Toro 13-32XLE Lawn Tractor User manual

Toro 13-32XLE Lawn Tractor User manual
Form No. 3326-504
13-32XLE
Wheel Horse Lawn Tractor
Model No. 71209—Serial No. 220010001 and Up
Operator’s Manual
International English (GB)
This spark ignition system complies with Canadian
ICES-002.
Draining the Fuel Tank . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . .
Servicing the Fuse . . . . . . . . . . . . . . . . . . . . . . . .
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Cutting Blade . . . . . . . . . . . . . . . . .
Removing the Mower . . . . . . . . . . . . . . . . . . . . . .
Installing the Mower . . . . . . . . . . . . . . . . . . . . . .
Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower from Side-to-Side . . . . . . . .
Adjusting the Front-to-Rear Blade Slope . . . . . . .
Washing the Underside of the Mower . . . . . . . . .
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Safe Operation Practices for Ride-on (riding) Rotary
Lawnmower Machines . . . . . . . . . . . . . . . . . . .
3
Safe Operating Practices . . . . . . . . . . . . . . . . . . . .
3
Toro Riding Mower Safety . . . . . . . . . . . . . . . . . .
5
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . .
5
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . .
5
Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Safety and Instruction Decals . . . . . . . . . . . . . . . .
9
Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Recommended Gasoline . . . . . . . . . . . . . . . . . . . .
11
Using Stabilizer/Conditioner . . . . . . . . . . . . . . . .
12
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . .
12
Checking the Engine Oil Level . . . . . . . . . . . . . .
12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . .
12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . .
13
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Using the Blade Control (PTO) . . . . . . . . . . . . . .
13
Setting the Height of Cut . . . . . . . . . . . . . . . . . . .
14
Starting and Stopping the Engine . . . . . . . . . . . . .
14
The Safety System . . . . . . . . . . . . . . . . . . . . . . . .
15
Testing the Safety System . . . . . . . . . . . . . . . . . . .
16
Driving Forward or Backward . . . . . . . . . . . . . . .
16
Selecting Ground Speeds . . . . . . . . . . . . . . . . . . .
16
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . .
17
Side Discharge or Mulch Grass . . . . . . . . . . . . . .
17
Installing the Discharge Cover . . . . . . . . . . . . . . .
17
Tips for Mowing Grass . . . . . . . . . . . . . . . . . . . . .
18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Recommended Maintenance Schedule . . . . . . . . .
19
Servicing the Engine Oil . . . . . . . . . . . . . . . . . . .
20
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . .
21
Servicing the Brake . . . . . . . . . . . . . . . . . . . . . . .
23
Greasing and Lubrication . . . . . . . . . . . . . . . . . . .
23
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . .
23
Servicing the Spark Plug . . . . . . . . . . . . . . . . . . .
25
Checking the Tire Pressure . . . . . . . . . . . . . . . . . .
26
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Page
26
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27
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29
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37
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
m–1856
Figure 1
1. Location of the model and serial numbers
All Rights Reserved
2
Printed in the USA
Training
Write the product model and serial numbers in the space
below:
• Read the instructions carefully. Be familiar with the
controls and the proper use of the equipment.
Model No.
• Never allow children or people unfamiliar with these
instructions to use the lawnmower. Local regulations
can restrict the age of the operator.
Serial No.
• Never mow while people, especially children, or pets
are nearby.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
• Do not carry passengers.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
• All drivers should seek and obtain professional and
practical instruction. Such instruction should
emphasize:
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
– the need for care and concentration when working
with ride-on machines;
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• insufficient wheel grip;
• being driven too fast;
• inadequate braking;
Safety
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
Safe Operation Practices for
Ride-on (riding) Rotary
Lawnmower Machines
• incorrect hitching and load distribution.
Preparation
This machine meets or exceeds European Standards 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
symbol, which means CAUTION,
WARNING, or DANGER—“personal safety
instruction.” Failure to comply with the instruction may
result in personal injury or death.
• While mowing, always wear substantial footwear and
long trousers. Do not operate the equipment when
barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
• Warning—Fuel is highly flammable.
Safe Operating Practices
– Store fuel in containers specifically designed for this
purpose.
The following instructions are from the CEN standard EN
836:1997.
– Refuel outdoors only and do not smoke while
refuelling.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
3
• Stop the blades rotating before crossing surfaces other
than grass.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
– Replace all fuel tanks and container caps securely.
• Never operate the machine with damaged guards or
without safety protective devices in place.
• Replace faulty silencers.
• Before using, always visually inspect to see that the
blades, blade bolts and cutter assembly are not worn or
damaged. Replace worn or damaged blades and bolts in
sets to preserve balance.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed can increase the hazard of personal injury.
• Before leaving the operator’s position:
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
– disengage the power take-off and lower the
attachments;
Operation
– change into neutral and set the parking brake;
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
– stop the engine and remove the key.
• Disengage drive to attachments, stop the engine, and
disconnect the spark plug wire(s) or remove the ignition
key
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches and shift into neutral.
– before clearing blockages or unclogging chute;
• Do not use on slopes of more than
– before checking, cleaning or working on the
lawnmower;
– 5 when mowing on side hills;
– after striking a foreign object. Inspect the
lawnmower for damage and make repairs before
restarting and operating the equipment;
– 10 when mowing uphill;
– 15 when mowing downhill.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– if the machine starts to vibrate abnormally (check
immediately).
• Disengage drive to attachments when transporting or
not in use.
– do not stop or start suddenly when going up or
downhill;
• Stop the engine and disengage drive to attachment
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– before refuelling;
– before removing the grass catcher;
– machine speeds should be kept low on slopes and
during tight turns;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– stay alert for humps and hollows and other hidden
hazards;
• Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.
– never mow across the face of the slope, unless the
lawnmower is designed for this purpose.
• Use care when pulling loads or using heavy equipment.
Maintenance and Storage
– Use only approved drawbar hitch points.
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
– Limit loads to those you can safely control.
– Do not turn sharply. Use care when reversing.
• Never store the equipment with fuel in the tank inside a
building where fumes can reach an open flame or spark.
– Use counterweight(s) or wheel weights when
suggested in the instruction handbook.
• Allow the engine to cool before storing in any
enclosure.
• Watch out for traffic when crossing or near roadways.
4
• To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of grass,
leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Replace worn or damaged parts for safety.
• If the fuel tank has to be drained, this should be done
outdoors.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
• When machine is to be parked, stored or left
unattended, lower the cutting means unless a positive
mechanical lock is used.
Toro Riding Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN standard.
• Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of: 86 dB(A), based on
measurements of identical machines per procedures
outlined in Machine Directive 98/37/EC and amendments.
Sound Power Level
This unit has a sound power level of: 100 Lwa, based on
measurements of identical machines per procedures
outlined in Noise Directive 2000/14/EC and amendments.
