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ProLine 21” Recycler
Walk-behind Power Mower
Model No. 22038 — 9900001 & Up
FORM NO. 3321–941
Operator’s Manual
International English (GB)
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
2
3
3
Preparation
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Storage
Sound Pressure Level
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
3
3
Symbol Glossary
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Gas Tank and Fuel Line . . . . . . . . . . . . . . .
5
8
4
4
Install Starter Rope . . . . . . . . . . . . . . . . . . . . . . . . .
Install Air Cleaner Cover . . . . . . . . . . . . . . . . . . . .
9
9
8
8
Install Discharge Tunnel Plug . . . . . . . . . . . . . . . .
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Mix Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recycler r
Mower Features . . . . . . . . . . . . . . . . . .
Cutting Grass . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
12
12
12
9
10
10
Tips For Cutting Leaves . . . . . . . . . . . . . . . . . . . . .
Tips For Cutting Leaves . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Stopping, And Self–propelling . . . . . . . .
Using Discharge Tunnel Plug . . . . . . . . . . . . . . . .
Using Grass Bag . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Height–of–cut . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Air Cleaner
Replacing Spark Plug
Draining Gasoline
Adjusting Throttle
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
15
16
16
16
13
13
13
14
Cleaning Cooling System
Cleaning Muffler And Exhaust Port
Adjusting Wheel Drive
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
Adjusting Ground Speed Control Cable
Inspecting/Removing/Sharpening Blade
. . . . . . . .
. . . . . . . .
17
18
18
16
16
17
17
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating Gear Case . . . . . . . . . . . . . . . . . . . . . .
Servicing Wheels
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Blade Brake . . . . . . . . . . . . . . . . . . . . . .
Preparing Mower For Storage . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
24
20
20
20
21
Introduction
Thank you for purchasing a Toro product.
All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local
Authorized Service Dealer for help with service, genuine
Toro parts, or other information you may require.
Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number decal located in a unique place on the product
(Fig. 1).
m-2302
Figure 1
1.
Model and serial number decal
For your convenience, write the product model and serial numbers in the space below.
Model No:
Serial No.
Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although Toro designs, produces and markets safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons who you allow to use the product about safe operation.
The Toro warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death.
DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.
E
The Toro Company – 1999
All Rights Reserved 2
Printed in USA
DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed.
WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed.
CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.
Two other words are also used to highlight information.
“Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.
The left and right side of the machine is determined by standing behind the handle in the normal operator’s position.
Safety
Training
1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with these instructions to use the lawnmower. Local regulations may restrict the age of the operator.
3. Never mow while people, especially children, or pets are nearby.
4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.
Preparation
1. While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
2. Always wear safety glasses or eye shields during operation to protect eyes from foreign objects that may be thrown from the machine. Wearing of hearing protection, protective gloves and a safety helmet is advisable.
3. Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.
4. WARNING – Petrol is highly flammable.
•
Store fuel in containers specifically designed for this purpose.
•
Refuel outdoors only and do not smoke while refuelling.
•
Add fuel before starting the engine. Never remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.
•
If petrol is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until petrol vapors have dissipated.
•
Replace all fuel tanks and container caps securely.
5. Replace faulty silencers.
6. Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.
7. On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.
Operation
1. Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.
2. Mow only in daylight or in good artificial light.
3. Avoid operating the equipment in wet grass, where feasible.
4. Always be sure of your footing on slopes.
5. Walk, never run.
6. For wheeled rotary machines, mow across the face of slopes, never up and down.
7. Exercise extreme caution when changing direction on slopes.
8. Do not mow excessively steep slopes.
9. Use extreme caution when reversing or pulling the lawnmower towards you.
10. Stop the blade(s) if the lawnmower has to be tilted for transportation when crossing surfaces other than grass, and when transporting the lawnmower to and from the area to be mowed.
11. Never operate the lawnmower with defective guards or shields, or without safety devices, for example deflectors and/or grass catchers, in place.
12. Do not change the engine governor settings or overspeed the engine.
13. Disengage all blade and drive clutches before starting the engine.
14. Start the engine or switch on the motor carefully according to instructions and with feet well away from the blade(s).
3
15. Do not tilt the lawnmower when starting the engine or switching on the motor, except if the lawnmower has to be tilted for starting. In this case, do not tilt it more than absolutely necessary and lift only the part which is away from the operator.
16. Do not start the engine when standing in front of the discharge chute.
17. Do not put hands or feet near or under rotating parts.
Keep clear of the discharge opening at all times.
18. Never pick up or carry a lawnmower while the engine is running.
19. Stop the engine and disconnect the spark plug wire.
• before clearing blockages or unclogging chute;
• before checking, cleaning or working on the lawnmower;
• after striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the lawnmower;
• if lawnmower starts to vibrate abnormally (check immediately).
20. Stop the engine
• whenever you leave the lawnmower;
• before refuelling.
