Toro Mid-Size Proline Gear Traction Unit, 17 hp Walk Behind Mower Operator's Manual

Form No. 3327–505
Mid–Size Traction Unit
Proline Gear 17hp
Model No. 30169—Serial No. 220000001 and Up
Operator’s Manual
Domestic English (EN)
Warning
Connecting the Throttle Cable . . . . . . . . . . . . . . .
Adjusting the Choke . . . . . . . . . . . . . . . . . . . . . .
Connecting the Wire Harness . . . . . . . . . . . . . . .
Installing the Control Rods . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake . . . . . . . . . . . . . . . .
Starting and Stopping the Engine . . . . . . . . . . . .
Operating the Mower Blade Control (PTO) . . . .
The Safety Interlock System . . . . . . . . . . . . . . . .
Driving Forward or Backward . . . . . . . . . . . . . . .
Operating the Lower Control Bar . . . . . . . . . . . .
Stopping the Machine . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule . . . . . . . .
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil . . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication . . . . . . . . . . . . . . . . . . .
Cleaning the Cooling System . . . . . . . . . . . . . . .
Checking the Tire Pressure . . . . . . . . . . . . . . . . .
Servicing the Brake . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Tank . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter . . . . . . . . . . . . . . . . . . .
Replacing the Drive Belt . . . . . . . . . . . . . . . . . . .
Replacing the Traction Belt . . . . . . . . . . . . . . . . .
Adjusting the Electric Clutch . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee . . . . . . . . . . . . .
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
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices . . . . . . . . . . . . . . . . . . .
Toro Mower Safety . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . . . . . .
Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline . . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner . . . . . . . . . . . . . . . .
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Shift Lever . . . . . . . . . . . . . . . . . . .
Installing the Control Panel and Fuel Tank . . . . .
Installing the Upper Handle . . . . . . . . . . . . . . . . .
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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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.
All Rights Reserved
Printed in the USA
2
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
1
The following instructions are from ANSI standard
B71.4—1999.
m–4189
Figure 1
Training
1. Location of the model and serial numbers
• 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.
Write the product model and serial numbers in the space
below:
Model No.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
Serial No.
• 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.
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.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
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.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
• Wear appropriate clothing including hard hat, safety
glasses and ear protection. Long hair, loose clothing or
jewelry may get tangled in moving parts.
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.
• 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.
Safety
• Use only an approved container
This machine meets or exceeds the B71.4 1999
specifications of the American National Standards
Institute, in effect at time of production.
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
• 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.
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
3
Operation
Maintenance and storage
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Disengage drives, set parking brake, stop engine and
remove key or disconnect spark plug wire. Wait for all
movement to stop before adjusting, cleaning or
repairing.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine from
the operator’s position.
• Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Slow down and use extra care on hillsides. Be sure to
travel side–to–side on hillsides. Turf conditions can
affect the machine’s stability. Use caution while
operating near drop–offs.
• 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.
• Slow down and use caution when making turns and
when changing directions on slopes.
• Park machine on level ground. Set parking brake.
Never allow untrained personnel to service machine.
• Never raise deck with the blades running.
• Use jack stands to support components when required.
• Never operate with the PTO shield, or other guards not
securely in place. Be sure all interlocks are attached,
adjusted properly, and functioning properly.
• Carefully release pressure from components with
stored energy.
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• 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.
• Do not change the engine governor setting or
overspeed the engine.
• 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.
• Stop on level ground, disengage drives, engage
parking brake (if provided), shut off engine before
leaving the operator’s position for any reason
including emptying the catchers or unclogging the
chute.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Stop equipment and inspect blades after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
• 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 hands and feet away from the cutting unit.
• Look behind and down before backing up to be sure of
a clear path.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
• Keep pets and bystanders away.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
Toro Mower Safety
• Be aware of the mower discharge direction and do not
point it at anyone.
The following list contains safety information
specific to Toro products and other safety information
you must know.
• Do not operate the mower under the influence of
alcohol or drugs
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
• Use care when loading or unloading the machine into
or from a trailer or truck
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.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
4
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
General Operation
• Allow only responsible adults who are familiar with
the instructions to operate the machine.
• Mow slopes side–to–side.
• Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the area.
DO NOT
• Do not mow slopes greater than 15 degrees.
• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
• Avoid turning on slopes. If you must turn, turn slowly
and gradually downhill, if possible.
• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
• Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly turn over if a wheel goes
over the edge of a cliff or ditch, or if an edge caves in.
• Slow down before turning. Sharp turns on any terrain
may cause loss of control.
• Do not mow on wet grass. Reduced traction could
cause sliding.
• Turn off blades when not mowing.
• Do not use a grass catcher on steep slopes. Heavy
grass bags could cause loss of control of the machine.
• Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and
any moving parts while engine is running.
• Do not mow up and down slopes.
• Stop the engine before removing the grass catcher or
unclogging the chute.
Service
• Never store the machine or fuel container inside where
there is an open flame, such as near a water heater or
furnace.
• Mow only in daylight or good artificial light.
• Watch for traffic when operating near or crossing
roadways.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good condition.
• Do not touch equipment or attachment parts which
may be hot from operation. Allow to cool before
attempting to maintain, adjust or service.
• Never tamper with safety devices. Check safety
systems for proper operation before each use.
• Use only Toro-approved attachments. Warranty may
be voided if used with unapproved attachments.
• Use only genuine replacement parts to ensure that
original standards are maintained.
Slope Operation
• Check brake operation frequently. Adjust and service
as required.
Slopes and ramps are a major factor related to
loss-of-control and accidents, which can result in severe
injury or death. All slopes and ramps require extra
caution. If you feel uneasy on a slope, do not mow it.
• Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes and clothing. Protect your face,
eyes and clothing when working with a battery.
DO
• Battery gases can explode. Keep cigarettes, sparks and
flames away from battery.
• Remove obstacles such as rocks, tree limbs, etc. from
the mowing area. Watch for holes, ruts or bumps. Tall
grass can hide obstacles.
• Hydraulic fluid escaping under pressure can penetrate
the skin and cause injury. Use cardboard or paper to
find hydraulic leaks. Never use your hands.
• Use slow speed so that you will not have to stop while
on the slope.
• Use extra care with grass catchers or other
attachments. These can change the stability of the
machine.
• Keep all movement on slopes slow and gradual. Do
not make sudden changes in speed or direction.
• Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades.
5
6
Slope Chart
7
8
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.
82-2280
82-2290
52-2010
82-7750
63-8440
1. Hot surface
95-2814
98-4387
1. Warning—wear hearing protection.
82-7730
1. Squeeze the blade control
bail.
2. Press the switch.
9
105-0884
10
Gasoline and Oil
Recommended Gasoline
Warning
Use Unleaded Regular Gasoline suitable for automotive
use (85 pump octane minimum). Leaded regular gasoline
may be used if unleaded regular is not available.
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
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.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Danger
Using Stabilizer/Conditioner
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.
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.
• 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.
• 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 fuel tank cap and remove the cap. Add
unleaded regular gasoline to fuel tank, 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 tank completely full.
3. Install fuel tank cap securely. Wipe up any gasoline
that may have spilled.
Check 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 23.
11
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 all parts have been shipped.
DESCRIPTION
QTY.
Shift lever
1
Shift lever mounting bracket
1
Washer, 1/4 in.
1
Bolt, 1/4 x 2 in.
1
Fuel tank
1
Control panel
1
Bolt, 5/16 x 7/8 in.
4
Lock washer, 5/16 in.
4
Washer, 5/16 in.
4
Hose clamp
2
Upper handle
1
Flanged bolt, 3/8 x 1 in.
4
Flange nut, 3/8 in.
4
Screw self-tapping
1
Star washer
1
Wire tie
1
Rod fitting
2
Clevis pin
2
Washer, 1/4 in.
2
Hairpin cotter
2
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
Registration card
1
Installing the Shift Lever
USE
Installing the shift lever
Installing the control panel and fuel tank
Installing the upper handle
Installing the wire harness
Installing the control rods
Read before operating machine
Fill out and return to Toro
2. Align mounting hole in lever with mounting block on
transmission. Secure lever to transmission with 2 in.
(51 mm) bolt and washer. Torque bolt to 115 in.–lb.
(13 N.m).
1. Align mounting block with flats of shaft on top of
transmission and slide onto shaft (Fig. 2).
Note: Do not remove rubber washer on transmission shaft.
12
3
3
4
2
6
5
2
1
1
4
m–1717
Figure 4
m–4762
1. Bolt, 5/8 x 7/8 in.
2. Lock washer
3. Washer
Figure 2
1. Mounting block
2. Shift lever
3. Bolt, 1/4 x 2 in.
4. Washer
4. Fuel line
5. Hose clamp
6. Fuel fitting
4. Shift lever to second gear and check alignment of
lever in shifter plate slot. The clearance between top
and bottom of the shift lever should be equal (Fig. 5).
Installing the Control Panel
and Fuel Tank
5. If clearance is not correct, remove lever and bend it
slightly to adjust (Fig. 2).
1. Slide control panel over shift lever and under bottom
of rear frame (Fig. 3). Align fuel tank to top of rear
frame (Fig. 3).
Note: Do not bend lever while attached to transmission
shaft or damage may occur.
6. Shift lever to neutral and check alignment of lever in
slot of shifter plate. The clearance on the sides of shift
lever should be equal (Fig. 5).
3
7. If clearance is not correct, loosen control panel and
adjust it side–to–side. Tighten the control panel.
1
1
2
2
m–1716
Figure 3
1. Rear frame
2. Control panel
3. Fuel tank
4
4
Rear View
2. Secure control panel and fuel tank to rear frame with 4
bolts (5/16 x 7/8 in.), 4 lock washers (5/16 in.) and
washers (Fig. 4).
2
3. Slide hose clamp onto fuel line (Fig. 4). Push fuel line
onto fuel tank fitting and secure with hose clamp
(Fig. 4).
3
m–5458
Figure 5
1. Shift lever, 2nd gear
2. Control panel
13
3. Shift lever, neutral
4. Equal distance
Installing the Upper Handle
Connecting the Throttle Cable
1. Align upper handle with upper mounting holes in rear
frame (Fig. 6).
1. Route engine speed control cable around left side of
engine.
2. Secure each upper mounting hole with a flange bolt
(3/8 x 1 in.) and flange nut (Fig. 6). Torque bolts to
25 ft.–lb. (34 N.m).
2. Place throttle control in the fast position.
3. Hook wire Z-bend into speed control lever on engine
(Fig. 7).
3. Select high, medium or low position for the lower
mounting hole (Fig. 6). This allows the upper handle
to be adjusted to the user’s height preference.
4. Loosen cable clamp bolt and insert cable, but do not
tighten (Fig. 7).
4. Secure each lower mounting hole with a flange bolt
(3/8 x 1 in.) and flange nut (Fig. 6). Torque bolts to
25 ft.–lb. (34 Nm).
5. Align the hole in the speed control lever with the hole
in the base plate (Fig. 7) by moving the lever. Insert a
1/4 in. (6 mm) diameter pin or bolt through two holes.
