Form No.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Toro Mower Safety . . . . . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . Recommended Gasoline . . . . . . . . . . . . . . Using Stabilizer/Conditioner . . . . . . . . . . . Filling the Fuel Tank . . . . . . . . . . . .
Safety This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production. Note: The addition of certain attachments that do not meet American National Standards Institute certification will cause noncertification of this machine. Improper use or maintenance by the operator or owner can result in injury.
Safety Operation • Never run an engine in an enclosed area. • Only operate in good light, keeping away from holes and hidden hazards. • Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided. • • Be sure of your footing while using pedestrian controlled equipment, especially when backing up. Walk, don’t run. Never operate on wet grass. Reduced footing could cause slipping.
Safety • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Safety • Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service. • When operating machine on slopes, banks or near drop offs, always have ROPS (roll over protection) installed. • Before operating a machine with ROPS (roll over protection) be certain the seat belts are attached to prevent the seat from pivoting forward. • When operating a machine with ROPS (roll over protection) always use seat belt.
Safety • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required. • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery. • Battery gases can explode. Keep cigarettes, sparks and flames away from battery. • Hydraulic fluid escaping under pressure can penetrate the skin and cause injury.
Safety Slope Chart Read all safety instructions on pages 2–9.
8
Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. ON UPPER CONTROL BAR (Part No. 82-2290) ON TOP-FRONT OF MOWER (Part No. 66-1340) ON LOWER CONTROL BAR (Part No. 82-2280) ON CONTROL PANEL (Part No. E323564) ON THE GEAR SELECTION PANEL (Part No. E323560) ABOVE MUFFLER (Part No. 63-8440) ABOVE GRASS DEFLECTOR (Part No.
Safety ON REAR OF MOWER (Part No. 99-3943) ON PARKING BRAKE (Part No. E323558) 99–3943 ON LEFT SIDE OF HANDLE FRAME (Part No. E323563) ALONG LEFT SIDE OF FUEL TANK (Part No. 95-2814) ON REAR-LEFT CORNER OF MOWER (Part No. 98-5130) ON REAR FRAME (Part No.
Gasoline and Oil Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive.
Gasoline and Oil Filling the Fuel Tank POTENTIAL HAZARD • Gasoline is harmful or fatal if swallowed. Long–term eposure to vapors has caused cancer to laboratory animals. 1. Shut the engine off. 2. Clean around the fuel tank cap and remove the cap. Use a funnel and add unleaded regular gasoline to the fuel tank, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. 3.
Assembly Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
Assembly DESCRIPTION QTY. Fuel tank 1 Bolt 5/16–1/ x 7/8” (22.5 mm) 2 Lock washer 5/16” 2 Washer 5/16” 4 Stud 2 Spring 2 Hose clamp 1 Operator’s Manual 1 Engine Operator’s Manual 1 Parts Catalog 1 Registration card 1 USE Install fuel tank Read before operating machine Fill out and return to Toro Install Front Castors Install Upper Handle 1. Align castors with holes on top and front of mower and insert (8) 3/8–16 x 3/4” (19 mm) bolts through mower.
Assembly Connect Wire Harness Install Traction Control Rods 4. 1. Thread trunnions equal distance onto each control rod. For a starting point thread on approximately 2 in. (51 mm) (Fig. 5). 2. With trunnion rod up, slide clevis pins through rod fittings and mounting holes in idler brackets (from outside) (Fig. 5). Secure with 1/4” (6 mm) washers and hairpin cotters (Fig. 5). 5. Route wire harness inside of frame, along left handle and over throttle cable.
Assembly 3. 4. 5. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 in. (25–32 mm) (Fig. 6). Connect Throttle Cable 1. Place throttle control lever in FAST position.(Fig. 7). Note: 2. Hook wire Z–bend into hole of speed control lever (Fig. 7). 3. Loosen cable clamp screw allowing cable installation, but do not tighten (Fig. 7). 4.
Assembly Install Blade Control (PTO) Rod 1. Install Shift Lever 1. Rotate blade control lever (PTO) vertical away from left handle so rod drops down. 2. Remove hairpin cotters from bottom end of blade control rod (PTO) (Fig. 8). 3. Secure blade control (PTO) rod through hole in bellcrank with hairpin cotters (Fig. 8). Note: Slide shift lever through control panel and align mounting hole in lever with square on transmission shaft.
Assembly Mount Fuel Tank 1. 2. 3. Align fuel tank to top of rear frame and secure fuel tank right side with (2) 5/16–18 x 7/8 in. (22.5 mm) bolts, (2) 5/16 lock washers and (2) 5/16 washers (Fig. 10). Push fuel line onto fuel tank fitting and secure with hose clamp (Fig. 11). 1 Secure fuel tank left side to frame with (2) 5/16–18 x 7/8 in. (22.5 mm) studs, (2) 5/16 washers and (2) 5/16 locknuts (Fig. 10). 2 3 Figure 11 1. Fuel line 2. Hose clamp 4 3 3 2 5 6 1 m–3771 Figure 10 1.
