100in Rear Discharge Mower

• Read the operator's manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment. If the operator or mechanic can not read the language of this manual, 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.

• 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.

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

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• 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. Always use the seat belt when the ROPS is in the raised position. Do not use the seat belt when the ROPS is in the lowered position.

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

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

• Never raise deck with the blades running.

• Never operate with guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property.

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

• Stop on level ground, lower the cutting units, disengage drives, engage parking brake (if provided), shut off engine before leaving the operator's position for any reason.

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

• Keep hands and feet away from the cutting units.

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

• Never carry passengers and keep pets and bystanders away.

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

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

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

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

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

• The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law.

• Disengage drives, lower the cutting units, move traction pedal to Neutral, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives and muffler. Let engine cool before storing and do not store near flames, 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. 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 before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the blades or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

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

• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

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

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

• Use full width ramps for loading machine into trailer or truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine

• Check the blade mounting bolts frequently to be sure that they are tightened to specification.

• Make sure that all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units to the ground.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away.

• Do not overspeed the engine by changing governor settings. To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• The engine must be shut off before checking the oil or adding oil to the crankcase.

• Make sure that the mower fuel tank is empty if the machine is to be stored in excess of 30 days. Do not store the mower near any open flame or where gasoline fumes may be ignited by a spark.

• Perform only those maintenance instructions described in this manual. If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.

• To make sure of optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

The height of cut on the center deck is achieved by moving the stop pin into different hole locations.

1. With the engine running, push back on the mower lift switch until the mower is fully raised and release the switch immediately.

2. To adjust, rotate the stop pin until the nub on it lines up with the slots in the holes in the height-of-cut bracket and remove it (Figure 2).

   

   Figure 2

   1. Stop pin

3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, insert the pin, and rotate it down to lock it in place (Figure 2).

   Note: There are 4 rows of hole positions (Figure 2). The top row gives you the height of cut listed above the pin. The second row down gives you the height listed plus 6 mm (1/4 inch). The third row down gives you the height listed plus 12 mm (1/2 inch). The bottom row gives you the height listed plus 18 mm (3/4 inch). For the 127 mm (5 inch) position there is only one hole, located in the second row. This does not add 6 mm (1/4 inch) to the 127 mm (5 inch) position.

4. Adjust the anti-scalp rollers and skids as required.

The height-of-cut on the wing decks is achieved by positioning the castor wheel axles in the upper or lower holes of the castor forks, add or remove an equal number of spacers from the castor forks and secure the height of cut collar to the desired holes in the height of cut rod.

1. Start the engine and raise the cutting unit off the floor so that the height-of-cut can be changed. Stop the engine and remove the key after the cutting unit is raised.

2. Position the castor wheel axles in the same holes in both castor forks. Refer to Figure 3 to determine the correct holes for the setting.

   

   Figure 3

   1. Tensioning cap
   2. Spacers
   3. Shims
   4. Axle mounting holes
   5. Castor Wheel

   Note: When operating in 64 mm (2-1/2 inch) height of cut or higher, the axle bolt must be installed in the lower castor fork hole to prevent grass buildup between the wheel and the fork. When operating in height of cuts lower than 64 mm (2-1/2 inch) and grass buildup is detected, reverse the machines direction to pull any clippings away from the wheel/fork area.

3. Remove the tensioning cap from the spindle shaft (Figure 3) and slide the spindle out of the castor arm. Put the 2 shims (1/8 inch) onto the spindle shaft as they were originally installed. These shims are required to achieve a level across the entire width of the cutting units. Slide the appropriate number of 1/2 inch spacers onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft.

   Note: When using 25 mm (1 inch), 38 mm (1-1/2 inch), or occasionally 51 mm (2 inch) height of cut, move the skids and roller to the highest holes.

4. Secure the adjustment with the tensioning cap.

Cutting unit pitch is the difference in height-of-cut from the front of the blade plane to the back of the blade plane. Toro recommends a blade pitch of approximately 8 to 11 mm (5/16 to 7/16 inch). This means the back of the blade plane is 8 to 11 mm (5/16 to 7/16 inch) higher than the front.

1. Position the machine on a level surface on the shop floor.

2. Set the mower to the desired height-of-cut, move the throttle lever to the Slow position, stop the engine, set the parking brake, and remove the ignition key.

