Toro 30528 Operator's Manual

Form No. 3352–529
Mid-Size Mower
ProLine Hydro 15 hp with 48in Side Discharge Mower
Model No. 30528—Serial No. 250000001 and Up
Operator’s Manual
Register your product at www.Toro.com
Original Instructions (EN)
Warning
CALIFORNIA
Proposition 65 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 mower. 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 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . .
Using Fuel Stabilizer/Conditioner 12. . . . . . . . . . . .
Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil Level 12. . . . . . . . . . . . . .
Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Front Casters 14. . . . . . . . . . . . . . . . . .
Installing the Upper Handle 14. . . . . . . . . . . . . . . . .
Connecting the Throttle Cable 15. . . . . . . . . . . . . . .
Installing the Blade Control (PTO) Rod 15. . . . . . . .
Installing the Control Rods 15. . . . . . . . . . . . . . . . . .
Installing the Control Arm Rods 16. . . . . . . . . . . . .
W 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196
Installing the Speed Control Rod 16. . . . . . . . . . . . .
Installing the Fuel Tank 17. . . . . . . . . . . . . . . . . . . .
Setting up the Hydro Linkage 17. . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 18. . . . . . . . . . . . . . .
Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 19. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 19. . . . . . . . . . . . . . . .
Starting and Stopping the Engine 20. . . . . . . . . . . . .
Operating the Neutral Locks 21. . . . . . . . . . . . . . . .
Operating the Mower Blade Control (PTO) 21. . . . .
The Safety Interlock System 22. . . . . . . . . . . . . . . .
Driving the Machine Forward or Backward 22. . . . .
Bringing the Machine to Neutral Position 23. . . . . .
Stopping the Machine 23. . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 23. . . . . . . . . . . . . . .
Transporting Machines 24. . . . . . . . . . . . . . . . . . . . .
Using the Side Discharge or Mulching Grass 24. . . .
Adjusting the Height-of-Cut 24. . . . . . . . . . . . . . . . .
Adjusting the Caster Position 25. . . . . . . . . . . . . . . .
Height-of-Cut Chart 26. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 27. . . . . . . . .
Servicing the Cutting Blades 28. . . . . . . . . . . . . . . .
Servicing the Air Cleaner 30. . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 31. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 32. . . . . . . . . . . . . . . . . . .
Servicing the Brake 33. . . . . . . . . . . . . . . . . . . . . . .
Checking the Tire Pressure 34. . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 34. . . . . . . . . . . . . . . .
Greasing and Lubricating the Machine 34. . . . . . . .
Cleaning the Cooling System 35. . . . . . . . . . . . . . . .
Draining the Fuel Tank 35. . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter 35. . . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 36. . . . . . . . . . . . . .
Performing the Hydro Linkage Adjustments 37. . . .
Adjusting the Speed Control Linkage 37. . . . . . . . .
Adjusting the Neutral Control Linkages 38. . . . . . . .
Adjusting the Hydro Control Linkages 39. . . . . . . .
Adjusting the Control Rod 41. . . . . . . . . . . . . . . . . .
Tracking the Adjustment 41. . . . . . . . . . . . . . . . . . .
Adjusting the Spring Anchor Links 41. . . . . . . . . . .
Checking the Belts 42. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Belt 42. . . . . . . . . . . . . . . . . .
Adjusting the Mower Belt Tension 43. . . . . . . . . . . .
Adjusting the Blade Brake 43. . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 44. . . . . . . . . . . . . . .
Wiring Diagram 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Diagram 45. . . . . . . . . . . . . . . . . . . . . . . .
Contact us at www.Toro.com
All Rights Reserved
Printed in the USA
Page
Cleaning and Storage 46. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .
Page
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.
Introduction
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.
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space below:
Safety
This machine meets or exceeds the B71.4–2004 specifications of the American National Standards Institute in effect at the time of production.
Note: The addition of attachments made by other
manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
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—2004.
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.
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.
Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.
All operators and mechanics should be trained. The
owner is responsible for training the users.
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 hearing 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.
Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
Use only an approved container
Look behind and down before backing up to be sure of
a clear path.
Keep pets and bystanders away.
Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not mowing.
Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling. Do not smoke.
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 parking brake is
engaged 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, engage parking
brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.
Be aware of the mower discharge direction and do not
point it at anyone.
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, set parking brake, 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. Set parking brake. 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.
Stop equipment and inspect blades after striking objects
or if an abnormal vibration occurs. Make necessary repairs before resuming operations.
Keep hands and feet away from the cutting unit.
Toro Mower Safety
The following list contains safety information specific to Toro products and other safety information you must know.
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
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
Allow only responsible adults who are familiar with the
instructions to operate the machine.
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.
Slow down before turning. Sharp turns on any terrain
may cause loss of control.
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.
Stop the engine before removing the grass catcher or
unclogging the chute.
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
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.
Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any objects and do not contact them.
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. Keep equipment in good condition.
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.
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.
DO
Remove obstacles such as rocks, tree limbs, etc. from
the mowing area.
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.
Slope Chart
Example: Compare
slope with folded
edge.
Fold along appropriate line
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.
1-403005
66-1340
93-1122
1-523552
95-2814
95-5537
1. Read the Operator’s Manual for instructions on operating the cutting blade
2. Push forward to engage
3. Pull back to disengage
98-0776
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).
