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

FORM NO. 3318-213
x
ProLine Mid-Size
16 HP Traction Unit
Model No. 30182 — 690001 & Up
Operator’s Manual
IMPORTANT: Read this manual carefully. it contains information about your
safety and the safety of others. Also become familiar with the controls and
their proper use before you operate the product.
N
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FOREWORD
The Proline mid size mowers have advanced concepts in engineering, design and safety; and if maintained proper-
ly, 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 instructions. 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 re-
lated 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 .................... 1-2
SAFETY AND INSTRUCTION DECALS ......... 3
SPECIFICATIONS ............................ 3
LOOSE PARTS .............. reee 4
SET-UP INSTRUCTIONS ................... 4-7
BEFORE OPERATING ........................ 8
CONTROLS i, 9
OPERATING INSTRUCTIONS ................. 9
MAINTENANCE ......................... 10-13
GreaseWheels ................... ua ane 10
Grease Transmission Couplers ............. 10
ServicingAirCleaner ...................... 10
Changing Crankcase Oil and Filter .......... 10
Page
Replacing Fuel Filter ...................... 11
Replacing Spark Plugs .................... 11
Adjusting Choke Control ................... 12
Adjusting Throttle Control .................. 12
Replacing TractionBelt .................... 12
AdjustingClutch .......................... 12
AdjustingBrake .............. LL 13
Replacing Drive Belt ...................... 13
Cleaning Cooling System .................. 13
WIRING SCHEMATIC ........................ 14
IDENTIFICATION AND ORDERING ............ 14
ENGINE OWNER'S MANUAL ................. 14
THETOROPROMISE ........................ 15
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.
This cutting unit has been tested and certified for
compliance with the B71.4—-1990 specifications of
the American National Standards Institute. Al-
though hazard control and accident prevention par-
tially are dependent upon the design and configura-
tion of the machine, these factors are also depen-
dent upon awareness, concern, and proper training
of the personnel involved in the operation, trans-
port, maintenance, and storage of the machine. im-
proper use or maintenance of the machine can re-
sult on injury or death. To reduce the potential for in-
jury or death, comply with the following safety
instructions.
WARNING: Engine exhaust contains carbon monox-
ide which is an odorless, deadly poison. Carbon mon-
oxide is also known to the State of California to cause
birth defects. Do not run engine indoors or in an en-
closed area.
1
BEFORE OPERATING
1. Read and understand the contents of this Opera-
tors 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
Bloomington, Minnesota 55420-1196
2. Never allow children to operate the machine. Do
not allow adults to operate machine without proper in-
struction. 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 neutral
and lock parking brake.
5. Remove all debris or other objects that might be
picked up and thrown by the cutter blades. Keep all by-
standers away from the mowing area.
6. Do not operate unless all shields and safety de-
vices are in place. If a shield, safety device or decal is
illegible or damaged, repair or replace it before opera-
tion is commenced. Also tighten any loose nuts, bolts
and screws to assure machine is in safe operating con-
dition.
©The Toro Company — 1995
SAFETY INSTRUCTIONS
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 pre-
vent loss of control:
A. Mow only in daylight or when there is good artifi-
cial 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. Do not operate unless grass deflector, Recycler®
cover or entire grass collector is installed. The grass
deflector must always be installed and in lowest posi-
tion on the side discharge cutting unit. This product is
designed to drive objects into the ground where they
lose energy quickly in grassy areas. However, don’t
take an injury risk!! When a person or pet appears un-
expectedly in or near the mowing area, STOP MOW-
ING. Careless operation, combined with terrain
angles, ricochets, or improperly positioned guards,
can lead to thrown object injuries. Do not resume mow-
ing until area is cleared.
13. Never raise the cutting unit while the blades are ro-
tating.
14. If the cutting blades strike a solid object or the ma-
chine vibrates abnormally, shut the engine off. Remove
spark plug wire from spark plug to prevent possibility of
accidental starting. Check cutting unit and traction unit
for damage and malfunctioning parts. Repair any dam-
age before restarting the engine and operating the cut-
ting 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 run-
ning 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, release con-
trol bail and shut OFF engine.
