Toro Mid-Size Proline Gear Traction Unit, 16 hp Walk Behind Mower Operator's Manual

FORM NO. 3314-492
To assure maximum safety, optimum perform-
ance, and to gain knowledge of the product, it is
essential that you or any other operator of the ma-
chine read and understand the contents of this
manual before the engine is ever started. Pay par-
ticular attention to the SAFETY INSTRUCTIONS
highlighted by this symbol —
The safety alert symbol means CAUTION, WARN- |
ING or DANGER — personal safety instruction. Fail- #
ure to comply with the instruction may result in per-
sonal injury.
©The Toro Company — 1991
FOREWORD
The Proline mid size mowers have advanced concepts in engineering, design and safety; and if maintained
properly, will give excellent service.
Since this is a high-quality product, Toro is concerned about the future use of the machine and safety of the
user. Therefore, read this manual to familiarize yourself with proper set-up, operation and maintenance instruc-
tions. The major sections of the manual are:
1. Safety Instructions
2. Set-up Instructions
3. Before Operating
4. Operation
5. Maintenance
Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety
related information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read
this directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies
general information worthy of special attention.
TABLE OF CONTENTS
Page
SAFETY INSTRUCTIONS .................. 2-3
SAFETY AND INSTRUCTION DECALS .......... 4
SPECIFICATIONS ......... iii 4 0 5
LOOSE PARTS ..... i iii 4 4 1 0 4 4 ea 6 5
SET-UP INSTRUCTIONS ................... 6-9
BEFORE OPERATING ................... 10-11
CONTROLS RR 12
OPERATING INSTRUCTIONS ................ 12
MAINTENANCE ............. ou... 13-18
Grease Wheels ........................ 13
Grease Transmission Couplers ........... 13
Servicing Air Cleaner ............ 0... 13
Changing Crankcase Oil & Filter .......... 14
Fuel Filter Replacement .................
Page
Replacing Spark Plugs .. . ............... 15
Adjusting Throttle Control ............... 15
Adjusting Choke Control ................ 15
Adjusting Carburetor ................... 16
Adjusting and Replacing Traction Belt ..... 16
Adjusting Clutch . . ..................... 16
Brake Adjustment ..................... 17
Drive Belt Replacement ................. 17
Cleaning Cooling System ............... 17
WIRING SCHEMATIC ...................... 18
IDENTIFICATION AND ORDERING ........... 18
МАМТЕМАМСЕ СНАВТ .................... 19
THE TORO PROMISE .............. Back Cover
SAFETY INSTRUCTIONS
The safety alert symbol means
CAUTION, WARNING or DAN-
GER — “personal safety in-
struction”. Read and under
stand the instruction because
it has to do with safety. Failure to comply with
the instruction may result in personal injury.
The Proline mid size mower was tested and certi-
fied by TORO for compliance with the B71.4 - 1984
specifications of the American National Standard
Institute. Hazard control and accident prevention
are dependent upon the awareness, concern, and
proper training of the personnel involved in the op-
eration, transport, maintenance, and storage of the
machine. Improper use or maintenance of the ma-
chine can result in injury or death. To reduce the
potential for injury or death, comply with the follow-
ing safety instructions.
BEFORE OPERATING
1. Read and understand the contents of this Opera-
tor's Manual before operating the machine. Become
familiar with all controls and know how to stop quickly.
A free replacement manual is available by sending
complete Model and Serial Number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420
2. Never allow children to operate the machine. Do
not allow adults to operate machine without proper
instruction. Only trained operators who have read this
manual should operate this machine,
3. Never operate the machine when under the influ-
ence of drugs or alcohol.
4. Before attempting to start engine, shift into neu-
tral and lock parking brake.
5. Remove all debris or other objects that might be
picked up and thrown by the cutter blades. Keep all
bystanders away from the mowing area.
SAFETY INSTRUCTIONS
6. Keep all shields and safety devices in place. If a
shield, safety device or decal is illegible or damaged,
repair or replace it before operation is commenced.
Aiso tighten any loose nuts, bolts and screws to as-
sure machine is in safe operating condition.
7. Do not operate machine while wearing sandals,
tennis shoes, sneakers or shorts. Also, do not wear
loose fitting clothing which could get caught in moving
parts. Always wear long pants and substantial shoes.
Wearing safety glasses, safety shoes and a helmet is
advisable and required by some local ordinances and
insurance regulations.
8. Fill fuel tank with gasoline before starting the en-
gine. Avoid spilling gasoline. Since gasoline is flam-
mable, handle it carefully.
A. Use an approved gasoline container.
B. Do not fill tank while engine is hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and up to about one inch
(25 mm) from top of the tank, not the filler neck.
E. Wipe up any spilled gasoline.
WHILE OPERATING
9, Start engine when parking brake is set, blade is
disengaged, and transmission is in neutral.
10. Do not run the engine in a confined area without
adequate ventilation. Exhaust fumes are hazardous
and could possibly be deadly.
11. Using the machine demands attention, and to
prevent loss of control:
A. Mow only in daylight or when there is good arti-
ficial light.
B. Watch for holes or other hidden hazards.
C. Do not drive close to a sand trap, ditch, creek
or other hazard.
D. Reduce speed when making sharp turns and
when turning on hillsides.
