Form No. 3350-546 Mid–Size Mower ProLine Gear 15 hp with 48in Side Discharge Mower Model No. 30531—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Installing the Shift Lever . . . . . . . . . . . . . . . . . . . . Mounting the Fuel Tank . . . . . . . . . . . . . . . . . . . . . Installing the Muffler . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake and Neutral Locks . . Starting the Engine . . .
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 98-5954 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.
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. 14). 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 inch 1 2 3.
Installing the Control Rods 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. 1. Thread the rod fittings an equal distance onto each control rod (Fig. 5). 6. Adjust the control rod length by repeating steps 3 and 4 (Fig. 6). 6 4 1 3 Adjusting the Parking Brakes Refer to Servicing the Brakes, page 32 for checking the brakes and adjusting them. 5 Connecting the Throttle Cable 2 1.
6 Installing the Blade Control (PTO) Rod 5 1. Rotate the blade control (PTO) lever vertically away from the left handle so that the blade control (PTO) rod drops down (Fig. 8). 1 4 3 1 2 2 m–3772 Figure 9 1. Shift lever 2. Control panel 3. Rubber seal washer 3 4 4. Square hole washer 5. Spring washer 6. Locknut 3/8 m–3783 Figure 8 1. Blade control lever 2. Blade control (PTO) rod Adjusting the Shift Lever Plate 3. Bell crank 4. Hairpin cotter 1.
1 5. Push the fuel line onto the fuel tank connection and secure it with a hose clamp (Fig. 12). 2 2 3 4 1 Rear View 4 m–6442 Figure 12 2 3 1. Fuel line 2. Hose clamp Installing the Muffler m–7454 Figure 10 1. Shift lever, 2nd gear 2. Shift lever plate 3. Fuel fitting 1. Loosen the clamp (Fig. 13). 3. Shift lever, neutral 4. Equal distance 1 Mounting the Fuel Tank 1. Align fuel tank with the top of the rear frame (Fig. 11). 2.
Controls Operation Become familiar with all the controls (Fig. 14) before you start the engine and operate the machine. Note: Determine the left and right sides of the machine from the normal operating position. 10 1 5 2 7 Think Safety First 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.
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. 2. Place your thumbs on the upper part of the locks and move them rearward until they are in the Drive position (Fig. 15). Neutral/parking brake locks—Squeeze the drive levers back and move the locks rearward to activate the neutral lock.
Note: If the engine has been working hard or is hot, let it idle for a minute before stopping it to help cool it. • The blade control (PTO) lever is disengaged. 2. Turn the ignition key to the Off position. • The ignition key is in the Run position. • The machine is shifted into the Neutral position. 3. Set the parking brakes. The safety interlock system is designed to stop the engine when: 4.
Transporting the Mower 2. Squeeze the OPC levers against the handles. 3. Move the shift lever into a forward gear. 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. Release the parking brakes; refer to Releasing the Parking Brakes, page 19. 5.
Adjusting the Blade Height 2. Disconnect the wires from the spark plugs. 3. Disengage the neutral/parking brake locks, and release the drive levers to reduce the spring force. Adjust the blades by using the 4 spacers (1/4 inch) on the blade spindle bolts. This allows a range, in 1/4 inch (6 mm) increments, of cutting height in any axle position. Use the same number of blade spacers on all blades to achieve a level cut (2 above and 2 below, 1 above and 3 below, etc.). 4.
3. Install the caster in the support and insert the clevis pin (Fig. 19). 3. Loosen, but do not remove, the 2 axle pivot bolts and the 2 axle adjustment bolts (Fig. 18). 1 2 A B C D E m–3789 Figure 18 1. Axle pivot bolt 2. Axle adjustment bolt 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. 18). 5.
Height-of-Cut Chart No.
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. 20). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 20), 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 24 1. Sharpen at original angle 2. Sail 2. Check the balance of the blade by putting it on a blade balancer (Fig. 25). If the blade stays in a horizontal position, the blade is balanced and can be used.
Removing the Foam and Paper Elements Cleaning the Paper Element 1. Disengage the PTO, turn the ignition key to off, and remove the key. Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly. 2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 1.
