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Toro Liquefied Petroleum Gas (LPG) Remanufacture Kit - Non-retailed Units for EPA Compliance Installation guide

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FormNo.3375-820RevA
LiqueedPetroleumGas(LPG)RemanufactureKit
-Non-retailedUnitsforEPACompliance
ModelNo.125-5518
InstallationInstructions
Safety
ThisSafetyAlertSymbol(Figure1)isusedinthisinstruction
sheetandonthemachinetoidentifyimportantsafety
messageswhichmustbefollowedtoavoidaccidents.
Thissymbolmeans:ATTENTION!BECOMEALERT!
YOURSAFETYISINVOLVED!
Figure1
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformationwhich
alertsyoutounsafeactionsorsituationsandwillbefollowed
bythewordDANGER,WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.Indicatesan
imminentlyhazardoussituationwhich,ifnotavoided,Will
resultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.Indicates
apotentiallyhazardoussituationwhich,ifnotavoided,Could
resultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.Indicates
apotentiallyhazardoussituationwhich,ifnotavoided,May
resultinminorormoderateinjury.
Thisinstructionsheetusestwootherwordstohighlight
information.Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
Description
Qty.
Use
Hose-LPG(5/8x22)
1
Elbow-90x5/8inch
1
Asm-Regulator1
Clamp-Hose
2
Label–LPGEmissions
2
Sheet-OnyxEmissionControlWarranty
Statement
1
RemanufactureInstructions
WARNING
Whilemaintenanceoradjustmentsarebeingmade,
someonecouldstarttheengine.Accidentalstarting
oftheenginecouldseriouslyinjureyouorother
bystanders.
Removethekeyfromtheignitionswitch,engage
parkingbrake,andpullthewire(s)offthespark
plug(s)beforeyoudoanymaintenance.Alsopush
thewire(s)asidesoitdoesnotaccidentallycontact
thesparkplug(s).
©2012—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved
*3375-820*A
DANGER
LPGfuelisextremelyammableandvaporsare
explosive.
AreorexplosionfromLPGfuelcanburnyou,
others,andcausepropertydamage.
•Neversmokearoundtank(s)andstayawayfrom
anopenameorwherefumesmaybeignited
byaspark.
•Extinguishallsourcesofsparkoramewhen
approachingLPGtanksormowers.The
hazardincreasesforenclosedtrailersorstorage
locationswherevaporleakagemayoccurand
collect.
•LPGisheavierthanairandmayaccumulatein
lowlyingareas,suchasditches,drains,orpits.
•LPGtank(s)shouldbelledbytrainedand
qualiedpersonnelONLY.
•Nevertamperwithorrepairthetank(s);contact
trainedandqualiedpersonnel.
•DoNotchangethetank(s)whentheengineis
running.
•Beforedisconnectingthehose(s),purgeallLPG
vaporsfromthesystem,byclosingthefuel
valve(s)onALLtanksandallowingtheengine
torununtilitstops.
•Storethetank(s)awayfromheat,sparks,or
openames.
•DoNotoperatewithoutentireexhaustsystem
inplaceandinproperworkingcondition.
DANGER
LPGfuelisextremelyammableandvaporsare
explosive.
•Incaseofretakethefollowingsteps:
1.Ifyoucansafelydoso,stoptheowof
gasasquicklyaspossible.Neverputout
ameunlessgascanbeshutoff.
2.NotifytheFireDepartmentandclear
immediateareaofallpeople.
3.Whengasowisstopped,putoutthere.
Usuallywhenowofgasiscutoff,rewill
automaticallystop.
4.Ifgasowcannotbeimmediatelystopped,
directwaterontankstokeepthemcool,
butDoNotputoutre.
•Storagelocationsandtrailersshouldbe
equippedwithatleastoneapprovedportable
reextinguisherhavingaminimumcapacityof
18lb(8.2kg)drychemicalwithaB:Crating.
