FORM NO GB Rev A OPERATOR S MANUAL MODEL NO & UP GREENSMASTER 500

Transcription

1 FORM NO GB Rev A MODEL NO & UP OPERATOR S MANUAL GREENSMASTER 500 The Toro Company 998

2 To assure maximum safety, optimum performance, and to gain knowledge of the product, it is essential that you or any other operator of the mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol: Keep your TORO all TORO. Buy genuine TORO parts and accessories. TABLE OF CONTENTS SAFETY INSTRUCTIONS 3 SPECIFICATIONS 8 The safety alert symbol means CAUTION, WARN- ING or DANGER personal safety instruction. Failure to comply with the instruction may result in personal injury. FOREWORD The GREENSMASTER 500 was developed to satisfy the demand for a maneuverable, intermediate size, turf maintenance rotary mower. The machine has advanced concepts in engineering, design and safety; and if maintained properly, it will give excellent service. BEFORE OPERATING 9 CONTROLS 4 OPERATING INSTRUCTIONS 5 MAINTENANCE 7 PRODUCT IDENTIFICATION 2 Since the GREENSMASTER 500 is a high quality product, Toro is concerned about the future use of the machine and the safety of the user. Read this manual to familiarize yourself with the proper set up, operation, and maintenance instructions. Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety related information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read the directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies general information worthy of special attention. If help concerning set up, operation, maintenance or safety is ever needed, contact a local Authorized Toro Distributor. In addition to genuine Toro replacement parts, the distributor also has optional equipment form the complete line of Toro turf care equipment. Keep your Toro all Toro buy genuine Toro replacement parts and accessories. Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a complete line of accessories and professional turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep your machine operating properly. 2

3 Safety Before Operating. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. 2. Never allow children or people unfamiliar with these instructions to use the machine. Keep everyone, especially children and pets away from the area of operation 3. Become familiar with the controls and know how to stop the machine quickly 4. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine. 5. Always wear substantial shoes. Do not operate the machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing that could get caught in moving parts and cause personal injury. 6. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local safety and insurance regulations. 7. Be sure the work area is clear of objects that might be picked up and thrown by the reel. 8. keep everyone, especially children and pets, away from the areas of operation. 9. Since gasoline is highly flammable, handle it carefully. A. Use an approved gasoline container. B. Do not remove the cap from the fuel tank when the engine is hot or running. C. Do not smoke while handling gasoline. D. Fill the fuel tank outdoors and not over one inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled gasoline. 0. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly.. Always stand behind the handle when starting and operating the machine. 2. Do not touch the engine, muffler or exhaust pip while the engine is running or soon after it is stopped because these areas could be hot enough to cause burns. 3. If you leave the machine unattended, be sure to stop the engine so the cutting reel is not spinning. Maintenance 4. Before servicing or making adjustments to the machine, stop the engine and pull the wire from the spark plug to prevent accidental starting. 5. To reduce potential fire hazard, keep the engine area free of excessive grease, grass, leaves and dirt. 6. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing and any part of the body away from the cutting unit and any moving parts. Keep everyone away. 7. Do not overspeed the engine by changing the governor settings. Maximum engine speed is 3000 rpm. To assure safety and accuracy, have an authorized Toro distributor check engine speed with a tachometer. 8. Shut off the engine before checking or adding oil. 9. Check the performance of the clutch system daily. Do not defeat this system, it is for your own protection. While Operating 3

4 Safety Sound & Vibration Levels Sound Levels This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 82.5 db(a), based on measurements of identical machines per 9/386/EEC. This unit has a sound power level of 94.5 LWA, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments Vibration Levels This unit has a vibration level of 0.05 m/s 2 at the hands/arms, based on measurements of identical machines per ISO 5349 procedures. 4

