Form No. 3360-264 Rev A Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Gear-Drive, with 32in Cutting Unit or 36in TURBO FORCE® Cutting Unit Model No. 39682—Serial No. 280000001 and Up Model No. 39684—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.
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 104-8569 105-4104 1. Reverse 2. Neutral 3. Transmission speeds 105-4111 106-0699 9 3.
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 Operator Training Material 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 Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. 32 inch mowers: Width with deflector down 45.8 inches (116.3 cm) Length 78 inches (198.1 cm) Height 41 inches (104.
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. 2. Place your thumbs on the upper part of the locks and move them forward until they are in the drive position (Figure 6). Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 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.
4. Disconnect the wire from the spark plug to prevent someone from accidentally starting the machine while transporting or storing it. 5. 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. Power take off lever (PTO) The Safety Interlock System Figure 7 1. Throttle control 2.
Driving Backward • The machine is shifted into gear without holding the OPC levers. • The blade control (PTO) lever is engaged without holding the OPC levers. 1. Ensure that the parking brakes are engaged. 2. Squeeze the OPC levers against the handles. 3. Move the shift lever into the reverse gear. Testing the Safety Interlock System 4. Release the parking brakes; refer to Releasing the Parking Brakes and Neutral Locks. Test the safety interlock system before you use the machine each time.
Side Discharging or Mulching the Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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. Figure 9 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.
3. Remove the lower bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 14). 4. Pivot the handle to the desired operating position and install the lower flange bolts (3/8 x 1 inch)and flange nuts into the mounting holes. Tighten all flange bolts. Figure 12 1. Latch pin 2. Spacer, 3/16 inch (5 mm) 3. Spacer, 1/2 inch (13 mm) 2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 12). 3.
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.
Note: Remove the mower deck cover to access the grease fitting for the mower belt idler arm. 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. Lubricating the Caster and Wheel Bearings 1. Lubricate the front wheel bearings and front spindles (Figure 15). 2. Lubricate the drive wheel bearings.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. 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.
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 18). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 18). Servicing the Engine Oil Service Interval/Specification Figure 20 Change the engine oil as follows: 1. Oil dipstick • After the first 8 operating hours • After every 100 operating hours 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 20).
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 22). 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 22). 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.
Important: Always replace the spark plugs when it has worn electrodes, an oily film, or cracks. 3. Check the gap between the center and side electrodes (Figure 24). Bend the side electrode (Figure 24) if the gap is not correct. 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 24). Figure 23 1. Spark-plug wire/spark plug 4.
Fuel System Maintenance Draining the Fuel Tank 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 25 1. Fuel shut-off valve 2. Fuel filter • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 6. Wipe up any spilled fuel.
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 27). 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 26 1. Hose clamp 2. Fuel line 3. Filter 5. Remove the filter from the fuel lines. 6.
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. Check all belts after every 50 operating hours or monthly, whichever occurs first. Checking the Belts Important: When you release the parking brakes, the rear wheels should rotate freely when you push the mower.
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 32). Figure 31 1. Idler pulley in slot 2. Traction belt 3. Mower belt 4. Belt guide 5. 3/4 inch (19 mm) 6. Mower belt 5. Loosen the pivot bolt enough to slide the idler pulley in the slot and remove the traction belt from the engine and the drive pulleys (Figure 31). Figure 32 1. Mower belt with 1/2 inch (13mm) deflection 6.
1. Disengage the blade control (PTO) lever and set the parking brakes. 12. Disengage the blade control (PTO) lever. Note: If the assist arm does not contact the front stop on the mower deck (Figure 34), adjust the clevis to bring the bell crank closer to the transmission output shaft (Figure 33). 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Loosen the locknut on the turnbuckle (Figure 34). 4.
Controls System Maintenance Adjusting the Control Rods 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 35). Figure 36 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 36). 4. Check the operation of the control rod.
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 37 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. Cutting Edge 2. Curved Area 3. Wear/slot Forming 2. Inspect the blades, especially the curved area (Figure 37).
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. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
Figure 42 1. Blade 2. Balancer Installing the Blades 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 40). Figure 43 Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. 1. Spring mounting bolts 2. Blade brake pad 2. Install the remaining spacer(s) and secure them with a thin washer and a nut (Fig. Figure 40). 3.
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. 3. Figure 44 1. Bolt 2. Spacer 3. Locknut 4. Spring 4. 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: 43
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.
