Form No. 3371-897 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. 312000001 and Up Model No. 30078—Serial No. 312000001 and Up Model No. 39074—Serial No. 312000001 and Up Model No. 39078—Serial No. 312000001 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 Replacing the Caster Wheel Fork Bushings ........................................................ 30 Servicing the Caster Wheel and Bearings ............. 31 Adjusting the Electric Clutch .............................. 31 Cooling System Maintenance .................................. 32 Cleaning the Air Intake Screen ............................ 32 Brake Maintenance ................................................. 33 Servicing the Brakes ...........................................
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. 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. 106-0635 105-7798 106-0699 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.
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) 3. Choke control 7. Blade control bail 8. Upper control bar 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.
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 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 2. Loosen the upper flange bolts (3/8 x 1 inch) and the flange nut securing the handle to the rear frame (Figure 18). g012676 Figure 19 2. Nut 1. Slot Figure 18 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.
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 5. Install the grease cap. 6. Install the rear wheel and tire assembly. Grease with No. 2 general purpose lithium base or molybdenum base grease. Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. How to Grease Greasing the Transmission Couplers 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.
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.
5. Unscrew the hose clamp and remove the air cleaner assembly (Figure 29). 6. Carefully pull the foam element off the paper element (Figure 29). Viscosity: Refer to the table (Figure 30). 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 Figure 30 1.
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). 6. When oil has drained completely, close the drain valve. 7.
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 35). 1 Figure 34 1. Spark-plug wire/spark plug 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 35).
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. DANGER Note: Wipe up any spilled fuel. 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. • Drain gasoline from the fuel tank when the engine is cold.
Electrical System Maintenance Drive System Maintenance Servicing the Fuse Adjusting the Control Bar 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. 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).
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. Figure 40 1. Control rod and fitting 5. Washer 2. 3-1/2 inch (89 mm) 6.
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 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 44). 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Figure 44). 4.
Cooling System Maintenance 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. 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. Figure 46 3.
Belt Maintenance 4. Raise the front of the machine and hold with jack stands. 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.
5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 49 or Figure 50). 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.
9. Roll the belt onto the center pulley on the mower deck (Figure 51). Use caution when install the belt as tension will increase because of the spring loaded idler pulley. 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.
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. Figure 53 1. PTO drive belt idler pulley 4. Most tension for worn belts 2. PTO drive Belt 5. Medium tension for normal belt conditions 6.
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 60 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 57). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 57). 2. For 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 57). 3. For 36 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 58). 4. Torque the blade bolt to 85-110 ft-lb (115-140 N-m).
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 29) . 4. Measure engine deck height at location A (Figure 62). 3. Place a long straight edge on top of the engine deck as shown in Figure 61. 4. At the carrier frame cross channel, measure the height at location A (Figure 61).
Checking the Mower Deck Front-to-Rear Pitch 2. Measure carrier frame height at location A (Figure 63). 3. Measure carrier frame height at location B (Figure 63). 4. The height at location A must be a 1/4-3/8 inch (6 mm -10 mm) lower than location B (Figure 63). 5. If the carrier frame is not correct, move caster spacers to make it a 1/4-3/8 inch (6 -10 mm) pitch (Figure 63). Move spacers from top or bottom to make the correct pitch. 6.
Changing 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). Figure 68 48 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at points C and D Figure 67 1. Caster Wheel 2. Carrier Frame 4. Jam nut 5. Ball joint 3. Front height-of-cut pins 2.
Replacing the Grass Deflector 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 70). For 36 inch mower decks use Figure 71. WARNING 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.
Storage 10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. Cleaning and Storage 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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.
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.
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 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. The following time periods apply from the date of purchase by the original owner: Products 21 in.
