Form No. 3325–882 Mid–Size Mower ProLine Hydro 15 HP with 36 in. Side Discharge Mower Model No.
Warning Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Understanding Controls . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating Neutral Locks . . . . . . . . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Bringing Machine to Neutral Position . . . . . . . . . Stopping the Machine . . . . .
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . . Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. Page 49 50 50 56 This manual uses two other words to highlight information.
• Keep pets and bystanders away. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing. • Use only an approved container • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Be aware of the mower discharge direction and do not point it at anyone.
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. 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.
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.
5–4146 104–8569 1–523552 98–0776 105–4143 98–4387 104–8172 95–1543 10
105–4110 105–0840 105–4109 104–8185 104–8171 105–4106 11
105–4108 12
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 Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY. USE Fuel tank 1 Bolt 5/16 x 7/8 in. (22.5 mm) 2 Lock washer 5/16 in. 2 Washer 5/16 in. 4 Stud 2 Spring 2 Hose clamp 1 Upper handle 1 Flanged bolt 3/8 x 1 in. (26 mm) 4 Flange nut 3/8 in.
7 8 8 7 5 9 1 3 4 6 3 2 3 5 5 6 6 4 m–5339 Figure 2 1. Bolt, 5/8 x 7/8 in. (22.5 mm) 2. Lock washer, 5/16 in. 3. Washer, 5/16 in. 4. Stud 5. 6. 7. 8. Spring Locknut Hose clamp Fuel tank connection m–5401 Figure 3 1. Upper handle 2. Rear frame 3. Flange bolt, 3/8 x 1 in. (26 mm) 4. Flange nut, 3/8 in. 3. Slide the hose clamp onto the fuel line (Fig. 2). 5. 6. 7. 8. 9. Upper mounting hole Lower mounting hole Low position Medium position High position—Do not use 4.
1 6 2. Thread yoke onto speed control rod approximately 3/4 in. (19 mm) (Fig. 5). 2 3. Install yoke to the speed control crank with a clevis pin, washer and hairpin cotter (Fig. 5). 4. Secure yoke with jam nut (Fig. 5). 3 4 5 7 m–5400 1 Figure 4 1. 2. 3. 4. Left handle shown Neutral lock Clevis pin Drive lever 4 5. Control rod 6. Operator Presence Control lever (OPC) 7. Hairpin cotter 3 2 7 6 5 m–5402 4. Thread rod fittings equal distance onto each control rod.
Adjust Tracking Warning Refer to Adjusting Tracking on page 37. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Checking the Hydraulic Fluid • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Think Safety First Neutral lock – 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. 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. Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: RUN and OFF.
8 3 6 9 5 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 Stopping 1. Move the throttle lever to “SLOW” (Fig. 11). 2. Move drive levers to neutral and set neutral locks. 3. Let engine idle for 30 to 60 seconds before turning the ignition key “OFF.” 7 4. Turn the ignition key to “OFF” (Fig. 11). 4 1 2 m–5381 1 Figure 10 1. Throttle control 2. Operator Presence Control levers (OPC) 3.
Disengaging the Mower Blades (PTO) 2. Place thumbs on the upper part of of locks and move them forward until in forward slot (Fig. 12). The mower blades can be disengaged by one of the following steps. 2 1. Push the blade control switch (PTO) to off (Fig. 13). 1 2. Release Operator Presence Control (OPC) levers to disengage blades (Fig. 13). This will also kill the engine. 6 5 The Safety Interlock System 3 Caution 4 m–5388 Figure 12 1. Handle 2. Neutral lock 3.
3. Push the blade control switch off. 2. Release the neutral lock. Refer to Releasing the Neutral Locks on page 19. 4. With engine running, hold down the OPC levers. Pull the blade control switch (PTO) up. The clutch should engage and the mower blades begin rotating. 3. Slowly squeeze the drive levers back together to move rearward (Fig. 14). 5. Release the OPC levers. The engine should kill. Bringing Machine to Neutral Position 6. With the engine running, move the speed control lever forward.
