Toro 16401 User manual
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The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
WARNING:
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Do not touch muffler or engine while they are
running or shortly after they have stopped because
muffler and engine will be hot enough to cause a
burn.
Refuel only after engine is cool.
Perform only those maintenance instructions deĆ
scribed in this manual. If major repairs are ever
needed or if assistance is desired, contact your local
Authorized TORO Service Dealer.
Before mower is cleaned, inspected, serviced, or
adjusted, stop engine and disconnect wire from
spark plug. Keep wire away from plug to prevent acĆ
cidental starting.
To ensure the mower is in safe operating condiĆ
tion, frequently check and keep all nuts, bolts, and
screws tight. Ensure blade bolt is tightened to proper
specifications.
To reduce fire hazard, keep engine free of excesĆ
sive grease, grass, leaves, and accumulation of dirt.
Check optional grass catcher bag frequently for
wear or deterioration. If worn, replace with a new
bag for your protection.
Allow engine to cool before storing mower in any
enclosure. Do not store mower near any open flame
or where gasoline fumes may be ignited by a spark.
Do not overspeed the engine by changing govĆ
ernor settings.
At the time of manufacture, the mower conĆ
formed to the safety standards in effect for rotary
mowers. To ensure best performance and continued
safety certification of the mower, use genuine TORO
replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
may result in non-conformance with the safety stanĆ
dards, and that could be dangerous.
"
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Page Page
Set- p Instructions 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Air Cleaner 7. . . . . . . . . . . . . . . . . . . . . . .
Replacing Spark Plug 7. . . . . . . . . . . . . . . . . . . . . .
Draining Gasoline 8. . . . . . . . . . . . . . . . . . . . . . . . .
Changing Crankcase Oil 8. . . . . . . . . . . . . . . . . . . .
Inspecting/Removing/Sharpening Blade 8. . . . . .
Lubrication 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transmission Oil Level 10. . . . . . . . . . .
Adjusting Wheel Drive Control 11. . . . . . . . . . . . . .
Adjusting Blade Brake 11. . . . . . . . . . . . . . . . . . . . .
Adjusting Throttle Cable 11. . . . . . . . . . . . . . . . . . .
Cleaning Mower Housing 12. . . . . . . . . . . . . . . . . .
Preparing Mower For Storage 12. . . . . . . . . . . . . .
Optional Equipment 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Toro Service Support 13. . . . . . . . . . . . . . . . . . . . . . . . .
Product Identification 13. . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Performance Warranty 16. . . . . . . . . . . . . . . .
LOWER HANDLES (Fig. 1)ĊM ke sure control
c bles re between lower h ndle tubes. Push ends
of h ndle together nd inst ll on pivot pins. Bend
h ndle l tches slightly inw rd. Move h ndle nd
l tches b ckw rd until h ndle studs sn p into center
hole. Push h ir pin cotters through holes in pivot
pins.
358
UPPER HANDLE (Fig. 2)ĊSecure upper nd
lower h ndle in pl ce with h ndle bolts nd locknuts.
Control c bles must be in b ck of lower h ndle
cross member. Secure control c bles in position with
c ble ties.
Self-propelled model shown
1165
STARTER ROPE (Fig. 3)ĊPull st rter rope
through opening in rope guide. By squeezing control
b r (Fig. 5) g inst h ndle, bl de br ke will rele se
nd llow rope to be pulled e sily up to rope guide.
207
"
! %"
Initially, crankcase must be filled with a maximum of
20 ounces (0.6 L) of SAE 30 oil. 10W30 oil may be
substituted if SAE 30 oil is not available. Use any
high quality detergent oil having the American PetroĆ
leum Institute (API) service classification"ĊSF, SG,
SH or SJ.
Before each use, ensure oil level is between FULL
and ADD marks on dipstick (Fig. 4). Add oil if level is
at or below ADD mark.
Position mower on level surface and clean
around oil dipstick.
emove dipstick by rotating cap counterclockĆ
wise 1/4 turn.
