Form No. 3327–394 Mid–Size Mower ProLine Gear 15hp with 36 in. Side Discharge Mower Model No. 30430—Serial No.
Warning Checking the Tire Pressure . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake and Neutral Lock . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . . The Safety Interlock System . . . . . . . . . . . .
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. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
• Use care when loading or unloading the machine into or from a trailer or truck • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Never refuel or drain the machine indoors. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
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. • Avoid starting or stopping on a slope. If tires lose traction, disengage the blades. General Operation • Mow slopes side–to–side. • 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. 43-8480 93-1122 95-2814 66-1340 98-0776 67-5360 98-4387 1. Warning—wear hearing protection.
6-5532 104-8185 106-0699 104-8569 105-4111 105-4146 106-5511 106-0635 10
106-5496 1. Reverse 2. Neutral 1. Choke 2. Fast 3. Forward speeds 106-5501 3. Continuous variable setting 4. Slow 106-5514 1. Keep bystanders a safe distance from the machine. 2. Do not allow bystanders to be hit by thrown objects. 3. Do not operate the mower with the deflector up or removed. 4. Stop the engine and pick up debris before operating. 5. Cutting of hand or foot, mower. 6. Engine—stop 7. Engine—run 8. Hour meter 9. To park, move the controls as illustrated. 10.
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.
Setup 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. Step Description 1 Handle assembly 1 Flanged bolt 3/8 x 1 inch 4 Flange nut 3/8 inch 4 Fuel tank with studs installed 1 Shift lever plate 1 Bolt, 5/16 x 7/8 inch 2 Lock washer, 5/16 inch 2 Washer, 5/16 inch 4 Spring 2 Hose clamp 1 2 3 4 5 6 7 Qty.
Step 1 Step 2 Parts needed for this step: Parts needed for this step: • 1 Handle assembly • 1 Fuel tank with studs installed • 4 Flange bolts, 3/8 x 1 inch • 1 Shift lever plate • 4 Flange nuts, 3/8 inch • 2 Bolts, 5/16 x 7/8 inch • 2 Lock washers, 5/16 inch Installing the Handle Assembly • 2 Flat washers, 5/16 inch 1. Align handle with upper mounting holes in rear frame (Fig. 2). • 2 Springs • 1 Hose clamp 2.
Step 2 1 3 m–6504 Figure 4 1. Fuel line 2. Clamp 3 No parts needed for this step. 3. Fuel tank connection Adjusting the Shift Lever Plate 5. Slide the shift lever plate over the shift lever (Fig. 6). 1. Shift lever to second gear and check alignment of lever in slot of shifter lever plate. The clearance between top and bottom of the shift lever should be equal (Fig. 7). 6. Secure the right side of shift lever plate and fuel tank to the rear frame (Fig.
1 1 3 2 2 4 4 Rear View m–6592 2 Figure 8 1. Control rod 2. Bell crank 3 m–5458 2. Adjust control rod length by threading rod in or out of rod fitting until there is a 3/16 to 1/4 inch (5 mm to 6 mm) clearance between the control rod and bottom of neutral/brake lock (Fig. 9). Figure 7 1. Shift lever, 2nd gear 2. Shift lever plate Step 3. Hairpin cotter 3. Shift lever, neutral 4. Equal distance 3. Install control rod to drive lever and neutral/brake lock.
Step 5 Step Parts needed for this step: 6 No parts needed for this step. • 2 Hairpin cotter pins Checking the Tire Pressure Installing the Hairpin Cotter Pins and Washers Refer to Page 29 for the correct correct tire pressure. Unused height–of–cut spacers may be stored on posts and retained by a hairpin cotter. 1. On the opposite side of the muffler, install unused washers and hairpin cotter pins into front and rear height–of–cut pins (Fig. 10). 3 2 1 m-6505 Figure 10 1. Hairpin cotter 2.
Drive levers – Shift to desired gear and release drive levers to engage forward traction operation and squeeze to reverse. Squeeze right side of drive lever to turn right and left side to turn left. Operation Note: Determine the left and right sides of the machine from the normal operating position. Neutral lock and Parking brake locks – 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.
Parking Brake and Neutral Lock Starting and Stopping the Engine Always set the parking brake when you stop the machine or leave it unattended. Starting 1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open. Setting the Parking Brake 2. Move the shift lever to neutral, set the parking brake, and turn ignition key to the Run position. 1. Squeeze the drive levers back to the neutral position (Fig. 13). 3.
Understanding the Safety Interlock System Operating Mower Blade Control (PTO) The safety interlock system is designed to prevent the engine from starting unless: The blade control switch (PTO) in conjunction with the Operator Presence Control (OPC) levers engage and disengage power to the electric clutch and mower blades. • The blade control switch (PTO) is off. • The machine is shifted into neutral. Engaging the Mower Blades (PTO) The safety interlock system is designed to kill the engine when: 1.
2. Release the parking brake; refer to Releasing the Parking Brake, page 19. Caution 3. Slowly release the drive levers to move forward (Fig. 16). Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. To go straight, release drive levers equally (Fig. 16). To turn, squeeze the drive lever on the side and direction you want to turn (Fig. 16).
Adjusting the Height-of-Cut Adjusting the Center Gage Wheels The height-of-cut can be adjusted from 1 to 4-1/2 inch (25 to 114 mm) in 1/4 inch (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers. The gage wheels need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground. 1.
