Form No. 3352–610 Mid–Size Mower ProLine Hydro 17 HP with 44 inch Side Discharge Mower Model No. 30440—Serial No. 250000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Installing the Hairpin Cotter Pins and Washers . . Checking the Tire Pressure . . . . . . . . . . . . . . . . . Activating the Battery . . . . . . . . . . . . . . . . . . . . . Checking the Hydraulic Fluid and Engine Oil . . Setting Up the Hydro Linkage . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Deck Front-to-Rear Pitch . . . . . . . Checking the Deck Side-to-Side Leveling . . . . . 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 . . . . . . . . . . . . . . .
• 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.
• Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. • 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. Slope Operation • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
• 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.
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.
5-4110 98-0776 105-4109 98-4387 1. Warning—wear hearing protection.
Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 106-5513 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
106-5501 1. Choke 2. Fast 3. Continuous variable setting 12 4.
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 Description Qty.
Step Description 10 11 Qty. Use No parts needed – Setting up the hydro control linkage Oil drain hose 1 Use for draining the engine oil Operator’s Manual 1 Read before operating machine Engine Operator’s Manual 1 Read before operating machine Safety Video 1 Watch before operating machine Parts Catalog 1 Registration card 1 Step Fill out and return to Toro 3 1 1 Removing the Shipping Bracket 1. Center Gage Wheels and Spacer 2. Nut None Procedure 1.
7 Step 2 9 8 5 4 1 3 2 Installing the Handle Assembly 6 Parts needed for this step: Qty. Part 1 Handle assembly 2 Flanged bolt, 3/8 x 1 inch 2 Flanged bolt, 3/8 x 1–1/4 inch 4 Flange nut, 3/8 inch 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.
3. Push the fuel line onto the fuel tank connection and secure it with the hose clamp that is on the fuel line (Fig. 6). Step 3 Note: To ease assembly of the fuel line to fuel tank connection, apply a light lubricant, such as WD 40, to the end of the fuel line. Note: Make sure the fuel line and clamp are on as shown in Figure 6. Installing the Fuel Tank Parts needed for this step: Qty.
5 6 7 3 2 3 4 2 5 1 1 4 m–6583 3 Figure 7 1. 2. 3. 4. Bolt, 5/8 x 7/8 inch Lock washer, 5/16 inch Washer, 5/16 inch Spring m–6601 5. Locknut 6. Hose clamp 7. Fuel tank connection Figure 8 1. Control rod 2. Rod fitting 3. 2–1/2 inch (63.5 mm) from bottom Step 4. E–ring 5. Control arm 3. Place the clevis pin into the control rod, drive lever and neutral lock (Fig. 9). 4 4. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Fig. 9).
Step Step 5 6 Installing the Speed Control Rod Installing the Hairpin Cotter Pins and Washers Parts needed for this step: Parts needed for this step: Qty. Part Qty. Part 1 Washer 2 Hairpin cotter pin 1 Cotter pin 6 Spacers Procedure Procedure 1. Install the swivel into the speed control crank and secure it with a washer and cotter pin (Fig. 10). Unused height–of–cut spacers may be stored on posts and retained by a hairpin cotter.
3 Step 8 2 1 Activating the Battery m-6505 Figure 12 1. Hairpin cotter 2. Unused spacers 3. Height–of–cut post (front shown) Parts needed for this step: Qty. 80 ounces Step 7 Part Bulk electrolyte with 1.265 specific gravity (Purchase from a battery supply outlet.) Procedure Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.
8. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 14). 2. Clean the top of the battery with a paper towel. Note: Never fill the battery with electrolyte while the battery installed in the machine. Electrolyte can be spilled on other parts and cause corrosion. 4 3. Remove the vent caps from the battery (Fig. 40). 2 4.
Operation Step 10 Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Setting Up the Hydro Linkage Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury. Parts needed for this step: The use of protective equipment for eyes, hearing, feet and head is recommended.
Note: Make sure maintenance is done at all recommended intervals shown in the Recommended Maintenance Schedule on page 30. Drive levers – Move the speed control lever to the desired forward speed, slowly release the drive levers to engage forward traction operation, and squeeze the drive levers to neutral or reverse. When moving forward, squeeze the right drive lever to turn right and the left drive lever to turn left.
