Toro 22163 User manual

FormNo.3358-226RevB
PT21CommercialLawnMower
ModelNo.22163—SerialNo.270000001andUp
ModelNo.22164—SerialNo.270000001andUp
Registeratwww.Toro.com.OriginalInstructions(EN)

Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Figure1
1.Modelandserialnumberplate
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Contents
Introduction.................................................................2
Safety...........................................................................3
GeneralLawnMowerSafety.................................3
SafetyandInstructionalDecals.............................4
Setup............................................................................5
1InstallingtheHandle..........................................5
2FillingtheCrankcasewithOil.............................6
3AdjustingtheHandleHeight..............................6
ProductOverview........................................................7
Operation.....................................................................8
CheckingtheEngineOilLevel..............................8
FillingtheFuelTankwithGasoline.......................9
StartingtheEngine.............................................10
StoppingtheEngine...........................................11
UsingtheSelf-propelDrive................................11
AdjustingtheCuttingHeight..............................11
RecyclingtheClippings.......................................12
Side-dischargingtheClippings............................12
OperatingTips...................................................13
Maintenance...............................................................15
RecommendedMaintenanceSchedule(s)................15
Lubrication.............................................................16
LubricatingtheWheelGears...............................16
EngineMaintenance...............................................16
ServicingtheAirFilter........................................16
ChangingtheEngineOil....................................17
ServicingtheSparkPlug.....................................17
FuelSystemMaintenance.......................................18
EmptyingtheFuelTankandCleaningthe
FuelFilter.......................................................18
BladeMaintenance.................................................18
MaintainingtheCuttingBlade.............................18
Cleaning.................................................................20
CleaningundertheMowerHousing....................20
Storage.......................................................................21
PreparingtheFuelSystem...................................21
PreparingtheEngine..........................................21
GeneralInformation..........................................21
RemovingtheLawnMowerfromStorage............21
Troubleshooting.........................................................22
©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Safety
ThislawnmowermeetsorexceedstheCPSC
bladesafetyrequirementsforwalk-behindrotary
lawnmowersandtheB71.4specicationsofthe
AmericanNationalStandardsInstituteineffectat
thetimeofproduction.
Improperlyusingormaintainingthislawnmower
canresultininjury.Toreducethepotentialfor
injury,complywiththesesafetyinstructions.
Torodesignedandtestedthislawnmowerfortooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultin
personalinjury.
Engineexhaustcontainscarbonmonoxide,an
odorless,deadlypoisonthatcankillyou.
Donotruntheengineindoorsorinanenclosed
area.
Toensuremaximumsafety,bestperformance,and
togainknowledgeoftheproduct,itisessentialthat
youandanyotheroperatorofthelawnmowerread
andunderstandthecontentsofthismanualbefore
theengineiseverstarted.Payparticularattention
tothesafetyalertsymbol(Figure2)whichmeans
Caution,Warning,orDanger—“personalsafety
instruction.”Readandunderstandtheinstruction
becauseithastodowithsafety.Failuretocomply
withtheinstructionmayresultinpersonalinjury.
GeneralLawnMowerSafety
Thislawnmoweriscapableofamputatinghandsand
feetandofthrowingobjects.Failuretoobservethe
followingsafetyinstructionscouldresultinserious
injuryordeath.
ThefollowinginstructionsarefromtheANSI/OPEI
B71.4-2004standard.
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtothemselves,other
people,orproperty.
Preparation
•Onlyuseaccessoriesandattachmentsapprovedby
themanufacturer.
•Wearappropriateclothingincludinghardhat,safety
glasses,andearprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.
•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.
–Useonlyanapprovedcontainer.
–Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling.
Donotsmoke.
–Neverrefuelordrainthemachineindoors.
•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.
Operation
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.
•Onlystartenginefromtheoperator’sposition.
•Besureofyourfooting,especiallywhenbacking
up.Walk,don’trun.Neveroperateonwetgrass.
Reducedfootingcouldcauseslipping.
•Slowdownanduseextracareonhillsides.Besure
totravelsidetosideonhillsides.Turfconditions
canaffectthemachine’sstability.Usecautionwhile
operatingneardrop-offs.
•Donotoperatethelawnmowerwithouteitherthe
grasscatcherortheguardinplace.
•Donotchangetheenginegovernorsettingor
overspeedtheengine.
•Stoponlevelgroundandshutoffenginebefore
leavingtheoperator’spositionforanyreason
3