Vibration Level
This unit has a maximum hand-arm vibration level of
5.39 m/s2 and whole body vibration level of 0.27 m/s2,
based on measurements of identical machines per EN 1033
and EN 1032.
5
6
Slope Chart
7
8
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
92-5730
1. Choke
2. Throttle—fast
3. Throttle—slow
93-6675
1. To set the parking brake, push the clutch/brake pedal, lift the
parking brake lever, and take your foot off of the clutch/brake
pedal.
2. To release the parking brake, push the clutch/brake pedal.
3. Throttle—fast
4. Throttle—slow
5. Warning—read the operator’s manual.
6. Warning—tipping hazard. Do not drive across slopes greater
than 5 degrees, up slopes greater than 10 degrees, or down
slopes greater than 15 degrees.
7. Thrown object hazard—keep bystanders away.
8. Thrown object hazard from mower—keep the deflector in
place.
9. Cutting/dismemberment hazard of hands or feet—stay away
from rotating blades and moving parts.
10. Crushing/dismemberment hazard—keep bystanders away.
93-6673
1. Parking brake
2. PTO—engage
3. PTO—disengage
99-2986
1. Crushing and
dismemberment
hazard—look back and
down while backing up.
2. Do not activate the
operating-in-reverse
feature when bystanders
are present.
3. Keep children away.
93-7009
1. Thrown object hazard from mower—keep the deflector in
place.
2. Cutting/dismemberment hazard of hands and feet—stay away
from rotating blades and moving parts.
9
104–4164
1. Contains lead,—do not
throw the battery in the
garbage.
2. Recycle
3. Wear eye
protection—explosive gases
can cause blindness and
other injuries.
4. No sparks, flame, or
smoking
5. Sulfuric acid can cause
blindness or severe burns.
6. Flush eyes immediately with
water and get medical help
fast.
7. Maximum fill line
8. Minimum fill line
9. Instructions for activating the
battery.
93-6674
1. Crushing hazard of fingers or hand—read the operator’s
manual before performing maintenance work.
93-7010
1. Thrown objects hazard—keep bystanders away.
2. Thrown object hazard from mower—keep the deflector in
place.
3. Cutting/dismemberment hazard of hands and feet—stay away
from rotating blades and moving parts.
99-5340
1. KeyChoice—turn to mow in reverse.
10
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.
104-4163
1. Explosion hazard
2. No sparks, flame, or
smoking
3. Caustic liquid
hazard—burns to hand
and damage to items
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.
4. Wear eye protection
5. Read the operator’s
manual
6. Keep bystanders away
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 in. (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
99-8142
1. Operating-in-reverse light
2. Engine off
3. Engine on
4. Engine start
11
Using Stabilizer/Conditioner
Operation
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
Think Safety First
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage, drain the fuel tank.
Please carefully read all of the safety instructions and
decals in the safety section. Knowing this information
could help you, your family, pets, or bystanders avoid
injury.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel system,
which causes hard starting
Controls
Important Do not use fuel additives containing
methanol or ethanol.
Become familiar with all of the controls (Fig. 2) before you
start the engine and operate the machine.
Add the correct amount of gas stabilizer/conditioner to the
gas.
1
10
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at all
times.
2
9
3
4
Filling the Fuel Tank
11
1. Shut the engine off and set the parking brake.
2. Clean around the fuel tank cap and remove the cap. Add
unleaded regular gasoline to the fuel tank until the level
is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the
filler neck. This space in the tank allows gasoline to
expand. Do not fill the fuel tank completely full.
5
8
6
7
3. Install the fuel tank cap securely. Wipe up any gasoline
that may have spilled.
12
Checking the Engine Oil Level
Before you start the engine and use the machine, check the
oil level in the engine crankcase; refer to Checking the Oil
Level, page 20.
Figure 2
1. Steering wheel
2. Light switch—on/off
(selected models)
3. Ignition switch
4. Clutch/brake pedal
5. Blade control (PTO)
6. Ground speed selector
12
7. Height-of-cut lever
(deck lift)
8. Parking brake lever
9. Throttle lever
10. Hood opening
11. Operating-in-reverse light
12. KeyChoice switch
Parking Brake
Always set the parking brake when you stop the machine or
leave it unattended.
1
Setting the Parking Brake
1. Push the clutch/brake pedal (Fig. 3) down and hold it in
the depressed position.
2. Lift the parking brake lever (Fig. 3) up and gradually
take your foot off of the clutch/brake pedal. The
clutch/brake pedal should stay in the depressed (locked)
position.
m–1862
Figure 4
1. Adjustment knob
Releasing the Parking Brake
1. Push down on the clutch/brake pedal (Fig. 3). The
parking brake lever should release.
Headlights
2. Gradually release the clutch/brake pedal.
Headlights are optional on some models. A dash-mounted
On/Off switch (Fig. 2) controls the headlights. The lights
only shine while the engine is running and the switch is On.
1
Using the Blade Control (PTO)
2
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
m–1880
Figure 3
1. Clutch/brake pedal
1
2. Parking brake lever
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.
3
m–1852
Figure 5
1. Disengaged
2. Engaged
1. Raise the seat and loosen the adjustment knob (Fig. 4).
2. Move the seat to the desired position and tighten the
knob.
13
3. Blade control (PTO)
Disengaging the Blade(s)
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 37.
1. Depress the clutch/brake pedal to stop the machine.
2. Move the PTO to Disengaged (Fig. 5).
7. 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.
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. The cutting height
may be set in one of seven positions from approximately 1
to 4 in. (25 to 102 mm).
1
Pull on the height-of-cut lever (deck lift) and move it to the
desired position (Fig. 6).
m–1893
Figure 7
1 in. (25 mm)
1
1. Ground speed selector
1-1/2 in. (38 mm)
2 in. (51 mm)
2
2-1/2 in. (64mm)
3 in. (76 mm)
3-1/2 in. (89 mm)
4 in. (102 mm)
m–1881
1
Figure 6
1. Height-of-cut lever (deck lift)
3
Starting and Stopping the
Engine
m–1852
Figure 8
1. Disengaged
2. Engaged
Starting
3. Blade control (PTO)
1. Sit down on the seat.
1
2. Set the parking brake; refer to Setting the Parking
Brake, page 13.
2
Note: The engine will not start unless you set the parking
brake or fully depress the clutch/brake pedal.
3
3. Move the ground speed selector into neutral (N)
(Fig. 7).
4. Move the PTO to Disengaged (Fig. 8).
m–1859
Figure 9
5. Move the throttle lever to Choke (Fig. 9).
1. Choke
2. Fast
Note: An engine that has been running and is warm may
not require step 5.
6. Turn the ignition key clockwise and hold it in the Start
position (Fig. 10). When the engine starts, release the
key.