6. 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 7 1 5 Stopping 1. Move the throttle lever to the slow position (Fig. 17). 2. Squeeze the drive levers to the Neutral position and set the neutral locks. 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.
If the parking brake does not hold securely, an adjustment is required. Refer to Servicing the Brake on page 47. 3 2 Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 1 4 Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. m–6638 Figure 21 1. Handle 2. Operator Presence Control levers (OPC) Setting the Parking Brake 1. Pull the brake handle rearward (Fig. 20).
Testing the Safety Interlock System 2 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. 1. Set the neutral locks and place speed control lever in neutral. Start the engine; refer to Starting and Stopping the Engine, page 23. 1 2. Without holding the Operator Presence Control (OPC) levers, pull the blade control switch (PTO) up. The engine should kill.
Note: The machine will not drive unless by-pass valves are closed. Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Transporting Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury.
Adjusting the Gage Wheels 1. To adjust, remove hairpin cotter from height-of-cut post (Fig. 24). 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. 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 25 and 26). 3 2. If adjustment is needed, remove the bolt, washer(s) and nut (Figures 25 and 26).
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 1. Remove the hairpin cotter pin and clevis pin from the drive lever and neutral lock (Fig. 27). 9 6 8 5 4 1 1 4 3 2 2 6 3 5 m–6600 m–6639 Figure 29 7 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.
4. Clean around the oil dipstick (Fig. 31) so that dirt cannot fall into the filler hole and damage the engine. 2. Replace the paper element if it is damaged or excessively dirty. Installing the Foam and Paper Elements 2 Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1 1. Carefully slide the foam element onto the paper air cleaner element (Fig. 30). 2.
2 1 1 2 Figure 32 1. Oil drain valve m–7451 Figure 34 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. 34). 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. 34). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 32. 1 6.
2. Tighten the spark plugs to 16 ft-lb (22 NS m). 1 3. Connect the wires to the spark plugs (Fig. 35). 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 35 1.
Fuse Service Removing the Battery Service Interval/Specification Warning 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. 38) to remove or replace it. Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.
3. Using the bolt and nut, connect the positive (red cover) cable to the positive (+) battery post (Fig. 39). Slide the rubber cover over the battery post. 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 36. 4. Using the bolt and nut, connect the negative (black) cable to the negative (–) battery post (Fig. 39). Slide the rubber cover over the battery post.
4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. Important Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 5. Wipe up any excess grease. 1. Remove the battery from the chassis; refer to Removing the Battery, page 35. Where to add Grease 2. Check the electrolyte level; refer to Checking Electrolyte Level, page 36.
Cleaning the Cooling System Greasing the PTO Drive Belt Idler and Deck Belt Idler Service Interval/Specification 1. Grease the idler pulley pivots (Fig. 44). 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 39. 3. The proper disengaged clearance between the clutch plates is 0.012–0.024 inch (0.30-0.60 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. 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 47 1.
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. 8. Check for fuel leaks and repair if needed. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Fig. 50). 1 7. Install cap on filler neck. 1 2 3 1 2 m–7545 4 Figure 49 1. Hose clamp 2. Fuel line 3 3. Filter m–5615 Servicing the Hydraulic System Figure 50 1. Cap 2. Baffle 3. Cold fluid level—full 4.
Change the hydraulic filter: • After the first 200 operating hours. 1 • Yearly, before storage. 3 1. Position machine on a level surface, stop the engine, and remove key from ignition switch. 2 Important Do not substitute automotive oil filter or severe hydraulic system damage may result. 2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. m–1256 Figure 52 3.
Checking the Hydraulic Lines 2 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. 4 1 Note: Keep areas around hydraulic system clean from grass and debris build up. 3 5 Warning m–6477 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 53 1. Speed control lever 2. Full speed position 3.
9. Check the travel of the shift lever in the control panel slot. The shift lever travel should be approximately centered in the control panel slot (Fig. 53). 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. 56). 10. If needed, adjust the swivel on the speed control rod to center the shift lever travel (Fig. 54). 5. Tighten the nut against the yoke (Fig. 56). 11.
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 57 1. Hydro control linkage 2. Swivel Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers taped or fastened in the engaged position. 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 58. 1 1 3 3 2 2 5 m–5396 Figure 59 1. Speed control lever 2. Rear pivot spring 3. spring 4 m–6605 Figure 60 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. 53). 2. Place the right drive lever in the full forward position (Fig. 63). 4. 1 inch (26 mm) 5.
