Toro 38696 Operator's Manual

FormNo.3361-969RevA

CommercialWalk-BehindMower

FixedDeck,T-Bar,Gear,with40inTURBO
FORCE

ModelNo.38696—SerialNo.290000001andUp

®

CuttingUnit

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

Theenclosed

Engine Owner’ s Man ual

forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCalifornia
EmissionControlRegulationofemissionsystems,
maintenance,andwarranty.Replacementsmaybe
orderedthroughtheenginemanufacturer.

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Introduction.................................................................2

Safety...........................................................................3

SafeOperatingPractices.......................................3

ToroMowerSafety...............................................4

SlopeChart..........................................................6

SafetyandInstructionalDecals.............................7

ProductOverview........................................................9

Controls.............................................................10

Specications.....................................................11

Attachments/Accessories...................................11

Operation...................................................................12

AddingFuel.......................................................12

ThinkSafetyFirst...............................................13

OperatingtheParkingBrake...............................13

StartingandStoppingtheEngine........................13

©2009—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

OperatingtheBladeControlLever

(PTO)............................................................14

TheSafetyInterlockSystem................................15

DrivingForwardorBackward.............................15

UsingtheLowerControlBar..............................15

StoppingtheMachine.........................................16

TransportingMachines.......................................17

SideDischargingorMulchingtheGrass..............17

AdjustingtheHeight-of-Cut...............................17

AdjustingtheFlowBafe...................................18

PositioningtheFlowBafe.................................19

AdjustingtheHandleHeight..............................20

HeightofCutChart............................................22

Maintenance...............................................................23

RecommendedMaintenanceSchedule(s)................23

Lubrication.............................................................23

HowtoGrease...................................................23

LubricatingtheCasterandWheel

Bearings.........................................................24

GreasingtheTransmissionCouplers...................24

GreasingtheMowerBeltIdler............................24

EngineMaintenance...............................................25

ServicingtheAirCleaner....................................25

ServicingtheEngineOil.....................................26

ServicingtheSparkPlugs....................................27

FuelSystemMaintenance.......................................28

ServicingtheFuelTank......................................28

ServicingtheFuelFilter......................................29

DriveSystemMaintenance.....................................30

CheckingtheTirePressure.................................30

CoolingSystemMaintenance..................................30

CleaningtheAirIntakeScreen............................30

CleaningtheCoolingSystem...............................30

BrakeMaintenance.................................................31

ServicingtheBrakes...........................................31

BeltMaintenance....................................................32

CheckingtheBelts..............................................32

ReplacingtheTractionDriveBelt........................32

ReplacingtheTransmissionDriveBelt................32

ReplacingtheMowerBelt...................................32

AdjustingtheMowerBeltTension......................33

MowerDeckMaintenance......................................36

ServicingtheCuttingBlades...............................36

AdjustingtheBladeBrake...................................37

ReplacingtheGrassDeector.............................38

Storage.......................................................................39

Troubleshooting.........................................................40

Schematics.................................................................42

Safety

Note:Theadditionofattachmentsmadeby

othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
CAUTION,WARNING,orDANGER-“personalsafety
instruction."Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

–Useonlyanapprovedcontainer

3

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

–Neverrefuelordrainthemachineindoors.

•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Usecarewhenloadingorunloadingthemachine
intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator’sposition.

•Besureofyourfootingwhileusingthismachine,
especiallywhenbackingup.Walk,don’trun.Never
operateonwetgrass.Reducedfootingcouldcause
slipping.

•Slowdownanduseextracareonhillsides.Besure
totravelsidetosideonhillsides.Turfconditions
canaffectthemachine’ sstability.Usecautionwhile
operatingneardrop-offs.

•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguards
notsecurelyinplace.Besureallinterlocksare
attached,adjustedproperly,andfunctioningproperly .

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Stoponlevelground,disengagedrives,engage
parkingbrake(ifprovided),shutoffenginebefore
leavingtheoperator’spositionforanyreason
includingemptyingthecatchersoruncloggingthe
chute.

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopbladesifnot
mowing.

Maintenanceandstorage

•Disengagedrives,setparkingbrake,stopengineand
removekeyordisconnectsparkplugwire.Waitfor
allmovementtostopbeforeadjusting,cleaningor
repairing.

•Cleangrassanddebrisfromcuttingunit,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.
Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectthebatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositivelast.Reconnectthe
positiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyoumust
know .

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

4

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

GeneralOperation

•Besuretheareaisclearofotherpeoplebefore
mowing.Stopthemachineifanyoneentersthearea.

•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowtocoolbefore
attemptingtomaintain,adjustorservice.

•UseonlyToro-approvedattachments.W arrantymay
bevoidedifusedwithunapprovedattachments.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)before
operatingunderanyobjectsanddonotcontact
them.