Wipe dipstick and insert it into filler neck. otate
cap clockwise 1/4 turn. Then remove dipstick and
check level of oil on side of dipstick with FULL and
ADD marks (Fig. 4). If level is low, add only enough
oil to raise level to FULL mark on dipstick. "
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Insert dipstick into filler neck and rotate cap
clockwise 1/4 turn to lock.
6:- Check oil level each time mower is used or
after every 5 operating hours. Initially, change oil afĆ
ter the first 5 hours of operation; thereafter, change
oil after every 50 hours of operation. More frequent
oil changes are required in dusty or dirty conditions.
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6:-: The Toro Company strongly recommends the
use of fresh, clean, # regular grade gasoĆ
line in Toro gasoline powered products. Unleaded
gasoline burns cleaner, extends engine life, and proĆ
motes good starting by reducing the build-up of
combustion chamber deposits. Leaded gasoline can
be used if unleaded is not available.
Toro also recommends that Toro Stabilizer/ConditionĆ
er be used regularly in all Toro gasoline powered
products during operation and storage seasons.
Toro Stabilizer/Conditioner cleans the engine during
operation and prevents gumĆlike varnish deposits
from forming in the engine during periods of storage.
Clean around fuel tank cap and remove cap
from tank. Using unleaded gasoline, fill fuel tank to
within 1/4" to 1/2" (6 to 13 mm) from top of tank, not
into filler neck. Do not fill tank full.
Install fuel tank cap and wipe up any spilled gasĆ
oline.
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BEFORE OPERATINGĊEnsure engine brake,
selfĆpropelled drive (self-propelled model only), and
control bar function properly. When control bar is
released, blade and engine are designed to stop.
CUTTING AND BAGGINGĊTo improve quality of
cut, discharge clippings toward previously cut area.
Best results are achieved when engine is running at
maximum speed and only about 1/3 of the grass
blade is cut. If long grass must be cut, use highest
heightĆofĆcut setting for first mowing. Then recut the
grass at a more normal setting. If too long of grass is
cut, mower may plug and cause engine to stall.
SHARP BLADEĊBegin each cutting season with
a sharp blade. Periodically file down nicks.
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Wheel drive control (self-propelled model only),
throttle, control bar and fingertip starter are on upper
handle (Fig. 5).
*(63&
!
Push spark plug wire onto spark plug (Fig. 6).
SELFĆPROPELLED MODELS ONL -Move wheel
drive control to DISENGAGE.
Move throttle to (FAST) position.
Push primer three (3) times (Fig. 6). "*5 "#065
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05& Do not use primer to restart a warm engine
after a short shutdown. However, cool weather may
require priming to be repeated.
*(63&
PRIMER 1344
SPARK
PLUG
Hold control bar against handle. Pull fingertip
starter out until positive engagement results (Fig. 5);
then pull vigorously to start the engine. Regulate
throttle as desired when engine starts.
Release control bar to stop engine and blade.
On self-propelled model, move wheel drive control
to DISENGAGE position.
Pull wire off spark plug if mower will be unatĆ
tended or not used.
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Normally, replace air cleaner after every 25 operatin
hours. More frequent replacement is required when
mower is operated in dusty or dirty conditions.
Stop en ine and pull wire off spark plu
(Fi . 11).
Loosen screw securin air cleaner cover to enĆ
ine (Fi . 9). Tilt cover down and clean thorou hly.
Remove paper air cleaner filter (Fi . 10) and disĆ
card.
(&30$
331
Insert new paper air cleaner filter cartrid e so lip
touches back plate as shown in Fi ure 10.
Close air cleaner cover and secure with screw.
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253
Use a Champion RJ19LM spark plu or equivalent.
Correct air ap is 0.030" (0.76 mm). Remove plu
after every 25 operatin hours and check its condiĆ
tion.
Stop en ine and pull wire off spark plu
(Fi . 11).
Clean around spark plu and remove plu from
cylinder head.
