Toro 30438, Operator'S Manual

Page 1: ...perator s Manual Original Instructions EN Register your product at www Toro com Form No 3350 757 Mid Size Mower ProLine Gear 17 HP with 52in Side Discharge Mower Model No 30438 Serial No 240000001 and Up ...

Page 2: ...emoving the Shipping Bracket 17 Installing the Handle Assembly 17 Installing the Fuel Tank 18 Checking and Adjusting the Shift Lever Plate 19 Installing the Control Rods 20 Page Installing the Hairpin Cotter Pins and Spacers 21 Operation 22 Think Safety First 22 Controls 22 Parking Brake and Neutral Lock 23 Starting and Stopping the Engine 23 Operating Mower Blade Control PTO 24 The Safety Interlo...

Page 3: ...al mechanical information and Note emphasizes general information worthy of special attention Safety 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 s...

Page 4: ...ake necessary repairs before resuming operations Keep hands and feet away from the cutting unit 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 Be aware of the mower discharge direction and do not point it at anyone Do not operate the mower under th...

Page 5: ...bstacles such as rocks tree limbs etc from the mowing area Watch for holes ruts or bumps Tall grass can hide obstacles Use caution 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 Use extra care with grass catchers or other attachments These can change the stability of the machine Keep all movement o...

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Page 7: ...7 Slope Chart Fold along appropriate line Align this edge with a vertical surface Tree Building Fence post pole etc Example Compare slope with folded edge ...

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Page 9: ...ecals 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 43 8480 66 1340 67 5360 68 8340 93 1122 95 2814 98 0776 98 3256 ...

Page 10: ...10 98 4387 1 Warning wear hearing protection 104 8186 104 8569 105 4111 105 4146 106 5532 106 0699 106 5511 ...

Page 11: ...rown objects 3 Do not operate the mower with the deflector up or removed 4 Stop the engine and pick up debris before operating 5 Cutting of hand or foot mower 6 Engine stop 7 Engine run 8 Hour meter 9 To park move the controls as illustrated 10 To drive move the controls as illustrated 11 To place the machine in neutral move the controls as illustrated 12 Power take off PTO ...

Page 12: ...ot 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...

Page 13: ...olt 5 16 x 7 8 inch Lock washer 5 16 inch Washer 5 16 inch Spring Hose clamp 1 2 2 2 4 2 1 Installing the fuel tank 4 No parts needed Checking and adjusting the shift lever 5 Clevis pin Washer Hairpin cotter pin 2 2 2 Installing the control rods 6 Hairpin cotter pin Spacers 2 6 Installing the hairpin cotter pins and spacers 7 Oil drain hose 1 Use for draining the engine oil 8 Operator s Manual Eng...

Page 14: ...Fig 3 1 2 3 4 4 m 7678 5 Figure 3 1 Center Gage Wheels and Spacer 2 Nut 3 Bolt 4 Washer 5 Spacer Step 2 Installing the Handle Assembly Parts needed for this step Qty Part 1 Handle assembly 4 Bolt 5 16 X 7 8 inch 4 Lock nut 5 16 inch 1 Align handle with upper mounting holes in rear frame Fig 4 2 Secure the handle at each upper mounting hole with a flange bolt 3 8 x 1 inch and flange nut Fig 4 3 Sel...

Page 15: ... X 7 8 inch 2 Lock nut 5 16 inch 4 Washer 5 16 inch 1 Hose clamp 2 Lock washer 5 16 inch 2 Spring Procedure 1 Align fuel tank with the top of the rear frame Fig 5 2 Secure the right side of the fuel tank to the rear frame with 2 bolts 5 16 x 7 8 inch lock washers 5 16 inch and washers 5 16 inch Fig 5 3 Secure the left side of the fuel tank to the rear frame with 2 studs washers 5 16 inch springs a...

Page 16: ...fter lever plate The clearance between top and bottom of the shift lever should be equal Fig 8 2 If clearance is not correct remove lever and bend it slightly to adjust Fig 8 1 2 6 5 4 3 m 7679 Figure 7 1 Shift lever 2 Shift lever plate 3 Rubber seal washer 4 Square hole washer 5 Spring washer 6 Locknut 3 8 inch Note Do not bend lever while attached to transmission shaft or damage may occur 3 Shif...