21. Reduce the throttle setting during engine shut down and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.
22. Go slow when using a trailing seat.
Maintenance and Storage
1. Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
2. Never store the equipment with petrol in the tank inside a building where fumes may reach an open flame or spark.
3. Allow the engine to cool before storing in any enclosure.
4. To reduce the fire hazard, keep the engine, silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease.
5. Check the grass catcher frequently for wear or deterioration.
6. Replace worn or damaged parts for safety.
7. If the fuel tank has to be drained, this should be done outdoors.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 83.5 dB(A), based on measurements of identical machines per ANSI
B71.5-1984 procedures.
Sound Power Level
This unit has a sound power level of: 100 dB(A)/1 pW, based on measurements of identical machines per
Directive 84/538/EEC and amendments.
Vibration Level
This unit has a maximum hand-arm vibration level of
3.6 m/s
@
, based on measurement of identical machines per
ISO 5349 procedures.
4
Symbol Glossary
Safety alert triangle — symbol within triangle indicates a hazard.
Safety alert symbol
Read operator’s manual.
Consult technical manual for proper service procedures.
Stay a safe distance from the machine.
Stay a safe distance from the mower.
Throw or flying objects — Whole body exposure
Thrown or flying objects — Rotary side-mounted mower.
Keep deflector shield in place.
Stop engine before leaving operator position.
5
Do not open or remove safety shields while engine is running.
Rotating blade can cut off toes or fingers.
Stay clear of mower blade as long as engine is running.
To avoid blade failure when mulching, use blade stiffener when mower is equipped with mulching plug.
Transmission
Oil
On/Run
Engage
Disengage
Battery charging condition
Hourmeter/elapsed operating hours
Fast
Slow
Decreasing/Increasing
Grease lubrication point
Engine start
Engine stop
Choke
Primer (start aid)
6
Fuel
Neutral
First gear
Second gear
Third gear
Cutting element — basic symbol
Cutting element — height adjustment
Pull rope.
Wheel
Push primer three times.
Properly dispose of batteries.
Insert key in ignition switch.
Turn key in ignition switch.
Move control.
Move control forward.
Move control rearward.
Wheel traction
Lower control bar.
Raise control bar.
Raise/lower control bar.
Raise/lower control bar.
Raise control bar.
Raise control bar.
Lower control bar.
7
Assembly
Install Handles
1. Mount handle to outside of mower housing, using bottom hole, with (2) 5/16–18 x 1–1/4” lg. capscrews, washers, and thin nylon insert locknuts.
5 5
3
2
5
4
6
7
3
4
2
1
534
1.
Handle
2.
Handle latch
3.
Bag support rod
Figure 2
4.
Cap locknut
5.
Cable tie
2. Secure handle latches to handle with (2) 5/16–18 x
1–1/2” lg. capscrews, washers and nylon insert locknuts. Position locknuts and washers on inside of handle.
Note: Handle height is adjustable for operator comfort.
Stand behind mower handle to gauge height. To adjust handle height, reposition capscrews and locknuts securing handle latches to handle into other mounting holes in latches.
3. Slide bag support rod thru top mounting holes in handle and secure each end with a cap locknut (Fig. 2).
4. Secure control cables in position with cable ties.
Install Gas Tank and Fuel Line
1. Start self–tapping screws into bottom of gas tank and then remove screws.
2. Hook the plastic clips on the rear of the gas tank onto gas tank bracket (Fig. 3).
1.
Fuel line
2.
Elbow fitting
1.
Self-tapping screws
2.
Gas tank
3.
Plastic clips
4.
Gas tank retainer
1
Figure 3
5.
Gas tank bracket
6.
Locknut
7.
Tank base m-2942
3. Secure gas tank to tank base with the (2) self–tapping screws (Fig. 3). Do not overtighten screws.
4. Hook gas tank retainer onto gas tank and slide end of retainer into hole in tank bracket. Secure retainer to tank bracket with locknut (Fig 3). Do not overtighten.
5. Slide end of fuel line onto elbow fitting. Secure in place with fuel line clamp (Fig. 4).
1
3
2
Figure 4
3.
Fuel line clamp
8
Install Starter Rope
1. Pull the starter rope through the rope guide on the handle (Fig. 5). To make the rope easier to loop, squeeze the control bar on the handle to release the blade brake.
Install Discharge Tunnel Plug
1. Open the discharge door by pulling forward on the handle and moving it rearwards (Fig. 7). Hold the discharge door handle to prevent the spring–loaded door from closing while inserting the plug.
1
2
1
1.
Rope guide
Figure 5
2.
Starter rope
Install Air Cleaner Cover
1. Insert bottom tabs of air cleaner cover into slots.
Rotate cover upwards and snap into place (Fig. 6).
1.
Plug rotated clockwise
Figure 7
2. Since the plug is slightly wider than the discharge tunnel opening, rotate the plug clockwise slightly while inserting it (Fig. 7). Make sure the arrow on the plug decal is pointing upwards.
262
1.
Cover
2.
Tabs
3
1
Figure 6
3.
Foam element
2
196
1
404
Figure 8
1.
Spring clip
3. Push the plug all the way in until the spring clip on the bottom of the plug clicks into place, locking the plug securely into the discharge tunnel (Fig. 8). Release discharge door handle to lock top of plug.
9
Before Starting
POTENTIAL HAZARD
•
In certain conditions gasoline is extremely flammable and highly explosive.