4
6. Pull up the outer housing of the throttle cable until the
inner wire has almost no slack, and tighten the cable
clamp bolt (Fig. 7). Remove the 1/4 in. (6 mm)
diameter pin or bolt.
5
6
Note: Make sure that the carburetor choke valve (Fig. 8)
is closed completely when the throttle lever is moved to
the choke position. If not, refer to Adjusting the Choke;
page 15.
2
1
3
7
8
m–5317
Figure 6
1.
2.
3.
4.
Upper handle
Rear frame
Flange bolt, 3/8 x 1 in.
Flange nut, 3/8 in.
5.
6.
7.
8.
Upper mounting hole
Lower mounting holes
Low position
High position
7
2.7mm
4
6
5
1
2
3
m–4687
Figure 7
1.
2.
3.
4.
14
Speed control lever
Z-bend in wire
Cable clamp bolt
Align holes
5. Throttle cable outer
housing
6. Throttle cable inner wire
7. Choke setting screw
Connecting the Wire Harness
1. Route wire harness along inside of left handle bracket.
2. Plug clutch wire into connector (Fig. 9).
3. Secure the black ground wire to engine mount with a
nut (5/16 in.) (Fig. 9).
1
4. Secure wire harness to upper handle with cable tie.
2
m–4712
Figure 8
1
1. Carburetor choke valve
Adjusting the Choke
m–4713
Figure 9
1. Place throttle control in the choke position.
1. Clutch wire connector
2. Align the hole in the speed control lever with the hole
in the base plate (Fig. 7) by moving the lever. Insert a
1/4 in. (6 mm) diameter pin or through two holes.
2. Ground wire
5. Route the other part of the wire harness around to the
right side of the engine and secure with clamp and nut
on engine base (Fig. 10).
3. Turn the choke setting screw so that the clearance
between the screw end and the tongue of the lever is
.11 in. (2.7 mm) (Fig. 7). Remove the 1/4 in. (6 mm)
diameter pin or bolt.
6. Push the two wires together (Fig. 10).
Note: Make sure that the choke valve turns from fully
closed position to fully opened position when moving
throttle control to fast position.
2
1
3
m–4688
Figure 10
1. Clamp and nut
2. Wire harness
3. Engine wire
Installing the Control Rods
1. Thread rod fittings equal distance onto each control
rod. For a starting point thread on approximately 2 in.
(51 mm) (Fig. 11).
2. Slide clevis pins through rod fittings and mounting
holes in idler brackets (from outside) (Fig. 11). Secure
with washers and hairpin cotters (Fig. 11).
15
2
1
4
1
3
4
2
m–2073
m–5233
Figure 11
1. Control rod and fitting
2. 2 in. (51 mm)
3. Idler bracket
Figure 13
4. Clevis pin, washer and
hairpin cotter
1. Upper control bar
2. Parking brake lever
6. If brake adjustment is required, remove hairpin cotter
and washer securing brake rod fitting to idler bracket
(Fig. 14).
3. Check the gap between upper control bar and fixed bar
with wheel drive fully engaged. Gap should be
approximately 1 to 1-1/4 in. (25–32 mm) (Fig. 12).
7. Adjust wing nut up or down on brake rod and secure
fitting to idler bracket (Fig. 14). Check adjustment and
readjust if necessary.
Note: The upper control bar and fixed bar must be parallel
when in engaged, drive, relaxed and brake positions.
Note: Make sure brake rod is installed in front (F)
mounting hole in idler bracket.
4. Check operation. If adjustment is required, remove
hairpin cotter securing rod to upper control bar. Thread
rod in or out of fitting for proper position and install
into upper control bar with hairpin cotter.
8. Repeat procedure on opposite side if adjustment is
required to keep control bar and fixed bar.
5
2
4
1
3
4
3
1
2
m–2073
m–4183
Figure 14
Figure 12
1. Control rod
2. Fixed control bar
3. Parking brake lever
1. Idler bracket
2. Brake rod fitting
4. Upper control bar
5. 1 to 1–1/4 in. (25–32 mm)
3. Hairpin cotter and washer
4. Wing nut
Operation
5. Check parking brake adjustment. Brake rods should be
adjusted so parking brake lever is tight when swung
into position against the fixed bar while pulling back
on upper control bar (Fig. 13).
Note: Determine the left and right sides of the machine
from the normal operating position.
16
Think Safety First
Lower Control Bar – Shift transmission to reverse and
squeeze the lower control bar and handle together to
engage rearward traction operation.
Please carefully read all the safety instructions and
symbols in the safety section. Knowing this information
could help you, your family, pets or bystanders avoid
injury.
Parking Brake Lever – Pull back on upper control bar
and swing brake lever up against the upper handle.
Ignition Switch – Key switch is used in conjunction with
recoil starter. Switch has two positions: run and off.
The use of protective equipment for eyes, hearing, feet
and head is recommended.
Recoil Starter – Pull recoil Starter handle to start engine.
Caution
Fuel Shut–off Valve – (Under fuel tank) Close fuel
shut–off valve when transporting or storing mower.
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause
hearing loss through extended periods of
exposure.
2
5
7
9
Wear hearing protection when operating this
machine.
1
2
3
6
8
Figure 15
1. Caution
1
2. Wear hearing protection
4
Controls
Become familiar with all the controls (Fig. 16) before you
start the engine and operate the machine.
m–4183
Figure 16
Throttle Control – The throttle control has three
positions: Choke, Fast and Slow.