12. The grass deflector must always be installed and
in down position on the side discharge cutting unit,
except when using the optional grass catcher. This
product is designed to drive objects into the ground
where they lose energy quickly in grassy areas. How-
ever, don't take an injury risk!! When a person or pet
appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets, or improperly positioned
guards, can lead to thrown object injuries. Do not re-
sume mowing until area is cleared. If the cutting unit
discharge area ever plugs, shut engine off before re-
moving the obstruction.
13. Never raise the cutting unit while the blades are
rotating.
14. If the cutting blades strike a solid object or the
machine vibrates abnormally, shut the engine off. Re-
move high tension wires from spark plugs to prevent
possibility of accidental starting. Check cutting unit
and traction unit for damage and malfunctioning
parts. Repair any damage before restarting the en-
gine and operating the cutting unit. Be sure blades
are in good condition and blade bolts are tight.
15. Cut grass slopes carefully. Do not start, stop, or
turn suddenly.
16. Do not touch engine or muffler while engine is
running or soon after it is stopped. These areas could
be hot enough to cause a burn.
17. Before leaving the operator’s position — behind
handle or leaving mower unattended, shift transmis-
sion into NEUTRAL, apply parking brake and shut OFF
engine.
MAINTENANCE
18. Disconnect wires from spark plugs to prevent ac-
cidental starting of the engine when servicing, adjust-
ing or storing the machine.
19. If tractor and mower must be tipped to perform
maintenance or an adjustment, drain gasoline from
fuel tank and oil from crankcase.
20. When driving unit forward, always use upper
“Forward” traction drive handle. When backing up,
always use lower “Reverse” traction drive handle.
21. To reduce potential fire hazard, keep the engine
free of excessive grease, grass, leaves and accumu-
lations of dirt.
22. Be sure machine is in safe operating condition by
Keeping nuts, bolts and screws tight. Check the blade
mounting bolts and nuts frequently to be sure they
are tightened to specification.
23. If the engine must be running to perform a main-
tenance adjustment, keep hands, feet, clothing and
other parts of the body away from the cutting unit
blades and other moving parts.
24. Do not overspeed the engine by changing gover-
nor settings. To be sure of safety and accuracy, have
an Authorized TORO Proline Service Dealer check
maximum engine speed with a tachometer.
25. Engine must be shut off before checking oil or
adding oil to the crankcase.
26. Allow engine to cool before storing mower in any
enclosure such as a garage or storage shed. Make
sure the mower fuel tank is empty if machine is to be
stored in excess of 30 days. Do not store mower near
any open flame or where gasoline fumes may be ig-
nited by a spark. Always store gasoline in a safety-
approved, red metal container.
SAFETY INSTRUCTIONS
27. Perform only those maintenance instructions de-
scribed in this manual. If major repairs are ever need-
ed or assistance is desired, contact an Authorized
Toro Proline Service Dealer. To ensure optimum per-
formance and safety, always purchase genuine TORO
replacement parts and accessories to keep the Toro
all TORO. NEVER USE “WILL—FIT” REPLACEMENT
PARTS AND ACCESSORIES MADE BY OTHER MAN-
UFACTURERS. Look for the TORO logo to assure gen-
uineness. Using unapproved replacement parts and
accessories could void the warranty of The Toro
Company.
SAFETY AND INSTRUCTION DECALS
The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part
number is listed below and in your parts catalog. Replacement can be ordered from your Authorized Toro Distrib-
utor.
4 FORWARD - TRACTION DRIVE 8 REVERSE - TRACTION DRIVE
4 PULL TO BRAKE
ON UPPER CONTROL BAR ON LOWER CONTROL BAR
(Part No. 82-2290) (Part No. 82-2280)
"Te q a A] con
OFF © NY ou 04
now 8 X "1 d THIS MACHINE. REPLACEMENT MANUAL AVAIL ARE!
@ ay ©) BY SINGING MODEL ANO SERIAL NUMBER TO THE
ao Eon ee ann eco. LYNOALE AVE. MINNEAPOLIS. MN
ENGINE ON CONTROL PANEL
(Part No. 65-3080)
ON CONTROL PANEL
(Part No. 82-7740)
USE REVERSE - TRACTION
DRIVE BAR ONLY.
R®
USE FORWARD - TRACTION DRIVE BAR ONLY
DO NOT SHIFT UNDER LOAD.
2 3 4
ON CONTROL PLATE
(Part No. 82-7750)
IMPORTANT
SHUT OFF FUEL
BEFORE
TRANSPORTING
ON REAR FRAME
(Part No. 74-0490)
ow Or
SARIN IE
ÑROTATINE BLADES ot A OTE „AMD THROW OBJECTS.
avis / Font
* Ка pid In
* or position. Ry we fram hyde. + Rare Aly nf.
ON CONTROL PANEL
(Part No. 71-1280)
SPECIFICATIONS
16 hp Kohler Engine: four cycle, air cooled, electric
start vertical shaft engine has output of 16 hp @ 3600
RPM and 28 ft-lb torque @ 2300 RPM. Displacement
is 42.18 cubic inches. Crankcase oil capacity is 4
pints w/ filter and fuel tank capacity is 5 gallons. Cor-
rect spark plug is Champion RV 15YC or equivalent.
Frame: 11 ga. formed steel box with 1 in. dia. axle
with 1/4” x 4 U-strap rear frame bolted to frame.
Wheels and Tires: 6.5 x 13 pneumatic tires are
mounted on welded steel wheels which have grease-
able ball bearings. Recommended tire pressure is
16 psi.
Transmission: Permanently lubricated and fully en-
closed gear box. In line shift pattern with 4 forward
speeds, neutral and reverse.
