Form No. 3360-254 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear with 32in Cutting Unit Model No. 39092—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.
2 Installing the Fuel Tank.................................... 11 3 Checking and Adjusting the Shift Lever Plate............................................................... 11 4 Installing the Control Rods .............................. 12 5 Reading the Manual and Viewing the Training Material ............................................ 13 Product Overview ...................................................... 14 Controls ............................................................. 14 Operation........
Safety – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. – 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. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders. • 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 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.
8-3256 98-0776 98-4387 1. Warning—wear hearing protection. 105-0884 106-0699 110-4971 1. Engine—stop 2. Engine—Start 3. Engage bale then pull out on the PTO to engage the blade.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Use Qty.
Figure 4 1. Bolt, 5/16 x 7/8 inch 2. Lock washer, (5/16 inch) 3. Washer, (5/16 inch) Figure 3 1. 2. 3. 4. Upper handle Rear frame Flange nut, (3/8 inch) Flange bolt, (3/8 x 1 inch) 5. 6. 7. 8. Upper mounting hole Lower mounting holes Low position High position 4. Stud 5. Spring 6. Locknut Note: Remove the plastic cap from the fuel fitting before installing the fuel line. Note: Handle assembly must be installed before fuel tank is installed. 4. Slide the hose clamp onto the fuel line (Figure 5). 5.
4 Installing the Control Rods Parts needed for this procedure: Figure 6 1. Shift lever 2. Shift lever plate 3. Rubber seal washer 4. Square hole washer 5. Spring washer 6. Locknut, 3/8 inch 2 Control rods 2 Cotter pin 2 Clevis Pin 2 Washer 2 Hairpin cotter pin Procedure 2. If clearance is not correct, remove lever and bend it slightly to adjust (Figure 6). 1. Install the control rods into the upper control bar and the blade control bail. Secure the control rods with 2 cotter pins (Figure 8).
Figure 9 1. 2. 3. 4. Control rod and fitting 3-1/2 inch (89 mm) Idler bracket Clevis pin 5. 6. 7. 8. Washer Hairpin cotter pin Rod fitting Hole F Figure 10 1. Control rod 2. Fixed control bar 4. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 inch (25-32 mm) (Figure 10). 4. Upper control bar 5. 1 to 1-1/4 inch (25-32 mm) gap 3. Parking brake lever 7. Check the parking brake adjustment.
Product Overview Figure 12 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 11 1. Side discharge chute 2. Mower deck 3. Engine 4. Gas tank 5. Controls 6. Front caster wheel 7. Blade control bail 8. Upper control bar 9. 10. 11. 12. Upper handle Throttle control Ignition switch Fuel shut off valve Throttle Control The throttle control has two positions: Fast and Slow.
Upper Control Bar Operation 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. 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. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
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. Figure 13 1. Warning—wear hearing protection. Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to the fast position. Operating the Parking Brake 4.
The Safety Interlock System Important: Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. Operating the Blade Control Switch (PTO) If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. The blade control switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades. • Do not tamper with the interlock switches.
throttle control in the fast position for best mowing performance. 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. Driving Forward 1. To go forward, move the shift lever to a forward gear (Figure 17). 2. Release the parking brake; refer to Releasing the Parking Brake in Brake Maintenance , page 34. 3. Slowly press on the upper control bar to move forward (Figure 17).
Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Transporting Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions.
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. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
2. Loosen the upper flange bolts (3/8 x 1 inch) and flange nut securing handle to rear frame (Figure 21). 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.
Mowing Direction shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. Alternate mowing direction to keep the grass standing straight.
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. Grease the spindle bearing. Check the engine oil level. Clean the air intake screen. Check the brakes. Inspect the blades.
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 Lubricate the wheel bearings and front spindles (Figure 22). Figure 23 Greasing the Spindle Bearing Service Interval: Before each use or daily Grease the spindle bearing through the hole in the mower cover (Figure 24).
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/Yearly (whichever comes first)—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. Removing the Foam and Paper Elements Figure 25 1.
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 25). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 25). Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. Figure 27 1. Oil dipstick After the first 8 hours—Change the engine oil. 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 27).