SlopeOperation

•Useonlygenuinereplacementpartstoensurethat
originalstandardsaremaintained.

•Checkbrakeoperationfrequently.Adjustandservice
asrequired.

Allslopesandrampsrequireextracaution.Ifyoufeel
uneasyonaslope,donotmowit.

•Removeobstaclessuchasrocks,treelimbs,etc.from
themowingarea.

•Watchforholes,rutsorbumps.Tallgrasscanhide
obstacles.

•Usecautionneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifawheel
goesovertheedgeofaclifforditch,orifanedge
cavesin.

•Useextracarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machine.

•Keepallmovementonslopesslowandgradual.Do
notmakesuddenchangesinspeedordirection.

•Mowslopessidetoside.

•Donotmowslopesgreaterthan20degrees.

Service

•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade
attachmentboltsandnuts.Keepequipmentingood
condition.

•Nevertamperwithsafetydevices.Checksafety
systemsforproperoperationbeforeeachuse.

5

SlopeChart6SafetyandInstructional
Decals

82- 2280

REV E R S E  TRACT ION DR I V E

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

98-0776

43-8480

66-1340

82-2280

82-2290

98-3256

98-3266

95-2814

7

95-5537

1.ReadtheOperator’s
Manualforinstructionson

operatingthecuttingblade

2.Pushforwardtoengage

3.Pullbacktodisengage

98-4387

1.Warning—wearhearingprotection.

98-5130

1.Warning—readtheOperator’sManualforinstructionson
torquingthebladebolt/nutto75-80ft-lb(102-106N-m).

99-3943

1.Engine

104-8569

106-0699

98-5954

110-2067

8

110-2068

1.ReadtheOperator’sManual.

105-0884

110-6916

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

ProductOverview

9

Figure3

1.Sidedischarge

2.Mowerdeck6.Handle

3.Recoilstarter7.Frontcasterwheel

4.Gastank

5.T-barcontrol

Controls

Becomefamiliarwithallthecontrols(Figure4)before
youstarttheengineandoperatethemachine.

Figure4

1.Throttlecontrol7.Parkingbrake

2.Bladecontrolbail

3.Powertakeofflever(PTO)

4.Gearshiftlever

5.Uppercontrolbar11.Lowerhandle

6.Lowercontrolbar

lever-releasedposition

8.Choke

9.Ignitionswitch

10.Upperhandle

ThrottleControl

Thethrottlecontrolhastwopositions:FastandSlow.

BladeControlBail

Thebailisusedinconjunctionwiththebladecontrol
lever(PTO)toengagetheclutchanddrivethemower
blades.Releasingthebladecontrolbailwillstopthe
enginewiththePTOengaged.

BladeControlLever(PTO)

Thisleverisusedinconjunctionwiththebladecontrol
bailtoengageanddisengagethemowerdeckbeltand
drivethemowerblades.

GearShiftLever

Thetransmissionhasveforwardspeeds,neutraland
reverse,andhasanin-lineshiftpattern.

Important:Donotshiftwhileunitismoving,as
transmissiondamagemayoccur.

10

UpperControlBar

Shifttothedesiredgearandpushforwardontheupper
controlbarandbladecontrolbailtoengageforward
tractionoperationandpullbacktobrakeforward
movement.Pullbackonrightsideofuppercontrolbar
toturnrightandleftsidetoturnleft.

LowerControlBar

Shiftthetransmissiontoreverseandsqueezethelower
controlbarandhandletogethertoengagetherearward
tractionassist.

ParkingBrakeLever

Pullbackonuppercontrolbarandswingbrakelever
upagainsttheupperhandletosettheparkingbrake
(Figure4).

IgnitionSwitch

Thisswitchisusedinconjunctionwithrecoilstarterand
hastwopositions:RunandOff.

enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.Toro.comforalistofallapprovedattachments
andaccessories.

RecoilStarter

Pullrecoilstarterhandletostartengine(notshownin
Figure4).

FuelShut-offValve

Closethefuelshut-offvalvewhentransportingor
storingmower.

Choke

Usethechoketostartacoldengine.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Widthwithdeectordown55–1/2inches(141cm)

Length

Height

Weight

69–3/8inches(176cm)

41inches(104.1cm)

475lb(215kg)

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesareavailableforusewiththemachineto

11

Operation

AddingFuel

UseUnleadedRegularGasolinesuitablefor
automotiveuse(85pumpoctaneminimum).Leaded
regulargasolinemaybeusedifunleadedregularisnot
available.

Important:Neverusemethanol,gasoline
containingmethanol,orgasoholcontainingmore
than10%ethanolbecausethefuelsystemcouldbe
damaged.Donotmixoilwithgasoline.