14
3. Slow
Setting the KeyChoice Switch to
Operate in Reverse
2
3
An interlock feature on the tractor prevents the power take
off (PTO) from operating when backing up. If you shift into
reverse with the PTO engaged (i.e., with mower blades or
other attachment running), the engine will stop. Do not
mow in reverse unless absolutely necessary.
If you need to use the PTO while backing up, you can turn
off this interlock feature using the KeyChoice switch
located near the seat bracket (Fig. 11).
1
Figure 10
1. Start
2. On
3. Off
Danger
You could back over a child or bystander while the
mower blade(s) or other attachment is engaged
and cause serious injury or death.
Stopping
• Do not mow in reverse unless absolutely
necessary.
• Do not insert the KeyChoice key unless it is
absolutely necessary.
• Always look backward and down before
backing up.
• Use the KeyChoice switch only if you are certain
no children or other bystanders will enter the
mowing area.
• Be very observant after deactivating the
interlock because the sound of the engine may
prevent you from noticing that a child or
bystander has entered the work area.
• Always remove both the ignition and KeyChoice
keys and put them in a safe place out of the
reach of children or unauthorized users when
leaving the unit unattended.
1. Move the throttle lever to Slow (Fig. 9).
2. Turn the ignition key to Off (Fig. 10).
The Safety System
Caution
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly,
causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
• Replace switches every two years regardless of
whether they are operating properly or not.
1. Engage the PTO.
2. Insert the KeyChoice key into the switch (Fig. 11).
Understanding the Safety System
The safety system is designed to prevent the engine from
starting unless:
• The clutch/brake pedal is depressed.
1
• The PTO is 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 is Engaged.
M-4157
Figure 11
1. KeyChoice switch
15
3. Turn the KeyChoice key.
4. Put the PTO lever in the Disengage position, the ground
speed selector in Neutral, and set the parking brake.
Start the engine. While the engine is running, move the
PTO lever to the Engage position, push in the clutch,
and put the ground speed selector in Reverse. The
engine should stop.
A red light on the front console (Fig. 12) turns on,
indicating that the interlock is disabled.
5. Put the PTO lever in the Disengage position, the ground
speed selector in Neutral, and set the parking brake.
Start the engine. Move the PTO lever to the Engage
position and turn the KeyChoice key and release it. The
operating-in-reverse warning light should illuminate.
Move the PTO lever to the Disengage position and the
operating-in-reverse warning light should turn off.
1
Driving Forward or Backward
m–1863
Figure 12
The throttle control regulates the engine speed as measured
in RPM (revolutions per minute).
1. Operating-in-reverse light
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. Shift into reverse and complete your task.
5. Stop the PTO of the engine to activate the interlock.
6. Remove the KeyChoice key and put it in a safe place
out of reach of children.
Note: For reverse motion, with the PTO engaged, the
operating-in-reverse interlock must be deactivated by the
KeyChoice switch located in front of and below the seat.
Testing the Safety System
Caution
Caution
Sudden release of the clutch pedal could cause you
to lose control and suddenly put the machine in
motion.
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
Always release the clutch pedal slowly when
starting the machine in motion.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
Selecting Ground Speeds
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. While sitting in the seat, perform the
following checks:
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 is powerful enough to move out in
any speed. If it will not move out in a selected speed
(i.e., #5) due to a heavy load, use a lower speed (i.e., #2).
1. Move the ground speed selector into Neutral. Set the
parking brake. Move the PTO to Engaged. Now turn the
ignition key to Start; the engine should not crank.
2. With the ground speed selector in Neutral, move the
PTO to Disengaged and release the parking brake. Turn
the ignition key to Start; the engine should not crank.
Important Do not shift on slopes. Choose a slow speed
so that you will not have to stop or shift while on the slope.
3. With the ground speed selector in Neutral, set the
parking brake and move the PTO to Disengaged. Start
the engine. While the engine is running, release the
parking brake and rise slightly from the seat; the engine
should stop.
16
Stopping the Machine
Installing the Discharge Cover
To stop the machine, depress the clutch/brake pedal, shift
into neutral, disengage the 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 13. Remember to remove the keys from the
ignition and KeyChoice switches.
To convert from side discharge to a mulching mower,
install the discharge cover into the opening at the side of
the mower.
1. Shut the engine off and remove the ignition key.
2. Lift the grass deflector and place the discharge cover
over the opening onto the lower lip of the mower and
slide it into the front hinge (Fig. 13).
Caution
3. Slide the hinge pin through the hinge (Fig. 13).
Children or bystanders may be injured if they
move or attempt to operate the tractor while it is
unattended.
4. Secure the discharge cover to the mower with the wing
nut (Fig. 13).
Always remove the ignition and KeyChoice keys
and set the parking brake when leaving the
machine unattended, even if just for a few minutes.
1
4
5
Important To prevent excessive wear, 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.
Side Discharge or Mulch Grass
Danger
3
2
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. Contact with rotating mower
blade(s) and thrown debris will cause injury or
death.
m–1896
Figure 13
1. Grass deflector
2. Discharge cover
3. Lower lip
• Never remove the grass deflector from the
4. Hinge pin
5. Wing nut
5. To convert back to a side discharge mower, remove the
discharge cover and lower the grass deflector over the
discharge opening.
mower because the grass deflector routes
material down toward the turf. If the grass
deflector is ever damaged, replace it
immediately.
• Never put your hands or feet under the mower.
• Never try to clear discharge area or mower
blades unless you move the PTO to Off and
rotate the ignition key to Off. Also remove the
key and pull the wire off the spark plug(s).
The mower has a hinged grass deflector that disperses
clippings to the side and down toward the turf.
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 17.
17
Tips for Mowing Grass
When Stopping
Fast Throttle Setting
If the machine must be stopped while mowing, a clump of
grass clippings may drop onto your lawn. To avoid this:
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.
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.
Using the Mower for the First Time
Keep the Underside of the Mower Clean
Cut the grass slightly longer than normal to ensure that the
cutting height of the mower does not scalp any uneven
ground. However, the cutting height used in the past is
generally the best one to use. When cutting grass longer
than 6 in. (15 cm) tall, you may want to cut the lawn twice
to ensure an acceptable quality of cut.
Use the washout port to 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.
Cut 1/3 of the Grass Blade
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.
Blade Maintenance
It is best to cut only about 1/3 of the grass blade. Cutting
more than that is not recommended, unless grass is 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.
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 is not cut too short.
Long Grass
If the grass is 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.
18
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
Maintenance Procedure
After first 5 hours of use
• Change the engine oil.
Each use
• Check the engine oil level.
• Check the safety system.
• Clean the mower housing.
Every 5 hours
• Check the brakes.
• Check the cutting blade.
Every 25 hours
•
•
•
•
Every 50 hours
• Change the engine oil.2
• Check the battery electrolyte.