MAINTENANCE
18. Disconnect spark plug wire from spark plug to pre-
vent accidental starting of the engine when servicing,
adjusting or storing the machine.
19. If traction unit and mower must be tipped to per-
form maintenance or an adjustment, drain gasoline
from fuel tank and oil from crankcase.
20. When driving unit forward, always use upper “For-
ward” 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 accumula-
tions 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 mainte-
nance adjustment, keep hands, feet, clothing and oth-
er 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 maxi-
mum engine speed with a tachometer.
25. Engine must be shut off before checking oil or add-
ing 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 — ap-
proved, red metal container.
27. Perform only those maintenance instructions de-
scribed in this manual. If major repairs are ever needed
or assistance is desired, contact an Authorized Toro
ProLine Service Dealer. At the time of manufacture, the
machine conformed to the safety standards in effect.
To ensure optimum performance and continued safety
conformance of the machine, use genuine TORO re-
placement parts and accessories. Replacement parts
and accessories made by other manufacturers may re-
sult in non-conformance with safety standards and
could void the warranty.
2
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 Distribu-
tor.
x FORWARD - TRACTION DRIVE 9 REVERSE - TRACTION DRIVE
@ PULL TO BRAKE ON LOWER CONTROL BAR
ON (Part No 82-2900) (Part No. 82-2280)
FAST 4 None
| Dorr © o т
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3U11041d
A DANGER
CONE
ROTATING BLADES CAN cur HANDS /FEET AND ‚THROW OBJECTS.
* Sie ap engine beto! « Keap bystand {eel x Kan su wards in pla ace.
aving operator г ров osition. — mowlng arm, a pa Y ada. * a debris fro
ON CONTROL PANEL
Jo
ENGINE IGNITION BLADE ra © .
SPEED ver ENGAGEMENT ENGINE
ON CONTROL PANEL
(Part No. 82-7740)
Р
А
R IMPORTANT
SHUT OFF FUEL
N BEFORE
G TRANSPORTING
B ON REAR FRAME
A (Part No. 74-0490) USE REVERSE - TRACTION
K ORIVE BAR ONLY.
E
ON PARKING BRAKE LEVER
(Part No. 52—2010)
(Part No. 71-1280)
READ OPERATORS MAMUAL GÉFORE OPERATING
THIS MACHINE REPLACEMENT MANUAL AVAILABLE
BY SENDING MODEL AND SERIAL RUMBEN TO THE
TORO CO. 4111 LYNDALE AVE, MINNEAPOLIS MN
55420
ON CONTROL PANEL
(Part No. 65-3090)
DA NOT SHIFT UNDER LOAD.
USE FORWARD - TRACTION ORIVE BAR ONLY
R Ni 1 2 3 4
ON CONTROL PLATE
(Part №. 82-7750)
SPECIFICATIONS
16 hp Briggs & Stratton Engine: four cycle, recoil
start with automatic compression release, vertical shaft
engine has output of 16 hp @ 3600 RPM and 26 ft—Ib
torque @ 2600 RPM. Displacement is 29.3 cubic in-
ches. Crankcase oil capacity is 4 pints with filter. Fuel
tank capacity is 5 gallons. Correct spark plug is Cham-
pion RC12 YC or equivalent. Spark arrester muffler.
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 16 pneumatic tires are
mounted on welded steel wheels which have grease-
able ball bearings. Recommended tire pressure is
15 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 — 2.2 MPH
2nd gear — 3.5 MPH
3rd gear — 4.5 MPH
4th gear — 5.2 MPH
Rev. — 2.5 MPH
Optional Accessories:
Sulky attachment, Model #30122
Sulky attachment, Model #30123
Lift Kit Part No. 84-5010 *
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 17 Ig.
Flangenut 3/8—16
Shift lever
Shift lever mounting biock
Plain washer (thick black)
Capscrew 1/4-28 x 2” Ig.
Rod fitting
Clevis pin
Washer
Hairpin cotter
Install upper handle to frame
Install shift lever to transmission
Install control rods
Fuel tank
Control panel
Capscrew 5/16—1/ x 7/8” lg.