98-5954
99-3943
1. Engine
105-4109
105-4110
10
106-0699
106-2743
1. Forward
2. Neutral
3. Reverse
4. Warning—wear hearing protection.
106-0829
5. Fast
6. Continuous variable setting
7. Slow
8. Neutral
11
Gasoline and Oil
Warning
Recommended Gasoline
Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Use leaded regular gasoline 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.
Never fill the fuel tank inside an enclosed trailer.
Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 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
and 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.
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 Fuel 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, drain the fuel tank.)
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. Disengage the power take off (PTO) and turn the engine off.
2. Wait for all moving parts to stop before leaving the operating position and then set the parking brake.
3. Clean around the fuel tank cap and remove the cap. Add unleaded regular gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.
4. Install the fuel tank cap securely. Wipe up any spilled gasoline.
Checking the Engine Oil Level
Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 31.
12
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. USE
Caster assemblies
Bolt, 3/8 x 3/4 inch
Flange nut, 3/8 inch
Upper handle
Flanged bolt, 3/8 x 1 inch
Flanged nut, 3/8 inch
Spring washer
Wire tie
Hairpin cotter 1 Installing the blade control rod
Clevis pin
Hairpin cotter
Washer
Hairpin cotter
Clevis pin
Hairpin cotter
Fuel tank
Bolt, 5/16 x 3/4 inch
Installing the front casters
Installing the upper handle and wire harness
Installing the control rods
Installing the drive linkage
Installing the speed control rod
Lock washer, 5/16 inch
Locknut
Washer, 5/16 inch
Stud
Spring
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Video
Registration card 1 Fill out and return to Toro
13
Installing the fuel tank
Review before operating machine
Installing the Front Casters
1. Align the casters with the holes on the top and front of the mower, and insert 8 bolts (3/8 x 3/4 inch) through the mower. Secure the caster with 8 flange nuts (3/8 inch) below the mower (Fig. 2).
m–3777
Figure 2
1. Front caster
2. Bolt
3. Flange nut
Note: Tighten the lower bolts first to pull the caster against the front, then tighten the top bolts.
2. Torque the bolts to 30–35 ft.-lb. (40–47 NSm).
Installing the Upper Handle
1. Align the holes in upper handle with the mounting holes in the rear frame and bracket (Fig. 3).
m–5969
Figure 3
1. Upper handle
2. Rear frame bracket
3. Flange bolt (26 mm)
4. Spring washer
5. Flange nut
Important Install the flange bolts with the bolt head on
the outside of the upper handle. Refer to figure 3.
2. Secure each leg of the upper handle to the rear frame and bracket with two flange bolts (3/8 x 1 inch (26 mm), spring washers and flange nuts (Fig. 3). Tighten until spring washers are compressed.
3. Route the wire harness along the inside of the left handle and under the control panel (Fig. 17).
4. Connect the right-angled insulated terminals to the switch (Fig. 4).
1
2
Figure 4
1. Switch 2. Right-angled insulated
terminals
5. Use the wire ties to secure the wire harness to the inside of the left handle, away from the blade control (PTO) rod (Fig. 17). Secure at bottom and top of handle.
14
m–6490
Connecting the Throttle Cable
1. Place throttle control lever in the fast position (Fig. 5).
2. Hook wire Z–bend into hole of speed control lever
(Fig. 5).
3. Loosen cable clamp screw allowing cable installation, but do not tighten (Fig. 5).
4. Move control cable casing and wire until hole in speed control lever is aligned with hole in base plate. Insert a 1/4 in. (6 mm) diameter pin or bolt into aligned holes to hold adjustment.
5. Pull throttle cable slightly to remove any slack and tighten cable clamp screw to lock adjustment in place.
6. Remove alignment pin and check control operation.
Figure 6
1. Blade control (PTO) rod
2. Bell crank
3. Hairpin cotter
2. Secure the blade control (PTO) rod to the bell crank with a hairpin cotter (Fig. 6).
Installing the Control Rods
m–5997
Figure 5
1. Wire Z-bend
2. Speed control lever
3. Base plate
4. Alignment holes 1/4 in. (6 mm)
5. Cable clamp
Installing the Blade Control (PTO) Rod
1. From outer side of bell crank, insert end of blade control (PTO) rod thru hole (Fig. 6).
m–2596
1. Install the control rod to the drive lever and neutral lock with a clevis pin and washer (Fig. 7). Washer to be positioned between drive lever and neutral lock.
2. Install a hairpin cotter between drive lever and washer and into clevis pin (Fig. 7).
Note: Make sure the clevis pin is inserted into the neutral lock.
3. Repeat this procedure for the opposite side.
15
Installing the Control Arm Rods
1. Insert control arm swivel thru hole in speed control crank and secure with hairpin cotter (Fig. 9).
m–5998
Figure 7
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 inch (64 mm) from the bottom (Fig. 8).
5. Install rod fittings to idler brackets with clevis pins and e–ring (Fig. 8).
m–5994
Figure 9
1. Control arm
2. Swivel
3. Speed control crank
2. Repeat this procedure for the opposite side.
Installing the Speed Control Rod
1. Move the speed control lever fully forward (Fig. 10).
1. Control rod
2. Idler bracket
3. Rod fitting
Figure 8
m–5400
4. E–ring
5. 2–1/2 inch (64 mm) from bottom
Figure 10
1. Speed control lever
2. Install speed control rod to right side of speed control lever (under control panel) with a hair pin cotter (Fig. 11).
16
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