Toro 30338 Operator's Manual
Form No. 3325–888
Mid–Size Mower
ProLine Hydro 15 HP with 44 in. Side Discharge
Mower
Model No. 30338—210000001 and Up
Operator ’s Manual
English (EN)
Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest–covered, brush–covered or grass–covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner ’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner ’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . .
Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .
Set Up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Fuel Tank and Fuel Line 14. . . . . . . . . . .
Install Upper Handle 15. . . . . . . . . . . . . . . . . . . . . .
Install Control Rods 15. . . . . . . . . . . . . . . . . . . . . . .
Install Speed Control Rod 16. . . . . . . . . . . . . . . . . .
Hydro Linkage Set Up 16. . . . . . . . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 17. . . . . . . . . . . . . . .
Install Hairpin Cotter Pins 17. . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Page
Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 19. . . . . . . . . . . .
Operating Neutral Locks 19. . . . . . . . . . . . . . . . . . .
Operating Mower Blade Control (PTO) 20. . . . . . .
The Safety Interlock System 20. . . . . . . . . . . . . . . .
Driving Forward or Backward 21. . . . . . . . . . . . . . .
Bringing Machine to Neutral Position 21. . . . . . . . .
Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 21. . . . . . . . . . . . . . .
Transporting Machines 22. . . . . . . . . . . . . . . . . . . .
Side Discharge or Mulch Grass 22. . . . . . . . . . . . . .
Adjusting Height-of-Cut 22. . . . . . . . . . . . . . . . . . .
Adjusting Center Gage Wheels 23. . . . . . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 24. . . . . . . .
Air Cleaner Service 25. . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Service 26. . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Service 27. . . . . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 28. . . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 29. . . . . . . . . . . . . . .
Checking Tire Pressure 30. . . . . . . . . . . . . . . . . . . .
Fuel Tank Service 30. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Service 30. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Service 31. . . . . . . . . . . . . . . . . .
Adjusting By-pass Valve 32. . . . . . . . . . . . . . . . . . .
Hydro Linkage Adjustments 33. . . . . . . . . . . . . . . .
Adjust Speed Control Linkage 33. . . . . . . . . . . . . . .
Adjust Neutral Control Linkages 34. . . . . . . . . . . . .
Adjust Hydro Control Linkages 35. . . . . . . . . . . . . .
Control Rod Adjustment 36. . . . . . . . . . . . . . . . . . .
Tracking Adjustment 37. . . . . . . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch 37. . . . . . . . . . . . . . .
Fuse Service 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Blade Service 38. . . . . . . . . . . . . . . . . . . . .
Correcting Cutting Unit Mismatch 40. . . . . . . . . . .
Frame Set Up 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Deck Front-to-Rear Pitch 41. . . . . . .
Changing the Deck Front-to-Rear Pitch 42. . . . . . .
Checking the Deck Side-to-Side Leveling 42. . . . .
Changing the Side-to-Side Leveling 42. . . . . . . . . .
Matching Height of Cut 42. . . . . . . . . . . . . . . . . . . .
Replacing the Traction Belt 43. . . . . . . . . . . . . . . . .
Replacing the Deck Belt 43. . . . . . . . . . . . . . . . . . .
Replacing the PTO Drive Belt 44. . . . . . . . . . . . . . .
Replacing the Caster Wheel Fork Bushings 44. . . .
Caster Wheel and Bearings Service 45. . . . . . . . . . .
Replacing the Grass Deflector 46. . . . . . . . . . . . . . .
Wiring Diagram 47. . . . . . . . . . . . . . . . . . . . . . . . . .
All Rights Reserved
Printed in the USA
2
Hydraulic Diagram 48. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 49. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .
Introduction
Page
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
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.
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.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
m–5404
Figure 1
1. Location o f the model and serial numbers
Safety
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—1999.
Training
• Read the Operator ’s Manual and other training
material. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this
material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments
approved by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and ear protection. Long hair, loose clothing or
jewelry may get tangled in moving parts.
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
3
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Keep pets and bystanders away.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
• Be aware of the mower discharge direction and do not
point it at anyone.
• Never refuel or drain the machine indoors.
• Check that operator ’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
Operation
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and wheels are
chocked and blocked before starting engine. Only start
engine from the operator’s position.
• Be sure of your footing while using this machine,
especially when backing up. Walk, don’t run. Never
operate on wet grass. Reduced footing could cause
slipping.