Traction Drive Belts: A-section, V-belt with 3 in. dia.
take up idler to gear box from engine. 2 rib A-section
banded belt to each wheel from gear box output
shafts.
Gear Drive Reduction:
1st gear - 7.0
2nd gear - 4.5
3rd gear - 3.5
4th gear -3.0
Rev. - 6.0
Ground Speed @ 3200 Engine rpm:
1st gear — 1.9 MPH
2nd gear - 3.0 MPH
3rd gear - 3.9 MPH
4th gear - 4.5 MPH
Rev. - 2.2 MPH
Optional Accessories:
Sulky attachment, Model #30122
Sulky attachment, Model #30123
Specifications and design subject to change
without notice.
LOOSE PARTS
NOTE: Use this chart as a checklist to assure all parts have been received. Without these parts, total set-up
cannot be completed.
Description
Qty. Use
Upper Handle
Flange Capscrew 3/8 - 16 X 1” Lg.
Flangenut 3/8-16
Install Upper Handle To Frame.
+ + —
Shift Lever
Shift Lever Mounting Block
Plain Washer
Capscrew 1/4 - 28 X 2” Lo.
Install Shift Lever To Transmission
Rod Fitting
Clevis Pin
Washer
Hairpin Cotter
Install Control Rods
NN NN
Fuel Tank
Control Panel
Capscrew 5/16 — 18 X 7/8" Lg.
Lockwasher 5/16
Flatwasher 5/16
Hose Clamp
Install Fuel Tank And Control Panel
RA
Lock nut 5/16-18
Lock nut 1/4-20
Wire tie
Secure negative battery cable to engine bolt
Secure positive battery cable to solenoid
Secure wire harness
Keys -
NI (2 — —
Use in ignition switch
Battery
Battery Holder
Capscrew 3/8-16 x 1-3/4" Lg.
Locknut 3/8-16
Battery Strap
Battery Support Rod
Lock Nut 1/4-20
Battery Pad
Carriage Bolt 5/16-18
Locknut 5/16-18
Battery Cable - Positive
Battery Cable - Negative
Install Battery
a — PI PO POR STON —
Operator's Manual
Parts Catalog
Registration Card
Read Before Operating Machine
Fill Out And Return To Toro
——]— ll,
MOUNT FUEL TANK AND CONTROL PANEL
1. Position fuel tank onto rear frame aligning mount-
ing holes as shown in Fig. 1.
Figure 1
1. Fuel tank
2. Rear frame
3. Control panel
2. Loosely mount control panel to bottom of rear
frame and fuel tank with (4) capscrews, lockwashers
and washers (Fig. 1 & 2). Do not tighten capscrews at
this time.
a
Zn
Figure 2
i. Capscrews, lockwashers & washers
2. Fuel line hose clamps
3. Secure fuel line to tank fitting with hose clamp
(Fig. 2).
INSTALL SHIFT LEVER
1. Position shift lever mounting block onto shaft on
top of transmission. DO NOT remove rubber washer
on transmission,
2. Insert shift lever thru slot in control panel and
align mounting hole in lever with mounting block on
transmission. Secure lever to transmission with
1/4-28 x 2” lg, capscrew and plain washer. Torque
capscrew to 100-125 in — fo (Fig. 3).
MEME
Figure 3
1. Shift lever mounting block
2. Shift lever
3. Capscrew & washer
3. Move shift lever to reverse and 4ih gear. Control
pane! mounting holes are slotted to enable it to be
moved from side to side (Fig. 2). Position control
panel as needed to achieve full shift range. Tighten
mounting screws to a maximum of 90 in — Ib. DO NOT
OVER TIGHTEN,
INSTALL UPPER HANDLE
1. Align upper handle mounting holes with desired
mounting holes in frame (upper or lower set of holes)
and secure each side with (2) 3/8 ~16 x 1" lg. flange
capscrews and flange nuts (Fig. 4).
Figure 4
1. Upper handie
2, Frame
CONNECT
1. Position remote throttle control lever forward
until th
E
front end of slot in control base.
à. Route throttle cable under fuel tank supports
and around right side of engine (Fig. 5).
Figure
1. Throttle cable
2. Choke cable
3. Cable clamp
3. Hook cable end into top hole in governor arm
(Fig. ©).
TEN e a
о
о о
o SOS 2 St
Figure €
1. Governor arm
2. Throttle cable
3. Cable clamp screw
4, Loosen cable clamping screw allowing cable
installation, but do not tighten (Fig. 6).
8. Pull firmly on throttle cable until governor arm
contacts stop and tighten cable clamping screw
(Fig. O).
ММ HOKE CAD
1. Position remate choke control in full choke
position,
д. Route choke cable around right side of engine
(Fig. 5). Hook cable end into hole in carburetor
choke lever (Fig. 7).
3. Loosen cable clamping screw allowing cable
installation, but do not tighten (Fig. 7).
4. Pull firmly on choke cable and tighten cable
clamp screw (Fig. 7).
re is approximately 1/37 between lever and
1. Choke cable 3, Cable clamp screw
2. Choke lever 4, Connectors
5. Secure choke and throttle cables to right side
of engine with cable clamp and engine cover
mounting bolt (Fig. b).
CONNE
1. Route harness around left side of engine and
secure male and female connectors at front of
engine (Fig. 7).
