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Toro 21in Heavy-Duty Recycler/Rear Bagger Lawn Mower Walk Behind Mower Operator's Manual
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Form No. 3359-636 Rev A 21in Heavy-Duty Recycler® / Rear-Bagger Lawn Mower Model No. 22187—Serial No. 280000001 and Up Register at www.Toro.com. Original Instructions (EN) Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1. Model and serial number plate Model No. This spark ignition system complies with Canadian ICES-002. Serial No. The enclosed Engine Owner’s Manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Introduction Figure 2 Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. 1. Safety alert symbol This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. © 2007—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 2 Contact us at www.Toro.com. Printed in the USA All Rights Reserved Contents Storage....................................................................... 25 Preparing the Fuel System................................... 25 Preparing the Engine.......................................... 25 General Information .......................................... 25 Removing the Lawn Mower from Storage............ 25 Troubleshooting......................................................... 26 Introduction................................................................. 2 Safety ........................................................................... 4 General Lawn Mower Safety ................................. 4 Training................................................................ 4 Preparation .......................................................... 4 Operation............................................................. 5 Maintenance and Storage...................................... 5 Safety and Instructional Decals ............................. 6 Setup............................................................................ 7 1 Installing the Handle.......................................... 7 2 Installing the Starter Rope .................................. 8 3 Installing the Fuel Tank and the Fuel Line.................................................................. 8 4 Installing the Discharge Tunnel Plug................... 9 5 Filling the Crankcase with Oil............................. 9 Product Overview ...................................................... 10 Controls ............................................................. 10 Operation................................................................... 10 Checking the Engine Oil Level............................ 10 Filling the Fuel Tank with Gasoline ..................... 11 Starting the Engine............................................. 12 Stopping the Engine ........................................... 13 Using the Self-propel Drive ................................ 13 Using the Discharge Tunnel Plug ........................ 13 Adjusting the Cutting Height .............................. 14 Using the Grass Bag ........................................... 14 Operating Tips ................................................... 15 Maintenance............................................................... 17 Recommended Maintenance Schedule(s) ................ 17 Lubrication............................................................. 18 Lubricating the Pivot Arms................................. 18 Lubricating the Gear Case................................... 18 Engine Maintenance............................................... 18 Servicing the Air Filter........................................ 18 Changing the Engine Oil .................................... 19 Changing the Oil Filter ....................................... 19 Servicing the Spark Plug ..................................... 20 Fuel System Maintenance ....................................... 20 Emptying the Fuel Tank and Cleaning the Fuel Filter....................................................... 20 Drive System Maintenance ..................................... 21 Adjusting the Self-propel Drive........................... 21 Controls System Maintenance................................. 21 Adjusting the Blade Brake Cable ......................... 21 Blade Maintenance ................................................. 22 Maintaining the Cutting Blade............................. 22 Cleaning ................................................................. 23 Cleaning under the Lawn Mower Housing ........... 23 Cleaning the Discharge Tunnel and Plug................................................................ 24 Cleaning under the Belt Cover............................. 24 3 Training Safety • Read the Operator’s Manual and other training material. This lawn mower meets or exceeds the CPSC blade safety requirements for walk-behind rotary lawn mowers and the B71.4 specifications of the American National Standards Institute in effect at the time of production. • If the operator(s) or mechanic(s) cannot read English it is the owner’s responsibility to explain this material to them. • Become familiar with the safe operation of the equipment, operator controls, and safety signs. Improperly using or maintaining this lawn mower can result in injury. To reduce the potential for injury, comply with these safety instructions. • All operators and mechanics should be trained. The owner is responsible for training the users. Toro designed and tested this lawn mower for to offer reasonably safe service; however, failure to comply with the following instructions may result in personal injury. • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property. Engine exhaust contains carbon monoxide, an odorless, deadly poison that can kill you. Preparation Do not run the engine indoors or in an enclosed area. • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. To ensure maximum safety, best performance, and to gain knowledge of the product, it is essential that you and any other operator of the lawn mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the safety alert symbol (Figure 2) which means Caution, Warning, or Danger—“personal safety instruction.” Read and understand the instruction because it has to do with safety. Failure to comply with the instruction may result in personal injury. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. General Lawn Mower Safety • Use extra care when handling gasoline and other fuels. • Only use accessories and attachments approved by the manufacturer. • Wear appropriate clothing, including safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. – They are flammable and vapors are explosive. This lawn mower is capable of amputating hands and feet and of throwing objects. Failure to observe the following safety instructions could result in serious injury or death. – Use only an approved container. The following instructions are from the ANSI/OPEI B71.4–2004 standard. – Do not smoke. – Never remove gas cap or add fuel when engine is running. – Never refuel or drain the machine indoors. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. 4 Operation Maintenance and Storage • Never run an engine in an enclosed area. • Wait for all movement to stop before adjusting, cleaning or repairing. • Only operate in good light, keeping away from holes and hidden hazards. • Clean grass and debris from cutting unit, muffler, and engine to help prevent fires. • Be sure all drives are in neutral and parking brake is engaged before starting engine. • Clean up oil or fuel spillage. • Only start engine from the operator’s position. • Let engine cool before storing and do not store near flame. • Be sure of your footing while using pedestrian controlled equipment, especially when backing up. • Do not store fuel near flames or drain indoors. • Walk, don’t run. • Never allow untrained personnel to service machine. • Never operate on wet grass. Reduced footing could cause slipping. • Use care when checking blade. • Wrap the blade or wear gloves, and use caution when servicing. • Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. • Only replace blade. Never straighten or weld them. • Use caution while operating near drop-offs. • Keep hands and feet away from moving parts. • Slow down and use caution when making turns and when changing directions on slopes. • If possible, do not make adjustments with the engine running. • Never raise deck with the blades running. • Keep all parts in good working condition and all hardware tightened. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher. • Replace all worn or damaged decals. • Do not change the engine governor setting or overspeed the engine. • Stop on level ground and shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute. • Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs. • Use care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. 5 Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Manufacturer’s Mark 68-7410 1. Indicates the blade is identified as a part from the original machine manufacturer. 74-1970 1. Transmission speeds 2. Neutral 98-4387 1. Warning—wear hearing protection. 39-5770 106-0690 110-4989 6 Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Use Qty. Handle Bolt (5/16 x 1-1/4 inches) Washer Thin locknut (5/16 inch) Bolt (5/16 x 1-1/2 inches) Locknut (5/16 inch) Bag support rod Cap locknut Cable tie 1 2 4 2 2 2 1 2 1 Install the handle. No parts required – Install the starter rope. Self-tapping screw Fuel tank 2 1 Install the fuel tank and fuel line. Discharge tunnel plug 1 Install the discharge tunnel plug. No parts required – Fill the crankcase with oil. Note: Determine the left and right sides of the machine from the normal operating position. x 1-1/4 inches), washers, and thin locknuts (5/16 inch) (Figure 3). 1 Installing the Handle Parts needed for this procedure: 1 Handle 2 Bolt (5/16 x 1-1/4 inches) 4 Washer 2 Thin locknut (5/16 inch) 2 Bolt (5/16 x 1-1/2 inches) 2 Locknut (5/16 inch) 1 Bag support rod 2 Cap locknut 1 Cable tie Figure 3 1. Handle latch 2. Bag support rod 3. Cap locknut (2) 4. Handle 5. Bolt (5/16 x 1-1/2 inches) 6. Bolt (5/16 x 1-1/4 inches) 2. Secure the handle latches to the handle with 2 bolts (5/16 x 1-1/2 inches), washers, and locknuts (5/16 inch) (Figure 3). Note: You can adjust the handle height for comfortable operation. Stand behind the handle to determine the height. To adjust the handle height, position the cap screws and the locknuts that secure Procedure 1. Mount the handle to the outside of the lawn mower housing (using the bottom hole) with 2 bolts (5/16 7 the handle latches to the handle into the other mounting holes in the latches. 3 3. Slide the bag support rod through the second from the top mounting holes in the handle and secure each end with a cap locknut (Figure 3). Installing the Fuel Tank and the Fuel Line 4. Use a cable tie to secure the control cables to the left handle below the bag support rod. Parts needed for this procedure: 2 Installing the Starter Rope 2 Self-tapping screw 1 Fuel tank Procedure 1. Slide the end of the fuel line onto the elbow fitting (Figure 5). No Parts Required Procedure Pull the starter rope through the rope guide on the handle (Figure 4). Figure 4 1. Starter rope Figure 5 2. Rope guide 1. Fuel tank 2. Elbow fitting Note: To make the rope easier to install, squeeze the control bar on the handle. 3. Fuel line 4. Fuel line clamp 2. Secure the fuel line in place with the fuel line clamp (Figure 5). 3. Slide the plastic clips on the front of the fuel tank onto the fuel tank mount (Figure 6). 8 Figure 7 1. Discharge door handle 2. Plug, rotated clockwise 2. Since the plug is slightly wider than the discharge tunnel opening, rotate the plug clockwise slightly while inserting it (Figure 7). Figure 6 Note: Ensure that the arrow on the plug decal points upward. 1. Plastic clip (2) 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 (Figure 8). 4. Secure the bottom of the fuel tank to the fuel tank bracket by installing the self-tapping screws from the bottom. Torque the screws to 40 to 50 in-lb (4.5 to 5.6 Nm). 4 Installing the Discharge Tunnel Plug Figure 8 Parts needed for this procedure: 1 1. Spring clip Discharge tunnel plug 4. Release the discharge door handle to lock the top of the plug. Procedure 1. Open the discharge door by pulling forward on the handle and moving it rearward (Figure 7). Hold the discharge door handle to prevent the spring-loaded door from closing while you insert the plug. 5 Filling the Crankcase with Oil No Parts Required Procedure The engine crankcase is shipped without oil. You must fill it with approximately 29 ounces (0.85 l) of oil before starting the engine. Refer to Checking the Engine Oil Level for oil specifications and instructions. 