5 Symbol Glossary Caustic liquids, chemical burns to fingers or hand Poisonous fumes or toxic gases, asphyxiation Electrical shock, electrocution High pressure fluid, injection into body High pressure spray, erosion of flesh High pressure spray, erosion of flesh Crushing of fingers or hand, force applied from above Crushing of toes or foot, force applied from above Crushing of whole body, applied from above Crushing of torso, force applied from side Crushing of fingers or hand/, force applied from side Crushing of leg, force applied from side Crushing of whole body Crushing of head, torso and arms Cutting of fingers or hand Cutting of foot Cutting or entanglement of foot, rotating auger Severing of foot, rotating knives Severing of fingers or hand, impeller blade Wait until all machine components have completely stopped before touching them Severing of fingers or hand, engine fan Whole body entanglement, implement input drive line Fingers or hand entanglement, chain drive Hand & arm entanglement, belt drive Thrown or flying objects, whole flying objects, Thrown or body exposure face exposure Runover/backover, (relevant riding mower Machine tipping, machine to appear in dashed box) Machine rollover, ROPS (relevant machine to appear in dashed box) Stored energy hazard, kickback or upward motion Hot surfaces, burns to fingers or hands Explosion Fire or open flame Secure lifting Stay a safe cylinder with locking distance from device before getting the machine in hazardous area Stay clear of articulation area while engine is running Do not open Do not step on Do not step or remove safety loading platform if shields while PTO is connected to tractor engine is & engine is running running Shut off engine Riding on this & remove key before machine is allowed performing maintenance or repair only on a passen- work ger seat & only if the driver s view is not hindered Consult technical manual for proper service procedures Fasten seat belts Safety alert triangle outline safety alert symbol Read operator s manual 5

6 Safety Eye protection must be worn Head protection must be worn Hearing protection must be worn Caution, toxic risk First aid Flush with water Engine Transmission Fire, open light & smoking prohibited Hydraulic system Brake system Oil Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level Filter Temperature Failure/ Malfunction Start switch/ mechanism On/start Off/stop Engage Disengage Attachment lower Attachment raise Spacing distance Snow thrower, collector auger Plus/increase/ positive polarity Minus/decrease/ negative polarity Horn Battery charging condition Hourmeter/elapsed operating hours Fast Slow Continuous variable, linear Volume empty Volume full Machine travel Control lever direction, operating forward/rearward direction, dual direction Control lever Clockwise operating rotation direction, multiple direction Counter-clockwise rotation Grease lubrication point Oil lubrication point Lift point Jack or support point Draining/ emptying Engine lubricating oil Engine lubricating oil pressure Engine lubricating Engine lubricating Engine oil level oil filter lubricating oil temperature Engine coolant 6

7 Safety Engine failure/ malfunction n/min Engine rotational speed/frequency Choke Primer (start aid) Electrical preheat (low temperature start aid) Transmission oil Transmission oil pressure Transmission oil temperature N H L F R P Transmission Clutch Neutral High Low Forward Reverse Park failure/malfunction 2 3 First gear Second gear Third gear (other #'s Hydraulic oil Hydraulic may be used until the maximum # of forward gears is reached.) oil pressure Hydraulic oil level Hydraulic oil filter Hydraulic oil temperature Hydraulic oil Parking brake Fuel Fuel level Fuel filter Fuel system Diesel fuel failure/malfunction failure/malfunction Unleaded fuel Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off, Reel cutting rotational speed element Reel cutting element, height adjustment Traction Above working temperature range Drilling Manual metal arc Manual welding 0356 Water pump 0626 Keep dry 0430 weight Do not dispose in the garbage CE logo 7