3. Rotate the center blade so that it points straight forward.

4. Using a short ruler, measure from the floor to the front tip of the blade.

5. Rotate the same blade tip to the rear and measure from the floor to the tip of the blade at the rear of the mower.

6. Subtract the front dimension from the rear dimension to calculate the blade pitch.

7. Adjust the U-bolt jam nuts (Figure 6) securing the rear deck chains (Figure 7) to the mower deck to raise the rear of the mower so that the blade pitch is set to 8 to 11 mm (5/16 to 7/16 inch).

   

   Figure 6

   1. U-bolt
   2. Jam nut
   

   Figure 7

   1. Left rear lift chain
   2. Right rear lift chain

If the cut is uneven across the mower swath, correct it as follows:

1. Position the machine on a level surface on the shop floor

2. Set the cutting unit to the desired height of cut, move the throttle lever to the Slow position, stop the engine, set the parking brake, and remove the ignition key.

3. Check and adjust front and rear tractor tire pressure; refer to Checking Tire Pressure.

4. Check for bent blades.

5. Remove the covers from the top of the cutting units

6. Rotate the blade on each spindle until the ends face forward and backward.

7. Measure from the floor to the front tip of the cutting edge

8. Adjust the jam nuts securing the deck chains to the mower deck until the mower deck is level (Figure 7).

To gain access to or from the operator area when the wing decks are folded up, release the castor arm latch (Figure 8) and rotate the castor arm away from the traction unit.

Figure 8

1. Castor arm latch

Important: Make sure to rotate the castor arm back to the traction unit before mowing.

Before transporting the machine, raise the cutting units and secure the wing deck transport latches (Figure 9).

Figure 9

1. Wing deck transport latches

To maintain enough power for the machine and deck while mowing, operate the engine at the fast throttle position and adjust your ground speed for conditions. A good rule to follow is: decrease ground speed as the load on the cutting blades increases; and increase ground speed as load on the blades decreases.

Alternate mowing direction to avoid making ruts in the turf over time. This also helps disperse clippings which enhances decomposition and fertilization.

To improve cut quality, use a slower ground speed.

Remove approximately 25 mm (1 inch) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to slow down the forward speed and/or raise the height-of-cut to the next higher setting.

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.

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.

To reduce the risk of fire hazard, keep the engine, muffler, battery compartment, parking brake, cutting units, and fuel storage compartment free of grass, leaves, or excessive grease. Clean up any spilled oil or fuel.

Use compressed air or a leaf blower to clean the belt drive area. Make sure to install any removed guards or covers when cleaning has been completed.

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 blades daily for sharpness, and for any wear or damage. Sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. Refer to Servicing the Cutting Blades.

1. Position the machine and cutting unit on a level surface.

2. Lower the mower deck to the 2.5 cm (1 inch) height-of-cut.

3. Disengage the PTO, release the traction pedal and set the parking brake.

4. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

5. Lift the footrest, exposing the top of the mower deck.

6. Remove the dipstick/fill plug from the top of the gear box (Figure 18) and make sure that the lubricant is between the marks on the dipstick.

   

   Figure 18

   1. Fill plug and dipstick
   2. Drain location

7. If the lubricant level is low, add enough lubricant until the level is between the marks on the dipstick.

   Note: Do not over fill or the gearbox may be damaged.

1. Position the machine and cutting unit on a level surface.

2. Lower the mower deck to the 2.5 cm (1 inch) height-of-cut.

3. Disengage the PTO, release the traction pedal and set the parking brake.

4. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

5. Lift the footrest, exposing the top of the mower deck.

6. Remove the dipstick/fill plug from the top of the gear box (Figure 18).

7. Place a drain pan under the drain plug located under the front of the gear box and remove the plug, draining the lubricant into the pan.

8. Replace the drain plug.

9. Add enough lubricant, approximately 414 ml (14 ounces), until the level is between the marks on the dipstick.

   Note: Do not over fill or the gearbox may be damaged.

1. Disengage the PTO, release the traction pedal and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

1. Inspect the cutting edges (Figure 21). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades.

2. Inspect the blades, especially the sail area (Figure 21). If you notice any damage, wear, or a slot forming in this area (Figure 21), immediately install a new blade.

   Danger

   If you allow the blade to wear, a slot will form between the sail and flat part of the blade. Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury or death to you or bystanders.

   • Inspect the blade periodically for wear or damage.

   • Never try to straighten a blade that is bent or weld a broken or cracked blade.

   • Replace a worn or damaged blade.

   

   Figure 21

   1. Cutting Edge
   2. Sail Area
   3. Wear/slot Forming
   4. Crack

1. Disengage the PTO, release the traction pedal and set the parking brake.

2. Move the throttle lever to the Slow position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Rotate the blades until the ends face forward and backward (Figure 22). Measure from a level surface to the cutting edge, position A, of the blades (Figure 22). Note this dimension.

