Toro Mid-Size ProLine T-Bar Gear, 15 HP Walk Behind Mower Operator's Manual

Form No. 3350–538

Mid–Size Mower

Proline Gear 15hp with 48in Side Discharge

Mower

Model No. 30140—Serial No. 240000001 and Up

Operator’s Manual

Register your product at www.Toro.com

Original Instructions (EN)

Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important This engine is not equipped with a spark arrester muffler. It is a violation of California Public

Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian

ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental

Protection Agency (EPA) and the California Emission

Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit.

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

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3

3

Slope Chart

Gasoline and Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline . . . . . . . . . . . . . . . . . . . . .

12

12

7

9

Using Stabilizer/Conditioner

Filling the Fuel Tank

Connecting the Throttle Cable

Installing the Shift Lever

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level

Setup

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Front Casters . . . . . . . . . . . . . . . . . .

Installing the Upper Handle and Wire Harness

Installing the Traction Control Rods

. . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . .

Installing the Blade Control (PTO) Rod . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

13

14

14

15

12

12

12

13

15

16

16

2004 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196 2

Mounting the Fuel Tank . . . . . . . . . . . . . . . . . . . . .

Installing the Muffler . . . . . . . . . . . . . . . . . . . . . . .

Page

17

17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First

Controls

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake . . . . . . . . . . . . . . . . .

18

18

18

18

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

Operating the Blade Control (PTO) . . . . . . . . . . . .

The Safety Interlock System

Driving Forward or Backward

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

Operating the Lower Control Bar

Stopping the Machine

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Using Side Discharge or Mulch Grass . . . . . . . . . .

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

Height-of-Cut Chart . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule

Servicing the Cutting Blades

Servicing the Engine Oil

Servicing the Spark Plugs

. . . . . . . . .

. . . . . . . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

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

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

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

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

21

21

21

22

19

19

20

20

26

28

29

30

24

25

25

Servicing the Fuel Tank

Servicing the Fuel Filter

Checking the Belts

Replacing the Wheel Belt

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

Replacing the Traction Belt

Replacing the Mower Belt

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

Adjusting the Mower Belt Tension

Adjusting the Blade Brake

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

Adjusting the Grass/Mud Scraper . . . . . . . . . . . . .

33

34

34

34

31

31

32

32

Replacing the Grass Deflector

Wiring Diagram

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

37

38

38

39

44

35

35

36

36

37

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.

Contact us at www.Toro.com

All Rights Reserved

Printed in the USA

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.

1 m–3775

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.

Safety

This machine meets or exceeds the B71.4 1999 specifications of the American National Standards

Institute, in effect at time of production.

Note: The addition of attachments made by other manufacturers that do not meet American National

Standards Institute certification will cause noncompliance of this machine.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means

CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

Safe Operating Practices

The following instructions are from ANSI standard

B71.4—1999.

Training

•

Read the Operator’s Manual and other training material.

If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

•

Become familiar with the safe operation of the equipment, operator controls, and safety signs.

•

All operators and mechanics should be trained. The owner is responsible for training the users.

•

Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

•

The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.

Preparation

•

Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

•

Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

•

Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

•

Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

•

Use only an approved container

3

•

Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling.

Do not smoke.

•

Never refuel or drain the machine indoors.

•

Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

•

Never run an engine in an enclosed area.

•

Only operate in good light, keeping away from holes and hidden hazards.

•

Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position.

•

Be sure of your footing while using this machine, especially when backing up. Walk, don’t run. Never operate on wet grass. Reduced footing could cause slipping.

•

Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

•

Slow down and use caution when making turns and when changing directions on slopes.

•

Never raise deck with the blades running.

•

Never operate with the PTO shield, or other guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

•

Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

•

Do not change the engine governor setting or overspeed the engine.

•

Stop on level ground, disengage drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

•

Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

•

Keep hands and feet away from the cutting unit.

•

Look behind and down before backing up to be sure of a clear path.

•

Keep pets and bystanders away.

•

Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing.

•

Be aware of the mower discharge direction and do not point it at anyone.

•

Do not operate the mower under the influence of alcohol or drugs.

•

Use care when loading or unloading the machine into or from a trailer or truck.

•

Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

Maintenance and storage

•

Disengage drives, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

•

Clean grass and debris from cutting unit, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

•

Let engine cool before storing and do not store near flame.

•

Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

•

Park machine on level ground. Set parking brake. Never allow untrained personnel to service machine.

•

Use jack stands to support components when required.

•

Carefully release pressure from components with stored energy.

•

Remove spark plug wire before making any repairs.

•

Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them.

Only replace blades. Never straighten or weld them.

•

Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

•

Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

Toro Mower Safety

The following list contains safety information specific to

Toro products and other safety information you must know.

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

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass.

Any use for purposes other than these could prove dangerous to user and bystanders.

4

General Operation

•

Allow only responsible adults who are familiar with the instructions to operate the machine.

•

Be sure the area is clear of other people before mowing.

Stop the machine if anyone enters the area.

•

Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing.

•

Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

•

Slow down before turning. Sharp turns on any terrain may cause loss of control.

•

Turn off blades when not mowing.

•

Keep hands, feet, hair and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running.

•

Stop the engine before removing the grass catcher or unclogging the chute.

•

Mow only in daylight or good artificial light.

•

Watch for traffic when operating near or crossing roadways.

•

Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

•

Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments.

Slope Operation

Slopes and ramps are a major factor related to loss-of-control and accidents, which can result in severe injury or death. All slopes and ramps require extra caution.

If you feel uneasy on a slope, do not mow it.

DO

•

Remove obstacles such as rocks, tree limbs, etc. from the mowing area. Watch for holes, ruts or bumps. Tall grass can hide obstacles.

•

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

•

Use slow speed so that you will not have to stop while on the slope.

•

Use extra care with grass catchers or other attachments.

These can change the stability of the machine.

•

Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction.

•

Avoid starting or stopping on a slope. If tires lose traction, disengage the blades.

•

Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.

•

Mow slopes side to side.

DO NOT

•

Do not mow slopes greater than 15 degrees.

•

Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible.

•

Do not mow near drop-offs, ditches, or embankments.

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

•

Do not mow on wet grass. Reduced traction could cause sliding.

•

Do not use a grass catcher on steep slopes. Heavy grass bags could cause loss of control of the machine.

