Form No. 3327-570 Mid–Size Mower ProLine Gear 15 hp with 48 Side Discharge Mower Model No. 30523—Serial No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake and Neutral Locks . Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . Operating the Blade Control (PTO) Lever . . . . . . Understanding 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. This machine meets or exceeds the B71.4–1999 specifications of the American National Standards Institute in effect at the time of production.
• 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.
Toro Mower Safety • Use slow speed so that you will not have to stop while on the slope. The following list contains safety information specific to Toro products and other safety information you must know. • Use extra care with grass catchers or other attachments. These can change the stability of the machine. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. • Keep all movement on slopes slow and gradual.
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. 1-403005 66-1340 67-5360 54-9220 95-2814 63-8440 1.
99-3943 95-5537 1. Engine 1. Read the Operator’s Manual for instructions on operating the cutting blade 2. Push forward to engage 3. Pull back to disengage 105-4104 1. Reverse 2. Neutral 3. Transmission speeds 98-0776 105-4111 98-5130 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 75-80 ft.-lb.(102-106 N⋅m). 106-2733 1. Fast 2. Continuous variable setting 10 3.
106-2737 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 11 6. Warning—wear hearing protection.
Gasoline and Oil Warning Recommended Gasoline Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Use leaded regular gasoline if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and fuel tank or conditioner opening. • Keep gasoline away from eyes and skin.
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. DESCRIPTION QTY. Caster assemblies 2 Bolt, 3/8 x 3/4 in. 8 Flange nut, 3/8 in. 8 Upper handle 1 Flanged bolt, 3/8 x 1 in. 4 Flanged nut, 3/8 in. 4 Wire tie 2 Clevis pin 2 Washer 2 Hairpin cotter 2 Fuel tank 1 Bolt, 5/16 x 3/4 in. 2 Lock washer, 5/16 in. 2 Locknut 2 Washer, 5/16 in.
4. Secure each side of the handle to the rear frame (using the lower mounting hole) with a flange bolt (3/8 in. x 1 in.) and a flange nut (Fig. 3). 1 Note: If you change the handle position, you must readjust the control rods and brakes. 5. Route the wire harness along the inside of the left handle and under the control panel (Fig. 13). 3 2 6. Connect the right-angled insulated terminals to the switch (Fig. 4). m–3777 Figure 2 1. Front caster 2. Bolt, 3/8 x 3/4 in. 1 2 3. Flange nut, 3/8 in.
6 4 1 4. Install the control rod to the drive lever and the neutral/parking brake lock. Secure the control rod with a clevis pin and a hairpin cotter. 3 5. Check the operation of the control rod. If you need to adjust it, remove the hairpin cotter and the clevis pin that secure the control rod to the drive levers. 5 6. Adjust the control rod length by repeating steps 3 and 4 (Fig. 6).
Installing the Blade Control (PTO) Rod 2. Slide the shift lever through the control panel, and align the mounting hole in the shift lever with the square on the transmission shaft (Fig. 9). 1. Rotate the blade control (PTO) lever vertically away from the left handle so that the blade control (PTO) rod drops down (Fig. 8). 3. Secure the lever to the transmission with the spring washer and locknut you previously removed (Fig. 9). 4. Install the spring washer (dish down) and the locknut (Fig. 9). 1 5.
3. Push the fuel line onto the fuel tank fitting, and secure the fuel line with a hose clamp (Fig. 11). Operation Note: Determine the left and right sides of the machine from the normal operating position. 3 Think Safety First 2 1 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. m–3778 Figure 11 1. Fuel line 2. Hose clamp Caution 3.
Controls respectively. The sharpness of the turn depends on how much you squeeze the drive lever. To move the mower straight forward (or backward), smoothly release both drive levers simultaneously. Become familiar with all the controls (Fig. 13) before you start the engine and operate the machine. 1 10 7 Neutral/parking brake locks—Squeeze the drive levers back and move the locks rearward to activate the neutral lock.
