Toro 16-38HXLE Lawn Tractor User manual

Toro 16-38HXLE Lawn Tractor User manual
Form No. 3323-539
Wheel Horse
16–38 HXL Lawn Tractor
71241—200000001 & Up
Operator’s Manual
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The Toro Company, Attn: Parts Dept., 8111 Lyndale Ave S, Bloomington, MN 55420–1196
International English (GB)
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
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.
1856
1. Model and Serial Number Plate
(under the seat)
For your convenience, write the product model and
serial numbers in the space below.
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 is determined
by sitting on the seat in the normal operator’s
position.
Model No:
Serial No.
The Toro Company – 1999
Printed in USA
All Rights Reserved
Contents
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Safe Operation Practices for Ride-on
(riding) Rotary Lawnmower Machines . .
2
Safe Operating Practices . . . . . . . . . . . . . .
2
Sound Pressure Level . . . . . . . . . . . . . . . . .
4
Sound Power Level . . . . . . . . . . . . . . . . . .
4
Vibration Level . . . . . . . . . . . . . . . . . . . . . .
4
Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . .
5
Symbols Glossary . . . . . . . . . . . . . . . . . . .
7
Symbols Glossary . . . . . . . . . . . . . . . . . . .
8
Symbols Glossary . . . . . . . . . . . . . . . . . . .
9
Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Gasoline . . . . . . . . . . . . . . . 10
Stabilizer/Conditioner . . . . . . . . . . . . . . . .
11
Filling the Fuel Tank . . . . . . . . . . . . . . . . .
11
Check Engine Oil Level . . . . . . . . . . . . . . .
11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Think Safety First . . . . . . . . . . . . . . . . . . . 12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . 12
Positioning the Seat . . . . . . . . . . . . . . . . . . 13
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . 13
Using the Blade Control (PTO) . . . . . . . . . 13
Setting the Height-of-Cut . . . . . . . . . . . . . . 14
Adjusting Mower Wheels . . . . . . . . . . . . . 14
Starting and Stopping the Engine . . . . . . . 14
The Safety Interlock System . . . . . . . . . . . 16
Operating–in–Reverse . . . . . . . . . . . . . . . . 16
Testing the Safety System . . . . . . . . . . . . . 17
Pushing the Machine by Hand . . . . . . . . . . 18
Driving Forward or Backward . . . . . . . . . . 18
Stopping the Machine . . . . . . . . . . . . . . . . 19
Side Dischargeor Mulch Grass . . . . . . . . . . 20
Installing theDischarge Cover . . . . . . . . . . 20
Tips for Mowing Grass . . . . . . . . . . . . . . . 21
Page
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart . . . . . . . . . . . . . . . .
Greasing and Lubrication . . . . . . . . . . . . . .
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . .
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Blade . . . . . . . . . . . . . . . . . . . . . . .
Removing the Mower . . . . . . . . . . . . . . . . .
Installing the Mower . . . . . . . . . . . . . . . . .
Blade Drive Belt . . . . . . . . . . . . . . . . . . . . .
Side-to-Side Mower Leveling . . . . . . . . . .
Front-to-Rear Blade Slope . . . . . . . . . . . . .
Washing Underside of Mower . . . . . . . . . .
Cleaning and Storage . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
23
23
24
25
26
26
27
29
30
31
31
33
35
37
39
41
41
42
44
45
46
1
Safety
Safe Operation Practices for
Ride-on (riding) Rotary
Lawnmower Machines
•
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.
All drivers should seek and obtain professional
and practical instruction. Such instruction should
emphasize:
•
the need for care and concentration when
working with ride-on machines;
•
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:
•
insufficient wheel grip;
•
being driven too fast;
•
inadequate braking;
•
the type of machine is unsuitable for
its task;
•
lack of awareness of the effect of
ground conditions, especially slopes;
•
incorrect hitching and load
distribution.
Safe Operating Practices
The following instructions are from the CEN standard
EN 836:1997.
This product is capable of amputating hands and feet
and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
Preparation
Training
•
While mowing, always wear substantial
footwear and long trousers. Do not operate the
equipment when barefoot or wearing open
sandals.
•
Read the instructions carefully. Be familiar with
the controls and the proper use of the equipment.
•
Never allow children or people unfamiliar with
these instructions to use the lawnmower. Local
regulations can restrict the age of the operator.
•
Thoroughly inspect the area where the
equipment is to be used and remove all objects
which may be thrown by the machine.
•
Never mow while people, especially children, or
pets are nearby.
•
WARNING – Petrol is highly flammable.
•
Keep in mind that the operator or user is
responsible for accidents or hazards occurring to
other people or their property.
•
2
Do not carry passengers.
•
Store fuel in containers specifically
designed for this purpose.
•
Refuel outdoors only and do not smoke
while refuelling.
Safety
•
•
•
Add fuel before starting the engine. Never
remove the cap of the fuel tank or add
petrol while the engine is running or when
the engine is hot.
If petrol 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 petrol vapors
have dissipated.
engage clutch slowly, always keep machine
in gear, especially when travelling
downhill;
•
machine speeds should be kept low on
slopes and during tight turns;
•
stay alert for humps and hollows and other
hidden hazards;
•
never mow across the face of the slope,
unless the lawnmower is designed for this
purpose.
Replace all fuel tanks and container caps
securely.
•
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.
•
•
•
On multi-bladed machines, take care as rotating
one blade can cause other blades to rotate.
Use care when pulling loads or using heavy
equipment.
•
Use only approved drawbar hitch points.
•
Limit loads to those you can safely control.
•
Do not turn sharply. Use care when
reversing.
•
Use counterweight(s) or wheel weights
when suggested in the instruction
handbook.
Operation
•
Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can
collect.
•
Mow only in daylight or in good artificial light.
•
Before attempting to start the engine, disengage
all blade attachment clutches and shift into
neutral.
•
Do not use on slopes of more than
•
•
5 when mowing on side hills;
•
10
•
15 when mowing downhill.
when mowing uphill;
Remember there is no such thing as a “safe”
slope. Travel on grass slopes requires particular
care. To guard against overturning:
•
do not stop or start suddenly when going up
or downhill;
•
Watch out for traffic when crossing or near
roadways.
•
Stop the blades rotating before crossing surfaces
other than grass.
•
When using any attachments, never direct
discharge of material toward bystanders nor
allow anyone near the machine while in
operation.
•
Never operate the machine with defective guards
or without safety protective devices in place.
•
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:
•
disengage the power take-off and lower the
attachments;
3
Safety
•
•
change into neutral and set the parking
brake;
•
Allow the engine to cool before storing in any
enclosure.
•
stop the engine and remove the key.
•
To reduce the fire hazard, keep the engine,
silencer, battery compartment and petrol 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.
