Toro 4130, greensmaster 500 Operator's Manual

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FORM NO. 3319-870 GB Rev A

MODEL NO. 04130—80001 & UP

GREENSMASTER

OPERATOR’S

MANUAL

500

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To assure maximum safety, optimum performance, and to gain knowledge of the product, it is essential that you or any other operator of the mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol:

The safety alert symbol means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply with the instruction may result in personal injury.

FOREWORD

The GREENSMASTER 500 was developed to satisfy the demand for a maneuverable, intermediate size, turf maintenance rotary mower. The machine has advanced concepts in engineering, design and safety; and if maintained properly, it will give excellent service.

Since the GREENSMASTER 500 is a high quality product, Toro is concerned about the future use of the machine and the safety of the user. Read this manual to familiarize yourself with the proper set up, operation, and maintenance instructions.

Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety related information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read the directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies general information worthy of special attention.

If help concerning set up, operation, maintenance or safety is ever needed, contact a local Authorized Toro Distributor. In addition to genuine Toro replacement parts, the distributor also has optional equipment form the complete line of Toro turf care equipment. Keep your Toro all Toro – buy genuine Toro replacement parts and accessories.

Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a complete line of accessories and professional turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep your machine operating properly.

Keep your TORO all TORO. Buy genuine TORO parts and accessories.

TABLE OF CONTENTS

SAFETY INSTRUCTIONS 3

SPECIFICATIONS 8

BEFORE OPERATING 9

CONTROLS 14

OPERATING INSTRUCTIONS 15

MAINTENANCE 17

PRODUCT IDENTIFICATION 21

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Safety

Before Operating

1. Read the instructions carefully. Be familiar

with the controls and the proper use of the equipment.

2. Never allow children or people unfamiliar with

these instructions to use the machine. Keep everyone, especially children and pets away from the area of operation

3. Become familiar with the controls and know

how to stop the machine quickly

4. Keep all shields, safety devices and decals in

place. If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine.

5. Always wear substantial shoes. Do not operate

the machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing that could get caught in moving parts and cause personal injury.

6. Wearing safety glasses, safety shoes, long pants

and a helmet is advisable and required by some local safety and insurance regulations.

7. Be sure the work area is clear of objects that

might be picked up and thrown by the reel.

8. keep everyone, especially children and pets,

away from the areas of operation.

9. Since gasoline is highly flammable, handle it

carefully.

A. Use an approved gasoline container. B. Do not remove the cap from the fuel tank

when the engine is hot or running.

C. Do not smoke while handling gasoline. D. Fill the fuel tank outdoors and not over one

inch (25 mm) from the top of the tank, not the filler neck. Do not overfill.

E. Wipe up any spilled gasoline.

While Operating

10. Do not run the engine in a confined area with-

out adequate ventilation. Exhaust fumes are hazardous and could be deadly.

11. Always stand behind the handle when starting

and operating the machine.

12. Do not touch the engine, muffler or exhaust pip

while the engine is running or soon after it is stopped because these areas could be hot enough to cause burns.

13. If you leave the machine unattended, be sure to

stop the engine so the cutting reel is not spinning.

Maintenance

14. Before servicing or making adjustments to the

machine, stop the engine and pull the wire from the spark plug to prevent accidental starting.

15. To reduce potential fire hazard, keep the engine

area free of excessive grease, grass, leaves and dirt.

16. If the engine must be running to perform a

maintenance adjustment, keep hands, feet, clothing and any part of the body away from the cutting unit and any moving parts. Keep everyone away.

17. Do not overspeed the engine by changing the

governor settings. Maximum engine speed is 3000 rpm. To assure safety and accuracy, have an authorized Toro distributor check engine speed with a tachometer.

18. Shut off the engine before checking or adding

oil.

19. Check the performance of the clutch system

daily. Do not defeat this system, it is for your own protection.

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Safety

Sound & Vibration Levels

Sound Levels

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 82.5 dB(A), based on measurements of identical machines per 91/386/EEC.

This unit has a sound power level of 94.5 LWA, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments

Vibration Levels

This unit has a vibration level of 10.05 m/s2at the hands/arms, based on measurements of identical machines per ISO 5349 procedures.

