53cm Heavy-Duty 60V Recycler®/Rear Bagger Lawn Mower

The safety-alert symbol (Figure 2) shown in this manual and on the machine identifies important safety messages that you must follow to prevent accidents.

Figure 2

Safety-alert symbol

The safety-alert symbol appears above information that alerts you to unsafe actions or situations and is followed by the word DANGER, WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) tool.

1. Work area safety

   1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.

   2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gasses or dust. Power tools create sparks which may ignite the dust or fumes.

   3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2. Electrical safety

   1. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

   2. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

   3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

   4. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

   5. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

   6. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

3. Personal safety

   1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

   2. Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or, or hearing protection used for appropriate conditions will reduce personal injuries.

   3. Prevent unintentional starting. Ensure the switch is in the OFF position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

   4. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

   5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

   6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

   7. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

   8. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

4. Power tool use and care

   1. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

   2. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

   3. Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventative safety measures reduce the risk of starting the power tool accidentally.

   4. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

   5. Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

   6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

   7. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

   8. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

5. Battery tool use and care

   1. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.

   2. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.

   3. When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.

   4. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.

   5. Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.

   6. Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire temperature above 130°C (265°F) may cause an explosion.

   7. Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

6. Service

   1. Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

   2. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

• Do not operate the lawn mower in rain or wet conditions. This may increase the risk of electric shock.

• Do not use the lawn mower in bad weather conditions, especially when there is a risk of lightning. This decreases the risk of being struck by lightning.

• Thoroughly inspect the area for wildlife where the lawn mower is to be used. Wildlife may be injured by the lawn mower during operation.

• Thoroughly inspect the area where the lawn mower is to be used and remove all stones, sticks, wires, bones, and other foreign objects. Thrown objects can cause personal injury.

• Before using the lawn mower, always visually inspect to see that the blade and the blade assembly are not worn or damaged. Worn or damaged parts increase the risk of injury.

• Check the grass catcher frequently for wear or deterioration. A worn or damaged grass collector may increase the risk of personal injury.

• Keep guards in place. Guards must be in working order and be properly mounted. A guard that is loose, damaged, or is not functioning correctly may result in personal injury.

• Keep all cooling air inlets clear of debris. Blocked air inlets and debris may result in overheating or risk of fire.

• While operating the lawn mower, always wear non-slip and protective footwear. Do not operate the lawn mower when barefoot or wearing open sandals. This reduces the chance of injury to the feet from contact with the moving blade.

• While operating the lawn mower, always wear long trousers. Exposed skin increases the likelihood of injury from thrown objects.

• Do not operate the lawn mower in wet grass. Walk, never run. This reduces the risk of slipping and falling which may result in personal injury.

• Do not operate the lawn mower on excessively steep slopes. This reduces the risk of loss of control, slipping and falling which may result in personal injury.

• When working on slopes, always be sure of your footing, always work across the face of slopes, never up or down and exercise extreme caution when changing direction. This reduces the risk of loss of control, slipping and falling which may result in personal injury.

• Use extreme caution when reversing or pulling the lawn mower towards you. Always be aware of your surroundings. This reduces the risk of tripping during operation.

• Do not touch blades and other hazardous moving parts while they are still in motion. This reduces the risk of injury from moving parts.

• When clearing jammed material or cleaning the lawn mower, make sure all power switches are off and the battery pack is disconnected. Unexpected operation of the lawn mower may result in serious personal injury.

1. Training

   • The operator of the machine is responsible for any accidents or hazards occurring to others or their property.

   • Do not allow children to use or play with the machine, battery pack, or the battery charger; local regulations may restrict the age of the operator.

   • Do not allow people with reduced physical, sensory, or mental capabilities or without experience and knowledge to use the machine, battery pack, or battery charger unless they receive instruction or supervision on using it safely and understand the hazards involved while using it.

   • Before using the battery pack and battery charger, read all the instructions and cautionary markings on these products.

2. Preparation

   • Replace any damaged or unreadable labels.

   • Use only the battery pack specified by Toro. Using other accessories and attachments may increase the risk of injury and fire.

   • Plugging the battery charger into an outlet that is not of the proper voltage can cause a fire or electric shock. For a different style of connection, use an attachment plug adapter of the proper configuration for the power outlet if needed.

