Toro 39094 Operator'S Manual Download | Manualshive

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Schematics

Electrical Schematic (Rev. A)

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Summary of Contents for 39094

Page 1: ...mercial 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 Original Instructions EN ...

Page 2: ...rectly at www Toro com for product and accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the number...

Page 3: ...Servicing the Spark Plugs 27 Fuel System Maintenance 28 Draining the Fuel Tank 28 Replacing the Fuel Filter 29 Electrical System Maintenance 30 Servicing the Fuse 30 Drive System Maintenance 30 Adjusting the Control Bar 30 Checking the Tire Pressure 31 Replacing the Caster Wheel Fork Bushings 31 Servicing the Caster Wheel and Bearings 32 Adjusting the Electric Clutch 32 Cooling System Maintenance ...

Page 4: ...machine Use extra care when handling gasoline and other fuels They are flammable and vapors are explosive Use only an approved container 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 oper...

Page 5: ...ains safety information specific to Toro products and other safety information you must know This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death 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 p...

Page 6: ... Use only genuine replacement parts to ensure that original standards are maintained Check brake operation frequently Adjust and service as required 6 ...

Page 7: ...Slope Chart 7 ...

Page 8: ...ly visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost 43 8480 52 2010 66 1340 68 8340 82 2280 REVERSE TRACTION DRIVE 82 2280 82 2290 95 2814 98 0776 98 3256 98 4387 1 Warning wear hearing protection 98 5954 8 ...

Page 9: ...104 8185 104 8186 104 8569 105 7798 106 0699 110 2067 110 2068 1 Read the Operator s Manual 106 0635 9 ...

Page 10: ...h all the controls Figure 4 before you start the engine and operate the machine Figure 4 1 Gear shift lever 7 Blade control bail 2 Power take off switch PTO 8 Upper control bar 3 Choke control 9 Upper handle 4 Lower handle 10 Throttle control 5 Lower control bar 11 Ignition switch 6 Parking brake lever released position 12 Fuel shut off valve Throttle Control The throttle control has two positions...

Page 11: ...t operation Parking Brake Lever Pull back on upper control bar and swing brake lever up against the upper handle Figure 4 Ignition Switch This switch is used in conjunction with recoil starter and has two positions Run and Off Recoil Starter Pull recoil starter handle to start engine not shown in Figure 4 Fuel Shut off Valve Close the fuel shut off valve when transporting or storing mower Specific...

Page 12: ...n 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 Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic tru...

Page 13: ... safety instructions and decals in the safety section Knowing this information could help you or any bystanders avoid injury The use of protective equipment for eyes hearing feet and head is recommended This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Figu...

Page 14: ...on key 4 Set the parking brake and remove key 5 Pull the wire off spark plug s to prevent possibility of accidental starting before storing machine 6 Close the fuel shut off valve before storing machine Important Make sure the fuel shut off valve is closed before transporting or storing machine as fuel leakage may occur Operating the Mower Power Take Off PTO The power take off switch PTO in conjun...

Page 15: ...utch should engage and the mower blades begin rotating 4 Release the blade control bail The blades should stop rotating 5 With the engine running pull up the power take off switch PTO and release without holding the blade control bail The blades should not rotate Driving Forward or Backward The throttle control regulates the engine speed as measured in RPM revolutions per minute Place the throttle...

Page 16: ...ower control bar and lift up on the lower handle Figure 9 and Figure 10 Note Lifting up on the lower handle will assist driving the machine up a curb and not spin the drive wheels Stopping the Machine 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 ...

Page 17: ... is done by relocating four hairpin cotter pins in different hole locations and by adding or removing spacers Note All height of cut pins need at least one spacer or damage can occur to the bushing if none are used 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 h...

Page 18: ...re 15 Figure 13 40 inch Mower Deck 1 Mower deck 4 Anti scalp rollers 2 Bolt 5 Nut 3 Spacer Figure 14 40 inch Mower Deck 1 Mower deck 4 Bushing 2 Bolt 5 Anti scalp rollers 3 Spacer 6 Nut Figure 15 36 inch Mower Deck 1 Mower deck 4 Anti scalp rollers 2 Bolt 5 Nut 3 Spacer 5 In certain mowing conditions and terrain a mismatch of cutting height may be seen Adjusting the outside anti scalp rollers to t...

Page 19: ...n 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 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake ...

Page 20: ...llows Use for short light grass mowing conditions Use in dry conditions For smaller grass clippings Propels grass clippings farther away from the mower Figure 19 Position B Use this position when bagging Figure 20 Figure 20 Position C This is the full open position The suggested use for this position is as follows Figure 21 Use in tall dense grass mowing conditions Use in wet conditions Lowers the...

