Form No. 3353-997 Rev B Commercial Walk-Behind Mower For Fixed Deck, Pistol Grip, Hydro, with a 40in, 48in, or 52in TURBO FORCE® Cutting Unit Model No. 30986—Serial No. 260000001 and Up Model No. 30988—Serial No. 260000001 and Up Model No. 30989—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.
Product Overview ............................................. 12 Controls ........................................... 12 Specifications ................................... 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 • 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. 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 Manual for instructions on operating the cutting blade 2. Pull back to disengage 95-2814 8 3.
8-5954 105-4110 106-0699 99-3943 1. Engine 106-2733 1. 2. 103—2103 104-8569 105-4109 9 Fast 3.
6-2738 4. 5. 6. 1. Park 2. Drive 3. Neutral Engine—stop Engine—run Warning—wear ear protection. 7. Fast 10. 8. Continuous variable setting 9. Slow Neutral 106-2743 Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer. 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. Step Use Qty. Description 1 No parts required – Check the uids 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. 6. 7. Controls Handle Caster wheel Figure 4 1. 2. 3. 4. 5. Controls Become familiar with all the controls (Figure 4) before you start the engine and operate the machine. Throttle control Speed control lever Ignition switch Neutral lock Operator Presence Control levers (OPC) 6. 7. 8. 9. 10.
Ignition Switch This switch is used in conjunction with recoil starter and has two positions: Run and Off. 44 inches (111.8 cm) Weight 570 lb (259 kg) 52 inch mowers: Speed Control Lever This machine has a variable speed control with a neutral position. This controls how fast the machine will travel forward.
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.
Operating the Parking Brake • 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. Always set the parking brake when you stop the machine or leave it unattended. Before each use, check the parking brake for proper operation. Add the correct amount of gas stabilizer/conditioner to the gas. If the parking brake does not hold securely, adjust it.
To use the cold start kit: 11. Push the choke to off as the engine warms up (Figure 8). 12. If the engine is cold, allow it to warm up and then move the throttle control to the fast position. • Grasp split ring (Figure 7) on right side of machine, pull ring and chain straight out from side of machine and hook ring over control shield bolt. Stopping the Engine 1. Move the throttle lever to slow (Figure 8). 2. Move drive levers to neutral and set neutral locks. 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. 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. Neutral lock 3. Neutral position 4. 5. 6.
The Safety Interlock System 1. Set the neutral locks and place speed control lever in neutral. 2. Start the engine; refer to Starting and Stopping the Engine. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 3. Without holding the Operator Presence Control (OPC) levers, pull the blade control knob (PTO) up. The engine should kill. • Do not tamper with the interlock switches. 4. Push the blade control knob down to off. 5.
Pushing the Machine by Hand The by-pass valves allow the machine to be pushed by hand without the engine running. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To Push the Machine 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 12 1. Drive lever 2. 2. Open the by-pass valves by turning them counter clockwise 1 to 2.
Figure 13 1. By-pass valve Figure 14 Adjusting the Flow Bafe 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot 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. Positioning the Flow Bafe 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. The following figures are only recommendations for use.
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.
2. Turn the ignition switch to off. 3. Wait for all moving parts to stop before leaving the operating position. Set the parking brake. 2. Wait for all moving parts to stop before leaving the operating position and then set the parking brake. 4. Hold the blade bolt and remove the nut. Slide the bolt down through the spindle, and change the spacers as needed (Figure 18). 3. Place a jack under the rear center of the engine frame. Raise the back end of the engine frame up enough to remove the drive wheels.
2. Loosen the upper flange bolts (3/8 x 1-1/4 inch) and flange nut securing handle to rear frame (Figure 22). 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 22). 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. Figure 20 1. Latch pin 2. Spacer, 3/16 inch (5 mm) 3. Spacer, 1/2 inch (13 mm) 2.
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 (29 mm) A 0 1 1–1/8 inch (29 mm) 1–3/8 inch (29 mm) 1–5/8 inch (29 mm) 1–7/8 inch (29 mm) 2–1/8 inch (55 mm) A 1 0 1–3/8 inch (35 mm) 1–5/8 inch (29 mm) 1–7/8 inch (29 mm) 2–1/8 inch (55 mm) 2–3/8 inch (29 mm) B 0 1 1–3/8 inch (35 mm) 1–1/8 inch (29
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 rst 8 operating hours • Change the engine oil. • Check the mower belt tension. After the rst 25 operating 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.
Lubrication Use Figure 23 for locating the grease points on the machine. Grease with No. 2 general purpose lithium base or molybdenum base grease. 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. Figure 23 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 1. 2. 3. 4. Connect a grease gun to the fitting.
4. Unscrew the cover knob and remove the air cleaner cover (Figure 24). 5. Remove the 2 wing nuts and remove the air cleaner assembly (Figure 24). 6. Carefully pull the foam element off the paper element (Figure 24). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 3. Replace the paper element if it is damaged. 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.
Changing the Oil 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 3. Disengage the PTO and set the parking brake. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 25 5. Slide the drain hose over the oil drain valve. 6. Place a pan below the drain hose.
