Toro 21in Heavy-Duty Recycler/Rear Bagger Lawn Mower Walk Behind Mower Operator's Manual

Form No. 3359-644 Rev A

21in Heavy-Duty Recycler

®

/Rear

Bagger Lawn Mower

Model No. 22190—Serial No. 290000001 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.

This spark ignition system complies with Canadian

ICES-002.

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.

Figure 1

1.

Model and serial number plate

Model No.

Serial No.

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

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.

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.

1.

Safety alert symbol

Figure 2

This manual uses 2 words to highlight information.

Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

© 2008—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

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 Discharge Tunnel Plug................... 8

4 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

Storage ....................................................................... 25

Preparing the Fuel System................................... 25

Preparing the Engine .......................................... 25

General Information .......................................... 25

Removing the Lawn Mower from Storage............ 25

Troubleshooting......................................................... 26

3

Safety

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.

Improperly using or maintaining this lawn mower can result in injury. To reduce the potential for injury, comply with these safety instructions.

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.

Engine exhaust contains carbon monoxide, an odorless, deadly poison that can kill you.

Do not run the engine indoors or in an enclosed area.

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.

General Lawn Mower Safety

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.

The following instructions are from the ANSI/OPEI

B71.4–2004 standard.

Training

• Read the Operator’s Manual and other training material.

• 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.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• 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.

Preparation

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.

• 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.

• 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.

• Use extra care when handling gasoline and other fuels.

– They are flammable and vapors are explosive.

– Use only an approved container.

– Never remove gas cap or add fuel when engine is running.

– Do not smoke.

– Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

4

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes and hidden hazards.

• Be sure all drives are in neutral and parking brake is engaged before starting engine.

• Only start engine from the operator’s position.

• Be sure of your footing while using pedestrian controlled equipment, especially when backing up.

• Walk, don’t run.

• Never operate on wet grass. Reduced footing could cause slipping.

• Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides.

• Use caution while operating near drop-offs.

• Slow down and use caution when making turns and when changing directions on slopes.

• Never raise deck with the blades running.

• Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

• 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.

Maintenance and Storage

• Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting unit, muffler, and engine to help prevent fires.

• Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near flame.

• Do not store fuel near flames or drain indoors.

• Never allow untrained personnel to service machine.

• Use care when checking blade.

• Wrap the blade or wear gloves, and use caution when servicing.

• Only replace blade. Never straighten or weld them.

• Keep hands and feet away from moving parts.

• If possible, do not make adjustments with the engine running.

• Keep all parts in good working condition and all hardware tightened.

• Replace all worn or damaged decals.

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

1.

Indicates the blade is identified as a part from the original machine manufacturer.

68-7410

1.

Transmission speeds

74-1970

2.

Neutral

98-4387

1.

Warning—wear hearing protection.

39-5770

115-1003

110-4989

6

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Procedure

1

Description

Handle

Bolt (5/16 x 1-1/4 inches)

Washer

Thin nylon insert locknut (5/16 inch)


Carriage bolt

Locknut (5/16 inch)

Bag support rod

Bag aligning plate

Cap locknut

Cable tie

No parts required 2

3

4

Discharge tunnel plug

No parts required

Note: Determine the left and right sides of the machine from the normal operating position.

Qty.

2

1

1

2

1

3

3

1

2

4

2

–

1

–

Install the handle.

Use

Install the starter rope.

Install the discharge tunnel plug.

Fill the crankcase with oil.

1

Installing the Handle

Parts needed for this procedure:

1

2

2

2

1

1

3

3

1

2

4

Handle


Washer

Thin nylon insert locknut (5/16 inch)


Carriage bolt

Locknut (5/16 inch)

Bag support rod

Bag aligning plate

Cap locknut

Cable tie

Procedure

1. Mount the handle to the outside of the mower housing (using the bottom hole) with two bolts

7

(5/16 x 1-1/4 inches), washers, and thin locknuts

(5/16 inch) (Figure 3).

2

Installing the Starter Rope

No Parts Required

Procedure

Pull the starter rope through the rope guide on the

handle (Figure 4).

Figure 3

1.

2.

3.