8 Specifications Engine: 3.7 horsepower (2.7 kw) engine with 2.64 quarts (2.5 l) capacity gas tank. Handle: 7/8 in.(22 cm) diameter, 7-gauge welded steel tubing with formed steel reinforcement panel. Traction Unit: Cast aluminum housing. Reel Unit: Cast aluminum and zinc side plates, aluminum extrusion back plate. Reel unit independent of traction unit and catcher. Front Rollers: 2 in. (5 mm) O.D. Steel tube with ball bearings, moisture excluding oil seals and replaceable wear sleeves. Height Of Cut: /8 to /6 in. (3 to 7 mm). (Optional micro-cut bedknife 6mm to 24) Width Of Cut: 2 in. (0.53 m). Clip: 0.97 in. (5.0 mm). Ground Speed: 2. mph (3.4 Km/hr) at 600 RPM and 4.0 mph (6.4 Km/hr.) at 300 RPM. Traction Drive: "A section "V" belt on 2.0 pitch diameter and 3.70 pitch diameter. to countershaft (. 85:) 8T and 48T gear 2.67: and 20T and 56T gear (2. 8:). All gears 6 pitch, 20 involute full depth, /2 in. (3 mm) wide. Gears running in oil. Reel Drive: A section V-belt on 2.0 RD. and 3.70 RD. to countershaft (. 85:) 3/8 in. pitch x 3/6 in. wide chain on 20T and 4T sprockets from countershaft. Reduction Engine to Reel.30:. Reel Clutch: Engaging jaw type hand operated at the transaxle. Reel: 3-/2 in. (89 mm) diameter 9-blade, welded tubular construction. Reel blades, high carbon heat treated steel. Reel bearings, taper roller with adjustment. Bedknife and Bar: Single-edge high carbon steel knife, extra hard for long life, screwed to extruded aluminum one-piece bed bar and back plate. Dimensions: Width: 27 in. (0.69 m) Height: 44-3/4 in. (. m) with handle Length: 60 in. (.5 m) including handle and catcher Weight: 69 kilograms with catcher and cutting unit. Optional Equipment: Cutting Unit Model 0426 Brush Kit Part No Skid Kit, Part No Sectional Roller Kit Part No Urethane Comb Kit Part No Full Roller Kit Part No Micro-cut Bedknife Part No Reduction, Engine to Traction Drum: 3.86:. Traction Drum: 6 in. (5.2 cm) diameter solid rubber on 6 gauge (.5 mm) steel rims. Two sections running on ball bearings. Traction Drive Clutch: Friction Disk type Hand operated latch and bail at handle. Differential: Enclosed spur gears. 8

9 Before Operating CHECK ENGINE OIL BEFORE EACH USE OR EVERY 5 OPER- ATING HOURS Refer to the Engine Operator's Manual for oil requirements.. Position the mower on a level surface. 2. Clean around the oil gauge (Fig. ) then remove it by turning it counterclockwise.. Oil level gauge Figure 3. Wipe it clean and re-insert it, but do not screw it into the port. Then remove it and check the oil check level. Add only enough oil to raise the level to the filler opening. FILL THE FUEL TANK. Clean around fuel tank cap and remove cap from tank (Fig. 2). Fill the fuel tank no higher than to the bottom of the filter screen. DO NOT OVER FILL. 3. Install fuel tank cap and wipe up any spilled gasoline. DANGER Because fuel is flammable, caution must be used when storing or handling it. Do not fill the fuel tank while the engine is running, hot or when the machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill the fuel tank outside and wipe up any spilled fuel before starting the engine. Use a funnel or spout to prevent spilling, and fill the tank no higher than 2.5 cm (one inch) below top of the tank, (bottom of the filler neck). DO NOT OVER FILL. Store fuel in a clean safety approved container and keep the cap on the container. Keep fuel in a cool, well-ventilated place; never in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 30-day supply of gasoline, or a 6-month supply of diesel fuel. Since many children like the smell of gasoline, keep it out of their reach because the fumes are explosive and dangerous to inhale. CHECK TRANSAXLE OIL LEVEL Check the transaxle oil level before initial startup and after every 50 hours of operation.. Place mower on level surface and remove the plug at the rear of the gear case. Oil should be to the bottom of the hole (Fig. 3). 2. If the level is too low, remove the plug in the top cover (Fig. 4) and add SAE 90 gear oil. 3. To drain the transaxle, remove both plugs and tip the unit rearward. Fuel tank cap Figure 2 9

