Toro HMR-1600 Riding Product Operator's Manual

 FORM NO. 3313-655
( >
MODEL 55620 — 9000001 & UP OPERATOR'S
MANUAL
HMR™ 1600
The TORO RIDER meets or
exceeds the American Na-
tional Standards Insti-
tute's safety stan-
dards for Lawn
Tractors; thus,
Toro proudly displays the OPEI safety seal.
ANSIB71.1-1986 SAFETY STANDARD *
To assure maximum safety and optimum perform-
ance, and to gain knowledge of the rider, it is
essential that you or any other operator, read and
understand the contents of this manual before
the engine is started. Failure to comply with
the safety instructions may result in per-
sonal injury.
FOREWORD
The TORO Rider contains the latest engineering and technical workmanship and should provide long
troublefree performance and service.
Since you have purchased this fine product, we are sure that dependability and performance are important to
you. TORO is also concerned about future use of the machine and of safety to the user. Therefore, you should
read this manual thoroughly so that proper safety, operation and maintenance procedures are practiced at all
times. The major sections of this manual are:
1. Safety Instructions 3. Before Operating 5. Maintenance
2. Setting Up Instructions 4. Operating Instructions 6. Trouble Shooting
Safety, mechanical and some general information in this manual is emphasized. DANGER, WARNING and
CAUTION identify safety messages. Whenever the triangular safety symbol appears it is followed by a safety
message that must be read and understood. More complete details concerning safety are contained on page 3, 4
and 5. IMPORTANT identifies special mechanical information and NOTE identifies general information worthy
of special attention.
OPTIONAL SPARK ARRESTER
In some areas there are local, state or federal regulations requiring that a spark arrester be used on the engine of
this mower. If a spark arrester is required, order the following parts from your local Authorized Toro Service
Dealer.
1 Spark Arrester, part no. 68-3790
These parts are approved by the United States Department of Agriculture Forestry Service.
When a mower is used or operated on any California forest, brush or grass covered land, a working
order spark arrester must be attached to muffler. If not, the operator is violating state law, Section
4442 Public Resources Code.
gag TRE WE WE we we
Further assistance concerning safety, operation and maintenance can be acquired by contacting your local
Authorized TORO Service Dealer. Your TORO Authorized Service Dealer can provide you with genuine TORO
replacement parts and also optional equipment for your TORO Rider. Keep your TORO all TORO. Buy genuine
TORO parts and accessories.
TABLE OF CONTENTS
Page Page
SAFETY INSTRUCTIONS sus cm 2:07:00 3-4 MAINTENANCE + u5 cs Peur eau craquer 15-25
SAFETY AND INSTRUCTION DECALS ............ 5 Grease Front Axle Spindles and
SPECIFICATIONS .......roeresosroeerorearererc. 6 Front 8: Back Wheels ..................... 15
LOOSE PARTO sions as son STE 7 Grease Steering Spindle .................... 15
SETTING UP INSTRUCTIONS ever eee 7-8 Lubricate Mechanical Pivot Points ............ 16
Install :Frort Wheels... 2... 7 Servicing Air Cleaner ..........ceeereeeeeooo 16
Install Steering Wheel Assembly .............. 8 Changing Crankcase Oil .................... 16
ACJUSNEDOR Ts e à 8 Fuel Filter Replacement ..........ñeoeeeecrono 17
BEFORE OPERATING ................00 m0... 8-10 Replacing Spark Plugs ........... Y ua ed aa 18
Activating and Charging Battery (12 Volt) ....... 8 Adjusting Throttle Control .......=......eí..e.o— 18
Check Crankcase Oil Level ................... 9 Adjusting Choke Control .................... 19
Fill Fuel Tank With Gasoline ................. 10 Adiusting Carburetor 1140004004 000 ÜWE WW 19
Check Tire Pressure ........... RRR a 10 Andjustino Drive CHBINS «==v==0= een. 19
CONTROLS.....ñ_eereeoosssroroaooeooovrarore, 11 Replacing Drive Chains ......o_oeeeceecreeroo 20
STARTING AND STOPPING INSTRUCTIONS... 12-13 Adjusting Front Wheel Alignment ............ 20
To Start Machine -::= asus 12 Aciustino Brakes <=... 5.0.0.5 Us 20
Oparate Cutter D0K === == === WE 12 Adjusting Electric Deck Clutch ............... 21
To Stop .......eeeesenroooecaarereanercarne. 12 Adjusting Transmission Linkage . ............. 21
Break-In 77 ds Sa da 12 Shift Linkage Adjustment .........o_eeeere.. 21
Using Parking BIákO ::=- =1:====2 === Za arte 12 Adjusting Linkage to Steering Clutches ........ 22
Adjusting Height-of-Cut..................... 12 Replacing Traction Belts .................... 22
Adjust Gage Wheels ..........coc_eeevvceooo 12 Wheel Removal ........awceweee0oreosseccooo 23
Adjust Rear Rollers ........0.0000000000 000000 13 Checking Safety Interlock System. ............ 24
OPERATING INSTRUCTIONS ............... 13-14 Battery Charging System......r.o_eeeoeecrreoo 24
EA E eos oo | 13 Preparing Mower For Storage... ............. 24
Operating Procedure ........erwwee—eeeeeosreoo 13 WIRING DIAGRAM ........e_eo.eceoosoocorevoo 26
Grass Cutting TIDS +3: 65745 506 CADA 14 IDENTIFICATION AND ORDERING .............. 26
MAINTENANCE INTERVAL CHART ............. 14 A ET ing on e 27
THE TORO GUARANTEE ............... Back Cover
COPYRIGHT © ALL RIGHTS RESERVED
The Toro Company — 1988
2 MINNEAPOLIS, MN 55420 — U.S.A.
SAFETY INSTRUCTIONS
This safety alert symbol
means CAUTION,WARN-
ING or DANGER —
“personal safety instruc-
tion”. Read and under-
stand the instruction
because it has to do with
safety. Failure to comply with the instruction
may result in personal injury.
de an ale Sie 16 6 00 GEL GE A A. A 4
a
Improper use or maintenance of the machine can
result in injury. To reduce the potential for injury,
comply with the following safety instructions.
BEFORE OPERATING
1. Read and understand the contents of this
Operator'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. Do not allow children to operate the machine.
Do not allow adults to operate the machine
without proper instruction.
3. 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.
4. Keep all shields and safety devices in place. If
a shield, safety device or decal is defective or
damaged, repair or replace it before operation is
commenced. Also tighten any loose nuts, bolts and
screws to assure machine is in safe operating
condition.
5. 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 sub-
stantial shoes. Wearing safety glasses, safety shoes
and a helmet is advisable and required by some
local ordinances and insurance regulations.
6. Fill fuel tank with gasoline before starting the
engine. Avoid spilling gasoline. Since gasoline is
flammable, handle it carefully.
A. Use an approved gasoline container.
B. Do not fill fuel tank indoors, when the engine
IS running, or until engine cools for several
minutes after running.
O
Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and up to about one half
inch from top of the tank, not the filler neck.
E. Open doors if engine will be run in the garage
because exhaust fumes are dangerous and
could possibly be deadly. Do not run engine
indoors.
F. Wipe up any gasoline that spilled, and install
gasoline container cap and rider fuel tank cap
before starting the engine.
7. Before attempting to start the engine, shift into
neutral, move deck engagement switch into DIS-
ENGAGE position and lock parking brake. Engine will
not start unless gear shift is in neutral, deck engage-
ment switch is in DISENGAGE position, and the
operator is on the vehicle seat.
8. Assure interlock system is functioning correctly
before each use of the rider. Have all safety related
components and safety interlock switches checked by
an Authorized TORO Service Dealer every two years
to assure safe operation of the rider.
WHILE OPERATING
9. Never carry passengers on the rider.
10. Keep people and pets a safe distance away from
the rider and area of operation.
11. Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes are
hazardous and could possibly be deadly.
12. Using the machine demands attention, and to
prevent loss of control:
A. Mow only in daylight or when there is goo
artificial light. о
Watch for holes or other hidden hazards.
Do not drive close to a drop off, ditch, creek or
other hazard.
D. Reduce speed when making sharp turns and
when turning on hillsides.
E. Never mow steep slopes.
Never mow side hills over 10°. See slope
gage on page 27.
13. During operation the grass deflector must be
installed on mower housing. Move deck engagement
switch into DISENGAGE, shift into neutral, set park-
ing brake, and shut engine off before unclogging
discharge chute. Use a stick to remove any
obstruction.
SAFETY INSTRUCTIONS
14. Before backing up, move deck engagement switch
into DISENGAGE. Do not mow in reverse unless ab-
solutely necessary and then only after careful obser-
vation of the entire area behind the mower.
