Form No. 3356-677 Rev B Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Hydro, with a 40in, 48in, or 52in TURBO FORCE® Cutting Unit Model No. 30986—Serial No. 270000001 and Up Model No. 30988—Serial No. 270000001 and Up Model No. 30989—Serial No. 270000001 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. This spark ignition system complies with Canadian ICES-002. Figure 1 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.
Specifications ..................................................... 13 Attachments/Accessories................................... 13 Operation................................................................... 14 Adding Fuel ....................................................... 14 Think Safety First ............................................... 15 Operating the Parking Brake ............................... 15 Starting and Stopping the Engine ........................ 15 Operating the Neutral Locks......
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. 98-0776 1-523552 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). 43-8480 95-5537 66-1340 1. Read the Operator’s 3. Push forward to engage Manual for instructions on operating the cutting blade 2.
105-4109 105-4110 99-3943 1. Engine 106-0699 103—2103 106-2733 104-8569 1. Fast 2. Continuous variable setting 106-2743 9 3.
110-2067 110-2068 1. Read the Operator’s Manual. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 106-2738 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection. 7. Fast 10. Neutral 8. Continuous variable setting 9.
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.
Product Overview Figure 3 1. 2. 3. 4. Side discharge Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel Figure 4 1. 2. 3. 4. 5. Controls Throttle control Speed control lever Ignition switch Neutral lock Operator Presence Control levers (OPC) 6. 7. 8. 9. 10. Handle Drive Lever Blade control knob (PTO) Choke Fuel shut-off valve Become familiar with all the controls (Figure 4) before you start the engine and operate the machine.
Ignition Switch 52 inch mowers: This switch is used in conjunction with recoil starter and has two positions: Run and Off. Speed Control Lever This machine has a variable speed control with a neutral position. This controls how fast the machine will travel forward. Neutral Lock Squeeze drive levers back until an increase in force is felt and move locks to the rear for neutral lock. Recoil Starter Pull the recoil starter handle to start engine (Figure 3).
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. 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Important: Do not use fuel additives containing methanol or ethanol. If the parking brake does not hold securely, adjust it. Refer to Servicing the Parking Brake. 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.
4. Let engine idle for 30 to 60 seconds before turning the engine off. 5. To stop the engine, turn the ignition key to off. Figure 7 1. Split ring 2. Control shield bolt • After the engine is started, pull the chain straight out from side of machine until ring can be removed from shield bolt. Slowly release tension on chain. Figure 8 1. Throttle lever 2. Ignition switch 3. Disengage the blade control knob (PTO) and move the speed control lever to neutral. 3.
Engaging the Mower Blades (PTO) 1. To engage blades, squeeze the Operator Presence Control (OPC) levers against handle grips (Figure 11). 2. Pull blade control knob (PTO) up. Hold the OPC levers against handle grip. Note: The engine will kill if the OPC levers are released with the mower running and the speed control lever is not in neutral. 3. Restart the engine and repeat the procedure to engage the mower blades if the operator presence control (OPC) levers are released. Figure 9 1. Handle 2.
The Safety Interlock System 2. Start the engine; refer to Starting and Stopping the Engine. 3. Without holding the Operator Presence Control (OPC) levers, pull the blade control knob (PTO) up. The engine should kill. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 4. Push the blade control knob down to off. 5. With engine running, hold down the OPC levers. Pull the blade control knob (PTO) up.
Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Pushing the Machine by Hand The by-pass valves allow the machine to be pushed by hand without the engine running. Figure 12 1. Drive lever Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 2.
Figure 13 1. By-pass valve Figure 14 1. Cam lock Adjusting the Flow Baffle 2. Lever The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. 1. Disengage the PTO, move the motion control levers to the neutral locked position and 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.
Figure 15 Figure 16 Position B Position C Use this position when bagging (Figure 16). This is the full open position. The suggested use for this position is as follows (Figure 17). • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower.
Side Discharging or Mulching the Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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.
5. Loosen, but do not remove, the 2 top axle bolts (Figure 19). 4. Hold the blade bolt and remove the nut. Slide the bolt down through the spindle, and change the spacers as needed (Figure 18). 6. Remove the 2 lower axle bolts (Figure 19). Figure 19 1. Top axle bolt 2. Lower axle bolt 7. Raise or lower the mounting bracket, so that you can install the 2 axle adjustment bolts in the desired hole location (Figure 19). A tapered punch can be used to help align the holes. 8. Tighten all 4 bolts. 9.
2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 20). 3. Install the caster in the support and insert the latch pin (Figure 20). Adjusting the Handle Height The handle position can be adjusted to match the operator’s height preference. 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 21). Figure 22 7. Control rod fitting Lower mounting holes 8. 9. Rear frame Lower flange bolt (3/8 x 1 10. inch) 11. 5.
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.