WHAT CAN HAPPEN
•
A fire or explosion from gasoline can burn you, others, and cause property damage.
HOW TO AVOID THE HAZARD
•
Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.
•
Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4” to
1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.
•
Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark.
•
Store gasoline in an approved container and keep it out of the reach of children.
•
Never buy more than a 30-day supply of gasoline.
Oil Mix Ratio
For simplicity and best engine performance, mix the contents of one bottle of Toro 50:1 Two-Cycle Oil with
7.6 liters (two gallons) of fresh, unleaded regular gasoline.
Leaded regular gasoline may be used if unleaded regular is not available.
Toro Two-Cycle Oil is specially formulated to provide superior lubrication, make starting easy, and prolong engine life. If Toro Two-Cycle Oil is not available, mix
7.6 liters (two gallons) of gasoline and 154 ml
(5.2 ounces) of another high grade two-cycle oil that has the NMMA or BIA-TCW certification printed on the label.
50:1 Gas/Oil Mixing Chart
U.S. GALLON
Gasoline
1 gallon
2 gallons
Oil
2.6 oz.
5.2 oz.
Toro also recommends that Toro Stabilizer/Conditioner be used regularly in all Toro gasoline powered products during operation and storage seasons. Toro
Stabilizer/Conditioner cleans the engine during operation and prevents gum-like varnish deposits from forming in the engine during periods of storage.
IMPORTANT: Never use automotive oil (i.e. SAE 30,
10W30 etc.), two-cycle oil that is not certified
NMMA/BIA-TCW, or the wrong mix ratio because the engine can be damaged, and it would not be covered by the Toro warranty.
IMPORTANT: Never use methanol, gasoline containing methanol, gasohol containing more than
10% ethanol, premium gasoline, or white gas because engine fuel system damage could result.
Do not use fuel additives other than those manufactured for fuel stabilization during storage such as Toro’s stabilizer/conditioner or a similar product.
Toro’s stabilizer/conditioner is a petroleum distillate based stabilizer/conditioner. Toro does not recommend stabilizers with an alcohol base such as ethanol, methanol or isopropyl. Stabilizers should not be used to try to enhance the power or performance of machine.
Mixing Gasoline and Oil (Fig. 9)
1. Pour correct amount of gasoline into an approved gasoline container and add the correct amount of two-cycle oil.
2. Install cap on gasoline container and shake the container to mix oil and gas thoroughly.
3. Remove cap and add remaining amount of gasoline.
Note: Do not mix gasoline and oil in the product fuel tank. Oil that is at room temperature mixes easier and more thoroughly than cold oil.
1 2 3
111
1.
Add oil to small amount of gasoline
2.
Install cap and shake can to mix
Figure 9
3.
Add remaining amount of gasoline
Recycler Mower Features
The Toro Recycler mower has a new and completely different cutting concept that leaves your lawn with a bagged look without bagging clippings.
Your Recycler mower is equipped with special parts which increase your mower’s ability to cut and recut grass clippings, leaves, and other yard debris into tiny particles and inject them down into the grass. These parts are:
A. A special blade and blade stiffener
10
B. Three special “kicker plates” positioned on the underside of the mower deck in strategic positions
(Fig. 10)
1
Figure 10
1.
Kicker plates
C. A special plug which locks into the mower’s discharge tunnel (a fourth kicker is on the plug)
(Fig. 11)
1
2
757
1.
Kicker
Figure 11
2.
Plug
The blade and three kicker plates are permanent parts of your mower. The blade should be removed only for sharpening or replacement. The kickers should never be removed, unless they need to be replaced. They do not interfere with the normal bagging or optional side discharge operations of the mower.
264
WARNING
POTENTIAL HAZARD
•
Operating mower without stiffener in place could cause blade to flex, bend or break.
WHAT CAN HAPPEN
•
A broken blade could cause serious injury or death to operator or bystanders.
HOW TO AVOID THE HAZARD
•
Do not operate mower without stiffener.
The plug, however, is a removable part, just as the grass bag and optional side discharge chute are removable parts.
You cannot use the plug in combination with either the grass bag or the side discharge chute.
It is possible to mow without using the plug by closing the discharge tunnel door. However, your lawn appearance will be much more satisfactory if you use the plug as it has an additional kicker (Fig. 11) that helps drive the clippings down into the grass.
WARNING
Grass clippings and other debris can be thrown from an open discharge tunnel with enough force to cause personal injury. Never start or operate the mower unless one of the following is true:
•
The discharge tunnel plug is locked securely in discharge tunnel.
•
The grass bag is locked in place.
•
The optional side discharge chute is locked in place.
•
The discharge tunnel door is locked closed.
POTENTIAL HAZARD
•
Wet grass or leaves can cause you to slip and contact blade.
WHAT CAN HAPPEN
•
Blade contact can seriously injure you.
HOW TO AVOID THE HAZARD
•
Mow only in dry conditions.
11
Cutting Grass
•
Grass grows at different rates at different times of the year. In the heat of the summer, it is generally best to cut grass at the 44 mm (1-
#
/
4
”), 57 mm (2-
!
/
4
”) or 70 mm (2-
#
/
4
”) height-of-cut settings (Fig. 12). Only about
!