Lockwasher 5/16”
Flatwasher 5/16”
Hose clamp
Install fuel tank and control panel
Exhaust defiector
Screws (small tapping)
Cable tie
Operator’s Manual
Parts catalog
Registration card
Install on muffler
Secure wire harness to frame
Read before operating machine
+ A | SLI В 4 В —к — | № ГО В ГО | — Ii oa
Fill out and return to Toro
SET-UP INSTRUCTIONS
MOUNT FUEL TANK AND 2. Loosely mount control panel to bottom of rear
CONTROL PANEL frame and fuel tank with (4) capscrews, lockwashers,
and flatwashers (Fig. 1). Do not tighten capscrews.
1. Place fuel tank onto rear frame and align mounting |
holes (Fig. 1). 3. Remove cap from fuel filter. Secure fuel line to fuel
filter, using the hose clamp. (Fig. 6).
INSTALL SHIFT LEVER
1. Position shift lever mounting block onto shaft on
top oftransmission. 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 trans-
mission. Secure lever to transmission with 1/4— 28 x 2”
lg. capscrew and thick, black washer. Torque
capscrew to 100—125 in — Ib (Fig. 2).
1717
Figure 1
1. Fuel tank
2. Rear frame
3. Control panel
4. Capscrews, lockwashers, and flatwashers
5. Slots for adjustment
Nl
1718
Figure 2
1. Shift lever
2. Control panel
3. Mounting block
4. Capscrew and thick, black washer
3. Move shift lever to reverse and 4th gear. Control
panel mounting holes are slotted to enable it to be
moved from side to side (Fig. 1). 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 (two) 3/8 — 16 x 17 ig. flange
capscrews and flange nuis. Tighten capscrews to
23—27ft.— los. Route cables and wire harness inside of
frame (Fig. 3).
Figure 3
1. Upper handie 3. Wire harness
2, Frame 4. Cables
CONNECT THROTTLE CABLE
1. Route throtile cable around right side of engine
(Fig. 4).
2. Move throtile lever on control panel to FAST posi-
tion.
3. Hook Z-bend at end of throttle wire into throttle arm
(Fig. 4).
4. Loosen cable clamp screw and insert throttle cable
behind the cable clamp (Fig. 4).
5. Pull slightly on the throttle cable to remove any
slack and tighten the clamp (Fig. 4).
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Figure 4
1. Throttle cable
2. Z-bend hooked in
5. Choke cable
6. Z-bend hooked in
throtile arm choke arm
3. Screw 7. Screw
4. Gable clamp 8. Cable clamp
CONNECT CHOKE CABLE
1. Route choke cable around left side of engine
(Fig. 4).
2. Move choke lever on control panel to CHOKE posi-
tion.
3. Hook Z-bend at end of choke wire into choke arm
(Fig. 4).
4. Loosen cable clamp screw and insert choke cabie
behind the cable clamp (Fig. 4).
5. Pull slightly onthe choke cable to remove any slack
and tighten the clamp screw (Fig. 4).
1. Route wire harness along the inside of the left han-
dle.
2. Push the rectangular connector together (Fig. b).
3. Route the other part of the wire harness around to
the right side of the engine. Push the red wire connec-
tors together (Fig. 6). Secure the black ground wire
with the small O-ring connector to the terminal on the
engine, using the #8 nut (Fig. 6). Also secure the other
black ground wire with the large O-ring connector to
the engine mount, using the 5/18" nut (Fig. 6).
4. Secure the wire harness to the handle frame, using
the cable tie (Fig. 5).
Figure 5
1. Wire harness
2. Rectangular connectors
3. Cable tie
Figure 6
1. Bed wire connectors
2. Black wire/small connector
3. Black wire/large connector
4. Fuel filter
5. Hose clamp
FALL
1. Thread a rod fitting onto each control rod approxi-
mately 2” (Fig. 7) or until upper control rod (Fig. 8) is
perpendicular to ground.