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Symbol Glossary

Caustic liquids, chemical burns to fingers or hand

Poisonous fumes or toxic gases, asphyxiation

Electrical shock, electrocution

High pressure fluid, injection into body

High pressure spray, erosion of flesh

Crushing of fingers

or hand,

force

applied from

above

Crushing of toes or foot, force applied from above

Crushing of whole body, applied from above

Crushing of torso, force applied from side

Crushing of fingers or hand/, force applied from side

Crushing of whole body

Crushing of head, torso and arms

Cutting of fingers or hand

Cutting of footCrushing of leg, force applied from side

Cutting or entanglement of foot, rotating auger

Severing of foot, rotating knives

Severing of fingers or hand, impeller blade

Wait until all machine components have completely stopped before touching them

Severing of fingers or hand, engine fan

Whole body entanglement, implement input drive line

Fingers or hand entanglement, chain drive

Runover/backover, (relevant machine to appear in dashed box)

Machine tipping, riding mower

Machine rollover, ROPS (relevant machine to appear in dashed box)

Stored energy hazard, kickback or upward motion

Hot surfaces, burns to fingers or hands

Hand & arm entanglement, belt drive

Thrown or flying objects, whole body exposure

Thrown or flying objects, face exposure

Explosion Fire or open

flame

Secure lifting cylinder with locking device before getting in hazardous area

Stay a safe distance from the machine

Stay clear of articulation area while engine is running

Do not open or remove safety shields while engine is running

Do not step on loading platform if PTO is connected to tractor & engine is running

Do not step

Shut off engine & remove key before performing maintenance or repair work

Riding on this machine is allowed only on a passenger seat & only if the driver’s view is not

Consult technical manual for proper service procedures

Fasten seat belts Safety alert

triangle

outline safety alert symbol

Read operator’s manual

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Safety

Eye protection must be worn

Fire, open light & smoking prohibited

Level indicator

Head protection must be worn

Hydraulic system

Liquid level Filter Temperature Failure/

Hearing protection must be worn

Brake system

Caution, toxic risk

Oil Coolant (water) Intake air Exhaust gas Pressure

First aid

Malfunction

Flush with water Engine Transmission

Start switch/ mechanism

On/start Off/stop

Engage Disengage

Horn Battery charging

Machine travel direction, forward/rearward

Jack or support point

condition

Control lever operating direction, dual direction

Draining/ emptying

Attachment lower

Hourmeter/elapsed operating hours

Control lever operating direction, multiple direction

Engine lubricating oil

Attachment raise

Fast Slow Continuous

Clockwise rotation

Engine lubricating oil pressure

Spacing distance Snow thrower,

Counter-clockwise rotation

Engine lubricating oil level

collector auger

variable, linear

Grease lubrication point

Engine lubricating oil filter

Plus/increase/ positive polarity

Volume empty Volume full

Oil lubrication point

Engine lubricating oil temperature

Minus/decrease/ negative polarity

Lift point

Engine coolant

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Safety

Transmission failure/malfunction

Clutch Neutral High Low Forward Reverse Park

N H L F R P

First gear Second gear

Third gear (other #'s may be used until the maximum # of forward gears is reached.)

Hydraulic oil Hydraulic oil

temperature

2 31

Hydraulic oil pressure

Hydraulic oil level Hydraulic oil filter

Hydraulic oil failure/malfunction

Parking brake Fuel Fuel level Fuel filter Fuel system

failure/malfunction

Diesel fuel Unleaded fuel

Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,

rotational speed

Reel cutting element

Reel cutting element, height adjustment

Traction Above working

temperature range

Drilling Manual metal arc

welding

Manual 0356 Water pump

0626 Keep dry

0430 weight Do not dispose

in the garbage

CE logo

Engine failure/ malfunction

Engine rotational speed/frequency

Choke Primer (start aid) Electrical preheat

(low temperature start aid)

Transmission oil Transmission oil

pressure

n/min

Transmission oil temperature

Page 8

Engine: 3.7 horsepower (2.7 kw) engine with 2.64

quarts (2.5 l) capacity gas tank.

Handle: 7/8 in.(22 cm) diameter, 17-gauge welded

steel tubing with formed steel reinforcement panel.

