21in Heavy-Duty Recycler®/Rear Bagger Lawn Mower

• Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) cannot read English, it is the owner's responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property.

• Use only accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety glasses, and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and remove all objects, such as rocks, toys, and wire, which can be thrown by the machine.

• Check that operator's presence controls, safety switches, and shields are attached and functioning properly. Do not operate the machine unless they are functioning properly.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow the engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or the fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove the equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill the fuel tank. Replace fuel cap and tighten securely.

• Never run an engine in an enclosed area.

• Operate the machine only in good light, keeping away from holes and hidden hazards.

• Start the engine only from the operating position.

• Be sure of your footing, especially when backing up. Walk, don't run. Never operate the machine on wet grass. Reduced footing could cause slipping.

• Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. Turf conditions can affect the stability of the machine. Use caution while operating the machine near drop-offs.

• Do not operate the machine without either the grass catcher or the guard in place.

• Do not change the engine governor setting or overspeed the engine.

• Stop the machine on level ground and shut off the engine before leaving the operating position for any reason, including emptying the catcher or unclogging the chute.

• Stop the machine and inspect the blade after striking objects or if an abnormal vibration occurs. Make necessary repairs to the machine before resuming operation.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of a clear path.

• Keep pets and bystanders away.

• Slow down and use caution when crossing roads and sidewalks. Stop the blade if you are not mowing.

• Be aware of the machine discharge direction and do not point it at anyone.

• Do not operate the machine while under the influence of alcohol or drugs.

• Use care when loading or unloading the machine into a trailer or truck.

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• Stop the engine and disconnect the spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing the machine.

• Clean grass and debris from the cutting unit, drive, muffler, and engine to help prevent fires. Clean up oil or fuel spills.

• Let the engine cool before storing the machine, and do not store it near a flame.

• Shut off the fuel while storing or transporting the machine. Do not store fuel near flames or drain fuel indoors.

• Never allow untrained personnel to service the machine.

• Remove the spark-plug wire before making any repairs.

• Use care when checking the blade. Wrap the blade or wear gloves, and use caution when servicing the blade. Only replace the blade; never straighten or weld it.

• Keep hands and feet away from moving parts. If possible, do not make adjustments to the machine while the engine is running.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• To best protect your investment and maintain optimal performance of your Toro equipment, count on Toro genuine parts. When it comes to reliability, Toro delivers replacement parts designed to the exact engineering specifications of our equipment. For peace of mind, insist on Toro genuine parts.

• Use care when loading or unloading the machine into a trailer or truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both the front and the rear straps should be directed down and outward from the machine.

1. Install the empty grass bag on the machine.

2. Start the engine.

3. Engage the blade.

   Note: The bag should begin to inflate, indicating that the blade is engaged and rotating.

4. Release the blade-control bar.

   Note: If the bag does not immediately deflate, the blade is still rotating. The blade-brake clutch may be deteriorating and, if ignored, could result in an unsafe operating condition. Have the machine inspected and serviced by an Authorized Service Dealer.

5. Stop the engine and wait for all moving parts to stop.

1. Move the machine onto a paved surface in a non-windy area.

2. Set all 4 wheels to the 76 mm (3 inch) cutting-height setting; refer to Adjusting the Cutting Height.

3. Take a half sheet of newspaper and crumple it into a ball small enough to go under the machine housing (about 76 mm or 3 inches in diameter).

4. Place the newspaper ball about 13 cm (5 inches) in front of the machine (Figure 19).

   

   Figure 19

5. Start the engine.

6. Engage the blade.

7. Release the blade-control bar.

8. Immediately push the machine over the newspaper ball.

9. Stop the engine and wait for all moving parts to stop.

10. Go to the front of the machine and check the newspaper ball.

    Note: If the newspaper ball did not go under the machine, repeat steps 4 through 10.

    Note: If the newspaper is unravelled or shredded, the blade did not stop properly, which could result in an unsafe operating condition. Contact an Authorized Service Dealer.

1. Stop the engine and wait for all moving parts to stop.

2. Raise and hold up the rear door (Figure 21).

   

   Figure 21

   1. Rear door
   2. Bag-rod end (2)
   3. Notch (2)

3. Remove the rear-discharge plug by pushing in the latch with your thumb and pulling the plug out from the machine (Figure 20).

4. Install the bag-rod ends into the notches at the base of the handle, and rock the bag back and forth to ensure that the bag-rod ends are seated at the bottom of both notches (Figure 21).