DoNotuseCarbonTetrachlorideextinguishers
(Pyreneetc.).
DANGER
LPGvaporsandliquidescapingfromthetankmay
causeseriousinjuryordeath.Vaporsorliquidmay
causesuffocation,freezingoftissue,orfrostbite.
•Storeandservicethemowerinawellventilated
area.
•AnapprovedLPGdetectorinstalledintrailers
andstorageareasisrecommended.
•LPGisheavierthanairandmayaccumulatein
lowlyingareas,suchasditches,drains,orpits.
•Avoidbreathingofvapors.
•Keepawayfromventvalve.
•Keepawayfromeyesandskin.
•Contacttrainedandqualiedpersonneliftank
showssignsoffrostedareas,makesahissing
sound,oremitsafoulodor.
•Obtainimmediatemedicalattentionifcontact
occurswithvaporsorliquid.
2
RemanufactureInstructions
Important:Failuretofollowtheseinstructionswhen
installingthiskitmayviolateFederalLaw(40CFR
1068.105(b))andbesubjecttonesorotherpenaltiesas
describedinthe“CleanAirAct”.
1.Retaintheboxandbubblewrapthatcontainedthese
instructionsandremanufacturekitparts.Thisboxand
bubblewrapwillbeusedtoreturntheoldpartsback
tothefactory.
2.Parktheunitonalevelsurface.
3.Withtheenginerunning,shutoffthefuelsupplyatthe
tankandallowtheenginetorunoutoffuel.
4.Shutofftheignitionswitch,engageparkingbrake,
removethekey,andallowunittocoolbeforestarting
thenextsetofinstructions.
5.Removethecoverthatisovertheregulatorassembly.
6.Disconnectthehighpressurehosefromthefueltank.
7.Removethehighpressurehosefromtheregulator.
8.Locatethelowpressurevaporhoserunningbetween
theregulatorassemblyandtheLPGcarburetor.
9.Loosenandremovethehoseandhoseclamponthe
LPGcarburetorend.Discardthehoseclamp.
10.Unplugthetwoblackwiresfromthesolenoid.
11.Unboltandremovetheregulatorandlowpressure
hoseassembly.
12.Measuretheinsidediameterofthelowpressurehose.
Ifitmeasures1/2inch(13mm),continuewithstep
13.
Ifitis5/8inch(16mm),skiptostep23.Removeand
discardthelowpressurehoseandclamp.
13.Loosenthehoseclampandremovetheendoftheair
cleanerhosethatisconnectedtotheairinletelbow
ofthemixer.
14.Removetheaircleanermountingbrackethardware
fromthelefthandrearbumperguard,removethe
mountingbracketandaircleanerassembly.
15.Removethecrankcasebreatherhoseclampandhose
fromtheairinletelbowofthemixer.
16.Removetheairinletelbowfromthemixer,including
thesupportbracketforthethrottleplateassembly.
Whenremovingtheelbow,becarefulnotdamagethe
gasketbetweentheelbowandthemixer.
17.Notetheinstalledangleofthe90degreeelbowinthe
carburetor.Removethe90degreex1/2inchelbow
fromthecarburetor.
18.ApplyTeonpipesealertothethreadsofthenew90
degreex5/8inchelbowfromthiskit.Assembleitinto
thecarburetortothesameinstalledangleastheold
elbow .
19.Reinstalltheairinletelbow ,supportbracketandrelated
hardware.Torquethefastenersto52-69in-lb(5.9-7.8
Nm)inan“X”pattern.Donotovertighten.
20.Reinstallthecrankcasebreatherhoseandhoseclamp.
Besurethehoseisfullyengagedwiththehosebarb
andtheclampispositionedattheendofthehose.
21.Reinstalltheaircleanermountingbracketandair
cleanerassemblyusingtheoriginalhardware.Tighten
securely.
