Toro Lawnmower Walk Behind Mower Operator's Manual

a
MODEL NO. 22043 — 4900001 & UP
FORM NO. 3316—374
OPERATOR’S
MANUAL
PROLINE 21” RECYCLER" ||
MOWER J
ÁN SAFETY INSTRUCTIONS
injury.
This mower meets or exceeds CPSC blade safety requirements for walk behind rotary mowers and the
B71.4—1990 specifications of the American National Standards Institute. However, improper use or
maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply
with these safety instructions and always pay attention to the safety alert symbol
CAUTION, WARNING and DANGER. Failure to comply with these instructions may result in personal
which means
WARNING: Engine exhaust contains carbon monox-
ide which is an odorless, deadly poison. Carbon
monoxide is also known to the State of California to
cause birth defects. Do not run engine indoors or in
an enclosed area.
BEFORE OPERATING
1. Read this manual carefully before operating the
mower. Become familiar with the controls and proper
use of the mower. Never allow children to operate
the mower or adults to operate it without proper
instructions.
2. Keep everyone, especially children and pets,
away from area of operation. Thoroughly inspect
area where mower will be used and remove sticks,
stones, wire, and debris.
3. Wear long pants and substantial shoes. Do not
operate mower while wearing open—toed shoes,
jewelry, loose clothing or when barefoot.
4. Always wear safety glasses or eye shields during
operation to protect eyes from foreign objects that
may be thrown from the machine.
5. Check fuel level before starting engine. Because
fuel is highly flammable, handle it carefully.
A. Use an approved container.
B. Fill fuel tank outdoors, not indoors. NEVER ADD
FUEL TO AN ENGINE THAT IS RUNNING OR
HOT.
C. Install gas cap on fuel container and gas tank,
and wipe up any spilled gasoline before starting
engine.
6. Keep all guards, shields, safety devices, grass
catcher, discharge tunnel plug or optional discharge
chute in place. Repair or replace damaged or mis-
sing parts, including decals. Check all safety devices
before each use.
7. Blade and traction drive are designed to stop
when the control bar is released. Ensure control bar
functions properly before and during each use of
mower.
WHILE OPERATING
8. Do not run engine indoors.
9. Always maintain secure footing. Keep a firm grip
on the handle and walk; never run. Never operate
mower in wet grass. Mow only in daylight or in good
artificial light.
10. Mow across the face of slopes; never up and
down. Use extreme caution when changing direction
on slopes. Do not mow excessively steep slopes.
11. Keep face, hands, and feet away from the mow-
er housing and cutter blade when the engine is run-
ning. Stay behind the handle until the engine stops
and keep clear of discharge opening at all times.
12. When bagging grass, stop engine and ensure
discharge door is closed before removing and emp-
tying bag.
13. Stop the engine and wait for all moving parts to
stop before unclogging discharge tunnel, removing
grass bag or discharge tunnel plug. Use a stick, not
your hand, to unclog discharge tunnel. Never at-
tempt to unclog the tunnel with the engine running.
14. Since the blade rotates for a few seconds after
releasing the blade control bar, stay behind the han-
dle until all moving parts stop.
15. After striking a foreign object or if mower vibrates
abnormally, stop engine and remove wire from spark
plug. Check mower for damage and make all repairs
before using mower again.
16. Stop the engine and wait for all moving parts to
stop before adjusting the height—of—cut.
17. Stop the blade when crossing a gravel driveway,
road or sidewalk.
18. Stop engine before leaving the operator’s posi-
tion—behind the handle. Disconnect wire from spark
plug if mower will be unattended or not used.
OThe Toro Company— 1993
All Rights Reserved TPS
A\ SAFETY INSTRUCTIONS
19. Do not touch engine while it is running or shortly
after it is stopped because engine will be hot enough
to cause a burn.
20. Refuel only when engine is cool.
MAINTENANCE
21. Perform only those maintenance instructions de-
scribed in this manual. If major repairs are ever
needed or if assistance is desired, contact your local
Authorized TORO Service Dealer.
22. Before mower is cleaned, inspected, serviced, or
adjusted, stop engine and disconnect wire from
spark plug. Keep wire away from plug to prevent ac-
cidental starting.
23. To ensure the mower is in safe operating condi-
tion, frequently check and keep all nuts, bolts, and
screws tight. Ensure blade nuts are tightened to
15-27 ft—Ib (20—37 N-m).
24. To reduce fire hazard, keep engine free of exces-
sive grease, grass, leaves, and accumulation of dirt.
25. Check grass catcher bag frequently for wear or
deterioration. Replace with a new bag for your
protection. Check that replacement bags comply
with original TORO recommendations or specifica-
tions.
26. Allow engine to cool before storing mower in any
enclosure. Do not store mower near any open flame
or where gasoline fumes may be ignited by a spark.
27. Do not overspeed the engine by changing gov-
ernor settings.
28. At the time of manufacture, the mower con-
formed to the safety standards in effect for rotary
mowers. To ensure best performance and continued
safety certification of the mower, use genuine TORO
replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
may result in non—conformance with the safety stan-
dards, and that could be dangerous.
A\ SAFETY DECALS AND INSTRUCTIONS
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.
Mu у ЦИН, 17.) ‚7: AND FÜR
ON DISCHARGE TUNNEL
DANGER
KEEP HANDS and FEET AWAY
ON MOWER HOUSING
(Part No. 43-8480)
IMPORTANT
GREASE PIVOT ARMS EVERY 25
HOURS OF OPERATION.
