LANDSCAPER WPM SERVICE MANUAL Table of Contents – Page 1 of 3 ABOUT THIS MANUAL SAFETY INSTRUCTIONS SAFETY TIPS...
LANDSCAPER WPM SERVICE MANUAL Table of Contents – Page 2 of 3 SECTION 3 SELF - PROPELSYSTEM GEAR SELECTION CONTROL - GEAR SELECTION CONTROL - OPERATION GEAR SELECTION CONTROL - REMOVAL GEAR SELECTION CONTROL - INSTALLATION TRACTION CONTROL - OPERATION TRACTION CONTROL - REMOVAL TRACTION CONTROL - INSTALLATION TRACTION CONTROL - ADJUSTMENT REAR HEIGHT OF CUT SYSTEM (HOC) AND WHEEL PINION CLUTCH (WPC) REAR HOC AND WPC - DISASSEMBLY REAR HOC AND WPC - ASSEMBLY TRANSMISSION - OPERATION TRANSMISSION - REMOVAL TR
LANDSCAPER WPM SERVICE MANUAL Table of Contents – Page 3 of 3 SECTION 9 GRASS BAG AND DISCHARGE DOOR -Continued GRASS BAG - ASSEMBLY DISCHARGE DOOR - OPERATION DISCHARGE DOOR - DISASSEMBLY DISCHARGE DOOR - ASSEMBLY SECTION 10 SIDE DISCHARGE CHUTE (OPTIONAL) SIDE DISCHARGE CHUTE - OPERATION SIDE DISCHARGE CHUTE - DISASSEMBLY SIDE DISCHARGE CHUTE - ASSEMBLY SECTION 11 - DETHATCHER (OPTIONAL) DETHATCHER - SAFETY INFORMATION DETHATCHER - OPERATION DETHATCHER - INTRODUCTION DETHATCHER - ASSEMBLY DETHATCHER - DIS
ABOUT THIS MANUAL This service manual was written expressly theforToro Landscaper" Mower. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the service technicianin mind. It is organized so that information used most often up is front. As a result, you will find reference information on safety, identification, specifications, troubleshooting and maintenance, allin the front third of the manual.
gging SAFETY INSTRUCTIONS andrepair manual This manualis intendedas a service only. The safety instructions provided in this manual of the product are for the troubleshooting and service only. The individual Operator’s Manuals will contain safety and instructional information on the operation of Vacu-Power mowers. Servicing ofany outdoor power equipment requires careand common sense to prevent Injury. Safety alert ‘CAUTION’ statementshave been placed throughout this manualto enhance safety.
TABLE OF CONTENTS Reference Information ............................................. Page 1 Table of contents................................................... 2 5 Identification ....................................................... Specifications ...................................................... 6 Troubleshooting .................................................... 9 13 Maintenance ...................................................... Safety Instructions Service Procedures .
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) P Section Three (cont’d) Transmission Operation .........,...,,..............................Page27 Removal ................................................. Assembly ................................................. ,30 Installation ................................................. .32 Disassembly Section Four Zone Start Brake ....................................................... Operation ...................................................
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) Section Nine (cont’d) Discharge Door Operation .. , . . .. . . . .. . . . . . . . . . , . . . . . .. . . . , . .. . . . . . . , , . . . . . .41 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section Ten Side Discharge Chute (Optional) ..........................................
PRODUCT IDENTIFICATION mower. In additionto the model number, each product alsohasauniqueserialnumberwhichServes to withsame model differentiateit from other products the number. The serial number has seven digits, the first of which identifies the year of manufacture 0022576 (ie. indicates that the product was built in the 1990 model year). decal that is about 1' These numbers are printedaon high and 3' wide. The decal canbe found on thetop side of the cuttingdeck betweenthe rear wheels on 1.
SPECIFICATIONS General Specifications Specification Toro 2-Cycle Die Cast Aluminum 53.3 cm(21.OO*) heat treated alloy steel Steel with double sealed ball bearing 20.3 X 5.1 cm (8.0X 2.V) wide semi-pneumatic radial style 2.5 cm (1') diameter gauge plated steel tubing. Adjustable to three different positions. Wheels individually adjustable from 25 to 75 mmin 13 mm increments (1'to 3' in l/2 increments) ' 53.3 cm (213 55.2 cm (21.75') 85.7 cm (33.75') 55 crn (21.
