Form No. 3371-969 Rev A Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Hydro Drive with 48in TURBO FORCE® Cutting Unit Model No. 30938—Serial No. 312000001 and Up Model No. 39938—Serial No. 312000001 and Up G017540 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. 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.
Contents Adjusting the Neutral Control Linkages .............. 32 Adjusting the Hydro Control Linkages ................ 33 Adjusting the Control Rod.................................. 35 Adjusting the Tracking ....................................... 36 Adjusting the Spring Anchor Links ..................... 36 Checking the Tire Pressure ................................. 36 Cooling System Maintenance .................................. 37 Cleaning the Air Intake Screen ............................
Safety – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. – 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.
• 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 the influence of alcohol or drugs. • Use care when loading or unloading the machine into or from a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
• Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 20 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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 43-8480 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). 66-1340 98-5954 95-5537 3. Pull back to disengage 1. Read the Operator's Manual for instructions on operating the cutting blade 2.
104-8569 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 105-4109 105-4110 10.
6-2743 Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual. 110-2067 106-0699 110-2068 1. Read the Operator's Manual.
106-2738 1. Park 4. Engine—stop 7. Fast 2. Drive 5. Engine—run 8. Continuous variable setting 3. Neutral 6. Warning—wear ear protection. 9. Slow 11 10.
Product Overview G017541 Figure 4 1. Side discharge 5. Controls 2. Mower deck 3. Recoil starter 4. Gas tank 6. Handle 7. Caster wheel Figure 5 Controls 1. Throttle control 2. Speed control lever 6. Handle 7. Drive Lever 3. Ignition switch 8. Blade control knob (PTO) 4. Neutral lock 5. Operator Presence Control levers (OPC) Become familiar with all the controls (Figure 5) before you start the engine and operate the machine. 9. Choke 10.
Fuel Shut-off Valve Operation Close the fuel shut-off valve when transporting or storing mower. Adding Fuel • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). Choke Use the choke to start a cold engine. • Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable. Specifications Width with deflector down 63–1/2 inches (161.
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. DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
CAUTION 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. Setting the Parking Brake Pull the parking brake lever rearward (Figure 7). Figure 8 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.
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 10 Figure 9 1. Throttle lever 2. Ignition switch 1. Handle 2. Neutral lock 4. Drive lever 5. Full speed forward 3. Neutral position 6. Reverse position Releasing the Neutral Lock 3. Choke 1. Squeeze the drive levers back until an increase in force is felt. 2.
Operating the Mower Blade Control Knob (PTO) The Safety Interlock System The blade control knob (PTO) is used in conjunction with the Operator Presence Control (OPC) levers to engage and disengage the mower blades. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
3. Without holding the Operator Presence Control (OPC) levers, pull the blade control knob (PTO) up. The engine should kill. 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. The drive belt should engage and the mower blades begin rotating. 6. With engine running, release the OPC levers. The engine should kill. 7. With the engine running, move the speed control lever forward slightly. Release the OPC levers.
Adjusting the Flow Baffle CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 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. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 1.
G012679 G012677 Figure 18 Figure 16 Transporting Machines Position B Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. Use this position when bagging (Figure 17). To transport the machine: 1. Stop the engine, remove the key, set the brake, and close the fuel valve.
Side Discharging or Mulching the Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER 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.
Adjusting the Handle Height 6. Remove the 2 lower axle bolts (Figure 20). 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 22). Figure 20 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 20). A tapered punch can be used to help align the holes. 8.
Figure 23 1. Control rod fitting 6. High position 2. Lower mounting holes 7. Lower position 3. Rear frame 8. Upper mounting hole 4. Lower flange bolt (3/8 x 1 inch) 9. Handle 5. Upper flange bolt (3/8 x 1-1/4 inches) 10. Flange nut (3/8 inch) 5. Adjust the control rod length by rotating the control rod in the rod fitting (Figure 23). 6. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Figure 22).
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 • • • • After the first 25 hours • Check the mower belt tension. Before each use or daily • • • • • • Change the engine oil. Check the mower belt tension. Check the hydraulic fluid level. Change the hydraulic filter. Check the safety system. Grease the caster wheels and caster pivot.
Lubrication Greasing the Pump Control and Bell Crank Use Figure 24 for locating the grease points on the machine. Service Interval: Every 50 hours—Grease the pump drive idler pivot. Grease with No. 2 general purpose lithium base or molybdenum base grease. Every 50 hours—Grease the pump control. How to Grease Every 100 hours—Grease the blade engagement bellcrank. 1. Disengage the PTO and set the parking brake. Every 400 hours—Lubricate cam lock with Never-Seez®. 2.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Service Interval: Every 25 hours—Clean foam air cleaner element. Every 50 hours—Check the paper air cleaner element. Every 200 hours—Replace the paper air cleaner element. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. Figure 25 1. Cover 3. Paper element 2. Hose clamp 4. Foam element Important: Do not oil the foam or paper element.
Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. Figure 27 1. Oil dipstick Every 200 hours—Change the oil filter. 2. Filler tube Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 5. Unscrew the oil dipstick and wipe the end clean (Figure 27).
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 29). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter and drain valve. 7. Check the engine oil level and add oil if needed. 8. Wipe up any spilled oil.
Checking the Spark Plugs Fuel System Maintenance 1. Look at the center of the spark plugs (Figure 31). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Servicing the Fuel Tank 2. If needed, clean the spark plug with a wire brush to remove carbon deposits. DANGER In certain conditions, gasoline is extremely flammable and highly explosive.
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 32). 8. Check for fuel leaks and repair if needed. 9. Wipe up any spilled fuel. Servicing the Fuel Vent System Service Interval: Every 200 hours/Yearly (whichever comes first) Figure 32 1. Fuel shut-off valve 2. Clamp 1. Disengage the PTO and set the parking brake. 2.
Drive System Maintenance 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 36). 8. If needed, adjust switch location to create the 5/16 inch (8 mm) space (Figure 36). 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.
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 to raise the drive wheels off the ground. 4. Disengage the parking brake. 5. Start the engine and move the throttle ahead to the full throttle position. 6. Place the neutral locks in the full forward position and move the speed control lever to the medium speed position. 7. Hold OPC levers down. 14.
Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 14. Make sure the speed control lever is in the neutral position and the tire does not rotate. 15. Repeat the adjustment if needed. 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.
Adjusting the Control Rod 4. Turn the knob clockwise 1/4 of a turn at a time. Then move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Figure 41). 1. Adjust the rod length by releasing the drive lever and removing the hairpin cotter pin and clevis pin. Rotate the rod in the rod fitting (Figure 42). 5. Hold the OPC levers down. 2. Lengthen the control rod if the tire is turning in reverse and shorten the rod if the tire is turning forward.
2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. For a heavier drive setting, relocate the spring anchor links to either the medium or heavy duty positions (Figure 45). The spring anchor links are attached to the upper rear corner of the hydro drive shields on the left and right sides of the machine. Note: In the medium or heavy duty positions, the drive lever forces at the upper handle will also be increased Figure 43 1. Handle 5. Neutral position 2.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily—Clean 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.
Brake Maintenance Servicing the Brake Before each use, check the parking brake for proper operation. Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, adjust it. Checking the Parking Brake 1. Move the machine onto a level surface. 2. Disengage the power take off (PTO) and stop the engine. 3. Set the parking brake. Figure 47 1. Air intake screen 2. Fan housing Note: Setting the parking brake should take a reasonable amount of force.
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 48). 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 48). Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the belts.
positioned to the middle or front hole (Figure 51). Use the hole that will give the correct adjustment. 7. When the idler pulley is moved the belt guide must be moved. Move the belt guide to the front position (Figure 51). Figure 49 1. Mower belt with 1/2 inch (13mm) deflection Figure 51 2. Idler pulley 1. Rear idler pulley 4. Belt guide in back position 2. Middle hole 5. Front idler pulley 3.
Adjusting the PTO Engagement Linkage 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 53). Figure 54 1. Yoke 2. Nut 3.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50 Figure 55 1. Bellcrank 3. Switch mounting bracket 2. Bolts and nuts 4. Switch body Hydraulic System Oil Capacity: 77 oz. (2.3 l) Important: Use oil specified. Other fluids could cause system damage. Note: There are two ways of checking the hydraulic oil.
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. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is warm (Figure 56). 9. Install cap on filler neck. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
wheels rotate slowly, the system may prime after additional running. Recheck hydraulic fluid level. through normal operation once the charge pump is primed. 9. Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position. 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. 10. Check the hydro control linkage adjustment.
Mower Deck Maintenance Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 60). 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. WARNING 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.
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 62). Figure 63 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 64). If the blade stays in a horizontal position, the blade is balanced and can be used.
Figure 65 1. Spring mounting bolts 3. 1/8-3/16 inch (3mm-5mm) 2. Blade brake pad Figure 66 Replacing the Grass Deflector WARNING 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 or death. Also, contact with the blade could occur. 1. Bolt 5. Spring installed 2. Spacer 6. Grass Deflector 3. Locknut 7. L end of spring, place behind deck edge before installing bolt 4. Spring 8. J hook end of spring 2.
Storage 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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. 2.
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.
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship. The following time periods apply from the date of purchase by the original owner: Products 21 in.
