Installation Instructions

ManualsBrandsToro ManualsWalk-Behind MowersEngine Conversion Kit, Serial Number 280000001 and After Kawasaki-Powered Walk-Behind Greensmaster 1000, 1600, 2000 and 2600 Mowers

FormNo.3430-367RevA

EngineConversionKit

SerialNumber280000001andAfterKawasaki-Powered

Walk-BehindGreensmaster

1000,1600,2000and2600Mowers

ModelNo.120-2736

InstallationInstructions

Introduction

Important:Theseinstallationinstructionscontain

engineoperationandmaintenanceinformation

thatsupersedestheengineinformationinyour

machineOperator’sManual.

Beforeoperatingormaintainingthemachine

orengine,alwaysrefertothesafetyinyour

Operator’sManual.

Savetheseinstructions.

Important:Thisengine'swarrantyisprovided

bytheenginemanufacturer.Pleaserefertothe

enginemanufacturer'swarrantyandemissions

systemwarrantyincludedintheliteraturepacket.

Thatwarrantyappliesonlytotheengine.Itdoes

notexpandorotherwisealteranyexpressor

impliedwarrantytermsorwarrantyperiodthat

mayapplytotheproductintowhichtheengine

isinstalled.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Contents

Introduction...............................................................1

Safety.......................................................................2

SafetyandInstructionalDecals..........................2

Installation................................................................3

1RemovingtheOldEngine................................3

2InstallingtheNewEngine.................................3

ProductOverview.....................................................8

Controls.............................................................8

Operation..................................................................8

FuelSpecication...............................................8

UsingStabilizer/Conditioner...............................8

FillingtheFuelTank............................................9

OpeningandClosingtheFuel-Shut-Off

Valve...............................................................9

Maintenance...........................................................10

RecommendedMaintenanceSchedule(s)...........10

PreparingtheMachineforMaintenance............10

ServicingtheAirCleaner...................................11

EngineOilSpecication....................................12

CheckingtheEngine-OilLevel..........................12

ChangingtheEngineOil...................................12

ServicingtheSparkPlug...................................14

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3430-367*A

Summary of content (16 pages)