Traction Unit: Cast aluminum housing.

Reel Unit: Cast aluminum and zinc side plates, alu-

minum extrusion back plate. Reel unit independent of traction unit and catcher.

Front Rollers: 2 in. (51 mm) O.D. Steel tube with

ball bearings, moisture excluding oil seals and replaceable wear sleeves.

Height Of Cut: 1/8 to 11/16 in. (3 to 17 mm).

(Optional micro-cut bedknife 6mm to 24)

Width Of Cut: 21 in. (0.53 m).

Clip: 0.197 in. (5.0 mm).

Ground Speed: 2.1 mph (3.4 Km/hr) at 1600 RPM

and 4.0 mph (6.4 Km/hr.) at 3100 RPM.

Traction Drive: "A” section "V" belt on 2.0 pitch

diameter and 3.70 pitch diameter. to countershaft (1. 85:1) 18T and 48T gear 2.67:1 and 20T and 56T gear (2. 8:1). All gears 16 pitch, 20° involute full depth, 1/2 in. (13 mm) wide. Gears running in oil.

Reduction, Engine to Traction Drum: 13.86:1.

Traction Drum: 6 in. (15.2 cm) diameter solid rub-

ber on 16 gauge (1.5 mm) steel rims. Two sections running on ball bearings.

Traction Drive Clutch: Friction Disk type—Hand

operated latch and bail at handle.

Differential: Enclosed spur gears.

Reel Drive: “A” section V-belt on 2.0 RD. and 3.70

RD. to countershaft (1. 85:1) 3/8 in. pitch x 3/16 in. wide chain on 20T and 14T sprockets from counter-

shaft. Reduction Engine to Reel—1.30:1.

Reel Clutch: Engaging jaw type—hand operated at

the transaxle.

Reel: 3-1/2 in. (89 mm) diameter 9-blade, welded

tubular construction. Reel blades, high carbon heat treated steel. Reel bearings, taper roller with adjustment.

Bedknife and Bar: Single-edge high carbon steel

knife, extra hard for long life, screwed to extruded aluminum one-piece bed bar and back plate.

Dimensions:

Width: 27 in. (0.69 m) Height: 44-3/4 in. (1.1 m) with handle Length: 60 in. (1.5 m) including handle and catcher

Weight: 69 kilograms with catcher and cutting unit.

Optional Equipment:

Cutting Unit Model 04216 Brush Kit Part No. 2-2949 Skid Kit, Part No. 4-7299 Sectional Roller Kit Part No. 4-7319 Urethane Comb Kit Part No. 8-2560 Full Roller Kit Part No. 4-7309 Micro-cut Bedknife Part No. 95-3147

Specifications

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CHECK ENGINE OIL BEFORE EACH USE OR EVERY 5 OPERATING HOURS

Refer to the Engine Operator's Manual for oil requirements.

1. Position the mower on a level surface.

2. Clean around the oil gauge (Fig. 1) then remove

it by turning it counterclockwise.

Figure 1

1. Oil level gauge

3. Wipe it clean and re-insert it, but do not screw

it into the port. Then remove it and check the oil check level. Add only enough oil to raise the level to the filler opening.

FILL THE FUEL TANK

1. Clean around fuel tank cap and remove cap

from tank (Fig. 2). Fill the fuel tank no higher than to the bottom of the filter screen. DO NOT OVER FILL.

Figure 2

1. Fuel tank cap

3. Install fuel tank cap and wipe up any spilled

gasoline.

CHECK TRANSAXLE OIL LEVEL

Check the transaxle oil level before initial startup and after every 50 hours of operation.

1. Place mower on level surface and remove the

plug at the rear of the gear case. Oil should be to the bottom of the hole (Fig. 3).

2. If the level is too low, remove the plug in the

top cover (Fig. 4) and add SAE 90 gear oil.

3. To drain the transaxle, remove both plugs and

tip the unit rearward

Before Operating

Because fuel is flammable, caution must be used when storing or handling it. Do not fill the fuel tank while the engine is running, hot or when the machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill the fuel tank outside and wipe up any spilled fuel before starting the engine. Use a funnel or spout to prevent spilling, and fill the tank no higher than 2.5 cm (one inch) below top of the tank, (bottom of the filler neck). DO NOT OVER FILL.

