Form No. 3327–404 Rev A Mid–Size Mower ProLine Hydro 15 HP with 44 in. Side Discharge Mower Model No. 30434—Serial No.
Warning Checking the Tire Pressure . . . . . . . . . . . . . . . . . Checking the Hydraulic Fluid and Engine Oil . . Setting Up the Hydro Linkage . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating Neutral Locks . . . . . . . . . . . . . . . . . .
Changing the Side-to-Side Leveling . . . . . . . . . . Matching the Height of Cut . . . . . . . . . . . . . . . . . Replacing the Mower Belt . . . . . . . . . . . . . . . . . . Replacing the PTO Drive Belt . . . . . . . . . . . . . . . Replacing the Caster Wheel Fork Bushings . . . . Caster Wheel and Bearings Service . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Diagram . . . . . . . . . . . . .
• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.
• Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. Slope Operation Slopes and ramps are a major factor related to loss-of-control and accidents, which can result in severe injury or death.
• Never tamper with safety devices. Check safety systems for proper operation before each use. • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required. • 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.
5-4110 98-0776 105-4146 98-4387 1. Warning—wear hearing protection.
105-4109 106-0635 106-5515 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 drive forward, move the controls as illustrated. 10. To place the machine in neutral, move the controls as illustrated. 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.
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 1 2 3 4 5 6 7 8 9 Description Qty.
1 Step Step 2 Parts needed for this step: Parts needed for this step: • 1 Handle assembly • 1 Fuel tank with studs installed • 2 Flange bolts, 3/8 x 1 inch • 2 Bolts, 5/16 x 7/8 inch • 2 Flange bolts, 3/8 x 1–1/4 inch • 2 Lock washers, 5/16 inch • 4 Flange nuts, 3/8 inch • 2 Flat washers, 5/16 inch • 2 Springs Installing the Handle Assembly • 1 Hose clamp 1. Align handle with upper mounting holes in rear frame (Fig. 2). Installing the Fuel Tank 2.
Note: Tighten left side of shift lever plate until it is completely tight and then unscrew the locknut one full turn. This will allow the spring to work. Step 6 7 3 Parts needed for this step: • 2 E–clips 3 3 4 2 5 1 Installing the Control Rods m–6583 1. For a starting point, make sure the rod fittings are threaded approximately 2–1/2 inches (63 mm) onto the control rods (Fig. 5). Figure 4 1. 2. 3. 4. Bolt, 5/8 x 7/8 inch Lock washer, 5/16 inch Washer, 5/16 inch Spring 5. Locknut 6.
Step 4 Step 5 Parts needed for this step: Parts needed for this step: • 1 Cotter pin • 2 Hairpin cotter pins • 1 Washer Installing the Hairpin Cotter Pins and Washers Installing the Speed Control Rod Unused height–of–cut spacers may be stored on posts and retained by a hairpin cotter. 1. Install the swivel into the speed control crank and secure it with a washer and cotter pin (Fig. 6). 1.
Step 7 Checking the Neutral Stud Refer to Adjusting the Neutral Stud on page 38. Checking the Control Rods Refer to Adjusting the Control Rods on page 39. Checking the Tracking No parts needed for this step. Refer to Adjusting the Tracking on page 40. Checking the Hydraulic Fluid and Engine Oil Operation Check the hydraulic fluid level before the engine is first started. Note: Determine the left and right sides of the machine from the normal operating position.
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. 8 3 9 5 6 2 Blade control switch (PTO) – Pull switch used in conjunction with OPC levers to release blade brake and engage clutch to drive mower blades. Speed control lever – This machine has a variable speed control with a neutral position.
2. Place thumbs on the upper part of the neutral locks and rotate them forward until in forward slot (Fig. 11). 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 7 1. Move the throttle lever to the Slow position (Fig. 10). 1 2. Squeeze the drive levers to the Neutral position and set the neutral locks. 3. Let the engine idle for 30 to 60 seconds before turning the ignition key Off.
Disengaging the Mower Blades (PTO) 2 1 1. Release Operator Presence Control (OPC) levers to disengage blades (Fig. 13). The Safety Interlock System Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. m–6614 Figure 12 1. Parking brake lever (released position) 2.
5. With the engine running, move the speed control lever forward. Release the OPC levers. The engine should kill. Bringing Machine to Neutral Position 6. If all the above conditions are not met have an Authorized Service Dealer repair the safety system immediately. Always set the neutral lock when you stop the machine. Set the parking brake if it is left unattended. 1. Squeeze the drive levers back toward the grips to neutral position. Driving Forward or Backward 2. Set the neutral locks.
