Form No. 3356-894 Rev C 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. 270000001 and Up Model No. 30496—Serial No. 270000001 and Up Model No. 30498—Serial No. 270000001 and Up Model No. 30499—Serial No. 270000001 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.
Operating the Parking Brake ............................... 13 Starting and Stopping the Engine ........................ 14 Operating the Mower Blade Control (PTO) ............................................................ 15 The Safety Interlock System................................ 15 Driving Forward or Backward............................. 16 Stopping the Machine......................................... 16 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 Fold along appropriate line Example: Compare slope with folded edge. THIS IS A LOP 15° S E LOPE 7 A 10° S SLOPE (Tree, Building, Fence post, pole, etc.
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. 95-2814 1-523552 98-0776 98-5954 43-8480 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 66-1340 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 68-8340 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.
114-3423 1. Fast 2. Continuous variable setting 3. Engine 4. Slow 5. Choke 114-3424 1. Traction control 2. Fast 5. Reverse 6. Disengage the PTO (Power Take Off) 3. Slow 4. Neutral 114-3425 1. Thrown object hazard—keep deflector in place. 4. Engine—run 2. Cutting, dismemberment hazard of hand or foot—stay away from moving parts. 3. Engine—stop 5. Engine—start 7. Push in on the PTO (Power 10. Warning—stop the engine and remove the spark plug Take Off) to disengage the wire before performing blades.
Choke Use the choke to start a cold engine. Blade Control Switch (PTO) The blade control switch (PTO) is used to engage the electric clutch to drive the mower blades with the right side motion control lever in the center, un-locked position. Pull the switch up to engage the blades and release. To disengage the blades, push the blade control switch (PTO) down or move or release the right side motion control lever into the neutral lock position. Ignition Switch Figure 2 1. 2. 3. 4.
Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Operation Specifications Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Adding Fuel Note: Specifications and design are subject to change without notice.
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
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. If the parking brake does not hold securely, adjust it. Refer to Servicing the Parking Brake. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Operating the Mower Blade Control (PTO) The Safety Interlock System The blade control switch (PTO) is used in conjunction with the right side motion control lever to engage and disengage the mower blades. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Engaging the Mower Blades (PTO) • Do not tamper with the interlock switches. 1.
9. Move the right side motion control lever to the center, un-locked position. 10. Continue holding the right side motion control lever in the center, un-locked position and pull up on the blade control switch (PTO) and release. The clutch should engage and the mower blades begin rotating. 11. Push the blade control switch (PTO) down to the off position. The blades should stop rotating. 12.
Pushing the Machine by Hand 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. The by-pass valves allow the machine to be pushed by hand without the engine running. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To transport the machine: 1.
Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
Figure 13 36 inch Mower Deck Figure 11 40 inch, 48 inch, and 52 inch Mower Decks 1. Mower deck 2. Bolt 3. Spacer 1. Mower deck 2. Bolt 3. Spacer 4. Anti-Scalp Rollers 5. Nut 4. Anti-Scalp Rollers 5. Nut 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.
Figure 14 1. Cam lock 2. Lever 3. Rotate cam to increase or decrease locking pressure 4. Slot Figure 15 Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Position B Use this position when bagging (Figure 16). 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 15).
• Allows increased ground speed in heavy conditions. Using the Mid-Size Weight • This position is similar to the benefits of the Toro SFS mower. 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 18 or Figure 19). The following table indicates the position of the weight as installed at the factory.
Figure 18 Installing the front weight. 1. Bolt 2. Washer 3. Weight 4. Nut Figure 19 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 operating 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 Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 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. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5.
Engine Maintenance 6 2 Servicing the Air Cleaner 3 Service Interval/Specification Foam element: Clean it after every 25 operating hours. 4 Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. 5 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.
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 23). 2 3. Place the air cleaner cover into position and tighten the cover knob (Figure 23). 1 Servicing the Engine Oil Service Interval/Specification G001464 Check the engine oil level daily. Figure 25 1. Oil dipstick Change the engine oil as follows: 2. Filler tube • After the first 8 operating hours 5. Unscrew the oil dipstick and wipe the end clean (Figure 25).
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 27). 1 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 27). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 2 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter and drain valve.
Important: Always replace the spark plugs when it has worn electrodes, an oily film on it, or has cracks in the porcelain. 1 3. Check the gap between the center and side electrodes (Figure 29). Bend the side electrode (Figure 29) if the gap is not correct. Installing the Spark Plugs 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). 3. Connect the wires to the spark plugs (Figure 29). G001469 Figure 28 1.
Fuel System Maintenance Draining the Fuel Tank 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 30 • 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 shut-off valve • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 2.
