Form No. 3359-837 Rev B Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Hydro, Fitted with a 48in (122cm), 36in (91cm) or 32in (81cm) Rear Discharge Cutting Unit Model No. 30033 (Traction Unit)—Serial No. 280000001 and Up Model No. CODE648E (48in (122cm) Cutting Unit)—Serial No. 280000001 and Up Model No. CODE649E (36in (91cm) Cutting Unit)—Serial No. 280000001 and Up Model No. CODE647E (32in (81cm) Cutting Unit)—Serial No.
Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. This manual should be considered as part of the machine, as it contains, safety, operational and maintenance information. The mower is a precision built machine designed solely for cutting grass and similar low lying ground vegetation within the limitations stated in this manual. You are responsible for operating the product properly and safely. Figure 2 1.
Contents Fuel System Maintenance ....................................... 27 Servicing the Fuel Tank ...................................... 27 Servicing the Fuel Filter ...................................... 28 Drive System Maintenance ..................................... 29 Adjusting the Speed Control Linkage .................. 29 Adjusting the Neutral Control Linkages .............. 29 Adjusting the Hydro Control Linkages ................ 30 Adjusting the Control Rod..................................
Safety • If gasoline is spilled, do not attempt to start the engine but move the mower away from the area of spillage and avoid creating any source of ignition until gasoline vapors have dissipated. • Replace all fuel tank and container caps securely. Improperly using or maintaining this mower can result in injury. To reduce the potential for injury, comply with these safety instructions.
– limit loads to those you can safely control. • Slopes: – Do not mow excessively steep slopes. – do not turn sharply: use care when reversing. – Exercise extreme caution when on slopes. – do not carry passengers. – Mow across the face of slopes, never up and down and exercise extreme caution when changing direction on slopes. • Watch out for traffic when crossing or near roadways. • Before leaving the operator’s position – disengage the power take-off and lower the attachments.
Sound Pressure for the 32 RD, 36 RD and 48 RD The 32 RD and 36 RD have an equivalent continuous A-weighted sound pressure level at the operator ear of 84 dBA, based on measurements of identical machines per EN 11094 and EN 836. The 48 RD has an equivalent continuous A-weighted sound pressure level at the operator ear of 87 dBA, based on measurements of identical machines per EN 11094 and EN 836.
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. Keep safety signs clear and visible, replace any decal that is damaged or lost. 105-4110 40-13–010 1. Cutting hazard of hand 2. Cutting hazard of foot 93-9353 1. Shut off fuel valve before transporting, rotate knob clockwise until it stops. 106-2733 1. Fast 2. Continuous variable setting 3. Slow 106-5517 95-5537 1. Warning—do not touch the hot surface.
115-1039 107-2131 1. Hydraulic oil level 1. Parking brake—disengaged 2. Warning—do not touch the hot surface. 2. Parking brake—engaged Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 115-1038 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Forward Neutral Reverse To turn right move the left hand lever into the forward position while the right hand lever is in the neutral position.
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 tyre pressure. 2 Operator’s Manual Engine Operator’s Manual Parts Catalog Operator training material Registration Card Oil drain hose 1 1 1 1 1 1 Read the Operator’s Manual and watch the operator training material before operating the machine. Note: Determine the left and right sides of the machine from the normal operating position.
Product Overview Figure 4 1. Mower deck 2. Brake 3. Gas tank 4. Controls 5. Handle 6. Caster wheel Figure 5 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 5) before you start the engine and operate the machine. Throttle Control The throttle control has two positions: Fast and Slow.
Ignition Switch 48 inch mowers: This switch is used in conjunction with recoil starter and has two positions: Run and Off. Width 49–1/2 inches (126 cm) Length 76–1/2 inches (194 cm) Speed Control Lever Height 44 inches (112 cm) Weight 547 lb (248 kg) This machine has a variable speed control with a neutral position. This controls how fast the machine will travel.
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). • Always place gasoline containers on the ground away from your vehicle before filling. In certain conditions, gasoline is extremely flammable and highly explosive.
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 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. Slowly release tension on chain. Figure 9 1. Throttle lever 2. Ignition switch 3. Disengage the blade control knob (PTO) and move the speed control lever to neutral. 3.
2. Pull blade control knob (PTO) up. Hold the OPC levers against handle grip. Note: Releasing the OPC levers with the mower blades running will kill the engine. 3. Restart the engine and repeat the procedure to engage the mower blades if the operator presence control (OPC) levers are released. Figure 10 1. Handle 2. Neutral lock 3. Neutral position 4. Drive lever 5. Full speed forward 6. Reverse position Releasing the Neutral Lock 1. Squeeze the drive levers back until an increase in force is felt. 2.
Understanding the Safety Interlock System 7. With the engine running, move the speed control lever forward. Release the OPC levers. The engine should kill. The safety interlock system is designed to prevent the mower from starting unless: • The blade control knob (PTO) is pushed off. • The speed control lever is in neutral. 8. If all the above conditions are not met have an Authorized Service Dealer repair the safety system immediately.
Bringing the Machine to Neutral Position Note: Rotate the by-pass valves a maximum of 2 turns so the valve does not come out of the body causing fluid to run out. Always set the neutral lock and parking brake when you stop the machine. 1. Squeeze the drive levers to neutral position. 2. Set the neutral locks. Refer to Operating Neutral Locks. 3. Move speed control lever to neutral position. Important: Do not start or operate the machine with the by-pass valves open. Damage to system may occur.
1. Disengage the PTO and pull the throttle to the slow position. 2. Turn the ignition switch to off. 3. Wait for all moving parts to stop before leaving the operating position. 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 15). 3. Place a jack under the engine frame. Raise the back end of the engine frame up enough to remove the drive wheels. 4. Remove the drive wheels. 5.