9 Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Each time before you mow, make sure that the self-propel drive and the blade control bar operate properly. When you release the blade control bar, the blade and self-propel drive should stop. If they do not, contact an Authorized Service Dealer. This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Figure 9 1. 2. 3. 4. 5. Handle Throttle control lever Grass bag Fuel tank Oil filter 6. 7. 8. 9. 10. Air filter Cutting height lever Spark plug Oil fill/dipstick Blade control bar Wear hearing protection when operating this machine. Controls Figure 11 1. Warning—wear hearing protection. Checking the Engine Oil Level Service Interval: Before each use or daily Initially, fill the crankcase with 29 ounces (0.85 liters) of oil. Use only high-quality SAE 30 or SAE 10W30 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ. Figure 10 1. Blade control bar 2. Throttle control lever 3. Recoil starter handle Oil Capacity With oil filter 29 ounces (0.85 L) Without oil filter 22 ounces (0.65 L) Before each use, ensure that the oil level is between the Add and Full marks on the dipstick (Figure 12). 10 Filling the Fuel Tank with Gasoline For best results, use clean, fresh, lead-free gasoline with an octane rating of 87 or higher. To ensure freshness, purchase only the quantity of gasoline that you expect to use in 30 days. Using unleaded gasoline results in fewer combustion deposits and longer engine life. You may use leaded gasoline if unleaded gasoline is not available. Important: Do not add oil to the gasoline. Important: Do not use methanol, gasoline containing methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas. Using these fuels can damage the engine’s fuel system. Important: Do not use gasoline that has been stored since the last mowing season or longer. Figure 12 1. Dipstick 2. Full 3. Add 1. Move the lawn mower to a level surface. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 2. Clean around the dipstick (Figure 12). 3. Remove the dipstick by rotating the cap counterclockwise and pulling it out. • Fill the fuel tank outdoors, in an open area, and when the engine is cold. Wipe up any gasoline that spills. Note: When the crankcase is empty, pour about 3/4 of the crankcase capacity of oil in the crankcase. 4. Wipe the dipstick clean with a clean cloth. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows the gasoline to expand. 5. Insert the dipstick into the filler neck, then remove it. Note: To ensure an accurate oil level reading, you must fully install the dipstick. • Never smoke when handling gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 6. Read the oil level on the dipstick (Figure 12). 7. If the oil level reading is below the Add mark on the dipstick, slowly pour only enough oil into the filler hole to raise the oil level to the Full mark on the dipstick. • Store gasoline in an approved fuel container and keep it out of the reach of children. • Never buy more than a 30-day supply of gasoline. Important: Do not overfill the crankcase with oil and run the engine; engine damage will result. Drain the excess oil until the oil level on the dipstick reads Full. 8. Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight. 11 When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. A fire or explosion from gasoline can burn you and others and damage property. • Always place gasoline containers on the ground and away from your vehicle before filling. • Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. • When practical, remove gasoline-powered equipment from the truck or trailer and refuel the equipment with its wheels on the round. Figure 13 3. Air cleaner 4. Spark plug 1. Oil fill/dipstick 2. Fuel tank cap • If this is not possible, then refuel such equipment on a truck or trailer from a portable container, not from a gasoline dispenser nozzle. 2. Remove the cap from the tank. 3. Fill the fuel tank with unleaded gasoline to within 1/4 to 1/2 inch (6 to 13 mm) from the top of the tank. Do not fill into the filler neck. • If you must use a gasoline dispenser nozzle, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Important: Do not fill the tank more than 1/4 inch (6 mm) from the top of the tank because the gasoline must have room to expand. 4. Install the fuel tank cap and wipe up any spilled gasoline. Use a fuel stabilizer/conditioner regularly during operation and storage. A stabilizer/conditioner cleans the engine during operation and prevents gum-like varnish deposits from forming in the engine during periods of storage. Starting the Engine Important: Do not use fuel additives other than a fuel stabilizer/conditioner. Do not use fuel stabilizers with an alcohol base such as ethanol, methanol, or isopropanol. 1. 2. 3. 4. 1. Clean around the fuel tank cap (Figure 13). Connect the wire to the spark plug (Figure 13). Open the fuel valve (Figure 23). Move the throttle control to the Choke position. Move the ground speed control to the Neutral (N) position (Figure 14). Figure 14 1. Ground speed control 12 5. Pull the starter handle lightly until you feel resistance, then pull it sharply. 6. Regulate the throttle and the ground speed control as desired when the engine starts. the Run/Drive position; this can damage the transmission. Move the blade control bar to the Run/Shift position (Figure 16) when you change the ground speed. Note: You can vary the ground speed by increasing or decreasing the distance between the control bar and the handle. Lower the control bar to slow the lawn mower when making a turn or if the lawn mower is moving too fast for you. If you lower the control bar too far, the lawn mower stops self-propelling. Squeeze the control bar closer to the handle to increase the ground speed. When you hold the control bar tight against the handle, the lawn mower self-propels at the maximum ground speed. Move the ground speed control to the Neutral (N) position when you use the lawn mower for trimming and whenever you leave the lawn mower. Note: If the engine fails to start after 3 pulls, repeat steps 3 through 6. Stopping the Engine 1. Release the blade control bar and move the throttle control to the Off position. 