includingemptyingthecatcheroruncloggingthe
chute.
•Stopequipmentandinspectbladeafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunits.
•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.
•Keeppetsandbystandersaway.
•Slowdownandusecautionwhencrossingroadsand
sidewalks.Stopbladeifyouarenotmowing.
•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.
•Donotoperatethemowerundertheinuenceof
alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
MaintenanceandStorage
•Stopengineanddisconnectsparkplugwire.Wait
forallmovementtostopbeforeadjusting,cleaning
orrepairing.
•Cleangrassanddebrisfromcuttingunit,drive,
mufer,andenginetohelppreventres.Cleanup
oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear
ame.
•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.
•Neverallowuntrainedpersonneltoservicemachine.
•Removesparkplugwirebeforemakinganyrepairs.
•Usecarewhencheckingblade.Wrapthebladeor
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblade.Neverstraightenorweldit.
•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.
•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.
SafetyandInstructional
Decals
Safetydecalsandinstructionsareeasily
visibletotheoperatorandarelocated
nearanyareaofpotentialdanger.
Replaceanydecalthatisdamagedor
lost.
Manufacturer’sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.
98-4387
1.Warning—wearhearingprotection.
105-6838
110-4989
4

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Oval-headbolt(Model22163only)2
Oval-headbolt(Model22164only)6
Hexheadbolt(Model22164only)2
Locknut(Model22163only)2
Locknut(Model22164only)6
Upperhandle(Model22164only)1
1
Cabletie1
Installthehandle.
2Nopartsrequired–Fillthecrankcasewithoil.
3Nopartsrequired–Adjustthehandleheight.
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1
InstallingtheHandle
Partsneededforthisprocedure:
2Oval-headbolt(Model22163only)
6Oval-headbolt(Model22164only)
2Hexheadbolt(Model22164only)
2Locknut(Model22163only)
6Locknut(Model22164only)
1Upperhandle(Model22164only)
1Cabletie
Procedure
1.Attachtheupperhandletothelowerhandleusing4
oval-headboltsand4locknuts(model22164only).
Note:Ensurethattheboltheadsaretotheoutside
ofthehandle.
2.Removetheboltsandwashersfromthemower
housingthatwillholdthehandletothehousing
(model22163only).
3.Movethehandletotheoperatingposition.
4.Attachthehandletothemowerhousingwiththe
boltsandwashersthatyouremovedinstep2(model
22163only)butdonottightenthem(Figure3).
Figure3
1.Endcaponreardoorrod4.Handlebrace(2)
2.Boltandwasher(2)5.Boltheadalignedwiththe
handle.
3.Locknut(2)
5.Attachthehandlebracestothelowerhandlesides
with2oval-headboltsandsecurethemngertight
using2locknuts(Figure3).
Important:Ensurethattheboltheadsareto
the
inside ofthehandle.
5