Adjusting the Handle Height The handle position can be adjusted to match the operator’s height preference. 1. Remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket (Fig. 19). 2 3 1 4 5 6 7 8 m–6591 Figure 19 1. 2. 3. 4. Upper handle Rear frame Flange nut, 3/8 inch Flange bolt, 3/8 x 1 inch 5. 6. 7. 8. Upper mounting hole Lower mounting holes Low position High position 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Servicing the Air Cleaner 2 Service Interval/Specification 1 Foam Element: Clean and re-oil after every 25 operating hours. Paper Element: Clean after every 25 operating hours. Replace after every 100 operating hours. m–5193 Figure 21 Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy. 1. Foam element 2. Oil Removing the Foam and Paper Elements Cleaning the Paper Element 1.
Servicing the Engine Oil 1 2 Service Interval/Specification Change oil: 3 • After the first 8 operating hours. • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF, SG or SH) Figure 23 Crankcase Capacity: w/filter, 64 oz. (1.9 l) 1. Oil dipstick 2. Metal end Viscosity: See table below 3. Filler tube USE THESE SAE VISCOSITY OILS Changing the Oil 10W–30 1.
7. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 23). Refer to Servicing the Engine Oil, page 26. Servicing the Spark Plug 8. Check the oil level; refer to Checking the Oil Level, page 26. 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. 27). Bend the side electrode (Fig. 27) if the gap is not correct. 2 3 1 0.040 in. (1.02 mm) Figure 27 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Figure 28 Installing the Spark Plug(s) 1. Install the spark plug(s) and metal washer. Make sure the air gap is set correctly. Lubricating the Caster and Wheel Bearings 2. Tighten the spark plug(s) to 20 ft-lb (27 N.m). 3. Push the wire(s) onto the spark plug(s) (Fig.
Lubricate the Transmission and Idler Bracket Checking the Tire Pressure Service Interval/Specification 1. Lubricate the transmission couplers located in the back of the machine (Fig. 30). 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. 32). Check the tires when they are cold to get the most accurate pressure reading.
8. Check for fuel leaks and repair if needed (Fig. 33). 3. Squeeze the ends of the hose clamp together and slide it away from valve (Fig. 33). 3 4. Pull the fuel line off the valve (Fig. 33). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. 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 30. 5. Install the fuel line onto the valve.
4. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock. Refer to Adjusting the Brake on page 31. 2. Check adjustment by inserting feeler gauge thru slots next to studs (Fig. 36). 3. The proper disengaged clearance between the clutch plates is 0.012–0.018 inch (0.30-0.45 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other. 5.
Before Inspecting or Servicing the Blades 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. Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s). 5 3 7 8 Inspecting the Blades 4 1.
Front 3 1 A 2 A 5 m–1078 6 Figure 39 4 m–6368 Figure 41 1. Sail Area of Blade 2. Blade 3. Blade spindle MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 4. Blade Bolt 5. Blade stiffener 6. Flat washer Sharpening the Blades m–1087 Figure 40 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. 2. Rotate the opposite ends of the blades forward. 3.
Important The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Fig. 41). 4. At the carrier frame cross tube, measure location A height (Fig. 44). This measurement must be 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm). 2. Install the lock washer and blade bolt (Fig. 41). Torque the blade bolt to 85–110 ft-lb (115–140 N m). 5. If the height at location A is not correct, adjustment is needed. 6.
6. If the height at location A and B are not the same, change tire pressure slightly to make them the same. 5 3 24 in. (61cm) 2 3 3 5 A B 4 A 2 4 B 1 m–6370 Figure 46 4 1 4 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 inch (6 mm–10 mm) pitch over 24 inch (61 cm) length m–5237 Figure 45 1. Back view of machine 2. Top of engine deck 3. Tires 4. Same height at locations A and B 4. Height at locations A and B 5. Caster spacers Checking Carrier Frame Side–to–Side 1.
5 3 2 5 2 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE B A m–1087 Figure 49 1 4 1 4 Changing the Deck Front-to-Rear Pitch m–6371 Figure 47 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins 4. Same height at locations A and B 5. Caster spacers Changing the front–to–rear pitch is done by adjusting the front height–of–cut posts. 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 inch (101.6 mm) 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.
• Position B – Low belt wear 6. Tighten the bottom two mounting screws enough to allow the belt to pass between the drive pulley and idler support (Fig. 56). • Position C – Medium belt wear • Position D – Most severe belt wear Note: Do not over extend the spring. The spring length should not exceed 7–5/8 inches with the paring brake engaged (Fig. 55). 3 1 5 6. Install adjustment bolt assembly and spring. 7. Repeat for opposite side. 4 2 Figure 56 5 1. Top capscrew 2. Idler bracket 3.
3 1 1 4 5 4 3 7 2 6 8 m–5321 Figure 57 1. 2. 3. 4. Transmission 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 58 1. Mower belt 2. Idler arm spring 3. Outward pulley Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 4.
10. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs/rubber washers. 1 2 11. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the knobs/rubber washers. 3 2 4 1 3 m–6372 Figure 60 1. Locking Pin 2. Spacers (locate as required) 2 4 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 61). Clean the inside of the mounting tube. m–5247 Figure 59 1. PTO clutch pulley 2. Drive belt idler 3.
Caster Wheel and Bearings Service Replacing the Grass Deflector Warning The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly caster wheel usually indicates a worn bearing. An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury.
Wiring Diagram WIRE COLOR CODES W 1 PK 2 PTO Switch (Off) 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 Y 7 5 Neutral Switch (In Neutral) 8 4 PK BU F1 10A IGNITION MODULES Y Clutch HR MTR (OPTIONAL) AC 1 Operator Presence Switch No Operator) PK PK REG 5 AC K1 Interlock Relay W MAG 2 Y T 3 4 Y KEY SWITCH HR MTR BK (OPTIONAL) BK SPARK PLUG SPARK PLUG (OPEN = ON) (CLOSED = OFF) GND 42
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 29, 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 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 the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
