Form No. 3325–870 Mid–Size Mower ProLine Gear 15 HP with 36 in.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake and Neutral Lock . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . .
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 and other safety information you must know. • 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. Always follow all safety instructions to avoid serious injury or death.
• 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.
4–8185 105–0840 105–4141 98–0776 105–4111 98–4387 104–8569 10
104–8171 105–4104 105–4105 105–4108 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.
Set Up 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. (22.5 mm) 2 Lock washer, 5/16 in. 2 Washer, 5/16 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.
8. Slide the hose clamp onto the fuel line (Fig. 3). 3 9. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 3). 2 Install Shift Lever 1 1. Remove the 3/8 in. locknut and spring disk washer from the stud on top of the transmission. m–5221 Figure 2 1. Rear frame 2. Control panel Note: Do not remove rubber seal washer and square hole washer from transmission shaft. 3. Fuel tank 4. Place the transmission in neutral. 2.
8. If clearance is not correct, loosen control panel and adjust it side–to–side. Tighten control panel. 1 4 6 1 3 2 5 2 4 4 Rear View 7 8 9 2 m–5382 Figure 6 3 1. Handle 2. Rear frame 3. Flange bolt, 3/8 x 1 in. (26 mm) 4. Flange nut, 3/8 in. m–5458 Figure 5 1. Shift lever, 2nd gear 2. Control panel 5. 6. 7. 8. 9. Upper mounting hole Lower mounting holes Low position Middle position High position 3. Shift lever, neutral 4. Equal distance Install Control Rods Install Handles 1.
3. Adjust control rod length by threading rod in or out of rod fitting until there is a 3/16 to 1/4 in. (5 mm to 6 mm) clearance between the control rod and bottom of neutral/brake lock (Fig. 8). 3 4. Install control rod to drive lever and neutral/brake lock. Secure with clevis pin and hairpin cotter. 2 5. Check operation. If adjustment is required, remove hairpin cotter and clevis pin securing rod to drive levers. 1 6. Adjust control rod length by repeating steps 3 and 4 (Fig. 8).
3 Controls 7 6 Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine. 2 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.
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. 2 3 1 Stopping 6 1. Move the throttle lever to “SLOW” (Fig. 13). 2. Let engine idle for 30 to 60 seconds before turning the ignition key “OFF.” 4 3. Set the parking brake. 5 m–5386 4. Turn the ignition key to “OFF” (Fig. 13). Figure 12 1. Handle 2. Neutral/Parking brake lock 3. Park position 2 4. Neutral position 5. Drive lever 6.
3 • The Operator Presence Control (OPC) levers are released. 2 1 • 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 you use the machine each time. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately. m–5379 Figure 14 1. Handle 2.
4 1 1 2 2 6 m–5379 Figure 15 1. Drive lever 3 5 m–5372 Figure 16 2. Gear shift lever 1. Position A, Normal Conditions 2. Position B, More Severe 3. Position C, Most Severe 4. Drive spring 5. Adjustment bolt, In position A 6. Drive pulley shield Backward 1. To go backward, move the shift lever to reverse gear. Stopping the Machine 2. Release the parking brake: refer to Releasing the Parking Brake, page 17. 1. To stop the machine, squeeze the drive levers all the way back to engage brakes. 3.
Transporting Machines 2. Select hole in height-of-cut post corresponding to the height-of-cut desired (Fig. 17). Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. 3. Lift on side of deck and remove hairpin cotter (Fig. 17). 4.
2. Select a hole position so the gage wheels are a minimum of 3/8 in. (9.5 mm) off the ground for the height-of-cut to be used (Fig. 18). 3 4 3. Reinstall the stud nut and washer (Fig. 18). 4. Repeat adjustment on other gage wheels. 1 4 2 m–5200 Figure 19 4 1. Center Gage Wheels and Spacer 2. Nut 1 3 2 5 m–5201 Figure 18 1. Gage Wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do Not Remove.
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. Air Cleaner Service 1 Service Interval/Specification 2 Foam Element: Clean and re-oil after every 25 operating hours. 3 Paper Element: Clean after every 25 operating hours.
3. Install the air cleaner cover and secure with cover nuts (Fig. 20). 2 1 Engine Oil Service Service Interval/Specification Change oil: m–5193 • After the first 5 operating hours. Figure 21 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. 22).
5. Slowly pour approximately 80% of the specified oil on page 25, into the filler tube (Fig. 23). Now check the oil level; refer to Checking Oil Level, page 25. Slowly add additional oil to bring to “FULL” mark on dipstick. Important Do not overfill the crankcase with oil because the engine may be damaged. 1 2 Change Oil Filter 3 Service Interval/Specification Replace the oil filter every 200 hours or every other oil change.
2 Type: Champion RC12YC or Champion Premium Gold 2071 (or equivalent) Air Gap: 0.040 in. (1.00 mm) 3 1 0.040 in. (1.02 mm) Removing the Spark Plug(s) 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2. Pull the wire(s) off the spark plug(s) (Fig. 26). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Figure 27 3. Remove the spark plug(s) and metal washer.
