Form No. 3326-323 Mid–Size Mower ProLine Gear 15 HP with 44 in. Side Discharge Mower Model No.
This spark ignition system complies with Canadian ICES-002. Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Service . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . Greasing and Lubrication . . . . . . . . . . . . . . . . . . . Cleaning the Cooling System . . . . . . . . . . . . . . . Checking Tire Pressure . . . . . . . . . . . . . . . . . . . . Fuel Tank Service . . . . . . . . . . . . . . . . . . . . . . . .
or danger — “personal safety instruction.” Read and understand the instruction because it has to do with safety. Failure to comply with the instruction may result in personal injury. General Lawn Mower Safety 1 The following instructions have been adapted from the ISO standard 5395. m–3097 Figure 1 This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. 1.
• Before using, always visually inspect to see that guards, and safety devices, such as deflectors and/or grass catchers, are in place and working correctly. Stop the blades if the lawn mower has to be tilted for transportation when crossing surfaces other than grass and when transporting the lawn mower to and from the area to be mowed. • Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged.
• To reduce the fire hazard, keep the engine, silencer, battery compartment and gasoline storage are free of grass, leaves, or excessive grease. • Check the grass catcher frequently and replace if worn or deteriorated. • Replace worn or damaged parts for safety. • Replace faulty silencers. • If the fuel tank has to be drained, do this out–doors. • Do not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed can increase the hazard of personal injury.
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. 93-8069 1. Warning hot surface—stay away. 95–5851 1. Read the operator’s manual before adjusting by–pass valve. 2. Unlock jam nut. 3. Close by–pass valve. 4. Open by–pass valve counterclockwise, a 1/2 turn. 5. Lock jam nut by tightening 100-3952 1. Hydraulic oil level 2. Hot surface hazard—stay away.
95–5852 1. Warning—Chock or block wheels when parking on slope 93–7010 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard—keep the deflector in place. 98–4387 3. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 1. Caution—wear hearing protection. 93–7828 1. Thrown object hazard—keep the deflector in place. 2. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 104–8186 1.
93-7818 1. Warning—read the operator’s manual for proper blade bolt torque. 93–7824 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard—keep the deflector in place. 3. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 105–0841 1. Read the operator’s manual for proper procedure. 2. Anti–scalp roller height adjustment 3. Read the operator’s manual before performing maintenance. 93–7316 1. Thrown object hazard—keep bystanders away. 2.
95–1545 1. Read the operator’s manual for proper procedure. 2. Thrown object hazard—keep bystanders away. 3. Thrown object hazard—keep the deflector in place. 4. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 1. Choke 2. Fast 3. Variable speed 4. Slow 5. Warning—stop engine before leaving the machine. 6. Use lever to lock reference bar in desired speed 7. Slow 8. Fast 104–8179 5. Engine stop 6. Engine start 12 7.
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 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.
2 8 1 7 4 6 5 4 3 3 3 7 5 5 8 6 6 m–5339 m–5336 Figure 2 1. Bolt, 5/16 x 7/8 in. (22.5 mm) 2. Lock washer, 5/16 in. 3. Washer, 5/16 in. 4. Stud 5. 6. 7. 8. Figure 3 Spring Locknut Hose clamp Fuel tank connection 1. Upper handle 2. Rear frame 3. Flange bolt, 3/8 x 1 in. (26mm) 4. Flange nut, 3/8 in. 5. 6. 7. 8. Upper mounting hole Lower mounting hole Low position High position 3. Slide the hose clamp onto the fuel line (Fig. 2). Install Control Rods 4.
2. Remove hairpin cotter and rod from upper control bars (Fig. 4). 1 3. Press and hold upper control bars against reference bar, so stop hits (Fig. 4). 3 2 4. Push rod full forward until bearing is against control bracket stop. Loosen wing nut and thread turnbuckle in or out until rod aligns with holes in upper control bars (Fig. 6). 4 5. When rod and holes in upper control bars line up, rotate turnbuckle one additional turn, so rod is shorter.
