Toro 265-H Lawn and Garden Tractor User manual
Form No. 3323–949 Wheel Horse 265H Lawn and Garden Tractor Model No. 72071 – 200000001 & Up Operator’s Manual 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 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. The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed. WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed. CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed. Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention. 1 1202 1. Model and Serial Number Plate The left and right side of the machine is determined by sitting on the seat in the normal operator’s position. For your convenience, write the product model and serial numbers in the space below. Model No: Serial No. Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although we design, produce and market 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 Company – 1999 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 Key Choice Switch . . . . . . . . . . . . . . . . . . . 12 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . 12 Starting and Stopping the Engine . . . . . . . 13 Operating the Power Take Off (PTO) . . . . 14 The Safety Interlock System . . . . . . . . . . . 15 Operating–in–Reverse . . . . . . . . . . . . . . . . 15 Indicator Control Module . . . . . . . . . . . . . 17 Driving Forward or Backward . . . . . . . . . . 17 Page Stopping the Machine . . . . . . . . . . . . . . . . Attachment Lift Lever . . . . . . . . . . . . . . . . Adjusting Dial-A-Height . . . . . . . . . . . . . . Positioning the Seat . . . . . . . . . . . . . . . . . . Headlights . . . . . . . . . . . . . . . . . . . . . . . . . Positioning the Tilt Steering Wheel . . . . . . Using the Cruise Control . . . . . . . . . . . . . . Pushing the Machine by Hand . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Interval Chart . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . Greasing and Lubrication . . . . . . . . . . . . . . Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Toe-In . . . . . . . . . . . . . . . . . . Transaxle Fluid . . . . . . . . . . . . . . . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlights . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 18 18 19 19 19 19 20 20 21 21 22 24 26 27 27 28 29 30 30 31 32 32 33 35 36 37 1 Safety Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines 6. 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; Safe Operating Practices lack of awareness of the effects of ground conditions, especially slopes; This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. incorrect hitching and load distribution. Preparation 1. While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. 2. Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. 3. WARNING –Fuel is highly flammable. Training 1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. 2. Never allow children or people unfamiliar with these instructions to use the lawnmower. Local regulations may restrict the age of the operator. 3. Never mow while people, especially children, or pets are nearby. 4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property. 5. Do not carry passengers. 2 • Store fuel in containers specifically designed for this purpose. • Refuel outdoors only and do not smoke while refuelling. • 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. Safety • If fuel is spilled, do not attempt to start the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated. • Replace all fuel tanks and container caps securely. 4. Replace faulty silencers. 5. 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. 6. On multi–bladed machines, take care as rotating one blade can cause other blades to rotate. 7. When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. 8. Never operate the lawnmower with damaged guards or without safety protective devices in place. 9. Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury. 10. Before leaving the operator’s position: • disengage the power take-off and lower the attachments; Operation • change into neutral and set the parking brake; 1. • stop the engine and remove the key. Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect. 2. Mow only in daylight or in good artificial light. 3. Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral. 4. 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. 5. Watch out for traffic when crossing or near roadways. 6. Stop the blades before crossing surfaces other than grass. 11. Disengage drive to attachments, stop the engine, and disconnect the spark plug wire(s) or remove the ignition key • before cleaning blockages or unclogging chute; • before checking, cleaning or working on the lawnmower; • after striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the equipment; • if the machine starts to vibrate abnormally (check immediately). 12. Disengage drive to attachments when transporting or not in use. 13. Stop the engine and disengage drive to attachment • before refuelling; • before removing the grass catcher; 3 Safety • before making height adjustment unless adjustment can be made from the operator’s position. 4. To reduce the fire hazard, keep the engine, silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease. 14. 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. 5. Check the grass catcher frequently for wear or deterioration. 6. Replace worn or damaged parts for safety. 7. If the fuel tank has to be drained, this should be done outdoors. 8. On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. 9. When machine is to be parked, stored or left unattended, lower the cutting means unless a positive mechanical lock is used. Slope Operation 1. 