Page 21: ...weight 36 inches none none 40 inches 1 Front Any rear weight must be removed when a Tru Track Sulky is installed When a Tru Track Sulky is installed front weights are needed Contact an Authorized Service Dealer for the correct quantity of weights and placement The front end of the machine can rapidly rise up when the mower is removed This could cause serious injury to you or bystanders Support the...

Page 22: ...0 hours Replace the paper air cleaner element Change the oil filter Replace the fuel filter Every 250 hours Grease the transmission couplers more often in dirty or dusty conditions Every 400 hours Grease the front wheel bearings more often in dirty or dusty conditions Before storage Paint chipped surfaces Perform all maintenance procedures listed above before storage Important Refer to your engine...

Page 23: ...the rear wheel grease cap Lubricate the rear wheel bearing Figure 24 5 Install the grease cap 6 Install the rear wheel and tire assembly Note Make sure the rear wheel grease caps are removed before lubricating rear wheels Figure 24 Greasing the Transmission Couplers Service Interval Every 250 hours Lubricate the transmission couplers located in the back of the machine Figure 25 Figure 25 Greasing ...

Page 24: ...are extremely dusty or sandy Important Do not oil the foam or paper element Removing the Foam and Paper Elements 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 Clean around the air cleaner to prevent dirt from getting into the engine and causing damage Figure 28 4 Unscrew the cover knob an...

Page 25: ...ir 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 Note Change...

Page 26: ...ait for all moving parts to stop before leaving the operating position 5 Slide the drain hose over the oil drain valve 6 Place a pan below the drain hose Rotate oil drain valve to allow oil to drain Figure 31 7 When oil has drained completely close the drain valve 8 Remove the drain hose Figure 31 Note Dispose of the used oil at a recycling center Figure 31 1 Oil drain valve 2 Oil drain hose 9 Slo...

Page 27: ...pping tool feeler gauge to check and adjust the air gap Install a new spark plugs if necessary Type Champion RCJ8Y or equivalent Air Gap 0 030 inch 0 75 mm Removing the Spark Plugs 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 Disconnect the wires from the spark plugs Figure 33 Figure 33 ...

Page 28: ...old Do this outdoors in an open area Wipe up any gasoline that spills Never smoke when draining gasoline and stay away from an open flame or where a spark may ignite the gasoline fumes 1 Park the machine on a level surface to ensure the fuel tank drains completely Then disengage the power take off PTO set the parking brake and turn the ignition key to off Remove the key 2 Close the fuel shut off v...

Page 29: ...all moving parts to stop before leaving the operating position 3 Close fuel shut off valve at fuel tank Figure 35 Note Remove the fuel line from the fuel valve that is closest to the engine 4 Squeeze the ends of the hose clamps together and slide them away from the filter Figure 36 Figure 36 1 Hose clamp 3 Filter 2 Fuel line 5 Remove the filter from the fuel lines 6 Install a new filter and move t...

Page 30: ...d The gap should be approximately 1 to 1 1 4 inch 25 32 mm Figure 38 Note The upper control bar and fixed bar must be parallel when the upper control bar is in the engaged drive neutral or brake positions Figure 38 1 Upper control bar 4 Handle 2 Parking brake lever 5 1 to 1 1 4 inch 25 32mm gap 3 Fixed control bar 2 Check the operation If adjustment is required remove hairpin cotter washer and cle...

Page 31: ...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 2 Remove the locking pin and spacer s from the top of the caster wheel fork Figure 41...

Page 32: ... Figure 43 Figure 43 1 Locknut 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 43 3 Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub Figure 43 4 Inspect the roller bearing bushings spanner bushing and inside of the wheel hub for wear Replace any d...

Page 33: ...ot Cooling System Maintenance 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 This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechan...

Page 34: ...ntil it is 1 1 4 inches from the top of the rod Figure 45 1 Park the machine on a level surface 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 Check the brake before you adjust it refer to Checking the Brakes 4 Release the parking brake refer to Releasing the Parking Brake in Operation page ...

Page 35: ...Belt in the Belt Maintenance page 35 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 Figure 47 1 Transmission belt 5 Clutch wire connector 2 Idler pulley 6 Pivot bolt 3 Clutch retainer 7 Drive pulley 4 Tension spring 8 Engine deck 7 Unhook tension spring from side of frame Fi...