• Slow down and use extra care on hillsides. Be sure to
travel side–to–side on hillsides. Turf conditions can
affect the machine’s stability. Use caution while
operating near drop–offs.
• Slow down and use caution when making turns and
when changing directions on slopes.
• Never raise deck with the blades running.
• Never operate with the PTO shield, or other guards not
securely in place. Be sure all interlocks are attached,
adjusted properly, and functioning properly.
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Do not change the engine governor setting or
overspeed the engine.
• Stop on level ground, disengage drives, chock or block
wheels, shut off engine before leaving the operator’s
position for any reason including emptying the
catchers or unclogging the chute.
• Stop equipment and inspect blades after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
• Do not operate the mower under the influence of
alcohol or drugs
• Use care when loading or unloading the machine into
or from a trailer or truck
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Maintenance and storage
• Disengage drives, chock or block wheels, stop engine
and remove key or disconnect spark plug wire. Wait
for all movement to stop before adjusting, cleaning or
repairing.
• Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Chock or block wheels
when it is parked. Never allow untrained personnel to
service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with
stored energy.
• 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.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
Toro Mower Safety
• Keep hands and feet away from the cutting unit.
• Look behind and down before backing up to be sure of
a clear path.
The following list contains safety information
specific to Toro products and other safety information
you must know.
4
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
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 mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
• Turn off blades when not mowing.
• Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and
any moving parts while engine is running.
• Mow only in daylight or good artificial light.
• Watch for traffic when operating near or crossing
roadways.
• 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. Warranty may
be voided if used with unapproved attachments.
Slope Operation
Slopes and ramps are a major factor related to
loss-of-control and accidents, which can result in severe
injury or death. All slopes and ramps require extra
caution. If you feel uneasy on a slope, do not mow it.
• Mow slopes side–to–side.
DO NOT
• Do not mow slopes greater than 15 degrees.
• Avoid turning on slopes. If you must turn, turn slowly
and gradually downhill, if possible.
• Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly turn over if a wheel goes
over the edge of a cliff or ditch, or if an edge caves in.
• Do not mow on wet grass. Reduced traction could
cause sliding.
• Do not use a grass catcher on steep slopes. Heavy
grass bags could cause loss of control, of the machine.
• Do not mow up and down slopes.
Service
• Never store the machine or fuel container inside where
there is an open flame, such as near a water heater or
furnace.
• Keep nuts and bolts tight, especially the blade
attachment bolts.
• Never tamper with safety devices. Check safety
systems for proper operation before each use.
• Use only Toro genuine replacement parts to ensure that
original standards are maintained.
• Hydraulic fluid escaping under pressure can penetrate
the skin and cause injury. Use cardboard or paper to
find hydraulic leaks. Never use your hands.
DO
• Watch for holes, ruts or bumps. Tall grass can hide
obstacles.
• Use slow speed so that you will not have to stop while
on the slope.
• Use extra care with grass catchers or other
attachments. These can change the stability of the
machine.
• Keep all movement on slopes slow and gradual. Do
not make sudden changes in speed or direction.
• Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades.
5
6
Slope Chart
7
8
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.
82–4590
67–5360
95–2814
63–8440
66–1340
43–8480
68–8340
54–9220
9
105–4146
1–523552
98–0776
104–8569
98–4387
95–1543
105–4144
104–8172
10
105–4109
105–0840
105–4110
104–8186
104–8171
105–4106
11
105–4108
12
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is not
available.
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.
Danger
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.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 in.
to 1/2 in. (6 mm to 13 mm) below the bottom of
the filler neck. This empty space in the tank
allows gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline
dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
fueling is complete.
Warning
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at
all times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around fuel tank cap and remove the cap. Add
unleaded regular gasoline to fuel tank, until the level is
1/4 to 1/2 inch below the bottom of the filler neck.
This space in the tank allows gasoline to expand. Do
not fill the fuel tank completely full.
3. Install fuel tank cap securely. Wipe up any gasoline
that may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking Oil
Level, page 26.
13
Set Up
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
DESCRIPTION QTY. USE
Fuel tank
Bolt 5/16 x 7/8 in. (22 mm)
Lock washer 5/16 in.
Washer 5/16 in.
Stud
Spring
Hose clamp
Upper handle
Flanged bolt 3/8 x 1 in. (26 mm)
Flange nut 3/8 in.