•

Do not mow up and down slopes.

Service

•

Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace.

•

Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.

•

Never tamper with safety devices. Check safety systems for proper operation before each use.

•

Use only genuine replacement parts to ensure that original standards are maintained.

•

Check brake operation frequently. Adjust and service as required.

5

6

Slope Chart

7

8

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.

67-5360

1-403005

82-2280

82-2290

54-9220

66-1340

1.

Engine

99-3943

9

95-2814

98-3266

98-4387

1.

Warning—wear hearing protection.

95-5537

1.

Read the Operator’s Manual for instructions on operating the cutting blade

2.

Push forward to engage

3.

Pull back to disengage

98-5130

1.

Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 75–80 ft.-lb.(102–106 N

⋅ m).

98-0776

98-5954

98-3256

106-0699

10

106-0841

105-0884

11

Gasoline and Oil

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

Important Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

•

Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.

•

Never fill the fuel tank inside an enclosed trailer.

•

Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to

1/2 inch (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

•

Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark.

•

Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

•

Always place gasoline containers on the ground away from your vehicle before filling.

•

Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

•

When practical, remove gas–powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

•

If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

•

If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Warning

Gasoline is harmful or fatal if swallowed.

Long-term exposure to vapors can cause serious injury and illness.

•

Avoid prolonged breathing of vapors.

•

Keep face away from nozzle and gas tank or conditioner opening.

•

Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

•

Keeps gasoline fresh during storage of 90 days or less.

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

•

Cleans the engine while it runs

•

Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

Important Do not use fuel additives containing methanol or ethanol.

Add the correct amount of gas stabilizer/conditioner to the gas.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Clean around the fuel tank cap and remove the cap. Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.

4. Install fuel tank cap securely. Wipe up any gasoline that may have spilled.

Checking the Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the

Engine Oil Level, page 29.

12

Setup

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

Loose Parts

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

DESCRIPTION

Caster assemblies

Bolt, 3/8 x 3/4 inch

Flange nut, 3/8 inch

Upper handle

Bolt, 3/8 x 1 inch

Locknut, 3/8 inch

Plastic terminal

Wire tie

Rod fitting

Clevis pin

Washer, 1/4 inch

Hairpin cotter

PTO rod

Hairpin cotter

Shift lever

Rubber seal

Square hole washer

Spring washer

Locknut

Fuel tank


Lock washer, 5/16 inch

Washer, 5/16 inch

Stud

Spring

Hose clamp

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Registration card

QTY.

4

1

1

1

4

2

8

8

2

4

2

2

1

2

2

2

1

1

2

2

4

1

1

1

1

1

1

1

1

1

USE

Installing the front casters

Installing the upper handle and wire harness

Installing the traction control rods

Installing the PTO rod

Installing the shift lever

Installing the fuel tank

Read before operating machine

Fill out and return to Toro

13

Installing the Front Casters

1. Align casters with holes on top and front of mower and insert 8 bolts (3/8 x 3/4 inch) through mower. Secure with 8 flange nuts (3/8 inch) below mower (Fig. 2).

Note: Tighten lower bolts first to pull caster against front, then top bolts last.

2. Torque bolts to 30–35 ft. lb. (40–47 N m).

3

1.

Front caster

2.


2 m-3777

Figure 2

3.

Flange nut, 3/8 inch

1

6

5

1

1.

Upper handle

2.

Rear frame

3.

Bolt, 3/8 x 1 inch

3

4

2

Figure 3

4.

Locknut, 3/8 inch

5.

Low

6.

High

4 m–6484

4. Route wire harness inside of frame, along left handle and over throttle cable. Compress wire harness covering and press into lower and upper holes in rear of control panel (Fig. 4).

5. Thread harness up through rear tube of traction handle

(Fig. 4).

1

3

2

Installing the Upper Handle and

Wire Harness

1. Position handle outside frame and align upper handle mounting holes with desired mounting holes in rear frame. Select high, medium or low according to operators height (Fig. 3).

2. Secure each side with 2 bolts (3/8 x 1 inch) and

2 locknuts (3/8 inch) (Fig. 3).

3. Torque bolts to 25 ft–lbs (34 N m).

4 m–6482

1.

Wire harness

2.

Control panel

Figure 4

3.

Rear tube

4.

Wire tie

6. Insert terminals into plastic plug until the clips snap into position (Fig. 5). If they do not snap, turn the plastic plug around and try again.

7. Push plug onto switch until it latches (Fig. 5).

8. Secure wire harness and throttle cable to left handle, away from PTO lever, with wire tie (Fig. 4).

14

4

3

1

5. After adjusting control rods, check parking brake adjustment; refer to Servicing the Brake, page 32.

3

2

5

4

6

3

1.

Terminal

2.

Clip

2

Figure 5

3.

Plastic plug

4.

Switch

Installing the Traction Control

Rods

1. Thread trunnions equal distance onto each control rod.

For a starting point, thread on approximately 2 inch

(51 mm) (Fig. 6).

2. With trunnion rod up, slide clevis pins through rod fittings and mounting holes in idler brackets (from outside) (Fig. 6). Secure with washers (1/4 inch) and hairpin cotters (Fig. 6).

1 5

2

4 m–3782

1.

Control rod

2.

Fixed control bar

3.

Parking brake lever

4.

Upper control bar

1

7

6 m–6482

Figure 7

5.

1 to 1–1/4 inch

(25–32 mm) gap

6.

Throttle cable

7.

Left side of upper handle

Connecting the Throttle Cable

1. Route the throttle cable inside the left side of the upper handle, under the fuel tank support, and to the left of the engine (Fig. 7).

2. Position the throttle control (Fig. 16) 1/4 inch (6 mm) from the upper end of the slot.

3. Attach the inner wire of the throttle cable to the top hole in the throttle control lever as shown in Figure 8.

Figure 6

4.

Clevis pin

5.

Washer, 1/4 inch

6.

Hairpin cotter m–3785

1.

Control rod

2.

Trunnion

3.

Idler bracket

3. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 inch (25–32 mm) (Fig. 7).

Note: The upper control bar and fixed bar must be parallel in the engaged, relaxed and brake positions.

4. Check operation. If adjustment is required, remove hairpin cotter securing rod to upper control bar. Thread rod in or out of trunnion for proper position and install into upper control bar with hairpin cotter.

m–5939

1 2 3

1.