4.

5.

Bag support rod

Carriage bolt

Bag aligning plate

Cap locknuts (3)

Handle

6.

Bolt, (5/16 x 1-1/2 inches)

(2)

7.

Handle latch (2)

8.

Thin nylon insert locknut

(2)

9.

Bottom hole in housing

10.

Washer (4)

11.

Locknut (2)

12.

Bolt, (5/16 x 1-1/4 inches)

(2)

13.

Cable tie (3)

1.

Starter rope

Figure 4

2.

Rope guide

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: Install the washers with the cup side facing the handle.

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 bolts and the locknuts that secure the handle latches to the handle into the other mounting holes in the latches.

3. Insert the carriage bolt through the bag aligning plate and the second hole from the top on the left side of the handle, and secure it with a cap locknut

(Figure 3).

4. Slide the bag support rod through the third from the top mounting holes in the handle, and secure each

end with a cap locknut (Figure 3).

5. Use cable ties to secure the control cables to the

handle (Figure 3).

Note: To make the rope easier to install, squeeze the control bar on the handle.

3

Installing the Discharge Tunnel

Plug

Parts needed for this procedure:

1 Discharge tunnel plug

Procedure

1. Open the discharge door by pulling forward on the

handle and moving it rearward (Figure 5). Hold the

discharge door handle to prevent the spring-loaded door from closing while you insert the plug.

8

1.

Discharge door handle

Figure 5

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 5).

Note: Ensure that the arrow on the plug decal points upward.

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 6).

4

Filling the Crankcase with Oil

No Parts Required

Procedure

The engine crankcase is shipped without oil.

You must fill it with approximately 22 ounces (0.65 l) of oil before starting the engine. Refer to Checking the

Engine Oil Level in , page , for oil specifications and instructions.

Figure 6

1.

Spring clip

4. Release the discharge door handle to lock the top of the plug.

9

Product Overview Operation


Each time before you mow, make sure that the self-propel drive and the control bar operate properly.

When you release the control bar, the blade, the engine, and the self-propel drive should stop. If they do not, contact an Authorized Service Dealer.

1.

Handle

2.

Throttle control lever

3.

Grass bag

4.

Fuel tank

5.

Oil filter (not shown)

6.

Air filter

Figure 7

7.

Cutting height lever (4)

8.

Spark plug

9.

Discharge tunnel

10.

Oil fill/dipstick

11.

Starter handle

12.

Control bar

Controls

1.

Control bar

2.


Figure 8

3.

Recoil starter handle

This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

Figure 9

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.

With oil filter

Without oil filter

Oil Capacity

29 ounces (0.85 liters)

22 ounces (0.65 liters)

Before each use, ensure that the oil level is between the

Add and Full marks on the dipstick (Figure 10).

10

1.

Dipstick

2.

Full

Figure 10

3.

Add

Note: When the crankcase is empty, pour about 3/4 of the crankcase capacity of oil in the crankcase, then follow the procedure in this section.

1. Move the lawn mower to a level surface.

2. Clean around the dipstick (Figure 11).

3. Remove the dipstick by rotating the cap counterclockwise and pulling it out.

4. Wipe the dipstick clean with a clean cloth.

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.

6. Read the oil level on the dipstick (Figure 11).

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.

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.

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.

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.

• Fill the fuel tank outdoors, in an open area, and when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows the gasoline to expand.

• Never smoke when handling gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

• 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.

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.

• If this is not possible, then refuel such equipment on a truck or trailer from a portable container, not from a gasoline dispenser nozzle.

• 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.

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.

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. Clean around the fuel tank cap (Figure 11).

1.

Oil fill/dipstick

2.

Fuel tank cap

Figure 11

3.

Air cleaner

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.

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.

Starting the Engine

1. Connect the wire to the spark plug (Figure 12).

12

1.


2.

Primer

Figure 12

3.

Starter handle

4.

Spark plug

2. Move the throttle control to the Fast position.

3. Move the ground speed control to the Neutral (N)

position (Figure 13).

2. Start the engine.

3. Squeeze the control bar against the handle to the

Run/Drive position (Figure 15).

1.