5. Lower the rear door until it rests on the grass bag.

1. Stop the engine and wait for all moving parts to stop.

2. Raise the rear door.

3. Remove the bag rod on the grass bag from the notches at the base of the handle (Figure 21).

4. Install the discharge plug; refer to Recycling the Clippings.

5. Lower the rear door.

• Review the safety instructions and read this manual carefully before operating the machine.

• Clear the area of sticks, stones, wire, branches, and other debris that the blade could hit and throw.

• Keep everyone, especially children and pets, away from the area of operation.

• Avoid striking trees, walls, curbs, or other solid objects. Never deliberately mow over any object.

• If the machine strikes an object or starts to vibrate, immediately stop the engine, disconnect the wire from the spark plug, and examine the machine for damage.

• Maintain a sharp blade throughout the cutting season. Periodically file down nicks on the blade.

• Replace the blade when necessary with an original Toro replacement blade.

• Mow only dry grass or leaves. Wet grass and leaves tend to clump on the yard and can cause the machine to plug or the engine to stall.

  Warning

  Wet grass or leaves can cause serious injury if you slip and contact the blade.

  Mow only in dry conditions.

• Clean under the machine after each mowing; refer to Cleaning under the Machine.

• Keep the engine in good running condition.

• Clean the air filter frequently. Mulching stirs up more clippings and dust which clogs the air filter and reduces engine performance.

• Set the engine speed to the fastest position for the best cutting results.

  Warning

  Operating a machine with its engine running at a speed greater than the factory setting can cause the machine to throw a part of the blade or engine at you or bystanders, resulting in serious personal injury or death.

  • Do not change the engine speed setting.

  • If you suspect the engine speed is faster than normal, contact an Authorized Service Dealer.

• Grass grows at different rates at different times of the year. In the summer heat, it is best to cut grass at the 64 mm (2-1/2 inch), 76 mm (3 inch), or 89 mm (3-1/2 inch) cutting-height settings. Cut only about a third of the grass blade at a time. Do not cut below the 64 mm (2-1/2 inch) setting unless the grass is sparse or it is late fall when grass growth begins to slow down.

• When cutting grass over 15 cm (6 inches) tall, first mow at the highest cutting height setting and walk slower; then mow again at a lower setting for the best lawn appearance. If the grass is too long and the leaves clump on top of the lawn, the machine may plug and cause the engine to stall.

• Alternate the mowing direction. This helps disperse the clippings over the lawn for even fertilization.

If the finished lawn appearance is unsatisfactory, try 1 or more of the following:

• Sharpen the blade.

• Walk at a slower pace while mowing.

• Raise the cutting height on your machine.

• Cut the grass more frequently.

• Overlap cutting swaths instead of cutting a full swath with each pass.

• Set the cutting height on the front wheels a notch lower than the rear wheels. For example, set the front wheels at 64 mm (2-1/2 inches) and the rear wheels at 76 mm (3 inches).

• After cutting the lawn, ensure that half of the lawn shows through the cut leaf cover. You may need to make more than a single pass over the leaves.

• For light leaf coverage, set all the wheels at the same cutting height setting.

• If there are more than 13 cm (5 inches) of leaves on the lawn, set the front cutting height 1 or 2 notches higher than the rear cutting height. This makes it easier to feed the leaves under the machine.

• Slow down your mowing speed if the machine does not cut the leaves finely enough.

Important: Do not operate the engine without the air filter assembly in place; otherwise, extreme engine damage will occur.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove the 2 nuts that secure the cover (Figure 22).

4. Remove the cover.

   Note: Be careful to prevent dirt and debris from falling into the base of the air cleaner.

5. Remove the foam and paper elements from the base of the air cleaner (Figure 22).

6. Remove the foam element from the paper element (Figure 22).

   

   Figure 22

   1. Nut (2)
   2. Cover
   3. Paper element
   4. Foam element
   5. Base

7. Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty.

8. If the paper element is excessively dirty, replace it.

   Note: Never try to brush dirt off the paper element; brushing forces the dirt into the fibers.

9. Clean the foam element in warm, soapy water or in a nonflammable solvent.

   Note: Do not use gasoline to clean the foam element because it could create a risk of fire or explosion.

10. Rinse and dry the foam element thoroughly.

11. Dip the foam element in clean engine oil, then squeeze out the excess oil.

    Note: Excess oil in the foam element restricts the air flow through the element and may reach the paper filter and clog it.