10 Before Operating. Plug Figure 3 Figure 5. Gauge bar 2. Height adjustment screw 3. Nut. Transaxle oil fill plug Figure 4 ADJUSTING HEIGHT OF CUT You can select rollers, skids or bedknives suitable for all types of greens turf grasses. For example, progressively lower heights of cut with the same gauge setting may be obtained by selecting,, in the following order: the skid, full front roller, sectional roller or the Wiehle roller. The micro-cut bedknife provides a height of cut to /6 (2 mm) inch, if desired.. Loosen the nut on the gauge bar and set the adjusting screw to obtain the desired distance between the bottom of the screw head and the face of the bar (Fig. 5). Tighten the nut, making sure adjustment is not altered. 2. Remove the cutting unit; refer to Removal and Installation of the Cutting Unit. 3. Place the cutting unit upside down on a bench, position the gauge bar on the end of the unit with one end on the front support: skid, full roller, sectional roller, etc., the other end on the rear roller (Fig. 9). Figure 6. Gauge bar against rollers 2. Screw head over cutting edge 3. Top nut 4. Adjustment nut 4. Loosen the top nut on the adjusting screws on each side plate (Fig. 6) and turn the nut to raise or lower the front roller or skid assembly. Adjust to make contact with the outer end of the gauge bar. When proper adjustment is obtained, the screw head on the gauge bar will just pass over the cutting edge of the bedknife. ASSURE HEIGHT OF CUT IS EXACTLY IDENTICAL AT BOTH ENDS OF THE BEDKNIFE. 5. Tighten the top nuts to secure roller adjustment (Fig. 6). Turn the cutting unit over and place it on a level surface (Fig. 7). Press down on each end of the front and rear rollers (Fig. 7). Each roller should contact a level surface completely across the unit (Fig. 7). If the rollers do not 0

11 Before Operating contact, repeat steps 3 and 4.. Level surface 2. Press down Figure 7 REEL-TO-BEDKNIFE ADJUSTMENT. Loosen the nuts securing the left and right reel brackets to the side plates (Fig. 8). 2. Adjust reel-to-knife clearance with the adjusting screws at each end of the unit (Fig. 9). NEVER ALLOW THE BEDKNIFE TO BEAR HEAVI- LY AGAINST REEL.. Reel adjusting screw Figure 9 3. Place a newspaper at right angles to the top face of the bedknife against the front cutting edge and rotate the reel blades against the paper. The reel blades should cut the paper cleanly all across the bedknife. If the paper is not cleanly cut, the mower should be either backlapped or resharpened; refer to Backlap Operation and Reel and Bedknife Grinding. 4. Place a strip of newspaper flat on the top face of the bedknife and adjust the reel down until the reel blades pinch the paper equally all across the bedknife. 5. Tighten the nuts to secure the adjustment. ADJUST REAR ROLLER SCRAPER. Nut 2. Reel bracket 3. Side plate Figure 8. Adjust the scraper rod locknuts and brackets to attain.06".0" ( mm) clearance between the scraper rod and the roller surface. The distance between the bottom of the rod and the level surface should be the same height as the height-of-cut setting. 2. Assure scraper rod is parallel to the roller and level surface. Note: Readjust the height of the scraper rod if height-of cut is changed.

