Form No. 3392-709 Rev A Commercial Walk-Behind Mower Fixed Deck, T-Bar, Gear Drive with 48in TURBO FORCE® Cutting Unit Model No. 39678—Serial No. 315000001 and Up G017538 Register at www.Toro.com.
operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. It is not designed for cutting brush or for agricultural uses. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Adjusting the PTO Engagement Linkage ...................36 Adjusting the PTO Safety Switch ..............................36 Mower Deck Maintenance...........................................37 Servicing the Cutting Blades.....................................37 Adjusting the Blade Brake........................................40 Replacing the Grass Deflector ..................................40 Storage ........................................................................41 Troubleshooting ........
Operation Safety • Lightning can cause severe injury or death. If lightning Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. • • Improperly using or maintaining the machine can result in injury.
Safe Handling of Fuels • Keep hands and feet away from moving parts. If possible, • To avoid personal injury or property damage, use • • • • • • • • • • • • extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Extinguish all cigarettes, cigars, pipes, and other sources of ignition. Use only an approved fuel container. Never remove the fuel cap or add fuel with the engine running. Allow the engine to cool before refueling. Never refuel the machine indoors.
• Use extra care with grass catchers or other attachments. These can change the stability of the machine. • Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. • Mow slopes side to side. • Do not mow slopes greater than 20 degrees. Service • Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. • Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.
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. Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 93-7442 1. Parking brake 93-7010 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3.
8-5130 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 75-80 ft-lb (102-106 N⋅m). 98-3296 For Models with 2–Blade Mower Decks 106-5517 1. Warning—do not touch the hot surface. 98-4387 1. Warning—wear hearing protection. 106-5519 1. Severing hazard of hand or foot, mower 3. Warning—read the Operator's Manual. blade—stay away from moving parts. 2. Warning—release the bar and ensure the engine has stopped before walking away from the machine. 5.
126-1400 1. Warning—Read the Operator’s Manual. Use only Toro riding attachments. Use of other riding attachments may create a hazardous condition resulting in injury. 121-6049 1. Thrown object hazard—keep bystanders away from the machine. 3. Cutting/dismemberment hazard of hand or foot, mower blade—keep hands away from moving parts. 2. Thrown object hazard, mower—do not operate the mower with guards or shields removed. 130-8374 1. Fast 3. Engine—stop 2. Slow 130-9821 10 4.
131-1180 1. Read the Operator's Manual.
Controls Product Overview Become familiar with all the controls (Figure 5) before you start the engine and operate the machine. G017539 Figure 4 1. Side discharge 5. T-bar control 2. Mower deck 3. Recoil-start handle 4. Gas tank 6. Handle 7. Front caster wheel Figure 5 1. Throttle control 7. Parking brake lever—released position 2. Blade-control bail 8. Choke 3. Power take-off lever (PTO) 9. Ignition switch 4. Gear-shift lever 10. Upper handle 5. Upper control bar 11. Lower handle 6.
Specifications Important: Do not shift while the machine is moving, as transmission damage may occur. Note: Specifications and design are subject to change without notice. Upper Control Bar Width with deflector down Shift to the desired gear and push forward on the upper control bar and blade control bail to engage forward traction operation and pull back to brake forward movement. Pull back on right side of upper control bar to turn right and left side to turn left.
Operation DANGER In certain conditions during fueling, static electricity can cause a spark, which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. Adding Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Always place fuel containers on the ground away from your vehicle before filling.
Filling the Fuel Tank Setting the Parking Brake 1. Pull the upper control bar rearward and hold it in this position (Figure 7). 1. Shut the engine off and set the parking brake. 2. Clean around the fuel-tank cap and remove the cap. Add unleaded regular gasoline to the fuel tank, until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. 3. Install the fuel-tank cap securely.
Operating the Blade-Control Lever (PTO) Note: Allow the rope to recoil slowly. Important: Do not pull the recoil rope to its limit or release the starter handle when you pull out the rope because the rope may break or the recoil assembly may be damaged. The blade-control lever (PTO) engages and disengages power to the mower blades. 10. Push the choke to the Off position as the engine warms up. Engaging the Mower Blades 1.
The Safety-Interlock System 2. Release the parking brake; refer to Releasing the Parking Brake (page 15). CAUTION 3. Slowly press on the upper control bar to move forward (Figure 10). If safety-interlock switches are disconnected or damaged the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily, and replace any damaged switches before operating the machine.