Every 100 hours
•
•
•
•
Service the paper air cleaner.1
Replace the spark plug.
Replace the fuel filter.
Clean the cooling system.1
Before storage
•
•
•
•
•
Perform all of the maintenance procedures listed above.
Check the belts for wear/cracks.
Drain the fuel tank.
Paint chipped surfaces.
Charge the battery and disconnect the cables.
After storage
•
•
•
•
•
Check the safety system.
Check the brakes.
Check the spark plug.
Check the battery electrolyte.
Check the tire pressure.
1More
2More
Grease the chassis.1
Service the foam air cleaner.1
Check the spark plug.
Check the tire pressure.
often in dusty, dirty conditions
often when operating the engine under heavy load or in high temperatures
Important
Refer to your engine operator’s manual for additional maintenance procedures.
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug before you do any
maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
19
Servicing the Engine Oil
1
2
Check the oil level daily or after every 8 hours.
Change the oil after the first 5 operating hours and every 50
operating hours thereafter.
3
Note: Change the oil more frequently when operating
conditions are extremely dusty or sandy.
Oil Type: Detergent oil (API service SF, SG, SH, SJ, or
higher)
Crankcase Capacity: 48 oz./1-1/2 qt. (1400 cc/1.4 l)
m–1868
Viscosity: See the table below.
Figure 14
1. Oil dipstick
2. Metal end
USE THESE SAE VISCOSITY OILS
3. Filler tube
Changing and Draining the Oil
1. Start the engine and let it run for five minutes. This
warms the oil so that it drains better.
–20
°F
0
–30
°C
–20
20
–10
40
0
60
10
80
20
100
30
2. Park the machine so that the right front side is slightly
lower than the left side to ensure that the oil drains
completely. Then disengage the PTO, shift into neutral,
set the parking brake, stop the engine, and remove the
ignition key.
40
3. Open the hood.
Checking the Oil Level
4. Place a pan below the oil dipstick/fill tube and remove
the drain plug (Fig. 15).
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
5. When the oil has drained completely, install the drain
plug.
2. Open the hood.
Note: Dispose of the used oil at a certified recycling center.
3. Clean around the oil dipstick (Fig. 14) so that dirt
cannot fall into the filler hole and damage the engine.
6. Slowly pour approximately 80% of the specified
amount of oil into the filler tube (Fig. 14). Check the oil
level; refer to Checking the Oil Level, page 20,
steps 4–5.
4. Unscrew the oil dipstick and wipe the metal end clean
(Fig. 14).
5. Screw the oil dipstick fully onto the filler tube (Fig. 14).
Unscrew the dipstick again and look at the metal end. If
the oil level is low, slowly pour only enough oil into the
filler tube to raise the level to the Full mark on the
dipstick.
2
Important Do not overfill the crankcase with oil
because the engine may be damaged.
1
m–1869
Figure 15
1. Oil drain plug
20
2. Oil dipstick/fill tube
Servicing the Battery
4. Slide the rubber cover up the positive (red) cable.
Disconnect the positive (red) cable from the battery post
(Fig. 16).
Warning
5. Remove the battery box and battery from the chassis
(Fig. 16).
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
2
5
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, 155 Cold Cranking Amps
1
4
Removing the Battery
3
m–4965
Figure 16
Warning
1. Negative cable (black)
2. Rubber cover
3. Positive cable (red)
Battery terminals or metal tools could short
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
4. Battery box
5. Bolt and wing nut
Installing the Battery
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the tractor.
1. Put the battery into the battery box and install it into the
chassis (Fig. 16).
2. Using the bolt and wing nut, connect the positive (red)
cable to the positive (+) battery post (Fig. 16). Slide the
rubber cover over the battery post.
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
3. Using the bolt and wing nut, connect the negative
(black) cable to the negative (–) battery post (Fig. 16).
2. Tip the seat forward to see the battery.
3. Disconnect the negative (black) ground cable from the
battery post (Fig. 16).
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
21
Checking the Electrolyte Level
Important Do not overfill the battery because
electrolyte (sulfuric acid) can cause severe corrosion and
damage to the chassis.
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. 17). Do not allow the
electrolyte to fall below the Lower line (Fig. 17).
5. Wait five to ten minutes after filling the battery cells.
Add distilled water, if necessary, until the electrolyte
level is up to the Upper line (Fig. 17) on the battery
case.
3. If the electrolyte is low, add the required amount of
distilled water; refer to Adding Water to the Battery,
page 22.
6. Reinstall the battery vent caps.
Charging the Battery
1
Warning
2
3
Charging the battery produces gasses that can
explode.
m-5004
Never smoke near the battery and keep sparks and
flames away from battery.
Figure 17
1. Vent caps
2. Upper line
3. Lower line
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).
Danger
1. Remove the battery from the chassis; refer to Removing
the Battery, page 21.
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
2. Check the electrolyte level; refer to Checking the
Electrolyte Level, page 22.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
3. Make sure that the vent caps are installed in the battery.
Charge the battery for 1 hour at 25 to 30 amps or 6
hours at 4 to 6 amps. Do not overcharge the battery.
4. When the battery is fully charged, unplug the charger
from the electrical outlet, then disconnect the charger
leads from the battery posts (Fig. 18).
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.
4
2
1. Remove the battery from the tractor; refer to Removing
the Battery, page 21.
1
3
2. Clean the top of the battery with a paper towel.
Important Never fill the battery with distilled water
while the battery is installed in the tractor. Electrolyte could
be spilled on other parts and cause corrosion.
3. Remove the vent caps from the battery (Fig. 17).
m–4970
4. Slowly pour distilled water into each battery cell until
the electrolyte level is up to the Upper line (Fig. 17) on
the battery case.
Figure 18
1. Positive battery post
2. Negative battery post
22
3. Red (+) charger lead
4. Black (–) charger lead
5. Install the battery in the tractor and connect the battery
cables; refer to Installing the Battery, page 21.
Greasing and Lubrication
Note: Do not run the tractor with the battery disconnected.
Electrical damage may occur.
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.
Servicing the Brake
Grease Type: General-purpose grease
The brake is on the right side of the rear axle, inside the
rear tire (Fig. 19). If the brake does not hold securely or
stopping power is insufficient, an adjustment is required.
How to Grease
Checking the Brake
2. Clean the grease fittings with a rag. Make sure to scrape
any paint off of the front of the fitting(s).
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
3. Connect a grease gun to the fitting. Pump grease into
the fittings.
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
4. Wipe up any excess grease.
2. If the rear wheels lock and skid when you push the
tractor forward, no adjustment is required. An
adjustment is required if the wheels turn and do not
lock; refer to Adjusting the Brake, page 23.
Where to Add Grease
1. Lubricate the front wheels and steering spindles until
grease begins to ooze out of the bearings (Fig. 20).