Important:Ifthehandlehasroundholes,the
squareshankoftheboltswillnottintothe
holesinthehandleatthistime.
6.Securethehandleasfollows:
•Iftheholesinthehandlearesquare,alignand
insertthesquareshankoftheoval-headboltsinto
thehandlesothattheboltheadsaretightagainst
thehandleandtightenthelocknuts(Figure3).
•Iftheholesinthehandleareround,alignthe
ovalboltheadswiththehandleasshownin
Figure3;then,holdingtheheadsinthatposition,
tighteneachnutwithawrenchtopullthesquare
shankintothehandleuntiltheboltheadsare
tightagainstthehandle.
7.Tightenallthefastenersonthehandleandhandle
braces.
8.Usethecabletieprovidedtosecurethecontrol
cable(s)tothehandle.
Note:Attachthecabletieaslowaspossibleonthe
handletopreventthecable(s)fromhookingonto
theendcaponthereardoorrodandinterferingwith
theself-propelsystem(Figure3).
2
FillingtheCrankcasewithOil
NoPartsRequired
Procedure
Theenginecrankcaseisshippedwithoutoil.Youmust
llitwithapproximately22ounces(0.65liters)ofoil
beforestartingtheengine.RefertoCheckingtheEngine
OilLevelin,pageforoilspecicationsandinstructions.
3
AdjustingtheHandleHeight
NoPartsRequired
Procedure
Youmayraiseorlowerthehandletoaposition
comfortableforyou.
1.Removethefastenerthatattachesthehandlebraces
tothelowerhandleends.
2.Inserttheboltthroughtheholeineachofthehandle
bracesthatsetsthehandletothedesiredposition
andtighten(Figure4).
Figure4
1.Highestposition3.Lowestposition
2.Middleposition(either
hole)
6

ProductOverview
Figure5
Model22163
1.Recoilstarthandle6.Airlter
2.Bladecontrolbar7.Cuttingheightlever(4)
3.Fueltank8.Sparkplug
4.Oilll/dipstick9.Primer
5.Sidedischarge
Figure6
Model22164
1.Upperhandle6.Airlter
2.Recoilstarthandle7.Primer
3.Bladecontrolbar8.Cuttingheightlever(4)
4.Fueltank9.Sparkplug
5.Oilll/dipstick10.Sidedischarge
Figure7
1.Sidedischargechute2.Reardischargeplug
(installed)
7

Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Eachtimebeforeyoumow,makesurethatthe
self-propeldriveandthebladecontrolbaroperate
properly.Whenyoureleasethebladecontrolbar,the
bladeandself-propeldriveshouldstop.Iftheydonot,
contactanAuthorizedServiceDealer.
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
Figure8
1.Warning—wearhearingprotection.
CheckingtheEngineOilLevel
ServiceInterval:Beforeeachuseordaily
Initially,llthecrankcasewith22ounces(0.65liters)
ofoil.Useonlyhigh-qualitySAE30orSAE10W30
weightdetergentoilthathastheAmericanPetroleum
Institute(API)serviceclassicationSF,SG,SH,orSJ.
Beforeeachuse,ensurethattheoillevelisbetweenthe
AddandFullmarksonthedipstick(Figure9).
Figure9
1.Dipstick3.Add
2.Full
Note:Whenthecrankcaseisempty,pourabout3/4
ofthecrankcasecapacityofoilinthecrankcase,then
followtheprocedureinthissection.
1.Movethelawnmowertoalevelsurface.
2.Cleanaroundthedipstick(Figure9).
3.Removethedipstickbyrotatingthecap
counterclockwiseandpullingitout.
4.Wipethedipstickcleanwithacleancloth.
5.Insertthedipstickintothellerneck,butdonot
screwitin.
6.Removethedipstickandreadtheoillevelonthe
dipstick(Figure9).
7.IftheoillevelreadingisbelowtheAddmarkon
thedipstick,slowlypouronlyenoughoilintothe
llerholetoraisetheoilleveltotheFullmarkon
thedipstick.
Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagewill
result.Draintheexcessoiluntiltheoillevelon
thedipstickreadsFull.
8.Insertthedipstickintothellerneckandrotatethe
capclockwiseuntilitistight.
8

