Form No. 3367-259 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear Drive with 36in, 40in, 48in or 52in TURBO FORCE® Cutting Unit Model No. 30074—Serial No. 311000001 and Up Model No. 30076—Serial No. 311000001 and Up Model No. 30078—Serial No. 311000001 and Up Model No. 30079—Serial No. 311000001 and Up g014793 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land.
Contents Checking the Tire Pressure ................................. 30 Replacing the Caster Wheel Fork Bushings ........................................................ 31 Servicing the Caster Wheel and Bearings ............. 31 Adjusting the Electric Clutch .............................. 32 Cooling System Maintenance .................................. 33 Cleaning the Air Intake Screen ............................ 33 Brake Maintenance .................................................
Safety – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. – 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.
• Keep pets and bystanders away. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing. • 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 care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
• 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. REVERSE TRACTION DRIVE 82-2280 82-2280 82-2290 43-8480 98-0776 98-3256 52-2010 98-4387 1. Warning—wear hearing protection.
110-2067 104-8185 110-2068 104-8186 1. Read the Operator’s Manual. 104-8569 106-0635 114-3489 1. Thrown object hazard; cutting/dismemberment hazard—do not operate the machine with the discharge opening uncovered; always operate the machine with the rear discharge deflector, discharge cover or grass collector installed.
5-0884 110-4971 1. Engine—stop 2. Engine—Start 3. Engage bale then pull out on the PTO to engage the blade. Product Overview Figure 5 1. Gear shift lever 2. Power take off switch (PTO) 3. Choke control 4. Lower handle 5. Lower control bar 6. Parking brake lever-released position g014794 Figure 4 1. 2. 3. 4. Side discharge chute Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel 7. Blade control bail 8. Upper control bar 9. 10. 11. 12.
Blade Control Bail Specifications The bail is used in conjunction with the power take off switch (PTO) to engage the clutch to drive the mower blades. Release the mower control bail to disengage the mower blades. Note: Specifications and design are subject to change without notice.
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.
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. parking brake when you stop the machine or leave it unattended. Filling the Fuel Tank 1. Pull the upper control bar (Figure 7) rearward and hold it in this position. 2. Lift the parking brake lock (Figure 7) up and gradually release the upper control bar. The brake lock should stay in the set (locked) position.
Important: Do not pull recoil rope to its limit or let go of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged. 3. Pull the power take off switch (PTO) up and release. Hold the blade control bail against the upper control bar while operating. 4. Repeat the procedure to engage the mower blades if the blade control bail is released. Stopping the Engine 1. Move the throttle lever to the slow position (Figure 8). 2.
The safety interlock system is designed to stop the mower blades if you release the blade control bail. Testing the Safety Interlock System Service Interval: Before each use or daily Test the safety interlock system before you use the machine each time. Note: If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Set the parking brake and start the engine; refer to Starting and Stopping the Engine. 2.
Stopping the Machine 5. Drive the machine until drive wheels contact the curb (Figure 11). To stop the machine, pull back on the upper control bar, release the blade control bail, and turn the ignition key to off. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake in Operation (page 12). Remember to remove the key from the ignition switch. 6. Lower the front of the machine (Figure 11).
Side Discharging or Mulching the Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER 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.
Figure 16 36 inch Mower Deck Figure 14 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.
5. Swing the lever back over to tighten the baffle and cam lock (Figure 19). 2. Loosen the upper flange bolts (3/8 x 1 inch) and the flange nut securing the handle to the rear frame (Figure 18). 6. If the cam does not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 18 1. 2. 3. 4. Upper handle Rear frame Flange nut, (3/8 inch) Flange bolt, (3/8 x 1 inch) 5. 6. 7. 8.
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 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.
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 23 or Figure 24). 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. Before each use or daily • • • • • • Check the safety interlock system. Grease the caster wheels and caster pivot. Check the engine oil level. Clean the air intake screen. Check the brakes on both a level surface and slope. Inspect the blades.
4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. Lubricating the Caster and Wheel Bearings Service Interval: Before each use or daily Every 400 hours 1. Lubricate the front caster wheel bearings and front pivots (Figure 25). 2. Raise the rear of the machine and use jack stands to support the machine. Figure 26 3. Remove the rear wheel and tire assemblies.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Service Interval: Every 25 hours—Clean foam air cleaner element. Every 50 hours—Check the paper air cleaner element. Every 200 hours—Replace the paper air cleaner element. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. g014675 Figure 28 36 inch Mower Deck shown Important: Do not oil the foam or paper element.
Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. Every 200 hours—Change the oil filter. Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Figure 29 1. Cover 2. Hose clamp 3. Paper element 4. Foam element Oil Type: Detergent oil (API service SF, SG, SH, SJ or SL) Crankcase Capacity: 58 ounces (1.
Figure 31 1. Oil dipstick 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 31). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 31). Figure 32 7. Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 31).
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 33). 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. Check the engine oil level and add oil if needed. 8. Wipe up any spilled oil. 4.
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 36 • 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 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Figure 36). Servicing the Fuse 8. Check for fuel leaks and repair if needed. The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows, check the component or circuit for malfunction or a short. To replace the fuse, pull out on the fuse (Figure 39) to remove or replace it.
Drive System Maintenance Adjusting the Control Bar 1. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. The gap should be approximately 1 to 1-1/4 inch (25-32 mm) (Figure 40). Note: The upper control bar and fixed bar must be parallel when the upper control bar is in the engaged, drive, neutral, or brake positions. Figure 41 1. 2. 3. 4. Control rod and fitting 3-1/2 inch (89 mm) Idler bracket Clevis pin 5. 6. 7. 8.
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. If a caster fork is loose, the bushings are worn and must be replaced. 1. Raise the cutting unit so the caster wheels are off the floor, then support the front of the mower with jack stands. 2.
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 45 1. Locknut 2. Cap 3. Roller Bearing Figure 46 4. Spanner Bushing 5. Wheel 6. Bushing 1. Adjusting nut 2. Slot 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 45). 3.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily—Check the brakes on both a level surface and slope. Servicing the Brakes Service Interval: Before each use or daily 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.
Belt Maintenance Replacing the Traction Drive Belt Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the traction drive belt Look for cracks, wear, and signs of overheating. 1. Remove the top bolt securing idler support and idler bracket to rear frame (Figure 48). Figure 47 1. Hairpin cotter and washer 2. Trunnion 3. Brake lever 4. Wing nut 5. Hole F 6. Initial adjustment- 1-1/4 inch (32 mm) 7. Rod Figure 48 6. Rotate the wing nut clockwise to increase the braking pressure. 1.
4. Unlatch and remove the belt covers. 4. Raise the front of the machine and hold with jack stands. 5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt. 5. Disconnect clutch wire connector from wire harness. 6. Disconnect clutch retainer from the engine deck (Figure 49). 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 50 or Figure 51). 7.
9. Roll the belt onto the center pulley on the mower deck (Figure 52). Use caution when install the belt as tension will increase because of the spring loaded idler pulley. Refer to Figure 53 to roll the new belt onto the left pulley for a 36 inch mower deck. 10. Install the heat shield to the engine deck and carrier frame. 11. Adjust the belt guide an 1/8 inch (3 mm) from the belt for 40, 48 and 52 inch mower decks (Figure 52). 12. Install the belt covers onto the cutting unit and secure the latches. 13.
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. Figure 53 36 inch Mower Deck shown 1. Mower deck belt 2. PTO Drive Belt 3.
Checking for Bent Blades steps 3 and 4 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. 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. Rotate the blades until the ends face forward and backward.
Figure 61 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 58). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 58). 2. For 40 inch and 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 58). 3. For 36 inch and 52 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 59). Figure 59 36 inch and 52 inch Mower Decks 1.
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 30) . 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 64 1. Carrier Frame 2. 1/4-3/8 inch (6-10 mm) pitch over 24 inch (61 cm) length 3. 24 inches (61 cm) 4. Height at locations A and B 5. Caster Wheel Figure 65 1. Caster Wheel 6. Caster spacers 2. Carrier Frame 3. Front height-of-cut pins 4. Same height at locations A and B 5. Caster spacers 2. Measure carrier frame height at location A (Figure 64). Checking the Mower Deck Front-to-Rear Pitch 3.
Figure 66 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure blade at points A and B Figure 68 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 68). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 68). 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 71). For 36 inch mower decks use Figure 72. Figure 69 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at points C and D Figure 71 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at point A Figure 70 36 inch Mower Deck shown 3.
Replacing the Grass Deflector Storage WARNING Cleaning and Storage 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. 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.
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. Possible Cause 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 2. Choke is not on. 3. Air cleaner is dirty. 2. Move the choke lever to choke position. 3. Clean or replace the air cleaner element. 4. Install wire on spark plug. 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. Dirt, water, or stale fuel is in the fuel system.
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 Electrical Schematic (Rev.
Notes: 49
Notes: 50
Notes: 51
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 3. 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. •Belts and Tires Warranty Period See engine manufacturer’s warranty1 90 days Parts and Labor 1 year Parts only 90 days •Attachments 1 year 21 in.
