Form No. 3379-902 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. 314000001 and Up Model No. 30078—Serial No. 314000001 and Up Model No. 39074—Serial No. 314000001 and Up Model No. 39078—Serial No. 314000001 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...........................................
Safety • Never run an engine in an enclosed area. • Only operate in good light, keeping away from holes and Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. • • Improper use or maintenance by the operator or owner can result in injury.
Hauling • Extinguish all cigarettes, cigars, pipes, and other sources • • • • • • • • • • of ignition. Use only an approved fuel container. Never remove fuel cap or add fuel with the engine running. Allow engine to cool before refueling. Never refuel the machine indoors. Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner.
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.
104-8186 48 inch mower 110-2068 1. Read the Operator's Manual. 104-8569 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.
105-0884 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 of 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) 3. Choke control 9 7. Blade control bail 8. Upper control bar 9.
Throttle Control Specifications The throttle control has 2 positions: Fast and Slow. Note: Specifications and design are subject to change without notice. Choke 36 inch mowers: Use the choke to start a cold engine. Blade Control Bail Width with deflector down 130 cm (51–1/8 inches) Length 210 cm (82–3/4 inches) Height with handle in lowest position The bail is used in conjunction with the power take off switch (PTO) 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.
Setting the Parking Brake of varnish deposits in the fuel system, use fuel stabilizer at all times. 1. Pull the upper control bar (Figure 7) rearward and hold it in this position. 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 the fuel tank cap and remove the cap.
Stopping the Engine 1. Move the throttle lever to the slow position (Figure 8). 2. Let engine idle for 30 to 60 seconds before turning the ignition key to off. 3. Turn the ignition key to off (Figure 8). Figure 9 1. Upper control bar 3. Power take off switch (PTO) 2. Blade control bail Figure 8 1. Throttle lever Disengaging the Mower Blades (PTO) 2. Ignition key Release the blade control bail to disengage the blades (Figure 9). 4. Set the parking brake and remove the key. 5.
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. Squeeze the blade control bail against upper control bar. The blades should not rotate. 3.
Driving Forward up a Curb Note: Lifting up on the lower handle will assist driving the machine up a curb and not spin the drive wheels. 1. Disengage the mower blades. 2. Select the first gear to drive the machine. 3. Drive machine until the caster wheels contact the curb (Figure 11). 4. Lift the front of the machine by pushing down on the lower handle (Figure 11). 5. Drive the machine until the drive wheels contact the curb (Figure 11). 6. Lower the front of the machine (Figure 11).
Stopping the Machine Side Discharging or Mulching the Grass 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. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Figure 15 48 inch Mower Decks 1. Mower deck 4. Anti-scalp rollers 2. Bolt 3. Spacer 5. Nut Figure 14 1. Carrier frame 4. Spacers 2. Hairpin cotter 5. Front height-of-cut post 3. Back height-of-cut post Adjusting the Anti-Scalp Rollers The anti-scalp rollers need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 10 mm (3/8 inch) minimum clearance above the ground.
2. Loosen the upper flange bolts (3/8 x 1 inch) and the flange nut securing the handle to the rear frame (Figure 19). Figure 17 36 inch Mower Deck 1. Mower deck 4. Anti-scalp rollers 2. Bolt 3. Spacer 5. Nut Figure 19 Note: 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 10 mm (3/8 inch) will help prevent the mower deck cutting too low on the outside and minimize the mismatch. 1. Upper handle 5.
Position B 1 2 Use this position when bagging (Figure 22). g012676 Figure 20 2. Nut 1. Slot G012678 Figure 22 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 C This is the full open position. The suggested use for this position is as follows (Figure 23). Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
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 24 or Figure 25). The following table indicates the position of the weight as installed at the factory. Mower Deck Size Number of weights install Position of the weight 36 inches none none 48 inches 2 Rear Figure 25 Installing the rear weight. 1. Nut 2.
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 Greasing the Machine 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.
Engine Maintenance Servicing the Air Cleaner 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. Important: Do not oil the foam or paper element. g014655 Removing the Foam and Paper Elements Figure 28 48 inch Mower Deck shown 1.
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 30). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 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 33). Figure 34 6.
Servicing the Spark Plugs 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: 0.75 mm (0.030 inch) Figure 36 Removing the Spark Plugs 1. Center electrode insulator 1.
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 25-32 mm (1 to 1-1/4 inch) (Figure 40). 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.
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 that the caster wheels are off of the floor, then support the front of the mower with jack stands. 2.
Figure 44 1. Mounting Tube Figure 45 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 43). 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 45). 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 the clutch wire connector from the wire harness. Replacing the Traction Drive Belt 6. Disconnect the clutch retainer from the engine deck (Figure 49). 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 49 1. Transmission belt 2. Idler pulley 5. Clutch wire connector 6. Pivot bolt 3.
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. Install the new mower belt around the 2 outside spindle pulleys, the idler pulley, and in the lower groove of the double spindle pulley (Figure 50 or Figure 51). 8. Connect the idler arm spring (Figure 50 or Figure 51). 9. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt. 10.
9. Roll the belt onto the center pulley on the mower deck (Figure 52). Refer to Figure 53 to roll the new belt onto the left pulley for a 36 inch mower deck. Note: Use caution when install the belt as tension will increase because of the spring loaded idler pulley. 10. Install the heat shield to the engine deck and carrier frame. 11. Adjust the belt guide an 3 mm (1/8 inch) from the belt for 48 inch mower decks (Figure 52). 12. Install the belt covers onto the cutting unit and secure the latches. 13.
Mower Deck Maintenance 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. Servicing the Cutting Blades 4. Measure from a level surface to the cutting edge, position A, of the blades (Figure 56 ). 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. Note: 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 61 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 58). 3. Place a long straight edge on top of the engine deck as shown in 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 Drive System Maintenance (page 28). 4. Measure the engine deck height at location A (Figure 63). Figure 64 1. Carrier frame 2. 6-10 mm (1/4-3/8 inch) pitch over 61 cm (24 inch) length 3. 61 cm (24 inches) 4. Height at locations A and B 5.
Figure 67 36 inch Mower Deck shown Figure 65 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 68). 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. 1. Change the rear tire pressure. 3. Measure at C and D locations from a level surface to the cutting edge of blade tips (Figure 69).
6 2 4 7 3 1 5 Figure 72 36 inch Mower Deck shown g015594 Figure 73 1. Bolt 5. Spring installed 6. The measurement should be 101.6 mm (4 inch). 2. Spacer 6. Grass deflector 7. 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. 8.
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 The starter does not crank. The engine will not start, starts hard, or fails to keep running Possible Cause 1. The blade control switch (PTO) is engaged. 1. Move the blade control switch (PTO) to disengaged. 2. The parking brake is not on. 3. The drive levers are not in neutral lock position. 4. The operator is not seated. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. The fuse is blown. 8. The relay or switch is defective. 2.
Problem The machine does not drive. The machine vibrates abnormally. Mowing is resulting in uneven cutting height. Possible Cause 1. The by pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. The pump belt is worn, loose or broken. The pump belt is off a pulley. The idler sprint is broken or missing. The hydraulic oil level is low or too hot. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4.
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 Instructions for Obtaining Warranty Service 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.
