Form No. 3371-902 Rev A Commercial Walk-Behind Mower Floating Deck, Split Lever, Hydro Drive with 36in, 40in, 48in and 52in TURBO FORCE® Cutting Unit Model No. 30484—Serial No. 312000001 and Up Model No. 30486—Serial No. 312000001 and Up Model No. 30488—Serial No. 312000001 and Up Model No. 30489—Serial No. 312000001 and Up Model No. 39484—Serial No. 312000001 and Up Model No. 39488—Serial No.
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.
Contents Servicing the Caster Wheel and Bearings ............. 36 Adjusting the Electric Clutch .............................. 36 Cooling System Maintenance .................................. 37 Cleaning the Air Intake Screen ............................ 37 Brake Maintenance ................................................. 37 Servicing the Brake............................................. 37 Belt Maintenance.................................................... 38 Replacing the Mower Belt .................
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. Battery Symbols Some or all of these symbols are on your battery 1-403005 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.
Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 104-8186 40in and larger mower decks 110-2067 104-8569 110-2068 105-7798 1. Read the Operator's Manual.
115-4212 1. Hydraulic oil level 115-4186 3. Warning—do not touch the hot surface. 1. Interval 2. Power Take-off (PTO) 2. Read the Operator's Manual. 3. Parking brake 4. Neutral 5. Operator presence switch 6. Battery 115–4179 1. Move the motion control lever to the neutral position, then pull 6. Warning—stop the engine and remove the spark plug wire out on PTO (Power Take Off) switch to engage the blades. before performing any maintenance on the machine. 2.
4-3424 1. Traction control 2. Fast 5. Reverse 6. Disengage the PTO (Power Take Off) 3. Slow 4.
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 6). 4 3 2 1 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 6).
Ignition Switch Specifications This switch is used to start the mower engine and has three positions: Start, Run and Off. Note: Specifications and design are subject to change without notice. Motion Control Levers 36 inch mowers: The motion control levers are used to drive the machine forward, reverse, and turn either direction. Neutral Lock Position The neutral lock position is used with the safety interlock system to engage and disengage the mower blades and to determine neutral position.
Operation 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.
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. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Filling the Fuel Tank Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 1. Shut the engine off and set the parking brake. 2.
Operating the Mower Blade Control (PTO) The blade control switch (PTO) is used in conjunction with the right side motion control lever to engage and disengage the mower blades. Engaging the Mower Blades (PTO) 1. To engage the mower blades, move the right side motion control lever to the center, un-locked position (Figure 9). 2. Pull the blade control switch (PTO) up and release it while holding down the right side motion control lever in the center, un-locked position. Figure 8 1. Ignition switch 3.
The Safety Interlock System 2. Set the parking brake. 3. Move the right side motion control lever to the center, un-locked position. The blades should not rotate. CAUTION 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. 4. Move the motion control levers forward.
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 11). 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. Remember to remove the key from the ignition switch. Note: The engine will kill if the traction control levers are moved with the parking brake engaged.
Side Discharging or Mulching the Grass 3. Release the parking brake. 4. Push the machine to the desired location. 5. Set the parking brake. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 6. Close the by-pass valves, but do not overtighten them. DANGER Important: Do not start or operate the machine with the by-pass valves open. Damage to system may occur.
Figure 15 40 inch, 48 inch, and 52 inch Mower Decks 1. Mower deck 4. Anti-Scalp Rollers 2. Bolt 3. Spacer 5. Nut Figure 14 1. Carrier Frame 4. Spacers 2. Hairpin Cotter 5. Front height-of-cut post 3. Back height-of-cut post Adjusting the Anti-Scalp Rollers The anti-scalp rollers need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground.
1 2 g012676 Figure 17 36 inch Mower Deck Figure 18 2. Nut 1. Slot 1. Mower deck 4. Anti-Scalp Rollers 2. Bolt 3. Spacer 5. Nut Positioning the Flow Baffle 5. In certain mowing conditions and terrain, a mismatch of cutting height may be seen. Adjusting the outside anti-scalp rollers to the minimum setting of 3/8 inch (10 mm) will help prevent the mower deck cutting too low on the outside and minimize the mismatch. The following figures are only recommendations for use.
Position B Using the Mid-Size Weight Use this position when bagging (Figure 20). 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 22 or Figure 23). The following table indicates the position of the weight as installed at the factory.
Figure 23 Installing the rear weight. 1. Nut 2. Weight 3. Washer 4.
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 Every 50 hours How to Grease Grease the idler pulley pivots (Figure 25 or Figure 26). 1. Disengage the PTO and set the parking brake. Note: You will have to remove the carrier covers to access the grease fitting for the mower deck. 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 27 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 29 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 29).
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 31). 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 33). 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. Draining 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.
Figure 34 1. Fuel filter 2. Clamp 3. Fuel shut-off valve Figure 35 1. Hose clamp 3. Filter 2. Fuel line Servicing 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. Replacing the Fuel Filter 7. Open fuel shut-off valve at fuel tank (Figure 34). 8. Check for fuel leaks and repair if needed. Never install a dirty filter if it is removed from the fuel line.
