Toro Groundsmaster 300 Series User manual

FORM NO. 3326467
The Toro Company  2001
OPERATOR'S
MANUAL
72Flex DeckSide Discharge Mower
FOR GROUNDSMASTER300 SERIES TRACTION UNITS
MODEL NO. 30799 - 210000001 & UP
To ensure maximum safety, optimum performance,
and to gain knowledge of the product, it is essential
that you or any other operator of the machine read
and understand the contents of this manual before
the engine is ever started. Pay particular attention
to the SAFETY INSTRUCTIONS highlighted by this
symbol 
The safety alert symbol means CAUTION,
WARNING or DANGER  personal safety
instruction. Failure to comply with the instruction
may result in personal injury.

2
FOREWORD
The 72" Flex Deck Side Discharge Mower has advanced concepts in engineering, design and safety; and if
maintained properly, will give excellent service.
Since this is a high-quality product, Toro is concerned about the future use of the machine and safety of the user.
Therefore, read this manual to familiarize yourself with proper set-up, operation and maintenance instructions. The
major sections of the manual are:
1. Safety Instructions 3. Before Operating 5. Lubrication
2. Setup Instructions 4. Operation 6. Maintenance
Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety
related information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read
this directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies general
information worthy of special attention.
TABLE OF CONTENTS
Page Page
SAFETY AND INSTRUCTION DECALS 3. . . . . . . . .
SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOOSE PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP INSTRUCTIONS 6. . . . . . . . . . . . . . . . . . . . . . .
Mount Hose Clamp 6. . . . . . . . . . . . . . . . . . . . . . . .
Grass Deflector 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount Rear Castor Wheels 6. . . . . . . . . . . . . . . . .
Connect RightHand Push Arm to Cutting Unit 6
Connect LeftHand Push Arm to Cutting Unit 7. .
Mount Front Lift Arm 8. . . . . . . . . . . . . . . . . . . . . . .
Mount Rear Lift Bracket 8. . . . . . . . . . . . . . . . . . . .
Install Drive Shaft to Traction Unit 9. . . . . . . . . . . .
Install Lift Chains 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Counterbalance Spring 9. . . . . . . . . . . . . .
Grease Cutting Unit 9. . . . . . . . . . . . . . . . . . . . . . . .
Install Rear Weight 10. . . . . . . . . . . . . . . . . . . . . . . .
BEFORE OPERATING 11. . . . . . . . . . . . . . . . . . . . . . .
Check Lubricant in Gear Box 11. . . . . . . . . . . . . . .
Adjusting HeightofCut 11. . . . . . . . . . . . . . . . . . . .
Check Tire Pressure 12. . . . . . . . . . . . . . . . . . . . . .
Adjust Skid 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Rollers 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 13. . . . . . . . . . . . . . . . .
Grass Deflector 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Tips 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease Bearings, Bushings and Gear Box 14. . .
MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting 15. . . . . . . . . . . . . . . . . . . . . . . . .
Separating Cutting Unit from Traction Unit 16. . .
Mounting Cutting Unit to Traction Unit 16. . . . . . .
Adjusting Drive Belts 16. . . . . . . . . . . . . . . . . . . . . .
Replacing Drive Belts 17. . . . . . . . . . . . . . . . . . . . .
Servicing Front Bushings in Castor Arms 17. . . .
Servicing Castor Wheels and Bearings 17. . . . . .
Replacing Grass Deflector 18. . . . . . . . . . . . . . . . .
Removing Cutter Blade 18. . . . . . . . . . . . . . . . . . . .
Inspecting and Sharpening Blade 19. . . . . . . . . .
Correcting Cutting Unit Mismatch 20. . . . . . . . . . .
IDENTIFICATION AND ORDERING 20. . . . . . . . . . . .

3
SAFETY AND INSTRUCTION DECALS
The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part
number is listed below and in your parts catalog. Replacements can be ordered from your Authorized Toro
Distributor.
93-3709
100-6582
1. Warning—Cuttinghazard of hands
93-6696
1. Warning—part is spring loaded. Read the operator’s manual.
100-8038
1. Height-of-cut setting for rear deck chain
93-7818
1. Warning—torque the blade bolt to 115–149 N⋅m. Read the
operator’s manual for further instructions.
104-2526
1. Warning—read the operator’s manual.
2. Lower cutting unit before going down hills. When operating the
Groundsmaster 325-D or 345 two-wheel drive or four-wheel
drive, rear weight must be added to the machine.
54-9220
100-8046
100-6578
1. Entanglement hazard—keep belt covers in place. Stay away
from moving parts.