GREASE GEAR BOX INPUT SHAFT
(TWO PUMPS) EVERY 100 HOURS
OF OPERATION. SEE OPERATOR'S
MANUAL 52-2620
(Part No. 52-2620)
A DANGER
| « CONTACT WITH MOVING PARTS
OR THROWN OBJECTS CAN
SERIOUSLY INJURE.
| * DO NOT OPERATE WITHOUT ALL
COVERS AND SHIELDS IN PLACE
AND DOORS AND ATTACHMENTS
LOCKED IN PLACE.
ON BELT COVER ON ENGINE
(Part No. 62-7600)
71-9370
ON MOWER HOUSING
(Part No. 71-9370)
A\ SAFETY DECALS AND INSTRUCTIONS
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.
READ YOUR OPERATOR'S MANUAL FOR
A ZN. OPERATING AND SAFETY INSTRUCTIONS.
Lal, I|TO GETA REPLACEMENT MANUAL, SEND MODEL AND SERIAL
WARNING NUMBERS TO: THE TORO CO.. 8111 LYNDALE AVE. S.
BLOOMINGTON, MN 55420-1196
CHOKE
OPERATING INSTRUCTIONS
TO START: MOVE THROTTLE TO CHOKE. PULL ROPE.
WHEN ENGINE STARTS, MOVE THROTTLE TO FAST.
TO ENGAGE BLADE: MOVE CONTROL BAR TO RIGHT
AND LIFT TO MIDDLE POSITION.
TO DRIVE MOWER: SQUEEZE CONTROL BAR FORWARD.
TO STOP BLADE OR STOP DRIVE: RELEASE CONTROL BAR.
TO STOP ENGINE: MOVE THROTTLE TO OFF.
(3) DRIVE
MIDDLE
POSITION
ON CONTROL PANEL
(Part No. 85—6730)
DANGER}
o KEEP BYSTANDERS FROM AREA
® a vu BEING MOWED.
STOP ENGINE BEFORE LEAVING
ron OPERATOR POSITION.
=~ KEEP ALL GUARDS IN PLACE,
ON REAR OF CONTROL PANEL
(Part No. 63—9060)
TABLE OF CONTENTS
Page
Set—Uplnstructions ........................... 4
BeforeOperating .............................. 6
Recycling Tips .........110010200 02 a ea aa ana ne 7
Operating Instructions ......................... 8
Maintenance ................ iii, 11
Servicing AirCleaner ...................... 11
Replacing Spark Plug ..................... 11
Draining Gasoline ........................ 11
Adjusting Throttle ......................... 11
Cleaning Cooling System .................. 12
Cleaning Muffler Exhaust Port .............. 12
Adjusting Wheel Drive ..................... 12
Page
Inspecting/Removing/Sharpening Blade ..... 13
Lubrication .............................. 14
Lubricating GearCase .................... 14
Adjusting Blade Brake Cable ............... 15
CleaningMower .......................... 15
Cleaning Blade Brake Clutch Shield ......... 16
ServicingWheels ......................... 17
Preparing Mower For Storage .............. 18
Optional Equipment .......................... 19
Toro Service Support ............. co... 19
Product Identification ......................... 19
The Toro Total Coverage Guarantee ..... Back Page
SET-UP INSTRUCTIONS
INSTALL HANDLE (Fig. 1)
1. Mount handle to outside of mower housing, us-
ing bottom hole, with (2) 5/16—18 x 1-1/4" Ig.
capscrews, washers, and thin nylon insert locknuts.
\
BAG SUPPORT
ROD \
САР
LOCKNUT
err / HANDLE
e,
4
7
3. Slide bag support rod thru top mounting holes in
handle and secure each end with a cap locknut
(Fig. 1).
4. Use a cable tie to secure the control cables to
left handle below the bag support rod.
INSTALL GAS TANK AND FUEL LINE
1. Start self—tapping screws into bottom of gas
tank and then remove screws.
2. Hook plastic clips on front of gas tank onto gas
tank bracket (Fig. 2).
534
Figure 1
2. Secure handle latches to handle with (2)
5/16—18 x 1-1/2” Ig. capscrews, washers and nylon
insert locknuts. Position locknuts and washers on
inside of handle.
Note: Handle height is adjustable for operator com-
fort. Stand behind mower handle to gauge height. To
adjust handle height, reposition capscrews and lock-
nuts securing handle latches to handle into other
mounting holes in latches.
4
GAS TANK
PLASTIC
LL. GAS TANK
BRACKET
>
GAS TANK
RETAINER
Je
LOCKNUT /
«— TANK
| BASE
SELF-TAPPING SCREWS
537
Figure 2
SET UP INSTRUCTIONS
3. Secure gas tank to tank base with the (2) self—
tapping screws (Fig. 2). Do not overtighten screws.
4. Hook gas tank retainer onto rear of gas tank and
slide end of retainer into hole in tank bracket. Secure
retainer to tank bracket with locknut (Fig 2). Do not
overtighten locknut.
5. Remove red cap from end of fuel line and from
end of elbow fitting on gas tank. Slide end of fuel line
onto elbow fitting (Fig. 3). Secure fuel line in place
with fuel line clamp.
— y
FUEL LINE
\
9 J\
o e
ELBOW
FITTING
FUEL LINE
CLAMP
538
Figure 3
INSTALL AIR CLEANER COVER (Fig. 4)
1. Insert bottom tabs of air cleaner cover into slots.
Rotate cover upwards and snap into place.
SPARK PLUG
WIRE
PRIMER
COVER
discharge door handle to prevent the spring—loaded
door from closing while inserting the plug.