PAGE 1
Form No. 3430-367 Rev A Engine Conversion Kit Serial Number 280000001 and After Kawasaki-Powered Walk-Behind Greensmaster® 1000, 1600, 2000 and 2600 Mowers Model No. 120-2736 Installation Instructions Introduction Important: These installation instructions contain engine operation and maintenance information that supersedes the engine information in your machine Operator’s Manual. Before operating or maintaining the machine or engine, always refer to the safety in your Operator’s Manual.
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Safety Safety and Instructional 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 missing. decal115-1614 115-1614 1. Warning—read the Operator's Manual. 3. Thrown object hazard—keep bystanders away. 2. Warning—do not operate the machine unless you are trained. 4. Warning—stay away from moving parts; keep all guards and shields in place. decal120-2769 120-2769 1.
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Installation 2 For models 04034, 04035, 04036, 04037, 04052 (TE), and 04060 (TE) made in 2008 or newer. Installing the New Engine Note: If the machine is equipped with an incandescent light kit, you may need to order a new kit; contact your local Toro dealer for more information.
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Procedure Note: If the machine does not have an engine switch on the console, add a space for one using the dimensions in Figure 1. g025179 Figure 2 1. Lock nut 6. Torque spring 2. Belt guide 7. Washer 3. Idler pulley assembly 8. Bolt 4. Clutch lever 5. Cotter pin 9. Cable link g021517 Figure 1 1. 2.13 cm (0.84 inches) 3. 3.68 cm (1.45 inches) 2. 1.90 cm (0.75 inches) 4. 13.97 cm (5.50 inches) 5. Install the old cable link to the clutch lever and secure it using the washer and cotter pin.
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10. Install the engine conversion mounting bracket to the machine with the previously removed bolts. 20. Using the old throttle cable clip, attach the new throttle cable to the rear of the differential housing (Figure 4). Note: To make installing the engine to the frame easier, tighten the bolts 90% of the way. 11. Mount the engine onto the engine conversion mounting bracket using 3 of the existing bolts and nuts, leaving the front right mounting hole open.
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26. Install the engine switch in the console and connect it to the wiring harness. Note: Connect the wiring harness to the hour meter if the machine is equipped with one. 27. Snap the wiring harness into place under the console cover. Note: You may need to drill holes for the wiring harness clips to snap through. 28. Mount the green ground wire using the cowling bolt under the fuel tank, and connect the red wire to the engine. Note: Apply skin-over grease to the bolt and ground lug terminal. 29.
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g025181 Figure 6 1. wiring harness 14. Washer 2. Cable tie 3. Traction bracket 15. Lock washer 16. Long bolt 4. Engine switch 17. Bellcrank cover 5. Throttle lever 6. Throttle cable 18. Locknut 19. Belt guide 7. Flange-head bolt 20. Idler pulley assembly 8. Interlock module 9. Wire harness plate 21. Clutch lever 22. Flat washer 10. Key 23. Cotter pin 11. Clutch bracket 24. Engine 12. Short bolt 25. Engine conversion mounting bracket 13. Drive pulley input 26.
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Operation Product Overview Fuel Specification Petroleum Use unleaded gasoline with an octane rating of 87 fuel or higher ((R+M)/2 rating method). Use an unleaded-gasoline blend with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Ethanol blended fuel Important: For best results, use only clean, fresh fuel (less than 30 days old). g264589 Figure 7 1. Choke lever 2.
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Filling the Fuel Tank Opening and Closing the Fuel-Shut-Off Valve Fuel tank capacity: 2.7 L (0.71 US gallons) 1. Park the machine on a level surface and shut off the engine. Control fuel flow to the engine with the fuel-shut-off valve as follows: 2. Allow the engine to cool. • Rotate the handle for the fuel-shut-off valve 90 3. Clean around the fuel-tank cap and remove it (Figure 8). degrees clockwise to the open the valve.
PAGE 10
Maintenance Important: Refer to your engine owner’s manual for additional maintenance procedures. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 20 hours • Change the engine oil. Before each use or daily • Check the engine-oil level. Every 50 hours • Clean the foam air-cleaner element (More often under severe conditions). Every 100 hours • Change the engine oil • Check and gap the spark plug.
PAGE 11
Servicing the Air Cleaner 4. Rotate the wing nut that secures the paper and foam-filter elements counterclockwise and remove the filter elements from the hold-down rod (Figure 11). 5. Carefully pull the foam element off the paper element (Figure 11). Service Interval: Every 200 hours Important: Do not apply oil to the foam or paper element. Removing the Foam and Paper Elements Note: Inspect the paper and foam-filter 1.
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Engine Oil Specification 5. Oil Type: Detergent oil (API service SJ or higher) Insert the dipstick from the engine as shown in Figure 13. Note: Do not thread the dipstick into the filler Oil viscosity: Refer to the table below. 6. neck when checking the engine oil level. Remove the dipstick from the filler neck and look at the oil level in the dipstick (Figure 13). 7. Note: The engine oil level must cover between the hatch marked areas on the dipstick (Figure 13).
PAGE 13
4. Remove the drain plug from the engine and allow the oil to drain completely. 5. Push down on the handle to tip the machine and engine backward, allowing all the oil to run into the drain pan. Important: Do not tip the machine at an angle greater than 25°. Tipping the machine beyond 25° leads to oil leaking into the combustion chamber and/or fuel leaking out of the fuel-tank cap. 6. 7. 8.
PAGE 14
Servicing the Spark Plug Installing the Spark Plug Service Interval: Every 100 hours Tighten the spark plug as follows: • New spark plug—12 to 15 N∙m (8.7 to 10.8 ft-lb) Spark Plug Specification • In-service spark plug—23 to 27 N∙m (16.6 to 19.5 ft-lb) Spark Plug Type: NGK BR6HS, Champion RTL86C, or equivalent Removing the Spark Plug 1. 2. Prepare the machine for maintenance; refer to Preparing the Machine for Maintenance (page 10). g008795 Figure 19 Remove the spark plug as shown in Figure 17.
PAGE 15
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
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