Form No. 3350–745 Mid–Size Mower ProLine Hydro 15 HP with 44in Side Discharge Mower Model No. 30439—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Installing the Hairpin Cotter Pins and Spacers . . 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 . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . .
• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • Never operate with the PTO shield, or other guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.
• Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. • Remove spark plug wire before making any repairs. • 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. • Mow slopes side to side. • Do not mow slopes greater than 15 degrees. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
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.
5-4146 98-4387 1. Warning—wear hearing protection.
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 1. Choke 2. Fast 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 identify parts for assembly. Step 1 2 3 4 5 6 7 8 9 10 Description Qty.
Step 3 4 1 Removing the Shipping Bracket 1 4 2 m–6510 Figure 3 Parts needed for this step: 1. Center Gage Wheels and Spacer 2. Nut None 3. Bolt 4. Washer Procedure 1. Remove the center gage wheel nut, 2 large washers, angle bracket and 1 small washer (Fig. 4). 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. m–7585 Figure 2 1. Center Gage Wheels and Spacer 2. Nut 3. Large washer—discard 4.
4. Secure the handle at each lower mounting hole with a flange bolt (3/8 x 1 inch) and flange nut (Fig. 4). Step 3 Note: The handle position can be adjusted to match the operator ’s height preference. 7 8 9 5 4 Installing the Fuel Tank 1 Parts needed for this step: 3 2 Qty. 6 m–6600 Figure 4 1. 2. 3. 4. 5. Handle assembly Rear frame Flange nut, 3/8 inch Flange bolt, 3/8 x 1 inch Upper mounting hole 6. 7. 8. 9.
Note: Make sure the fuel line and clamp are on as shown in Figure 6. Step 4 1 2 3 Installing the Control Rods m–6504 Figure 6 1. Fuel line 2. Clamp Parts needed for this step: 3. Fuel tank connection Qty. Part 2 E–ring 4. Secure the right side of the fuel tank to the rear frame (Fig. 7) with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 7). Procedure 5. Secure the left side of the fuel tank to the rear frame (Fig.
4. Install hairpin cotter pins between drive levers and neutral locks and into clevis pins (Fig. 9). 6 1 4 2 1 3 4 3 2 5 5 7 3 6 m–6639 m–6602 Figure 9 1. 2. 3. 4. Left handle shown Neutral lock Clevis pin Drive lever Figure 10 5. Control rod 6. Operator Presence Control lever (OPC) 7. Hairpin cotter pins 1. Speed control rod 2. Swivel 3. Nut 4. Speed control crank 5. Cotter pin 6.
2. Install a spacer onto both rear height–of–cut posts and install the hairpin cotter pins. Step 8 2 3 1 Checking the Hydraulic Fluid and Engine Oil m–7584 Figure 11 1. Hairpin cotter 2. Spacer Parts needed for this step: 3. Height–of–cut post (rear shown) None Procedure 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. 12). Check the hydraulic fluid level before the engine is first started.
Checking the Temporary Neutral Stud Adjustment 1 2 Refer to Temporary Neutral Stud Adjustment on page 38. Checking the Hydro Control Linkages Figure 13 Refer to Adjusting the Hydro Control Linkages on page 38. 1. Caution 2. Wear hearing protection Checking the Neutral Stud Refer to Adjusting the Neutral Stud on page 40. Controls Checking the Control Rods Become familiar with all the controls (Fig. 14) before you start the engine and operate the machine.
4. Grasp the recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly. Perform any recommended maintenance at these intervals. Refer to Recommended Maintenance Schedule on page 27. Note: Make sure maintenance is done at all recommended intervals shown in the Recommended Maintenance Schedule on page 27.
2 Caution 7 1 5 Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 6 3 4 m–7553 Setting the Parking Brake Figure 16 1. 2. 3. 4. Handle Neutral lock Neutral position Drive lever 1. Pull the brake handle rearward (Fig. 17). 5. Grip 6. Forward slot 7. Reverse position 2 1 Releasing the Neutral Lock 1.
3 • The speed control lever is shifted out of neutral with the parking brake set. 2 • The blade control switch (PTO) is pulled on without holding the OPC levers. 1 Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately. 4 m–6638 1. Set the neutral locks and place speed control lever in neutral.
To go straight, release drive levers equally (Fig. 20). Caution To turn, squeeze the drive lever on the side and direction you want to turn (Fig. 20). Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 2 Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
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. 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.
Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter. 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 1 3 5 4 1 Figure 23 1. Gage wheel 2. Nut 3. Bolt 5 1 m–6470 4. Washer 5. Spacer m-4856 2 4 3 4 2 m–5230 1 4 Figure 22 1. Carrier Frame 2. Hairpin Cotter 3. Front height–of–cut post 4. Spacers 5. Back height–of–cut post Figure 24 1. Center Gage Wheels and Spacer 2.
Adjusting the Handle Height 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. The handle position can be adjusted to match the operator ’s height preference. 7 Note: 8 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Fig. 25). 9 4 6 1 4 5 1 3 2 6 2 3 m–6600 5 Figure 27 m–6639 1. 2. 3. 4.
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 6 2 Service Interval/Specification Foam element: Clean it after every 25 operating hours.
3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 3. Replace the paper element if it is damaged, or cannot be cleaned thoroughly. 4. Clean around the oil dipstick (Fig. 29) so that dirt cannot fall into the filler hole and damage the engine.
Note: Dispose of the used oil at a recycling center. 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. 31). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 29. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter. 7. Check the engine oil level and add oil if needed.
