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FORM NO. 3317-294 x N Wheel Horse” 12—32 XL Lawn Tractor Model No. 71182 — 5910001 & Up Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product. x ZZ Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine Toro replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number plate located in a unique place on the product as shown below. 1. Model and Serial Number Plate (under the seat) For your convenience, write the product model and serial numbers in the space below. Model No: Serial No. Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although Toro designs, produces and markets safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons who you allow to use the product about safe operation. The Toro warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed. WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed. CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed. Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention. The left and right side of the machine 1s determined by sitting on the seat in the normal operator’s position. ©The Toro Company — 1993 Printed in USA All Rights Reserved Contents Safety ....... a aa aa 1141 aa ana о Safe Operating Practices .............. SlopeChart ......................... Safety and Instruction Decals .......... — Gasoline and Oil ................ LLL. Recommended Gasoline .............. Stabilizer/Conditioner ................ Filling the Fuel Tank ................. Check Engine Oil Level ............... Operation ........... ieee. Think Safety First ................... Controls ....................... .... Parking Brake . ...................... Positioning the Seat .................. Positioning the Tilt Steering Wheel ...... Headlights ......................... Using the Blade Control (PTO) ......... Setting the Height-of-Cut .............. Starting and Stopping the Engine ....... The Safety System ................... Driving Forward or Backward .......... Selecting Ground Speeds .............. Stopping the Machine ................ Side Discharge or Mulch Grass ......... Installing the Discharge Cover .......... Tips for Mowing Grass ............... =~ de OOO © © © 00 00 09 00 = ло в ©® — < 10 10 11 12 13 14 14 14 15 15 16 Page Maintenance . ..... o.oo... 17 Service Interval Chart ................ 17 Greasing and Lubrication .............. 18 Tire Pressure .............. 00... 19 Brake ............ i... 19 Wiring Diagram ..................... 20 Fuse .......... iii. 21 Headlights ......................... 21 Battery ........... iii. 22 Spark Plug ......................... 24 Fuel Tank .......................... 25 Fuel Filter . ......................... 25 Throttle and Choke Control ............ 26 Carburetor .................. een 27 AirCleaner ......................... 28 Engine Oil ......................... 30 Cutting Blade ....................... 32 Removing the Mower ................. 34 Installing the Mower ................. 36 Blade Drive Belt... .................. 38 Side-to-Side Mower Leveling .......... 39 Front-to-Rear Blade Slope ............. 40 Storage ...........eeea0reararor ee 42 Troubleshooting ......................... 43 Warranty ..... o.oo iii Back Cover — Safety This machine meets or exceeds the B71.1-1990 specifications of the American National Standards Institute, in effect at the time of production. However, 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 Á symbol, which means CAUTION, WARNING, or DANGER— “personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Safe Operating Practices This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. POTENTIAL HAZARD e Engine exhaust contains carbon monoxide, Which is an odorless, deadly poison. WHAT CAN HAPPEN e Carbon monoxide can kill you and is also known to the State of California to cause birth defects. HOW TO AVOID THE HAZARD e Do not run engine indoors or in an enclosed area. General Operation 1. Read, understand, and follow all instructions in the operator’s manual and on the machine before starting. 2. Allow only responsible adults who are familiar with the instructions to operate the machine. 3. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade. 4. Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area. 5. Never carry passengers. 6. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing. 7. 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. 8. Slow down before turning. Sharp turns on any terrain may cause loss of control. 9. Never leave a running machine unattended. Always turn oft blades, set parking brake, stop engine, and remove key before dismounting. 10. Turn off blades when not mowing. 11. Keep hands, feet, hair and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running. 12. Stop the engine before removing the grass catcher or unclogging the chute. 13. Mow only in daylight or good artificial light. 14. Do not operate the machine while under the influence of alcohol or drugs. 15. Watch for traffic when operating near or crossing roadways. 16. Use extra care when loading or unloading the machine into a trailer or truck. 17. Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service. Slope Operation Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it. DO e Mow up and down slopes greater than 5°, not across. e Mow downhill only on slopes above 10°, never mow uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear. e Remove obstacles such as rocks, tree limbs, etc. from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles. e Use slow speed. Choose a low gear so that you will not have to stop or shift while on the slope. e Follow the manufacturer’s recommendations for wheel weight or counterweights to improve stability. e Use extra care with grass catchers or other attachments. These can change the stability of the machine. Safety 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 and proceed slowly straight down the slope. DO NOT Do not operate machine on hillsides or slopes exceeding 15°. Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, it possible. 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. Do not mow on wet grass. Reduced traction could cause sliding. Do not try to stabilize the machine by putting your foot on the ground. Do not use a grass catcher on steep slopes. Heavy grass bags could cause loss of control or overturn the machine. Children Tragic accidents can occur if the operator 1s not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. Be alert and turn the machine off if children enter the area. Before and while backing, look behind and down for small children. Never carry children. They may fall off and be seriously injured or interfere with safe machine operation. Never allow children to operate the machine. Use extra care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure vision. Service 1. Stop the engine and disconnect spark plug wire(s) before performing any service, repairs, maintenance or adjustments. Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. A. Use only an approved container. B. Never remove the gas cap or add fuel when the engine is running. Allow the engine to cool before refueling. Do not smoke. Never refuel the machine indoors. D. Never store the machine or fuel container inside where there 1s an open flame, such as near a water heater or furnace. Never run a machine inside a closed area. 10. 11. 12. 13. Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition. Never tamper with safety devices. Check safety systems for proper operation before each use. Keep the machine free of grass, leaves, or other debris build-up. Clean up oil or fuel] spillage. Allow the machine to cool before storing. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. Use only genuine Toro replacement parts to ensure that original standards are maintained. Check brake operation frequently. Adjust and service as required. Battery acid 1s poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery. Battery gases can explode. Keep cigarettes, sparks and flames away from battery. Safety Slope Chart Read all safety instructions on pages 2-4. TH; S is A 150 si OPE THIS 18 475; SLoPE THIS IS A 5° SLOPE ALIGN THIS EDGE WITH A VERTICAL SURFACE = L Ш ALLE URI LEE ETI IE AIR . —.]s iii LLE E (TREE, BUILDING, FENCEPOST, POLE ETC.) (FOLD ALONG APPROPRIATE LINE Lor + I = EXAMPLE: COMPARE 7 SLOPE WITH FOLDED EDGE, ON GRASS DEFLECTOR 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 1s damaged or lost. ON MOWER LEFT SIDE (Part No. 92-7110) ALONGSIDE MOWER LIFT BRACKETS (Part No. 55-4300) (À WARNING ) SPRING LOADED MECHANISM SEE OPERATOR'S MANUAL FOR DISASSEMBLY PROCEDURE. AND ON MOWER RIGHT SIDE (Part No. 93-1122) сен Emme — de LA Se = de ROTATING BLED eee WAND À OPERATE ONLY WITH DEFLECTOR OR ENTIRE CATCHER IN PLACE ce OI MOWER D E! . — Hi Coma [fh : [FEET AWAY KEEP DÉCERS ón Lo OTE 55-4300 DANGER q KEEP HANDS and FEET AWAY UNDER GRASS DEFLECTOR (Part No. 68-3650) | A DANGER =») (___DEFLECTOR IS NOT IN PLACE. DO NOT OPERATE. ) ON DASH RIGHT SIDE (Part No. 92-2478) ON DASH LEFT SIDE (Part No. 92-2461) ON STEERING TOWER (Part No. 92-2462) ON FRAME STEP (Part No. 92-2484) PARKING BRAK] oT ae > —— TO APPLY PARKING BRAKE: MUSTBE RELEASE - MOVE SPEED SELECTOR TO NEUTRA: - DEP H PEDAL INTO FORWARD GEAR. + В = POSITION, RELEASE BRAKE/CLUTCH PEDAL. TO DISENGAGE PARKING BRAKE: D N G E R + DEPRESS BRAKE/CLUTCH PEDAL и `` | \ | - BUSH DOWN ON PARKING BRAKE LEVER Jems CHOKE FAST OPERATING INSTRUCTIONS OVER 5° ENGAGE то START: NOTE: Engine will nat start unless instructions are folicwed, - GPERATOR [S ON SEAT. . MOVE GROUND SPEED SELECTOR 70 "NEUTRAL". OH TO "НЕ Y y VER 10° - PTO LEVER MUST BE IN "DISENGAGE" FOSTTION, ON OVER 10 LE LEVER " FF - TURN IGNITION SWITCH TO "START" POSITION, о AFLEASE WHEN ENGINE STARTS. q NEVER MOW TO DRIVE: Ne SLOPE PTO * RELEASE PARKING BRAKE. PE OVER 15* - MOVE GROUND SPEED SELECTOR TO DESIRED POSTION. 5 15 - RELEASE CLUTCHERAKE PEDAL SLOWLY. fa) 5 HE DAL SLO a * TO STOP: a “FULLY DEPRESS CLUTCHBRAKE PEDAL «Li TO TUAN OFF ENGINE: 2 GROUND SPEED START ‘в. = DEPRESS CLUTCHBRAKE PEDAL AND APPLY PARKING BRAKE. = PLACE ALL CONTROLS IN NEUTRAL OF DISENGAGE POSITION. Xu, SLOW «TURN IGKITION SWITCH TO "OFF", IGNITION DISENGAGE 92-2361 0 CLUTCH/BRAKE PEDAL в ©) TO AVOID SERIOUS INJURY OR DEATH: a - READ AND UNDERSTAND THE OPERATOR'S MANUAL Le Y PARKING - KNOW LOCATION AND FUNCTION OF CONTROLS. - NEVER USE WHEN UNDER THE INFLUÉNCE OF ALCOHOL OR DRUGS. «a BRAKE Fae A * USE SAFELY; MACHINE 15 NOT A TOY, - NEVER MOW WHEN CHILDREN, PEOPLE OR PETS ARE IN MOWING AREA. - NEVER CARRY CHILDREN OR OTHER PASS ] - LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING UP. - KEEP SAFETY DEVICES IN PLACE AND WORKING. « REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE. « AVCID BLADE UNLESS BLADE AND ENGINE ARE STOPPED, « SET PABKING BRAKE AND REMOVE KEY BEFQHE LEAVING MACHINE. - GO UP AND DOWN SLOPES, ROT ACROSS. - AVOID SHARP OR SUDDEN TURNS AND SLIPPERY OR STEEP AREAS. й + IF MACHINE STOPS GOING UPHILL, STOP BLADE AND BACK SLOWLY DOWN. | NTE ETT rra e A Gasoline and Oil Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. ÁN DANGER — POTENTIAL HAZARD ¢ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN e A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD e Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. e Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand. e Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark. e 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. Stabilizer/Conditioner Toro Stabilizer/Conditioner Add the correct amount of Toro Gas Stabilizer/Conditioner to the gas. Using Toro Stabilizer/Conditioner or an isopropyl-based conditioner/stabilizer in the machine: e Keeps gasoline fresh during storage e (Cleans the engine while it runs e Eliminates gum-like buildup in the fuel system, which causes hard starting IMPORTANT: Never use fuel additives containing methanol or ethanol. Filling the Fuel Tank 1. Shut the engine off and open the hood. 2. Clean around the fuel tank cap and remove the cap. Use a funnel and add unleaded regular gasoline to the fuel tank, until the level 1s 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space 1n the tank allows gasoline to expand. Do not fil! the fuel tank completely full. 3. Install the fuel tank cap securely. Wipe up any gasoline that may have spilled. 4. Close the hood. Check Engine Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 30. Operation Think Safety First Please carefully read all the safety instructions on pages 2-7. Knowing this information could help you, your family, pets or bystanders avoid injury. Controls Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine. Figure 1 1. Steering wheel 7. Height-of-cut lever 2. Light switch—on/off (deck lift) (selected models) 8. Parking brake lever 3. Ignition switch 9. Tilt button (selected 4. Clutch/brake pedal models) 5. Blade control (PTO) 10. Throttle lever 6. Ground speed selector 11. Hood opening Parking Brake Always set the parking brake when you stop the machine or leave 1t unattended. Setting the Parking Brake 1. Push the clutch/brake pedal (Fig. 2) down and hold it in the depressed position. 2. Lift the parking brake lever (Fig. 2) up and gradually take your foot off the clutch/brake pedal. The clutch/brake pedal should stay in the depressed (locked) position. Releasing the Parking Brake 1. Push down on the clutch/brake pedal (Fig. 2). The parking brake lever should release. 2. Gradually release the clutch/brake pedal. Figure 2 1. Clutch/brake pedal 2. Parking brake lever Operation Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. (Fig. 3). the knob. 1. Raise the seat and loosen the adjustment knob Move the seat to the desired position and tighten Figure 3 Adjustment knob Positioning the Tilt Steering Wheel On select models the steering wheel tilts up and down. Position the steering wheel where you have the best control of the machine and are most comfortable. 1. Push in on the tilt button (Fig. 4). 2. Move the steering wheel to any of three positions; then release the button. Figure 4 1. Tilt button 2. Steering wheel Headlights Headlights are optional on some models. A dash-mounted “ON/OFF” switch (Fig. 1) controls the headlights. The lights only shine while the engine 1s running and the switch 1s “ON.” Using the Blade Control (PTO) The blade control (PTO) engages and disengages power to the blade(s). Engaging the Blade(s) 1. Depress the clutch/brake pedal to stop the machine. 2. Move the blade control (PTO) to “ENGAGED” (Fig. 5). 2 NTT (ADANGER) | Mm <= ur © E ua 1 Ta © = { 3 Figure 5 1. Disengaged 3. Blade control (PTO) 2. Engaged Operation Disengaging the Blade(s) 1. Depress the clutch/brake pedal to stop the machine. 2. Move the blade control (PTO) to “DISENGAGED” (Fig. 5). Setting the Height-of-Cut The height-of-cut lever (deck lift) is used to raise and lower the mower to the desired cutting height. 1. The cutting height may be set in one of seven positions from approximately 1 to 4 inches (25 to 102 mm). 2. Pull on the height-of-cut lever (deck lift) and move it to the desired position (Fig. 6). OUT 1" (25 mm) — 1-1/2” (38 mm) TT 2” (51 mm) TT 2-1/2” (64 mm) a 3” (76 mm) TT 3-1/2” (89 mm) 7 — 4* (102 mm) Figure 6 1. Height-of-cut lever (deck lift) 11 Operation Starting and Stopping the Engine Starting 1. 