Toro 74178, 74197 Operator's Manual

Form No. 3329-519
Z150 and Z153
Z Master with 52 SFS Side Discharge Mower
Model No. 74178—Serial No. 230006001 and Up Model No. 74197—Serial No. 230006001 and Up
Operator ’s Manual
Domestic English (EN)
Warning
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.
Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Slope Chart 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 8. . . . . . . . . . . . . . . .
Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13. . . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil Level 13. . . . . . . . . . . . . .
Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Wheels 14. . . . . . . . . . . . . . . . .
Checking the Tire Pressure 14. . . . . . . . . . . . . . . . . .
Installing the Seat Retaining Rod 15. . . . . . . . . . . . .
Installing the Motion Control Levers 15. . . . . . . . . .
Activating the Battery 16. . . . . . . . . . . . . . . . . . . . . .
Installing the Air Cleaner Cap 16. . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 17. . . . . . . . . . . . . . .
Greasing the Bearings 17. . . . . . . . . . . . . . . . . . . . . .
Checking the Leveling of the Mower Deck 17. . . . .
Checking the Side Discharge Chute 17. . . . . . . . . . .
2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196
Page
Checking the Engine Oil Level 17. . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 18. . . . . . . . . . . . . . . .
Starting and Stopping the Engine 19. . . . . . . . . . . . .
Operating the Power Take Off (PTO) 20. . . . . . . . . .
The Safety Interlock System 20. . . . . . . . . . . . . . . .
Driving Forward or Backward 21. . . . . . . . . . . . . . .
Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . . .
Adjusting the Height-of-Cut 22. . . . . . . . . . . . . . . . .
Adjusting the Anti-Scalp Rollers 22. . . . . . . . . . . . .
Positioning the Seat 23. . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 23. . . . . . . . . . . . . . .
Operating with Side Discharge 23. . . . . . . . . . . . . . .
Using a Rollover Protection System (ROPS) 23. . . .
Transporting the Machine 24. . . . . . . . . . . . . . . . . . .
Loading Machines 24. . . . . . . . . . . . . . . . . . . . . . . .
Tips for Mowing Grass 25. . . . . . . . . . . . . . . . . . . . .
Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 26. . . . . . . . .
Servicing the Cutting Blades 27. . . . . . . . . . . . . . . .
Servicing the Air Cleaner 29. . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 30. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 31. . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 32. . . . . . . . . . . . . . . . . . .
Draining the Fuel Tank 32. . . . . . . . . . . . . . . . . . . . .
Cleaning the Cooling Systems 33. . . . . . . . . . . . . . .
Greasing and Lubrication 33. . . . . . . . . . . . . . . . . . .
Checking the Tire Pressure 34. . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 34. . . . . . . . . . . . . .
Adjusting the Handle Neutral 36. . . . . . . . . . . . . . . .
Setting the Hydraulic Pump Neutral 38. . . . . . . . . . .
Adjusting the Tracking 39. . . . . . . . . . . . . . . . . . . . .
Adjusting the Caster Pivot Bearing 39. . . . . . . . . . .
Checking the Wheel Hub Slotted Nut 40. . . . . . . . .
Adjusting the Mower Level 40. . . . . . . . . . . . . . . . .
Adjusting the Push Arms 41. . . . . . . . . . . . . . . . . . .
Cleaning Under the Deck 41. . . . . . . . . . . . . . . . . . .
Inspecting the Belts 41. . . . . . . . . . . . . . . . . . . . . . .
Replacing the Deck Belt 41. . . . . . . . . . . . . . . . . . . .
Replacing the Pump Drive Belt 42. . . . . . . . . . . . . .
Adjusting the Parking Brake 43. . . . . . . . . . . . . . . .
Servicing the Fuses 43. . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Battery 44. . . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 46. . . . . . . . . . . . . . .
Waste Disposal 47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Tilt Switch 47. . . . . . . . . . . . . . . . . . . . . . .
Mercury Tilt Switch Disposal 47. . . . . . . . . . . . . . . .
All Rights Reserved
Printed in the USA
2
Page
Wiring Diagram 48. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 49. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .
Introduction
Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.
1
Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.
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.
Safety
This machine meets or exceeds the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.
Note: The addition of attachments made by other
manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.
Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.
m–3648
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space below:
Model No.
Serial No.
This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.
Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.
Safe Operating Practices
The following instructions are from ANSI standard B71.4—1999.
Training
Read the Operator’s Manual and other training material.
If the operator(s) or mechanic(s) can not 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.
3
The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself, other people or property.
Keep hands and feet away from the cutting units.
Never carry passengers and keep pets and bystanders
away.
Preparation
Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.
Wear appropriate clothing including hard hat, safety
glasses and hearing 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.
Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
Use only an approved container
Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling. Do not smoke.
Never refuel or drain the machine indoors.
Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do not operate unless they are functioning properly.
Operation
Never run an engine in an enclosed area.
Only operate in good light, keeping away from holes
and hidden hazards.
