft 4. Remove the worn drive belt (Fig. 26). 5. Install the new drive belt onto the traction unit drive pulley and the top groove of the left spindle pulley (Fig. 26). 1 m–2541 Figure 27 1. 5” between the Spacer and Bushing 7. 2. Jam Nuts Reinstall the deck cover onto the cutting unit, then reinstall and tighten the hand knobs. 17 Maintenance Replacing the Castor Wheel Fork Bushings 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 29). Clean the inside of the mounting tube. The castor wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the castor forks back and forth and side-to-side. If a castor fork is loose, the bushings are worn and must be replaced. 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 castor wheel fork for wear and replace if necessary (Fig. 28). 7. Slide the castor wheel fork through the bushings in the mounting tube. Replace the spacer and thrust washer(s) onto the fork and secure with the retaining ring (Fig 28). 1. Raise the cutting unit so the castor wheels are off the floor, then block up the front of the mower with jack stands. 2. Remove the retaining ring, thrust washer(s) and spacer from the top of the castor wheel fork (Fig. 28). 3. Pull the castor wheel fork out of the mounting tube, leaving the thrust washer(s) on the bottom of the fork. Remember the location of the thrust washers and spacer on each fork to ensure correct installation, and to maintain a level deck. 1 IMPORTANT: The inside diameter of the bushings may collapse slightly when installed. If the castor wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 in. (28.6mm). 8. Grease the fitting on the carrier frame mounting tube using No. 2 general purpose lithium base or molybdenum base grease. 2 3 2 4 2 1 5 2 m-1076 m-2551 Figure 28 1. Retaining Ring 2. Thrust Washers (locate as required) 3. Spacer 18 4. Carrier Frame Mounting Tube 5. Castor Wheel Fork Figure 29 1. Carrier Frame Mounting Tube 2. Bushing Maintenance Servicing the Castor Wheels and Bearings The castor 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 castor wheel usually indicates a worn bearing. 1. 2. 3. 4. 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. 30). 6. Install the castor wheel into the castor fork and secure with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the castor forks (Fig. 30). 7. Grease the fitting on the castor wheel. Remove the locknut and wheel bolt holding the castor wheel to the castor fork (Fig. 30). 1 Remove the washer and bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 30). Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 30). 2 4 7 Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 30). 6 5 4 3 Figure 30 1. 2. 3. 4. Locknut Wheel Bolt Washer Bushing 5. Spanner Bushing 6. Roller Bearing 7. Wheel Hub 19 Maintenance Replacing the Grass Deflector Storage 1. Remove the locknuts, bolts and springs holding the deflector mounts to the pivot brackets (Fig. 31). 1. Clean any dirt and chaff from the top of the mower. 2. 2. If the pivot brackets need to be replaced, remove the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets. Make sure the carriage bolt heads are on the inside of the cutting unit (Fig. 31). Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose. 3. Check the condition of the blades. Refer to Cutting Blades on page 11. 4. Check the condition of the drive and deck belts. 5. Check and tighten all bolts, nuts and screws. Repair or replace any part that is damaged or defective. 6. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 7. Store the machine in a clean, dry garage or storage area. Cover the machine to protect it and keep it clean. 3. 4. Install the deflector mounts onto the pivot brackets with the bolts, springs and locknuts. Make sure the straight ends of the springs are positioned between the deflector mounts and the grass deflector (Fig. 31). Tighten the locknuts until they contact the pivot brackets (Fig. 31). IMPORTANT: The grass deflector must be spring-loaded in the down position. Lift the deflector up to test that it snaps to the full down position. 4 2 3 7 1 5 Figure 31 1. 2. 3. 4. 20 Bolt Deflector Mount Spring Cone Locknut 5. Pivot Bracket 6. Carriage Bolt 7. Locknut 6 m–2549 Troubleshooting PROBLEM Abnormal vibration. Uneven cutting height. Blades do not rotate. POSSIBLE CAUSES CORRECTIVE ACTION 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Engine mounting bolts are loose. 3. Tighten engine mounting bolts. 4. Loose engine pulley, idler pulley, or blade pulley. 4. Tighten the appropriate pulley. 5. Engine pulley is damaged. 5. Contact Authorized Service Dealer. 6. Blade spindle bent. 6. Contact Authorized Service Dealer. 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 and front-to-rear. 4. Underside of mower is dirty. 4. Clean the underside of the mower. 5. Tire pressure is incorrect. 5. Adjust tire pressure. 6. Blade spindle bent. 6. Contact Authorized Service Dealer. 1. Drive belt is worn, loose or broken. 1. Install new drive belt. 2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Deck belt is worn, loose or broken. 3. Install new deck belt. 4. Deck belt is off pulley. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 21
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