/
3
of the grass blade should be cut off. Cutting below the 44 mm (1-
#
/
4
”) setting is not recommended unless grass is sparse or it is late fall when grass growth begins to slow down.
83mm 70mm 57mm 44mm 32mm
19mm
976
Figure 12
•
When cutting grass over 15 cm (six inches) tall, you may want to first mow using the highest height-of-cut setting and a slower walking speed; then mow again at a lower setting for best lawn appearance. If grass is too long and leaves clumps on top of lawn, mower may plug and cause engine to stall.
•
Alternate mowing direction. This helps disperse clippings over lawn for even fertilization.
If the finished cut lawn appearance is unsatisfactory, try one or more of the following:
•
Sharpen the blade.
•
Walk at a slower pace while mowing.
•
Raise the height-of-cut setting on your mower.
•
Cut grass more frequently.
•
Overlap cutting swaths instead of cutting a full swath with each pass.
•
Mow across the marginal areas a second time.
•
Set height-of-cut on front wheels one notch lower than rear wheels. (example: set front wheels at 44 mm
(1-
#
/
4
”) setting and rear wheels at 57 mm (2-
!
/
4
”) setting)
Tips For Cutting Leaves
You can cut up leaves in the fall instead of bagging. If you decide to bag, the Recycler r
mower reduces the number of leaf bags you will need by finely chopping up the leaves before they are bagged. Some leaf particles will be injected back down into the soil. When spring arrives, the leaf particles will have decomposed and returned valuable nutrients to the soil.
•
Ensure leaves are dry.
•
When cutting is complete, always be sure that 50% of the lawn shows through the cut leaf cover. This may require one or more passes over the leaves.
•
For light leaf coverage, position all wheels at the same height-of-cut setting.
•
If there are more than 5” of leaves on lawn, set the front wheels one or two notches higher than the rear wheels. This makes it easier to feed leaves under mower deck.
•
Walk at a slower mowing speed if leaves are not being cut up finely enough to be hidden down in the grass.
•
If you cut up a lot of oak leaves, you might want to add lime to your grass in the spring. Lime reduces the acidity of oak leaves.
•
Mow across the marginal areas a second time.
•
Set height-of-cut on front wheels one notch lower than rear wheels. (example: set front wheels at 44 mm
(1-
#
/
4
”) setting and rear wheels at 57 mm (2-
!
/
4
”) setting)
Tips For Cutting Leaves
You can cut up leaves in the fall instead of bagging. If you decide to bag, the Recycler r
mower reduces the number of leaf bags you will need by finely chopping up the leaves before they are bagged. Some leaf particles will be injected back down into the soil. When spring arrives, the leaf particles will have decomposed and returned valuable nutrients to the soil.
•
Ensure leaves are dry.
•
When cutting is complete, always be sure that 50% of the lawn shows through the cut leaf cover. This may require one or more passes over the leaves.
•
For light leaf coverage, position all wheels at the same height-of-cut setting.
•
If there are more than 5” of leaves on lawn, set the front wheels one or two notches higher than the rear wheels. This makes it easier to feed leaves under mower deck.
•
Walk at a slower mowing speed if leaves are not being cut up finely enough to be hidden down in the grass.
12
•
If you cut up a lot of oak leaves, you might want to add lime to your grass in the spring. Lime reduces the acidity of oak leaves.
Operation
Starting, Stopping, And
Self–propelling
1. CONTROLS—Throttle, ground speed control, blade control bar, self-propel control bar and fingertip starter are on upper handle (Fig. 13).
2
3
5
1
4
6. STOPPING—To stop the self–propel drive, release the self-propel control bar. To stop engine, release blade control bar. Pull wire off spark plug if mower will be unattended or not used.
Using Discharge Tunnel Plug
1. Make sure engine is off. Open the discharge door by pulling forward on the handle and moving it rearwards
(Fig. 14). Hold the discharge door handle to prevent the spring–loaded door from closing while inserting the plug.
2. Since the plug is slightly wider than the discharge tunnel opening, you must rotate the plug clockwise slightly while inserting it (Fig. 14). Make sure the arrow on the plug decal is pointing upwards.
1 m-4325
1.
Throttle
2.
Blade control bar
3.
Self-propel control bar
Figure 13
4.
Fingertip starter
5.
Ground speed control
2. Push wire onto spark plug.
3. STARTING—Move ground speed control to neutral and throttle to (CHOKE). Cover hole in center of primer with thumb and push once. Squeeze blade control bar against handle. Pull fingertip starter out until positive engagement results; then pull vigorously to start the engine. Regulate throttle as desired when engine starts.
Note: When starting a warm engine, CHOKE may not be necessary.
4. Move ground speed control to desired speed selection
(Fig. 13).
5. TRACTION OPERATION—Squeeze self-propel control bar against handle to drive. Ground speed varies, depending on space between control bar and handle (Fig. 13).
262
1.
Plug rotated clockwise
Figure 14
3. Push the plug all the way in until the spring clip on the bottom of the plug clicks into place, locking the plug securely into the discharge tunnel (Fig. 15). Release the discharge door handle to lock the top of the plug.