Rod fitting
E–ring
Clevis pin
Hairpin cotter
Hairpin cotter 2 Install hairpin cotter pins
Operator’s Manual
Engine Operator’s Manual
1
2
2
4
2
2
1
1
4
4
2
2
2
2
1
1
Install fuel tank and fuel line
Install upper handle to frame
Install control rods
Read before operating machine
Parts Catalog
Registration card
Installing Fuel Tank and Fuel
Line
1. Align fuel tank to top of rear frame and secure fuel
tank right side with 2 bolts (5/16 x 7/8 in. (22 mm)), 2
lock washers (5/16 in.) and 2 washers (5/16) (Fig. 2).
2. Secure fuel tank left side to frame with 2 studs (5/16
x 7/8 in. (22 mm)), 2 washers (5/16 in.), 2 springs and
2 locknuts (5/16 in.) (Fig. 2).
Note: Tighten left side until it is completely tight and then
unscrew locknut one full turn. This will allow the spring
to work.
1
1
14
Fill out and return to Toro
7
8
7
8
5
9
3
4
6
1
3
3
5
6
5
6
m–5339
Figure 2
1. Bolt, 5/8 x 7/8 in. (22 mm)
2. Lock washer, 5/16 in.
3. Washer, 5/16 in.
4. Stud
5. Spring
6. Locknut
7. Hose clamp
8. Fuel tank connection
3. Slide the hose clamp onto the fuel line (Fig. 2).
4. Push the fuel line onto the fuel tank connection and
secure it with a hose clamp (Fig. 2).
Install Upper Handle
Important Install the flange bolts
(3/8 x 1 in. (26 mm)) with the bolt head on the inside of
machine frame. Refer to figure 3.
1. Align upper handle with upper mounting holes in rear
frame (Fig. 3).
2. Secure each upper mounting hole with a flange bolt
(3/8 x 1 in. (26 mm)) and flange nut (Fig. 3).
3. Select medium or low position for the lower mounting
hole (Fig. 3). This allows the upper handle to be
adjusted to the user’s height preference.
2
4
m–5401
Figure 3
1. Upper handle
2. Rear frame
3. Flange bolt, 3/8 x 1 in.
(26 mm)
4. Flange nut, 3/8 in.
5. Upper mounting hole
6. Lower mounting hole
7. Low position
8. Medium position
9. High position—Do not use
Install Control Rods
1. Install control rod to drive lever and neutral lock using
a clevis pin (Fig. 4).
2. Install hairpin cotter between drive lever and neutral
lock and into clevis pin (Fig. 4).
Note: Make sure the clevis pin is inserted into the neutral
lock.
3. Repeat this procedure for the opposite side.
Note: Do not put in high position. Machine can not be
used in the high position.
4. Secure each lower mounting hole with a flange bolt
(3/8 x 1 in. (26 mm)) and flange nut (Fig. 3).
15
1
6
2
2. Thread yoke onto speed control rod approximately
3/4 in. (19 mm) (Fig. 5).
3. Install yoke to the speed control crank with a clevis
pin, washer and hairpin cotter (Fig. 5).
3
4
5
7
m–5400
Figure 4
1. Left handle shown
2. Neutral lock
3. Clevis pin
4. Drive lever
5. Control rod
6. Operator Presence
Control lever (OPC)
7. Hairpin cotter
4. Thread rod fittings equal distance onto each control
rod. For a starting point, thread rod fittings onto
control rod approximately 2–1/2 in. (63.5 mm) from
the bottom (Fig. 5).
5. Install rod fittings to idler brackets with clevis pins and
e–ring (Fig. 5).
4. Secure yoke with jam nut (Fig. 5).
4
2
6
5
Figure 6
1. Speed control rod
2. Yoke
3. Jam nut
4. Speed control crank
5. Hair pin cotter
6. Washer
7. Clevis pin
1
3
7
m–5402
2
1
4
3
5
Figure 5
1. Control ro d
2. Idler bracket
3. Rod fitting
4. E–ring
5. 2–1/2 in. (63.5 mm) from
bottom
Install Speed Control Rod
1. Place the speed control lever full forward (Fig. 5).
m–5400
Hydro Linkage Set Up
Perform the following adjustments when the machine is
first set up and when any adjustment is needed. Do them
in the order that they are listed here.
Adjust Speed Control Linkage
Refer to Adjusting Speed Control Linkages on page 33.
Adjust Neutral Control Linkages
Refer to Adjusting Neutral Control Linkages on page 34.
Adjust Hydro Control Linkages
Refer to Adjusting Hydro Control Linkages on page 35.
Adjust Control Rods
Refer to Adjusting Control Rods on page 36.
16
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