Form No. 3355-217 Rev A Mid-Size, T-bar, Gear, 15hp with 52in Side-Discharge Mower Model No. 30319—Serial No. 260000001 and Up Register your product at www.Toro.
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. This spark ignition system complies with Canadian ICES-002 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 the engine on any forest-covered, brush-covered, or grass-covered land.
1 Removing the Shipping Bracket and Shipping Washers............................. 12 2 Installing the Handle Assembly .......................... 12 3 Installing the Fuel Tank ................... 13 4 Checking and Adjusting the Shift Lever Plate ........................ 13 5 Installing the Control Rods.............. 14 6 Installing the Hairpin Cotter Pins and Spacers ....................... 15 7 Reading the Manual and Viewing the Safety Video................. 16 Product Overview .............................
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. – Use only an approved container – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Improper use or maintenance by the operator or owner can result in injury.
• 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. • 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.
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 on slopes slow and gradual. Do not make sudden changes in speed or direction. • Mow slopes side to side. • Do not mow slopes greater than 15 degrees. Service • Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace.
Slope Chart 7
Safety and Instructional 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.
106-0699 98-0776 98-3256 98-4387 1. Warning—wear hearing protection.
6-0635 106-5499 10
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 2 3 4 5 6 7 Qty.
Step 1 Removing the Shipping Bracket and Shipping Washers Figure 4 No Parts Required 1. Center Gage Wheels and Spacer 2. Nut 3. Bolt Procedure 1. Remove the center gage wheel nut, 2 large washers, angle bracket and 1 small washer (Figure 3). Discard the 2 large washers and the angle bracket. 4. Washer 5. Spacer Step 2 Installing the Handle Assembly Parts needed for this step: 1 4 4 Procedure Figure 3 1. Center Gage Wheels and Spacer 2. Nut 3. Large washer-discard 4. Angle bracket-discard 5.
Note: Tighten left side of the fuel tank until it is completely tight and then unscrew locknut one full turn. This will allow the spring to work. Figure 5 1. 2. 3. 4. Upper handle Rear frame Flange nut, (3/8 inch) Flange bolt, (3/8 x 1 inch) 5. 6. 7. 8. Upper mounting hole Lower mounting holes Low position High position Figure 6 1. 2. 3. Note: Handle assembly must be installed before fuel tank is installed. Bolt, 5/16 x 7/8 inch Lock washer, (5/16 inch) Washer, (5/16 inch) 4. 5. 6.
Step 4 Checking and Adjusting the Shift Lever Plate No Parts Required Procedure 1. Shift lever to second gear and check alignment of lever in slot of shift lever plate. The clearance between top and bottom of the shift lever should be equal (Figure 8). Figure 9 1. Shift lever in 2nd gear 3. 2. Shift lever plate 4. Shift lever in neutral position Equal distance Step 5 Installing the Control Rods Figure 8 1. Shift lever 2. Shift lever plate 3. Rubber seal washer 4. 5. 6.
Note: The upper control bar and fixed bar must be parallel when the upper control bar is in the engaged, drive, neutral, or brake positions. 5. Check the operation. If adjustment is required, remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket. 6. Thread fitting up or down on rod until proper position is attained and install the fitting into the idler bracket with clevis pin, washer and hairpin cotter. Figure 10 1. Control rod 2. Upper control bar 3. 4.
Step 6 Installing the Hairpin Cotter Pins and Spacers Parts needed for this step: 2 6 Hairpin cotter pin Spacers Figure 14 1. Hairpin cotter Procedure 2. Unused spacers Unused height-of-cut spacers may be stored on posts and retained by a hairpin cotter. 3. Height-of-cut post (front shown) Step 7 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 (Figure 13).
Product Overview Figure 15 1. 2. 3. 4. 5. Gas tank Upper handle Blade control bail Throttle control Handle 6. 7. 8. 9. Engine Mower deck Front caster Side discharge chute Figure 16 1. 2. Controls 3. 4. 5. 6. Become familiar with all the controls (Figure 16) before you start the engine and operate the machine. Power take off switch (PTO) 7. Parking brake 8. lever-released position Upper handle 9. Blade control bail 10. Upper control bar 11.
