Toro 30431 User manual

Operator’s Manual
English (EN)
Form No. 3327-396 Rev A
Mid–Size Mower
ProLine Pistol Grip Gear 15 HP with 44 inch
Side Discharge Mower
Model No. 30431—Serial No. 230000001 and Up

2
All Rights Reserved
Printed in the USA
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Warning
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest–covered, brush–covered or grass–covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . . .
Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . .
Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level 12. . . . . . . . . . . . . . . . . . . .
Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Handle Assembly 14. . . . . . . . . . . . . .
Installing the Shift Lever Plate and Fuel Tank 14. . .
Adjusting the Shift Lever Plate 15. . . . . . . . . . . . . .
Installing the Control Rods 16. . . . . . . . . . . . . . . . . .
Installing the Hairpin Cotter Pins and Washers 17. .
Page
Checking the Tire Pressure 17. . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake and Neutral Lock 18. . . . . . . . . . . . .
Starting and Stopping the Engine 19. . . . . . . . . . . . .
Operating Mower Blade Control (PTO) 19. . . . . . . .
The Safety Interlock System 19. . . . . . . . . . . . . . . .
Driving Forward or Backward 20. . . . . . . . . . . . . . .
Stopping the Machine 20. . . . . . . . . . . . . . . . . . . . . .
Transporting Machines 21. . . . . . . . . . . . . . . . . . . . .
Side Discharge or Mulch Grass 21. . . . . . . . . . . . . .
Adjusting the Height-of-Cut 21. . . . . . . . . . . . . . . . .
Adjusting the Gage Wheels 22. . . . . . . . . . . . . . . . .
Adjusting the Handle Height 22. . . . . . . . . . . . . . . .
Using the Mid–Size Weight Kit 23. . . . . . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 24. . . . . . . . .
Air Cleaner Service 25. . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Service 26. . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Service 27. . . . . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 28. . . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 29. . . . . . . . . . . . . . . .
Checking the Tire Pressure 29. . . . . . . . . . . . . . . . . .
Fuel Tank Service 30. . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Service 30. . . . . . . . . . . . . . . . . . . . . . . .
Fuse Service 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch 31. . . . . . . . . . . . . . . .
Servicing the Brakes 31. . . . . . . . . . . . . . . . . . . . . . .
Servicing the Cutting Blades 32. . . . . . . . . . . . . . . .
Correcting the Mower Quality of Cut 34. . . . . . . . . .
Frame Set Up 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Deck Front-to-Rear Pitch 36. . . . . . . .
Changing the Deck Front-to-Rear Pitch 36. . . . . . . .
Checking the Deck Side-to-Side Leveling 37. . . . . .
Changing the Side-to-Side Leveling 37. . . . . . . . . .
Matching Height of Cut 37. . . . . . . . . . . . . . . . . . . .
Adjusting the Traction Drive Belt Tension 38. . . . . .
Replacing the Traction Drive Belt 38. . . . . . . . . . . .
Replacing the Transmission Belt 39. . . . . . . . . . . . .
Replacing the Mower Belt 39. . . . . . . . . . . . . . . . . .
Replacing the PTO Drive Belt 40. . . . . . . . . . . . . . .
Replacing the Caster Wheel Fork Bushings 40. . . . .
Caster Wheel and Bearings Service 41. . . . . . . . . . .
Replacing the Grass Deflector 42. . . . . . . . . . . . . . .
Wiring Diagram 43. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 44. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 48. . . . . . . . . . . . .

3
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. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1m–6594
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—1999.
Training
•Read the Operator’s Manual and other training material.
If the operator(s) or mechanic(s) can not read English it
is the owner’s responsibility to explain this material to
them.
•Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
•All operators and mechanics should be trained. The
owner is responsible for training the users.
•Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
•The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
•Wear appropriate clothing including hard hat, safety
glasses and 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