Page 36: ...m spring 2 PTO drive belt 5 Drive belt pulley 3 Drive belt pulley Replacing the PTO Drive Belt Service Interval Every 50 hours Squealing when the belt is rotating blades slipping when cutting grass frayed belt edges burn marks and cracks are signs of a worn drive belt Replace the drive belt if any of these conditions are evident 1 Disengage the PTO and set the parking brake 2 Stop the engine remov...

Page 37: ...frame cover onto the carrier frame and secure the latches Figure 50 40 inch Mower Deck shown 1 PTO drive belt guide 4 PTO engagement pulley 2 PTO drive Belt 5 PTO drive belt idler pulley 3 Idler spring 6 Center spindle pulley Figure 51 36 inch Mower Deck shown 1 Mower deck belt 4 Clutch pulley 2 PTO Drive Belt 5 Idler pulley 3 Idler arm and spring Adjusting the PTO Drive Belt Idler Spring Anchor T...

Page 38: ...ng the Blades Figure 53 1 Cutting Edge 3 Wear slot forming in curved area 2 Sail 4 Crack in the curved area 2 Inspect the blades especially the curved area Figure 53 If you notice any cracks wear or a slot forming in this area item 3 in Figure 53 immediately install a new blade Checking for Bent Blades 1 Disengage the PTO move the motion control levers to the neutral locked position and set the pa...

Page 39: ... or is bent To ensure optimum performance and continued safety conformance of the machine use genuine Toro replacement blades Replacement blades made by other manufacturers may result in non conformance with safety standards 1 Hold the blade end using a rag or thickly padded glove 2 For 40 inch mower decks remove the blade bolt curved washer and blade from the spindle shaft Figure 56 Figure 56 40 ...

Page 40: ...brake 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 Adjust the tire pressure in the rear tires to specifications refer to Drive System Maintenance page 30 4 Check that the blades and spindle shafts are not bent Refer to Checking for Bent Blades 5 Set the height of cut to the 4 in...

Page 41: ... 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 62 1 Carrier Frame 4 Height at locations A and B 2 1 4 3 8 inch 6 10 mm pitch over 24 inch 61 cm length 5 Caster Wheel 3 24 inches 61 cm 6 Caster spacers 2 Measure carrie...

Page 42: ...Rear Pitch 1 Adjust the tire pressure in the rear tires to specifications refer to Drive System Maintenance page 30 2 Position one blade front to rear Measure at A and B locations from a level surface to the cutting edge of the blade tips Figure 64 or Figure 65 For 36 inch mower decks use Figure 65 3 The mower blade should be a 1 4 inch 6 mm lower in front at A than in the rear at B Rotate blades ...

Page 43: ...e blades side to side Measure at C and D locations from a level surface to the cutting edge of blade tips Figure 67 For 36 inch mower decks use Figure 68 Figure 67 40 inch Mower Deck shown 1 Measure from a level surface 2 Measure blade at points C and D Figure 68 36 inch Mower Deck shown 3 The difference between measurements C and D should be no more than 1 4 inch 6 mm Changing the Mower Deck Side...

Page 44: ...n 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 Remove damaged or worn grass deflector Figure 71 1 Bolt 5 Spring installed 2 Spacer 6 Grass Deflector 3 Locknut 7 L end of spring place behind ...

Page 45: ... in the tank B Run engine to distribute conditioned fuel through the fuel system 5 minutes C Stop engine allow to cool and drain the fuel tank refer to Servicing the Fuel Tank in Fuel System Maintenance page 28 or operate engine until it stops D Restart engine and run until it stops Repeat on Choke until engine will not restart E Dispose of fuel properly Recycle as per local codes Note Do not stor...

Page 46: ...ized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Oil level in the crankcase is low 2 Add oil to the crankcase Engine overheats 3 Cooling fins and air passages under the engine blower housing are plugged 3 Remove the obstruction from the cooling fins and air passages 1 Shift lever is in neutral 1 Move shift lever to a drive gear position 2 Traction belt is worn loose or br...

Page 47: ...lley and check the idler pulley idler arm and spring for correct position and function 5 Broken or missing idler spring 5 Replace the spring 6 Electric clutch out of adjustment 6 Adjust the clutch air gap 7 Clutch connector or wire damaged 7 Contact an Authorized Service Dealer 8 Damaged electric clutch 8 Contact an Authorized Service Dealer 9 Safety interlock system prevents blade rotation 9 Cont...

Page 48: ...Schematics Electrical Schematic Rev A 48 ...

Page 49: ...Notes 49 ...

Page 50: ...Notes 50 ...

Page 51: ...Notes 51 ...

Page 52: ...is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as lters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack...

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