SPECIFICATIONS (cont'd) Service Specifications BBC bellcrank spring to be 2.59 k .127 cm Rear 4.32 f .15 cm (1.702 .060') Front 4.07 f . I 5 cm (1.60 k .060') Rear 5.49 k .15 cm (2.1 6f ,060.) Front 5.33 f .15 cm (2.10f 0.60') Rear 6.60 f .15 cm (2.60 r---? 0.60.) Front 6.60 f . I 5 cm (2.60 f 0.60') Rear 7.70 f .15 cm (3.03 f 0.60') Front 7.85 A .15 cm (3.09 f .060') Rear 8.74 k .15 cm (3.44f .060') .318 cm (.
SPECIFICATIONS (cont’d) Torque Specifications 0 Landscaper Rear Bagging Mower ~ ~ _-_ ~ ~~
TROUBLESHOOTING The Troubleshooting Section has been divided into three sections. Use the below guideto locate to the proper page for possible causes information on the symptom you are observing, then turn and remedies. Quality of Cut Symptom Page Scalping10 Stragglers ,lo Clumping 10 Unlevel height-of-cut 10 Bag will notfill completely .
TROUBLESHOOTING (cont’d) Quality of Cut Symptom: Scalping I Possible Height-of-cut too low All wheels notin same height-of-cut Lawn hasruts height-of-cut Raise Move height-of-cut adjustersto uniform Repair lawn Symptom: Stragglers (some grass bladesleft uncut) Symptom: Clumping Possible Cause to ramp clearance Grass too long Grass too grass Allow wet Remedy Adjust engine and grass ramp Excessive blade Use bag or optional side discharge chute to dry before mowing Symptom: Unlevel height-of-cut I Po
ause TROUBLESHOOTING (cont’d) Transmission Symptom: Drive slips S m tom: Intermittent drive Symptom: Transmissionslow going into gear Possible Cause in slots Shift keysin between gears Remedy Clean key slots, then lightly grease slot area Shift keys stickin Adjust gear selector cable,if difficulty persists,see Service Bulletin43 Sheared output shaft roll pin Replace rollpin Symptom: Inaccurate gear selection Possible Cause Flexing of gear selection cable Remedy Install new shift lever and cable per
TROUBLESHOOTING (cont'd) Transmission (cont'd) Symptom: Only one wheel drives wheel pinion clutch Miscellaneous Symptom: Thatcher does not fit correctly ice Bulletins 45 and 46 Symptom: All four tires do not touch the ground Deck warped,less than 6 mrn (1/4') Deck warped, more than 6 mrn (1/4”) P Elongate low pivot arm bolt hole upward Replace deck the 12 Landscaper Rear Bagging Mower
MAINTENANCE CAUTION: Pull the wire off the spark plug before performing adjustments maintenance. or 1. 2. Maintenance Servicing Air Cleaner 25 operating Normally, cleanthe air cleaner after every hours. More frequent cleaning is required when the mower is operated in dusty ordirty conditions. Stoptheengine and pull the wire off the spark plug.Figure See 2. Cleanaroundthespark plug andremovethe plug from the cylinder head. IMPORTANT Replace a cracked, fouled,dirty or spark plug.
3. Maintenance Draining Gasoline (cont'd) 3. Removethe cap fromthefuel tank andusea pump-type siphonto drain the fuel into a clean gas can. 4. NOTE: Thisis the only procedure recommended 5. for draining fuel. f-- Repeat steps 2 and 3 until properly adjusted. Tighten the jam nut to lock the adjustment. Maintenance Cleaning the Cooling System After every 75 operating hours, clean dirt and chaff from the cylinder, cylinder headfins and from around the carburetor and linkage.
Maintenance Servicing Blade 1. Stop the engine and pull the wire off the spark plug. See figure2. f- CAUTION! Do not attemptto inspect, remove or replace the blade without first removing the s so that plug wire fromspark plug. Fasten the wire it does not accidentally touch the plug. 2. Drainthegasolinefromthefueltank;refer to Maintenance Draining Gasoline, page 13. 3. Tip the mower on its right side. See Figure 10. Figure 8 Maintenance Adjusting Throttle See Figure9.
Assembly I. Position the tire on the wheel half, aligning lugs on each. See Figure17. HANDLE 2. Place the bearing support hub into the center hole of wheel half. Make sure the legsof the hub are positioned over the flange of the hole. 3. Place the other wheel half onto the bearing support hub aligning the wheel and the tire lugs and mounting holes. 4. To facilitate assembly, u s etwo 1/2-20X1.50”long fully threaded screws or bolts and non-locking nuts, loosely secure the wheel halves together.