4
SAFETY AND INSTRUCTION DECALS
93-6697
1. Changethe gearbox oil every 50 hours. Read the operator’s
manual for further instructions.
93-7824
1. Thrown object hazard—keep bystanders away.
2. Thrown object hazard from mower—keep the deflector in place.
3. Cutting/dismemberment hazard of hands or feet—stay away
from rotating blades and moving parts.
100-8039
1. Height-of-cut setting for rear castor wheels on left chamber
104-7449
1. Height-of-cut setting for rear castor wheels on right chamber
92-3035
1. Height-of-cut setting for front castor wheels.
SPECIFICATIONS
Width of Cut: 72″
Configuration: Three blades, one blade center
section, and two 1 blade floating wings. Wings flex up
and down 12 degrees in a single plane perpendicular
to from center section.
Height of Cut: Adjustable front and rear, in .50 inch
increments from 1 to 4 inches.
Construction: 12gauge steel, 5.25 inches deep,
welded construction and reinforced with 10gauge
steel channels.
Blades: Three 25 inch long, .25 inch thick, heat treated
steel blades.
Cutter Drive: PTO driven gearbox with 1.26-1 spiral
bevel gears. One B" section belt on center section.
One B" section belt on each wing. Center section
tensioned through spring loaded idler. Wings
tensioned through adjustable fixed idler.
Spindles: Cast iron housing, 11/4 inch dia shaft with
welded blade retainer. Turning on two greaseable
tapered roller bearings. A positive splined connection
attaches pulley to spindle shaft.
Castor Wheels: Front: Four 8 inch pneumatic wheels
with greaseable roller bearings. Rear: Two 8 inch
pneumatic wheels with greaseable roller bearings (one
on each wing). Center section suspended from push
arms.
Anti Scalp: Antiscalp cup (11 inch diameter) located
on each blade. One antiscalp roller on rear of center
section. Adjustable skid on right wing.
Trimability: 34″uncut circle, 25″uncut circle with use
of individual wheel brakes.
Tip Speed: 15,000 ft./min. @ 3200 engine RPM.
Discharge: Lefthand, side discharge (recycler kit
available).
Safety Certification: To meet, proposed ANSI
B71.4-1990 and 1999, safety specifications for power
lawn mowers, and CE requirements.
Belt Covers: Steel covers bolted down, meets CE
requirements.
Sound Levels: 90 dBa @ operator ear.
Weight: 550 lb.
Width: 831/2 in.

5
SPECIFICATIONS
Options:
High Lift Blade: Part No. 232410
Height of cut spacers 1/4″Part No. 548810
Foam Filled 8″Tire Part No. 935974
Specifications and design subject to change without notice.
LOOSE PARTS
NOTE: Use this chart as a checklist to ensure that all parts have been received. Without these parts, total set-up
cannot be completed.
Description Qty. Use
Hose clamp
Hose bracket
Capscrew, 1/4 x 1 in.
Nut
1
2
2
2
Install hose clamp
Push arm adapter
Push arm plate
Capscrew, 3/8 x 2-3/4 in.
Flat washer
Nut
1
1
4
4
4
Install right push arm adapter
Front lift arm
Locknut
Capscrew, 3/8 x 3 in.
1
2
2
Rear lift bracket
Square U-bolt
U-bolt
Height-of-cut chain
Clevis pin
Hairpin
Nut
1
1
1
1
1
1
6
Install rear lift support
Capscrew, 3/8 x 7/8 in. 4Secure covers for CE
Roll pin 1Install drive shaft
Danger decal 1Place over 54-9220 on deflector for CE.
Parts catalog 1
Operator’s manual 1Read before operating the machine.
Registration card 1Fill out and return to Toro.

6
SETUP INSTRUCTIONS
MOUNT HOSE CLAMP (Fig. 1 -2)
1. Using dimensions shown in figure 1, locate, mark
and drill (2) .28 in. dia. holes in traction unit platform.
Use caution when drilling as there are hoses and
cables under platform.
Figure 1
.75"
4.41"
12.75"
2. Secure hoses to under side of platform with clamp,
(2) brackets, capscrews and nuts. Position brackets to
fit contour of hoses and platform.
Figure 2
1
1. Clamp
2. Bracket (2)
2
GRASS DEFLECTOR (Fig. 3)
3. Remove shipping bands allowing deflector to be
lowered.
Deflector is spring loaded in the down position
and will rotate downward, if not retrained,
when band is cut. If done improperly, personal
injury may occur.
WARNING
Figure 3
1. grass Deflector
1
MOUNT REAR CASTOR WHEELS (Fig. 4)
The rear castor wheels are shipped secured upside
down to deck brackets.
1. Remove capscrew and locknut securing front of
rear castor pivot to deck bracket.
Figure 4
1. Rear castor pivot arm
1
2. Turn pivot right side up and secure front of castor
pivot arm to front of deck bracket with capscrew and
locknut removed.
3. Align the pivot arm holes with selected
heightofcut bracket holes in the deck frame, install
clevis pin and secure with hairpin cotter.
4. Repeat procedure on other castor wheel
assembly.
CONNECT RIGHTHAND PUSH ARM TO
CUTTING UNIT (Fig. 5- 6)
Note: Ball joints are shipped with traction unit.
1. Thread a jam nut fully onto ball joint.
2. Thread ball joint into push arm adapter until a
dimension of 23/8 in. from end of adapter to center of
ball joint is attained. Do not tighten jam nut.