2. Loosen jam nuts and rotate by-pass valves open 5 turns to push. This allows hydraulic fluid to by-pass the pump and the wheels to turn (Fig. 15). Using Side Discharge or Mulching Grass Important Rotate by-pass valve a maximum of 5 turns so the valve does not come out of the body causing fluid to run out. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Important All four hairpin cotter pins must be in the same hole location and with the correct number of spacers for a level cut. 3 4 3 4 1 1 4 Figure 17 5 1 1. Center Gage Wheels and Spacer 2. Nut m-4856 2 4 2 m–5230 Figure 16 1. Carrier Frame 2. Hairpin Cotter 3. Front height–of–cut post 4. Spacers 5. Back height–of–cut post Adjusting Center Gage Wheels The gage wheels must be adjusted in the proper hole location for each height-of-cut position. 1.
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. 18). 2 1 Servicing the Engine Oil Service Interval/Specification Change oil: m–5193 • After the first 5 operating hours. Figure 19 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. 20).
5. Slowly pour approximately 80% of the specified oil on page 26, into the filler tube (Fig. 21). Now check the oil level; refer to Checking Oil Level, page 26. 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 Changing 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., 1.02 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. 24). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Figure 25 3. Remove the spark plug(s) and metal washer.
Where to Add Grease Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 26). m–5247 Figure 28 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.
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 30. 5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line. 1 2 m–2147 Figure 29 1. Rear Tire 2. Caster tire 1 Servicing the Fuel Tank 2 m–5185 Danger Figure 30 1. Fuel shut-off valve In certain conditions, gasoline is extremely flammable and highly explosive.
7. Check for fuel leaks and repair if needed (Fig. 30). 1 3 1 2 3 1 M-4280 3 2 Figure 32 m–5234 1. Cap 2. Baffle Figure 31 1. Hose clamp 2. Fuel line 3. Filter 3. Fluid level—full Warning Servicing the Hydraulic System Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.
Bleeding Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. 2. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand. 3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minute). 1 m–5208 Figure 33 4.
Test Procedure Important By–pass valve adjustment is very sensitive, do not adjust more than 1/6 turn (one flat) at a time. 1. Start engine and run for 5 minutes at 3/4 throttle, to warm hydraulic fluid. 6. If the machine is too aggressive or tends to jump forward, the valve needs to be opened further. 2. Drive the machine to a clear and level open area such as a driveway. 7. If the machine is slow to respond, the valve needs to be closed further.
Adjusting Neutral Control Linkages 4. Adjust the threaded yoke at the bottom of the speed control linkage until the tabs are at the 6 o’clock position (Fig. 37). 3 Warning 1 5 Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. 4 2 Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. m–5398 Figure 36 1. Speed control rod 2. Yoke 3.
Adjusting Hydro Control Linkages 6. If the wheel turns while holding the drive lever in neutral, the neutral control linkages need to be adjusted (Fig. 38). If wheel stops then go to step 12. 7. Loosen the nut against the neutral control linkage yoke (Fig. 38). Warning 8. Adjust the neutral control linkage until the respective drive wheel stops while the drive lever is pulled against the neutral spring (neutral position) (Fig. 38). Engine must be running so control linkage adjustments can be performed.
7. Turn the rear adjusting nut clockwise 1/4 of a turn at a time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Fig. 39). 1 8. Turn the rear nut an additional 1/2 turn and tighten the front nut. Note: Make sure flat part of linkage is perpendicular to pin part of swivel. 9. After adjusting the left hydro control linkage, move the speed control lever forward and then back to the neutral position. 3 2 m–5396 Figure 40 1.
2 1 1 5 3 2 6 3 4 m–5388 Figure 42 1. Handle 2. Neutral lock 3. Neutral position 4 m–5403 4. Drive lever 5. Full speed forward 6. Control rod Figure 41 1. Hydro control linkage 2. Quick track knob 3. Spring 4. 1 inch (26 mm) Adjusting Tracking 1. Remove machine from any jack stands. Adjusting Control Rod 2. Check the rear tire pressure. Refer to Tire Pressure Service on page 29. Checking Control Rod 3.
Servicing the Cutting Blade 2. Check adjustment by inserting feeler gauge through slots next to studs (Fig. 44). 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. 3. The proper disengaged clearance between the clutch plates is .012–.024 in. (0.30-0.60 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.