Store fuel in a clean safety approved container and keep the cap on the container. Keep fuel in a cool, well-ventilated place; never in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 30-day supply of gasoline, or a 6-month supply of diesel fuel.

Since many children like the smell of gasoline, keep it out of their reach because the fumes are explosive and dangerous to inhale.

DANGER

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Figure 3

1. Plug

Figure 4

1. Transaxle oil fill plug

ADJUSTING HEIGHT OF CUT

You can select rollers, skids or bedknives suitable for all types of greens turf grasses. For example, progressively lower heights of cut with the same gauge setting may be obtained by selecting,, in the following order: the skid, full front roller, sectional roller or the Wiehle roller. The micro-cut bedknife provides a height of cut to 1/16 (2 mm) inch, if desired.

1. Loosen the nut on the gauge bar and set the

adjusting screw to obtain the desired distance between the bottom of the screw head and the face of the bar (Fig. 5). Tighten the nut, making sure adjustment is not altered.

2. Remove the cutting unit; refer to Removal and

Installation of the Cutting Unit.

3. Place the cutting unit upside down on a bench,

position the gauge bar on the end of the unit with one end on the front support: skid, full roller, sectional roller, etc., the other end on the rear roller (Fig. 9).

Figure 5

1. Gauge bar

2. Height adjustment screw

3. Nut

Figure 6

1. Gauge bar against rollers

2. Screw head over cutting edge

3. Top nut

4. Adjustment nut

4. Loosen the top nut on the adjusting screws on

each side plate (Fig. 6) and turn the nut to raise or lower the front roller or skid assembly. Adjust to make contact with the outer end of the gauge bar. When proper adjustment is obtained, the screw head on the gauge bar will just pass over the cutting edge of the bedknife. ASSURE HEIGHT OF CUT IS EXACTLY IDENTICAL AT BOTH ENDS OF THE BEDKNIFE.

5. Tighten the top nuts to secure roller adjustment

(Fig. 6). Turn the cutting unit over and place it on a level surface (Fig. 7). Press down on each end of the front and rear rollers (Fig. 7). Each roller should contact a level surface completely across the unit (Fig. 7). If the rollers do not

Before Operating

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contact, repeat steps 3 and 4.

Figure 7

1. Level surface

2. Press down

REEL-TO-BEDKNIFE ADJUSTMENT

1. Loosen the nuts securing the left and right reel

brackets to the side plates (Fig. 8).

2. Adjust reel-to-knife clearance with the adjusting

screws at each end of the unit (Fig. 9). NEVER ALLOW THE BEDKNIFE TO BEAR HEAVILY AGAINST REEL.

Figure 8

1. Nut

2. Reel bracket

3. Side plate

Figure 9

1. Reel adjusting screw

3. Place a newspaper at right angles to the top face

of the bedknife against the front cutting edge and rotate the reel blades against the paper. The reel blades should cut the paper cleanly all across the bedknife. If the paper is not cleanly cut, the mower should be either backlapped or resharpened; refer to Backlap Operation and

Reel and Bedknife Grinding.

4. Place a strip of newspaper flat on the top face

of the bedknife and adjust the reel down until the reel blades pinch the paper equally all across the bedknife.

5. Tighten the nuts to secure the adjustment.

ADJUST REAR ROLLER SCRAPER

1. Adjust the scraper rod locknuts and brackets to

attain .06"–.10" (1.5– 2.5 mm) clearance between the scraper rod and the roller surface. The distance between the bottom of the rod and the level surface should be the same height as the height-of-cut setting.

2. Assure scraper rod is parallel to the roller and

level surface.

Note: Readjust the height of the scraper rod if

height-of cut is changed.

Before Operating

Page 12

Before Operating

Figure 10

1. Scraper rod

2. Bracket

CHECK CUTTING UNIT ALIGNMENT

The cutting unit must be in alignment with the front yoke roller so that the machine will track in a straight line across the greens. Also, the driveshaft must also be aligned with the transaxle shaft.

Alignment procedures:

1. Loosen the jam nut securing the ball sockets to

the pull arms on both sides of the yoke (Fig. 11).