2. Place your thumbs on the upper part of the locks and move them rearward until they are in the Drive position (Fig. 14). Note: If the engine has been working hard or is hot, let it idle for a minute before stopping it to help cool it. Setting the Neutral Locks 3. Set the parking brakes. 2. Turn the ignition key to the Off position. 4. Disconnect the wires from the spark plugs to prevent someone from accidentally starting the machine while transporting or storing it. 1.
• The blade control (PTO) lever is disengaged. Driving Forward • The machine is shifted into the Neutral position. 1. Ensure that the parking brakes are engaged. • The ignition key is in the Run position. 2. Squeeze the OPC levers against the handles. The safety interlock system is designed to stop the engine when: 3. Move the shift lever into a forward gear. 4. Release the parking brakes; refer to Releasing the Parking Brakes, page 18.
Transporting the Mower 3. Disengage the neutral/parking brake locks, and release the drive levers to reduce the spring force. Use a heavy-duty trailer or truck to transport the mower. Ensure that the trailer or truck has all the 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. 4. Remove the drive spring from the adjustment bolt (Fig. 15).
1. Disengage the blade control (PTO) lever and set the parking brakes. 1 2 A 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. B C D 3. Hold the blade bolt and remove the nut (Fig. 16). E 6 m–3789 5 4 4 Figure 17 1. Axle pivot bolt 1 3 4. Place a jack under the rear center of the engine frame. Raise the back end of the engine frame up enough to remove the front 2 axle adjustment bolts (Fig. 17). 2 5.
Height-of-Cut Chart No. of Spacers Below Caster Axle Position 1/2 in. (13mm) 3/16 in. (5 mm) A 0 A Number of 1/4 in. Blade Spacers Below Spindle 4 3 2 1 0 0 1 in. (26 mm) 1–1/4 in. (32 mm) 1–1/2 in. (38 mm) 1–3/4 in. (45 mm) 2 in. (45 mm) 0 1 1–1/8 in. (29 mm) 1–3/8 in. (35 mm) 1–5/8 in. (41 mm) 1–7/8 in. (48 mm) 2–1/8 in. (55 mm) A 1 0 1–3/8 in. (35 mm) 1–5/8 in. (41 mm) 1–7/8 in. (48 mm) 2–1/8 in. (55 mm) 2–3/8 in. (55 mm) B 0 1 1–3/8 in. (35 mm) 1–5/8 in.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important Refer to your engine operator’s manual for additional maintenance procedures.
Caution Someone could accidently start the engine and seriously injure you or other bystanders. Disconnect the wires from the spark plugs before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Servicing the Cutting Blades 2. Inspect the blades, especially the curved area (Fig. 19). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 19), immediately install a new blade.
2 Warning 1 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. m–1854 • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of the blade. Figure 23 1. Sharpen at original angle 2. Sail 2. Check the balance of the blade by putting it on a blade balancer (Fig. 24). If the blade stays in a horizontal position, the blade is balanced and can be used.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Important worn. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Pull out the retaining locks and remove the air cleaner cover (Fig. 25). Cleaning the Paper Element Replace the foam element if it is torn or 1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 27). 4.
Oil Type: Detergent oil (API service SE/CC, SE, SF, or SG) Important Do not overfill the crankcase with oil and run the engine; engine damage can result. Crankcase Capacity: with filter, 57.5 oz. (1.6 l); without filter, 51 oz. (1.4 l) Changing the Engine Oil Viscosity: Refer to the table below 1. Start the engine and let it run five minutes. This warms the oil so that it drains better. USE THESE SAE VISCOSITY OILS 2. Stop the engine, remove the key, and wait for all moving parts to stop. 3.
1 1 2 m 4294 m 4288 Figure 30 1. Oil filter Figure 31 2. Adapter 1. Spark-plug (2) 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 30). 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 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. 30). 5.
Installing the Spark Plugs Applying the Grease 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 1. Disengage the blade control (PTO) lever and set the parking brakes. 2. Tighten the spark plugs to 11 ft.-lb. (15 N.m). 2. Clean the grease fittings with a rag and scrape any paint from the front of the fittings. 3. Connect the wires to the spark plugs (Fig. 31). 3.