1. Throttle control
2. Blade control bail
3. Blade control switch
(PTO)
4. Gear shift lever
Deck Engagement Control Bail – Control bail used in
conjunction with deck engagement switch (PTO) to
release blade brake and engage clutch to drive mower
blades. Release bail to disengage mower blades.
Blade Control Switch (PTO) – Rocker switch used in
conjunction with control bail to release blade brake and
engage clutch to drive mower blades.
5.
6.
7.
8.
9.
Upper control bar
Lower control bar
Parking brake lever
Ignition switch
Handle
Operating the Parking Brake
Always set the parking brake when you stop the machine
or leave it unattended.
Gear Shift Lever – Transmission has four forward
speeds, neutral and reverse, and has an in-line shift
pattern. Do not shift while unit is moving, as transmission
damage may occur.
Setting the Parking Brake
Upper Control Bar – Shift to desired gear and push
forward on control bar to engage forward traction
operation and pull back to brake. Pull right side of control
bar to turn right and left side to turn left.
1. Pull the upper control bar (Fig. 17) rearward and hold
it in this position.
17
Stopping the Engine
2. Lift the parking brake lock (Fig. 17) up and gradually
release the upper control bar. The brake lock should
stay in the set (locked) position.
1. Move the throttle lever to slow (Fig. 18).
1. Pull rearward on the upper control bar (Fig. 17).
Lower the parking brake lock to the released position.
Note: If the engine has been working hard or is hot, let it
idle for a minute before turning the ignition key off. This
helps cool the engine before it is stopped. In an
emergency, the engine may be stopped by turning the
ignition key to off.
2. Gradually release the upper control bar.
2. Turn the ignition key to off. (Fig. 18).
Releasing the Parking Brake
2
1
2
1
m–4184
m–4184
Figure 17
1. Upper control bar
Figure 18
2. Parking brake lock
1. Throttle lever
2. Ignition key
3. Set the parking brake.
Starting and Stopping the
Engine
4. Pull wire off spark plug(s) to prevent possibility of
accidental starting before storing machine.
Starting the Engine
5. Close fuel shut off valve before storing machine.
1. Make sure spark plug wire(s) are installed on spark
plug(s) and fuel valve is open.
Important Make sure fuel shut off valve is closed
before transporting or storing machine, as fuel leakage
may occur.
2. Move the shift lever to neutral, set the parking brake
and turn ignition key to the run position.
3. Move the throttle control to the choke position before
starting a cold engine.
Operating the Mower Blade
Control (PTO)
Note: A warm or hot engine usually does not require any
choking. To start a warm engine, move throttle control to
the fast position.
The blade control switch (PTO) in conjunction with the
blade control bail engages and disengages power to the
electric clutch and mower blades.
4. Grasp recoil starter handle firmly and pull out until
positive engagement results; then pull handle
vigorously to start engine and allow rope to recoil
slowly.
Engaging the Mower Blades (PTO)
1. Pull on the upper control bar to stop the machine
(Fig. 19).
Important Do not pull recoil rope to its limit or let go
of the starter handle when rope is pulled out because rope
may break or recoil assembly may be damaged.
2. To engage blade, squeeze blade control bail against
upper control bar
3. Press rocker switch forward to on and release. Hold
blade control bail against control bar while operating.
18
Testing the Safety Interlock System
4. Repeat procedure to engage mower blades if blade
control bail is released.
Test the safety interlock system before you use the
machine each time. If the safety system does not operate
as described below, have an Authorized Service Dealer
repair the safety system immediately.
2
1
3
1. Set the parking brake and start the engine :refer to
Starting and Stopping the Engine, page 18
2. Squeeze the blade control bail against upper control
bar. The blades should not rotate.
3. Then continue holding the blade control bail and press
the rocker switch forward to on and release. The clutch
should engage and the mower blades begin rotating.
m–4184
4. Release the blade control bail. The blades should stop
rotating.
Figure 19
1. Upper control bar
2. Blade control bail
3. Blade control switch
(PTO)
5. Then push the blade control switch (PTO) to on
without holding the blade control bail. The blades
should not rotate.
Disengaging the Mower Blades (PTO)
Driving Forward or Backward
1. Releasing blade control bail to disengage blades (PTO)
(Fig. 19).
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place the
throttle control in the fast position for best performance.
The Safety Interlock System
Driving Forward
Caution
1. To go forward, move the shift lever to a forward gear.
2. Release the parking brake: refer to Releasing the
Parking Brake, page 18.
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
3. Slowly press on the upper control bar to move forward
(Fig. 20).
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
To go straight, apply equal pressure to both ends of the
upper control bar (Fig. 20).
To turn, release pressure on the upper control bar side
away from the direction you want to turn (Fig. 20).
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
mower blades from rotating unless:
• The control bail is depressed.
• The blade control switch (PTO) is pressed on.
The safety interlock system is designed to stop the mower
blades if you released the blade control bail.
19
1
1
2
m–4186
2
Figure 21
1. Lower Control Bar
(Engaged)
1. Handle
m–4184
Figure 20
1. Upper control bar
1
2. Lower control bar
2
Driving Backward
1. To go backward, move the shift lever to reverse gear.
2. Release the parking brake; refer to Releasing the
Parking Brake, page 18.
3. Slowly squeeze the lower control bar and handle
together to move rearward (Fig. 20).
m–4185
Figure 22
Operating the Lower Control
Bar
1. Lower Control Bar
engaged and mower in
reverse.
2. Pull up to assist machine
This procedure is for driving up a curb. This can be
performed while driving forward or backward.
Stopping the Machine
1. Disengage the mower blades.
To stop the machine, pull back on the upper control bar,
release the blade control bail (PTO), and turn the ignition
key to off. Also set the parking brake if you leave the
machine unattended; refer to Setting the Parking Brake,
page 17. Remember to remove the key from the ignition
switch.
