Form No. 3357-396 Rev A 21in Heavy-Duty Recycler®/Rear Bagger Lawn Mower Model No. 22196—Serial No. 270000001 and Up Register at www.Toro.com.
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. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Contents Safety Introduction................................................................. 2 Safety ........................................................................... 3 General Lawn Mower Safety ................................. 3 Safety and Instructional Decals ............................. 5 Setup............................................................................ 7 1 Installing the Handle.......................................... 7 2 Installing the Starter Rope .....................
• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. including emptying the catcher or unclogging the chute. • Stop equipment and inspect blade after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations. • The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property. • Keep hands and feet away from the cutting units.
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 lost. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 93-6654 1. Thrown object—hazard, mower-keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 68-7410 98-4387 74-1970 1. Transmission speeds 1.
107-4098 6
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 Description Use Qty. Handle Bolt (5/16 x 1-1/4 inches) Washer Thin nylon insert locknut (5/16 inch) Bolt (5/16 x 1-1/2 inches) Carriage bolt Locknut (5/16 inch) Bag support rod Bag aligning plate Cap locknut Cable tie 1 2 4 2 2 1 2 1 1 3 3 Install the handle. No parts required – Install the starter rope. Discharge tunnel plug 1 Install the discharge tunnel plug.
2 Installing the Starter Rope No Parts Required Procedure Pull the starter rope through the rope guide on the handle (Figure 4). Figure 3 1. Bag support rod 2. 3. 4. 5. 6. 7. 8. Thin nylon insert locknut (2) 9. Bottom hole in housing Carriage bolt Bag aligning plate 10. Washer (4) Cap locknuts (3) 11. Locknut (2) Handle 12. Bolt, (5/16 x 1-1/4 inches) (2) Bolt, (5/16 x 1-1/2 inches) 13. Cable tie (3) (2) Handle latch (2) Figure 4 1. Starter rope 2.
Before each use, ensure that the oil level is between the lower limit and upper limit marks on the dipstick (Figure 7). Figure 5 1. Discharge door handle 2. Plug, rotated clockwise 2. Since the plug is slightly wider than the discharge tunnel opening, rotate the plug clockwise slightly while inserting it (Figure 5). Note: Ensure that the arrow on the plug decal points upward. 3.
Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Each time before you mow, make sure that the self-propel drive and the blade control bar operate properly. When you release the blade control bar, the blade and self-propel drive should stop. If they do not, contact an Authorized Service Dealer. This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.
Filling the Fuel Tank with Gasoline Checking the Engine Oil Level Service Interval: Before each use or daily For best results, use clean, fresh, lead-free gasoline with an octane rating of 87 or higher. To ensure freshness, purchase only the quantity of gasoline that you expect to use in 30 days. Using unleaded gasoline results in fewer combustion deposits and longer engine life. You may use leaded gasoline if unleaded gasoline is not available.
When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. A fire or explosion from gasoline can burn you and others and damage property. • Always place gasoline containers on the ground and away from your vehicle before filling. • Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
4. Pull the starter handle lightly until you feel resistance, then pull it sharply. Allow the rope to return to the handle slowly. 5. When the engine starts, move the throttle control to the Fast position, and set the ground speed control as desired. 1. Move the ground speed control to the Neutral position (Figure 14). 2. Start the engine. 3. Squeeze the blade control bar to the Run/Shift position (Figure 15) and move the ground speed control to the desired speed setting (Figure 14).
Note: When grass is thick and lush, clippings may collect on and around the discharge tunnel plug. This may make removing the plug difficult. Clean the plug thoroughly after each use. Checking the Blade Brake Clutch Figure 17 Check the operation of the blade control bar and the blade brake clutch before each use to ensure that it is operating properly. 9. Push the blade control bar to the right. 10. Lift the blade control bar up to about one inch (2.
operating condition. Contact an Authorized Service Dealer. brake clutch system could be deteriorating to the point where it could result in an unsafe operating condition. Contact an Authorized Service Dealer for an inspection and repair of your mower. To check for a problem with the blade brake clutch system before it affects its normal operation, you can perform the Special Test that follows.
Adjusting the Cutting Height Each wheel is adjusted individually with a wheel height adjustment lever. Cutting heights are 3/4 inch (19 mm), 1-1/4 inches (32 mm), 1-3/4 inches (44 mm), 2-1/4 inches (57 mm), 2-3/4 inches (70 mm), and 3-1/4 inches (83 mm). Figure 22 Adjusting the cutting height levers could bring your hands into contact with a moving blade and result in serious injury. 1. Bag frame on retaining post 2.
Removing the Grass Bag • Maintain a sharp blade throughout the cutting season. Periodically file down nicks on the blade. 1. Stop the engine and wait for all moving parts to stop. 2. Raise the discharge door handle and move it forward to engage the pin with the catch (Figure 22). 3. Grasp the handles at the front and the rear of the bag and lift the bag off the mower. 4. Gradually tip the bag forward to empty the clippings. 5. To install the bag, refer to Installing the Grass Bag.
the leaves clump on top of the lawn, the mower may plug and cause the engine to stall. • Alternate the mowing direction. This helps disperse the clippings over the lawn for even fertilization. If the finished lawn appearance is unsatisfactory, try one or more of the following: • Sharpen the blade. • Walk at a slower pace while mowing. • Raise the cutting height on your mower. • Cut the grass more frequently. • Overlap cutting swaths instead of cutting a full swath with each pass.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. Before each use or daily • • • • • • • Check the engine oil level. Check the blade brake clutch operation. Inspect the air cleaner elements. Inspect the mower blades for wear or damage. Clean under the mower housing.