15. Cut grass slopes up and down, never across the
face. When going uphill or downhill do not stop or
start suddenly. To prevent tipping or loss of control,
reduce speed on slopes and when making turns.
Extreme caution must be used when changing
direction on slopes. If machine stops while going
uphill, stop blade and back slowly down.
16. Watch out for traffic when crossing or near roads.
Always yield the right-of-way.
17. If the cutting blades strike a solid object or the
machine vibrates abnormally, shut engine off.
Remove high tension wires from spark plugs to
prevent possibility of accidental starting. Check
cutting unit and traction unit for damage and defec-
tive parts. Repair any damage before restarting the
engine and operating the cutting unit. Be sure blades
are in good condition and blade bolts are tight.
18. Keep face, hands, feet, or any other part of the
body and clothing away from concealed, moving, or
rotating parts such as the cutter blades, discharge
area, wheels, belts, and engine. Always sit on the seat
while operating the rider and mower.
19. When driving from one area to another, crossing
a gravel driveway, road, or sidewalk, move deck
engagement switch into DISENGAGE and raise
mower housing to its highest level. This will prevent
loose sand, rocks, and other debris from being thrown
by the whirling blades.
20. 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.
21. Before leaving the operator 's position on the seat,
or leaving rider unattended, shift transmission into
NEUTRAL, apply parking brake, move deck engage-
ment switch to OFF, and shut OFF engine.
22. Use only the drawbar hitch point at rear of chassis
to pull atrailer or cart. Limit loads to those that can be
controlled safely. Be very careful when backing and
turning: Make wide turns with trailer attached. Turn-
Ing too sharp could damage trailer or vehicle.
MAINTENANCE
23. Disconnect high tension wires from spark plugs
to prevent accidental starting of the engine when
servicing, adjusting or storing the machine.
24. If rider and mower has to be tipped to perform
maintenance or an adjustment, drain gasoline from
fuel tank, oil from crankcase, and remove battery.
Rider is not designed to stand on rear end.
25. Perform only those maintenance instructions
described in this manual. If major repairs are ever
needed or assistance is desired, contact an Author-
ized Toro Dealer.
26. To reduce potential fire hazard, keep the engine
free of excessive grease, grass, leaves and accumu-
lations of dirt.
27. Be sure machine is in safe operating condition by
keeping nuts; bolts and screws tight. Check the blade
mounting bolts frequently to be sure they are
tightened to specification.
28. If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing
and other parts of the body away from the cutting
unit blades and other moving parts.
29.Do not overspeed the engine by changing
governor settings. To be sure of safety and accuracy,
have an Authorized TORO Dealer check maximum
engine speed (3300 RPM) with a tachometer.
30. Engine must be shut off before checking oil
or adding oil to the crankcase.
31. To ensure optimum performance 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 MANUFAC-
TURERS. Look for the TORO logo to assure
genuineness. Using unapproved replacment parts
and accessories could void the warranty of The
Toro Company.
TORO
A WARNING
USE EXTREME CAUTION
ON HILLS AND SLOPES
id) E
TO MINIMIZE THE RISK OF INJURY
= Never mow sleep slopes.
« Never mow side hills over 10°.
« Mow slopes up and down, not across the face.
= When going uphill ar dewnhill do net stop or start suddenly.
* Reduce speed and use extreme caution when making turns
on slopes to reduce the risk of tipping or losing control.
= Stay alert lor holes in the terrain and other hidden hazards.
Do not drive close to a ditch. creek. or dropoff to prevent
tipping or loss of contral. ва-3460
REAR OF STEERING TOWER
(Part No. 68-3460)
{ ENGAGED
{+ DISENGAGED
DECK ENGAGEMENT
LEFT FRONT
SIDE OF SEAT
(Part No. 68-3540)
SPRING LOADED MECHANISM
SEE OPERATOR'S MANUAL
SAFETY AND INSTRUCTION DECALS
The following safety and instruction decals are mounted on the TORO
Rider. Replace any that become damaged or illegible.
OFF
- ©
START
Se + “|
и
4 IGNITION $
AROUND KEY SWITCH
(Part No. 68-3440)
NEXT TO
CHOKE AND
THROTTLE CONTROLS
(Part No. 68-3520)
IMPORTANT
MAKE WIDE TURNS WITH TRAILER ATTACHED.
TURNING TOO SHARP COULD DAMAGE TRAILER OR VEHICLE.
FOR DISASSEMBLY PROCEDURE.
ON BOTH LIFT BARS
(Part No. 55-4300)
REAR OF FRAME ABOVE HITCH
(Part No. 68-3420)
CLUTCH PEDAL VEHICLE SPEED SELECTOR TO STOP: BRAKE PEDAL
а TO SHIFT: es Phy m,
Cp A a Fai ]
= METE GEMA SHIFT PO DESIMED AMEEN. =
J REVERSE — move eran ват то
BUPRESS CLUTCH WHEN SHIFT. REVERSE PORTIO LOGE ТО MERA AMD
SG M70 GLAR 08 CHANGE LET OUT CLUTCH PEBAL SLOWLY WHILE
=== =" [ACAUTION
TO KET START EMGIME : ТО STOP ENGINE:
NOTE: emnme ena wav 37007 = PLACE AL CONTRELS IN NEUTRAL BN
DESTACA
PORTION
BEALL PEDAL AND ЗЕ! РАМЕ. L
« DEPRESS
Rr rate O
POSI +
TEMPCLE SEAT Ti PA A МАРЕ:
MON GLAM SOLECTOR TO MEUTAAL
TE TF IMPORTANT:
« ATTACHMENT CLUTCH BWITCH MUST PARKING BAARE CANNOT BE AFPUSER
WF IH SECA POSICION. ULISES ELÁR SELCEROR rá om MEUEMAL
= ман стонал: км FO —— dai [+] ON RIVERS
AND THROTTLE LEVER WIDWAT
PANKING BRAKE MRT 0d RELELRED
SrTwite SLOW oe AND FART dg PAMKING BRAKE
= TURE IGNITION SWITCH TO STANT
re WELEDA WHIN [HEIN
ñ
ATTACHMENT CLUTCH SWITCH PARKING BRAKE o HEIGHT OF CUT
E V0 APPLE PARELISE BRAKE:
| mE = MON SHIFT SELECTOR TO ADETAAL | | arr ® dera
> - DEPRESS BRANT FIBA с) 6
ET AE {+ = HOLD FRANESE GRACE LEVES (a ón FES Ted 5
FULL SWITCH OUT ARE UF senora a Le
DECK EMERCLMINT SWITCH MUST NU sl TO DISENGAGE PARKING BRAKE: Lew
DIE MEAEID POST ION TO START HET a pPRESE PRALE FERAL
« FEE GOWN OF FARRIS BRAD] ITIL SB ы
ON FLOOR PANEL
(Part No. 68-3410)
HIGH
RIGHT
FRONT SIDE
OF SEAT
(Part No.
68-3430)
5
SPECIFICATIONS
Kohler Engine: 2 cylinder, 4 cycle, air cooled, electric
start, gasoline engine has output of 16 hp (12 Kw) @
3600 rpm and 28 ft-Ib (38 N-m) torque @ 2300 rpm.
Displacement is 42.18 cubic inches. Crankcase oil
capacity is 3-1/2 pints (1.66 1). Correct spark plug is a
Champion RV TEC or equivalent. Air gap setting is
0.025 in. (0.635 mm).
Fuel Tank: Capacity is 3.5 gallons (13.25 |).
Controls: Throttle and choke controls and ignition key
are located to left of operator's seat.
Traction Clutch: A foot operated pedal on the left
side of the steering tower simultaneously declutches
the input v-belts to the two transmissions. Operator
must be in the seat to engage or operate the traction
drive.
Transmission Control: Hand operated shift lever
with “Z" pattern located at right side of operator. The
two transmissions are synchronized to shift together
by a factory adjusted tie rod.
Traction Drive: (2) 5 speed forward, one speed
reverse transmissions with integral brake in each
transmission. Each transmission drives an individual
rear wheel through a chain and sprocket. Trans-
missions are driven by individually clutched v-belts
from the engine. Independent left and right trans-
mission clutching is controlled by steering angle.
Rear wheel declutching begins at approximately 20°
turn angle of the inside front wheel. There is no
differential.
Ground Speed @ 3200 Engine rpm:
1st gear — 1.55 mph (2.49 km/hr)
2nd gear — 2.41 mph (3.87 km/hr)
3rd gear — 3.61 mph (5.80 km/hr)
4th gear — 4.59 mph (7.38 km/hr)
5th gear — 5.89 mph (9.47 km/hr)
Rev. — 1.81 mph (2.91 km/hr)
Chain Drive to Rear Wheels: #40 chain drive.
