Toro 38494 Parts Catalogue

Form Number 3361-957 Rev B

Commercial Walk-Behind Mower

Floating Deck, T-Bar, Hydro Drive
with 36in TURBO FORCE Cutting Unit

Model No. 38494 - 290000001 and up.

®

Parts Catalog

Ordering Replacement Parts

To order replacement parts, please supply the part
number, the quantity, and the description of each part
desired.

Understanding Reference Numbers

Each Identified part in an illustration has a reference
number. The reference number for a part also
appears in the parts list, along with other information
about the part.

This catalog uses two special reference number
formats, one to indicate parts in a service assembly
and another to indicate the quantity of a given part in
an illustration.

Service Assembly Reference Numbers

Parts in service assemblies have reference numbers
in the form a:b. The a represents the reference
number of the entire service assembly and the b
represents a sequential number unique to each part
within the service assembly.

© The Toro Company - 2009

Register your product at www.Toro.com

All Rights Reserved

For example, a wheel assembly might be identified
by reference number 6, the tire by 6:1, the valve by
6:2, and the wheel by 6:3. When you order the
assembly identified by reference number 6, you
receive all parts identified by reference numbers 6:1,
6:2, and 6:3. However, you may also order any part
individually. Reference numbers of this type appear
in illustrations and in part lists.

Reference Numbers Indicating Quantity

In an illustration, if a reference number indicates
more than one part, the reference number has the
form nX y. The n represents the quantity of the part,
the X is the multiplication symbol, and the y
represents the reference number.

For example, in an illustration, the reference number
2X 37 means that two of the parts identified by
reference number 37 are indicated.

Contents

Description Page

. . . . . . 3Engine and Clutch Assembly

Fuel System, Hydraulic Pump and Filter
Assembly

. . . . . . 4

. . . . . . 5Hydraulic Pump Assembly No. 115-4480

. . . . . . 6Hydraulic Pump Assembly No. 115-4481

. . . . . . 7Pump Drive and Wheel Assembly

. . . . . . 8Hydraulic Motor Assembly 104-1171

. . . . . . 9Lower Control Assembly

. . . . . . 10Hydraulic Hose Assembly

. . . . . . 11Upper Control Assembly

. . . . . . 12Control Panel Assembly

. . . . . . 13Battery Assembly

. . . . . . 14Parking Brake Assembly

. . . . . . 15Power-Take-Off Idler Assembly

. . . . . . 16Carrier Frame Assembly

. . . . . . 17Deck Drive and Baffle Assembly

. . . . . . 18Deck Assembly No. 112-7080

. . . . . . 19Lever Assembly No. 107-1664

. . . . . . 20Spindle Assembly No. 110-0730

. . . . . . 21Spindle Assembly No. 110-0728

. . . . . . 22Outer Deck Assembly

. . . . . . 23Deflector Assembly No. 110-0790

Description Page

Cylinder and Crankcase Assembly Kawasaki
FH541V-ES24

Piston and Crankshaft Assembly Kawasaki
FH541V-ES24

Valve and Camshaft Assembly Kawasaki
FH541V-ES23

Lubrication Equipment Assembly Kawasaki
FH541V-ES24

Cooling Equipment Assembly Kawasaki
FH541V-ES24

Electric Equipment Assembly Kawasaki
FH541V-ES24

Control Equipment Assembly Kawasaki
FH541V-ES24

Air Filter and Muffler Assembly Kawasaki
FH541V-ES24

Fuel Tank and Valve Assembly Kawasaki
FH541V-ES24

. . . . . . 24

. . . . . . 25

. . . . . . 26

. . . . . . 27

. . . . . . 28

. . . . . . 29

. . . . . . 30

. . . . . . 31Carburetor Assembly Kawasaki FH541V-ES24

. . . . . . 32

. . . . . . 33

. . . . . . 34Starter Assembly Kawasaki FH541V-ES24

. . . . . . 35Label Set Kawasaki FH541V-ES24

. . . . . . 36Attachments and Accessories List

Part Description Abbreviations

Part descriptions in this catalog may include the following abbreviations.

