Form No. 3326–481 Mid–Size Mower ProLine Gear 15 HP with 36 in. Side Discharge Mower Model No.
Warning Using the Parking Brake . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . Checking the Safety Interlock System . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Operating the Lower Control Bar . . . . . . . . . . . . Stopping the Machine . . . . . . . . . . . . . . . . . . . . . Transporting Machines . . . . . . . . . . . . . . . . . . . . Using Side Discharge or Mulch Grass . .
Introduction Safety 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. This machine meets or exceeds the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.
• Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use only an approved container • 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.
Toro Mower Safety DO • Remove obstacles such as rocks, tree limbs, etc. from the mowing area. Watch for holes, ruts or bumps. Tall grass can hide obstacles. The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards. • Use slow speed so that you will not have to stop while on the slope. This product is capable of amputating hands and feet and throwing objects.
• 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.
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.
4–8569 104–8185 98–0776 P A R K I N G B R A K E 105–0840 52–2010 82–2290 82–2280 98–3256 98–4387 104–8176 10
104–8171 105–0884 104–8180 11
Gasoline and Oil Recommended Gasoline Warning Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. 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.
Assembly 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. USE Fuel tank 1 Control panel 1 Bolt, 5/16 x 7/8 in. 2 Lock washer, 5/16 in. 2 Washer, 5/16 in. 4 Spring 2 Stud 2 Hose clamp 1 Shift lever 1 Rubber seal 1 Square hole washer 1 Spring washer 1 Locknut, 3/8 in. 1 Upper handle 1 Flanged bolt 3/8 x 1 in. 4 Flange nut 3/8 in.
Installing the Shift Lever 3 1. Remove the locknut (3/8 in.) and spring washer from the stud on top of the transmission. 2 Note: Do not remove rubber seal washer and square hole washer from transmission shaft. 1 2. Slide shift lever through control panel and align mounting hole in lever with square on transmission shaft. Secure lever to transmission with previously removed spring washer and locknut (Fig. 4). m–5221 Figure 2 1. Rear frame 2. Control panel 3. Fuel tank 3.
4 1 5 6 2 2 1 3 4 4 Rear View 7 8 2 3 m–5317 Figure 6 1. 2. 3. 4. m–5458 Upper handle Rear frame Flange bolt, 3/8 x 1 in. Flange nut, 3/8 in. 5. 6. 7. 8. Upper mounting hole Lower mounting holes Low position High position Figure 5 1. Shift lever, 2nd gear 2. Control panel 3. Shift lever, neutral 4. Equal distance Installing the Control Rods 1. Thread rod fittings equal distance onto each control rod. For a starting point, thread fittings on approximately 1–3/4 in.
3. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 in. (25–32 mm) (Fig. 8). Note: Make sure brake rod is installed in front (F) mounting hole in idler bracket. 8. Repeat procedure on opposite side if adjustment is required to keep control bar and fixed bar parallel. Note: The upper control bar and fixed bar must be parallel when in engaged, drive, relaxed and brake positions. 4. Check operation.
Think Safety First Lower Control Bar – Shift transmission to reverse and squeeze the lower control bar and handle together to engage rearward traction operation. 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. Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle.
Stopping the Engine 2. Lift the parking brake lock (Fig. 14) up and gradually release the upper control bar. The brake lock should stay in the set (locked) position. 1. Move the throttle lever to slow (Fig. 15). 2. Let engine idle for 30 to 60 seconds before turning the ignition key off. Releasing the Parking Brake 3. Turn the ignition key to off (Fig. 15). 1. Pull rearward on the upper control bar (Fig. 14). Lower the parking brake lock to the released position. 2 2.
1. Set the parking brake and start the engine :refer to Starting and Stopping the Engine, page 18 2 1 2. Squeeze the blade control bail against upper control bar. The blades should not rotate. 3 3. Then continue holding the blade control bail and pull up on the blade control switch and release. The clutch should engage and the mower blades begin rotating. 4. Release the blade control bail. The blades should stop rotating. 5.