Warning
A blade can be bent or damaged when driving up
a curb. Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
• Do not run blades while driving up a curb
forward or backward.
Caution
Children or bystanders may be injured if they
move or attempt to operate the tractor while it is
unattended.
2. Select first gear or reverse to drive machine.
3. Drive machine until drive wheels contact curb
(Fig. 22).
Always remove the ignition and set the parking
brake when leaving the machine unattended, even
if just for a few minutes.
Note: Both drive wheels should contact the curb and
caster wheels straight.
4. At the same time engage lower control bar and lift up
on handle (Figures 21 and 22).
Note: Lifting up on handle will assist driving the machine
up a curb and not spin the drive wheels.
20
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
Each Use
5 Hours
After First 8 Hours
Maintenance Procedure
•
•
•
•
Oil—check level
Safety system—check
Brake—check
Engine—clean outside
• Wheel bearings—grease1
• Oil—change
25 Hours
• Foam air cleaner—service1
50 Hours
• Belts—check for wear/cracks
• Tires—check pressure
100 Hours
•
•
•
•
•
200 Hours
• Fuel filter—replace
• Oil filter—change (200 hours or every other oil change)
• Transmission couplings—grease1
300 Hours
• Paper air cleaner—replace1
At storage
• Chipped surfaces—paint
• Perform all maintenance procedures listed above before storage
1More often
Oil—change1
Electric clutch–adjust
Engine—clean outside
Spark plug(s)—check
Paper air cleaner—clean1
in dusty, dirty conditions.
Important
Refer to your engine operator’s manual for additional maintenance procedures.
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do
any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
21
Servicing the Air Cleaner
Important
worn.
Replace the foam element if it is torn or
Service Interval/Specification
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓ
2
Foam Element: Clean and re-oil after every 25 operating
hours.
1
Paper Element: Clean after every 100 operating hours.
Replace after every 300 operating hours or
yearly, which ever occurs first.
Note: Service the air cleaner more frequently (every few
hours) if operating conditions are extremely dusty or
sandy.
m–4694
Figure 24
1. Foam element
2. Oil
Removing the Foam and Paper Elements
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
Cleaning the Paper Elements
1. Lightly tap the element on a flat surface to remove
dust and dirt (Fig. 25).
2. Clean around the air cleaner to prevent dirt from
getting into the engine and causing damage. Pull out
on retaining latches and remove the air cleaner cover
(Fig. 23).
2. Inspect the element for tears, an oily film, and damage
to the rubber seal.
Important Never clean the paper element with
pressurized air or liquids. Replace the paper element if it
is damaged, defective, or cannot be cleaned thoroughly.
3. Unscrew nut and remove the air cleaner assembly
(Fig. 23).
4. Carefully pull the foam element off the paper element
(Fig. 23).
2
4
3
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
1
1
2
5
m–4695
m–4689
Figure 25
Figure 23
1. Retaining latch
2. Cover
3. Nut
1. Paper element
2. Rubber seal
4. Foam element
5. Paper element
Installing the Foam and Paper Elements
Important To prevent engine damage, always operate
the engine with the complete foam and paper air cleaner
assembly installed.
Cleaning the Foam Element
1. Wash the foam element in liquid soap and warm water.
When the element is clean, rinse it thoroughly.
1. Carefully place the foam element onto the paper air
cleaner element (Fig. 23).
2. Dry the element by squeezing it in a clean cloth.
2. Place the air cleaner assembly onto the air cleaner base
(Fig. 23). Secure with nut.
3. Put one or two ounces of oil on the element (Fig. 24).
Squeeze the element to distribute the oil.
22
3. Install the air cleaner cover and secure latches
(Fig. 23).
1
2
Servicing the Engine Oil
3
Service Interval/Specification
Change oil:
• After the first 8 operating hours.
• After every 100 operating hours.
Note: Change oil more frequently when operating
conditions are extremely dusty or sandy.
Figure 26
1. Oil dipstick
2. Metal end
Oil Type: Detergent oil (API service SE, SF, SG or SH)
3. Filler tube
Crankcase Capacity: w/filter, 61 oz. (1.8 l)
Viscosity: See table below
Changing the Engine Oil
USE THESE SAE VISCOSITY OILS
1. Start the engine and let it run five minutes. This warms
the oil so it drains better.
2. Park the machine so that the drain side is slightly
lower than the opposite side to assure the oil drains
completely. Then disengage the power take off (PTO),
set the parking brake, and turn the ignition key to off.
Remove the key.
3. Place a pan below the oil drain. Remove the oil drain
cap (Fig. 27).
m–4292
4. When oil has drained completely, install the oil drain
cap.
Note: Dispose of the used oil at a certified recycling
center.
Checking the Engine Oil Level
1. Park the machine on a level surface, disengage the
power take off (PTO), set the parking brake, and turn
the ignition key to off. Remove the key.
2. Clean around the oil dipstick (Fig. 26) so dirt cannot
fall into the filler hole and damage the engine.
3. Unscrew the oil dipstick and wipe the metal end clean
(Fig. 26).
4. Thread the oil dipstick fully onto the filler tube
(Fig. 26). Pull the dipstick out and look at the metal
end. If oil level is low, slowly pour only enough oil
into the filler tube to raise the level to the full mark.
1
m–4688
Important Do not overfill the crankcase with oil
because the engine may be damaged.
Figure 27
1. Oil drain cap
5. Slowly pour approximately 80% of the specified oil,
on page 23, into the filler cap (Fig. 26). Now check the
oil level; refer to Checking the Engine Oil Level, page
23. Slowly add additional oil to bring it to the full
mark.