д, At left side of engine, secure male and female
clutch connectors (Fig. 8).
ar
1 5. Engine mounting bolt
2. Starter solenoid 8. Remaining wire
3. Ring terminal wire 7. Positive battery cable
4, Negative battery cable 8. Small ring terminal wire
. Cilutoh connectors
3. Remove locknut from left rear engine mounting
bolt. Secure negative, black battery cable and ring
terminal wire trom ciutch connector to left rear
engine mounting bolt with locknut removed
(Fig. 8).
4. Secure remaining ring terminal wire from wire
harness and positive, red battery cable to rear
terminal of starter solenoid with a 1/4-20 locknut
(Fig. 8).
5. Secure small ring terminal wire to back end of
starter solenoid with a #10-32 locknut.
6. Secure wire harness and fuel line together with
cable tie (Fig. 9).
Figure 9
+. Cable tie
INSTALL CONTROL RODS
1. Thread a rod fitting onto each control rod approxi-
mately 2” (Fig. 10).
Figure 10
- 1. Control rod fitting 3. Clevis pin, washer
2. idier brackets & hairpin cotter
à. Mount rod fitting ends to mounting holes in idler
brackets (from outside) with clevis pins, washers and
hairpin cotters (Fig. 10).
Note: The control bar and upper handle must be par-
allel when in relaxed, drive and brake positions.
3. Check gap between control bar and upper handle
when fully engaging wheel belts. Gap should be ap-
proximately 1 to 1-1/4” (Fig. 11).
8
4. Check operation, If adjustment is required, re-
move hairpin cotter and washer securing end of con-
trol rod to upper control bar,thread rod into or out of
rod fitting to proper position and reinstall to control
bar with washer and hairpin cotter.
5. Brake rods should be adjusted so parking brake
lever can be swung into a snug position against the
upper handle while pulling back on upper control bar
(Fig. 11).
Figure 11
. Control rod
. Upper control bar
Washer & hairpin cotter
. Parking brake lever
ro UF DI i
6. If an adjustment to brake rods is required, re-
move hairpin cotter and washer securing brake rod
fitting to idler bracket (Fig. 12).
Figure 12
1. tdier bracket
2. Brake rod fitting
3. Hairpin cotter & washer
4. Wing nut
7. Adjust wing nut up or down on brake rod and re-
secure to idler bracket. Check adjustment and read-
just if necessary.
Note: Make sure brake rod is installed in forward
(“Е”) mounting hole in idler bracket.
8. Repeat procedure on opposite side if adjustment
is required.
INSTALL BATTERY
1. Mount battery holders to left rear comer or cut-
ting unit carrier frame with (2) 3/8-16 x 1-3/4” lg.
capscrews and locknuts (Fig. 13).
2. Peel off backing from battery pads and affix pads
to battery holder, positioning as shown in Fig.13.
3, Fil battery with electrolyte and charge, refer to
ACTIVATING AND CHARGING BATTERY, page 10.
Figure 13
1. Battery holders
2. Battery pads
4, Position battery onto holder with terminal posts
toward engine (Fig. 14).
5. Install the positive battery cable to positive (+)
battery terminal and the negative battery cable to the
negative (~) battery terminal and secure with car-
riage bolis and locknuts.
S. Mount battery to holders with (2) battery support
rods, battery strap and (2) lock nuts.
e
Figure 14
4. Negative battery cable
5. Battery support rod
6. Battery clamp
1. Battery bracket
2. Battery pads
3. Positive battery cable
ACTIVATE AND CHARGE BATTERY
(12 VOLT)
Since battery is not filled with electrolyte or acti-
vated, the battery, if you have not already done so,
must be removed from the machine so it can be filled
with electrolyte and charged. Bulk electrolyte with
1.260 specific gravity must be purchased from a local
battery supply outlet. Remove the battery and acti-
vate it as follows:
1. Remove filler caps from battery and slowly fill
each cel! until electrolyte is just above the plates. To
obtain best resulis, let battery set for 20 minutes.
Add electrolyte to the maximum capacity
2. Leave filler caps off and connect a 3 to 4 amp
battery charger to the battery posts. Charge the bat-
tery ata
Electrolyte gases are explosive and can
cause serious injury to eves, lungs and
skin. Wear safety goggles and rubber
gloves when working with electrolyte or
battery. Charge the battery in a well
ventilated place so gasses produced
while charging can dissipate. Since the
gases are explosive, keep open flames
and electrical spark away from the
battery; do not smoke. Nausea may
result if the gases are inhaled. Unplug
charger from electrical outlet before
connecting to or disconnecting charger
leads from battery posts.
3. When battery is charged, disconnect charger
from electrical outlet and battery posts.
4. Slowly add electrolyte to each cell until level is up
to fill ring. Install filler caps.
IMPORTANT: Do not overfill battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
FILL CRANKCASE WITH OIL
The engine does not have oil in the crankcase when
it is shipped from the factory. If engine is started
before oil is added to the crankcase, engine dam-
age could result. Therefore, before engine is
started for the first time:
1. Position mower on level surface.
2. Clean arsa around the oil dipstick to prevent for-
eign matter from entering the filler hole when dipstick
is removed.
3. Remove dipstick (Fig. 15).
a e ICAC т ® ia ue NA
N de et ie A LE сони с
DRAIN oreo at ie
E
Figure 15
1. Dipstick
4, Slowly pour approximately 4 pints of oil into the
filler neck. The engine uses any high quality detergent
oil having the American Petroleum Institute —API —
“service classification” SF. Oil viscosity (weight)
must be selected according to anticipated ambient
temperature:
A. Above +320F (09°C) — Use only SAE 30
B. Between +32°F (0°C) and 0° F (-18° C) - Use
SAE 10W30 or 10W40.