5. Make sure the vent caps are installed in the battery. Charge the battery for 1 hour at 25 to 30 amps or 6 hours at 4 to 6 amps. Do not overcharge the battery. Warning 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.
Operation Reference Handle – Limits forward travel of control bar to pre-set position to help maintain desired ground speed and direction of travel. It is locked in position with quick release levers. Note: Determine the left and right sides of the machine from the normal operating position. Ignition Switch – Key switch is used with the electric starter. Switch has three positions: “START”,“RUN” and “OFF”.
Parking Brake Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to FAST position. Always set the parking brake when you stop the machine or leave it unattended. Before each use, check brake for proper operation. 4. Grasp recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly. If the parking brake does not hold securely, an adjustment is required.
Understanding the Safety Interlock System 3. Pull blade switch (PTO) up and release. Hold blade control bail against control bar while operating. 4. Repeat procedure to engage mower blades if blade control bail is released. The safety interlock system is designed to prevent the mower from starting unless the control bar is in the neutral position and to prevent the blades from rotating when the blade control is released.
Operate the machine with the engine speed set at slow or medium when learning how to use the controls. Practice driving the machine in a level open area. 1 2 Ground Speed 1. Place the quick release levers in the unlock position (Fig. 14). 3 2. Move the reference bar forward or backward to set the desired forward speed. The pointer indicates approximate ground speed. When the bar is in the full forward position the ground speed is approximately 6.5 mph.
Important If the machine will be left unattended, close the fuel shut off valve and disconnect the wire(s) from the spark plug(s). Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 1 Always remove the ignition key and set parking brake when leaving the machine unattended, even if just for a few minutes. 2 m–5209 Figure 15 1. By-pass valve 2.
Danger 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. 3 4 1 • Never remove the grass deflector from the 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.
4 1 3 2 5 m–5203 Figure 17 1. Gage Wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do Not Remove. Adjusting Center Gage Wheels The gage wheels must be adjusted in the proper hole location for each height-of-cut position. 1. After adjusting height-of-cut remove bolt, washers and nut (Fig. 18). 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. Reinstall the bolt, washers and nut (Fig. 18).
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Air Cleaner Service Important worn. Replace the foam element if it is torn or Service Interval/Specification 2 Foam Element: Clean and re-oil after every 25 operating hours. 1 Paper Element: Clean after every 25 operating hours. Replace after every 100 operating hours. Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy. m–5193 Figure 20 Removing the Foam and Paper Elements 1. Foam element 1.
3. Install the air cleaner cover and secure with cover nuts (Fig. 19). 1 2 Engine Oil Service 3 Service Interval/Specification Change oil: • After the first 5 operating hours. • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Figure 22 1. Oil dipstick 2. Metal end Oil Type: Detergent oil (API service SF, SG or SH) 3. Filler tube Crankcase Capacity: w/filter, 64 oz. (1.
Spark Plug Service 5. Slowly pour approximately 80% of the specified oil on page 27, into the filler tube (Fig. 22). Now check the oil level; refer to Checking Oil Level, page 27. Slowly add additional oil to bring to “FULL” mark on dipstick. Service Interval/Specification Service Interval/Specification Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
2. Check the gap between the center and side electrodes (Fig. 26). Bend the side electrode (Fig. 26) if the gap is not correct. 2 3 1 0.040 in. (1.02 mm) m–2147 Figure 27 Greasing the Belt Idlers 1. Stop the engine, chock or block tires, remove the key and disconnect the spark plug wire(s) from the spark plug(s). Figure 26 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) 2. Grease the idler pulley pivot for the deck belt (Fig. 28). 3.
Checking Tire Pressure 3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from valve (Fig. 30). Service Interval/Specification 4. Pull the fuel line off the valve (Fig. 30). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 40 operating hours or monthly, whichever occurs first (Fig. 29).
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 Hydraulic System Service 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.
Bleeding Hydraulic System 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 33). 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.
