Form No. 3361-958 Rev B Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Gear-Drive, with 32in Cutting Unit or 36in TURBO FORCE® Cutting Unit Model No. 38682—Serial No. 290000001 and Up Model No. 38684—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. 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.
Safety Operating the Blade Control (PTO) Lever.............................................................. 13 The Safety Interlock System................................ 14 Driving Forward or Backward............................. 14 Stopping the Mower ........................................... 15 Transporting Machines....................................... 15 Side Discharging or Mulching the Grass .............. 15 Adjusting the Wheel Drive Tension..................... 15 Adjusting the Height-of-Cut ...
– 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. • 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.
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. • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required. General Operation • Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area.
Slope Chart 6
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.
98-5130 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 8 3.
106-2737 1. Park 2. Drive 3. Neutral 4. Engine—stop 5. Engine—run 6. Warning—wear ear protection. Product Overview Figure 4 1. 2. 3. 4. Throttle control Ignition switch Neutral/parking brake lock Operator Presence Control (OPC) lever 5. Handle Figure 3 1. 2. 3. 4. Side discharge Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel 6. 7. 8. 9.
Gear Shift Lever 36 inch mowers: The transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. Width with deflector down Length 80 inches (203.2 cm) Important: Do not shift while unit is moving, as transmission damage may occur. Height 41 inches (104.1 cm) Weight 462 lb (210 kg) 46.6 inches (118.4 cm) Drive Levers Attachments/Accessories Release drive levers to engage forward traction operation.
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. 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Important: Do not use fuel additives containing methanol or ethanol. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Add the correct amount of gas stabilizer/conditioner to the gas. 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.
Releasing the Neutral Locks 4. Disconnect the wire from the spark plug to prevent someone from accidentally starting the machine while transporting or storing it. 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). 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.
• The machine is shifted into gear without holding the OPC levers. • The blade control (PTO) lever is engaged without holding the OPC levers. Testing the Safety Interlock System 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.
Driving Backward Side Discharging or Mulching the Grass 1. Ensure that the parking brakes are engaged. 2. Squeeze the OPC levers against the handles. This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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.
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 9 1. Position A 2. Position B 3. Position C 4. Drive spring 5. Adjustment bolt ( In position A) 6. Drive pulley shield 5. Remove the locknut that secures the adjustment bolt to the drive pulley shield (Figure 9). 6.
Figure 11 1. Axle pivot bolt 2. Axle adjustment bolt Figure 12 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). 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. Install the caster in the support and insert the latch pin (Figure 12).
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 14 1. 2. 3. 4. 5. Upper handle Rear frame Flange bolt (3/8 x 1 inch) Lock nut (3/8 inch) Upper mounting hole 6. 7. 8. 9. Lower mounting holes Low position Middle position High position 5.
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.
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 1. Look at the center of the spark plugs (Figure 24). 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.
Figure 25 1. Fuel shut-off valve 2. Fuel filter Figure 26 6. Wipe up any spilled fuel. 1. Hose clamp 2. Fuel line Replacing the Fuel Filter 3. Filter 5. Remove the filter from the fuel lines. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 6. Install a new filter and move the hose clamps close to the filter. Never install a dirty filter if it is removed from the fuel line. 7. Open fuel shut-off valve at fuel tank (Figure 25). 8.
Drive System Maintenance Cooling System Maintenance Checking the Tire Pressure Cleaning the Air Intake Screen 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.
Brake Maintenance Servicing the Brakes 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. Before each use, check brakes on both a level surface and slope. 5. Check the operation of the brakes again; refer to Checking the Brakes. 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.
Belt Maintenance Checking the Belts Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating. Replacing the Traction Drive Belt Figure 31 1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Figure 30). 2. Remove bottom and loosen top bolts of shield to rotate for belt clearance (Figure 30). 3. Lift the belt past idler and off the drive pulley (Figure 30). 4.
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). 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). Figure 32 1. Mower belt with 1/2 inch (13mm) deflection 2. Idler pulley Figure 34 1. 1/2 inch (13 mm) deflection 4. Locknut here 2. Assist arm 5. Turnbuckle 3. Front stop 8.
Controls System Maintenance 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. Adjusting the Control Rods 3. Loosen the locknut on the turnbuckle (Figure 34). 1. Remove the hairpin cotter pins and clevis pins from the drive levers and neutral locks (Figure 35). 4. Rotate the turnbuckle toward the rear of the mower to increase the tension on the belt.
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). Mower Deck Maintenance 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. Servicing the Cutting Blades 5. Adjust the control rod length by repeating the previous steps. To ensure a superior quality of cut, keep the blades sharp.
2. Inspect the blades, especially the curved area (Figure 37). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 37), immediately install a new blade. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. Checking for Bent Blades • Always replace bent or damaged blade with a new blade. 1. Rotate the blades until the ends face forward and backward (Figure 38).
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). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. 2. Install the remaining spacer(s) and secure them with a thin washer and a nut (Fig. Figure 40). 3. Torque the blade bolt to 75-80 ft-lb (101-108 N•m).
Figure 43 1. Spring mounting bolts 2. Blade brake pad 3. 1/8-3/16 inch (3mm-5mm) Figure 44 Replacing the Grass Deflector 1. Bolt 2. Spacer 3. Locknut 4. Spring 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 or death. Also, contact with the blade could occur. 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8. J hook end of spring 2.
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 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.
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.
