Toro Proline 30138 User manual

Operator’s Manual
IMPORTANT: Read this manual carefully. It contains information about your
safety and the safety of others. Also become familiar with the controls and
their proper use before you operate the product.
FORM NO. 3321–807
ProLine
92cm Mower
for Mid-Size Traction Unit
Model No. 30138 – 990001 & Up

Printed in USA
Introduction
We want you to be completely satisfied with your
new product, so feel free to contact your local
Authorized Service Dealer for help with service,
genuine replacement parts, or other information you
may require.
Whenever you contact your Authorized Service
Dealer or the factory, always know the model and
serial numbers of your product. These numbers will
help the Service Dealer or Service Representative
provide exact information about your specific
product. You will find the model and serial number
plate located in a unique place on the product as
shown below .
1
1074
1. Model and Serial Number Plate
For your convenience, write the product model and
serial numbers in the space below.
Model No:
Serial No.
The warning system in this manual identifies
potential hazards and has special safety messages that
help you and others avoid personal injury, even death.
DANGER, WARNING and CAUTION are signal
words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
DANGER signals an extreme hazard that will cause
serious injury or death if the recommended
precautions are not followed.
WARNING signals a hazard that may cause serious
injury or death if the recommended precautions are
not followed.
CAUTION signals a hazard that may cause minor or
moderate injury if the recommended precautions are
not followed.
Two other words are also used to highlight
information. “Important” calls attention to special
mechanical information and “Note” emphasizes
general information worthy of special attention.
The left and right side of the machine is determined
by sitting on the seat in the normal operator’s
position.

1
Contents
Page
Safety and Instruction Decals 2.
. . . . . . . . . . . . .
Installation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 3 . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Castor Wheels 4 . . . . . . . . . . .
Installing the Carrier Frame to the
Traction Unit 4
. . . . . . . . . . . . . . . . . . . . . .
Installing the Deflector Guard 5 . . . . . . . . . .
Installing the Front Baffle 5 . . . . . . . . . . . . .
Installing the Cutting Deck 6 . . . . . . . . . . . .
Installing the Drive Belt 6 . . . . . . . . . . . . . . .
Operation 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Discharge
or Mulch Grass 8 . . . . . . . . . . . . . . . . . . . .
Engaging the Mower Blades (PTO) 8 . . . . . .
Adjusting the Height-of-Cut 9 . . . . . . . . . . .
Adjusting Center Gage Wheels 9 . . . . . . . . .
Tips for Mowing Grass 10 . . . . . . . . . . . . . . .
Page
Maintenance 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart 11 . . . . . . . . . . . . . . . .
Cutting Blades 11 . . . . . . . . . . . . . . . . . . . . . .
Correcting Cutting Unit Mismatch 14 . . . . . .
Setting the Front-to-Rear Pitch 14 . . . . . . . . .
Setting the Side-to-Side Leveling 15 . . . . . . .
Greasing the Bearings and Bushings 16 . . . . .
Replacing the Deck Belt 16 . . . . . . . . . . . . . .
Replacing the Drive Belt 17 . . . . . . . . . . . . . .
Replacing the Castor Wheel Fork Bushings 18
Servicing the Castor Wheels and Bearings 19
Replacing the Grass Deflector 20
. . . . . . . . . .
Storage 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 21 . . . . . . . . . . . . . . . . . . . . . . . . .

Safety
2
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.
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    
!#$ " 
   
!#$ " 
    
!#$ " 
    
    
!#$ " 
   
!#$ " 
See T raction Unit Operator ’s Manual for
Glossary of Safety Symbols

3
Installation
Loose Parts
Note: Use the chart below to identify parts used for assembly.
DESCRIPTION QTY. USE
Castor Wheel Assembly
Thrust W asher
Spacer
Retaining Ring
2
8
2
2
Install castor wheels to carrier frame
Carrier Frame
Flange Screw , 1/2”-13 x 25 mm (1”)
Flange Nut, 1/2”-13
1
6
6
Install carrier frame to traction unit
Adjusting Shaft
Jam Nut, 1/2”-13
Spacer, 13 mm (1/2”)
Spring
Bushing
2
4
2
2
2
Install adjusting shafts
Clevis Pin
Hairpin Cotter
4
4
Install cutting unit to carrier frame
Front Baf fle
Bolt, 5/16” x 19 mm (3/4”)
Locknut, 5/16”
1
6
6
Install front baf fle
Deflector Guard
Bolt, 5/16” x 19 mm (3/4”)
Locknut, 5/16”
1
2
2
Install deflector guard
Operator’ s Manual
Parts Catalog
1
1
Read before operating
Ordering parts