Fuel can be left in the gas tank only if a fuel additive, suchas Toro Preservit, is added to the gasoline before storing. Toro Preservitis a petroleum distillate based condtioner/stabilizer. Maintenance Cleaning the Mower Housing (cont’d) 3. Tip the mower on its right side. See Figure18. 4. Remove dirt and grass clippings that stick to the housing byspraying it withagardenhose. Serape out remainingdebriswithhardwood scraper. Avoid burrs and sharp edges. 5.
SECTION 1 FRONT SUSPENSION Front Suspension Operation The front wheels are not affixed directlyto the cutter housing. Rather, they are affixed through pivot arms which allow changesin height of cut. As the pivot arm is rotated, the distance fromthe ground to the blade will increase or decrease accordingly. Once in the desired position, the spring arm prevents the pivot arm from further rotation by means of a pin or rivet which falls into a slot on the front quadrant. See Figure 19.
REAR SUSPENSION (HP Models Only) SECTION 2 4. Hand Push Rear Suspension Operatlon The rear wheel and tire assemblies are fastened to the cutter deck through the pivot arms. They are retained by a hex head capscrew and nylon locknut. 5. Remove the carriage boltthat secures the wheel and tire assemblyto the pivot arm and remove the wheel spacer and nylon locknut. Removethe E-clips from each endof the axle. The pivot arms pivotin order to change the height-of6.
assembly onto each side of the axle, spring arm first. Slide aflat washer onto each end of the output shaft then secure the assembly with Eclip anon each end. 4. Installtheassemblyintothemowerhousing using only the2 front flanged head capscrews. 5. Position the safety shield componentsas shown in Figure 24, and secure the safety shield and endcaps with thetwo flanged head capscrews. Tighten all endcap capscrews. Endcap Capscrew Torque: 25 N-m (225 in Ibs) 6.
SECTION 3 SELF-PROPEL SYSTEM Pull the left side of the transmission out slightly and remove the cotter pin securing the gear selection control lever to the transmission. Remove the gear s e l e c t i o n control lever. GEAR SELECTION CONTROL Gear Selection Control Operatlon The self-propelled Toro Landscaper Mower is equipped with a three speed transmission.
4. Remove the two self-tappingscrewssecuring the lower tank bracket and the screen panel to 27. the cutter housing. See Figure Figure 29 NOTE: Use only 1 Eclip to secure the traction control cable to the control assembly. Do not use the grommet,as this may cause fraying and prethe cable. mature failure of Figure 27 2. 5. Move the fuel tank and bracket assembly out of the way and remove the screen panel. 6.
3. Traction Control Adjustment is properly adjusted when all The traction control cable slack is removed fromthe cable and the controlbar is at a point 3.8 cm (1-1/2”) from the handle. (Youcan tell when all the slack is removed fromthe traction cable 4. as the control baris by feeling for a slight resistance 5. raised.) Loosen the jam nut on the cableadjuster and rotate the fitting upor downto achievethe correct distance between the control bar and the handle. See Figure 32.
between the clutch washer and friction ring causes the clutch washer to lag the output shaft is slightly onceit is engaged. That slight rotation al that is necessary to raise the wheel pinion key and engage thepinion. pinions from the output shaft when the operator is not squeezing the handle, This allows the wheels to turn backwards without turning the gears inside the transmission and providespullbackforcessimilar to those found on a hand-push version.
- 3. Remove the special retaining clip at theendof the output shaft and pull off the following six wheel pinion clutch components: NOTE: Thedetentrivet separately. Spring Internally Tabbed Thrust Washer WheelPinion WheelPinion Key ClutchWasher FrictionRing 4. If thespring armknobrequiresreplacement, push in on the detent tab, then pull the knob straight off. IO. Rear HOC and WPC Disassembly (cont'd) is not replaceable - Rear HOCand WPC Assembly 1.
NOTE: The convex side of the spring arm rivet and the concave side of the knob on the spring arm should both be facing the housing. 10. Slide the externally tabbed thrust washer the and internally tabbed thrust washer onto the output shaft. (Make sure that the tab on the internally tabbed thrust washer follows the contour of the keyway.) Secure with the special retaining clip, fits properly into making surethat the center tab the keyway. This will prevent rotation of the clip on the output shaft. 16.