Adjusting the Brake
1. Check the brake before you adjust it; refer to Checking
the Brake, page 23.
2. To increase braking resistance, tighten the brake
adjusting nut (Fig. 19) 1/8 turn clockwise; then check
the brake again. Continue this adjusting and checking
process until the brake is set properly.
3. 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.
m–2346
Figure 20
Servicing the Air Cleaner
Foam Element: Clean and oil after every 25 operating
hours.
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.
1
Removing the Foam and Paper Elements
m–1895
Figure 19
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
1. Brake adjusting nut
2. Open the hood.
23
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. 21).
5. Unscrew the rubber nut and remove the paper element
(Fig. 23).
1
1
2
m–1865
2
Figure 23
m–1884
1. Rubber nut
2. Paper element
Figure 21
1. Knob
2. Air cleaner cover
Cleaning the Foam and Paper Elements
4. Carefully slide the foam element off of the paper
element (Fig. 22).
1. Foam Element
A. Wash the foam element in liquid soap and warm
water. When the element is clean, rinse it
thoroughly.
1
B. Dry the element by squeezing it in a clean cloth.
C. Put one or two ounces of oil on the element
(Fig. 24). Squeeze the element to distribute the oil.
2
Important
worn.
Replace the foam element if it is torn or
2
m–1864
Figure 22
1. Foam element
2. Paper element
1
m–1866
Figure 24
1. Foam element
24
2. Oil
Servicing the Spark Plug
2. Paper Element
A. Lightly tap the element on a flat surface to remove
dust and dirt (Fig. 25).
Install a new spark plug after every 100 operating hours.
Check the spark plug after every 25 operating hours. Make
sure that the air gap between the center and side electrodes
is correct before installing the spark plug. Use a spark plug
wrench for removing and installing the spark plug and a
gapping tool/feeler gauge to check and adjust the air gap.
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 or cannot be
cleaned thoroughly.
Type: Champion RJ-19LM (or equivalent)
Air Gap: 0.030 in. (0.762 mm)
Removing the Spark Plug
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
2. Open the hood.
1
3. Pull the wire off of the spark plug (Fig. 26). Clean
around the spark plug to prevent dirt from falling into
the engine and potentially causing damage.
2
m–1867
4. Remove the spark plug and metal washer.
Figure 25
1. Paper element
2. Rubber seal
Installing the Foam and Paper Elements
Important To prevent engine damage, always operate
the engine with the complete foam and paper air cleaner
assembly installed.
1. Carefully slide the foam element onto the paper air
cleaner element (Fig. 22).
1
2. Slide the air cleaner assembly onto the long rod. Screw
the rubber nut finger-tight against the air cleaner
(Fig. 23).
2
m–1884
Figure 26
Note: Make sure that the rubber seal is flat against the air
cleaner base.
1. Spark plug wire
2. Spark plug
3. Install the air cleaner cover and knob (Fig. 21). Tighten
the knob snugly.
Checking the Spark Plug
4. Close the hood.
1. Look at the center of the spark plug (Fig. 27). If you see
light brown or gray on the insulator, the engine is
operating properly. A black coating on the insulator
usually means the air cleaner is dirty.
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. 27). Bend the side electrode (Fig. 27) if the gap is
not correct.
25
2
Draining the Fuel Tank
3
1
Danger
0.030 in.
(0.762 mm)
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open area.
Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and stay
away from an open flame or where a spark may
ignite the gasoline fumes.
m–1870
Figure 27
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
1. Park the machine so that the left front side is slightly
lower than the right side to ensure that the fuel tank
drains completely. Disengage the PTO, shift into
neutral, set the parking brake, stop the engine, and
remove the ignition key.
Installing the Spark Plug
1. Install the spark plug and metal washer. Make sure that
the air gap is set correctly.
2. Open the hood.
2. Tighten the spark plug to 15 ft.-lb. (20 N⋅m).
3. Squeeze the ends of the hose clamp together and slide it
up the fuel line toward the fuel tank (Fig. 29).
3. Push the wire onto the spark plug (Fig. 26).
4. Close the hood.
4. Pull the fuel line off of the filter (Fig. 29) and allow
gasoline to drain into a gas can or drain pan.
Checking the Tire Pressure
Note: Now is the best time to install a new fuel filter
because the fuel tank is empty.
Maintain the air pressure in the front and rear tires at 20 psi
(138 kPa). 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.
5. Install the fuel line onto the filter. Slide the hose clamp
close to the filter to secure the fuel line and filter.
1
1
2
3
m–1873
Figure 29
m–1872
1. Hose clamp
2. Fuel line
Figure 28
1. Valve stem
26
3. Filter
Replacing the Fuel Filter
3. Rotate the bulb holder 1/4 turn counterclockwise and
remove it from the reflector (Fig. 31).
Replace the fuel filter after every 100 operating hours or
yearly, whichever occurs first.
4. Push and rotate the bulb counterclockwise until it stops
(approx. 1/4 turn) and remove the bulb from the bulb
holder (Fig. 32).
The best time to replace the fuel filter (Fig. 29) is when the
fuel tank is empty. Never install a dirty filter if it is
removed from the fuel line.
5
5
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
1
3
2. Open the hood.
4
2
3. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 29).
4. Remove the filter from the fuel lines.
5. Install a new filter and move the hose clamps close to
the filter.
4
m–1874
Figure 31
6. Close the hood.
1. Bulb holder
2. Reflector
3. Tabs
Servicing the Fuse
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. 30) to
remove it from the socket. Push down to insert it.
4. Slots
5. Terminals
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. 32). Push and rotate the bulb
clockwise until it stops.
Fuses: 10 amp, blade-type
1
1
2
2
2
4
3
4
m–1875
m–1672
Figure 32
Figure 30
1. Fuse (removed)
1. Bulb
2. Metal pins
2. Socket
3. Bulb holder
4. Slots
2. The bulb holder has two tabs (Fig. 31). 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.
Headlights
Specification: Bulb #1156, automotive type
Removing the Bulb
3. Push the wire connectors onto the terminals on the bulb
holder.
1. Disengage the PTO, shift into neutral, set the parking
brake, stop the engine, and remove the ignition key.
2. Open the hood. Pull the wire connectors off of both of
the bulb holder terminals.
27
Servicing the Cutting Blade
3. Remove the bolt (5/8 in. wrench), curved washer,
retainer, and blade (Fig. 34). A block of wood may be
wedged between the blade and the mower to lock the
blade when you are removing the bolt.
To ensure a superior quality of cut, keep the blade(s) sharp.
For convenient sharpening and replacement, you may want
to have an extra blade(s).
4. Inspect all parts. If damage is noticed, install new parts.
Danger
4
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator’s or
bystander’s area, resulting in serious personal
injury or death.
