Toro 30553 User manual

Operator’s Manual
English (EN, GB)
Form No. 3350–815
72Side Discharge Mower
Groundsmaster200 Series
Model No. 30553—Serial No. 240000001 and Up

2
All Rights Reserved
Printed in the USA
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 5. . . . . . . . . . . . . . . . .
Specifications 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7. . . . . . . . . . . . . . . . . . . . .
Optional Equipment 7. . . . . . . . . . . . . . . . . . . . . . . .
Setup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Castor Wheel Assemblies 9. . . . . . . .
Installing the Lift Arms to the Traction Unit 9. . . . .
Connecting the Lift Arms to the Cutting Unit 10. . . .
Connecting PTO Shaft to Cutting Unit Gear Box 11.
Installing the Weight Transfer Kit 11. . . . . . . . . . . . .
Installing Rear Weight 12. . . . . . . . . . . . . . . . . . . . . .
Before Operating 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Height-of-Cut 13. . . . . . . . . . . . . . . . .
Adjusting the Rollers and Gage Wheel 14. . . . . . . . .
Checking the Lubricant in the Gear Box 15. . . . . . . .
Greasing the Cutting Unit 15. . . . . . . . . . . . . . . . . . .
Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Grass Deflector 15. . . . . . . . . . . . . . . . . . .
Adjusting the Tension Spring 16. . . . . . . . . . . . . . . . .
Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 17. . . . . . . . .
Greasing the Bearings, Bushings, and Gear Box 17. .
Separating the Cutting Unit from the Traction Unit 18
Mounting the Cutting Unit to the Traction Unit 19. .
Servicing the Castor Arm Bushings 20. . . . . . . . . . . .
Servicing the Castor Wheels and Bearings 20. . . . . .
Checking for a Bent Blade 21. . . . . . . . . . . . . . . . . . .
Removing the Cutting Blade 21. . . . . . . . . . . . . . . . .
Inspecting and Sharpening the Blade 21. . . . . . . . . . .
Correcting Cutting Unit Mismatch 22. . . . . . . . . . . .
Replacing the Grass Deflector 23. . . . . . . . . . . . . . . .
Adjusting the Idler Pulley 23. . . . . . . . . . . . . . . . . . .
Adjusting the Cover Latches 24. . . . . . . . . . . . . . . . .
Replacing the Drive Belt 24. . . . . . . . . . . . . . . . . . . .
Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 28. . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. The numbers are
stamped into a plate which is located on the carrier frame
behind the right front castor wheel.
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 CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production.
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.

3
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI 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 ear protection. Long hair, loose clothing or
jewelry may get tangled in moving parts.
•Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
•Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
– Use only an approved container.
– Never remove fuel 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. Use seat belts if provided.
•Slow down and use extra care on hillsides. Be sure to
travel in the recommended direction 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 guards not securely in place. Be
sure all interlocks are attached, adjusted properly, and
functioning property.
•Do not change the engine governor setting or overspeed
the engine.
•Stop on level ground, lower the cutting units, disengage
drives, engage parking brake (if provided), shut off
engine before leaving the operator’s position for any
reason.
•Stop equipment and inspect the blades after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
•Keep hands and feet away from the cutting units.
•Look behind and down before backing up to be sure of
a clear path.
•Never carry passengers and keep pets and bystanders
away.
•Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
•Do not operate the mower under the influence of
alcohol or drugs.
•Use care when loading or unloading the machine into a
trailer or truck.
•Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
•The operator shall turn on flashing warning lights, if
provided, whenever traveling on a public road, except
where such use is prohibited by law.
Maintenance and Storage
•Disengage drives, lower the cutting units, move traction
pedal to Neutral, set parking brake, stop engine and
remove key and disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning or
repairing.
•Clean grass and debris from cutting units, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.