4
•Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
•Never refuel or drain the machine indoors.
•Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
•Never run an engine in an enclosed area.
•Only operate in good light, keeping away from holes
and hidden hazards.
•Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine from
the operator’s position.
•Slow down and use extra care on hillsides. Be sure to
travel side–to–side on hillsides. Turf conditions can
affect the machine’s stability. Use caution while
operating near drop–offs.
•Slow down and use caution when making turns and
when changing directions on slopes.
•Never raise deck with the blades running.
•Never operate with the PTO shield, or other guards not
securely in place. Be sure all interlocks are attached,
adjusted properly, and functioning properly.
•Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
•Do not change the engine governor setting or overspeed
the engine.
•Stop on level ground, disengage drives, engage parking
brake (if provided), shut off engine before leaving the
operator’s position for any reason including emptying
the catchers or unclogging the chute.
•Stop equipment and inspect blades after striking objects
or if an abnormal vibration occurs. Make necessary
repairs before resuming operations.
•Keep hands and feet away from the cutting unit.
•Look behind and down before backing up to be sure of
a clear path.
•Keep pets and bystanders away.
•Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
•Be aware of the mower discharge direction and do not
point it at anyone.
•Do not operate the mower under the influence of
alcohol or drugs
•Use care when loading or unloading the machine into or
from a trailer or truck
•Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Maintenance and storage
•Disengage drives, set parking brake, stop engine and
remove key or disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning or
repairing.
•Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
•Let engine cool before storing and do not store near
flame.
•Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
•Park machine on level ground. Set parking brake. Never
allow untrained personnel to service machine.
•Use jack stands to support components when required.
•Carefully release pressure from components with stored
energy.
•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 blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
•Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
•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 and other safety information you
must know.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.

5
This product is designed for cutting and recycling grass or,
when equipped with a grass bagger, for catching cut grass.
Any use for purposes other than these could prove
dangerous to user and bystanders.
General Operation
•Allow only responsible adults who are familiar with the
instructions to operate the machine.
•Be sure the area is clear of other people before mowing.
Stop the machine if anyone enters the area.
•Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
•Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
•Slow down before turning. Sharp turns on any terrain
may cause loss of control.
•Turn off blades when not mowing.
•Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and any
moving parts while engine is running.
•Stop the engine before removing the grass catcher or
unclogging the chute.
•Mow only in daylight or good artificial light.
•Watch for traffic when operating near or crossing
roadways.
•Do not touch equipment or attachment parts which may
be hot from operation. Allow to cool before attempting
to maintain, adjust or service.
•Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
Slope Operation
Slopes and ramps are a major factor related to
loss-of-control and accidents, which can result in severe
injury or death. All slopes and ramps require extra caution.
If you feel uneasy on a slope, do not mow it.
DO
•Remove obstacles such as rocks, tree limbs, etc. from
the mowing area. Watch for holes, ruts or bumps. Tall
grass can hide obstacles.
•Use slow speed so that you will not have to stop while
on the slope.
•Use extra care with grass catchers or other attachments.
These can change the stability of the machine.
•Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed or direction.
•Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades.
•Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
•Mow slopes side–to–side.
DO NOT
•Do not mow slopes greater than 15 degrees.
•Avoid turning on slopes. If you must turn, turn slowly
and gradually downhill, if possible.
•Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly turn over if a wheel goes
over the edge of a cliff or ditch, or if an edge caves in.
•Do not mow on wet grass. Reduced traction could cause
sliding.
•Do not use a grass catcher on steep slopes. Heavy grass
bags could cause loss of control of the machine.
•Do not mow up and down slopes.
Service
•Never store the machine or fuel container inside where
there is an open flame, such as near a water heater or
furnace.
•Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good condition.
•Never tamper with safety devices. Check safety systems
for proper operation before each use.
•Use only genuine replacement parts to ensure that
original standards are maintained.
•Check brake operation frequently. Adjust and service as
required.
•Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes and clothing. Protect your face,
eyes and clothing when working with a battery.
•Battery gases can explode. Keep cigarettes, sparks and
flames away from battery.
•Hydraulic fluid escaping under pressure can penetrate
the skin and cause injury. Use cardboard or paper to
find hydraulic leaks. Never use your hands.

6

7
Slope Chart

8

9
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.
43-8480
66-1340
67-5360
68-8340
93-1122
95-2814
98-0776
98-4387
1. Warning—wear hearing protection.