2. Disconnect the wire from the spark plug if you do not use the lawn mower or if you leave it unattended. Using the Self-propel Drive The lawn mower has 3 ground speeds: 1 is slow, 2 is medium, and 3 is fast. the ground speed control is located at the rear of the belt cover (Figure 15). Using the Discharge Tunnel Plug 1. Stop the engine and wait for all moving parts to stop. 2. Insert the plug; refer to Installing the Discharge Tunnel Plug. 3. To remove the plug, move the discharge door handle rearward and lift up the spring clip on the bottom of the plug. When the plug is unlocked, pull it out of the discharge tunnel. Figure 15 1. Ground speed control 1. Move the ground speed control to the Neutral (N) position. 2. Start the engine. 3. Squeeze the blade control bar against the handle to the Run/Drive position (Figure 16). Note: When grass is thick and lush, clippings may collect on and around the discharge tunnel plug. This may make removing the plug difficult. Clean the plug thoroughly after each use. Figure 16 1. Run/Drive position 2. Run/Shift position 3. Stop position Note: Do not shift speeds while you squeeze the blade control bar against the handle in 13 Adjusting the Cutting Height Each wheel is adjusted individually with a wheel height adjustment lever. Cutting heights are 1 inch (25 mm), 1-1/2 inches (38 mm), 2 inches (51 mm), 2-1/2 inches (64 mm), 3 inches (76 mm), and 3-1/2 inches (89 mm). Adjusting the cutting height levers could bring your hands into contact with a moving blade and result in serious injury. Figure 18 1. Bag frame on retaining post 2. Pin engaged in catch • Stop the engine and wait for all movement to stop before adjusting the cutting height. • Do not put your fingers under the housing when adjusting the cutting height. 3. Handle fully forward; discharge door closed 3. Slide the hole in the bag frame onto the retaining post on the discharge tunnel (Figure 18). 1. Pull the wheel height adjustment lever toward the wheel (Figure 17) and move it to the desired setting. 4. Set the rear of the bag frame onto the bag support rod. 5. Pull the discharge door handle forward until the pin clears the catch, and move the handle rearward until the pin locks in the bag notch (Figure 19). Figure 17 1. Wheel height adjustment lever 2. Release the wheel height adjustment lever and seat it securely in the notch. Figure 19 3. Adjust all the wheels to the same cutting height setting. 1. Pin locked in bag notch Using the Grass Bag Note: The discharge door in the lawn mower housing is now open. Occasionally, you may wish to use the grass bag for bagging extra long grass, lush grass, or leaves. Installing the Grass Bag 1. Stop the engine and wait for all moving parts to stop. 2. Ensure that the discharge door handle is fully forward and that the pin is engaged in the catch (Figure 18). 14 Mowing with the Grass Bag Operating Tips General Tips • Review the safety instructions and read this manual carefully before operating the lawn mower. A worn grass bag could allow small stones and other similar debris to be thrown in the operator’s or bystander’s direction and result in serious personal injury or death to the operator or bystanders. • Clear the area of sticks, stones, wire, branches, and other debris that the blade could hit and throw. • Keep everyone, especially children and pets, away from the area of operation. Check the grass bag frequently. If it is damaged, install a new Toro replacement bag. • Avoid striking trees, walls, curbs, or other solid objects. Never deliberately mow over any object. Removing the Grass Bag • If the lawn mower strikes an object or starts to vibrate, immediately stop the engine, disconnect the wire from the spark plug, and examine the lawn mower for damage. 1. Stop the engine and wait for all moving parts to stop. 2. Raise the discharge door handle and move it forward to engage the pin with the catch (Figure 18). • Maintain a sharp blade throughout the cutting season. Periodically file down nicks on the blade. 3. Grasp the handles at the front and the rear of the bag and lift the bag off the lawn mower. • Replace the blade when necessary with an original Toro replacement blade. 4. Gradually tip the bag forward to empty the clippings. • Mow only dry grass or leaves. Wet grass and leaves tend to clump on the yard and can cause the lawn mower to plug or the engine to stall. 5. To install the bag, refer to Installing the Grass Bag. If the discharge door does not close completely, the lawn mower could throw objects, causing serious personal injury or death. Wet grass or leaves can cause serious injury if you slip and contact the blade. If you cannot close the door because the grass clippings clog the discharge area, stop the engine and gently move the discharge door handle back and forth until you can close the door completely. If you still cannot close the door, remove the obstruction with a stick, not your hand. Mow only in dry conditions. • Clean the underside of the lawn mower deck after each mowing. See Cleaning the Underside of the Lawn Mower Housing. • Keep the engine in good running condition. • Set the engine speed to the fastest position for the best cutting results. The lawn mower can throw grass clippings and other objects through an open discharge tunnel. Objects thrown with enough force could cause serious personal injury or death to the operator or bystander. Never open the door on the discharge tunnel when the engine is running. 15 Cutting Leaves • After cutting the lawn, ensure that half of the lawn shows through the cut leaf cover. You may need to make more than one pass over the leaves. Operating a lawn mower with its engine running at a speed greater than the factory setting can cause the lawn mower to throw a part of the blade or engine into the operator’s or bystander’s area and result in serious personal injury or death. • For light leaf coverage, set all the wheels at the same cutting height setting. • If there are more than 5 inches (12.7 cm) of leaves on the lawn, set the front cutting height 1 or 2 notches higher than the rear cutting height. This makes it easier to feed the leaves under the lawn mower deck. – Do not change the engine speed setting. – If you suspect the engine speed is faster than normal, contact an Authorized Service Dealer. • Slow down your mowing speed if the lawn mower does not cut the leaves finely enough. • Clean the air filter