Disengage drive to attachments, stop the engine,
and disconnect the spark plug wire(s) or remove
the ignition key
•
before clearing blockages or unclogging
chute;
•
before checking, cleaning or working on the
lawnmower;
•
If the fuel tank has to be drained, this should be
done outdoors.
•
after striking a foreign object. Inspect the
lawnmower for damage and make repairs
before restarting and operating the
equipment;
•
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.
•
if the machine starts to vibrate abnormally
(check immediately).
•
Disengage drive to attachments when
transporting or not in use.
•
Stop the engine and disengage drive to
attachment
•
•
before refuelling;
•
before removing the grass catcher;
•
before making height adjustment unless
adjustment can be made from the operator’s
position.
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.
Maintenance and Storage
•
Keep all nuts, bolts and screws tight to be sure
the equipment is in safe working condition.
•
Never store the equipment with petrol in the tank
inside a building where fumes can reach an open
flame or spark.
4
Sound Pressure Level
This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 88 dB(A), based
on measurements of identical machines per Directive
84/538/EEC.
Sound Power Level
This unit has a sound power level of: 100 Lwa, based
on measurements of identical machines per
procedures outlined in Directive 84/538/EEC and
amendments.
Vibration Level
This unit has a maximum hand-arm vibration level of
4.0 m/s2 and whole body vibration level of 0.2 m/s2,
based on measurements of identical machines per EN
1033 and EN 1032.
Safety
Slope Chart
Read all safety instructions on pages 2–8.
5
6
Safety
Symbols Glossary
Safety alert symbol
Dismemberment–Mower
in rearward motion
Safety alert symbol
Stay a safe distance
from the machine
Read operator’s manual
Consult Technical Manual for
proper service procedures
Thrown or flying objects–
Whole body exposure
Thrown or flying objects–
Rotary side-mounted mower.
Keep deflector shield in place
Severing toes or foot–
mower blade
Severing fingers or hand–
mower blade
Rotating blade can cut off
toes or fingers. Stay clear
of blade as long as engine
is running
Do not open or
remove safety shields
while engine is running
Stay a safe distance
from the mower
Keep children a safe distance
from machine
Machine rollover
side hill
Machine rollover
up hill
Machine rollover
down hill
Machine rollover
Operating in reverse not
allowed unless deactivated
by Key Choice switch
7
Safety
Symbols Glossary
Cutting element–
basic symbol
Riding on this machine is allowed
only on a passenger seat & only
if the driver’s view is not hindered
Cutting element–
height adjustment
Cutting unit–lower
Crushing of fingers
or hands–Force applied
from side
Cutting unit-raised
Kickback or upward
motion–Stored energy
Cutting or entanglement
of foot–Rotating auger
Severing of fingers or hand–
impeller blade
Keep a safe distance from
snowthrower
Stay a safe distance
from the snowthrower
Shut off engine & remove key
before performing maintenance
or repair work
Machine travel direction–
combined
Low
High
Tractors must be equipped
with 45kg rear wheel weight
with this attachment installed
Reverse
Machine rollover
ROPS snowthrower
Neutral
First gear
Severing of hand–
Rotating knives
Second gear
Severing of foot–
Rotating knives
8
Third gear up to
maximum # of
forward gears
Safety
Symbols Glossary
Fast
Slow
Fuel
Fuel level
Decreasing/Increasing
On/Run
Volume empty
Off/Stop
Volume full
Engine
Battery charging conditin
Engine start
Head lights–
Main/high beam
Engine stop
Brake system
Choke
Parking brake
Engine temperature
Clutch
PTO (Power Take Off)
Engine lubricating
oil pressure
Engage
Disengage
Engine lubricating oil level
Unlock
Lock
Key Choice Switch
9
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.
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AVOID THE HAZARD
• Use a funnel and 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” (6 mm 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.
10
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AVOID THE HAZARD
• 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.
Gasoline and Oil
Stabilizer/Conditioner
Filling the Fuel Tank
Using a stabilizer/conditioner in the machine:
1.
Shut the engine off and set the parking brake.
•
Keeps gasoline fresh during storage of 90 days
or less. For longer storage it is recommended
that the fuel tank be drained.
2.
•
Cleans the engine while it runs
•
Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
Clean around each fuel tank cap and remove the
cap. Add unleaded regular gasoline to both fuel
tanks, until the level is 1/4 to 1/2 inch (6 mm to
13 mm) below the bottom of the filler neck. This
space in the tank allows gasoline to expand. Do
not fill the fuel tanks completely full.
3.
IMPORTANT: Never use fuel additives
containing methanol or ethanol.
Install fuel tank caps securely. Wipe up any
gasoline that may have spilled.
4.
Fuel gauge is located in right side tank.
Add the correct amount of gas stabilizer/conditioner
to the gas.
Note:
A fuel stabilizer/conditioner is most
efffective when mixed with fresh
gasoline. To minimize the chance of
varnish deposits in the fuel system, use
fuel stabilizer at all times.
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 33.
11
Operation
Think Safety First
Parking Brake
Please carefully read all the safety instructions and
symbols in the safety section. Knowing this
information could help you, your family, pets or
bystanders avoid injury.
Always set the parking brake when you stop the
machine or leave it unattended.
Setting the Parking Brake
Controls
Become familiar with all the controls (Fig. 1) before
you start the engine and operate the machine.
1.
Push the 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 brake pedal. The
brake pedal should stay in the depressed (locked)
position.
1
9
2
8
Releasing the Parking Brake
3
4
10
1.
Push down on the brake pedal (Fig. 2). The
parking brake lever should release.
2.
Gradually release the brake pedal.
1
7
5
2
6
11
1858
Figure 1
1. Steering wheel
2. Light switch—on/off
(selected models)
3. Ignition switch
4. Clutch/brake pedal
5. Blade control (PTO)
6. Height-of-cut lever
(deck-lift)
12
7.
8.
9.
10.
11.
Parking brake lever
Throttle lever
Hood opening
Operating-in-Reverse light
Key Choice switch
Figure 2
1. Brake pedal
2. Parking brake lever
Operation
Positioning the Seat
Using the Blade Control (PTO)
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
The blade control (PTO) engages and disengages
power to the blade(s).
1.
Engaging the Blade(s)
2.
Raise the seat and loosen the adjustment knob
(Fig. 3).
Move the seat to the desired position and tighten
the knob.
1.
Depress the brake pedal to stop the machine.
2.
Move the blade control (PTO) to “ENGAGED”
(Fig. 4).
2
1
1
1862
3
Figure 3
1852
Figure 4
1. Adjustment knob
1. Disengaged
2. Engaged
3. Blade control (PTO)
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 is
running and the switch is “ON.”
Disengaging the Blade(s)
1.
Depress the brake pedal to stop the machine.
2.
Move the blade control (PTO) to
“DISENGAGED” (Fig. 4).