AR. . . . . . . . . . . . . . .as required

ASM. . . . . . . . . . . . . assembly

BBC. . . . . . . . . . . . . blade brake clutch

CARR. . . . . . . . . . . . carriage

CCW. . . . . . . . . . . . . counter clock wise

CW. . . . . . . . . . . . . . clockwise

DEG. . . . . . . . . . . . . degrees

ECM. . . . . . . . . . . . . electronic control module

EXT. . . . . . . . . . . . . .external

FH. . . . . . . . . . . . . . . flat head

GA. . . . . . . . . . . . . . gauge

HD. . . . . . . . . . . . . . heavy-duty

HF. . . . . . . . . . . . . . . hex flange

HH. . . . . . . . . . . . . . hex head

HHF. . . . . . . . . . . . . hex head flange

HHFTF. . . . . . . . . . . hex head flange thread forming

HJ. . . . . . . . . . . . . . . hex jam

HLH. . . . . . . . . . . . . hex lag head

HOC. . . . . . . . . . . . . height-of-cut

HSBH. . . . . . . . . . . . hex socket button head

HSFH. . . . . . . . . . . . hex socket flat head

HSH. . . . . . . . . . . . . hex socket head

HWH. . . . . . . . . . . . . hex washer head

HWHTF. . . . . . . . . . . hex washer head thread

HYD. . . . . . . . . . . . . hydraulic

LH. . . . . . . . . . . . . . . left hand

NI. . . . . . . . . . . . . . . nylon insert

NPTF. . . . . . . . . . . . national pipe thread fine

PFH. . . . . . . . . . . . . phillips flat head

PPH. . . . . . . . . . . . . phillips pan head

PPHTF. . . . . . . . . . . phillips pan head thread

PRH. . . . . . . . . . . . . phillips round head

PTH. . . . . . . . . . . . . phillips truss head

PTO. . . . . . . . . . . . . power-take-off

RH. . . . . . . . . . . . . . right hand

ROPS. . . . . . . . . . . . roll-over protection system

SFH. . . . . . . . . . . . . slotted fillister head

SHH. . . . . . . . . . . . . slotted hex head

SHWH. . . . . . . . . . . . slotted hex washer head

SPH. . . . . . . . . . . . . slotted pan head

SQH. . . . . . . . . . . . . square head

SRH. . . . . . . . . . . . . slotted round head

STD. . . . . . . . . . . . . standard

TAP. . . . . . . . . . . . . .self tapping

TTH. . . . . . . . . . . . . .torx truss head

forming

forming

Footnotes

n

Not serviced separately

o

Obtain pa rts f rom www.kawpowe repc.com

2

3361-957 Rev B

Engine and Clutch Assembly

Ref Part No. Qty. Description

Screw-HWH1

32144-4
3220-2
115-4191
1-513075
112-7069
32128-20
1-613235
104-6373
1-633630
1-633543-03
1-633545
322-11
1-603610
322-7
3212-9
107-4136
105-2635
44-5940
608006
3256-23
94-5847-01
92-6877
103-1966
106-0699

2

Nut-Jam2

2

Harness-Wire3

1

Switch-Solenoid4

1

Grommet5

1

Nut-HF6

6

Washer7

4

Tube-Retainer8

1

Grommet-Brake9

2

Strap-Clutch, Brake10

1

Spacer11

2

Screw-HH12

1

Washer-Spring13

2

Screw-HH14

4

Screw-HH15

1

Washer16

1

Clutch / Brake17

1

Pulley18

1

Key-Square19

1

Washer-Flat20

5

Cover-Pulley21

1

Valve-Drain, Oil24

1

Adapter25

1

Decal-Warning26

1

Ref Part No. Qty. Description

no

322-9
2412-87
3255-8
112-9707
32149-2
56-6360
2412-72
12-3270
3253-4
115-4150-03
115-4154-03
322-3
94-2413
2412-134
3290-378
109102
109103
218-578
103-1964

Engine-Kawasaki, FH541V-Es2427 1
Screw-HH28

1

Clamp-Cable29

1

Washer-Lock30

1

Cable-Battery, Pos31

1

Nut-Keps32

1

Filter-Fuel33

1

Clip-Closed, Insulated34

1

Screw35

2

Washer-Lock37

2

Muffler Shield ASM38

1

Bracket-Muffler39

1

Screw-HH40

4

U-Nut41

4

Clamp-R42

1

Tie-Cable43

3

Fuse-25 Amp44

1

Fuse-30 Amp45

1

Fuse-10 Amp46

1

Hose-Drain, Oil99

1

3

3361-957 Rev B

3

Fuel System, Hydraulic Pump and Filter Assembly

Ref Part No. Qty. Description

Gas Cap ASM1

88-3980
88-4010
106-0730
103-2605
321-4
107-8433

n

103-1948
103-1949
115-4212
353-374
237-42
32128-33
3256-23
104-8121
1-633349
3296-47
32128-42
353-384
237-42
115-4480
340-101
237-30
237-79