< DISCHARGE
DOOR
HANDLE
— PLUG ROTATED
a CLOCKWISE
о 2
CD a
S | ;
S
Ss
И № 4
+ Tos
Y A, AM
! 9 мох FF
262
Figure 5
2. Since the plug is slightly wider than the dis-
charge tunnel opening, rotate the plug clockwise
slightly while inserting it (Fig. 5). Make sure the ar-
row on the plug decal is pointing upwards.
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. 6).
Release discharge door handle to lock top of plug.
Figure 4
INSTALL DISCHARGE TUNNEL PLUG
1. Open the discharge door by pulling forward on
the handle and moving it rearwards (Fig. 5). Hold the
SPRING
CLIP
275
Figure 6
BEFORE OPERATING
ÁN WARNING
spilling. Wipe up any spilled gas.
DANGER: Gasoline is extremely flammable and explosive under certain conditions. Do not smoke
when handling fuel and keep fuel far away from open flames and sparks. Never buy more than a 30
day supply of gasoline. Store it in an approved container. Keep gasoline out of reach of children.
Refuel outdoors and only when engine is cold. Do not fill tank full. Fill tank to 1/4” to 1/2” (6 to 13 mm)
from top of tank, not into filler neck. This space is for expansion of fuel. Use funnel or spout to prevent
MIX GASOLINE AND OIL—50:1 RATIO
1. APPROVED OIL—For simplicity and best engine
performance, mix the contents of one bottle of Toro
50:1 Two -— Cycle Oil with two gallons of fresh, un-
leaded regular gasoline. Leaded regular gasoline
may be used if unleaded regular is not available.
Toro Two—Cycle Oil is specially formulated to pro-
vide superior lubrication, make starting easy, and
prolong engine life. if Toro Two—Cycle Oil is not avail-
able, mix two gallons of gasoline and 5.2 ounces of
another high grade two-cycle oil that has the NMMA
or BIA—TCW certification printed on the label.
IMPORTANT: YOU CAN ALSO USE TORO “EASY —
MIX” TWO- CYCLE OIL (3.2 OUNCE BOTTLE MIXED
ONE PER GALLON OF GASOLINE: this is a 40:1 ra-
tio) IN THIS TORO TWO- CYCLE ENGINE.
NEVER USE AUTOMOTIVE OIL (i.e. SAE 30, 10W30
etc.), WO- CYCLE OIL THAT IS NOT CERTIFIED
NMMA/BIA— TCW, OR THE WRONG MIX RATIO BE-
CAUSE THE ENGINE CAN BE DAMAGED, AND IT
WOULD NOT BE COVERED BY THE TORO WAR-
RANTY.
Toro also recommends that Toro Stabilizer/Condition-
er 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.
2. Mixing Gasoline and Oil (Fig. 7)—Pour correct
amount of two—cycle oil into an approved gasoline
container and add a half gallon of gasoline. Install
cap on gasoline container and shake the container
to mix oil and gas thoroughly. Remove cap and add
remaining amount of gasoline.
IMPORTANT: NEVER USE METHANOL, GAS-
OLINE CONTAINING METHANOL, GASOHOL
CONTAINING MORE THAN 10% ETHANOL, PRE-
MIUM GASOLINE, OR WHITE GAS BECAUSE EN-
GINE FUEL SYSTEM DAMAGE COULD RESULT.
DO NOT USE FUEL ADDITIVES OTHER THAN
THOSE MANUFACTURED FOR FUEL STABILIZA-
TION DURING STORAGE SUCH AS TORO'S STA-
BILIZER/CONDITIONER OR A SIMILAR PROD-
UCT. TORO’S STABILIZER/CONDITIONER IS A
PETROLEUM DISTILLATE BASED CONDITIONER/
STABILIZER. TORO DOES NOT RECOMMEND
STABILIZERS WITH AN ALCOHOL BASE SUCH
AS ETHANOL, METHANOL OR ISOPROPYL. AD-
DITIVES SHOULD NOT BE USED TO TRY TO EN-
HANCE THE POWER OR PERFORMANCE OF MA-
CHINE.
NOTE: Do not mix gasoline and oil in the product
fuel tank. Oil that is at room temperature mixes easi-
er and more thoroughly than cold oil.
50:1 GAS/OIL Mixing Chart
Gasoline
1 gallon
2 gallons
U.S. GALLON
Oil
2.6 OZ.
5.2 oz.
O
Add oil to small
amount of gasoline.
e)
can to mix.
Install cap and shake
®
Add remaining amount
of gasoline.
111
RECYCLING TIPS
GENERAL TIPS
Follow these instructions whether cutting grass or
leaves for the best cutting results and lawn appear-
ance:
e Maintain a sharp blade throughout the cutting
season. Periodically file down nicks on blade.
e Only mow dry grass or leaves. Wet grass and
leaves tend to clump on yard and may cause mower
to plug or engine to stall. They also may be slippery
to walk on and could cause you to slip and fall.
Æ WARNING
e Wet grass or leaves can cause you to slip
and contact blade.
e Blade contact can seriously injure you.
e Mow only in dry conditions.
e Set engine speed to fastest position. Maximum
horsepower provides best cutting results.
e Clean clippings or leaves from underside of
mower deck after each mowing.
e Keep engine in good running condition. Cutting
and recutting requires more horsepower.
e Clean air filter more frequently. Cutting and re-
cutting stirs up more clippings and dust which clogs
the air filter and reduces engine performance.
