Installation Instructions

ManualsBrandsToro ManualsWalk-Behind MowersEngine Conversion Kit, Serial Number 270000001 and Before Kawasaki-Powered Walk-Behind Greensmaster 1600

FormNo.3422-784RevB

EngineConversionKit

SerialNumber270000001andBeforeKawasaki-Powered

Walk-BehindGreensmaster

1000and1600

ModelNo.130-6454

ModelNo.130-6455

InstallationInstructions

Introduction

Ifyourequireasparkarrester,contactyourAuthorized

ServiceDealer.GenuineTorosparkarrestersare

approvedbytheUSDAForestryService.

Important:Theseinstallationinstructions

containengineoperationandmaintenance

informationthatsupersedestheengineoperation

andmaintenanceproceduresinyourmachine

Operator’sManual.

Beforeoperatingormaintainingthemachineor

engine,alwaysrefertotheoperationandsafety

instructionsinyourOperator’sManual.

Savetheseinstructions.

Important:Thisengine'swarrantyisprovided

bytheenginemanufacturer.Pleaserefertothe

enginemanufacturer'swarrantyandemissions

systemwarrantyincludedintheliteraturepacket.

Thatwarrantyappliesonlytotheengine.Itdoes

notexpandorotherwisealteranyexpressor

impliedwarrantytermsorwarrantyperiodthat

mayapplytotheproductintowhichtheengine

isinstalled.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3422-784*B

Summary of content (16 pages)

PAGE 1
Form No. 3422-784 Rev B Engine Conversion Kit Serial Number 270000001 and Before Kawasaki-Powered Walk-Behind Greensmaster® 1000 and 1600 Model No. 130-6454 Model No. 130-6455 Installation Instructions Introduction If you require a spark arrester, contact your Authorized Service Dealer. Genuine Toro spark arresters are approved by the USDA Forestry Service.
PAGE 2
Safety WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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. Contents Introduction ............................................................... 1 Safety .....................
PAGE 3
Installation For Models 04052 and 04060 made in 2008 or later. Note: If the machine is equipped with an incandescent light kit, order a new kit; contact your Authorized Service Dealer for more information. 1 g025977 Figure 1 Removing the Existing Engine 1. Bolt 4. Handle pivot pin 2. Washer 5. Flange-head nut 3. Handle assembly No Parts Required 9. Procedure 10. Important: Save all removed parts unless otherwise noted. 1. Remove and discard the wire harness. 2.
PAGE 4
2 Installing the New Engine Parts needed for this procedure: 1 Engine assembly 1 Engine conversion mounting bracket Procedure g025180 Note: Refer to Figure 7 for installing the new engine. Figure 3 1. Clean the frame and check for damage or wear. 1. Bolt 4. Nut (existing) 2. Install the existing torsion spring, washer, and bolt to the new clutch lever (Figure 2). 2. Washer 5. Cable link (existing) 3. Torsion spring 6. Traction lever assembly 5.
PAGE 5
3 Installing the Cables Parts needed for this procedure: 1 Handle assembly 2 Clip g021514 Figure 5 Procedure 1. 1. existing clip Install the new handle assembly to the machine using the previously removed bolt, washer, handle pivot pin, and flange-head nut (Figure 4). 5. Attach the new clip to the throttle cable and bolt it to the engine conversion mounting bracket using the front right bolt (Figure 6). g025977 Figure 4 1. Bolt 4. Handle pivot pin 2. Washer 5. Flange-head nut 3.
PAGE 6
4 Completing the Installation Parts needed for this procedure: 1 Bellcrank cover 4 Cable tie Procedure 1. Install the V-belts. 2. Align the pulleys, and adjust the traction cable and V-belt tension; refer to your Operator’s Manual. Note: If you cannot properly adjust the traction cable, order Part No. 94-5870. 3. Tighten all of the engine and engine conversion mounting bracket bolts. 4. Route the wire harness up the left side of the handle. 5.
PAGE 7
g025938 Figure 7 1. Bellcrank cover 5. Handle assembly 2. Engine assembly 6. Clutch cable 3. Throttle cable 4. Cable ties 7. Brake cable 8.
PAGE 8
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 8 1. Choke lever 2.
PAGE 9
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 12). 5. Carefully pull the foam element off the paper element (Figure 12). 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.
PAGE 12
Engine Oil Specification 5. Oil Type: Detergent oil (API service SJ or higher) Insert the dipstick from the engine as shown in Figure 14. 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 14). 7. Note: The engine oil level must cover between the hatch marked areas on the dipstick (Figure 14).
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 20 Remove the spark plug as shown in Figure 18.
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.
PAGE 16