4

1

Gasket-Cap, Gas1:3

1

Fuel Tank ASM2

1

Fitting-Fuel, Bulkhead2:2

1

Screw-HH3

2

HYD Reservoir ASM4

1

Reservoir-HYD4:1 1
Cap-Reservoir, HYD4:1:1

1

Gasket-Cap4:1:2

1

Decal-Warning4:2

1

Elbow-90 DEG5

4

O-Ring5:1

1

Nut-HF6

2

Washer-Flat7

4

Stud-Threaded8

2

Spring-Tank, Fuel9

2

Nut-Lock, NI10

2

Nut-HF11

4

Fitting-Straight12

3

O-Ring12:1

1

Pump-Hydraulic13

1

Fitting-HYD, 45 DEG14

4

O-Ring14:1

1

O-Ring14:2

1

Ref Part No. Qty. Description

Screw-HH15

324-5
353-212
237-42
1-633750
1-633752
104-7836
2412-98
110-4894
1-603770
322-4
3253-4
107-0588
112-7069
3253-3
321-3
115-4481

4

Fitting-HYD, 45 DEG16

1

O-Ring16:1

1

Filter-Oil, HYD17

1

Filter-HYD, Winter17

1

Head-Filter18

1

Clamp19

4

Hose-Fuel20

1

Valve-Fuel21

1

Screw-HH22

2

Washer-Lock23

2

Hose-Fuel24

1

Grommet25

1

Washer-Lock26

2

Screw-HH27

2

Pump-Hydraulic28

1

A2

3361-957 Rev B

Hydraulic Pump Assembly No. 115-4480

Ref Part No. Qty. Description

Housing Kit1

115-4464
106-8752
106-8753
106-8754
106-8755
106-8756
104-2122
106-8757
104-2111
106-8759
103-2664
104-5311
104-5310
104-5308
104-5309
103-2666
94-1936
94-1937
105-6185
94-1907
94-6922
115-4458
94-1910
98-3252

1

End Cap Kit (W/Poppets)2

1

Pin-Headless, Straight3

2

Bolt-HF4

4

O-Ring5

1

Charge Pump Kit6

1

Gerotor ASM7

1

O-Ring8

1

Capscrew10

2

Bypass Valve Kit15

1

Input Shaft Kit18

1

Bearing-Ball19

1

Seal-Lip20

1

Spacer21

1

Ring-Retaining22

1

Cylinder Block Kit25

1

Spring-Block29

1

Washer-Thrust, Block30

1

Plate-Valve31

1

Swashplate-Variable32

1

Bearing-Thrust34

1

Arm-Trunnion, Tapered Square37

1

Guide-Slot38

1

Valve-Check (W/Poppet)42

2

Ref Part No. Qty. Description

1

106-8760
114-8155
106-8762
106-8763
115-4459
105-6184

Charge Relief Valve Kit44
Trunnion Seal Kit49

1

Plug-HSH56

1

Plug-HSH66

1

Kit-Return98

1

Seal Overhaul Kit99

1

5

3361-957 Rev B

A1

Hydraulic Pump Assembly No. 115-4481

Ref Part No. Qty. Description

Housing Kit1

115-4464
106-8752
106-8753
106-8754
106-8755
106-8756
104-2122
106-8757
104-2111
106-8759
103-2664
104-5311
104-5310
104-5308
104-5309
103-2666
94-1936
94-1937
105-6185
94-1907
94-6922
115-4458
94-1910
98-3252

6

1

End Cap Kit (W/Poppets)2

1

Pin-Headless, Straight3

2

Bolt-HF4

4

O-Ring5

1

Charge Pump Kit6

1

Gerotor ASM7

1

O-Ring8

1

Capscrew10

2

Bypass Valve Kit15

1

Input Shaft Kit18

1

Bearing-Ball19

1

Seal-Lip20

1

Spacer21

1

Ring-Retaining22

1

Cylinder Block Kit25

1

Spring-Block29

1

Washer-Thrust, Block30

1

Plate-Valve31

1

Swashplate-Variable32

1

Bearing-Thrust34

1

Arm-Trunnion, Tapered Square37

1

Guide-Slot38

1

Valve-Check (W/Poppet)42

2

Ref Part No. Qty. Description

1

106-8760
114-8155
106-8762
106-8763
115-4459
105-6184

Charge Relief Valve Kit44
Trunnion Seal Kit49

1

Plug-HSH56

1

Plug-HSH66

1

Kit-Return98

1

Seal Overhaul Kit99

1

4

3361-957 Rev B

Pump Drive and Wheel Assembly

Ref Part No. Qty. Description

Nut-Lock1

3296-6
98-0776
114-0243-01
95-1526
104-1171
340-6
237-30
237-80
3257-8
95-1529
105-0800
10-6830
106-0892
104-6322
106-0893
232-27
85-7310
242-50
325-12
3234-32
105-5648
3234-22
68-9950
110-5049