Lubrication Lubricating the Gear Case Service Interval: Every 100 hours Lubricating the Pivot Arms 1. Remove the grass bag. 2. Install a grease gun onto the fitting through the belt cover opening (Figure 25). Service Interval: Every 25 hours 1. Move the rear wheel cutting height levers to the center setting. 2. Wipe the grease fittings with a clean rag (Figure 24). Figure 25 1. Belt cover 2. Grease fitting Figure 24 3. Gently apply one to 2 pumps of #2 multi-purpose lithium-base grease. 1.
Engine Maintenance 7. Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty. Servicing the Air Cleaner 8. If the paper element is excessively dirty, replace it. Note: Never try to brush dirt off the paper element; brushing forces the dirt into the fibers. Service Interval: Before each use or daily—Inspect the air cleaner elements. 9. Clean the foam element in warm, soapy water or in a nonflammable solvent. Every 25 hours—Clean the air filter elements.
Changing the Engine Oil Servicing the Spark Plug Service Interval: After the first 5 hours Service Interval: Every 100 hours—Inspect, clean, and adjust the spark plug; replace it if necessary. Every 50 hours 1. Run the engine to warm the engine oil. Every 250 hours—Replace the spark plug. Note: Warm oil flows better and carries more contaminants. ® or Use an NGK BPR5ES® ®W16EPR-U spark plug or equivalent. Nippondenso® 1. Stop the engine and wait for all moving parts to stop.
Drive System Maintenance Controls System Maintenance Adjusting the Self-propel Drive Adjusting the Blade Brake Cable Service Interval: Every 75 hours Service Interval: Every 100 hours—Adjust the blade brake cable. If the mower does not self-propel or has a tendency to creep forward when the blade control bar is more than 1-1/2 inches (3.8 cm) from the handle, adjust the wheel drive control knob on the rear of the gear box (Figure 28).
Blade Maintenance Note: For the best performance, install a new blade before the cutting season begins. During the year, file down any small nicks to maintain the cutting edge. Maintaining the Blade Always mow with a sharp blade. A sharp blade cuts cleanly and without tearing or shredding the grass blades. 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug. 3. Drain the gasoline from the fuel tank. 4.
Cleaning Note: You can also check the balance using a commercially manufactured blade balancer. 2. If either end of the blade rotates downward, file that end (not the cutting edge or the end near the cutting edge). The blade is properly balanced when neither end drops. Cleaning under the Mower Housing To ensure the best performance, keep the underside of the mower housing clean. Be especially careful to keep the kickers free of debris (Figure 35). Installing the Blade 1.
Scraping Method Cleaning under the Belt Cover If washing does not remove all debris from under the mower, scrape it clean. Service Interval: Every 50 hours—Remove grass clippings and debris from under the belt cover. 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug. 3. Remove the bolts that secure the belt cover (Figure 37) to the mower housing. 1. Disconnect the wire from the spark plug. 2. Drain the fuel from the fuel tank.
5. Remove 2 blade nuts, the accelerator, and the blade (Figure 35). Storage 6. Loosen the tabs that secure the blade brake clutch shield to the housing by loosening the nuts or the bolts on the tabs (Figure 38). Rotate the tabs 180° to move them out of the way. To prepare the mower for off-season storage, perform the recommended maintenance procedures. Refer to Maintenance. Store the mower in a cool, clean, dry place. Cover the mower to keep it clean and protected.
3. Remove grass clippings, dirt, and grime from the external parts of the engine, the shrouding, and the top of the mower housing. 4. Check the condition of the blade. Refer to Maintaining the Blade. 5. Service the air filter; refer to Servicing the Air Filter. 6. Lubricate the pivot arms; refer to Lubricating the Pivot Arms. 7. Tighten all nuts, bolts, and screws. 8. Touch up all rusted or chipped paint surfaces with paint available from an Authorized Service Dealer. Removing the mower from Storage 1.
Troubleshooting Problem Engine does not start Engine starts hard or loses power Possible Cause 1. The fuel tank is empty or the fuel system contains stale fuel. 1. Drain and/or fill the fuel tank with fresh gasoline. If the problem persists, contact an Authorized Service Dealer. 2. The throttle lever is not in the Choke position. 3. The wire is not connected to the spark plug. 4. The spark plug is pitted, fouled, or the gap is incorrect. 2. Move the throttle lever to the Choke position. 3.
Problem Lawn mower does not self-propel Possible Cause Corrective Action 1. The self-propel drive cable is out of adjustment or is damaged. 1. Adjust the self-propel drive cable. Replace the cable if necessary. 2. There is debris under the belt cover. 2. Clean the debris from under the belt cover.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2007 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
Toro 21” The Toro Total Coverage Guarantee Commercial Walk Power A Two-Year Full Warranty (Limited Warranty for Commercial Use) Mower Conditions and Products Covered The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product, when used for residential purposes*, if defective in materials or workmanship or if it stops functioning due to the failure of a component.