12. Wipe dirt from both the base and the cover of the air cleaner with a moist rag.

    Note: Be careful to prevent dirt and debris from entering the air duct leading to the carburetor.

13. Install the air cleaner elements and ensure that they are properly in place.

14. Securely install the cover with the 2 nuts that you removed in step 3.

1. Run the engine to warm the engine oil.

   Note: Warm oil flows better and carries more contaminants.

   Warning

   Oil may be hot after engine has been run, and contact with hot oil can cause severe personal injury.

   Avoid contacting the hot engine oil when you drain it.

2. Stop the engine and wait for all moving parts to stop.

3. Disconnect the wire from the spark plug.

4. Close the fuel valve by moving the fuel-valve lever to the left (Figure 14).

5. Drain the gasoline from the fuel tank.

6. Place a suitable drain pan under the dipstick/oil drain.

7. Clean around the dipstick.

8. Remove the dipstick by rotating the cap counterclockwise and pulling it out.

9. Tip the machine onto its right side (air filter up) to drain the oil into the drain pan.

10. After draining the oil, return the machine to the operating position.

11. Fill the crankcase to the upper-limit mark on the dipstick with fresh oil; refer to Filling the Crankcase with Oil.

12. Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight.

13. Wipe up any spilled oil.

14. Recycle the used oil according to local codes.

Use an NGK BPR5ES spark plug or equivalent.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Clean around the spark plug.

4. Remove the spark plug from the cylinder head.

   Important: Replace a cracked, fouled, or dirty spark plug. Do not clean the electrodes because grit entering the cylinder can damage the engine.

5. Set the gap on the plug to 0.76 mm (0.030 inch); refer to Figure 23.

   

   Figure 23

   1. Center-electrode insulator
   2. Side electrode
   3. Air gap (not to scale)

6. Carefully install the spark plug by hand (to avoid cross threading) until it is hand tight.

7. Tighten the spark plug to 23 N-m (2.3 kgf-m, 17 ft-lb).

   Important: A loose spark plug can become very hot and can damage the engine; overtightening a spark plug may damage the threads in the cylinder head.

8. Connect the wire to the spark plug.

If the machine is new, does not self-propel, or it tends to creep forward, adjust the drive cable.

1. Move the machine outside and onto a paved surface near a solid wall to safely prevent the machine from moving forward while the engine is running.

2. Position the machine with the front tires against the wall.

   Note: Ensure that the area is well ventilated and clear of debris that could be thrown by the machine.

3. Shift the transmission to third gear.

4. Start the engine; refer to Starting the Engine.

5. Pull the self-propel-drive bar to the handle.

   Note: The wheels should start to turn as the self-propel-drive bar just touches the handle.

6. Shut off the engine.

7. If you must adjust the machine, do the following:

   • If the wheels do not spin when you engage the self-propel-drive bar, the traction belt is too loose. Rotate the wheel-drive-control knob (Figure 24) clockwise 1 turn and repeat steps 4 through 6.

     

     Figure 24

     1. Wheel-drive-control knob

   • If the wheels spin before you fully engage the self-propel-drive bar, the traction belt is too tight. Rotate the wheel-drive-control knob (Figure 24) counterclockwise 1 turn and repeat steps 4 through 6.

8. For a new traction belt, rotate the drive cable adjustment knob clockwise 1 additional turn to allow for the normal stretching of the belt during the break-in period.

   Note: You can skip this step if you are adjusting a used belt.

Always mow with a sharp blade. A sharp blade cuts cleanly and without tearing or shredding the grass blades.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Close the fuel valve by moving the fuel-valve lever to the left (Figure 14).

4. Drain the gasoline from the fuel tank.

5. Tip the machine onto its right side (air cleaner up) as shown in Figure 25.

   

   Figure 25

   1. Blade
   2. Blade nuts
   3. Accelerator

Inspecting the Blade

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Inspect the mower blades for wear or damage.

Carefully examine the blade for sharpness and wear, especially where the flat and the curved parts meet (Figure 26A). Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine. If you notice a slot or wear (Figure 26B and Figure 26C), replace the blade; refer to Removing the Blade.

Figure 26

1. Sail
2. Flat part of the blade
3. Wear
4. Slot formed

Note: For the best performance, install a new blade before the mowing season begins. During the year, file down any small nicks to maintain the cutting edge.

Danger

A worn or damaged blade can break, and a piece of the blade could be thrown in your direction or in the direction of bystanders, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Replace a worn or damaged blade.

Inspecting the Accelerator

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Inspect the accelerator for wear or damage.