Page 17: ...locks and into the clevis pins Fig 10 5 6 1 m 7669 4 2 3 Figure 10 1 Control rod 2 Drive lever 3 Hairpin cotter 4 Clevis pin 5 Handle 6 Neutral parking brake lock 4 Loosen the turn buckle wing nut Fig 11 3 1 m 6592 2 Figure 11 1 Turnbuckle 2 Wing nut 3 Control rod 5 Adjust the control rod length by rotating the turnbuckle until there is 3 16 to 1 4 inch 5 to 6mm clearance between the control rod e...

Page 18: ...in cotter Note Make sure there is at least one spacer used on each height of cut post 1 Remove the existing rear hairpin cotter pins from the rear height of cut posts 2 Install a spacer onto both rear height of cut posts and install the hairpin cotter pins 3 2 1 m 7584 Figure 13 1 Hairpin cotter 2 Spacer 3 Height of cut post rear shown 3 On the opposite side of the muffler install unused spacers o...

Page 19: ...e Off Switch PTO This pull switch is used in conjunction with the blade control bail to engage the clutch to drive the mower blades Gear Shift Lever Transmission has five forward speeds neutral and reverse and has an in line shift pattern Important Do not shift while unit is moving as transmission damage may occur Drive levers Shift to desired gear and release drive levers to engage traction opera...

Page 20: ...king brake lock 3 Park position 4 Drive lever 5 Full speed forward position 6 Grip Releasing the Neutral Lock 1 Squeeze the drive levers back to the grip 2 Place thumbs on the upper part of of locks and rotate them forward until in forward speed slot Starting and Stopping the Engine Starting 1 Make sure spark plug wire s are installed on spark plug s and fuel valve is open 2 Move the shift lever t...

Page 21: ...ol OPC levers against handle grip 3 Repeat procedure to engage mower blades if OPC levers are released 3 2 1 m 6581 Figure 20 1 Handle 2 Operator Presence Control levers OPC 3 Power take off switch PTO Disengaging the Mower Blades PTO 1 Release Operator Presence Control OPC levers to disengage blades Fig 20 This will also kill the engine The Safety Interlock System If safety interlock switches are...

Page 22: ...iately Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control in the Fast position for best performance Driving Forward 1 To go forward move the shift lever to a forward gear 2 Release the parking brake refer to Releasing the Parking Brake page 20 3 Slowly release the drive levers to move forward Fig 21 To go...

Page 23: ...grass deflector routes material down toward the turf If the grass deflector is ever damaged replace it immediately Never put your hands or feet under the mower Never try to clear discharge area or mower blades unless you release the bail and the power take off PTO is off Rotate the ignition key to Off Also remove the key and pull the wire off the spark plug s Adjusting the Height of Cut The height...

Page 24: ...r 6 Bushing spacer 1 2 3 4 4 m 7678 5 Figure 25 1 Center Gage Wheels and Spacer 2 Nut 3 Bolt 4 Washer 5 Spacer Adjusting the Handle Height The handle position can be adjusted to match the operator s height preference 1 Remove hairpin cotter washer and clevis pin securing control rod fitting to idler bracket Fig 26 m 6591 1 2 4 3 5 6 7 8 Figure 26 1 Upper handle 2 Rear frame 3 Flange nut 3 8 inch 4...

Page 25: ...y is installed The weight mounted in the back position must be removed when the when a Tru Trak Sulky is installed With the weight installed in the rear position the front end of the machine can rapidly raise up when the mower is removed This could cause serious injury to you or bystanders Support the rear of the machine when removing the mower from the carrier frame Warning 1 3 2 4 Figure 27 1 We...

Page 26: ...k Electric Clutch adjust Engine clean outside 200 Hours Fuel Filter replace Engine Oil Filter change 200 hours or every other oil change Paper Air Cleaner replace 250 Hours Transmission Couplings grease1 400 Hours Wheel Bearings grease1 At storage or 400 Hours Chipped Surfaces paint Perform all maintenance procedures listed above before storage 1More often in dusty dirty conditions Important Refer...

