Form No. 3428-319 Rev A Commercial Walk-Behind Mower Fixed Deck, T-Bar, Gear Drive with 48in TURBO FORCE® Cutting Unit Model No. 39678—Serial No. 404324200 and Up Register at www.Toro.com.
It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.
Contents Belt Maintenance ................................................ 37 Inspecting the Belts .......................................... 37 Replacing the Traction-Drive Belt...................... 37 Replacing the Drive Belt ................................... 38 Replacing the Mower Belt ................................. 38 Adjusting the Mower Belt Tension ..................... 39 Adjusting the PTO-Engagement Linkage .........................................................
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. decal93-7298 93-7298 decaloemmarkt Manufacturer's Mark 1. Traction drive—Forward 2. Pull to brake. 1. Indicates the blade is identified as a part from the original machine manufacturer. decal93-7299 93-7299 1.
decal98-5130 98-5130 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 102 to 106 N∙m (75 to 80 ft-lb). decal95-5537(gear) 95-5537 1. Read the Operator's Manual for instructions on operating the cutting blade. 2. Push forward to engage. 3. Pull back to disengage. decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal98-3264 98-3264 1. Read the Operator's Manual. decal98-3296 98-3296 1. Belt routing 2. Engine decal98-4387 98-4387 1.
decal106-5519 106-5519 1. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 3. Warning—read the Operator's Manual. 2. Warning—shut off the engine before leaving the machine. 4. Thrown object hazard—keep bystanders away. 5. Thrown object hazard, mower—lower the deflector before using the machine. decal121-6049 121–6049 decal112-8760 112-8760 1. Thrown object hazard—keep bystanders away. 1. Thrown object hazard—keep bystanders away. 2.
decal130-8374 130-8374 1. Fast 3. Engine—stop 2. Slow decal131-1180 131-1180 1. Read the Operator's Manual. 2. Short, light grass; dry conditions 3. Bagging setting 4. Tall, dense grass; wet conditions decal133-8062 133-8062 8 4.
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 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. Upper control bar 11.
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 • Look behind and down before backing up to be sure of a clear path. 1. Park the machine on a level surface. 2.
• 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 Adding Fuel (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. Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
WARNING Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2.
Charging the Battery WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. g000537 Figure 34 1. Vent caps Important: Always keep the battery fully charged 3. Lower line (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1. Remove the battery from the machine; refer to Removing the Battery (page 32). 2.
Drive System Maintenance Cooling System Maintenance Checking the Tire Pressure Cleaning the Air-Intake Screen Service Interval: Every 50 hours/Monthly (whichever comes first) 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.
Brake Maintenance Servicing the Parking Brake Check the brakes on both a level surface and a slope. Always engage the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, adjust it. Checking the Parking Brake Service Interval: Before each use or daily 1. Park the machine on a level surface and disengage the PTO. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
3. Check the brake before you adjust it; refer to Checking the Parking Brake (page 36). 4. Disengage the parking brake. 5. To adjust the brake, rotate the wing nuts on the brake rods (Figure 38). Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Turn the wing nuts clockwise to tighten the brake and counterclockwise to loosen the brake. Replace the belt if it is worn.
8. Install the mower belt (Figure 40). 9. Check the belt guide under the engine frame for the proper adjustment (Figure 40). 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 g001474 Figure 39 1. Hairpin cotter 3. Shield 2. Brake rod 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. g001477 Figure 41 After the first 25 hours—Check the mower belt tension. 1. 2 to 3 mm (1/16 to 1/8 inch) 4. Hairpin cotter 2. Bell crank 5.
13 mm (1/2 inch) halfway between the pulleys (Figure 44). 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 45). 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 45). g001565 Figure 43 1. Idler pulley 2.
g001475 Figure 46 g017648 1. Idler pulley in the slot 4. Belt guide 2. Traction belt 5. 19 mm (3/4 inch) 3. Mower belt 6. Mower belt Figure 47 Adjusting the PTO-Engagement Linkage The adjustment for the PTO-engagement linkage is located beneath the front, left corner of the engine deck. 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 wait for all moving parts to stop before leaving the operating position. 3.
9. Mower Deck Maintenance Loosen the nut against the yoke (Figure 47). 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 48). 12. Check if the assist arm hits against the stops correctly. 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.
g001563 Figure 53 1. Measure from the cutting edge to a level surface. g006530 Figure 50 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack 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).
Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 55). g000553 Figure 56 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the curved washer and then the blade onto the bolt. Select the proper number of spacer(s) for the height of cut, and slide the bolt into the spindle (Figure 54). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting.
Adjusting the Blade Brake 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 57). 4. Adjust the nut at the end of the blade brake rod until there is 3 mm to 5 mm (1/8 to 3/16 inch) between the nut and spacer (Figure 57). 5.
7. Cleaning Place one J-hook end of the spring around the grass deflector (Figure 58). 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. 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.
Storage Cleaning and Storing the Machine 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 wait for all moving parts to stop before leaving the operating position. 3. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Check the parking brake operation; refer to Checking the Parking Brake (page 36). 5.
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 does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 1. The shift lever is in the NEUTRAL position. 1. Move the shift lever to a drive gear position. 2. The traction belts are worn, loose, or broken. 3. The traction belt is off a pulley. 4. The idler spring is broken or missing. 2. Contact an Authorized Service Dealer. 1. The cutting blade(s) is/are bent or unbalanced. 1.
Schematics g001471 Electrical Schematic (Rev.
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.