10
104-8186
104-8569
105-4111
105-4146
106-5532
106-0699
106-5511
106-0635

11
106-5496
1. Reverse 2. Neutral 3. Forward speeds
106-5501
1. Choke 2. Fast 3. Continuous variable setting 4. Slow
106-5514
1. Keep bystanders a safe
distance from the machine.
2. Do not allow bystanders to
be hit by thrown objects.
3. Do not operate the mower
with the deflector up or
removed.
4. Stop the engine and pick up
debris before operating.
5. Cutting of hand or foot,
mower.
6. Engine—stop
7. Engine—run
8. Hour meter
9. To park, move the controls
as illustrated.
10. To drive, move the controls
as illustrated.
11. To place the machine in
neutral, move the controls as
illustrated.
12. Power take-off (PTO)

12
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for automotive
use (85 pump octane minimum). Leaded regular gasoline
may be used if unleaded regular is not available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
•Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
•Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 inch
to 1/2 inch (6 mm to 13 mm) below the bottom
of the filler neck. This empty space in the tank
allows gasoline to expand.
•Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
•Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
•Always place gasoline containers on the ground
away from your vehicle before filling.
•Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
•When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
•If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
•If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
•Avoid prolonged breathing of vapors.
•Keep face away from nozzle and gas tank or
conditioner opening.
•Keep gas away from eyes and skin.
Warning
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
•Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
•Cleans the engine while it runs
•Eliminates gum-like varnish buildup in the fuel system,
which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at all
times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around fuel tank cap and remove the cap. Add
unleaded regular gasoline to fuel tank, until the level is
1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of
the filler neck. This space in the tank allows gasoline to
expand. Do not fill the fuel tank completely full.
3. Install fuel tank cap securely. Wipe up any gasoline that
may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine, check the
oil level in the engine crankcase; refer to Checking Oil
Level, page 26.

13
Setup
Note: Determine the left and right sides of the machine
from the normal operating position.
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Step Description Qty. Use
1Handle assembly
Flanged bolt 3/8 x 1 inch
Flange nut 3/8 inch
1
4
4
Installing the handle assembly
2
Fuel tank with studs installed
Shift lever plate
Bolt, 5/16 x 7/8 inch
Lock washer, 5/16 inch
Washer, 5/16 inch
Spring
Hose clamp
1
1
2
2
4
2
1
Installing shift lever plate and fuel tank
3No parts needed Adjusting the shift lever plate
4Clevis pin
Washer
Hairpin cotter pin
2
2
2
Installing the control rods
5Hairpin cotter pin 2Installing the hairpin cotter pins and
washers
6No parts needed Checking the tire pressure
7Oil drain hose
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Registration card
1
1
1
1
1
Use for draining engine oil
Read before operating machine
Read before operating machine
Fill out and return to Toro

14
1
Step
Parts needed for this step:
•1 Handle assembly
•4 Flange bolts, 3/8 x 1 inch
•4 Flange nuts, 3/8 inch
Installing the Handle Assembly
1. Align handle with upper mounting holes in rear frame
(Fig. 2).
2. Secure the handle at each upper mounting hole with a
flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).
3. Select the low position for the lower mounting hole
(Fig. 2).
4. Secure the handle at each lower mounting hole with a
flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).
Note: The handle position can be adjusted to match the
operator’s height preference.
m–6591
1
2
4
3
5
6
7
8
Figure 2
1. Upper handle
2. Rear frame
3. Flange nut, 3/8 inch
4. Flange bolt, 3/8 x 1 inch
5. Upper mounting hole
6. Lower mounting holes
7. Low position
8. High position
Note: Handle assembly must be installed before fuel tank is
installed.
2
Step
Parts needed for this step:
•1 Fuel tank with studs installed
•1 Shift lever plate
•2 Bolts, 5/16 x 7/8 inch
•2 Lock washers, 5/16 inch
•2 Flat washers, 5/16 inch
•2 Springs
•1 Hose clamp
Installing the Shift Lever Plate
and Fuel Tank
1. Remove the bolts and nuts holding the shift lever plate
to the rear frame. Discard these nuts and bolts.
2. Slide the shift lever plate over the shift lever and under
the bottom of the rear frame (Fig. 3).
m–5221
3
1
2
Figure 3
1. Rear frame
2. Shift lever plate 3. Fuel tank
3. Align fuel tank with the top of the rear frame (Fig. 3).
4. Push the fuel line onto the fuel tank connection and
secure it with the hose clamp that is on the fuel line
(Fig. 5).
Note: To ease assembly of the fuel line to fuel tank
connection, apply a light lubricant, such as WD 40, to the
end of the fuel line.
Note: Make sure the fuel line and clamp are on as shown in
Figure 4.

