Form No. 3436-971 Rev A Commercial Walk-Behind Mower Fixed Deck, T-Bar, Gear Drive with 48in TURBO FORCE® Cutting Unit Model No. 39678—Serial No. 405457997 and Up Register at www.Toro.com.
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Contents Replacing the Drive Belt ................................... 35 Replacing the Mower Belt ................................. 36 Adjusting the Mower Belt Tension ..................... 37 Adjusting the PTO-Engagement Linkage ......................................................... 38 Adjusting the PTO-Safety Switch ...................... 39 Mower Deck Maintenance.................................... 40 Blade Safety ..................................................... 40 Servicing the Cutting Blades .
Safety This machine has been designed in accordance with ANSI B71.4-2017. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. • Read, understand, and follow the instructions and warnings in this Operator’s Manual and on the machine and attachments before starting the engine. • Do not put your hands or feet near moving parts of or under the machine. Keep clear of any discharge opening.
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 missing. decaloemmarkt Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. decal93-7442 93-7442 1. Parking brake decal93-7010 93-7010 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard, mower—keep the deflector in place. 3.
decal98-3296 decal112-8760 98-3296 1. Belt routing 112-8760 2. Engine 1. Thrown object hazard—keep bystanders away. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. decal98-4387 98-4387 decal112-9028 1. Warning—wear hearing protection. 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place. decal98-5130 98-5130 1.
decal126-1400 126-1400 1. Warning—read the Operator’s Manual for information about attachments; certain attachments can cause you to fall. decal130-8374 130-8374 1. Fast 3. Engine—stop 2. Slow 4. Engine—slow decal133-8062 133-8062 decal131-1180 131-1180 1. Read the Operator's Manual. 2. Short, light grass; dry conditions 3. Bagging setting 4.
decal140-1877 140-1877 1. Warning—read the Operator’s Manual. 5. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 2. Warning—all operators should be trained before operating the machine. 3. Warning—wear hearing protection. 6. Thrown object hazard—keep bystanders away. 7. Warning—shut off the engine and disconnect the spark plug before performing maintenance. 4. Thrown object hazard, mower—keep the deflector lowered. 8.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g213356 Figure 3 1. Side-discharge deflector 5. Fuel tank 2. Mower deck 3. Spark plug 6. T-bar control 7. Handle 4. Recoil-start handle 8. Front caster wheel g001446 Figure 4 1. Throttle control 7. Parking-brake lever 2. Blade-control bail 3. Blade-control lever (power takeoff) 8. Choke 9. Key switch 4. Gear-shift lever 10. Upper handle 5.
Blade-Control Lever (Power Takeoff) Specifications Use the blade-control lever in conjunction with the blade-control bail to engage and disengage power to the mower blades (Figure 4). change without notice. Note: Specifications and design are subject to Recoil-Start Handle Pull the recoil-start handle to start the engine (Figure 3). Fuel-Shutoff Valve Close the fuel-shutoff valve when transporting or storing the machine.
Operation • If you spill fuel, do not attempt to start the engine; Note: Determine the left and right sides of the machine from the normal operating position. • Do not fill containers inside a vehicle or on a truck avoid creating a source of ignition until the fuel vapors have dissipated. or trailer bed with a plastic liner. Always place containers on the ground, away from the vehicle before filling. Before Operation • Remove equipment from the truck or trailer and refuel it on the ground.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. • Wet grass or leaves can cause serious injury if you slip and contact the blade. Avoid mowing in wet conditions. • Keep your hands and feet away from the cutting unit. Filling the Fuel Tank 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4.
• If you lose control of the machine, step away from toward you. Stop the blade(s) when crossing gravel surfaces. the direction of travel of the machine. – Start the engine carefully according to instructions and with your feet well away from the blade(s) and not in front of the discharge chute. • Always keep the machine in gear when going – Use extreme caution when reversing or pulling the machine toward you. Operating the Parking Brake down slopes.
Shutting Off the Engine Starting the Engine 1. Connect the spark-plug wires. 2. Open the fuel valve. 3. Disengage the PTO and shift to the NEUTRAL position. 4. Engage the parking brakes. 5. Turn the ignition key to the RUN position. Important: In an emergency, you can stop the engine immediately by turning the ignition key to the Off position. 1. Move the throttle lever to the SLOW position (Figure 6). 2. Idle the engine for 30 to 60 seconds before turning the ignition key to the OFF position.
Operating the Blade-Control Lever (PTO) Using the Safety-Interlock System The blade-control lever (PTO) engages and disengages power to the mower blades. WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. Engaging the Mower Blades 1. Squeeze the blade-control bail against the upper control bar (Figure 7). 2. Push the blade-control lever (PTO) firmly forward, until it latches over the center.