   • Do not use a damaged or modified battery pack or battery charger, which may exhibit unpredictable behavior that results in fire, explosion, or risk of injury.

   • If the supply cord to the battery charger is damaged, contact an Authorized Service Dealer to replace it.

   • Do not use non-rechargeable batteries.

   • Charge the battery pack with only the battery charger specified by Toro. A charger suitable for one type of battery pack may create a risk of fire when used with another battery pack.

   • Charge the battery pack in a well-ventilated area only.

   • Do not expose a battery pack or battery charger to fire or to temperatures higher than 68°C (154°F).

   • Follow all charging instructions and do not charge the battery pack outside of the temperature range specified in the instructions. Otherwise, you may damage the battery pack and increase the risk of fire.

3. Operation

   • Keep clear of any discharge opening.

   • Disengage the self-propel drive (if equipped) before starting the machine.

   • Prevent unintentional starting—Ensure that the electric-start button is removed from the ignition before connecting the battery pack and handling the machine.

   • Stop the machine, remove the electric-start button, remove the battery pack from the machine, and wait for all movement to stop before servicing or cleaning the machine.

   • Remove the battery pack and electric-start button from the machine whenever you leave it unattended or before changing accessories.

   • Do not direct the discharge material toward anyone. Avoid discharging material against a wall or obstruction; material may ricochet toward you. Stop the blade(s) when crossing gravel surfaces.

   • Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could cause you to lose your balance or footing.

   • If the machine strikes an object or starts to vibrate, immediately shut off the machine, remove the electric-start button, remove the battery pack, and wait for all movement to stop before examining the machine for damage. Make all necessary repairs before resuming operation.

   • Stop the machine and remove the electric-start button before loading the machine for hauling.

   • Under abusive conditions, the battery pack may eject liquid; avoid contact. If you accidently come into contact with the liquid, flush with water. If the liquid contacts your eyes, seek medical help. Liquid ejected from the battery pack may cause irritation or burns.

4. Maintenance and Storage

   • Stop the machine, remove the electric-start button, remove the battery pack from the machine, and wait for all movement to stop before servicing or cleaning the machine.

   • Do not attempt to repair the machine except as indicated in the instructions. Have an Authorized Service Dealer perform service on the machine using identical replacement parts.

   • Sharpen a dull blade on both sides to maintain balance. Clean the blade and ensure that it is balanced.

   • When servicing the blade, be aware that the blade can still move even though the power source is off.

   • For best performance, use only genuine Toro replacement parts and accessories. Other replacement parts and accessories could be dangerous, and such use could void the product warranty.

   • Maintain the machine—Keep cutting edges sharp and clean for the best and safest performance. Keep handles dry, clean, and free from oil and grease. Keep guards in place and in working order. Keep blades sharp. Use identical replacement blades only.

   • Unless indicated in the instructions, have an Authorized Service Dealer repair or replace a damaged guard or part.

   • When the battery pack is not in use, keep it away from metal objects such as paper clips, coins, keys, nails, and screws that can make a connection from one terminal to another. Shorting the battery terminals may cause burns or a fire.

   • Check the blade and motor mounting bolts frequently for tightness.

   • CAUTION—A mistreated battery pack may present a risk of fire or chemical burn. Do not disassemble the battery pack. Do not heat the battery pack above 68°C (154°F) or incinerate it. Replace the battery pack with a genuine Toro battery pack only; using another type of battery pack may cause a fire or explosion. Keep battery packs out of the reach of children and in the original packaging until you are ready to use them.

   • Do not dispose of the battery in a fire. The cell may explode. Check with local codes for possible special disposal instructions.

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.

112-8760

1. Thrown object hazard—keep bystanders away.
2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.

131-0822

1. Self-propel drive—Attention; premature wear of the transmission may occur if the belt is over-tightened; before servicing or performing maintenance, read the Operator's Manual.

137-9461

1. Battery charge status

140-8492

1. Keep away from open fire or flames.
2. Do not expose to rain.
3. Read the Operator’s Manual.
4. Recycle the battery properly.
5. Contains lithium ions; do not dispose improperly.

145-3129

1. The battery pack is charging.
2. The battery pack is fully charged.
3. The battery pack is over or under the appropriate temperature range.
4. Battery pack charging fault

134-4691

1. Auto speed
2. Max speed

Model 81875

137-9490

1. Read the Operator’s Manual.
2. Recycle
3. Contains lithium ions; do not discard.
4. Keep away from open flames.
5. Do not expose to rain.