7
SETUP INSTRUCTIONS
Figure 5
1. Ball joint
2. Jam nut
3. Push arm adapter
1
323/8
in.
2
3. Remove 2 flange head capscrews and flange nuts
securing right hand ball joint mount to castor arm.
Remove ball joint mount from castor arm.
4. Install ball joint to right hand ball joint mount with a
castle nut and cotter pin (Fig. 6).
5. Loosely mount push arm adapter to bottom of right
push arm with a push arm bracket and (4) capscrews,
flat washers, and flange head locknuts. Push arm
adapter to be positioned approximately 1 in. (25 mm)
from end of square tube on right push arm (Fig. 6).
Note: Push arm plate to be positioned on top of push
arm. Push arm adapter is mounted to under side of
push arm.
6. Move cutting unit into position in front of traction
unit.
Figure 6
1. RightHand Push Arm
2. Push arm adapter
3. Push arm bracket
4. Ball Joint Mount
12
3
4
1 in. (25 mm)
Since the right hand push arm is spring loaded
to about 100 pounds, a helper is needed to
push the arm down. Sudden release of the
push arm could cause injury.
WARNING
7. Have a helper carefully push down on the right
push arm until holes in ball joint mount line up with
holes in castor arm. Immediately slide a 4 x 4 in. block
of wood between top of push arm and underside of
chassis.
8. Secure ball joint mount to castor arm with 2 flange
head capscrews and flange nuts previously removed.
Note: Capscrew heads to be positioned on inside of
castor arm.
9. Tighten large jam nut securing ball joint to push
arm adapter (FIg. 5). When tightening jam nut, hold
ball joint straight to permit proper oscillation during
raising and lowering of cutting unit. Carefully remove
wood block holding push arm down.
CONNECT LEFTHAND PUSH ARM TO
CUTTING UNIT (Fig. 7- 8)
Since the left hand push arm is spring loaded
to about 150 pounds, a helper is needed to
push the arm down. Sudden release of the
push arm could cause injury.
WARNING
1. Thread a jam nut fully onto ball joint.
2. Thread ball joint into left push arm until a
dimension of 23/8 in. from end of push arm to center of
ball joint is attained. Do not tighten jam nut.
Figure 7
1. Ball joint
2. Jam nut
2. Left push arm
1
3
23/8 in.
2

8
SETUP INSTRUCTIONS
3. Remove 2 flange head capscrews and flange nuts
securing lefthand ball joint mount to castor arm.
Remove ball joint mount from castor arm.
4. Install ball joint to lefthand ball joint mount with a
castle nut and cotter pin.
Figure 8
1. L.H. Push Arm
2. Ball joint
3. Ball Joint Mount
1
2
3
5. Have a helper carefully push down on the push
arm until holes in ball joint mount line up with holes in
castor arm. Immediately slide a 4 x 4 in. block of wood
between top of push arm and underside of chassis.
Make sure the wooden block does not slip out
accidentally. Sudden release of the push arm
could cause injury.
WARNING
6. Secure ball joint mount to castor arm with flange
head capscrews and flange nuts previously removed.
Note: Flange head capscrew heads to be positioned
on inside of castor arm.
7. Tighten large jam nut securing ball joint to push
arm. When tightening jam nut, hold ball joint straight to
permit proper oscillation during raising and lowering of
cutting unit. Carefully remove wood block holding
push arm down.
Note: Position deck so there is a 2 in. gap between
front of traction unit tires and rear of deck (Fig. 9).
2 in.
Figure 9
8. Tighten fasteners securing right push arm adapter
to right push arm.
Note: Periodically check and tighten the push arm
adapter capscrews.
MOUNT FRONT LIFT ARM (Fig. 10 & 11)
1. Remove rubber bumper from bottom of traction
Tbar.
Figure 10
1. Traction Tbar
2. Rubber bumper
1
2
2. Slide front lift arm onto traction unit tbar,
positioning as shown in Figure 11.
3. Secure front lift arm to tbar with with 2 capscrews
and locknuts.
Figure 11
1. Front lift arm
2. Traction unit Tbar
1
2
MOUNT REAR LIFT BRACKET (Fig. 12-13)
1. Loosely mount rear lift bracket to right push arm
with square Ubolt, 2 nuts, and flange nuts. Bracket to
be positioned on push arm so it is centered and parallel
to castor arm.
Figure 12
1. Lift bracket
2. Square u-bolt
3. U-bolt
1
2
3

