Form No. 3361-918 Rev A Commercial Walk-Behind Mower with Floating Deck, T-Bar, Hydro with 36in, 40in, 48in or 52in TURBO FORCE® Cutting Unit Model No. 30494—Serial No. 280001101 and Up Model No. 30496—Serial No. 280001101 and Up Model No. 30498—Serial No. 280001101 and Up Model No. 30499—Serial No. 280001101 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. This spark ignition system complies with Canadian ICES-002. Figure 1 1. Location of the model and serial numbers Important: This engine is not equipped with a spark arrester muffler.
Starting and Stopping the Engine ........................ 14 Operating the Mower Blade Control (PTO) ............................................................ 15 The Safety Interlock System................................ 16 Driving Forward or Backward............................. 16 Stopping the Machine......................................... 17 Pushing the Machine by Hand............................. 17 Transporting Machines.......................................
Safety – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. – Never refuel or drain the machine indoors. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs. • Use care when loading or unloading the machine into or from a trailer or truck.
• Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
Slope Chart 7
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 98-0776 43-8480 98-5954 66-1340 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 68-8340 5. Read the Operator’s Manual. 95-2814 8 6.
106-0699 104-8185 Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 104-8186 110-2067 104-8569 110-2068 1. Read the Operator’s Manual.
115-4212 1. Hydraulic oil level 115-4186 3. Warning—do not touch the hot surface. 1. 2. 3. 4. 5. 6. 2. Read the Operator’s Manual. Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 115–4179 1. Move the motion control lever to the neutral position, then pull 6. Warning—stop the engine before leaving the machine. out on PTO (Power Take Off) switch to engage the blades. 2. Push in on the PTO (Power Take Off) to disengage the blades. 7.
4-3424 1. Traction control 2. Fast 5. Reverse 6. Disengage the PTO (Power Take Off) 3. Slow 4. Neutral Product Overview Figure 3 1. Ignition switch 2. Left motion control lever Figure 2 1. 2. 3. 4. Side discharge chute Engine Gas tank Controls 3. Throttle control 4. Hour meter 5. Fuel tank 5. Parking brake 6. Mower deck 7. Front caster wheel 6. Choke 7. Neutral lock position for right motion control lever 8. Right motion control lever 9. blade control switch (PTO) 10.
enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Specifications Note: Specifications and design are subject to change without notice. Figure 4 1. Safety interlock symbols 2. Battery light 36 inch mowers: 3. Hour meter Throttle Control The throttle control has two positions: Fast and Slow.
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). Leaded regular gasoline may be used if unleaded regular is not available. • Always place gasoline containers on the ground away from your vehicle before filling.
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.
Operating the Mower Blade Control (PTO) 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. To engage the mower blades, move the right side motion control lever to the center, un-locked position (Figure 7). 2.
The Safety Interlock System 1. Start the engine; refer to Starting and Stopping the Engine in , page . 2. Set the parking brake. 3. Move the right side motion control lever to the center, un-locked position. The blades should not rotate. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 4. Move the motion control levers forward. The engine should kill. • Do not tamper with the interlock switches.
Driving Forward Stopping the Machine 1. Release the parking brake; refer to Releasing the Parking Brake in , page . 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, un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 9).
Figure 11 1. Traction unit tie down loop Figure 10 1. Pump by-pass valve Side Discharging or Mulching the Grass 3. Release the parking brake. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 4. Push the machine to the desired location. 5. Set the parking brake. 6. Close the by-pass valves, but do not overtighten them.
Note: All height-of-cut pins can use two spacers maximum. 1. After adjusting height-of-cut, check the anti-scalp rollers so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figure 13, Figure 14, Figure 15). 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Figure 12). 2. If adjustment is needed, remove the bolt, washers and nut (Figure 13, Figure 14, Figure 15). 2.
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. To adjust the cam lock, swing the lever up to loosen the cam lock (Figure 16). 4. Adjust the baffle and cam lock in the slot to the desired discharge flow. 5. Swing the lever back over to tighten the baffle and cam lock (Figure 16). 6.
Figure 19 Figure 17 Position B Use this position when bagging (Figure 18). Figure 18 Position C This is the full open position. The suggested use for this position is as follows (Figure 19). • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower.
Using the Mid-Size Weight Weights are installed on certain mowers to improve balance and improve performance. The weights can be moved or removed to create optimized performance under different mowing conditions and for operator preference (Figure 20 or Figure 21). The following table indicates the position of the weight as installed at the factory.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the hydraulic fluid level. • Change the hydraulic filter. Before each use or daily • • • • • • • Check the safety interlock system. Grease the front caster pivot bearing. Check the engine oil level. Clean the air intake screen. Check the brakes.
Lubrication Greasing the PTO Drive Belt Idler and Mower Deck Belt Idler Grease with No. 2 general purpose lithium base or molybdenum base grease. Service Interval: Every 50 hours How to Grease Every 50 hours 1. Disengage the PTO and set the parking brake. Grease the idler pulley pivots (Figure 23 or Figure 24). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. Inspect the foam and paper elements and replace them if they are damaged or excessively dirty. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.
Installing the Foam and Paper Elements 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 27) so that dirt cannot fall into the filler hole and damage the engine. Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 25). 2.
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (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 29). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter and drain valve. 7.
Fuel System Maintenance 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Draining the Fuel Tank Checking the Spark Plugs Service Interval: Every 100 hours 1. Look at the center of the spark plugs (Figure 31). 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 32 1. Fuel shut-off valve 2. Clamp Figure 33 1. Hose clamp 2. Fuel line Servicing the Fuel Filter 3. Filter 5. Remove the filter from the fuel lines. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs 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 32). Service Interval: Every 200 hours 8. Check for fuel leaks and repair if needed.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery Check the electrolyte level in the battery every 25 hours. 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.