Installation
4
Installing the Castor Wheels
1. Place two (2) thrust washers onto the castor
wheel fork (Fig. 1).
2. Insert the castor wheel fork into the carrier frame
mounting tube (Fig. 1).
3. Install the spacer and two (2) thrust washers onto
the castor wheel fork, then secure with a
retaining ring (Fig. 1).
3
2
2
1
4
5

Figure 1
1. Retaining Ring
2. Thrust W asher (4)
3. Carrier Frame Mounting
Tube
4. Spacer
5.
Castor Wheel Fork
Installing the Carrier Frame to
the T raction Unit
1. Align the carrier frame holes with the mounting
holes in the traction unit frame (Fig. 2).
2. Fasten each side of the carrier frame to the
traction unit with three (3) 1/2” x 25 mm (1”)
flange screws and locknuts. Torque the mounting
screws to 81–109 Nm (60–80 ft-lb) (Fig. 2).
2
1

Figure 2
1. Carrier Frame 2. T raction Unit Frame

Installation
5
Installing the Deflector Guard
1. Measure 10 mm in from the rear outer corner of
the grass deflector and mark a line to the inside
corner (Fig. 3). Cut the grass deflector along the
line.
2. Mark and drill a 9 mm hole 13 mm up from the
lower edge, and 6.5 mm in from the end of the
grass deflector (Fig. 3).
3. Hold the deflector guard in a level position along
the rear of the deflector.
4. Mark and drill a second 9 mm hole in the grass
deflector (Fig. 3).
5. Secure the deflector guard to the grass deflector
with two (2) 5/16” bolts from the inside, and
secure with 5/16” thin locknuts (Fig. 3).
ÇÇ
ÇÇ
ÇÇ
2043
2
1
4
3
10 mm
6.5 mm
5
6
13 mm
Figure 3
1. Grass Deflector
2. Cut of f Grass Deflector
3. Mark and drill 9 mm hole
(2)
4.
Deflector Guard
5. Bolt, 5/16”-18 x 19 mm
(3/4”)
6. Locknut,
8mm (5/16”) Thin
Installing the Front Baffle
1. Locate the front baffle inside the front of the
mower so the left end fits into the angle, and the
top fits up against the top front edge. Using the
baffle as a guide, mark and drill six (6) 9 mm
holes in the front of the mower as shown
(Fig. 4).
2. Install the front baffle inside the mower with
5/16” bolts from the inside, and secure with
5/16” thin locknuts (Fig. 4).
1
3
2
5
4

Figure 4
1. 36” Mower
2. Front Baf fle
3.
Drill 9 mm Hole (6)
4. Bolt, 5/16”-18 x 19mm (
3/4”) (6)
5. Locknut, 8mm (5/16”) Thin
(6)

Installation
6
Installing the Cutting Deck
1. Position the cutting deck under the carrier frame.
2. Mount the cutting deck to the carrier frame with
four (4) clevis pins and hairpin cotters (Fig. 5).
Note: All four pins must be in the same hole
locations to prevent uneven cutting.
8
11
1
3
5
7
2
4
6

9
10
Figure 5
1. 26 mm (1”) Cut Height
2. 38 mm (1-1/2”) Cut Height
3. 51 mm (2”) Cut Height
4. 63 mm (2-1/2”) Cut Height
5. 76 mm (3”) Cut Height
6. 89mm (3-1/2”) Cut Height
7. 102 mm (4”) Cut Height
8. Clevis Pin
9. Carrier Frame
10. Cutting Deck
11. Hairpin Cotter
Installing the Drive Belt
1. Remove the hand knobs holding the deck cover
to the top of the cutting unit and remove the
deck cover.
2. Install the drive belt around the drive pulley on
the traction unit and the upper groove of the left
spindle pulley . The belt must be between the belt
guides (Fig. 6).
3. Reinstall the deck cover onto the cutting unit,
then reinstall and tighten the hand knobs.
1
23
4
Figure 6
1. Traction Unit Drive Pulley
2. Drive Belt
3. Belt Guide (2)
4. Left Spindle Pulley