Ground speed control

Figure 13

4. Push in the primer once with your thumb, holding

it in for a second before releasing it (Figure 12).

5. Lift the control bar to the handle and hold it.

6. Pull the starter handle lightly until you feel resistance, then pull it sharply.

7. Regulate the throttle and the ground speed control as desired when the engine starts.

Note: If the engine fails to start after 3 pulls, repeat

steps 2 through 7.

Stopping the Engine

1. Release the 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 14).

1.

Ground speed control

Figure 14

1. Move the ground speed control to the Neutral (N) position.

1.

Run/Drive position

2.

Run/Shift position

Figure 15

3.

Stop/Off position

Note: Do not shift speeds while you squeeze the control bar against the handle in the Run/Drive position; this can damage the transmission. Move

the control bar to the Run/Shift position (Figure 15)

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.

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.

Note: When grass is thick and lush, clippings may collect on and around the discharge tunnel plug.

13

This may make removing the plug difficult. Clean the plug thoroughly after each use.

Adjusting the Cutting Height

Each wheel is adjusted individually with a wheel height adjustment lever. Cutting heights are 3/4 inch (19 mm),

1-1/4 inches (32 mm), 1-3/4 inches (44 mm), 2-1/4 inches (57 mm), 2-3/4 inches (70 mm), and 3-1/4 inches (83 mm).

Adjusting the cutting height levers could bring your hands into contact with a moving blade and result in serious injury.

• 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.

1. Pull the wheel height adjustment lever toward the

wheel (Figure 16) and move it to the desired setting.

1.

Bag frame on retaining post

2.

Pin engaged in catch

Figure 17

3.

Handle fully forward; discharge door closed

3. Slide the hole in the bag frame onto the retaining

post on the discharge tunnel (Figure 17).

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 18).

Figure 16

1.

Wheel height adjustment lever

2. Release the wheel height adjustment lever and seat it securely in the notch.

3. Adjust all the wheels to the same cutting height setting.

Using the Grass Bag

Occasionally, you may wish to use the grass bag for bagging extra long grass, lush grass, or leaves.

Installing the Grass Bag


2. Ensure that the discharge door handle is fully forward and that the pin is engaged in the catch

(Figure 17).

Figure 18

1.

Pin locked in bag notch

Note: The discharge door in the lawn mower housing is now open.

14

Mowing with the Grass Bag

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.

Check the grass bag frequently. If it is damaged, install a new Toro replacement bag.

Removing the Grass Bag


2. Raise the discharge door handle and move it forward

to engage the pin with the catch (Figure 17).

3. Grasp the handles at the front and the rear of the bag and lift the bag off the lawn mower.

4. Gradually tip the bag forward to empty the clippings.

5. To install the bag, refer to Installing the Grass Bag.

Operating Tips

General Tips

• Review the safety instructions and read this manual carefully before operating the lawn mower.

• 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.

• Avoid striking trees, walls, curbs, or other solid objects. Never deliberately mow over any object.

• 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.

• Maintain a sharp blade throughout the cutting season. Periodically file down nicks on the blade.

• Replace the blade when necessary with an original

Toro replacement blade.

• 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.

If the discharge door does not close completely, the lawn mower could throw objects, causing serious personal injury or death.

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.

Wet grass or leaves can cause serious injury if you slip and contact the blade.

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

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.

– Do not change the engine speed setting.

– If you suspect the engine speed is faster than normal, contact an Authorized Service

Dealer.

• Clean the air filter frequently. Mulching stirs up more clippings and dust which clogs the air filter and reduces engine performance.

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 2-1/4 inch (57 mm), 2-3/4 inch (70 mm), or

3-1/4 inch (83 mm) cutting height settings. Cut only about a third of the grass blade at a time. Do not cut below the 2-1/4 inch (57 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).

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.

• 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.

• Slow down your mowing speed if the lawn mower does not cut the leaves finely enough.

• If you mow over oak leaves, you can add lime to the grass in the spring to reduce the acidity of the oak leaves.

16

Maintenance


Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 8 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 300 hours

Yearly or before storage

Maintenance Procedure

• Change the engine oil without the oil filter.