12 Before Operating. Scraper rod 2. Bracket Figure 0. Jam nut 2. Ball socket 3. Ball stud Figure CHECK CUTTING UNIT ALIGNMENT 2 The cutting unit must be in alignment with the front yoke roller so that the machine will track in a straight line across the greens. Also, the driveshaft must also be aligned with the transaxle shaft. Alignment procedures:. Loosen the jam nut securing the ball sockets to the pull arms on both sides of the yoke (Fig. ). 5 Figure 2. Spring 2. Sleeve 3. Socket ball joint receiver 4. Retaining ring 4. Ball Stud Slide back the sleeves on each ball joint and rotate each pull arm upward off the ball studs. 3. Align the cutting unit with the roller and driveshaft with the transaxle shaft and lengthen or shorten the pull rods by threading the ball socket on the rod (Fig. ). INSTALL THE GRASS CATCHER. Set the studs on the catcher pivots into the brackets on the yoke and allow the catcher adjusting screw to rest onto the yoke (Fig. 3). 4. Align the ball sockets with the ball studs so the hooded portion of the socket is at the top and the open side is toward the stud (Fig. 2). 5. Slide the sleeve back on the ball joint and rotate the pull arm down so the socket fits over the ball stud. Release the sleeve so it slides forward over the stud and locks the assemblies together. Tighten the jam nuts to secure the sockets in position (Fig. 5) Catcher pivot 2. Yoke bracket 3. Adjusting screw 4. Jam nut Figure 3 2

13 Before Operating 2. Measure the distance between the lip of the catcher and the edge of the cutting unit shield. There should be a clearance between the components of no more than /4 inch (6 mm) (Fig. 4). If not, adjust the catcher. Note: The catcher should be lower in front to assist clipping throw. Adjust the screw to lower the catcher (Fig. 3). Make sure the catcher clears the roller by at least /6 in. (.6 mm). 3. Tighten the jam nuts on each side of the catcher (Fig. 3), making sure the dimension is equal on both sides of the unit. Figure 4. /4 inch (6 mm) maximum 3

14 Controls Throttle Control Lever (Fig. 5) The throttle lever connects to and operates the throttle linkage to the carburetor. It has two positions: SLOW and FAST. Engine speed can be varied between the two settings. 2 2 Figure 7. Engine stop switch 2. Recoil starter Figure 5. Throttle control lever 2. Clutch control bail Clutch Control Bail (Fig. 5) The clutch bail controls traction and cutting unit drive. It has two positions: ENGAGE and DISENGAGE. Choke Lever (Fig. 6) Located at rear of engine. It has two positions: RUN and CHOKE. Move the lever to the CHOKE position when starting a cold engine. After engine start,s move the lever to the RUN position. 2 Engine Stop Switch (Fig. 7) Located at the front of the engine. Rotate to OFF to stop the engine. Recoil Starter (Fig. 7) Pull the recoil starter handle to start the engine. Reel Drive Control (Fig. 8) Located at right side transaxle, has two positions: ENGAGE and DISEN- GAGE. Pull out the knob to engage the reel drive clutch. Push in the knob to disengage. Figure 8. Reel drive control knob Pull out to ENGAGE Figure 6. Fuel shut-off valve lever 2. Choke lever Fuel Shut-off Valve (Fig. 6) Located at the right side of the engine, it has two positions: CLOSED and OPEN. Move the valve lever to the CLOSED position when storing the machine. Open the valve before starting the engine. 4