C. Below +329 F — Use 5W20 ar 5W30.
5. Wipe end of dipstick with clean rag and insert it
into filler neck. Then remove the dipstick and check
level of oil by reading the dipstick (Fig. 15). If level of
oi is low, add only enough oil to raise level to “F”
mark on dipstick. DO NOT ADD OIL SO LEVEL RISES
ABOVE “F” MARK BECAUSE ENGINE COULD BE DAM-
AGED WHEN IT IS STARTED,
6. Insert dipstick into filler neck and tighten.
Note: Check level of oil after every 5 operating hours
or each time the mower is used. Initially, change oil
after the first 5 hours of operation; thereafter, when
conditions are normal, change oil after every 25
hours of operation. However, change oil more fre-
quently when mower is operated in dusty or dirty con-
ditions.
CHECK TIRE PRESSURE
Tires are over inflated at the factory. Check tires and
insure they are inflated to 15 psi.
BEFORE OPERATING
FILL FUEL TANK WITH GASOLINE
THE TORO COMPANY STRONGLY RECOMMENDS THE
USE OF FRESH CLEAN, UNLEADED REGULAR GRADE
GASOLINE IN TORO GASOLINE POWERED PROD-
UCTS. UNLEADED GASOLINE BURNS CLEANER, EX-
TENDS ENGINE LIFE, AND PROMOTES GOOD START-
ING BY REDUCING THE BUILD-UP OF COMBUSTION
CHAMBER DEPOSITS.
NOTE: NEVER USE METHANOL, GASOLINE CON-
TAINING METHANOL, GASOHOL CONTAINING
MORE THAN 10% ETHANOL, GASOLINE ADDI-
TIVES, PREMIUM GASOLINE, OR WHITE GAS BE-
CAUSE ENGINE FUEL SYSTEM DAMAGE COULD RE-
SULT.
1. Clean area around fuel tank cap and remove cap
from tank.
2. Fill fuel tank to about 1 inch from top of the tank,
not filler neck. install fuel tank cap securely.
3. Wipe up spilled gasoline.
Because gasoline is flammable, caution
must be used when storing or handling
it. Do not fill fuel tank while engine is
running, hot or when machine is in an
enclosed area. Vapors may build up and
be ignited by a spark or flame source
many feet away. DO NOT SMOKE while
filling the fuel tank to prevent the
possibility of an explosion. Always fill
fuel tank outside and wipe up any spilled
gasoline before starting engine. Use a
funnel or spout to prevent spilling
gasoline before starting engine and fill
tank to about l inch from top of tank, not
filler neck.Store gasoline in a clean
safety- approved container and keep the
cap in place on the container. Keep
gasoline in a cool, well-ventilated place;
never in an enclosed area such as a hot
storage shed. To assure volatility, do not
buy more than a 30 day supply of
gasoline. Gasoline is a fuel for internal
combustion engines; therefore, do not
use it for any other purpose. Since many
children like the smell of gas, keep it out
of their reach because the fumes are
explosive and dangerous to inhale.
11
Throttle Control (Fig. 18) ~ The throttle control has
two positions: FAST and SLOW.
Choke Control (Fig. 16) ~ The choke control has two
positions: CHOKE and RUN.
Deck Engagement Control Ball (Fig. 16) — Control
bail used in conjunction with deck engagement switch
io release blade brake and engage electromagnetic
clutch to drive deck pulleys. Release bail to disen-
gage deck pulleys.
Deck Engagement Switch {Fig. 18) — Rocker switch
used in conjunction with control bail 10 release blade
brake and engage electromagnetic cluich to drive
deck pulleys.
Gear Shift Lever (Fig. 15) - Transmission has four
forward speeds, neutral and reverse, and has an in-
line shift pattern. Do not shift wnile unit is moving, as
transmission damage may occur.
Upper Control Bar (Fig. 16) — Shift to desired gear
and push forward on control bar to engage forward
traction operation and pull back to brake. Pull right
side of control bar to turn right and left side to turn
left.
Lower Control Bar (Fig. 16) — Shift transmission to
reverse and pull rearward on lower control bar 10 en-
gage rearward traction operation.
Parking Brake Lever (Fig. 16) ~ Pull back on upper
control bar and swing brake lever up against the up-
per handle.
STARTING AND STOPPING
1. Make sure spark plug wires are installed on spark
plugs and fuel valve is open.
2. Shift into neutral and turn ignition Key to RUN.
3. Move throttle contro! to half throttle.
4, Move choke control to CHOKE position before
starting a cold engine.
Note: A warm or hot engine usually does not require
as much choking.
5. Rotate ignition key to START. When engine starts,
release key, gradually move choke to run and regu-
late throttle to desired speed.
IMPORTANT: To prevent overheating of the starter
motor, do not engage starter longer than 10 sec-
onds. After 10 seconds of continuous cranking,
wait 60 seconds before engaging starter motor
again,
12
ignition Switch (Fig. 10) - Switch is part of battery
ignition system and it has three positions: OFF, RUN
and START. Key automatically returns to RUN position
from position when released after engine starts.
Fuel Shut-off Valve —- (Under fuel tank) Close fuel
snut-off valve when transporting or storing mower,
Figure 16
, Throttle control
. Choke control
6. Upper control bar
7. Lower control bar
. Deck engagement control ball 8. Parking brake lever
. Deck engagement switch 9.
