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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Symbols Glossary . . . . . . . . . . . . . . . . . . . Symbols Glossary . . . . . . . . . . . . . . . . . . . Symbols Glossary . . . . . . . . . . . . . . . . . . . Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . Recommended Gasoline . . . . . . . . . . . . . . Stabilizer/Conditioner . . . . . . . . . . . . . . . . Filling the Fuel Tank . . . . . .
Safety Toro designed this lawn mower for cutting and mulching grass, or, when equipped with a grass bag, for catching cut grass. Any use for purposes other than these could prove dangerous to the operator or to bystanders. Note: This engine is not equipped with a spark arrester muffler. Operating this mower on any forest-covered, brush-covered, or unimproved grass-covered land without an approved spark arrester muffler may violate your state law. Training • Read the instructions carefully.
Safety – Refuel outdoors only and do not smoke while refuelling. – Add fuel before starting the engine. Never remove the cap of the fuel tank or add gasoline while the engine is running or when the engine is hot. – If gasoline is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until gasoline vapors have dissipated. – Replace all fuel tank and container caps securely.
Safety • Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Stop the blade(s) when crossing gravel drives, walks, or roads. • Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catcher. • tamper with safety devices. Check their proper operation regularly. • Keep the mower free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage.
Safety Slope Chart Read all safety instructions on pages 2–9.
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Safety Symbols Glossary Safety alert triangle– symbol within triangle indicates a hazard Fire, open light & smoking prohibited Fire or open flame Safety alert symbol Explosion Read operator’s manual Do not dispose of lead battery in garbage Caustic liquids, chemical burns to fingers or hand Stay a safe distance from the machine Caution, toxic risk Stay safe distance from machine Eye protection must be worn First aid, flush with water Stay safe distance from machine Keep children away from battery
Safety Symbols Glossary Do not open or remove safety shields while engine is running Cutting of foot Thrown or flying objects, whole body exposure Hot surface, burns to fingers or hands Thrown or flying objects, whole body exposure Do not operate without safety shield in place Stop engine before leaving operator position Machine being transported Keep guards and safety sheilds in place Blade cutting elementheight adjustment Severing of toes & fingers, rotary mower blade Fuel shut off control ope
Safety Symbols Glossary Parking brake Fast Slow Traction drive Decreasing/Increasing Reverse Stop Engine STOP Neutral Choke First gear Fuel Second gear Power take off (PTO) Third gear Engage Fourth gear Disengage Fifth gear Parking brake Forward F 9
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 22.5 mm (7/8”) 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 19 mm (3/4”) bolts through mower.
Assembly Connect Wire Harness Install Traction Control Rods 1. 1. Thread trunnions equal distance onto each control rod. For a starting point thread on approximately 51 mm (2 in.) (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 6 mm (1/4”) washers and hairpin cotters (Fig. 5). 2. 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 25–32 mm (1 to 1-1/4 in.) (Fig. 6). Connect Throttle Cable 1. Place throttle control lever in FAST detent position.(Fig. 7). Note: 2. Route cable along left handle, under fuel tank mount and up to engine throttle base plate. 3. Hook wire Z–bend into hole of speed control lever (Fig. 7). 4.
Assembly Install Blade Control (PTO) Rod 1. Rotate blade control lever (PTO) away from left handle so rod drops down. 2. Remove hairpin cotter from bottom end of blade control rod (PTO) (Fig. 8). 3. Slide blade control (PTO) rod through hole in bellcrank and secure with hairpin cotter (Fig. 8). 3. Replace the spring washer,dish down, and locknut (Fig. 8). 4. Torque nut to 47 NSm (35 ft. lbs.). 5. Shift lever to second gear and check alignment of lever in slot of shifter plate.
Assembly Mount Fuel Tank 1. 5. Align fuel tank to top of rear frame and secure fuel tank right side with (2) 5/16–18 x 22.5 mm (7/8 in.) bolts, (2) 5/16 lock washers and (2) 5/16 washers (Fig. 10). 2. Torque bolts to 13 NSm (10 ft. lbs.). 3. Secure fuel tank left side to frame with (2) 5/16–18 x 22.5 mm (7/8 in.) studs, (2) 5/16 washers and (2) 5/16 locknuts (Fig. 10). 4. Push fuel line onto fuel tank fitting and secure with hose clamp (Fig. 11).
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. Note: Starting 1. 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 brake. 3. Move the throttle control to CHOKE position before starting a cold engine. 2. Note: 4. Move the throttle lever to “SLOW” (Fig. 14). A warm or hot engine usually does not require any choking.