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et air gap at 0.030" (0.76 mm) (Fig. 12). Install
correctly gapped spark plug and gasket seal. TightĆ
en plug firmly to 15 ft-lb (20 Nm).
-+74)
00
!
top engine and pull wire off spark plug
(Fig. 11).
26) Drain gasoline from a cold engine only.
Remove cap from fuel tank and use pump-type
syphon to drain fuel into clean gas can.
26) This is the only procedure recommended for
draining fuel.
!
Change crankcase oil after the first 5 operating
hours and after every 50 hours thereafter. ince
warm oil drains better and carries more contamiĆ
nants than cold, run engine for a minute or so before
draining oil.
top engine and pull wire off spark plug
(Fig. 11).
If necessary, remove grass bag. Drain gasoline
from fuel tank: refer to Draining Gasoline, page 8.
The oil drain plug is on the underside of the
mower deck (Fig. 13). The recommended procedure
for tipping the mower to access the plug is to tip the
mower backward onto its handle and have someone
firmly hold the mower in this position while you reĆ
move the plug. " " % !!
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/6)41&6-8) )6,2( Tip the mower backward onto
handle and place a heavy object such as a sandbag
on handle to hold mower securely in tilted position.
Position a drain pan under the mower so it will be
in line with the oil drain plug when the mower is
tipped back onto all four wheels.
Remove drain plug from underside of mower
using the male end of a 3/8" square socket extenĆ
sion with a ratchet for turning (Fig. 13).
Lower the mower onto all four wheels to allow oil
to drain into drain pan.
After draining, clean drain plug and tip mower
backward onto handle. Have someone firmly hold
handle while you reinstall the drain plug.
Lower mower onto all four wheels. Wipe up any
spilled oil. Fill engine with fresh oil: refer to Fill CrankĆ
case With Oil, page 4.
!" $!
top engine and pull wire off spark plug
(Fig. 11).
Drain gasoline from fuel tank; refer to Draining
Gasoline, page 8.
Tip the mower backward onto its handle and
have someone firmly hold the mower in this position.
,3%1.!3)5% %3(/$ Tip the mower backward onto
handle and place a heavy object such as a sandbag
on handle to hold mower securely in tilted position.
INSPECTING BLADEĊCarefully examine blade
for sharpness and wear, especially where flat and
curved parts meet (Fig. 14A). Since sand and abraĆ
sive material can wear away the metal that connects
the flat and curved parts of the blade, check blade
before using the mower. If a slot or wear is noticed,
(Fig. 14B & C), replace blade. Refer to step 5.
/3% For best performance, install new blade before
cutting season begins. During the year, file down
small nicks to maintain the cutting edge.
)'41%
REMOVING BLADEĊGrasp end of blade using a
rag or thickly padded glove. Remove blade bolt,
lockwasher, and blade (Fig. 15).
)'41%
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SHARPENING BLADEĊ sing a file, sharpen top
side of blade and maintain original cutting angle
(Fig. 16). The blade will remain balanced if same
amount of material is removed from both cutting
edges.
/3% Blade should not be ground beyond original
cutting edge length from outside ends.
)'41%
153
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Install sharp, balanced blade with lockwasher
and blade bolt. Sail part of blade must point toward
top of mower housing to ensure correct installation.
Tighten blade bolt to 50 ft-lb (68 Nm).
After every 25 operating hours or when season ends,
front and rear wheels must be lubricated.
IL FR NT AND REAR WHEELSĊApply 2 or 3
drops of light oil on inside and outside of wheel
bolts. Spin wheels to distribute oil into bushings.
Wipe up excess oil.
GREASE FR NT AXLE PIV TS (Fig. 17)
(self-propelled model only)ĊAdjust height-of-cut
to 3-inch setting and loosen wheel bolt to get addiĆ
tional clearance around grease fitting. Wipe grease
fittings with clean rag. Install grease gun onto fitting
and gently apply 2 or 3 pumps of #2 Multi-Purpose
Lithium Base Grease.