FillingtheFuelTankwith
Gasoline
Forbestresults,useclean,fresh,lead-freegasolinewith
anoctaneratingof87orhigher.Toensurefreshness,
purchaseonlythequantityofgasolinethatyouexpectto
usein30days.Usingunleadedgasolineresultsinfewer
combustiondepositsandlongerenginelife.Youmay
useleadedgasolineifunleadedgasolineisnotavailable.
Important:Donotaddoiltothegasoline.
Important:Donotusemethanol,gasoline
containingmethanol,gasoholcontainingmore
than10%ethanol,premiumgasoline,orwhitegas.
Usingthesefuelscandamagetheengine’sfuel
system.
Important:Donotusegasolinethathasbeen
storedsincethelastmowingseasonorlonger.
Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.
•Fillthefueltankoutdoors,inanopenarea,
andwhentheengineiscold.Wipeupany
gasolinethatspills.
•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4
to1/2in.(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsthegasolinetoexpand.
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwherea
sparkmayignitethegasolinefumes.
•Storegasolineinanapprovedfuelcontainer
andkeepitoutofthereachofchildren.
•Neverbuymorethana30-daysupplyof
gasoline.
Whenfueling,undercertaincircumstances,a
staticchargecandevelop,ignitingthegasoline.
Areorexplosionfromgasolinecanburnyou
andothersanddamageproperty.
•Alwaysplacegasolinecontainersonthe
groundandawayfromyourvehiclebefore
lling.
•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.
•Whenpractical,removegasoline-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
round.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,notfromagasoline
dispensernozzle.
•Ifyoumustuseagasolinedispensernozzle,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.
Useafuelstabilizer/conditionerregularlyduring
operationandstorage.Astabilizer/conditionercleans
theengineduringoperationandpreventsgum-like
varnishdepositsfromformingintheengineduring
periodsofstorage.
Important:Donotusefueladditivesotherthan
afuelstabilizer/conditioner.Donotusefuel
stabilizerswithanalcoholbasesuchasethanol,
methanol,orisopropanol.
1.Cleanaroundthefueltankcap(Figure10).
9

Figure10
1.Oilll/dipstick3.Aircleaner
2.Fueltankcap
2.Removethecapfromthetank.
3.Fillthefueltankwithunleadedgasolinetowithin
1/4to1/2inch(6to13mm)fromthetopofthe
tank.Donotllintothellerneck.
Important:Donotllthetankmorethan1/4
inch(6mm)fromthetopofthetankbecause
thegasolinemusthaveroomtoexpand.
4.Installthefueltankcapandwipeupanyspilled
gasoline.
StartingtheEngine
1.Connectthewiretothesparkplug(Figure11).
Figure11
1.Spark-plugwire
2.Firmlypushintheprimeroncewithyourthumb
(Figure12).
Note:Donotpushintheprimerexcessivelyto
preventoodingtheenginewithfuel.
Figure12
3.Holdthebladecontrolbaragainstthehandle
(Figure13)or(Figure14).
Figure13
Model22163
Figure14
Model22164
10

4.Pulltherecoilstarter(Figure15)or(Figure16).
Figure15
Model22163
Figure16
Model22164
5.Ifthemowerdoesnotstartin1or2pulls,pressthe
primerbutton1or2timesandtrystartingitagain.
Note:Ifthemowerstilldoesnotstart,contactan
AuthorizedServiceDealer.
StoppingtheEngine
1.Releasethebladecontrolbar(Figure17).
Figure17
2.Whentheenginestops,removetheignitionkey
whenyouleavethemower.
Important:Whenyoureleasethebladecontrol
bar,boththeengineandbladeshouldstop
within3seconds.Iftheydonotstopproperly,
stopusingyourmowerimmediatelyandcontact
anAuthorizedServiceDealer.
UsingtheSelf-propelDrive
Model22164only
Tooperatetheself-propeldrive,simplywalkwithyour
handsontheupperhandleandyourelbowsatyour
sides,andthemowerwillautomaticallykeeppacewith
you(Figure18).
Figure18
AdjustingtheCuttingHeight
Adjustingthecuttingheightmaybringyouinto
contactwiththemovingblade,causingserious
injury.
•Stoptheengineandwaitforallmovingparts
tostop.
•Donotputyourngersunderthehousing
whenadjustingthecuttingheight.
Iftheenginehasbeenrunning,themuferwill
behotandcanseverelyburnyou.Keepaway
fromthehotmufer.
Adjustthecuttingheightasdesired.Setallfourwheels
tothesameheight.
Note:Toraisethemower,moveall4cuttingheight
leversforward;tolowerthemower,movethemall
rearward(Figure19).
11