4
•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. Never allow untrained
personnel to service machine.
•Use jack stands to support components when required.
•Carefully release pressure from components with stored
energy.
•Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
•Use care when checking blades. Wrap the blades 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.
•Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
•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 or other safety information that you must
know that is not included in the ANSI standards.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Operation
•Know how to stop the machine and engine quickly.
•Always wear substantial shoes. Do not operate the
machine while wearing sandals, tennis shoes, or
sneakers.
•Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
•Fill fuel tank until level is 1 in. (25 mm) below the
bottom of the filler neck. Do not overfill.
•Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all three interlock switches in the safety system,
regardless if they are working properly or not.
•Pay attention when using the machine. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Avoid sudden stops and starts.
– Watch for traffic when near or crossing roads.
Always yield the right-of-way.
– Lower the cutting unit when going down slopes.
•The grass deflector must always be installed and in the
lowest position on the side discharge cutting unit. Never
operate the mower without the deflector or entire grass
collector.
•If the cutting unit discharge area ever plugs, shut the
engine off before removing the obstruction.
•Cut grass slopes carefully. Do not start, stop, or turn
suddenly.
•Do not touch the engine or muffler while the engine is
running or soon after it has stopped because these areas
could be hot enough to cause burns.
Maintenance and Storage
•Check the blade mounting bolts frequently to be sure
that they are tightened to specification.
•Make sure that all hydraulic line connectors are tight
and all hydraulic hoses and lines are in good condition
before applying pressure to the system.
•Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury.
•Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units to the ground.
•If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts. Keep everyone away.
•Do not overspeed the engine by changing governor
settings. To ensure safety and accuracy, have an
Authorized Toro Distributor check the maximum engine
speed with a tachometer.

5
•The engine must be shut off before checking the oil or
adding oil to the crankcase.
•Make sure that the mower fuel tank is empty if the
machine is to be stored in excess of 30 days. Do not
store the mower near any open flame or where gasoline
fumes may be ignited by a spark.
•Perform only those maintenance instructions described
in this manual. If major repairs are ever needed or if
assistance is desired, contact an Authorized Toro
Distributor.
•To make sure of optimum performance and continued
safety certification of the machine, use only genuine
Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
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.
107-2908
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Thrown object hazard,
mower—keep the
deflector in place.
3. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts.
93-7818
1. Warning—read the Operator’s Manual for instructions on
torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-lb.).
92-3035
1. Height of cut 2. Height settings
107-2916
1. Remove the ignition key and
read the instructions before
servicing or performing
maintenance.
2. Do not operate the mower
with the deflector up or
removed; keep the deflector
in place.
3. Thrown object hazard—keep
bystanders a safe distance
from the machine.
4. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts

6
93-6697
1. Read the Operator’s
Manual.
2. Add SAE 80w–90 (API
GL-5) oil every 50 hours.
100-6578
1. Entanglement hazard, belt—do not operate the machine with
the shields or guards removed; always keep the shields and
guards in place. Stay away from moving parts.
106-6753
Cover 43–8480 for CE
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts.
43-8480
99-5172
105-9554
1. Warning—read the Operator’s Manual.
2. Tipping hazard—lower the cutting unit when driving down
slopes. For 2 wheel drive units, add a 41 kg (90 lb) rear weight
to GM 228D units and a 63.5 kg (140 lb) rear weight to GM
225 units. For 4 wheel drive units, do not add weight.
107-2915
1. Entanglement hazard, shaft—keep bystanders a safe distance
from the machine.
93-6696
1. Stored energy hazard—read the Operator’s Manual.

7
Specifications
General Specifications
Width of Cut 71-5/8 in. (1.82 m)
Height of Cut Adjustable from 1 to 4 in. (25 to 102 mm) in 1/2 inch increments
Blade Tip Speed 16,270 ft./min. @ 3250 engine RPM
Cutting Blades 3 heat-treated steel blades, each 3/16 in. (4.8 mm) thick and 24-3/4 in. (55 cm) long
Unit Drive System PTO driven gear box transmits power through a “AA” section belts to all blade
spindles.
Castor Wheels Front: 8 in. (203 mm) diameter pneumatic wheels with greaseable roller bearings
(inflated to 35–50 psi [241–345 kPa])
Rear: 6 in. (152 mm) diameter hard rubber wheels with greaseable roller bearings
Note: Specifications and design subject to change without notice.
Optional Equipment
Leaf Mulcher Model No. 30779
Leaf Mulcher Discharge Plate Part No. 57-0700
Baffle Kit Part No. 99–5155
Atomic Blade Part No. 104–1304
Front Castor Wheel (Foam Filled) Part No. 93–5974