Operation Think Safety First Please carefully read all the safety instructions and symbols in the safety section. Knowing this information could help you, pets or bystanders avoid injury. Recoil Starter – Pull recoil starter handle to start engine. Fuel Shut–off Valve – (In fuel line) Close fuel shut–off valve when transporting or storing mower. 2 5 Controls 7 Become familiar with all the controls (Fig. 12) before you start the engine and operate the machine.
Operation Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 1. Pull the upper control bar rearward and hold it in this position (Fig. 13). 2. Lift the parking brake lock up and gradually release the upper control bar (Fig. 13). The brake lock should stay in the set (locked) position. Releasing the Parking Brake 1. Pull rearward on the upper control bar (Fig. 13). Lower the parking brake lock to the released position. 2.
Operation Starting and Stopping the Engine Stopping 1. Starting 1. Note: Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open. 2. Move the blade control to off, the shift lever to neutral and set the parking. 3. Move the throttle control to CHOKE position before starting a cold engine. Note: 4. Move the throttle lever midway between FAST and SLOW (Fig. 14). 2. Allow the engine to run a minimum of 15 seconds and then stop the engine.
Operation Operating Blade Control (PTO) The Safety Interlock System The blade control (PTO) lever engages and disengages power to the mower blades. Understanding the Safety Interlock System Engaging the Mower Blades (PTO) The safety interlock system is designed to prevent the engine from starting if: 1. Pull on the upper control bar to stop the machine (Fig. 15). • The throttle lever is all the way back, past SLOW 2. Hold the bail against the upper control bar (Fig. 15).
Operation Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the “FAST” position for best performance. Forward 1. To go forward, move the shift lever to a forward gear. 2. Release the parking brake: refer to Releasing the Parking Brake, page 20. 3. Slowly press on the upper control bar to move forward (Fig. 16). Backward 1. To go backward, move the shift lever to reverse gear. 2.
Operation Lower Control Bar Operation 1 This procedure is for driving up a curb. This can be performed while driving forward or backward. 1. 2 Disengage the mower blades. POTENTIAL HAZARD • A blade can be bent or damaged when driving up a curb. Blades could break apart and pieces could be thrown at bystanders or at you as you use the mower. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders.
Operation Adjusting Height-of-Cut Adjust Axle Height A 1” to 4-1/4” range for height-of-cut can be achieved by adjusting blade spacers, rear axle height and front castor spacers. Use the Height-of-Cut chart on page 26 to select the combination required Adjust Blade Height Blades are adjusted by using the four, 1/4” spacers found on the blade spindle bolts. This allows a range, in 1/4” increments, of cutting height in any axle position.
Operation Adjust Caster Position 1. 2 1 Using the height-of-cut chart, adjust the caster spacers to match with the axle hole selected (Fig. 21). 2. Remove clevis pin, slide castor from support and change spacers(Fig. 21). 3. Install castor in support and insert clevis pin(Fig. 21). 3 m–3791 Figure 21 1. Clevis pin 2. 3/16” (5 mm) spacer 3. 1/2” (13 mm) spacer Height-of-Cut Chart Axle Position 26 No.
Maintenance Service Interval Chart Service Operation Oil—check level Each Use 8 Hours 25 Hours 50 Hours 100 Hours 200 Hours X Oil—change* Storage Service X Initial X Oil Filter–change (200 hours or every other oil change) X X X Safety System—check X X Brakes—check X X Cutting Blades – check Wheel Bearings—grease* X X X X Transmission Couplers – grease* Idler Pivots – grease* X X X X X Belt Blade Idler Pivots – grease* X Foam Air Cleaner—service* X X X Paper Air Cleaner—
Maintenance Air Cleaner Cleaning the Foam and Paper Elements 1. Service Interval/Specification Foam Element Foam Element: Clean and re-oil after every 25 operating hours. A. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. Paper Element: Replace after every 100 operating hours. B. Dry the element by squeezing it in a clean cloth. C. Put one or two ounces of oil on the element (Fig. 23). Squeeze the element to distribute the oil.
Maintenance 2. Paper Element Engine Oil A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 24). Service Interval/Specification B. Change oil: Inspect the element for tears, an oily film, and damage to the rubber seal. IMPORTANT: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly. • After the first 8 operating hours.
Maintenance Checking Oil Level Changing/Draining Oil 1. 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 3. Place a pan below the oil drain. Remove the oil drain cap (Fig. 26). 4.
Maintenance Spark Plug Change Oil Filter Service Interval/Specification Service Interval/Specification Replace the oil filter every 200 hours or every other oil change. Note: 1. Change oil filter more frequently when operating conditions are extremely dusty or sandy. Drain the oil from the engine; refer to Changing/Draining Oil, page 30. 2. Remove the old filter and wipe the filter adapter (Fig. 27) gasket surface. 3.