2. Slide back the sleeves on each ball joint and

rotate each pull arm upward off the ball studs.

3. Align the cutting unit with the roller and drive-

shaft with the transaxle shaft and lengthen or shorten the pull rods by threading the ball socket on the rod (Fig. 11).

4. Align the ball sockets with the ball studs so the

hooded portion of the socket is at the top and the open side is toward the stud (Fig. 12).

5. Slide the sleeve back on the ball joint and rotate the pull arm down so the socket fits over the ball stud. Release the sleeve so it slides forward over the stud and locks the assemblies together. Tighten the jam nuts to secure the sockets in position (Fig. 15).

Figure 11

1. Jam nut

2. Ball socket

3. Ball stud

Figure 12

1. Spring

2. Sleeve

3. Socket ball joint receiver

4. Retaining ring

4. Ball Stud

INSTALL THE GRASS CATCHER

1. Set the studs on the catcher pivots into the

brackets on the yoke and allow the catcher adjusting screw to rest onto the yoke (Fig. 13).

Figure 13

1. Catcher pivot

2. Yoke bracket

3. Adjusting screw

4. Jam nut

Page 13

2. Measure the distance between the lip of the

catcher and the edge of the cutting unit shield. There should be a clearance between the components of no more than 1/4 inch (6 mm) (Fig.

14). If not, adjust the catcher.

Note: The catcher should be lower in front to

assist clipping throw. Adjust the screw to lower the catcher (Fig. 13). Make sure the catcher clears the roller by at least 1/16 in. (1.6 mm).

3. Tighten the jam nuts on each side of the catcher

(Fig. 13), making sure the dimension is equal on both sides of the unit.

Figure 14

1. 1/4 inch (6 mm) maximum

Before Operating

Page 14

Throttle Control Lever (Fig. 15)—The throttle lever

connects to and operates the throttle linkage to the carburetor. It has two positions: SLOW and FAST. Engine speed can be varied between the two settings.

Figure 15

1. Throttle control lever

2. Clutch control bail

Clutch Control Bail (Fig. 15)—The clutch bail con-

trols traction and cutting unit drive. It has two positions: ENGAGE and DISENGAGE.

Choke Lever (Fig. 16)—Located at rear of engine.

It has two positions: RUN and CHOKE. Move the lever to the CHOKE position when starting a cold engine. After engine start,s move the lever to the RUN position.

Figure 16

1. Fuel shut-off valve lever

2. Choke lever

Fuel Shut-off Valve (Fig. 16)—Located at the right

side of the engine, it has two positions: CLOSED and OPEN. Move the valve lever to the CLOSED position when storing the machine. Open the valve before starting the engine.

Figure 17

1. Engine stop switch

2. Recoil starter

Engine Stop Switch (Fig. 17)—Located at the front

of the engine. Rotate to OFF to stop the engine.

Recoil Starter (Fig. 17)—Pull the recoil starter han-

dle to start the engine.

Reel Drive Control (Fig. 18)—Located at right side

transaxle, has two positions: ENGAGE and DISENGAGE. Pull out the knob to engage the reel drive clutch. Push in the knob to disengage.

Figure 18

1. Reel drive control knob—Pull out to ENGAGE

Controls

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STARTING AND STOPPING INSTRUCTIONS

Note: Make sure the wire is installed on the spark

plug.

1. Assure the traction clutch control bail (Fig. 15)

and the reel drive knob (Fig. 18) are in the DISENGAGED position.

2. Open the fuel valve at the right side of the

engine (Fig. 16).

3. Turn the engine stop switch to ON (Fig. 17)

4. Only if necessary, move the choke lever (Fig.

16) to the CHOKE position before starting a cold engine.

Note: A warm or hot engine does

not require any choking. To start a warm engine, move the throttle control to the mid throttle position.

5. Stand behind the machine and move the throttle

control lever (Fig. 15( to the mid throttle position. Pull the recoil starter handle out until positive engagement results. Pull the handle to start the engine and allow the rope to recoil slowly. If used, open the choke as the engine warms up.

IMPORTANT: Do not pull the recoil rope to

its limit or let go of the starter handle when the rope is pulled out because the rope may break or the recoil assembly may be damaged.