CUTTING GRASS
e (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 1-3/4”, 2-1/4” or 2-3/4” height-
of-cut settings (Fig. 8). Only about 1/3 of the grass
blade should be cut off. Cutting below the 1-3/4” set-
ting is not recommended unless grass is sparse or it
is late fall when grass growth begins to slow down.
3-1/4” UN 2-1/4 1-3/4 1-1/4 3/4”
SA Tr а
ne
976
Figure 8
e When cutting grass over six inches tall, you may
want to first mow using the highest height-of-cut set-
ting 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.
e 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:
e Sharpen the blade.
e Walk at a slower pace while mowing.
e Raise the height-of-cut setting on your mower.
e (Cut grass more frequently.
e Overlap cutting swaths instead of cutting a full
swath with each pass.
e Mow across the marginal areas a second time.
e Set height-of-cut on front wheels one notch lower
than rear wheels. (example: set front wheels at
1-3/4” setting and rear wheels at 2-1/4” setting)
CUTTING LEAVES
e 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.
e For light leaf coverage, position all wheels at the
same height-of-cut setting.
e [f there are more than five inches 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.
e Walk at a slower mowing speed if leaves are not
being cut up finely enough to be hidden down in the
grass.
e |f 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.
OPERATING INSTRUCTIONS
OPERATING TIPS
1. BEFORE EACH MOWING— Be sure blade brake,
self—propelled drive, and control bar function prop-
erly. When control bar is released, blade and self—
propelled drive are designed to stop. If controls are
not functioning properly, do not use mower until con-
trols are repaired.
2. SHARP BLADE— Begin each cutting season with
a sharp blade. Periodically file down nicks.
STARTING, STOPPING, AND
SELF-—PROPELLING
1. CONTROLS—Throttle control and blade/self—
propelled control bar are on upper handle (Fig. 9).
Ground speed control is located at rear of belt cover
(Fig. 10). Recoil starter is on top of engine.
2. Push spark plug wire onto spark plug.
— THROTILE
CONTROL
;
BLADE/SELF-PROPELLED
CONTROL BAR
512
NOTE: When starting a warm engine, CHOKE may
not be necessary.
4. BLADE AND TRACTION OPERATION
(Fig. 11)—When control bar is in position “A”, slide
control bar to right and raise to position “B” to en-
gage blade. Squeeze control bar against handle to
position “C” to drive. To disengage traction drive but
keep blade engaged, gradually release control bar to
position “B”. To self—propel with blade disengaged,
simply squeeze control bar against handle to posi-
tion “C”, without sliding control bar to right.
“В”
Figure 9
w
— GROUND
SPEED
CONTROL
ZU.
Figure 10
3. STARTING—Move ground speed control to neu-
tral and throttle to CHOKE. Cover hole in center of
primer with thumb and push once. Brace yourself
and mower securely by placing your foot on the top
left side of mower housing. Pull recoil starter out until
positive engagement results; then pull vigorously to
start the engine. Regulate throttle as desired when
engine starts.
8
Figure 11
5. STOPPING—To stop engine, release control bar
and move throttle to OFF. 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. 12). Hold the discharge door handle
to prevent the spring—loaded door from closing
while inserting the plug.
|
v=
NU DISCHARGE
DOOR
HANDLE
| PLUG
— ROTATED
a CLOCKWISE
§
№ В = N)
& pr В
© |
7 N E
\ NS Я
EX >
| aN o
Figure 12
OPERATING INSTRUCTIONS
2. Since the plug is slightly wider than the dis- locks in bag notch (Fig. 15). Discharge door in mow-
charge tunnel opening, you must rotate the plug er housing is now open.
clockwise slightly while inserting it (Fig. 12). Make
sure the arrow on the plug decal is pointing up-
wards. ys yd
| BAG FRAME ON PIN ENGAGED
3. Push the plug all the way in until the spring clip RETAINING POST IN CATCH
on the bottom of the plug clicks into place, locking
the plug securely into the discharge tunnel (Fig. 13).
Release the discharge door handle to lock the top of
the plug.
SPRING
HANDLE FULLY
FORWARD. DISCHARGE
DOOR CLOSED. 261
Figure 14
| 275
Figure 13
| À DANGER
4. To remove the plug, move the discharge door
handle rearwards while at the same time lift up the e Grass clippings and other objects can be
spring clip on the bottom of the plug. When the plug thrown from an open discharge tunnel.
is unlocked, pull it out of the discharge tunnel.
e Objects thrown with enough force could
Note: When grass is thick and lush, clippings may cause serious personal injury or death to
collect on and around the discharge tunnel plug. operator or bystander.
This may make plug removal difficult. Clean plug
thoroughly after each use. Refer to Cleaning Mower
Housing, Discharge Tunnel, Belt Cover, and Dis-
charge Tunnel Plug, page 15.
e Never open door on discharge tunnel when
engine is running unless the grass bag, op-
tional side discharge attachment or dis-
charge tunnel plug is securely installed.