Belt Drive to Gear Box: (2) “A" section v-belts from
engine to each transmission.
Steering: Pinion and sector gear to cross-axle tie
rods which control front wheels. 15 inch steering
wheel turns 1-3/4 turns lock-to-lock. Inside front tire
will turn up to 80° from straight ahead.
Wheels and Tires:
Front — Heavy duty wheel bearings and 13 x 5.0
— 6 pneumatic tube-type tires.
Rear — Welded steel rims with 16 x 6.5 — 8
pneumatic tubeless tires. Wheels include flange
for chain sprockets and have two sealed HD ball
bearings in each hub. Rear axle is adjustable for
chain tension.
Brake: A foot operated pedal on the right side of the
steering tower, via an extension spring, simultan-
eously operates a brake caliper on each of the two
transmissions.
Parking Brake: Hand operated lever located on the
right side of the operator on the front of the seat base.
Lift to engage while depressing the brake pedal.
Press on brake pedal to disengage. Transmission
must be in neutral or reverse to apply parking brake.
Deck Control Switch: Toggle switch (pull out and up
to engage) on left front of seat support tower. Switch
releases blade brake and engages clutch to drive
cutter deck. Operator must be in seat to engage or
operate the cutter deck.
Height-of-Cut Control: Hand operated lever located
at right of operator. Seven height positions from 1-
1/2 10 4-1/2 т. (38 10 114 тт).
Deck Suspension: Full floating, front-to-rear and
side-to-side. Decks have adjustable gage wheels for
following uneven terrain. Decks are supported by
flotation lift springs. Deck suspension is adjustable for
both front-to-rear and side-to-side tilt.
General Dimensions (approx):
Wheel Base — 45 in. (1.14 m)
Tread Width; center to center —
Front — 30.5 in. (0.775 m)
Rear — 29 in. (0.737 m)
Width — 35.5 in. (0.902 m) without deck
Height — 45.7 in. (1.160 m)
Length — 69.9 in. (1.77 m)
Turning Radius —4 in. (0.102 m) outside edge of rear
tire
Weight — 604 |b (274 kg) without deck
Safety Features: Meets B71.1 — 1986 ANSI safety
specifications.
Traction drive, blade drive and seat interlocks.
- Electromagnetic blade clutch and brake.
Parking brake lockout for forward gears.
Automatically slows down in sharp turns.
Optional Accessories and Attachments:
52" Cutter Deck Model 55670
44" Cutter Deck Model 55660 )
Deluxe Seat Kit Part No. 68-3800 =
Exhaust Elbow Kit
Spark Arrestor for
Standard Muffler
Part No. 68-3750
Part No. 68-3790
LOOSE PARTS
DESCRIPTION
©
<
USE
Tire and Wheel Assembly
Mount to front axles.
Cotter Pin 1/8 in. x 1-1/4 in.
Secure wheels to axles.
Flange Washer
Mount to front axles.
Hub Cap
Mount to front axles.
Steering Shaft Cover
On steering shaft.
Steering Wheel
On steering shaft.
Steering Wheel Cap
On steering wheel.
Roll Pin Secure steering wheel to shaft.
| Carriage Bolt 1/4 - 20 x 3/4 in. Install battery cables.
Wing Nut Install battery cables.
Deck Tension Rod
Jam Nuts Install on deck tension rods when
mounting cutting deck. Refer to
Washer Cutting Deck Operator's Manual for
Spacer installation instructions.
Spring
Washer Secure deck tension rods to rider frame when
mounting cutting deck. Refer to Cutting Deck
Cotter Pin Operator's Manual for installation instructions.
Key Install in start switch.
fe
Operator's Manual
Read manual before operating rider.
Engine Owners Manual
Reg. Card
= | IN IN |N|N|S N|N[N|—-|=-|=|=-|[N|[N|N|N
Fill out and return to Toro.
SETTING UP INSTRUCTIONS
INSTALL FRONT WHEELS
Tools Required: Pliers, hammer and grease gun.
Note: Apply grease to axle shafts before installing.
1. Install wheel onto axle with air valve to outside.
2. Mount flange washer onto axle (flange side out),
Insert cotter pin and open pin ends with pliers (Fig. 1).
3. Install hub cap.
4. Repeat steps 1-3 on opposite side.
5. Check front and rear tires for 14 psi (96.5 kPa)
inflation.
Figure 1
1. Flange washer
2. Cotter pin
SETTING UP INSTRUCTIONS
6. Lubricate both front wheels w/No. 2 general
purpose grease. Pump grease gun until grease
comes through bearings. Wipe up any excess grease.
INSTALL STEERING WHEEL ASSEMBLY
Tools Required: Small ball peen hammer and drift
punch.
1. Position front wheels in straight ahead direction
and slide steering shaft cover over steering shaft.
2. Slip steering wheel over shaft and align the
steering wheel mount hole with the shaft mounting
hole. Steering wheel cap should be readable from
operator's position when installed.
Figure 2
1. Steering shaft cover
2. Вой рт
3. Insert a drift punch partially through the holes to
maintain alignment and insert the roll pin in from the
opposite side.
4. Drive the roll pin in until it is flush with the
outside of the wheel (Fig. 2).
ADJUSTING SEAT
Tip the seat forward, loosen the seat mounting
capscrews and relocate the seat for operator comfort.
Retighten the capscrews and lower the seat.
5 | ЧИ
Figure 3
1. Seat adjusting screws
INSTALL & LEVEL CUTTING DECK
Note: Refer to Cutting Deck Operator's Manual for
deck installation, deck leveling, operation and
adjustments.
BEFORE OPERATING
ACTIVATING AND CHARGING BATTERY
(12 Volt)
Tools Required: 3 to 4 Amp Battery Charger.
Since the battery for the rider is not filled with
electrolyte or activated, the battery 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 activate it as follows:
1. Tip the seat forward exposing battery (Fig. 4).
2. Remove wing nut securing battery hold downs to
rider chassis. (Fig. 4).
8
A CAUTION
Wear safety goggles and rubber gloves
when working with electrolyte. Charge
the battery in a well ventilated place so
gases produced while charging can dis-
sipate. Since the gases are explosive,
keep open flame and electrical spark
away from the battery; do not smoke.
Nausea may result if the gases are in-
haled. Unplug charger from electrical
outlet before connecting or disconnect-
ing charger leads from battery posts.
ци ое, i i ae. aie aie. ce ie i i i i i аль
a i i ie
WO A
-
BEFORE OPERATING
Figure 4
1. Battery hold down
2. Vent tube
3. Lift up on top battery hold down and pivot off
battery.
4. Disconnect vent tube from battery.
5. Remove battery from chassis and set it aside.
6. Remove filler caps from battery and slowly fill
each cell until electrolyte is just above the plates. To
obtain best results, let battery set for 20 minutes. Add
electrolyte to the maximum capacity.
A
y FILLER CAPS
LL
Figure 5
7. Leave filler caps off and connect a 3 to 4 amp
battery charger to the battery posts. Charge the
battery at a rate of 4 amperes or less for 4 hours.
8. When battery is charged, disconnect charger
from electrical outlet and then from battery posts.
9. Slowlyaddelectrolyte 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.
10. Install the battery with the battery vent tube
toward the rear. Reconnect vent tube.
11. Reinstall battery hold downs.
12. Install the positive cable to the positive (+)
terminal and the negative cable (black) to the
negative (-) terminal of the battery and secure with
carriage bolts and wing nuts (Fig. 6).
Figure 6
1. Positive cable 2. Negative cable 3. Vent tube
CHECK CRANKCASE OIL LEVEL
The rider is shipped from the factory with oil in the
crankcase. However, check the oil level in the
crankcase prior to starting the engine.
1. Place rider on a level surface to assure an
accurate oil leveireading. Ensure the oil drain plug is
securely tightened (Fig. 7).
Figure 7
1. Drain plug
BEFORE OPERATING
2. Remove the dipstick from the oil fill tube (Fig. 8).
Figure 8
1. Dipstick
3. If oil level is low, insert a funnel into the tube and
slowly add engine oil into the crankcase. Use a high
quality detergent oil classified “For Service SF”. Oil
viscosity (weight) must be selected according to
anticipated ambient temperature.
A. Above +32° F (Of C) — Use only SAE 30.
B. Between+32° F(0° C)and O° Е (-18° С) — Озе
SAE 10W30 or 10W40.
C. Below +32° F (0° C) — Use 5W20 or 5W30.
Note: Read engine oil information and cautions in
engine owner's manual.
Note: Avoid premature engine failure by insuring the
funnel used is clean so contaminents are not intro-
duced into the crankcase. Wipe any oil spilled, so it
will not cause dirt to collect on the engine.