Page 27: ...mage Fig 28 4 Unscrew the cover knob and remove the air cleaner cover Fig 28 5 Unscrew the 2 wing nuts and remove the air cleaner assembly Fig 28 6 Carefully pull the foam element off the paper element Fig 28 m 7452 2 3 4 5 1 6 Figure 28 1 Engine 2 Cover 3 Wing nut 4 Foam element 5 Paper element 6 Cover knob Cleaning the Foam Element 1 Wash the foam element in liquid soap and warm water When the e...

Page 28: ... parts to stop before leaving the operating position 4 Clean around the oil dipstick Fig 29 so that dirt cannot fall into the filler hole and damage the engine m 7449 2 1 Figure 29 1 Oil dipstick 2 Filler tube 5 Unscrew the oil dipstick and wipe the end clean Fig 29 6 Slide the oil dipstick fully into the filler tube but do not thread onto tube Fig 29 7 Pull the dipstick out and look at the end If...

Page 29: ...ter clockwise until the rubber gasket contacts the filter adapter then tighten the filter an additional 3 4 turn Fig 32 5 Fill the crankcase with the proper type of new oil refer to Servicing the Engine Oil page 28 6 Run the engine for about 3 minutes stop the engine and check for oil leaks around the oil filter 7 Check the engine oil level and add oil if needed Servicing the Spark Plugs Service I...

Page 30: ...ark Plugs 1 Install the spark plugs and the metal washer Ensure that the air gap is set correctly 2 Tighten the spark plugs to 16 ft lb 22 N m 3 Connect the wires to the spark plugs Fig 33 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 ...

Page 31: ... the front wheel bearings and front spindles Fig 37 2 Raise the rear of the machine and use jack stands to support the machine 3 Remove the rear wheel and tire assembly 4 Remove rear wheel grease cap Lubricate the rear wheel bearing Fig 37 5 Install the grease cap 6 Install the rear wheel and tire assembly Note Make sure the rear wheel grease caps are removed before lubricating rear wheels m 6367 ...

Page 32: ... 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 41 and push in new fuse 1 m 7676 Figure 41 1 Fuse 10 amp blade type Adjusting the Electric Clutch The clutch is adjustable to ensure proper engagement and proper braking Check adjustment after every 100 hours of operation 1 To adjust the clutch tighten o...

Page 33: ...llow the gasoline to drain into a gas can or drain pan 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 33 5 Install the fuel line onto the fuel filter Slide the hose clamp close to the valve to secure the fuel line 2 1 m 5235 Figure 43 1 Fuel shut off valve 2 Clamp Servicing the Fuel Filter Service Interval Specification...

Page 34: ...osition D Most severe belt wear 5 Spring 6 Adjustment bolt In position A Servicing the Brakes Service Interval Specification Before each use check brakes on both a level surface and slope 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 1 Park the machine on a level surface disenga...

Page 35: ... the trunnion into the hole for the brake rod Fig 46 Tighten the wing nut 9 Secure trunnion to brake lever with washer and hair pin cotter Fig 46 10 Check the brake operation again refer to Checking the Brake page 34 Important With the parking brake released the rear wheels must rotate freely when you push the mower If brake action and free wheel rotation cannot be achieved contact your service de...

Page 36: ...ade control bail and set the parking brake Turn the ignition key to off Remove the key and disconnect the spark plug wire s from the spark plug s Inspecting the Blades 1 Inspect the cutting edges Fig 48 If the edges are not sharp or have nicks remove and sharpen the blades Refer to Sharpening the Blades on page 37 2 Inspect the blades especially the curved area Fig 48 If you notice any damage wear...

Page 37: ...368 6 Figure 51 1 Sail Area of Blade 2 Blade 3 Blade spindle 4 Blade Bolt 5 Blade stiffener 6 Flat washer Sharpening the Blades 1 Use a file to sharpen the cutting edge at both ends of the blade Fig 52 Maintain the original angle The blade retains its balance if the same amount of material is removed from both cutting edges 1 m 1854 Figure 52 1 Sharpen at original angle 2 Check the balance of the ...

Page 38: ... be 1 5 16 inch 33 mm plus or minus a 1 4 inch 6 mm 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 54 7 Align the carrier frame and engine deck to match 1 5 16 inch 33 mm plus or minus a 1 4 inch 6 mm at location A Fig 54 8 Tighten the carrier frame mounting bolts on both sides of the machine 1 A 3 5 4 2 ...