3. To adjust the brakes, rotate the wing nuts on the brake rods (Fig. 37). Rotate the wing nuts clockwise to tighten the brakes; rotate them counterclockwise to loosen them. 2 1 m–4731 Figure 36 m–5372 Servicing the Brakes Figure 37 Service Interval/Specification 1. Brake rod Before each use, check the brakes for proper operation. 2. Wing nut Always set the parking brakes when you stop the machine or leave it unattended. If the parking brakes do not hold securely, adjust them. 4.
2. Disengage the blade control (PTO) lever and set the parking brakes. 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 3. Close the fuel shut-off valve in fuel line (Fig. 38). 7. Open the fuel shut-off valve at the fuel tank (Fig. 38). 8. Check for fuel leaks and make any needed repairs. Checking the Belts Service Interval/Specification 3 2 Check all belts after every 50 operating hours or monthly, whichever occurs first.
Replacing the Traction Belt 3. Remove the knobs and the belt cover on the mower. 4. Remove the idler pulley and the worn belt (Fig. 40). 1. Disengage the blade control (PTO) lever and set the parking brakes. 5. Install the new mower belt. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6. Install the idler pulley. 7. Engage the blade control (PTO) lever and check the belt tension. Refer to Adjusting the Mower Belt Tension, page 34. 3.
10. Remove the hairpin cotter and the clevis pin from the bell crank. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 11. Rotate the clevis clockwise on the rod to increase the clearance; rotate it counterclockwise to decrease it (Fig. 42). 3. Loosen the locknut on the turnbuckle (Fig. 43). 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt.
4 Adjusting the Grass/Mud Scraper 3 5 2 1. Loosen the locknut that holds the scraper to the engine frame (Fig. 45). 3 2 1 6 m-3781 Figure 46 1. Deflector 2. Spring 3. Deflector mount 1 m-3776 Figure 45 1. Scraper 2. Locknut 4. Locknut 5. Bolt 6. Spacer 2. Straighten the deflector mounts if they are bent (Fig. 46). 3. Pulley 3. Install a new deflector between the mounts with a spacer and a spring. 2. Rotate the scraper until it aligns with the center of the pulley grooves (Fig. 45). 4.
DELTA MODULE (2001)) INTERLOCK MODULE 36 F E D C B A GN R BN BK OR BK R Y (SWITCH CLOSED WHEN IN OFF POSITION) SW4 IGN SWITCH SW2 NEUTRAL SWITCH GN OPERATOR IS PRESENT) (SWITCH CLOSED WHEN Y SW3 OPERATOR PRESENCE SWITCH WHEN BLADE IS ENGAGED) WHEN IN NEUTRAL) GND MAG BK R OR BU BN (BLADE SWITCH OPENS (NEUTRAL SWITCH CLOSES SW1 BLADE SWITCH OR BLUE BU SPARK PLUG YELLOW SPARK PLUG ORANGE RED IGNITION MODULES R BROWN BN GREEN Y BLACK BK WIRE COLOR CODES Wiring Diag
Cleaning and Storage 14. Paint all scratched or bare metal surfaces with paint available from an Authorized Service Dealer. 1. Disengage the blade control (PTO) lever and set the parking brakes. 15. Store the machine in a clean, dry garage or storage area, and cover it to protect it and keep it clean. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing.
Troubleshooting Problem The engine g will not start, starts h d or ffails hard, il to kkeep running. i The engine g loses power. The engine g overheats. Possible Causes Corrective Action 1. The fuel tank is empty. 1. Fill the fuel tank with gasoline. 2. The ignition key is in the Off position. 2. Turn the ignition key to the Run position. 3. The choke is not on. 3. Set the throttle control to the Choke position. 4. The blade control (PTO) lever is engaged. 4.
Problem The machine does not drive. There is abnormal vibration. The cutting g height g is uneven. The blades do not rotate. The blades do not stop when they are disengaged. g g Possible Causes Corrective Action 1. The shift lever is in the Neutral position. 1. Move the shift lever to a drive gear position. 2. The traction belt is worn, loose, or broken. 2. Change the belt. 3. The traction belt is off the pulley. 3. Change the belt. 1. The cutting blades are bent or unbalanced. 1.
The Toro Total Coverage Guarantee LCE A One-Year 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 any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.