15 Operation STARTING AND STOPPING INSTRUCTIONS Note: Make sure the wire is installed on the spark plug.. Assure the traction clutch control bail (Fig. 5) and the reel drive knob (Fig. 8) are in the DISENGAGED position. 2. Open the fuel valve at the right side of the engine (Fig. 6). 3. Turn the engine stop switch to ON (Fig. 7) 4. Only if necessary, move the choke lever (Fig. 6) to the CHOKE position before starting a cold engine. Note: A warm or hot engine does not require any choking. To start a warm engine, move the throttle control to the mid throttle position. 5. Stand behind the machine and move the throttle control lever (Fig. 5( to the mid throttle position. Pull the recoil starter handle out until positive engagement results. Pull the handle to start the engine and allow the rope to recoil slowly. If used, open the choke as the engine warms up. IMPORTANT: Do not pull the recoil rope to its limit or let go of the starter handle when the rope is pulled out because the rope may break or the recoil assembly may be damaged. 6. To stop the engine during operation, release the clutch bail to the DISENGAGE position, the throttle control to SLOW (Fig. 5) and turn the ON/OFF switch to OFF (Fig. 7). 7. Pull the wire off the spark plug to prevent the possibility of accidental starting before storing the machine. 8. Close the fuel valve before storing the machine (Fig. 6). TRANSPORT OPERATION. Disengage the clutch bail and start the engine. 2. Disengage the cutting unit drive (Fig. 8). IMPORTANT: Excessive operating of the cutting unit with the absence of any grass clippings (lubricant) can damage the cutting unit. 3. Place the handle assembly in the uppermost notch on the handle adjusting bar. Set the throttle control in SLOW, tip the front of the machine up and slowly increase engine speed while gradually engaging the clutch control bail so the mower moves forward slowly. 4. Adjust the throttle to operate the mower at the desired ground speed and transport the mower to the desired destination. BEFORE MOWING Remove dew and worm casts from turf before mowing by whipping the turf with a bamboo pole or by dragging a hose over the area. Be sure the Greensmaster is carefully adjusted and is set evenly on both sides of the reel. Improper mower adjustment is magnified many times over in the appearance of the clipped turf. A three- to five-foot wide (9 to 52 cm) "collar" should be mowed around the area at a slightly higher cut than the putting green area. This will provide sufficient space for turning the Greensmaster without turning on the green area. METHOD OF MOWING The greens should be mowed in straight back-andforth direction across the green. Avoid circular mowing or turning the mower on greens areas since scuffing may occur. Turning the mower should be done off the green proper by raising the cutting reel (pushing the handle down) and turning on the large rubber-covered traction drums. The greens areas should not be mowed in the same direction at any two successive mowings. Cutting in different directions at each mowing will keep the grass growing in an upright position, preventing grain formation. Mowing should be done at a normal walking pace. Faster speed saves very little time and will result in an inferior mowing job. 5

16 Operating OPERATING CONTROLS To operate the controls for mowing; 2. Empty the grass catcher of clippings, install the grass catcher and begin transport operation; refer to Transport Operation.. Start the engine, push down on the handle to elevate the cutting unit, raise the traction clutch bail the handle and transport the machine onto the collar of the green. 2. Release the traction clutch bail (Fig. 9) to the DISENGAGE position and pull the reel drive control knob on the transaxle out fully to ENGAGE the reel (Fig. 20). Figure 9. Traction clutch control bail Figure 20. Reel drive control knob Pull out to ENGAGE 3. Raise the clutch control bail to the handle, increase the throttle speed until the unit is traveling at the desired ground speed, drive the mower out onto the greens area, drop the front of the mower down and begin mowing. AFTER MOWING. Drive off the green, release the clutch control bail to DISENGAGE, stop the engine and push the reel drive control knob fully in to DISEN- GAGE. 6

17 Maintenance Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Service the air filter foam element Check for loose fasteners Lubricate all grease fittings Every 25 hours Every 50 hours Every 00 hours Every 200 hours Change the engine oil filter Adjust the traction drive belts Clean the fuel filter and bowl Check the transmission oil level Check the spark plug Service the air cleaner filter Clean the combustion chamber Replace the spark plug Adjust valves and torque the head bolts Initial break in at 0 hours Initial break in at 25 hours Adjust the reel drive chain Recommendations: Adjust the reel drive chain annually. DAILY MAINTENANCE CHECKLIST Fuel level Engine oil level Air filter pre-cleaner Clean engine cooling fins Unusual engine noises Unusual operating noises Reel-to-bedknife adjustment Height-of-cut adjustment Lubricate control linkage Lubricate all grease fittings Touch-up damaged paint = Immediately after every washing, regardless of interval listed. 7