Installation
7
4. Thread two (2) 13mm (1/2”) jam nuts
approximately 22.8 cm (9”) up on each adjusting
shaft (Fig. 7).
5. Slide a 13mm (1/2”) spacer, spring and bushing
onto each adjusting shaft. Make sure to install
the bushing with the flange end against the
spring (Fig. 7).
m–2542
5
1
2
3
46
Figure 7
1. 13mm (1/2”) Jam Nut (2)
2. 13mm (1/2”) Spacer
3. Spring
4. Bushing
5.
Adjusting Shaft
6. Locknut (already installed
on Adjusting Shaft)
6. Insert the spring end of the adjusting shaft into
the hole in the deck mounting bracket. Note that
the small end of the bushing fits into the hole in
the deck bracket. Insert the locknut end of the
adjusting shaft into the carrier frame mounting
tab (Fig. 8).
7. To tension the belt, tighten the front jam nut on
each adjusting shaft until the springs are
compressed to 12.7 cm (5”). Measure the spring
compression between the spacer and the bushing
(Fig. 8).
8. Tighten the rear jam nuts (Fig. 8).
m–2541
2
1
4
3
5
Figure 8
1. 12.7cm (5”) between the
Spacer and Bushing
2. Deck Mounting Bracket
3. Front Jam Nut
4. Rear Jam Nut
5. Carrier Frame Mounting
Tab
9. Check the position of the belt guides. The guides
should be positioned about 3 mm (1/8”) away
from the belt (Fig. 9). Adjust the belt guides as
necessary.
12

2
Figure 9
1. Drive Belt 2. Belt Guide
10. Check the front-to-rear blade pitch. Refer to
Setting the Front-to-Rear Pitch in the
Maintenance section.

8
Operation
Side Discharge
or Mulch Grass
The mower has a hinged grass deflector that disperses
clippings to the side and down toward the turf.
POTENTIAL HAZARD
•Without the grass deflector or complete
grass catcher assembly mounted in place,
you and others are exposed to blade contact
and thrown debris.
WHAT CAN HAPPEN
•Contact with rotating mower blade(s) and
thrown debris will cause injury or death.
HOW TO AV
OID THE HAZARD
• NEVER r emove the grass deflector from
the mower because the grass deflector
routes material down toward the turf. If the
grass deflector is ever damaged, replace it
immediately.
•Never put your hands or feet under the
mower.
•Never try to clear discharge area or mower
blades unless you move the power take-off
(PTO) to “OFF” and rotate the ignition key
to “OFF.” Also remove the key and pull the
wire(s) off the spark plug(s).
Engaging the Mower Blades
(PTO)
The blade control switch (PTO) in conjunction with
the blade control bail engages and disengages power
to the electric clutch and mower blades.
1. Pull on the upper control bar to stop the machine
(Fig. 10).
2. To engage the blades, squeeze the blade control
bail against the upper control bar.
3. Press the blade control rocker switch forward to
“ON”. Hold the blade control bail against the
control bar while operating.
Note: Repeat the procedure to engage the
mower blades if the blade control bail
is released.
4. To disengage the blades, release the blade
control bail, or push the blade control switch to
the “OFF” position.
13
2

Figure 10
1. Upper Control Bar
2. Blade Control Bail
3. Blade Control Switch
(PTO)

Operation
9
Adjusting the Height-of-Cut
The height-of-cut is adjustable from 26 to 102 mm
(1” to 4”) in 13 mm (1/2-inch) increments by
relocating the clevis pins in different hole locations in
brackets at each corner of the cutting unit (Fig. 11).
Stop the engine before adjusting the height-of-cut.
Note: All four pins must be in the same hole
location for even cutting.
8
9
1
3
5
7
2
4
6