Top hole in the throttle control lever

2.

Inner wire of throttle cable

Figure 8

3.

Cable clamp

4.

Cable clamp screw

4

4. Loosen the cable clamp and insert the cable behind it

(Fig. 8).

5. Pull on the cable and move the throttle control to the

Fast position. Tighten clamp screw.

15

Installing the Blade Control

(PTO) Rod

1. Rotate blade control lever (PTO) vertical away from left handle so rod drops down.

2. Remove hairpin cotters from bottom end of blade control rod (PTO) (Fig. 9).

3. Secure blade control (PTO) rod through hole in bellcrank with hairpin cotters (Fig. 9).

1

4. Replace the spring washer, dish down, and locknut

(Fig. 10).

5. Torque the nut to 35 ft–lb (47 N m).

6

5

1

4

3

2

2

1.

Shift lever

2.

Control panel

3.

Rubber seal washer m–3772

Figure 10

4.

Square hole washer

5.

Spring washer

6.

Locknut 3/8

3

1.

Blade control lever

2.

Blade control rod

4

Figure 9

3.

Bellcrank

4.

Hairpin cotter m–3783

Installing the Shift Lever

1. Remove the locknut (3/8 inch) and spring washer from the stud on top of the transmission (Fig. 10).

Note: Do not remove rubber seal washer and square hole washer from transmission shaft.

2. Slide the shift lever through the control panel and align the mounting hole in lever with square on transmission shaft (Fig. 10).

3. Secure lever to transmission with previously removed spring washer and locknut (Fig. 10).

Adjusting the Shift Lever Plate

1. Shift lever to second gear and check alignment of lever in slot of shifter lever plate. The clearance between top and bottom of the shift lever should be equal (Fig. 11).

2. If clearance is not correct, remove lever and bend it slightly to adjust (Fig. 11).

Note: Do not bend lever while attached to transmission shaft or damage may occur.

3. Shift lever to neutral and check alignment of lever in slot of shifter lever plate. The clearance on the sides of shift lever should be equal (Fig. 11).

4. If clearance is not correct, loosen shift lever plate and adjust it side–to–side. Tighten the shift lever plate.

16

4 4

1

2

Rear View

2

5. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 13).

2

3

1 m–6442

1.

Fuel line

2.

Hose clamp

Figure 13

3.

Fuel fitting

3

1.

Shift lever, 2nd gear

2.

Shift lever plate

Figure 11

3.

Shift lever, neutral

4.

Equal distance m–7454

Installing the Muffler

1. Loosen the clamp (Fig. 14).

1

Mounting the Fuel Tank

1. Align fuel tank with the top of the rear frame (Fig. 12).

2. Secure the right side of the fuel tank to the rear frame with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 12).

3. Secure the left side of the fuel tank to the rear frame with 2 studs, washers (5/16 inch), springs and locknuts

(5/16 inch) (Fig. 12).

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

m–3771

2

3

Figure 14

3.

Muffler bracket m–5941

1.

Muffler

2.

Clamp

2. Rotate the muffler forward into the position shown in

Figure 14.

3. Secure the muffler bracket (Fig. 14) to the engine bracket with the hardware provided.

4. Tighten the clamp.

3

2

1

1.


2.

Lock washer, 5/16 inch

3.

Washer, 5/16 inch

Figure 12

4.

Stud

5.

Spring

6.

Locknut

4. Slide the hose clamp onto the fuel line (Fig. 13).

4

3

5

6

17

Operation


Think Safety First

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

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

Caution

This machine produces sound levels in excess of

85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

1

1.

Caution

2

Figure 15

2.

Wear hearing protection

Controls

Become familiar with all the controls (Fig. 16) before you start the engine and operate the machine.

Throttle Control – The throttle control has two positions:

Fast and Slow.

Choke – Use the choke to start a cold engine.

Bail – The bail, in conjunction with the PTO switch, allows the engine to be started with the PTO disengaged. With the bail compressed the blade control (PTO) can be engaged.

Release the bail with the PTO engaged and the engine stops.

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

Blade Control (PTO) – The blade control lever (PTO) engages and disengages power to the mower blades. Move the PTO lever forward to engage the blades. Pull rearward to stop driving mower blades

Gear Shift Lever – Transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. Do not shift while unit is moving, as transmission damage may occur.

Upper Control Bar – Shift to desired gear and push forward on control bar to engage forward traction operation and pull back to brake. Pull right side of control bar to turn right and left side to turn left.

Lower Control Bar – Shift transmission to reverse and pull rearward on lower control bar to engage rearward traction operation.

Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle to keep brake engaged.

Recoil Starter – Pull recoil starter handle to start engine.

Fuel Shut–off Valve – (In fuel line) Close fuel shut–off valve when transporting or storing mower.

2

5

7

8

3

1

6

4

1.

Throttle control

2.

Bail

3.

Blade control (PTO)

4.

Gear shift lever

5.

Upper control bar

9

Figure 16

6.

Lower control bar

7.

Parking brake lever

8.

Ignition switch/Key

9.

Choke m–6482

Operating the Parking Brake

Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

1. Pull the upper control bar rearward and hold it in this position (Fig. 17).

18

2. Lift the parking brake lock up and gradually release the upper control bar (Fig. 17). The brake lock should stay in the set (locked) position.

Releasing the Parking Brake

1. Pull rearward on the upper control bar (Fig. 17). Lower the parking brake lock to the released position.

2. Gradually release the upper control bar.

Stopping the Engine

1. Move the throttle lever to slow (Fig. 18).

Note: If the engine has been working hard or is hot, let it idle for a minute before stopping. This helps cool the engine. In an emergency, the engine may be stopped by pulling the throttle all the way back, to stop.

2. Turn the key to the off position (Fig. 18).

3

1

2 1

2

1.

Upper control bar

Figure 17

2.

Parking brake lock

Starting and Stopping the

Engine

Starting the Engine

1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open.

2. Move the blade control to off, the shift lever to neutral and set the parking brake.

3. Turn the ignition key to the run position.

4. Move the throttle control to fast and pull choke out before starting a cold engine.

Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to fast position.

5. Grasp the recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine. Allow rope to recoil slowly.

6. Return the choke to the off position.

Important Do not pull recoil rope to its limit or let go of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged.

1.

Blade control (PTO)

2.