(&2/$
330
The transmission is filled with E.P. 90 gear oil that
has a GL-5 or GL-6 rating. Level of gear oil must
be checked at least every 25 operating hours, before
storage and before the mowing season begins.
Stop engine and pull wire off spark plug
(Fig. 11).
Remove two screws and lift off transmission covĆ
er (Fig. 18).
(&2/$
337
CHECKING GEAR IL LEVEL (Fig. 19)ĊPosition
mower on level surface and clean around plastic
plug. Remove plastic plug and watch for oil to ooze
out of hole. If gear oil oozes out, quickly install plasĆ
tic plug because oil is at proper level. If oil does not
flow, add gear oil: see step 4.
-4 -(* *$3$* + 6 (,#(" 1$ *$ )
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ADDING GEAR ILĊSlowly add E.P. 90 gear oil
that has a GL-5 or GL-6 rating. Stop when oil
oozes out of hole in gear case, and quickly install
plastic plug. D N T VERTIGHTEN PLASTIC
PLUG BECAUSE THREADS MAY STRIP.
(&2/$
-1$ A clean Plews type oil container or any other
clean container with a small tip can be used to add
oil. Using a dirty oil container could contaminate
transmission case and eventually cause damage.
"
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1'+(4/0./'++'& ,.&'+ .-+3
If front wheels do not engage and disengage or if a
new wheel drive control cable is installed, an adjustĆ
ment is required.
Stop engine and pull wire off spark plug
(Fig. 11).
Remove transmission cover (Fig. 18).
ADJUSTMENT (Fig. 20)ĊLoosen belt guide
screw until cable conduit slides. Move handle-
mounted wheel drive control to DISENGAGE posiĆ
tion. Move shift arm toward clamp screw and hold in
place. ull cable conduit to remove slack and tighten
belt guide screw.
Reinstall transmission cover.
!"
*)20'
" #
! %
#"
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Whenever a new blade brake cable assembly is
installed, an adjustment is required.
Stop engine and pull wire off spark plug
(Fig. 11).
CHECK ADJUSTMENT (Fig. 21)ĊMove control
bar toward handle until slack in wire is removed.
Gap between brake lever and handle must be
1/8"-3/16". See step 3 for adjustment.
*)20'
346
$
ADJUST CABLE CONDUITĊLoosen locknut on
cable support (Fig. 22). Insert 1/8"-3/16" object beĆ
tween brake lever and handle. ull down on cable
conduit until slack is removed. Then tighten locknut.
*)20'
!# "
#"
#"
347
#!" " ""
Throttle control adjustment may be required if engine
does not start. Whenever a new throttle control cable
is installed, throttle must be adjusted.
Stop engine and pull wire off spark plug
(Fig. 11).
Loosen cable clamp screw until throttle cable
slides (Fig. 23).
Move throttle control to (FAST) position.
Move throttle cable until lever contacts stop
(Fig. 23).
*)20'
! %
" ""
" ""
$ !"
2348
Tighten cable clamp screw to lock adjustment in
place.
To ensure best performance, keep underside of
mower housing and inside of deflector shield area
clean.
Stop engine and pull wire off spark plug
(Fig. 11).
Drain gasoline from fuel tank: refer to Draining
Gasoline, page 8.
Tip the mower backward onto its handle and
have someone firmly hold the mower in this position.
Avoid rotating blade
because starting problems may result.
&*#)'!*%+# #*$(" Tip the mower backward onto
handle and place a heavy object such as a sandbag
on handle to hold mower securely in tilted position.
Remove dirt and grass clippings that stick to
housing with hardwood scraper. Avoid burrs and
sharp edges.
For long term storage, either drain gasoline from
fuel tank or use a fuel additive before storing. To
drain gasoline, refer to Draining Gasoline, page 8.
After fuel is drained, start engine and let it idle until
all fuel is consumed and engine stops. Repeat the
starting procedure two more times to ensure all gas
is removed from the engine. If gasoline is not
drained, gum-like varnish deposits will form and
cause poor engine operation, even starting probĆ
lems.