8
Setup
Loose Parts
Note: Use this chart as a checklist to ensure that all parts have been received. Without these parts, total setup cannot be
completed.
Description Qty. Use
Front castor wheel assembly
Rear castor wheel assembly 2 2Installing the castor wheel assemblies
Right-hand lift arm
Left-hand lift arm
Pivot pin assembly
Cotter pin, 5/32 in. x 1-3/4 in.
1
1
2
2
Mount to traction unit pivot brackets
Capscrew, 7/16 x 3 in.
Flange nut, 7/16 in. 4 4Connecting the lift arms to the cutting unit
Mounting bracket
Lock pin assembly
Self-tapping screw
Spring cover assembly
Clevis pin
Hairpin cotter
Spring end—top
Heavy extension spring
Lower spring end
Knee link
Capscrew, 3/8 x 2-1/4 in.
Capscrew, 3/8 x 1 in.
Shoulder bolt
Flat washer
Locknut, 3/8 in.
2
4
4
2
2
2
2
2
2
2
4
4
4
4
12
Mounting the weight transfer kit
Decal 1 Apply for CE
Parts Catalog 1
Operator’s Manual 1Read before operating the machine.
Note: Determine the left and right sides of the machine from the normal operating position.

9
Danger
If the engine is started and the PTO shaft is
allowed to rotate, serious injury could result.
Do not start the engine and engage the PTO lever
when the PTO shaft is not connected to the gear
box on the cutting unit.
Installing the Castor Wheel
Assemblies
The thrust washers, spacers, and tensioning caps have been
installed on the castor wheel spindles for shipping.
1. Remove the tensioning caps from the spindle shafts and
slide off the spacers and thrust washers (Fig. 1 and 2).
1
2
2
3
4
Figure 1
1. Tensioning cap
2. Thrust washers 3. Spacers 4. Front castor spindle
2. Slide the spacers onto the castor spindle to get the
desired height-of-cut; refer to the Height-of-Cut Chart
on page 13. Slide a thrust washer onto the spindle, push
the round castor spindle through the front castor arm,
and the hex castor spindle through the rear castor arm.
Install another thrust washer and the remaining spacers
onto the spindle and install the tensioning cap to secure
the assembly.
Important The thrust washers, not the spacers, must
contact the top and bottom of the castor arm.
3. Ensure that all four castor wheels are set at the same
height-of-cut and roll the cutting unit off of the pallet.
1
2
2
3
4
Figure 2
1. Tensioning cap
2. Thrust washers 3. Spacers 4. Rear castor spindle
Installing the Lift Arms to the
Traction Unit
1. On one side of the traction unit, loosen (do not remove)
the wheel nuts securing the wheel and tire assembly to
the front wheel studs.
2. Jack up the machine until the front wheel is off of the
floor. Use jack stands or block the machine to prevent it
from accidentally falling.
3. Remove the wheel nuts and slide the wheel and tire
assembly off of the studs.
4. Mount a lift arm to the pivot bracket with a pivot pin
and cotter pin (5/32 x 1-3/4 in.) (Fig. 3). Mount the lift
arm with the ball joint end positioned outward.
5. Mount the rear of the lift arm to the lift cylinder with a
pivot pin and 2 cotter pins (supplied with the traction
unit).

10
1
2
34
Figure 3
1. Pivot pin
2. Lift arm 3. Lift arm pivot bracket 4. Brake return spring
6. Hook the brake return spring to the hole in the lift arm
(Fig. 3).
7. Install the wheel and tire assembly. Torque the wheel
nuts to 45–55 ft.-lb. (62–72 N⋅m).
8. Repeat the procedure on the opposite side of the
machine.
Connecting the Lift Arms to the
Cutting Unit
1. Move the cutting unit into position in front of the
traction unit.
2. Measure the distance from the end of each lift arm to
the center of the ball joint (grease fitting). The distance
should be 2-1/4 in. (57 mm) (Fig. 4). If distance is not
2-1/4 in. (57 mm), loosen the jam nut securing the ball
joint to the lift arm and rotate the ball joint in or out
until the distance is attained. Do not tighten the jam nuts
at this time.
2-1/4 in.
(57 mm)
1
2
3
Figure 4
1. Lift arm
2. Ball joint 3. Jam nut
3. Move the lift lever to the Float position. Push the lift
arms down until the holes in the ball joint mounts line
up with the holes in the castor arms.
4. Secure the ball joint mounts to each castor arm with 2
capscrews (7/16 x 3 in.) and flange nuts (7/16 in.)
(Fig. 5).
Note: The ball joint mount should be above the castor arm
when it is assembled.
1
2
3
5
4
Figure 5
1. Castor arm
2. Ball joint mount
3. Ball joint
4. Capscrew
5. Flange nut
5. Tighten the large jam nut securing the ball joint to the
lift arm (Fig. 5). When tightening the jam nut, hold the
ball joint straight to permit proper oscillation during
raising and lowering of the cutting unit.