9
SETUP INSTRUCTIONS
Figure 13
1. Lift bracket
2. Castor arm
1
2
2. Hook H.O.C. chain onto remaining Ubolt.
3. Thread a hex nut onto each end of Ubolt.
4. Loosely mount Ubolt and H.O.C. chain to rear lift
bracket 2 nuts and 2 flange nuts
5. Mount heightofcut chain to 2 in. heightofcut hole
with clevis pin and hairpin cotter.
6. Position rear castors in 2 in. heightofcut.
7. Adjust nuts on Ubolt until rear of deck is parallel to
floor (Distance from floor to bottom rear edge of all
three deck chambers must be equal).
INSTALL DRIVE SHAFT TO TRACTION
UNIT
NOTE: To ease installation of PTO shaft, remove
right traction tire.
1. Slide smaller yoke end of drive shaft onto traction
unit PTO shaft while aligning mounting holes. Secure
with roll pin.
Figure 14
1. Drive shaft
1
INSTALL LIFT CHAINS (Fig. 15)
1. Connect lift chains to lift arm and cutting unit chain
brackets with (6) shackles, (3/8 x 11/2 in.) shackle pins
and (1/8 x 3/4 in.) cotter pins. To ensure that cutting unit
lifts properly, secure chains to the following links when
connecting:
Front Left - 8th link
Front Right - 8th link
Rear - 14th link (All links)
Check operation to ensure that all chains lift deck tight
against stops when lift arm is raised.
Figure 15
1. Front Left Lift Chain
2. Front Right Lift Chain
3. Rear Lift Chain
1
2
3
ADJUST COUNTER BALANCE SPRING
(Fig. 16)
1. Tighten nuts on adjusting rod until there is equal
weight on castor wheels of left and left center
chambers.
Figure 16
1. Counter balance spring
2. Adjusting rod
1
2
GREASE CUTTING UNIT
Before the cutting unit is operated, it must be greased
to ensure proper lubricating characteristics: refer to
Lubrication, page 13. Failure to properly grease the
cutting unit will result in premature failure of critical
parts.

10
SET-UP INSTRUCTIONS
INSTALL REAR WEIGHT
GROUNDSMASTER 300 Series Traction Units comply with ANSI B71.4-1999 Standard when equipped with rear
weight. Use chart below to determine combinations of weight required. Order parts from your local Authorized Toro
Distributor.
Rear Weight Kit
(includes two 35 lb.
weights and mounting
hardware)
Groundsmaster 328D
(30626/30630*)
Rear Weight
Required
Weight Part
Number
Weight
Description Qty.
Groundsmaster 325D
(30788/30739*) 245780
210 lb. Rear Weight Kit
(includes two 35 lb.
weights and mounting
hardware)
3
Traction Unit
Description
245780245 lb. Rear Weight Kit
(includes two 35 lb.
weights and mounting
hardware)
&
3
245790 Rear Weight Kit
(includes one 35 lb.
weight and mounting
hardware)
1
Groundsmaster 325D
4 Wheel Drive
(30795/30741)
70 lb. 1245780
245780210 lb. Rear Weight Kit
(includes two 35 lb.
weights and mounting
hardware)
3
Groundsmaster 345
(30789)
Rear Weight Kit
(includes two 35 lb.
weights and mounting
hardware)
Groundsmaster 328D
4 Wheel Drive
(30627/30631)
70 lb. 245780 1
*Models 30739 and 30630 include 1 Rear Weight Kit.
BEFORE OPERATING
CHECK LUBRICANT IN 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 on a level surface.
2. Remove check plug from side of gear box and
make sure lubricant is up to bottom of hole. If level of
lubricant is low, add enough lubricant to bring it up to
bottom of hole.
Figure 17
2. Drain Plug
1
2
1. Fill/Check Plug