3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 19). 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 17 1. Latch pin 2. Spacer, 3/16 inch (5 mm) 3. Spacer, 1/2 inch (13 mm) 2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 17). 3.
Height of Cut Chart Number of spacers below caster Number of 1/4 inch (6 mm) blade spacers below spindle 1/2 inch (13mm) 3/16 inch (5mm) 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 in
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. Replace the hydraulic oil filter. Check the safety system.
Lubrication Grease the blade engagement (PTO) bellcrank (Figure 20). Use Figure 20 for locating the grease points on the machine. Lubricate cam lock with Never-Seez® or equivalent lubricant. Grease with No. 2 general purpose lithium base or molybdenum base grease. Note: Remove the guards fitted under the machine to access the grease fitting on the pump drive idler pivot. How to Grease 1. Disengage the PTO and set the parking brake. 2.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
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 2. Filler tube 1. Oil dipstick Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 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. Servicing 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. Fuel filter Figure 29 1. Hose clamp 2. Fuel line Servicing the Fuel Filter 3. Filter Replacing the Fuel Filter 5. Remove the filter from the fuel lines. Service Interval: Every 200 hours/Yearly (whichever comes first) 6. Install a new filter and move the hose clamps close to the filter. Never install a dirty filter if it is removed from the fuel line. 7. Open fuel shut-off valve at fuel tank (Figure 28). 8. Check for fuel leaks and repair if needed.
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 31). Perform the following linkage adjustments when the machine needs maintenance. Perform steps Adjust the Speed Control Linkage through Adjusting the Tracking. If any adjustment is needed , do them in the order that they are listed. 8. If needed, adjust switch location to create the 5/16 inch (8 mm) space (Figure 31).
pulled against the neutral spring (neutral position) (Figure 32). 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 32). • Use jack stands when supporting machine. • Do not use hydraulic jacks. 13.
Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stands when supporting machine. • Do not use hydraulic jacks. 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. Figure 33 4. Disengage the parking brake. 1.
5. Hold the OPC levers down. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 6. The spring that keeps tension on the knob should normally not need adjustment. However if an adjustment is needed, adjust the length of spring to 1 inch (26 mm) between the washers (Figure 36). 7. Adjust spring length by turning nut at front of spring (Figure 36). Figure 34 1. Hydro control linkage 2. Front adjustingnut 3. Rear adjusting nut 4.
2. Lengthen the control rod if the tyre is turning in reverse and shorten the rod if the tyre is turning forward. Adjusting the Tracking 3. Rotate the rod several turns if the tyre is rotating fast. Then, adjust the rod in 1/2 turn increments. 2. Check the rear tyre pressure. Refer to Checking the tyre Pressure. 4. Place the clevis pin into the drive lever (Figure 37). 3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt. 1.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily Before each use remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor-governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine. Figure 40 1. Spring anchor 2. Standard setting 3.
Brake 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 43). Servicing the Brake Note: There should be approximately 1/4 inch clearance between the tyre and the flat bar when the parking brake in the released position (Figure 43). Before each use, check the parking brake for proper operation.
Belt Maintenance Adjusting the Mower Belt Tension Checking the Belts Adjusting the Tension Service Interval: Every 50 hours/Monthly (whichever comes first) Service Interval: After the first 8 hours After the first 25 hours Every 50 hours Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.
Adjusting the PTO Engagement Linkage 6. If there is no adjustment left in the turnbuckle and the belt is still loose, the rear idler pulley needs to be positioned to the middle or front hole (Figure 46). 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 46). The PTO engagement linkage adjustment is located beneath the front left hand corner of the engine deck. 1.
Figure 49 1. 2. 3. 4. Assist arm Front assist arm stop Rear assist arm stop Turnbuckle 5. Assist arm link 6. Yoke 7. Hairpin cotter pin Figure 50 1. Bellcrank 2. Bolts and nuts 8. To adjust the assist arm link, remove the hairpin cotter pin from the assist arm (Figure 49). 9. Loosen the nut against the yoke (Figure 48). 10. Remove the assist arm link from the assist arm and rotate the link to adjust the length. 11.
Hydraulic System Maintenance 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 51). Servicing the Hydraulic System 9. Install cap on filler neck. Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
through normal operation once the charge pump is primed. 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 up onto jack stands high enough to raise the drive wheels off the ground. 4. Check the hydraulic fluid level. 5. Start the engine and move the throttle control to the full throttle position.
Mower Deck Maintenance wheels rotate slowly, the system may prime after additional running. Recheck hydraulic fluid level. 9. Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position. Servicing the Cutting Blades 10. Check the hydro control linkage adjustment. Refer to Adjusting the Hydro Control Linkages. To ensure a superior quality of cut, keep the blades sharp.
Checking for Bent Blades 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. 1. Rotate the blades until the ends face forward and backward (Figure 55). 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 57). Figure 55 Figure 56 1.
Figure 58 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 59). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 59). Repeat this procedure until the blade is balanced. Figure 60 1. Spring mounting bolts 2. Blade brake pad Figure 59 1. Blade 2. Balancer Installing the Blades 1. Install the bolt, curved washer, and blade.
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. 4. Air cleaner is dirty. 2. Open the fuel shut off valve. 3. Apply the choke. 4. Clean or replace the air cleaner element. 5. Install wire on spark plug. 5. Spark plug wire is loose or disconnected. 6. Spark plug is pitted, fouled, or the gap is incorrect. 7. Dirt in the fuel filter. 8.
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: 48
Notes: 49
Notes: 50
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The Toro Warranty 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 during the warranty period your Toro LCE (Lanscape Contractor Equipment) (“Product”) if it requires repair due to defects in materials or workmanship.