Electrical System Maintenance 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. Voltage: 12 V g014686 1 2 WARNING Figure 36 1. Fuel vent filter 2.
WARNING Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7 6 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. 5 8 9 4 3 2 10 11 1. Disengage the PTO and set the parking brake. 2.
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. Figure 38 1. Vent caps 3. Lower line 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. 2. Upper line 2.
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. 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 41). Figure 40 1. Red wire 3. Fuse, 25 amp, blade type 2. Fuse, 30 amp, blade type 4.
Maintain the air pressure in the rear tires at 12-14 psi (83-97 kPa). Uneven tire pressure can cause an uneven cut. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance. Figure 43 Figure 42 Replacing the Caster Wheel Fork Bushings 1. Locking Pin 3. Carrier frame pivot tube 2. Spacers 4. Caster wheel fork 3. Pull the caster wheel fork out of the mounting tube, leaving the spacer(s) on the bottom of the fork.
6. Inspect the caster wheel fork for wear and replace if necessary (Figure 43). 7. Slide the caster wheel fork through the bushings in the mounting tube. Replace the spacer(s) onto the fork and secure with the retaining ring (Figure 43). 4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Figure 45). 5. To assemble, place one bushing into the wheel hub.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Before each use, check brakes on both a level surface and slope. Service Interval: Before each use or daily 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.
Belt Maintenance 9. Tighten the top and bottom jam nuts (Figure 47). 10. Check the brake operation again; refer to Checking the Brake. 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.
Replacing the PTO Drive 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 drive belt. Replace the drive 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.
Adjusting the PTO Drive Belt Idler Spring Anchor The position of the PTO idler can be adjusted to increase or decrease belt tension. Use Figure 52 for the idler position options. g014677 Figure 50 40 inch, 48 inch, and 52 inch Mower Deck shown 1. PTO drive belt guide 4. PTO engagement pulley 2. PTO drive Belt 5. PTO drive belt idler pulley 3. Idler spring 6. Center spindle pulley Figure 52 1. PTO drive belt idler pulley 4. Most tension for worn belts 2. PTO drive Belt 5.
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 56 1. Right side motion control lever pivot shown under controls 2. Right side motion control lever 3. 1/16 inch to 3/32 inch (1.6 mm to 2.4 mm) gap needed between switch and control lever 4. Switch Figure 55 1. Cam 2. Nut and bolt 3. Wing nut 4. Turnbuckle 5. Switch screws Adjusting the Neutral Position for the Motion Control Levers 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 Note: There are two ways of checking the hydraulic oil. One is when the oil is warm and one is when the oil is cold. The baffle inside the tank has two levels depending if the oil is warm or cold. 1. Position machine on a level surface. 2. Disengage the power take off (PTO) and shut off the engine. 3.
WARNING 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 60 • Use cardboard or paper to find hydraulic leaks.
check for leaks. If one or both wheels will not drive, refer to Bleeding Hydraulic System. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 11. Recheck level and add fluid, if required. Do not overfill. • 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.
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. 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. • Inspect the blades periodically for wear or damage. • Replace a worn or damaged blade.
WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. 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.
Figure 68 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 65). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 65). 2. For 40 inch and 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 65). 3. For 36 inch and 52 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 66). Figure 66 36 inch and 52 inch Mower Decks 1.
Checking the Engine Deck Height Frame Set Up 1. Disengage the PTO and set the parking brake. Checking the Carrier Frame and Engine Deck Alignment 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Note: Misalignment can cause excess wear on the PTO drive belt. 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.
Figure 71 1. Carrier Frame 2. 1/8 inch -3/8 inch (3-10 mm) pitch over 24 inch (61 cm) length 3. 24 inches (61 cm) Figure 72 4. Height at locations A and B 5. Caster Wheel 1. Caster Wheel 2. Carrier Frame 4. Same height at locations A and B 5. Caster spacers 3. Front height-of-cut pins 6. Caster spacers Checking the Mower Deck Front-to-Rear Pitch 2. Measure carrier frame height at location A (Figure 71). 3. Measure carrier frame height at location B (Figure 71). 4.
Checking the Mower Deck Side-to-Side Height 1. Adjust the rear tire pressure to specifications; refer to Drive System Maintenance (page 34) . 2. Position the blades side-to-side. Measure at C and D locations from a level surface to the cutting edge of blade tips (Figure 76). For 36 inch mower decks use Figure 77. Figure 74 36 inch Mower Deck shown Changing the Mower Deck Front-to-Rear Pitch Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1.
Changing the Mower Deck Side-to-Side Height Changing the side-to-side height is done by adjusting the rear tire pressure and caster spacers. 1. Change the rear tire pressure. Do this to the corresponding side that needs adjustment. 2. Adjust the caster spacer. 3. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. Figure 79 36 inch Mower Deck shown Matching Height of Cut 1. Check the rear tire pressure. 4. The measurement should be 4 inch (101.6 mm). 2.
Cleaning 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. Waste Disposal Figure 80 1. Bolt 5. Spring installed 2. Spacer 6.
Storage 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). 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.
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: 59
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.