6. To stop the engine during operation, release the

clutch bail to the DISENGAGE position, the throttle control to SLOW (Fig. 15) and turn the ON/OFF switch to OFF (Fig. 17).

7. Pull the wire off the spark plug to prevent the

possibility of accidental starting before storing the machine.

8. Close the fuel valve before storing the machine

(Fig. 16).

TRANSPORT OPERATION

1. Disengage the clutch bail and start the engine.

2. Disengage the cutting unit drive (Fig. 18).

IMPORTANT: Excessive operating of the cut-

ting unit with the absence of any grass clippings (lubricant) can damage the cutting unit.

3. Place the handle assembly in the uppermost

notch on the handle adjusting bar. Set the throttle control in SLOW, tip the front of the machine up and slowly increase engine speed while gradually engaging the clutch control bail so the mower moves forward slowly.

4. Adjust the throttle to operate the mower at the

desired ground speed and transport the mower to the desired destination.

BEFORE MOWING

Remove dew and worm casts from turf before mowing by whipping the turf with a bamboo pole or by dragging a hose over the area. Be sure the Greensmaster is carefully adjusted and is set evenly on both sides of the reel. Improper mower adjustment is magnified many times over in the appearance of the clipped turf. Athree- to five-foot wide (91 to 152 cm) "collar" should be mowed around the area at a slightly higher cut than the putting green area. This will provide sufficient space for turning the Greensmaster without turning on the green area.

METHOD OF MOWING

The greens should be mowed in straight back-andforth direction across the green. Avoid circular mowing or turning the mower on greens areas since scuffing may occur. Turning the mower should be done off the green proper by raising the cutting reel (pushing the handle down) and turning on the large rubber-covered traction drums.

The greens areas should not be mowed in the same direction at any two successive mowings. Cutting in different directions at each mowing will keep the grass growing in an upright position, preventing grain formation.

Mowing should be done at a normal walking pace. Faster speed saves very little time and will result in an inferior mowing job.

Operation

Page 16

OPERATING CONTROLS

To operate the controls for mowing;

1. Start the engine, push down on the handle to

elevate the cutting unit, raise the traction clutch bail the handle and transport the machine onto the collar of the green.

2. Release the traction clutch bail (Fig. 19) to the

DISENGAGE position and pull the reel drive control knob on the transaxle out fully to ENGAGE the reel (Fig. 20).

Figure 19

1. Traction clutch control bail

Figure 20

1. Reel drive control knob—Pull out to ENGAGE

3. Raise the clutch control bail to the handle,

increase the throttle speed until the unit is traveling at the desired ground speed, drive the mower out onto the greens area, drop the front of the mower down and begin mowing.

AFTER MOWING

1. Drive off the green, release the clutch control

bail to DISENGAGE, stop the engine and push the reel drive control knob fully in to DISENGAGE.

2. Empty the grass catcher of clippings, install the

grass catcher and begin transport operation; refer to Transport Operation.

Operating

Page 17

DAILY MAINTENANCE CHECKLIST

✓ Fuel level ✓ Engine oil level ✓ Air filter pre-cleaner ✓ Clean engine cooling fins ✓ Unusual engine noises ✓ Unusual operating noises ✓ Reel-to-bedknife adjustment ✓ Height-of-cut adjustment ✓ Lubricate control linkage ✓ Lubricate all grease fittings

✓ Touch-up damaged paint

1 = Immediately after every washing, regardless of interval listed.

Maintenance

Maintenance Procedure Maintenance Interval & Service

✝Initial break in at 10 hours ‡Initial break in at 25 hours

Adjust the reel drive chain

Clean the combustion chamber Replace the spark plug Adjust valves and torque the head bolts

Check the spark plug Service the air cleaner filter

‡Change the engine oil filter ✝Adjust the traction drive belts Clean the fuel filter and bowl Check the transmission oil level

Service the air filter foam element Check for loose fasteners Lubricate all grease fittings

Every

200 hours

Every

100 hours

Every 50

hours

Every 25

hours

Minimum Recommended Maintenance Intervals

Recommendations:

Adjust the reel drive chain annually.