Page 39: ...nd set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Adjust the tire pressure in all tires to specifications on page 32 4 Measure carrier frame height at location A Fig 57 5 Measure carrier frame height at location B Fig 57 6 If the carrier frame height is not the same move spacers from top or bottom of caster wheel...

Page 40: ...ons Fig 58 from a level surface to the cutting edge of the blades Fig 59 5 Check the side to side leveling of the cutting unit 6 Tighten the jam nuts Fig 60 Checking the Deck Side to Side Leveling 1 Check the tire pressure on both deck and traction unit 2 Position the blades side to side Fig 61 Measure at A and B locations Fig 61 from a level surface to the cutting edge of blade tips Fig 62 3 The ...

Page 41: ...lley and idler support Fig 65 3 Raise the wheel off the ground to allow the belt to be removed and remove the belt 4 Install a new belt 5 Install the top capscrew securing the idler support and idler bracket to the rear frame Fig 65 6 Tighten the bottom two mounting screws enough to allow the belt to pass between the drive pulley and idler support Fig 65 2 1 4 3 5 m 6597 Figure 65 1 Top capscrew 2...

Page 42: ...nch 3 mm from belt Fig 67 10 Reinstall the deck covers onto the cutting unit then reinstall and tighten the knobs 11 Install the carrier frame cover onto the cutting unit then install and tighten the hand knobs 4 3 1 5 3 2 6 m 6530 Figure 67 1 Deck belt 2 Idler arm spring 3 Outside pulley 4 PTO drive Belt 5 Center Spindle Pulley 6 Deck belt guide Replacing the PTO Drive Belt Squealing when the bel...

Page 43: ...rrect installation and to maintain a level deck 4 2 1 3 2 m 6372 Figure 69 1 Locking Pin 2 Spacers locate as required 3 Carrier frame mounting tube 4 Caster wheel fork 4 Insert a pin punch into the mounting tube and carefully drive out the bushings Fig 70 Clean the inside of the mounting tube 5 Grease the inside and outside of the new bushings Use a hammer and flat plate to carefully drive the bus...

Page 44: ...wheel bolt and locknut Tighten the locknut until the spanner bushing bottoms against the inside of the caster forks Fig 71 7 Grease the fitting on the caster wheel Replacing the Grass Deflector An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s direction and result in serious injury Also contact with the blade could occur Never operate the l...

Page 45: ... Neutral W PK Y BU Y GND 10A F1 BU BN BK RED PINK Y BK BK 1 2 5 4 7 8 PK TAN PK Y GREY W GREEN VIO K1 Interlock Relay Clutch PTO Switch Off Pistol Grip M S KAW Gear KEY SWITCH ORANGE T BROWN WIRE COLOR CODES BLACK R PK 2 3 5 4 1 HR MTR OPTIONAL OPEN ON CLOSED OFF BLUE AC AC SPARK PLUG RECTIFIER MAG DC IGNITION MODULES SPARK PLUG ...

Page 46: ...tabilizer conditioned gasoline over 90 days 9 Remove the spark plug s and check its condition refer to Servicing the Spark Plug Service page 29 With the spark plug s removed from the engine pour two tablespoons of engine oil into the spark plug hole Now use the starter to crank the engine and distribute the oil inside the cylinder Install the spark plug s Do not install the wire on the spark plug ...

Page 47: ...low 2 Add oil to crankcase 3 Cooling fins and air passages under engine blower housing are plugged 3 Remove obstruction from cooling fins and air passages Machine does not drive 1 Shift lever is in NEUTRAL 1 Move shift lever to a drive gear position 2 Traction belt is worn loose or broken 2 Change Belt 3 Traction belt is off pulley 3 Change Belt 4 Broken or missing idler spring 4 Replace spring 5 ...

Page 48: ...ect 5 Adjust tire pressure 6 Blade spindle bent 6 Contact Authorized Service Dealer Blades do not rotate 1 PTO Drive belt is worn loose or broken 1 Install new drive belt 2 PTO Drive belt is off pulley 2 Install drive belt and check adjusting shafts and belt guides for correct position 3 Deck belt is worn loose or broken 3 Install new deck belt 4 Deck belt is off pulley 4 Install deck pulley and c...

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Page 52: ...vered There is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear acc...