Driving the Machine Using the Lower Control Bar The throttle control regulates the engine speed (rpm). Move the throttle control to the FAST position for the best mowing performance. This procedure is for driving up a curb. You can do this while driving forward or backward. WARNING Note: Some curbs do not allow the rear drive tires to contact the curb. If this happens, drive the machine up the curb at an angle. The machine can spin very rapidly.
g001452 Figure 10 1. Lower control bar—engaged g000211 Figure 9 1. Lower control bar—engaged and the machine going reverse 3. Lower control bar—engaged and the machine going forward 2. Handle Stopping the Machine 2. Pull up to assist the machine. CAUTION You or bystanders may be injured if you move or attempt to operate the machine while it is unattended. Driving Backward up a Curb 1. Disengage the mower blades. 2. Select the REVERSE position to drive the machine. 3.
Position B Use this position when bagging. g012676 Figure 11 2. Nut 1. Slot g012678 Figure 13 Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. Position C This is the full open position. The suggested use for this position is as follows: Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
Side Discharging or Mulching Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and bystanders are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris can cause serious injury or death.
g001455 Figure 16 1. Axle-pivot bolt 2. Axle-adjustment bolt g001456 Figure 17 4. Place a jack under the rear center of the engine frame. Raise the rear end of the engine frame up enough to remove the front 2 axle-adjustment bolts (Figure 16). 1. Latch pin 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 16). Note: Use a tapered punch to help align the holes.
Adjusting the Control Rods 1. With the wheel drive fully engaged, check the gap between the upper control bar and the fixed bar. The gap needs to be approximately 25 to 32 mm (1 to 1-1/4 inches) as shown in Figure 18. Note: The upper control bar and the fixed bar must be parallel in the engaged, relaxed, and brake positions. g018809 Figure 18 1. 25 to 32 mm (1 to 1-1/4 inches) gap 4. Upper control bar 2. Fixed control bar 3. Parking-brake lever 5. Control rod 2. Check the operation.
Height-of-Cut Chart Number of spacers below the caster Number of 1/4-inch blade spacers below the spindle Axle position 13 mm (1/2 inch) 5 mm (3/16 inch) 4 3 2 1 0 A 0 0 26 mm (1 inch) 32 mm (1-1/4 inches) 38 mm (1-1/2 inches) 45 mm (1-3/4 inches) 51 mm (2 inches) A 0 1 29 mm (1-1/8 inches) 35 mm (1-3/8 inches) 41 mm (1-5/8 inches) 48 mm (1-7/8 inches) 54 mm (2-1/8 inches) A 1 0 35 mm (1-3/8 inches) 41 mm (1-5/8 inches) 48 mm (1-7/8 inches) 54 mm (2-1/8 inches) 60 mm (2-3/8
After Operation After Operation Safety General Safety • Always shut off the machine, remove the ignition key (if equipped), wait for all moving parts to stop, and allow the machine to cool before adjusting, servicing, cleaning, or storing it. • Clean grass and debris from the machine to help prevent fires. Clean up oil or fuel spills. • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • Before adjusting, cleaning, servicing, or leaving the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. – Disengage the cutting units. – Ensure that the transmission is in neutral. – Engage the parking brake. – Shut off the engine and remove the key. – Wait for all moving parts to stop.
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-interlock system. Grease the caster wheels and caster pivot. Check the engine-oil level. Clean the air-intake screen. Clean the grass and debris from the air-intake screen. Check the parking brake. Inspect the blades.
Lubrication Greasing the Transmission Couplers Greasing the Machine Lubricate the transmission couplers and idler-arm pivots located at the rear of the machine (Figure 21). Grease the machine more often in dirty or dusty conditions. Grease Type: No. 2 lithium or molybdenum grease 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
Engine Maintenance Engine Safety • Do not change the governor speed or overspeed the engine. • Run the engine dry or remove the fuel with a hand pump; never siphon the fuel. If you must drain the fuel tank, do it outdoors. Servicing the Air Cleaner Service Interval: Every 25 hours—Clean the foam air-cleaner element. g012619 Figure 23 Every 50 hours—Check the paper air-cleaner element. Every 200 hours—Replace the paper air-cleaner element.
Servicing the Engine Oil Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Engine-Oil Specifications Engine-Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 1.7 L (58 oz) with the filter removed; 1.5 L (51 oz) without the filter removed g001464 Figure 25 Viscosity: Refer to the table (Figure 24). 1. Oil dipstick 2. Filler tube 4. Unscrew the oil dipstick and wipe the end clean (Figure 25). 5.
g001466 Figure 26 1. Oil-drain valve 2. Oil-drain hose 10. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 25). 11. Check the engine-oil level. 12. Slowly add the additional oil to bring it to the Full mark. Changing the Engine-Oil Filter Note: Change the engine-oil filter more frequently when the operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine. 2. Remove the old filter (Figure 27). g001465 Figure 27 1. Engine-oil filter 3.