2. Sit down on the seat. Set the parking brake; refer to Setting the Parking Brake, page 9. Note: The engine will not start unless you set the parking brake or fully depress the clutch/brake pedal. Move the ground speed selector into neutral “N” (Fig. 7). Move the blade control (PTO) to “DISENGAGED” (Fig. 8). Move the throttle lever to “CHOKE” (Fig. 9). Note: An engine that has been running and is warm may not require step 5. Turn the ignition key clockwise and hold it in the “START” position (Fig. 10). When the engine starts, release the key. IMPORTANT: If the engine does not start after 30 seconds of continuous cranking, turn the ignition key to “OFF” and let the starter motor cool; refer to Troubleshooting, page 43. After the engine starts, slowly move the throttle lever to “FAST” (Fig. 9). If the engine stalls or hesitates, move the throttle lever back to “CHOKE” for a few seconds. Then move the throttle lever to “FAST.” Repeat this as required. 12 [ADANGER EVER фены SIDE HLL Figure 7 Figure 8 1. Ground speed 1. Disengaged selector 2. Engaged 3. Blade control (PTO) IGNITION \ 1 Figure 9 Figure 10 1. Choke 1. Start 2. Fast 2. On 3. Slow 3. Off Stopping Move the throttle lever to “SLOW” (Fig. 9). Turn the ignition key to “OFF” (Fig. 10). Note: If the engine has been working hard or 1s hot, let it 1dle 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” The Safety System Understanding the Safety System The safety system is designed to prevent the engine from starting unless: e You are sitting on the seat e The clutch/brake pedal is depressed e The blade control (PTO) 1s “DISENGAGED” The safety system is designed to stop the engine if you rise from the seat when the clutch/brake pedal is released or the blade 1s “ENGAGED.” Testing the Safety System Test the safety 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. 1. Move the ground speed selector into neutral “N.” Set the parking brake. Move the blade control (PTO) to “ENGAGED.” Now turn the ignition key to “START”; the engine should not crank. 2. With the ground speed selector in neutral “N,” move the blade control (PTO) to “DISENGAGED” and release the parking brake. Now turn the ignition key to “START”; the engine should not crank. 3. With the ground speed selector in neutral “N,” set the parking brake and move the blade control (PTO) to “DISENGAGED.” Now start the engine. While the engine is running, release the parking brake and rise slightly from the seat; the engine should stop. Operation 13 Operation Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm (revolutions per minute). To go forward or backward, depress the clutch/brake pedal. Move the ground speed selector to the desired forward speed or reverse. As you slowly release the pedal, the machine will begin to move. Steer the machine with the steering wheel. 4 CAUTION POTENTIAL HAZARD o If you release the clutch/brake pedal too quickly when the ground speed selector is in gear, you could suddenly put the machine in motion. WHAT CAN HAPPEN ¢ Sudden engagement of the machine’s drive system could cause you to lose control. HOW TO AVOID THE HAZARD e Always release the clutch/brake pedal slowly when starting the machine in motion (forward or reverse). Selecting Ground Speeds IMPORTANT: To avoid transmission damage, always depress the clutch/brake pedal before shifting into or out of reverse. Always start the machine in motion by depressing the clutch/brake pedal and shifting into the desired speed. Once the machine is in motion, you can shift into any forward speed without depressing the clutch/brake pedal. In most conditions, the machine 1s powerful enough to move out in any speed. If 1t will not move out in a selected speed (i.e., #5) due to a heavy load, use a lower speed (i.e., #2). IMPORTANT: Do not “Ride the Brakes,” shift to a lower speed for slower ground speed. Choose a slow speed so that you will not have to stop or shift while on the slope. 14 Stopping the Machine To stop the machine, depress the clutch/brake pedal, shift into neutral, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 9. Remember to remove the key from the ignition switch. E Ce le N POTENTIAL HAZARD e Someone could move or attempt to operate the tractor while it is unattended. WHAT CAN HAPPEN e Children or bystanders may be injured if they use the tractor. HOW TO AVOID THE HAZARD e Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Side Discharge or Mulch Grass POTENTIAL HAZARD e Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. WHAT CAN HAPPEN e Contact with rotating mower blade(s) and thrown debris will cause injury or death. HOW TO AVOID THE HAZARD e NEVER remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. e Never put your hands or feet under the mower. e Never try to clear discharge area or mower blades unless you move the blade control (PTO) to “DISENGAGED” and rotate the ignition key to “OFF.” Also remove the key and pull the wire off the spark plug. 1. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 2. To mulch grass clippings you must install the discharge cover (optional on some models) into the opening in the side of the mower; refer to Installing the Discharge Cover, page 15. Operation Installing the Discharge Cover To convert from side discharge to a mulching mower, install the discharge cover into the opening at the side of the mower. 1. Lift the grass deflector and place the discharge cover over the opening onto the lower lip of the mower and slide into the front hinge (Fig. 11). 2. Slide the hinge pin through the hinge (Fig. 11). 3. Secure the discharge cover to the mower with the wing nut (Fig. 11). Figure 11 1. Grass deflector 4. Hinge pin 2. Discharge cover 5. Wing nut 3. Lowerlip 4. To convert back to a side discharge mower, remove the discharge cover and lower the grass deflector over the discharge opening. 15 Operation Tips for Mowing Grass Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at “FAST.” Air is required to thoroughly cut grass clippings, so do not set the height-of-cut too low or totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower. Cutting a Lawn for the First Time Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past 1s generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to assure an acceptable quality-of-cut. Cut 1/3 of the Grass Blade It 1s best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended, unless grass 1s sparse or it is late fall when grass grows more slowly. Mowing Direction Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. Mow at Correct Intervals Normally, mow every 4 days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again 2 days later at a lower height setting. 16 Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used, raise the cutting height one notch to ensure uneven turf 1s not cut too short. Long Grass If the grass 1s ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this: 1. With the blade(s) “ENGAGED,” move onto a previously cut area. 2. To disperse the clippings evenly, raise the mower one or two height-of-cut settings while driving forward with the blade(s) “ENGAGED.” Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Every 30 days, check the cutter blade(s) for sharpness and file down any nicks. Maintenance Service Interval Chart Each 5 25 | Storage | Spring Service Operation Use | Hours | Hours | Service | Service Notes Oil—initial change X Oil—periodic change X X Oil—check level X Safety System—check X X X X Cutter Blade—check X X X Brake—check X X X X Chassis—grease X X More often in Foam Air Cleaner—service X X dusty, dirty Paper Air Cleaner—replace X conditions Spark Plug—check X X X Belts—check for wear/cracks X Gasoline—drain X Engine—clean outside X X Mower Housing—clean X X X Chipped Surfaces—paint X Battery—check electrolyte X X X X X Battery—charge, disconnect cables X Fuel Filter—replace X Tires—check pressure X X X 4 cauTION POTENTIAL HAZARD | e If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN e Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD | e Remove the key from the ignition switch and pull the wire off the spark plug before you do any maintenance. Also push the wire aside so it does not accidentally contact the spark plug. Maintenance Greasing and Lubrication Service Interval/Specification Grease the machine after every 25 operating hours or once a year, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General -purpose grease. How to Grease 1. Disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 3. Connect a grease gun to the fitting. Pump grease into the fittings. 