Form No. 3325–894 Mid–Size Mower ProLine Hydro 17 HP with 52 in. Side Discharge Mower Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating Neutral Locks . . . . . . . . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . .
Caster Wheel and Bearings Service . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . .
• Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. • 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. • Be aware of the mower discharge direction and do not point it at anyone.
Toro Mower Safety • Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. The following list contains safety information specific to Toro products and other safety information you must know. • Avoid starting or stopping on a slope. If tires lose traction, disengage the blades. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
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.
1–523552 98–0776 105–4144 54–9220 104–8172 95–1543 105–0840 104–8569 105–4109 10
105–4110 104–8186 104–8171 105–4107 11
105–4108 104–4163 104–4164 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 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.
3. Slide the hose clamp onto the fuel line (Fig. 2). Note: Make sure the clevis pin is inserted into the neutral lock. 4. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 2). 3. Repeat this procedure for the opposite side. 1 Install Upper Handle 6 2 Important Install the flange bolts (3/8 x 1 in. (26 mm)) with the bolt head on the inside of machine frame. Refer to figure 3. 3 1. Align upper handle with upper mounting holes in rear frame (Fig. 3). 4 5 2.
Install Speed Control Rod Adjust Control Rods 1. Place the speed control lever full forward (Fig. 5). Refer to Adjusting Control Rods on page 37. 2. Thread yoke onto speed control rod approximately 3/4 in. (19 mm) (Fig. 5). Adjust Tracking 3. Install yoke to the speed control crank with a clevis pin, washer and hairpin cotter (Fig. 5). Refer to Adjusting Tracking on page 38. 4. Secure yoke with jam nut (Fig. 5). Activating the Battery Bulk electrolyte with 1.
9. Install the battery in the machine and connect the battery cables. Refer to Installing Battery on page 40. Note: Do not run the machine with the battery disconnected, electrical damage may occur. 2 3 Checking the Hydraulic Fluid Check the hydraulic fluid level before engine is first started. 1 m-5004 Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 7 1. Filler caps 2. UPPER line 3. LOWER line Important Use oil specified or equivalent.
1 3 2 2 3 1 M-4280 m–5314 Figure 9 1. Cap 2. Baffle Figure 10 3. Fluid level—full 1. Hairpin cotter 2. Extra spacers Warning 3. Height–of–cut post Operation Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Note: Determine the left and right sides of the machine from the normal operating position. • 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.
Controls 8 3 6 9 5 2 Become familiar with all the controls (Fig. 12) before you start the engine and operate the machine. 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.
4. When engine starts, move the throttle control between the “FAST” and “Slow” position. Allow engine to warm up and then move the throttle control to the “FAST” position. 2 1 6 Stopping 5 1. Move the throttle lever to “SLOW” (Fig. 13). 3 Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.
1. Push the blade control switch (PTO) to off (Fig. 15). 5. Release the OPC levers. The engine should kill. 2. Release Operator Presence Control (OPC) levers to disengage blades (Fig. 15). This will also kill the engine. 6. With the engine running, move the speed control lever forward. Release the OPC levers. The engine should kill. The Safety Interlock System 7. If all the above conditions are not met have an Authorized Service Dealer repair the safety system immediately.
Bringing Machine to Neutral Position 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. 17). Always set the neutral lock when you stop the machine. Chock or block wheels if it is left unattended. 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. 1. Squeeze the drive levers back. 2. Set the neutral locks.
Side Discharge or Mulch Grass Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Danger 3 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.
4 1 3 2 5 m–5203 Figure 19 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. 20). 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. 20). 3. Reinstall the bolt, washers and nut (Fig. 20).
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 Service Interval/Specification 2 4 Foam Element: Clean and re-oil after every 25 operating hours. Paper Element: Clean after every 50 operating hours.
ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ 2. Place the air cleaner assembly onto the air cleaner base (Fig. 21). Secure with nut. 2 1 3. Install the air cleaner cover and secure latches (Fig. 21). Engine Oil Service m–4694 Service Interval/Specification Figure 22 1. Foam element Change oil: 2. Oil • After the first 8 operating hours. • After every 100 operating hours.
