Form No. 3364-485 Rev B Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Gear Drive with 32in, 36in or 48in Cutting Unit Model No. 39632—Serial No. 311000001 and Up Model No. 39634—Serial No. 311000001 and Up Model No. 39638—Serial No. 311000001 and Up g014946 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. 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.
Contents Replacing the Traction Drive Belt........................ 30 Replacing the Drive Belt ..................................... 30 Replacing the Mower Belt ................................... 31 Adjusting the Mower Belt Tension ...................... 32 Controls System Maintenance................................. 36 Adjusting the Control Rods ................................ 36 Mower Deck Maintenance ...................................... 37 Servicing the Cutting Blades ...............................
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 capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. • 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.
• Never tamper with safety devices. Check safety systems for proper operation before each use. • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
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. 98-0776 43-8480 98-3296 66-1340 98-5130 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 75-80 ft-lb (102-106 N⋅m). 98-5954 95-5537 3. Pull back to disengage 1. Read the Operator’s Manual for instructions on operating the cutting blade 2.
106-2733 99-3943 For Models with 48 Inch Mower Decks 1. Fast 2. Continuous variable setting 1. Engine 3. Slow 104-8569 110-2067 105-4104 1. Reverse 2. Neutral 3. Transmission speeds 110-2068 1. Read the Operator’s Manual.
6-2737 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection.
Throttle Control Product Overview The throttle control has two positions: Fast and Slow. 5 Operator Presence Control (OPC) Levers 4 3 6 When you squeeze the OPC levers against the handles, the OPC system senses that the operator is in the normal operating position.
Specifications Operation Note: Specifications and design are subject to change without notice. Adding Fuel 32 inch mowers: Width with deflector down Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. 45.8 inches (116.3 cm) Length 78 inches (198.1 cm) Height 41 inches (104.
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. 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.
Setting the Parking Brakes 2. Open the fuel valve. 1. Squeeze the drive levers (Figure 7). 3. Disengage the blade control (PTO) lever and move the shift lever to the neutral position. 4. Set the parking brakes. 5. Turn the ignition key to the run position (Figure 8). 6. To start a cold engine, move the throttle control midway between the fast and slow positions. 7. To start a warm engine, move the throttle control to the fast position. 8. Pull the choke knob if the engine is cold (Figure 8).
Figure 8 1. Throttle control 2. Ignition switch Figure 9 3. Choke 1. Operator Presence Control (OPC) lever Operating the Blade Control (PTO) Lever 2. Power take off lever (PTO) The Safety Interlock System CAUTION The blade control (PTO) lever engages and disengages the power to the mower blades. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
Testing the Safety Interlock System 2. Squeeze the OPC levers against the handles. 3. Move the shift lever into the reverse gear. 4. Release the parking brakes; refer to Releasing the Parking Brakes and Neutral Locks. 5. Slowly release the drive levers. Test the safety interlock system before you use the machine each time. If the safety system does not operate as described, have an Authorized Service Dealer repair the safety system immediately. 1.
5. Remove the locknut that secures the adjustment bolt to the drive pulley shield (Figure 10). 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 12 1. Axle pivot bolt 2. Axle adjustment bolt 4. Place a jack under the rear center of the engine frame. Raise the back end of the engine frame up enough to remove the front 2 axle adjustment bolts (Figure 12). Note: Use jack stands to support the machine. 5. Raise or lower the engine frame with the jack so that you can install the front 2 axle adjustment bolts in the desired hole location (Figure 12). Note: Use a tapered punch to help align the holes. 6. Tighten all 4 bolts and lower the mower. 7.
2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 13). 3. Install the caster in the support and insert the latch pin (Figure 13). Adjusting the Handle Height The handle position can be adjusted to match the operator’s height preference. 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 14). Figure 15 1. 2. 3. 4. 5. Upper handle Rear frame Flange bolt (3/8 x 1 inch) Lock nut (3/8 inch) Upper mounting hole 6. 7. 8. 9.
Height of Cut Chart Number of spacers below caster Number of 1/4 inch blade spacers below spindle 1/2 inch (13mm) 3/16 inch (5 mm) 4 3 2 1 0 A 0 0 1 inch (26 mm) 1–1/4 inch (32 mm) 1–1/2 inch (38 mm) 1–3/4 inch (45 mm) 2 inch (51 mm) A 0 1 1–1/8 inch (29 mm) 1–3/8 inch (35 mm) 1–5/8 inch (41 mm) 1–7/8 inch (48 mm) 2–1/8 inch (54 mm) A 1 0 1–3/8 inch (35 mm) 1–5/8 inch (41 mm) 1–7/8 inch (48 mm) 2–1/8 inch (54 mm) 2–3/8 inch (60 mm) B 0 1 1–3/8 inch (35 mm) 1–5/8 inch (41
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 mower belt tension. After the first 25 hours • Check the mower belt tension. Before each use or daily • • • • • • • • Check the safety system. Grease the caster wheels and caster pivot. Check the engine oil level. Clean the air intake screen.
Lubrication Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 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. Figure 17 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). Greasing the Mower Belt Idler 4. Connect a grease gun to the fitting.
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 19 1. Cover 2. Hose clamp 3. Paper element 4. Foam element Important: Do not oil the foam or paper element.
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. Figure 21 1. Oil dipstick Every 200 hours—Change the oil filter. 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 21). Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 6.
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 23). 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.
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 25). 1 Figure 24 1. Spark-plug wire/spark plug 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. Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 25).
Fuel System Maintenance Draining the Fuel Tank DANGER 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 26 • 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 2. Fuel filter 6. Wipe up any spilled fuel.