USING GRASS BAG
Occasionally you may wish to use the grass bag for
bagging extra long grass, lush grass or leaves. A DANGER
1. Stop engine and wait for all moving parts to e A worn grass bag could allow small stones
stop. and other similar debris to be thrown in
2. Ensure discharge door handle is fully forward operator's or bystanders direction.
and pin is engaged in catch (Fig. 14). e Thrown objects can cause serious person-
inj h tand-
3. INSTALLING BAG—Slide hole in bag frame onto al injury or death to operator or bystand
retaining post on discharge tunnel (Fig. 14). Set rear ers.
of bag frame onto support rod. e Check the grass bag frequently. If it is
| LL damaged, install a new genuine TORO
4. Pull discharge door handle forward until pin replacement bag.
clears catch and move handle rearward until pin
OPERATING INSTRUCTIONS
PIN LOCKED
IN BAG NOTCH
A
<
TS <
260
, 2-3/4” 2-1/4” 1-3/4” 1-1/4”
NL
A
3-1/4 3/4”
976
Figure 16
Figure 15
A DANGER
@ DANGER
e Thrown objects may result if discharge
door does not close completely.
e Thrown objects can cause serious
personal injury or death.
e If discharge door cannot be closed
because grass clippings clog discharge
area, stop engine and gently move dis-
charge 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.
e Adjusting height-of-cut levers could bring
hands into contact with moving blade.
e Contact with blade could cause serious
personal injury.
e Stop engine and wait for all moving parts
to stop before changing height-of-cut.
e Do not put fingers under housing to lift
mower when adjusting height-of-cut levers.
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. 14). Grasp handles at front and rear of
bag and lift bag off mower. Gradually tip bag for-
ward to empty clippings.
6. Toreinstall bag, repeat steps 3-4.
ADJUSTING HEIGHT-OF-CUT
The height-of-cut is adjustable from approximately
3/4 to 3-1/4 inches (19 mm to 83 mm), in 1/2 inch
(12.7 mm) increments (Fig. 16). Moving height-of-cut
adjuster forward raises height-of-cut.
10
1. Stop the engine and wait for all moving parts to
stop.
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. 17) and move it to the desired setting. Assure
pin on adjusting lever engages notch in mower
housing wear plate. Adjust all wheels to the same
setting.
HEIGHT -OF-CUT
ADJUSTER
225
Figure 17
MAINTENANCE
A\ CAUTION
e Engine could start accidentally.
e Accidental starting of engine could
cause serious injury to operator or
bystanders.
e Pull wire off spark plug before perform-
ing 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. 18).
2. Lift tabs at top of air cleaner cover and pivot cov-
er down. Clean cover thoroughly.
3. If outside of foam element is dirty, remove it from
air cleaner body. 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 thorough-
ly 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 ele-
ment to remove excess oil and to distribute oll
thoroughly. A damp element is desirable.
REPLACING SPARK PLUG
Use an NGK BPMR4A spark plug or equivalent. Cor-
rect air gap is 0.032” (0.81 mm). Remove plug after
every 25 operating hours and check its condition.
1. Stop engine and pull wire off spark plug
(Fig. 18).
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. Setair gap at 0.032” (0.81 mm) (Fig. 19). Install
correctly gapped spark plug and gasket seal. Tight-
en plug firmly to 10 ft—1b (13.6 N-m).
0.032”
(0.813 mm)
110
FOAM
ELEMENT
SPARK PLUG
WIRE
PRIMER
COVER
Figure 18
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.
Figure 19
DRAINING GASOLINE
1. Stop engine and pull wire off spark plug
(Fig. 18).
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
(Fig. 18).
2. Move throttle control to @ (FAST) position.
3. Loosen cable clamp screw until throttle cable
slides (Fig. 20).
4. Check to see if holes in throttle bracket and
choke lever are aligned (Fig. 20). If not, follow adjust-
ment procedure in step 5.
5. ADJUSTMENT—A small diameter pin may be
inserted into aligned holes to hold adjustment. Push
throttle cable until throttle lever contacts choke lever
(Fig. 20). Tighten cable clamp screw. Remove pin if
used.
11
MAINTENANCE
THROTTLE LEVER
— CHOKE LEVER
ALIGNED N
HOLES C CABLE CLAMP
SS = uu SCREW
3 II NN
к < > THROTTLE
; 4 NEZ/ CABLE
|) —e KL
THROTTLE / lf =
BRACKET
269
5. Clean carbon from exhaust port (Fig. 22) with
flat, hard wood scraper.
IMPORTANT: Do not use a metal scraper or simi-
lar object to clean exhaust port because acciden-
tal damage to the piston or cylinder could easily
occur.
6. Reinstall muffler with screw, (2) nuts and lock-
washers (Fig. 22). After cleaning exhaust port, make
sure muffler gasket is still usable.
Figure 20
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 assure proper
cooling and optimum engine performance.
CLEANING MUFFLER AND EXHAUST
PORT
Clean end of muffler pipe and exhaust port after ev-
ery 75 hours of operation.
SCREW, NUTS,
dA CAUTION
e Muffler and engine surface become hot
when mower is in operation.
e Contact with hot muffler surface could
cause a burn.
eo Clean muffler and exhaust port only af-
ter engine and muffler are cool.
1. Stop engine and remove wire from spark plug.
2. Use hard wood scraper and remove carbon from
end of muffler pipe (Fig. 21).
3. Remove screw, two nuts, and lockwashers
(Fig. 21). Slide muffler off mounting pins.
4. Slowly pull recoil starter so piston covers exhaust
port (Fig. 22).
12
LOCKWASHERS MUFFLER
PIPE 202
Figure 21
a ©
EXHAUST
PORT
203
Figure 22
ADJUSTING WHEEL DRIVE
If mower does not self—propel or self—propels when
control bar is more than 11/2 inches from the handle,
adjust wheel drive control knob on rear of gear box.
1. Close door in mower housing and remove bag.
2. ADJUSTMENT (Fig. 23)—Rotate control knob
clockwise 1/2 turn if mower does not self—propel. If
mower creeps forward, rotate knob 1/5 turn counter-
clockwise to loosen belt.
