Toro 22580, 22581, 22685 Service Manual

LANDSCAPER WPM SERVICE MANUAL

Table of Contents – Page 1 of 3

ABOUT THIS MANUAL

SAFETY INSTRUCTIONS

SAFETY TIPS...

PRODUCT IDENTIFICATION

SPECIFICATIONS GENERAL SPECIFICAT IO NS SELF-PROPELLED MODEL SPECIFICATIONS SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS

TROUBLESHOOTING

QUALITY OF CUT TRANSMISSION MISCELLANEOUS

MAINTENANCE

MAINTENANCE - SERVICING AIR CLEANER MAINTENANCE - REPLACING SPARK PLUG MAINTENANCE - DRAINING GASOLINE MAINTENANCE - ADJUSTING WHEEL TRACTION DRIVE MAINTENANCE - CLEANING THE COOLING SYSTEM MAINTENANCE--CLEANING MUFFLER AND EXHAUST PORT MAINTENANCE - ADJUSTING THROTTLE MAINTENANCE - SERVICING BLADE MAINTENANCE - LUBRICATION MAINTENANCE - ADJUSTING BLADE BRAKE MAINTENANCE - SERVICING WHEELS - REMOVAL ASSEMBLY MAINTENANCE - CLEANING THE MOWER HOUSING MAINTENANCE - PREPARING MOWER FOR STORAGE

SECTION 1 FRONT SUSPENSION FRONT SUSPENSION - OPERATION FRONT SUSPENSION - DISASSEMBLY FRONT SUSPENSION - ASSEMBLY

SECTION 2 REAR SUSPENSION (HP MODELS ONLY) HAND PUSH REAR SUSPENSION - OPERATION HAND PUSH REAR SUSPENSION - DISASSEMBLY HAND PUSH REAR SU SPENSION - ASSEMBLY

LANDSCAPER WPM SERVICE MANUAL

Table of Contents – Page 2 of 3

SECTION 3 SELF - PROPELSYSTEM GEAR SELECTION CONTROL - GEAR SELECTION CONTROL - OPERATION GEAR SELECTION CONTROL - REMOVAL GEAR SELECTION CONTROL - INSTALLATION TRACTION CONTROL - OPERATION TRACTION CONTROL - REMOVAL TRACTION CONTROL - INSTALLATION TRACTION CONTROL - ADJUSTMENT REAR HEIGHT OF CUT SYSTEM (HOC) AND WHEEL PINION CLUTCH (WPC) - REAR HOC AND WPC - DISASSEMBLY REAR HOC AND WPC - ASSEMBLY TRANSMISSION - OPERATION TRANSMISSION - REMOVAL TRANSMISSION - DISASSEMBLY TRANSMISSION - ASSEMBLY OUTPUT SHAFT ASSEMBLY: INTERMEDIATE SHAFT ASSEMBLY: TRANSMISSION - INSTALLATION:

SECTION 4 ZONE START BRAKE ZONE START BRAKE - INTRODUCTION ZONE START BRAKE SYSTEM - OPERATION ZONE START BRAKE SYSTEM - DISASSEMBLY ZONE START BRAKE SYSTEM - ASSEMBLY ZONE START BRAKE SYST EM - ADJ USTMENT

SECTION 5 ELECTRICAL SYSTEM ELECTRICAL SYSTEM - OPERATION ELECTRICAL - TROUBLESHOOTING

SECTION 6 HANDLE ASSEMBLY HANDLE ASSEMBLY - INTRODUCTION HANDLE ASSEMBLY - REMOVAL HANDLE ASSEMBLY - INSTALLATION

SECTION 7 ENGINE

SECTION 8 CUTTING DECK CUTTING DECK - OPERATION CUTTING DECK - ADJUSTMENTS CUTTING DECK - REPAIR

SECTION 9 GRASS BAG AND DISCHARGE DOOR GRASS BAG - CONSTRUCTION GRASS BAG - DISASSEMBLY

LANDSCAPER WPM SERVICE MANUAL

Table of Contents – Page 3 of 3

SECTION 9 GRASS BAG AND DISCHARGE DOOR -Continued GRASS BAG - ASSEMBLY DISCHARGE DOOR - OPERATION DISCHARGE DOOR - DISASSEMBLY DISCHARGE DOOR - ASSEMBLY

SECTION 10 SIDE DISCHARGE CHUTE (OPTIONAL) SIDE DISCHARGE CHUTE - OPERATION SIDE DISCHARGE CHUTE - DISASSEMBLY SIDE DISCHARGE CHUTE - ASSEMBLY

