Form No. 3361-965 Rev A Commercial Walk-Behind Mower Fixed Deck, T-Bar, Gear with a 32in Cutting Unit or 36in TURBO FORCE® Cutting Unit Model No. 38692—Serial No. 290000001 and Up Model No. 38694—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) ............................................................ 13 The Safety Interlock System................................ 14 Driving Forward or Backward............................. 14 Using the Lower Control Bar .............................. 14 Stopping the Machine......................................... 15 Transporting Machines....................................... 16 Side Discharging or Mulching the Grass .............. 16 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.
98-3296 98-3266 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). Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
110-6916 Product Overview 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 2. 3. 4. 5. 6. Controls 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. Lower handle Lower control bar Become familiar with all the controls (Figure 4) before you start the engine and operate the machine.
Blade Control Lever (PTO) 32 inch mowers: This lever is used in conjunction with the blade control bail to engage and disengage the mower deck belt and drive the mower blades. Width with deflector down Gear Shift Lever The transmission has five forward speeds, neutral and reverse, and has an in-line shift pattern. 45.8 inches (116.3 cm) Length 72 inches (183 cm) Height 41 inches (104.
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.
Figure 16 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 16). 4. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch)and flange nuts into mounting holes. Tighten all flange bolts. 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.
Greasing the Mower Belt Idler 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). Grease the fitting on the mower belt idler arm pivot (Figure 19). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. Note: Remove the mower deck cover to access the grease fitting for the mower belt idler arm. 5. Wipe up any excess grease.
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 20). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 20). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 20). Servicing the Engine Oil Figure 22 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 24). 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 24). 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 26). 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 27). 8. Check for fuel leaks and repair if needed. 9. Wipe up any fuel that spilled. Figure 27 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 Service Interval: Before each use or daily 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.
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 Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the blade control (PTO). Figure 30 1. Air intake screen 2. Fan housing 3. Recoil starter 2.
Belt Maintenance Checking the Belts Service Interval: Every 50 hours/Monthly (whichever comes first) 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. Replace the deck belt if any of these conditions are evident. Figure 31 1. Brake rod Replacing the Traction Drive Belt 2. Wing nut 1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Figure 32).
7. Engage the blade control (PTO) lever and check the belt tension. Refer to Adjusting the Mower Belt Tension. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Raise the rear of the machine and hold it up with jack stands. 4. Remove the mower belt; refer to Replacing the Mower Belt (Figure 33). 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 34). Figure 33 1.
11. Rotate the clevis clockwise on the rod to increase the clearance; rotate it counterclockwise to decrease it (Figure 35). 12. Disengage the blade control (PTO) lever. Note: If the assist arm does not contact the front stop on the mower deck (Figure 36), adjust the clevis to bring the bell crank closer to the transmission output shaft (Figure 35). Figure 37 1. Idler pulley in slot 2. Traction belt 3. Mower belt 4. Belt guide 5. 1-1/4 inch (32 mm) 6.
Mower Deck Maintenance Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 39). 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. 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.
Removing the Blades Replace the blades if you hit a solid object or if the blades are out of balance or 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. Figure 42 1. Sharpen at original angle 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 41).
Figure 44 1. Spring mounting bolts 2. Blade brake pad 3. 1/8-3/16 inch (3mm-5mm) Figure 45 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 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: 39
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.