4. To remove the plug, move the discharge door handle rearwards while at the same time lift up the spring clip on the bottom of the plug. When the plug is unlocked, pull it out of the discharge tunnel.
13
1
Figure 15
1.
Spring clip
Using Grass Bag
Occasionally you may wish to use the grass bag for bagging extra long grass, lush grass or leaves.
1. Stop engine and wait for all moving parts to stop.
2. Ensure discharge door handle is fully forward and pin is engaged in catch (Fig. 16).
2
1
404
DANGER
POTENTIAL HAZARD
•
Grass clippings and other objects can be thrown from an open discharge tunnel.
WHAT CAN HAPPEN
•
Objects thrown with enough force could cause serious personal injury or death to operator or bystander.
HOW TO AVOID THE HAZARD
•
Never open door on discharge tunnel when engine is running unless the grass bag, optional side discharge attachment or discharge tunnel plug is securely installed.
DANGER
POTENTIAL HAZARD
•
A worn grass bag could allow small stones and other similar debris to be thrown in operator’s or bystander’s direction.
WHAT CAN HAPPEN
•
Thrown objects can cause serious personal injury or death to operator or bystanders.
HOW TO AVOID THE HAZARD
•
Check the grass bag frequently. If it is damaged, install a new genuine TORO replacement bag.
1
3 m-1912
1.
Bag frame on retaining post
2.
Pin engaged in catch
Figure 16
3.
Handle fully forward.
Discharge door closed.
3. INSTALLING BAG—Slide hole in bag frame onto retaining post on discharge tunnel (Fig. 16). Set rear of bag frame onto lower handle.
1.
Pin locked in bag notch
Figure 17
14 m-1913
4. Pull discharge door handle forward until pin clears catch and move handle rearward until pin locks in bag notch (Fig. 17). Discharge door in mower housing is now open.
DANGER
POTENTIAL HAZARD
•
Thrown objects may result if discharge door does not close completely.
WHAT CAN HAPPEN
•
Thrown objects can cause serious personal injury or death.
HOW TO AVOID THE HAZARD
•
If discharge door cannot be closed because grass clippings clog discharge area, stop engine and gently move discharge door handle back and forth until door can be closed completely. If door still cannot be closed, remove obstruction with a stick, not your hand.
5. EMPTYING BAG—Stop engine and wait for all moving parts to stop. Raise discharge door handle and move it forward to engage the locking pin with catch
(Fig. 16). Grasp handles at front and rear of bag and lift bag off mower. Gradually tip bag forward to empty clippings.
6. To reinstall bag, repeat steps 3-4.
Adjusting Height–of–cut
The height–of–cut is adjustable from approximately
19 mm to 83 mm (3/4 to 3–1/4 inches), in 12.7 mm (1/2 inch) increments. Moving height–of–cut adjuster forward raises height–of–cut.
1. Stop the engine.
DANGER
POTENTIAL HAZARD
•
Adjusting height-of-cut levers could bring hands into contact with moving blade.
WHAT CAN HAPPEN
•
Contact with blade could cause serious personal injury.
HOW TO AVOID THE HAZARD
•
Stop engine and wait for all moving parts to stop before changing height-of-cut.
•
Do not put fingers under housing to lift mower when adjusting height-of-cut levers.
2. For easier adjustment, lift housing up so wheel is off ground. Do not place hands under deck to lift
housing. Squeeze adjusting lever toward wheel
(Fig. 18) and move it to the desired setting. Ensure pin on adjusting lever engages notch in mower housing wear plate. Adjust all wheels to the same setting.
Figure 18
225
15
Maintenance
CAUTION
POTENTIAL HAZARD
•
Engine could start accidentally.
WHAT CAN HAPPEN
•
Accidental starting of engine could cause serious injury to operator or bystanders.
HOW TO AVOID THE HAZARD
•
Pull wire off spark plug before performing any maintenance or adjustments.
Servicing Air Cleaner
Normally, clean air cleaner after every 25 operating hours.
More frequent cleaning is required when mower is operated in dusty or dirty conditions.
1. Stop engine and pull wire off spark plug (Fig. 19).
2. Lift tabs at top of air cleaner cover and pivot cover down. Clean cover thoroughly (Fig. 19).
4. Reinstall foam element and air cleaner cover.
IMPORTANT: Do not operate engine without air cleaner element because extreme engine wear and damage will likely result.
Replacing Spark Plug
Use an NGK BPMR4A spark plug or equivalent. Correct air gap is 0.81 mm (0.032”). Remove plug after every 25 operating hours and check its condition.
1. Stop engine and pull wire off spark plug.
2. Clean around spark plug and remove plug from cylinder head.
IMPORTANT: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean electrodes because engine damage could result from grit entering cylinder.
3. Set air gap at 0.81 mm (0.032”) (Fig. 20). Install correctly gapped spark plug and gasket seal. Tighten plug firmly to 13.6 N m (10 ft–lb).
0.81 mm
(0.032")
110
Figure 20
3
4
1
2
1.
Spark plug wire
2.
Primer
Figure 19
3.
Cover
4.
Foam element
3. If outside of foam element is dirty, remove it from air cleaner body (Fig. 19). Clean thoroughly.
A. WASH foam element in a solution of liquid soap and warm water. Squeeze to remove dirt, but do not twist because foam may tear. Rinse thoroughly in clear water.