Be sure all drives are in neutral and parking brake is
engaged before starting engine. Start the engine only from the operator’s position.
Never raise deck with the blades running.
Never operate without the PTO shield, or other guards
securely in place. Be sure all interlocks are functioning properly.
Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
Do not change the engine governor setting or overspeed
the engine.
Stop on level ground, lower implements, disengage
drives, engage parking brake, shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.
Stop equipment and inspect blades after striking objects
or if an abnormal vibration occurs. Make necessary repairs before resuming operations.
Be alert, slow down and use caution when making
turns. Look behind and to the side before changing directions.
Slow down and use caution when crossing roads and
sidewalks. Stop blades if not mowing.
Be aware of the mower discharge direction and do not
point it at anyone.
Do not operate the mower under the influence of
alcohol or drugs.
Use extreme 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.
Slope Operation
Do not mow slopes greater than 15 degrees.
Do not mow near drop–offs, ditches, steep banks or
water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning.
Do not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding and loss of control.
Do not make sudden turns or rapid speed changes.
Use a walk behind mower and/or a hand trimmer near
drop–offs, ditches, steep banks or water.
Reduce speed and use extreme caution on slopes.
Remove or mark obstacles such as rocks, tree limbs,
etc. from the mowing area. Tall grass can hide obstacles.
Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could overturn the machine.
Avoid sudden starts when mowing uphill because the
mower may tip backwards.
Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering.
Always avoid sudden starting or stopping on a slope. If
tires lose traction, disengage the blades and proceed slowly off the slope.
Follow the manufacturer’s recommendations for wheel
weights or counterweights to improve stability.
4
Use extreme care with grass catchers or other
attachments. These can change the stability of the
machine and cause loss of control.
Using the Rollover Protection System (ROPS)
A rollbar is available and its use is recommended for
areas where there are slopes, drop–offs or water.
When operating a machine with ROPS always use the
seat belt.
Be certain that the seat belt can be released quickly if
the machine is driven or rolls into ponds or water.
Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
Maintenance and storage
Disengage drives, lower implement, set parking brake,
stop engine and remove key or disconnect spark plug
wire. Wait for all movement to stop before adjusting,
cleaning or repairing.
Clean grass and debris from cutting units, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
Let engine cool before storing and do not store near
flame.
Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
Park machine on level ground. Never allow untrained
personnel to service machine.
Use jack stands to support components when required.
Carefully release pressure from components with stored
energy.
Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
Use care when checking blades. Wrap the blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
5
Slope Chart
6
7
Safety and Instruction 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 lost.
1-633818
1–653140
1–653147
1-643401
43-8480
1-523552
54-9220
8
66-1340
67-5360
98-4387
1. Warning—wear hearing protection.
98-5954
93-7818
1. Warning—read the
torquing the blade bolt/nut to 115–149 Nm (85–110 ft–lb).
Operator’s Manual
for instructions on
98-3798
99–3924
9
1. Engine
104-8172
99-3943
104-8569
65–2690
103–0262
1. Explosion hazard
2. No fire, open flames, or smoking.
3. Caustic liquid/chemical burn hazard
104-4163
4. Wear eye protection
5. Read the
6. Keep bystanders a safe
Manual.
Operator’s
distance from the battery.
103–2644
10
106-6586
106-6571
103-1997
11
1. Contains lead; do not discard.
2. Recycle
3. Wear eye protection; explosive gases can cause blindness and other injuries
4. No sparks, flame, or smoking
5. Sulfuric acid can cause blindness or severe burns.
104-4164
6. Flush eyes immediately with water and get medical help fast.
7. Maximum fill line
8. Minimum fill line
9. Instructions for activating the battery
12
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Danger
In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.
Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline that spills.
Never fill the fuel tank inside an enclosed trailer.
Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.
Never smoke when handling gasoline, and stay
away from an open flame or where gasoline fumes may be ignited by a spark.
Store gasoline in an approved container and
keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.
Always place gasoline containers on the ground
away from your vehicle before filling.
Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
When practical, remove gas–powered
equipment from the truck or trailer and refuel the equipment with its wheels on the ground.
If this is not possible, then refuel such
equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.
Do not operate without entire exhaust system in
place and in proper working condition.
Warning
Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness.
Avoid prolonged breathing of vapors.
Keep face away from nozzle and gas tank or
conditioner opening.
Keep gas away from eyes and skin.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide the following benefits:
Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank be drained.
Cleans the engine while it runs
Eliminates gum-like varnish buildup in the fuel system,
which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the
gas. Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the cap.
Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tanks completely full.
3. Install fuel tank caps securely. Wipe up any gasoline
that may have spilled.
Checking the Engine Oil Level
Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 30.
13
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use the chart below to verify that all parts have been shipped.
Description Qty. Use
Rear wheels 2 Installing the wheels to the traction unit Retaining rod
Bolt, 5/16 x 1 in. Locknut, 5/16 in.