Figure19
RecyclingtheClippings
Yourmowercomesfromthefactoryreadytorecycle
thegrassandleafclippingsbackintothelawn.
Ifthegrassbagisonthemower,removeit(referto
RemovingtheGrassBag)beforerecyclingtheclippings.
Ifthesidedischargechuteisonthemower,removeit
andlockthesidedischargedoor(refertoRemovingthe
SideDischargeChute)beforerecyclingtheclippings.
Important:Ensurethatthereardischarge
plugisinplacebeforeyourecycletheclippings
(Figure20).
Figure20
Side-dischargingthe
Clippings
Usethesidedischargeforcuttingverytallgrass.
Ifthebagisonthemower,removeitandinsertthe
reardischargeplug(refertoRemovingtheGrassBag)
beforeside-dischargingtheclippings.
Important:Ensurethatthereardischarge
plugisinplacebeforeyourecycletheclippings
(Figure21).
Figure21
Thebladeissharp;contactingthebladecan
resultinseriouspersonalinjury.
Stoptheengineandwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.
InstallingtheSideDischargeChute
1.Unlockthesidedischargedoor(Figure22).
12

Figure22
2.Liftopenthesidedischargedoor(Figure23).
Figure23
3.Installthesidedischargechuteandclosethedoor
ontothechute(Figure24).
Figure24
RemovingtheSideDischargeChute
Toremovethesidedischargechute,reversethesteps
above.
Important:Lockthesidedischargedoorafteryou
closeit(Figure25).
Figure25
OperatingTips
GeneralTips
•Maintainasharpbladethroughoutthecutting
season.Periodicallyledownnicksontheblade.
•Replacethebladewhennecessarywithanoriginal
Tororeplacementblade.
•Mowonlydrygrassorleaves.Wetgrassandleaves
tendtoclumpontheyardandcancausethemower
toplugortheenginetostall.
Wetgrassorleavescancauseseriousinjuryif
youslipandcontacttheblade.
Mowonlyindryconditions.
•Cleanunderthemowerhousingaftereachmowing.
SeeCleaningundertheMowerHousing.
•Keeptheengineingoodrunningcondition.
•Settheenginespeedtothefastestpositionforthe
bestcuttingresults.
Operatingamowerwithitsenginerunningat
aspeedgreaterthanthefactorysettingcan
causethemowertothrowapartofthebladeor
engineintotheoperator’sorbystander’sarea
andresultinseriouspersonalinjuryordeath.
–Donotchangetheenginespeedsetting.
–Ifyoususpecttheenginespeedisfaster
thannormal,contactanAuthorizedService
Dealer.
•Cleantheairlterfrequently.Mulchingstirsup
moreclippingsanddustwhichclogstheairlter
andreducesengineperformance.
CuttingGrass
•Grassgrowsatdifferentratesatdifferenttimesof
theyear.Inthesummerheat,itisbesttocutgrass
atthe2-1/4inch(57mm),2-3/4inch(70mm),or
3-1/4inch(83mm)cuttingheightsettings.Cut
onlyaboutathirdofthegrassbladeatatime.Do
notcutbelowthe2-1/4inch(57mm)settingunless
thegrassissparseoritislatefallwhengrassgrowth
beginstoslowdown.
•Whencuttinggrassover6inches(15cm)tall,rst
mowatthehighestcuttingheightsettingandwalk
13