Figure 7
1. Control rod fitting 3. Clevis pin, washer
2. idler brackets & hairpin cotter
2. Mount rod fitting ends to mounting holes in idler
brackets (from outside) with clevis pins, washers and
hairpin cotters (Fig. 7).
3. Check gap between conirol bar and upper handle
when fully engaging wheel belts. Gap should be ap-
proximately 1 to 1-1/4" (Fig. 8).
Note: The control bar and upper handle must be paral-
lel when in relaxed, drive and brake positions.
4. Check operation. lf adjustment is required, remove
hairpin cotter and washer securing end of control 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 cotier.
5. Brake rods should be adjusted so parking brake le-
ver can be swung into a snug position against the up-
per handle while pulling back on upper control bar
(Fig. 8).
Figure 8
1. Control rod
2. Upper contro! bar
3. Hairpin cotter
4. Parking brake lever
6. [If an adjustment to brake rods is required, remove
hairpin cotter and washer securing brake rod fitting to
idler bracket (Fig. 9).
Figure 9
1. idler bracket 3. Hairpin cotier & washer
2. Brake rod fitting 4. Wing nut
7. Adjust wing nut up or down on brake rod and rese-
cure to idler bracket. Check adjustment and readjust if
necessary.
Note: Make sure brake rod is installed in forward (“F”
mounting hole in idler bracket.
8. Repeat procedure on opposite side if adjustment is
required.
Mount exhaust deflector to muffier, using four mount-
ing screws (Fig. 10).
2407
Figure 10
. Exhaust deflector
. Screws (4)
BD we
BEFORE OPERATING
FILL CRANKCASE WITH OIL
Crankcase capacity is 56 oz. with new filter, 48 oz. if fil-
ter is not changed.
The engine does not have oil in the crankcase when
itis shipped from the factory. If engine is started be-
fore oil is added to the crankcase, engine damage
could result. Therefore, before engine is started for
the first time:
1. Position mower on level surface.
2. Clean area around the oil dipstick to prevent for-
eign matter from entering the filler hole when dipstick is
removed.
3. Unscrew the dipstick (Fig. 11).
2403
Figure 11
1. Dipstick
2. Filler neck
4. Slowly pour approximately 4 pints of oil into the fill-
er neck (Fig. 11). The engine uses any high quality de-
tergent oil having the American Petroleum Institute
— АР| — “service classification” SE, SF, or SG. The rec-
ommended oil to use is SAE 30 above 40°F and 10W30
or 5W40 below 40°F.
5. Wipe end of dipstick with clean rag and screw it
onto the filler neck. Then unscrew the dipstick and
check level of oil by reading the dipstick (Fig. 10). If lev-
el of oil is low, add only enough oil to raise level to FULL
mark on dipstick. DO NOT ADD OIL SO LEVEL RISES
ABOVE FULL MARK BECAUSE ENGINE COULD BE
DAMAGED WHEN IT IS STARTED.
6. Screw dipstick onto filler neck tightly.
Note: Check level of oil after every 5 operating hours or
each time the mower is used. Initially, change oll after
the first 5 hours of operation; thereafter, when condi-
tions are normal, change oil after every 50 hours of op-
eration. However, change oil more frequently when
mower is operated in dusty or dirty conditions.
CHECK TIRE PRESSURE
Tires are over inflated at the factory. Check tires and in-
sure they are inflated to 15 psi.
FILL FUEL TANK WITH GASOLINE
THE TORO COMPANY STRONGLY RECOMMENDS
THE USE OF FRESH CLEAN, UNLEADED REGULAR
GRADE GASOLINE. UNLEADED GASOLINE BURNS
CLEANLY, EXTENDS ENGINE LIFE, AND PROMOTES
GOOD STARTING.
NOTE: NEVER USE METHANOL, GASOLINE CON-
TAINING METHANOL, GASOHOL CONTAINING
MORE THAN 10% ETHANOL, GASOLINE ADDI-
TIVES, PREMIUM GASOLINE, OR WHITE GAS BE-
CAUSE THE FUEL SYSTEM COULD BE DAMAGED.
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.
