Form No. 3353-992 Rev C Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Gear-Drive, with a 40in or 48in TURBO FORCE® Cutting Unit Model No. 30686—Serial No. 260000001 and Up Model No. 30688—Serial No. 260000001 and Up Register at www.Toro.com.
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. Figure 1 This spark ignition system complies with Canadian ICES-002. 1. Model and serial number location Important: This engine is not equipped with a spark arrester muffler.
Adding Fuel ....................................................... 13 Think Safety First ............................................... 14 Operating the Parking Brake and Neutral Locks ............................................................. 14 Starting and Stopping the Engine ........................ 15 Operating the Blade Control (PTO) Lever.............................................................. 16 The Safety Interlock System................................ 16 Driving Forward or Backward....
Safety – 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. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
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. • 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 only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
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. 43-8480 95-5537 3. Pull back to disengage 1. Read the Operator’s Manual for instructions on operating the cutting blade 2. Push forward to engage 66-1340 98-0776 95-2814 99-3943 1.
8-5130 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 104-8569 105-4104 1. Reverse 2. Neutral 3. Transmission speeds 105-4111 106-0699 9 3.
6-2737 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection. 110-2067 110-2068 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Check the fluids and tire pressure. 2 Operator’s Manual Engine Operator’s Manual Parts Catalog Safety Video Registration Card Oil drain hose 1 1 1 1 1 1 Read the Operator’s Manual and watch the video before operating the machine. Note: Determine the left and right sides of the machine from the normal operating position.
Throttle Control Product Overview The throttle control has two positions: Fast and Slow. Operator Presence Control (OPC) Levers When you squeeze the OPC levers against the handles, the OPC system senses that the operator is in the normal operating position.
Specifications Operation Note: Specifications and design are subject to change without notice. Adding Fuel Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. 40 inch mowers: Width with deflector down 55–1/2 inches (141 cm) Length 75–3/8 inches (191.3 cm) Height 41 inches (104.
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Releasing the Neutral Locks 1. Squeeze the drive levers back. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 2. Place your thumbs on the upper part of the locks and move them forward until they are in the drive position (Figure 6). Always set the parking brake when leaving the machine unattended, even if just for a few minutes. Starting and Stopping the Engine Setting the Parking Brakes Starting the Engine 1.
5. Disconnect the wire from the spark plug to prevent someone from accidentally starting the machine while transporting or performing maintenance on it. 6. Close the fuel shut-off valve before transporting or storing the machine. Important: Close the fuel shut-off valve before transporting or the storing the machine to prevent fuel leakage. Figure 8 1. Operator Presence Control (OPC) lever 2. Blade control lever (PTO) The Safety Interlock System Figure 7 1. Throttle control 2.
Testing the Safety Interlock System 2. Squeeze the OPC levers against the handles. 3. Move the shift lever into the reverse gear. 4. Release the parking brakes; refer to Releasing the Parking Brakes and Neutral Locks. 5. Slowly release the drive levers. Service Interval: Before each use or daily Test the safety interlock system before you use the machine each time. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately. 1.
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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. Figure 9 • Never put your hands or feet under the mower. 1. Position A 2.
2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Hold the blade bolt and remove the nut (Figure 10). Figure 11 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 (Figure 11). Note: Use jack stands to support the machine. 5.
Figure 12 1. Latch pin 2. Spacer, 3/16 inch (5 mm) Figure 13 3. Spacer, 1/2 inch (13 mm) 1. Cam lock 2. Lever 2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 12). 3. Rotate cam to increase or decrease locking pressure 4. Slot 3. Install the caster in the support and insert the latch pin (Figure 12). Positioning the Flow Baffle Adjusting the Flow Baffle The following figures are only recommendations for use.
Position A This is the full rear position. The suggested use for this position is a follows (Figure 14). • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 15 Position C This is the full open position. The suggested use for this position is as follows (Figure 16). • Use in tall, dense grass mowing conditions. • Use in wet conditions. Figure 14 • Lowers the engine power consumption.
Figure 17 5. Neutral lock 6. Hairpin cotter pin 7. Left handle shown 1. Control rod 2. Clevis pin 3. Operator Presence Control lever (OPC) 4. Handle 8. Drive lever 2. Loosen the upper bolts (3/8 x 1-1/4 inch) and flange nut securing handle to rear frame (Figure 18). 3. Remove the lower bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 18). 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch)and flange nuts into mounting holes.
5. Adjust the control rod length by rotating the control rod in the rod fitting (Fig. 8). 6. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Fig. 25). Note: Make sure the clevis pins are inserted into the neutral locks. 7. Check the parking brake adjustment. Refer to Checking the Brakes in Brake Maintenance , page 35.
Height of Cut Chart Number of spacers below caster Number of 1/4 inch blade spacers below spindle 1/2 inch (13mm) 3/16 inch (5 mm) 4 3 2 1 0 A 0 0 1 inch (26 mm) 1–1/4 inch (32 mm) 1–1/2 inch (38 mm) 1–3/4 inch (45 mm) 2 inch (51 mm) A 0 1 1–1/8 inch (29 mm) 1–3/8 inch (35 mm) 1–5/8 inch (41 mm) 1–7/8 inch (48 mm) 2–1/8 inch (54 mm) A 1 0 1–3/8 inch (35 mm) 1–5/8 inch (41 mm) 1–7/8 inch (48 mm) 2–1/8 inch (54 mm) 2–3/8 inch (60 mm) B 0 1 1–3/8 inch (35 mm) 1–5/8 inch (41
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 After the first 8 hours • Change the engine oil. • Check the mower belt tension. After the first 25 hours • Check the mower belt tension. Before each use or daily • • • • • • • Check the safety system. Grease the caster wheels and caster pivot. Check the engine oil level. Clean the air intake screen.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 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.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. Inspect the foam and paper elements and replace them if they are damaged or excessively dirty. 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 4. Clean around the oil dipstick (Figure 24) so that dirt cannot fall into the filler hole and damage the engine. 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 22). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 22). 3.