Driving Forward up a Curb Note: Lifting up on the lower handle will assist driving the machine up a curb and not spin the drive wheels. 1. Disengage the mower blades. 2. Select the first gear to drive the machine. 3. Drive machine until the caster wheels contact the curb (Figure 11). 4. Lift the front of the machine by pushing down on the lower handle (Figure 11). 5. Drive the machine until the drive wheels contact the curb (Figure 11). 6. Lower the front of the machine (Figure 11).
Adjusting the Flow Baffle You can adjust the mower discharge flow for different types of mowing conditions. Position the 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. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Loosen the nut (Figure 13). 4. Adjust the baffle and nut in the slot to the desired discharge flow, and tighten the nut.
adjustment range, in 6 mm (1/4 inch) increments, of cutting height in any axle position. Use the same number of blade spacers on all blades to achieve a level cut (2 above and 2 below, 1 above and 3 below, etc.). 1. Disengage the blade control (PTO) lever and set the parking brakes. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Hold the blade bolt and remove the nut (Figure 17).
Adjusting the Axle Height Adjust the axle position to the selected height-of-cut setting. Refer to the Height-of-Cut Chart. 1. Disengage the blade control (PTO) lever and set the parking brakes. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Loosen, but do not remove, the 2 axle pivot bolts and the 2 axle adjustment bolts (Figure 18). Figure 19 1. Latch pin 3. Spacer, 13 mm (1/2 inch) 2. Spacer, 5 mm (3/16 inch) 2.
1 4 2 3 Figure 21 1. Upper handle 4. Locknut (3/8 inch) 2. Rear frame 5. Upper mounting hole 3. Flange bolt (3/8 x 1 inch) 6. Lower mounting hole 5 g018809 Figure 22 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 21). 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. 1. 25 to 32 mm (1 to 1-1/4 inches) gap 4. Upper control bar 2. Fixed control bar 3.
Height-of-Cut Chart Number of spacers below the caster 13 mm (1/2 inch ) 5 mm (3/16 inch) A 0 A Axle position Number of 1/4 inch blade spacers below the spindle 4 3 2 1 0 0 26 mm (1 inch) 32 mm (1-1/4 inch) 38 mm (1-1/2 inch) 45 mm (1-3/4 inch) 51 mm (2 inch) 0 1 29 mm (1-1/8 inch) 35 mm (1-3/8 inch) 41 mm (1-5/8 inch) 48 mm (1-7/8 inch) 54 mm (2-1/8 inch) A 1 0 35 mm (1-3/8 inch) 41 mm (1-5/8 inch) 48 mm (1-7/8 inch) 54 mm (2-1/8 inch) 60 mm (2-3/8 inch) B 0 1 35 mm (1-3
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. 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. Clean the air intake screen from grass and debris before each use. Check the brakes.
Lubrication Grease Type: #2 general-purpose lithium-based or molybdenum-based grease Lubricating the Machine 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 24 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings.
Engine Maintenance 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. Servicing the Air Cleaner Servicing the Paper Air-Cleaner Element Service Interval: Every 25 hours—Clean the foam air-cleaner element. Every 50 hours—Check the paper air-cleaner element. Every 200 hours—Replace the paper air-cleaner element. 1. Do not clean the paper filter, replace it (Figure 27). 2.
Changing the Engine Oil Checking the Engine-Oil Level 1. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 1. Park the machine on a level surface. 2. Disengage the PTO and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the PTO and set the parking brake. 3.
1 Figure 31 1. Oil filter 2. Adapter Figure 32 1. Spark-plug wire/spark plug 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 31). 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 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 31). 5.
Installing the Spark Plugs Fuel System Maintenance 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 22 N-m (16 ft-lb). Servicing the Fuel System 3. Connect the wires to the spark plugs (Figure 33). 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. • Drain gasoline from the fuel tank when the engine is cold.
Replacing the Fuel Filter Service Interval: Every 200 hours/Yearly (whichever comes first) Never install a dirty filter if it is removed from the fuel line. Note: Note how the fuel filter is installed in order to install the new filter correctly. Note: Wipe up any spilled fuel. 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. Close the fuel-shutoff valve at the fuel tank (Figure 34). 4.
Drive System Maintenance Cooling System Maintenance Checking the Tire Pressure Cleaning the Air-Intake Screen Service Interval: Every 50 hours/Monthly (whichever comes first) Before each use, 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.