4. Wipe up any excess grease. Where to Add Grease 1. Lubricate the front wheels until grease begins to ooze out the bearings (Fig. 12). Figure 12 18 2. Lubricate the rear axle with 3-4 pumps of grease (Fig. 13). — НВ “~~ Less > < Figure 13 Tire Pressure Service Interval/Specification Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 25 operating hours or yearly, whichever occurs first. Check the tires when they are cold to get the most accurate pressure reading. Pressure: 12 psi (.85 kPa) front and rear Figure 14 1. Valve stem Maintenance Brake The brake is on the right side of the rear axle, inside the rear tire (Fig. 15). If the brake does not hold securely or stopping power is insufficient, an adjustment is required. Checking the Brake 1. Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. If the rear wheels lock and skid when you push the tractor forward, no adjustment 1s required. An adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 19. 1. Adjusting the Brake Check the brake before you adjust it; refer to Checking the Brake, page 19. To increase braking resistance, tighten the brake adjusting nut (Fig. 15) 1/8 turn clockwise; then check the brake again. Continue this adjusting and checking process until the brake 1s set properly. Push down on the clutch/brake pedal to release the parking brake. IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If the brake seems to “drag,” loosen the adjusting nut slightly until the wheels rotate freely. If both conditions cannot be achieved, contact an authorized service dealer immediately. > DY» y WWW « == Figure 15 1. Brake adjusting nut 19 Maintenance jagram D iring W (NMOHS LON) SSINHYH LH917 | | 98LE—0 IND HOLD3INNOD SLHDM — INON S+1+9 1HYIS'€ A+X Y+1+g NAH 'Z | 3INON 3INON 130 "1 - Ive (siopopy ewos) 918 IVIL LINOHIO NOLLISOd { GION370S OIDOT LINOHIO HOLIMS A9M | Day LETTE 13nd 1109 ON р У 1HOM aay | HOLIMS TYHLNIN OLINOYIN | _ 3NION3 p © HOLIMS A3M vas = MOTI3A HOLIMS 1Y3S Ш AYER : MOTISA A Ce | ana MHYVa AYHO ano eZ T 3505 = FLIHM D o I > 3 1HAV/M19 I gs C A В E asn4 = | © 5 ; Le monas AHI LIYE - | re | € © SC e MOVE dau ol T7 HOLIMS Old GIONTIOS уса SM MOV 19 AY138 Al33YS \_ 1HM/O3H ‘ON SLHOIT 20 Fuse Service Interval/Specification The electrical system is protected by fuses. No maintenance is required, however, if a fuse blows check the circuit wiring for a short. To replace a fuse pull up (Fig. 16) to remove from socket. Push down to insert. Fuse: 7.5 amp, blade-type ss ООАОНИ LT GG || ZZ] DE 2 = u LOY) © Es | КС sell Figure 16 1672 1. Fuse (removed) 2. Socket Headlights Specification: Bulb # 1156, automotive type. Removing the Bulb 1. Disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. Open the hood. Pull wire connectors off both bulb holder terminals. 3. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the reflector (Fig. 17). 4. Push and rotate the bulb counterclockwise until it stops (approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 18). Maintenance Figure 17 1. Bulb holder 4. Slots 2. Reflector 5. Terminals 3. Tabs Installing the Bulb 1. The bulb has metal pins on the side of its base. Align the pins with the slots in the bulb holder and insert the base into the holder (Fig. 18). Push and rotate the bulb clockwise until it stops. т Figure 18 1. Bulb 3. Bulb holder 2. Metal pins 4. Slots 2. The bulb holder has two tabs (Fig. 17). Align the tabs with the slots in the reflector, insert the bulb holder into the reflector and rotate it 1/4 turn clockwise until it stops. 3. Push the wire connectors onto the terminals on the bulb holder. Maintenance Battery Service Interval/Specification Check the electrolyte level in the battery before each use. Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Voltage: 12 v, 160 Cold Cranking Amps Removing the Battery 1. Disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. Tip the seat forward to see the battery. 3. Disconnect the negative (black) ground cable from the battery post (Fig. 19). 4. Slide the rubber cover up the positive (red) cable. Disconnect the positive (red) cable from the battery post (Fig. 19). 5. Remove the battery box, battery, and long vent tube from the chassis (Fig. 20). 3 Figure 19 4. Battery box 5. Bolt and wing nut 1. Negative cable (black) 2. Rubber cover 3. Positive cable (red) Installing the Battery 1. Put the battery into the battery box and slide the — vent tube into the channel and through the slot in the bottom of the box (Fig. 20). IMPORTANT: Look down into the cut out area where the battery box fits into the chassis. Notice the hole at the end of the right frame member (Fig. 20). Always install the long battery vent tube through the hole to prevent battery acid from corroding the tractor and mower. 1 2 5 Figure 20 1. Battery 4. Slot in battery box 2. Battery box 5. Hole in frame 3. Vent tube 2. Install the battery box and battery into the chassis (Fig. 20). Make sure to slide the end of the vent tube through the hole in the frame (Fig. 20). 3. Using the bolt and wing nut, connect the positive (red) cable to the positive (+) battery post (Fig. 19). Slide the rubber cover over the battery post. 4. Using the bolt and wing nut, connect the negative (black) cable to the negative (—) battery post (Fig. 19). Checking Electrolyte Level 1. Tip the seat forward to see the battery. 2. Look at the side of the battery. The electrolyte must be up to the “UPPER” line (Fig. 21). Do not allow the electrolyte to get below the “LOWER” line (Fig. 21). 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 23. 32 ES A0 17 Ba | — Figure 21 1. Filler caps 3. LOWER line 2. UPPER line Adding Water to the Battery The best time to add distilled water to the battery is Just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 1. Clean the top of the battery with a paper towel. 2. Unscrew the filler caps (Fig. 21). 3. Slowly pour distilled water into each battery cell until the level is up to the “UPPER” line (Fig. 21) on the battery case. IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. 4. Screw the filler caps onto the battery. Maintenance Charging the Battery IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery, page 22. 2. Check the electrolyte level; refer to Checking Electrolyte Level, page 23, steps 2-3. 3. Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery 1s fully charged. POTENTIAL HAZARD e Charging the battery produces gasses. WHAT CAN HAPPEN e Battery gasses can explode. HOW TO AVOID THE HAZARD o Keep cigarettes, sparks and flames away from battery. 4. Install the battery in the chassis; refer to Installing the Battery, page 22. 23 Maintenance Spark Plug Service Interval/Specification Install a new spark plug after every 100 operating hours. Check the spark plug after every 25 operating hours. Make sure the air gap between the center and side electrodes 1s correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool/feeler gauge to check and adjust the air gap. Type: Champion RJ-191.M (or equivalent) Air Gap: 0.030” (0.762 mm) Removing the Spark Plug 1. Disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. “Open the hood. 3. Pull the wire off the spark plug (Fig. 22). Now clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage. 4. Remove the spark plug and metal washer. Figure 22 1. Spark plug wire 2. Spark plug 24 Checking the Spark Plug 1. Look at the center of the spark plug (Fig. 23). 