23
Change the Engine Oil Filter
Servicing the Spark Plug
Service Interval/Specification
Service Interval/Specification
Replace the oil filter every 200 hours or every other oil
change.
Check the spark plug(s) after every 100 operating hours.
Make sure the air gap between the center and side
electrodes is correct before installing the spark plug. Use a
spark plug wrench for removing and installing the spark
plug(s) and a gapping tool/feeler gauge to check and
adjust the air gap. Install a new spark plug(s) if necessary.
Note: Change oil filter more frequently when operating
conditions are extremely dusty or sandy.
1. Drain the oil from the engine; refer to Changing the
Engine Oil, page 23.
2. Remove the old filter (Fig. NO TAG).
Type: Champion RCJ8Y or equivalent
Air Gap: 0.040 in. (1.00 mm)
3. Apply a thin coat of new oil to the rubber gasket on
the replacement filter (Fig. 28).
Removing the Spark Plug(s)
4. Install the replacement oil filter to the filter adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 3/4 turn (Fig. 28).
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
2. Pull the wire(s) off the spark plug(s) (Fig. 29). Now
clean around the spark plug(s) to prevent dirt from
falling into the engine and potentially causing damage.
3. Remove the spark plug(s).
3
1
1
2
m–1256
2
Figure 28
1. Oil filter
2. Gasket
3. Adapter
M–4294
Figure 29
5. Fill the crankcase with the proper type of new oil;
refer to Changing the Engine Oil, page 23.
1. Spark plug wire installed
24
2. Spark plug
Checking the Spark Plug
2. Clean the grease fittings with a rag. Make sure to
scrape any paint off the front of the fitting(s).
1. Look at the center of the spark plug(s) (Fig. 30). If you
see light brown or gray on the insulator, the engine is
operating properly. A black coating on the insulator
usually means the air cleaner is dirty.
3. Connect a grease gun to the fitting. Pump grease into
the fittings until grease begins to ooze out of the
bearings.
Important Never clean the spark plug(s). Always
replace the spark plug(s) when it has: a black coating,
worn electrodes, an oily film, or cracks.
4. Wipe up any excess grease.
2. Check the gap between the center and side electrodes
(Fig. 30). Bend the side electrode if the gap is not
correct (Fig. 30).
1. Lubricate the wheel bearings and front spindles until
grease begins to ooze out of the bearings (Fig. 31).
2
Where to Add Grease
3
1
0.040 in.
(1.00 mm)
m–2147
Figure 31
Figure 30
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
2. Lubricate the transmission couplers (Fig. 32).
Installing the Spark Plug(s)
1. Install the spark plug(s). Make sure the air gap is set
correctly.
2. Tighten the spark plug(s) to 11 ft.-lb. (15 Nm).
3. Push the wire(s) onto the spark plug(s) (Fig. 29).
Greasing and Lubrication
m–4189
Service Interval/Specification
Figure 32
Grease the wheel bearings every 8 operating hours and the
transmission couplers every 200 operating hours. Grease
more frequently when operating conditions are extremely
dusty or sandy.
Cleaning the Cooling System
Grease Type: General-purpose grease.
Service Interval/Specification
Before each use, check and clean engine cooling system.
Remove any build–up of grass, dirt or other debris from
the cylinder and cylinder head cooling fins, air intake
screen on flywheel end, and carburetor–governor levers
and linkage. This will help insure adequate cooling and
correct engine speed and will reduce the possibility of
overheating and mechanical damage to the engine.
How to Grease
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
25
Checking the Tire Pressure
1. Check the brake before you adjust it; refer to Checking
the Brake, page 26.
Service Interval/Specification
2. Release the parking brake; refer to Releasing the
Parking Brake, page 18.
Maintain the air pressure in the front and rear tires as
specified. Check the pressure at the valve stem after every
50 operating hours or monthly, whichever occurs first
(Fig. 33). Check the tires when they are cold to get the
most accurate pressure reading.
3. To adjust the brake remove the cotter pin and washer
from the brake lever (Fig. 34).
4. Rotate the trunnion so it smoothly slides into brake
lever (Fig. 34). Tighten wing nut.
Pressure: 15 psi (103 kPa) rear tires
25–30 psi (172–207 kPa) caster tires
5. Secure trunnion to brake lever with washer and cotter
pin (Fig. 34).
6. Check the brake operation again; refer to Checking the
Brake, page 26.
1
Important With the parking brake released, the rear
wheels must rotate freely when you push the mower. If
brake action and free wheel rotation cannot be achieved
contact your service dealer immediately.
4
Figure 33
1. Valve stem
3
1
Servicing the Brake
Service Interval/Specification
2
Before each use, check brakes for proper operation.
m–2073
Figure 34
Always set the parking brake when you stop the machine
or leave it unattended. If the parking brake does not hold
securely, an adjustment is required.
1. Hairpin cotter and washer
2. Trunnion
Checking the Brake
3. Brake lever
4. Wing nut
Servicing the Fuel Tank
1. Park the machine on a level surface, disengage the
power take off (PTO), set the parking brake, and turn
the ignition key to off. Remove the key.
Draining The Fuel Tank
Danger
2. Rear wheels must lock when you try to push the
machine forward. Adjustment is required if the wheels
turn and do not lock; refer to Adjusting the Brake,
page 26.
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.
3. Release the brake and press upper control bar very
lightly, approximately 1/2 in. (13 mm), wheels should
rotate freely.
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open area.
Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and stay
away from an open flame or where a spark may
ignite the gasoline fumes.