Figure 1 1
1. 26 mm (1” ) Cut Height
2. 38 mm (1-1/2”) Cut Height
3. 51 mm (2”) Cut Height
4. 63 mm (2-1/2”) Cut Height
5. 76 mm (3”) Cut Height
6. 89 mm (3-1/2”) Cut Height
7. 102 mm (4”) Cut Height
8. Clevis Pin
9. Hairpin Cotter
Adjusting Center Gage Wheels
The gage wheels must be adjusted in the proper hole
location for each height-of-cut position.
1. After adjusting height-of-cut remove bolt and
nut (Fig. 12).
2. Select a hole position so the gage wheel is 9.5
mm (3/8”) off the ground for the height-of-cut to
be used (Fig. 12).
3. Reinstall the bolt and nut (Fig. 12).
m–4124
12
3
Figure 12
1. Center Gage Wheels
2. Nut 3. Bolt

Operation
10
Tips for Mowing Grass
Fast Throttle Setting
For best mowing and maximum air circulation,
operate the engine at “FAST.” Air is required to
thoroughly cut grass clippings, so do not set the
height-of-cut so low as to totally surround the mower
by uncut grass. Always try to have one side of the
mower free from uncut grass, which allows air to be
drawn into the mower.
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure the
cutting height of the mower does not scalp any
uneven ground. However, the cutting height used in
the past is generally the best one to use. When cutting
grass longer than six inches tall, you may want to cut
the lawn twice to ensure an acceptable quality of cut.
Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows
more slowly.
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.
Mow at Correct Intervals
Normally, mow every four days. But remember, grass
grows at different rates at different times. So to
maintain the same cutting height, which is a good
practice, mow more often in early spring. As the
grass growth rate slows in mid summer, mow less
frequently. If you cannot mow for an extended period,
first mow at a high cutting height; then mow again
two days later at a lower height setting.
Cutting Speed
To improve cut quality, use a slower ground speed.
Avoid Cutting Too Low
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height
to ensure that uneven turf is not cut too short.
Long Grass
If the grass is ever allowed to grow slightly longer
than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then cut the grass
again using the lower, normal setting.
When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may drop
onto your lawn. To avoid this, move onto a
previously cut area with the blades “ENGAGED”.
Keep the Underside of the Mower Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.
Blade Maintenance
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the cutter
blades daily for sharpness, and for any wear or
damage. File down any nicks and sharpen the blades
as necessary . If a blade is damaged or worn, replace it
immediately with a genuine T ORO replacement
blade.

11
Maintenance
Service Interval Chart
Service Operation
Each
Use 8 Hours 25 Hours Storage Service Notes
Cutting Blades – check X X
Belts – check for wear/cracks X
Blade Spindle Bearings – grease X
Castor Wheels – grease X
Mower Housing – clean X X X
Chipped Surfaces – paint X
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.
POTENTIAL HAZARD
•A blade that is worn or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
•Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AV
OID THE HAZARD
•Periodically inspect the blade for wear and
damage. Immediately install a new blade if
it is worn or damaged.
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the
blade control (PTO) and set the parking brake. Turn
the ignition key to “OFF” to stop the engine. Remove
the key and disconnect the spark plug wire(s) from
the spark plug(s).

Maintenance
12
Inspecting the Blades
1. Inspect the cutting edges (Fig 13). If the edges
are not sharp or have nicks, remove and sharpen
the blades. Refer to Sharpening the Blades on
page 13.
2. Inspect the blades, especially the curved area
(Fig. 13). If you notice any damage, wear, or a
slot forming in this area (item 3 in Fig. 13),
immediately install a new blade.
1
2
3
m–151
Figure 13
1. Cutting Edge
2. Curved Area
3. W ear/slot Forming
Checking for Bent Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 14). Measure from a level
surface to the cutting edge of the blades
(Fig. 15). Note this dimension.

m–2466
Figure 14
 
   
  m–1087
Figure 15
2. Rotate the opposite ends of the blades forward.
Measure from a level surface to the cutting edge
of the blades at the same position as in step 1
above. The difference between the dimensions
obtained in steps 1 and 2 must not exceed 3 mm
(1/8”). If this dimension exceeds 3 mm (1/8”)
1/8” (3 mm), the blade is bent and must be
replaced. Refer to Removing the Blades, and
Installing the Blades on page 13.