A DANGER
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 possi-
bility 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 one
inch from top of tank, not filler neck.
Store gasoline in a clean safety— ap-
proved 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 combus-
tion 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.
CONTROLS
Throttle Control (Fig. 12) — The throttle control has
three positions: CHOKE, FAST and SLOW.
Deck Engagement Control Bail (Fig. 12) — Control
bail used in conjunction with deck engagement switch
to release blade brake and engage electromagnetic
clutch to drive deck pulleys. Release bail to disengage
deck pulleys.
Deck Engagement Switch (Fig. 12) — Rocker switch
used in conjunction with control bail to release blade
brake and engage electromagnetic clutch to drive
deck pulleys.
Gear Shift Lever (Fig. 12) — Transmission has four
forward speeds, neutral and reverse, and has an in—
line shift pattern. Do not shift while unit is moving, as
transmission damage may occur.
Upper Control Bar (Fig. 12) — 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. 12) — Shift transmission to
reverse and pull rearward on lower control bar to en-
gage rearward traction operation.
Parking Brake Lever (Fig. 12) — Pull back on upper
control bar and swing brake lever up against the upper
handle.
Choke Control (Fig. 12) — Two positions: CHOKE
and RUN.
Ignition Switch (Fig. 12) — Key switch is used in con-
junction with recoil starter. Switch has two positions:
RUN and OFF
Recoil Starter — Pull recoil Starter handle to Start en-
gine.
Fuel Shut-off Valve — (Under fuel tank) Close fuel
shut—off valve when transporting or storing mower.
Figure 12
1. Throttle control 6. Lower control bar
2. Deck engagement control bail 7. Parking brake lever
3. Deck engagement switch 8. Ignition switch
4. Gear shift lever 9. Choke control
5. Upper control bar
OPERATING INSTRUCTIONS
STARTING AND STOPPING
1. Make sure Spark plug wire is installed on spark
plug and fuel shut-off valve is open.
2. Shift into neutral and turn ignition key to RUN.
3. Move throttle control to FAST position and choke
control to CHOKE before starting a cold engine.
Note: A warm or hot engine usually does not require
any choking. To start a warm engine, move throttle con-
trol to FAST position.
4, Grasp recoil starter handle firmly and pull out until
positive engagement results; then pull handle vigor-
ously to start engine and allow rope to rewind slowly.
IMPORTANT: Do not pull recoil rope to its limit or let
go of the starter handle when rope is pulled out be-
cause rope may break or recoil assembly may be
damaged.
9
5. When engine starts move choke control to RUN
position.
6. To engage blade, squeeze deck engagement con-
trol bail against upper control bar and press rocker
switch forward. Hold control bail against control bar
while operating. Releasing control bail disengages
deck pulleys. Repeat procedure to engage deck pul-
leys if control ball is released.
7. To stop engine, release control bail and control bar,
shift to Neutral, move throttle to SLOW and turn ignition
key to OFF. Wait for all parts to stop moving before leav-
ing the operating position behind handle.
8. Pull wire off spark plug to prevent possibility of ac-
cidental starting before storing machine.
9. Close fuel shut off valve before transporting or stor-
ing machine because fuel may leak.
To prevent accidental starting of the en-
gine while performing maintenance, shut
engine off. Also, pull both wires off spark
plugs. Make sure wires do not contact
plugs accidentally.
Lubricate the wheel bearings every 8 hours with No. 2
general purpose grease. Wipe up any excess grease.
Lubricate the transmission couplers (Fig. 13) every 250
hours with No. 2 general purpose grease. Pump
grease gun about 4 times. Wipe up any excess grease.
Figure 13
RR CLE
Service foam pre-cleaner every day. Replace paper
cartridge after every 100 operating hours. Service the
foam pre-cleaner and replace the paper cartridge more
frequently when operating in extremely dusty and dirty
conditions.
1. Pull out on the retaining tabs and remove the air
cleaner cover (Fig. 14).
> “Ez a
2406
Figure 14
1. Retaining tabs 4. Paper cartridge
à. Air cleaner cover 5. Foam element
3. Knob
2. Unscrew the knob and remove air cleaner assem-
bly (Fig. 14).