2. For operation on slopes: • Never mow side hills over 5_ • Never mow uphill over 10_ • Never mow downhill over 15_ 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; • 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 bumps and hollows and other hidden hazards; • never mow across the face of the slope, unless the lawnmower is designed for this purpose. Sound Pressure Level This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 90 dB(A), based on measurements of identical machines per Directive 84/538/EEC. Sound Power Level This unit has a sound power level of: 105 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments. Maintenance and storage Vibration Level 1. Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. 2. Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. 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. 3. Allow the engine to cool before storing in any enclosure. 4 Safety Slope Chart Read all safety instructions on pages 2–NO TAG. 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 • 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 Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine: 1. Shut the engine off and set the parking brake. 2. 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. Install fuel tank caps securely. Wipe up any gasoline that may have spilled. 4. Fuel gauge is located in right side tank. • Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained. • Cleans the engine while it runs • Eliminates gum-like buildup in the fuel system, which causes hard starting IMPORTANT: Never use fuel additives containing methanol or ethanol. 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 24. 11 Operation Think Safety First Key Choice Switch 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. A turn and release switch used for deactivating the “Operating–In–Reverse” interlock feature. Located on the seat bracket on the right side just below the seat (Fig. 2). Controls Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine. 1 13 11 1 6 10 9 m–4220 7 2 12 Figure 2 3 1. “Key Choice” switch 8 5 Parking Brake 4 14 Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 1. Push the 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 the brake pedal. The brake pedal should stay in the depressed (locked) position. 1200 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 12 Steering wheel Ignition switch Brake pedal Parking brake lever Ground speed selector Throttle lever Choke lever Power take off (PTO) 9. Cruise control switch 10. Indicator control module/Hourmeter 11. Attachment lift lever 12. Tilt wheel lever 13. Hood opening 14. Dial-a-height knob Releasing the Parking Brake 1. Push down on the brake pedal (Fig. 3). The parking brake lever should release. 2. Gradually release the brake pedal. Operation 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 7. 2 After the engine starts, move the choke lever to “OFF”and slowly move the throttle to the desired setting (Fig. 5). If the engine stalls or hesitates, move the choke lever back to “ON” for a few seconds. Then move the throttle lever to “FAST.” Repeat this as required. 2 1201 1 Figure 3 1. Brake pedal 3 2. Parking brake lever 1 2 Starting and Stopping the Engine 1207 1206 Figure 4 Starting 1. Sit down on the seat. 2. Set the parking brake; refer to Setting the Parking Brake, page 12. Note: 3. 4. Figure 5 1. PTO—Off 2. Choke–On 3. Choke–Off 1. Fast 2. Slow 1 2 The engine will not start unless you set the parking brake or fully depress the brake pedal and are seated. 3 4 Push the PTO (power take off) to “OFF” (Fig. 4). 1208 Move the choke lever to “ON” (Fig. 4). Note: An engine that has been running and is warm may not require step 4. 5. Move throttle lever to “FAST” (Fig. 5). 6. Turn the ignition key clockwise and hold it in the “START” position (Fig. 6). When the engine starts, release the key. Figure 6 1. Off 2. Lights 3. Run 4. Start 13 Operation Stopping 1. Move the throttle lever to “SLOW” (Fig. 5). 2. Turn the ignition key to “OFF” (Fig. 6). 2 1 Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.” 1206 Figure 7 1. Off-Disengaged Operating the Power Take Off (PTO) The power take off (PTO) engages and disengages power to the electric clutch that drives the attachments. While the ignition key is in “RUN” or “LIGHTS” position and the power take off (PTO) is engaged “ON”, the PTO light, in the Indicator Module, will be “ON”. When this light is “ON” it is a reminder that the starter will not crank and to turn the PTO off before getting off the tractor. 2. On-Engaged Disengaging the Power Take Off (PTO) 1. Depress the brake pedal to stop the machine. 2. Push the power take off (PTO) to “OFF” (Fig. 7). The Safety Interlock System Understanding the Safety Interlock System Engaging the Power Take Off (PTO) The safety interlock system is designed to prevent the engine from starting unless: 1. Depress the brake pedal to stop the machine. • You are sitting on the seat 2. Pull the power take off (PTO) to “ON” (Fig. 7). • The brake pedal is depressed • The power take off (PTO) is “OFF” • The hydro control pedal is in the neutral position. The safety interlock system is designed to stop the engine if: • 14 You rise from the seat when the brake pedal is released Operation • You rise from the seat when the power take off (PTO) is “ON”or gear selector is not in “N” neutral. • You move the hydro control pedal out of the neutral position when the parking brake is engaged. The safety interlock system is designed to stop the power take off (PTO) if: • You shift into reverse with the power take off (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 PTO 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 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. 