MAINTENANCE
|
M CONTROL
KNOB
A\ CAUTION
e Engine could start accidentally.
e Accidental starting of engine could
cause serious injury to operator or
bystanders.
e Do not attempt to inspect, remove or
replace blade without first removing
the spark plug wire from spark plug
and fastening it away from accidental
contact with spark plug.
Figure 23
3. CHECK ADJUSTMENT—SIlowly pull mower
backward while control bar is gradually moved to-
ward handle. Adjustment is correct when rear
wheels stop turning and control bar is about 1—inch
from handle (Fig. 24).
BLADE BLADE NUTS
ANTI-SCALP CUP ACCELERATOR
796
X
1 INCH
513
Figure 24
INSPECTING/REMOVING/SHARPENING
BLADE
Always mow with a sharp blade. A sharp blade cuts
cleanly and without tearing or shredding the grass
blades like a dull blade.
1. Stop engine and wait for all moving parts to
stop. Pull wire off spark plug (Fig. 18).
2. Drain gasoline from fuel tank; refer to Draining
Gasoline, page 11.
3. Tip mower on its right side (Fig. 25).
Figure 25
4. INSPECTING BLADE—Carefully examine blade
for sharpness and wear, especially where flat and
curved parts meet (Fig. 26A). Since sand and abra-
sive 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. 26B & C), replace blade. Refer to step 5.
| —
o(( 3
3 C=
|
SAIL
A
FLAT PART
OF BLADE SAIL
7 YN:
hr md
— L
WEAR
NE чате
e e AN
C ARES SIS PR
MA
E"
ET
L
[ y”
SLOT 7
FORMED 270
SAIL
Figure 26
13
MAINTENANCE
Note: For best performance, install new blade before
cutting season begins. During the year, file down
small nicks to maintain the cutting edge.
A\ DANGER
e A worn or damaged blade could break
and a piece of blade could be thrown
into operator’s or bystander’s area.
e A thrown piece of blade could cause
serious personal injury or death to
operator or bystanders.
e Inspect blade periodically for wear or
damage.
e Replace a worn or damaged blade.
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. 28).
Install grease gun onto fitting and gently apply 2 or 3
pumps of #2 Multi—Purpose Lithium Base Grease.
Excessive grease pressure may damage seals.
5. REMOVING BLADE—Grasp end of blade using a
rag or thickly padded glove. Remove blade nuts,
anti—scalp cup, accelerator, and blade (Fig. 25).
6. SHARPENING BLADE—Using a file, sharpen top
side of blade and maintain original cutting angle
(Fig. 27). The blade will remain balanced if same
amount of material is removed from both cutting
edges.
GREASE
FITTING
232
SHARPEN AT
THIS ANGLE ONLY
и
„
153
Figure 27
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 unbal-
anced blade settles to the heavy side. If blade is
not balanced, file more metal off cutting edge on
heavy end of blade.
7. Reinstall sharp, balanced blade, accelerator,
anti—scalp cup, and blade nuts. Sail part of blade
must point toward top of mower housing to assure
correct installation. Tighten blade bolt to 15-27 ft—Ib
(20-37 N.m).
ÁN WARNING
e Operating mower without accelerator in place
could cause blade to flex, bend or break.
e À broken blade could cause serious injury or
death to operator or bystanders.
e Do not operate mower without accelerator.
14
Figure 28
LUBRICATING GEAR CASE
After every 100 operating hours, grease the gear
case with #2 Multi—Purpose Lithium Base Grease.
1. Remove bag.
2. Install grease gun onto fitting thru belt cover
opening (Fig. 29). Gently apply 1-2 pumps of
grease.
3. Reinstall bag.
esc F7
FITTING
Figure 29
MAINTENANCE
ADJUSTING BLADE BRAKE CABLE
Whenever a new blade brake cable assembly is in-
stalled or the belt is replaced, the blade brake cable
should be adjusted.
1. Stop engine and wait for all moving parts to
stop. Pull wire off spark plug (Fig. 18).
2. Loosen cable clamp screw until brake cable con-
duit slides (Fig. 30). Pull cable to remove slack, but
do not put tension on spring. Tighten screw to lock
adjustment in place.
CLEANING MOWER
Plug
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.
Discharge Tunnel
Always be sure that discharge tunnel door closes
securely when handle is released. If debris prevents
discharge door from closing securely, clean inside of
discharge tunnel and door thoroughly.
A WARNING
A\ WARNING
e Do not over—tighten blade brake cable.
Over —tightening could cause blade brake
to be pulled off brake drum. If brake does
not contact drum, blade will not stop rotat-
ing when control bar is released.
e A rotating blade could cause serious per-
sonal injury.
e Check the blade brake mechanism each
time brake cable is adjusted to ensure
brake is stopping blade in 3 seconds or
less.
e |f blade does not stop rotating in 3 se-
conds or less, bring unit to your local Au-
thorized Toro Service Dealer for inspection
e Grass clippings and other objects can be
thrown from an open discharge tunnel.
e Thrown objects can cause serious injury
or kill operator or bystanders.
e Never start or operate the mower unless
one of the following is true:
1. The discharge tunnel plug is locked
securely in discharge tunnel.
2. The grass bag is locked in place.
3. The optional side discharge chute is
locked in place.
4. The discharge tunnel door is locked
closed.
and repair.
CABLE CLAMP
SCREW ^^
dada do aaa
CABLE |
CONDUIT
——————
> CE
SPRING
Figure 30
Underside of Mower Housing
Keep underside of mower housing clean. Be espe-
cially careful to keep kickers free of debris (Fig. 32).
Washing Method
After every use, follow this procedure for washing
debris out from the underside of the mower housing.