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) 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. Figure 27 1. Hose clamp 2. Fuel line 3. Filter 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Before each use, check brakes on both a level surface and slope. Servicing the Brakes 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. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.
4. Position the wing nuts so that the brakes engage when you squeeze the drive levers enough to place the neutral/parking brake locks forward, and then set the brakes. Belt Maintenance 5. Check the operation of the brakes again; refer to Checking the Brakes. Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the belts. Checking the Belts Check belts for cracks, frayed edges, burn marks, wear, signs of overheating or any other damage. Replace damaged belts.
Note: The proper mower belt tension is 10-15 lbf. (44-67 N) with the belt deflected 1/2 inch (13 mm) halfway between the pulleys (Figure 36 or Figure 37). 4. Remove the mower belt (Figure 32). 8. Engage the blade control (PTO) lever. 9. Check the clearance between the bell crank and the transmission output shaft (Figure 33). Figure 32 1. Idler pulley in slot 2. Traction belt 3. Mower belt 4. Belt guide 5. 3/4 inch (19 mm) 6. Mower belt 5.
Adjusting the Mower Belt Tension Adjusting the Tension for 32in and 36in Mower Decks Service Interval: After the first 8 hours—Check the mower belt tension. After the first 25 hours—Check the mower belt tension. Every 50 hours—Check the mower belt tension. Important: The brake needs to be adjusted when the belt tension or the brake linkage is adjusted. Figure 34 32in and 36in Mower Deck Important: The belt must be tight enough to not slip during heavy loads while cutting grass.
Figure 36 32in and 36in Mower Deck 1. Mower belt with 1/2 inch (13mm) deflection 2. Idler pulley Figure 37 48in Mower Deck 1. Mower belt with 1/2 inch (13mm) deflection 6. Tighten the locknut on the turnbuckle. 7. Check the blade brake adjustment; refer to Adjusting the Blade Brake. 2. Idler pulley Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16 inch (8 mm).
Adjusting the PTO Engagement Linkage positioned to the middle or front hole (Figure 39). Use the hole that will give the correct adjustment. 7. When the idler pulley is moved the belt guide must be moved. Move the belt guide to the front position (Figure 39). The PTO engagement linkage adjustment is located beneath the front left hand corner of the engine deck. 1. Disengage the blade control (PTO) lever and set the parking brakes. 2.
Figure 42 1. 2. 3. 4. Yoke Nut Rear assist arm stop Front assist arm stop 5. Assist arm link 6. Assist arm 7. Turnbuckle Figure 43 1. Bellcrank 2. Bolts and nuts 8. To adjust the assist arm link, remove the hairpin cotter pin from the assist arm (Figure 42). 9. Loosen the nut against the yoke (Figure 41). 10. Remove the assist arm link from the assist arm and rotate the link to adjust the length. 11. Install the assist arm link into the assist arm and secure it with the hairpin cotter pin (Figure 42).
Controls System Maintenance Adjusting the Control Rods 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 44). Figure 45 1. Handle 4. Drive lever 2. Neutral/ parking brake lock 5. Forward speed 3. 3/16 to 1/4 inch (5 to 6 6. Control rod mm) clearance 3. Install the control rod to the drive lever and the neutral/parking brake lock. Secure the control rod with a clevis pin and a hairpin cotter (Figure 45). 4. Check the operation of the control rod.
Mower Deck Maintenance Inspecting the Blades Service Interval: Before each use or daily 1. Inspect the cutting edges (Figure 46). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. 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.
1. Hold the blade bolt with a wrench. 2. Remove the nut, blade bolt, curved washer, blade, spacers, and thin washer from the spindle (Figure 50). Figure 48 2. Measure from a level surface to the cutting edge, position A, of the blades (Figure 49). Note this dimension. Figure 49 1. Measure from the cutting edge to a level surface 3. Rotate the opposite ends of the blades forward. 4. Measure from a level surface to the cutting edge of the blades at the same position as in step 1.
horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 52). Repeat this procedure until the blade is balanced. Figure 52 1. Blade 2. Balancer Installing the Blades Figure 53 1. Place the blade onto the bolt and over the curved washer. Select the proper number of spacer(s) for the height-of- cut, and slide the bolt into the spindle (Figure 50). 1. Spring mounting bolts 2.
Storage 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. g012749 Figure 54 1. Bolt 2. Spacer 3. Locknut 4. Spring 5. Spring installed 6. Grass Deflector 7.
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 the fuel tank with gasoline. 2. Fuel shut off valve is closed. 3. Choke is not on. 2. Open the fuel shut off valve. 3. Move the throttle lever to choke position. 4. Clean or replace the air cleaner element. 5. Install the wire on spark plug. 4. Air cleaner is dirty. 5. Spark plug wire is loose or disconnected. 6. Spark plug is pitted, fouled, or the gap is incorrect. 7.
Problem Blades do not rotate. Possible Cause Corrective Action 1. Mower deck belt is worn or loose. 1. Check the belt tension. 2. Mower deck belt is broken. 3. Mower deck belt is off pulley. 2. Install a new deck belt. 3. Inspect the belt and replace if damaged. Check the pulleys and idlers and adjust the belt tension. 4. Replace the spring. 4. Broken or missing idler spring.
Schematics Electrical Schematic (Rev.
Notes: 45
Notes: 46
Notes: 47
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 3. 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. Warranty Period •Engine •Battery See engine manufacturer’s warranty1 90 days Parts and Labor 1 year Parts only •Belts and Tires 90 days •Attachments 1 year 21 in.