22.Reinstalltheaircleanerhoseandhoseclamptothe
airinletelbowofthemixer.Besurethehoseisfully
engagedwiththeelbow,positionthehoseclampatthe
endofthehoseandtightensecurely.
23.Installthenewhoseandhoseclamptothecarburetor.
Orientthehoseupwardsoitdoesnotcontactany
movingorhotsurfaces,andisnotkinked.
24.Installthenewregulatorassemblyonthemower.
25.Assemblethesecondhoseclamptotheupperendof
thelowpressurehose.Installthehoseontothebarb
ttingontheregulator.Tightenbothclampssecurely.
26.Withthetankvalvestillturnedoff,installthehigh
pressurecouplingontothetanktting.Tightenby
hand.Thiswillensurethehighpressurecouplingis
rotatedinthecorrectdirectionaftertighteningthehigh
pressurehosetotheregulatorassembly.
27.Assemblethehighpressurehosetotheregulator
assembly,usingtwo3/4inchwrenches.Placeone
wrenchonthehexofthehosecouplingsoitdoesnot
twistthehoseduringtightening.
28.Plugthetwoblacksolenoidwiresintotheharness.
29.Installtheregulatorcover.
30.RemoveanddestroytheoldOnyxemissions
informationlabelfromtheenginefanshroud.
Note:Inspectthenewemissionslabeltobesure
thatitisforthe“OnyxEnvironmentalSolutions
CNYXS.8522EMDisplacement:852cc”engine
family.Thisinformation*islocatedattheupper
portionofthelabelasshownin
Figure2.Ifthe
emissionslabelisnotcorrect,contactToroCustomer
Serviceat1-800-348-2424.
Figure2
InstallthenewOnyxemissionsinformationlabelin
thesamelocationontheenginefanshroud.
31.Slowlyopenthefuelvalveonthetankandcheckfor
leakspertheMaintenancesectionoftheOperator’s
manual.
32.Ifnoleaksaredetectedstarttheengine.
3
33.Ensuretheengineisrunningsmoothandina
controlledmannerbyperformingstepsAthroughE:
A.IncreasethethrottletofullRPM.
B.ReducethethrottletohalfRPMandengage
blades.
C.IncreasethethrottletofullRPM.
D.ReducetheRPManddisengagetheblades.
E.ReducetheRPMtoidle.
Iftheenginefailstokeeprunningorhasother
issues,refertotheTroubleshootingsectioninthe
Operator’sManual.Iffurtherassistanceisneeded,
callToroCustomerServiceat1-800-348-2424.
34.Theregulatorprimarypressureandidlesettingsare
adjustedandsealedatOnyx.
Important:Noadjustmentsshouldbemadeto
theregulator.
35.Detachthelastpageofthisinstructionsheetandllout
thePropaneRemanufactureCompletionCertication
form.
36.Packtheoldregulatorwithbubblewrapandplace
itintheboxthatwasretainedinstep1.Insertthe
completedPropaneRemanufactureCompletion
Certicationformintothebox.
Note:RefertotheToroDealerSpecialBulletinfor
detailstoreturntheregulator.
37.InserttheOnyxEmissionControlWarrantyStatement
sheetintotheLiteraturepacketwiththeOperator’s
manual.
4
Notes:
5
Notes:
6
Notes:
7
PropaneRemanufactureCompletionCertication
Important:ThisformmustbecompletedandreturnedtoToroinordertodocumenttheremanufactureofthenotedunitbelowandto
complywithEPAregulations.
ModelNo:
7497574977
SerialNo:____________________________________________________________
IcertifythatIcompletedthePropaneRemanufactureprocessonthe
aboveunitpertheremanufactureinstructionsprovided.
DealerName:_________________________________________________________
WorkCertiedby:______________________________________________________(PrintName)
WorkCertiedby:______________________________________________________(Signature)
RemanufactureProcessCompletionDate:__________________________________
RevA
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