Throttle lever

Figure 18

3.

Key m–6482

3. Set the parking brake.

4. Pull wire off spark plug(s) to prevent possibility of someone accidentally starting the machine while transporting or storing machine.

5. Close the fuel shut off valve before transporting or storing machine.

Important Make sure the fuel shut off valve is closed before transporting or storing machine, or fuel leakage may occur.

Operating the Blade Control

(PTO)

The blade control (PTO) lever engages and disengages power to the mower blades.

Engaging the Mower Blades (PTO)

1. Pull on the upper control bar to stop the machine

(Fig. 19).

2. Hold the bail against the upper control bar (Fig. 19).

19

3. To engage blade(s), push the blade control lever firmly forward, until it latches over-center (Fig. 19).

2

1

3

1.

Upper control bar

2.

Bail

Figure 19

3.

Blade control (PTO) m–6482

Disengaging the Mower Blades (PTO)

1. To disengage the blade(s), pull blade control lever rearward, all the way (Fig. 19).

Note: It is necessary to fully and manually disengage mower.

The Safety Interlock System

Understanding the Safety Interlock

System

Caution

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

•

Do not tamper with the interlock switches.

•

Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

The safety interlock system is designed to prevent the engine from starting if:

•

The throttle lever is all the way back, to stop.

•

The blade control lever (PTO) is engaged.

The safety interlock system is also designed to stop the engine if you released the bail with the PTO engaged or move the throttle all the way back, to stop.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

1. Set the parking brake, disengage the PTO and place the throttle forward. Start the engine. With the engine running squeeze the bail against upper control bar and push the mower blade control lever forward. The mower blades begin rotating.

2. With the engine running, release the bail. The engine should stop.

3. Start the engine again.

4. With the engine running, move the throttle lever all the way back, to stop. The engine should stop.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the fast position for best performance.

Driving Forward

1. To go forward, move the shift lever to a forward gear.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 19.

3. Slowly press on the upper control bar to move forward

(Fig. 20).

To go straight, apply equal pressure to both ends of the upper control bar (Fig. 20).

To turn, release pressure on the upper control bar side toward the direction you want to turn (Fig. 20).

1

2

1.

Upper control bar

Figure 20

2.

Lower control bar m–6482

20

Driving Backward

1. To go backward, move the shift lever to a reverse gear.



3. Slowly squeeze on the lower control bar and handle together to move rearward (Fig. 20).

Operating the Lower Control

Bar

This procedure is for driving up a curb. This can be performed while driving forward or backward.

1. Disengage the mower blades.

Warning

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

•

Do not run blades while driving up a curb forward or backward.

2. Select first gear or reverse to drive machine.

3. Drive machine until drive wheels contact curb (Fig. 22).

Note: Both drive wheels should contact the curb and caster wheels straight.

4. At the same time engage lower control bar and lift up on handle (Fig. 21 and 22).

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

1

2 m-4185

1.

Lower Control Bar engaged and mower in reverse.

Figure 22

2.

Pull up to assist machine

Stopping the Machine

To stop the machine apply the brakes, pull back on the upper control bar, release the bail and set the parking brake; refer to Setting the Parking Brake, page 18.

Caution

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

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

Using Side Discharge or Mulch

Grass

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

m–6483

1.

Lower Control Bar

(Engaged)

Figure 21

2.

Handle

21

Danger

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

•

•

•

Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

Never put your hands or feet under the mower.

Never try to clear discharge area or mower blades unless you release the bail and the power take off (PTO) is off. Also pull the wire off the spark plug(s).

Adjusting Height-of-Cut

This machine has a 1 to 4-1/4 inch (26 to 108 mm) range for height-of-cut. This can be achieved by adjusting blade spacers, rear axle height and front caster spacers. Use the

Height-of-Cut chart on page 24 to select the combination required

Adjusting the Blade Height

Blades are adjusted by using the four, 1/4 inch (6 mm) spacers found on the blade spindle bolts. This allows a range, in 1/4 inch (6 mm) increments, of cutting height in any axle position. The same number of blade spacers must be used on all blades to achieve a level cut (two above and two below, one above and three below, etc.).

1. Stop engine and remove spark plug wire(s).

2. Hold blade bolt and remove nut. Slide bolt down, through spindle, and change spacers as required

(Fig. 23).

3. Insert bolt, add extra spacer(s), and secure with thin washer and nut (Fig. 23).

4. Torque blade bolt to 75–80 ft–lb (101–108 N m).

4

1

2

1.

Blade

2.

Blade bolt

3.

Cone washer

3

Figure 23

4.

Spacer

5.

Thin washer

6.

Nut m–3779

Adjusting the Axle Height

Desired height-of-cut range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm (see chart).

1. Stop engine and remove spark plug wire(s).

2. Loosen but do not remove the 2 axle pivot bolts and the

2 axle adjustment bolts (Fig. 24).

3. Place a jack under the rear center of the engine frame.

Raise the back end of the engine frame up enough to remove front 2 axle adjustment bolts (Fig. 24).

4. Raise or lower the engine frame with the jack, so that front 2 axle adjustment bolts can be installed in the desired hole location (Fig. 24). A tapered punch can be used to help align the holes.

5. Tighten all 4 bolts and lower the unit.

6. Adjust control rods and brake linkages as required.

Refer to Servicing the Brake on page 32 and Installing the Traction Control Rod on page 15.

Important It will be necessary to adjust control rods and brake linkage when changing axle positions for proper traction and brake function.

6

5

4

22

1

1.

Axle pivot bolt

2

E

D

C

B

A m–3789

Figure 24

2.

Axle adjustment bolt

Adjusting the Caster Position

1. Using the height-of-cut chart, adjust the caster spacers to match with the axle hole selected (Fig. 25).

2. Remove clevis pin, slide caster from support and change spacers (Fig. 25).

3. Install caster in support and insert clevis pin (Fig. 25).

2 1

3 m–3791

Figure 25

1.

Clevis pin

2.

Spacer, 3/16 inch (5 mm)

3.