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 15$ dirty. IMPORTANT: Never clean the spark plug. Always replace the spark plug when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Fig. 23). Bend the side electrode (Fig. 23) 1f the gap 1s not correct. 3 — 0.030” (0.762 mm) Figure 23 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Installing the Spark Plug 1. Install the spark plug and metal washer. Make sure the air gap 1s set correctly. 2. Tighten the spark plug to 15 ft-Ib (20.4 Nm). 3. Push the wire onto the spark plug (Fig. 22). 4. Close the hood. Maintenance Fuel Tank Draining The Fuel Tank — 4h DANGER POTENTIAL HAZARD e In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN e A fire or explosion from gasoline can burn you, others, and cause property damage. Figure 24 HOW TO AVOID THE HAZARD - 1. Hose clamp 3. Filter e Drain gasoline from the fuel tank when the 2. Fuelline engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. e Never drain gasoline near an open flame or = where gasoline fumes may be ignited by a Fuel Filter spark. e Never smoke a cigarette, cigar or pipe. Service Interval/Specification Replace the fuel filter after every 100 operating hours 1. Park the machine so that the left front side is or yearly, whichever occurs first. slightly lower than the right side to assure fuel tank drains completely. Then disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. | Replacing the Fuel Filter The best time to replace the fuel filter (Fig. 24) 1s when the fuel tank 1s empty. Never install a dirty 2. Open the hood. filter if it is removed from the fuel line. 3. Squeeze the ends of the hose clamp together and 1. Pisengage - place contre (PTO), shift into slide it up the fuel line toward the fuel tank neutral, set the parking rake, and turn the (Fig. 24). ignition key to “OFF” to stop the engine. 4. Pull the fuel line off the filter (Fig. 24) and allow 2. Open the hood. gasoline to drain into a gas can or drain pan. 3. Squeeze the ends of the hose clamps together Note: Now is the best time to install a new and slide them away from the filter (Fig. 24). fuel filter because the fuel tank 1s 4. empty. Remove the filter from the fuel lines. 5. Install a new filter and move the hose clamps 5. Install the fuel line onto the filter. Slide the hose close to the filter. clamp close to the filter to secure the fuel line and filter. 6. Close the hood. 25 Maintenance Throttle and Choke Control Normally the throttle and choke control does not require adjustment. However, you should check the control adjustment: e Before adjusting the carburetor e If the engine starts hard Checking and Adjusting the Throttle and Choke Control 1. Disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine 2. “Open the hood. 3. Checking Throttle Setting A. Move the dash-mounted throttle lever to “SLOW” and back to “FAST.” The lever must snap into a notch. B. With the throttle in the “FAST” position, index holes in the governor control lever and the governor plate must align (Fig. 25). If they do not align, refer to step 4 for adjustment procedure. 26 Dn. = © Г 7 | Tree Ts НК Г a q 0) Al Af pty №5 E 2 3 4 1671 Figure 25 . Governor plate 4. Throttle cable casing Governor control lever 5. Index hole Screw Adjusting the Throttle A. Make sure the dash-mounted throttle lever 1s in the “FAST” notch. B. Loosen the throttle cable clamp screw until you can slide the throttle cable casing (Fig. 25). C. Move the throttle cable casing until the index holes 1n the governor control lever and the governor plate align (Fig. 25). Now tighten the cable clamp screw. D. Check the throttle setting; refer to steps 3A and 3B. Carburetor To adjust the carburetor, you will need a tachometer to set the idle speed. If you do not have a tachometer or the special knowledge required to adjust the carburetor, contact an authorized service dealer. IMPORTANT: Before you adjust the carburetor: (1) check the throttle control and adjust it if required; refer to Throttle and Choke Control, page 26, and (2) check the air cleaner and clean it if required; refer to Air Cleaner, page 28. POTENTIAL HAZARD e The engine must be running for you to adjust the carburetor. This potentially could be unsafe. WHAT CAN HAPPEN e If you contact a rotating blade or engine blower screen, touch a hot muffler, or the tractor accidentally moves, you or bystanders could be seriously injured or killed. HOW TO AVOID THE HAZARD e Although the engine must be running, set the parking brake, shift into neutral, and disengage the blade control (PTO). Do not touch rotating engine blower screen or the hot muffler. 1. Initial Adjustment A. Gently turn the idle mixture screw (Fig. 26) clockwise until 1t just closes. Do not force (tighten) the idle mixture screw because the carburetor could be damaged. B. Open the idle mixture screw (Fig. 26) one turn counterclockwise. This setting allows you to start the engine. C. Start the engine, move the throttle to “SLOW” and let the engine idle for five minutes. Maintenance 1 À L TT 477 Figure 26 1. Idle mixture screw 3. Throttle arm 2. Idle speed screw 2. Final Adjustment A. Hold the carburetor throttle arm against the idle speed screw (Fig. 26). Adjust the idle speed screw so the engine idles at 1750 rpm. Check the rpm with a tachometer. While you continue holding the throttle arm against the idle speed screw, slowly turn the idle mixture screw (Fig. 26) in (clockwise) until the engine begins to slow (lean mixture). Next, turn the 1dle mixture screw out (counterclockwise) until the engine begins to run roughly (rich mixture). Now rotate the idle mixture screw (Fig. 26) midway between the lean and rich mixture until the engine runs smoothly. Make sure the idle speed is still 1750 rpm. Adjust the idle speed screw if required; step 2A. Move the dash-mounted throttle lever from “SLOW” to “FAST.” If the engine does not accelerate smoothly, turn the 1dle mixture screw counterclockwise to a slightly richer mixture. 27 Maintenance Air Cleaner Service Interval/Specification Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Paper Elements 1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. “Open the hood. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Unscrew the knob and remove the air cleaner cover (Fig. 27). Figure 27 1. Knob 2. Air cleaner cover 28 4. 1. Unscrew the rubber nut and remove the paper clement (Fig. 28). Figure 28 Rubber nut . 2. Paper element Cleaning the Paper Elements 5. Paper Element A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 29). B. 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, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly. Maintenance Figure 29 1. Paper element 2. Rubber seal Installing the Paper Element IMPORTANT: To prevent engine damage, always operate the engine with the complete air cleaner assembly installed. 1. Slide the air cleaner assembly onto the long rod. Now screw the rubber nut finger-tight against the air cleaner (Fig. 28). Note: Make sure the rubber seal 1s flat against the air cleaner base. 2. Install the air cleaner cover and knob (Fig. 27). Tighten the knob snugly. 3. Close the hood. 29 Maintenance Engine Oil Service Interval/Specification Change oil: e After the first 5 operating hours. e After every 25 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SE, SF or SG) Crankcase Capacity: 48 07/1—1/2 qt (1400 cc/1.4 1) Viscosity: See table below USE THESE SAE VISCOSITY OILS 5W-30, 10W-30 pro 0 20 40 60 80 100 Checking Oil Level 1. Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. Open the hood. 3. Clean around the oil dipstick (Fig. 30) so dirt cannot fall into the filler hole and damage the engine. 