3. Slowly squeeze the lower control bar and handle together to move rearward (Fig. 17). 1 Operating the Lower Control Bar 2 This procedure is for driving up a curb. This can be performed while driving forward or backward. 1. Disengage the mower blades. Warning m–4185 Figure 19 1. Lower Control Bar engaged and mower in reverse. A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders.
Using Side Discharge or Mulch Grass Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter. Important All four hairpin cotter pins must be in the same hole location and with the correct number of spacers for a level cut. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
3. Reinstall the bolt, washers and nut (Fig. 21). 3 4 1 4 2 m–5213 Figure 21 1. Center Gage Wheels and Spacer 2. Nut 3. Bolt 4.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and 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 Air Cleaner 1 Service Interval/Specification 2 Foam Element: Clean and re-oil after every 25 operating hours.
3. Install the air cleaner cover and secure with cover nuts (Fig. 22). 2 1 Servicing the Engine Oil Service Interval/Specification Change oil: m–5193 • After the first 5 operating hours. Figure 23 1. Foam element • After every 100 operating hours. 2. Oil Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Cleaning the Paper Element Oil Type: Detergent oil (API service SF, SG or SH) 1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 24).
1 Changing the Oil Filter 2 Service Interval/Specification Replace the oil filter every 200 hours or every other oil change. 3 Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 26. 2. Remove the old filter and wipe the filter adapter (Fig. 27) gasket surface. Figure 25 1. Oil dipstick 2. Metal end 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 27).
2 Removing the Spark Plug(s) 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 3 1 0.040 in. (1.02 mm) 2. Pull the wire(s) off the spark plug(s) (Fig. 28). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 3. Remove the spark plug(s) and metal washer. 2 Figure 29 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Installing the Spark Plug(s) 1 1.
4. Wipe up any excess grease. Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 30). m–2147 Figure 31 Lubricating the transmission couplers 1. Lubricate the transmission couplers located in the back of the machine (Fig. 32). Figure 30 Lubricating the castor and wheel bearings m–5191 Figure 32 1. Lubricate the front wheel bearings and front spindles until grease begins to ooze out of the bearings (Fig. 31). 2. Remove rear wheel grease cap.
1 2 m–2147 Figure 34 1. Rear Tire 2. Castor tire Servicing the Fuse m–5247 Figure 33 Service Interval/Specification The electrical system is protected by a fuse. It requires no maintenance, however, if the fuse blows check component/circuit for malfunction or short. To replace fuse pull out on the fuse (Fig. 35) to remove or replace it. Cleaning the Cooling System Service Interval/Specification Before each use, check and clean engine cooling system.
Checking the Brake Important With the parking brake released, the rear wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately. 1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Set the parking brake (Fig. 36). 3 2 1 4 2 1 5 m–5233 Figure 37 Figure 36 1. Upper control bar m–5316 1.
Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 31. 2 1 5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line. 3 m–2600 Figure 38 1. Adjusting nut 2. Slot 3. Feeler gauge 1 2 m–5185 Servicing the Fuel Tank Figure 39 1. Fuel shut-off valve Danger In certain conditions, gasoline is extremely flammable and highly explosive.
3 1 2 1 1 3 3 2 m–5234 Figure 40 1. Hose clamp 2. Fuel line m–151 Figure 41 3. Filter 1. Cutting Edge 2. Curved Area Servicing the Cutting Blades 3. Wear/slot Forming Checking for Bent 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. 1. Rotate the blades until the ends face forward and backward (Fig. 42). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 43).
dimension exceeds 1/8 in. (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 33. 1 Warning m–1854 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. Figure 45 1. Sharpen at original angle • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. 2. Check the balance of the blade by putting it on a blade balancer (Fig.
5. Perform steps in the following sections Frame Set Up, Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling. Checking Engine Deck Height Setting up the Frame 2. Adjust the tire pressure in all tires to specifications on page 29. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 3. Measure engine deck height at location A (Fig. 48). Checking Carrier Frame and Deck Alignment 4. Measure engine deck height at location B (Fig. 48). 5.