• Check the engine oil level.

• Ensure that the engine stops within 3 seconds after releasing the control bar.

• Inspect the mower blades for wear or damage.

• Clean under the lawn mower housing.

• Clean the discharge tunnel and plug.

• Lubricate the pivot arms.

• Clean the foam pre-cleaner (more frequently in dusty conditions).

• Change the engine oil (more often in dusty conditions).

• Check the fuel hose and replace it if necessary.

• Clean under the belt cover.

• Lubricate the gear case.

• Clean the air cooling fins.

• 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.

• Replace the paper air filter (more frequently in dusty conditions).

• 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

Lubricating the Pivot Arms

Service Interval: Every 25 hours

1. Move the rear wheel cutting height levers to the center setting.

2. Wipe the grease fittings with a clean rag (Figure 19).

Engine Maintenance

Servicing the Air Filter

Service Interval: Every 25 hours—Clean the foam pre-cleaner (more frequently in dusty conditions).

Every 300 hours—Replace the paper air filter (more frequently in dusty conditions).

Important: Do not operate the engine without the air filter assembly; extreme engine damage will occur.


2. Disconnect the wire from the spark plug (Figure 12).

3. Remove the cover and clean it thoroughly (Figure 21).

Figure 19

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


1. Remove the grass bag.

2. Install a grease gun onto the fitting through the belt

cover opening (Figure 20).

1.

Cover

2.

Paper air filter

Figure 21

3.

Air filter base

1.

Belt cover

Figure 20

2.

Grease fitting

3. Gently apply one to 2 pumps of #2 multi-purpose lithium-base grease.

4. Install the grass bag.

4. Remove and inspect the paper air filter (Figure 21),

and discard it if it is excessively dirty.

Important: Do not try to clean a paper filter.

5. Remove the foam pre-cleaner and wash it with a mild

detergent and water, then blot it dry (Figure 21).

6. Install the foam pre-cleaner onto the paper air filter.

7. Install the air filter assembly.

Note: Install a new paper air filter if you discarded the old one.

8. Install the cover.

18

Changing the Engine Oil

Service Interval: After the first 8 hours—Change the engine oil without the oil filter.

Every 50 hours—Change the engine oil (more often in dusty conditions).

1. Run the engine to warm the engine oil.

Note: Warm oil flows better and carries more contaminants.



4. Drain the engine oil; refer to Changing the Engine

Oil.

5. Place a rag under the oil filter to catch any oil that may leak out as you remove the filter.

6. Remove the oil filter (Figure 22).

Oil may be hot after engine has been run, and contact with hot oil can cause severe personal injury.

Avoid contacting the hot engine oil when you drain it.



4. Place a suitable drain pan under the right side of the lawn mower.

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.

9. Recycle the used oil according to local codes.

10. Fill the crankcase to the Full line on the dipstick with fresh oil. Refer to the Filling the Crankcase with Oil.

11. Wipe up any spilled oil.

Changing the Oil Filter

Service Interval: Every 100 hours—Change the engine oil and oil filter.

1. Run the engine to warm the oil.

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.

1.

Oil filter

1.

Gasket

Figure 22

7. Use your finger to coat the gasket on the new filter

with oil (Figure 23).

Figure 23

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.

10. Connect the wire to the spark plug.

11. Run the engine for about 3 minutes.

12. Stop the engine, wait for all moving parts to stop, and check for oil leakage around the filter.

13. Add oil to compensate for the oil in the oil filter.

Refer to Checking the Engine Oil Level.

14. Recycle the used oil filter according to local codes.

19

Servicing the Spark Plug

Service Interval: Every 100 hours—Check the spark plug.

Use an NGK BPR5ES spark plug or equivalent.



3. Clean around the spark plug.

4. Remove the spark plug from the cylinder head.

Important: Replace a cracked, fouled, or dirty spark plug. Do not clean the electrodes because grit entering the cylinder can damage the engine.

5. Set the gap on the plug to 0.030 in. (0.76 mm)

(Figure 24).

Figure 24

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).