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 19. 3. Slowly press on the upper control bar to move forward (Fig. 16). To go straight, apply equal pressure to both ends of the upper control bar (Fig. 16).
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. m–4185 Figure 18 1. Lower Control Bar engaged and mower in reverse. 2.
Operation Adjusting Height-of-Cut Adjust Axle Height A 25mm to 108mm (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, 6.35mm (1/4”) spacers found on the blade spindle bolts. This allows a range, in 6.35mm (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. 5 mm (3/16”) spacer 3.
Operation Height-of-Cut Chart 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 Blade Belt Idler Pivot – grease* X Foam Air Cleaner—service* X X X Paper Air Cleaner—r
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. Park the machine on a level surface, disengage the blade control (PTO) and set the parking. 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Clean around the oil dipstick (Fig. 25) so dirt cannot fall into the filler hole and damage the engine. 2. 3. Unscrew the oil dipstick and wipe the metal end clean (Fig. 25).
Maintenance Tire Pressure Change Oil Filter Service Interval/Specification Service Interval/Specification Replace the oil filter every 200 hours or every other oil change. Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 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. 28).
Maintenance Spark Plug Checking the Spark Plug 1. Service Interval/Specification Look at the center of the spark plug(s) (Fig. 30). 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. Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
Maintenance Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. POTENTIAL HAZARD • A blade that is worn or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. Inspecting the Blades 1. Inspect the cutting edges (Fig 31). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 35. 2.
Maintenance Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Fig. 32). Measure from a level surface to the cutting edge of the blades (Fig. 33). Note this dimension. POTENTIAL HAZARD • A blade that is bent or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. Front WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders.
Maintenance Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 35). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 2 1 m–1854 Figure 35 1. Sharpen at original angle 2. 2. Sail Check the balance of the blade by putting it on a blade balancer (Fig. 36). If the blade stays in a horizontal position, the blade is balanced and can be used.
Maintenance Greasing and Lubrication 2. Service Interval/Specification Lubricate the transmission couplers every 50 hours and idler arm pivots every 8 hours (Fig 38). Grease the areas shown and at intervals in Where to Add Grease section below. Grease more frequently when operating conditions are extremely dusty or sandy. 1 Grease Type: General-purpose grease. How to Grease 1. 2 Disengage the blade control (PTO) and set the parking brake. m–3797 Figure 38 2.
Maintenance Brake Service Interval/Specification Before each use, check brakes for proper operation. 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. 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. 1. Remove belt guard. 2. Check the brake before you adjust it; refer to Checking the Brake, page 37.
Maintenance Fuel Tank 4. Draining The Fuel Tank 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: POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN • A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area.
Maintenance Fuel Filter Replacing the Wheel Belt Service Interval/Specification Service Interval/Specification Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating. Replacing the Fuel Filter 1. Remove belt guard. Never install a dirty filter if it is removed from the fuel line. 2.
Maintenance Replacing the Traction Belt 1. Stop the engine, set the parking brake and remove the spark plug wire(s). 2. Raise the rear of the machine and hold with jack stands. 3. Remove mower belt (Fig. 47). 4. Loosen pivot bolt enough to slide idler pulley in slot and remove traction belt from the engine and drive pulleys. 5. Install new belt around engine and drive pulleys (Fig. 44). 6. Slide idler pulley in engine frame to tension traction belt (Fig. 44). 7. Install the mower belt (Fig.
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 6 5 m–3860 Figure 46 4. Install new belt. 5. Install idler pulley. 6. Engage PTO and check belt tension. See Adjusting Mower Belt Tension, page 42. Note: 2 1 1. 2mm–3mm (1/16” –1/8”) 2.
Maintenance Adjusting Mower Belt Tension Adjusting the Blade Brake Service Interval/Specification 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. Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation. 1. 2. IMPORTANT: Belt must be tight enough to not slip during heavy loads while cutting grass.
Maintenance Adjusting Grass\Mud Scraper Replacing the Grass Deflector 1. Remove belt guard. 1. Remove the locknut, bolt, spring and spacer holding deflector to the mounts (Fig. 50). 2. Loosen the locknut holding scraper to the engine frame (Fig. 49). 2. Straighten deflector mounts if they are bent (Fig. 50). Rotate scraper until they align with center of pulley grooves (Fig. 49). 3. Install new deflector between mounts with spacer and spring.
Maintenance Wiring Diagram J3 J4 J1 W1 KILL W3 W2 J2 GND WIRE LIST DESIG.
Maintenance Cleaning and Storage 1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 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. IMPORTANT: You can wash the machine with mild detergent and water. Do not pressure wash the machine.
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. 46 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 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. Blade mounting bolt is loose.