. Gear shift lever
ignition switch
LA Ls 1 ВО e
6. To engage blade, squeeze deck engagement
contro! bail against upper control bar and press rock-
er switch forward. Hold control bail against control bar
while operating. Releasing control bail disengages
deck pulleys. Repeat procedure 10 engage deck pul-
leys if control bail is released.
7. Ta stop engine, release control ball and control
bar, shift to Neutral, move throttie to SLOW and turn
ignition key to OFF. Wait for all parts to stop moving
before leaving the operating position behind handie.
8. Pull wires off spark plugs to prevent possibility of
accidental starting before storing machine.
9. Close fuel shut off valve before storing machine.
IVPORTANT: Make sure fuel shut off valve is
closed before transporting or storing machine, as
fuel leakage may occur.
To prevent accidental starting of the
engine while performing maintenance,
shut engine off. Also, pull wires off spark
ugs. Make sure wires do nat contact
ugs accidentally.
GREASE WHEELS
Lubricate the wheel bearings every 8 hours with No. 2
general purpose grease. Wipe up any excess grease.
ERE
GREASE TRAI SSION COUPLERS
Lubricate the transmission couplers (Fig. 17) every
250 hours with No. 2 general purpose grease. Pump
grease gun about 4 times. Wipe up any excess
grease.
SERVICING AIR CLEANER
The foam pre-cieaner must be cieaned and re-olled
after every 25 hours engine operation if engine is op-
erated in clean air conditions. However, air cleaner
must be cleaned every few hours if operating condi-
tions are extremely dusty or sandy,
1. Remove wing nut and cover (Fig. 18).
Figure 18
1. Wing nut
2. Cover
2. Remove foam pre-cieaner by sliding it off the pa-
per element (Fig. 19).
Figure 19
. Foam pre-cleaner
Element
. Cover seal
. Element cover
> A
3. a. Wash foam pre-cleaner in detergent and warm
water.
b. Rinse the pre-clieaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (do not wring). Air dry.
C. Saturate foam pre-cieaner in engine oil.
Squeeze to remove excess oil.
4. Reinstall on paper cartridge.
Inspect paper element every 50 hours of operation
and replace when dirty or damaged. Do not wash pa-
per element or do not clean with compressed air as
damage will occur.
Note: With air cleaner disassembled, check air clean-
er components for damage. Replace if necessary.
Make sure rubber tube in base plate is securely in
place or severe engine damage may occur.
5. Reinstall element with pre-cleaner, element cov-
er seal, air cleaner element cover, nut, air cleaner
cover and wing nut.
6. Tighten wing nut 1/2 to 1 turn after nut contacts
cover. Do not overtighten.
IMPORTANT: Always operate engine with air clean-
er element in place or engine damage will result.
13
CHANGING CRANKCASE OIL AND FILTER
i. Check level of oil before starting engine and after
every 5 hours of operation. Maintain oil level at FULL
mark on dipstick.
To check level of oil:
a. Position mower on level surface.
b. Clean the area around oil dipstick so foreign
matter cannot enter filler hole when dipstick is re-
moved.
Cc. Remove dipstick and wipe oil off with a clean
rag.
d. Insert dipstick fully into filler neck; then remove
it and check oil level on dipstick. If level is low,
add only enough to raise level to FULL mark. Do
not overfill or engine damage may result,
e. Insert dipstick back into filler neck.
2. Change oil after first 5 hours of operation; every
25 hours thereafter. Change oil more frequently when
operating conditions are extremely dusty or dirty.
To change oil:
a. Position mower on level surface. Start and run
engine for a period ta warm the oil.
b. Turn engine off and place drain pan under
frame, below drain plug (Fig. 20). Remove drain
plug and allow all oil to flow into drain pan. Install
drain plug after oil stops flowing.
c. Remove dipstick and add oil to crankcase. Re-
fer to FILL CRANKCASE WITH OIL, page 10. Ca-
pacity of crankcase is 4 pints when changing fil-
ter, 3 pints when changing oil only. DO NOT
OVERFILL or engine damage may result.
3. Change the oil filter every other oil change. To
change filter:
To change filter:
a. Drain the oil from the engine crankcase, refer
To Change Oil, page 14.
ae
DTO
Figure 20
1. Drain plug
о. Remove old filter and wipe off the filter adapt-
er.
14
Cc. Apply a thin coating of new oil to the rubber
gasket on the new oll filter.
d. Install the new oil filter to the filter adapter.
Tighten oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter
an additional 1/4 turn. Fill the crankcase with new
oil (4 points). Refer to FILL CRANKCASE WITH OIL,
page 10.
PUEL FILTER REPLACEMENT
An in-line filter is incorporated into the fuel line be-
tween the fuel tank and carburetor (Fig. 21). Use the
following procedures should replacement become
necessary:
Figure 21
1. Fuel filter
2. Hose clamps
1. Close fuel shut off valve, loosen the hose clamp
on the carburetor side of filter and remove the fuel
ine from the filter.
à. Place a drain pan under filter, loosen the remain-
ing hose clamp and remove filter.
since gasoline is highly flammable, drain it
outdoors and make sure engine is cool ta
prevent a potential fire hazard. Wipe up any
gasoline that may have spilled. Do not drain
gasoline near any open flame or where gas-
oline fumes may be ignited by a spark. Do
not smoke a cigar, cigarette, or a pipe when
handling gasoline.
3. Install the new filter with arrow on the filter body
pointing towards the carburetor.