13
Operation
Setting the Height-of-Cut
2
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. 5).
4
1
3
1505
Figure 6
1. Wheel
2. Wheel bracket
3. Locknut
4. Wheel bolt
1” (25 mm)
1
1–1/2” (38 mm)
Starting and Stopping the
Engine
2” (51 mm)
2–1/2” (64 mm)
3” (76 mm)
3–1/2” (89 mm)
4” (102 mm)
Starting
1881
Figure 5
1. Height-of-cut lever
(deck lift)
1.
Sit down on the seat.
2.
Set the parking brake; refer to Setting the
Parking Brake, page 12.
Note:
Adjusting Mower Wheels
The mower front wheels are to guide it over uneven
ground. The height of these wheels can be changed to
closer match the height-of-cut selected for the mower.
1.
2.
3.
Move the blade control (PTO) to
“DISENGAGED” (Fig. 7).
4.
Move the throttle lever to “CHOKE” (Fig. 8).
To change the height of mower wheels remove
wheel mounting bolt and change hole into which
it is mounted (Fig. 6).
Use the top hole for lowest height-of-cut and the
bottom hole for higher heights-of-cut (Fig. 6).
The engine will not start unless you set
the parking brake or fully depress the
brake pedal.
Note:
5.
An engine that has been running and is
warm may not require step 4.
Turn the ignition key clockwise and hold it in
the “START” position (Fig. 9). 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 47.
14
Operation
6.
After the engine starts, slowly move the throttle
lever to “FAST” (Fig. 8). 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.
Stopping
1.
Move the throttle lever to “SLOW” (Fig. 8).
2.
Turn the ignition key to “OFF” (Fig. 9).
Note:
2
1
If the engine has been working hard or
is hot, let it idle for a minute before
turning the ignition key “OFF.” This
helps cool the engine before it is
stopped. In an emergency, the engine
may be stopped by turning the ignition
key to “OFF.”
1852
3
Figure 7
1. Disengaged
2. Engaged
3. Blade control (PTO)
1
2
3
1859
Figure 8
1. Choke
2. Fast
3. Slow
3
2
1
Figure 9
1. Start
2. On
3. Off
15
Operation
The Safety Interlock System
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless:
•
You are sitting on the seat
•
The brake pedal is depressed
•
The blade control (power take off/PTO) is
“DISENGAGED”
The safety interlock system is designed to stop the
engine if:
•
•
You rise from the seat when the brake pedal is
released
You rise from the seat when the blade control
(PTO) is “ENGAGED”.
The safety interlock system is designed to stop the
engine if:
•
You shift into reverse with the blade control
(PTO) engaged.
Operating-in-Reverse
An interlock feature is provided that prevents the
Power Take Off (PTO) from operating while the
tractor is traveling in reverse. If the unit is shifted into
reverse while the mower blade or other PTO driven
attachment is engaged, the engine will stop.
Do not mow while backing up unless it is
absolutely necessary. If you need to mow while in
reverse gear or use other PTO driven attachments
(such as a snowthrower or tiller), this no
operating-in-reverse interlock may be temporarily
deactivated.
Before deactivating this interlock, be sure there are no
children present on or near the property where you are
using the tractor, and that none are likely to appear
while you are mowing or operating an attachment. Be
extra observant after you have chosen to deactivate
16
the interlock because the sound of the tractor’s engine
might prevent you from being aware that a child or a
bystander has entered the area where you are
operating the tractor.
If you are certain that you can safely mow in reverse
or operate an attachment, deactivate the no
operating-in-reverse interlock by turning the Key
Choice switch (Fig. 10), located on the seat bracket
on the right hand side just below the seat, after
engaging the blade (PTO). A red light on the front
console (Fig. 11) will turn on as a reminder that the
no operating–in–reverse interlock has been
deactivated. Once the interlock is deactivated it stays
in this mode—with your mower blade or PTO-driven
attachment operating whenever you back up—and the
console light stays on until either the blade (PTO) is
disengaged, or the engine is turned off.
Note:
Do not insert the “Key Choice” key
unless it is absolutely necessary to
mow in reverse or operate an
attachment. The “Key Choice” key
should also be removed from the unit
if it will be operated by someone other
than a responsible, experienced
operator. This will prevent the unit
from operating in reverse with the
mower blade or other PTO attachment
engaged. Always remove both the
ignition and the “Key Choice” keys
and put them in a safe place out of the
reach of children when leaving the unit
unattended.
Operation
POTENTIAL HAZARD
• A child or bystander could be backed over
by a riding mower with its blade(s)
engaged.
WHAT CAN HAPPEN
• Blade contact will cause serious personal
injury or death.
HOW TO AVOID THE HAZARD
• Do not mow in reverse unless absolutely
necessary.
• Always look backward and down before
backing up.
• Use “Key Choice” switch only if you are
certain no children or other bystanders will
appear in the mowing area.
• Always remove both the ignition and “Key
Choice” keys and put them in a safe place
out of the reach of children or unauthorized
users when leaving the unit unattended.
1
m–1863
Figure 11
1. Operating-in-Reverse light
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. While setting
in the seat, perform the following checks.
1.
Set the parking brake. Move the blade control
(PTO) to “ENGAGED.” Now turn the ignition
key to “START”; the engine should not crank.
2.
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.
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.
4.
Put the PTO lever in the “disengage” position
and the foot pedal in neutral. Now start the
engine. While the engine is running, move the
PTO lever to the “engage” position and move the
foot pedal to reverse. The engine should stop.
1
Figure 10
1. “Key Choice” switch
17
Operation
5.
Put the PTO lever in the “disengage” position
and the foot pedal in neutral. Now start the
engine. Move the PTO lever to the “engage”
position and turn the “Key Choice” key and
release. 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.
2
1
Pushing the Machine by Hand
IMPORTANT: Always push the machine by
hand. Never tow the machine because
transaxle damage may occur.
1882
Figure 12
1. Operate position
2. Push position
To Push the Machine
1.
2.
Disengage the blade control (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine.
Move the drive control to the “PUSH” position.
This disengages the drive system and allows the
wheels to turn freely (Fig. 12).
To Operate the Machine
1.
Move the drive control to the “OPERATE”
position. This engages the drive system
(Fig. 12).
Note:
The machine will not drive unless the
drive control is in the “OPERATE”
position.
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place the
throttle control in the “FAST” position for best
performance.
To go forward or backward, release the parking brake:
refer to Releasing the Parking Brake, page 12. Place
your foot on the traction control pedal and slowly
press on the top of the traction control pedal to move
forward or on the bottom of the traction control pedal
to move backward (Fig. 13). The farther you move
the traction control pedal in either direction, the faster
the machine will move in that direction.
To slow down release the pressure on the traction
control pedal.
IMPORTANT: To avoid transmission
damage, always release the parking brake
before moving the traction control pedal.