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4
to1/2inch(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsgasolinetoexpand.

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitethegasolinevapors.Are
orexplosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Never
buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditionerbottleopening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

12

Important:Donotusefueladditives
containingmethanolorethanol.

Addthecorrectamountofgas
stabilizer/conditionertothegas.

Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshgasoline.To
minimizethechanceofvarnishdepositsinthefuel
system,usefuelstabilizeratalltimes.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundfueltankcapandremovethecap.
Addunleadedregulargasolinetofueltank,untilthe
levelis1/4to1/2inch(6to13mm)belowthe
bottomofthellerneck.Thisspaceinthetank
allowsgasolinetoexpand.Donotllthefueltank
completelyfull.

3.Installfueltankcapsecurely.Wipeupanygasoline
thatmayhavespilled.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsanddecalsin
thesafetysection.Knowingthisinformationcould
helpyouoranybystandersavoidinjury.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

SettingtheParkingBrake

1.Pulltheuppercontrolbarrearwardandholditin
thisposition(Figure6).

2.Lifttheparkingbrakelockupandgraduallyrelease
theuppercontrolbar.Thebrakelockshouldstayin
theset(locked)position(Figure6).

ReleasingtheParkingBrake

1.Pullrearwardontheuppercontrolbar.Lowerthe
parkingbrakelocktothereleasedposition.

2.Graduallyreleasetheuppercontrolbar.

Theuseofprotectiveequipmentforeyes,hearing,feet
andheadisrecommended.

Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

Figure5

1.Warning—wearhearingprotection.

OperatingtheParkingBrake

Stoponlevelground,disengagedrives,engageparking
brake,shutoffengineandremovekey.Alwayssetthe
parkingbrakewhenyoustopthemachineorleaveit
unattended.

Figure6

1.Uppercontrolbar3.Fixedbar

2.Parkingbrakelever-set
position

StartingandStoppingthe
Engine

StartingtheEngine

1.Connectthewirestothesparkplugs.

2.Openthefuelvalve.

3.Disengagethebladecontrol(PTO)leverandmove
theshiftlevertotheneutralposition.

4.Settheparkingbrakes.

5.Turntheignitionkeytotherunposition(Figure7).

13

6.Tostartacoldengine,movethethrottlecontrol
midwaybetweenthefastandslowpositions.

7.Tostartawarmengine,movethethrottlecontrol
tothefastposition.

8.Pullthechokeknobiftheengineiscold(Figure7).

5.Pullwireoffsparkplug(s)topreventpossibilityof
accidentalstartingbeforestoringorperforming
maintenanceonthemachine.

6.Closethefuelshutoffvalvebeforestoringor
transportingthemachine.

Note:Awarmorhotengineusuallydoesnot
requireanychoking.

9.Grasptherecoilstarterhandlermlyandpullit
outuntilpositiveengagementresults;thenpullthe
handlevigorouslytostarttheengine.Allowthe
ropetorecoilslowly .

Important:Donotpulltherecoilropetoits
limitorreleasethestarterhandlewhenyoupull
outtheropebecausetheropemaybreakorthe
recoilassemblymaybedamaged.

10.Pushthechoketooffastheenginewarmsup.

11.Iftheengineiscold,allowittowarmupandthen
movethethrottlecontroltothefastposition.

StoppingtheEngine

Important:Inanemergency ,youcanstopthe

engineimmediatelybyturningtheignitionkeyto
the

of f

position.

1.Movethethrottlelevertotheslowposition
(Figure7).

Important:Makesurefuelshutoffvalveis
closedbeforetransportingorstoringmachine,
asfuelleakagemayoccur.

OperatingtheBladeControl
Lever(PTO)

Thebladecontrollever(PTO)engagesanddisengages
powertothemowerblades.

EngagingtheMowerBlades

1.Toengagetheblades,squeezebladecontrolbail
againsttheuppercontrolbar(Figure8).

2.Pushthebladecontrolleverrmlyforward,untilit
latchesover-center.

3.Restarttheengineandrepeattheprocedureto
engagethemowerbladesifthebladecontrolbail
isreleased.

2.Letengineidlefor30to60secondsbeforeturning
theignitionkeytooff.

3.Turntheignitionkeytooff(Figure7).

Figure7

1.Bladecontrollever(PTO)

2.Throttlelever

3.Ignitionkey

4.Settheparkingbrakeandremovekey.

Figure8

1.Uppercontrolbar

2.Bladecontrolbail

3.Bladecontrollever(PTO)

DisengagingtheMowerBlades(PTO)

Todisengagetheblades,pullthebladecontrollever
rearwardalltheway(Figure8).Theenginewillkill
whenthebladecontrolbailisreleasedwiththeblade
controlleverengaged.

14