11
BEFORE OPERATING
ADJUSTING HEIGHTOFCUT
The heightofcut is adjustable from 1 to 4 inches in 1/4
inch increments.
1. Start the engine and raise the cutting unit so
heightofcut can be changed. Stop engine after
cutting unit is raised.
FRONT CASTOR WHEELS
Figure 18
1. Remove H.O.C. cap from spindle shaft and slide
spindle out of front castor arm. Slide spacers onto
spindle shaft to get desired heightofcut.
Figure 19
1. Front castor wheel
2. H.O.C. Cap
3. Spacer
4. Washer
2
3
4
4
1
2. Push castor spindle through front castor arm install
remaining spacers onto spindle and install HOC cap to
secure assembly.
REAR CASTOR WHEELS
Figure 20
1. Remove hairpin cotter and cotter pin securing rear
castor pivot arm to deck bracket.
Figure 21
1. Rear Castor Pivot
1
2. Align the pivot arm holes with selected
heightofcut bracket holes in the deck frame, install
cotter pin and secure with hairpin cotter.
REAR DECK CHAIN
1. Remove hair pin cotter and clevis pin securing
heightofcut chain to chamber bracket.
2. Mount heightofcut chain to desired heightofcut
hole with clevis pin and hair pin cotter.
Figure 22
1. H.O.C. Chain
1

12
BEFORE OPERATING
Figure 23
CHECK TIRE PRESSURE
Ensure that the air pressure in the front and rear castor
wheels is 40 psi (276 kPa).
IMPORTANT: Maintain even pressure in all tires to
ensure a good qualityofcut and proper machine
performance. Do not underinflate.
ADJUST SKID
Skid, on right side of cutting unit, should be located in
upper holes for 1 and 11/2 inch heightsofcut and
lower holes for 2 to 4 inch heightsofcut.
1. Adjust skid by removing flange nuts, positioning as
desired and reinstalling flange nuts.
Figure 24
1. Skid
1
ADJUST ROLLERS
The front antiscalp rollers and the rear antiscalp
rollers, located on the center deck, should be located
in upper holes for 1 and 11/2 inch heightsofcut and
lower holes for 2 to 5 inch heightsofcut. Six rollers are
located on the deck, two under the main deck and two
on each wing.
1. Adjust antiscalp rollers by removing screw
securing roller shaft to deck, positioning roller as
desired, and reinstalling shaft with screw, washers,
and nut (Fig. 25).
2. The two outside wing deck rollers can be adjusted
at the roller, or the bracket can be repositioned on the
deck.
Figure 25
1. Roller
1

13
OPERATING INSTRUCTIONS
GRASS DEFLECTOR (Fig. 26)
WARNING
The grass deflector (Fig. 26) is a safety
device that diverts grass and other foreign
objects being discharged downward. WE
STRONGLY RECOMMEND THAT THE
DEFLECTOR BE IN ITS NORMAL
OPERATING POSITION WHENEVER THE
CUTTING UNIT IS ENGAGED. NEVER
OPERATE CUTTING UNIT WITH THE
DEFLECTOR REMOVED FROM THE
CUTTING UNIT OR IT TIED/BLOCKED IN A
RAISED POSITION. SINCE THE BLADES
COULD THEN THROW DEBRIS A
CONSIDERABLE DISTANCE WITH
SUFFICIENT FORCE TO CAUSE PERSONAL
INJURY OR DAMAGE TO PROPERTY. If the
grass deflector is damaged, repair or
replace the affected part(s).
Note: The deflector is spring loaded into its
downward normal operating position, but
the operator can temporarily swing it out of
the way to facilitate loading in a trailer or
when otherwise necessary.
Figure 26
1. Grass deflector
2. Springs
2
1
OPERATING TIPS
1. MOW WHEN GRASS IS DRY-Mow either in the
late morning to avoid the dew, which causes grass
clumping or in late afternoon to avoid the damage that
can be caused by direct sunlight on the sensitive,
freshly mowed grass.
2. SELECT THE PROPER HEIGHT-OF-CUT
SETTING TO SUIT CONDITIONS - Remove
approximately one inch or no more than 1/3 of the
grass blade when cutting. In exceptionally lush and
dense grass you may have to raise your
height-of-cut setting another notch. When cutting in
1 in. or 11/2 in. heightofcut, add a second washer
between rear castor forks and bottom of castor arm
housings to increase blade rake.
3. MOWING IN EXTREME CONDITIONS - Air is
required to cut and recut grass clippings in mower
housing, so do not set heightofcut too low or totally
surround housing by uncut grass. Always try to have
one side of the mower housing free from uncut grass,
allowing air to be drawn into housing. When making an
initial cut thru center of uncut area, operate machine
slower and back up if mower starts to clog.
4. ALWAYS START MOWING WITH SHARP BLADES
- A sharp blade cuts cleanly and without tearing or
shredding the grass blades like a dull blade. Tearing
and shredding causes the grass to turn brown at the
edges which impairs growth and increases
susceptibility to diseases. Make sure blade is in good
condition and a full sail is present.
5. CHECK CONDITION OF DECK - Make sure
cutting chambers are in good condition. Straighten
any bends in chamber components to ensure correct
blade tip/chamber clearance.
6. STOPPING - If forward motion has to be stopped
while cutting, a clump of grass clippings may be
deposited on lawn. Follow this procedure for stopping
while cutting:
A. With deck engaged, move onto a previously cut
area.
B. Shift to neutral, move throttle control lever to SLOW
position and rotate ignition key to OFF.
7. AFTER OPERATING - To ensure optimum
performance, clean underside of mower housing,
especially around inserts (kickers) after each use. If
residue is allowed to build up in mower housing and on
inserts, cutting performance will decrease.