3. Remove foam pre-cleaner by sliding it off the paper
cartridge (Fig. 14).
4. a. Wash foam pre-cleaner in solution of liquid
soap and warm water. Squeeze foam to remove
dirt. Do not twist the foam because it may tear.
b. Rinse foam pre-cleaner thoroughly until all soap
suds are eliminated. Squeeze out excess water. Do
not twist pre-cleaner.
c. Wrap foam pre-cleaner in a cloth and squeeze
dry. Do not twist pre-cleaner.
d. Saturaie foam pre-cleaner with engine oil.
squeeze to remove excess oil. A damp foam is de-
sirable.
5. Clean paper cartridge by gently tapping its flat side
against a flat surface. Replace the paper cartridge if it is
very dirty.
IMPORTANT: Do not wash the paper element or use
pressurized air, as damage will occur.
6. Install air cleaner assembly.
IMPORTANT. Always operate engine with air clean-
er assembly installed or engine will be damaged.
= MT ER
1. 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,
c. Unscrew dipstick and wipe oil off with a clean
rag.
d. Screw dipstick back onto filler neck.
e. Unscrew dipstick and check oil level. if level is
low, add only enough oil io raise level to FULL
mark. Do not overfill or engine damage may result.
f. Screw dipstick back onto filler neck tightly.
2. Change oil after first 5 hours of operation; every 50
hours thereafier.
To Change Oil:
a. Position mower on level surface. Start and run
engine until the oil gets warm.
b. Shut engine off. Place drain pan below drain
plug (Fig. 15). Remove drain plug and allow all oil
to flow into drain pan. install drain plug after oil
stops flowing.
10
3.
hou
MAINTENANCE
c. Remove dipstick and add oil to crankcase. Refer
to Check Level of Oil, page 10. Capacity of crank-
case is 4 pints when changing filter, 48 oz. when
changing oil only. DO NOT OVERFILL because the
engine may be damaged.
Change the oil filter after every 100 operating
rs. To change filter:
a. Drain the oil from the engine crankcase, refer To
Change Oil, page 10.
2403
Figure 15
1. Drain plug
b. Remove the oil filter drain plug located at the
base of the oil filter adapter (Fig. 16). Drain oil into
pan.
c. Remove old filter and wipe off the filter adapter.
Reinstall the filter drain plug.
d. Apply a thin coating of new oil to the rubber gas-
ket on the new oil filter.
11
Figure 16
1. Drain plug
2. Oil filter
e. Install the new oil filter to the filter adapter. Tight-
en oil filter clockwise until the rubber gasket con-
tacts the filter adapter, then tighten the filter an ad-
ditional 1/4 turn. Fill the crankcase with fresh oil; re-
fer to Fill Crankcase with Oil, page 8.
REPLACING FUEL FILTER
An in-line filter is in the fuel line between the fuel tank
and carburetor (Fig. 6). Replace fuel filter once a year.
1. Place a drain pan under fuel filter.
2. Close fuel shut-off valve. Slide the hose clamps off
the filter and separate the fuel lines from the filter
(Fig. 6).
CAUTION
Since gasoline is highly flammable, drain it
outdoors and make sure engine is cool to
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 toward the carburetor.
REPLACING SPARK PLUGS
This engine has two spark plugs.
Since air gap between center and side electrodes of
the spark plug increases gradually during normal oper-
ation of the engine, check condition of electrodes after
every 50 operating hours. Recommended air gap is
0.040 of an inch (1.02 mm). Correct spark plug is a
Champion RC 12YC.
Note: The spark plug usually lasts a long time; howev-
er, the plug should be removed and checked whenever
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 cracked, 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 fall into the cylinder. The result is
usually a damaged engine.
4. Set air gap between center and side of electrodes
at 0.040 of an inch (1.02 mm) (Fig. 17). Install correctly
gapped spark plug w/gasket seal, and tighten plug to
30 ft—Ib (40 Nm). If torque wrench is not used, tighten
plug firmly.