18 Maintenance LUBRICATION GREASE FITTINGS The grease fittings on the mower should be greased at least every 25 hours. Lubricate using a No. 2 multi-purpose lithium base grease. A hand operated grease gun is recommended for best results.. Wipe each grease fitting with a clean cloth. GREASING THE TRACTION CLUTCH. At the end of each season s cutting, remove the traction clutch assembly and clean and re-pack the cam and roller assembly with No. 5 multipurpose (wheel) bearing grease (Fig. 22). Take extreme care to make sure that grease is kept off the clutch friction discs (Fig. 22) Apply grease to the points shown in Figure 2. Clutch assembly 2. Clutch friction discs Figure 22. Grease points Figure 2 LINKAGE PIVOT POINTS Oil all pivot points of control linkages weekly with SAE 30 engine oil (Fig. 23, 24). IMPORTANT: Do not apply too much pressure or grease seals will be permanently damaged. 3. Wipe excess grease away.. Oil points Figure 23. Oil points Figure 24 8

19 Maintenance CAUTION Disconnect spark plug wire before performing any of the maintenance procedures on your mower. REMOVAL AND INSTALLATION OF CUTTING UNIT. Remove the catcher and unhook the two chains from the support hooks (Fig. 25) behind the handle. To install the cutting unit:. Slide the cutting unit under the yoke from the right side, line the drive shaft up with the transaxle shaft and install the drive shaft. 2. Install the chains onto the support hooks (Fig. 25). 3. Align the pull arms with the ball studs, slide the sleeves back on the sockets and drop the arm sockets down on the ball studs (Fig. 26). 4. Make sure the cutting unit is aligned with the yoke roller and the drive shaft with the transaxle shaft. If there is misalignment, refer to Check Cutting Unit Alignment. REMOVING THE YOKE ASSEMBLY To remove the yoke: Figure 25. Chains 3. Cotter pin 2. Support hooks 4. Yoke pivot 2. Slide the sleeves back on pull arm ball joints and lift the pull arm sockets straight up off the ball studs (Fig. 26).. Remove the catcher and unhook the chains from the support hooks (Fig. 25). 2. Remove the cotter pin from the yoke pivot and slide the yoke assembly off the pivot (Fig. 25). 3. Reverse the procedure to install the yoke. CHANGING ENGINE OIL. Run the engine to warm the engine oil. 2. Stop engine, place a drain pan under the plug in the crankcase on the handle side of the engine, remove the oil drain plug and allow oil to drain into the drain pan (Fig. 27).. Sleeve 2. Pull arm socket 3. Ball stud Figure Grasp the cutting unit chain case and pull the cutting unit and drive shaft out to the right, away from the traction unit. 3. Install the drain plug; remove the oil fill plug (Fig. 27), assure the engine is level and fill the crankcase with fresh clean oil; refer to the Engine Operator's Manual for oil requirements. Note: Right and left sides are determined from 9

20 Maintenance BACKLAP OPERATION. Oil fill plug 2. Oil drain plug Figure 27 TRACTION DRIVE BELT ADJUSTMENT The belt should be tight enough so the traction wheels will spin on a cement floor when the clutch is engaged with the engine running. The belt should be checked after the first eight hours of operation and tightened if necessary. To adjust the belt:. Remove the belt cover from the left side of the machine (Fig. 28). 2. Loosen the four engine hold-down screws. 3. Slide the engine rearward equally on both sides until the belt is tight. Tighten the mounting fasteners and check adjustment by placing the unit on a cement floor, starting the engine and checking to see if the traction wheels spin when the clutch is engaged. 4. Continue adjustment until tension is correct and install the belt guard (Fig. 28). 2 2 Backlap when the reel blades and bedknife edge are slightly rounded and do not cut the grass cleanly with a light reel-to-bedknife adjustment. Also backlap after a reel and bedknife have been reground to assure a perfect match between reel and bedknife cutting edge. Backlapping will not correct nicked or severely rounded reel blades or uneven bedknife wear. Correct these conditions by repairing, replacing or re-grinding the components.. Using a fine-tooth file, remove high spots from the reel blades. If a blade is bent, straighten it by placing a hammer on one side of the blade and tapping on the opposite side. 2. Make the reel-to-bedknife adjustment to obtain a light contact; refer to Reel to Bedknife Adjustment. 3. Connect a lapping machine to the cutting unit with an extension coupler and socket. 4. Use a good grade of medium grit (80) commercial lapping compound with a water soluble carrier to assure the compound will be easily washed away after the backlapping operation. Dry lapping compound should be mixed with liquid detergent until the material is free flowing. Note: Paste-type, pre-mixed lapping compound is also sold in some areas. This is generally used in its original composition and therefore is not free flowing. 5. Operate the lapping machine so the reel turns in a reverse direction for about three minutes; apply the lapping solution continuously with a paintbrush across the full width of the reel. 6. Again,, lightly adjust the bedknife and reel. Then, lap for approximately two additional minutes. Apply lapping solution continuously. Figure 28. Cover 2. Engine mounting fastener Wash off all lapping solution. 7. Using newspaper, check for sharpness along the entire length of each reel blade. If the newspaper cannot be cut cleanly along the entire length of each blade, grinding or re-grinding is neces- 20