REPLACING SPARK PLUGS
Since air gap between center and side electrodes of
the spark plug increases gradually during normal op-
aration of the engine, check condition of electrodes
after every 25 operating hours. Recommended air
gan is 0.025 of an inch (0.035 mm). Correct spark
plug to use is a Champion RY 15YC or equivalent.
Note: The spark plug usually lasts a long time; howev-
er, the plug should be removed and checked when-
ever the engine malfunctions.
1, Clean area around spark plug so foreign matter
cannot fall into cylinder when spark plug is removed.
2. Pull spark plug wire off spark plug and remove
plug from cylinder head.
3. Check condition of side electrode, center elec-
trode, and center electrode insulator to assure there
is no damage.
IMPORTANT: A eracked, fouled, dirty or otherwise
malfunctioning spark plug must be replaced. Do
not sand blast, scrape, or clean electrodes by using
a wire brush because grit may eventually release
from the plug and fail into the cylinder, The result is
usually a damaged engine.
8. Set air gap between center and side of electrodes
at 0.025 of an inch (0.635 mm) (Fig. 22). Install cor-
rectly gapped spark plug w/gasket seal, and tighten
plug to 10-15 ft-Ib (14-20 N mj). If torque wrench 15
not used, tighten plug firmly.
0.025"
(0.635 mm)
ATLAS
|
Figure 22
ADJUSTING THROTTLE CONTROL
Proper throttle operation is dependent upon proper
adjustment of throttle control. Before adjusting the
carburetor, assure the throttle control is operating
properly.
1. Loosen cable clamp screw securing cable to en-
gine.
2. Move remote throttle control lever forward until
there is approximately 1/8” between laver and front
end of slot in control base.
3. Pull firmiy on throttle cable till governor arm con-
tacts stop (Fig. 23).
8
Зоне а" :
© ZA
Figure 23
1. Governor arm
2. Stop
4. Tighten cable clamp screw and check engine
RPM setting.
3200 + 100 - High idle
1200 + 100 — Low ide
Al
JUSTING CHOKE CONTROL
1. Loosen cable clamp screw securing cable to en-
gine.
г. Place choke control in ON position.
3. Pull firmly on choke cable and tighten cable
clamp screw (Fig. 24).
Figure 24
1. Idle fuel adjusting needle
2. die speed adjusting screw
JUSTING CARB
AD URETOR
The carburetor is designed to deliver the correct fuel
air mixture to the engine under all operating condi-
tions. The main fuel jet is calibrated at the factory and
is not adjustable. The idle fuel adjusting needle is also
set at the factory and normally does not need adjust-
ment. If, however, the engine is hard starting or does
not operate correctly at idle speeds, it may be neces-
sary to adjust the idle fuel needle.
IMPORTANT: Before the carburetor is adjusted, the
air cleaner must be clean, and throttle and choke
controls must be checked for proper operation: re-
fer to Servicing Air Cleaner, page 13 and Adjusting
Throttle and Choke Controls, page 15.
1, ldle Fuel Adjusting Needle (Fig. 24) — Close
needle by gently rotating it clockwise.
IMPORTANT: Do not close the needle too tight be-
cause the needle and seat in carburetor will likely
be damaged.
2. Rotate — open — the needle 1 turn counterclock-
wise (Fig. 24).
3. Start engine and let it run at half throttle for ap-
proximately five to ten minutes to warm up.
Engine must be running so final adjustment
of the carburetor can be performed. To
guard against possible personal Injury, shift
into neutral, and engage parking brake.
Keep hands, feet, face, and other paris of
the body away from the cutter blades, un-
derside of mower housing, discharge area,
and any rotating engine parts.
4, Idle Speed Setting ~—Move the throttle control to
SLOW setting. Set the idle speed to 1200 rpm + 75
RPM by turning the idle speed adjusting screw in or
out (Fig. 24). Check speed with a tachometer.
5. Final Setting Idie Fuel Needie — Move the
throttle control to the slow position. Turn the idle fuel
adjusting needie out {counterclockwise) until the en-
gine speed decreases (rich). Note position of the
needle.
Now turn the adjusting needle in (clockwise). The en-
gine speed may increase, then it will decrease as the
needle is turned In (lean). Note position of the
needio.
Set the needle midway between the rich and lean set-
tings.
16
6. Recheck idle speed using a tachometer.
ADJUSTIN
BELT
1. Loosen capscrew and flange nut securing idler
pulley to frame (Fig. 25). Slide pulley outward reliev-
ing belt tension,
Figure 25
. idier pulley
. Clutch retainer
. Locknut on flange stud
lo IQ we
2. Remove left front engine mounting bolt securing
clutch retainer to frame (Fig. 25). Unhook retainer
from cluich and remove retainer.
3. Disconnect in-line wire connector and remove
belt from drive pulley and clutch (Fig. 25).
4. Install new belt around clutch and drive pulley.
5. Secure in-line connectors and reinstall clutch re-
tainer to cluich and frame with engine mounting bolt.
Torque engine mounting bolt to 170-220 in-Ib.
6. Position and secure idler pulley to frame so belt
deflection is no more than 11/64” when 5-1/2 Ib of
force is applied to mid span of long leg of belt
(Fig. 25).
ADJUSTING CLUTCH
The clutch is adjustable to ensure proper engage-
ment and proper braking.
1. To adjust ciutch, tighten or loosen locknuts on
flange studs (Fig. 25).