6. The tire pressure may also be adjusted slightly to make a 1/4–3/8 in. (6 mm – 10 mm) pitch. 5 3 5 3 2 5 2 (6.1cm) 24 in. A B 5 A 4 2 4 B 4 1 1 4 m–5231 Figure 50 m–5242 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins Figure 49 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 in. (6 mm–10 mm) pitch over 24 in. (6.1 cm) length 1 4. Height at locations A and B 5. Caster spacers 4. Same height at locations A and B 5.
Checking the Deck Side-to-Side Level 1. Check the tire pressure on both deck and traction unit. MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2. Position the blades side-to-side (Fig. 54). Measure at A and B locations (Fig. 54) from a level surface to the cutting edge of blade tips (Fig. 55). m–2539 Figure 52 3. The difference between measurements A and B should be no more than 1/4 in. (6 mm).
2. Set the height-of-cut to the 4 in. (102 mm) position following the height-of-cut decal. 1. Remove top capscrew securing idler support and idler bracket to rear frame (Fig. 58). 3. With the machine on level surface, position one blade front-to-rear (Fig. 56). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 57). 2. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Fig. 58). 4. The measurement should be 4 in. (102 mm).
11. Install PTO drive belt. 3 11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 1 4 1 5 4 7 2 6 8 m–5321 3 Figure 59 1. 2. 3. 4. Traction belt Idler pulley Clutch retainer Tension spring 5. 6. 7. 8. Clutch wire connector Pivot bolt Drive pulley Engine deck 2 5 m–5247 Figure 60 1. Deck belt 2. Idler arm spring 3.
3. Pull the castor wheel fork out of the mounting tube, leaving the spacer(s) on the bottom of the fork. Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck. 9. Adjust PTO drive belt guides an 1/8 in. from belt (Fig. 61). 10. install the heat shield to the the engine deck and carrier frame. 11. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs. 1 12.
2 2 1 1 3 2 m–5197 5 4 Figure 63 1. Carrier Frame Mounting Tube 3 m-3986 Figure 64 2. Bushing 1. Locknut 2. Wheel Bolt 3. Bushing Castor Wheel and Bearings Service 4. Spanner Bushing 5. Roller Bearing 5. To assemble, place one (1) bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Fig. 64). The castor wheels rotate on a roller bearing supported by a spanner bushing.
2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in figure 65. 3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 65). Important The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 8 6 4 2 3 5 1 7 m-5 Figure 65 1. 2. 3. 4. 5.
Wiring Diagram S1 IGNITION G M KEY SWITCH BK OFF ON W G+M NONE WIRE COLOR CODES BK BN BU GN GY OR M G KEY SW. F1 BLACK BROWN BLUE GREEN GREY ORANGE PK PINK R T VIO W Y RED TAN VIOLET WHITE YELLOW PK 7.5A PK PK S3 S2 CLUTCH SW. BAIL SW.
Cleaning and Storage A. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. B. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank, page 31, or operate engine until it stops. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
PROBLEM Engine g loses power. Engine g overheats. Machine does not drive. Abnormal vibration. POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine load is excessive. 1. Reduce ground speed. 2. Air cleaner is dirty. 2. Clean air cleaner element. 3. Oil level in crankcase is low. 3. Add oil to crankcase. 4. Cooling fins and air passages under engine blower housing are plugged. 4. Remove obstruction from cooling fins and air passages. 5. Spark plug is pitted, fouled, or gap is incorrect. 5.
PROBLEM Uneven cutting g height. g Blades do not rotate. POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade(s) not sharp. 1. Sharpen blade(s). 2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s). 3. Mower is not level. 3. Level mower from side-to-side and front-to-rear. 4. Underside of mower is dirty. 4. Clean the underside of the mower. 5. Tire pressure is incorrect. 5. Adjust tire pressure. 6. Blade spindle bent. 6. Contact Authorized Service Dealer. 1.
The Toro Total Coverage Guarantee LCE A One-Year 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 any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.