frequently. Mulching stirs up more clippings and dust which clogs the air filter and reduces engine performance. • If you mow over oak leaves, you can add lime to the grass in the spring to reduce the acidity of the oak leaves. Cutting Grass • Grass grows at different rates at different times of the year. In the summer heat, it is best to cut grass at the 2 inch (51 mm), 2-1/2 inch (64 mm), or 3 inch (76 mm) cutting height settings. Cut only about a third of the grass blade at a time. Do not cut below the 2 inch (51 mm) setting unless the grass is sparse or it is late fall when grass growth begins to slow down. • When cutting grass over 6 inches (15 cm) tall, first mow at the highest cutting height setting and walk slower; then mow again at a lower setting for the best lawn appearance. If the grass is too long and the leaves clump on top of the lawn, the lawn mower may plug and cause the engine to stall. • Alternate the mowing direction. This helps disperse the clippings over the lawn for even fertilization. If the finished lawn appearance is unsatisfactory, try one or more of the following: • Sharpen the blade. • Walk at a slower pace while mowing. • Raise the cutting height on your lawn mower. • Cut the grass more frequently. • Overlap cutting swaths instead of cutting a full swath with each pass. • Set the cutting height on the front wheels one notch lower than the rear wheels. For example, set the front wheels at 2 inches (51 mm) and the rear wheels at 2-1/2 inches (64 mm). 16 Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil without the oil filter. Before each use or daily • • • • • Check the engine oil level. Ensure that the engine stops within 3 seconds after releasing the blade control bar. Inspect the mower blades for wear or damage. Clean under the lawn mower housing. Clean the discharge tunnel and plug. Every 25 hours • Lubricate the pivot arms. • Clean the foam pre-cleaner (more frequently in dusty conditions). Every 50 hours • Change the engine oil (more often in dusty conditions). • Check the fuel hose and replace it if necessary. • Clean under the belt cover. Every 100 hours • • • • • • • Every 300 hours • Replace the paper air filter (more frequently in dusty conditions). Yearly or before storage Lubricate the gear case. Change the engine oil and oil filter. Check the spark plug. Clean the fuel filter. Adjust the self-propel drive. Adjust the blade brake cable. Clean the air cooling fins. • Empty the fuel tank. Important: Refer to your Engine Operator’s Manual for additional maintenance procedures. If you leave the wire on the spark plug, someone could accidently start the engine and seriously injure you or other bystanders. Disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidently contact the spark plug. 17 Lubrication Engine Maintenance Lubricating the Pivot Arms Servicing the Air Filter Service Interval: Every 25 hours Service Interval: Every 25 hours—Clean the foam pre-cleaner (more frequently in dusty conditions). 1. Move the rear wheel cutting height levers to the center setting. Every 300 hours—Replace the paper air filter (more frequently in dusty conditions). 2. Wipe the grease fittings with a clean rag (Figure 20). Important: Do not operate the engine without the air filter assembly; extreme engine damage will occur. 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug (Figure 13). 3. Remove the cover and clean it thoroughly (Figure 22). Figure 20 1. Grease fitting 3. Install a grease gun onto the fitting and gently apply 2 or 3 pumps of #2 multi-purpose lithium-base grease. Important: Excessive grease pressure may damage the seals. Lubricating the Gear Case Service Interval: Every 100 hours 1. Remove the grass bag. 2. Wipe the grease fittings with a clean rag (Figure 21). Figure 22 1. Cover 2. Paper air filter 3. Air filter base 4. Remove and inspect the paper air filter (Figure 22), and discard it if it is excessively dirty. Important: Do not try to clean a paper filter. Figure 21 1. Belt cover 5. Remove the foam pre-cleaner and wash it with a mild detergent and water, then blot it dry (Figure 22). 2. Grease fitting 6. Install the foam pre-cleaner onto the paper air filter. 3. Install a grease gun onto the fitting through the belt cover opening (Figure 21). 7. Install the air filter assembly. Note: Install a new paper air filter if you discarded the old one. 4. Gently apply one to 2 pumps of #2 multi-purpose lithium-base grease. 5. Install the grass bag. 8. Install the cover. 18 Changing the Engine Oil Changing the Oil Filter Service Interval: After the first 8 hours Service Interval: Every 100 hours 1. Run the engine to warm the oil. Every 50 hours 1. Run the engine to warm the engine oil. Note: Warm oil flows better and carries more contaminants. Oil may be hot after the engine has been run, and contact with hot oil can cause severe personal injury. Avoid contacting the hot engine oil when you drain it. Oil may be hot after engine has been run, and contact with hot oil can cause severe personal injury. 2. Stop the engine and wait for all moving parts to stop. Avoid contacting the hot engine oil when you drain it. 3. Disconnect the wire from the spark plug (Figure 13). 4. Drain the engine oil; refer to Changing the Engine Oil. 2. Stop the engine and wait for all moving parts to stop. 5. Place a rag under the oil filter to catch any oil that may leak out as you remove the filter. 3. Disconnect the wire from the spark plug (Figure 13). 4. Place a suitable drain pan under the right side of the lawn mower. 6. Remove the oil filter. 5. Remove the dipstick by rotating the cap counterclockwise and pulling it out. 6. Raise the left side of the lawn mower to drain the oil into the drain pan. Note: You can also remove the oil from the crankcase using an oil extractor. 7. Lower the left side of the lawn mower. 8. Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight. Figure 23 9. Recycle the used oil according to local codes. 1. Fuel valve 10. Fill the crankcase to the Full line on the dipstick with fresh oil. Refer to the Filling the Crankcase with Oil. 2. Oil filter 7. Use your finger to coat the gasket on the new filter with oil (Figure 24). 