Figure 35 1. Vent caps 2. Upper line 3. Lower line 2. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery in , page . Adding Water to the Battery The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 1. Remove the battery from the machine; refer to Removing the Battery in , page .
Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery. 2. Check the electrolyte level; refer to Checking the Electrolyte Level. 3. Make sure the filler caps are installed in battery. Charge battery for 1 hour at 25 to 30 amps or 6 hours at 4 to 6 amps. 4.
Drive System Maintenance Adjusting the Tracking 1. If the machine does not track straight, adjustment is required. 2. Check the rear tire pressure. Refer to Checking the Tire Pressure. 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 38). 4.
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 41). Clean the inside of the mounting tube. Figure 42 1. Locknut 2. Wheel Bolt 3. Bushing 4. Spanner Bushing 5. Roller Bearing Figure 41 1. Mounting Tube 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 42). 2. Bushing 3.
Cooling System Maintenance 2. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Figure 43). 3. Repeat this for the remaining slots. Cleaning the Air Intake Screen 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them.
Brake Maintenance 9. Tighten the top and bottom jam nuts (Figure 44). 10. Check the brake operation again; refer to Checking the Brake. Servicing the Brake Before each use, check brakes on both a level surface and slope. Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. Checking the Parking Brake Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the PTO. 2.
Belt Maintenance Replacing the Mower Belt Service Interval: Every 50 hours Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Unlatch and remove the carrier frame cover.
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. Unlatch and remove the belt covers. 5. Remove the heat shield from the engine deck and carrier frame. 6. Roll the belt off of the center pulley on the mower deck (Figure 47).
Use Figure 49 for the idler position options. Figure 50 1. 2. 3. 4. Figure 49 1. PTO drive belt idler pulley 2. PTO drive Belt 3. Idler spring 4. Most tension for worn belts 5. Medium tension for normal belt conditions 6. Least tension for new belts Hydraulic pumps Idler pulley Clutch retainer Tension spring 5. 6. 7. 8. Clutch wire connector Pivot bolt Drive pulley Pump drive belt 7. Unhook the idler spring from the frame (Figure 50). 8. Install the new belt around clutch and the two drive pulleys.
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 53 1. Right side motion control lever pivot shown under controls 2. Right side motion control lever 3. 1/8 inch (3mm) gap needed between switch and control lever 4. Switch Figure 54 1. Left motion control lever 2. Right motion control lever 3. Neutral locked position 4. Align the control levers front to back here 2. 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.
Hydraulic System Maintenance 5. Remove cap from filler neck. Look inside to check the fluid level in the reservoir. (Figure 56). 6. Add fluid to the reservoir until it reaches the cold level of the baffle. Servicing the Hydraulic System 7. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine. Checking the Hydraulic Fluid 8. Recheck the fluid level while the fluid is warm.
Change the hydraulic filter as follows: • After the first 8 operating hours. • After every 200 operating hours or yearly before storage. 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. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. Figure 58 1. Hydraulic filter 2. Gasket 3.
After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Mower Deck Maintenance Note: Keep areas around hydraulic system clean from grass and debris build up. 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.
Figure 60 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure here from blade to hard surface 2. Position A Figure 59 1. Cutting Edge 2. Sail 3. Wear/slot forming in curved area 4. Crack in the curved area 2. Inspect the blades, especially the curved area (Figure 59). If you notice any cracks, wear, or a slot forming in this area (item 3 in Figure 59), immediately install a new blade. Figure 61 36 inch Mower Deck shown Checking for Bent Blades 4. Rotate the opposite ends of the blades forward.
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.
Frame Set Up Checking the Carrier Frame and Engine Deck Alignment Figure 65 1. Blade Note: Misalignment can cause excess wear on the PTO drive belt. 2. Balancer 1. Disengage the PTO and set the parking brake. Installing the Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Install the blade onto the spindle shaft (Figure 62).
Checking the Engine Deck Height 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. Adjust the tire pressure in the rear tires to specifications; refer to , page . 4. Measure engine deck height at location A (Figure 67). 5. Measure engine deck height at location B (Figure 67). Figure 68 6. If the height at location A and B are not the same, change tire pressure slightly to make them the same.
Figure 71 36 inch Mower Deck shown Figure 69 1. Caster Wheel 2. Carrier Frame 3. Front height-of-cut pins 4. Same height at locations A and B 5. Caster spacers Changing the Mower Deck Front-to-Rear Pitch Checking the Mower Deck Front-to-Rear Pitch Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1. To change the front-to-rear pitch, the front height-of-cut posts can be adjusted (Figure 72). 1.
Checking the Mower Deck Side-to-Side Height 2. Adjust the caster spacer. 3. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. 1. Adjust the rear tire pressure to specifications; refer to , page . 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 73). For 36 inch mower decks use Figure 74. Matching Height of Cut 1. Check the rear tire pressure. 2. Set the height-of-cut to the 4 inch (101.
Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in Figure 77. B. Adjust the caster fork spacers. C. Adjust the front mower deck support pins. 6. Check the carrier frame front-to-rear pitch. 3. Install bolt and nut. Place the J hook end of spring around grass deflector (Figure 77). Replacing the Grass Deflector Important: The grass deflector must be able to rotate.
Cleaning Storage Cleaning Under the Mower Cleaning and Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 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 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 Guarantee A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