Fuel can be left in gas tank only if a fuel additive,
such as Toro's Stabilizer/Conditioner, is added to
gasoline before storing. Toro's Stabilizer/Conditioner
is a petroleum distillate based conditioner/stabilizer.
Toro does not recommend stabilizers with an alcohol
base, such as ethanol, methanol or isopropyl. Use
fuel additive in recommended quantities as specified
on container.
Under normal conditions, fuel additives remain effecĆ
tive in fuel for 6-8 months.
Drain oil: refer to Changing Crankcase Oil,
page 8. After oil is drained, do not fill crankcase
with oil until the following steps (3Ć11) are comĆ
pleted.
Remove spark plug and pour 2 tablespoons of
SAE 30 oil into hole in cylinder. Pull starter rope slowĆ
ly to coat inside of cylinder. Reinstall spark plug and
tighten to 15 ft-lb (20 m).
Clean mower housing: refer to Cleaning Mower
Housing, page 12.
Check condition of blade: refer to Inspecting/ReĆ
moving/Sharpening Blade, page 8.
Tighten all nuts, bolts, and screws.
Clean dirt and chaff from cylinder, cylinder head
fins, and blower housing. Also remove grass clipĆ
pings, dirt, and grime from external parts of the enĆ
gine, shrouding, and top of mower housing.
Clean air cleaner: refer to Servicing Air Cleaner,
page 7.
Lubricate the wheels: refer to Lubrication,
page 10.
Check transmission oil level: refer to Checking
Transmission Oil, page 10.
Touch up all rusted or chipped paint surfaces.
Toro Re-Kote paint is available from an Authorized
TORO Service Dealer.
Fill crankcase with oil; refer to Fill Crankcase
With Oil, page 4.
Store mower in a clean, dry place, out of the
reach of children. Cover mower to keep it clean and
protected.
For spec al cond t ons, the follow ng accessor es
may be purchased at your local Author zed Toro SerĆ
v ce Dealer.
($% (/#'".&% "&&(+& (0 ,$%* ,
2ĊS de bag k t (F g. 24) lets you bag lush
grass n spr ng to help keep your lawn free of cl pĆ
p ngs. In the fall, bag leaves wh le you mow to el m Ć
nate the hand-bl ster ng rak ng job.
-".) ..%/0,. ".0 , 2ĊIf a spark
arrestor s requ red because of local, state, or federal
regulat ons, t may be purchased at your local AuthoĆ
r zed Toro Serv ce Dealer. If mower s operated on
any Cal forn a forest, brush, or grass covered land
w thout a properly operat ng spark arrestor, the operĆ
ator s v olat ng state law, Sect on 4442 Publ c ReĆ
sources Code.
(&1.%
!
If help - concern ng safety, set-up, operat on, ma ntenance, or troubleshoot ng - s ever needed, contact the
local Author zed TORO Serv ce Dealer or D str butor. Refer to the ``Yellow Pages" for ass stance. In add t on to
sk lled serv ce techn c ans, the dealer and d str butor have factory approved accessor es and replacement
parts. Keep your Toro all TORO. Buy genu ne TORO replacement parts and accessor es.
A model and a ser al number decal s located at rear of mower hous ng. Always refer to spec f c numbers on
th s decal n correspondence or when replacement parts are needed.
$. - )0!,! 3 $%- 2*,!-- ,,(.3
The Toro Company promises to repair any TORO Product
used for normal residential purposes* if defective in materials
or workmanship or if it stops functioning due to the failure of a
component. The following time periods apply from the date of
purchase:
DSuper Recyclerr Walk Mowers 5 year full warranty.
DVacuPowert Walk Mowers 5 year full warranty. . . .
DAll Others 2 year full warranty. . . . . . . . . . . . . . . . . . .
The cost of parts and labor is included, but the customer pays
the transportation costs.
$. ,) /.- ,! )0!,! 3 $%- ,,(.3
This warranty applies to all gasoline powered consumer walk
power mowers. Riding products and wide area walk behind
mowers are covered by separate warranty statements.