11. Wipe up any spilled oil. Figure 24 1. Gasket 19 Fuel System Maintenance 8. Install the new filter and hand tighten it 2/3 turn only. 9. Fill the crankcase to the Full line on the dipstick with fresh oil Refer to Filling the Crankcase with Oil. 11. Run the engine for about 3 minutes. Emptying the Fuel Tank and Cleaning the Fuel Filter 12. Stop the engine, wait for all moving parts to stop, and check for oil leakage around the filter. Service Interval: Every 50 hours—Check the fuel hose and replace it if necessary. 10. Connect the wire to the spark plug. 13. Add oil to compensate for the oil in the oil filter. Refer to Checking the Engine Oil Level. Every 100 hours—Clean the fuel filter. 14. Recycle the used oil filter according to local codes. Yearly or before storage—Empty the fuel tank. Servicing the Spark Plug The fuel filter (screen) element is located inside the fuel tank. Service Interval: Every 100 hours 1. Stop the engine and wait for it to cool down. Use an NGK BPR5ES spark plug or equivalent. Important: Drain gasoline from a cold engine only. 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug (Figure 13). 2. Disconnect the wire from the spark plug (Figure 13). 3. Clean around the spark plug. 3. Close the fuel valve (Figure 23). 4. Remove the spark plug from the cylinder head. 4. Disconnect the fuel line by loosening the tube clamp at the carburetor. Important: Replace a cracked, fouled, or dirty spark plug. Do not clean the electrodes because grit entering the cylinder can damage the engine. 5. Open the fuel valve. 6. Drain the gasoline completely from the tank and fuel line into an approved fuel container. 5. Set the gap on the plug to 0.030 in. (0.76 mm) (Figure 25). 7. Remove the fuel tank from the mower. 8. Close the fuel valve. 9. Pour a small amount of fuel in the fuel tank, move the fuel around in the tank, and pour it out into an approved fuel container. 10. Install the fuel tank and fuel line; refer to Installing the Fuel Tank and the Fuel Line. Figure 25 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) 6. Install the spark plug and the gasket seal. 7. Torque the plug to 17 ft-lb (23 N⋅m). 8. Connect the wire to the spark plug. 20 Drive System Maintenance Controls System Maintenance Adjusting the Self-propel Drive Adjusting the Blade Brake Cable Service Interval: Every 100 hours Service Interval: Before each use or daily—Ensure that the engine stops within 3 seconds after releasing the blade control bar. If the lawn mower does not self-propel or has a tendency to creep forward when the control bar is more than 1-1/2 inches (3.8 cm) from the handle, adjust the wheel drive control knob on the rear of the gear box. Every 100 hours—Adjust the blade brake cable. 1. Close the door in the lawn mower housing and remove the grass bag. Whenever you install a new blade brake cable assembly, adjust it. 2. Rotate the control knob clockwise a half turn if the lawn mower does not self-propel. If the lawn mower creeps forward, rotate the knob a half turn counterclockwise to loosen the belt (Figure 26). 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug. 3. Check the adjustment of the cable by moving the blade control bar toward the handle until you remove the slack in the cable. Note: The gap between the brake lever and the handle must be between 3/16 and 1/4 inch (5 and 6 mm). to adjust the cable. 4. To adjust the cable, do the following: A. Loosen the nut on the cable bracket (Figure 28). Figure 26 1. Control knob 3. Slowly pull the lawn mower backward while you gradually move the control bar toward the handle. Note: The adjustment is correct when the rear wheels stop turning and the control bar is about one inch (2.5 cm) from the handle (Figure 27). Figure 28 1. Handle 2. Brake lever 3. 3/16 to 1/4 inch (5 to 6 mm) 4. Cable bracket B. Insert a 3/16 to 1/4 inch (5 to 6 mm) object between the brake lever and the handle (Figure 16). Figure 27 1. 1 inch (2.5 cm) C. Pull down on the cable conduit until you remove the slack from the wire (Figure 16). D. Tighten the nut (Figure 16). 21 Blade Maintenance Note: For the best performance, install a new blade before the cutting season begins. During the year, file down any small nicks to maintain the cutting edge. Maintaining the Cutting Blade Always mow with a sharp blade. A sharp blade cuts cleanly and without tearing or shredding the grass blades. A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug. 3. Drain the gasoline from the fuel tank; refer to Emptying the Fuel Tank and Cleaning the Fuel Filter. • Inspect the blade periodically for wear or damage. 4. Tip the mower onto its right side (Figure 29). • Replace a worn or damaged blade. Removing the Blade Grasp the end of the blade using a rag or a thickly padded glove. Remove the blade bolt, the lock washer, the accelerator, and the blade (Figure 29). Sharpening the Blade File the top side of the blade to maintain its original cutting angle (Figure 31A) and inner cutting edge radius (Figure 31B). The blade will remain balanced if you remove the same amount of material from both cutting edges. Figure 29 1. Blade 3. Accelerator 2. Blade bolt and lock washer Inspecting the Blade Service Interval: Before each use or daily Carefully examine the blade for sharpness and wear, especially where the flat and the curved parts meet (Figure 30A). Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the lawn mower. If you notice a slot or wear (Figure 30B and Figure 30C), replace the blade; refer to Removing the Blade. Figure 31 1. Sharpen at this angle only. 2. Maintain the original radius here. Balancing the Blade 1. Check the balance of the blade by placing the center hole of the blade over a nail or screwdriver shank clamped horizontally in a vise (Figure 32). Figure 32 Figure 30 1. Sail 2. Flat part of the blade 3. Wear 4. Slot formed 22 Cleaning Note: You can also check the balance using a commercially manufactured blade balancer. 2. If either end of the blade rotates downward, file that end (not the cutting edge or the end near the cutting edge). The blade is properly balanced when neither end drops. Cleaning under the Lawn Mower Housing Installing the Blade To ensure the best performance, keep the underside of the lawn mower housing clean. Be especially careful to keep the kickers free of debris (Figure 33). Service Interval: Before each use or daily 1. Install a sharp, balanced Toro blade, the accelerator, the lock washer, and the blade bolt. The sail of the blade must point toward the top of the lawn mower housing for proper installation. Torque the blade bolt to 50 ft-lb (68 N·m). Operating the lawn mower without the accelerator in place can cause the blade to flex, bend, or break, resulting in serious injury or death to the operator or bystanders. Figure 33 Do not operate the lawn mower without the accelerator. 