Form No. 3350–757 Mid–Size Mower ProLine Gear 17 HP with 52in Side Discharge Mower Model No. 30438—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Installing the Hairpin Cotter Pins and Spacers . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake and Neutral Lock . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . . Operating Mower Blade Control (PTO) . . . . . . . . The Safety Interlock System . . . . . . . . . . . .
The Toro Total Coverage Guarantee . . . . . . . . . . . . . . This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Page 52 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.
• 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. • Use only an approved container • Be aware of the mower discharge direction and do not point it at anyone. • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Do not operate the mower under the influence of alcohol or drugs.
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. General Operation • Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area. • Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service. • Use only Toro-approved attachments.
Slope Chart Fold along appropriate line Example: Compare slope with folded edge. Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.
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.
98-4387 1. Warning—wear hearing protection.
106-0635 106-5501 1. Choke 2. Fast 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. 8. Hour meter 9. To park, move the controls as illustrated. 10. To drive, move the controls as illustrated. 4. Stop the engine and pick up debris before operating. 5. Cutting of hand or foot, mower. 6. Engine—stop 7. Engine—run 11 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.
Set Up Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to identify parts for assembly. Step 1 2 3 4 5 6 7 8 Description Qty.
Step 3 4 1 4 2 Removing the Shipping Bracket 1 5 m–7678 Figure 3 Parts needed for this step: 1. Center Gage Wheels and Spacer 2. Nut None 3. Bolt 4. Washer 5. Spacer Procedure 1. Remove the center gage wheel nut, 2 large washers, angle bracket and 1 small washer (Fig. 2). Discard the 2 large washers and the angle bracket. Step 2 5 Installing the Handle Assembly 3 1 2 Parts needed for this step: 3 4 Qty.
2 3 1 Step 3 4 5 6 7 Installing the Fuel Tank 8 Parts needed for this step: m–6591 Figure 4 1. 2. 3. 4. Upper handle Rear frame Flange nut, 3/8 inch Flange bolt, 3/8 x 1 inch 5. 6. 7. 8. Qty. Upper mounting hole Lower mounting holes Low position High position Note: Handle assembly must be installed before fuel tank is installed.
Procedure m–3771 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. 8). 2. If clearance is not correct, remove lever and bend it slightly to adjust (Fig. 8). 4 3 2 1 3 6 5 5 6 4 Figure 5 1. Bolt, 5/16 x 7/8 inch 2. Lock washer, 5/16 inch 3. Washer, 5/16 inch 3 4. Stud 5. Spring 6. Locknut 1 2 Note: Remove the plastic cap from the fuel fitting before installing the fuel line.
Step 6 5 5 4 Installing the Control Rods 1 Parts needed for this step: Qty. 2 3 m–7669 Figure 10 Part 1. Control rod 2. Drive lever 3. Hairpin cotter 2 Control rods 2 Cotter pin 2 Clevis Pin 2 Washer 2 Hairpin cotter pin 4. Clevis pin 5. Handle 6. Neutral/parking brake lock 4. Loosen the turn buckle wing nut (Fig. 11). 1 Procedure 2 3 1. Install control rods into the bell cranks and secure them with the hairpin cotters (Fig. 9).
3 2 2 3 1 1 5 m–7584 6 Figure 13 4 1. Hairpin cotter 2. Spacer m–6582 3. Height–of–cut post (rear shown) Figure 12 1. Handle 2. Neutral/Parking brake lock 3. 3/16 inch to 1/4 inch (5 mm to 6 mm) clearance 4. Drive lever 5. Drive position 6. Control Rod 3. On the opposite side of the muffler, install unused spacers onto front and rear height–of–cut pins and insert the hairpin cotter pins (Fig. 14). 3 2 Step 1 6 m-6505 Figure 14 1. Hairpin cotter 2.