Maintenance Cutting Blades Checking the Spark Plug 1. Look at the center of the spark plug(s) (Fig. 29). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. IMPORTANT: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Fig. 29). Bend the side electrode (Fig.
Maintenance Inspecting the Blades 1. 2. Inspect the cutting edges (Fig 30). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 34. Inspect the blades, especially the curved area (Fig. 30). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 30), immediately install a new blade. 2 1 m–2539 Figure 32 2. Rotate the opposite ends of the blades forward.
Maintenance Removing the Blades Sharpening the Blades Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 34). Maintain the original angle.
Maintenance Tire Pressure Greasing and Lubrication Service Interval/Specification Service Interval/Specification Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 36). Check the tires when they are cold to get the most accurate pressure reading. Grease the areas shown and at intervals in Where to Add Grease section below.
Maintenance 2. Lubricate the transmission couplers every 50 hours and idler arm pivots every 8 hours (Fig 38). Brake Service Interval/Specification Before each use, check brakes for proper operation. 1 Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. Checking the Brake 1. Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. 2.
Maintenance Fuel Tank Adjusting the Brake The brake lever is on the upper control bar (Fig. 12). If the parking brake does not hold securely, an adjustment is required. 1. Draining The Fuel Tank Check the brake before you adjust it; refer to Checking the Brake, page 36. 2. Release the parking brake; refer to Releasing the Parking Brake, page 20. 3. To adjust brake set the parking brake latch, and rotate the wing nuts on the brake rods (Fig. 40).
Maintenance 4. Pull the fuel line off the fuel filter (Fig. 41). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. Note: 5. Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 38. Install the fuel line onto the fuel filter. Slide the hose clamp close to the filter to secure the fuel line.
Maintenance Replacing the Wheel Belt Replacing the Traction Belt Service Interval/Specification 1. Stop the engine, set the parking brake and remove the spark plug wire(s). Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating. 2. Raise the rear of the machine and hold with jack stands. 1. Remove hairpin cotter securing brake rod to brake arm to relax belt idler tension (Fig. 43). 3. Remove mower belt (Fig. 45).
Maintenance Replacing the Mower Belt 3 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key and spark plug wire. 2. Remove the knobs and belt cover on mower. 3. Remove idler pulley and then remove worn belt (Fig. 45). 4 Install new belt. 5. Install idler pulley. 6. Engage PTO and check belt tension. See Adjusting Mower Belt Tension, page 41. 1. 1/16” (2mm)–1/8” (3mm) 2. Bellcrank 3. Transmission output shaft 9.
Maintenance Adjusting Mower Belt Tension 4. If the belt is still loose after making adjustments to the turnbuckle, reposition the rear idler pulley to the front hole. The belt guide next to the pulley must also be moved to the front hole (Fig. 47). 5. Readjust the turnbuckle. Service Interval/Specification Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation.
Maintenance Adjusting Grass\Mud Scraper Replacing the Grass Deflector 1. Loosen the locknut holding scraper to the engine frame (Fig. 49). 1. Remove the locknut, bolt, spring and spacer holding deflector to the mounts (Fig. 50). 2. Rotate scraper until they align with center of pulley grooves (Fig. 49). 2. Straighten deflector mounts if they are bent (Fig. 50). 3. Tighten the locknut (Fig. 49). 3. Install new deflector between mounts with spacer and spring.
Maintenance Wiring Diagram J3 KILL W2 J4 J5 WIRE LIST DESIG.
Maintenance Cleaning and Storage 1. Disengage the blade control (PTO), set the parking brake and turn the machine “OFF”. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Check the brake; refer to Brake, page 36. 4. Service the air cleaner; refer to Air Cleaner, page 28. 5. Grease the machine; refer to Greasing and Lubrication, page 35. 6.
Troubleshooting PROBLEM Engine g will not start, starts hard, or f il to keep fails k running. i Engine g loses power. g Engine overheats. Abnormal vibration. POSSIBLE CAUSES CORRECTIVE ACTION 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 2. Choke is not ON. 2. Move choke lever to ON. 3. Air cleaner is dirty. 3. Clean or replace air cleaner element. 4. Spark plug wire is loose or disconnected. 4. Install wire on spark plug. 5.
Troubleshooting PROBLEM Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Blades do not stop when disengaged. g g 46 POSSIBLE CAUSES CORRECTIVE ACTION 1. Shift lever is in NEUTRAL. 1. Move shift lever to a drive gear position. 2. Traction belt is worn, loose or broken. 2. Change Belt. 3. Traction belt is off pulley. 3. Change Belt. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2.
A OneĆYear Limited Warranty (A TwoĆYear Full Warranty for Residential Use) LCE What Is Covered By This Express Warranty? The Toro Company promises to repair any TORO Product used for commercial, institutional, or rental purposes if defective in materials or workmanship. The following time frames apply from the date of purchase: Product Warranty Period All Products . . . . . . . . . . . . . . . . . . 1 year All Spindles . . . . . . . . . . . . . . . . . . .
