Toro 12-32XL Lawn Tractor Riding Product Operator's Manual

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 ...............
=~
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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).
—
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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.
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Figure 15
1. Brake adjusting nut
19
Maintenance
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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
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Figure 16
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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
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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
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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
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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.