Form No. 3356-887 Rev B Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear with 36in, 40in, 48in or 52in TURBO FORCE® Cutting Unit Model No. 30094—Serial No. 270000001 and Up Model No. 30096—Serial No. 270000001 and Up Model No. 30098—Serial No. 270000001 and Up Model No. 30099—Serial No. 270000001 and Up Register at 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.
Specifications ..................................................... 11 Attachments/Accessories................................... 11 Operation................................................................... 12 Adding Fuel ....................................................... 12 Checking the Engine Oil Level............................ 13 Think Safety First ............................................... 13 Using the Parking Brake......................................
Safety – Use only an approved container – 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.
• 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 Chart 7
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 95-2814 52-2010 98-0776 98-3256 66-1340 98-4387 1. Warning—wear hearing protection.
104-8569 104-8185 105-7798 104-8186 106-0699 106-0635 110-2067 110-2068 1. Read the Operator’s Manual.
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 4 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 Figure 3 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 36 inch mowers: 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. Width with deflector down 51–1/8 inches (130 cm) Length 82–3/4 inches (210 cm) Power Take Off Switch (PTO) Weight Height with handle in lowest position This pull switch is used in conjunction with the blade control bail to engage the clutch to drive the mower blades.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.
Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. Figure 5 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. 1. Warning—wear hearing protection. Using the Parking Brake Filling the Fuel Tank Stop on level ground, disengage drives, engage parking brake, shut off engine and remove key.
Operating the Mower Power Take Off (PTO) 2. Move the shift lever to neutral, set the parking brake and turn ignition key to run. 3. Move the throttle control to fast and move the choke lever to the on position before starting a cold engine. The power take off switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades. Note: A warm or hot engine usually does not require any choking.
Driving Forward The Safety Interlock System 1. To go forward, move the shift lever to a forward gear (Figure 9). 2. Release the parking brake; refer to Releasing the Parking Brake in Brake Maintenance , page 35. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 3. Slowly press on the upper control bar to move forward (Figure 9). • Do not tamper with the interlock switches.
Driving Backward Up a Curb 1. Disengage the mower blades. 2. Select reverse to drive machine. 3. Drive the machine until drive wheels contact curb (Figure 10). A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders. Do not run blades while driving up a curb forward or backward. Note: Both drive wheels should contact the curb and caster wheels straight. 4.
Note: All height-of-cut pins can use two spacers maximum. 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Figure 12). 2. Using the lift handle, raise side of deck and remove hairpin cotter (Figure 12). 3. Add or remove spacers if needed and then align holes and insert hairpin cotter (Figure 12). Figure 11 Note: Spare height-of-cut spacers may be stored on posts and retained by a hairpin cotter. 1.
1. After adjusting height-of-cut, check the anti-scalp rollers so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figure 13, Figure 14, Figure 15). 2. If adjustment is needed, remove the bolt, washers and nut (Figure 13, Figure 14, Figure 15). 3. Select a hole position so the anti-scalp rollers are a minimum of 3/8 inch (10 mm) off the ground (Figure 13, Figure 14, Figure 15). 4. Install the bolt and nut (Figure 13, Figure 14, Figure 15).
1. Remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket (Figure 16). 5. Check the control bar for correct adjustment. Refer to Adjusting the Control Bar in the maintenance section. 6. Check the parking brake adjustment. Refer to Checking the Brakes in the maintenance section. Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. 1.
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 19). The suggested use for this position is a follows. • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 20 Position C This is the full open position. The suggested use for this position is as follows (Figure 21).
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 22 or Figure 23). The following table indicates the position of the weight as installed at the factory.
Figure 22 Installing the front weight. 1. Bolt 2. Washer 3. Weight 4. Nut Figure 23 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. Inspect the blades. Every 25 hours • Clean foam air cleaner element.
Lubricate the transmission couplers located in the back of the machine (Figure 25). 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 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.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. Inspect the foam and paper elements and replace them if they are damaged or excessively dirty. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.
Installing the Foam and Paper Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 28). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 28). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 28).
3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 8. Remove the drain hose (Figure 31). Note: Dispose of the used oil at a recycling center. 4. Clean around the oil dipstick (Figure 30) so that dirt cannot fall into the filler hole and damage the engine. Figure 30 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 30). Figure 31 6.
Figure 32 1. Oil filter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 32). Figure 33 1. Spark-plug wire/spark plug 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 32). 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5.
Fuel System Maintenance Important: Always replace the spark plugs when it has worn electrodes, an oily film on it, or has cracks in the porcelain. 3. Check the gap between the center and side electrodes (Figure 34). Bend the side electrode (Figure 34) if the gap is not correct. Draining the Fuel Tank Installing the Spark Plugs 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. 1.
Figure 35 1. Fuel shut-off valve Figure 36 2. Clamp 1. Hose clamp 2. Fuel line 3. Filter Replacing the Fuel Filter 5. Remove the filter from the fuel lines. Service Interval: Every 200 hours 6. Install a new filter and move the hose clamps close to the filter. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 7. Open fuel shut-off valve at fuel tank (Figure 35). 8. Check for fuel leaks and repair if needed.
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 component or circuit for malfunction or short. To replace fuse pull out on the fuse (Figure 37) 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 38).
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. Remove the locking pin and spacer(s) from the top of the caster wheel fork (Figure 41). Figure 39 1. 2. 3. 4. Control rod and fitting 3-1/2 inch (89 mm) Idler bracket Clevis pin 5. 6. 7. 8.
Figure 42 1. Mounting Tube Figure 43 2. Bushing 1. Locknut 2. Cap 3. Roller Bearing 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 5. Wheel 6. Bushing 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 43). 6. Inspect the caster wheel fork for wear and replace if necessary (Figure 41). 3.
Cooling System Maintenance 2. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Figure 44). 3. Repeat this for the remaining slots. Cleaning the Air Intake Screen 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them.
Brake Maintenance Servicing the Brakes Before each use, check 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 Service Interval: Before each use or daily 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. 1.
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 47). Replacing the Traction Drive Belt Service Interval: Every 50 hours Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for cracks, wear, and signs of overheating. 1. Remove the top capscrew securing idler support and idler bracket to rear frame (Figure 46). Figure 47 1. 2. 3.
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 48 or Figure 49). 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 48 or Figure 49). 8. Connect the idler arm spring (Figure 48 or Figure 49). 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 50). Use caution when install the belt as tension will increase because of the spring loaded idler pulley. Refer to Figure 51 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 50). 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. 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. • Replace a worn or damaged blade.
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.
Figure 59 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 56). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 56). 2. For 40 inch and 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 56). 3. For 36 inch and 52 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 57). Figure 57 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 31 . 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 62 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 63 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 62). Checking the Mower Deck Front-to-Rear Pitch 3.
Figure 64 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure blade at points A and B Figure 66 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 66). 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 66). 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 69). For 36 inch mower decks use Figure 70. Figure 67 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 69 40 inch, 48 inch, and 52 inch Mower Deck shown 1. Measure from a level surface 2. Measure blade at point A Figure 68 36 inch Mower Deck shown 3.
Replacing the Grass Deflector position and ensure that it rotates into the full down position. 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. Never operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or bagger. 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 71).
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.
Notes: 51
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