11
Connecting the PTO Shaft to
the Cutting Unit Gear Box
1. Remove (2) capscrews and lockwashers securing PTO
guard mounting brackets to gearbox (Fig. 6). Retain
fasteners for re–installation.
3
1
2
Figure 6
1. Gearbox
2. PTO guard 3. PTO shaft
2. Slide PTO shaft guard onto PTO shaft, positioning
guard as shown in figure 6.
3. Slide male PTO shaft into female PTO shaft. Align
mounting holes in gear case input shaft with holes in
PTO shaft and slide together.
4. Secure with roll pin.
5. Tighten capscrews and nuts.
6. Re–install PTO shaft guard to gearbox with (2)
capscrews and lockwashers previously removed.
Installing the Weight Transfer
Kit
1. Fully raise the cutting deck, set the parking brake, stop
the engine, and remove the ignition key.
2. Place blocks under the cutting deck to prevent it from
falling during assembly.
Note: The mounting brackets for the weight transfer kit
must be installed in different locations depending on the
cutting deck. Refer to Figure 7 for mounting location.
123 34
Figure 7
1. 52″side discharge deck
2. 52″deck w/bagger 3. 62″and 72″decks 4. 52″rear discharge deck
3. To install the mounting brackets, insert 2 flange head
capscrews (3/8 x 1 in.) through the slotted bracket
holes. Thread the screws into the captivated frame nuts
and torque them to 45–50 ft.-lb. (61–68 N⋅m) (Fig. 8).
2
1
3
Figure 8
1. Flange head capscrew
2. Slotted hole 3. Frame
4. Thread the top extension spring coil into the top spring
end holes and the bottom extension spring coil into the
bottom spring end holes (Fig. 9).
5. Mount the knee link to the lower spring end with the
wide part of the knee link pointing forward and the
spring end stop pointing forward. Secure the knee link
to the outer side of the spring end (Fig. 11) with a
shoulder bolt, washer, and locknut (Fig. 9 and 10).
Important The knee link must be assembled pointing
in the proper direction or the spring will not pivot correctly
when the deck is raised.
6. Mount the bottom of the knee link to the deck bracket
with a shoulder bolt and locknut.

12
7. Align the slotted holes in the spring cover (slot toward
the bottom) with the mounting bracket holes. Insert the
lock pin assemblies into the bracket holes and secure
each to the bracket with the self-tapping screws (Fig. 9).
Torque the screws to 20 ft.-lb. (27 N⋅m).
1
2
3
4
8
11
10
13
7
5
6
9
12
Figure 9
1. Mounting bracket
2. Spring cover
3. Lock pin assembly
4. Self-tapping screw
5. Extension spring
6. Top spring end
7. Bottom spring end
8. Clevis pin
9. Hairpin cotter
10. Knee link
11. Shoulder bolt
12. Spring end stop
13. Locknut (2)
1
Figure 10
1. Wide part of knee link
1
2
3
4
5
6
Figure 11
1. Weight transfer spring
2. Spring end plate
3. Knee link bracket
4. Deck bracket
5. Deck frame
6. Flotation frame
8. From the bottom, insert the spring and top spring end
into the spring cover. Select a hole that matches the
cutter deck height-of-cut setting; i.e., the top cover hole
matches the highest height setting, the bottom cover
hole the lowest, etc. Align the top spring end hole with
the selected spring cover holes and insert the clevis pin
to secure the spring inside the cover (Fig. 9). Secure the
clevis pin with a hairpin cotter.
9. Remove the blocks from under the cutting unit. Make
the final counterbalance adjustments under actual
cutting conditions; refer to Adjusting the Tension
Spring, page 16.
Installing Rear Weight
Two Wheel Drive Groundsmaster 1000 and 200 Series
traction units comply with the ANSI B71.4-1999 Standard
when equipped with rear weight. Refer to the chart in the
traction unit Operator’s Manual to determine the
combinations of weight required. Order the parts from your
local Authorized Toro Distributor.
Four Wheel Drive Groundsmaster 200 Series traction units
do not need additional rear weight to comply with the
ANSI B71.4-1999 Standard.