14
LUBRICATION
GREASING THE CUTTING UNIT
The cutting unit must be lubricated regularly. If
machine is operated under normal conditions,
lubricate castor bearings and bushings with No. 2
general purpose lithium base grease or molybdenum
base grease, after every 8 hours of operation or daily,
whichever comes first.
1. The cutting unit has bearings and bushings that
must be lubricated, and these lubrication points are:
front castor spindle bushings (2) (Fig. 27); front castor
wheel bearings (4) (Fig. 27); rear castor wheel
bearings (2) (Fig. 28); blade spindle bearings (3)
(Fig. 29); right and left push arm ball joints (Fig. 29);
drive shaft (3) (Fig. 29) idler arm pivots (3) (Fig. 30); and
deck pivot pins (4) (Fig. 31)
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
2. Position the machine on a level surface and lower
cutting unit. Remove fill/check plug from side of gear
box (Fig. 32) and make sure lubricant is up to bottom of
hole. If level of lubricant is low, add SAE 80-90 wt. gear
lube until level is up to bottom of hole.
Figure 32
2. Drain Plug
1
2
1. Fill/Check Plug

15
MAINTENANCE
TROUBLE SHOOTING
85 To 110

16
MAINTENANCE
To prevent accidental starting of the engine,
while performing maintenance, shut engine
off and remove key from ignition switch.
CAUTION
SEPARATING CUTTING UNIT FROM
TRACTION UNIT
1. Position machine on level surface, lower cutting
unit to floor, shut engine off and engage parking brake.
2. Remove self tapping screws securing shield to top
of cutting unit and set shield aside.
3. Drive out roll pin securing drive shaft yoke to input
shaft of gear box. Loosen capscrews and locknuts and
slide yoke off input shaft. If traction unit will be used
without the cutting unit, drive roll pin out of yoke at
traction unit PTO shaft and remove entire drive shaft
from traction unit.
Do not start the engine and engage the PTO
lever when PTO shaft is not connected to gear
box on cutting unit. If engine is started and
PTO shaft is allowed to rotate, serious injury
could result.
DANGER
4. Disconnect cotter pins and clevis pins securing lift
chains to lift arms.
Since the right hand push arm is spring loaded
to about 100 pounds and the left hand push
arm is spring loaded to about 150 pounds, a
helper is needed to push the arm down.
Sudden release of the push arm could cause
injury.
WARNING
5. Have a helper push down on the right push arm
while you remove the flange head capscrews and
locknuts securing the ball joint mount to castor arm on
cutting unit. Now the helper can carefully allow push
arm to move upward, which will gradually release the
100 pounds of spring load.
6. Have a helper push down on the left push arm
while you remove the flange head capscrews and
locknuts securing the ball joint mount to castor arm on
cutting unit. Now the helper can carefully allow push
arm to move upward, which will gradually release the
150 pounds of spring load.
7. Roll the cutting unit away from the traction unit.
MOUNTING CUTTING UNIT TO
TRACTION UNIT
1. Position machine on a level surface and shut
engine off.
2. Move cutting unit into position in front of traction
unit.
Since the right hand push arm is spring loaded
to about 100 pounds and the left hand push
arm is spring loaded to about 150 pounds, a
helper is needed to push the arm down.
Sudden release of the push arm could cause
injury.
WARNING
3. Have a helper carefully push down on the right
push arm until holes in ball joint mount line up with
holes in castor arm.
4. Secure ball joint mount to castor arm with flange
head capscrews and flange nuts. Capscrew heads to
be positioned to inside of castor arm.
5. Have a helper carefully push down on the left push
arm until holes in ball joint mount line up with holes in
castor arm. Immediately slide a 4 x 4 in. block of wood
between top of push arm and underside of chassis
Make sure the wooden block does not slip out
accidentally. Sudden release of the push arm
could cause injury.
WARNING
6. Secure ball joint mount to castor arm with flange
head capscrews and flange nuts. capscrew heads to
be positioned to inside of castor arm. Chain bracket to
be mounted in forward set of holes.
7. Carefully remove wood block holding push arm
down.
8. Line up holes in yoke and input shaft of gear box.
Slide yoke onto shaft and secure together with a roll pin
and 2 capscrews (5/16 x 13/4 in.) and locknuts
(5/16 in.).
ADJUSTING DRIVE BELTS (Fig. 33 )
The blade drive belts are tensioned by the spring
loaded idlers, are very durable. However, after many
hours of use, the belts will stretch and will need
adjusting.
1. Lower cutting unit to the shop floor. Remove belt
covers from top of cutting unit and set covers aside.
2. Adjust spring tensioning rods until 10 lb. tension is
achieved for side belts and 30 lb. tension for center
gear box belt.

