Form No. 3360-616 Rev A Commercial Walk-Behind Mower with Floating Deck, T-Bar, Hydro with 40in or 48in TURBO FORCE® Cutting Unit Model No. 39496—Serial No. 280000001 and Up Model No. 39498—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. Figure 1 1. Location of the model and serial numbers Important: This engine is not equipped with a spark arrester muffler.
Starting and Stopping the Engine ........................ 14 Operating the Mower Blade Control (PTO) ............................................................ 15 The Safety Interlock System................................ 16 Driving Forward or Backward............................. 16 Stopping the Machine......................................... 17 Pushing the Machine by Hand............................. 17 Transporting Machines.......................................
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. 98-0776 43-8480 98-5954 66-1340 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 68-8340 5. Read the Operator’s Manual. 95-2814 8 6.
Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 104-8186 104-8569 110-2067 105-7798 110-2068 1. Read the Operator’s Manual.
115-4212 1. Hydraulic oil level 115-4186 3. Warning—do not touch the hot surface. 1. 2. 3. 4. 5. 6. 2. Read the Operator’s Manual. Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 115–4179 1. Move the motion control lever to the neutral position, then pull 6. Warning—stop the engine before leaving the machine. out on PTO (Power Take Off) switch to engage the blades. 2. Push in on the PTO (Power Take Off) to disengage the blades. 7.
4-3424 1. Traction control 2. Fast 5. Reverse 6. Disengage the PTO (Power Take Off) 3. Slow 4. Neutral Product Overview Figure 3 1. Ignition switch 2. Left motion control lever Figure 2 1. 2. 3. 4. Side discharge chute Engine Gas tank Controls 3. Throttle control 4. Hour meter 5. Fuel tank 5. Parking brake 6. Mower deck 7. Front caster wheel 6. Choke 7. Neutral lock position for right motion control lever 8. Right motion control lever 9. blade control switch (PTO) 10.
enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Specifications Note: Specifications and design are subject to change without notice. Figure 4 1. Safety interlock symbols 2. Battery light 40 inch mowers: 3. Hour meter Throttle Control The throttle control has two positions: Fast and Slow.
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. 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Important: Do not use fuel additives containing methanol or ethanol. If the parking brake does not hold securely, adjust it. Refer to Servicing the Parking Brake. Add the correct amount of gas stabilizer/conditioner to the gas. 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.
Operating the Mower Blade Control (PTO) Note: A warm or hot engine may not require choking. To start a warm engine, move throttle control midway between the fast and slow positions. The blade control switch (PTO) is used in conjunction with the right side motion control lever to engage and disengage the mower blades. Engaging the Mower Blades (PTO) 1. To engage the mower blades, move the right side motion control lever to the center, un-locked position (Figure 7). 2.
The Safety Interlock System 8. Move or release the right side motion control lever into the neutral lock position. The blades should stop rotating. 9. Move the right side motion control lever to the center, un-locked position. 10. Continue holding the right side motion control lever in the center, un-locked position and pull up on the blade control switch (PTO) and release. The clutch should engage and the mower blades begin rotating. 11. Push the blade control switch (PTO) down to the off position.
Pushing the Machine by Hand To stop, pull the motion control levers back to the neutral position. The by-pass valves allow the machine to be pushed by hand without the engine running. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To Push the Machine 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Open the by-pass valve on both pumps by turning them counter clockwise 1 to 2 turns.
law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. 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. To transport the machine: 1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2.
Figure 12 1. Mower deck 2. Bolt 3. Spacer 4. Anti-Scalp Rollers 5. Nut Figure 11 1. Carrier Frame 2. Hairpin Cotter 3. Back height-of-cut post 4. Spacers 5. Front height-of-cut post Adjusting the Anti-Scalp Rollers The anti-scalp rollers need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground. Note: If the anti-scalp rollers are adjusted too low it can cause excess wear of the rollers. Figure 13 1.
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. To adjust the cam lock, swing the lever up to loosen the cam lock (Figure 14). 4. Adjust the baffle and cam lock in the slot to the desired discharge flow. 5. Swing the lever back over to tighten the baffle and cam lock (Figure 14). 6.
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 18 or Figure 19). The following table indicates the position of the weight as installed at the factory.
Figure 19 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. • Check the hydraulic fluid level. • Change the hydraulic filter. Before each use or daily • • • • • • • Check the safety interlock system. Grease the front caster pivot bearing. Check the engine oil level. Clean the air intake screen. Check the brakes.
Lubrication Greasing the PTO Drive Belt Idler and Mower Deck Belt Idler Grease with No. 2 general purpose lithium base or molybdenum base grease. Service Interval: Every 50 hours How to Grease Every 50 hours 1. Disengage the PTO and set the parking brake. Grease the idler pulley pivots (Figure 21). 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/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 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Clean around the oil dipstick (Figure 24) so that dirt cannot fall into the filler hole and damage the engine. 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 22). 2.
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 26). 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 26). 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.
Fuel System Maintenance 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Draining the Fuel Tank Checking the Spark Plugs Service Interval: Every 100 hours 1. Look at the center of the spark plugs (Figure 28). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty.
Figure 29 1. Fuel shut-off valve 2. Clamp Figure 30 1. Hose clamp 2. Fuel line Servicing the Fuel Filter 3. Filter 5. Remove the filter from the fuel lines. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 6. Install a new filter and move the hose clamps close to the filter. Replacing the Fuel Filter 7. Open fuel shut-off valve at fuel tank (Figure 29). Service Interval: Every 200 hours 8. Check for fuel leaks and repair if needed.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda.