15
m–6504
21
3
Figure 4
1. Fuel line
2. Clamp 3. Fuel tank connection
5. Slide the shift lever plate over the shift lever (Fig. 6).
6. Secure the right side of shift lever plate and fuel tank to
the rear frame (Fig. 5) with 2 bolts (5/16 x 7/8 inch),
lock washers (5/16 inch) and washers (5/16 inch)
(Fig. 5).
7. Secure the left side shift lever plate and fuel tank to the
rear frame (Fig. 5) with washers (5/16 inch), springs
and locknuts (5/16 inch) (Fig. 5).
Note: Tighten left side of shift lever plate until it is
completely tight and then unscrew locknut one full turn.
This will allow the spring to work.
3
8
7
3
6
2
1
5
4
10
9
m–6465
Figure 5
1. Bolt, 5/16 x 7/8 inch
2. Lock washers, 5/16 inch
3. Washer, 5/16 inch
4. Fuel line
5. Hose clamp
6. Stud
7. Spring
8. Locknut
9. Shift lever plate
10. Fuel tank connection
3
Step
No parts needed for this step.
Adjusting the Shift Lever Plate
1. Shift lever to second gear and check alignment of lever
in slot of shifter lever plate. The clearance between top
and bottom of the shift lever should be equal (Fig. 7).
2. If clearance is not correct, remove lever and bend it
slightly to adjust (Fig. 6).
m–5250
12
6
5
4
3
Figure 6
1. Shift lever
2. Shift lever plate
3. Rubber seal washer
4. Square hole washer
5. Spring washer
6. Locknut, 3/8 inch
Note: Do not bend lever while attached to transmission
shaft or damage may occur.
3. Shift lever to neutral and check alignment of lever in
slot of shifter lever plate. The clearance on the sides of
shift lever should be equal (Fig. 7).
4. If clearance is not correct, loosen shift lever plate and
adjust it side–to–side. Tighten the shift lever plate.
Note: Tighten the left side of the shift lever plate until it is
completely tight and then unscrew the locknut one full turn.
This will allow the spring to work.

16
4Rear View
1
m–5458
4
3
2
2
Figure 7
1. Shift lever, 2nd gear
2. Shift lever plate 3. Shift lever, neutral 4. Equal distance
4
Step
Parts needed for this step:
•2 Clevis pins
•2 Washers
•2 Hairpin cotter pins
Installing the Control Rods
1. Install control rods into the bell cranks and secure with
hairpin cotters (Fig. 8).
Note: Install rod fittings so the clevis pin is above the
control rod, as shown in Figure 8.
31
m–6592
2
Figure 8
1. Control rod
2. Bell crank 3. Hairpin cotter
2. Adjust control rod length by threading rod in or out of
rod fitting until there is a 3/16 to 1/4 inch (5 mm to
6 mm) clearance between the control rod and bottom of
neutral/brake lock (Fig. 9).
3. Install control rod to drive lever and neutral/brake lock.
Secure with clevis pin and hairpin cotter.
4. Check operation. If adjustment is required, remove
hairpin cotter and clevis pin securing rod to drive
levers.
5. Adjust the control rod length by repeating steps 3 and 4
(Fig. 9).
6. Check the parking brake. Refer to Servicing the Brakes
on page 31.
3
4
2
1
5
6
m–658
2
Figure 9
1. Handle
2. Neutral/Parking brake
lock
3. 3/16 inch to 1/4 inch
(5 mm to 6 mm)
clearance
4. Drive lever
5. Forward speed
6. Control Rod