Side Discharge or Mulch Grass 3. Open the by-pass valves, by turning them counter clockwise 1 to 2 turns, to push the machine. This allows hydraulic fluid to by-pass the pump and the wheels to turn (Fig. 15). This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Important Rotate by-pass valve a maximum of 2 turns so the valve does not come out of the body causing fluid to run out.
Important All four hairpin cotter pins must be in the same hole location and with the correct number of spacers for a level cut. 2 4 3 3 1 4 1 5 Figure 17 5 1 m–6470 1. Gage wheel 2. Nut 3. Bolt m-4856 4. Washer 5. Spacer 2 4 3 4 2 m–5230 Figure 16 1. Carrier Frame 2. Hairpin Cotter 3. Front height–of–cut post 1 4. Spacers 5. Back height–of–cut post 4 Figure 18 1. Center Gage Wheels and Spacer 2.
Adjusting the Handle Height 4. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Fig. 21). The handle position can be adjusted to match the operator ’s height preference. 5. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. Tighten all flange bolts. Note: 7 1. Remove the hairpin cotter pin and clevis pin from the drive lever and neutral lock (Fig. 19).
Using the Mid–Size Weight Kit A weight kit is available for this machine. This kit is optional and can be obtain from an Authorized Service Dealer • The weight kit mounted in the front position is required when a Tru–Trak Sulky is installed. • The weight kit mounted in the back position is optional when a Tru–Trak Sulky is not installed (Fig. 22). • Installing this weight kit can improve performance on slopes without the Tru–Trak Sulky. 1 3 2 4 Figure 22 1. Weight mounted in rear position 2.
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 spark plug 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 Service Interval and Specification 2 4 3 ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ Foam Element: Clean and re-oil after every 25 operating hours.
ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ 2. Place the air cleaner assembly onto the air cleaner base (Fig. 23). Secure with nut. 2 1 3. Install the air cleaner cover and secure latches (Fig. 23). Servicing the Engine Oil m–4694 Service Interval and Specification Figure 24 1. Foam element Change oil: 2. Oil • After the first 8 operating hours. • After every 100 operating hours.
1 9. Slowly pour approximately 80% of the specified oil, page 28, into the filler tube (Fig. 26). 2 10. Check the oil level; refer to Checking the Engine Oil Level, page 28. 3 11. If needed, slowly add additional oil to bring to the full mark on dipstick. Changing the Oil Filter Service Interval and Specification Replace the oil filter every 200 hours or every other oil change. Figure 26 1. Oil dipstick 2. Metal end 3.
2 Type: Champion RCJ8Y or NGK BPR4ES Air Gap: 0.030 inch (.75 mm) 3 1 Removing the Spark Plug(s) 0.030 inch (.75 mm) 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Pull the wire(s) off the spark plug(s) (Fig. 29). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Figure 30 4. Remove the spark plug(s). 1.
Greasing and Lubrication Service Interval/Specification Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. m–6367 Figure 33 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting.
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. 2 Checking the Tire Pressure Service Interval/Specification 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. 35). Check the tires when they are cold to get the most accurate pressure reading.
5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line. 1 1 3 2 1 2 M-4294 Figure 38 m–5235 1. Hose clamp 2. Fuel line 3. Filter Figure 37 1. Fuel shut-off valve 2. Clamp Servicing the Hydraulic System Servicing the Fuel Filter Service Interval/Specification Checking the Hydraulic Fluid Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Check the hydraulic fluid level before engine is first started.
6. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle. Important Do not substitute automotive oil filter or severe hydraulic system damage may result. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is warm (Fig. 39). 2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. 7. Install cap on filler neck. 3.
Hydraulic Linkage Adjustments 9. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 35. Perform the following linkage adjustments when the machine needs maintenance or set–up for the first time. 10. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Do not overfill.
Temporary Neutral Stud Adjustment Side View 12 3 9 4 1. Move the left and righthand neutral lock latches to the unlatched position (Fig. 11). 1 6 2. Move the speed control lever to the neutral position (Fig. 42). 1 3. Loosen the nut against the yoke (Fig. 45). 3 4. Adjust the length of the neutral stud and yoke assembly so the clevis pin does not contact the back of the slot in the control arm bracket (Fig. 45). 2 5. Tighten the nut against the yoke (Fig. 45). 4 2 5 1 m–6607 Figure 43 1.
1 Warning 2 Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. Back View • Use jack stands when supporting the machine. • Do not use hydraulic jacks. 4 Adjusting the Left Side Hydro Control Linkage 90 Degrees 3 2 m–6606 Warning Figure 46 1. Hydro control linkage 2. Swivel Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place. 3. Incorrect position 4. Correct position 8.
