Form No. 3361-969 Rev A Commercial Walk-Behind Mower Fixed Deck, T-Bar, Gear, with 40in TURBO FORCE® Cutting Unit Model No. 38696—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 Lever (PTO) ............................................................ 14 The Safety Interlock System................................ 15 Driving Forward or Backward............................. 15 Using the Lower Control Bar .............................. 15 Stopping the Machine......................................... 16 Transporting Machines....................................... 17 Side Discharging or Mulching the Grass .............. 17 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.
95-5537 99-3943 3. Pull back to disengage 1. Read the Operator’s Manual for instructions on operating the cutting blade 2. Push forward to engage 1. Engine 104-8569 98-4387 1. Warning—wear hearing protection. 106-0699 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).
110-2068 1. Read the Operator’s Manual. 105-0884 110-6916 Product Overview Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
Figure 3 1. 2. 3. 4. Side discharge Mower deck Recoil starter Gas tank 5. T-bar control 6. Handle 7. Front caster wheel Figure 4 1. Throttle control Controls 2. 3. 4. 5. 6. Become familiar with all the controls (Figure 4) before you start the engine and operate the machine. 7. Parking brake lever-released position Blade control bail 8. Choke Power take off lever (PTO) 9. Ignition switch 10. Upper handle Gear shift lever Upper control bar 11.
Upper Control Bar 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. Shift to the desired gear and push forward on the upper control bar and blade control bail to engage forward traction operation and pull back to brake forward movement. Pull back on right side of upper control bar to turn right and left side to turn left.
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.
6. To start a cold engine, move the throttle control midway between the fast and slow positions. 7. To start a warm engine, move the throttle control to the fast position. 8. Pull the choke knob if the engine is cold (Figure 7). 5. Pull wire off spark plug(s) to prevent possibility of accidental starting before storing or performing maintenance on the machine. 6. Close the fuel shut off valve before storing or transporting the machine.
Note: It is necessary to fully and manually disengage the blade control lever. throttle control in the fast position for best mowing performance. The Safety Interlock System Driving Forward 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. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 3.
Driving Backward Up a Curb 1. Disengage the mower blades. 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. 2. Select reverse to drive the machine. 3. Drive the machine until drive wheels contact curb (Figure 10). 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.
Transporting Machines Adjusting the Blade Height 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. Adjust the blades by using the 4 spacers (1/4 inch) (6 mm) on the blade spindle bolts.
Adjusting the Axle Height Adjust the axle position to the selected height-of-cut setting. Refer to the Height-of-Cut Chart. 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, but do not remove, the 2 axle pivot bolts and the 2 axle adjustment bolts (Figure 13). Figure 14 1. Latch pin 2. Spacer, 3/16 inch (5 mm) 3. Spacer, 1/2 inch (13 mm) 2.
Position A This is the full rear position. The suggested use for this position is a follows (Figure 16). • 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 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.
Figure 17 Figure 18 Position C Adjusting the Handle Height This is the full open position. The suggested use for this position is as follows (Figure 18). The handle position can be adjusted to match the operator’s height preference. • Use in tall, dense grass mowing conditions. 1. Remove hairpin cotter, washer and clevis pin securing control rod fitting to idler bracket (Figure 19). • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions.
Figure 19 1. Control rod 2. Control rod fitting 3. Idler bracket 4. Clevis pin 5. Washer 6. Hairpin cotter pin 2. Loosen the upper flange bolts (3/8 x 1 inch) and flange nut securing handle to rear frame (Figure 20). Figure 20 1. Upper handle 2. Rear frame 3. Flange bolt (3/8 x 1 inch) 4. Lock nut (3/8 inch) 5. Upper mounting hole 6. Lower mounting hole 3. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Figure 20). 4.
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.
Greasing the Mower Belt Idler 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Grease the fitting on the mower belt idler arm pivot (Figure 23). 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). Note: Remove the mower deck cover to access the grease fitting for the mower belt idler arm. 4. Connect a grease gun to the fitting.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
1. Carefully slide the foam element onto the paper air cleaner element (Figure 24). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 24). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 24). Servicing the Engine Oil Figure 26 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 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 28). 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. Servicing the Fuel Tank Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 30). 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 31). 8. Check for fuel leaks and repair if needed. 9. Wipe up any fuel that spilled. Figure 31 1. Fuel shut-off valve 2. Clamp Servicing the Fuel Filter Replacing the Fuel Filter 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 Cooling System Maintenance Checking the Tire Pressure Cleaning the Air Intake Screen Service Interval: Every 50 hours/Monthly (whichever comes first)—Check the tire pressure 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 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 1. Park the machine on a level surface, disengage the blade control (PTO). 1. Brake rod 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2.
Belt Maintenance 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. Checking the Belts 3. Raise the rear of the machine and hold it up with jack stands. Service Interval: Every 50 hours/Monthly (whichever comes first) 4. Remove the mower belt; refer to Replacing the Mower Belt (Figure 37). 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.
6. Install the idler pulley. 7. Engage the blade control (PTO) lever and check the belt tension. Refer to Adjusting the Mower Belt Tension. 3. Loosen the locknut on the turnbuckle (Figure 39). 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 39). Note: The proper mower belt tension is 10-15 lbf.
The PTO engagement linkage adjustment is located beneath the front left hand corner of the engine deck. 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. Engage the blade control lever (PTO). 4. Adjust the linkage length to where the lower end of the bellcrank just clears the axle support gusset (Figure 42). Figure 40 1. Rear idler pulley 2. Middle hole 3. Front hole 4.
Figure 43 1. Assist arm 2. Front assist arm stop 3. Rear assist arm stop 4. Turnbuckle Figure 44 1. Bellcrank 2. Bolts and nuts 8. To adjust the assist arm link, remove the hairpin cotter pin from the assist arm (Figure 43). 9. Loosen the nut against the yoke (Figure 42). 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). 12.
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. • Inspect the blade periodically for wear or damage. Figure 47 1.
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 48). 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 50). Repeat this procedure until the blade is balanced. Figure 50 1. Blade 2. Balancer Installing the Blades 1. Place the blade onto the bolt and over the cone washer.
Figure 51 1. Spring mounting bolts 3. 1/8-3/16 inch (3 mm–5 mm) 2. Blade brake pad Figure 52 1. Bolt 2. Spacer 3. Locknut Replacing the Grass Deflector 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. 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 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 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.