13
Before Operating
Adjusting the Height-of-Cut
The height-of-cut is adjustable from 1 to 4 inches (25 to
102 mm) in 1/2 inch (13 mm) increments, by adding or
removing an equal number of spacers on the front and rear
castor forks. The height-of-cut chart below gives the
combinations of spacers to use for all height-of-cut settings.
Height-of-Cut
Setting
Spacers Below Castor Arm
Setting
(inches) Front Rear
1 (25 mm) 0 0
1-1/2 (38 mm) 1 1
2 (51 mm) 2 2
2-1/2 (64 mm) 3 3
3 (76 mm) 4 4
3-1/2 (89 mm) 5 5
4 (102 mm) 6 6
Start the engine and raise the cutting unit so that the
height-of-cut can be changed. Stop the engine after the
cutting unit is raised.
Front Castor Wheels
1. Remove the tensioning cap from the spindle shaft and
slide the spindle out of the front castor arm (Fig. 12).
Remove the washer from the spindle shaft. Slide the
spacers onto the spindle shaft to get the desired
height-of-cut, then slide the washer onto the shaft.
1
2
3
4
Figure 12
1. Front castor wheel
2. Tensioning cap 3. Spacers 4. Thrust washers
2. Push the castor spindle through the front castor arm,
install the other thrust washer and remaining spacers
onto the spindle, and install the tensioning cap to secure
the assembly.
Rear Castor Wheels
1. Remove the tensioning cap from the spindle shaft
(Fig. 13).
1
2
3
4
Figure 13
1. Rear castor wheel
2. Tensioning cap 3. Spacers 4. Thrust washers
Note: The rear castor fork assembly does not need to be
removed from the castor arm to change the height-of-cut.

14
2. Remove or add ”C” shaped spacers at the narrow
portion of the spindle shaft, below the castor arm, to get
the desired height-of-cut. Make sure that the thrust
washers, not the spacers, contact the top and bottom of
the castor arm.
3. Install the tensioning cap to secure the assembly.
4. Ensure that all four castor wheels are set at the same
height-of-cut.
Adjusting the Rollers and Gage
Wheel
Note: If the cutting unit is to be used in the 1 in. (25 mm)
or 1-1/2 in. (38 mm) height-of-cut setting, the cutting unit
rollers must be repositioned in the top bracket holes.
Adjusting the Front Roller
1. Remove the capscrew and nut securing the roller shaft
to the cutting unit bracket (Fig. 14).
2. Slide the shaft out of the lower bracket holes, align the
roller with the top holes, and install the shaft.
3. Secure the roller shaft to the cutting unit bracket with
the capscrew and nut.
12
Figure 14
1. External roller 2. Roller shaft
Adjusting the Front Gage Wheel
1. Remove the capscrew and nut securing the gage wheel
to the cutting unit brackets (Fig. 15).
2. Align the roller and spacer with the top holes in the
brackets and secure them with the capscrew and nut.
1
Figure 15
1. Gage wheel
Adjusting the Rear (Internal) Rollers
1. Remove the cotter pins securing the roller shafts to the
brackets on the underside of the deck (Fig. 16).
2. Slide the shafts out of the lower bracket holes, align the
rollers with the top holes, and install the shafts.
3. Install the cotter pins to secure the assemblies.
1
Figure 16
1. Internal rollers