Drive levers – Shift to desired gear and release drive levers to engage traction operation and squeeze them back to disengage the drive. 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 2 Always set the parking brake when you stop the machine or leave it unattended. 6 Setting the Parking Brake 1 5 1. Squeeze the drive levers back to the grip (Fig. 17). 4 2. Place thumbs on the upper part of the locks and rotate them forward (Fig. 17). m–7559 3. Release the drive levers. Figure 18 1. Handle 2. Neutral/Parking brake lock 3. Park position 2 3 4. Drive lever 5. Full speed forward position 6. Grip Releasing the Neutral Lock 6 1 3 5 1.
Stopping 3 2 1. Move the throttle lever to the Slow position (Fig. 19). 1 2. Let engine idle for 30 to 60 seconds before turning the ignition key to off. 3. Set the parking brake. 4. Turn the ignition key to the Off position (Fig. 19). 2 m–6581 Figure 20 1. Handle 2. Operator Presence Control levers (OPC) 3. Power take off switch (PTO) 1 Disengaging the Mower Blades (PTO) m–6581 1. Release Operator Presence Control (OPC) levers to disengage blades (Fig. 20). This will also kill the engine.
• The power take off switch (PTO) is pulled on without holding the OPC levers. Testing the Safety Interlock System Test the safety interlock system before each use of the machine. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately. 1 1. Set the parking brake and place shift lever in neutral. Start the engine; refer to Starting and Stopping the Engine, page 20. 2 m–6581 Figure 21 2.
Adjusting the Height-of-Cut Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 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. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Adjusting the Gage Wheels 3 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. 4 4 2 1. After adjusting height-of-cut, check the gage wheels so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figures 23, 24, and 25). 2. If adjustment is needed, remove the bolt, washer(s) and nut (Figures 23, 24, and 25). 1 5 3.
6. Check the parking brake adjustment; refer to Checking the Brakes, page 34. Using the Mid–Size Weight This machine includes a weight installed in the rear position (Fig. 27). • The weight mounted in the rear position is recommended, except when a Tru–Trak Sulky is installed. • The weight mounted in the back position, must be removed when the when a Tru–Trak Sulky is installed.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Servicing the Air Cleaner 6 2 Service Interval/Specification Foam element: Clean it after every 25 operating hours. 3 Paper element: Clean it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. 4 Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. Important 5 Do not oil the foam or paper element. Removing the Foam and Paper Elements 1 1.
Installing the Foam and Paper Elements 4. Clean around the oil dipstick (Fig. 29) so that dirt cannot fall into the filler hole and damage the engine. Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 2 1. Carefully slide the foam element onto the paper air cleaner element (Fig. 28). 1 2. Place the air cleaner assembly onto the air cleaner base and secure it with the nut (Fig. 28). 3.
2 1 1 2 m–7451 Figure 30 1. Oil drain valve Figure 32 2. Drain hose 1. Oil filter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 32). 4. Install the replacement oil filter to the filter adapter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 32). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 28. 1 6.
2. Tighten the spark plugs to 16 ft-lb (22 N m). 1 3. Connect the wires to the spark plugs (Fig. 33). Cleaning the Cooling System Clean the air intake screen from grass and debris before each use. Check and clean cooling fins and engine shrouds every 100 hours or yearly, which ever comes first. 1. Disengage the PTO and set the parking brake. m–7453 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 33 1. Spark-plug wire/spark plug 3.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. m–6367 Where to Add Grease Figure 37 1. Lubricate the grease fittings as show on the Check Service Reference Aid decal (Fig. 36).
Servicing the Fuse Service Interval/Specification 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. 41) and push in new fuse. m–5196 Figure 39 Checking the Tire Pressure 1 Service Interval/Specification m–7676 Figure 41 Maintain the air pressure in the front and rear tires as specified.
5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the valve to secure the fuel line. 2 1 3 2 m–2600 Figure 42 1. Adjusting nut 2. Slot 1 3. Feeler gauge m–5235 Figure 43 1. Fuel shut-off valve 2. Clamp Servicing the Fuel Tank Servicing the Fuel Filter Danger Service Interval/Specification In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.