1. Kickers 2. Return the lawn mower to its upright position. Washing Method 3. Connect the wire to the spark plug. 1. Position the lawn mower on a flat concrete or asphalt surface near a garden hose. 2. Start the engine. 3. Hold the running garden hose at handle level and direct the water to flow on the ground just in front of the right rear tire (Figure 34). Figure 34 1. Right rear wheel Note: The blade will draw in water and wash out clippings. Let the water run until you no longer see clippings being washed out from under the housing. 4. Stop the engine and wait for all moving parts to stop. 5. Turn off the water. 6. Start the lawn mower and let it run for a few minutes to dry out the moisture on the lawn mower and its components. 23 Scraping Method If washing does not remove all debris from under the lawn mower, scrape it clean. 1. Disconnect the wire from the spark plug (Figure 13). 2. Drain the fuel from the fuel tank. Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter. Grass clippings and other objects can be thrown from an open discharge tunnel and cause serious injury or kill the operator or bystanders. Never start or operate the lawn mower unless one of the following is true: • The discharge tunnel plug is locked securely in the discharge tunnel. Tipping the lawn mower may cause the fuel to leak from the carburetor or the fuel tank. Gasoline is extremely flammable, highly explosive, and, under certain conditions, can cause personal injury or property damage. • The grass bag is locked in place. • The optional side discharge chute is locked in place. • The discharge tunnel door is locked in place. Avoid fuel spills by running the engine dry or by removing the gasoline with a hand pump; never siphon. Cleaning under the Belt Cover Service Interval: Every 50 hours 3. Tip the lawn mower onto its right side . 4. Remove the dirt and grass clippings with a hardwood scraper. Avoid burrs and sharp edges. 5. Turn the lawn mower upright. 6. Fill the fuel tank. 7. Connect the wire to the spark plug. Keep the area under the belt cover free of debris. 1. Stop the engine and wait for all moving parts to stop. 2. Remove the bolts that secure the belt cover (Figure 35) to the lawn mower housing. Cleaning the Discharge Tunnel and Plug Service Interval: Before each use or daily Remove the plug from the discharge tunnel and clean it after each use. Figure 35 1. Belt cover Always be sure that the discharge tunnel door closes securely when you release the handle. If the debris prevents the discharge door from closing securely, clean the inside of the discharge tunnel and the door thoroughly. 3. Lift off the cover and brush out all the debris around the belt area. 4. Install the belt cover. 24 General Information Storage 1. Clean the lawn mower housing. Refer to Clean under the Lawn Mower Housing. To prepare the lawn mower for off-season storage, perform the recommended maintenance procedures. Refer to Maintenance. 2. Clean any dirt and chaff from the cylinder, cylinder head fins, and blower housing. Store the lawn mower in a cool, clean, dry place. Cover the lawn mower to keep it clean and protected. 3. Remove grass clippings, dirt, and grime from the external parts of the engine, the shrouding, and the top of the lawn mower housing. Preparing the Fuel System 4. Check the condition of the blade. Refer to Maintaining the Cutting Blade. 5. Clean the blade brake clutch shield; refer to Cleaning the Blade Brake Clutch Shield. Gasoline can vaporize if you store it over long periods of time and explode if it comes into contact with an open flame. 6. Service the air filter; refer to Servicing the Air Filter. 7. Lubricate the pivot arms; refer to Lubricating the Pivot Arms. • Do not store gasoline over long periods of time. 8. Tighten all nuts, bolts, and screws. • Do not store the lawn mower with gasoline in the fuel tank or the carburetor in an enclosure with an open flame. (For example, a furnace or a water heater pilot light.) 9. Touch up all rusted or chipped paint surfaces with paint available from an Authorized Service Dealer. • Allow the engine to cool before storing it in any enclosure. Removing the Lawn Mower from Storage 1. Check and tighten all fasteners. Empty the fuel tank when mowing the last time before storing the lawn mower. 2. Remove the spark plug and spin the engine rapidly using the starter to blow excess oil from the cylinder. 1. Run the lawn mower until the engine stops from running out of fuel. 3. Clean the spark plug or replace it if it is cracked, broken, or if the electrodes are worn. 2. Prime the engine and start it again. 4. Install the spark plug and torque it to 17 ft-lb (23 N⋅m). 3. Allow the engine to run until it stops. When you can no longer start the engine, it is sufficiently dry. 5. Perform any needed maintenance procedures; refer to Maintenance. Preparing the Engine 6. Fill the fuel in the fuel tank with fresh gasoline. 1. While the engine is still warm, change the oil from the crankcase. Refer to Changing the Engine Oil. 7. Check the engine oil level. 8. Connect the wire to the spark plug. 2. Remove the spark plug (Figure 13). 3. Using an oil can, add about one tablespoon of oil to the crankcase through the spark plug hole. 4. Slowly rotate the engine several times, using the starter rope, to distribute the oil. 5. Install the spark plug but do not connect the wire to the spark plug. 25 Troubleshooting Problem Engine does not start Engine starts hard or loses power Possible Cause 1. The fuel tank is empty or the fuel system contains stale fuel. 1. Drain and/or fill the fuel tank with fresh gasoline. If the problem persists, contact an Authorized Service Dealer. 2. The throttle lever is not in the Choke position. 3. The wire is not connected to the spark plug. 4. The spark plug is pitted, fouled, or the gap is incorrect. 2. Move the throttle lever to the Choke position. 3. Connect the wire to the spark plug. 1. Drain and fill the fuel tank with fresh gasoline. 2. The fuel cap vent hole is plugged. 