Form No. 3364-507 Rev A Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Hydro Drive with a 36in or 48in TURBO FORCE® Cutting Unit Model No. 39934—Serial No. 310000001 and Up Model No. 39938—Serial No. 310000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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. This spark ignition system complies with Canadian ICES-002. Figure 1 1. Model and serial number location Important: This engine is not equipped with a spark arrester muffler.
Contents Adjusting the Hydro Control Linkages ................ 34 Adjusting the Control Rod.................................. 35 Adjusting the Tracking ....................................... 36 Adjusting the Spring Anchor Links ..................... 36 Checking the Tire Pressure ................................. 37 Cooling System Maintenance .................................. 37 Cleaning the Air Intake Screen ............................ 37 Cleaning the Cooling System...............................
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 capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing. • 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.
• Never tamper with safety devices. Check safety systems for proper operation before each use. • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
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. 43-8480 95-5537 1. Read the Operator’s 3. Push forward to engage Manual for instructions on operating the cutting blade 2. Pull back to disengage 66-1340 98-3296 For Models with 36 Inch Mower Decks 98-0776 98-5954 98-5130 1.
105-4109 105-4110 99-3943 For Models with 48 Inch Mower Decks 1. Engine 106-0699 103-2103 106-2733 1. Fast 2. Continuous variable setting 104-8569 106-2743 9 3.
110-2067 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator’s Manual. 117–2718 110-2068 1. Read the Operator’s Manual. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 106-2738 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection. 7. Fast 10. Neutral 8. Continuous variable setting 9.
Product Overview Figure 4 1. 2. 3. 4. Side discharge chute Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel Figure 5 1. 2. 3. 4. 5. Controls Become familiar with all the controls (Figure 5) before you start the engine and operate the machine. Throttle control Speed control lever Ignition switch Neutral lock Operator Presence Control levers (OPC) 6. 7. 8. 9. 10.
Ignition Switch Attachments/Accessories This switch is used in conjunction with recoil starter and has two positions: Run and Off. A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Speed Control Lever This machine has a variable speed control with a neutral position.
Operation DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Filling the Fuel Tank Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 1. Shut the engine off and set the parking brake. 2.
4. Let engine idle for 30 to 60 seconds before turning the engine off. 5. To stop the engine, turn the ignition key to off. Figure 8 1. Split ring 2. Control shield bolt • After the engine is started, pull the chain straight out from side of machine until ring can be removed from shield bolt. Slowly release tension on chain. Figure 9 1. Throttle lever 2. Ignition switch 3. Disengage the blade control knob (PTO) and move the speed control lever to neutral. 3.
2. Pull blade control knob (PTO) up. Hold the OPC levers against handle grip. Note: The engine will kill if the OPC levers are released with the mower running and the speed control lever is not in neutral. 3. Restart the engine and repeat the procedure to engage the mower blades if the operator presence control (OPC) levers are released. Figure 10 1. Handle 2. Neutral lock 3. Neutral position 4. Drive lever 5. Full speed forward 6. Reverse position Releasing the Neutral Lock 1.
Understanding the Safety Interlock System 7. With the engine running, move the speed control lever forward slightly. Release the OPC levers. The engine should kill. The safety interlock system is designed to prevent the mower from starting unless: 8. If all the above conditions are not met have an Authorized Service Dealer repair the safety system immediately. • The blade control knob (PTO) is pushed off. • The speed control lever is in neutral.
Bringing the Machine to Neutral Position 5. Set the parking brake. 6. Close the by-pass valves, but do not overtighten them. Always set the neutral lock and parking brake when you stop the machine. 1. Squeeze the drive levers to neutral position. 2. Set the neutral locks. Refer to Operating Neutral Locks. 3. Move speed control lever to neutral position. Note: Rotate the by-pass valves a maximum of 2 turns so the valve does not come out of the body causing fluid to run out.
Figure 15 1. Cam lock 2. Lever 3. Rotate cam to increase or decrease locking pressure 4. Slot Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position A Figure 16 This is the full rear position (see Figure 16). The suggested use for this position is a follows.
Figure 17 Figure 18 Position C Transporting Machines This is the full open position. The suggested use for this position is as follows (Figure 18). • Lowers the engine power consumption. Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury.
Side Discharging or Mulching the 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 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.
Adjusting the Handle Height 6. Remove the 2 lower axle bolts (Figure 20). The handle position can be adjusted to match the operator’s height preference. 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 22). Figure 20 1. Top axle bolt 2. Lower axle bolt 7. Raise or lower the mounting bracket, so that you can install the 2 axle adjustment bolts in the desired hole location (Figure 20). A tapered punch can be used to help align the holes. Figure 22 1. 2.
Figure 23 7. Control rod fitting Lower mounting holes 8. 9. Rear frame Lower flange bolt (3/8 x 1 10. inch) 11. 5. Upper flange bolt (3/8 x 1-1/4 inches) 6. High position 1. 2. 3. 4. Lower position Upper mounting hole Handle Flange nut (3/8 inch) 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.
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 • • • • After the first 25 hours • Check the mower belt tension. Before each use or daily • • • • • • Change the engine oil. Check the mower belt tension. Check the hydraulic fluid level. Change the hydraulic filter. Check the safety system. Grease the caster wheels and caster pivot.
Lubrication Use Figure 24 for locating the grease points on the machine. Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease 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). 1. Pump drive idler arm 2. Pump control arm 3. Bellcrank 4.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Service Interval: Every 25 hours—Clean foam air cleaner element. Every 50 hours—Check the paper air cleaner element. Every 200 hours—Replace the paper air cleaner element. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. Figure 25 1. Cover 2. Hose clamp 3. Paper element 4. Foam element Important: Do not oil the foam or paper element.
Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. Figure 27 1. Oil dipstick Every 200 hours—Change the oil filter. 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 27). Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. 6.
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 29). 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. Check the engine oil level and add oil if needed. 8. Wipe up any spilled oil.
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 31). 1 Figure 30 1. Spark-plug wire/spark plug 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. Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 31).
Fuel System Maintenance Servicing the Fuel Tank 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. Figure 32 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1. Fuel shut-off valve • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 2.
Drive System Maintenance Perform the following linkage adjustments when the machine needs maintenance. Perform steps Adjust the Speed Control Linkage through Adjusting the Tracking. If and adjustment is needed , do them in the order that they are listed. Adjusting the Speed Control Linkage 1. Disengage the PTO and set the parking brake. Figure 33 1. Hose clamp 2. Fuel line 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Filter 3.
7. Check to make sure the safety switch is depressed and there is a 5/16 inch (8 mm) space between the actuating tab and the switch. (Figure 35). 1. Disengage the PTO and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Raise the rear of the machine onto jack stands to raise the drive wheels off the ground. 4. Disengage the parking brake. 5. Start the engine and move the throttle ahead to the full throttle position. 6.
14. After adjustments are made, tighten the nuts against the yokes. 15. Repeat this procedure for the opposite side. 6. Place the left drive lever in the full forward position. 7. Place the speed control lever in the neutral position. WARNING Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place. • Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.
14. Make sure the speed control lever is in the neutral position and the tire does not rotate. 15. Repeat the adjustment if needed. 5. Hold the OPC levers down. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 6. The spring that keeps tension on the knob should normally not need adjustment. However if an adjustment is needed, adjust the length of spring to 1 inch (26 mm) between the washers (Figure 40). 7.
2. Lengthen the control rod if the tire is turning in reverse and shorten the rod if the tire is turning forward. Adjusting the Tracking 3. Rotate the rod several turns if the tire is rotating fast. Then, adjust the rod in 1/2 turn increments. 2. Check the rear tire pressure. Refer to Checking the Tire Pressure. 4. Place the clevis pin into the drive lever (Figure 41). 3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt. 1.
Cooling System Maintenance Cleaning the Air Intake Screen 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. Figure 44 1. Spring anchor 2. Standard setting 3. Medium setting 4.
Brake Maintenance 4. Rotate the lower brake link yoke clockwise into the yoke to tighten the parking brake; rotate the brake link yoke counterclockwise out of the yoke out to loosen the parking brake (Figure 47). Servicing the Brake Note: There should be approximately 1/4 inch clearance between the tire and the flat bar when the parking brake in the released position (Figure 47). Before each use, check the parking brake for proper operation.
Belt Maintenance Note: The clearance should be 1/16-1/8 inch (2-3 mm). Checking the Belts 10. Remove the hairpin cotter pin and the clevis pin from the bell crank. Service Interval: Every 50 hours/Monthly (whichever comes first) 11. Rotate the clevis clockwise on the rod to increase the clearance; rotate it counterclockwise to decrease it (Figure 48). Check belts for cracks, frayed edges, burn marks, wear, signs of overheating or any other damage. Replace damaged belts. 12.
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 the locknut on the turnbuckle (Figure 51). 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt. Rotate the turnbuckle toward the front of the mower to decrease the tension on the belt (Figure 51).
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 the locknut on the turnbuckle (Figure 53). 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt. Rotate the turnbuckle toward the front of the mower to decrease the tension on the belt (Figure 53). Note: The proper mower belt tension is 10-15 lbf.
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 55). 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 56 1. Bellcrank 2. Safety switch located under engine deck 3. Bellcrank just clears the gusset with the PTO engageded 4. Yoke 5. Nut 6.
Hydraulic 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 57). 12. Check if the assist arm hits against the stops correctly. Servicing the Hydraulic System Adjusting the PTO Safety Switch Checking the Hydraulic Fluid 1. Disengage the blade control (PTO) lever and set the parking brakes.
5. Apply a thin coat hydraulic fluid to the rubber gasket on the replacement filter. 6. Install replacement hydraulic filter onto the filter adapter. Do not tighten. 7. Fill the hydraulic tank with hydraulic fluid until the fluid overflows the filter and then turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Figure 60). WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
9. Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position. 1. Disengage the PTO and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 10. Check the hydro control linkage adjustment. Refer to Adjusting the Hydro Control Linkages. 3. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground. 4. Check the hydraulic fluid level.
Mower Deck Maintenance Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 63). 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. WARNING 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.
Sharpening the Blades WARNING 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 67). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade.
4. Adjust the nut at the end of the blade brake rod until there is 1/8-3/16 inch (3 mm -5 mm) between the nut and spacer (Figure 69). 5. Engage the blades. Ensure the blade brake pad no longer contacts the pulley groove. Figure 70 1. Bolt 2. Spacer 3. Locknut Figure 69 1. Spring mounting bolts 2. Blade brake pad 3. 1/8-3/16 inch (3mm-5mm) 4. Spring Replacing the Grass Deflector 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8.
Storage 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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. 2.
Troubleshooting Problem Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Fuel tank is empty. 1. Fill 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 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. 4. Broken or missing idler spring.
Schematics Electrical Schematic (Rev. -) Hydraulic Schematic (Rev.
Notes: 53
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Notes: 55
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 3. 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.