15
Checking the Lubricant in the
Gear Box
The gear box in designed to operate on SAE 80–90 wt. gear
lube. Although the gear box is shipped with lubricant from
the factory, check the level before operating the cutting
unit.
1. Position the machine and cutting unit on a level surface.
2. Position the machine and cutting unit on a level surface
and lower the cutting unit. Remove the dipstick/fill plug
from the top of the gear box (Fig. 23) and make sure
that the lubricant is between the marks on the dipstick.
If the lubricant level is low, add SAE 80–90 wt. gear
lube until the level is between the marks.
1
Figure 17
1. Fill/check plug
Greasing the Cutting Unit
Before the cutting unit is operated, it must be greased to
ensure proper lubricating characteristics; refer to Greasing
the Bearings, Bushings, and Gear Box, page 17. Failure to
properly grease the cutting unit will result in premature
failure of critical parts.
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Using the Grass Deflector
Danger
Without the grass deflector mounted in place, you
and others are exposed to blade contact and
thrown debris. Contact with the 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 operate the mower with the deflector
removed from the cutting unit or tied/blocked in
a raised position.
Note: The deflector is spring loaded into its downward
normal operating position (Fig. 18), but the operator can
temporarily swing it out of the way to facilitate loading in a
trailer or when otherwise necessary.
1
2
Figure 18
1. Grass deflector 2. Springs

16
Adjusting the Tension Spring
For best performance, the cutting unit bounce on uneven
turf is minimal and it does not ride heavily over flat terrain.
If scalping occurs or the cut is uneven from side to side,
there may too much weight on the deck and weight may
have to be transferred to the traction unit: i.e. increased
spring tension.
By contrast, if too much weight is transferred to the traction
unit, the deck will bounce excessively and the cut will be
uneven. If the cutting unit does not perform properly, adjust
the tension spring as follows:
1. Stop the machine on a level surface, set the parking
brake, fully raise the cutting unit, turn the ignition key
to Off, and remove the key.
2. Remove the hairpin cotter from the clevis pin securing
the spring end to the spring cover and remove the clevis
pin. Align the top spring end hole with the new hole
selected in the spring cover, insert the clevis pin, and
secure it with the hairpin cotter.
3. Resume operations. If further adjustments are required,
repeat the procedure.
The counterbalance spring is in tension when the
deck is in the lowered position.
Always raise the deck before adjusting or
removing the spring.
Caution

17
Maintenance
Note: Determine the left and right sides of the machine
from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval Maintenance Procedure
After first 2 hours •Tighten the castor wheel nuts.
After first 10 hours •Tighten the castor wheel nuts.
•Torque the blade bolts.
Daily •Check the blades.
•Lubricate the castor arm bushings.
•Lubricate the castor wheel bearings.
Every 50 hours
•Tighten the castor wheel nuts.
•Torque the blade bolts.
•Lubricate the grease fittings.
•Clean under the cutting unit belt covers.
•Check the blade drive belt adjustment.
•Check the gear box oil level.
Every 400 hours •Change the gear box oil.
Greasing the Bearings,
Bushings, and Gear Box
The cutting unit must be lubricated regularly. If the
machine is operated under normal conditions, lubricate the
castor bearings and bushings with No. 2 general purpose
lithium base grease or molybdenum base grease after every
8 hours of operation or daily, whichever comes first.
1. Lubricate the following areas:
•front castor spindle bushings (Fig. 19)
•rear castor spindle shaft (remove the shaft from the
castor arm and coat the hexagonal shaft with
designated grease every 50 hours) (Fig. 20)
•castor wheel bearings (Fig. 19 and 20)
•right and left lift arm pivot pins (Fig. 21)
•blade spindle bearings (Fig. 22)
•right and left push arm ball joints (Fig. 22)
Figure 19

18
Figure 20
Figure 21
Figure 22
2. Position the machine and cutting unit on a level surface
and lower the cutting unit. Remove the dipstick/fill plug
from the top of the gear box (Fig. 23) and make sure
that the lubricant is between the marks on the dipstick.
If the lubricant level is low, add SAE 80–90 wt. gear
lube until the level is between the marks.
1
Figure 23
1. Fill/check plug
Separating the Cutting Unit
from the Traction Unit
1. Position the machine on a level surface, raise the cutting
unit, engage the parking brake, put the traction pedal in
neutral, the PTO lever in the Off position, shut the
engine off, and remove the ignition key.
The counterbalance spring is in tension when the
deck is in the lowered position.
Always raise the deck before adjusting or
removing the spring.
Caution
2. Disconnect the counterbalance from the traction unit,
remove the lock pins from the brackets, separate the
spring tension assemblies from the brackets, and lay
them down on the deck. Loosely secure the lock pins to
the brackets to prevent losing them (Fig. 24).

