Form No. 3376-433 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear Drive with 36in or 48in TURBO FORCE® Cutting Unit Model No. 30074—Serial No. 313000001 and Up Model No. 30078—Serial No. 313000001 and Up Model No. 39074—Serial No. 313000001 and Up Model No. 39078—Serial No. 313000001 and Up g014793 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 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. Figure 1 Important: This engine is not equipped with a spark arrester muffler.
Contents Servicing the Brakes................................................32 Belt Maintenance ......................................................33 Replacing the Traction Drive Belt .............................33 Replacing the Transmission Belt ...............................33 Replacing the Mower Belt ........................................33 Replacing the PTO Drive Belt ..................................34 Adjusting the PTO Drive Belt Idler Spring Anchor...........................................
Operation Safety • Lightning can cause severe injury or death. If lightning Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. is seen or thunder is heard in the area, do not operate the machine; seek shelter. • Never run an engine in an enclosed area.
Maintenance and storage Slope Operation • Disengage drives, set parking brake, stop engine and All slopes and ramps require extra caution. If you feel uneasy on a slope, do not mow it. remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. • Remove obstacles such as rocks, tree limbs, etc. from the • Clean grass and debris from cutting unit, drives, mufflers, mowing area. and engine to help prevent fires. Clean up oil or fuel spillage.
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. 82-2290 1-403005 98-0776 98-3256 52-2010 98-4387 1. Warning—wear hearing protection.
110-2067 104-8186 48 inch mower 104-8569 110-2068 1. Read the Operator's Manual.
110-4971 1. Engine—stop 2. Engine—Start 3. Engage bale then pull out on the PTO to engage the blade. Product Overview Controls Become familiar with all the controls (Figure 5) before you start the engine and operate the machine. g014794 Figure 4 1. Side discharge chute 5. Controls 2. Mower deck 3. Recoil starter 4. Gas tank 6. Handle 7. Caster wheel Figure 5 1. Gear shift lever 2. Power take off switch (PTO) 7. Blade control bail 8. Upper control bar 3. Choke control 9. Upper handle 4.
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. 36 inch mowers: Power Take Off Switch (PTO) This pull switch is used in conjunction with the blade control bail to engage the clutch to drive the mower blades.
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.
Filling the Fuel Tank 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. 1. Shut the engine off and set the parking brake. 2. Clean around each fuel tank cap and remove the cap. 3. Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tanks completely full.
3. Turn the ignition key to off (Figure 8). Figure 9 Figure 8 1. Throttle lever 1. Upper control bar 2. Ignition key 3. Power take off switch (PTO) 2. Blade control bail 4. Set the parking brake and remove key. Disengaging the Mower Blades (PTO) 5. Pull the wire off spark plug(s) to prevent possibility of accidental starting before storing machine. Release the blade control bail to disengage the blades (Figure 9). 6. Close the fuel shut off valve before storing machine.
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. Squeeze the blade control bail against upper control bar. The blades should not rotate. 3. Then continue holding the blade control bail and pull up on the blade control switch and release. The clutch should engage and the mower blades begin rotating. 4.
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 (page ). Remember to remove the key from the ignition switch. 6. Lower the front of the machine (Figure 11). Note: Both drive wheels should contact the curb and caster wheels straight. 7.
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 48 inch Mower Decks 1. Mower deck 4. Anti-scalp rollers 2. Bolt 3. Spacer 5. Nut 1. Mower deck 4. Anti-scalp rollers 2. Bolt 3. Spacer 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.
1 2 g012676 Figure 19 Figure 18 2. Nut 1. Slot 1. Upper handle 5. Upper mounting hole 2. Rear frame 6. Lower mounting holes 3. Flange nut, (3/8 inch) 7. Low position 4. Flange bolt, (3/8 x 1 inch) 8. High 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. 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing the handle to the rear frame (Figure 18).
Position B Using the Mid-Size Weight Use this position when bagging (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 23 or Figure 24). The following table indicates the position of the weight as installed at the factory.
Figure 24 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. 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.
Lubrication Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. Grease with No. 2 general purpose lithium base or molybdenum base grease. Greasing the Transmission Couplers How to Grease 1. Disengage the PTO and set the parking brake. Service Interval: Every 250 hours 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Lubricate the transmission couplers located in the back of the machine (Figure 26). 3.