4. Unscrew the oil dipstick and wipe the metal end clean (Fig. 30). 30 5. Screw the oil dipstick fully onto the filler tube (Fig. 30). Unscrew the dipstick again and look at the metal end. If oil level 1s low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark. IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged. Figure 30 1. Oil dipstick 3. Fillertube 2. Metal end Changing/Draining Oil 1. Start the engine and let 1t run five minutes. This warms the oil so it drains better. 2. Park the machine so that the right front side 1s slightly lower than the left side to assure the oil drains completely. Then disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. 3. Open the hood. 4. Place a pan below the oil dipstick/fill tube and remove the drain plug (Fig. 31). 5. When oil has drained completely, install the drain plug. Note: Dispose of the used oil at a certified recycling center. 6. Slowly pour approximately 80% of the specified amount of oil into the filler tube (Fig. 30). Now check the oil level; refer to Checking Oil Level, page 30, steps 4-5. — ) Figure 31 1. Oil drain plug 2. Oil dipstick/fill tube Maintenance Maintenance Cutting Blade To assure a superior quality of cut, keep the blade(s) sharp. For convenient sharpening and replacement, you may want to have an extra blade(s). ÁN WARNING POTENTIAL HAZARD ‚ ® А blade that is worn or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. WHAT CAN HAPPEN e Pieces of blade that may be thrown could seriously injure or kill you or bystanders. HOW TO AVOID THE HAZARD e Periodically inspect the blade for wear and damage. Immediately install a new blade if it is worn or damaged. Inspecting the Blade(s) 1. Remove the mower; refer to Removing the Mower, page 34. Inspect the cutting edges (Fig. 32). If the edges are not sharp or have nicks, remove the blade(s) and sharpen them; refer to Sharpening the Blade(s), page 33. Inspect the blade(s), especially the curved area (Fig. 32). If you notice any damage, wear, or a slot forming in this area (Fig. 32), immediately install a new blade. 32 1. bere, pr mmm of a F 151 Figure 32 Cutting edge 3. Wear/slot forming 2. Curved area Removing the Blade 1. Remove the mower; refer to Removing the Mower, page 34. Carefully tip the mower over. Remove the bolt (5/87 wrench), curved washer, retainer and blade (Fig. 33). A block of wood may be wedged between the blade and the mower to lock the blade when you are removing the bolt. Inspect all parts. If a defect or damage is noticed, install new parts. Figure 33 1. Bolt 4. Spindle 2. Retainer 5. Curved washer 3. Blade Sharpening the Blade(s) 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 34). Maintain the original angle. The blade retains its balance if the same amount of material 1s removed from both cutting edges. DA — Figure 34 1. Sharpenatoriginal angle 2. Check the balance of the blade by putting 1t on a blade balancer (Fig. 35). If the blade stays in a horizontal position, the blade 15 balanced and can be used. If the blade 1s not balanced, file some metal off the back side of the blade. Repeat this procedure until the blade 1s balanced. A [= |] / “2 1 Figure 35 1. Blade 2. Balancer Maintenance Installing the Blade(s) 1. Install the blade, blade retainer, curved washer (cupped side toward blade), and the blade bolt (Fig. 33). IMPORTANT: The curved part of the blade must be pointing toward the inside of the mower to assure proper cutting. Tighten the blade bolt to 45-60 ft—Ib (61-81 Nm). 33 Maintenance Removing the Mower | 4A CAUTION | ‚ level surf i 1. Park the machine on a level surface, disengage POTENTIAL HAZARD the blade control (PTO), shift into neutral, set | o the parking brake, and turn the ignition key to * The height-of-cut lever (deck lift) is “OFF” to stop the engine. spring-tensioned. WHAT CAN HAPPEN 2. Remove the key from the ignition switch and e When the mower is being removed, this pull the wire off the spark plug. spring-loaded mechanism could suddenly release and injure you or someone else. 3. Move the height-of-cut lever (deck lift) into the HOW TO AVOID THE HAZARD “О” notch. e Move the height-of-cut lever (deck lift) to 4. Remove the height-of-cut lift assist spring from the “D” position and remove the the retaining bolt (Fig. 36), using the spring tool height-of-cut lift assist spring to release the provided with the machine. The spring is spring tension. between the frame and the right rear wheel. 5. Move the height-of-cut lever (deck lift) into the a “A” notch. = = 6. Remove the hair pin cotter and washer from the 7 ; blade control arm on the left side of the mower it (Fig. 37). Slide the rod off the arm. Figure 37 1. Hair pin cotter and washer 2. Rod Figure 36 1. Spring 3. Spring tool 2. Bolt 34 Maintenance 7. Remove the bolts and lock nuts and pull the two IMPORTANT: Tape or tie the long rods mower pivot mount brackets down from the against the chassis to protect them from front axle (Fig. 38). damage when you remove the mower. \ / 10. Remove the mower belt from the lower engine 1 pulley (Fig. 40). If you are careful, you can flex the belt guide(s) just far enough away from the К pulley to remove the belt. If it 1s too difficult to Ny remove the belt, loosen the bolts and nuts N securing the belt guides. > IMPORTANT: Do not bend the belt guide(s) N away from the pulley because the belt will not x operate properly when the mower is installed | E later. X 5 N A K EEE ES 2 a 2 Figure 38 N 4 1. Pivot mount brackets ey 8. Remove the hair pin cotter and washer at the top 5 of the mower leveling bracket (Fig. 39). Now 1 N и slide the bracket off the mounting pin. Repeat this step on the opposite side of the mower. 2 e / 3 1 o © N. и 2 g y > | Figure 40 1. Hair pin cotter and washer 3. Hair pin cotter and washer 1. Mower belt 4. Idler pulley 2. Leveling bracket 4. Long rod 2. Engine pulley 5. 32” mower O 3. Belt guide 9. Remove the hair pin cotter and washer from the end of the long rod (Fig. 39). Now slide the rod 11. Turn the front wheels fully to the left. Slide the out of the mower mount. Repeat this step on the mower out to the right to complete removal. opposite side of the mower. 35 Maintenance Installing the Mower 1. Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key from the ignition switch and pull the wire off the spark plug. Turn the front wheels fully to the left. Slide the mower under the chassis from the right side. Install mower belt onto the lower engine pulley (Fig. 40). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to install the belt. If it is too difficult to install the belt, loosen the bolts and nuts securing the belt guides. IMPORTANT: Do not bend the belt guides away from the pulley. There must be a maximum 1/8” (3.175 mm) between the belt guide and the edge of the pulley to keep the belt on the pulley during operation. If the space is more than 1/8” (3.175 mm), adjust the belt guide(s) and tighten them securely. The belt guide must not contact the pulley. Install the mower pivot mount brackets to the front axle with bolts and lock nuts (Fig. 41). | J \—) 4 Г | 7777077 77777 7777 М yu 0e " 3 ANI SN oh A | = Figure 41 1. Pivot mount brackets — my O E | Le Move the height-of-cut lever (deck lift) into the “A” notch. Slide the end of the long rod through the hole in the mower mount (Fig. 42). Install the washer and hair pin cotter to secure the rod in place. Repeat this step on the opposite side of the mower. Mount the slotted mower leveling bracket onto the pin on the height-of-cut arm (Fig. 42). Install the washer and hair pin cotter to secure the mower. Repeat this step on the opposite side of the mower. Их Figure 42 Rod 3. Leveling bracket Hair pin cotter and washer 4. Mower mount 9. Install the blade control rod onto the blade control arm and secure it with the washer and hair pin cotter (Fig. 43). Figure 43 1. Hair pin cotter and washer 2. Rod 10. Move the height-of-cut lever (deck lift) into the “ID” notch to make it easier to install the height-of-cut lift assist spring. Maintenance 11. Hook the height-of-cut lift assist spring onto the retaining bolt (Fig. 44), using the spring tool provided with the machine. Figure 44 1. Spring 2. Bolt 3. Spring tool 12. Check side-to-side blade level; refer to Side-to-Side Mower Leveling, page 39. 