Form No. 3362-766 Rev A Commercial Walk-Behind Mower Floating Deck, T-Bar, Gear with 40in TURBO FORCE® Cutting Unit Model No. 38096—Serial No. 290000001 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. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land.
Specifications ..................................................... 11 Attachments/Accessories................................... 11 Operation................................................................... 12 Adding Fuel ....................................................... 12 Checking the Engine Oil Level............................ 13 Think Safety First ............................................... 13 Using the Parking Brake......................................
Safety – Use only an approved container – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine. – Never refuel or drain the machine indoors. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly.
• Keep pets and bystanders away. • 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. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
• 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. REVERSE TRACTION DRIVE 82-2280 82-2280 82-2290 43-8480 95-2814 52-2010 98-0776 98-3256 66-1340 98-4387 1. Warning—wear hearing protection.
106-0699 104-8186 104-8569 110-2067 105-7798 110-2068 1. Read the Operator’s Manual.
110-4971 1. Engine—stop 2. Engine—Start 3. Engage bale then pull out on the PTO to engage the blade. Product Overview Figure 4 1. Gear shift lever 2. Power take off switch (PTO) 3. Choke control 4. Lower handle 5. Lower control bar 6. Parking brake lever-released position Figure 3 1. 2. 3. 4. Side discharge chute Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel 7. Blade control bail 8. Upper control bar 9. 10. 11. 12.
Power Take Off Switch (PTO) Specifications This pull switch is used in conjunction with the blade control bail to engage the clutch to drive the mower blades. Note: Specifications and design are subject to change without notice. Gear Shift Lever Width with deflector down 55–1/2 inches (141 cm) Length 79–1/2 inches (202 cm) Height with handle in lowest position The transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. 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.
Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. Figure 5 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. 1. Warning—wear hearing protection. Using the Parking Brake Filling the Fuel Tank Stop on level ground, disengage drives, engage parking brake, shut off engine and remove key.
Operating the Mower Power Take Off (PTO) 2. Move the shift lever to neutral, set the parking brake and turn ignition key to run. 3. Move the throttle control to fast and move the choke lever to the on position before starting a cold engine. The power take off switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades. Note: A warm or hot engine usually does not require any choking.
The Safety Interlock System throttle control in the fast position for best mowing performance. Driving Forward If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 1. To go forward, move the shift lever to a forward gear (Figure 9). 2. Release the parking brake; refer to Releasing the Parking Brake in Operation. 3. Slowly press on the upper control bar to move forward (Figure 9). • Do not tamper with the interlock switches.
Driving Backward Up a Curb 1. Disengage the mower blades. 2. Select reverse to drive machine. 3. Drive the machine until drive wheels contact curb (Figure 10). A blade can be bent or damaged when driving up a curb. Pieces of blade that may be thrown could seriously injure or kill you or bystanders. Do not run blades while driving up a curb forward or backward. Note: Both drive wheels should contact the curb and caster wheels straight. 4.
Note: All height-of-cut pins can use two spacers maximum. 1. Select hole in height-of-cut post and number of spacers corresponding to the height-of-cut desired (Figure 12). 2. Using the lift handle, raise side of deck and remove hairpin cotter (Figure 12). 3. Add or remove spacers if needed and then align the holes and insert the hairpin cotter (Figure 12). Figure 11 Note: Spare height-of-cut spacers may be stored on posts and retained by a hairpin cotter. 1.
1. After adjusting the height-of-cut, check the anti-scalp rollers so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Figure 13 and Figure 14). 2. If adjustment is needed, remove the bolt, washers and nut (Figure 13 and Figure 14). 3. Select a hole position so the anti-scalp rollers are a minimum of 3/8 inch (10 mm) off the ground (Figure 13 and Figure 14). 4. Install the bolt and nut (Figure 13, Figure 14, @@@5). Figure 14 1. Mower deck 2. Bolt 3. Spacer 4. Bushing 5.
2. Loosen the upper flange bolts (3/8 x 1 inch) and the flange nut securing the handle to the rear frame (Figure 16). 5. Swing the lever back over to tighten the baffle and cam lock (Figure 17). 6. If the cam does not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 16 1. 2. 3. 4. Upper handle Rear frame Flange nut, (3/8 inch) Flange bolt, (3/8 x 1 inch) 5. 6. 7. 8.
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 This is the full rear position (see Figure 18). The suggested use for this position is a follows. • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings.
Using the Mid-Size Weight Weights are installed on certain mowers to improve balance and improve performance. The weights can be moved or removed to create optimized performance under different mowing conditions and for operator preference (Figure 21 or Figure 22). The following table indicates the position of the weight as installed at the factory. Mower Deck Size 40 inches Number of weights install Position of the weight 1 Front Figure 22 Installing the rear weight. 1. Nut 2.
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 interlock system. Grease the caster wheels and caster pivot. Check the engine oil level. Clean the air intake screen. Check the brakes on both a level surface and slope. Inspect the blades.
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 Service Interval: Before each use or daily Every 400 hours 1. Lubricate the front caster wheel bearings and front pivots (Figure 23). 2. Raise the rear of the machine and use jack stands to support the machine. 3.
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. Important: Do not oil the foam or paper element. Removing the Foam and Paper Elements 1.
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 26). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 26). Servicing the Engine Oil Service Interval/Specification Service Interval: Before each use or daily—Check the engine oil level. Figure 28 1. Oil dipstick After the first 8 hours—Change the engine oil. 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 28).