4. Insure the oil level is to the “F” mark on the
dipstick when it is fully installed. Do not overfill or
engine damage may result.
5. Insert the dipstick and push it all the way down
into fill tube.
Note: Check the oil level every 5 operating hours or
each time rider is used. Initially, drain the oil and
replace it after the first 5 hours of operation to
remove the contaminents produced by normal
engine break-in; thereafter, under normal condi-
tions, change oil after 25 hours of operation. Change
the oil more frequently when the engine is operated
in dusty or dirty conditions.
10
FILL FUEL TANK WITH 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
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, and fill tank to about 1/2 inch
(12.7 mm) from top of tank, not the 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 interal 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.
THE TORO COMPANY STRONGLY RECOMMENDS
THE USE OF CLEAN, FRESH UNLEADED REGULAR
GASOLINE IN TORO GASOLINE POWERED PRO-
DUCTS. UNLEADED GASOLINE BURNS CLEANER,
EXTENDS ENGINE LIFE, AND PROMOTES GOOD
STARTING BY REDUCING THE BUILD-UP OF COM-
BUSTION CHAMBER DEPOSITS. LEADED GASO-
LINE CAN BE USED IF UNLEADED IS NOT AVAIL-
ABLE.
NOTE: NEVER USE METHANOL, GASOLINE
CONTAINING METHANOL, GASOHOL CON-
TAINING MORE THAN 10% ETHANOL, GASO-
LINE ADDITIVES, PREMIUM GASOLINE, OR
WHITE GAS BECAUSE ENGINE FUEL SYSTEM
DAMAGE COULD RESULT.
1. Clean area around fuel tank cap so foreign matter
cannot enter tank when cap is removed.
2. Remove cap from fuel tank (Fig. 8) and fill tank
with gasoline up to about one half inch from top of
tank, not the filler neck. Then reinstall fuel tank cap.
3. Wipe up any gasoline that may have spilled.
CHECK TIRE PRESSURE
Check and insure the tires are inflated to 14 psi (96.5
kpa) before operating the machine.
CONTROLS
Clutch Pedal (Fig. 9) — Foot operated clutch pedal is
used in conjunction with the gear shift and brakes.
Depress clutch fully when shifting gears or braking.
Brake Pedal (Fig. 9) — Foot operated pedal, which
when depressed, actuates a disc brake assembly at
the side of each transmission. Clutch pedal must also
be depressed while braking.
Figure 9
I. Clutch pedal
2. Brake pedal
Throttle Control (Fig. 10) — Throttle control connects
to and operates carburetor mounted throttle. Control
has two positions: SLOW and FAST.
Choke Control (Fig. 10) — Choke control connects to
and operates carburetor mounted choke. Choke may
not be required when starting a warm engine.
1. Ignition switch
2. Throttle control
3. Choke control
4. Deck engagement switch
5. Hour meter
Ignition Switch (Fig. 10) — Switch is part of bat-
tery ignition system, and it has three positions:
OFF, ON and START. Key automatically returns
to ON position from START position when re-
leased after engine starts.
Deck Engagement Switch (Fig. 10) — Toggle switch
(Pull out and up to engage) releases blade brake and
engages electromagnetic clutch to drive cutter blades.
Operator must be on the seat to engage or operate
cutter deck.
Hour Meter (Fig. 10) — Indicates the total hours of
machine operation. The Hour Meter starts to function
whenever the key switch is rotated to "ON".
Parking Brake (Fig. 11) — Parking brake is used in
conjunction with standard brake assembly. When
brake pedal is depressed and parking brake lever
is pulled upward, a latch plate secures the brake
assembly in the engaged position preventing the
machine from moving.
Note: Transmission must be in neutral or reverse to
engage parking brake.
Figure 11
1. Gear shift
2. Height-of-cut control lever
3. Parking brake
Gear Shift (Fig. 11) — Transmission has five forward
speeds, neutral and reverse, and has a “Z"" shaped
pattern. An interlock switch, which prevents engine
from being started when the transmission is in gear,
is mounted on the top of one transmission. Operator
must be on the seat to engage or operate trans-
mission.
Height-of-Cut Control (Fig. 11) — Height-of-cut
control varies the cutting height from 1 1/2to4 1/2
inches (38 to 114 mm) in seven increments. Gage
wheels on deck must be reset when height-of-cut is
changed.
11
STARTING AND STOPPING INSTRUCTIONS
Note: Engine will not start unless deck engagement
switch is DISENGAGED, shift lever is in neutral and
operator is sitting on the seat.
TO START MACHINE
1. Shift into neutral, move deck engagement switch
to DISENGAGE and lock parking brake.
2. Sit on seat, move choke control to CHOKE
position, throttle control in half throttle position, and
rotate ignition key to START. When engine starts,
release key. Regulate the choke to keep engine
running smoothly until warm, then move throttle to
FAST position.
Note: Choke may not be required when starting a
warm engine.
IMPORTANT: To prevent overheating of the starter
motor, do not engage starter longer than 10
seconds. After 10 seconds of continuous cranking,
wait 60 seconds before engaging starter motor
again.
OPERATE CUTTER DECK
1. Select desired height-of-cut, adjust gage wheels,
start machine and pull out and up on deck engage-
ment switch to ENGAGE.
2. Release parking brake, depress clutch pedal and
shift into forward gear.
TO STOP
1. Depress brake and clutch pedals, move throttle
control lever to SLOW position, move deck
engagement switch to DISENGAGE, and rotate
ignition key to OFF.
2. Shift transmission to neutral and engage park-
ing brake.
3. Remove key from ignition switch.
IMPORTANT: Never leave the deck engagement
switch in the engaged position when the engine is
not running. Doing so with the ignition switch ON
will discharge the rider battery.
BREAK-IN
The engine requires no special break-in other than
changing oil after the first five hours of operation.
Operate the transmission in all gears to assure that
drive system is functioning correctly.
USING PARKING BRAKE
1. Depress brake pedal fully, shift transmission
to neutral.
12
2. Move parking brake control upward and re-
lease brake pedal.
3. Torelease the parking brake, depress brake pedal
(Fig. 9), and push parking brake lever (Fig. 11) down to
return it to its disengaged position. Release brake
pedal slowly.
A CAUTION
If the engine stalls or must be stopped
while operating on a hill or slope, the
engine must be shut off and parking
brake engaged.
ADJUSTING HEIGHT-OF-CUT
The height-of-cut may be set in one of seven positions
from approximately 1-1/2 to 4-1/2 inches (38 to
114 mm).
Deck Lever Height-of-Cut
Selection Setting (Approx.)
1 1-1/2 in.
2 2 in.
3 2-1/2 in.
4 3 in.
5 3-1/2 in.
6 4 in.
T (TRANSPORT) 4-1/2 in.
1. Assure the deck engagement switch is in DIS-
ENGAGE position (Fig. 10).
2. Move height-of-cut control (Fig. 11) into desired
setting. Adjust gage wheels.
ADJUST GAGE WHEELS (Fig. 12)
With rider on a flat surface, tires inflated to 14 psi and
height-of-cut in desired setting, gage wheels are to
be positioned so they are approximately 1/4" to 3/8"
above the ground.
IMPORTANT: It is important that gage wheels be
adjusted each time height-of-cut is changed, so
that the deck will follow the contour of the ground
and does not scalp the turf.
1. Remove hairpin cotter and clevis pin securing
gage wheel to cutting deck.
2. Move gage wheel up or down to required setting
and reinstall clevis pin and cotter pin.
STARTING AND STOPPING INSTRUCTIONS
3. Reposition gage wheels each time height-of-cut
setting is changed.
ADJUST REAR ROLLERS
Note: If cutting deck isto be used in 1-1/2" height-of-
cut setting, rear internal cutting deck roller(s) must be
repositioned in the top bracket holes. (1 roller on
model 55660 and 2 on model 55670). Refer to Cutting
Deck Operator's Manual for procedure.
GRASS DEFLECTOR
y QU
The grass deflector (Fig. 13) is a safety
device that diverts grass and other
foreign objects being discharged down-
ward. Without deflector mounted in
place on the cutting unit and spring
loaded hinges holding deflector in down
position, the blades could hurl grass and
foreign objects out the discharge open-
ing with enough force to cause injury or
property damage. If the grass deflector
or spring hinges are worn, broken or
damaged, repair or replace the affected
part(s). Never operate cutting unit with-
out deflector mounted on the cutting
unit. Always be sure the deflector chute
is in the lowest possible position.
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A
OPERATING PROCEDURE
1. Move deck engagement switch into DIS-
ENGAGE.
2. Start the engine: refer to Starting/Stopping
Instructions, page 12.