)1 )/. )''!,%& -!
TORO Consumer Products used for commercial, institutional
or rental use are warranted against defects in material or
workmanship. Components failing due to normal wear are not
covered by this warranty. The following time periods apply
from the date of purchase:
Products Warranty Period
Engine Entire Unit
D21" Commercial Duty
Walk Mowers
With GTS 200 Engine 2 year limited 1 year limited. . . .
Without GTS 200 Engine 1 year limited 1 year limited.
DAll Others 45 day limited 45 day limited. . . . . . . . . . . . . .
)1 ) )/ !. ,,(.3 !,0%!
Should you feel your TORO Product requires warranty serĆ
vice, contact the dealer who sold you the product or any AuĆ
thorized TORO Service Dealer or TORO Master Service DealĆ
er. The Yellow Pages of your telephone directory is a good
reference source. The dealer will either arrange service at
his/her dealership or recommend another Authorized Service
Dealer who may be more convenient. You may need proof of
purchase (copy of registration card, sales receipt, etc.) for
warranty validation.
If for any reason you are dissatisfied with the Service Dealer's
analysis of the defect in materials or workmanship or if you
need a referral to a TORO Service Dealer, please feel free to
contact us at the following address:
Toro Customer Service Department
8111 Lyndale Avenue South
Bloomington, M 55420-1196
612-888-8801
800-348-2424
A Full Warranty
(Limited Warranty for Commercial Use)
Walk
Mowers
$. /-. )/ ) ) !!* $! ,,(.3 ( ""!.
You must maintain your TORO Product by following the mainĆ
tenance procedures described in the operator's manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
$. )!- $%- ,,(.3 ). )0!,
(
)1 )!- )/, ..! 1 !&.! ) $%- ,,(.3
There is no other express warranty except for special emission
system coverage on some products and the TORO Starting
Guarantee on GTS Engines. This express warranty does not
cover:
DCost of regular maintenance service or parts, such as filters,
fuel, lubricants, oil changes, spark plugs, blade sharpening,
blade worn out, cable/linkage adjustments or brake and clutch
adjustments.
DAny product or part which has been altered or misused or
required replacement or repair due to accidents or lack of
proper maintenance.
DRepairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non-use over three months.
DPickup and delivery charges.
All repairs covered by this warranty must be performed by an
Authorized TORO Service Dealer using Toro approved replaceĆ
ment parts.
Repair by an Authorized TORO Service Dealer is your sole
remedy under this warranty.
$! ),) )'*(3 %- (). &%&! "), %( %,!. %(% !(.& ),
)(-!+/!(.%& '#!- %( )((!.%)( 1%.$ .$! /-! )" .$!
,) /.- )0!,! 3 .$%- 1,,(.3 %(&/ %(# (3
)-. ), !2*!(-! )" *,)0% %(# -/-.%./.! !+/%*'!(. ), -!,4
0%! /,%(# ,!-)(&! *!,%) - )" '&"/(.%)( ), ()(/-!
*!( %(# )'*&!.%)( )" ,!*%,- /( !, .$%- 1,,(.3 )'!
-..!- ) (). &&)1 !2&/-%)(- )" %(% !(.& ), )(-!+/!(4
.%& '#!- -) .$! )0! !2&/-%)( '3 (). **&3 .)
3)/
$%- 1,,(.3 #%0!- 3)/ -*!%"% &!#& ,%#$.- ( 3)/ '3
&-) $0! ).$!, ,%#$.- 1$%$ 0,3 ",)' -..! .) -..!
* ormal residential purposes means mowing the lawn on
the same lot as your home. Use at more than one location
is considered commercial use and the commercial use
warranty would apply.
Customers who have purchased TORO products exported from the United States or Canada should contact their TORO
Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied
with your Distributor's service or have difficulty obtaining guarantee information, contact the TORO importer. If all other
remedies fail, you may contact us at The Toro Company.
Rev. 11/21/97
This manual suits for next models
1
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