slower;thenmowagainatalowersettingforthe
bestlawnappearance.Ifthegrassistoolongand
theleavesclumpontopofthelawn,themowermay
plugandcausetheenginetostall.
•Alternatethemowingdirection.Thishelpsdisperse
theclippingsoverthelawnforevenfertilization.
Ifthenishedlawnappearanceisunsatisfactory,try
oneormoreofthefollowing:
•Sharpentheblade.
•Walkataslowerpacewhilemowing.
•Raisethecuttingheightonyourmower.
•Cutthegrassmorefrequently.
•Overlapcuttingswathsinsteadofcuttingafull
swathwitheachpass.
•Setthecuttingheightonthefrontwheelsonenotch
lowerthantherearwheels.Forexample,setthe
frontwheelsat2-1/4inches(57mm)andtherear
wheelsat2-3/4inches(70mm).
CuttingLeaves
•Aftercuttingthelawn,ensurethathalfofthelawn
showsthroughthecutleafcover.Youmayneedto
makemorethanonepassovertheleaves.
•Forlightleafcoverage,setallthewheelsatthesame
cuttingheightsetting.
•Iftherearemorethan5inches(12.7cm)ofleaves
onthelawn,setthefrontcuttingheight1or2
notcheshigherthantherearcuttingheight.This
makesiteasiertofeedtheleavesunderthemower
housing.
•Slowdownyourmowingspeedifthemowerdoes
notcuttheleavesnelyenough.
•Ifyoumowoveroakleaves,youcanaddlimeto
thegrassinthespringtoreducetheacidityofthe
oakleaves.
14

Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Aftertherst8hours•Changetheengineoil.
Beforeeachuseordaily
•Checktheengineoillevel.
•Inspectthemowerbladesforwearordamage.
•Cleanunderthemowerhousing.
Every25hours•Lubricatetherearwheelgears.
•Cleanthefoampre-cleaner(morefrequentlyindustyconditions).
Every50hours•Changetheengineoil(moreoftenindustyconditions).
Every100hours•Checkthesparkplug.
Every300hours•Replacethepaperairlter(morefrequentlyindustyconditions).
Yearly•Emptythefueltankandcleanthefuellter.
Important:Refertoyour Engine Operator’ s Man ual foradditionalmaintenanceprocedures.
Ifyouleavethewireonthesparkplug,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.
Disconnectthewirefromthesparkplugbeforeyoudoanymaintenance.Setthewireasidesothatit
doesnotaccidentlycontactthesparkplug.
15

Lubrication
LubricatingtheWheelGears
ServiceInterval:Every25hours
Lubricateeachrearwheelwithgreaseyearly.
1.Wipethegreasettingsjustinsidetherearwheels
withacleanrag(Figure26).
Figure26
1.Greasetting
2.Installagreasegunontoeachttingandgentlyapply
2or3pumpsof#2multi-purposelithium-base
grease.
EngineMaintenance
ServicingtheAirFilter
ServiceInterval:Every25hours
Every300hours
Cleanthefoampre-cleanerevery25operatinghours.
Replacethepaperairlteronceeveryseasonorevery
300operatinghours;replaceitmorefrequentlyindusty
conditions.
Important:Donotoperatetheenginewithoutthe
airlterassembly;extremeenginedamagewill
occur.
1.Stoptheengineandwaitforallmovingpartstostop.
2.Removethescrewthatsecurestheairlter
coverFigure27).
Figure27
1.AirFilterhousing4.Cover
2.Foampre-cleaner5.Screw
3.Paperairlter
3.Removethecoverandcleanitthoroughly(Figure27).
4.Removeandinspectthepaperairlter(Figure27),
anddiscarditifitisexcessivelydirty.
Important:Donottrytocleanapaperlter.
5.Removethefoampre-cleanerandwashitwitha
milddetergentandwater,thenblotitdry.
6.Saturatethepre-cleanerwithoil,thensqueezeit(do
nottwist)toremovetheexcessoil.
7.Installthefoampre-cleaner.
8.Installthepaperairlter.
16