IMPORTANT: When rider is used for the first
time, operate the transmission in all gears to assure
that drive system is functioning correctly, and be-
come familiar with the controls and operating
characteristics. Never shift without first depressing
the clutch pedal or transmission damage could
result.
Figure 12
1. Gage wheel
OPERATING INSTRUCTIONS
Pi) у
Figure 13
1. Deflector
2. Spring hinges
3. Depress clutch pedal and shift transmission into a
low gear. Then release pedal slowly until traction
drive engages. Do not downshift into a lower gear
without first slowing down or transmission damage
could occur.
IMPORTANT: Do not operate machine with
foot resting on either brake or clutch pedal or
mechanical damage can occur.
IMPORTANT: To avoid a jerky start and putting a
heavy load on the transmissions, release clutch
pedal slowly. If shifting into reverse gear is difficult,
let out clutch pedal slowly while maintaining a
slight rearward pressure on gear shift. Do not
force the gear shift because damage may result.
Should you encounter a jerking or grabbing condi-
tion during operation, contact your local Author-
ized TORO Service Dealer for assistance.
13
OPERATING INSTRUCTIONS
A WARNING
To avoid loss of control, slow down
when turning, backing and changing
direction. Before backing up, move deck
engagement switch into DISENGAGE.
Do not mow in reverse unless absolutely
necessary and then only after careful
observation of the entire area behind the
mower.
4. Toengage blades for cutting, move height-of-cut
control to the desired setting, then pull out and up on
deck engagement switch.
5. To stop the engine, in sequence, depress clutch
and brake pedals, move throttle control to SLOW,
deck engagement switch into DISENGAGE, gear
shift into neutral, engage parking brake, and rotate
key to OFF position.
IMPORTANT: Never leave the deck engagement
switch in the engaged position when the engine is
not running. Doing so with the ignition switch ON
will discharge the rider battery.
Note: Remove the ignition key and store it in a
memorable place between operating periods.
GRASS CUTTING TIPS
1. When the rider is used to cut a lawn for the
first time, cut grass slightly longer than normal to
assure that cutting width of mower housing will
not cause scalping, which could result from severe
undulations of the ground. In general, however,
the cutting height used in the past is probably the
best one to use.
2. If the grass is ever allowed to grow slightly
longer than normal, or if it contains a high degree
of moisture, raise cutting height higher than usual
and cut the grass at this setting. Next, cut the
grass again using the lower, normal setting. This
method of cutting long grass results in an even
distribution of clippings and an acceptable quality-
of-cut.
3. Very long or extremely wet grass can be cut, but
specific operating techniques must be used. Start by
setting height-of-cut in Position #6. Using a low gear
and maximum throttle speed, move into the grass and
cut a swath that is only half as wide as the mower
housing. Direct grass clippings toward area that was
cut previously. Stop forward movement occasionally
to allow discharge area to clear itself. Cutting too
much grass may clog the mower housing and dis-
charge area. If mower housing does clog, shut engine
off, disengage blades and remove the obstruction
with a stick.
A DANGER
Before removing obstruction from mower
housing, move deck engagement switch
into DISENGAGE, depress clutch and
brake pedals, shift into neutral, turn
ignition key to OFF position and set
parking brake. Remove wires from spark
plugs to prevent possibility of accidental
starting.
4. When mowing, operate engine at full throttle.
This maintains proper blade speed and air flow
to facilitate discharge of clippings. Mowing with a
lower rpm causes the blades to tear the grass,
resulting in poor lawn appearance. Lower rpm also
reduces alternator charging efficiency which may
affect battery performance.
MAINTENANCE INTERVAL CHART
5 25
Hours Hours
Storage
Service
More often in dusty,
dirty conditions.
Spring 2
Service Years
Change Oil (Initial) X
Change Oil (Periodic)
xx
X
Check Safety Interlock X
Check Brakes Xx
Grease Front Axle Spindles
and Wheels
Grease Steering Spindle
Lubricate Pivot Points
Grease Rear Wheels
Service Air Cleaner
XxX XX
Check Spark Plug
Check Battery Electrolyte Level
Check Tire Pressure
Xx Xx
Clean Outside of Engine
2 2 C2 XX XX
Check Chain Tension
Check Traction Drive Belts
Drain Gasoline
Paint Chipped Surfaces
Check Interlock Switches
HII X |X
14
MAINTENANCE
A CAUTION
To prevent accidental starting of the
engine while performing maintenance,
shut engine off, remove key from ignition
switch, and pull wires off spark plugs
(Fig. 14). Make sure wires do not contact
plugs accidentally.
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a ES E EWE WE wa we we wt age owe ag ag gt gt a
Figure 14
1. Spark plugs (2)
GREASE FRONT. AXLE SPINDLES AND FRONT
& BACK WHEELS
Tools Required: Clean Rag and Grease Gun
w/No. 2 General Purpose Lithium Grease
The front axle spindles and wheels must be lubri-
cated after every 25 hours of operation; however,
lubricate more frequently when conditions are
dusty or sandy.
1. Wipe grease fittings on spindles and wheels
(Fig. 15, 16) with acleanraqg. If there is paint on front
of fittings, scrape it off.
2. Lubricate both axle spindles and front and back
wheels w/No. 2 general purpose grease (Fig. 15).
Continue to pump grease until it oozes out the
spindle. Wipe up any excess grease.
Figure 15
1. Steering spindle location
Figure 16
GREASE STEERING SPINDLE
Tools Required: Clean Rag and grease gun w/No. 2
General Purpose Lithium Grease.
The steering spindle, above steering rack, must be
lubricated after every 25 hours of operation; however
lubricate more frequently when conditions are dusty
or sandy.
1. Wipe grease fitting on spindle with a clean rag. If
there is paint on fitting, scrape it off. (Fig. 15, Inset).
2. Lubricate spindle w/No. 2 general purpose
grease. Wipe up any excess grease.
15
MAINTENANCE
LUBRICATE MECHANICAL PIVOT POINTS
Tools Required: Oil can filled with SAE 10 engine oil
or a pressurized can of spray lubricant similar to
WD-40.
Lubricate the mechanical pivot points every 25 hours
with a few drops of SAE 10 oil or WD-40 spray
lubricant.
Note: Keep all lubricants away from drive belts,
pulleys and brake discs.
SERVICING AIR CLEANER
The foam pre-cleaner must be cleaned and re-oiled
after every 25 hours engine operation if engine is
operated 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. 17).
Figure 17
1. Wing nut
2. Cover
2. Remove foam pre-cleaner by sliding it off the
paper element (Fig. 18).
3. A. Wash foam pre-cleaner in detergent and
warm water.
B. Rinse the pre-cleaner thoroughly until all
traces of detergent are eliminated. Squeeze
out excess water (do not wring). Air dry.
C. Saturate foam pre-cleaner in engine oil.
Squeeze to remove excess oil.
16
4. Reinstall on paper cartridge.
Figure 18
3. Cover seal
4. Element cover
1. Foam pre-cleaner
2. Element
Inspect paper element every 50 hours of operation
and replace when dirty or damaged. Do not wash
paper element or do not clean with compressed air as
damage will occur.
Note: With air cleaner disassembled, check air
cleaner components for damage. Replace if neces-
sary. Make sure rubber tube in base plate is securely
in place or severe engine damage may occur.
5. Reinstall element with pre-cleaner, element
cover 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
cleaner element in place or engine damage will
result.
CHANGING CRANKCASE OIL
Tools Required: Clean rag, 7/16 inch open end
wrench, and shallow oil drain pan.
1. Check level of oil before starting engine and
after every 5 hours of operation. Maintain oil level
at FULL mark on dipstick.
MAINTENANCE
To check level of oil:
A. Position rider on level surface.
B. Clean the area around oil dipstick so
foreign matter cannot enter filler hole when
dipstick is removed.
C. Remove dipstick and wipe oil off.
D. Insert dipstick fully in to filler neck; then
remove it and check oil level on dipstick. If level is
low, add only enough oil 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 fre-
quently when operating conditions are extremely
dusty or dirty.
To change oil:
A. Position rider on level surface. Start and run
engine for a period to warm the oil.
B. Turn engine off, set parking brake and place
drain pan below drain plug (Fig. 19). Remove
drain plug and allow all oil to flow into drain pan.
Install drain plug securely after oil stops flowing.
Figure 19
1. Dram plug
C. Remove dipstick and add oil to crankcase.
Refer to CHECK CRANKCASE OIL LEVEL, page
10. Capacity is 56 oz. (1.66 1). DO NOT OVERFILL
or engine damage may result. Recheck oil level
before operating.