MAINTENANCE
x
= bow
(1.02 mm)
Figure 17
ADJUSTING CHOKE CONTROL
The choke may need to be adjusted if the engine does
not start, especially a cold engine.
Proper choke operation is dependent upon proper ad-
justment of the throttle control. Before adjusting the
carburetor, assure the throttle control is operating
properly.
1. Remove the air cleaner assembly.
2. Loosen cable clamp screw until choke cable is
loose (Fig. 18).
3. Move choke lever on control panel to CHOKE posi-
tion. Pull firmly on the choke cable until the choke plate
inside the carburetor closes completely. Then tighten
the screw to lock the adjustment.
4. Install the air cleaner assembly.
>, -
In
y — | a
4 LT «ТТ UT
TT
Aer LL
Figure 18
3. Screw
4. Throttle cable
2401
1. Screw
2. Choke cable
ADJUSTING THROTTLE CONTROL
1. Loosen the cable clamp screw until the throttle
cable is loose (Fig. 18).
2. Move throttle lever on control panel to FAST posi-
tion. Pull slightly on the throttle cable and tighten the
screw to lock the adjustment.
REPLACING TRACTION BELT
1. Raise the front of the machine and hold with jack
stands.
1221
Figure 19
4. Tension spring
5. Adjusting nut
6. Pivot bolt
1. Traction belt
2. Idler pulley
3. Clutch retainer
2. Disconnect in-line wire connectors from wiring
harness (Fig. 19).
3. Remove left front engine mounting bolt securing
clutch retainer to frame. Unhook retainer from clutch
and remove retainer (Fig. 19).
4. Unhook tension spring from side of frame (Fig. 19).
5. Loosen pivot bolt enough to remove traction belt
from the drive pulley and clutch.
6. Install new belt around clutch and drive pulley.
7. Install belt around idler pulley (Fig. 19).
8. Torque pivot bolt to 35-40 ft-ib. Install tension
spring between idler arm and frame bracket (Fig. 19).
9. Hook clutch retainer into clutch and secure to
frame with engine mounting bolt. Torque engine
mounting bolt to 170-220 in—lb.
10. Connect clutch in—line connector to wire harness.
ADJUSTING CLUTCH
The clutch is adjustable to ensure proper engagement
and proper braking.
1. To adjust clutch, tighten or loosen locknuts on
flange studs (Fig. 19).
2. Check adjustment by inserting feeler gauge thru
slots next to flange studs.
3. The proper disengaged clearance between the
clutch plates is .012 — .018 inches. lt will be necessary
to check this clearance at each of the three slots to en-
sure the plates are parallel to each other.
12
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 Rods,
page 6.
1. Remove top capscrew securing idler support and
idler bracket to rear frame (Fig. 20).
и
3
wh Ss
Tor
Figure 20
1. idler bracket
. Hairpin cotter, washer
& brake rod fitting
3. idler support
4. Top capscrew
5. Bottom capscrews
Der
2. Loosen bottom two mounting screws enough to al-
low belt to pass between drive pulley and idler support
(Fig. 20).
3. Raise wheel off ground enough to allow belt remov-
al.
CLEA COOLIN YSTE
Clean engine cooling system after every 100 operating
nours. Remove any build-up of grass, dirt or other de-
bris from the cylinder and cylinder head cooling fins, air
intake screen on flywheel end, and carburetor —gover-
nor levers and linkage. This will help insure adequate
cooling and correct engine speed and will reduce the
possibility of overheating and mechanical damage.
WIRING SCHEMATIC
RED
RED
[
CLUTCH SWITCH
N.O.
IGNITION SWITCH
BLACK
7.5A
FUSE
— BROWN
LT BLUE
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O
=
= |
N
= ‚О.
МАСМЕТО < |
m |
ENGINE
RED
ALTERNATOR
1
—
GROUND
ORANGE
GROUND
85 87
> >
N.O.O
RELAY
с BLADE CLUTCH COIL
3 OHMS
@3000 RPM
CLUTCH 11.6 VDC
86 30 CONNECTOR (22.9 AMPS
GREEN
———+
| qu
| — CLUTCH
| GROUND
MODULE |
|
DN
| 3
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 con-
cerning the mower, supply the model and serial num-
bers to assure that correct information and replace-
ment parts are obtained.