SECTION 11 - DETHATCHER (OPTIONAL) DETHATCHER - SAFETY INFORMATION DETHATCHER - OPERATION DETHATCHER - INTRODUCTION DETHATCHER - ASSEMBLY DETHATCHER - DISASSEMBLY DETHATCHER - INSTALLATION DETHATCHER - ADJUSTMENT DETHATCHER - MAINTENANCE

ABOUT THIS MANUAL

This service manual was written expressly for the Toro Landscaper" Mower. The

in

Toro Company has made every effort to make the information

complete and correct.

this manual

This manual was written with the service technician

that

information used most often is up front. information on safety, identification, specifications, troubleshooting and maintenance, all

Disassembly, inspection and reassembly procedures are covered

two-thirds of the manual and are grouped by component. We tried to cover each

common repair with its own section or sub-section. For example, you will

that

wheel pinion clutch service and transmission service are addressed

separately.

Most

sectiQns will include some component theory. This information can

found

at

the front of each service procedure section.

We are hopeful that you will find this manual a valuable addition to your shop. you have any questions or comments regarding this manual, please contact us

at the following address:

The Toro Company reserves the right to change product specifications or this

manual without notice.

in

the front third of the manual.

The Toro Company

Consumer Service Department

8111

Lyndale Avenue South

Minneapolis,

As

MN

in

mind.

It

is organized

a result, you will

55420

find

in

so

reference

the last

find

be

If

55420

1990

USA

The Toro Company

Minneapolis,

MN

SAFETY

Servicing of any outdoor power equipment requires care and common sense to prevent Injury.

Safety

alert

been placed throughout this manual to enhance safety. Whenever you encounter the word

CAUTION read the-instruction because

to

do with safety. Failure to comply with the instruction may result death.

‘CAUTION’ statements have only.

it

has

In

personal Injury or

INSTRUCTIONS

is

This manual only. The safety instructions provided

for

are safety and instructional information on the operation

Vacu-Power mowers. Operator’s Manuals are available through:

the troubleshooting and service

The

intended

individual Operator’s Manuals will contain

The Toro Company

Publications Department

81I1

Lyndale Avenue South

Minneapolis,

as

a service

MN

55420

and

repair manual

in

this manual

of

the product

U.S.A.

of

SAFETY

Avoid lacerations and amputations Stay clear of all moving parts whenever the engine running. Treat all normally moving parts moving whenever the engine is running or has the potential to start.

Avoid burns

Do

not touch engine while running or shortly after

running.

Avoid fails

Do

not operate the mower on slippery surfaces or

footing is questionable. Avoid fires and falls

Wipe up any spilled fuel or oil. Avold asphyxiation

Never operate an engine in a confined area without proper ventilation.

Avoid possible eye injuries Wear eye protection when working with springs or cables and when running engine.

as

if

they were

is

if

TIPS

Avoid unexpected starting of engine

off

Always turn before attempting any cleaning, adjustment or repair.

Avoid possible fires and exploslons Use a container designed for gasoline. Avoid spilling gasoline and never smoke while working around gasoline.

Avoid accidental misuse of fuel Always store fuel

that is properly labeled. Avoid possible injury due to inferior parts

Use only Toro original parts to insure safety criteria are met.

Avold Injury to bystanders Always clear the area of bystanders before starting or testing a lawn mower.

Avoid Injury due to projectiles Always clear the area to be mowed of sticks, rocks and other debris that could mower.

key and disconnect

in

a container designed for gasoline

be

picked up and thrown by the

spark

that

plug wire

important

Landscaper Rear Bagging Mower

1

Safety Instructions

Reference Information

TABLE

OF

CONTENTS

Service Procedures

Section One Front Suspension

Section Two Rear Suspension (Push Models Only)

Safety Instructions Table of contents Identification

Specifications Troubleshooting

Maintenance

Operation .............................................Pa gel9

Disassembly Assembly

.......................................................

......................................................

.............................................

Page 1

...................................................

....................................................

13

.

................................................

..................................................

19 19

2

5

6 9

Section Three Self-Propel System

Gear Selection Control

Drive

Control

Rear Height-of-Cut and Wheel Pinion Clutch

Operation Disassembly Assembly

Operation Removal Installation

Operation Removal

Installation

Adjustment

Operation

...................................................

..................................................

................................................

..................................................

.................................................

..................................................

20 20 20

22 22 22

22

23

24

Table

of

Contents

Disassembly Assembly

................................................

..................................................