18
Operation
2
3
1
1861
Figure 13
1. Traction control pedal
2. Forward
3. Backward
Stopping the Machine
To stop the machine, release the traction control
pedal, 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 12. Remember to remove the key from the
ignition switch.
POTENTIAL HAZARD
• Someone could move or attempt to operate
the tractor while it is unattended.
WHAT CAN HAPPEN
• Children or bystanders may be injured if
they use the tractor.
HOW TO AVOID THE HAZARD
• Always remove the ignition and “key
choice” keys and set the parking brake
when leaving the machine unattended, even
if just for a few minutes.
19
Operation
Side Discharge
or Mulch Grass
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.
POTENTIAL HAZARD
• 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
• Contact with rotating mower blade(s) and
thrown debris will cause injury or death.
HOW TO AVOID THE HAZARD
• 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.
• Never put your hands or feet under the
mower.
• 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.
Lift the grass deflector and slide the tabs on top
of the discharge cover under the grass deflector
retaining rod. Rotate the discharge cover down
over the opening, and onto the lower lip of the
mower (Fig. 14).
2.
Secure the discharge cover to the lower lip of the
mower with bolts and nuts (Fig. 14).
1
2
6
6
5
5
3
1.
2.
20
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 20.
4
1883
Figure 14
1. Grass deflector
2. Tabs under rod
3. Discharge cover
3.
4. Lower lip
5. Bolt
6. Nut
To convert back to a side discharge mower,
remove the discharge cover and lower the grass
deflector over the discharge opening.
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 is 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.
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.
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.”
Cut 1/3 of the Grass Blade
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.
Keep the Underside of the Mower Clean
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.
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.
21
Maintenance
Service Interval Chart
Service Operation
Each
Use
Oil—initial change
5
Hours
X
X
X
Cutter Blade—check
X
X
X
Brake—check
X
X
X
Chassis—grease
X
X
Foam Air Cleaner—service
X
X
X
Paper Air Cleaner—replace
X
X
X
Belts—check for wear/cracks
X
Gasoline—drain
X
Engine—clean outside
X
X
X
More often
in dusty,
d st
dirty
conditions
X
X
X
Chipped Surfaces—paint
X
X
X
X
X
Battery—charge, disconnect cables
X
Fuel Filter—replace
X
Tires—check pressure
X
X
Spark Plug—check
Battery—check electrolyte
X
X
X
X
POTENTIAL HAZARD
• If you leave the key in the ignition switch, someone could start the engine.
WHAT CAN HAPPEN
• Accidental starting of the engine could seriously injure you or other bystanders.
HOW TO AVOID THE HAZARD
• 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.
22
Notes
X
X
Mower Housing—clean
Spring
Service
X
Oil FIlter
Safety System—check
50
Storage
Hours Service
X
Oil—periodic change
Oil—check level
25
Hours
Maintenance
Greasing and Lubrication
Tire Pressure
Service Interval/Specification
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.
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 (Fig. 16). Check the tires when
they are cold to get the most accurate pressure
reading.
Grease Type: General-purpose grease.
How to Grease
1.
Disengage the blade control (PTO), 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.
1
1872
Figure 16
1. Valve stem
Wipe up any excess grease.
Where to Add Grease
1.
Lubricate the front wheels until grease begins to
ooze out the bearings (Fig. 15).
2346
Figure 15
23
Maintenance
Brake
The brake is on the right side of the rear axle, inside
the rear tire (Fig. 17). If the parking brake does not
hold securely, an adjustment is required.
Checking the Brake
1.
2.
3.
Park the machine on a level surface, disengage
the blade control (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine.
Move the drive control wire to the “PUSH”
position; refer to Pushing the Machine by Hand,
page 18.
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 24.
Adjusting the Brake
(0.020” (5.08 mm) feeler gauge required)
1.
Check the brake before you adjust it; refer to
Checking the Brake, page 24.
2.
Release the parking brake; refer to Releasing the
Parking Brake, page 12.
3.
To adjust the brake remove the cotter pin and
loosen the brake adjusting nut slightly (Fig. 17).
4.
Carefully insert a 0.020” (5.08 mm) feeler gauge
between the two outer brake pads (Fig. 17).
5.
Tighten the brake adjusting nut until slight
resistance is felt on the feeler gauge when sliding
it in and out. Install cotter pin.
6.
Check the brake operation again; refer to
Checking the Brake, page 24.
IMPORTANT: With the parking brake
released, the rear wheels must rotate freely
when you push the mower. If the 0.020”
(5.08 mm) clearance and free wheel rotation
cannot be achieved contact your service
dealer immediately.
1
0.020” (5.08 mm)
Figure 17
1. Brake adjusting nut
24
2. Cotter pin
2
1674
Maintenance
Wiring Diagram
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25
Maintenance
Fuse
5
5
Service Interval/Specification
1
3
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. 18) to remove from the socket. Push
down to insert.
4
2
Fuse: 10 amp, blade-type.
4
1
1874
Figure 19
2
1. Bulb holder
2. Reflector
3. Tabs
4. Slots
5. Terminals
Installing the Bulb
1.
1672
Figure 18
1. Fuse (removed)
2. Socket
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. 20).
Push and rotate the bulb clockwise until it stops.
1
Headlights
2
2
4
Specification: Bulb # 1156, automotive type.
3
4
Removing the Bulb
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. Pull wire connectors off both
bulb holder terminals.
3.
Rotate the bulb holder 1/4 turn counterclockwise
and remove it from the reflector (Fig. 19).
4.
Push and rotate the bulb counterclockwise until
it stops (approx. 1/4 turn) and remove bulb from
the bulb holder (Fig. 20).
26
1875
Figure 20
1. Bulb
2. Metal pins
3. Bulb holder
4. Slots
2.
The bulb holder has two tabs (Fig. 19). 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
2
5
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.
1
Voltage: 12 v, 160 Cold Cranking Amps
4
3
Removing the Battery
1.
Disengage the blade control (PTO), 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. 21).
4.
5.
Slide the rubber cover up the positive (red)
cable. Disconnect the positive (red) cable from
the battery post (Fig. 21).
Remove the battery box, battery, and long vent
tube from the chassis (Fig. 22).
1876
Figure 21
1. Negative cable (black)
2. Rubber cover
3. Positive cable (red)
4. Battery box
5. Bolt and wing nut
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. 22).
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. 22). Always install the
long battery vent tube through the hole to
prevent battery acid from corroding the
tractor and mower.
27
Maintenance
1
2
2
3
3
4
1
1878
5
Figure 23
2347
1. Filler caps
2. UPPER line
3. LOWER line
Figure 22
1. Battery
2. Battery box
3. Vent tube
2.
3.
4.
4. Slot in battery box
5. Hole in frame
Install the battery box and battery into the
chassis (Fig. 22). Make sure to slide the end of
the vent tube through the hole in the frame
(Fig. 22).