19
123
Figure 24
1. Lock pin
2. Bracket 3. Spring tension assembly
3. Position the machine on a level surface, lower the
cutting unit to the floor, move the lift lever to the float
position, shut the engine off, and engage the parking
brake.
4. Remove the capscrews and locknuts securing the ball
joint mounts to the castor arms on the cutting unit
(Fig. 25).
2
1
Figure 25
1. Castor arm 2. Ball joint mount
5. Roll the cutting unit away from the traction unit,
separating the male and female sections of the PTO
shaft (Fig. 26).
1
Figure 26
1. PTO shaft
Danger
If the engine is started and the PTO shaft is
allowed to rotate, serious injury could result.
Do not start the engine and engage the PTO lever
when the PTO shaft is not connected to the gear
box on the cutting unit.
Mounting the Cutting Unit to
the Traction Unit
1. Position the machine on a level surface and shut the
engine off.
2. Move the cutting unit into position in front of the
traction unit.
3. Slide the male PTO shaft into the female PTO shaft.
(Fig. 26)
4. Move the lift lever to the Float position. Push the lift
arms down until the holes in the ball joint mounts line
up with the holes in the castor arms (Fig. 25).
5. Secure the ball joint mounts to the castor arms with the
capscrews and flange nuts.
6. Raise the cutting unit and place blocks under it to
prevent it from falling during assembly.
7. Connect the counterbalance to the traction unit brackets
with lock pins (Fig. 24).
8. Remove the blocks from under the cutting unit. Make
the final counterbalance adjustments under actual
cutting conditions; refer to Adjusting the Tension
Spring, page 16.

20
Servicing the Castor Arm
Bushings
The castor arms have bushings pressed into the top and
bottom of the tube and after many hours of operation, the
bushings will wear. To check the bushings, move the castor
fork back and forth and from side to side. If the castor
spindle is loose inside the bushings, the bushings are worn
and must be replaced.
1. Raise the cutting unit so that the wheels are off of the
floor and block it so that it cannot accidentally fall.
2. Remove the tensioning cap, spacer(s), and thrust washer
from the top of the castor spindle.
3. Pull the castor spindle out of the mounting tube. Allow
the thrust washer and spacer(s) to remain on the bottom
of the spindle.
4. Insert a pin punch into the top or bottom of the
mounting tube and drive the bushing out of the tube.
Also drive the other bushing out of the tube (Fig. 27).
Clean the inside of the tubes to remove dirt.
1
2
Figure 27
1. Front castor arm tube 2. Bushings
5. Apply grease to the inside and outside of the new
bushings. Using a hammer and flat plate, drive the
bushings into the mounting tube.
6. Inspect the castor spindle for wear and replace it if it is
damaged.
7. Push the castor spindle through the bushings and
mounting tube. Slide the thrust washer and spacer(s)
onto the spindle. Install the tensioning cap on the castor
spindle to retain all of the parts in place.
Servicing the Castor Wheels
and Bearings
The castor wheel rotates on a high-quality roller bearing
and is supported by a spanner bushing. Even after many
hours of use, provided that the bearing was kept well
lubricated, bearing wear will be minimal. However, failure
to keep the bearing lubricated will cause rapid wear. A
wobbly castor wheel usually indicates a worn bearing.
1. Remove the locknut from the capscrew holding the
castor wheel assembly between the castor fork
(Fig. 28). Grasp the castor wheel and slide the capscrew
out of the fork.
2. Pull the spanner bushing out of the wheel hub (Fig. 28).
3. Remove the bushing from the wheel hub and allow the
bearing to fall out. Remove the bushing from the
opposite side of the wheel hub.
4. Check the bearing, spanner, and inside of the wheel hub
for wear. Replace damaged parts.
5. To assemble the castor wheel, push the bushing into the
wheel hub. Slide the bearing into the wheel hub. Push
the other bushing into the open end of the wheel hub to
captivate the bearing inside the wheel hub (Fig. 28).
6. Carefully slide the spanner through the bushings and the
wheel hub.
7. Install the castor wheel assembly between the castor
fork and secure it in place with the capscrew, washers,
and locknut.
8. Lubricate the castor wheel bearing through the grease
fitting, using No. 2 general purpose lithium base grease.
1
2
5436
Figure 28
1. Castor wheel
2. Capscrew and locknut
3. Bushing (2)
4. Spanner bushing
5. Roller bearing
6. Washer (2)