1 5. Slowly pour approximately 80% of the specified oil, page 27, into the filler tube (Fig. 24). Now check the oil level; refer to Checking Oil Level, page 27. Slowly add additional oil to bring to “FULL” mark on dipstick. 2 3 Change Oil Filter Service Interval/Specification Replace the oil filter every 200 hours or every other oil change. Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. Figure 24 1. Oil dipstick 2. Metal end 3. Filler tube 1.
2 Type: Champion RCJ8Y or NGK BPR4ES Air Gap: 0.030 in. (.75 mm) 3 1 Removing the Spark Plug(s) 0.030 in. (.75 mm) 1. Disengage the power take off (PTO), chock or block tires, 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. 27). 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). Figure 28 1. Center electrode insulator 2.
Where to Add Grease Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Figure 29). m–5196 Figure 31 Cleaning the Cooling System Service Interval/Specification Lubricate the caster and wheel bearings 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 31. 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 32 1. Rear Tire 2. Caster tire 3 2 1 Fuel Tank Service m–5235 Figure 33 Danger 1. Fuel line 2. Hose clamp In certain conditions, gasoline is extremely flammable and highly explosive.
1 1 2 3 3 1 2 M-4280 M-4294 Figure 34 1. Hose clamp 2. Fuel line Figure 35 1. Cap 2. Baffle 3. Filter 3. Fluid level—full Warning Hydraulic System Service Checking the Hydraulic Fluid Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Check the hydraulic fluid level: • 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 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 36). 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 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.
Adjust Neutral Control Linkages 3 1 5 Warning 4 2 Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. m–5398 Figure 39 1. Speed control rod 2. Yoke 3. Speed control crank 4. Tabs, 6 o’clock position 5. Jam nut Warning 5. Pull the speed control lever back to neutral.
6. If the wheel turns while holding the drive lever in neutral, the neutral control linkages need to be adjusted (Fig. 41). If wheel stops then go to step 12. Warning Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 7. Loosen the nut against the neutral control linkage yoke (Fig. 41). • Use jack stand when supporting machine. • Do not use hydraulic jacks. 8.
5. Turn the knob clockwise 1/4 of a turn at a time. Then move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Fig. 44). 1 6. The spring that keeps tension on the knob should normally not need adjustment. However if adjustment is needed, adjust the length of spring to 1 in. (26 mm) between the washers (Fig. 44). 3 7. Adjust spring length by turning nut at front of spring (Fig. 44). 2 1 m–5394 Figure 42 1. Hydro control linkage 2. Front nut 3 2 3.
2. Lengthen the rod if the tire is turning in reverse and shorten the rod if the tire is turning forward. 3. Rotate the rod several turns if the tire is rotating fast. Then, adjust the rod in 1/2 turn increments. 4. Release and engage neutral lock checking that the tire does not rotate. Continue this process until the tire does not rotate. 1 5. Place the hairpin back into clevis pin (Fig. 45). 6. Repeat this adjustment for opposite side. m–5398 2 Figure 46 1 1.
Fuse Service parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Service Interval/Specification Voltage: 12 v, 300 Cold Cranking Amps The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows check component or circuit for malfunction or short. To replace fuse pull out on the fuse (Fig. 48) to remove or replace it.
5. Remove the battery hold down plate (Fig. 49). Remove battery from the machine. 5 6 8 1 2 4 1 2 3 9 3 7 m-5004 Figure 50 11 1. Filler caps 2. UPPER line 3. LOWER line Danger 10 Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands.
6. Reinstall battery vent caps. Cutting Blade Service Charging the Battery 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. Warning Warning Charging the battery produces gasses that can explode. 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.
not exceed 1/8 in. (3 mm) If this 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 43. Warning 1 2 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 3 • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. m–151 Figure 52 1. Cutting Edge 2. Curved Area 3.