Adjusting the Control Rods Checking the Control Rods 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 2 1 Before each use, check brake for proper operation. 8 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. Checking the Brake 6 3 5 7 1. Park the machine on a level surface. 2. Disengage the PTO and set the parking brake. 4 3.
2 Inspecting the Blades 8 1 1. Inspect the cutting edges (Fig. 66). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 49. 2. Inspect the blades, especially the curved area (Fig. 66). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 66), immediately install a new blade. 5 6 1 5 3 4 7 1 2 m–6614 Figure 65 1. Yoke 2. Parking brake lever (released position) 3. Clevis pin 4. Hairpin cotter 5. 6. 7. 8.
3 2 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2539 1 4 Figure 68 6 2. Rotate the opposite ends of the blades forward. 5 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. m–5199 Figure 69 1.
Installing the Blades 4. At the carrier frame cross tube, measure location A height (Fig. 72). This measurement must be 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm). 1. Install the blade onto the spindle shaft (Fig. 69). Important The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Fig. 69). 5. If the height at location A is not correct, adjustment is needed. 6. Loosen the carrier frame mounting bolts on both sides of the machine (Fig. 72).
5. If the carrier frame is not correct, move caster spacers to make it a 1/4–3/8 inch (6 –10 mm) pitch (Fig. 74). Move spacers from top or bottom to make the correct pitch. 3 3 6. The tire pressure may also be adjusted slightly to make a 1/4 inch (6 mm) pitch. A Checking Carrier Frame Side–to–Side B 1. Disengage the PTO and set the parking brake. 4 2 4 1 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. m–7554 Figure 73 1.
Checking the Deck Front-to-Rear Pitch 3 2 4 1. Check the tire pressure on both deck and traction unit. 2. Position one blade front-to-rear (Fig. 76). Measure at C and D locations (Fig. 76) from a level surface to the cutting edge of the blade tips (Fig. 77). 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. 5 Front C 1. Caster Wheel 2.
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. 81). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 81). 1. Check the tire pressure on both deck and traction unit. 2. Position the blades side-to-side (Fig. 79). Measure at A and B locations (Fig. 79) from a level surface to the cutting edge of blade tips (Fig.
5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt on page 54. 4. Remove the knobs holding the belt covers to the top of the cutting unit and remove the belt covers. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn deck belt (Fig. 83). 5. Remove the idler spring from idler arm. Remove the drive belt from the PTO engagement pulley and the center spindle pulley (Fig. 84). 7.
Replacing the Caster Wheel Fork Bushings 6. Inspect the caster wheel fork for wear and replace if necessary (Fig. 85). 7. Slide the caster wheel fork through the bushings in the mounting tube. Replace the spacer(s) onto the fork and secure with the retaining ring (Fig 85). The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the caster forks back and forth and side-to-side.
3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 88). 2 Important The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position. 1 2 4 8 6 3 3 5 4 3 1 m–5210 Figure 87 1. Locknut 2. Wheel Bolt 3. Bushing 4. Spanner Bushing 5. Roller Bearing 5 5. To assemble, place one bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub.
CLUTCH BK BN BK BN BK Hour Meter GN GN SW4 NEUTRAL Y (Out of Neutral) BN D1 7 GND PTO SWITCH (Shown Off) 4 1 + SW2 5 BK 2 – PK W 4 3 57 BK 1 KILL RELAY K1 PK SW5 Park Brake Switch (On) SW3 Operator Presence Switch (No Operator) OR GN W OR BU I R 5 S SOLENOID R 3 A R 4 B F2 25A VIO VIO 1 X R 2 Y F1 30A PK W R VIO I S 1 2 5 MAG START REG B+ A B KEY SW Y X T VIO W Y GREEN GREY ORANGE BU GN GY OR + SOLENOID FUEL AC AC SPARK PLUG – STARTE
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 58
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 fails to keep running. Engine g loses power. p 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. 6. Battery is dead. 5. Choke is not ON. 4. Move choke lever to ON. 7.
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. Machine drive is too aggressive. 1. By-pass valve is adjusted too far closed. 1. Adjust by-pass valve. Machine tracks left or right. g 1.
The Toro Total Coverage Guarantee A Limited Warranty Landscape Contractor Equipment (LCE) 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 product if defective in materials or workmanship.