10. Repeat adjustment if needed. 11. Tighten the front nut on left hydro control linkage shown in figure 47. 1 1 3 3 2 2 5 m–5396 Figure 48 1. Speed control lever 2. Rear pivot spring 3. spring 4 m–6605 Figure 49 Right Side Linkage Adjustment 1. Hydro control linkage 2. Quick track knob 3. Spring 1. With the machine on jack stands, place the speed control lever in the neutral position (Fig. 42). 4. 1 inch (26 mm) 5. Nut in front of spring 2.
Adjusting the Control Rod Checking the Control Rod 1 1. With rear of machine still on jack stands and engine running at full throttle, move the speed control lever to the medium speed position. 3 Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 7 5 4 8 2. Move the respective drive lever upward until it reaches the neutral position and engage neutral locks. 2 6 3.
Note: Make sure the clevis pins are inserted into the neutral locks. Servicing the Brake 7. Repeat this adjustment for opposite side. Service Interval/Specification Before each use, check brake for proper operation. 2 Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. 7 8 5 1 Checking the Brake 6 1. Park the machine on a level surface. 3 4 2. Disengage the PTO and set the parking brake. 3.
2 8 1 1 2 5 3 1 5 3 m–2600 4 Figure 55 1. Adjusting nut 2. Slot 7 3. Feeler gauge m–6614 Figure 54 1. Yoke 2. Parking brake lever (released position) 3. Clevis pin 4. Hairpin cotter 5. 6. 7. 8. Jam nut Brake rod Lower brake lever 1 o’clock position Servicing the Cutting Blades 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.
Inspecting the Blades 1. Inspect the cutting edges (Fig. 56). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 43. MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2. Inspect the blades, especially the curved area (Fig. 56). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 56), immediately install a new blade. m–2539 Figure 58 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. 59). 3 2 2. Install the lock washer and blade bolt (Fig. 59). Torque the blade bolt to 85–110 ft-lb (115–140 N m). Correcting the Mower Quality of Cut 1 4 6 5 If one deck blade cuts lower than the other, correct as follows. m–5199 Figure 59 1. Sail Area of Blade 2. Blade 3. Blade spindle Note: Tire air pressure is critical in these procedures.
8. Tighten the carrier frame mounting bolts on both sides of the machine. 6 A 4 1 5 2 3 3 2 A B 4 m–6369 3 4 m–5237 Figure 63 1. Back view of machine 2. Top of engine deck 3. Tires Figure 62 1. Carrier Frame 2. Top of engine deck 3. Carrier frame mounting bolts 1 4. Location A, 1–5/16 inch (33 mm) ±1/4 inch (6 mm) 5. Straight edge 6. Carrier frame cross tube 4.
5 3 Checking the Deck Front-to-Rear Pitch 24 in. (61cm) 1. Check the tire pressure on both deck and traction unit. 2. Position one blade front-to-rear (Fig. 66). Measure at C and D locations (Fig. 66) from a level surface to the cutting edge of the blade tips (Fig. 67). 5 A B 2 4 4 3. The mower blade should be 1/4 inch (6 mm) lower in front at C than in the rear at D. Rotate blades and repeat for other blades. If it is not correct, proceed to Changing the Deck Front–to–Rear Pitch.
3 2 4 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2550 Figure 70 5 Changing the Side-to-Side Leveling m–6371 1 Figure 68 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins Changing the side–to–side leveling is done by adjusting tire pressure. 4. Jam nut 5. Ball joint Changing the Side–to–Side Leveling with Tire Pressure 4. Position the blades front-to-rear (Fig. 66). Measure at C and D locations (Fig. 66) from a level surface to the cutting edge of the blades (Fig. 67). 1.
Front 8. Reinstall the PTO drive belt. Refer to Replacing the PTO Drive Belt page 47. A 9. Adjust deck belt guide an 1/8 inch (3 mm) from belt (Fig. 73). 10. Reinstall the deck covers onto the cutting unit, then reinstall and tighten the knobs. 11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. m–1078 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 4 3 Figure 71 m–2550 Figure 72 3 5 6 5.
8. Adjust PTO drive belt guides an 1/8 inch (3 mm) from belt (Fig. 74). 1 2 9. Install the belt covers onto the cutting unit, then install and tighten the knobs. 3 10. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 2 5 3 6 1 4 m–6372 2 Figure 75 1. Locking Pin 2. Spacers (locate as required) 5 4 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 76). Clean the inside of the mounting tube. m–6529 Figure 74 1.
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 PTO Switch (Off) 1 2 PK W PINK BK BLACK PK 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 Y 1 2 + BK BK K1 Interlock Relay W HR MTR – Operator Presence Switch (No Operator) REG AC 5 3 4 Y AC PK PK D1 Park Brake Switch (On) HR MTR Y T MOD SPARK PLUG MAG KEY SWITCH (OPEN = ON) (CLOSED = OFF)
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 51
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 the Fuel Tank, page 32. 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 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.