Figure 26 1. Oil filter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 26). 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 3/4 turn (Figure 26). Figure 25 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 24). 5.
Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 3. Check the gap between the center and side electrodes (Figure 28). Bend the side electrode (Figure 28) if the gap is not correct. Installing the Spark 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 (Figure 28). Figure 27 1. Spark-plug wire/spark plug 4.
Fuel System Maintenance Servicing the Fuel Tank 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. Figure 29 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1. Fuel shut-off valve • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 2.
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 50 hours Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 31). Rear Tire Pressure: 15 psi (103 kPa) Caster Tire Pressure: 25-30 psi (172-207 kPa) Figure 30 1. Hose clamp 2. Fuel line 3. Filter 5. Remove the filter from the fuel lines. 6.
4. 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. 5. Adjust the control rod length by repeating the previous steps. Figure 32 1. Control rod 2. Clevis pin 3. Operator Presence Control lever (OPC) 4. Handle 5. Neutral lock 6. Hairpin cotter pin 7. Left handle shown 8. Drive lever 2.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily Before each use remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor-governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.
Brake Maintenance Servicing the Brakes 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 Brakes Figure 35 Service Interval: Before each use or daily 1. Brake rod 1. Park the machine on a level surface, disengage the blade control (PTO). 2. Wing nut 2.
Belt Maintenance 4. Remove the mower belt (Figure 37). Checking the Belts Service Interval: Every 50 hours Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating. Replacing the Traction Drive Belt 1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Figure 36). 2. Remove bottom and loosen top bolts of shield to rotate for belt clearance (Figure 36). 3.
Note: The proper mower belt tension is 10-15 lbf. (44-67 N) with the belt deflected 1/2 inch (13 mm) halfway between the pulleys (Figure 38). 1. Disengage the blade control (PTO) lever and set the parking brakes. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Loosen the locknut on the turnbuckle (Figure 39). 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt.
The PTO engagement linkage adjustment is located beneath the front left hand corner of the engine deck. 1. Disengage the blade control (PTO) lever and set the parking brakes. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Engage the blade control lever (PTO). 4. Adjust the linkage length to where the lower end of the bellcrank just clears the axle support gusset (Figure 42). Figure 40 1. Rear idler pulley 2. Middle hole 3. Front hole 4.
Figure 43 1. Assist arm 2. Front assist arm stop 3. Rear assist arm stop 4. Turnbuckle Figure 44 1. Bellcrank 2. Bolts and nuts 8. To adjust the assist arm link, remove the hairpin cotter pin from the assist arm (Figure 43). 9. Loosen the nut against the yoke (Figure 42). 10. Remove the assist arm link from the assist arm and rotate the link to adjust the length. 11. Install the assist arm link into the assist arm and secure it with the hairpin cotter pin (Figure 43). 12.
Controls System Maintenance Adjusting the Control Rods 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 45). Figure 46 1. Handle 4. Drive lever 2. Neutral/ parking brake lock 5. Forward speed 3. 3/16 to 1/4 inch (5 to 6 6. Control rod mm) clearance 3. Install the control rod to the drive lever and the neutral/parking brake lock. Secure the control rod with a clevis pin and a hairpin cotter (Figure 33). 4. Check the operation of the control rod.
Mower Deck Maintenance 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. A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. Figure 47 1. Cutting Edge 2. Curved Area • Inspect the blade periodically for wear or damage. 3. Wear/slot Forming 2.
3. Rotate the opposite ends of the blades forward. 4. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
the end of the sail area only (Figure 52). Repeat this procedure until the blade is balanced. Figure 52 1. Blade 2. Balancer Installing the Blades 1. Place the blade onto the bolt and over the cone washer. Select the proper number of spacer(s) for the height-of- cut, and slide the bolt into the spindle (Figure 50). Figure 53 1. Spring mounting bolts 2. Blade brake pad Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. 2.
Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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’s cylinder head fins and blower housing. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate, and engine. 3.
11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 12. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.
Troubleshooting Problem Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Fuel tank is empty. 1. Fill the fuel tank with gasoline. 2. Fuel shut off valve is closed. 3. Choke is not on. 2. Open the fuel shut off valve. 3. Move the throttle lever to choke position. 4. Clean or replace the air cleaner element. 5. Install the wire on spark plug. 4. Air cleaner is dirty. 5. Spark plug wire is loose or disconnected. 6. Spark plug is pitted, fouled, or the gap is incorrect. 7.
Problem Blades do not rotate. Possible Cause Corrective Action 1. Mower deck belt is worn or loose. 1. Check the belt tension. 2. Mower deck belt is broken. 3. Mower deck belt is off pulley. 2. Install new deck belt. 3. Inspect the belt and replace if damaged. Check the pulleys and idlers and adjust the belt tension. 4. Replace the spring. 4. Broken or missing idler spring.
Schematics Electrical Schematic (Rev.
The Toro Total Coverage Guarantee Landscape Contractor Equipment (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.