17
MAINTENANCE
Figure 33
1. Spring tensioning rod (3)
1
REPLACING DRIVE BELTS
The blade drive belts, tensioned by the spring loaded
idlers, are very durable. However, after many hours of
use, the belts will show signs of wear. Signs of a worn
belt are: squealing when belt is rotating, blades
slipping when cutting grass, frayed edges, burn
marks, and cracks. Replace the belt if any of these
conditions are evident.
1. Lower cutting unit to the shop floor. Remove belt
covers from top of cutting unit and set covers aside.
2. To replace gear box belt, loosen spring tension rod
and remove belt. Retention new belt to 30 lb. Refer to
Figure 34 for belt routing.
Figure 34
3. To replace wing belts, loosen spring tension rod
and remove gear box belt.
4. Pull spring loaded idler pulley away from belt, with
hand, to relieve belt tension and remove belt. Retention
new belts to 10 lb. Refer to Figure 34 for belt routing.
8. Install belt covers.
SERVICING FRONT BUSHINGS IN
CASTOR ARMS
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 castor fork back and forth and from
side to side. If castor spindle is loose inside the
bushings, bushings are worn and must be replaced.
1. Raise cutting unit so wheels are off floor and block
it so it cannot fall accidentally.
2. Remove tensioning cap, spacer(s) and thrust
washer from top of castor spindle.
3. Pull castor spindle out of mounting tube. Allow
thrust washer and spacer(s) to remain on bottom of
spindle.
4. Insert pin punch into top or bottom of mounting
tube and drive bushing out of tube. Also drive other
bushing out of tube. Clean inside of tubes to remove
dirt.
Figure 35
1. Front Castor Arm Tube
2. Bushings
1
2
5. Apply grease to inside and outside of new
bushings. Using a hammer and flat plate, drive
bushings into mounting tube.
6. Inspect castor spindle for wear and replace it if
damaged.
7. Push castor spindle through bushings and
mounting tube. Slide thrust washer and spacer(s) onto
spindle. Install tensioning cap on castor spindle to
retain all parts in place.
SERVICING 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 bearing lubricated will cause
rapid wear. A wobbly castor wheel usually indicates a
worn bearing.

18
MAINTENANCE
1. Remove locknut from capscrew holding castor
wheel assembly between castor fork. Grasp castor
wheel and slide capscrew out of fork.
2. Pull spanner bushing out of wheel hub.
Figure 36
1. Castor wheel
2. Capscrew & Locknut
3. Bushing (2)
4. Spanner Bushing
5. Roller Bearing
6. Washer (2)
1
2
3
4
5
6
6
3. Remove bushing from wheel hub and allow
bearing to fall out. Remove bushing from opposite side
of wheel hub.
4. Check the bearing, spanner and inside of wheel
hub for wear. Replace defective parts.
5. To assemble the castor wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
6. Carefully slide spanner through the bushings and
the wheel hub.
7. Install castor wheel assembly between castor fork
and secure in place with capscrew, washers and
locknut.
8. Lubricate castor wheel bearing through grease
fitting, using No. 2 general purpose lithium base
grease.
REPLACING GRASS DEFLECTOR (Fig. 37)
1. Position machine on a level surface, raise cutting
unit, engage parking brake, be sure traction pedal is in
neutral position, PTO lever in OFF position, shut engine
OFF, and remove key from switch. Block cutting unit to
prevent it from falling accidentally.
2. Remove two capscrews, locknuts, and springs
securing deflector mounts to pivot brackets.
3. To remove the pivot brackets, remove carriage
bolts and nuts.
4. Reinstall pivot brackets on top of discharge
opening with carriage bolts and nuts. Head of carriage
bolts must be on inside of cutting unit.
5. Position deflector mounts on pivot brackets and
secure parts together with capscrews, locknuts and
springs. Both locknuts must face each other. Tighten
locknuts until they are flush against deflector pivots.
Figure 37
1. Deflector mounts
2. Pivot brackets
3. Pivot springs
3
2
1
6. Lift deflector and allow it to drop to check spring
tension. Deflector must be held firmly in full downward
position by spring tension. Correct if necessary.
REMOVING CUTTER BLADE (Fig. 38)
The blade must be replaced if a solid object is hit, the
blade is outofbalance or if the blade is bent. Always
use genuine Toro replacement blades to be sure of
safety and optimum performance. Never use
replacement blades made by other manufacturers
because they could be dangerous.
1. Raise cutting unit to highest position, shut the
engine off and engage the parking brake. Block cutting
unit to prevent it from falling accidentally.
2. Grasp end of blade using a rag or thickly padded
glove. Remove blade bolt, lock washer, antiscalp cup,
and blade from spindle shaft.