3
2
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
5
1
m–1886
Inspecting the Blade(s)
Figure 34
1. Bolt
2. Retainer
3. Blade
1. Remove the mower; refer to Removing the Mower,
page 29.
2. Inspect the cutting edges (Fig. 33). If the edges are not
sharp or have nicks, remove the blade(s) and sharpen
them; refer to Sharpening the Blade(s), page 28.
4. Spindle
5. Curved washer
Sharpening the Blade(s)
3. Inspect the blade(s), especially the curved area
(Fig. 33). If you notice any damage, wear, or a slot
forming in this area (Fig. 33), immediately install a new
blade.
1. Use a file to sharpen the cutting edge at both ends of the
blade (Fig. 35). Maintain the original angle. The blade
retains its balance if the same amount of material is
removed from both cutting edges.
1
2
1
m–1854
Figure 35
3
1. Sharpen at original angle
m–151
2. Check the balance of the blade by putting it on a blade
balancer (Fig. 36). If the blade stays in a horizontal
position, the blade is balanced and can be used. If the
blade is not balanced, file some metal off of the back
side of the blade. Repeat this procedure until the blade
is balanced.
Figure 33
1. Cutting edge
2. Curved area
3. Wear/slot forming
Removing the Blade
1. Remove the mower; refer to Removing the Mower,
page 29.
2
1
2. Carefully tip the mower over.
m–1855
Figure 36
1. Blade
28
2. Balancer
Installing the Blade(s)
6. Remove the hairpin cotter and washer from the blade
control arm on the left side of the mower (Fig. 38).
Slide the rod off of the arm.
1. Install the blade, blade retainer, curved washer (cupped
side toward blade), and the blade bolt (Fig. 34).
Important The curved part of the blade must be
pointing toward the inside of the mower to ensure proper
cutting.
2. Tighten the blade bolt to 45–60 ft.-lb. (61–81 N⋅m).
1
Removing the Mower
2
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
m–1897
2. Pull the wire off of the spark plug.
Figure 38
3. Move the height-of-cut lever (deck lift) into the “D”
notch.
1. Hairpin cotter and washer
4. Remove the height-of-cut lift assist spring from the
retaining bolt (Fig. 37), using the spring tool provided
with the machine. The spring is between the frame and
the right rear wheel.
7. Remove the bolts and locknuts and pull the two mower
pivot mount brackets down from the front axle
(Fig. 39).
2. Rod
1
1
1
2
3
m–1851
Figure 37
1. Spring
2. Bolt
3. Spring tool
m–1888
Figure 39
1. Pivot mount brackets
Caution
When the mower is being removed, the
spring-tensioned height-of-cut lever (deck lift)
could suddenly release and injure you or someone
else.
Move the height-of-cut lever to the “D” position
and remove the height-of-cut assist spring to
release the spring tension.
5. Move the height-of-cut lever into the “A” notch.
29
8. Remove the hairpin cotter and washer at the top of the
mower leveling bracket (Fig. 40). Slide the bracket off
of the mounting pin. Repeat this step on the opposite
side of the mower.
2
2
3
4
1
5
1
4
1
3
m–1805
Figure 40
1. Hairpin cotter and washer
2. Long rod
3. Leveling bracket
4. Mower mount
9. Remove the hairpin cotter and washer from the end of
the long rod (Fig. 40). Slide the rod out of the mower
mount. Repeat this step on the opposite side of the
mower.
m–1898
Figure 41
Top View
Important Tape or tie the long rods against the chassis
to protect them from damage when you remove the mower.
1. Mower belt
2. Engine pulley
3. Belt guide
10. Remove the mower belt from the lower engine pulley
(Fig. 41). If you are careful, you can flex the belt
guide(s) just far enough away from the pulley to
remove the belt. If it is too difficult to remove the belt,
loosen the bolts and nuts securing the belt guides.
4. Idler pulley
5. 32” mower
11. Turn the front wheels fully to the left. Slide the mower
out to the right to complete the removal process.
Important Do not bend the belt guide(s) away from the
pulley because the belt will not operate properly when the
mower is installed later.
Installing the Mower
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
2. Pull the wire off of the spark plug.
3. Turn the front wheels fully to the left. Slide the mower
under the chassis from the right side.
4. Install the mower belt onto the lower engine pulley
(Fig. 41). 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 guide(s) away from the
pulley. There must be a maximum 1/8 in. (3.2 mm)
between the belt guide(s) and the edge of the pulley to keep
the belt on the pulley during operation. If the space is more
than 1/8 in. (3.2 mm), adjust the belt guide(s) and tighten
them securely. The belt guide(s) must not contact the
pulley.
30
5. Install the mower pivot mount brackets to the front axle
with bolts and locknuts (Fig. 42).
1
1
1
2
m–1897
Figure 44
1. Hairpin cotter and washer
2. Rod
Figure 42
1. Pivot mount brackets
10. Move the height-of-cut lever into the “D” notch to
make it easier to install the height-of-cut lift assist
spring.
6. Move the height-of-cut lever into the “A” notch.
11. Hook the height-of-cut lift assist spring onto the
retaining bolt (Fig. 45) using the spring tool provided
with the machine.
7. Slide the end of the long rod through the hole in the
mower mount (Fig. 43). Install the washer and hairpin
cotter to secure the rod in place. Repeat this step on the
opposite side of the mower.
8. Mount the slotted mower leveling bracket onto the pin
on the height-of-cut arm (Fig. 43). Install the washer
and hairpin cotter to secure the mower. Repeat this step
on the opposite side of the mower.
1
2
3
1
2
m–1851
Figure 45
4
1. Spring
2. Bolt
3. Spring tool
3
2
12. Check the side-to-side blade level; refer to Leveling the
Mower from Side-to-Side, page 32.
Figure 43
1. Rod
2. Hairpin cotter and washer
3. Leveling bracket
4. Mower mount
9. Install the blade control rod onto the blade control arm
and secure it with the washer and hairpin cotter
(Fig. 44).
31
Blade Drive Belt
Leveling the Mower from
Side-to-Side
Removing the Blade Drive Belt
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 in the front and rear tires to
the recommended inflation; refer to Checking the Tire
Pressure, page 26.
1. Remove the mower; refer to Removing the Mower,
page 29.
2. Loosen the belt guide mounting bolts and move the belt
guides away from the pulley (Fig. 46).
3. Remove the belt from the pulley.
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
Installing the Blade Drive Belt
1. Install the new belt around the blade pulley and inside
both of the belt guides (Fig. 46).
2. Pull the wire off of the spark plug.
3. Move the height-of-cut lever into the “C” notch.
2. Adjust the belt guides so they are 1/8 in. (3 mm) away
from the pulley. Tighten the mounting bolts (Fig. 46).