Figure 32 1. Vent caps 2. Upper line 3. Lower line 2. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery in , page . Adding Water to the Battery The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 1. Remove the battery from the machine; refer to Removing the Battery in , page .
Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery. 2. Check the electrolyte level; refer to Checking the Electrolyte Level. 3. Make sure the filler caps are installed in battery. Charge battery for 1 hour at 25 to 30 amps or 6 hours at 4 to 6 amps. 4.
Drive System Maintenance Adjusting the Tracking 1. If the machine does not track straight, adjustment is required. 2. Check the rear tire pressure. Refer to Checking the Tire Pressure. 3. Loosen the wing nuts on the right control rod and rotate the turnbuckle in or out to ensure the right side control lever is centered in the neutral lock position. Secure the turnbuckle in position with the wing nuts (Figure 35). 4.
to ensure correct installation, and to maintain a level deck. 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Figure 38). Clean the inside of the mounting tube. Figure 39 1. Locknut 2. Wheel Bolt 3. Bushing 4. Spanner Bushing 5. Roller Bearing Figure 38 1. Mounting Tube 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 39). 2. Bushing 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 40). 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 9. Tighten the top and bottom jam nuts (Figure 41). 10. Check the brake operation again; refer to Checking the Brake. Servicing the Brake 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 Parking Brake Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the PTO. 2.
Belt Maintenance Replacing the Mower 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 deck belt. Replace the deck belt if any of these conditions are evident. 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. Unlatch and remove the carrier frame cover. Figure 42 4.
11. Adjust the belt guide an 1/8 inch (3 mm) from the belt (Figure 43). 12. Install the belt covers onto the cutting unit and secure the latches. 13. Install the carrier frame cover onto the carrier frame and secure the latches. Figure 44 1. PTO drive belt idler pulley 2. PTO drive Belt 3. Idler spring Replacing the Pump Drive Belt Figure 43 1. PTO drive belt guide 2. PTO drive Belt 3. Idler spring 4. Most tension for worn belts 5. Medium tension for normal belt conditions 6.
Controls System Maintenance Adjusting the Motion Control Handle Positions Adjusting the Right Side Motion Control Lever If the motion control levers do not align horizontally, adjust the right side motion control lever. Note: Adjust the horizontal alignment before the front to back alignment. 1. Disengage the PTO, move the right side motion control lever to the neutral position and set the parking brake. 2.
Figure 48 1. Right side motion control lever pivot shown under controls 2. Right side motion control lever Figure 47 1. Cam 2. Nut and bolt 3. Wing nut 3. 1/8 inch (3mm) gap needed between switch and control lever 4. Switch Adjusting the Neutral Postion for the Motion Control Levers 4. Turnbuckle 5. Switch screws Important: Ensure the tracking of the mower is correct after adjusting the motion control levers.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours Check the hydraulic fluid level as follows: • Check the hydraulic fluid level before engine is first started. • Check the hydraulic fluid level after first 8 operating hours. • Check the hydraulic fluid level after every 25 operating hours. Figure 49 1. Left motion control lever 2. Right motion control lever 3. Neutral locked position 4.
5. Remove cap from filler neck. Look inside to check the fluid level in the reservoir. (Figure 51). Change the hydraulic filter as follows: • After the first 8 operating hours. 6. Add fluid to the reservoir until it reaches the cold level of the baffle. • After every 200 operating hours or yearly before storage. 7. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine. 1.
After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Note: Keep areas around hydraulic system clean from grass and debris build up. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 53 1. Hydraulic filter 2.
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.
Figure 55 1. Measure here from blade to hard surface 2. Position A Figure 56 1. Sail Area of Blade 2. Blade 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in 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. 3.
Installing the Blades must be 1-5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm). 1. Install the blade onto the spindle shaft (Figure 56). 5. If the height at location A is not correct, adjustment is needed. Important: The sail part of the blade must be pointing upward, toward the inside of the mower to ensure proper cutting (Figure 56). 6. Loosen the carrier frame mounting bolts on both sides of the machine (Figure 59). 2. Install the blade, curved washer, and blade bolt (Figure 56). 7.
(Figure 61). Move spacers from top or bottom to make the correct pitch. 6. The tire pressure may also be adjusted slightly to make an 1/8-3/8 inch (3 -10 mm) pitch. Checking the Carrier Frame Side-to-Side Height The carrier frame needs to be parallel side-to-side from the ground. Figure 60 1. Back view of machine 2. Top of engine deck 1. Disengage the PTO and set the parking brake. 3. Tires 4. Same height at locations A and B 2.
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 63). 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 and repeat for other blades. If it is not correct, proceed to Changing the Deck Front-to-Rear Pitch. 2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Figure 64). 3.
Matching Height of Cut 1. Check the rear tire pressure. 2. Set the height-of-cut to the 4 inch (101.6 mm) position following the height-of-cut decal. 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 66). Figure 67 1. Bolt 2. Spacer 3. Locknut Figure 66 1. Measure from a level surface 4. Spring 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8.
Cleaning Storage Cleaning Under the Mower 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. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 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. Engine loses power. Engine overheats. Machine does not drive. Abnormal vibration. Uneven cutting height. Possible Cause Corrective Action 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 2. Choke is not on. 3. Air cleaner is dirty. 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.
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 Hydraulic Schematic (Rev.
Electrical Schematic (Rev.
The Toro Total Coverage Guarantee 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 repair the listed Toro Products if defective in materials or workmanship.