1. Position mower on a flat surface near a garden
hose.
2. Start the engine.
3. Engage the blade.
4. Hold the running garden hose at handle level
and direct water to flow on ground just in front of
right rear tire (Fig. 31). The rotating blade will draw
water under the housing and wash out clippings. Let
the water run for a few minutes or until you no longer
see clippings being washed out from under housing.
15
MAINTENANCE
s)) (©
7
1
1093
Figure 31
1. Right rear wheel
5. Disengage the blade.
6. Turn off the garden hose.
7. Restart mower and let it run for a few minutes to
dry out moisture on the mower and its components.
While the engine is running, engage and disengage
the safety system and traction drive several times to
dry them out.
Scraping Method
If washing does not remove all debris from under
deck, tip mower and scrape it clean.
1. Pull wire off spark plug. Remove key from switch
on electric start models.
2. Drain gasoline from fuel tank: refer to Draining
Gasoline, page 11.
3. Tip mower on its right side (Fig. 32).
4. Remove dirt and grass clippings with a hard-
wood scraper. Avoid burrs and sharp edges.
5. Turn mower upright.
6. Refill gas tank.
7. Reconnect spark plug wire.
Belt Cover
Keep area under belt cover free of debris.
1. Remove bolts securing belt cover (Fig. 33) to
mower housing. Lift off cover and brush out all de-
bris from belt area. Reinstall belt cover.
KICKER PLATES 796
Figure 32
16
Figure 33
CLEANING BLADE BRAKE CLUTCH
SHIELD
The BBC (Blade Brake Clutch) shield should be
cleaned periodically during the mowing season and
at the end of each mowing season to ensure best
performance and to prevents parts degradation. It is
convenient to clean the BBC shield at the same time
the blade is being sharpened because the blade
needs to be removed in order to remove the BBC
shield.
1. Stop engine and wait for all moving parts to
stop. Pull wire off spark plug (Fig. 18).
2. Drain gasoline from fuel tank; refer to Draining
Gasoline, page 11.
3. Tip mower on its right side.
4. Remove (2) blade nuts, anti—scalp cup, acceler-
ator, and blade (Fig. 34).
MAINTENANCE
ANTI-SCALP CUP
ACCELERATOR
796
Figure 34
5. Loosen tabs securing BBC shield to deck by
loosening nuts or bolts on tabs (Fig. 35). Rotate tabs
180° to Move them out of the way.
BBC SHIELD
]
Ji
\
TABS AND NUTS
OE
TAB AND BOLT
796
Figure 35
‚ 6. Remove BBC shield and brush or blow all debris
from under shield and around BBC system.
7. Reinstall BBC shield. Rotate tabs 180° back into
position. Tighten nuts or bolts on tabs to secure BBC
shield to deck.
8. Reinstall blade, accelerator, anti—scalp cup, and
(2) blade nuts.
9. Turn mower upright.
10. Reinstall spark plug wire on spark plug.
SERVICING WHEELS (Fig. 36)
Removal
1. Stop engine and wait for all moving parts to
stop. Pull wire off spark plug (Fig. 18).
2. Remove capscrew, wheel spacer, and locknut
mounting wheel to pivot arm.
3. Separate wheel halves from tire by removing (4)
capscrews and locknuts.
BEARING/HUB
ASSEMBLY
LOCKNUTS
WHEEL HALF
WHEEL SPACER
~-&—
CAPSCREW
PLASTIC COVER LUG
(REAR WHEELS WHEEL HALF
ONLY) 914
Figure 36
Assembly
1. Position tire onto (1) wheel half aligning lugs on
each.
2. Place bearing/hub assembly into center hole of
wheel half. Make sure legs of hub are positioned
over flange of hole.
3. Place other wheel half onto bearing/hub assem-
bly, aligning wheel and tire lugs and mounting holes.
4. Using (2) 1/4—20 x 1.50” Ig. fully threaded
screws or bolts and non—locking nuts, loosely se-
cure 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
with (2) 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.
17
MAINTENANCE
PREPARING MOWER FOR STORAGE
1. For long term storage, either drain gasoline from
fuel tank or add a fuel stabilizer to the gasoline. To
drain gasoline, refer to Draining Gasoline, page 11.
After fuel is drained, start engine and let it idle until
all fuel is consumed and engine stops. Repeat the
starting procedure two more times to assure all gas
is removed from the engine. If gasoline is not
drained, gum—like varnish deposits will form and
cause poor engine operation, even starting prob-
lems.
Fuel can be left in gas tank only if a fuel additive,
such as Toro's Stabilizer/Conditioner, is added to
gasoline and run through engine before storing.
Toro's Stabilizer/Conditioner is a petroleum distillate
based conditioner/stabilizer. Toro does not recom-
mend stabilizers with an alcohol base, such as etha-
nol, methanol or isopropyl. Use fuel additive in rec-
ommended quantities as specified on container.
Under normal conditions, fuel additives remain effec-
tive 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
18
plug and tighten to 10 ft—Ib (13.6 N.m). DO NOT
INSTALL WIRE ON SPARK PLUG.
3. Clean underside of housing: refer to Cleaning
Mower, page 15.
4. Check condition of blade: refer to Inspecting/Re-
moving/Sharpening Blade, page 13.
5. Tighten all nuts, bolts, and screws.
6. Clean dirt and chaff from cylinder, cylinder head
fins, and blower housing. Also remove grass clip-
pings, dirt, and grime from external parts of the en-
gine, shrouding, and top of mower housing.
7. Clean BBC shield: refer to Cleaning Blade Brake
Clutch Shield, page 16.