Spacer, 1/2 inch (13 mm)

23

Height-of-Cut Chart

Axle

Position

A

No. of Spacers Below

Caster

1/2 inch

(13mm)

3/16 inc h (5 mm)

0 0

A

A

B

B

B

B

C

C

C

C

D

D

D

D

E

E

E

0

1

0

1

1

2

1

2

2

3

2

3

3

4

3

4

4

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

Number of 1/4 inch Blade Spacers Below Spindle

3

1–1/4 inch

(32 mm)

1–3/8 inch

(35 mm)

1–5/8 inch

(41 mm)

1–5/8 inch

(41 mm)

1–7/8 inch

(48 mm)

2 inch

(52 mm)

2–1/4 inch

(58 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(61 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

2–5/8 inch

(67 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/8 inch

(79 mm)

3–3/8 inch

(86 mm)

3–1/2 inch

(89 mm)

4

1 inch

(26 mm)

1–1/8 inch

(29 mm)

1–3/8 inch

(35 mm)

1–3/8 inch

(35 mm)

1–5/8 inch

(41 mm)

1–3/4 inch

(45 mm)

2 inch

(45 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

2–1/4 inch

(58 mm)

2–1/2 inch

(64 mm)

2–3/8 inch

(61 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3–1/8 inch

(79 mm)

3–1/4 inch

(82 mm)

2

1–1/2 inch

(38 mm)

1–5/8 inch

(41 mm)

1–7/8 inch

(48 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

2–1/4 inch

(58 mm)

2–1/2 inch

(64 mm)

2–3/8 inch

(61 mm)

2–5/8 inch

(67 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/8 inch

(86 mm)

3–5/8 inch

(92 mm)

3–3/4 inch

(96 mm)

0

2 inch

(45 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(55 mm)

2–3/8 inch

(61 mm)

2–5/8 inch

(67 mm)

2–3/4 inch

(70 mm)

3 inch

(76 mm)

2–7/8 inch

(73 mm)

3–1/8 inch

(79 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/8 inch

(86 mm)

3–1/2 inch

(89 mm)

3–3/4 inch

(96 mm)

4 inch

(102 mm)

3–7/8 inch

(99 mm)

4–1/8 inch

(105 mm)

4–1/4 inch

(108 mm)

1

1–3/4 inch

(45 mm)

1–7/8 inch

(48 mm)

2–1/8 inch

(55 mm)

2–1/8 inch

(55 mm)

2–3/8 inch

(61 mm)

2–1/2 inch

(64 mm)

2–3/4 inch

(70 mm)

2–5/8 inch

(67 mm)

2–7/8 inch

(73 mm)

3 inch

(76 mm)

3–1/4 inch

(82 mm)

3–1/8 inch

(79 mm)

3–1/4 inch

(82 mm)

3–1/2 inch

(89 mm)

3–3/4 inch

(96 mm)

3–5/8 inch

(92 mm)

3–7/8 inch

(99 mm)

4 inch

(102 mm)

24

Maintenance


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

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

After first 8 Hours

8 Hours

After first 25 Hours

25 Hours

50 Hours

100 Hours

200 Hours

At storage

Maintenance Procedure

•

Engine Oil—check level

•

Safety System—check

•

Brake—check

•

Engine—clean engine screen

•

Idler Pivots—grease

•

Engine Oil—change

•

Mower Belt—check tension

•

Cutting Blades—check

•

Mower Housing—clean

•

Caster Wheels—grease

•

Wheel Bearings—grease 1

•


•

Foam Air Cleaner—clean

1

•

Paper Air Cleaner—clean

1

•

Belts—check for wear/cracks

•


•

Mower Belt Idler Pivots—grease

•

Tires—check pressure

•

Engine Oil—change 1

•

Transmission Couplings—grease 1

•

Spark Plug(s)—check

•

Engine—clean cooling system

•

Paper Air Cleaner—replace

1

•

Fuel Filter—replace

•

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

•

Chipped Surfaces—paint

•

Perform all maintenance procedures listed above before storage

1 More often in dusty, dirty conditions.

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

25

Caution

Someone could accidently start the engine and seriously injure you or other bystanders.

Disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Servicing the Cutting Blades

To ensure a superior quality of cut, keep the blades sharp.

For convenient sharpening and replacement, you may want to keep extra blades on hand.

Warning

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death.

•

Inspect the blade periodically for wear or damage.

•

Replace a worn or damaged blade.

2

1

3

Figure 26

3.

Wear/slot Forming m–151

1.

Cutting Edge

2.

Curved Area

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake.

Inspecting the Blades

1. Inspect the cutting edges (Fig 26). If the edges are not sharp or have nicks, remove and sharpen the blades.

Refer to Sharpening the Blades on page 27.

2. Inspect the blades, especially the curved area (Fig. 26).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 26), immediately install a new blade.

Checking for Bent Blades

1. Rotate the blades until the ends face forward and backward (Fig. 27). Measure from a level surface to the cutting edge of the blades (Fig. 28). Note this dimension.

Front m–1078

Figure 27

26

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

Figure 28 m–2539

2. Rotate the opposite ends of the blades forward.

3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 27.

Warning

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

•

Always replace bent or damaged blade with a new blade.

•

Never file or create sharp notches in the edges or surfaces of blade.

Removing the Blades

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades.

Replacement blades made by other manufacturers may result in non-conformance with safety standards.

Hold the blade bolt with a wrench. Remove the nut, blade bolt, cone washer, blade, spacers and thin washer from the spindle (Fig. 29).

4

1

2

1.

Blade

2.

Blade bolt

3.

Cone washer

3

Figure 29

4.

Spacer

5.

Thin washer

6.

Nut m–3779

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 30). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

2

1 m–1854

Figure 30

1.

Sharpen at original angle 2.

Sail

2. Check the balance of the blade by putting it on a blade balancer (Fig. 31). 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. 30). Repeat this procedure until the blade is balanced.

6

5

4

1

1.

Blade

2

Figure 31

2.

Balancer m–1855

Installing the Blades

1. Place the blade onto the bolt, over cone washer. Select proper number of spacer(s) for height-of-cut and slide bolt into spindle (Fig. 29).

27

Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

2. Install remaining spacer(s) and secure with thin washer and nut (Fig. 29).

3. Torque the blade bolt to 75–80 ft–lb (101–108 N m).

Servicing the Air Cleaner

Service Interval/Specification

Foam element: Clean it after every 25 operating hours.

Paper element: Clean it after every 50 operating hours.

Replace it after every 200 operating hours or yearly, which ever comes first.

Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.

Important Do not oil the foam or paper element.