Electrical System Maintenance 1 Servicing the Battery 3 1 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. Apply a light coating of grease to the battery terminals to prevent corrosion. 2 G001468 Voltage: 12 V Figure 31 1. Hose clamp 2. Fuel line Warning 3.
Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • 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. 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 2 1. Remove the battery from the chassis; refer to Removing the Battery. 3 G000537 2. Check the electrolyte level; refer to Checking the Electrolyte Level. Figure 33 1. Vent caps 2. Upper line 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.
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 36). Figure 35 1. Red wire 2. Fuse, 30 amp, blade type 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 39). Clean the inside of the mounting tube. G001055 Figure 37 Replacing the Caster Wheel Fork Bushings The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting pivot tubes. To check the bushings, move the caster forks back and forth and side-to-side.
3. Repeat this for the remaining slots. 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. Figure 40 1. Locknut 2. Wheel Bolt 3. Bushing Figure 41 4. Spanner Bushing 5. Roller Bearing 1. Adjusting nut 2. Slot 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 40). 3.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Before each use, check brakes on both a level surface and slope. Servicing the Brake Before each use remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor-governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.
Belt Maintenance 9. Tighten the top and bottom jam nuts (Figure 42). 10. Check the brake operation again; refer to Checking the Brake. Replacing the Mower Belt 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.
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 45). Refer to Figure 46 to roll the belt off left pulley for a 36 inch mower deck.
Use Figure 47 for the idler position options. Figure 45 40 inch, 48 inch, and 52 inch Mower Deck shown 1. PTO drive belt guide 2. PTO drive Belt 3. Idler spring Figure 47 4. PTO engagement pulley 5. PTO drive belt idler pulley 6. Center spindle pulley 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 Replacing the Pump Drive Belt 1. Disengage the PTO and set the parking brake. 2.
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 51 1. Right side motion control lever pivot shown under controls 2. Right side motion control lever Figure 50 1. Cam 2. Nut and bolt 3. Wing nut 3. 1/8 inch (3mm) gap needed between switch and control lever 4. Switch Adjusting the Neutral Postion for the Motion Control Levers 4. Turnbuckle 5. Switch screws 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 Check the hydraulic fluid level as follows: • Check the hydraulic fluid level before engine is first started. • Check the hydraulic fluid level after first 8 operating hours. • Check the hydraulic fluid level after every 25 operating hours. Figure 52 1. Left motion control lever 2. Right motion control lever 3. Neutral locked position 4.
6. Add fluid to the reservoir until it reaches the cold level of the baffle. 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. 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. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 8.
Checking the Hydraulic Lines 1 2 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. 3 Note: Keep areas around hydraulic system clean from grass and debris build up. G001043 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 56 1. Hydraulic filter 2. Gasket 3.
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. 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.
2 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. A A A • 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 1 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.
2 1 G000277 Figure 63 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 60). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 60). 2. For 40 inch and 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 60). 3. For 36 inch and 52 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 61).
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. 3. Adjust the tire pressure in the rear tires to specifications; refer to Drive System Maintenance , page 33 . 1. Disengage the PTO and set the parking brake. 2.
make it level. The tire pressure may also be adjusted slightly to make it level. Figure 66 1. Carrier Frame 4. Height at locations A and B 5. Caster Wheel Figure 67 2. 1/8 inch -3/8 inch (3-10 mm) pitch over 24 inch (61 cm) length 3. 24 inches (61 cm) 6. Caster spacers 1. Caster Wheel 2. Carrier Frame 3. Front height-of-cut pins 2. Measure carrier frame height at location A (Figure 66). 4. Same height at locations A and B 5. Caster spacers Checking the Mower Deck Front-to-Rear Pitch 3.
2 4 3 2 A B 5 1 G001041 1 G000292 Figure 70 Figure 68 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure blade at points A and B 1. Caster Wheel 2. Carrier Frame 3. Front height-of-cut pins 2. Measure from a level surface 4. Jam nut 5. Ball joint 2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Figure 70). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 70). 4. Position the blades front-to-rear.
3. With the machine on level surface, position one blade front-to-rear. Measure at A and from level surface to the cutting edge of the blade tips (Figure 73). For 36 inch mower decks use Figure 74. 2 A A A Figure 71 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at points C and D 1 G000975 Figure 73 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at point A Figure 72 36 inch Mower Deck shown 3.
Replacing the Grass Deflector position and ensure that it rotates into the full down position. 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. Never operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or bagger. 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 75).
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. Remove the grass buildup under the mower daily. 1.
inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). 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.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2007 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.