17
5
Step
Parts needed for this step:
•2 Hairpin cotter pins
Installing the Hairpin Cotter
Pins and Washers
Unused height–of–cut spacers may be stored on posts and
retained by a hairpin cotter.
1. On the opposite side of the muffler, install unused
washers and hairpin cotter pins into front and rear
height–of–cut pins (Fig. 10).
m-6505
3
2
1
Figure 10
1. Hairpin cotter
2. Unused spacers 3. Height–of–cut post
6
Step
No parts needed for this step.
Checking the Tire Pressure
Refer to Page 29 for the correct correct tire pressure.
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Think Safety First
Carefully read all the safety instructions and decals in the
safety section. Knowing this information could help you,
your family, pets or bystanders avoid injury.
The use of protective equipment for eyes, hearing, feet and
head is recommended.
This machine produces sound levels in excess of
85dBA at the operator’s ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Caution
12
Figure 11
1. Caution 2. Wear hearing protection
Controls
Become familiar with all the controls (Fig. 12) before you
start the engine and operate the machine.
Throttle control – The throttle control has three positions:
CHOKE, FAST and SLOW.
Operator Presence Control (OPC) levers – OPC levers
are used in conjunction with deck engagement switch
(PTO) to release blade brake and engage clutch to drive
mower blades. Release OPC levers to disengage mower
blades.
Blade control switch (PTO) – Pull switch used in
conjunction with OPC levers to release blade brake and
engage clutch to drive mower blades.
Gear shift lever – Transmission has five forward speeds,
neutral and reverse, and has an in-line shift pattern. Do not
shift while unit is moving, as transmission damage may
occur.

18
Drive levers – Shift to desired gear and release drive levers
to engage forward traction operation and squeeze to
reverse. Squeeze right side of drive lever to turn right and
left side to turn left.
Neutral lock and Parking brake locks – Squeeze drive
levers back and move locks to the rear for neutral lock.
Squeeze drive levers back and move locks to the front for
parking brake lock.
Ignition Switch – Key switch is used in conjunction with
recoil starter. Switch has two positions: Run and Off.
Recoil Starter – Pull recoil Starter handle to start engine.
Fuel Shut–off Valve – (Under fuel tank) Close fuel
shut–off valve when transporting or storing mower.
1
3
8
7
4
5
62
m–6581
9
Figure 12
1. Throttle control
2. Operator Presence
Control levers (OPC)
3. Blade control switch
(PTO)
4. Gear shift lever
5. Drive levers
6. Neutral lock and Parking
brake locks
7. Ignition switch
8. Handle
9. Fuel shut–off valve
Parking Brake and Neutral
Lock
Always set the parking brake when you stop the machine or
leave it unattended.
Setting the Parking Brake
1. Squeeze the drive levers back to the grip (Fig. 13).
2. Place thumbs on the upper part of the locks and rotate
them forward (Fig. 13).
3. Release the drive levers.
Releasing the Parking Brake
1. Squeeze the drive levers back to the grip (Fig. 13).
2. Place thumbs on the upper part of of locks and rotate
them rearward until in forward speed slot (Fig. 13).
6
1
2
3
45m–6580
7
8
Figure 13
1. Handle
2. Neutral/Parking brake
lock
3. Park position
4. Neutral position
5. Drive lever
6. Full speed forward
position
7. Grip
8. Forward speed slot
Setting the Neutral Lock
1. Squeeze the drive levers back to the grip (Fig. 13).
2. Place thumbs on the upper part of of locks and rotate
them rearward (Fig. 13).
Releasing the Neutral Lock
1. Squeeze the drive levers back to the grip (Fig. 13).
2. Place thumbs on the upper part of of locks and rotate
them forward until in forward speed slot (Fig. 13).