1

Decal-Caution2

1

Frame ASM4

1

Shield-Trailing5

1

Motor-Wheel6

2

Fitting-HYD, Straight7

4

O-Ring7:1

1

O-Ring7:2

1

Key-Woodruff8

2

Rod-Shield9

1

Wheel Hub / Stud ASM10

2

Stud-Type, Drive10:2

4

Wheel And Tire ASM11

2

Tire11:1

1

Wheel11:2

1

Stem-Valve11:3

1

Nut-Motor, Wheel12

2

Nut-Lug13

8

Screw-HH14

8

Screw-HHF15

4

Pulley-Pump16

2

Screw-HHF17

2

Spring-Traction18

1

Belt-V19

1

Ref Part No. Qty. Description

1

27-6230
3296-39
86-4770
93-1622
323-9
3241-5
1-807272
9202204
32128-49
108-6657-01
32128-23
3256-24

Bolt-Wheel20
Nut-Lock, NI21

1

Idler Lever ASM22

1

Pulley-Idler23

1

Screw-HH24

1

Screw-Set25

4

Key26

2

Washer27

1

Nut-HHF28

8

Plate-Frame29

2

Nut-HF30

6

Washer-Flat32

1

7

3361-957 Rev B

A3

Hydraulic Motor Assembly 104-1171

Ref Part No. Qty. Description

Seal Kit1

1-000119

n
n

n

n

n

n

3257-8
85-7310
106-5549
106-8764

1

Ring-Back Up1:1 1
Seal-Commutator1:2

1

Seal-Shaft (Viton)1:3

1

Washer-Back Up, Steel1:4

1

Ring-Seal (Viton)1:5

5

Seal-Dirt And Water1:7

1

Key-Woodruff2

1

Nut-Motor, Wheel3

1

Bolt-Special4

6

Shaft-Coupling5

1

8

5

3361-957 Rev B

Lower Control Assembly

Ref Part No. Qty. Description

Bracket-Adapter, Pump1

114-0227
322-4
3296-29
3296-2
114-0282
3217-5
105-0023
32105-13

2

Screw-HH2

4

Nut-Lock, NI3

4

Nut-Lock, NI4

4

Screw-HH5

2

Nut-Hex6

2

Switch-Proximity9

2

Screw-HWH10

4

9

3361-957 Rev B

6

Hydraulic Hose Assembly

Ref Part No. Qty. Description

HYD Hose ASM1

112-9704
114-3430
114-3436
105-5699
114-3434

2

HYD Hose ASM2

2

HYD Hose ASM3

1

HYD Hose ASM4

1

HYD Hose ASM5

1

10

7

3361-957 Rev B

Upper Control Assembly

Ref Part No. Qty. Description

T-Bar Handle ASM1

115-4200
115-4179
3234-42
32128-43
3229-1
3234-4
114-0235
114-0272-03
114-0260
114-0234
103-9928
3296-42
114-0268
114-0239
114-0238-03
3296-47
114-0241
114-0249
1-513152
1-633181
32105-13
3256-22
114-3424
115-4189

1

Decal-Warning, Control1:2

1

Screw-HHF2

6

Nut-Flange3

6

Screw-CARR4

2

Screw-HHF5

4

Bracket-Support6

1

Control Lever ASM7

1

Shaft-Pivot8

2

Motion Control ASM9

1

Bearing10

6

Nut-Lock, NI11

3

Cam-Lever, Handle Stop13

1

Screw-HSH14

1

Lever ASM15

1

Nut-Lock, NI16

1

Grip-Lever17

2

Spring-Extension18

1

Switch-Closed, Normally19

1

Plate-Tapped20

1

Screw-HWH21

2

Washer-Flat22

1

Decal-Control23

1

Decal-Panel, Control24

1

Ref Part No. Qty. Description

1

117-2718

Decal-Arrester, Spark26

11

3361-957 Rev B

8

Ref Part No. Qty. Description

Rod-Control, Upper1

114-0275
114-0276
114-0279
110-4994
104-7050
115-4180
114-0270-03
2412-120
95-1504
32103-3
3290-360
116-0050
32104-76
3256-23
3290-307
3296-2
63-8360
104-7048
110-4995
3290-378
114-0281

2

Rod-Control, Lower2

2

Switch-PTO3

1

Cable-Throttle4

1

Tube-Manual5

1

Module-Meter, Hour6

1

Cover-Panel, Control7

1

R-Clamp8

2

Turnbuckle9

2

Nut-Wing10

2

Screw-HH12

4

Switch-Ignition13

1

Screw14

6

Washer-Flat15

4

Pin-Hair16

4

Nut-Lock, NI18

4

Key-Ignition19

1

Cap-Housing20

1

Cable-Choke21

1

Tie-Cable22

4

Nut-Wing, LH23

2

Control Panel Assembly

12