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. g014655 Figure 27 48 inch Mower Deck shown Important: Do not oil the foam or paper element.
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. 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. Servicing the Paper Air Cleaner Element 1. Do not clean the paper filter, replace it (Figure 29). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. Figure 30 3. Replace the paper element if it is damaged.
Changing the Engine Oil 1. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 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 32). Figure 33 6.
Servicing the Spark Plugs Service Interval/Specification Service Interval: Every 100 hours—Check the spark plugs. Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plugs if necessary. Type: Champion® RCJ8Y or equivalent Air Gap: 0.030 inch (0.75 mm) Figure 35 1. Center electrode insulator 3.
Replacing the Fuel Filter Fuel System Maintenance Service Interval: Every 200 hours Never install a dirty filter if it is removed from the fuel line. Draining the Fuel Tank Note: Note how the fuel filter is installed. Note: Wipe up any spilled fuel. DANGER 1. Disengage the PTO and set the parking brake. 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. 2.
Electrical System Maintenance Drive System Maintenance Servicing the Fuse 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 39). 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 38) to remove or replace it.
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.
Figure 43 1. Mounting Tube Figure 44 2. Bushing 1. Locknut 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. 4. Spanner Bushing 2. Cap 5. Wheel 3. Roller Bearing 6. Bushing 6. Inspect the caster wheel fork for wear and replace if necessary (Figure 42). 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 44). 7.
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 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 Brakes Service Interval: Before each use or daily—Check the 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 Brakes 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. 3. Apply the parking brake.
Belt Maintenance 5. Disconnect clutch wire connector from wire harness. 6. Disconnect clutch retainer from the engine deck (Figure 48). 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 47). Figure 48 1. Transmission belt 2. Idler pulley 4. Bottom bolt 2. Idler bracket 3. Idler support 5.
7. Install the new mower belt around the two outside spindle pulleys, the idler pulley, and in the lower groove of the double spindle pulley (Figure 49 or Figure 50). 8. Connect the idler arm spring (Figure 49 or Figure 50). 9. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt. 10. Adjust the belt guide an 1/8 inch (3 mm) from the belt (Figure 49 or Figure 50). 11. Install the belt covers onto the cutting unit and secure the latches. 12.
Refer to Figure 52 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 48 inch mower decks (Figure 51). 12. Install the belt covers onto the cutting unit and secure the latches. 13. Install the carrier frame cover onto the carrier frame and secure the latches. Figure 52 36 inch Mower Deck shown 1. Mower deck belt 4. Clutch pulley 2. PTO Drive Belt 5.
Mower Deck Maintenance Checking for Bent 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. Servicing the Cutting Blades 3. Rotate the blades until the ends face forward and backward. Measure from a level surface to the cutting edge, position A, of the blades (Figure 55 ). Note this dimension.
WARNING 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 60 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 57). 3. Place a long straight edge on top of the engine deck as shown in Figure 61.
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 Drive System Maintenance (page 28) . 4. Measure engine deck height at location A (Figure 62). Figure 63 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.
Figure 66 36 inch Mower Deck shown Figure 64 1. Caster Wheel 2. Carrier Frame 4. Same height at locations A and B 5. Caster spacers Changing the Mower Deck Front-to-Rear Pitch 3. Front height-of-cut pins 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 67). 1.
Checking the Mower Deck Side-to-Side Height Changing the Mower Deck Side-to-Side Height 1. Adjust the rear tire pressure to specifications; refer to Drive System Maintenance (page 28) . Changing the side-to-side height is done by adjusting the rear tire pressure and caster spacers. 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 68). For 36 inch mower decks use Figure 69. 1. Change the rear tire pressure.
6 2 4 7 3 1 5 Figure 71 36 inch Mower Deck shown g015594 Figure 72 1. Bolt 5. Spring installed 4. The measurement should be 4 inch (101.6 mm). 2. Spacer 6. Grass Deflector 5. If it does not measure correctly: 3. Locknut 7. J hook end of spring 4. Spring A. Adjust the rear tire pressure. B. Adjust the caster fork spacers. C. Adjust the front mower deck support pins. 2. Place the spacer and spring onto the grass deflector. Place one J end of the spring behind the deck edge. 6.
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. 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.
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: 47
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.