Use any high-quality A.P.l. classification SF
engine oil. Recommended viscosity of oil to use is:
A. Above +32° F (0° C) — Use only SAE 30.
B. Between+32°F (0° C) and 0° F(-18° C) — Use
SAE 10W30 or 10W40.
C. Below +32° F (0° C) — Use 5W20 or 5W30.
Note: Read engine oil information and cautions in
engine owner s manual.
Note: Avoid premature engine failure by insuring the
funnel used is clean so contaminents are not intro-
duced into the crankcase. Wipe any oil spilled, so it
will not cause dirt to collect on the engine.
FUEL FILTER REPLACEMENT
Tools Required: Hose clamp pliers, drain pan.
An in-line filter is incorporated into the fuel line
between the fuel tank and carburetor (Fig. 20).
Use the following procedures should replacement
become necessary:
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 gasoline fumes may be
ignited by a spark. Do not smoke a
cigar, cigarette, or a pipe when handling
gasoline.
A a ae ae i a a ae ie i i ge ge ie i ie aie aie i e iE
WEE WT OWT EP OWT WT WET WET WEE WEE Wg me mg EF wg oe we age we
Figure 20
1. Fuel filter
2. Hose clamps
1. Close fuel shut off valve, located under fuel tank
(access from under seat).
17
MAINTENANCE
2. Place a drain pan under filter, loosen the hose
clamp on the carburetor side of filter and remove the
fuel line from the filter.
3. Loosen the remaining hose clamp and remove
filter.
4. Install the new filter with arrow on the filter body
pointing towards the carburetor. Reinstall clamps.
5. Open fuel shut-off valve fully.
REPLACING SPARK PLUGS
Tools Required: Spark Plug Socket, Spark Plug
Gapping Tool, and Clean Rag.
Since air gap between center and side electrodes of
the spark plug increases gradually during normal
operation of the engine, check condition of
electrodes after every 25 operating hours. Recom-
mended air gap is 0.025 of an inch (0.635 mm).
Correct spark plug to use is:
Champion RV 15YC or equivalent.
Note: The spark plugs usually last a long time;
however, the plugs should be removed and checked
whenever the engine malfunctions.
1. Clean area around spark plugs so foreign matter
cannot fall into cylinders when spark plugs are
removed.
2. Pull high tension wires off spark plugs and
remove plugs from cylinder heads.
3. Check condition of side electrode, center
electrode, and center electrode insulator to assure
there is no damage.
IMPORTANT: A cracked, fouled, dirty or defec-
tive 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.
5. Setair gap between center and side electrodes at
0.025 of an inch (0.635 mm) (Fig. 21). Install correctly
gapped spark plug w/ gasket seal, and tighten plug to
10-15 ft-lb (14-20 N-m). If torque wrench is not used,
tighten plug firmly.
6. Push high tension wires onto spark plugs but do
not leave key in the ignition. This will prevent
accidental starting when mower is being stored
between use periods. Keep key in memorable place so
it is not lost.
18
| 0.025"
1 (0.635 mm)
CROLL
NO NN
TN ON
LN 250%
SISK
RRA
Figure 21
ADJUSTING THROTTLE CONTROL
Tools Required: Medium blade screwdriver.
Proper throttle operation is dependent upon proper
adjustment of remote control. Before adjusting the
carburetor, assure the throttle control is operating
properly.
1. Loosen cable clamp screw securing cable to
engine (Fig. 22).
2. Position throttle control lever forward approxi-
mately 5/8” from front of slot in control plate.
3. Pull firmly on throttle cable till governor arm
contacts stop (Fig. 22).
4. Tighten cable clamp screw and check engine
RPM setting.
3200 + 100 — High Idle
1200 + 100 — Low Idle
Figure 22
1. Throttle cable clamp screw
2. Governor arm
3. Stop
MAINTENANCE
ADJUSTING CHOKE CONTROL
1. Loosen cable clamp screw securing cable to
engine (Fig. 23).
2. Place choke control in ON position.
3. Pullfirmly on choke cable and tighten cable clamp
screw (Fig. 23).
Figure 23
1. Choke cable clamp screw
2. Idle fuel adjusting needle
3. Idle speed adjusting screw
ADJUSTING CARBURETOR
Tools Required: Medium Blade Screwdriver
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, air
cleaner must be clean, and throttle and choke
controls must be checked for proper operation:
refer to Servicing Air Cleaner, page 16, and Ad-
justing Throttle and Choke Controls, pages 18 &
19.
1. Idle Fuel Adjusting Needle (Fig. 23) — Close
needle by gently rotating it clockwise.
IMPORTANT: Do not close the needle too tight
because the needle and seat in carburetor will likely
be damaged.
2. Rotate — open — the needle 1 turn counterclock-
wise (Fig. 23).
3. Start the engine and let it run at half throttle for
5-10 minutes to warm up. Engine must be warm
before making final settings.
М Lun
Engine must be running so final ad-
justment of the carburetor can be per-
formed. To guard against possible per-
sonal injury, move deck engagement
switch into DISENGAGE detent, shift
into neutral, and engage parking brake.
Keep hands, feet, face, and other parts
of the body away from the cutter blade,
underside of mower housing, discharge
area, and any rotating engine parts.
4. Idle Speed Setting — Move the throttle control to
SLOW position. Set the idle speed 1200 rpm + 75
rpm by turning the idle speed adjusting screw in or
out. Check speed using a tachometer.
5. Final Setting — Idle Fuel Needle: Move the
throttle control to SLOW position. Turn the idle fuel
adjusting needle out (counterclockwise) until the
engine speed decreases (rich). Note position of the
needle.
Now turn the adjusting needle in (clockwise). The
engine speed may increase, then it will decrease as
the needle is turned in (lean). Note the position of the
needle.
Set the adjusting needle midway between the rich
and lean settings noted.
Note: To ensure best results when setting the idle
fuel needle, t he idle speed must not exceed 1500 rpm.
Typical idle speed is 1200 rpm.
6. Recheck idle speed using a tachometer. Readjust
speed as required.
7. After carburetor is adjusted, shut engine off.
IT mower will not be used immediately, remove key
from switch to prevent possibility of accidental
starting. Keep key in a memorable place so it is
not lost accidentally.
ADJUSTING DRIVE CHAINS
The drive chains must be adjusted to maintain 1/2"
deflection when a 10 |b force is applied perpendicular
to chain at the mid span between transmission and
sprocket. Check chain deflection after first 5 hours of
operation and after every 25 hours of operation,
thereafter.
19
MAINTENANCE
CAUTION: If chain is worn, loose or adjusted
incorrectly, chain could come off sprockets, re-
sulting in no brakes or traction drive. If assistance is
needed, contact your local authorized Toro Dealer.
1. Check deflection of drive chain by pressing up on
chain with approximately 10 Ibs force (moderate
pressure) at mid span. There should be 1/2" deflec-
tion (Fig. 24). If deflection is not as specified an
adjustment is required.
ee TL,
Figure 24
1. Axle 3. Chain deflection
2. Chain tensioner
2. Block up rear of rider chassis, so rear wheels are
off the floor and axle can be moved.
3. Slightly loosen (4) flange nuts securing both sides
of axle to rider frame.
4. On both sides of axle, loosen rear jam nuts on
chain tensioners.
5. Rotate inside nut on chain tensioner until desired
chain tension is attained on each side.
6. Tighten rear jam nuts on chain tensioners.
7. Tighten (4) flange nuts securing both sides of axle
to rider frame.
8. Recheck chain tension.
REPLACING DRIVE CHAINS
1. Block up rear of rider chassis, so rear wheels are
off the floor.
2. Loosen (4) flange nuts securing both sides of axle
to rider frame.
3. On both sides of axle, loosen rear jam nuts on
chain tensioners.
20
4. Rotate inside nut on chain tensioners until chain
IS loose.
5. The master link on the chain may now be
removed and chain removed from sprockets.
IMPORTANT: Whenever changing chains or sproc-
kets, both sides should be changed. Inspect (4)
sprockets and replace both chains and sprockets if
necessary.
6. Install new chains and adjust, refer to Adjusting
Drive Chains, page 19.
ADJUSTING FRONT WHEEL ALIGNMENT
1. Assure Front Axle is level with frame and steering
rack timing mark is centered on steering stop pin
(Fig. 25).
2. To align front wheels, loosen jam nuts and turn
tie rods until centerline distance across front of
wheels is equal to or 3/16" max less than centerline
distance across rear of front wheels (Fig. 25). Wheels
should be straight ahead or toe-in should be equal
when timing mark is centered.
Figure 25
1. Front axle 2. Timing mark 3. Steering stop pin
3. Tighten jam nuts.
Note: No toe-out is allowable.
ADJUSTING BRAKES
Adjust brakes if parking brake does not hold or brak-
Ing power is not sufficient when brake pedal is
depressed.