19
Starting and Stopping the
Engine
Starting
1. Make sure spark plug wire(s) areinstalled on spark
plug(s) and fuel valve is open.
2. Move the shift lever to neutral, set the parking brake,
and turn ignition key to the Run position.
3. Move the throttle control to the Choke position before
starting a cold engine.
Note: A warm or hot engine usually does not require any
choking. To start a warm engine, move throttle control to
the Fast position.
4. Grasp recoil starter handle firmly and pull out until
positive engagement results; then pull handle
vigorously to start engine and allow rope to recoil
slowly.
Important Do not pull recoil rope to its limit or let go
of the starter handle when rope is pulled out because rope
may break or recoil assembly may be damaged.
Stopping
1. Move the throttle lever to the Slow position (Fig. 14).
2. Let engine idle for 30 to 60 seconds before turning the
ignition key to off.
3. Set the parking brake.
4. Turn the ignition key to the Off position (Fig. 14).
1
2
m–6581
Figure 14
1. Throttle lever 2. Ignition key
Important Make sure fuel shut off valve is closed
before transporting or storing machine, as fuel leakage may
occur. Before storing the machine, pull the wire off the
spark plug(s) to prevent possibility of accidental starting.
Operating Mower Blade
Control (PTO)
The blade control switch (PTO) in conjunction with the
Operator Presence Control (OPC) levers engage and
disengage power to the electric clutch and mower blades.
Engaging the Mower Blades (PTO)
1. To engage blade, squeeze the Operator Presence
Control (OPC) levers against handle grips (Fig. 15).
2. Pull blade switch (PTO) up and release. Hold the
Operator Presence Control (OPC) levers against handle
grip.
3. Repeat procedure to engage mower blades if OPC
levers are released.
3 2
1
m–658
1
Figure 15
1. Handle
2. Operator Presence
Control levers (OPC)
3. Blade control switch
(PTO)
Disengaging the Mower Blades (PTO)
1. Release Operator Presence Control (OPC) levers to
disengage blades (Fig. 15). This will also kill the
engine.
The Safety Interlock System
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
•Do not tamper with the interlock switches.
•Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
Caution

20
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless:
•The blade control switch (PTO) is off.
•The machine is shifted into neutral.
The safety interlock system is designed to kill the engine
when:
•The Operator Presence Control (OPC) levers are
released while the machine is in gear and/or the mower
is engaged.
•The machine is shifted into gear without holding OPC
levers.
•The blade control switch (PTO) is pulled on without
holding the OPC levers.
Testing the Safety Interlock System
Test the safety interlock system before each use of the
machine. If the safety system does not operate as described,
have an Authorized Service Dealer repair the safety system
immediately.
1. Set the parking brake and place shift lever in neutral.
Start the engine; refer to Starting and Stopping the
Engine, page 19.
2. Without holding the Operator Presence Control (OPC)
levers, pull the blade control switch (PTO) up. The
engine should kill.
3. Release the blade control switch (PTO).
4. With engine running, hold down the OPC levers. Pull
the blade control switch (PTO) up and then release. The
clutch should engage and the mower blades begin
rotating.
5. Release the OPC levers. The engine should kill.
6. With the engine is running and holding the OPC levers
down, move shift lever into a gear. Release the OPC
levers. The engine should kill.
7. If all the above conditions are not met have an
Authorized Service Dealer repair the safety system
immediately.
Driving Forward or Backward
The throttle control regulates the engine speed as measured
in rpm (revolutions per minute). Place the throttle control in
the Fast position for best performance.
Driving Forward
1. To go forward, move the shift lever to a forward gear.
2. Release the parking brake; refer to Releasing the
Parking Brake, page 18.
3. Slowly release the drive levers to move forward
(Fig. 16).
To go straight, release drive levers equally (Fig. 16).
To turn, squeeze the drive lever on the side and direction
you want to turn (Fig. 16).
1
2
m–6581
Figure 16
1. Drive lever 2. Gear shift lever
Driving Backward
Note: To drive backward, the machine may need to be
assisted by pulling the machine backwards.
1. To go backward, move the shift lever to the reverse
gear.
2. Release the parking brake; refer to Releasing the
Parking Brake, page 18.
3. Slowly release the drive levers together to move
rearward (Fig. 16).
Stopping the Machine
1. To stop the machine, squeeze the drive levers back to
the grips to engage brakes.
2. Move neutral/brake locks into the park position. Refer
to Setting the Parking Brake on page 18.
3. Shift transmission into neutral.
4. Turn the ignition key to Off.
Note: Remember to remove the key from the ignition
switch if you leave the machine.