Brake Maintenance 3. Check the brake before you adjust it; refer to Checking the Brakes (page 32). Servicing the Brakes 4. Release the parking brake; refer to Releasing the Parking Brake (page 15). 5. To adjust the brake, rotate the wing nuts on the brake rods (Figure 39). Turn the wing nuts clockwise to tighten the brake and counterclockwise to loosen the brake. Before each use, check brakes on both a level surface and slope.
Belt Maintenance 4. Remove the mower belt (Figure 41). Checking the Belts Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the belts. Check the belts for cracks, frayed edges, burn marks, wear, signs of overheating, or any other damage. Replace any damaged belts. Replacing the Traction Drive Belt Figure 41 1. Remove the hairpin cotter securing the brake rod to the brake arm to relax the tension on the belt idler (Figure 40). 2.
Note: The proper mower belt tension is 44 to 67 N-m (10 to 15 ft-lb) with the belt deflected 13 mm (1/2 inch) halfway between the pulleys (Figure 44). 8. Engage the blade-control (PTO) lever. 9. Check the clearance between the bell crank and the transmission output shaft (Figure 42). Figure 43 48-inch mower deck Figure 42 1. 13 mm (1/2 inch) deflection 4. Locknut here 2. Assist arm 5. Turnbuckle 3. Front stop 1. 2 to 3 mm (1/16 to 1/8 inch) 4. Hairpin cotter 2. Bell crank 5. Clevis pin 3.
positioned to the middle or front hole (Figure 46). Use the hole that will give 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 46). g017651 Figure 44 48-inch mower deck 1. Idler pulley Figure 46 2. Mower belt with 13 mm (1/2 inch) deflection 1. Rear idler pulley 4. Belt guide in back position 2. Middle hole 5. Front idler pulley 3.
Adjusting the PTO Engagement Linkage 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. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Engage the blade-control lever (PTO). 4. Adjust the linkage length to where the lower end of the bellcrank just clears the axle support gusset (Figure 48). g017649 1 3 Figure 49 1. Yoke 2. Nut 3.
Mower Deck Maintenance Servicing the Cutting Blades 2 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 3 WARNING g017650 Figure 50 1. Bellcrank 3. Switch mounting bracket 2. Bolts and nuts 4. Switch body 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.
Checking for Bent Blades inch). If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced. Refer to Removing the Blades (page 38) and Installing the Blades (page 39). 1. Disengage the blade-control switch (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. WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 3.
balanced, file some metal off the end of the sail area only (Figure 57). Repeat this procedure until the blade is balanced. Figure 57 1. Blade 2. Balancer 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 55). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. 2.
Adjusting the Blade Brake Replacing the Grass Deflector 1. Disengage the PTO, turn the ignition key to the off position, and remove the key. WARNING An uncovered discharge opening could allow the lawn mower to throw objects in the operator's or bystander's direction and result in serious injury. Also, contact with the blade could occur. 2. Wait for all moving parts to stop before leaving the operating position and setting the parking brake. 3.
Storage Note: Do not connect the spark-plug wires to the spark plugs. 10. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or worn. 1. Disengage the power take-off (PTO), set the parking brake, turn the ignition key to the Off position, and remove the key. 11. Paint all scratched or bare metal surfaces with paint available from your Authorized Service Dealer. 2.
Troubleshooting Problem The engine will not start, starts hard, or fails to keep running. Possible Cause 1. The fuel tank is empty. 1. Fill the fuel tank with gasoline. 2. The fuel-shutoff valve is closed. 3. The choke is not in the correct position. 2. Open the fuel-shutoff valve. 3. Close the choke if the engine is cold; open the choke if the engine is warm. 4. Clean or replace the air-cleaner element. 5. Install the wire on spark plug. 4. The air cleaner is dirty. 5.
Problem The blades do not rotate. Possible Cause Corrective Action 1. The mower deck belt is worn or loose. 1. Check the belt tension. 2. The mower deck belt is broken. 3. The mower deck belt is off pulley. 2. Install a new deck belt. 3. Inspect the belt and replace it if it is damaged. Check the pulleys and idlers and adjust the belt tension. 4. Replace the spring. 4. The idler spring is broken or missing.
Schematics Electrical Schematic (Rev.
Notes: 45
Notes: 46
Notes: 47
The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) 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 the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