Using the bolt and wing nut, connect the positive
(red) cable to the positive (+) battery post
(Fig. 21). Slide the rubber cover over the battery
post.
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. 23).
3.
Slowly pour distilled water into each battery cell
until the level is up to the “UPPER” line
(Fig. 23) on the battery case.
Using the bolt and wing nut, connect the
negative (black) cable to the negative (–) battery
post (Fig. 21).
IMPORTANT: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
Checking Electrolyte Level
4.
1.
Tip the seat forward to see the battery.
Charging the Battery
2.
Look at the side of the battery. The electrolyte
must be up to the “UPPER” line (Fig. 23). Do
not allow the electrolyte to get below the
“LOWER” line (Fig. 23).
3.
If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery, page 28.
28
Screw the filler caps onto 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 27.
2.
Check the electrolyte level; refer to Checking
Electrolyte Level, page 28, steps 2–3.
Maintenance
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 is fully charged.
Removing the Spark Plug
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.
Pull the wire off the spark plug (Fig. 24). 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.
POTENTIAL HAZARD
• Charging the battery produces gasses.
WHAT CAN HAPPEN
• Battery gasses can explode.
HOW TO AVOID THE HAZARD
• Keep cigarettes, sparks and flames away
from battery.
4.
Install the battery in the chassis; refer to
Installing the Battery, page 27.
Spark Plug
Service Interval/Specification
1
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 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.
m–1798
Figure 24
1. Spark plug wire
Type: Champion RC12YC (or equivalent)
Air Gap: 0.030” (0.762 mm).
29
Maintenance
Checking the Spark Plug
1.
Fuel Tank
Look at the center of the spark plug (Fig. 25). 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.
Draining The Fuel Tank
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
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.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
Check the gap between the center and side
electrodes (Fig. 25). Bend the side electrode
(Fig. 25) if the gap is not correct.
2
HOW TO AVOID THE HAZARD
• 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 drain gasoline near an open flame or
where gasoline fumes may be ignited by a
spark.
• Never smoke a cigarette, cigar or pipe.
3
1
0.030”
(0.762 mm)
1.
Park the machine so that the left front side is
slightly lower than the right side to assure fuel
tank drains completely. Then 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.
Squeeze the ends of the hose clamp together and
slide it up the fuel line toward the fuel tank
(Fig. 26).
4.
Pull the fuel line off the filter (Fig. 26) and allow
gasoline to drain into a gas can or drain pan.
1870
Figure 25
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 is set correctly.
2.
Tighten the spark plug to 15 ft-lb (20.4 Nm).
3.
Push the wire onto the spark plug (Fig. 24).
4.
Close the hood.
30
Note:
5.
Now is the best time to install a new
fuel filter because the fuel tank is
empty.
Install the fuel line onto the filter. Slide the hose
clamp close to the filter to secure the fuel line
and filter.
Maintenance
Air Cleaner
Service Interval/Specification
Foam Element: Clean and re-oil after every 25
operating hours, or yearly, whichever occurs first.
1
Paper Element: Replace after every 100 operating
hours or yearly, whichever occurs first.
2
3
Note:
1873
Figure 26
1. Hose clamp
2. Fuel line
Service the air cleaner more frequently
(every few hours) if operating
conditions are extremely dusty or
sandy.
3. Filter
Removing the Foam and Paper Elements
1.
Disengage the blade control (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine.
Service Interval/Specification
2.
Open the hood.
Replace the fuel filter after every 100 operating hours
or yearly, whichever occurs first.
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).
Fuel Filter
Replacing the Fuel Filter
The best time to replace the fuel filter (Fig. 26) is
when the fuel tank is empty. Never install a dirty
filter if it is removed from the fuel line.
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.
Squeeze the ends of the hose clamps together
and slide them away from the filter (Fig. 26).
4.
Remove the filter from the fuel lines.
5.
Install a new filter and move the hose clamps
close to the filter.
6.
Close the hood.
1
2
m–1798
Figure 27
1. Knob
2. Air cleaner cover
31
Maintenance
4.
Carefully slide the foam element off the paper
element (Fig. 28).
Cleaning the Foam and Paper Elements
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. 30). Squeeze the element to distribute
the oil.
2
IMPORTANT: Replace the foam element if it
is torn or worn.
1864
Figure 28
1. Foam element
5.
2. Paper element
2
Unscrew the rubber nut and remove the paper
element (Fig. 29).
1
1
1866
Figure 30
1. Foam element
2
2.
2. Oil
Paper Element
A. Lightly tap the element on a flat surface to
remove dust and dirt (Fig. 31).
1865
Figure 29
1. Rubber nut
32
2. Paper element
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.
Maintenance
Engine Oil
Service Interval/Specification
Change oil:
1
•
After the first 5 operating hours.
•
After every 25 operating hours.
Note:
Change oil more frequently when
operating conditions are extremely
dusty or sandy.
2
1867
Figure 31
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. 28).
2.
Slide the air cleaner assembly onto the long rod.
Now screw the rubber nut finger-tight against the
air cleaner (Fig. 29).
Note:
3.
4.
Make sure the rubber seal is flat
against the air cleaner base.
Oil Type: Detergent oil (API service SF, SG or SH)
Crankcase Capacity: 48 oz/1–1/2 qt (1400 cc/1.4 l)
when filter is not changed;
56 oz (1700 cc/1.7 l) when
filter is changed.
Viscosity: See table below
USE THESE SAE VISCOSITY OILS
–20
°F
0
–30
°C
–20
20
–10
40
0
60
10
80
20
100
30
40
Install the air cleaner cover and knob (Fig. 27).
Tighten the knob snugly.
Checking Oil Level
Close the hood.
1.
Park the machine on a level surface, 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 oil dipstick (Fig. 32) so dirt
cannot fall into the filler hole and damage the
engine.
4.
Unscrew the oil dipstick and wipe the metal end
clean (Fig. 32).
33
Maintenance
5.
Screw the oil dipstick fully onto the filler tube
(Fig. 32). Unscrew the dipstick again and look at
the metal end. If oil level is low, slowly pour
only enough oil into the filler tube to raise the
level to the “FULL” mark.
7.
Slowly pour approximately 80% of the specified
amount of oil into the filler tube (Fig. 32). Now
check the oil level; refer to Checking Oil Level,
page 33, steps 4–5.
2
IMPORTANT: Do not overfill the crankcase
with oil because the engine may be damaged.
1
2
3
1
1869
1868
Figure 32
1. Oil dipstick
2. Metal end
3. Filler tube
Changing/Draining Oil
1.
Start the engine and let it run five minutes. This
warms the oil so it drains better.
2.
Park the machine so that the right front side is
slightly lower than the left side to assure the oil
drains completely. Then disengage the blade
control (PTO), 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. 33).