Control lever—right Control lever—left Bolt, 3/8 x 1 in. Spring washer, 3/8 in.
Key Operator’s Manual Engine Operator’s Manual Parts Catalog
Registration card 1 Fill out and return to Toro.
Installing the Drive Wheels
1. Uncrate the mower.
2. Remove the wheel bolts or nuts from the rear wheel
hubs.
3. Align the holes. Mount the drive wheels with the valve
stem to the outside of the traction unit.
4. Secure the wheels using the wheel bolts or nuts
provided. Torque to 95 ft–lb (128 N⋅m).
1 1 1
1 1 4 4
2 1 1 1
Installing the seat retaining rod
Installing the motion control levers
Read before operating the machine.
Checking the Tire Pressure
Check the air pressure in the front and rear tires (Fig. 2). Pressure: 13 psi (90 kPa)
1
1. Valve stem
14
m–1872
Figure 2
Installing the Seat Retaining Rod
1. Tilt the seat up. Remove the locknut (5/16 in.) from the
bolt attaching the seat retaining rod to the seat frame (Fig. 3).
2. Remove the retaining rod from the seat and insert the L
shaped end of the rod into the hole directly above the left-side hydraulic pump (Fig. 3).
4. Align the front\rear position of the levers, with each
other, in the neutral position. Loosen the hardware and adjust by sliding/tilting the lever(s) forward or backward until they are properly aligned (Fig. 4).
2
1
3. Place the seat retaining rod to the outside of the
mounting tab of the seat frame and secure it with the bolt (5/16 x 1 in.) and locknut (5/16 in.) (Fig. 3).
4. Tighten until snug, then loosen them so that the rod
pivots freely.
2
3
m–3750
Figure 3
1. L end of retaining rod
2. Locknut, 5/16 in.
3. Bolt, 5/16 x 1 in.
4 5 6
3
m–5596
1
1. Mounting plate
2. Bolt, 3/8 x 1 in.
3. Spring washer, 3/8 in.
Figure 4
4. Top hole
5. Middle hole
6. Bottom hole
5. If the ends of the levers hit against each other while in
the drive position (Fig. 5) (levers rotated in as far as possible), make adjustments by moving the levers outward to the neutral lock position and carefully bend them outward. Move them back to the drive position and check for clearance. Repeat if necessary.
FRONT
OF
UNIT
Installing the Motion Control Levers
There are two positions to install the control levers: high and low. Install the levers in the top and middle holes for the high position. Install the levers in the middle and bottom holes for the low position.
1. Remove the 4 bolts (3/8 x 1 in.) and 4 spring washers
(3/8 in.) which attach the motion control levers to the control arm shafts for shipping (Fig. 4).
2. Place the levers (with the mounting plate toward the
rear) on the outside of the control arm shaft and secure them with 4 bolts (3/8 x 1 in.) and 4 spring washers (3/8 in.) (Fig. 4).
3. Position the lever so that the bolts are in the center of
the slots on the lever mounting plate and tighten until snug.
LEVERS IN
ALIGNMENT
Figure 5
15
Activating the Battery
Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.
Danger
Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.
Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands.
Fill the battery where clean water is always
available for flushing the skin.
Follow all instructions and comply with all
safety messages on the electrolyte container.
Warning
Charging battery produces gasses that can explode and cause serious injury.
Keep cigarettes, sparks and flames away from
battery.
Make sure the ignition switch is off.
Ventilate when charging or using battery in an
enclosed space.
7. Charge the battery; refer to Charging the Battery,
page 46.
8. Install the battery into the machine; refer to Installing
the Battery, page 44.
Note: Do not run the machine with the battery disconnected, electrical damage may occur.
1. Remove the battery from the machine; refer to
Removing the Battery, page 45.
2. Clean the top of the battery with a paper towel. Note: Never fill the battery with electrolyte while the
battery is installed in the machine. Electrolyte could be spilled on other parts and cause corrosion.
3. Remove the vent caps from the battery (Fig. 6).
4. Slowly pour electrolyte into each battery cell until the level is up to the upper line (Fig. 6) on the battery case.
Important Do not overfill the battery because
electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.
5. Wait five to ten minutes after filling the battery cells. Add electrolyte, if necessary, until the electrolyte level is up to the upper line (Fig. 6) on the battery case.
6. Reinstall battery filler caps.
2
Installing the Air Cleaner Cap
1. Locate the air cleaner cap (Fig. 7).
2. Remove the plastic plug from the air intake in the air
cleaner canister (Fig. 7).
3. Place the clamp onto the air cleaner cap (Fig. 7).
4. Slide the clamp and air cleaner cap onto air cleaner
canister (Fig. 7).
5. Tighten the clamp to hold the air cleaner cap (Fig. 7).
3
4
2
1
3
1
1. Filler caps
2. Upper line
Figure 6
3. Lower line
m–5004
1. Air cleaner canister
2. Air intake
16
m–6277
Figure 7
3. Air cleaner cap
4. Clamp
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