Changing the Oil Filter installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plugs if necessary. Replace the oil filter every 200 operating hours or every other oil change. Type: Champion® RCJ8Y or equivalent Air Gap: 0.030 inch (0.75 mm) Note: Change the oil filter more frequently when the operating conditions are extremely dusty or sandy. Removing the Spark Plugs 1. Drain the oil from the engine; refer to Changing the Engine Oil. 1.
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 30 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
Figure 31 1. Fuel shut-off valve 2. Clamp Figure 32 1. Hose clamp 2. Fuel line Servicing the Fuel Filter Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 3. Filter 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Figure 31). 8. Check for fuel leaks and repair if needed. 9. Wipe up any spilled fuel.
5. Adjust the threaded yoke at the bottom of the speed control linkage until the tabs are at the 6 o’clock position (Figure 33). Figure 33 1. Speed control rod 2. Yoke 3. Speed control crank 4. 5. Figure 34 Tabs, 6 o’clock position Jam nut 1. 2. 6. Pull the speed control lever back to neutral. Actuating tab 5/16 inch (8 mm) space 3. Safety switch Adjusting the Neutral Control Linkages 7.
2. Stop the engine and wait for all moving parts to stop before leaving the operating position. turn counter-clockwise if the wheel is turning forward (Figure 35). 13. Release the drive lever to the forward drive position and squeeze back into the neutral position. Check to see if the wheel stops. If not, repeat the above adjustment procedure. 14. After adjustments are made, tighten the nuts against the yokes. 15. Repeat this procedure for the opposite side. 3.
Adjusting the Left Side 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. 3. Raise the rear of the machine onto jack stands high enough to raise the drive wheels off of the ground. 4. Disengage the parking brake. 5. Start the engine and move the throttle ahead to the full throttle position. 6. Place the left drive lever in the full forward position. 7. Place the speed control lever in the neutral position.
Note: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring. Repeat above adjustments if necessary (Figure 38). Figure 38 1. Speed control lever 2. Rear pivot spring 3. Figure 39 spring 1. Hydro control linkage 2. Quick track knob 3. 4. Spring 1 inch (26 mm) Adjusting the Right Side Linkage Adjusting the Control Rod 1. Place the speed control lever in the neutral position.
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 40 1. 2. 3. 4. Control rod 5. Clevis pin 6. 7. Drive lever Operator Presence Control lever (OPC) Left handle shown Neutral lock Hairpin cotter pin Figure 42 1. 5.
Cooling System Maintenance Cleaning the Air Intake Screen 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. Figure 43 1. Spring anchor 2. Standard setting 3. 4.
2. Release the parking brake; refer to Releasing the Parking Brake. 3. Remove the spring hair pin from the lower brake link (Figure 46). Figure 45 1. Air intake screen 2. Fan housing 3. Recoil starter 4. 5. Bolt Nut Figure 46 1. 2. 3. Brake Maintenance Brake linkage yoke Lower brake lever Spring clevis pin 4. 5. 6. Lower brake link 1/4 inch (6 mm) Hair pin 4.
Replacing the Mower Belt • After the first 8 operating hours. • After the first 25 operating hours. 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. Remove the knobs and the belt cover on the mower. 4. Remove the idler pulley and the worn belt (Figure 47). 5. Install the new mower belt. 6. Install the idler pulley. 7. Engage the blade control (PTO) lever and check the belt tension.
8. Check the belt guide under the engine frame for proper adjustment (Figure 50). 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 48 1. 1/2 inch (13 mm) deection here 2. Assist arm 3. Front stop 4. Locknut 5. Turnbuckle 5.
8. To adjust the assist arm link, remove the hairpin cotter pin from the assist arm (Figure 52). 9. Loosen the nut against the yoke (Figure 51). 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. Adjusting the PTO Safety Switch 1. Disengage the blade control (PTO) lever and set the parking brakes. 2.
Hydraulic System Maintenance 5. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir. (Figure 54). 6. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle. Servicing the Hydraulic System 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.
2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 12. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer to Bleeding Hydraulic System. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 13. Recheck level and add fluid, if required. Do not overfill. 3.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 56 1. Charge pump cap 2. Socket head screw • Use cardboard or paper to find hydraulic leaks. 6.
Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade 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 Figure 58 Inspect the blades every 8 hours. 1. Inspect the cutting edges (Figure 57). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. Figure 59 1.
safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the blade bolt with a wrench. 2. Remove the nut, blade bolt, curved washer, blade, spacers, and thin washer from the spindle (Figure 60). Figure 61 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 62).
4. Adjust the nut at the end of the blade brake rod until there is 1/8-3/16 inch (3 mm -5 mm) between the nut and spacer (Figure 63). 5. Engage the blades. Ensure the blade brake pad no longer contacts the pulley groove. Figure 64 Figure 63 1. Spring mounting bolts 2. Blade brake pad 3. 1/8-3/16 inch (3mm-5mm) Replacing the Grass Deector 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8.
Storage 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). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 2.
Troubleshooting Problem Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Fuel tank is empty. 2. Fuel shut off valve is closed. 3. Choke is not on. 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. Dirt in the fuel lter. 8. 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. 1. Move the 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.
Schematics Electrical Schematic (Rev. -) Hydraulic 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.
LCE The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered Items and Conditions Not Covered 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.