8. Clean air cleaner: refer to Servicing Air Cleaner,
page 11.
9. Lubricate the pivot arms: refer to Lubrication,
page 14.
10. Touch up all rusted or chipped paint surfaces.
Toro Re—Kote paint is available from an Authorized
TORO Service Dealer.
11. Store mower in a clean, dry place, out of the
reach of children. Cover mower to keep it clean and
protected.
OPTIONAL EQUIPMENT
For special conditions, the following accessories
may be purchased at your local Authorized Toro Ser-
vice Dealer.
1. Side Discharge Kit, Model No. 59168—Installs
in seconds. Rear mounted in place of the grass bag
or discharge tunnel plug. Disperses clippings while
trimming on both sides (Fig. 37).
2. Spark Arrestor (Part No. 81 -0200)—If a spark
arrestor is required because of local, state, or federal
regulations, it may be purchased at your local Autho-
rized TORO Service Dealer. Clean screen after every
75 hours of operation. If mower is operated on any
California forest, brush, or grass covered land with- 7 SIDE DISCHARGE
out a properly operating spark arrestor, the operator CHUTE 781
is violating state law, Section 4442 Public Resources = —
Code. Figure 37
TORO SERVICE SUPPORT
If help — concerning safety, set—up, operation, maintenance, or troubleshooting — is ever needed, contact the
local Authorized TORO Service Dealer or Distributor. Refer to the “Yellow Pages” for assistance. In addition to
skilled service technicians, the dealer and distributor have factory approved accessories and replacement
parts. Keep your Toro all TORO. Buy genuine TORO replacement parts and accessories.
PRODUCT IDENTIFICATION
The model and serial number decal/tag is located at rear of mower housing, near the discharge door. Always
refer to specific numbers on this decal in correspondence or when replacement parts are needed.
59386 19
Consumer
@ Products
THE TORO TOTAL COVERAGE
GUARANTEE
A Full Two—Year Warranty
(Limited Warranty for Commercial Use)
What Is Covered By This Express Warranty?
The Toro Company promises to repair any TORO Product
used for residential purposes if defective in materials or work-
manship for a period of two years from the date of purchase.
The cost of parts and labor are included, but the customer
pays the transportation costs.
Transportation within a 15 mile radius of the servicing dealer
is covered under this warranty for two—stage snowthrowers,
walk behind debris equipment and all TORO Wheel Horse
riding products. Walk power mowers, single stage
snowthrowers, and other products not specifically covered,
are excluded from the transportation coverage provided by
this warranty.
What Products Are Covered By This Warranty?
This warranty applies to all gasoline powered Consumer
Products (including TORO Wheel Horse riding products).
ProLine riding products, wide area walk behind mowers and
21” Commercial mowers without blade stop controls are cov-
ered by separate warranty statements.
How About Commercial Use?
TORO Consumer Products used for commercial, institutional
or rental use are covered by a limited warranty for the follow-
ing time periods from the date of purchase:
Products Warranty Period
e (Garden Tractors
Chassis ....... 1 year limited warranty
Engine ....... 2 year limited warranty
e 21” Commercial Duty Walk Mower
with blade stop controls .... 1 year limited warranty
e Lawn Tractors, Yard Tractors, Rear Engine Riders,
3.0 and 3.5 HP Edgers,
Straight Shaft Trimmers,
and Backpack Blowers ..... 90 day limited warranty
e All Others ................. 45 day limited warranty
How Do You Get Warranty Service?
Should you feel your TORO product contains a defect in ma-
terial or workmanship, contact the dealer who sold you the
product or any Authorized TORO Service Dealer or TORO
Master Service Dealer. The Yellow Pages of your telephone
directory is a good reference source. The dealer will either
arrange service at his/her dealership or recommend another
Authorized Service Dealer who may be more convenient. You
may need proof of purchase (copy of registration card, sales
receipt, etc.) for warranty validation.
If for any reason you are dissatisfied with the Service Dealer's
analysis of the defect in materials or workmanship or if you
need a referral to a TORO Service Dealer, please feel free to
contact us at the following address:
Toro Customer Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
612-888-8801
What Must You Do To Keep The Warranty In Effect?
You must maintain your TORO Product by following the main-
tenance procedures described in the operator's manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
What Does This Warranty Not Cover?
and
How Does Your State Law Relate To This Warranty?
There is no other express warranty except the TORO Starting
Guarantee on GTS Engines. This express warranty does not
cover:
e (Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune—up parts, blade sharpening, brake and
clutch adjustments.
e Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance.
e Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non—use over three months.
e Pickup and delivery charges for distances beyond a 15 mile
radius from an Authorized TORO Service Dealer (covered
products only).
All repairs covered by this warranty must be performed by an
Authorized TORO Service Dealer using Toro approved replace-
ment parts.
Repair by an Authorized TORO Service Dealer is your sole
remedy under this warranty.
The Toro Company is not liable for indirect, incidental or
consequential damages in connection with the use of the
TORO Products covered by this warranty, including any
cost or expense of providing substitute equipment or ser-
vice during reasonable periods of malfunction or non—use
pending completion of repairs under this warranty. Some
states do not allow exclusions of incidental or consequen-
tial damages, so the above exclusion may not apply to
you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
COUNTRIES OTHER THAN THE UNITED STATES OR CANADA
Customers who have purchased TORO products exported from the United States or Canada should contact their TORO DisH
tributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with
your Distributor's service or have difficulty obtaining guarantee information, contact the TORO importer. If all other remedies
fail, you may contact us at The Toro Company.