2. Clean the fuel cap vent hole or replace the fuel cap. 3. Clean the air filter pre-cleaner and/or replace the paper air filter. 4. Clean the underside of the lawn mower deck. 5. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked. 6. Check the engine oil. Change the oil if it is dirty or add oil if it is low. 6. The engine oil level is low or the oil is dirty. 1. The wire is not connected to the spark plug. 1. Connect the wire to the spark plug. 2. The spark plug is pitted, fouled, or the gap is incorrect. 2. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked. 3. Move the throttle lever to the Fast position. 4. Clean the air filter pre-cleaner and/or replace the paper air filter. 3. The throttle lever is not in the Fast position. 4. The air filter element is dirty and is restricting the air flow. Lawn mower or engine vibrates excessively Uneven cutting pattern Discharge chute plugs 4. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked. 1. The fuel tank contains stale fuel. 3. The air filter element is dirty and is restricting the air flow. 4. The underside of the lawn mower deck contains clippings and debris. 5. The spark plug is pitted, fouled, or the gap is incorrect. Engine runs rough Corrective Action 1. The blade is bent or is out of balance. 1. Balance the blade. If the blade is bent, replace it. 2. The blade mounting nuts are loose. 3. The underside of the lawn mower deck contains clippings and debris. 4. The engine mounting bolts are loose. 2. Tighten the blade mounting nuts. 3. Clean the underside of the lawn mower deck. 4. Tighten the engine mounting bolts. 1. All 4 wheels are not at the same height. 1. Place all 4 wheels at the same height. 2. The blade is dull. 3. You are mowing in the same pattern repeatedly. 4. The underside of the lawn mower deck contains clippings and debris. 2. Sharpen and balance the blade. 3. Change the mowing pattern. 4. Clean the underside of the lawn mower deck. 1. The throttle lever is not in the Fast position. 1. Move the throttle lever to the Fast position. 2. 3. 4. 5. 2. 3. 4. 5. The cutting height is too low. You are mowing too fast. The grass is wet. The underside of the lawn mower deck contains clippings and debris. 26 Raise the cutting height. Slow down. Allow the grass to dry before mowing. Clean the underside of the lawn mower deck. Problem Lawn mower does not self-propel Possible Cause Corrective Action 1. The self-propel drive cable is out of adjustment or is damaged. 1. Adjust the self-propel drive cable. Replace the cable if necessary. 2. There is debris under the belt cover. 2. Clean the debris from under the belt cover. 27 Toro 21” The Toro Total Coverage Guarantee Commercial Walk Power A Two-Year Full Warranty (Limited Warranty for Commercial Use) Mower Conditions and Products Covered The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product, when used for residential purposes*, if defective in materials or workmanship or if it stops functioning due to the failure of a component. The following time periods apply from the date of original purchase: Products Warranty Period 2-year full warranty All Products and attachments This warranty covers the cost of parts and labor, but you must pay transportation costs. This warranty applies to all Toro Commercial Duty Walk Power Mowers and their attachments. Limited Warranty for Commercial Use Toro Products used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for the following time periods from the original date of purchase: Products Engine All Products and attachments Warranty Period 2-year limited warranty 1-year limited warranty Components failing due to normal wear are not covered by this warranty. Items and Conditions Not Covered There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover the following: • Cost of regular maintenance service or parts, such as lters, fuel, lubricants, oil changes, air lter, blade sharpening/worn blade on mowers, paddles/scrapers/skids on snowthrowers, cable/linkage adjustments, or brake and clutch adjustments • Any product or part which has been altered or misused and requires replacement or repair due to accidents or lack of proper maintenance • Repairs necessary due to improper battery care, electrical supply irregularities, or failure to use fresh fuel (less than one month old), or failure to properly prepare the unit prior to any period of non-use over one month • Operational misuse, neglect, or accidents • Repairs or attempted repairs by anyone other than an Authorized Toro Service Dealer. • Pickup and delivery charges All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts. Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense. Instructions for Obtaining Warranty Service If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure: 1. Contact any Toro Authorized Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under "Lawn Mowers" or “Snow Removal”) or access our website at www.Toro.com. U.S. Customers may also call the number listed in item #3 to use our 24-hour Toro dealer locator system. 2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. The dealer will diagnose the problem and determine if it is to be covered under warranty. If for any reason you are dissatised with the Service Dealer’s analysis or with the assistance provided, contact us at: Customer Care Department — Consumer, Toro Warranty Company, 8111 Lyndale Avenue South, Bloomington, MN 55420-1196; or call us toll free at 1-888-865-5676 (U.S. Customers) or 1-888-865-5691 (Canada customers). General Conditions All repairs covered by these warranties must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts. Neither The Toro® Company nor Toro Warranty Company is liable for indirect, incidental, or consequential damages in connection with the use of the Toro Products covered by these warranties, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under these warranties. Some states do not allow exclusions of incidental or consequential damages, so the above exclusions and limitations may not apply to you. This warranty gives you specic 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 Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company. * Residential purposes means use of the product on the same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply. 374-0083 Rev A
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