19
MAINTENANCE
Figure 38
1. Blade bolt
2. Lockwasher
3. Anti-Scalp Cup
1
2
3
2. Install bladesail facing toward cutting unit with
antiscalp cup, lock washer, and blade bolt. Tighten
blade bolt to 85-110 ft.lb.
WARNING
Do not try to straighten a blade that is bent, and
never weld a broken or cracked blade. Always
use a new blade to ensure continued safety
certification of the product.
INSPECTING AND SHARPENING BLADE
1. Raise cutting unit to highest position, shut the
engine off and engage the parking brake. Block cutting
unit to prevent it from falling accidentally.
2. Examine cutting ends of the blade carefully,
especially where the flat and curved parts of the blade
meet (Fig. 39A). Since sand and abrasive material can
wear away the metal that connects the flat and curved
parts of the blade, check the blade before using the
machine. If wear is noticed (Fig. 39B), replace the
blade: refer to Removing Cutter Blade.
Figure 39
DANGER
If blade is allowed to wear, a slot will form
between the sail and flat part of the blade
(Fig. 39C). Eventually a piece of the blade
may break off and be thrown from under the
housing, possibly resulting in serious injury to
yourself or bystander.
3. Inspect cutting edges of all blades. Sharpen the
cutting edges if they are dull or nicked. Sharpen only
the top of the cutting edge and maintain the original
cutting angle to make sure of sharpness (Fig. 27). The
blade will remain balanced if same amount of metal is
removed from both cutting edges.
Figure 40
SHARPEN AT THIS
ANGLE ONLY
END VIEW
4. To check blade for being straight and parallel, lay
blade on a level surface and check its ends. Ends of
blade must be slightly lower than the center, and
cutting edge must be lower than the heel of the blade.
This blade will produce good quality of cut and require
minimal power from the engine. By contrast a blade
that is higher at the ends than the center, or if cutting
edge is higher than the heel, the blade is bent or
warped and must be replaced.
5. Install bladesail facing toward cutting unit with
antiscalp cup, lock washer, and blade bolt. Tighten
blade bolt to 85-110 ft.lb.

20
MAINTENANCE
CORRECTING CUTTING UNIT MISMATCH
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be
corrected by making sure the blades are straight and
all blades are cutting on the same plane.
1. Using a 3 foot long carpenters level, find a level
surface on the shop floor.
2. Raise heightofcut to the highest position: refer to
Adjusting HeightofCut.
3. Lower cutting unit onto flat surface. Remove
covers from top of cutting unit.
4. Unhook spring from idler arm bracket to release
belt tension.
5. Rotate blades until the ends face forward and
backward. Measure from floor to front tip of cutting
edge and remember this dimension. Then rotate same
blade so opposite end is forward and measure again.
The difference between dimensions must not exceed
1/8 of an inch. If dimension exceeds 1/8 of an inch,
replace the blade because it is bent. Make sure to
measure all blades.
6. Compare measurements of outer blades with the
center blade. Center blade must not be more than 3/8
of an inch lower than the outer blades. If center blade is
more than 3/8 of an inch lower than the outer blades.
proceed to step 7 and add shims between spindle
housing and bottom of cutting unit.
7. Remove capscrews, flatwashers, lockwashers
and nuts from outer spindle in the area where shims
must be added. To raise or lower the blade, add a shim,
Part No. 325624, between spindle housing and
bottom of cutting unit. Continue to check alignment of
blades and add shims until tips of blades are within the
required dimension.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
8. Hook spring onto idler arm bracket. Reinstall belt
covers.
IDENTIFICATION AND ORDERING
MODEL AND SERIAL NUMBERS
The cutting deck has two identification numbers: a
model number and a serial number. The two numbers
are stamped into a plate on rear of the mower deck,
under cover. In any correspondence concerning the
mower, supply the model and serial numbers to ensure
that correct information and replacement parts are
obtained.
To order repIacement parts from an authorized Toro
Distributor, supply the following information:
1. Model and serial numbers of the machine.
2. Part number, description and quantity of parts
desired.
Note: Do not order by reference number if a parts
cataIog is being used; use the part number.