Page 18

LUBRICATION

GREASE FITTINGS

The grease fittings on the mower should be greased at least every 25 hours. Lubricate using a No. 2 multi-purpose lithium base grease. Ahand operated grease gun is recommended for best results.

1. Wipe each grease fitting with a clean cloth.

2. Apply grease to the points shown in Figure 21

Figure 21

1. Grease points

IMPORTANT: Do not apply too much pres-

sure or grease seals will be permanently damaged.

3. Wipe excess grease away.

GREASING THE TRACTION CLUTCH

1. At the end of each season’s cutting, remove the

traction clutch assembly and clean and re-pack the cam and roller assembly with No. 5 multipurpose (wheel) bearing grease (Fig. 22). Take extreme care to make sure that grease is kept off the clutch friction discs (Fig. 22).

Figure 22

1. Clutch assembly

2. Clutch friction discs

LINKAGE PIVOT POINTS

Oil all pivot points of control linkages weekly with SAE 30 engine oil (Fig. 23, 24).

Figure 23

1. Oil points

Figure 24

1. Oil points

Maintenance

Page 19

Maintenance

REMO VAL AND INSTALLATION OF CUTTING UNIT

1. Remove the catcher and unhook the two chains

from the support hooks (Fig. 25).

Figure 25

1. Chains 3. Cotter pin

2. Support hooks 4. Yoke pivot

2. Slide the sleeves back on pull arm ball joints

and lift the pull arm sockets straight up off the ball studs (Fig. 26).

Figure 26

1. Sleeve

2. Pull arm socket

3. Ball stud

3. Grasp the cutting unit chain case and pull the

cutting unit and drive shaft out to the right, away from the traction unit.

Note: Right and left sides are determined from

behind the handle.

To install the cutting unit:

1. Slide the cutting unit under the yoke from the

right side, line the drive shaft up with the transaxle shaft and install the drive shaft.

2. Install the chains onto the support hooks

(Fig. 25).

3. Align the pull arms with the ball studs, slide the

sleeves back on the sockets and drop the arm sockets down on the ball studs (Fig. 26).

4. Make sure the cutting unit is aligned with the

yoke roller and the drive shaft with the transaxle shaft. If there is misalignment, refer to Check Cutting Unit Alignment.

REMOVING THE YOKE ASSEMBLY

To remove the yoke:

1. Remove the catcher and unhook the chains from

the support hooks (Fig. 25).

2. Remove the cotter pin from the yoke pivot and

slide the yoke assembly off the pivot (Fig. 25).

3. Reverse the procedure to install the yoke.

CHANGING ENGINE OIL

1. Run the engine to warm the engine oil.

2. Stop engine, place a drain pan under the plug in

the crankcase on the handle side of the engine, remove the oil drain plug and allow oil to drain into the drain pan (Fig. 27).

3. Install the drain plug; remove the oil fill plug

(Fig. 27), assure the engine is level and fill the crankcase with fresh clean oil; refer to the Engine Operator's Manual for oil requirements.

Disconnect spark plug wire before performing any of the maintenance procedures on your mower.

CAUTION

Page 20

Maintenance

Figure 27

1. Oil fill plug

2. Oil drain plug

TRACTION DRIVE BELT ADJUSTMENT

The belt should be tight enough so the traction wheels will spin on a cement floor when the clutch is engaged with the engine running. The belt should be checked after the first eight hours of operation and tightened if necessary. To adjust the belt:

1. Remove the belt cover from the left side of the

machine (Fig. 28).

2. Loosen the four engine hold-down screws.

3. Slide the engine rearward equally on both sides

until the belt is tight. Tighten the mounting fasteners and check adjustment by placing the unit on a cement floor, starting the engine and checking to see if the traction wheels spin when the clutch is engaged.

4. Continue adjustment until tension is correct and

install the belt guard (Fig. 28).

Figure 28

1. Cover

2. Engine mounting fastener

BACKLAP OPERATION

Backlap when the reel blades and bedknife edge are slightly rounded and do not cut the grass cleanly with a light reel-to-bedknife adjustment. Also backlap after a reel and bedknife have been reground to assure a perfect match between reel and bedknife cutting edge.

Backlapping will not correct nicked or severely rounded reel blades or uneven bedknife wear. Correct these conditions by repairing, replacing or re-grinding the components.