Where to Add Grease Lubricate the Transmission and Idler Bracket Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Figure 28). 1. Lubricate the transmission couplers located in the back of the machine (Fig. 29). 2. Lubricate the idler bracket pivots located in the back of the machine (Fig. 29). m–5389 Figure 30 Greasing the PTO Drive Belt Idler Figure 28 1.
Cleaning the Cooling System Service Interval/Specification Before each use, check and clean engine cooling system. Remove any build–up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor–governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.
Adjusting the Brake If the parking brake does not hold securely, an adjustment is required. 2 1. Check the brake before you adjust it; refer to Checking the Brake, page 29. 2. Release the parking brake; refer to Releasing the Parking Brake, page 17. 1 3. To adjust brake, rotate the wing nuts on the brake rods (Fig. 34). Rotate clockwise to tighten the brake and counterclockwise to loosen the brake. 3 m–2600 4.
5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line. 3 1 1 3 2 1 m–5234 Figure 37 2 1. Hose clamp 2. Fuel line m–5185 3. Filter Figure 36 1. Fuel shut-off valve 2. Clamp Cutting Blade Service Fuel Filter Service 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.
2. Inspect the blades, especially the curved area (Fig. 38). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 38), immediately install a new blade. 2 2. Rotate the opposite ends of the blades forward. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 in. (3 mm). If this dimension exceeds 1/8 in.
Sharpening the Blades 2. Adjust the tire pressure in all tires to specifications on page 29. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 42). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 3. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 32. 4. Set the height-of-cut to the 4 in. position.
6 4 A 1 5 Checking Carrier Frame Front–to–Rear Pitch 2 The carrier frame must have a pitch of a 1/4 in. over the length of 24 inches on the carrier frame. 1. Measure out 24 inches on the carrier frame (Fig. 46). 2. Measure carrier frame height at location “A” (Fig. 46). 3. Measure carrier frame height at location “B” (Fig. 46). 4. The height at location “A” must be a 1/4–3/8 in. lower than location “B” (Fig. 46). 3 5. If the carrier frame is not correct, move caster spacers to make it a 1/4–3/8 in.
5 3 2 2 5 A MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE B m–2539 Figure 49 4 1 1 Changing the Deck Front-to-Rear Pitch 4 m–5231 Figure 47 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins Changing the front–to–rear pitch is done by adjusting the front height–of–cut posts. 4. Same height at locations A and B 5. Caster spacers Changing the Deck Front–to–Rear Pitch by Adjusting Front Height–of–Cut Posts Checking the Deck Front-to-Rear Pitch 1.
Checking the Deck Side-to-Side Leveling 2. Set the height-of-cut to the 4 in. position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear (Fig. 53). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 54). 1. Check the tire pressure on both deck and traction unit. 2. Position the blades side-to-side (Fig. 51). Measure at “A” and “B” locations (Fig. 51) from a level surface to the cutting edge of blade tips (Fig. 52). 4.
3 1 4 5 2 3 7 1 4 m–5372 2 6 8 m–5321 Figure 55 1. Drive belt 2. Drive spring Figure 56 3. Tire 4. Adjustment bolt 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 Replacing the Traction Belt 1. Raise the front of the machine and hold with jack stands. Replacing the Deck Belt 2. Disconnect clutch wire connector from wire harness.
7. Install the new drive belt onto the PTO engagement pulley and the top groove of the center spindle pulley (Fig. 58). 9. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt on page 38. 10. Reinstall the deck cover onto the cutting unit, then reinstall and tighten the knobs. 8. Install belt onto idler pulley and then install idler spring (Fig. 58). 11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 9. Adjust PTO drive belt guides an 1/8 in.
2. Remove the locking pin and spacer(s) from the top of the castor wheel fork (Fig. 59). Important The inside diameter of the bushings may collapse slightly when installed. If the castor wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 in. (28.6mm). 3. Pull the castor wheel fork out of the mounting tube, leaving the spacer(s) on the bottom of the fork.
Note: Make sure the “L” end of spring is installed behind deck edge before installing the bolt as shown in figure 62. 4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 61). 3. Install bolt and nut. Place “J” hook end of spring around grass deflector (Fig. 62). 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.
Wiring Diagram WIRE COLOR CODES PTO SwitchW (Off) 1 2 PK W BK BLACK PK PINK BN BROWN R RED BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW Neutral Switch (In Neutral) Y BU 7 5 8 4 PK OPT HR MTR F1 10A SPARK PLUG IGNITION MODULES Y Clutch 1 Operator Presence Switch (No Operator) BK OPT HR MTR BK AC PK PK REG 5 AC K1 Interlock Relay W MAG 2 Y T 3 4 Y BK SPARK PLUG KEY SWITCH (OPEN = ON) (CLOSED = OFF) GND 41
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” to stop the engine. Remove the key. B. Stop engine, allow to cool and drain the fuel tank; refer to Fuel Tank, page 30, 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.