Form No. 3361-955 Rev A Commercial Walk-Behind Mower with Floating Deck, T-Bar, Hydro with 36in TURBO FORCE® Cutting Unit Model No. 38494—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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 1. Location of the model and serial numbers Important: This engine is not equipped with a spark arrester muffler.
Starting and Stopping the Engine ........................ 14 Operating the Mower Blade Control (PTO) ............................................................ 15 The Safety Interlock System................................ 15 Driving Forward or Backward............................. 16 Stopping the Machine......................................... 17 Pushing the Machine by Hand............................. 17 Transporting Machines.......................................
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. 98-5954 43-8480 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 66-1340 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7.
105-7798 110-2068 1. Read the Operator’s Manual. 106-0635 112-8720 106-0699 Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 115-4186 1. 2. 3. 4. 5. 6.
117–2718 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator’s Manual. 114-3424 1. Traction control 2. Fast 5. Reverse 6. Disengage the PTO (Power Take Off) 3. Slow 4. Neutral 115–4179 1. Move the motion control lever to the neutral position, then pull 6. Warning—stop the engine before leaving the machine. out on PTO (Power Take Off) switch to engage the blades. 2. Push in on the PTO (Power Take Off) to disengage the blades. 7.
Hour Meter Product Overview The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 4). Safety Interlock Indicators There are symbols on the hour meter and indicate with a black triangle that the interlock component is in the correct position (Figure 4).
Ignition Switch Operation This switch is used to start the mower engine and has three positions: Start, Run and Off. 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. Motion Control Levers The motion control levers are used to drive the machine forward, reverse, and turn either direction.
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.
Note: A warm or hot engine may not require choking. To start a warm engine, move throttle control midway between the fast and slow positions. If the parking brake does not hold securely, adjust it. Refer to Servicing the Parking Brake. 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.
Operating the Mower Blade Control (PTO) The Safety Interlock System The blade control switch (PTO) is used in conjunction with the right side motion control lever to engage and disengage the mower blades. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Engaging the Mower Blades (PTO) • Do not tamper with the interlock switches. 1.
Driving Forward 1. Start the engine; refer to Starting and Stopping the Engine in , page . 1. Release the parking brake; refer to Releasing the Parking Brake in , page . 2. Set the parking brake. 3. Move the right side motion control lever to the center, un-locked position. The blades should not rotate. 2. Move the right side motion control lever to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 9). 4. Move the motion control levers forward.
Stopping the Machine To stop the machine, move the motion control levers to neutral, move the right side motion control lever into the neutral lock position, disengage the power take off (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in , page . Remember to remove the key from the ignition switch. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Figure 10 1.
Note: All height-of-cut pins can use two spacers maximum. 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Figure 12). 2. Using the lift handle, raise side of deck and remove hairpin cotter (Figure 12). 3. Add or remove spacers if needed and then align holes and insert hairpin cotter (Figure 12). Figure 11 Note: Spare height-of-cut spacers may be stored on posts and retained by a hairpin cotter. 1.
1. After adjusting height-of-cut, check the anti-scalp rollers so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figure 13). 5. Swing the lever back over to tighten the baffle and cam lock (Figure 14). 6. If the cam does not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved. 2. If adjustment is needed, remove the bolt, washers and nut (Figure 13). 3.
Figure 17 Figure 15 Position B Use this position when bagging (Figure 16). Figure 16 Position C 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.
Using the Mid-Size Weight Weights are installed on certain mowers to improve balance and improve performance. The weights can be moved or removed to create optimized performance under different mowing conditions and for operator preference (Figure 18). The following table indicates the position of the weight as installed at the factory. Mower Deck Size 36 inches Number of weights install Position of the weight 1 Front • Any rear weight must be removed when a Tru–Track® Sulky is installed.
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 hydraulic fluid level. • Change the hydraulic filter. Before each use or daily • • • • • • • Check the safety interlock system. Grease the front caster pivot bearing. Check the engine oil level. Clean the air intake screen. Check the brakes.
Lubrication Greasing the PTO Drive Belt Idler and Mower Deck Belt Idler Grease with No. 2 general purpose lithium base or molybdenum base grease. Service Interval: Every 50 hours How to Grease Every 50 hours 1. Disengage the PTO and set the parking brake. Grease the idler pulley pivots (Figure 20). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification 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. Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1. Disengage the PTO and set the parking brake. 2.
1. Carefully slide the foam element onto the paper air cleaner element (Figure 21). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 21). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 21). Servicing the Engine Oil Figure 23 Service Interval/Specification 1. Oil dipstick Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 2. Filler tube 5.
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 25). 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 25). 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.
Fuel System Maintenance 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Draining the Fuel Tank Checking the Spark Plugs Service Interval: Every 100 hours 1. Look at the center of the spark plugs (Figure 27). 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.
Figure 28 1. Fuel shut-off valve 2. Clamp Figure 29 1. Hose clamp 2. Fuel line Servicing the Fuel Filter 3. Filter 5. Remove the filter from the fuel lines. Replacing the Fuel Filter 6. Install a new filter and move the hose clamps close to the filter. Service Interval: Every 200 hours 7. Open fuel shut-off valve at fuel tank (Figure 28). Never install a dirty filter if it is removed from the fuel line. 8. Check for fuel leaks and repair if needed.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.
Figure 31 1. Vent caps 2. Upper line 3. Lower line 2. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery in , page . Adding Water to the Battery The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 1. Remove the battery from the machine; refer to Removing the Battery in , page .
Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery. 2. Check the electrolyte level; refer to Checking the Electrolyte Level. 3. Make sure the filler caps are installed in battery. Charge battery for 1 hour at 25 to 30 amps or 6 hours at 4 to 6 amps. 4.