5.
When oil has drained completely, install the
drain plug.
Note:
6.
34
Dispose of the used oil at a certified
recycling center.
Change oil filter (Fig. 34).
Figure 33
1. Oil drain plug
2. Oil dipstick/fill tube
Maintenance
Change Oil Filter—Service
Interval/Specification
Cutting Blade
Replace the oil filter every 50 hours or every other oil
change.
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).
Note:
Change oil filter more frequently when
operating conditions are extremely
dusty or sandy.
1.
Drain the oil from the engine; refer to
Changing/Draining Oil, page 34.
2.
Remove the old filter and wipe the filter adapter
(Fig. 34) gasket surface.
3.
POTENTIAL HAZARD
• A 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
• Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 34).
HOW TO AVOID THE HAZARD
• Periodically inspect the blade for wear and
damage. Immediately install a new blade if
it is worn or damaged.
3
2
Inspecting the Blade(s)
1
Remove the mower; refer to Removing the
Mower, page 37.
2.
Inspect the cutting edges (Fig. 35). If the edges
are not sharp or have nicks, remove the blade(s)
and sharpen them; refer to Sharpening the
Blade(s), page 36.
3.
Inspect the blade(s), especially the curved area
(Fig. 35). If you notice any damage, wear, or a
slot forming in this area (Fig. 35), immediately
install a new blade.
1256
Figure 34
1. Oil filter
2. Gasket
1.
3. Adapter
4.
Install the replacement oil filter to the filter
adapter. Turn the oil filter clockwise until the
rubber gasket contacts the filter adapter, then
tighten the filter an additional 1/2 turn (Fig. 34).
5.
Slowly pour approximately 80% of the specified
amount of oil into the filler tube (Fig. 32). Now
check the oil level; refer to Checking Oil Level,
page 33, steps 4 and 5.
35
Maintenance
Sharpening the Blade(s)
1.
2
1
Use a file to sharpen the cutting edge at both
ends of the blade (Fig. 37). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
3
1
151
Figure 35
1. Cutting edge
2. Curved area
1854
3. Wear/slot forming
Figure 37
1. Sharpen at original angle
2.
1.
Remove the mower; refer to Removing the
Mower, page 37.
2.
Carefully tip the mower over.
Check the balance of the blade by putting it on a
blade balancer (Fig. 38). 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 the back side of the blade. Repeat this
procedure until the blade is balanced.
3.
Remove the bolt (5/8” wrench), curved washer
and blade (Fig. 36). A block of wood may be
wedged between the blade and the mower to
lock the blade when you are removing the bolt.
1
Removing the Blade
4.
Inspect all parts. If a defect or damage is noticed,
install new parts.
2
1855
Figure 38
1. Blade
2. Balancer
Installing the Blade(s)
3
1.
2
IMPORTANT: The curved part of the blade
must be pointing toward the inside of the
mower to assure proper cutting.
4
5
Install the blade, blade retainer, curved washer
(cupped side toward blade), and the blade bolt
(Fig. 36).
1
m–1886
Figure 36
1. Bolt
2. Blade
3. Spindle
36
4. Curved washer
5. Stiffener (Recycler only)
2.
Tighten the blade bolt to 45–60 ft-lb
(61–81 Nm).
Maintenance
Removing the Mower
1.
Park the machine on a level surface, disengage
the blade control (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine.
POTENTIAL HAZARD
• The height-of-cut lever (deck lift) is
spring-tensioned.
2.
Remove the key from the ignition switch and
pull the wire off the spark plug.
3.
Move the height-of-cut lever (deck lift) into the
“D” notch.
WHAT CAN HAPPEN
• When the mower is being removed, this
spring-loaded mechanism could suddenly
release and injure you or someone else.
4.
HOW TO AVOID THE HAZARD
• Move the height-of-cut lever (deck lift) to
the “D” position and remove the
height-of-cut lift assist spring to release the
spring tension.
Remove the height-of-cut lift assist spring from
the retaining bolt (Fig. 39), using the spring tool
provided with the machine. The spring is
between the frame and the right rear wheel.
5.
Move the height-of-cut lever (deck lift) into the
“A” notch.
6.
Unhook the blade control (PTO) cable ring end
from the idler spring (Fig. 40).
7.
Remove jam nut from blade control (PTO) cable
at mounting bracket. Slide the cable from the
bracket (Fig. 40).
8.
Move the cable out of the way and lay inside
frame rail so it cannot get caught in drive belts
or pulleys.
1
2
3
1851
Figure 39
1. Spring
2. Bolt
3. Spring tool
37
Maintenance
11. Remove the hairpin cotter and washer at the
mower leveling bracket (Fig. 42). Slide the
bracket off the mounting pin. Re-install the
washer and hairpin cotter for storage.
4
1
2
5
12. Rotate the leveling bracket up, toward the frame,
and hook the long rod into one of the holes to
store. Secure long rod with washer and hairpin
cotter. Repeat for opposite side of the mower.
3
2384
13. Move the height-of-cut lever (deck lift) into the
“D” notch. Hook lift assist spring onto retaining
bolt for storage (Fig. 39).
Figure 40
1. Blade control (PTO) cable
2. Ring end
3. Idler spring
9.
2
4. Jam nut
5. Mounting bracket
1
Remove the bolts and lock nuts and pull the two
mower pivot mount brackets down from the
front axle (Fig. 41).
4
1
2
3
1805
Figure 42
1. Hairpin cotter and washer
2. Long rod
1
3
m–4630
Figure 41
1. Pivot mount bracket
2. Bolt 5/16-18 x 2-1/2”
3. Lock nut
10. Remove the hair pin cotter and washer from the
end of the long rod (Fig. 42). Now slide the rod
out of the mower mount. Repeat this step on the
opposite side of the mower.
38
3. Leveling bracket
4. Mower mount
14. Remove the mower belt from the lower engine
pulley (Fig. 43). 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.
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.
Maintenance
3
2
1
3
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” (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” (3.2 mm), adjust the
belt guide(s) and tighten them securely. The
belt guide(s) must not contact the pulley.
1890
Figure 43
Top View
1. Mower belt
2. Engine pulley
5.
3. Belt guides
Install the mower pivot mount brackets to the
front axle with bolts and lock nuts (Fig. 44).
2
15. Turn the front wheels fully to the left. Slide the
mower out to the right to complete removal.
1
Installing the Mower
1.
Park the machine on a level surface, disengage
the blade control (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine.
3
m–4630
Figure 44
2.
Remove the key from the ignition switch and
pull the wire off the spark plug.
1. Pivot mount bracket
2. Bolt 5/16-18 x 2-1/2”
3. Lock nut
3.
Turn the front wheels fully to the left. Slide the
mower under the chassis from the right side.
6.
