Form No. 3392-453 Rev A Commercial Walk-Behind Mower Floating Deck, Split Lever, Hydro Drive with 48in and 52in TURBO FORCE® Cutting Unit Model No. 30488—Serial No. 315000001 and Up Model No. 30489—Serial No. 315000001 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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.
Contents Adjusting the PTO-drive Belt Idler-Spring Anchor..............................................................40 Replacing the Pump-Drive Belt ................................40 Controls System Maintenance .....................................41 Adjusting the Motion-Control Handle .......................41 Hydraulic System Maintenance ....................................43 Servicing the Hydraulic System.................................43 Mower Deck Maintenance......................................
Preparation Safety • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions, and pay attention to the safety alert symbol , which means Caution, Warning, or Danger—“personal safety instruction.” Failure to comply with the instructions may result in personal injury or death.
Maintenance and Storage • Keep pets and bystanders away from an operating machine. • Disengage drives, set the parking brake, stop the engine, • Slow down and use caution when making turns and and remove the key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing. crossing roads and sidewalks. Stop the blades if you are not mowing. • Be aware of the mower-discharge direction and do not • Park the machine on a level surface. point it at anyone.
General Operation Service • Be sure that the area is clear of bystanders before mowing. • Do not store the machine or a fuel container inside where there is an open flame, such as near a water heater or furnace. Stop the machine if anyone enters the area. • Do not touch equipment or attachment parts which may • Keep the nuts and bolts tight, especially the be hot from operation. Allow all of the parts to cool before attempting to maintain, adjust, or service the machine. blade-attachment bolts.
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. Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 104-8186 48 inch mower 93-7010 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 106-5517 3.
112-9028 1. Warning—stay away from moving parts; keep all guards in place. 112-8760 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment of hand or foot—stay away from moving parts. 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.
115-4186 1. Interval 2. Power Take-off (PTO) 3. Parking brake 4. Neutral 5. Operator presence switch 6. Battery 115–4189 1. Fast 2. Engine speed 3. Slow 4. Choke 126-1400 1. Warning-Read the Operator’s manual. Use only Toro riding attachments. Use of other riding attachments may create a hazardous condition resulting in injury. 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual.
130-0765 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before performing maintenance. 2. Height-of-cut selection 130-8372 1. Height-of-cut 3. Turn off power before changing height-of-cut. 2. Hairpin cotter 4. Read the Operator's Manual.
131-1180 12
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 Safety-Interlock Indicators 1 There are symbols on the hour meter and indicate with a black triangle that the interlock component is in the correct position (Figure 6).
Motion-Control Levers Specifications The motion-control levers are used to drive the machine forward, reverse, and turn either direction. Note: Specifications and design are subject to change without notice. Neutral-Lock Position 48-inch mowers: The neutral-lock position is used with the safety-interlock system to engage and disengage the mower blades and to determine the neutral position. Width with deflector down 161 cm (63.5 inches) Length 198 cm (77.
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.
Operating the Parking Brake of varnish deposits in the fuel system, use fuel stabilizer at all times. Always set the parking brake when you stop the machine or leave it unattended. Before each use, check the parking brake for proper operation. Filling the Fuel Tank 1. Shut the engine off and set the parking brake. If the parking brake does not hold securely, adjust it; refer to Setting the Parking Brake (page 16). 2. Clean around the fuel tank cap and remove the cap.
Operating the Mower-Blade Control (PTO) 4. Move the throttle control to Fast, and move the choke lever to the On position before starting a cold engine (Figure 9). 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. 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.
Using the Safety-Interlock System 2. Set the parking brake. 3. Move the right side motion-control lever to the center, unlocked position. CAUTION Note: The blades should not rotate. 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.
Driving Forward Stopping the Machine 1. Release the parking brake; refer to Releasing the Parking Brake (page 16). 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. 2. Move the right side motion-control lever to the center, unlocked position. Set the parking brake when you leave the machine; refer to Setting the Parking Brake (page 16).
Side Discharging or Mulching the Grass 6. Close the bypass valves, but do not overtighten them. Important: Do not start or operate the machine with the bypass valves open. Damage to the system may occur. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Transporting the Machine DANGER Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law.