137-9461

1. Battery charge status

161-3784

1. The battery pack is charging.
2. The battery pack is fully charged.
3. The battery pack is over or under the appropriate temperature range.
4. Battery pack charging fault

161-3764

1. Battery charge status

161-3763

1. Battery charge status

145-8299

1. Read the Operator’s Manual .
2. High Energy Battery recycling program
3. Recycle the battery
4. Do not dispose improperly
5. Keep away from open fire or flames
6. Do not expose to rain
7. Electrical shock hazard

161-3783

1. Do not dispose improperly
2. Read the Operator’s Manual.
3. For indoor use
4. Double insulated

144-3175

1. Read the Operator’s Manual.
2. To start the machine, squeeze the bar to the handle and press the button.
3. To shut off the machine, release the bar.

116-7583

1. Warning—read the Operator’s Manual; do not operate this machine unless you are trained.
2. Thrown object hazard—keep bystanders away.
3. Thrown object hazard—do not operate the mower without the rear discharge plug or bag in place.
4. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards in place.
5. Warning—wear hearing protection.
6. Cutting/dismemberment hazard of hand or foot, mower blade—do not operate up and down slopes; operate side to side on slopes; shut off the engine before leaving the machine; pick up any debris before mowing; look behind you when moving in reverse.

Model 81805

137-9496

1. The battery pack is charging.
2. The battery pack is fully charged.
3. The battery pack is over or under the appropriate temperature range.
4. Battery pack charging fault

144-6035

1. Do not dispose improperly
2. Read the Operator’s Manual.
3. For indoor use
4. Double insulated

161-3755

1. Read the Operator’s Manual .
2. High Energy Battery recycling program
3. Recycle the battery
4. Do not dispose improperly
5. Keep away from open fire or flames
6. Do not expose to rain
7. Electrical shock hazard

Parts needed for this procedure:

If desired, mount the battery charger securely on a wall using the wall-mount key holes on the back of the charger.

Mount it indoors (such as a garage or other dry place), near a power outlet, and out of the reach of children.

Refer to Figure 3 for assistance in mounting the charger.

Slide the charger over the appropriately positioned hardware to secure the charger in place (hardware not included).

Figure 3

Parts needed for this procedure:

Assemble the lower handle as shown in Figure 5.

Figure 5

1. Flange locknut (5/16 inch)
2. Curved washer
3. Upper handle assembly
4. Lower handle
5. Bolt (5/16 x 1-3/4 inches)

A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories.

To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous.

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 motor is turned on.

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. Start the motor; refer to Starting the Machine.

4. 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.

5. Shut off the motor.

6. 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 22) clockwise 1 turn and repeat steps 3 through 5.

     

     Figure 22

     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 22) counterclockwise 1 turn and repeat steps 3 through 5.

7. 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. Shut off the machine and wait for all moving parts to stop.

2. Remove the battery pack; refer to Removing the Battery Pack from the Machine.

3. Tip the machine onto its side as shown in Figure 23.

   

   Figure 23

   1. Blade
   2. Accelerator
   3. Blade bolt and lock washer

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 24A). 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 24B and Figure 24C), replace the blade; refer to Removing the Blade.

Figure 24

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 toward you or 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 25). Because sand and abrasive material can wear away the metal (especially in the area shown as item 2 in Figure 25), 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.

Figure 25

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 26A) and inner cutting edge radius (Figure 26B). The blade will remain balanced if you remove the same amount of material from both cutting edges.

Figure 26

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

1. Remove the rear wheels and clean any debris from the wheel-gear area.

   

   Figure 28

   1. Gears

2. After cleaning, apply a small amount of anti-seize compound to the gears.

Note: If you operate the machine in extreme conditions, cleaning the wheels more frequently than recommended will increase gear life.

Note: To prevent damage to the bearing seals, do not use a high-pressure water spray on the bearings.

Important: Upon removal, cover the terminals of the battery pack with heavy-duty adhesive tape. Do not attempt to destroy or disassemble the battery pack or remove any of its components.

Contact your local municipality or your authorized Toro distributor for more information on how to responsibly recycle the battery.