4. If both conditions are met no adjustment is required.
Adjusting the Brake
The brake lever is on the upper control bar (Fig. 16). If the
parking brake does not hold securely, an adjustment is
required.
26
1. Park the machine on a level surface, to assure fuel tank
drains completely. Then disengage the power take off
(PTO), set the parking brake, and turn the ignition key
to off. Remove the key.
4. Remove the filter from the fuel lines.
2. Close fuel shut–off valve at fuel tank (Fig. 35).
6. Open fuel shut-off valve at fuel tank (Fig. 35).
5. Install a new filter and move the hose clamps close to
the filter.
3. Squeeze the ends of the hose clamp together and slide
it up the fuel line away from valve (Fig. 35).
4. Pull the fuel line off the valve (Fig. 35). Open fuel
shut-off valve and allow gasoline to drain into a gas
can or drain pan.
3
Note: Now is the best time to install a new fuel filter
because the fuel tank is empty. Refer to Replacing the
Fuel Filter; page 27.
5. Install the fuel line onto the valve. Slide the hose
clamp close to the valve to secure the fuel line.
1
2
M–4294
Figure 36
1. Hose clamp
2. Fuel line
3. Filter
Replacing the Drive Belt
1
2
Service Interval/Specification
Check all belts after every 50 operating hours or monthly,
whichever occurs first. Look for dirt, wear, cracks and
signs of overheating.
m–1717
1. Remove top capscrew securing idler support and idler
bracket to rear frame (Fig. 37).
Figure 35
1. Fuel shut-off valve
2. Clamp
2. Loosen bottom two mounting screws enough to allow
belt to pass between drive pulley and idler support
(Fig. 37).
Servicing the Fuel Filter
3. Raise wheel off ground enough to allow belt removal.
Service Interval/Specification
Replace the fuel filter after every 200 operating hours or
yearly, whichever occurs first.
Replacing the Fuel Filter
Never install a dirty filter if it is removed from the fuel
line.
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
2. Close fuel shut–off valve at fuel tank (Fig. 35).
3. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 36).
27
1
3
1
3
4
4
5
6
2
m–1722
m–1221
2
Figure 37
1. Top capscrew
2. Idler bracket
Figure 38
3. Idler support
4. Bottom capscrew
1. Traction belt
2. Idler pulley
3. Clutch retainer
Replacing the Traction Belt
4. Tension spring
5. Adjusting nut
6. Pivot bolt
Adjusting the Electric Clutch
1. Raise the front of the machine and hold with jack
stands.
The clutch is adjustable to ensure proper engagement and
proper braking. Check adjustment after every 100 hours of
operation.
2. Disconnect in–line wire connector from wire harness
to electric clutch.
1. To adjust clutch, tighten or loosen lock nuts on flange
studs (Fig. 39).
3. Remove mower drive belt; refer to mower Operator’s
Manual.
2. Check adjustment by inserting feeler gauge thru slots
next to studs (Fig. 39).
4. Remove left front engine mounting bolt securing
clutch retainer to frame (Fig. 38). Unhook retainer
from clutch and remove retainer.
3. The proper disengaged clearance between the clutch
plates is .012–.018 in. (0.30-0.45 mm). It will be
necessary to check this clearance at each of the three
slots to ensure the plates are parallel to each other.
5. Unhook tension spring from side of frame (Fig. 38).
6. Loosen pivot bolt enough to remove traction belt from
the drive pulley and clutch.
7. Install new belt around clutch and drive pulley.
8. Torque pivot bolt to 35-40 ft.–lb. (47-54 N.m). Install
tension spring between idler arm and frame bracket
(Fig. 38).
2
9. Hook clutch retainer into clutch and secure to frame
with engine mounting bolt. Torque engine mounting
bolt to 170-220 in.–lb. (19-24 N.m).
1
3
10. Connect clutch in–line wire connector to wire harness.
m–2600
Figure 39
1. Adjusting nut
2. Slot
28
3. Feeler gauge
Wiring Diagram
WIRE LIST
DESIG. AWG COLOR ROUTE
W1
16 PINK P2–1 J8
W2
16 WHITE P3–1 J7
W3
16 BLACK J1
P1–1
W4
16 BLACK P1–1 P3–2
W5
18 BLACK P3–2 P4–4
W6
16 PINK J3
P2–2
W7
16 PINK J3
P4–2
W8
16 GREEN P1–2 P4–3
W9
18 ORANGE J4
P4–1
W10
18 ORANGE J2
P4–1
W11
18 BROWN J5
J6
2
W8
1
W4
W3
P1
CLUTCH
J8
CHARGE
COIL
P2
FUSE
2
J7
MAGNETO
P3
IGNITION
1
1
W6
2
W4
W5
W1
W2
W5
4
W8
3
W7
2
W9
P4
DELAY
MODULE
1
W10
J2
W7
W6
CLUTCH
SWITCH
J3
W11
W3
W9
J1
GND
J4 J5
BAIL SWITCH
J6
Cleaning and Storage
6. Change the crankcase oil; refer to Servicing the
Engine Oil, page 23.
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
7. Check the tire pressure; refer to Checking the Tire
Pressure, page 26.
8. For long-term storage (more than 90 days) add
stabilizer/conditioner additive to fuel in the tank
(1 oz. per gallon).
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine. Clean dirt and chaff from the outside of the
engine’s cylinder head fins and blower housing.
A. Run engine to distribute conditioned fuel through
the fuel system (5 minutes).
Important You can wash the machine with mild
detergent and water. Do not pressure wash the machine.
Avoid excessive use of water, especially near the control
panel, and engine.