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 29). 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.
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 31). Bend the side electrode (Figure 31) if the gap is not correct. 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 31). Figure 30 1.
Fuel System Maintenance Servicing the Fuel Tank 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. Figure 32 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1. Fuel shut off valve • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 2.
Electrical System Maintenance 5. Install a new filter and move the hose clamps close to the filter. 6. Open fuel shut off valve at fuel tank (Figure 32). 7. Check for fuel leaks and repair if needed. Servicing the Fuse 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 34) to remove or replace it. Figure 34 1. Fuse, 7.
Drive System Maintenance Remember the location of the thrust washers and spacer on each fork to ensure correct installation and to maintain a level mower. Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Check the pressure at the valve stem (Figure 35). Maintain the air pressure in the rear tires at 12-14 psi (83-97 kPa). Uneven tire pressure can cause an uneven cut. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance.
Important: The inside diameter of the bushings may collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 inch (29 mm). locknut until the spanner bushing bottoms against the inside of the caster forks (Figure 38). 7. Grease the fitting on the caster wheel. Adjusting the Electric Clutch 11. Grease the fitting on the carrier frame mounting tube using No. 2 general purpose lithium base or molybdenum base grease.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily—Check the brakes. Servicing the Brakes Service Interval: Before each use or daily Check brakes on both a level surface and slope. Before each use 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.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours—Inspect the traction drive belt. Every 50 hours—Inspect the transmission belt. Every 50 hours—Inspect the mower belt. Squealing when the belt is rotating, blades slipping when cutting grass, check the belts for cracks, frayed edges, burn marks or any other damage. Replace the belt if any of these conditions are evident. Figure 40 1. Hairpin cotter and washer 2. Trunnion 3. Brake lever 4. Wing nut Replacing the Traction Drive Belt 5.
Replacing the Transmission Belt are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. Disengage the PTO and set the parking brake. 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. Raise the front of the machine and hold it with jack stands. 4. Check the belt for wear. 5. Disconnect clutch wire connector from wire harness. 6. Remove mower belt.
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. Figure 44 1. Front jam nut 2. Rear jam nut 4. 4–3/4 inches (12 cm) between the washer and bushing, minus one turn 5. Carrier frame mounting tab 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. 3.
Checking for Bent Blades 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, blade stiffener, washer, and blade from the spindle shaft (Figure 47). 1. Rotate the blade until the ends face forward and backward (Figure 46). Figure 46 1. Blade 2. Measure from cutting edge to level surface Figure 47 4. Anti-scalp cup 5. Lock washer 6. Blade Bolt 1. Sail Area of Blade 2. Blade 3. Spacer 2.
Installing the Blade 1. Install the blade onto the spindle shaft (Figure 47). Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 47). 2. Install the blade stiffener, flat washer and blade bolt (Figure 47). 3. Torque the blade bolt to 85-110 ft-lb (115-140 N⋅m). Correcting the Mower Quality of Cut Figure 50 1. Blade 2. Measure from cutting edge to level surface Note: Tire air pressure is critical in these procedures.
2. Position the blade side-to-side (Figure 52). Measure at A and B locations (Figure 52) from a level surface to the cutting edge of blade tips (Figure 52). Open holes in the mower could allow the mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Never operate the mower with open holes; install hardware in all open mounting hole when you remove the discharge cover. 8.
Storage 2. Remove the deflector assembly from the front (fixed) deflector pivot post and remove the deflector assembly from the mower (Figure 54). Cleaning and Storage 3. Install the spring onto the replacement deflector assembly, then install the deflector assembly into the front deflector pivot post. 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2.
11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 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.
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 Blade does not rotate. Possible Cause Corrective Action 1. Mower belt is worn, loose or broken. 1. Check the belt tension. 2. Mower belt is off pulley. 2. Install mower belt and check adjusting shafts and belt guides for correct position. 3. Install new mower belt. 4. Install mower pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring. 3. Mower belt is worn, loose or broken. 4. Mower belt is off pulley. 5.
Schematics Electrical Schematic (Rev.
Notes: 46
Notes: 47
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.