5. Perform steps in the following sections Frame Set Up, Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling. 1 Frame Set Up m–1854 Figure 56 Checking Carrier Frame and Deck Alignment 1. Sharpen at original angle 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Check the balance of the blade by putting it on a blade balancer (Fig. 57). If the blade stays in a horizontal position, the blade is balanced and can be used.
5 3. Measure engine deck height at location “A” (Fig. 59). 3 (6.1cm) 24 in. 4. Measure engine deck height at location “B” (Fig. 59). 5. If the height at location “A” and “B” are not the same, change tire pressure slightly to make them the same. 5 A 2 3 3 4 2 4 1 A 1 4 m–5242 Figure 60 B 4 B 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 in. (6mm–10mm) pitch over 24 in. (61 cm) length m–5237 4. Height at locations A and B 5. Caster spacers Figure 59 1. Back view of machine 2.
5 3 2 2 5 A MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE B m–2539 Figure 63 4 1 Changing the Deck Front-to-Rear Pitch 4 1 m–5231 Figure 61 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. (102 mm) position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear (Fig. 67). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 68). 1. Check the tire pressure on both deck and traction unit. 2. Position the blades side-to-side (Fig. 65). Measure at “A” and “B” locations (Fig. 65) from a level surface to the cutting edge of blade tips (Fig.
7. Install new belt around clutch and drive pulleys. 9. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs. 8. Torque pivot bolt to 35-40 ft. lb. (47-54 N.m). Install tension spring between idler arm and frame bracket (Fig. 69). 10. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 9. Install clutch retainer to the engine deck (Fig. 69). 11. Adjust deck belt guide an 1/8 in. (3 mm) from belt (Fig. 70). 10.
9. Adjust PTO drive belt guides an 1/8 in. (3 mm) from belt (Fig. 71). 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. 10. Install the heat shield to the the engine deck and carrier frame. 11. Install the belt covers onto the cutting unit, then install and tighten the knobs. 1 12.
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 74 m–5197 1. Locknut 2. Wheel Bolt 3. Bushing Figure 73 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. 74).
Note: Make sure the “L” end of spring is installed behind deck edge before installing the bolt as shown in figure 75. 3. Install bolt and nut. Place “J” hook end of spring around grass deflector (Fig. 75). 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 75 1. 2. 3. 4. 5. Bolt Spacer Locknut Spring Spring installed 6. Grass Deflector 7.
CLUTCH BK D1 Y BN BK GN Hour Meter GN SW4 NEUTRAL (Out of Neutral) BN GND BK BN + SW2 1 PTO SWITCH (Shown Off) 4 7 BK BK 5 2 – PK 4 3 51 1 OR K1 KILL RELAY W PK GN SW3 Operator Presence Switch (No Operator) OR BU I 5 S R 4 B PK SOLENOID R 3 A F2 25A VIO VIO 1 X R PK W VIO F1 30A R 2 Y X I S MAG REG START B+ A B KEY SW Y BK STARTER – AC AC Fuel Solenoid L1 IGNITION MODULE SPARK PLUG + BN BU TERMINAL VIEW FROM GN BACK OF SWITCH GY OR KEY SWITC
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 52
Cleaning and Storage D. Restart the engine and run it until it stops. E. Choke or prime the engine. 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Remove the key. F. Start and run the engine until it will not start again. Use the primer, if equipped on machine, several times to ensure no fuel remains in primer system. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
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. PTO is on (Pulled up). 2. Turn PTO off (Push in). 3. Speed control lever is in gear. 3. Move speed control lever to neutral. 4. Battery is dead. 4. Charge battery. 5. Choke is not ON. 5. Move choke lever to ON. 6.
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Machine does not drive up hills or inclines. 1. By-pass valve is adjusted too far open. 1. Adjust by-pass valve Machine moves slowly in neutral. 1. Neutral is mis-adjusted. 1. Adjust hydro linkages. 2. Neutral control spring is broken or missing. 2. Replace neutral control spring. 1. By-pass valve is adjusted too far closed. 1. Adjust by-pass valve 1. Tire pressure is not correct. 1. Adjust tire pressure. 2.
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.