Form No. 3360-268 Rev A Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Gear-Drive, with a 48in TURBO FORCE® Cutting Unit Model No. 39688—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. Figure 1 This spark ignition system complies with Canadian ICES-002. 1. Model and serial number location Important: This engine is not equipped with a spark arrester muffler.
Think Safety First ............................................... 14 Operating the Parking Brake and Neutral Locks ............................................................. 14 Starting and Stopping the Engine ........................ 15 Operating the Blade Control (PTO) Lever.............................................................. 16 The Safety Interlock System................................ 16 Driving Forward or Backward............................. 17 Stopping the Mower .......................
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. 43-8480 95-5537 3. Pull back to disengage 1. Read the Operator’s Manual for instructions on operating the cutting blade 2. Push forward to engage 66-1340 98-0776 95-2814 99-3943 1.
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). 106-2733 98-5954 1. Fast 2. Continuous variable setting 3. Slow 104-8569 105-4104 1. Reverse 2. Neutral 110-2067 3. Transmission speeds 110-2068 105-4111 1. Read the Operator’s Manual. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
6-2737 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Check the fluids and tire pressure. 2 Operator’s Manual Engine Operator’s Manual Parts Catalog Safety Video Registration Card Oil drain hose 1 1 1 1 1 1 Read the Operator’s Manual and watch the video before operating the machine. Note: Determine the left and right sides of the machine from the normal operating position.
Throttle Control Product Overview The throttle control has two positions: Fast and Slow. Operator Presence Control (OPC) Levers 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 Width with deflector down 63–1/2 inches (161.3 cm) Length 78–3/8 inches (198.9 cm) Height 41 inches (104.1 cm) Weight 500 lb (227 kg) Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Releasing the Neutral Locks 1. Squeeze the drive levers back. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 2. Place your thumbs on the upper part of the locks and move them forward until they are in the drive position (Figure 6). Always set the parking brake when leaving the machine unattended, even if just for a few minutes. Starting and Stopping the Engine Setting the Parking Brakes Starting the Engine 1.
5. Disconnect the wire from the spark plug to prevent someone from accidentally starting the machine while transporting or performing maintenance on it. 6. Close the fuel shut-off valve before transporting or storing the machine. Important: Close the fuel shut-off valve before transporting or the storing the machine to prevent fuel leakage. Figure 8 1. Operator Presence Control (OPC) lever 2. Blade control lever (PTO) The Safety Interlock System Figure 7 1. Throttle control 2.
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. Service Interval: Before each use or daily 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.
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. If the grass deflector is ever damaged, replace it immediately. Figure 9 • Never put your hands or feet under the mower. 1. Position A 2.
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 10). Figure 11 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 11). Note: Use jack stands to support the machine. 5.
Figure 12 1. Latch pin 2. Spacer, 3/16 inch (5 mm) Figure 13 3. Spacer, 1/2 inch (13 mm) 1. Cam lock 2. Lever 3. Rotate cam to increase or decrease locking pressure 4. Slot 2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 12). Positioning the Flow Baffle 3. Install the caster in the support and insert the latch pin (Figure 12). The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass.
Position A This is the full rear position. The suggested use for this position is a follows (Figure 14). • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 15 Position C This is the full open position. The suggested use for this position is as follows (Figure 16). • Use in tall, dense grass mowing conditions. • Use in wet conditions. Figure 14 • Lowers the engine power consumption.
Figure 17 5. Neutral lock 6. Hairpin cotter pin 7. Left handle shown 1. Control rod 2. Clevis pin 3. Operator Presence Control lever (OPC) 4. Handle 8. Drive lever 2. Loosen the upper bolts (3/8 x 1-1/4 inch) and flange nut securing handle to rear frame (Figure 18). 3. Remove the lower bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 18). 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch)and flange nuts into mounting holes.
5. Adjust the control rod length by rotating the control rod in the rod fitting (Fig. 8). 6. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Fig. 25). Note: Make sure the clevis pins are inserted into the neutral locks. 7. Check the parking brake adjustment. Refer to Checking the Brakes in Brake Maintenance , page 34.
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.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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. 5. Wipe up any excess grease.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification 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. Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1. Disengage the PTO and set the parking brake. 2.
1. Carefully slide the foam element onto the paper air cleaner element (Figure 22). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 22). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 22). Servicing the Engine Oil Figure 24 Service Interval/Specification 2. Filler tube 1. Oil dipstick Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 5.
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.
5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Figure 29). 8. Check for fuel leaks and repair if needed. 9. Wipe up any spilled fuel. Figure 29 1. Fuel shut-off valve 2. Clamp Replacing the Fuel Filter Service Interval: Every 200 hours 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.
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the tire pressure Check the pressure at the valve stem (Figure 31). 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 32 1. Control rod 2. Clevis pin 3. Operator Presence Control lever (OPC) 4. Handle 5. Neutral lock 6.
4. Check the operation of the control rod. If you need to adjust it, remove the hairpin cotter and the clevis pin that secure the control rod to the drive levers. Cooling System Maintenance 5. Adjust the control rod length by repeating the previous steps.
Brake Maintenance Servicing the Brakes 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 Brakes Figure 35 Service Interval: Before each use or daily 1. Brake rod 1. Park the machine on a level surface, disengage the blade control (PTO). 2. Wing nut 2.
Belt Maintenance 4. Remove the mower belt (Figure 37). Checking the Belts 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. Replacing the Traction Drive Belt Figure 37 1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Figure 36). 2.
Figure 39 1. 1/2 inch (13 mm) deflection 4. Locknut here 2. Assist arm 5. Turnbuckle 3. Front stop Figure 38 1. Mower belt with 1/2 inch (13mm) deflection 2. Idler pulley 5. Engage the bladed control lever (PTO) and check the belt tension. Adjusting the Mower Belt Tension 6. If there is no adjustment left in the turnbuckle and the belt is still loose, the rear idler pulley needs to be positioned to the middle or front hole (Figure 40). Use the hole that will give the correct adjustment.
Note: The distance between the belt guide and the mower belt should be 3/4 inch (19 mm) when you engage the mower belt (Figure 41). Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides and belt tension are properly adjusted. 9. Check the blade brake adjustment; refer to Adjusting the Blade Brake. Figure 42 1. Bellcrank 2. Safety switch located under engine deck 3. Bellcrank just clears the gusset with the PTO engageded 4. Yoke 5. Nut 6.
Controls System Maintenance 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 43). Adjusting the Control Rods 12. Check if the assist arm hits against the stops correctly. 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 45). Adjusting the PTO Safety Switch 1.
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. Figure 46 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. 1. Handle 4. Drive lever 2. Neutral/ parking brake lock 5. Forward speed 3. 3/16 to 1/4 inch (5 to 6 6.
Checking for Bent Blades performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Rotate the blades until the ends face forward and backward (Figure 48). 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 Figure 49 1.
Figure 51 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 52). If the blade stays in a 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 53 1. Spring mounting bolts 2. Blade brake pad Replacing the Grass Deflector Figure 52 1. Blade 3. 1/8-3/16 inch (3mm-5mm) 2.
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. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate, and engine. 3.
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 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. 5. Contact an Authorized Service Dealer. 4. Broken or missing idler spring. 5. Safety interlock system prevents blade rotation.
Schematics Electrical Schematic (Rev.
Notes: 47
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