   

   Figure 22

   1. Position A
   2. Measure here from blade to hard surface

4. Rotate the opposite ends of the blades forward.

5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 must not exceed 3 mm (1/8 inch). If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades.

   Warning

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

   • Always replace bent or damaged blade with a new blade.

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

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.

1. Hold the blade end using a rag or thickly-padded glove.

2. Remove the blade bolt, anti-scalp plate, and blade from the spindle shaft (Figure 25).

1. Sharpen the cutting edge at both ends of the blade (Figure 23). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

   

   Figure 23

   1. Sharpen at original angle

2. Check the balance of the blade by putting it on a blade balancer (Figure 24). 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 (Figure 25). Repeat this procedure until the blade is balanced.

   

   Figure 24

   1. Blade
   2. Balancer

Note: The 2 wing deck blades are not the same as the 3 center blades.

1. Install the blade onto the spindle shaft (Figure 25).

   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 plate and blade bolt (Figure 25).

   

   Figure 25

   1. Spindle
   2. Sail Area of Blade
   3. Anti-scalp plate
   4. Blade Bolt

3. Torque the blade bolt to 115-150 N⋅m (85-110 ft-lb).

1. Start the engine, lower the left and right decks, shut off the engine, remove the key, and wait for all moving parts to stop.

2. At the outer decks, wipe clean the tab of the inner channel (Figure 26).

   

   Figure 26

   1. Tab (inner channel—outer deck)
   2. Front of the machine
   3. Back of the machine

3. At the front of the deck, fully loosen the outboard serrated-flange nuts securing the 4 U-bolts (Figure 27).

   

   Figure 27

   1. Serrated-flange nut (inboard)
   2. U-bolt

4. At the back of the deck, fully loosen the inboard serrated-flange nuts securing the 4 U-bolts (Figure 28).

   

   Figure 28

   1. U-bolt
   2. Serrated-flange nut (outboard)

1. Install the deck shims at the front of the deck as shown in Figure 29.

   Note: Insert the part of the long tab of the shim under the belt cover.

   

   Figure 29

   1. Deck shim
   2. Inner-channel tab (outer deck)
   3. Belt cover

2. Install the deck shims at the front of the deck as shown in Figure 30.

   

   Figure 30

   1. Belt cover
   2. Inner-channel tab (outer deck)
   3. Deck shim

   Note: If you are using feeler gauges, use a piece of tape to adhere a feeler gauge—0.15 mm (0.060 inch) to the tab of the inner channel (Figure 31).

   

   Figure 31

   1. Inner-channel tab
   2. Feeler gauge
   3. Front of the machine
   4. Back of the machine

3. Start the engine, fully raise the left and right decks, shut off the engine, remove the key, and wait for all moving parts to stop.

1. At the front of the deck, tighten the outboard serrated-flange nuts until the chains are tensioned (Figure 32).

   Note: Ensure that the deck shim (or feeler gauge) contacts then pivot link.

   Important: Ensure that the upper and lower serrated-flange nut pairs are adjusted evenly.

   

   Figure 32

   1. Deck shim (or feeler gauge)
   2. Serrated-flange nut (outboard)
   3. Pivot link
   4. Chain (limit)
   5. U-bolt
   6. Front of the machine
   7. Serrated-flange nut (inboard)

2. Thread the inboard serrated-flange nuts (Figure 32) and torque them to 103 to 127 N∙m (76 to 94 ft-lb).

3. At the back of the deck, tighten the inboard serrated-flange nuts until the chains are tensioned (Figure 33).

   Note: Ensure that the deck shim (or feeler gauge) contacts then pivot link.

   Important: Ensure that the upper and lower serrated-flange nut pairs are adjusted evenly.

   

   Figure 33

   1. Deck shim (or feeler gauge)
   2. Pivot link
   3. Chain (limit)
   4. U-bolt
   5. Serrated-flange nut (inboard)
   6. Front of the machine
   7. Serrated-flange nut (outboard)

4. Thread the outboard serrated-flange nuts (Figure 33) and torque them to 103 to 127 N∙m (76 to 94 ft-lb).

5. Start the engine, lower adjusted deck, raise the other deck, shut off the engine, remove the key, and wait for all moving parts to stop.

6. Remove the shims or feeler gauges (Figure 34).

   

   Figure 34

7. Repeat steps in Assembling the Shim to the Deck and Tensioning the Chains for the other mower deck.