Carefully examine the accelerator for excessive wear (Figure 27). Because sand and abrasive material can wear away the metal (especially in the area shown as item 2 in Figure 27), check the accelerator before using the machine. If you notice that a tab on the accelerator has been worn down to a sharp edge or there is a crack, replace the accelerator; refer to Removing the Blade.

Figure 27

1. Accelerator
2. Wear area
3. Tab
4. Crack formed

Warning

A worn or damaged accelerator can break, and a piece of the accelerator could be thrown at you or bystanders, resulting in serious personal injury or death.

• Inspect the accelerator periodically for wear or damage.

• Replace a worn or damaged accelerator.

Sharpening the Blade

Maintenance Service Interval	Maintenance Procedure
Every 50 hours	Sharpen or replace the blade.Maintain it more frequently if the edge dulls quickly in rough or in sandy conditions.

File the top side of the blade to maintain its original cutting angle (Figure 28A) and inner cutting edge radius (Figure 28B). The blade will remain balanced if you remove the same amount of material from both cutting edges.

Figure 28

1. Sharpen the blade at this angle only.
2. Maintain the original radius here.

The blade-brake cable is adjusted at the factory; you do not need to adjust it unless you are replacing the cable or the blade-brake belt. If you need to replace the cable, replace both the cable and the belt at the same time.

1. Install a new blade-brake belt and assemble the machine except for the 2 belt covers on the top of the mower housing.

2. Install the new blade-brake cable, but do not tighten the cable clamp on the top of the mower housing (Figure 30).

   

   Figure 30

   1. Spring
   2. Cable clamp and screw

3. Insert a 8 mm (5/16-inch) thick spacer between the blade-brake-control lever and the control bracket on the handle (Figure 31).

   

   Figure 31

   1. Handle
   2. Self-propel-drive bar
   3. Control bracket
   4. Spacer—8 mm (5/16 inch) thick
   5. Blade-brake-control lever

   Important: Replacing the cable without replacing the belt may cause the gap between the blade-brake-control lever and the control bracket to be incorrect. If the gap is less than 8 mm (5/16 inch), the blade brake will not function properly and the blade will not stop within 3 seconds. If the gap is greater than 8 mm (5/16 inch), the belt will not properly drive the blade.

4. Pull the cable tight to remove the slack (but do not stretch the cable spring) and tighten the cable clamp screw to lock the adjustment in place.

5. Remove the spacer.

6. Ensure that there is slack in the cable and a gap between the blade-brake-control lever and the control bracket when the self-propel-drive bar is not engaged.

7. Install the 2 belt covers on the top of the mower housing.

   Important: After installing the new blade-brake belt and blade-brake cable, check that the blade-brake clutch is operating properly and that the blade stops within 3 seconds; refer to Checking the Blade-Brake Clutch.

To ensure the best performance, keep the underside of the machine clean. Be especially careful to keep the kickers free of debris (Figure 32).

Figure 32

1. Kickers

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Remove the belt cover (Figure 34) from the mower housing.

   

   Figure 34

   1. Belt cover

4. Lift off the cover and brush out all the debris around the belt area.

5. Install the belt cover.

6. Connect the wire to the spark plug.

Clean the blade-brake-clutch shield to ensure the best performance and to prevent parts from degrading. Clean the blade-brake-clutch shield when you sharpen the blade, because you need to remove the blade in order to remove the blade-brake-clutch shield.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Close the fuel valve by moving the fuel-valve lever to the left (Figure 14).

4. Drain the gasoline from the fuel tank.

5. Tip the machine onto its right side (air filter up).

   Warning

   Tipping the machine may cause the fuel to leak from the carburetor or the fuel tank. Gasoline is extremely flammable, highly explosive, and, under certain conditions, can cause personal injury or property damage.

   Avoid fuel spills by emptying the fuel tank as directed; never siphon.

6. Remove the 2 blade nuts, the accelerator, and the blade (Figure 35).

   

   Figure 35

   1. Blade
   2. Blade nuts
   3. Accelerator
   4. Screw
   5. Blade-brake-clutch shield

7. Remove the screws that secure the blade-brake-clutch shield to the mower housing (Figure 35).

8. Remove the blade-brake-clutch shield and brush or blow all the debris from under the shield and around the blade-brake-clutch.

9. Tighten the screws to secure the blade-brake-clutch shield to the housing.

10. Install the blade, the accelerator, and the 2 blade nuts.

11. Return the machine to the operating position.