Removing the Foam and Paper Elements

1. Disengage the PTO, turn the ignition key to off, and remove the key.

2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires.

3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage (Fig. 32).

4. Remove the air cleaner cover (Fig. 32).

5. Unscrew the 2 wing nuts and remove the air cleaner assembly (Fig. 32).

6. Carefully pull the foam element off the paper element

(Fig. 32).

1

2

1.

Engine

2.

Cover

3.

Wing nut

3

4

5

Figure 32

4.

Foam element

5.

Paper element m–7452

Cleaning the Foam Element

1. Wash the foam element in liquid soap and warm water.

When the element is clean, rinse it thoroughly.

2. Dry the element by squeezing it in a clean cloth.

Important Replace the foam element if it is torn or worn.

Cleaning the Paper Element

Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene.

Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly.

1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 32).

2. Inspect the element for tears, an oily film, and damage to the rubber seal.

Installing the Foam and Paper Elements

Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed.

28

1. Carefully slide the foam element onto the paper air cleaner element (Fig. 32).

2. Place the air cleaner assembly onto the air cleaner base and secure it with the nut (Fig. 32).

3. Install the air cleaner cover and secure the retaining locks (Fig. 32).

Servicing the Engine Oil


Change the engine oil:

•

After the first 8 operating hours

•

After every 100 operating hours

Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SE/CC, SF, SG, SH, or SJ)

Crankcase Capacity: 58 ounces (1.7 liter) with the filter removed; 51 ounces (1.5 liter) without the filter removed

Viscosity: Refer to the table below

USE THESE SAE VISCOSITY OILS

Checking the Engine Oil Level

1. Park the machine on a level surface.



4. Clean around the oil dipstick (Fig. 33) so that dirt cannot fall into the filler hole and damage the engine.

2

1 m–7449

1.

Oil dipstick

Figure 33

2.

Filler tube

5. Unscrew the oil dipstick and wipe the end clean

(Fig. 33).

6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Fig. 33).

7. Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark.

Important Do not overfill the crankcase with oil and run the engine; engine damage can result.

Changing the Oil

1. Start the engine and let it run five minutes. This warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.



5. Place a pan under the oil drain hole in the engine frame

(Fig. 34).

6. Open the oil drain (Fig. 34).

29

2

1

1 m–7453

Figure 34

1.

Oil drain plug

7. When oil has drained completely, close the oil drain.

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

8. Slowly pour approximately 80% of the specified oil

(refer to Service Interval/Specification, page 29) into the filler cap (Fig. 33).

9. Check the oil level; refer to Checking the Engine Oil

Level, page 29.

10. Slowly add the additional oil to bring it to the Full mark.

Changing the Oil Filter

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

Note: Change the oil filter more frequently when the operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to Changing the Oil, page 29.

2. Remove the old filter (Fig. 35).

m–7451

1.

Oil filter

Figure 35

2.

Adapter

3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 35).

4. Install the replacement oil filter to the filter adapter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 35).

5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 29.

Servicing the Spark Plugs


Check the spark plugs after every 100 operating hours.

Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plugs if necessary.

Type: Champion



RCJ-8Y or equivalent

Air Gap: 0.030 inch (0.75 mm)

Removing the Spark Plug

s



3. Disconnect the wires from the spark plugs (Fig. 36).

30

1 m–7453

Figure 36

1.

Spark-plug (2)

4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage.

5. Remove the spark plugs and the metal washers.

Checking the Spark Plugs

1. Look at the center of the spark plugs (Fig. 37). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty.

2

3

1

0.030 inch

(0.75 mm)

Installing the Spark Plug

s

1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly.

2. Tighten the spark plugs to 11 ft-lb (15 N m).

3. Connect the wires to the spark plugs (Fig. 36).

Checking the Tire Pressure


Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every

50 operating hours or monthly, whichever occurs first

(Fig. 38). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 15 psi (103 kPa) rear tires

25–30 psi (172–207 kPa) caster tires

Figure 38

1.

Valve stem

1

Figure 37

1.

Center electrode insulator

2.

Side electrode

3.

Air gap (not to scale)

Important Never clean the spark plugs. Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side electrodes

(Fig. 37). Bend the side electrode (Fig. 37) if the gap is not correct.

Cleaning the Cooling System

Clean the air intake screen from grass and debris before each use.

Clean cooling fins and engine shrouds every 100 hours or yearly, which ever comes first.

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the air intake screen, recoil starter and fan housing.

4. Clean the debris and grass from the engine parts.

31

5. Install air intake screen, recoil starter and fan housing.

5

3

1

2

4 m–7450 m–3780

Figure 40

2. Lubricate the transmission couplers every 100 hours and idler arm pivots every 8 hours (Fig 41).

1

1.

Air intake screen

2.

Fan housing

3.

Recoil starter

Figure 39

4.

Bolt

5.

Nut

Greasing and Lubrication


Grease the areas shown and at intervals in Where to Add

Grease section below. Grease more frequently when operating conditions are extremely dusty or sandy.

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

How to Grease

1. Disengage the blade control (PTO) and set the parking brake.

2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Where to Add Grease

1. Lubricate the drive and caster wheel bearings and front spindles (Fig. 40). Lubricate every 8 hours.

2 m–3797

Figure 41

2.

Transmission Couplers 1.

Idler Arm Pivots

3. Lubricate the blade belt idler arm pivot. (Fig. 42).

Lubricate every 50 hours.

m–4731

Figure 42

Servicing the Brakes


Before each use, check brakes for proper operation.

32

Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.

Checking the Brakes

1. Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake.

2. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the

Brake, page 33.

3. Release the brake and press upper control bar very lightly, approximately 1/2 inch (13 mm), wheels should rotate freely.

4. If both conditions are met, no adjustment is required.

Adjusting the Brakes

The brake lever is on the upper control bar (Fig. 16). If the parking brake does not hold securely, an adjustment is required.

1. Check the brake before you adjust it; refer to Checking the Brake, page 33.



3. To adjust brake set the parking brake latch, and rotate the wing nuts on the brake rods (Fig. 43). Clockwise to tighten the brake and counterclockwise to loosen the brake.

Note: Control bar should be parallel with reference bar when properly adjusted.

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

Brake, page 33.

Important With the parking brake released, the rear wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately.

2

1.