Move the height-of-cut lever (deck lift) into the
“A” notch.
4.
Install mower belt onto the lower engine pulley
(Fig. 43). If you are careful, you can flex the belt
guide(s) just far enough away from the pulley to
7.
Slide the end of the long rod through the hole in
the mower mount (Fig. 45). Install the washer
and hair pin cotter to secure the rod in place.
Repeat this step on the opposite side of the
mower.
39
Maintenance
8.
Mount the slotted mower leveling bracket onto
the pin on the height-of-cut arm (Fig. 45). Install
the washer and hair pin cotter to secure the
mower. Repeat this step on the opposite side of
the mower.
2
4
1
2
5
3
1
2384
Figure 46
4
1
3
1. Blade control (PTO) cable
2. Ring end
3. Idler spring
4. Jam nut
5. Mounting bracket
1805
Figure 45
1. Hairpin cotter and washer
2. Long rod
9.
3. Leveling bracket
4. Mower mount
Look under tractor and take down blade control
(PTO) cable nested inside frame rail.
12. Engage blade control (PTO) lever on dash.
Measure distance between hook ends of idler
spring (Fig. 47). Adjust jam nuts so 6”
(150 mm) dimension is obtained (Fig. 47).
13. Tighten jam nuts securely and disengage blade
control (PTO).
10. Remove first jam nut and thread second jam nut
onto the blade control (PTO) cable all the way.
Route cable through slot in deck bracket and
thread second jam nut onto cable (Fig. 46).
11. Hook end of blade control (PTO) cable onto
idler spring (Fig. 46).
2
6”
(150 mm)
1
3
2385
Figure 47
1. Blade control (PTO) cable
2. Jam nut
3. Idler spring
14. Move the height-of-cut lever (deck lift) into the
“D” notch to make it easier to install the
height-of-cut lift assist spring.
40
Maintenance
15. Hook the height-of-cut lift assist spring onto the
retaining bolt (Fig. 39), using the spring tool
provided with the machine.
3
1
16. Check side-to-side blade level; refer to
Side-to-Side Mower Leveling, page 41.
1
2
Blade Drive Belt
90°
Removing the Blade Drive Belt
1.
Remove the mower; refer to Removing the
Mower, page 37.
1890
2.
Remove the pulley cover mounting screws and
pulley covers from both blade pulleys (Fig. 48).
3.
Loosen, but do not remove the bolt and nut
securing the idler pulley and belt guide (Fig. 48).
4.
Remove the belt from the pulleys.
Figure 48
Top View
1. Pulley cover
2. Idler pulley belt guide
position
3. Mower belt
Installing the Blade Drive Belt
Side-to-Side Mower Leveling
1.
Install the new belt around the blade pulleys and
under the belt guide on the idler pulley.
2.
Position the idler pulley belt guide so it points
toward the left, 90° to the idler arm (Fig. 48).
Tighten the mounting bolt and lock nut securing
the idler pulley and belt guide.
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 “Tire Pressure” (page 23) in the Maintenance
Section.
3.
Install the left and right pulley covers with the
mounting screws (Fig. 48).
4.
Install the mower; refer to Installing the Mower,
page 39.
1.
Park the machine on a level surface, disengage
the blade control (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine.
2.
Remove the key from the ignition switch and
pull the wire off the spark plug.
3.
Move the height-of-cut lever (deck lift) into the
“C” notch.
41
Maintenance
4.
Carefully rotate blade(s) side to side (Fig. 49).
Measure between the outside cutting edges and
the flat surface (Fig. 49). If both measurements
are not within 3/16” (4.8 mm), an adjustment is
required; refer to steps 5 and 6.
1
6.
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 the
recommended inflation. Refer “Tire Pressure”
(page 23) in the Maintenance Section. If the front of
the mower is not within a range of 1/8”–3/8”
(3.5 mm–10.5 mm) lower than the rear of the mower,
adjust the blade slope using the following
instructions:
2
2
1.
Park the machine on a level surface, disengage
the blade control (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine.
2.
Remove the key from the ignition switch and
pull the wire off the spark plug.
3.
Check and adjust side-to-side blade level if you
have not checked the setting; refer to
Side-to-Side Mower Leveling, page 41.
4.
Move the height-of-cut lever (deck lift) into the
“C” notch.
5.
Measure the length of the rod extending out the
front of the adjusting block on the sides of the
chassis (Fig. 51). If the rod length is not 5/8”
(15.9 mm), remove the hair pin cotter and
washer from the end of the rod (Fig. 51), and
turn the rod until the 5/8” (15.9 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.
6.
Check the front to rear slope by measuring
between the bottom of the mower
(front center and rear center) and the flat surface
(Fig. 52). If the front is not within a range of
1/8”–3/8” (3.5mm–10.5mm) lower than the rear,
an adjustment is required.
3
3
1891
Figure 49
1. Blades side to side
2. Outside cutting edges
5.
3. Measure here
Remove the hair pin cotter and washer from the
leveling bracket (Fig. 50). To level the blade(s),
reposition the leveling bracket in a different hole
and install the washer and hair pin cotter.
(Fig. 50). A front hole lowers the blade height
and a rear hole raises its height. Repeat this
procedure on the opposite side.
2
1
4
1
3
1805
Figure 50
1. Hairpin cotter and washer
2. Long rod
42
3. Leveling bracket
4. Mower mount
Now check the front-to-rear blade slope; refer to
Front-to-Rear Blade Slope, page 42.
Maintenance
(15.875 mm)
8.
Rotate lock nuts on eyebolts to change
adjustment (Fig. 53). To raise the front of the
mower, tighten the eyebolt lock nuts. To lower
the front of the mower, loosen the eyebolt lock
nuts.
9.
After adjusting both eyebolt lock nuts evenly,
check the front-to-rear slope again. Continue
adjusting eyebolts until the front blade tip is
0–3/8” (0–9.2 mm) lower than the rear blade tip
(Fig. 53).
5/8”
1
2
3
4
10. When front-to-rear slope is correct, tighten the
pivot plate mounting bolts (Fig. 53).
1889
Figure 51
1. Adjusting block
2. Long rod
3. Hairpin cotter and washer
4. Mower mount
1
2
1
Figure 53
2
1
1. Pivot mounting bolt
2. Eyebolt locknut
11. When front-to-rear slope is correct, recheck the
side-to-side level of the mower; refer to
Side-to-Side Mower Leveling, page 41.
1
2
1892
Figure 52
1. Measure front center
7.
2. Measure rear center
To adjust front-to-rear blade slope loosen front
pivot plate mounting bolts slightly (Fig. 53).
43
Maintenance
Washing Underside of Mower
After each use wash the underside of the mower to
prevent grass build-up for improved mulch action and
clipping dispersal.
1.
2.