-

2

Landscaper Rear Bagging Mower

25 26

P

TABLE OF CONTENTS

Service Procedures (cont’d)

Section Three (cont’d)

Transmission

Operation .........,...,,..............................Page27

Removal

(cont’d)

P\

Section Four Zone Start Brake

Introduction

Section Five Electrical System

Handle Assembly Introduction

Disassembly

Assembly

Installation .32

.................................................

,30

.................................................

.......................................................

Operation

Disassembly Assembly Adjustment

Operation Troubleshooting

Removal

...................................................

.................................................

.......,....,.....,.............................,.35

............................................

........................................................

..................................................

.35

,36

Installation

Section seven Engine

Section Eight Cutting Deck

Section Nine Grass Bag and Discharge Door

Grass Bag

Landscaper Rear Bagging Mower

...........................................................

Operation Adjustments

Repair

Construction Disassembly

Assembly

......,,....,............................,,,......39

.......,,....,...........................,...,,.39

......................................................

...............................................

3

Table of Contents

.36

.41 .41

TABLE

Service Procedures (cont’d)

Section Nine (cont’d)

Discharge Door

OF

CONTENTS

(cont’d)

Operation Disassembly

Assembly

Section Ten Side Discharge Chute (Optional)

Operation Disassembly

Assembly

Section Eleven Dethatcher (Optional)

Safety Information Operation Introduction Assembly Disassembly Installation

Adjustment

. .

,

. . . .

..................................................

...................................................

. . .

. . . .

...................................................

....................................................

................................................

....................................................

..................................................

. .

.

,

.

. . . . . . . .

.................................................

. . .

. . . . . . . . . .

. . . . .

. , .

,

. . .

. . . . . .

.

. .

. . . . . . .

. . . .

,

.

. . . . , . , . . . .

. , . . .

. . . .

.

. . . . . .

. . . , . . .

. .

. . . .

. .

. . . .

. . . . . . . . . . . . . .

. .

. . . .

. . .

. .

. . . . .

. . .

. . . .

, ,

. .

. . .

. . . . . . .

,

.

. . .

. .

. . . .

.41

.44

.45

45

.48

49

Maintenance

.................................................

49

Table

of

Contents

4

Landscaper Rear

Bagging

Mower

PRODUCT IDENTIFICATION

Figure

Each

Toro

Walk Power Mower is assigned a model and serial number. The model number has five digits and reflects the engine, deck style and features of the

1

In

mower. also has a unique serial number which Serves to differentiate number. The serial number has seven digits, the first of which identifies the year of manufacture (ie. indicates that the product was

year). These numbers are printed on

high

side of the cutting deck between the rear wheels on some models. See Figure under the control panel. Always refer when ordering parts mower.

Engine model and serial numbers differ from the chassis model and serial numbers. Engine numbers

can generally be found on the blower housing of the engine. Use this information when ordering parts requesting information regarding the engine.

addition to the model number, each product

it

from other products with the same model

built

in

the

1990

a

decal that is

and

3'

wide. The decal can

1.

or

requesting information on the

be

found on the top

On others,

to

it

can be found

these numbers

0022576

model

about

1'

or

Landscaper Rear Bagging Mower

5

Product Identification

General Specifications

SPECIFICATIONS

Specification

Toro 2-Cycle Die Cast Aluminum

53.3 cm

Steel with double sealed ball bearing

20.3

2.5

Adjustable to three different positions.

(21.OO*)

X

5.1 cm (8.0 X 2.V) wide semi-pneumatic radial style

cm (1') diameter gauge plated steel tubing.

heat treated alloy steel

Self-Propelled

Item

~~

Ground Speed

#I

#2

Model

Wheels individually adjustable from 25

increments (1' to 3'

53.3 cm (213

55.2 cm (21.75')

85.7 cm (33.75')

55

crn

(21.50”)

40 kg (89 Ibs) Single bolt Non-asbestos

Spring loaded brake contacting bottom of flywheel

Specifications

Specification

2.9 kph (1.8 mph @ 3000 rpm)

1.9 kph (1.2 mph

4.3 kph (2.7 mph

2.9 kph (1.8 mph

in

wheels

@

2000 rpm)

@

3000 rpm)

@

2000 rpm)

to

l/2'

increments)

in

highest height-of-cut

75 mm

in

13 mm

Ground Speed #3 6.1 kph (3.8 mph

4.0 kph (2.5 mph Die cast aluminum with stamped steel cover Gearbox

177

cc

(6oz)

1

Gearbox Lubricant

Clutch Wheel Pinions Wheel Gears

Gearbox Divots on 15 tooth gear with wheel pinion clutches

42 tooth permanently fastened to wheel hub with rivets

lithium-base grease

@

3000 rpm)

@

2000 rpm)

output

shaft to tighten or loosen belt

SPECIFICATIONS

Service Specifications

BBC

bellcrank

Rear 4.32

Front

4.07

Rear 5.49

Front

5.33

Rear

6.60

(cont'd)

spring to

f

.15 cm (1.70 2 .060')

f

.I5

cm (1.60 k .060')

k

.15 cm (2.1 6 f ,060.)

f

.15 cm (2.10 f 0.60')

f

.15 cm (2.60

be

2.59

0.60.)

k

.127 cm

r---?