Fuel System

Maintenance

Emptying the Fuel Tank and

Cleaning the Fuel Filter

Service Interval: Every 50 hours—Check the fuel hose and replace it if necessary.

Every 100 hours—Clean the fuel filter.

Yearly or before storage—Empty the fuel tank.

The fuel filter (screen) element is located inside the fuel tank.

1. Stop the engine and wait for it to cool down.

Important: Drain gasoline from a cold engine only.


3. Disconnect the fuel line by loosening the tube clamp at the carburetor.

4. Drain the gasoline completely from the tank and fuel line into an approved fuel container.

5. Remove the fuel tank from the mower.

6. 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.

7. Install the fuel tank and fuel line; refer to Installing the Fuel Tank and the Fuel Line.

20

Drive System

Maintenance

Adjusting the Self-propel Drive


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.

1. Close the door in the lawn mower housing and remove the grass bag.

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 25).

Controls System

Maintenance

Adjusting the Blade Brake

Cable


Whenever you install a new blade brake cable assembly, adjust it.


2. Disconnect the wire from the spark plug.

3. Check the adjustment of the cable by moving the 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. Loosen the nut on the cable bracket (Figure 27).

Figure 25

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 26).

1.

Handle

2.

Brake lever

Figure 27

3.

3/16 to 1/4 inch (5 to 6 mm)

4.

Cable bracket

5. Insert a 3/16 to 1/4 inch (5 to 6 mm) object between

the brake lever and the handle (Figure 15).

6. Pull down on the cable conduit until you remove the

slack from the wire (Figure 15).

7. Tighten the nut (Figure 15).

Figure 26

1.

1 inch (2.5 cm)

21

Blade Maintenance

Maintaining the Cutting Blade

Always mow with a sharp blade. A sharp blade cuts cleanly and without tearing or shredding the grass blades.



3. Drain the gasoline from the fuel tank; refer to

Emptying the Fuel Tank and Cleaning the Fuel Filter.

4. Tip the mower onto its right

side (Figure 28).

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.

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.

• Inspect the blade periodically for wear or damage.

• 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 28).

Figure 28

1.

Blade

2.

Blade bolt and lock washer

3.

Accelerator

Sharpening the Blade

File the top side of the blade to maintain its original

cutting angle (Figure 30A) and inner cutting edge radius

(Figure 30B). The blade will remain balanced if you

remove the same amount of material from both cutting edges.

Inspecting the Blade

Service Interval: Before each use or daily—Inspect the mower blades for wear or damage.

Carefully examine the blade for sharpness and wear, especially where the flat and the curved parts meet

(Figure 29A). 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 29B and Figure 29C), replace the blade; refer to Removing

the Blade.

Figure 30

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 31).

Figure 31

1.

Sail

2.

Flat part of the blade

Figure 29

3.

Wear

4.

Slot formed

22

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.

Installing the Blade

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).

Cleaning

Cleaning under the Lawn

Mower Housing

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 32).

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.

Do not operate the lawn mower without the accelerator.

2. Return the lawn mower to its upright position.


1.

Kickers

Figure 32

Washing Method


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 33).

23

Figure 33

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.


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.

Scraping Method

If washing does not remove all debris from under the lawn mower, scrape it clean.


2. Drain the fuel from the fuel tank. Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter.

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.

Avoid fuel spills by running the engine dry or by removing the gasoline with a hand pump; never siphon.

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.


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.

• The grass bag is locked in place.

• The optional side discharge chute is locked in place.

• The discharge tunnel door is locked in place.

Cleaning under the Belt Cover


Keep the area under the belt cover free of debris.


2. Remove the bolts that secure the belt cover

(Figure 34) to the lawn mower housing.

Cleaning the Discharge Tunnel and Plug


Remove the plug from the discharge tunnel and clean it after each use.

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.

1.

Belt cover

Figure 34

3. Lift off the cover and brush out all the debris around the belt area.

4. Install the belt cover.

24

Storage

To prepare the lawn mower for off-season storage, perform the recommended maintenance procedures.

Refer to Maintenance.

Store the lawn mower in a cool, clean, dry place. Cover the lawn mower to keep it clean and protected.

