Form No. 3376-440 Rev A Commercial Walk-Behind Mower Floating Deck, Split Lever, Hydro Drive with 48in or 52in TURBO FORCE® Cutting Unit Model No. 30488—Serial No. 313000001 and Up Model No. 30489—Serial No. 313000001 and Up Model No. 39488—Serial No. 313000001 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 Replacing the Mower Belt ........................................38 Replacing the PTO Drive Belt ..................................39 Adjusting the PTO Drive Belt Idler Spring Anchor..............................................................40 Replacing the Pump Drive Belt.................................40 Controls System Maintenance .....................................41 Adjusting the Motion Control Handle Positions............................................................
Safety • Only operate in good light, keeping away from holes and Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. • • Improper use or maintenance by the operator or owner can result in injury.
Toro Mower Safety • Never refuel the machine indoors. • Never store the fuel container where there is an open • • • • • The following list contains safety information specific to Toro products and other safety information you must know. flame, spark, or pilot light such as on a water heater or on other appliances. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.
• 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 48 inch mower 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 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 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.
Setting the Parking Brake of varnish deposits in the fuel system, use fuel stabilizer at all times. Pull the parking brake lever rearward (Figure 7). Filling the Fuel Tank 1. Shut the engine off and set the parking brake. 2. Clean around fuel tank cap and remove the cap. Add unleaded regular gasoline to fuel tank, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. 3.
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. Choke 2. Throttle lever 5. Turn the ignition key to the start position to energize the starter. When the engine starts, release the key.
The Safety Interlock System 3. Move the right side motion control lever to the center, un-locked position. The blades should not rotate. CAUTION 4. Move the motion control levers forward. The engine should kill. 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. 5.
To go straight, apply equal pressure to both motion control levers (Figure 11). CAUTION Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. To turn, move the motion control lever toward neutral in the direction you want to turn (Figure 11). The farther you move the traction control levers in either direction, the faster the machine will move in that direction.
Transporting Machines Side Discharging or Mulching the Grass 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. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Important: All four hairpin cotter pins must be in the same hole location and with the correct number of spacers for a level cut. 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.
Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of 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 19). 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 Using the Mid-Size Weight This is the full open position. The suggested use for this position is as follows (Figure 21). 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). • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption.
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 Cleaning the Foam Air Cleaner Element 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. Servicing the Air Cleaner 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. Service Interval/Specification Service Interval: Every 25 hours—Clean foam air cleaner element. Servicing the Paper Air Cleaner Element Every 50 hours—Check the paper air cleaner element.
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. Slide the drain hose over the oil drain valve. 5. Place a pan below the drain hose. Rotate oil drain valve to allow oil to drain (Figure 30). 6. When oil has drained completely, close the drain valve. 7. Remove the drain hose (Figure 30). Note: Dispose of the used oil at a recycling center. Figure 28 Checking the Engine Oil Level 1.
1 Figure 31 1. Oil filter 2. Adapter Figure 32 1. Spark-plug wire/spark plug 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 31). 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 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.
Installing the Spark Plugs Fuel System Maintenance 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 16 ft-lb (22 N-m). Draining the Fuel Tank 3. Connect the wires to the spark plugs (Figure 33). 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. • Drain gasoline from the fuel tank when the engine is cold.
Servicing the Fuel Filter 3. Remove the existing fuel vent filter (Figure 36). Service Interval: Every 200 hours/Yearly (whichever comes first) 4. Install a new filter. Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. Note: Note how the fuel filter is installed in order to install the new filter correctly. Note: Wipe up any spilled fuel. 1. Disengage the PTO and set the parking brake. 2.
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 38 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 in Electrical System Maintenance (page 31). 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 37 1. J-bolt 7. Wing nut 2. Positive cable 8. Negative cable 3.
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. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 39). 5.
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 42 Replacing the Caster Wheel Fork Bushings 4.
4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Figure 44). Clean the inside of the mounting tube. Figure 45 Figure 44 1. Mounting Tube 1. Locknut 4. Spanner Bushing 2. Wheel Bolt 5. Roller Bearing 3. Bushing 2. Bushing 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 45). 5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the pivot tubes. 3.
Cooling System Maintenance 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. 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.
Brake Maintenance 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 47 3.
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 52 for the idler position options. Figure 53 1. Hydraulic pumps 4. Most tension for worn belts 2. PTO drive Belt 5. Medium tension for normal belt conditions 6. Least tension for new belts 3. Idler spring 2. Idler pulley 6. Pivot bolt 3. Clutch retainer 7. Drive pulley 4. Tension spring 8. Pump drive belt 7.
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 57 1. Left motion control lever 3. Neutral locked position 2. Right motion control lever 4. Align the control levers front to back here 2.
Hydraulic System Maintenance 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. Servicing the Hydraulic System Checking the Hydraulic Fluid • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Bleeding the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if 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. 4. Start the engine and move the throttle control to idle position.
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.
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. 1. Hold the blade end using a rag or thickly-padded glove. 2. For 40 and 48 inch mower decks, remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 65).
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.
Frame Set Up 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 Engine Deck Alignment 3. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance (page 34) . 4. Measure engine deck height at location A (Figure 70). Note: Misalignment can cause excess wear on the PTO drive belt. 5. Measure engine deck height at location B (Figure 70). 6.
3. Measure carrier frame height at location B (Figure 71). blade tips (Figure 73 or Figure 74). For 36 inch mower decks use Figure 74. 4. The height at location A must be an 1/8-3/8 inch (3 mm -10 mm) lower than location B (Figure 71). 3. The mower blade should be a 1/4 inch (6 mm) lower in front at A than in the rear at B. Rotate blades and repeat for other blades. If it is not correct, proceed to Changing the Deck Front-to-Rear Pitch. 5.
Figure 76 40 inch, 48 inch, and 52 inch Mower Deck shown Figure 75 1. Caster Wheel 2. Carrier Frame 4. Jam nut 5. Ball joint 1. Measure from a level surface 3. Front height-of-cut pins 2. Measure blade at points C and D 2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Figure 75). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 75). 4. Position the blades front-to-rear.
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.
Storage 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. Cleaning and Storage 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. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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: 58
Notes: 59
The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered This warranty includes the cost of parts and labor, but you must pay transportation costs. 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.