Brake rod

1

Figure 43

2.

Wing nut m–3773

Servicing the Fuel Tank

Draining The Fuel Tank

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

•

Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area.

Wipe up any gasoline that spills.

•

Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine on a level surface, to assure fuel tank drains completely. Then disengage the blade control

(PTO) and set the parking brake.

2. Close the fuel shut–off valve in fuel line (Fig. 44).

3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from fuel filter (Fig. 44).

4. Pull the fuel line off the fuel filter (Fig. 44). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel

Filter; page 34.

5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the filter to secure the fuel line.

33

2

3

1.

Fuel shut-off valve

2.

Fuel filter

Figure 44

3.

Clamp

1 m–6486

2

1

1.

Hose clamp

Figure 45

2.

Filter m–6486

Servicing the Fuel Filter


Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first.

Replacing the Fuel Filter

Never install a dirty filter if it is removed from the fuel line.



3. Close fuel shut–off valve (Fig. 44).

4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 45).

5. Remove the filter from the fuel lines.

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

7. Open the fuel shut-off valve at the fuel tank (Fig. 44).

Checking the Belts


Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating.

Replacing the Wheel Belt

1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Fig. 46).

2. Remove bottom and loosen top bolts of shield to rotate for belt clearance (Fig. 46).

3. Lift belt past idler and off drive pulley (Fig. 46).

4. Raise wheel off ground enough to allow belt removal.

Note: Make sure that the mud and grass scraper is adjusted properly and centered in the pulley grooves (see page 37).

The pointed part of the scraper should be centered and as deep in the pulley groove as possible, without rubbing at any point.

5. Replace the drive belt.

6. Secure shield with previously removed bolt and tighten bolts (Fig. 46).

7. Secure brake rod to brake arm with hairpin cotter

(Fig. 46).

34

1

2

1

3

3

4

2

1.

Hairpin cotter

2.

Brake rod

4

Figure 46

3.

Shield

4.

Drive belt m–3793

1.

Idler in slot

2.

Belt guide

2

Figure 47

3.

1-3/8 inch (35 mm)

4.

Mower belt m–4726

Replacing the Traction Belt



3. Raise the rear of the machine and hold with jack stands.

4. Remove mower belt (Fig. 48).

5. Loosen pivot bolt enough to slide idler pulley in slot and remove traction belt from the engine and drive pulleys.

6. Install new belt around engine and drive pulleys

(Fig. 47).

7. Slide idler pulley in engine frame to tension traction belt (Fig. 47).

8. Install the mower belt (Fig. 48).

9. Check the belt guide under the engine frame for proper adjustment (Fig. 47). The distance between the belt guide and mower belt should be 1-3/8 inch (35mm).

Adjust as necessary. The disengaged belt should not drag or fall off pulley when guides are properly adjusted.

Replacing the Mower Belt



3. Remove the knobs and belt cover on mower.

4. Remove idler pulley and then remove worn belt

(Fig. 48).

5. Install the new belt.

6. Install the idler pulley.

7. Engage PTO and check belt tension. See Adjusting

Mower Belt Tension, page 36.

Note: Proper belt tension is 10–15 lbf. (44–67 N) with the belt deflected a 1/2 inch (13mm) halfway between pulleys

(Fig. 48).

35

1

3

4

1.

Idler pulley

2.

1/2 inch (13 mm) deflection here

Figure 48

3.

Assist arm

4.

Front stop

2 m–4731

8. Engage PTO lever and check the clearance between the bellcrank and the transmission output shaft (Fig. 49).

Space should be 1/16–1/8 inch (2 mm–3 mm).

9. Remove hairpin cotter and clevis pin from bellcrank.

Rotate clevis clockwise on rod to increase or counterclockwise to decrease clearance (Fig. 49).

3

2

1

Adjusting the Mower Belt

Tension


Check belt tension after the first 8 and 25 hours of operation. Check the belt tension every 50 hours.

Important Belt must be tight enough to not slip during heavy loads while cutting grass. Over tensioning will reduce belt and spindle bearing life.



3. Loosen locknut on turnbuckle (Fig. 50).

4. Rotate turnbuckle toward rear of mower to increase tension on belt. Rotate turnbuckle toward front of mower to decrease tension on belt (Fig. 50).

Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16 inch (8mm).

3

2 1

4

4

5

6

Figure 49

1.

1/16–1/8 inch

(2mm–3mm)

2.

Bellcrank

3.

Transmission output shaft

4.

Hairpin cotter

5.

Clevis pin

6.

Clevis m–3860

10. Disengage the PTO. If the assist arm does not contact the front stop on the mower deck (Fig. 48), readjust the clevis to bring the bellcrank closer to the transmission output shaft (Fig. 49).

11. Check the belt guide under the engine frame for proper adjustment (Fig. 47). The distance between the belt guide and mower belt should be 1-3/8 inch (35mm).

Adjust as necessary. The disengaged belt should not drag or fall off pulley when guides are properly adjusted.

5

1.

Locknut

2.

Turnbuckle

3.

Rear idler pulley m–4731

Figure 50

4.

Front position for idler pulley

5.

Belt guide

5. If the belt is still loose after making adjustments to the turnbuckle, reposition the rear idler pulley to the front hole. The belt guide next to the pulley must also be moved to the front hole (Fig. 50).

6. Readjust the turnbuckle.

Adjusting the Blade Brake



36

3. If necessary, adjust the spring mounting bolts so that the blade brake pad rubs against the pulley edges (Fig. 51).

4. Adjust the nut at the end of the blade brake rod until there is 1/8–3/16 inch (3mm–5mm) between the nut and spacer (Fig. 51).

5. Engage the blades. Ensure the blade brake pad no longer contacts the pulley edges.

Adjusting the Grass/Mud

Scraper

3

2

1.

Spring mounting bolts

2.

Blade brake pad

1

Figure 51

3.

1/8–3/16 inch

(3mm–5mm) m–4727

1. Loosen the locknut holding scraper to the engine frame

(Fig. 52).

2. Rotate scraper until they align with center of pulley grooves (Fig. 52).

3. Tighten the locknut (Fig. 52).

Note: The scraper must not contact the pulley on the sides or bottom of grooves. Re-adjust if necessary.

2

3

Replacing the Grass Deflector

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury.

Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Remove the locknut, bolt, spring and spacer holding deflector to the mounts (Fig. 53).