1 5 3 4 2 1 3 1 2 6 m–7545 Figure 44 1. Hose clamp 2. Fuel line m–6595 Figure 45 1. Position A, New belt 2. Position B, Low belt wear 3. Position C, Medium belt wear 3. Filter Adjusting the Traction Drive Belt Tension 4. Position D, Most severe belt wear 5. Spring 6. Adjustment bolt, In position A Servicing the Brakes It may be necessary to increase the drive belt tension as the belt wears. Service Interval/Specification 1. Stop engine and remove spark plug wire(s).
Note: For the initial adjustment, adjust the wing nut until it is 1–1/4 inches from the top of the rod (Fig. 46). 5 3 7 1. Park the machine on a level surface, disengage the PTO, and set the parking brake. 8 4 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the brake before you adjust it; refer to Checking the Brakes, page 34. 4. Release the parking brake; refer to Releasing the Parking Brake, page 20. 6 5.
3 2. Inspect the blades, especially the curved area (Fig. 48). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 48), immediately install a new blade. 2 1 5 6 1 2 4 m–6582 Figure 47 1. Handle 2. Neutral/Parking brake lock 3. 3/16 inch to 1/4 inch (5 mm to 6 mm) clearance 3 4. Drive lever 5. Drive position slot 6. Control Rod m–151 Figure 48 1. Cutting Edge 2. Curved Area 3.
Sharpening the Blades 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 37. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 52). Maintain the original angle.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Disconnect the spark plug wire(s) from the spark plug(s). 6 A 4 1 5 2 3. Adjust the tire pressure in all tires to specifications on page 32. 4. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 36. 5. Set the height-of-cut to the 4 inch (101.6 mm) position. Refer to Adjusting the Height-Of-Cut in the Operation section. m–6369 3 6.
Checking Carrier Frame Front–to–Rear Pitch 5. Measure carrier frame height at location B (Fig. 57). 6. If the carrier frame height is not the same move spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level. The carrier frame must have a pitch of a 1/4 inch (6 mm) over the length of 24 inches (61 cm) on the carrier frame (Fig. 56). 1. Measure out 24 inches (61cm) on the carrier frame (Fig. 56). 5 3 2 5 2 2.
Checking the Deck Side-to-Side Leveling 1. Check the tire pressure on both deck and traction unit. MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2. Position the blades side-to-side (Fig. 61). Measure at A and B locations (Fig. 61) from a level surface to the cutting edge of blade tips (Fig. 62). m–2539 Figure 59 3. The difference between measurements A and B should be no more than 1/4 inch (6 mm).
Matching Height of Cut 3. Raise the wheel off the ground, to allow the belt to be removed, and remove the belt. 1. Check the tire pressure on both deck and traction unit. 4. Install a new belt. 2. Set the height-of-cut to the 4 inch (101.6 mm) position following the height-of-cut decal. 5. Install the top capscrew securing the idler support and idler bracket to the rear frame (Fig. 65). 3. With the machine on level surface, position one blade front-to-rear (Fig. 63).
11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. 12. Connect clutch wire connector to wire harness. 13. Install PTO drive belt. 3 4 3 1 4 5 7 2 6 8 m–5321 6 Figure 66 1. 2. 3. 4. Transmission belt Idler pulley Clutch retainer Tension spring 5. 6. 7. 8. 3 5 Clutch wire connector Pivot bolt Drive pulley Engine deck 1 2 m–6530 Figure 67 1. Deck belt 2. Idler arm spring 3. Outside pulley Replacing the Mower Belt 4. PTO drive Belt 5.
5 3 6 1 1 2 3 2 2 4 5 4 m–6530 m–6372 Figure 68 1. PTO engagement pulley 2. PTO drive belt idler 3. PTO drive Belt Figure 69 4. Center Spindle Pulley 5. PTO Drive belt guide 6. Idler Spring 1. Locking Pin 2. Spacers (locate as required) 3. Carrier frame mounting tube 4. Caster wheel fork Replacing the Caster Wheel Fork Bushings 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 70). Clean the inside of the mounting tube.
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.
WIRE COLOR CODES Pistol Grip M.S.
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 Draining the Fuel Tank, page 33, 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.