Checking for Bent Blades machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Rotate the blades until the ends face forward and backward (Fig. 47). Measure from a level surface to the cutting edge, position “A”, of the blades (Fig. 48). Note this dimension. 1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, blade stiffener and blade from the spindle shaft (Fig. 49).
Setting Up the Frame 2 1 Checking Carrier Frame and Deck Alignment m–1855 Figure 51 1. Blade 2. Balancer 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Place a long straight edge on top of the engine deck as shown in figure 52. Installing the Blades 3. At the carrier frame cross tube, measure location “A” height (Fig. 52). This measurement must be 2–13/16 in. (71.4 mm), plus or minus a 1/4 in. (6 mm). 1.
5 2. Adjust the tire pressure in all tires to specifications on page 29. 3 (6.1cm) 24 in. 3. Measure engine deck height at location “A” (Fig. 53). 4. Measure engine deck height at location “B” (Fig. 53). 5 5. If the height at location “A” and “B” are not the same, change tire pressure slightly to make them the same. A B 4 2 4 2 3 3 1 m–5242 Figure 54 A 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 in. (6mm–10mm) pitch over 24 in. (6.
Checking the Deck Front-to-Rear Pitch 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Fig. 58). 3 1. Check the tire pressure on both deck and traction unit. 2 4 2. Position one blade front-to-rear (Fig. 56). Measure at “C” and “D” locations (Fig. 56) from a level surface to the cutting edge of the blade tips (Fig. 57). 3. The mower blade should be 1/4 in. (6 mm) lower in front “C” than in the rear “D”. Rotate blades and repeat for other blades.
Front Front A A B m–1078 m–1078 Figure 59 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE Figure 61 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2550 Figure 60 m–2550 Figure 62 5. If it does not measure correctly, add air pressure in rear tires to raise height–of–cut Changing the Side-to-Side Leveling 6. If it does not measure correctly, decrease air pressure in rear tires to lower height–of–cut. Changing the side–to–side leveling is done by adjusting tire pressure. 7.
10. Connect clutch wire connector to wire harness. 11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 11. Install PTO drive belt. 3 1 1 4 4 5 3 7 6 2 8 m–5340 Figure 63 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 64 1. Deck belt 2. Idler arm spring 3.
10. install the heat shield to the the engine deck and carrier frame. 3. Pull the caster 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. 11. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs. 12. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the hand knobs.
8. Grease the fitting on the carrier frame mounting tube using No. 2 general purpose lithium base or molybdenum base grease. 1 2 2 1 3 5 4 2 3 m-5210 Figure 68 m–5197 1. Locknut 2. Wheel Bolt 3. Bushing Figure 67 1. Carrier Frame Mounting Tube 2. Bushing 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. 68).
Note: Make sure the “L” end of spring is installed behind deck edge before installing the bolt as shown in figure 69. 3. Install bolt and nut. Place “J” hook end of spring around grass deflector (Fig. 69). 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-5037 Figure 69 1. 2. 3. 4. 5. Bolt Spacer Locknut Spring Spring installed 6. Grass Deflector 7.
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 7 5 8 4 PK BN F1 10A SPARK PLUG IGNITION MODULES Y Clutch 5 3 4 – HR MTR BK PK REG AC K1 Interlock Relay W MAG 2 1 + D1 Operator Presence Switch (No Operator) AC HR MTR Y T PK MOD Y BK SPARK PLUG KEY SWITCH (OPEN = ON) (CLOSED = OFF) GND 48
Hydraulic Diagram Motor Right Side Pump Right Side B A Filter Expansion Tank Pump Left side B A Motor Left side Charge Pump Inlet Case Drain m–5225 49
Cleaning and Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Remove the key. C. Stop the engine, allow it to cool and drain the fuel tank; refer to Draining Fuel Tank, page 30. D. Restart the engine and run it 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. 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. Install new, correctly gapped spark plug. 6.
PROBLEM Abnormal vibration. Uneven cutting g height. g Blades do not rotate. 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. Contact Authorized Service Dealer. 6.
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.