Important: Do not shift while unit is moving, as transmission damage may occur. Upper Control Bar Shift to the desired gear and push forward on the upper control bar to engage forward traction operation and pull back to brake forward movement. Pull back on right side of upper control bar to turn right and left side to turn left. Lower Control Bar Shift transmission to reverse and squeeze the lower control bar and handle together to engage rearward traction assist operation.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• 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. Figure 17 1. Warning—wear hearing protection. Add the correct amount of gas stabilizer/conditioner to the gas. Using the Parking Brake 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.
Starting and Stopping the Engine Important: Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. Starting the Engine 1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open. 2. Move the shift lever to neutral, set the parking brake and turn ignition key to run. 3. Move the throttle control to the choke position before starting a cold engine.
The Safety Interlock System Driving Forward or Backward If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. The throttle control regulates the engine speed as measured in RPM (revolutions per minute). Place the throttle control in the fast position for best mowing performance. • Do not tamper with the interlock switches.
Using the Lower Control Bar This procedure is for driving up a curb. This can be performed while driving forward or backward. Note: Some curbs do not allow the rear drive tires to contact the curb. If this happens, drive the machine up the curb at an angle. A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders. Do not run blades while driving up a curb forward or backward. Figure 22 Driving Forward Up a Curb 1. 1.
Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 24 1. 2. Gage Wheels Nut 3. Washer Figure 23 1. Carrier Frame 2. Hairpin Cotter 3. Front height-of-cut post 4. 5. Spacers Back height-of-cut post Adjusting the Gage Wheels The gage wheels need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground. 1.
Adjusting the Handle Height 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. Tighten all flange bolts. 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 (Figure 27). 5.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure Before each use or daily • • • • • • Check the safety interlock system. Grease the caster wheels and caster pivot. Check the engine oil level. Clean the air intake screen. Check the brakes. Inspect the blades. Every 25 hours • Clean and re-oil the foam element (more often in dusty dirty conditions).
4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. Lubricating the Caster and Wheel Bearings 1. Lubricate the front wheel bearings and front spindles (Figure 29). 2. Raise the rear of the machine and use jack stands to support the machine. 3. Remove the rear wheel and tire assembly. Figure 30 4. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Figure 29). 5. Install the grease cap.
Paper element: Replace it after every 100 operating hours or yearly, which ever comes first. 2. Dry the element by squeezing it in a clean cloth. Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty. 3. Put one or two ounces of oil on the element (Figure 34). Squeeze the element to distribute the oil. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.
Installing the Foam and Paper Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 32). 2. Place the air cleaner assembly onto the air cleaner base (Figure 32). 3. Install the air cleaner cover and secure with cover nuts (Figure 32). Servicing the Engine Oil Figure 36 Change the engine oil after every 100 operating hours. 1. Oil dipstick 2.
Note: Dispose of the used oil at a recycling center. Figure 38 1. 2. Figure 37 1. Oil drain valve 2. Oil lter Gasket 3. Adapter Oil drain hose 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 1/2 turn (Figure 38). 9. Slowly pour approximately 80% of the specified oil into the filler cap (Figure 36). 10.
2. Tighten the spark plug(s) to 30 ft-lb (41 N·m). 3. Push the wire(s) onto the spark plug(s) (Figure 39). Fuel System Maintenance Draining the Fuel Tank Figure 39 1. Spark plug wire 2. 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. Spark plug Checking the Spark Plug 1. Look at the center of the spark plug(s) (Figure 40).
Figure 41 1. Fuel shut-off valve 2. Figure 42 Clamp 1. 2. Hose clamp Fuel line 3. Filter Replacing the Fuel Filter 5. Remove the filter from the fuel lines. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 6. Install a new filter and move the hose clamps close to the filter. Never install a dirty filter if it is removed from the fuel line. 7. Open fuel shut-off valve at fuel tank (Figure 41). Note: Note how the fuel filter is installed. 8.
Replacing the Caster Wheel Fork Bushings The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the caster forks back and forth and side-to-side. If a caster fork is loose, the bushings are worn and must be replaced. 1. Raise the cutting unit so the caster wheels are off the floor, then block up the front of the mower with jack stands. Figure 43 2.