Preparing the Fuel System

2. Clean any dirt and chaff from the cylinder, cylinder head fins, and blower housing.

3. Remove grass clippings, dirt, and grime from the external parts of the engine, the shrouding, and the top of the lawn mower housing.

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.

6. Service the air filter; refer to Servicing the Air Filter.

7. Lubricate the pivot arms; refer to Lubricating the

Pivot Arms.

8. Tighten all nuts, bolts, and screws.

9. Touch up all rusted or chipped paint surfaces with paint available from an Authorized Service Dealer.

Gasoline can vaporize if you store it over long periods of time and explode if it comes into contact with an open flame.

• Do not store gasoline over long periods of time.

• 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.)

• Allow the engine to cool before storing it in any enclosure.

Empty the fuel tank when mowing the last time before storing the lawn mower.

1. Run the lawn mower until the engine stops from running out of fuel.

2. Prime the engine and start it again.

3. Allow the engine to run until it stops. When you can no longer start the engine, it is sufficiently dry.

Preparing the Engine

1. While the engine is still warm, change the oil from the crankcase. Refer to Changing the Engine Oil.

2. Remove the spark plug (Figure 12).

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.

General Information

1. Clean the lawn mower housing. Refer to Clean under the Lawn Mower Housing.

Removing the Lawn Mower from Storage

1. Check and tighten all fasteners.

2. Remove the spark plug and spin the engine rapidly using the starter to blow excess oil from the cylinder.

3. Clean the spark plug or replace it if it is cracked, broken, or if the electrodes are worn.

4. Install the spark plug and torque it to 17 ft-lb (23

N ⋅ m).

5. Perform any needed maintenance procedures; refer to Maintenance.

6. Fill the fuel in the fuel tank with fresh gasoline.

7. Check the engine oil level.


25

Troubleshooting

Problem

Engine does not start

Engine starts hard or loses power

Engine runs rough

Lawn mower or engine vibrates excessively

Uneven cutting pattern

Discharge chute plugs

Possible Cause

1. The fuel tank is empty or the fuel system contains stale fuel.

Corrective Action

1. Drain and/or fill the fuel tank with fresh gasoline. If the problem persists, contact an Authorized Service Dealer.

2. Prime the engine.


2. The engine has not been primed.

3. The wire is not connected to the spark plug.

4. The spark plug is pitted, fouled, or the gap is incorrect.

1. The fuel tank contains stale fuel.

2. The fuel cap vent hole is plugged.

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.


4. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked.

1. Drain and fill the fuel tank with fresh gasoline.

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.


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.


3. The throttle lever is not in the Fast position.

4. The air filter element is dirty and is restricting the air flow.

1. The blade is bent or is out of balance.



3. Move the throttle lever to the Fast position.

4. Clean the air filter pre-cleaner and/or replace the paper air filter.

2. The blade mounting nuts are loose.


4. The engine mounting bolts are loose.

1. Balance the blade. If the blade is bent, replace it.

2. Tighten the blade mounting nuts.


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.


2. Sharpen and balance the blade.

3. Change the mowing pattern.


1. The throttle lever is not in the Fast position.

2. The cutting height is too low.

3. You are mowing too fast.

4. The grass is wet.


1. Move the throttle lever to the Fast position.

2. Raise the cutting height.

3. Slow down.

4. Allow the grass to dry before mowing.


26

Problem

Lawn mower does not self-propel

Possible Cause

1. The self-propel drive cable is out of adjustment or is damaged.

2. There is debris under the belt cover.

Corrective Action

1. Adjust the self-propel drive cable.

Replace the cable if necessary.

2. Clean the debris from under the belt cover.

27

Toro 21”

Commercial

Walk Power

Mower

The Toro Total Coverage Guarantee

A Two-Year Full Warranty (Limited Warranty for Commercial Use)

Conditions and Products Covered

The Toro® Company and its afliate, 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:

All Products and attachments

Products Warranty Period

2-year full warranty

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

Components failing due to normal wear are not covered by this warranty.

Warranty Period

2-year limited warranty

1-year limited 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 dissatised 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 specic 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 dissatised with your Distributor’s service or have difculty 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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