Front

6.60

f

.I5

cm (2.60

Rear 7.70 f .15 cm

Front

7.85 A .15 cm (3.09 f .060')

k

Rear 8.74 .318 cm (.125') max

.15 cm

(3.03

(3.44

f

0.60')

.060')

Landscaper

Rear

Bagging

Mower

7

Specifications

SPECIFICATIONS

(cont’d)

Torque

Specifications

0

Landscaper Rear Bagging Mower

~ ~

_-_

~ ~~

TROUBLESHOOTING

The Troubleshooting Section has been divided into three sections. Use the guide

on

information and remedies.

Quality

Symptom Page

Scalping 10 Stragglers

Clumping 10 Unlevel height-of-cut 10

Bag will not Mower picks up too much dust 10

the symptom you are observing, then turn to the proper page for possible causes

of

Cut

fill

completely

below

to

locate

Transmission

Symptom Page Driveslips

Intermittent drive Transmission Inaccurategearselection First geartoofa

Difficult to pull backwards .12

slow

going into gear 11

,lo

.10

11

Only one wheel drives

Miscellaneous

Symptom Page

Thatcher does not

All

four tires do not touch the ground .12

fit

correctly 12

Landscaper

Rear

Bagging

Mower

9

Troubleshooting

TROUBLESHOOTING

(cont’d)

Quality

of

Cut

Symptom: Scalping

Possible Cause Remedy

Height-of-cut too low

in

All wheels not Lawn has

same height-of-cut

ruts

Symptom: Stragglers (some grass blades

Raise height-of-cut Move height-of-cut adjusters to uniform Repair lawn

left

uncut)

Symptom: Clumping

Possible Cause

Grass too long Grass too wet Allow grass to

Remedy

Adjust engine and grass ramp Excessive blade to ramp clearance Use bag

or

optional side discharge chute

dry

before mowing

I

Symptom: Unlevel height-of-cut

Possible Cause Remedy

Wheels

Blade not level

Spongy turf

Symptom: Bag will not

Possible Cause Remedy

Grass too wet Allow grass to Excessive blade to ramp clearance Back of bag frame too

in

different height-of-cut Adjust wheels to uniform height

Check blade levelness

Allow turf to dry

fill

completely

Adjust engine and grass ramp positioning

high

Use part number

Symptom: Mower picks up too much dust

Lawn too Height-of-cut too low

Vacuum too aggressive for conditions Use standard blade,

dry

Water the day

dry

71-2970

before mowing

P/N

I

42-1000

Troubleshooting

10

Landscaper Rear Bagglng

Mower

Transmission

Symptom: Drive slips

S

m tom: Intermittent drive

TROUBLESHOOTING

(cont’d)

slow

Symptom: Transmission

Possible Cause

in

slots

Shift keys

Sheared output shaft roll

in

between gears

going into gear

Symptom: Inaccurate gear selection

Possible Cause Flexing

of

gear selection cable

Symptom: First gear too fast

Possible Cause Remedy Normal gearing not to operator’s liking

Symptom: Difficult to

pull

backwards

Remedy Clean key slots, then lightly grease slot area Shift keys sticking down

Adjust gear selector cable, Service Bulletin

Replace roll

Remedy Install new shift lever and cable per

43

if

difficulty persists,

see

Landscaper Rear Bagging Mower

Inspect wheel pinion clutch

11

and

repair

as

necessary

Troubleshooting

TROUBLESHOOTING

Transmission (cont'd)

Symptom: Only one wheel drives

Miscellaneous

Symptom: Thatcher does not fit correctly

(cont'd)

wheel pinion clutch

ice Bulletins 45 and 46

Symptom:

Deck warped,

P

Deck

warped,

All

four tires do not touch the ground

less

than 6 mrn (1/4')

more than

6

mrn

(1/4”)

Elongate Replace the deck

low

pivot arm

bolt

hole upward

12

Landscaper Rear Bagging Mower