Installation Instructions

ManualsBrandsToro ManualsWalk-Behind MowersEngine Conversion Kit, Subaru Powered Walk-Behind Greensmaster 1000 Mower

FormNo.3440-983RevA

EngineConversionKit

SubaruPoweredWalk-BehindGreensmaster

1000Mower

ModelNo.139-5636

InstallationInstructions

Thisengineconversionkitisonlyformachineswith

followingmodelandserialnumbers:

ModelNumber

SerialNumber

04038315000001through315000500

04039315000001through316999999

04054315000001through999999999

04055315000001through999999999

04056315000001through999999999

Lightkit,Model04063(xed-headtractionunits)is

compatiblewiththiskit.

Note:Olderlightkitsarenotcompatiblewiththiskit.

Introduction

ItisaviolationofCaliforniaPublicResourceCode

Section4442or4443touseoroperatetheengineon

anyforest-covered,brush-covered,orgrass-covered

landunlesstheengineisequippedwithaspark

arrester,asdenedinSection4442,maintainedin

effectiveworkingorderortheengineisconstructed,

equipped,andmaintainedforthepreventionofre.

Ifyourequireasparkarrester,contactyourAuthorized

ServiceDealer.

Important:Theseinstallationinstructions

containengineoperationandmaintenance

informationthatsupersedestheengineoperation

andmaintenanceproceduresinyourmachine

Operator’sManual.

Beforeoperatingormaintainingthemachineor

engine,alwaysrefertotheoperatingandsafety

instructionsinyourOperator’sManual.

Savetheseinstructions.

Important:Theenginewarrantyisprovided

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

1PreparingtheMachine.....................................3

2RemovingtheExistingEngine.........................3

3InstallingtheNewEngine.................................3

4LubricatingandAdjustingtheMachine.............6

ProductOverview.....................................................7

Controls.............................................................7

Operation..................................................................7

FuelSpecications.............................................7

UsingStabilizer/Conditioner...............................7

FillingtheFuelTank............................................8

OpeningandClosingtheFuel-Shutoff

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

Maintenance.............................................................9

RecommendedMaintenanceSchedule(s).............9

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

ServicingtheEngineOil....................................10

ServicingtheAirCleaner..................................12

ServicingtheSparkPlug...................................13

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3440-983*A

Summary of content (16 pages)

PAGE 1
Form No. 3440-983 Rev A Engine Conversion Kit Subaru Powered Walk-Behind Greensmaster® 1000 Mower Model No.
PAGE 2
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. decal130-8322 130-8322 1. Use only fuel with an alcohol content by volume under 10%. 3. Do not use fuel with an alcohol content by volume greater than 10%. 2. Read the Operator's Manual for more information on fuel. decal133-8062 133-8062 decal138-2138 138-2138 1.
PAGE 3
Installation 10. Clean the frame and check for damage or wear.
PAGE 4
. Install the traction pivot shaft to the gearbox (Figure 2). 5. Install the clutch bracket to the gearbox with 2 bolts (7/16 x 1 inch) as shown in Figure 3. g312392 Figure 3 1. Hex nut 2. Belt guide g312396 Figure 1 1. Clutch plate 2. 2. Bolt (1/4 x 3/4 inch) 6. Clutch bracket 7. Torque spring 3. Idler pulley assembly 8. Washer (3/8 x 1-3/8 inch) 4. Clutch lever 9. Bolt (3/8 x 3/4 inch) 5. Bolt (7/16 x 1 inch) Install the square key onto the output shaft (Figure 2). 6.
PAGE 5
g312403 Figure 5 1. Clutch plate 3. Clutch-cable spring end 2. Clutch cable 4. Clutch lever 6. Install the spring end of the clutch cable to the clutch lever (Figure 5). 7. Install the throttle cable to the machine, refer to the machine Service Manual (Figure 8). • Use the throttle cable that is 172.2 cm (67-13/16 inches) long for a Model 04056 traction unit; refer to Figure 6. g312414 g327886 Figure 4 1. Engine bolt (previously removed) 4. Engine nut (previously removed) 2.
PAGE 6
4 Lubricating and Adjusting the Machine No Parts Required Procedure Important: The engine gearbox does not require maintenance, as it is filled with a high-performance, long-life, synthetic semi-fluid grease. 1. Adjust the clutch cable; refer to your Operator’s Manual. 2. Adjust the throttle cable; refer to your Operator’s Manual. 3. Lubricate the machine according to the instructions in your Operator’s Manual. 4.
PAGE 7
Operation Product Overview Fuel Specifications Fuel tank capacity: 2.0 L (0.59 US gallons) Recommended fuel: Unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method) Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
PAGE 8
Filling the Fuel Tank WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full.
PAGE 9
Opening and Closing the Fuel-Shutoff Valve Maintenance Control fuel flow to the engine with the fuel-shutoff valve as follows: for additional maintenance procedures. Important: Refer to your engine owner’s manual Important: The engine gearbox (Figure 12) does not require maintenance, as it is filled with a high-performance, long-life synthetic semi-fluid grease. • To open the fuel valve, turn the fuel-shutoff valve handle toward the recoil starter handle (Figure 11).
PAGE 10
Preparing the Machine for Maintenance Servicing the Engine Oil Fill the crankcase with approximately 0.56 L (19 fl oz) of the proper viscosity oil before starting. The engine uses a high-quality oil that has the American Petroleum Institute (API) service classification of SJ or higher. Select the proper oil viscosity (weight) based on the ambient temperature. Figure 14 illustrates the temperature/viscosity recommendations.
PAGE 11
Changing the Engine Oil Service Interval: After the first 20 hours Every 100 hours WARNING Oil may be hot after the engine has been run, and contact with hot oil can cause severe personal injury. Avoid contacting the hot engine oil when you drain it. 1. Shut off the engine and wait for all moving parts to stop; refer to Preparing the Machine for Maintenance (page 10). 2. Raise the engine off the ground and place a pan under the drain plug to catch the oil. 3. Remove the drain plug (Figure 15). 4.
PAGE 12
Servicing the Air Cleaner 7. Service Interval: Before each use or daily Every 50 hours Every 300 hours/Yearly (whichever comes first) Note: Do not try to brush dirt off the paper element; brushing forces the dirt into the fibers. Replace the element if tapping it fails to remove the dirt. Important: Do not operate the engine without 8. the air filter assembly; extreme engine damage will occur. 1.
PAGE 13
Servicing the Spark Plug Service Interval: Every 100 hours Every 300 hours Use an NGK BPR6ES spark plug or equivalent. 1. Shut off the engine and wait for all moving parts to stop; refer to Preparing the Machine for Maintenance (page 10). 2. Clean around the spark plug. 3. Remove the spark plug from the cylinder head. Important: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean the electrodes because engine damage could result from grit entering the cylinder. 4.
PAGE 14
Notes:
PAGE 15
Notes:
PAGE 16
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.