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This engine conversion kit is only for machines with
following model and serial numbers:
Model Number
04034
04035
04036
04037
04038
04039
04052
04054
04055
04056
04060
Light kit, model 04063 (fixed-head traction units) is
compatible with this kit.
Note:
Older light kits are not compatible with this kit.
Introduction
It is a violation of California Public Resource Code
Section 4442 or 4443 to use or operate the engine on
any forest-covered, brush-covered, or grass-covered
land unless the engine is equipped with a spark
arrester, as defined in Section 4442, maintained in
effective working order or the engine is constructed,
equipped, and maintained for the prevention of fire.
If you require a spark arrester, contact your Authorized
Service Dealer.
Important:
These installation instructions
contain engine operation and maintenance
information that supersedes the engine operation
and maintenance procedures in your machine
Operator's Manual.
Before operating or maintaining the machine or
engine, always refer to the safety instructions in
your Operator's Manual.
Save these instructions.
© 2020-The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
CV
Engine Conversion Kit
Subaru and Kawasaki Powered Walk-Behind Greensmaster
Mower
Model No. 139-5638
Serial Number
310000001 through 311999999
310000001 through 311999999
311000001 through 311999999
310000001 through 311999999
313000001 through 314999999
313000001 through 314999999
310000001 through 311999999
312000001 through 314999999
312000001 through 314999999
312000001 through 314999999
310000001 through 311999999
Register at www.Toro.com.
Important:
The engine warranty is provided
by the engine manufacturer. Please refer to the
engine manufacturer's warranty and emissions
system warranty included in the literature packet.
That warranty applies only to the engine. It does
not expand or otherwise alter any express or
implied warranty terms or warranty period that
may apply to the product into which the engine
is installed.
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Contents
Introduction ............................................................... 1
Safety ....................................................................... 2
Safety and Instructional Decals .......................... 2
Installation ................................................................ 3
1 Preparing the Machine..................................... 3
2 Removing the Existing Engine ......................... 3
3 Installing the New Engine................................. 3
4 Lubricating and Adjusting the Machine ............. 9
Product Overview ..................................................... 9
Controls ............................................................. 9
Operation ................................................................ 10
Fuel Specifications ........................................... 10
Using Stabilizer/Conditioner ............................. 10
Filling the Fuel Tank .......................................... 10
Valve ..............................................................11
Maintenance ........................................................... 12
Recommended Maintenance Schedule(s) ........... 12
Preparing the Machine for Maintenance............ 12
Servicing the Engine Oil.................................... 13
Servicing the Air Cleaner .................................. 14
Servicing the Spark Plug................................... 15
All Rights Reserved *3440-998* A
Original Instructions (EN)
Printed in the USA
Form No. 3440-998 Rev A
®
1000
Installation Instructions
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Table of Contents
Related Manuals for Toro 139-5638
Summary of Contents for Toro 139-5638
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Page 1: Table Of Contents
Form No. 3440-998 Rev A Engine Conversion Kit Subaru and Kawasaki Powered Walk-Behind Greensmaster ® 1000 Mower Model No. 139-5638 Installation Instructions Important: This engine conversion kit is only for machines with The engine warranty is provided following model and serial numbers: by the engine manufacturer. -
Page 2: Safety
Safety Safety and Instructional Decals 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. decal130-8322 130-8322 1. Use only fuel with an 3. -
Page 3: Installation
Installation Disconnect the clutch cable from the clutch assembly on the engine and the console. Note: Discard the clutch cable. Remove the old engine. Retain the engine-mounting bolts and nuts. Preparing the Machine Remove the engine-mounting bracket and retain the engine-mounting bracket and bolts. Clean the frame and check for damage or wear. -
Page 4: Installing The New Engine
Throttle lever Proximity switch Flange bushing Traction pivot Installing the New Engine Locknut Flat washer (0.28 x 5/8 inch) Parts needed for this procedure: Bolt (1/4 x 7/8 inch) Engine Nut (1/4 inch) Wire harness plate Bolt (5/16 x 1-1/2 inch) Wire harness Flat washer (0.31 x 0.73 inch) Clutch-cable bracket... - Page 5 Install the idler pulley assembly to the clutch lever with a belt guide and a hex nut (Figure Installing the Wire Harness and Cables Attach the wire-harness bracket to the fuel tank using the 2 existing flange nuts that secure the tank to the engine.
- Page 6 For model year 2012 to 2014: Install the For model year 2008 to 2011: Install the previously removed engine-mounting bracket to engine-mounting bracket supplied with this kit to the machine with the previously-removed bolts the machine with the previously-removed bolts and 4 washers (3/8 x 1-1/8 inch) as shown in and 4 washers (3/8 x 1-1/8 inch) as shown in Figure...
- Page 7 Install the clutch cable to the clutch plate (Figure g312403 Figure 6 1. Clutch plate 3. Clutch-cable spring end 2. Clutch cable 4. Clutch lever Remove and retain the console cover and corresponding hardware. Install the traction bracket onto the handle using g313744 the previously removed hardware (Figure...
- Page 8 Install the previously removed console cover and corresponding hardware. For model year 2012 to 2014: Remove the rear left bolt from the engine base (Figure 4) and use the bolt to secure the R-clamp and throttle cable g327886 Figure 8 to the engine base.
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Page 9: Lubricating And Adjusting The Machine
Product Overview Lubricating and Adjusting the Machine No Parts Required Procedure Important: The engine gearbox does not require maintenance, as it is filled with a high-performance, long-life, synthetic semi-fluid grease. g265059 Figure 11 Adjust the clutch cable; refer to your Operator’s 1. -
Page 10: Operation
Filling the Fuel Tank Operation DANGER Fuel Specifications In certain conditions, fuel is extremely Fuel tank capacity: 2.0 L (0.59 US gallons) flammable and highly explosive. A fire or explosion from fuel can burn you and others Recommended fuel: Unleaded gasoline with an and can damage property. -
Page 11: Opening And Closing The Fuel-Shutoff Valve
Opening and Closing the WARNING Fuel-Shutoff Valve Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause Control fuel flow to the engine with the fuel-shutoff serious injury and illness. valve as follows: • Avoid prolonged breathing of vapors. •... -
Page 12: Maintenance
Maintenance Important: Refer to your engine owner’s manual for additional maintenance procedures. Important: The engine gearbox (Figure 14) does not require maintenance, as it is filled with a high-performance, long-life synthetic semi-fluid grease. g312416 Figure 14 1. Gearbox Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval... -
Page 13: Servicing The Engine Oil
for the day. If you have already ran the engine, allow the oil to drain back down to the sump for at least 10 minutes before you check the engine-oil level. Shut off the engine and wait for all moving parts to stop;... -
Page 14: Servicing The Air Cleaner
Ensure that the oil is at the correct level on the dipstick; refer to Checking the Engine-Oil Level (page 13). Replace and secure the dipstick. Wipe up any spilled oil. Connect the wire to the spark plug. Servicing the Air Cleaner Service Interval: Before each use or daily Every 50 hours Every 300 hours/Yearly (whichever comes first) -
Page 15: Servicing The Spark Plug
Servicing the Spark Plug Service Interval: Every 100 hours Every 300 hours Use an NGK BPR6ES spark plug or equivalent. Shut off the engine and wait for all moving parts to stop; refer to Preparing the Machine for Maintenance (page 12). - Page 16 While the exposure from Toro products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.