Maintenance
13
POTENTIAL HAZARD
•A blade that is bent or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
•Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AV
OID THE HAZARD
• Always r eplace 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 end using a rag or thickly-padded
glove. Remove the blade bolt, lock washer, anti–scalp
cup and blade from the spindle shaft (Fig. 16).
1082
1
2
3
4
5
Figure 16
1. Sail Area of Blade
2. Blade
3.
Anti–scalp Cup
4. Lock W asher
5.
Blade Bolt
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both
ends of the blade (Fig. 17). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
1
m–1854
Figure 17
1. Sharpen at original angle
2. Check the balance of the blade by putting it on a
blade balancer (Fig. 18). 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. 16).
Repeat this procedure until the blade is balanced.
12m–1855
Figure 18
1. Blade 2. Balancer
Installing the Blades
1. Install the blade onto the spindle shaft (Fig. 16).
IMPORTANT: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.
2. Install the anti–scalp cup, lock washer and blade
bolt (Fig. 16). Torque the blade bolt to 115–149
Nm (85–110 ft-lb).

Maintenance
14
Correcting Cutting Unit
Mismatch
If one cutter blade cuts lower than the other, correct
as follows:
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Adjust the tire pressure in all tires to
specifications and check that the blades are not
bent. Refer to Checking for Bent Blades on page
12.
3. Set the height-of-cut to the 64 mm (2-1/2”)
position. Refer to Adjusting the Height-Of-Cut
in the Operation section. Make sure the clevis
pins are resting on the frame cushions.
4. Rotate the blades so the tips line up with one
another. The tips of both blades must be within 3
mm (1/8”) of each other. If the blade tips are not
within 3 mm (1/8”) of each other, add shim
washers (Part No. 3256-24) between the
appropriate spindle housing and the bottom of
the cutting unit to align the blades.
Setting the Front-to-Rear Pitch
1. Check the tire pressure.
2. Position the blades front-to-rear (Fig. 19).
Measure at “C” and “D” locations (Fig. 19) from
a level surface to the cutting edge of the blades
(Fig. 20).
3. The mower should be 3–16 mm (1/8”–5/8”)
lower in front “C” than in the rear “D”.
m–1078



Figure 19
 
   
  m–1087
Figure 20

Maintenance
15
4. To change the front-to-rear pitch, move an equal
number of thrust washers on both castor wheel
forks. Move the thrust washers from the top of
the carrier frame mounting tube to the bottom to
raise the front of the mower. Move the thrust
washers from the bottom of the mounting tube to
the top to lower the front of the mower.
(Fig. 21).
5. Check the side-to-side leveling of the cutting
unit.
2
1
1
3

Figure 21
1. Thrust W asher (locate as
required)
2.
Carrier Frame Mounting
Tube
3.
Castor Wheel Fork
Setting the Side-to-Side Leveling
1. Check the tire pressure.
2. Position the blades side-to-side (Fig. 22).
Measure at “A” and “B” locations (Fig. 22) from
a level surface to the cutting edge of blades
(Fig. 23).
3. The difference between measurements “A” and
“B” should be no more than 1/4” (6 mm).


1666

Figure 22
 
   
  m–2558
Figure 23
4. To change the side-to-side leveling, move the
thrust washers on one castor wheel fork only.
Move the thrust washers from the top of the
carrier frame mounting tube to the bottom to
raise the corresponding side of the mower. Move
the thrust washers from the bottom of the
mounting tube to the top to lower the
corresponding side of the mower. (Fig. 21).
5. Recheck the front-to-rear pitch of the cutting
unit.

Maintenance
16
Greasing the Bearings and
Bushings
The cutting unit must be lubricated regularly. Refer to
the Service Interval Chart on page 11. Grease with
No. 2 general purpose lithium base or molybdenum
base grease.
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Grease the fittings on both spindle bearings
(Fig. 25).
Note: Y
ou can access the spindle grease
fittings through the holes in the mower
deck cover.
3. Grease the fittings on the carrier frame mounting
tubes and castor wheels (Fig. 24).

