Form No. 3350–538 Mid–Size Mower Proline Gear 15hp with 48in Side Discharge Mower Model No. 30140—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Mounting the Fuel Tank . . . . . . . . . . . . . . . . . . . . . Installing the Muffler . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . .
Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. 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.
• Be aware of the mower discharge direction and do not point it at anyone. • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Do not operate the mower under the influence of alcohol or drugs. • Never refuel or drain the machine indoors. • Use care when loading or unloading the machine into or from a trailer or truck. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly.
• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. General Operation • Allow only responsible adults who are familiar with the instructions to operate the machine. • Mow slopes side to side. • Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area. DO NOT • Do not mow slopes greater than 15 degrees. • Do not mow in reverse unless absolutely necessary.
Slope Chart 7
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. 67-5360 1-403005 82-2280 54-9220 82-2290 66-1340 99-3943 1.
95-2814 98-3266 98-4387 1. Warning—wear hearing protection. 95-5537 1. Read the Operator’s Manual for instructions on operating the cutting blade 2. Push forward to engage 3. Pull back to disengage 98-5130 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 75–80 ft.-lb.(102–106 N⋅m).
106-0841 105-0884 11
Gasoline and Oil Warning Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. 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. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
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. DESCRIPTION QTY.
Installing the Front Casters 1 1. Align casters with holes on top and front of mower and insert 8 bolts (3/8 x 3/4 inch) through mower. Secure with 8 flange nuts (3/8 inch) below mower (Fig. 2). 5 6 Note: Tighten lower bolts first to pull caster against front, then top bolts last. 4 2. Torque bolts to 30–35 ft. lb. (40–47 N m). 3 2 4 1 m–6484 Figure 3 1. Upper handle 2. Rear frame 3. Bolt, 3/8 x 1 inch 4. Locknut, 3/8 inch 5. Low 6. High 3 2 4.
5. After adjusting control rods, check parking brake adjustment; refer to Servicing the Brake, page 32. 5 1 4 4 2 3 3 2 m–3782 1 Figure 5 1. Terminal 2. Clip 7 3. Plastic plug 4. Switch 6 m–6482 Figure 7 Installing the Traction Control Rods 1. 2. 3. 4. 1. Thread trunnions equal distance onto each control rod. For a starting point, thread on approximately 2 inch (51 mm) (Fig. 6). 2.
Installing the Blade Control (PTO) Rod 4. Replace the spring washer, dish down, and locknut (Fig. 10). 5. Torque the nut to 35 ft–lb (47 N m). 1. Rotate blade control lever (PTO) vertical away from left handle so rod drops down. 6 5 2. Remove hairpin cotters from bottom end of blade control rod (PTO) (Fig. 9). 1 3. Secure blade control (PTO) rod through hole in bellcrank with hairpin cotters (Fig. 9). 4 3 1 2 2 m–3772 Figure 10 1. Shift lever 2. Control panel 3. Rubber seal washer 3 4 4.
1 5. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 13). 2 2 3 4 1 Rear View 4 m–6442 Figure 13 2 3 1. Fuel line 2. Hose clamp Installing the Muffler m–7454 Figure 11 1. Shift lever, 2nd gear 2. Shift lever plate 3. Fuel fitting 1. Loosen the clamp (Fig. 14). 3. Shift lever, neutral 4. Equal distance 1 Mounting the Fuel Tank 1. Align fuel tank with the top of the rear frame (Fig. 12). 2.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Upper Control Bar – Shift to desired gear and push forward on control bar to engage forward traction operation and pull back to brake. Pull right side of control bar to turn right and left side to turn left.
Stopping the Engine 2. Lift the parking brake lock up and gradually release the upper control bar (Fig. 17). The brake lock should stay in the set (locked) position. 1. Move the throttle lever to slow (Fig. 18). Note: If the engine has been working hard or is hot, let it idle for a minute before stopping. This helps cool the engine. In an emergency, the engine may be stopped by pulling the throttle all the way back, to stop. Releasing the Parking Brake 1. Pull rearward on the upper control bar (Fig. 17).
Testing the Safety Interlock System 3. To engage blade(s), push the blade control lever firmly forward, until it latches over-center (Fig. 19). Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 2 1 1. Set the parking brake, disengage the PTO and place the throttle forward. Start the engine.
Driving Backward 1 1. To go backward, move the shift lever to a reverse gear. 2. Release the parking brake; refer to Releasing the Parking Brake, page 19. 2 3. Slowly squeeze on the lower control bar and handle together to move rearward (Fig. 20). Operating the Lower Control Bar m-4185 This procedure is for driving up a curb. This can be performed while driving forward or backward. Figure 22 1. Lower Control Bar engaged and mower in reverse. 1. Disengage the mower blades. 2.
Danger 6 5 4 4 Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. 1 • Never remove the grass deflector from the 3 2 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.
1 2 A B C D E m–3789 Figure 24 1. Axle pivot bolt 2. Axle adjustment bolt Adjusting the Caster Position 1. Using the height-of-cut chart, adjust the caster spacers to match with the axle hole selected (Fig. 25). 2. Remove clevis pin, slide caster from support and change spacers (Fig. 25). 3. Install caster in support and insert clevis pin (Fig. 25). 2 1 3 m–3791 Figure 25 1. Clevis pin 2. Spacer, 3/16 inch (5 mm) 3.