4. Carefully rotate the blade(s) side to side (Fig. 47).
Measure between the outside cutting edges and the flat
surface (Fig. 47). If both measurements are not within
3/16 in. (5 mm), an adjustment is required; refer to
steps 5 and 6.
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 30.
1
2
1
2
2
2
3
3
Figure 47
3
1. Blade side to side
2. Outside cutting edges
3
Figure 46
Top View
1. Mower belt
2. Belt guide
3. Mounting bolt
32
3. Measure here
m–1900
5. Remove the hairpin cotter and washer from the leveling
bracket (Fig. 48). To level the blade(s), reposition the
leveling bracket in a different hole and install the
washer and hairpin cotter (Fig. 48). A front hole lowers
the blade height and a rear hole raises its height. Repeat
this procedure on the opposite side of the mower.
1
2
2
1
2
3
m–1801
Figure 49
1
1. Measure front center
4
6. Measure the length of the rod extending out of the front
of the adjusting block on the sides of the chassis
(Fig. 50). If the rod length is not 5/8 in. (16 mm),
remove the hairpin cotter and washer from the end of
the rod (Fig. 50) and turn the rod until the 5/8 in.
(16 mm) dimension is obtained. Then install the end of
the rod into the hole in the mower mount and secure it
in place with the washer and hairpin cotter. Repeat this
procedure on the opposite side of the mower.
m–1805
Figure 48
1. Hairpin cotter and washer
2. Leveling bracket
2. Measure rear center
3. Front hole
4. Rear hole
6. Check the front-to-rear blade slope; refer to Adjusting
the Front-to-Rear Blade Slope, page 33.
(16 mm)
Adjusting the Front-to-Rear
Blade Slope
5/8 in.
1
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 the recommended inflation; refer
to Checking the Tire Pressure, page 26. If the front of the
mower is more than 5/8 in. (16 mm) lower than the rear of
the mower, adjust the blade slope using the following
instructions:
2
3
4
1. Park the machine on a level surface, disengage the PTO,
shift into neutral, set the parking brake, stop the engine,
and remove the ignition key.
m–1805
Figure 50
2. Pull the wire off of the spark plug.
1. Adjusting block
2. Long rod
3. Check and adjust the side-to-side blade level if you
have not checked the setting; refer to Leveling the
Mower from Side-to-Side, page 32.
3. Hairpin cotter and washer
4. Mower mount
7. Check the front-to-rear slope again. If the front of the
mower is more than 5/8 in. (16 mm) lower than the rear
of the mower, proceed to step 8 for the adjusting
instructions. Otherwise, recheck the side-to-side level to
ensure it did not change.
4. Move the height-of-cut lever into the “C” notch.
5. 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. 49). If the front of the mower is more than 5/8 in.
(16 mm) lower than the rear of the mower, an
adjustment is required; refer to steps 6–10.
8. Adjust the front-to-rear slope by rotating the special
slope adjusting nuts on both sides of the mower pivot
mount (Fig. 51).
33
9. Using a 1 in. 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. 51). Rotate the slope
adjusting nut until the front of the mower is 1/4 to
5/8 in. (6 to 16 mm) lower than the rear of the mower.
3
3
4
1
B
2
2
m–1903
Figure 52
1. Mower pivot
2. Shoulder bolt
3. Locknut
4. Mower
15. Recheck the front-to-rear slope again; refer to step 5.
3
1
A
16. When the front-to-rear blade slope is correct, recheck
the side-to-side level of the mower; refer to Leveling
the Mower from Side-to-Side, page 32.
m–1902
Figure 51
1. Slope adjusting nut (left)
A = Down to raise mower
B = Up to lower mower
17. Push the wire onto the spark plug.
2. Bolt and locknut
3. Mower pivot mount
Washing the Underside of the
Mower
10. Slowly rotate the right side slope adjusting nut until
both adjusting nuts are in the same position.
After each use, wash the underside of the mower to prevent
grass buildup for improved mulch action and clipping
dispersal.
Important If the slope adjustment does not stay in
position after you adjust it, tighten the center bolt and
locknut and repeat step 9.
1. Park the machine on a hard level surface, disengage the
PTO, stop the engine, and remove the ignition key.
11. If the 1/4 to 5/8 in. (6 to 16 mm) front slope cannot be
achieved by rotating the slope adjusting nut, move the
mower pivot mount at the mower (Fig. 52).
2. Attach the hose coupling to the end of the mower
washout fitting, and turn the water on high (Fig. 53).
12. Remove the shoulder bolts and locknuts from the
mower (Fig. 52).
Note: Spread petroleum jelly on the washout fitting o-ring
to make the coupling slide on easier and protect the o-ring.
13. Lower the mower pivot one hole and install the
shoulder bolts and locknuts (Fig. 52).
1
2
3
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.
m–3118
Figure 53
1. Washout fitting
2. Coupling (not supplied)
3. Hose
3. Lower the mower to the lowest height of cut.
34
8. For storage over 30 days, prepare the traction unit as
follows:
4. Sit on the seat and start the engine. Engage the PTO and
let the mower run for one to three minutes.
6. Turn the water off and remove the coupling from the
washout fitting.
A. Add a petroleum based stabilizer/conditioner to fuel
in the tank. Follow the mixing instructions from the
stabilizer manufacturer (1 oz. per gallon). Do not
use an alcohol based stabilizer (ethanol or
methanol).
Note: If the mower is not clean after one washing, soak it
and let it stand for 30 minutes. Then repeat the process.
Note: A fuel stabilizer/conditioner is most effective
when mixed with fresh gasoline and used at all times.
7. Run the mower again for one to three minutes to
remove excess water.
B. Run the engine to distribute conditioned fuel
through the fuel system (5 minutes).
5. Disengage the PTO, stop the engine, and remove the
ignition key. Wait for all moving parts to stop.
C. Stop the engine, allow it to cool, and drain the fuel
tank; refer to Draining the Fuel Tank, page 26.
Warning
D. Restart the engine and run it until it stops.
A broken or missing washout fitting could expose
you and others to thrown objects or blade contact.
Contact with blade or thrown debris contact will
cause injury or death.
E. Choke or prime the engine.
F. Start and run the engine until it will not start again.
Use the primer, if equipped on the machine, several
times to ensure that no fuel remains in the primer
system.
• Replace broken or missing washout fitting
immediately, before using mower again.
• Plug any hole(s) in mower with bolts and
locknuts.
• Never put your hands or feet under the mower
or through openings in the mower.
G. Dispose of fuel properly. Recycle as per local codes.
Important Do not store stabilizer/conditioned gasoline
over 90 days.
9. Remove the spark plug(s) and check its condition; refer
to Servicing the Spark Plug, page 25. With the spark
plug(s) removed from the engine, pour two tablespoons
of engine oil into the spark plug hole. Use the electric
starter to crank the engine and distribute the oil inside
the cylinder. Install the spark plug(s); refer to Spark
Plug, page 25. Do not install the wire on the spark
plug(s).