37 Maintenance Blade Drive Belt Removing the Blade Drive Belt 1. Remove the mower; refer to Removing the Mower, page 34. 2. Loosen the belt guide mounting bolts and move belt guides away from the pulley (Fig. 45). 3. Remove the belt from the pulley. Installing the Blade Drive Belt 1. Install the new belt around the blade pulley and inside both belt guides (Fig. 45). 2. Adjust the belt guides so they are 1/8” away from the pulley and tighten mounting bolts (Fig. 45). IMPORTANT: Make certain the left side belt guide is very tight so it does not move when the brake spring pulls against it. 3. Install the mower; refer to Installing the Mower, page 36. DE Б MM a NN ZEN Figure 45 Top View 1. Mower belt 3. Mounting bolt 2. Belt guide 38 Side-to-Side Mower Leveling The mower blades must be level from side to side. Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn. Before you level the mower, set the air pressure 1n the front and rear tires to 12 ps1 (.85 kPa). 1. 1. Blade side to side Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key from the ignition switch and pull the wire off the spark plug. Move the height-of-cut lever (deck lift) into the “C” notch. Carefully rotate blade(s) side to side (Fig. 46). Measure between the outside cutting edges and the flat surface (Fig. 46). If both measurements are not within 3/16” (4.762mm), an adjustment is required; refer to steps 5 and 6. ‚= 3 Figure 46 3. Measure here 2. Outside cutting edges Remove the hair pin cotter and washer from the leveling bracket (Fig. 47). To level the blade(s), reposition the leveling bracket in a different hole and install the washer and hair pin cotter. (Fig. 47). A front hole lowers the blade height and a rear hole raises its height. Repeat this procedure on the opposite side. Maintenance . Hair pin cotter and washer 2. Leveling bracket Figure 47 3. Front hole 4. Rear hole Now check the front-to-rear blade slope; refer to Front-to-Rear Blade Slope, page 40. 39 Maintenance Front-to-Rear Blade Slope Check the front-to-rear blade slope any time you install the mower. Before you check the slope, set the air pressure in the front and rear tires to 12 psi (.85 kPa). If the front of the mower 1s more than 5/8” (15.875 mm) lower than the rear of the mower, adjust the blade slope using the following instructions: 1. Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key from the ignition switch and pull the wire off the spark plug. Check and adjust side-to-side blade level if you have not checked the setting; refer to Side-to-Side Mower Leveling, page 39. Move the height-of-cut lever (deck lift) into the “C” notch. Check the front—to-rear blade slope by measuring between the bottom of the mower (front center and rear center) and the flat surface (Fig. 48). If the front of the mower 1s more than 5/8” (15.875 mm) lower than the rear of the mower, an adjustment 1s required; refer to steps 6—10. 1. Measure front center Figure 48 2. Measure rear center 40 N — . Adjusting block Long rod Measure the length of the rod extending out the front of the adjusting block on the sides of the chassis (Fig. 49). If the rod length 1s not 5/8” (15.875 mm), remove the hair pin cotter and washer from the end of the rod (Fig. 49), and turn the rod until the 5/8” (15.875 mm) dimension is obtained. Then install the end of the rod into the hole in the mower mount and secure in place with washer and hair pin cotter. Repeat this procedure on the opposite side of the mower. (15.875 mm) — Figure 49 3. Hair pin cotter and washer 4. Mower mount Check the front-to-rear slope again. If the front of the mower is more than 5/8” (15.875 mm) lower than the rear of the mower, proceed to step 8 for adjusting instructions. Otherwise, recheck the side-to-side level to assure it did not change. Adjust the front-to-rear slope by rotating the special slope adjusting nuts on both sides of the mower pivot mount (Fig. 50). Using a 1” wrench or socket slowly rotate the left side slope adjusting nut down to raise the front of the mower and up to lower it (Fig. 50). Rotate the slope adjusting nut until the front of the mower 1s 1/4” to 5/8” (6.350 mm to 15.875 mm) lower than the rear of the mower. Maintenance 10. Now slowly rotate the right side slope adjusting nut until both adjusting nuts are in the same position. IMPORTANT: If the slope adjustment does not stay in position after you adjust it, tighten the center bolt and lock nut and — repeat step 9. Q № N Figure 51 TN A 1. Mower pivot 3. Lock nut ) 2. Shoulder bolt 4. Mower NO 15. Recheck the front-to-rear slope again; refer to LI step 5. > 16. When front-to-rear slope is correct, recheck the — | side-to-side level of the mower; refer to Side-to-Side Mower Leveling, page 39. A . . 17. Push the wire onto the spark plug. Figure 50 1. Slope adjusting nut (left) 2. Bolt and lock nut B = Up to lower mower 11. Ifthe 1/4” to 5/8” (6.350 mm to 15.875 mm) front slope cannot be achieved by rotating the slope adjusting nut, move the mower pivot mount at the mower (Fig. 51). 12. Remove the shoulder bolts and lock nuts from the mower (Fig. 51). 13. Lower the mower pivot one hole and install the shoulder bolts and lock nuts (Fig. 51). Note: If your mower has only one hole, see an Authorized Service Dealer. 14. Repeat front-to-rear blade slope adjustment; refer to steps 8-10. 41 Maintenance Storage 1. 10. 42 Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Also remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine, shrouding, and the top of the mower. 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, lights, engine, and the battery. Scrape heavy buildup of grass and dirt from the underside of the mower. Then wash the mower with a garden hose. Check the condition of the blade(s); refer to Cutting Blade, page 32. Check the condition of the blade drive belt. Check the brake; refer to Brake, page 19. Service the air cleaner; refer to Air Cleaner, page 28. Grease the chassis; refer to Greasing and Lubrication, page 18. Change the crankcase oil; refer to Engine Oil, page 30. Remove the spark plug and check its condition; refer to Spark Plug, page 24. With the spark plug removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the electric starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug and tighten it to 15 ft-lb (20.4 Nm). Do not install the wire on the spark plug. Remove the battery from the chassis, check the electrolyte level, and charge it fully; refer to Battery, page 22. Do not connect the battery cables to the battery posts during storage. 11. 12. 13. 14. 15. IMPORTANT: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32°F (0°C). A fully charged battery maintains its charge for about 50 days at temperatures lower than 40°F (4°C). If the temperatures will be above 40°F (4°C), check the water level in the battery and charge it every 30 days. Check the tire pressure; refer to Tire Pressure, page 19. During long-term storage, either drain gasoline from the fuel tank (step A) or add a fuel additive to a full tank of gasoline (step B). A. Drain gasoline from the fuel tank; refer to Fuel Tank, page 25. After fuel 1s drained, start the engine and let it idle until all gasoline is consumed and the engine stops. This eliminates gum-like buildup in the fuel system, which causes hard starting. Try to start the engine two more times to assure that no gasoline is in the fuel system. B. Add the correct amount of Toro Stabilizer/Conditioner or an isopropyl-based stabilizer/conditioner to a full tank of gasoline. Note: Stabilizer/conditioners normally preserve gasoline for six to eight months. Check and tighten ali bolts, nuts, and screws. Repair or replace any part that is damaged or defective. Paint all scratched or bare metal surfaces. Paint is available from you Authorized Service Dealer. 