Form No. 3362-496 Rev A Commercial Walk-Behind Mower Fixed Deck, Pistol Grip, Hydro Drive with a 48in TURBO FORCE® Cutting Unit Model No. 38988—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. Figure 1 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.
Operating the Parking Brake ............................... 13 Starting and Stopping the Engine ........................ 14 Operating the Neutral Locks............................... 15 Operating the Mower Blade Control Knob (PTO) ............................................................ 15 The Safety Interlock System................................ 16 Driving the Machine Forward and Backward ....................................................... 17 Bringing the Machine to Neutral Position ............
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. 98-0776 1-523552 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). 43-8480 95-5537 66-1340 1. Read the Operator’s 3. Push forward to engage Manual for instructions on operating the cutting blade 2.
105-4109 105-4110 99-3943 1. Engine 106-0699 103—2103 106-2733 104-8569 1. Fast 2. Continuous variable setting 106-2743 9 3.
110-2067 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 3 1. 2. 3. 4. Side discharge Mower deck Recoil starter Gas tank 5. Controls 6. Handle 7. Caster wheel Figure 4 1. 2. 3. 4. 5. Controls Become familiar with all the controls (Figure 4) 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 Operation This switch is used in conjunction with recoil starter and has two positions: Run and Off. 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. Speed Control Lever This machine has a variable speed control with a neutral position. This controls how fast the machine will travel.
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.
If the parking brake does not hold securely, adjust it. Refer to Servicing the Parking Brake. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Figure 7 Setting the Parking Brake 1. Split ring 2. Control shield bolt Pull the parking brake lever rearward (Figure 6).
Releasing the Neutral Lock 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. 1. Squeeze the drive levers back until an increase in force is felt. 2. Place thumbs on the upper part of locks and move them forward until the pins are in the forward slot (Figure 10). Figure 8 1. Throttle lever 2. Ignition switch 3. Choke Figure 10 1. Handle 2. Neutral lock 3.
The safety interlock system is designed to kill the engine when: • The Operator Presence Control (OPC) levers are released with the mower engaged and/or the speed control is out of neutral. • The speed control lever is shifted out of neutral without holding OPC levers or with the brake engaged. • The blade control knob (PTO) is pulled up without holding the OPC levers. Testing the Safety Interlock System Figure 11 1. Throttle lever 2. Operator Presence Control levers (OPC) 3.
Driving the Machine Forward and Backward 2. Set the neutral locks. Refer to Operating Neutral Locks. 3. Move speed control lever to neutral position. The throttle control regulates the engine speed as measured in RPM (revolutions per minute). Place the throttle control in the fast position for best mowing performance. Note: The speed control lever can also be used to bring the mower to neutral position and then set the neutral locks. Stopping the Machine Driving Forward 1.
Important: Do not start or operate the machine with the by-pass valves open. Damage to system may occur. Figure 14 1. Cam lock Figure 13 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. By-pass valve 2. Lever Adjusting the Flow Baffle Positioning the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. The following figures are only recommendations for use.
Figure 15 Figure 16 Position B Position C Use this position when bagging (Figure 16). This is the full open position. The suggested use for this position is as follows (Figure 17). • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower.
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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf.
5. Loosen, but do not remove, the 2 top axle bolts (Figure 19). 4. Hold the blade bolt and remove the nut. Slide the bolt down through the spindle, and change the spacers as needed (Figure 18). 6. Remove the 2 lower axle bolts (Figure 19). Figure 19 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 19). A tapered punch can be used to help align the holes. 8. Tighten all 4 bolts. 9.
2. Remove the latch pin, slide the caster from the support, and change the spacers (Figure 20). 3. Install the caster in the support and insert the latch pin (Figure 20). Adjusting the Handle Height 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 21). Figure 22 7. Control rod fitting Lower mounting holes 8. 9. Rear frame Lower flange bolt (3/8 x 1 10. inch) 11. 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.
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. 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. Figure 23 Lubricating the Caster and Wheel Bearings 1. Pump drive idler arm 2.
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 24). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 24). Servicing the Engine Oil Service Interval/Specification Figure 26 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 26).
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.
Figure 31 1. Fuel shut-off valve 2. Clamp Figure 32 1. Hose clamp 2. Fuel line Servicing the Fuel Filter 3. Filter Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 5. Remove the filter from the fuel lines. Replacing the Fuel Filter 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). Never install a dirty filter if it is removed from the fuel line. 8.
Drive System Maintenance 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 34). 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. 8. If needed, adjust switch location to create the 5/16 inch (8 mm) space (Figure 34).
pulled against the neutral spring (neutral position) (Figure 35). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 12. Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counter-clockwise if the wheel is turning forward (Figure 35). • Use jack stands when supporting machine. • Do not use hydraulic jacks. 13.
Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stands when supporting machine. • Do not use hydraulic jacks. Adjusting the Left Side Linkage 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 high enough to raise the drive wheels off of the ground. Figure 36 4. Disengage the parking brake. 12.
Figure 38 1. Speed control lever 2. Rear pivot spring 3. spring Adjusting the Right Side Linkage Figure 39 1. Hydro control linkage 2. Quick track knob 1. Place the speed control lever in the neutral position. 3. Spring 4. 1 inch (26 mm) 2. Place the right drive lever in the full forward position. 3. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Figure 39). Adjusting the Control Rod 4.
3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt. 4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Figure 42). Figure 40 1. 2. 3. 4. Control rod Clevis pin Drive lever Operator Presence Control lever (OPC) 5. Left handle shown 6. Neutral lock 7. Hairpin cotter pin Figure 42 1. Quick track knob 5.
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 43 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 46). 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 46). Before each use, check the parking brake for proper operation.
Belt Maintenance Adjusting the Mower Belt Tension Checking the Belts Adjusting the Tension Check all belts after every 50 operating hours or monthly, whichever occurs first. Adjust the mower belt tension as follows: • After the first 8 operating hours. Look for dirt, wear, cracks and signs of overheating. • After the first 25 operating hours. Replacing the Mower Belt • After every 50 operating hours. 1. Disengage the blade control (PTO) lever and set the parking brakes.
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 50). Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted. Figure 48 1. 1/2 inch (13 mm) deflection 4. Locknut here 2. Assist arm 5. Turnbuckle 3. Front stop Figure 50 1. Belt guide 5. Engage the bladed control lever (PTO) and check the belt tension. 9.
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 52). 12. Check if the assist arm hits against the stops correctly. Adjusting the PTO Safety Switch 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. Disengage the blade control lever (PTO).
Hydraulic System Maintenance 6. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle. 7. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine. 8. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle.
critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump. Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed. 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.
8. If either drive wheel still does not rotate, stop and repeat steps 4 and 5 on the respective pump. If wheels rotate slowly, the system may prime after additional running. Recheck hydraulic fluid level. Mower Deck Maintenance 9. Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position. Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp.
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. • Always replace bent or damaged blade with a new blade. Figure 57 1. Cutting Edge 2. Curved Area 3.
Figure 62 1. Blade 2. Balancer Installing the Blades 1. Install the bolt, curved washer, and blade. Select the proper number of spacer(s) for the height-of- cut, and slide the bolt into the spindle (Figure 60). 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 (Figure 60). 3. Torque the blade bolt to 75-80 ft-lb (101-108 N-m). Adjusting the Blade Brake 1.
Figure 63 1. Spring mounting bolts 2. Blade brake pad 3. 1/8-3/16 inch (3mm-5mm) Figure 64 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. 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: 51
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.
