Form No. 3360-257 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear with 36in or 40in TURBO FORCE® Cutting Unit Model No. 39094—Serial No. 280000001 and Up Model No. 39096—Serial No. 280000001 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.
106-0699 104-8185 110-2067 104-8186 104-8569 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 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 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.
The Safety Interlock System throttle control in the fast position for best mowing performance. Driving Forward If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 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 Operation. 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 the holes and insert the 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 the 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). Figure 14 40 inch Mower Deck 1.
5. Check the control bar for correct adjustment. Refer to Adjusting the Control Bar in the maintenance section. 1. Remove the hairpin cotter, washer and clevis pin securing control rod fitting to the idler bracket (Figure 16). 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.
Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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.
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. Mower Deck Size Number of weights install Position of the weight 36 inches none none 40 inches 1 Front Figure 23 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.
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. Lubricate the front caster wheel bearings and front pivots (Figure 24). 2. Raise the rear of the machine and use jack stands to support the machine. 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. Figure 27 36 inch Mower Deck shown Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1.
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). Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. Every 200 hours—Change the oil filter.
Figure 30 1. Oil dipstick 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 30). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 30). Figure 31 7. Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 30).
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). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter and drain valve. 7. Check the engine oil level and add oil if needed. 8. Wipe up any spilled oil.
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.
5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Figure 35). 8. Check for fuel leaks and repair if needed. Figure 35 1. Fuel shut-off valve 2. Clamp Replacing the Fuel Filter Service Interval: Every 200 hours Never install a dirty filter if it is removed from the fuel line. Note: Note how the fuel filter is installed. Note: Wipe up any spilled fuel. 1. Disengage the PTO and set the parking brake. 2.
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 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).
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 39 1. 2. 3. 4.
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). 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Figure 43). 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 45 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/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 46). Figure 47 1. 2. 3. 4.
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 inch mower decks (Figure 50). 12. Install the belt covers onto the cutting unit and secure the latches. 13.
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. 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 54 ). Note this dimension. For 36 inch mower decks use Figure 55.
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. 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.
Sharpening the Blades 1. Disengage the PTO and set the parking brake. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 58). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Disconnect the spark plug wire(s) from the spark plug(s). 3.
5. Measure engine deck height at location B (Figure 61). 6. If the height at location A and B are not the same, change tire pressure slightly to make them the same. Checking the Carrier Frame Front-to-Rear Pitch The carrier frame must have a pitch between 1/8 inch (3 mm) to 3/8 inch (9 mm) over the length of 24 inches (61 cm) on the carrier frame (Figure 62). 1. Measure out 24 inches (61 cm) on the carrier frame (Figure 62). Figure 60 1. Carrier Frame 2. Top of engine deck 3.
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 30 . 4. Measure carrier frame height at location A (Figure 63). 5. Measure carrier frame height at location B (Figure 63). 6. If the carrier frame height is not the same move spacers from top or bottom of caster wheel, to make it level.
Figure 67 40 inch Mower Deck shown Figure 66 1. Caster Wheel 2. Carrier Frame 3. Front height-of-cut pins 4. Jam nut 5. Ball joint 1. Measure from a level surface 2. Measure blade at points C and D 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.
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 69). For 36 inch mower decks use Figure 70. 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.
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The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