B. Stop engine, allow to cool and drain the fuel tank;
refer to Servicing the Fuel Tank, page 26, or
operate engine until it stops.
C. Restart engine and run until it stops. Repeat, on
choke until engine will not restart.
3. Check the brake; refer to Servicing the Brake, page 26.
4. Service the air cleaner; refer to Servicing the Air
Cleaner, page 22.
D. Dispose of fuel properly. Recycle as per local
codes.
5. Grease the machine; refer to Greasing and Lubrication,
page 25.
Note: Do not store stabilizer/conditioned gasoline over 90
days.
29
9. Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug, page 24. With the
spark plug(s) removed from the engine, pour two
tablespoons of engine oil into the spark plug hole.
Now use the starter to crank the engine and distribute
the oil inside the cylinder. Install the spark plug(s). Do
not install the wire on the spark plug(s).
11. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
12. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it in a memorable place. Cover the machine to
protect it and keep it clean.
10. Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged or defective.
Troubleshooting
PROBLEM
Engine
g
will not start,, starts hard,, or
f il to
fails
t keep
k
running.
i
Engine
g
loses power.
Engine
g
overheats.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. Fuel tank is empty.
1. Fill fuel tank with gasoline.
2. Choke is not on.
2. Move choke lever to the on
position.
3. Air cleaner is dirty.
3. Clean or replace air cleaner
element.
4. Spark plug wire is loose or
disconnected.
4. Install wire on spark plug.
5. Spark plug is pitted, fouled, or
gap is incorrect.
5. Install new, correctly gapped
spark plug.
6. Dirt in fuel filter.
6. Replace fuel filter.
7. Dirt, water, or stale fuel is in
fuel system.
7. Contact Authorized Service
Dealer.
1. Engine load is excessive.
1. Reduce ground speed.
2. Air cleaner is dirty.
2. Clean air cleaner element.
3. Oil level in crankcase is low.
3. Add oil to crankcase.
4. Cooling fins and air passages
under engine blower housing
are plugged.
4. Remove obstruction from
cooling fins and air passages.
5. Spark plug is pitted, fouled, or
gap is incorrect.
5. Install new, correctly gapped
spark plug.
6. Vent hole in fuel cap is
plugged.
6. Clean or replace the fuel cap.
7. Dirt in fuel filter.
7. Replace fuel filter.
8. Dirt, water, or stale fuel is in
fuel system.
8. Contact Authorized Service
Dealer.
1. Engine load is excessive.
1. Reduce ground speed.
2. Oil level in crankcase is low.
2. Add oil to crankcase.
3. Cooling fins and air passages
under engine blower housing
are plugged.
3. Remove obstruction from
cooling fins and air passages.
30
PROBLEM
Abnormal vibration.
Machine does not drive.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. Engine mounting bolts are
loose.
1. Tighten engine mounting bolts.
2. Loose engine pulley, idler
pulley, or blade pulley.
2. Tighten the appropriate pulley.
3. Engine pulley is damaged.
3. Contact Authorized Service
Dealer.
1. Shift lever is in neutral.
1. Move shift lever to a drive gear
position.
2. Traction belt is worn, loose or
broken.
2. Change Belt.
3. Traction belt is off pulley.
3. Change Belt.
31
The Toro Total Coverage Guarantee
LCE
A One-Year Limited Warranty
Conditions and Products Covered
Owner Responsibilities
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly promise to repair
any Toro Product used for commercial, institutional, or rental
purposes if defective in materials or workmanship. The following
time periods apply from the date of purchase:
You must maintain your Toro Product by following the maintenance
procedures described in the operator’s manual. Such routine
maintenance, whether performed by a dealer or by you, is at your
expense.
•
•
•
•
•
Warranty Period
1 year
2 years parts and labor;
third year, parts only
2 years
Products
All Products
All Spindles
Engines/Hydraulic Systems* on
the following:
Outfront and Mid-Mount Z’s
ProLine Mid-Size Mowers
Groundsmaster Riding Mowers
Backpack Blowers
Deck Shells (36″–72″) on the
following:
ProLine Mid-Size Mowers
Mid-Mount Z’s
Electric Clutch on 200 Series
Mid-Mount Z’s
2 years
2 years
This warranty includes the cost of parts and labor, but you must
pay transportation costs.
This warranty applies to:
• Outfront and Mid-Mount Z’s
• ProLine Mid-Size Mowers
• Groundsmaster Riding Mowers
• Turf Maintenance Equipment
• Debris Management Equipment
* Some engines used on Toro LCE Products are warranted by the
engine manufacturer.
Instructions for Obtaining Warranty Service
If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:
1. Contact any Toro Authorized or Master Service Dealer to
arrange service at their dealership. To locate a dealer
convenient to you, access our website at www.Toro.com.
U.S. Customers may also call 800-348-2424.
Items and Conditions Not Covered
There is no other express warranty except for special emission
system coverage on some products. This express warranty does
not cover the following:
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, blade sharpening, brake and
clutch adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance.
• Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non-use over three months.
• Pickup and delivery charges.
All repairs covered by this warranty must be performed by an
Authorized Toro Service Dealer using Toro approved replacement
parts.
General Conditions
Repair by an Authorized Toro Service Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable
for indirect, incidental or consequential damages in connection
with the use of the Toro Products covered by this warranty,
including any cost or expense of providing substitute equipment or
service during reasonable periods of malfunction or non-use
pending completion of repairs under this warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
2. Bring the product and your proof of purchase (sales receipt)
to the Service Dealer.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-577-7466 (U.S. customers)
877-484-9255 (Canada customers)
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0037 Rev. B