Checking the Engine Oil Level 1. Park the machine on a level surface. 2. Disengage the PTO, turn the ignition key to off, and remove the key. 3. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 4. Clean around the oil dipstick (Fig. 27) so that dirt cannot fall into the filler hole and damage the engine. 1 m–7453 2 Figure 28 1 1. Oil drain plug 7. When oil has drained completely, close the oil drain.
Checking the Spark Plugs 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 29). 1. Look at the center of the spark plugs (Fig. 31). 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. 4.
5. Install air intake screen, recoil starter and fan housing. 5 1 3 2 4 Figure 33 1. Valve stem Greasing and Lubrication Service Interval/Specification 1 Grease the areas shown at the intervals given in the Locating Where to Add Grease section below. Grease them more frequently when operating conditions are extremely dusty or sandy. m–7450 Figure 32 1. Air intake screen 2. Fan housing 3. Recoil starter 4. Bolt 5. Nut Grease with No. 2 general-purpose lithium-base or molybdenum-base grease.
Servicing the Brakes Service Interval/Specification Before each use, check the brakes for proper operation. Always set the parking brakes when you stop the machine or leave it unattended. If the parking brakes do not hold securely, adjust them. Checking the Brakes m–3780 1. Park the machine on a level surface, disengage the blade control (PTO) lever, and push the neutral/parking brake locks forward to set the brakes. Figure 34 2.
6. Open the fuel shut-off valve and allow the gasoline to drain into a fuel container or drain pan. 4. Position the wing nuts so that the brakes engage when you squeeze the drive levers enough to place the neutral/parking brake locks forward, and then set the brakes. Note: Install a new fuel filter while the fuel tank is empty. Refer to Replacing the Fuel Filter, page 33. 5. Check the operation of the brakes again; refer to Checking the Brakes, page 32. 7.
2. Stop the engine, remove the key, and wait for all moving parts to stop. 1 2 3. Remove the drive spring from the adjustment bolt (Fig. 39). 3 5 6 2 4 4 3 Figure 40 1 4 m–4726 1. Idler pulley in slot 2. Traction belt 3. Mower belt m–5372 4. Belt guide 5. 1-1/4 inch (32 mm) 6. Mower belt Figure 39 1. Drive belt 2. Drive spring 5. Loosen the pivot bolt enough to slide the idler pulley in the slot and remove the traction belt from the engine and the drive pulleys (Fig. 40). 3. Tire 4.
11. Rotate the clevis clockwise on the rod to increase the clearance; rotate it counterclockwise to decrease it (Fig. 42). 5. Install the new mower belt. 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 35. 12. Disengage the blade control (PTO) lever. Note: If the assist arm does not contact the front stop on the mower deck (Fig.
Adjusting the Grass/Mud Scraper 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt. Rotate the turnbuckle toward the front of the mower to decrease the tension on the belt (Fig. 43). 1. Loosen the locknut that holds the scraper to the engine frame (Fig. 45). Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16 inch (8 mm). 3 2 Adjusting the Blade Brake 1. Disengage the blade control (PTO) lever and set the parking brakes.
4 3 5 2 1 6 m-3781 Figure 46 1. Deflector 2. Spring 3. Deflector mount 4. Locknut 5. Bolt 6. Spacer 2. Straighten the deflector mounts if they are bent (Fig. 46). 3. Install a new deflector between the mounts with a spacer and a spring. 4. Hook the front end of the spring around the front deflector mount. 5. Insert the bolt through the spacer and secure it with a locknut. 6. Ensure that there is downward spring force on the deflector (Fig. 46). 7.
DELTA MODULE (2001)) INTERLOCK MODULE 38 F E D C B A GN R BN BK OR BK R Y (SWITCH CLOSED WHEN IN OFF POSITION) SW4 IGN SWITCH NEUTRAL SWITCH SW2 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 SPARK PLUG ORANGE RED YELLOW IGNITION MODULES R BROWN BN GREEN Y BLACK BK WIRE COLOR CODES Wiring Dia
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 fails hard, f il to keep k 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 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.