Park the machine on a hard, level surface,
disengage the power take off (PTO) and turn the
ignition key to “OFF” to stop the engine.
Attach coupling (not supplied) to mower
washout fitting and turn water on high (Fig. 54).
3.
Lower the mower to the lowest height-of-cut.
4.
Sit on the seat and start the engine. Engage
power take off (PTO) and let mower run for one
to three minutes.
5.
Disengage the power take off (PTO) and turn the
ignition key to “OFF” to stop the engine.
6.
Turn the water off, remove coupling from the
washout fitting and hose.
7.
Run mower again for one to three minutes to
remove excess water.
3
2
1
m–2921
Figure 54
1. Washout fitting
2. Coupling (Not Supplied)
44
3. Hose
POTENTIAL HAZARD
• A broken or missing washout fitting could
expose you and others to thrown objects or
blade contact.
WHAT CAN HAPPEN
• Contact with thrown debris or blade
contact will cause injury or death.
HOW TO AVOID THE HAZARD
• 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.
Maintenance
Cleaning and Storage
1.
Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the 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’s cylinder head fins and blower
housing.
IMPORTANT: You can wash the machine
with mild detergent and water. DO NOT
PRESSURE 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 the 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 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.
9.
Check the tire pressure; refer to Tire Pressure,
page 23.
10. Prepare the machine for storage when non–use
occurs over 30 days. Prepare machine for storage
as follows.
A. Add a petroleum based
stabilizer/conditioner to fuel in the tank.
Follow mixing instructions from stabilizer
manufacture. (1 oz. per gallon). Do not use
an alcohol based stabilizer (ethanol or
methanol).
3.
Check the brake; refer to Brake, page 24.
4.
Service the air cleaner; refer to Air Cleaner,
page 31.
5.
Grease the chassis; refer to Greasing and
Lubrication, page 23.
B.
Run engine to distribute conditioned fuel
through the fuel system (5 minutes).
6.
Change the crankcase oil; refer to Engine Oil,
page 33.
C.
Stop engine, allow to cool and drain the
fuel tank; refer to Fuel Tank, page 30.
7.
Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 29. With
the spark plug(s) 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(s); refer to Spark Plug,
page 29. Do not install the wire on the spark
plug(s).
8.
Remove the battery from the chassis, check the
electrolyte level, and charge it fully; refer to
Battery, page 27. Do not connect the battery
cables to the battery posts during storage.
Note:
A fuel stabilizer/conditioner is most
effective when mixed with fresh
gasoline and used at all times.
D. Restart engine and run it until it stops.
E.
Choke or prime the engine. Start and run
engine until it will not start. Operate primer,
if equipped on machine, several times to
ensure no fuel remains in primer system.
F.
Dispose of fuel properly. Recycle as per
local codes.
IMPORTANT: Do not store
stabilizer/conditioned gasoline over 90 days.
11. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged or
defective.
45
Maintenance
12. Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service
Dealer.
13. 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.
46
Troubleshooting
PROBLEM
Starter does not crank
Engine
g
will not start,, starts hard,, or
f il to
fails
t keep
k
running.
i
Engine
g
loses power.
p
POSSIBLE CAUSES
CORRECTIVE ACTION
1.
Blade control (PTO) is
ENGAGED.
1.
Move blade control (PTO) to
DISENGAGED.
2.
Parking brake is not on.
2.
Set parking brake.
3.
Battery is dead.
3.
Charge the battery.
4.
Electrical connections are
corroded or loose.
4.
Check electrical connections
for good contact.
5.
Fuse is blown.
5.
Replace fuse.
6.
Relay or switch is defective.
6.
Contact Authorized Service
Dealer.
1.
Operator is not seated.
1.
Sit on the seat.
2.
Fuel tank is empty.
2.
Fill fuel tank with gasoline.
3.
Air cleaner is dirty.
3.
Clean or replace air cleaner
element.
4.
Spark plug wire is loose or
disconnected.
4.
Install wire on spark plug.
5.
Spark plug is pitted, fouled, or
gap is incorrect.
5.
Install new, correctly gapped
spark plug.
6.
Choke is not closing.
6.
Adjust throttle cable.
7.
Dirt in fuel filter.
7.
Replace fuel filter.
8.
Idle speed is too low or
mixture is incorrect.
8.
Adjust carburetor idle speed
and idle mixture.
9.
Dirt, water, or stale fuel is in
fuel system.
9.
Contact Authorized Service
Dealer.
1.
Engine load is excessive.
1.
Reduce ground speed.
2.
Air cleaner is dirty.
2.
Clean air cleaner element.
3.
Oil level in crankcase is low.
3.
Add oil to crankcase.
4.
Cooling fins and air passages
under engine blower housing
are plugged.
4.
Remove obstruction from
cooling fins and air passages.
5.
Spark plug is pitted, fouled, or
gap is incorrect.
5.
Install new, correctly gapped
spark plug.
6.
Vent hole in fuel cap is
plugged.
6.
Clean or replace the fuel cap.
7.
Dirt in fuel filter.
7.
Replace fuel filter.
8.
Dirt, water, or stale fuel is in
fuel system.
8.
Contact Authorized Service
Dealer.
47
Troubleshooting
PROBLEM
Engine
g
over heats.
Abnormal vibration.
Blade(s) does not rotate.
Machine does not drive.
Uneven cutting
g height.
g
48
POSSIBLE CAUSES
CORRECTIVE ACTION
1.
Engine load is excessive.
1.
Reduce ground speed.
2.
Oil level in crankcase is low.
2.
Add oil to crankcase.
3.
Cooling fins and air passages
under engine blower housing
are plugged.
3.
Remove obstruction from
cooling fins and air passages.
1.
Cutting blade(s) is bent or
unbalanced.
1.
Install new cutting blade(s).
2.
Blade mounting bolt is loose.
2.
Tighten blade mounting bolt.
3.
Engine mounting bolts are
loose.
3.
Tighten engine mounting
bolts.
4.
Loose engine pulley, idler
pulley, or blade pulley.
4.
Tighten the appropriate
pulley.
5.
Engine pulley is damaged.
5.
Contact Authorized Service
Dealer.
1.
Blade drive belt is worn, loose
or broken.
1.
Install new blade drive belt.
2.
Blade drive belt is off pulley.
2.
Install blade drive belt and
check idler pulley and belt
guides for correct position.
1.
Drive control is in “PUSH”
position.
1.
Move drive control to
“OPERATE” position.
2.
Traction belt is worn, loose or
broken.
2.
Contact Authorized Service
Dealer.
3.
Traction belt is off pulley.
3.
Contact Authorized Service
Dealer.
1.
Tire pressure is incorrect.
1.
Set tire pressure.
2.
Mower is not level.
2.
Level mower from
side-to-side and front-to-rear.
3.
Underside of mower is dirty.
3.
Clean the underside of the
mower.
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