Transmission Operatlon (cont’d) speeds final drive ratio. For more information on final at various throttle settings, see Figure 41. Ground RPM @ 2000 RPM Figure 41 Figure 39 Gear SelectionSystem: Gear selectionis determined in a sleeve thatis fixed to by moving sliding shift keys of the three the outputshaft. These keys engage one gears that rotate on the gear sleeve. Once the key at the engages one of the gears, that gear will rotate same speedas the output shaft.
r Bagging Lubrication is provided by177 cc (6oz) base grease. of No. 2 lithium- Transmission Removal Complete transmission removal on the Landscaper mower is quite easy and is recommended for most self-propel system repairs. 1. Remove the spark plug lead from the engine to prevent accidental starting. 2. Drain the fuel from the tank and shutoff the valve under the tank. 3.
Transmisslon Disassembly (contd') 9. Pulltheseal,bearing,bearingholder,spacer, shift collar, shift keys with spring clip, and shift key sleeve from the output shaft. Address this situation by using an impact wrench or by removing the20 and 25 tooth gears from 10. Remove the three output shaft gears from the the intermediate shaft and then putting the output shaft. intermediate shaft assembly back onto the transmission. The hexagonal intermediate shaft 1 1.
7. Slidethe shift keyassemblyintothe shift key sleeve until the shift collar bottoms out. 8. Completetheoutputshaftassemblybyslidinga spacer washer and the other output bearing assembly onto the output shaft.See Figure 48. SHAFT BEARING HOLDERS E Figure 48 9. If the left pivot arm was removed for servicing, reassemblenowasdescribedunderHeightof-Cut System and Wheel Pinion Clutch - Assembly, page26. IO. 11.
Transmission Assembly (cont’d) 15. Slip an intermediate shaft bushing onto the left end of the intermediate shaft, flanged endfirst, See Figure 51. I 1 SPACERS Figure 51 16. Slidetheintermediateshaftgearsontothe intermediate shaftin this order: Figure 52 25-toothgear 20-toothgear 15-toothgear 17.Slideaspacerwasherontotheintermediate shaft next to the bevel gear and follow with an intermediate shaft bushing, flanged side first. 18.
SECTION 4 ZONE START BRAKE The switch leads are connected to the primary sideof ZoneStartBrake Introduction the coil and to ground. When the switch is closed, the In 1982 the federal government mandated that all so that it cannot electronic ignition module is bypassed consumer walk behind mowers with a cut 63.5 of cm interrupt primary coil current flow. This prevents the coil (25') or less be equipped with safety devices. Because the high voltage necessary for spark.
brake plate pivots freely Once the screws tightened. Tightento the proper torque. Zone Start Brake System Assembly (cont’d) are Brake Plate Pivot Screw Torque: 10.4 N-m (90 4. Slip the compression spring over the cable, then slip the lugged end of the cable into the slotin thebrakeplate.Slipthespringbetweenthe brake plate and mounting plate, then secure with the cable clamp and ground s t r a p stop as shown in Figure 57. Figure 56 2. Secure the mounting plate with one self-tapping screw.
Bagging SECTION 5 ELECTRICALSYSTEM to produce spark.To create an arc we must add one ElectricalSystemOperation more component:the electronic ignition module. While the ignition circuit is described in each of the be applicable engine manuals, the subject will also Theelectronicignitionmoduleopenstheprimary briefly described here since the wire harnessof is part circuit while the magnet is passing by, thereby causing the chassis.See Figure 58. a rapid decreasein primary current flow.
SECTION 6 HANDLE ASSEMBLY 3. Handle Assembly Introduction The handle assemblyon the Landscaper rear bagger is constructed of 25mm (1”) diameter 16 gauge steel. It is painted black with a dry powdered paint. The boltedto the handle and the handle handle latches are is of single piece design. Both these features are for 4. added durabilityand rigidity to stand upto the rigors of commercial use.See Figure 60.
1. If the handle studs were removed from the cutter housing, apply Loctite to prevent the studs from turning out. Then install the studs into the cutter housing. 6. Handle Stud Torque: 40.3N-m (350in Ibs) 2. Slip the lowest hole on the handle over the stud and secure with a washer and nylon locknut. 3. Bringthehandleup to thedesiredheightand secure with a hex head capscrew and nylon locknut on each side.If in doubt of adjustment, use the center hole. 4. capscrew, washer and nylon locknut.
SECTION 7 ENGINE The Landscaper Rear Bagging Mowers are powered bytheToro2-Cycleengine.Themanualcovering maintenance and service of this engine is available from The Toro Company at the following address: The Toro Company Consumer Service Department 8111 Lyndale AvenueSo.