Figure 46 1. Mounting Tube 2. Bushing Figure 47 5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the mounting tube. 1. 2. 3. Locknut Wheel Bolt Bushing 4. 5. Spanner Bushing Roller Bearing 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 47). 6. Inspect the caster wheel fork for wear and replace if necessary (Figure 45). 7.
slope. If the parking brake does not hold securely, an adjustment is required. 1. Park the machine on a level surface, disengage the PTO. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Apply the parking brake. The wheels must lock when you try to push the machine forward. 4. If the wheels do not lock, adjust the brakes. Refer to Adjusting the Brakes. 5.
1. Remove the top capscrew securing idler support and idler bracket to rear frame (Figure 50). Figure 50 Figure 49 1. Hairpin cotter and washer 2. Trunnion 5. 6. 3. Brake lever 4. Wing nut 7. 1. 2. 3. Hole F Initial adjustment- 1-1/4 inch (32 mm) Rod Top capscrew Idler bracket Idler support 4. 5. Bottom capscrew Traction drive belt 2. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Figure 50). 6.
5. Disconnect clutch wire connector from wire harness. 6. Disconnect clutch retainer from the engine deck (Figure 51). 4. Remove the knobs/rubber washers holding the belt cover to the cutting unit and remove the belt cover. 5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt in Belt Maintenance, page 37. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 52). 7.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Mower Deck Maintenance 3. Remove the knobs/rubber washers holding the carrier frame cover and remove the carrier frame cover. Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. 4.
Figure 54 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming Figure 55 2. Inspect the blades, especially the curved area (Figure 54). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 54), immediately install a new blade. 1. Measure here from blade to hard surface 2. Position A 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above.
Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. Figure 57 1. Hold the blade end using a rag or thickly-padded glove. 1. 2. Remove the blade bolt, blade stiffener, washer, and blade from the spindle shaft (Figure 56). Sharpen at original angle 2.
operating position. Disconnect the spark plug wire(s) from the spark plug(s). 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 (Figure 59). 3. Adjust the tire pressure in all tires to specifications on page . 8. Tighten the carrier frame mounting bolts on both sides of the machine. 4. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades. Checking the Engine Deck Height 5.
Figure 62 Figure 61 1. Caster Wheel 4. 5. 2. Carrier Frame 3. 1/4-3/8 inch (6-10 mm) pitch over 24 inch (61 cm) length Height at locations A and B Caster spacers 1. Caster Wheel 4. 2. 3. Carrier Frame Front height-of-cut pins 5. Same height at locations A and B Caster spacers 5. Measure carrier frame height at location B (Figure 62). 2. Measure carrier frame height at location A (Figure 61). 6.
3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 64). 4. Position the blades front-to-rear. Measure at C and D locations (Figure 63) from a level surface to the cutting edge of the blades. 5. Check the side-to-side leveling of the cutting unit. 6. Tighten the jam nuts (Figure 64). Checking the Deck Side-to-Side Leveling 1. Check the tire pressure on both deck and traction unit. Figure 63 1. Measure blade at points A and B 2.
Replacing the Grass Deector 1. Change the tire pressure on both deck and traction unit. Do this to the corresponding side that needs adjustment. 2. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. 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. Matching Height of Cut 1. Check the tire pressure on both deck and traction unit.
Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in Figure 67. 3. Install bolt and nut. Place the J hook end of spring around grass deflector (Figure 67). Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position.
Storage Engine Maintenance, page 28. 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(s). Cleaning and Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2.
Troubleshooting Problem Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Fuel tank is empty. 2. Choke is not on. 3. Air cleaner is dirty. 4. Spark plug wire is loose or disconnected. 5. Spark plug is pitted, fouled, or the gap is incorrect. 6. Dirt in the fuel lter. 7. Dirt, water, or stale fuel is in the fuel system. Engine loses power. 1. Engine load is excessive. 2. Air cleaner is dirty. 3. Oil level in the crankcase is low. 4.
Problem Machine does not drive. Possible Cause 1. Shift lever is in neutral. 2. Traction belt is worn, loose or broken. 3. Traction belt is off a pulley. 4. Broken or missing idler spring. Abnormal vibration. Uneven cutting height. Corrective Action 1. Move shift lever to a drive gear position. 2. Change the belt. 3. Change the belt. 4. Replace the spring. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 50 Corrective Action 1. Check the belt tension. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Inspect the belt and replace if damaged. Check the pulleys and idler pulleys. 5. Replace the spring.
Schematics Electrical Schematic (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, 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.