1. Shut engine off and remove wires from spark
plugs. Shift transmission into 1st gear.
2. Tighten locknut on each transmission brake lever
(Fig. 26) until lever cannot be wiggled from side to
side. DO NOT OVERTIGHTEN.
7
MAINTENANCE
Figure 26
1. Brake lever 2. Locknut
3. Back off each locknut 1/4 turn. Lever should be
loose enough to wiggle slightly.
4. Check operation of the brake by pushing rider: no
brake drag should be evident. If drag is evident, rotate
locknuts an additional 1/8 turn counter-clockwise.
ADJUSTING ELECTRIC DECK CLUTCH
The electric clutch is adjustable to ensure proper
engagement and braking of the cutter blades. If the
blades do not stop within a few seconds after the deck
engagement switch is DISENGAGED, check the
adjustment of the electric clutch.
1. Toadjust the clutch, tighten or loosen locknuts on
flange studs (Fig. 27).
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Figure 27
1. Clutch 2. Flange stud
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. It will be necessary
to check this clearance at each of the three slots to
ensure the plates are parallel to each other.
ADJUSTING TRANSMISSION LINKAGE
If engine will not start when gear shift lever is in
neutral position, but will start if the lever is pressed
slightly forward or backward, an adjustment to the
transmission linkage may be required.
Note: Check to make sure all shift linkage nuts and
bolts are securely fastened before proceeding.
1. Move gear shift lever to 5th gear.
2. Remove capscrew securing end of tie rod to left
transmission shift lever (Fig. 28).
3. Manually move right and left transmission levers
as far left as possible into fifth gear detent.
4. Without disturbing position of levers, reposition
tie rod over left transmission lever and check align-
ment of tie rod end mounting hole and lever mounting
hole.
Figure 28
1. Left transmission lever 2. Tie rod
5. If mounting holes do not align, loosen jam nuts on
tie rod and adjust rod until holes align.
6. Tighten jam nuts and resecure tie rod to lever
with capscrew.
SHIFT LINKAGE ADJUSTMENT
If the gear shift lever is not centered in neutral slot, an
adjustment to the shift linkage may be required.
1. Move gear shift lever to NEUTRAL position.
21
MAINTENANCE
2. Check position of gear shift lever. Lever should be
centered in neutral slot when viewed from side of
machine (Fig. 29).
Figure 29
1. Gear shift lever
3. Ifleveris not centered, loosen jam nuts and rotate
tie rod until lever is correctly positioned in neutral slot
(Fig. 30). Tighten jam nuts.
- e
Figure 30
1. Tie rod 2. Transmission lever
ADJUSTING LINKAGE TO STEERING
CLUTCHES
1. Assure Front Axle is level with frame and steering
rack timing mark is centered on steering stop pin
(Fig. 31).
2. Check to make sure ends of front pull rods are
positioned at the rear of the slots in the pull rod plate
(Fig. 31 inset).
22
Figure 31
1. Front Axle
2. Timing mark and stop pin
3. Front pull rods
4. Pull rod plate
5. Rear pull rods
6. Traction pivot plates
3. Adjust jam nuts on rear pull rods so the bent ends
of the rods are on center to 1/8” behind the center of
the slots in the traction pivot plates (Fig. 31 & 32).
IMPORTANT: Make sure that the bent ends of the
pull rods remain 90° to the pivot plates or binding
will occur.
REPLACING TRACTIONS BELTS
Note: Read and understand the following instruc-
tions before beginning. Contact your local authorized
TORO Dealer if assistance is required.
1. Remove cutting deck, refer to Cutting Deck
Operator's Manual. Block up rear of machine or use
wheel ramps for rear wheels. Block front tires and
apply parking brake. Disconnect spark plug wires.
2. Have a helper depress clutch pedal while you
insert (2) 1/4" capscrews into holes in pivot platform
(Fig. 32). Slowly release clutch pedal allowing pivot
plates to rest against capscrews, relieving tension
from the belts.
3. Unplug clutch wire connector and remove nut
and carriage bolt securing R-clamp to pivot platform.
4. Remove (3) capscrews and lockwashers securing
clutch retainer and pivot platform to rider. (Electric
clutch may have to be rotated to remove clutch
retainer) (Fig. 32).
atl”
MAINTENANCE
5. Loosen (4) belt guides on (2) driven pulleys.
Remove belts from driven pulleys.
Figure 32
4. Pivot platform
5. Clutch retainer
6. Driven pulleys
1. Holes in pivot platform
2. Clutch wire connector
3. R-clamp
7. Belt guides
8. Rear pull rods
8. Belt retainers
10. Jam nuts
6. Remove front jam nut from each rear pull rod so
that both pull rods can be disconnected (Fig. 32).
7. Remove assembly of pivot platform, pull rods and
traction belts.
A CAUTION
Pivot plates are spring loaded.
NU a a i i e. e
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8. Remove (2) capscrews securing (2) belt retainers
to pivot plates (Fig. 32) and remove belt retainers.
Replace both traction belts and reinstall belt retainers
and capscrews to pivot plates.
9. With (2) capscrews previously removed, reinstall
assembly of pivot platform and rear pull rods into rear
holes in pivot platform. Loosely install front jam nuts
on pull rods.
10. Reinstall belts around driven pulleys.
11. Reinstall clutch retainer to front hole in pivot
platform with remaining capscrew.
12. Reinstall R-clamp to pivot platform and connect
clutch wire connector.
13. Have a helper depress clutch pedal while you
remove the (2) capscrews installed in step #2.
14. Adjust and securely tighten (4) belt guides on (2)
driven pulleys.
IMPORTANT: Belt guides must be positioned .08-
.14” from back of traction belt or belt life will be
greatly reduced.
15. Adjust both rear pull rods, refer to Adjusting
Linkage to Steering Clutches, page 22.
16. Install cutting deck, refer to Cutting Deck Opera-
tor's Manual.
WHEEL REMOVAL
Tools Required: Pry Bar, Pliers, Floor Jack, Wheel
Blocks.
Front Wheels:
1. Assure parking brake is locked and block rear
wheels.
2. Place jack under front of frame and raise wheels
off floor. DO NOT DAMAGE STEERING COM-
PONENTS.
3. Use a pry bar to lever the hub cap off the axle. |
4. Remove the cotter pin and flange washer (Fig. 33)
and remove the wheel from the axle.
Figure 33
5. Assemble in reverse order.
23
MAINTENANCE
Rear Wheels:
1. Assure parking brake is locked and block the front
wheels.
2. Place jack under rear of frame and raise one
wheel at a time off floor.
3. Remove masterlink and chain from wheel hub.
4. Remove the cotter pin and washer and remove
the wheel from the axle (Fig. 34).
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EN Es
E Te
Figure 34
1. Cotter pin and washer
5. Assemble in reverse order.
CHECKING SAFETY INTERLOCK SYSTEM
The purpose of the safety interlock system is to pre-
vent the engine from cranking or starting unless the
operator is on the seat, the transmissions are shifted
into neutral and the cutting unit deck engagement
switch is in the Disengage position. In addition, the
engine will stop if the operator gets off the seat when
the deck engagement switch is engaged or trans-
missions are in gear. To assure interlock system is
functioning correctly, check it before each use of the
rider. Have the safety interlock switches checked by
an Authorized TORO Service Dealer every two years
to assure safe operation of the rider.
1. Sit on seat and move shift control into neutral
position. Engage the parking brake to prevent move-
ment of the rider.
2. Move deck engagement switch to the ENGAGE
position. Rotate the ignition key to START. Engine
should not crank. If engine cranks, the interlock
24
system is malfunctioning and it must be repaired by
an Authorized TORO Service Dealer. If engine does
not crank, proceed to step 3.
3. Move deck engagement switch to DISENGAGE
position, release parking brake but keep brake pedal
depressed, push clutch in and place shift control into
one of the gear selections. Rotate the ignition key to
START. Engine should not crank; but if it does, the
interlock system is malfunctioning and it must be
repaired by an Authorized TORO Service Dealer. If
engine does not crank, proceed to step 4.
4. Move shift control into neutral and deck engage-
ment switch to DISENGAGE position. Engage the
parking brake to prevent movement of the rider.
Rotate ignition key to START position and start
engine. Place the deck engagement switch in
ENGAGE position and carefully raise off the seat: the
engine should stop running. If engine does not stop
running, shut engine off and have interlock system
repaired by an Authorized TORO Service Dealer. If
engine shuts off when you raised off seat, the
interlock system is functioning correctly.
Do not operate the rider if the interlock
system is malfunctioning because it is a
safety device, designed for protection.