Height-of-Cut Chart No.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important Refer to your engine operator’s manual for additional maintenance procedures.
Caution Someone could accidently start the engine and seriously injure you or other bystanders. Disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Servicing the 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.
6 5 4 4 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 1 m–2539 3 Figure 28 2 2. Rotate the opposite ends of the blades forward. m–3779 3. 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 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 27. Figure 29 1.
Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2 2. Install remaining spacer(s) and secure with thin washer and nut (Fig. 29). 3 3. Torque the blade bolt to 75–80 ft–lb (101–108 N m). 4 Servicing the Air Cleaner 5 Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Clean it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first.
1. Carefully slide the foam element onto the paper air cleaner element (Fig. 32). 2 2. Place the air cleaner assembly onto the air cleaner base and secure it with the nut (Fig. 32). 1 3. Install the air cleaner cover and secure the retaining locks (Fig. 32). Servicing the Engine Oil Service Interval/Specification m–7449 Change the engine oil: Figure 33 • After the first 8 operating hours 1. Oil dipstick 2. Filler tube • After every 100 operating hours 5.
2 1 1 m–7451 m–7453 Figure 35 Figure 34 1. Oil filter 1. Oil drain plug 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 35). 7. When oil has drained completely, close the oil drain. Note: Dispose of the used oil at a certified recycling center. 8. Slowly pour approximately 80% of the specified oil (refer to Service Interval/Specification, page 29) into the filler cap (Fig. 33). 4.
Installing the Spark Plugs 1 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 11 ft-lb (15 N m). 3. Connect the wires to the spark plugs (Fig. 36). Checking the Tire Pressure Service Interval/Specification m–7453 Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 38).
5. Install air intake screen, recoil starter and fan housing. 5 3 2 4 m–3780 Figure 40 2. Lubricate the transmission couplers every 100 hours and idler arm pivots every 8 hours (Fig 41). 1 1 m–7450 Figure 39 1. Air intake screen 2. Fan housing 3. Recoil starter 4. Bolt 5. Nut 2 Greasing and Lubrication m–3797 Service Interval/Specification Figure 41 1. Idler Arm Pivots Grease the areas shown and at intervals in Where to Add Grease section below.
Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. 1 Checking the Brakes 1. Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. 2. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 33. 2 m–3773 Figure 43 3.
1 3 2 2 1 m–6486 m–6486 Figure 44 1. Fuel shut-off valve 2. Fuel filter Figure 45 3. Clamp 1. Hose clamp 2. Filter Checking the Belts Servicing the Fuel Filter Service Interval/Specification Service Interval/Specification Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating.
1 2 1 3 3 4 2 4 m–3793 2 Figure 46 1. Hairpin cotter 2. Brake rod m–4726 Figure 47 3. Shield 4. Drive belt 1. Idler in slot 2. Belt guide Replacing the Traction Belt 3. 1-3/8 inch (35 mm) 4. Mower belt Replacing the Mower Belt 1. Disengage the PTO, turn the ignition key to off, and remove the key. 1. Disengage the PTO, turn the ignition key to off, and remove the key. 2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 2.
1 Adjusting the Mower Belt Tension 3 4 Service Interval/Specification Check belt tension after the first 8 and 25 hours of operation. Check the belt tension every 50 hours. Important Belt must be tight enough to not slip during heavy loads while cutting grass. Over tensioning will reduce belt and spindle bearing life. 2 m–4731 1. Disengage the PTO, turn the ignition key to off, and remove the key. Figure 48 1. Idler pulley 2. 1/2 inch (13 mm) deflection here 2.
Replacing the Grass Deflector 3. If necessary, adjust the spring mounting bolts so that the blade brake pad rubs against the pulley edges (Fig. 51). 4. Adjust the nut at the end of the blade brake rod until there is 1/8–3/16 inch (3mm–5mm) between the nut and spacer (Fig. 51). Warning An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. 5. Engage the blades.
Wiring Diagram P2 IGNITION SWITCH 1 2 W5 J4 WIRE LIST DESIG. AWG COLOR W1 16 WHITE W2 16 WHITE W3 16 BLUE W4 16 BLACK W5 16 BLACK J2 MAG W1 J5 W4 W3 ROUTE J2 J4 J2 J3 P1–1 J5 P1–2 J1 J1 P2–1 1 P1 Cleaning and Storage W2 J1 GND 2 PTO A. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO) and set the parking brake. B.
Troubleshooting Problem Engine g will not start, starts hard, or f il to keep fails k running. i Engine g loses power. Engine g overheats. Machine does not drive. Possible Causes Corrective Action 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 2. Choke is not on. 2. Move choke lever to on. 3. Air cleaner is dirty. 3. Clean or replace air cleaner element. 4. Spark plug wire is loose or disconnected. 4. Install wire on spark plug. 5.
Problem Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Blades do not stop when disengaged. g g Possible Causes Corrective Action 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Engine mounting bolts are loose. 3. Tighten engine mounting bolts. 4. Loose engine pulley, idler pulley, or blade pulley. 4. Tighten the appropriate pulley. 5. Engine pulley is damaged. 5.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
