Form No. 3392-458 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear Drive with 36in or 48in TURBO FORCE® Cutting Unit Model No. Model No. Model No. Model No. 30074—Serial No. 30078—Serial No. 39074—Serial No. 39078—Serial No. 315000001 and Up 315000001 and Up 315000001 and Up 315000001 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. Important: This engine is not equipped with a spark arrester muffler.
Contents Belt Maintenance ......................................................35 Replacing the Traction-Drive Belt .............................35 Replacing the Transmission Belt ...............................35 Replacing the Mower Belt ........................................35 Replacing the PTO-Drive Belt..................................36 Adjusting the PTO-Drive-Belt-Idler-Spring Anchor..............................................................37 Mower Deck Maintenance............................
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. Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 93-7442 1. Parking brake 93-7010 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3.
98-4387 106-5517 1. Warning—wear hearing protection. 1. Warning—do not touch the hot surface. 104-8186 48 inch mower 106-5519 1. Severing hazard of hand or foot, mower 3. Warning—read the Operator's Manual. blade—stay away from moving parts. 2. Warning—release the bar and ensure the engine has stopped before walking away from the machine. 5. Thrown object hazard, raised baffle—lower the baffle before using the machine. 4. Thrown object hazard—keep bystanders away from the machine. 110-4972 1.
126-1400 1. Warning-Read the Operator’s manual. Use only Toro riding attachments. Use of other riding attachments may create a hazardous condition resulting in injury. 112-8760 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment of hand or foot—stay away from moving parts. 112-9028 1. Warning—stay away from moving parts; keep all guards in place. 130-0765 1. Read the Operator's Manual. 3.
Product Overview g014794 Figure 4 131-1180 10 1. Side discharge chute 5. Controls 2. Mower deck 3. Recoil starter 4. Gas tank 6. Handle 7.
Controls Upper Control Bar Become familiar with all the controls (Figure 5) before you start the engine and operate the machine. Shift to the desired gear and push forward on the upper control bar to engage forward traction operation and pull back to brake forward movement. Pull back on right side of upper control bar to turn right and left side to turn left.
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position.
of varnish deposits in the fuel system, use fuel stabilizer at all times. 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.
Stopping the Engine Setting the Parking Brake 1. Move the throttle lever to the slow position (Figure 8). 1. Pull the upper control bar (Figure 7) rearward and hold it in this position. 2. Let engine idle for 30 to 60 seconds before turning the ignition key to off. 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. 3. Turn the ignition key to off (Figure 8). Figure 7 1. Upper control bar 3. Fixed bar 2.
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 (page 14). 2. Squeeze the blade-control bail against upper control bar. Note: The blades should not rotate. 3.
Driving Forward up a Curb 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). Note: Both drive wheels should contact the curb and caster wheels straight. 7.
Stopping the Machine Note: Lifting up on the lower handle will assist driving the machine up a curb and not spin the drive wheels. 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 Setting the Parking Brake (page 14). Remember to remove the key from the ignition switch.
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 17 36 inch Mower Deck Figure 15 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 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 2 2. Loosen the upper flange bolts (3/8 x 1 inch) and the flange nut securing the handle to the rear frame (Figure 19). g012676 Figure 20 2. Nut 1. Slot Figure 19 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 22). 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.
Figure 25 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 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 the 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 28 48 inch Mower Deck shown Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1.
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 30). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. Figure 31 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 1. Center electrode insulator 3. Air gap (not to scale) 2.
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 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. 1. Locknut 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 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. • Replace a worn or damaged blade. Figure 54 1. PTO-drive-belt-idler pulley 4.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 3. Rotate the blades until the ends face forward and backward. 4. Measure from a level surface to the cutting edge, position A, of the blades (Figure 56 ). • Always replace bent or damaged blade with a new blade. Note: Note this dimension. For 36 inch mower decks use Figure 57.
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 48 inch mower decks, install the blade, curved washer, and blade bolt (Figure 58). 3. For 36 inch mower decks, install the blade, stiffener, curved washer, and blade bolt (Figure 59). Figure 59 36 inch Mower Decks 1. Sail area of blade 2. Blade 3.
Checking the Engine Deck Height Frame Setup 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). 4. Measure the engine deck height at location A (Figure 63). 1.
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) Figure 65 4. Height at locations A and B 5. Caster wheel 1. Caster wheel 2. Carrier frame 4. Same height at locations A and B 5. Caster spacers 3. Front height-of-cut pins 6. Caster spacers Checking the Mower Deck Front-to-Rear Pitch 2. Measure carrier frame height at location A (Figure 64). 3. Measure carrier frame height at location B (Figure 64). 4.
Checking the Mower Deck Side-to-Side Height 1. Adjust the rear tire pressure to specifications; refer to Drive System Maintenance (page 30) . 2. Position the blades side-to-side. 3. Measure at C and D locations from a level surface to the cutting edge of blade tips (Figure 69). 4. For 36 inch mower decks use Figure 70. Figure 67 36 inch Mower Deck shown 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.
Changing the Mower Deck Side-to-Side Height Changing the side-to-side height is done by adjusting the rear tire pressure and caster spacers. 1. Change the rear tire pressure. Note: Do this to the corresponding side that needs adjustment. 2. Adjust the caster spacer. 3. Recheck the front-to-rear pitch and side to side leveling of the cutting unit. Figure 72 36 inch Mower Deck shown Matching the Height-of-Cut 1. Check the rear tire pressure. 6. The measurement should be 101.6 mm (4 inch). 2.
6 2 4 7 3 1 5 g015594 Figure 73 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J hook end of spring 4. Spring 2. Place the spacer and spring onto the grass deflector. Place one J end of the spring behind the deck edge. Note: Make sure that one J end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 73. 3. Install the bolt and nut. Place one J hook end of the spring around the grass deflector (Figure 73).
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: 50
Notes: 51
The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) 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.