B. DRY by wrapping in a clean rag. Squeeze rag and foam element to dry.
C. SATURATE element with engine oil. Squeeze element to remove excess oil and to distribute oil thoroughly. A damp element is desirable.
196
Draining Gasoline
1. Stop engine. Pull wire off spark plug.
Note: Drain gasoline from a cold engine only.
2. Remove cap from fuel tank and use pump–type syphon to drain fuel into clean gas can.
Note: This is the only procedure recommended for draining fuel.
Adjusting Throttle
Throttle control adjustment may be required if engine does not start. Whenever a new throttle control cable is installed, throttle must be adjusted.
1. Stop engine and pull wire off spark plug.
2. Move throttle control to (FAST).
3. Loosen cable clamp screw until throttle cable slides
(Fig. 21). Align holes in choke arm and throttle bracket. A small dia. pin may be inserted into aligned
16
holes to hold adjustment. Push throttle cable until throttle arm makes contact with choke arm. Tighten cable clamp. Remove pin if used.
1. Use hard wood scraper and remove carbon from end of muffler pipe (Fig. 22).
1
2
3
1.
Throttle arm
2.
Choke arm
4
Figure 21
3.
Aligned holes
4.
Throttle bracket
Cleaning Cooling System
After every 75 operating hours, clean dirt and chaff from cylinder, cylinder head fins and from around carburetor and linkage. Also remove debris from air intake slots on recoil housing. This will ensure proper cooling and best engine performance.
Cleaning Muffler And Exhaust
Port
Clean end of muffler pipe and exhaust port after every 75 hours of operation.
CAUTION
POTENTIAL HAZARD
•
Muffler and engine surface become hot when mower is in operation.
WHAT CAN HAPPEN
•
Contact with hot muffler surface could cause a burn.
HOW TO AVOID THE HAZARD
•
Clean muffler and exhaust port only after engine and muffler are cool.
780
1
1.
Screws, nuts and lockwashers
Figure 22
2
2.
Muffler pipe
202
2. Remove screw, two nuts, and lockwashers (Fig. 22).
Slide muffler off mounting pins.
3. Pull wire off spark plug. Slowly pull recoil starter so piston covers exhaust port (Fig. 23).
4. Clean carbon from exhaust port (Fig. 23) with flat, hard wood scraper.
IMPORTANT: Do not use a metal scraper or similar object to clean exhaust port because accidental damage to the piston or cylinder could easily occur.
5. Reinstall muffler with screw, (2) nuts and lockwashers
(Fig. 22). After cleaning exhaust port, make sure muffler gasket is still usable.
1.
Exhaust port
Figure 23
1
Adjusting Wheel Drive
If mower does not self–propel or has a tendency to creep forward when drive is not engaged, adjust wheel drive control knob on rear of gear box.
203
17
1. If necessary, remove grass bag.
2. ADJUSTMENT (Fig. 24)—Rotate control knob clockwise 1/2 turn if mower does not self–propel. If mower creeps forward, rotate knob 1/2 turn counterclockwise to loosen belt.
1
Adjusting Ground Speed
Control Cable
1. Move the ground speed control (Fig. 13) to N
(neutral). Make sure the control is all the way back in the N slot.
2. Loosen the clamp screw (Fig. 26).
3
2 m-4315
Figure 24
1.
Control knob
3. CHECK ADJUSTMENT—Slowly pull mower backward while self-propel control bar is gradually moved toward handle. Adjustment is correct when rear wheels stop turning and self-propel control bar is about
25 m (1 inch) from handle (Fig. 25).
4. Repeat steps 2 and 3 until properly adjusted.
2,5 CM
(1 INCH)
Figure 25 m-4323
1
4
1.
Clamp screw
2.
Shift lever
Figure 26
3.
Stop
4.
Ground speed cable m–4326
3. Push the shift lever until it is tight against the stop
(Fig. 26).
4. Pull all slack out of the ground speed cable and tighten the clamp screw.
If the mower does not drive when the ground speed control is in one of the three speed slots, make sure the ground speed control is positioned fully forward in the desired speed slot.
Inspecting/Removing/
Sharpening Blade
1. Stop engine and pull wire off spark plug.
18
2. Drain gasoline from fuel tank; refer to Draining
Gasoline, page 16.
3. Tip mower on its right side (Fig.27). Avoid rotating blade. Starting problems may result.
1 2
5. REMOVING BLADE—Grasp end of blade using a rag or thickly padded glove. Remove blade bolt, lockwasher, blade accelerator and blade (Fig. 27).
1
A
2
B
3
C
3
Figure 27
1.
Blade
2.
Blade bolt and lockwasher
3.
Blade accelerator
757
4. INSPECTING BLADE—Carefully examine blade for sharpness and wear, especially where flat and curved parts meet (Fig. 28A). Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check blade before using the mower. If a slot or wear is noticed, (Fig. 28B & C), replace blade. Refer to step 5.
Note: For best performance, install new blade before cutting season begins. During the year, file down small nicks to maintain the cutting edge.