Figure 16 40 inch, 48 inch, and 52 inch Mower Decks 1. Mower deck 4. Anti-scalp rollers 2. Bolt 3. Spacer 5. Nut Figure 15 1. Carrier frame 4. Spacers 2. Hairpin cotter 5. Front of the height-of-cut post 3. Back of the 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 10 mm (3/8 inch) minimum clearance above the ground.
Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and the height of the grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position A This is the full rear position (see Figure 20). The suggested use for this position is a follows. • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings.
Position C This is the full open position. The suggested use for this position is as follows (Figure 22). • • • • Use in tall, dense grass mowing conditions. Use in wet conditions. Lowers the engine power consumption. Allows increased ground speed in heavy conditions. Figure 23 Installing the front weight 1. Bolt 3. Weight 2. Washer 4. Nut G012679 Figure 22 Using the Mid-Size Weight Weights are installed on certain mowers to improve balance and improve performance.
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 the Mower-Deck-Belt Idler Grease with No. 2 general purpose lithium base or molybdenum base grease. 1. Disengage the PTO and set the parking brake. Service Interval: Every 50 hours 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Every 50 hours Grease the idler-pulley pivots (Figure 26 or Figure 27). 3. Clean the grease fittings with a rag.
Engine Maintenance 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. Servicing the Air Cleaner Servicing the Paper Air-Cleaner Element Service Interval: Every 25 hours—Clean the foam air-cleaner element. Every 50 hours—Check the paper air-cleaner element. Every 200 hours—Replace the paper air-cleaner element. 1. Do not clean the paper filter, replace it (Figure 28). 2.
Checking the Engine-Oil Level 1. Park the machine on a level surface. 2. Disengage the PTO and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Clean around the oil dipstick (Figure 30) so that dirt cannot fall into the filler hole and damage the engine. Figure 31 Figure 30 1. Oil dipstick 1. Oil-drain valve 2. Oil-drain hose 2. Filler tube 9.
Checking the Spark Plugs 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 32). 1. Look at the center of the spark plugs (Figure 34). Note: 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. 5.
Fuel System Maintenance Draining the Fuel Tank DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Figure 35 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1. Fuel filter 2. Clamp • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 3.
Servicing the Fuel-Vent System Service Interval: Every 200 hours/Yearly (whichever comes first) 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. Remove the existing fuel-vent filter (Figure 37). 4. Install a new filter. Figure 36 1. Hose clamp 3. Filter 2. Fuel line 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7.
Electrical System Maintenance 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. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case.
7 6 8 9 5 Figure 39 4 3 2 1. Vent caps 10 3. Lower line 2. Upper line 11 2. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery (page 32). Adding Water to the Battery 1 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. g012916 Figure 38 1. J-bolt 7. Wing nut 2. Positive cable 8. Negative cable 3. Washer 9.
Charging the Battery Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance. If a fuse blows, check the component or circuit for a malfunction or short. WARNING Charging the battery produces gasses that can explode. 1. Remove the cover under the control panel. Never smoke near the battery and keep sparks and flames away from battery. 2. Pull out on the fuse to remove or replace it (Figure 41). 3. Install the cover under the control panel.
Drive System Maintenance Adjusting the Tracking If the machine does not track straight, adjustment is required. 1. Check the rear tire pressure; refer to Checking the Tire Pressure (page 34). 2. Loosen the wing nuts on the right control rod, and rotate the turnbuckle in or out to ensure that the right side control lever is centered in the neutral-lock position. Figure 43 3. Secure the turnbuckle in position with the wing nuts (Figure 42). Replacing the Caster-Wheel-Fork Bushings 4.
Servicing the Caster Wheel and Bearings Note: Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck. 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Figure 45). The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear.
Adjusting the Electric Clutch Cooling System Maintenance Service Interval: Every 100 hours The clutch is adjustable to ensure proper engagement and proper braking. Cleaning the Air-Intake Screen 1. Insert a 0.381 to 0.533 mm (0.015 to 0.021 inch) feeler gauge through one inspection slot in the side of the assembly.
Brake Maintenance 10. Check the brake operation again; refer to Checking the Parking Brake (page 37). Servicing the Brake Before each use, check the 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 and 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. g014676 4.