Test Procedure 6. If the machine is too aggressive or tends to jump forward, the valve needs to be opened further. 1. Start engine and run for 5 minutes at 3/4 throttle, to warm hydraulic fluid. 7. If the machine is slow to respond, the valve needs to be closed further. 2. Drive the machine to a clear and level open area such as a driveway. 8. Repeat “Test Procedure” to check for proper operation. Re-adjust the by–pass valves until proper performance is achieved.
Adjusting the Brake 5. Push down on Pump Arm until Sleeve contacts bottom nut (Fig. 36). Wheel should now be rotating slowly in reverse. The brake handle is on the right side of machine (Fig. 37). If the parking brake does not hold securely, an adjustment is required. 6. Turn bottom nut up slowly, moving sleeve and pump arm up, until wheel stops rotating (Fig. 36). 1. Check the brake before you adjust it; refer to Checking the Brake, page 34. 7.
Cutting Blade Service 1 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 Danger 3 A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. m–2600 Figure 38 1. Adjusting nut 2. Slot • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. 3.
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. 41). Measure from a level surface to the cutting edge, position “A”, of the blades (Fig. 42). Note this dimension. 1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, lock washer, washer and blade from the spindle shaft (Fig. 43).
2. Place a long straight edge on top of the engine deck as shown in figure 46. 2 1 3. At the carrier frame cross tube, measure location “A” height (Fig. 46). This measurement must be 2–13/16 in. (71.4 mm), plus or minus a 1/4 in. (6 mm). m–1855 Figure 45 1. Blade 2. Balancer 4. If the height at location “A” is not correct, adjustment is needed. 5. Loosen the carrier frame mounting bolts on both sides of the machine (Fig. 46). Installing the Blades 6.
5 3 2 3 24 in. (61cm) 3 5 A A B 4 2 4 1 4 1 4 m–5237 m–5242 Figure 48 Figure 47 1. Back view of machine 2. Top of engine deck 3. Tires B 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 in. (6mm–10mm) pitch over 24 in. (61 cm) length 4. Same height at locations A and B Checking Carrier Frame Front–to–Rear Pitch 4. Height at locations A and B 5. Caster spacers Checking Carrier Frame Side–to–Side 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).
5 3 2 2 5 A MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE B m–2539 Figure 51 4 1 Changing the Deck Front-to-Rear Pitch 4 1 m–5231 Figure 49 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. (101.6 mm) position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear (Fig. 55). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 56). 1. Check the tire pressure on both deck and traction unit. 2. Position the blades side-to-side (Fig. 53). Measure at “A” and “B” locations (Fig.
7. Install new belt around clutch and drive pulleys. 8. Adjust deck belt guide an 1/8 in. (3 mm) from belt (Fig. 58). 8. Torque pivot bolt to 35-40 ft. lb. (47-54 N.m). Install tension spring between idler arm and frame bracket (Fig. 57). 9. Reinstall the PTO drive belt. Refer to Replacing the PTO Drive Belt page 41. 9. Install clutch retainer to the engine deck (Fig. 57). 10. Reinstall the deck covers onto the cutting unit, then reinstall and tighten the knobs. 10.
7. Install the new drive belt onto the PTO engagement pulley and the top groove of the center spindle pulley (Fig. 59). 2. Remove the locking pin and spacer(s) from the top of the caster wheel fork (Fig. 60). 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. 8. Install belt onto idler pulley and then install idler spring (Fig. 59). 9.
2 1 1 2 3 2 5 m–5197 4 Figure 61 1. Carrier Frame Mounting Tube 2. Bushing 3 m-5210 Figure 62 1. Locknut 2. Wheel Bolt 3. Bushing Caster 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. 62). The caster 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 63. 3. Install bolt and nut. Place “J” hook end of spring around grass deflector (Fig. 63). 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 63 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 J2–1 HOURMETER (OPTIONAL) S3 S2 BAIL SW. CLUTCH SW.
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 46
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 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.