DANGER
POTENTIAL HAZARD
•
A worn or damaged blade could break and a piece of blade could be thrown into operator’s or bystander’s area.
WHAT CAN HAPPEN
•
A thrown piece of blade could cause serious personal injury or death to operator or bystanders.
HOW TO AVOID THE HAZARD
•
Inspect blade periodically for wear or damage.
•
Replace a worn or damaged blade.
1.
Sail
2.
Flat part of blade
4
Figure 28
3.
Wear
4.
Slot formed
6. SHARPENING BLADE—Using a file, sharpen top side of blade and maintain original cutting angle
(Fig. 29). The blade will remain balanced if same amount of material is removed from both cutting edges.
1
270
153
Figure 29
1.
Sharpen at this angle only
IMPORTANT: Check balance of blade by putting it on a blade balancer. An inexpensive balancer can be purchased at a hardware store. A balanced blade stays in a horizontal position and an unbalanced blade settles to the heavy side. If blade is not balanced, file more metal off cutting edge on heavy end of blade.
7. Install sharp, balanced blade, blade accelerator, lockwasher and blade bolt. Sail part of blade must point toward top of mower housing to ensure correct installation. Tighten blade bolt to 68 N m (50 ft–lb).
19
1
WARNING
POTENTIAL HAZARD
•
Operating mower without accelerator in place could cause blade to flex, bend or break.
WHAT CAN HAPPEN
•
A broken blade could cause serious injury or death to operator or bystanders.
HOW TO AVOID THE HAZARD
•
Do not operate mower without accelerator.
Lubrication
After every 25 operating hours or when season ends, pivot arms must be lubricated.
1. Move rear wheel height–of–cut levers to center setting. Wipe grease fittings with clean rag (Fig. 30).
Install grease gun onto fitting and gently apply 2 or 3 pumps of #2 Multi–Purpose Lithium Base Grease.
Excessive pressure may damage seals.
1.
Grease fitting
Figure 31
Servicing Wheels
Removal
1. Remove capscrew, wheel spacer, and locknut mounting wheel to pivot arm (Fig. 32).
1 2 3 4 5 m-4316
1
1
1.
Grease fitting
Figure 30
Lubricating Gear Case
After every 100 operating hours, grease the gear case with
#2 Multi–Purpose Lithium Base Grease.
1. Install grease gun onto fitting thru belt cover opening
(Fig. 31). Gently apply 1–2 pumps of grease.
232
6 7
1.
Locknut (4)
2.
Wheel spacer
3.
Bearing support hub
4.
Bearing spacer
5.
Wheel half
5 7
Figure 32
8 9
209
6.
Plastic cover (rear wheels only)
7.
Lug
8.
Bearing (2)
9.
Capscrew
2. Separate wheel halves from tire by removing (4) capscrews and locknuts (Fig. 32).
Note: If bearings are to be removed from bearing support hub, remove by pressing on bearing spacer.
Assembly
1. Position tire onto (1) wheel half, aligning lugs on each
(Fig. 32).
20
2. Place bearing support hub into center hole of wheel half. Make sure legs of hub are positioned over flange of hole.
3. Place other wheel half onto bearing support hub, aligning wheel and tire lugs and mounting holes.
4. Using (2) 1/4—20 x 1.50” lg. fully threaded screws or bolts and non–locking nuts, loosely secure wheel halves together. Mount screws or bolts in opposing holes.
5. Check alignment of all parts and tighten screws, alternating from side to side for a uniform fit, until wheel halves are drawn together.
6. Install (2) capscrews and locknuts, previously removed, in remaining holes in wheel halves and tighten. Remove (2) long screws or bolts and replace them with (2) flange capscrews and locknuts.
7. Reinstall wheel to pivot arm with capscrews, spacer, and locknut. Make sure spacer is positioned between wheel hub and pivot arm.
Cleaning
Plug And Discharge Tunnel
To ensure best performance, the discharge tunnel plug must be cleaned after each use. When grass is thick and lush, clippings may collect on and around the plug; this may make plug removal difficult. After each use, remove plug from discharge tunnel and clean off all debris.
Always be sure that discharge tunnel door locks closed when handle is released. If debris prevents discharge door from locking closed, clean inside of discharge tunnel and door thoroughly.
Underside of Mower Housing
Keep underside of mower housing clean. Be especially careful to keep kickers free of debris (Fig. 33).
1
757
Figure 33
1.
Kicker plates
Washing Method
1. Position mower on a flat surface near a garden hose.
2. Attach a quick disconnect coupling (sold separately) to the end of the garden hose. Attach coupling to mower washout fitting and turn water on high (Fig. 34).
3. Start the engine.
4. Let mower run for two minutes.
5. Stop the engine.
6. Turn the water off and remove coupling from the washout fitting.
7. Restart mower and let it run for one minute to dry out moisture on the mower and its components.
8. If underside of mower deck has excessive grass build-up or packing, reconnect the hose to the washout fitting, turn the water on high and run the mower for two minutes. Stop the mower and turn off the water.
Let the mower soak for 30 minutes. Then turn the water on high again and run the mower for another two minutes.
21
1
2
Figure 34
1.
Washout fitting
2.
Quick disconnect coupling
3.