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. Troubleshooting Parking brake is not on. Battery is dead. Electrical connections are corroded or loose. Fuse is blown. Relay or switch is defective. PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Starter does not crank Blade control (PTO) is Move blade control (PTO) to ENGAGED. DISENGAGED. Set parking brake. Charge the battery. Check electrical connections for good contact. Replace fuse. Contact Authorized Service Dealer. Engine will not start, starts hard, or fails to keep running. Operator is not seated. Fuel tank is empty. Air cleaner is dirty. Spark plug wire is loose or disconnected. Spark plug is pitted, fouled, or gap is incorrect. Choke is not closing. Dirt in fuel filter. Idle speed is too low or mixture is incorrect. Dirt, water, or stale fuel is in fuel system. Sit on the seat. Fill fuel tank with gasoline. Clean or replace air cleaner element. Install wire on spark plug. Install new, correctly gapped spark plug. Adjust throttie cable. Replace fuel filter. Adjust carburetor idle speed and idle mixture. Contact Authorized Service Dealer. Engine loses power. Engine load is excessive. Air cleaner is dirty. Oil level in crankcase is low. Cooling fins and air passages under engine blower housing are plugged. Spark plug is pitted, fouled, or gap is incorrect. Shift into lower gear to reduce ground speed. Clean air cleaner element. Add oil to crankcase. Remove obstruction from cooling fins and air passages. Install new, correctly gapped spark plug. 43 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Engine loses power (continued). Vent hole in fuel cap is plugged. Dirt in fuel filter. Dirt, water, or stale fuel is in fuel system. Clean or replace the fuel cap. Replace fuel filter. Contact Authorized Service Dealer. Engine over heats. Engine load is excessive. Qil level in crankcase is low. Cooling fins and air passages under engine blower housing are plugged. Shift into lower gear to reduce ground speed. Add oil to crankcase. Remove obstruction from cooling fins and air passages. Abnormal vibration. Cutting blade(s) is bent or unbalanced. . Blade mounting bolt is loose. Engine mounting bolts are loose. Loose engine pulley, idler pulley, or blade pulley. Engine pulley is damaged. Install new cutting blade(s). Tighten blade mounting bolt. Tighten engine mounting bolts. Tighten the appropriate pulley. Contact Authorized Service Dealer. Blade(s) does not rotate. Blade drive belt is worn, loose or broken. Blade drive belt is off pulley. Install new blade drive belt. Install blade drive belt and check idler puiley and belt guides for correct position. Machine does not drive. Traction belt is worn, loose or broken. Traction belt is off pulley. Transmission does not shift. Contact Authorized Service Dealer. Contact Authorized Service Dealer. Contact Authorized Service Dealer. Uneven cutting height. Tire pressure is incorrect. Mower is not level. Underside of mower is dirty. Set tire pressure. Level mower from side-to-side and front-to-rear. Clean the underside of the mower. 44 UPL-62184 Gas Powered Consumer Products Except WPM THE TORO TOTAL COVERAGE GUARANTEE A Full Two-— Year Warranty (Limited Warranty for Commercial Use) What Is Covered By This Express Warranty? The Toro Company promises to repair any TORO Product used for normal residential purposes* if defective in materials or workmanship for a period of two years from the date of purchase. The cost of parts and labor is included, but the customer pays the transportation costs. Transportation within a 15 mile radius of the servicing dealer is covered under this warranty for two —stage snowthrowers, walk behind debris equipment and all TORO Wheel Horse riding products. Single stage snowthrowers, and other prod- ucts not specifically covered, are excluded from the transpor- tation coverage provided by this warranty. What Products Are Covered By This Warranty? This warranty applies to all gasoline powered consumer prod- ucts except walk power mowers. ProLine riding products, wide area walk behind mowers and 18” and 21” mowers are covered by separate warranty statements. How About Commercial Use? TORO Consumer Products used for commercial, institutional or rental use are covered by a limited warranty for the follow- ing time periods from the date of purchase: Products Warranty Period e 300, 400 and 500 Series Lawn and Garden Tractors Chassis ....... 1 year limited warranty Engine ....... 2 year limited warranty e 260 Series Lawn and Garden Tractors, XL Lawn Tractors, Rear Engine Riders, Straight Shaft Trimmers, and Backpack Blowers ..... 90 day limited warranty e AllOthers ................. 45 day limited warranty How Do You Get Warranty Service? Should you feel your TORO Product contains a defect in ma- terial or workmanship, contact the dealer who sold you the product or any Authorized TORO Service Dealer or TORO Master Service Dealer. The Yellow Pages of your telephone directory is a good reference source. The dealer will either arrange service at his/her dealership or recommend another Authorized Service Dealer who may be more convenient. You may need proof of purchase (copy of registration card, sales receipt, etc.) for warranty validation. If for any reason you are dissatisfied with the Service Dealer's analysis of the defect in materials or workmanship or if you need a referral to a TORO Service Dealer, please feel free to contact us at the following address: Toro Customer Service Department 8111 Lyndale Avenue South Bloomington, MN 55420-1196 612-888-8801 800-348-2424 What Must You Do To Keep The Warranty In Effect? You must maintain your TORO Product by following the main- tenance procedures described in the operator's manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense. What Does This Warranty Not Cover? and How Does Your State Law Relate To This Warranty? There is no other express warranty except the TORO Starting Guarantee on GTS Engines. This express warranty does not cover: e Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune—up parts, blade sharpening, brake and clutch adjustments. e 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. e 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. e Pickup and delivery charges for distances beyond a 15 mile radius from an Authorized TORO Service Dealer (covered products oniy). All repairs covered by this warranty must be performed by an Authorized TORO Service Dealer using Toro approved replace- ment parts. Repair by an Authorized TORO Service Dealer is your sole remedy under this warranty. The Toro Company is not 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 ser- vice during reasonable periods of malfunction or non—use pending completion of repairs under this warranty. Some states do not allow exclusions of incidental or consequen- tial damages, so the above exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. * Normal residential purposes means mowing the lawn on the same lot as your home. Use at more than one location is considered commercial use and the commercial use war- ranty would apply. 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 Dis tributor (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 The Toro Company.
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