Checking the Spark Plugs 4. Clean the debris and grass from the engine parts. 1. Look at the center of the spark plugs (Fig. 33). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. 5. Install air intake screen, recoil starter and fan housing. 5 3 2. If needed, clean the spark plug with a wire brush to remove carbon deposits. 2 2 3 4 1 0.030 inch (0.75 mm) 1 m–7450 Figure 33 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 37 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.
Adjusting the Electric Clutch 2. Grease the bearings on both sides of the machine (Fig. 39). The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation. 1. To adjust clutch, tighten or loosen lock nuts on flange studs (Fig. 41). 2. Check adjustment by inserting feeler gauge thru slots next to studs (Fig. 41). 3. The proper disengaged clearance between the clutch plates is 0.012–0.024 inch (0.30-0.60 mm).
3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from fuel filter (Fig. 42). 6. Install a new filter and move the hose clamps close to the filter. 4. Pull the fuel line off the fuel filter (Fig. 42). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. 7. Open fuel shut-off valve at fuel tank (Fig. 42). 8. Check for fuel leaks and repair if needed. Note: Now is the best time to install a new fuel filter because the fuel tank is empty.
Replacing the Hydraulic Filter 4. If the fluid is low, add fluid to the reservoir until it reaches the cold level of the baffle. Warning 5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and heats the fluid. Refer to Starting and Stopping the Engine on page 20. Hot hydraulic fluid can cause severe burns. 6. Recheck the fluid level while the fluid is hot. If required, add fluid to the reservoir until it reaches the hot level of the baffle.
Checking the Hydraulic Lines 1 3 After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. 2 Note: Keep areas around hydraulic system clean from grass and debris build up. Warning m–1256 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 46 1. Hydraulic filter 2.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Side View 12 3. Move the speed control lever to the full forward position (Fig. 47). 3 9 4 1 6 2 1 3 4 1 2 3 5 4 2 m–6477 5 Figure 47 1. Speed control lever 2. Full speed position 3. Neutral position m–6607 Figure 48 4. Medium speed position 5. Control panel slot 1. Speed control rod 2. Nut 3. Speed control crank 4.
Adjusting the Hydraulic Control Linkages 12. To adjust the switch location, loosen the two neutral bracket screws holding the switch plate to the frame (Fig. 49). 13. Adjust the switch up or down to obtain an 1/8 to 1/4 inch (3 to 6 mm) space (Fig. 49). Warning 14. Tighten the two neutral bracket screws holding the switch plate (Fig. 49). Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.
5. Loosen the front nut on left hydro control linkage as shown in figure 52. 1 6. Turn the left rear adjusting nut counter–clockwise until wheel rotates forward (Fig. 52). 7. Turn the rear adjusting nut clockwise 1/4 of a turn at a time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Fig. 52). 3 2 Note: Make sure flat part of linkage is 90 degrees or perpendicular to pin part of swivel (Fig. 51). 1 2 m–6604 Figure 52 Back View 4 1.
Adjusting the Neutral Stud 4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Fig. 54). Warning 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. 54). Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers taped or fastened in the engaged position. 6.
Note: Make sure you have not reached the end of the neutral lock slot (Fig. 57). If you have, shorten the control rod. Refer to Adjusting the Control Rod on page 41. 6 1 4 6. If the wheel turns while holding the drive lever in neutral position, the neutral stud needs to be adjusted (Fig. 50). If the wheel does not rotate, then go to step 12. 2 7. Loosen the nut against the yoke (Fig. 55). 3 5 8.
Adjusting the Brake 3. Start and run the unit. Observe the tracking on a level, smooth, hard surface such as concrete or asphalt. The brake handle is on the left side of machine (Fig. 59). If the parking brake does not hold securely, an adjustment is required. 4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Fig. 58). 1. Check the brake before you adjust it; refer to Checking the Brake, page 42. 2.
Servicing the Cutting Blades Checking for Bent 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. 1. Rotate the blades until the ends face forward and backward (Fig. 61). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 62). Note this dimension.
Removing the Blades 2 Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1 m–1855 Figure 65 1. Blade 1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, washer, lock washer and blade from the spindle shaft (Fig. 63).
3. Place a long straight edge on top of the engine deck as shown in figure 66. 5. Measure engine deck height at location B (Fig. 67). 6. If the height at location A and B are not the same, change tire pressure slightly to make them the same. 4. At the carrier frame cross tube, measure location A height (Fig. 66). This measurement must be 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm). 3 3 5. If the height at location A is not correct, adjustment is needed. 6.
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. 70). Measure at C and D locations (Fig. 70) from a level surface to the cutting edge of the blade tips (Fig. 71). 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 74 5 Changing the Side-to-Side Leveling m–6371 1 Figure 72 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. 70). Measure at C and D locations (Fig. 70) from a level surface to the cutting edge of the blades (Fig. 71). 1.
4 3 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2550 Figure 76 5. If it does not measure correctly, add air pressure in rear tires to raise height–of–cut 3 5 6. If it does not measure correctly, decrease air pressure in rear tires to lower height–of–cut. 6 7. Check carrier frame front–to–rear pitch. 1 2 m–6529 Figure 77 Replacing the Mower Belt 1. Deck belt 2. Idler arm spring 3.
5 3 6 1 1 2 3 2 2 4 5 4 m–6529 m–6372 Figure 78 1. PTO engagement pulley 2. PTO drive belt idler 3. PTO drive Belt Figure 79 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 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 80). Clean the inside of the mounting tube. Replacing the Caster Wheel Fork Bushings 5.
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 52
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 33. 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.