Cleaning and Storage
1. Disengage the PTO, set the parking brake, stop the
engine, and remove the ignition key.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine. Clean dirt and chaff from the outside of the
engine cylinder head fins and blower housing.
10. Disconnect the negative battery cable. Clean the battery
and battery terminals. Check the electrolyte level and
charge it fully; refer to Servicing the Battery, page 21.
Leave the negative battery cable disconnected from the
battery during storage.
Important You can wash the machine with mild
detergent and water. Do not use a pressure washer to
wash the machine. Pressure washing may damage the
electrical system or wash away necessary grease at friction
points. Avoid excessive use of water, especially near the
control panel, lights, engine, and battery.
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 can be stored one
winter season without recharging.
3. Check the brake; refer to Checking the Brake, page 23.
11. Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is worn or damaged.
4. Service the air cleaner; refer to Servicing the Air
Cleaner, page 23.
12. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
5. Grease the chassis; refer to Greasing and Lubrication,
page 23.
13. Store the machine in a clean, dry garage or storage area.
Remove the ignition and KeyChoice keys from the
mower and keep them in a memorable place. Cover the
machine to protect it and keep it clean.
6. Change the crankcase oil; refer to Servicing the Engine
Oil, page 20.
7. Check the tire pressure; refer to Checking the Tire
Pressure, page 26.
35
Wiring Diagram
KEY SWITCH
OFF
NO CONNECTION
ON
BIA
START
AND X Y
WIRE COLOR CODES
BIS
BN
BROWN
PK
PINK
BU
BLUE
BK
BLACK
GY
GREY
Y
YELLOW
S
W
WHITE
T
TAN
B
VIO
VIOLET
GN
GREEN
R
RED
OR
ORANGE
S4
(IGNITION)
X
A
I
S
I
B
Y
A
KEY SW
PK
BU
OR
R
F2
R
R
10A
BATTERY
1
SHOWN WITH
S2
(PTO)
GND
PTO DISENGAGED
2
PK
3
GY
FUEL SOLENIOD
BU
GY
T
S5
ALTERNATOR
F1
VIO
SEAT
CLOSED WHEN OPERATOR
S3
IS IN THE SEAT
10A
R
STARTER
OVER RIDE
T
R
MOMENTARY
KEY SWITCH
3
Y
2
VIO
S1
OR
(NEUTRAL SW)
SHOWN IN
1
GN
NEUTRAL
SOLENOID
MAGNETO
W
Y
LIGHT COIL
F3
Y
OR
GN W
10A
K1
3
GY
5
4
NMIR MODULE
6
VIO
OR
S6
(REVERSE)
(KILL RELAY)
2
1
GY
SWITCH OPENS
IN REVERSE
VIO
GN
BN
T
BK
BN
HEADLIGHT HARNESS
2
S7
LAMP
5
4
(OVER RIDE)
1
BK
BK
3
GND
36
(LIGHT SWITCH)
Troubleshooting
Problem
The starter does not crank.
The engine
g
will not start, starts
h d or ffails
hard,
il tto kkeep running.
i
The engine loses power.
Possible Causes
Corrective Action
1. The blade control (PTO) is
Engaged.
1. Move the PTO to Disengaged.
2. The parking brake is not on.
2. Set the parking brake.
3. The battery is dead.
3. Charge the battery.
4. The electrical connections are
corroded or loose.
4. Check the electrical
connections for good contact.
5. A fuse is blown.
5. Replace the fuse.
6. A relay or switch is damaged.
6. Contact an Authorized Service
Dealer.
1. The operator is not seated.
1. Sit on the seat.
2. The fuel tank is empty.
2. Fill the fuel tank with gasoline.
3. The air cleaner is dirty.
3. Clean or replace the air cleaner
element.
4. The spark plug wire is loose or
disconnected.
4. Install the wire on the spark
plug.
5. The spark plug is pitted, fouled,
or the gap is incorrect.
5. Install a new, correctly-gapped
spark plug.
6. The choke is not closing.
6. Adjust the throttle cable.
7. There is dirt in the fuel filter.
7. Replace the fuel filter.
8. The idle speed is too low or the
mixture is incorrect.
8. Adjust the carburetor idle
speed and idle mixture.
9. Dirt, water, or stale fuel is in the
fuel system.
9. Contact an Authorized Service
Dealer.
1. The engine load is excessive.
1. Shift into a lower gear to
reduce ground speed.
2. The air cleaner is dirty.
2. Clean the air cleaner element.
3. The oil level in the crankcase is
low.
3. Add oil to the crankcase.
4. The cooling fins and air
passages under the engine
blower housing are plugged.
4. Remove the obstruction from
the cooling fins and air
passages.
5. The spark plug is pitted, fouled,
or the gap is incorrect.
5. Install a new, correctly-gapped
spark plug.
6. The vent hole in the fuel cap is
plugged.
6. Clean or replace the fuel cap.
7. There is dirt in the fuel filter.
7. Replace the fuel filter.
8. Dirt, water, or stale fuel is in the
fuel system.
8. Contact an Authorized Service
Dealer.
37
Problem
The engine overheats.
There is an abnormal vibration.
The blade(s) does not rotate.
The machine does not drive.
The cutting
g height
g is uneven.
Possible Causes
Corrective Action
1. The engine load is excessive.
1. Shift into a lower gear to
reduce ground speed.
2. The oil level in the crankcase is
low.
2. Add oil to the crankcase.
3. The cooling fins and air
passages under the engine
blower housing are plugged.
3. Remove the obstruction from
the cooling fins and air
passages.
1. The cutting blade(s) is bent or
unbalanced.
1. Install new cutting blade(s).
2. The blade mounting bolt is
loose.
2. Tighten the blade mounting
bolt.
3. The engine mounting bolts are
loose.
3. Tighten the engine mounting
bolts.
4. There is a loose engine pulley,
idler pulley, or blade pulley
4. Tighten the appropriate pulley.
5. The engine pulley is damaged.
5. Contact an Authorized Service
Dealer.
1. The blade drive belt is worn,
loose, or broken.
1. Install a new blade drive belt.
2. The blade drive belt is off of the
pulley.
2. Install the blade drive belt and
check the idler pulley and belt
guides for the correct position.
1. The traction belt is worn, loose,
or broken.
1. Contact an Authorized Service
Dealer.
2. The traction belt is off of the
pulley.
2. Contact an Authorized Service
Dealer.
3. The transmission does not
shift.
3. Contact an Authorized Service
Dealer.
1. The tire pressure is incorrect.
1. Set the tire pressure.
2. The mower is not level.
2. Level the mower from side to
side and from front to rear.
3. The underside of the mower is
dirty.
3. Clean the underside of the
mower.
38
39
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