Drive System Maintenance Adjusting the Tracking 1. If the machine does not track straight, adjustment is required. 2. Check the rear tire pressure. Refer to Checking the Tire Pressure. Figure 35 3. Loosen the wing nuts on the right control rod and rotate the turnbuckle in or out to ensure the right side control lever is centered in the neutral lock position. Secure the turnbuckle in position with the wing nuts (Figure 34). Replacing the Caster Wheel Fork Bushings 4.
Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck. 1. Remove the locknut and wheel bolt holding the caster wheel to the caster fork (Figure 38). 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Figure 37). Clean the inside of the mounting tube. Figure 38 1. Locknut 2. Wheel Bolt 3. Bushing Figure 37 1. Mounting Tube 4. Spanner Bushing 5. Roller Bearing 2. Bushing 2.
Cooling System Maintenance assembly. Make sure it is between the armature and the rotor friction surfaces. 2. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Figure 39). Cleaning the Air Intake Screen 3. Repeat this for the remaining slots. Service Interval: Before each use or daily 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them.
Brake Maintenance 9. Tighten the top and bottom jam nuts (Figure 40). 10. Check the brake operation again; refer to Checking the Brake. Servicing the Brake 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 Parking Brake Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the PTO. 2.
Belt Maintenance Replacing the Mower Belt Service Interval: Every 50 hours Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 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. Unlatch and remove the carrier frame cover. 4.
10. Install the heat shield to the engine deck and carrier frame. 11. Install the belt covers onto the cutting unit and secure the latches. 12. Install the carrier frame cover onto the carrier frame and secure the latches. Figure 43 1. PTO drive belt idler pulley 2. PTO drive Belt 3. Idler spring Replacing the Pump Drive Belt Figure 42 1. Mower deck belt 2. PTO Drive Belt 3. Idler arm and spring 4. Most tension for worn belts 5. Medium tension for normal belt conditions 6.
Controls System Maintenance Adjusting the Motion Control Handle Positions Adjusting the Right Side Motion Control Lever If the motion control levers do not align horizontally, adjust the right side motion control lever. Note: Adjust the horizontal alignment before the front to back alignment. 1. Disengage the PTO, move the right side motion control lever to the neutral position and set the parking brake. 2.
Figure 47 1. Right side motion control lever pivot shown under controls 2. Right side motion control lever Figure 46 1. Cam 2. Nut and bolt 3. Wing nut 3. 1/8 inch (3mm) gap needed between switch and control lever 4. Switch Adjusting the Neutral Postion for the Motion Control Levers 4. Turnbuckle 5. Switch screws Important: Ensure the tracking of the mower is correct after adjusting the motion control levers.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 48 1. Left motion control lever 2. Right motion control lever Important: Use oil specified or equivalent. Other fluids could cause system damage. 3. Neutral locked position 4. Align the control levers front to back here Hydraulic System Oil Capacity: 67 oz. (2.
3. Remove hydraulic reservoir cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydraulic fluid from draining out. 4. Locate the filter under the fuel tank and place drain pan under filter (Figure 51). 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 50). 9.
Important: Use oil specified or equivalent. Other fluids could cause system damage. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 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. • 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.
Mower Deck Maintenance Checking for Bent Blades 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Servicing the Cutting Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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. 3.
Removing the Blades 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. Sharpen at original angle 1. Hold the blade end using a rag or thickly-padded glove. 2. Check the balance of the blade by putting it on a blade balancer (Figure 58).
5. Set the height-of-cut to the 4 inch (101.6 mm) position. Refer to Adjusting the Height-Of-Cut in , page . 6. Perform the steps in the following sections Frame Set Up, Checking Front-to-Rear Pitch, and Checking Side-to-Side Leveling. Frame Set Up Checking the Carrier Frame and Engine Deck Alignment Note: Misalignment can cause excess wear on the PTO drive belt. 1. Disengage the PTO and set the parking brake. 2.
Checking the Carrier Frame Front-to-Rear Pitch 4. Measure carrier frame height at location A (Figure 62). The carrier frame must have a pitch between 1/8 inch (3 mm) to 3/8 inch (9 mm) over the length of 24 inches (61 cm) on the carrier frame (Figure 61). 5. Measure carrier frame height at location B (Figure 62). 6. If the carrier frame height is not the same move spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level. 1.
3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 65). 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 65). Checking the Mower Deck Side-to-Side Height Figure 63 1. Adjust the rear tire pressure to specifications; refer to Drive System Maintenance. 2.
Matching Height of Cut Replacing the Grass Deflector 1. Check the rear tire pressure. 2. Set the height-of-cut to the 4 inch (101.6 mm) position following the height-of-cut decal. 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. 3. With the machine on level surface, position one blade front-to-rear.
Cleaning position and ensure that it rotates into the full down position. Cleaning Under the Mower Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 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. Raise the front of the machine and use jack stands to support the mower.
Storage distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). Cleaning and Storage 10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 2.
Troubleshooting Problem Engine will not start, starts hard, or fails to keep running. Engine loses power. Engine overheats. Machine does not drive. Abnormal vibration. Uneven cutting height. Possible Cause Corrective Action 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 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 filter. 7.
Problem Blades do not rotate. Possible Cause Corrective Action 1. Drive belt is worn, loose or broken. 1. Check the belt tension. 2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring. 6. Adjust the clutch air gap. 7. Contact an Authorized Service Dealer. 8.
Schematics Hydraulic Schematic (Rev.
Electrical Schematic (Rev.
Notes: 55
The Toro Total Coverage Guarantee 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 repair the listed Toro Products if defective in materials or workmanship.