Hose
3
WARNING
POTENTIAL HAZARD
•
A broken or missing washout fitting could expose you and others to thrown objects or blade contact.
WHAT CAN HAPPEN
•
Contact with thrown debris or blade contact will cause injury or death.
HOW TO AVOID THE HAZARD
•
Replace broken or missing washout fitting immediately before using mower again.
•
Plug any hole(s) in mower with bolts and lock nuts.
•
Never put your hands or feet under the mower or through openings in the mower.
Scraping Method
If washing does not remove all debris from under deck, tip mower and scrape it clean.
1. Stop engine and pull wire off spark plug (Fig. 19).
2. Drain gasoline; refer to Draining Gasoline, page 16.
m-2858
WARNING
POTENTIAL HAZARD
•
Gasoline is extremely flammable, highly explosive and under certain conditions can cause personal injury or property damage.
WHAT CAN HAPPEN
•
Tipping mower may cause fuel leakage from carburetor or fuel tank.
HOW TO AVOID THE HAZARD
•
Avoid fuel spills by running engine dry or remove gas with hand pump, never siphon.
3. If grass bag is installed on mower, close door in mower housing and remove grass bag.
4. Tip mower on its right side (Fig. 33). Avoid rotating blade because starting problems may result.
5. Remove dirt and grass clippings with a hardwood scraper. Avoid burrs and sharp edges.
6. Turn mower upright.
7. Refill gas tank.
8. Reconnect spark plug wire.
Belt Cover
Keep area under belt cover free of debris.
1. With engine turned off, remove screws securing belt cover to mower housing (Fig. 35). Lift off cover and brush out all debris from belt area. Reinstall belt cover.
1 m-4316
1.
Belt cover
Figure 35
22
Adjusting Blade Brake
Whenever a new blade brake cable assembly is installed, an adjustment is required.
1. Stop engine and pull wire off spark plug (Fig. 19).
2. CHECK ADJUSTMENT (Fig. 36)—Move control bar toward handle until slack in wire is removed. Gap between brake lever and handle must be 4.8-6.4 mm
(3/16”-1/4”). See step 3 for adjustment.
3. (ADJUST CABLE (Fig. 37)–Loosen jam nut on brake cable. Insert 4.8-6.4 mm (3/16”-1/4”) object between brake lever and handle. Turn cable adjuster on brake cable until slack is removed. Then tighten nut.
1.
Brake lever
2
Figure 36
2.
Handle
1
4.8" Ć 6.4 mm
(3/16"Ć1/4")
2410
Preparing Mower For Storage
1. For long term storage, either drain gasoline from fuel tank or add a fuel additive to the gasoline. To drain gasoline, refer to Draining Gasoline. After fuel is drained, start engine and let it idle until all fuel is consumed and engine stops. If gasoline is not drained, gum–like varnish deposits will form and cause poor engine operation, even starting problems.
Fuel can be left in gas tank only if a fuel stabilizer, such as Toro’s Stabilizer/Conditioner, is added to gasoline before storing. Toro’s Stabilizer/Conditioner is a petroleum distillate based stabilizer/conditioner.
Toro does not recommend stabilizers with an alcohol base, such as ethanol, methanol or isopropyl. Use fuel stabilizer in recommended quantities as specified on container.
Under normal conditions, fuel stabilizers remain effective in fuel for 6–8 months.
2. Remove spark plug and pour 2 teaspoons of Toro
Two–Cycle Oil into hole in cylinder. Pull starter rope slowly to coat inside of cylinder. Install spark plug and tighten to 13.6 N m (10 ft–lb). DO NOT
REINSTALL WIRE ON SPARK PLUG.
3. Clean underside of housing: refer to Cleaning Mower
Housing, Discharge Tunnel, Belt Cover and Plug.
4. Check condition of blade: refer to
Inspecting/Removing/Sharpening Blade.
5. Tighten all nuts, bolts, and screws.
6. Clean dirt and chaff from cylinder, cylinder head fins, and blower housing. Also remove grass clippings, dirt, and grime from external parts of the engine, shrouding, and top of mower housing.
7. Clean air cleaner: refer to Servicing Air Cleaner.
8. Lubricate the pivot arms: refer to Lubrication.
9. Touch up all rusted or chipped paint surfaces. Toro
Re–Kote paint is available from an Authorized TORO
Service Dealer.
10. Store mower in a clean, dry place, out of the reach of children. Cover mower to keep it clean and protected.
1.
Cable adjuster
2.
Jam nut
2
1
3
Figure 37
3.
Brake cable m-4325
23
Accessories
For special conditions the following accessories may be purchased at your local authorized TORO Service Dealer.
1. Spark Arrestor, Part No. 81–0200—If a spark arrestor is required because of local, state, or federal regulations, it may be purchased from an Authorized
Toro Service Dealer. If mower is operated on any
California forest, brush, or grass covered land without a properly operating spark arrestor, the operator is violating state law, Section 4442 Public Resources
Code.
2. Side Discharge Kit, Model No. 59113—Installs in seconds. Rear mounted in place of the grass bag.
Disperses clippings while trimming on both sides
(Fig. 38).
1.
Side discharge chute
1
Figure 38
781
24
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