Checking the Spark Plugs Servicing the Spark Plugs 1. Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plugs if necessary. Look at the center of the spark plugs (Figure 29). Note: 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. Type: Champion RCJ8Y (or equivalent) Air Gap: 0.762 mm (0.03 inch) 2.
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Refer to Fuel Safety (page 11) for a complete list of fuel related precautions. g005243 Figure 30 Servicing the Fuel System 1. Fuel filter 2. Clamp 3. Fuel-shutoff valve Draining the Fuel Tank 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2.
6. Install a new filter and move the hose clamps close to the filter. 7. Open the fuel-shutoff valve at the fuel tank (Figure 30). 8. Check for fuel leaks and repair, if needed. 9. Wipe up any spilled fuel. Drive System Maintenance Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Servicing the Fuel-Vent System Maintain the air pressure in the rear tires at 83 to 97 kPa (12 to 14 psi). Uneven tire pressure can cause an uneven cut (Figure 33).
Cooling System Maintenance Cleaning the Air-Intake Screen Remove any buildup of grass, dirt, or other debris from the cylinder and cylinder head cooling fins, the air-intake screen on the flywheel end, and the carburetor-governor levers and linkage. This helps ensure adequate cooling and correct engine speed to reduce the possibility of overheating or mechanical damage to the engine. Cleaning the Cooling System g001472 Figure 34 1. Air-intake screen 2.
Brake Maintenance Servicing the Parking Brake 3. Check the brake before you adjust it; refer to Checking the Parking Brake (page 34). 4. Disengage the parking brake. 5. To adjust the brake, rotate the wing nuts on the brake rods (Figure 35). Check the brakes on both a level surface and a slope. Turn the wing nuts clockwise to tighten the brake and counterclockwise to loosen the brake. Always engage the parking brake when you stop the machine or leave it unattended.
Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. g001474 Replacing the Traction-Drive Belt Figure 36 Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the traction-drive belt. 1.
8. Install the mower belt (Figure 37). 9. Check the belt guide under the engine frame for the proper adjustment (Figure 37). Note: The distance between the belt guide and mower belt should be 19 mm (3/4 inch) when you engage the mower belt. Adjust the belt, if necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted. Replacing the Mower Belt g001477 Figure 38 Important: The brake needs to be adjusted when 1. 2 to 3 mm (1/16 to 1/8 inch) 4.
Note: The distance between the belt guide and mower belt should be 32 mm (1-1/4 inches) when you engage the mower belt. Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted. Adjusting the Mower Belt Tension 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.
13 mm (1/2 inch) halfway between the pulleys (Figure 41). 6. If there is no adjustment remaining in the turnbuckle and the belt is still loose, the rear idler pulley needs to be positioned to the middle or front hole (Figure 42). Use the hole that provides the correct adjustment. 7. When you move the idler pulley, you must move the belt guide. Move the belt guide to the front position (Figure 42). g001475 Figure 43 1. Idler pulley in the slot 4. Belt guide 2. Traction belt 5. 19 mm (3/4 inch) 3.
9. Loosen the nut against the yoke (Figure 44). 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 (Figure 45). 12. Check if the assist arm hits against the stops correctly. Adjusting the PTO-Safety Switch g017648 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Figure 44 1. Bellcrank 2.
Mower Deck Maintenance Blade Safety A worn or damaged blade can break and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. g006530 Figure 47 • Inspect the blades periodically for excessive wear or damage. • Use care when checking the blades. Wear gloves and use caution when servicing them. Only replace the blades; never straighten or weld them. 1. Cutting edge 3. Wear/slot forming 2. Curved area 4.
g001563 Figure 50 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. Note: The difference between the dimensions obtained in steps 1 and 2 must not exceed 3 mm (1/8 inch). If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing the Blades (page 41) and Installing the Blades (page 42).
Adjusting the Blade Brake Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 52). 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. If necessary, adjust the spring-mounting bolts so that the blade-brake pad rubs against both sides of the pulley groove (Figure 54). 4.
Replacing the Grass Deflector 7. Important: The grass deflector must be able to rotate. Lift the deflector up to the fully-open position and ensure that it rotates into the fully-down position. WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine without the grass deflector, the discharge cover, or the grass-collection system in place. 1.
Cleaning Cleaning under the Mower Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Raise the front of the machine using a jack and use jack stands to support the machine. 4. Clean the machine with a rag. Do not spray the machine.
Storage A. Add fuel stabilizer/conditioner to fresh fuel in the tank. Follow mixing instructions from the fuel stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C. Shut off the engine, allow it to cool, and drain the fuel tank. D. Start the engine and run it until it shuts off. E. Dispose of fuel properly. Recycle the fuel according to local codes.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3.
Problem The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4. The engine pulley, idler pulley, or blade pulley is loose. 5. The engine pulley is damaged. 6. The blade spindle is bent. 7. The motor mount is loose or worn. 2. Tighten the blade mounting bolt. 3.
Schematics g001471 Electrical Schematic (Rev.
Notes:
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