21 Maintenance sary; refer to Reel and Bedknife Grinding. Note: For a better cutting edge, run a file across the front face of the bedknife when the lapping operation is completed. This will remove any burr or rough edge that may have built up on the cutting edge. REEL AND BEDKNIFE GRINDING Refer to the TORO GUIDE TO REEL AND ROTARY MOWER SHARPENING. Copies are available from your local TORO distributor. CLEANING THE MOWER Wash the cutting unit, transaxle, and grass catcher after each day's use. Chemicals in the turf may cause premature deterioration to certain components if not washed daily. IMPORTANT. Do not direct "high-pressure" water at oil seals, bearings, electrical connectors/switches, hot engine, etc.; contamination of these parts could cause premature wear. STORAGE CAUTION Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury.. Drain gasoline from the fuel tank. Start the engine and let it run at slow speed until it stops because all the gasoline is used. 2. Drain the oil from the crankcase: refer to the Engine Operator's Manual. However, do not fill the crankcase with oil at this time. 3. Remove grass clippings, dirt and grime from the external parts of the mower housing and engine. Also clean the engine cooling system. 4. Clean carbon from the internal parts of the engine and re-assemble the engine. 5. Pull the wire off the spark plug and clean around the plug so dirt cannot fall into the cylinder when the plug is removed. Remove the plug from the cylinder head and pour two tablespoons (25 ml) of engine oil into the spark plug hole. Pull the recoil starter handle slowly to distribute oil on the inside of the cylinder. Reinstall the spark plug. If a torque wrench is not used, tighten the plug firmly. DO NOT INSTALL THE WIRE ON THE SPARK PLUG. 6. Remove the belt cover over the left side of the machine. Inspect the belt for excessive wear or damage., Repair or replace as necessary. Assure the belt is in the disengaged position. 7. Check the condition of the reel blades and bedknife and repair and sharpen them as necessary; refer to Reel And Bedknife Grinding. 8. Lubricate the mower: refer to Lubrication. 9. Clean the air cleaner. 0. Check and tighten all capscrews, screws, bolts, nuts and mating parts, If any part is damaged, repair or replace it.. "Touch up" all rusted or chipped paint surfaces. Make sure to sand affected area before painting. Note: TORO Re-Kote "touch-up" paint is available from an authorized Toro service dealer or distributor. The spray paint dries in minutes to a glossy, factoryfinish. 2. Fill the crankcase with oil: refer to Engine Operator's Manual. 3. Store the mower in a clean, dry place. Cover the mower to protect it and keep it clean. IDENTIFICATION AND ORDERING The mower has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate located at the rear of the transaxle case. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained. 2

22 Maintenance To order replacement parts from an authorized TORO distributor, supply the following information:. Model and serial number of the mower. 2. Part number, description and quantity of part(s) desired. Note: Do not order by reference number if a parts catalog is being used; use the PART NUMBER. 22

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