1. Using a fine-tooth file, remove high spots from

the reel blades. If a blade is bent, straighten it by placing a hammer on one side of the blade and tapping on the opposite side.

2. Make the reel-to-bedknife adjustment to obtain

a light contact; refer to Reel to Bedknife

Adjustment.

3. Connect a lapping machine to the cutting unit

with an extension coupler and socket.

4. Use a good grade of medium grit (80) commer-

cial lapping compound with a water soluble carrier to assure the compound will be easily washed away after the backlapping operation. Dry lapping compound should be mixed with liquid detergent until the material is free flowing.

Note: Paste-type, pre-mixed lapping compound

is also sold in some areas. This is generally used in its original composition and therefore is not free flowing.

5. Operate the lapping machine so the reel turns in

a reverse direction for about three minutes; apply the lapping solution continuously with a paintbrush across the full width of the reel.

6. Again,, lightly adjust the bedknife and reel.

Then, lap for approximately two additional minutes. Apply lapping solution continuously.

Wash off all lapping solution.

7. Using newspaper, check for sharpness along the

entire length of each reel blade. If the newspaper cannot be cut cleanly along the entire length of each blade, grinding or re-grinding is neces-

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sary; refer to Reel and Bedknife Grinding.

Note: For a better cutting edge, run a file across

the front face of the bedknife when the lapping operation is completed. This will remove any burr or rough edge that may have built up on the cutting edge.

REEL AND BEDKNIFE GRINDING

Refer to the TORO GUIDE TO REEL AND ROTARY MOWER SHARPENING. Copies are available from your local TORO distributor.

CLEANING THE MOWER

Wash the cutting unit, transaxle, and grass catcher after each day's use. Chemicals in the turf may cause premature deterioration to certain components if not washed daily.

IMPORTANT. Do not direct "high-pressure" water at

oil seals, bearings, electrical connectors/switches, hot engine, etc.; contamination of these parts could cause premature wear.

STORAGE

1. Drain gasoline from the fuel tank. Start the

engine and let it run at slow speed until it stops because all the gasoline is used.

2. Drain the oil from the crankcase: refer to the

Engine Operator's Manual. However, do not fill the crankcase with oil at this time.

3. Remove grass clippings, dirt and grime from

the external parts of the mower housing and engine. Also clean the engine cooling system.

4. Clean carbon from the internal parts of the

engine and re-assemble the engine.

5. Pull the wire off the spark plug and clean

around the plug so dirt cannot fall into the cylinder when the plug is removed. Remove the plug from the cylinder head and pour two tablespoons (25 ml) of engine oil into the spark plug hole. Pull the recoil starter handle slowly to distribute oil on the inside of the cylinder. Reinstall the spark plug. If a torque wrench is not used, tighten the plug firmly. DO NOT INSTALL THE WIRE ON THE SPARK PLUG.

6. Remove the belt cover over the left side of the

machine. Inspect the belt for excessive wear or damage., Repair or replace as necessary. Assure the belt is in the disengaged position.

7. Check the condition of the reel blades and bed-

knife and repair and sharpen them as necessary; refer to Reel And Bedknife Grinding.

8. Lubricate the mower: refer to Lubrication.

9. Clean the air cleaner.

10. Check and tighten all capscrews, screws, bolts,

nuts and mating parts, If any part is damaged, repair or replace it.

11. "Touch up" all rusted or chipped paint surfaces.

Make sure to sand affected area before painting.

Note: TORO Re-Kote "touch-up" paint is available

from an authorized Toro service dealer or distributor. The spray paint dries in minutes to a glossy, factoryfinish.

12. Fill the crankcase with oil: refer to Engine

Operator's Manual.

13. Store the mower in a clean, dry place. Cover the

mower to protect it and keep it clean.

IDENTIFICATION AND ORDERING

The mower has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate located at the rear of the transaxle case. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained.

Maintenance

Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury.

CAUTION

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To order replacement parts from an authorized TORO distributor, supply the following information:

1. Model and serial number of the mower.

2. Part number, description and quantity of part(s)

desired.

Note: Do not order by reference number if a parts

catalog is being used; use the PART NUMBER.

Maintenance

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