Note:Installanewpaperairlterifyoudiscarded
theoldone.
9.Installthecoverandsecureitwiththescrew.
ChangingtheEngineOil
ServiceInterval:Aftertherst8hours
Every50hours
Changetheoilaftertherst8operatinghoursandthan
afterevery50operatinghoursoreveryseason(more
frequentlyindustyordirtyconditions).
1.Runtheenginetowarmtheengineoil.
Note:Warmoilowsbetterandcarriesmore
contaminants.
Oilmaybehotafterenginehasbeenrun,and
contactwithhotoilcancauseseverepersonal
injury.
Avoidcontactingthehotengineoilwhenyou
drainit.
2.Stoptheengineandwaitforallmovingpartstostop.
3.Disconnectthewirefromthesparkplug(Figure11).
4.Placeasuitabledrainpanundertherightsideof
themower.
5.Removethedipstickbyrotatingthecap
counterclockwiseandpullingitout.
6.Tipthemowerontoitsrightsidetodraintheoil
intothedrainpan.
Note:Youcanalsoremovetheoilfromthe
crankcaseusinganoilextractor.
7.Returnthemowertoitsoperatingposition.
8.Insertthedipstickintothellerneckandrotatethe
capclockwiseuntilitistight.
9.Recycletheusedoilaccordingtolocalcodes.
10.FillthecrankcasetotheFulllineonthedipstickwith
freshoil.RefertotheFillingtheCrankcasewithOil.
11.Wipeupanyspilledoil.
ServicingtheSparkPlug
ServiceInterval:Every100hours
Checkthesparkplugafterevery100operatinghours.
UseanNGKBPR5ESsparkplugorequivalent.
1.Stoptheengineandwaitforallmovingpartstostop.
2.Disconnectthewirefromthesparkplug(Figure11).
3.Cleanaroundthesparkplug.
4.Removethesparkplugfromthecylinderhead.
Important:Replaceacracked,fouled,or
dirtysparkplug.Donotcleantheelectrodes
becausegritenteringthecylindercandamage
theengine.
5.Setthegapontheplugto0.030in.(0.76mm)
(Figure28).
Figure28
1.Centerelectrodeinsulator
2.Sideelectrode
3.Airgap(nottoscale)
6.Installthesparkplugandthegasketseal.
7.Torquetheplugto17ft-lb(23N⋅m).
8.Connectthewiretothesparkplug.
17

FuelSystem
Maintenance
EmptyingtheFuelTankand
CleaningtheFuelFilter
ServiceInterval:Yearly
Thefuellter(screen)elementislocatedinsidethefuel
tank.Cleanthefuellterelementyearly.
1.Stoptheengineandwaitforittocooldown.
Note:Draingasolinefromacoldengineonly.
2.Disconnectthewirefromthesparkplug(Figure11).
3.Disconnectthefuellinebylooseningthetubeclamp
atthecarburetor.
4.Openthefuelvalve.
5.Drainthegasolinecompletelyfromthetankandfuel
lineintoanapprovedfuelcontainer.
6.Removethefueltankfromthemower.
7.Pourasmallamountoffuelinthefueltank,move
thefuelaroundinthetank,andpouritoutintoan
approvedfuelcontainer.
8.Installthefueltankandfuelline;refertoInstalling
theFuelTankandtheFuelLine.
BladeMaintenance
MaintainingtheCuttingBlade
Alwaysmowwithasharpblade.Asharpbladecuts
cleanlyandwithouttearingorshreddingthegrassblades.
1.Stoptheengineandwaitforallmovingpartstostop.
2.Disconnectthewirefromthesparkplug(Figure11).
3.Drainthegasolinefromthefueltank;referto
EmptyingtheFuelTankandCleaningtheFuelFilter.
4.Tipthemowerontoitssidewiththeairlterup
(Figure29).
Figure29
InspectingtheBlade
ServiceInterval:Beforeeachuseordaily
Carefullyexaminethebladeforsharpnessandwear,
especiallywheretheatandthecurvedpartsmeet
(Figure30A).Becausesandandabrasivematerialcan
wearawaythemetalthatconnectstheatandcurved
partsoftheblade,checkthebladebeforeusingthe
mower.Ifyounoticeaslotorwear(Figure30Band
Figure30C),replacetheblade;refertoRemovingthe
Blade.
18