2. Straighten deflector mounts if they are bent (Fig. 53).

3. Install new deflector between mounts with spacer and spring. Hook the front end of the spring around the front deflector mount. Insert bolt through spacer and secure with locknut. Confirm there is downward spring force on deflector (Fig. 53).

4. Tighten the bolt and locknut until they lightly contact the pivot brackets (Fig. 53).

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 3

5

2

6

1.

Deflector

2.

Bolt

3.

Deflector mount

Figure 53

4.

Spring

5.

Spacer

6.

Locknut

1 m–3781

1.

Scraper

2.

Locknut

1

Figure 52

3.

Pulley m–3776

37

Wiring Diagram

J4

J5 W3

W1

P2

IGNITION SWITCH

1 2

W5

W2

W4

J2

MAG

J1

GND

WIRE LIST

DESIG. AWG COLOR ROUTE

W1 16 WHITE J2 J4

W2 16 WHITE J2 J3

W3 16 BLUE P1–1 J5

W4 16 BLACK P1–2 J1

W5 16 BLACK J1 P2–1

Cleaning and Storage

1. Disengage the power take off (PTO) and set the parking brake.

2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing.

Important You can wash the machine with mild detergent and water. Do not pressure wash the machine.

Avoid excessive use of water, especially near the control panel, and engine.

3. Check the brake; refer to Servicing the Brakes, page 32.

4. Service the air cleaner; refer to Servicing the Air

Cleaner, page 28.

5. Grease the machine; refer to Greasing and Lubrication, page 32.

6. Change the crankcase oil; refer to Servicing the Engine

Oil, page 29.

7. Check the tire pressure; refer to Checking the Tire

Pressure, page 31.

8. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank.

1

P1

2

PTO

A. Run engine to distribute conditioned fuel through the fuel system (5 minutes).

B. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank, page 33, or operate engine until it stops.

C. Restart engine and run until it stops. Repeat, on

choke until engine will not restart.

D. Dispose of fuel properly. Recycle as per local codes.

Note: Do not store stabilizer/conditioned gasoline over

90 days.

9. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug, page 30. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective.

11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.

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

Cover the machine to protect it and keep it clean.

38

Troubleshooting

Problem f il k i

Machine does not drive.

3.

Possible Causes

1.

Fuel tank is empty.

2.

Choke is not on.

Air cleaner is dirty.

4.

Spark plug wire is loose or disconnected.

5.

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

6.

Dirt in fuel filter.

7.

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

1.

Engine load is excessive.

2.

Air cleaner is dirty.

3.

Oil level in crankcase is low.

4.

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

5.

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

6.

Vent hole in fuel cap is plugged.

7.

Dirt in fuel filter.

8.

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

1.

Engine load is excessive.

2.

Oil level in crankcase is low.

3.

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

1.

Shift lever is in neutral.

2.

Traction belt is worn, loose or broken.

3.

Traction belt is off pulley.

Corrective Action

1.

Fill fuel tank with gasoline.

2.

Move choke lever to on.

3.

Clean or replace air cleaner element.

4.

Install wire on spark plug.

5.

Install new, correctly gapped spark plug.

6.

Replace fuel filter.

7.

Contact Authorized Service

Dealer.

1.

Reduce ground speed.

2.

Clean air cleaner element.

3.

Add oil to crankcase.

4.

Remove obstruction from cooling fins and air passages.

5.

Install new, correctly gapped spark plug.

6.

Clean or replace the fuel cap.

7.

Replace fuel filter.

8.


Dealer.

1.

Reduce ground speed.

2.

Add oil to crankcase.

3.

Remove obstruction from cooling fins and air passages.

1.

Move shift lever to a drive gear position.

2.

Change Belt.

3.

Change Belt.

39

Problem

Abnormal vibration.

Blades do not rotate.

Blades do not stop when

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.

4.

Loose engine pulley, idler pulley, or blade pulley.

5.

Engine pulley is damaged.

6.

Blade spindle bent.

3.

Tighten engine mounting bolts.

4.

Tighten the appropriate pulley.

5.


Dealer.

6.


Dealer.

1.

Blade(s) not sharp.

2.

Cutting blade(s) is/are bent.

3.

Mower is not level.

4.

5.

6.

Underside of mower is dirty.

Tire pressure is incorrect.

Blade spindle bent.

1.

Drive belt is worn, loose or broken.

2.

Drive belt is off pulley.

1.

Sharpen blade(s).

2.

Install new cutting blade(s).

3.

Level mower from side-to-side and front-to-rear.

4.

Clean the underside of the mower.

5.

Adjust tire pressure.

6.


Dealer.

1.

Check belt tension.

2.

Install drive belt and check adjusting shafts and belt guides for correct position.

3.

Deck belt is worn, loose or broken.

4.

Deck belt is off pulley.

3.

Install new deck belt.

4.

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

1.

Adjust blade brake.

1.

Blade brake is not adjusted properly.

2.

Belt guide is not set properly.

2.

Adjust belt guide.

40

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.

The following time periods apply from the date of purchase:

Owner Responsibilities

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

Products

•

All Products

•

All Spindles

Warranty Period

1 year

•

Engines/Hydraulic Systems* on the following:

Outfront and Mid-Mount Z’s

ProLine Mid-Size Mowers

Groundsmaster



Riding Mowers

2 years parts and labor; third year, parts only

2 years

Backpack Blowers

•

Deck Shells (36

″

–72

″

) on the following:


Mid-Mount Z’s

•

Electric Clutch on 200 Series

Mid-Mount Z’s

2 years

2 years

Items and Conditions Not Covered

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

•

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

•

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

•

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

•

Pickup and delivery charges.

All repairs covered by this warranty must be performed by an

Authorized Toro Service Dealer using Toro approved replacement parts.

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

This warranty applies to:

•

Outfront and Mid-Mount Z’s

•


•

Groundsmaster Riding Mowers

•

Turf Maintenance Equipment

•

Debris Management Equipment

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

Instructions for Obtaining Warranty Service

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

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. U.S.

Customers may also call 800-348-2424.

General Conditions

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

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

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

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

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

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

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

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

888-577-7466 (U.S. customers)

877-484-9255 (Canada customers)

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty

Company.

Part No. 374-0037 Rev. C

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