How to Grease 1. Disengage the PTO and 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. 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. Figure 23 Lubricating the Caster and Wheel Bearings 1. Pump drive idler arm 2.
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.
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 24). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 24). Servicing the Engine Oil Service Interval/Specification Change the engine oil as follows: Figure 26 • After the first 8 operating hours 1. Oil dipstick 2. Filler tube • After every 100 operating hours 5. Unscrew the oil dipstick and wipe the end clean (Figure 26).
Figure 28 1. Oil filter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 28). 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 28). Figure 27 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 26). 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 30). Bend the side electrode (Figure 30) 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 30). Figure 29 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 31 • 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 Perform the following linkage adjustments when the machine needs maintenance. Perform steps Adjust the Speed Control Linkage through Adjusting the Tracking. If and adjustment is needed , do them in the order that they are listed. Adjusting the Speed Control Linkage 1. Disengage the PTO and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. Figure 32 1. Hose clamp 2. Fuel line 3. Filter 3.
7. Check to make sure the safety switch is depressed and there is a 5/16 inch (8 mm) space between the actuating tab and the switch. (Figure 34). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 8. If needed, adjust switch location to create the 5/16 inch (8 mm) space (Figure 34). • Use jack stands when supporting machine. • Do not use hydraulic jacks. 1. Disengage the PTO and set the parking brake. 2.
pulled against the neutral spring (neutral position) (Figure 35). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 12. Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counter-clockwise if the wheel is turning forward (Figure 35). • Use jack stands when supporting machine. • Do not use hydraulic jacks. 13.
pivot spring. Repeat above adjustments if necessary (Figure 38). Figure 38 1. Speed control lever 2. Rear pivot spring 3. spring Figure 36 Adjusting the Right Side Linkage 12. After adjusting the left hydro control linkage, move the speed control lever forward and then back to the neutral position. 1. Place the speed control lever in the neutral position. 2. Place the right drive lever in the full forward position. 13. Hold the OPC levers down. 3.
Figure 40 1. 2. 3. 4. Figure 39 1. Hydro control linkage 2. Quick track knob 3. Spring 4. 1 inch (26 mm) Control rod Clevis pin Drive lever Operator Presence Control lever (OPC) 5. Left handle shown 6. Neutral lock 7. Hairpin cotter pin 5. Release and engage neutral lock checking that the tire does not rotate (Figure 41). Continue this process until the tire does not rotate. Adjusting the Control Rod Checking the Control Rod 6.
3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt. 4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Figure 42). Figure 43 1. Spring anchor 2. Standard setting 3. Medium setting 4. Heavy duty setting Figure 42 1.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Before each use, check the parking brake for proper operation. Servicing the Brake 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.
Belt Maintenance 4. Rotate the lower brake link yoke clockwise into the yoke to tighten the parking brake; rotate the brake link yoke counterclockwise out of the yoke out to loosen the parking brake (Figure 46). Checking the Belts Note: There should be approximately 1/4 inch clearance between the tire and the flat bar when the parking brake in the released position (Figure 46). Check all belts after every 50 operating hours or monthly, whichever occurs first.
Adjusting the Mower Belt Tension Adjusting the Tension Adjust the mower belt tension as follows: • After the first 8 operating hours. • After the first 25 operating hours. • After every 50 operating hours. Check the belt tension after the first 8 operating hours and 25 operating hours thereafter. Check the belt tension after every 50 operating hours. Important: The brake needs to be adjusted when the belt tension or the brake linkage is adjusted. Figure 48 1. 1/2 inch (13 mm) deflection 4. Locknut here 2.
Note: The distance between the belt guide and the mower belt should be 3/4 inch (19 mm) when you engage the mower belt (Figure 50). Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted. Figure 51 1. Bellcrank 2. Safety switch located under engine deck 3. Bellcrank just clears the gusset with the PTO engageded Figure 50 1. Belt guide 4. Yoke 5. Nut 6. Assist arm link 5.
Hydraulic System Maintenance 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 52). 12. Check if the assist arm hits against the stops correctly. Servicing the Hydraulic System Adjusting the PTO Safety Switch Checking the Hydraulic Fluid 1. Disengage the blade control (PTO) lever and set the parking brakes.
6. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle. 7. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine. 8. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle. 4. Locate filter under engine base and place drain pan under filter (Figure 55). 5.
Note: Hydraulic reservoir can be pressurized to up to 5 psi to speed this process. or any of the hydraulic lines are disconnected. The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump. Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed. 8.
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 57 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 62). Repeat this procedure until the blade is balanced. Figure 62 1. Blade 2. Balancer Installing the Blades 1. Install the bolt, curved washer, and blade. Select the proper number of spacer(s) for the height-of- cut, and slide the bolt into the spindle (Figure 60). Figure 63 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 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 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. -) Hydraulic Schematic (Rev.
Notes: 54
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 2007 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 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.