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 de-
sired.
Note: Do not order by reference number if a parts ca-
talog is being used; use the part number.
ENGINE OWNER’S MANUAL
The engine owners manual supplied with this product
contains information for California Emission Control
Regulation related to emission systems, engine main-
tenance, and warranty. information in the engine own-
er's manual should be used in place of information in
this Toro operator's manual.
V46-752
Keep the engine owners manual with your product.
Order a new manual from the engine manufacturer if
you lose the manual or if it becomes damaged or illeg-
ible.
14
ProLine
Products
THE TORO TOTAL COVERAGE
GUARANTEE
A One Year Limited Warranty
(A Full Two-Year Warranty for Residential Use)
What Is Covered By This Express Warranty?
The Toro Company promises to repair any TORO Pro-
Line product used for commercial, institutional, or
rental purposes if defective in materials or workman-
ship for a period of one year from the date of pur-
chase. The cost of parts and labor are included as
well as transportation within a 15 mile radius of a
TORO ProLine Service Dealer.
What Products Are Covered By This Warranty?
ProLine products covered by this warranty include
the ProLine 118, 120, 220, 616, 620, 724 riding prod-
ucts and wide area walk behind mowers and their
cutting decks and accessories.
How About Residential Use?
TORO ProLine products used for residential use are
covered by a full two—year warranty.
How Do You Get Warranty Service?
Should you feel your TORO ProLine product contains
a defect in materials or workmanship, contact the
dealer who sold you the product or any TORO Pro-
Line Service Dealer. The Yellow Pages of your tele-
phone directory is a good reference source; look un-
der TORO Commercial Service Dealers. The Service
Dealer will either arrange service at his/her dealership
or recommend another authorized Service Dealer
who may be more convenient. You may need proof of
purchase (copy of registration card, sales receipt,
etc.) for warranty validation.
If for any reason you are dissatisfied with a Service Deal-
ers analysis of the defect in materials or workmanship
or if you need a referral to a TORO ProLine Service Deal-
er, please feel free to contact us at the following ad-
dress:
Toro Customer Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
612-888-8801
What Must You Do To Keep The Warranty In Effect?
You must maintain your TORO Product by following
the maintenance procedures described in the opera-
tors manual. Such routine maintenance, whether per-
formed by a dealer or by you, is at your expense.
What Does This Warranty Not Cover?
and
How Does Your State Law Relate To This Warranty?
There is no other express warranty except as de-
scribed above. This express warranty does not cover:
e Cost of regular maintenance service or parts, such
as filters, fuel, lubricants, tune—up parts, blade
sharpening, brake and clutch adjustments.
e Any product or part which has been altered or mis-
used or required replacement or repair due to nor-
mal wear, accidents, or lack of proper mainte-
nance.
e Repairs necessary due to improper fuel, contami-
nants in the fuel system, or failure to properly pre-
pare the fuel system prior to any period of non—
use over three months.
e Pickup and delivery charges for distances beyond
a 15 mile radius from a TORO ProLine Service
Dealer.
All repairs covered by this warranty must be performed
by a TORO Service Dealer using Toro approved re-
placement parts.
Repair by a TORO Service Dealer is your sole remedy
under this warranty.
The Toro Company is not liable for indirect, inci-
dental or consequential damages in connection
with the use of the TORO Products covered by this
warranty, including any cost or expense of provid-
ing substitute equipment or service during reason-
able periods of malfunction or non—use pending
completion of repairs under this warranty. Some
states do not allow exclusions of incidental or con-
sequential damages, so the above exclusion may
not apply to you.
This warranty gives you specific legal rights, and
you may also have other rights which vary from
state to state.
fail, you may contact us at The Toro Company.
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 Dis-
tributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with
your Distributor’s service or have difficulty obtaining guarantee information, contact the TORO importer. If all other remedies
15