SECTION 8 CUTTINGDECK - Cutting Deck Operation TheLandscaperDeck isdesigned to providethe ultimate in quality\ of cut and bagging. It relies on air movement to carry the grass into the bag. Not all of theis drawn air from the sides; a considerable amount of air enters through the center ofthe deck. The perforated screen panel just behind the engine is the entry point. From there, the air passes throughthe belt opening in the deck, andfinallydown to the cutting chamber area.
If the clearance is uneven around the circumference of the deck, loosen the engine bolts, center the engine, If the heightof the bladeis too high within the housing, then retighten thebolts. Recheck to be sure that the be the engine mounting pads on the cutting can deck blade to tip clearance is now within the specification. lowered slightly. Using a caliper, measure the original height of the mounting pad.
SECTION 9 GRASS BAG AND DISCHARGE DOOR GRASS BAG - Grass Bag Construction The bag used on Toro Landscaper units consists of two pieces, the bag frame and the bag. See Figure 70. Grass Bag Assembly 1. Slip the bag frame into the bag. Make sure that up and that the plastic molding theToro logos are aligns properly with the front of the frame. Make sure that the handle is on the outside of the bag. 2. Gradually work the molding Over the bag frame until it is fuly seated. 3.
Discharge Door Operation (cont'd) hinge clamps. 9. sealed along thesides and bottom by foam adhesive "weather stripping'. It is important that this Weather stripping' be intact because otherwise dust and fine 10. particles will exit the bag area during mowing. Along the hinge lineis a special plastic seal which conforms 11. to the shape of the top of the door. This seal is also important in preventing the escape of fine particles.
2. Place the door brace into position, flanged side 8. down or away from the hinge, and secure to the handle using the two flanged head screws as shown in Figure 131. Tip the mower onits side and pull the bottom of thespringintopositionusing a thin ropeor 72. insulated electrical wire. See Figure 9. Check for proper operation of the spring by watching from the bottom of the unit while opening and closing the door. 10. Install the black plastic plate cover. 3.
SECTION 10 SIDE DISCHARGE CHUTE (Optional) Side Discharge Chute Operation The side discharge chute when attached, takes clippings, propelled rearwardbytheblade, and It allows redirects themoff to the left side of the mower. the operatorto mow without bagging grass. Side Discharge Chute Assembly 1. Place the chute hanger bracketand stress plate into positionas shown in Figure 75. Secure with two washer head capscrews and nylon locknuts. See Figure 75.
SECTION 11 DETHATCHER (Optional) Whencorrectlyassembled and adjusted,andwith of propercare,yourdethatcherwillprovideyears trouble-free lawn maintenance. Dethatcher Safety Information 1. Operateyourdethatcheronlywhenthereis adequate light. 2. 3. 4. 5. 6. Arrange each kind of hardware into a groupto ease assembly. Removealldebrissuch as wire,bottles,cans, sticks, and stones from the area to be dethatched.
- mount bar to the inside of tabs 'A' with offsets toward the center of the tray. See Figures 78 and 79. Dethatcher Assembly (cont'd) 2. 3. Nesteachtineloopbetweentheembossed 'dimples' with bent tips facingforward- toward X 3/4” tab cutouts'A' and secure with one 5/16' carriage bolt, a special washer, one 5/16' lock washer and a 5/16' hexnut . Tighten securely. OFFSETS TO INSIDE Install both safety wires through the tine coils and bend the ends over to secure (use pliers).
EEL MOUNT BRACKET Figure 80 10.See Figure 81,Placeone latchagainstthe outside of both mount bars with the tab up (and facing outward) and the long slot located infront slot. of the square hole near the mounting Secure each latch with one1/4”X 3/4” carriage bolt threads facing inward, a special washer, O-ring, special washer and1/4”hex locknut. AXLE Figure 82 CAUTION! Tlghten both locknuts until there is SOME friction when sliding the latches against the mount bars.Do not over-tighten1 13.
RIGHT MOWER WHEEL STEEL PIVOT STEEL PIVOT ARM Figure 86 Figure 84 RIGHT MOWER WHEEL CAST PIVOTARM MOWER Figure 87 Dethatcher Disassembly Disassembly is simply the reverse of the above steps. - Dethatcher Installation See Figure88. Install your dethatcher by sliding both First, slip one 1/2” flatwasherononenew shoulder bolt and insert thebolt through the hole latches upto clear the mounting slots on the mount in mower wheel (from 'outside' surface of wheel). bars.
- Dethatcher Adjustment See Figures 89 and 90.With the dethatcher mounted to your mower, position both units Over a smooth flat surface suchas a sidewalk, driveway or garage floor. Adjust the mower height (check your Operator's Manual for correct procedures)to the desired heightof-cut.