1
2
Figure 24
1. Carrier Frame Mounting
T ube Grease Fitting
2. Castor Wheel Grease
Fitting
Replacing the Deck Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks and
cracks are signs of a worn deck belt. Replace the deck
belt if any of these conditions are evident.
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Remove the hand knobs holding the deck cover
to the top of the cutting unit and remove the
deck cover.
3. Remove the drive belt. Refer to Replacing the
Drive Belt, steps 3 and 4 on page 17.
4. Disconnect the idler arm spring to relieve
tension on the idler arm and idler pulley, then
remove the worn deck belt (Fig. 25).
5. Install the new deck belt around the right spindle
pulley, idler pulley, and in the lower groove of
the left spindle pulley (Fig. 25).
6. Reconnect the idler arm spring (Fig. 25).
24
1
3

5
Figure 25
1. Deck Belt
2. Right Spindle Pulley
3. Idler Arm Spring
4. Idler Pulley
5. Left Spindle Pulley
7. Reinstall the drive belt. Refer to Replacing the
Drive Belt, steps 5 and 6 on page 17.
8. Reinstall the deck cover onto the cutting unit,
then reinstall and tighten the hand knobs.

Maintenance
17
Replacing the Drive Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks and
cracks are signs of a worn drive belt. Replace the
drive belt if any of these conditions are evident.
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Remove the hand knobs holding the deck cover
to the top of the cutting unit and remove the
deck cover.
3. Loosen the jam nuts on each adjusting shaft to
loosen the tension on the drive belt (Fig 26).
m–2541
12
Figure 26
1. Jam Nuts 2. Adjusting Shaft
4. Remove the worn drive belt (Fig. 27).
5. Install the new drive belt onto the traction unit
drive pulley and the top groove of the left
spindle pulley (Fig. 27).
1
23
4
Figure 27
1. Traction Unit Drive Pulley
2. Drive Belt
3. Belt Guide (2)
4. Left Spindle Pulley
6. Tighten the jam nuts on the adjusting shafts until
the springs are compressed to a length of 12.7
cm (5”) (Fig 28).
1
2
m–2541
Figure 28
1. 5” between the Spacer
and Bushing
2. Jam Nuts
7. Reinstall the deck cover onto the cutting unit,
then reinstall and tighten the hand knobs.

Maintenance
18
Replacing the Castor Wheel
Fork Bushings
The castor wheel forks are mounted in bushings
pressed into the top and bottom of the carrier frame
mounting tubes. To check the bushings, move the
castor forks back and forth and side-to-side. If a
castor fork is loose, the bushings are worn and must
be replaced.
1. Raise the cutting unit so the castor wheels are off
the floor, then block up the front of the mower
with jack stands.
2. Remove the retaining ring, thrust washer(s) and
spacer from the top of the castor wheel fork (Fig.
29).
3. Pull the castor wheel fork out of the mounting
tube, leaving the thrust washer(s) on the bottom
of the fork. Remember the location of the thrust
washers and spacer on each fork to ensure
correct installation, and to maintain a level deck.
42
2
1
3
5

Figure 29
1. Retaining Ring
2. Thrust W ashers (locate as
required)
3. Spacer
4.
Carrier Frame Mounting
Tube
5.
Castor Wheel Fork
4. Insert a pin punch into the mounting tube and
carefully drive out the bushings (Fig. 30). Clean
the inside of the mounting tube.
5. Grease the inside and outside of the new
bushings. Use a hammer and flat plate to
carefully drive the bushings into the mounting
tube.
6. Inspect the castor wheel fork for wear and
replace if necessary (Fig. 29).
7. Slide the castor wheel fork through the bushings
in the mounting tube. Replace the spacer and
thrust washer(s) onto the fork and secure with
the retaining ring (Fig 29).
IMPORTANT: The inside diameter of the
bushings may collapse slightly when installed.
If the castor wheel fork does not slide into the
new bushings, ream both bushings to an
inside diameter of 28.6mm (1.126 in.).
8. Grease the fitting on the carrier frame mounting
tube using No. 2 general purpose lithium base or
molybdenum base grease.
2
2
1

Figure 30
1. Carrier Frame Mounting
Tube 2. Bushing