PE E a ie ge ae le le pm am
TA
BATTERY CHARGING SYSTEM
An AGC 20 Amp Fuse is incorporated in the charging
circuit as a protective device against alternator
damage caused by possible “short-outs” in the wiring
harness. If the battery is fully charged, but fails to
crank the engine, have the electrical system checked
by an Authorized TORO Service Dealer.
PREPARING MOWER FOR STORAGE
1. Drain gasoline from fuel tank and fuel line:
refer to Fuel Filter Replacement, page 17. Next,
start engine and let it run at idle speed until it
stops and all gasoline is used. Replace the fuel
filter.
Note: All gasoline must be expended to prevent
gum-like varnish deposits from forming in the
carburetor, fuel line, and fuel tank. Such deposits,
if allowed to form, will cause starting problems
and poor engine operation.
MAINTENANCE
2. Pull high tension wires off spark plugs and clean
area around the plugs so foreign matter cannot fall
into cylinders when plugs are removed. Next, remove
plugs from cylinder heads and pour two tablespoons
of engine oil into each spark plug hole. Rotate engine
by hand slowly to distribute oil on inside of cylinders.
Then reinstall spark plugs and tighten to 15 ft-1b (20.4
N-m). If torque wrench is not used, tighten plugs
firmly. DO NOT INSTALL HIGH TENSION WIRES ON
SPARK PLUGS.
3. Drain oil from crankcase and refill with proper
viscosity oil: refer to Changing Crankcase Oil,
page 16.
4. Clean dirt and chaff from outside of cylinders,
cylinder head fins, and blower housing. Also,
remove grass clippings, dirt, and grime from external
parts of rider, engine, shrouding, and top of mower
housing.
5. Check and tighten all cap screws, bolts, screws,
nuts, and mating parts. If any part is damaged,
repair or replace it.
6. Lubricate wheels and spindles with grease: refer
to Grease Front Axle Spindles and Wheels, page 15.
7. Check air cleaner element: refer to Servicing
Air Cleaner, page 16.
8. Touch up all rusted or chipped paint surfaces.
Make sure to sand affected area before painting.
Note: TORO Re-Kote “touch-up” paint is available
from any Authorized TORO Service Dealer. The
spray paint dries in minutes to a glossy, factory-
finish.
9. Remove the battery from the machine, recharge
it and store it in a cool, dry place. Recharge it
every 30 days to prevent it from discharging. Refer
to Activating and Charging Battery, page 8.
IMPORTANT: Improper storage or failure to
recharge may cause battery failure.
10. Place blocks under the front and rear axles to
raise the wheels off floor and prevent tire deterior-
ation.
11. Store the rider in a clean, dry place. Remove key
from ignition switch and keep it in a memorable place.
Cover the rider to protect it and keep it clean.
25
WIRING DIAGRAM
GREEN
YELLOW
TRANS. SW SEAT SW.
= cb. Io|DECK
5 . EET ! ENGAGEMENT
KEY Ay BI EJSWITCH
IGNITION SWITCH BLACK RED
OFF MAG CLOSED
ON BAL CLOSED = FUSE
START BAS CLOSED = RED
GRAY
DECK ENGAGEMENT SW.
OFF с . D Oe +
ON 8 8A CLOS PURPLE
TRANS. SWITCH BLADE ы
NORMALLY CLOSED IN 1 CLUTCH MAG
NEUTRAL | ;
SEAT SWITCH
EEE“ | one PS e
= EE ENGINE L
o IGNITION |
SWITCH (STARTER
PURPLE WHITE
LT. BLUE
SOLENOID [ [
RED
RED BLACK
+ — = HOUR METER À
BAT TERY
WHITE
WHITE
IDENTIFICATION AND ORDERING
MODEL AND SERIAL NUMBERS
The TORO Rider has two identification numbers: a
model number and a serial number. The two numbers
are stamped on a decal that is located under the seat,
on inside of rider body.
In any correspondence concerning the rider, supply
model and serial numbers to assure that correct
information and replacement parts are obtained.
26
To order replacement parts from an Authorized
TORO Service Dealer, supply the following infor-
mation:
1. Model and serial numbers of the tractor.
2. Part number, description and quantity of part(s)
desired.
Note: Do not order by reference number if a parts
catalog is being used; use the PART NUMBER.
Read all safety decals and safety instructions on pages 3-5
10° SLOPE GAGE |
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCEPOST, POLE ETC.) J
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USE EXTREME CAUTION
ON HILLS AND SLOPES
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« Never mow НА aaa
= Never mow pide hie gear 10€
= Mow ziopes wp and down. nat scroas the lace
= When going phil pr downhill de med slog or alan] suddenly
« Reduce speed and wee extreme cawlion when making herm
on clopes ba reduce the righ ol Bpping pr leging conirgl
« Slay der! lor hades im the terrain pnd other Ridden hazards
De nel drive clone de y Bilch. creek or dropoll fo prevent
8 17
lipping & logs ol comrol
V36-463
SEU PY VAY PPA DPA PSP PPP PAP
Che Toro Total Coverage Guarantee
A Two Year Limited Warranty
On
Model 55620 — HMR 1600
LA
The Toro Company promises to repair TORO Riding Mowers if defective in materials or
workmanship. The following time periods from the date of purchase apply:
HeeiDentaLPENOUEL == mens mr sie rm Swan CR
Residential Products Used Commercially
2 Years
1 Year
т + < =: + ® = # # E = =E
The costs of parts and labor are included, as are transportation costs within a 15 mile radius of
the servicing dealer. Just contact any Authorized TORO Service Dealer or TORO
Distributor. Should you feel your TORO Rider is defective and wish to rely on The Toro
Total Coverage Guarantee, the following procedure is recommended:
1. Contact the dealer where you purchased the rider. If this is
not convenient, just contact any Authorized TORO Service
Dealer, TORO Master Service Dealer, or TORO Distributor
(the Yellow Pages of your telephone directory is a good
reference source).
2. The Service Dealer will either instruct you to return the
product to him or recommend another Authorized TORO
Service Outlet which might be more suitable (not all TORO
Dealers are equipped to service Riding Mowers).
3. Pickup and delivery of your TORO Rider by the servicing
dealer is covered up to a 15 mile radius from the dealer's
place of business. Mileage charges beyond a 15 mile
radius are not covered by this warranty and are the
responsibility of the owner.
If you wish to bring the rider in yourself, first obtain prior
approval from your dealer and the dealer will provide
reasonable monetary compensation as specified by Toro.
If repairs to your rider are not covered by this warranty,
transportation charges connected with repairs will be
charged at the dealer's prevailing rates.
4. Please make the original sales slip, copy of the TORO
Registration Card, or other evidence of purchase date
available to the dealer when the unit is brought to the
dealer's place of business.
The servicing dealer will inspect the unit, advise you
whether the product is defective and, if so, make all repairs
necessary to correct the defect without extra charge to
you.
If for any reason you are dissatisfied with the dealer's analysis
of the defect or the service performed, you may contact us.
Write:
TORO Customer Service Department
8111 Lyndale Avenue South
Minneapolis, MN 55420
The above remedy of product defects through repair by an
Authorized TORO Service Dealer is the purchaser's sole
remedy for any defect.
THERE IS NO OTHER EXPRESS WARRANTY FOR THIS
PRODUCT. ALL IMPLIED WARRANTIES OF MERCHANT-
ABILITY AND FITNESS FOR USE ARE LIMITED TO THE
DURATION OF THE EXPRESS WARRANTY.
Some states do not allow limitations on how long implied
warranty lasts, so the above limitation may not apply to you.
THIS WARRANTY APPLIES ONLY TO PARTS OR COM-
PONENTS WHICH ARE DEFECTIVE AND DOES NOT COVER
REPAIRS NECESSARY DUE TO NORMAL WEAR, MISUSE,
ACCIDENTS, OR LACK OF PROPER MAINTENANCE. REGU-
LAR, ROUTINE MAINTENANCE OF THE UNIT TO KEEP IT IN
PROPER OPERATING CONDITION IS THE RESPONSIBILITY
OF THE OWNER.
All warranty repairs reimbursable under this warranty must
be performed by an Authorized TORO Service Dealer using
TORO approved replacement parts and maintenance
procedures.
Repairs or attempted repairs by anyone other than an
Authorized TORO Service Account 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 CON-
NECTION WITH THE USE OF THE PRODUCT INCLUDING ANY
COST OR EXPENSE OF PROVIDING SUBSTITUTE EQUIP-
MENT OR SERVICE DURING PERIODS OF MALFUNCTION
OR NON-USE.
Some states do not allow the exclusion of incidental or
consequential 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.
Y IN ISIISIY IS (LSD IIO (IYD SUSY
CADDA CE НОНО ЕЕ
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 im-
porter. 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
Litho in U.S.A.