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 51 for the idler position options. Figure 52 2. PTO-drive belt 3. Idler spring 5. Clutch wire connector 2. Idler pulley 6. Pivot bolt 3. Clutch retainer 7. Drive pulley 4. Tension spring 8. Pump-drive belt 7. Unhook the idler spring from the frame (Figure 52). Figure 51 1. PTO-drive belt idler pulley 1. Hydraulic pumps 8.
Controls System Maintenance Adjusting the Motion-Control Handle Adjusting the Right Motion-Control Lever If the motion-control levers do not align horizontally, adjust the right motion-control lever. Note: Adjust the horizontal alignment before the front-to-back alignment. 1. Disengage the PTO, move the right motion-control lever to the neutral 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. Figure 54 3.
Figure 55 1. Right side motion-control-lever pivot shown under controls 2. Right side motion-control lever 3. 1.6 to 2.4 mm (1/16 to 3/32 inch) gap needed between switch and control lever 4. Switch Figure 56 1. Left motion-control lever 3. Neutral-locked position 2. Right motion-control lever 4. Align the control levers from front to back here 2.
Hydraulic System Maintenance 10. Install the cap onto the filler neck. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Servicing the 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. Gangrene may result if this is not done.
11. Check the level and add fluid, if required. Do not overfill. Bleeding the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if the fluid is changed or after work is performed on the system. 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.
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.
Figure 62 1. Measure here from blade to hard surface 2. Position A Figure 63 48-inch mower decks 4. Rotate the opposite ends of the blades forward. 1. Sail area of the blade 2. Blade 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 must not exceed 3 mm (1/8 inch).
Sharpening the Blades Correcting the Mower Quality of Cut 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 65). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. If one deck blade cuts lower than the other, correct as follows. Note: Tire air pressure is critical in these procedures. Make sure all tires have the correct pressure. 1. Disengage the PTO and set the parking brake. 2.
Setting up the Frame 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Checking the Carrier Frame and the Engine-Deck Alignment 3. Adjust the tire pressure in the rear tires to specifications; refer to Checking the Tire Pressure (page 34). 4. Measure engine-deck height at location A (Figure 68). Note: Misalignment can cause excess wear on the PTO-drive belt. 1. Disengage the PTO and set the parking brake. 2.
Checking the Mower Deck Front-to-Rear Pitch 3. Measure carrier-frame height at location B (Figure 69). 4. The height at location A must be 3 to 10 mm (1/8 inch to 3/8 inch) lower than location B (Figure 69). 1. Adjust the tire pressure in the rear tires to specifications; refer to Checking the Tire Pressure (page 34). 5. If the carrier frame is not correct, move caster spacers to make it an 3 to 10 mm (1/8 inch to 3/8 inch) pitch (Figure 69). 2. Position one blade front-to-rear.
Changing the Mower Deck Front-to-Rear Pitch Checking the Mower Deck Side-to-Side Height 1. Adjust the rear tire pressure to specifications; refer to Checking the Tire Pressure (page 34). Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 2. Position the blades side-to-side. 1. To change the front-to-rear pitch, the front height-of-cut posts can be adjusted (Figure 72). 3. Measure at C and D locations from a level surface to the cutting edge of blade tips (Figure 73).
Changing the Mower Deck Side-to-Side Height Replacing the Grass Deflector WARNING Changing the side-to-side height is done by adjusting the rear tire pressure and the caster spacers. 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. 1. Change the rear tire pressure. Do this to the corresponding side that needs adjustment. 2. Adjust the caster spacer.
Cleaning Storage Cleaning under the Mower Cleaning and Storing the Machine Service Interval: Before each use or daily 1. Disengage the power take off (PTO), set the parking brake, turn the ignition key to off, and remove the key. 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. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
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.
Troubleshooting Problem The engine will not start, starts hard, or fails to keep running. The engine loses power. The engine overheats. The machine does not drive. There is an abnormal vibration. The cutting height is uneven. Possible Cause Corrective Action 1. Fuel tank is empty. 1. Fill the 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 The 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: 58
Notes: 59
The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Instructions for Obtaining Warranty Service 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.