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 30). 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 32). 1 Figure 31 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 32).
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 33 • 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.
Electrical System Maintenance 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 33). Servicing the Fuse 8. Check for fuel leaks and repair if needed. The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows, check the component or circuit for malfunction or a short. To replace the fuse, pull out on the fuse (Figure 35) to remove or replace it. Figure 35 1.
Drive System Maintenance Adjusting the Control Bar 1. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. The gap should be approximately 1 to 1-1/4 inch (25-32 mm) (Figure 36). Note: The upper control bar and fixed bar must be parallel when the upper control bar is in the engaged, drive, neutral, or brake positions. Figure 37 1. 2. 3. 4. Control rod and fitting 3-1/2 inch (89 mm) Idler bracket Clevis pin 5. 6. 7. 8.
Replacing the Caster Wheel Fork Bushings The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting pivot tubes. To check the bushings, move the caster forks back and forth and side-to-side. If a caster fork is loose, the bushings are worn and must be replaced. 1. Raise the cutting unit so the caster wheels are off the floor, then support the front of the mower with jack stands. 2.
3. Repeat this for the remaining slots. 4. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. Figure 41 1. Locknut 2. Cap 3. Roller Bearing Figure 42 4. Spanner Bushing 5. Wheel 6. Bushing 1. Adjusting nut 2. Slot 2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 41). 3.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily—Check the brakes on both a level surface and slope. Servicing the Brakes Service Interval: Before each use or daily 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.
Belt Maintenance Replacing the Traction Drive Belt Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the traction drive belt Look for cracks, wear, and signs of overheating. 1. Remove the top bolt securing idler support and idler bracket to rear frame (Figure 44). Figure 43 1. Hairpin cotter and washer 2. Trunnion 3. Brake lever 4. Wing nut 5. Hole F 6. Initial adjustment- 1-1/4 inch (32 mm) 7. Rod Figure 44 6. Rotate the wing nut clockwise to increase the braking pressure. 1.
4. Raise the front of the machine and hold with jack stands. 5. Disconnect clutch wire connector from wire harness. 6. Disconnect clutch retainer from the engine deck (Figure 45). 5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt. 6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 46). 7.
4. Unlatch and remove the belt covers. Use Figure 48 for the idler position options. 5. Remove the heat shield from the engine deck and carrier frame. 6. Roll the belt off of the center pulley on the mower deck (Figure 47). 7. Remove the belt from the engine pulley and the spring loaded idler pulley (Figure 47). 8. Install the new belt onto the engine pulley and spring loaded idler pulley (Figure 47). 9. Roll the belt onto the center pulley on the mower deck (Figure 47).
Mower Deck Maintenance Checking for Bent Blades 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Servicing the Cutting Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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. 3.
Removing the Blades balanced, file some metal off the end of the sail area only (Figure 51) Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum 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. Hold the blade end using a rag or thickly-padded glove. 2.
Checking the Engine Deck Height Frame Set Up 1. Disengage the PTO and set the parking brake. Checking the Carrier Frame and Engine Deck Alignment 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Note: Misalignment can cause excess wear on the PTO drive belt. 3. Adjust the tire pressure in the rear tires to specifications; refer to , page . 1. Disengage the PTO and set the parking brake. 4.
Figure 56 1. Carrier Frame 2. 1/4-3/8 inch (6-10 mm) pitch over 24 inch (61 cm) length 3. 24 inches (61 cm) Figure 57 4. Height at locations A and B 5. Caster Wheel 1. Caster Wheel 2. Carrier Frame 3. Front height-of-cut pins 4. Same height at locations A and B 5. Caster spacers 6. Caster spacers Checking the Mower Deck Front-to-Rear Pitch 2. Measure carrier frame height at location A (Figure 56). 3. Measure carrier frame height at location B (Figure 56). 4.
Changing the Mower Deck Front-to-Rear Pitch Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1. To change the front-to-rear pitch, the front height-of-cut posts can be adjusted (Figure 59). Figure 60 1. Measure from a level surface 2. Measure blade at points C and D 3. The difference between measurements C and D should be no more than 1/4 inch (6 mm). Changing the Mower Deck Side-to-Side Height Figure 59 1. Caster Wheel 2. Carrier Frame 3.
Figure 61 1. Measure from a level surface 2. Measure blade at point A Figure 62 1. Bolt 2. Spacer 3. Locknut 4. The measurement should be 4 inch (101.6 mm). 5. If it does not measure correctly: A. Adjust the rear tire pressure. 4. Spring 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8. J hook end of spring B. Adjust the caster fork spacers. 2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. C.
Storage 11. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. Cleaning and Storage 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. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 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. Choke is not on. 3. Air cleaner is dirty. 2. Move the choke lever to choke position. 3. Clean or replace the air cleaner element. 4. Install wire on spark plug. 4. Spark plug wire is loose or disconnected. 5. Spark plug is pitted, fouled, or the gap is incorrect. 6. Dirt in the fuel filter. 7. Dirt, water, or stale fuel is in the fuel system.
Problem Blades do not rotate. Possible Cause Corrective Action 1. Drive belt is worn, loose or broken. 1. Check the belt tension. 2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring. 6. Adjust the clutch air gap. 7. Contact an Authorized Service Dealer. 8.
Schematics Electrical Schematic (Rev.
Notes: 47
The Toro Total Coverage Guarantee 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 repair the listed Toro Products if defective in materials or workmanship.