2. Check adjustment by inserting feeler gauge thru
siots next to flange studs.
3. The proper disengaged clearance between the
clutch plates is .012 — .018 inches. It will be neces-
sary to check this clearance at each of the three slots
to ensure the plates are parallel to each other.
BRAKE ADJUSTMENT
An adjustment to the brake may be required to com-
pensate for belt stretching or brake seating.
1. To adjust brakes, refer to Install Control Rod,
page 7.
DRIVE BELT REPLACEMENT
1. Remove top capscrew securing idler support and
idier bracket to rear frame (Fig. 26).
FO
Figure 21
. idler bracket
. Hairpin cotter, washer
& brake rod fitting
. Idler support
. Top capscrew
. Bottom capserews
=
Tn La 2
2. Loosen bottom two mounting screws enough 10
allow belt to pass between drive pulley and idler sup-
port (Fig. 26).
3. Raise wheel off ground enough to allow belt re-
moval.
CLEANING COOLING SYSTEM
Clean engine cooling system frequently, by removing
any build-up of grass, dirt or other debris from the
cylinder and cylinder head cooling fing, air intake
screen on flywheel end, and carburetor-governor le-
vers and linkage. This will help insure adequate cool-
ing and correct engine speed and will reduce the pos-
sibility of overheating and mechanical damage.
17
WIRING SCHEMATIC
White
White | e y White e
Clutch |
Switc/Orange |
L
86
Blue
- uE
|
o M White | Modulle |
B ¡Starter Switch | |
S e Brown | @ 3000 rpm
Black $ eo | 11.6 vdc
: Bail Switch | @ 2.9 amps
| | | Васк
A do
Blue / White
Red _
Black
Gray Alternator
= Magneto
| Starter Solenoid
e Starter Engine
| a =
Battery |
12 Volt DC =
IDENTIFICATION AND ORDERING
The mower has two identification numbers: a model
number and a serial number. The two numbers are
stamped into a plate that is riveted to the frame on
right front corner of mower. In any correspondence
concerning the mower, supply the model and serial
numbers to assure that correct information and re-
placement parts are obtained.
18
To order replacement parts from an authorized TORO
Distributor, supply the following information:
1. Model and serial numbers of the machine.
2. Part number, description and quantity of parts
desired.
Note: Do not order by reference number if a parts
catalog is being used; use the part number.
MAINTENANCE CHART
_ р | |
Hours Cooling | Air Cleaner Sharpen | Winter Spring Spark
Date ; БиС:
Used System Service Lubrication Blade Storage Service Plug
| —
[
V40-653 19
MUN Y VOY YON
Che Coro Yramise
A ONE YEAR LIMITED WARRANTY
The Toro Company promises to repair your TORO Product if defective in materials
or workmanship. The following time periods from the date of purchase apply:
Commercial Products
1 Year
The cost of parts and labor are included, but the customer pays the transportation
costs on walk rotary mowers with cutting unit widths of less than 25”.
If you feel your TORO product is defective and wish to
rely on The Toro Promise, the following procedure is
recommended:
1. Contact your Authorized TORO ProLine Service
Dealer (the Yellow Pages of your telephone direc-
tory is a good reference source).
2. The TORO ProLine Service Dealer wiil advise you on
the arrangements that can be made to inspect and
repair your product.
3. The TORO ProLine Service Dealer will inspect the
product and advise you whether the product is
defective and, if so, make all repairs necessary to
correct the defect without an extra charge to you.
If for any reason you are dissatisfied with the distri-
butor's analysis of the defect or the service performed,
you may contact us.
Write:
TORO Consumer Products Service Department
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420
The above remedy of product defects through repair by
an Authorized TORO ProLine Service Dealer 15 the
purchaser's sole remedy for any defect.
THERE 15 NO OTHER EXPRESS WARRANTY. ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR USE ARE LIMITED TO THE DURATION
OF THE EXPRESS WARRANTY.
Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not
apply to you.
This Warranty applies only to parts or components
which are defective and does not cover repairs neces-
sary due to normal wear, misuse, accidents, or lack or
proper maintenance. Regular, routine maintenance of
the unit to keep It in proper condition is the
responsibility of the owner.
All warranty repairs reimbursable under the Toro
Promise must be performed by an Authorized TORO
ProLine Service Dealer using Toro approved replace-
ment parts.
Repairs or attempted repairs by anyone other than an
Authorized TORO ProLine Service Dealer are not
reimbursable under the Toro Promise. In addition,
these unauthorized repair attempts may result in
additional malfunctions, the correction of which is not
covered by warranty.
THE TORO COMPANY IS NOT LIABLE FOR INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES IN
CONNECTION WITH THE USE OF THE PRODUCT
INCLUDING ANY COST OR EXPENSE OF PROVIDING
SUBSTITUTE EQUIPMENT OR SERVICE DURING
PERIODS OF MALFUNCTION OR NON-USE.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you
may also have other rights which vary from state to
state.
COUNTRIES OTHER THAN THE UNITED STATES OR CANADA
Customers who have purchased TORO products exported
from the United States or Canada should contact their
TORO Distributor (Dealer) to obtain guarantee policies
for your country, province or state. If for any reason
you are dissatisfied with your Distributor's service or
have difficulty obtaining guarantee information, contact
the TORO importer. If all other remedies fail, you may
contact us at The Toro Company.
Compliance with Radio Interference Regulations Certified.
Certifie Conforme au Reglement sur le Brouillage Radioelectrique.
Lthom USA