Figure30
1.Sail3.Wear
2.Flatpartoftheblade4.Slotformed
Note:Forthebestperformance,installanewblade
beforethecuttingseasonbegins.Duringtheyear,le
downanysmallnickstomaintainthecuttingedge.
Awornordamagedbladecanbreak,anda
pieceofthebladecouldbethrownintothe
operator’sorbystander’sarea,resultingin
seriouspersonalinjuryordeath.
•Inspectthebladeperiodicallyforwearor
damage.
•Replaceawornordamagedblade.
RemovingtheBlade
Grasptheendofthebladeusingaragorathickly
paddedglove.Removethebladebolt,accelerator,and
theblade(Figure29).
SharpeningtheBlade
Filethetopsideofthebladetomaintainitsoriginal
cuttingangle(Figure31A)andinnercuttingedgeradius
(Figure31B).Thebladewillremainbalancedifyou
removethesameamountofmaterialfrombothcutting
edges.
Figure31
1.Sharpenatthisangleonly.2.Maintaintheoriginalradius
here.
BalancingtheBlade
1.Checkthebalanceofthebladebyplacingthecenter
holeofthebladeoveranailorscrewdrivershank
clampedhorizontallyinavise(Figure32).
Figure32
Note:Youcanalsocheckthebalanceusinga
commerciallymanufacturedbladebalancer.
2.Ifeitherendofthebladerotatesdownward,lethat
end(notthecuttingedgeortheendnearthecutting
edge).Thebladeisproperlybalancedwhenneither
enddrops.
InstallingtheBlade
1.Installasharp,balancedToroblade,theaccelerator,
andthebladebolt.Torquethebladeboltto60
ft-lb(82N⋅ ⋅
⋅m).
2.Returnthemowertoitsoperatingposition.
3.Connectthewiretothesparkplug.
19

Cleaning
CleaningundertheMower
Housing
Toensurethebestperformance,keeptheundersideof
themowerhousingclean.
WashingMethod
ServiceInterval:Beforeeachuseordaily
1.Positionthemoweronaatconcreteorasphalt
surfacenearagardenhose.
2.Starttheengine.
3.Holdtherunninggardenhoseathandleleveland
directthewatertoowonthegroundjustinfront
oftherightrearwheel(Figure33).
Figure33
1.Rightrearwheel
Note:Thebladewillsplashintothepathofthe
blade,cleaningouttheclippings.
4.Stoptheengineandwaitforallmovingpartstostop.
5.Turnoffthewater.
6.Startthemowerandletitrunforafewminutes
todryoutthemoistureonthemowerandits
components.
ScrapingMethod
Ifwashingdoesnotremovealldebrisfromunderthe
mower,scrapeitclean.
1.Disconnectthewirefromthesparkplug(Figure11).
2.Drainthefuelfromthefueltank.RefertoEmptying
theFuelTankandCleaningtheFuelFilter.
Tippingthemowermaycausethefueltoleak
fromthecarburetororthefueltank.Gasoline
isextremelyammable,highlyexplosive,and,
undercertainconditions,cancausepersonal
injuryorpropertydamage.
Avoidfuelspillsbyrunningtheenginedryor
byremovingthegasolinewithahandpump;
neversiphon.
3.Tipthemowerontoitsrightside.
4.Removethedirtandgrassclippingswithahardwood
scraper.Avoidburrsandsharpedges.
5.Returnthemowertoitsoperatingposition.
6.Fillthefueltank.
7.Connectthewiretothesparkplug.
20