8), 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. 9) 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. 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. 15 Operation 1 m–4220 Figure 8 1. “Key Choice” switch Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Set the parking brake. Move the power take off (PTO) to “ON”. Now turn the ignition key to “START”; the engine should not crank. 2. Push the power take off (PTO) to “OFF” and release the parking brake. Now turn the ignition key to “START”; the engine should not crank. 3. Set the parking brake, move the power take off (PTO) to “OFF” and move the hydro control pedal forward from the neutral; the engine should not crank. 4. Set the parking brake and move the power take off (PTO) to “OFF”(On gear drive models the speed selector lever must be in “N” neutral). Now start the engine. While the engine is running, release the parking brake and rise slightly from the seat; the engine should stop. 5. Set the parking brake and restart the engine. While the engine is running, and the parking brake is engaged, move the hydro pedal forward; the engine should stop. 16 6. With the parking brake released, turn the ignition key to RUN without starting the engine. Pull the PTO switch to ON. You should hear an audible click indicating the PTO is activated and the PTO light will illuminate. Move the foot pedal to reverse. You should hear an audible click indicating the PTO is deactivated and the PTO light should turn off. 7. With the parking brake released, turn the ignition switch to RUN without starting the engine. Pull the PTO switch to ON. Turn the “Key Choice” key and release. The Operating–in–Reverse warning light should illuminate. Move the foot pedal to reverse. The PTO and PTO light on the dash should remain on. Push the PTO switch to OFF. The PTO light and the Operating–in–Reverse warning light should turn off. Operation Indicator Control Module Driving Forward or Backward The indicator control module (Fig. 9) contains lights for: 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. • Operating–in–Reverse • Power take off (PTO) 1 2 3 Figure 9 1. Operating–in–Reverse 2. Hourmeter 3. PTO (power take off) 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. 10). The farther you move the traction control pedal in either direction, the faster the machine will move in that direction. Note: The following are the conditions when the indicator lights will be “ON”. At other times the lights should be off. Operating–in–Reverse The Operating–in–Reverse light will illuminate whenever the “key choice” switch is used to deactivate the operating–in–reverse interlock. It is a reminder that the interlock system is deactivated. The light goes out whenever the power take off (PTO) is disengaged or the engine is shut off. For reverse motion, with the PTO engaged, the operating–in–reverse interlock must be deactivated by the “key choice” switch located on the seat bracket on the right hand side just below the seat. 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. 1 PTO (Power Take Off) The PTO (power take off) light will be “ON” when the key is in the “RUN” or “LIGHTS” positions and the PTO (power take off) is engaged “ON”. When this light is “ON” it is a reminder; the starter will not crank and turn off the PTO before getting off. 2 1210 Figure 10 Hourmeter 1. Forward 2. Backward The hourmeter records the number of hours the engine has operated. It is turned on when the ignition switch is in the “RUN” or “LIGHTS” positions. Use the times for scheduling regular maintenance. 17 Operation Stopping the Machine Attachment Lift Lever To stop the machine, release the traction control pedal, disengage the power take off (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 ignition and “key choice” keys from the switchs. The attachment lift lever (Fig. 11) is used to raise and lower various attachments. 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. Raising Attachments 1. Depress the brake pedal to stop the machine. 2. Pull attachment lift lever rearward until latch locks. In this position the lift will hold the attachment in the up, or raised position. Lowering Attachments 1. Depress the brake pedal to stop the machine. 2. Pull attachment lift lever rearward, to release lift pressure, and push the button on top to release the latch. Move lift lever forward to lower attachment. 2 1 3 5 4 6 Figure 11 1. Lift lever 2. Button 3. Dial-A-Height 18 4. Indicator 5. High 6. Mounting position 1205 Operation Adjusting Dial-A-Height Headlights The Dial-A-Height control (Fig. 11) is used to limit the downward travel of the attachment. The Dial-A-Height knob is rotated to change the location of this stop, up or down. The headlights are turned on with a separate position, “LIGHTS”, of the ignition switch (Fig. 13). The lights are on while the ignition switch is in the “LIGHTS” position even with the engine off. Remove the key when the machine is left unattended so lights can not be turned on discharging the battery. 1. 2. Raise the attachment lift lever: Refer to Raising Attachments. In the raised position the Dial-A-Height knob (Fig. 11) can be rotated to change the stop location. Turn clockwise to raise and counterclockwise to lower the height of the attachment. 1 The Dial-A-Height indicator (Fig. 11) will show the change, high to low, in attachment lift height as adjustment is made. 1208 Figure 13 Positioning the Seat 1. Lights The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. 2. Raise the seat and loosen the adjustment knobs (Fig. 12). Slide the seat to the desired position and tighten the knobs. 1 Positioning the Tilt Steering Wheel The steering wheel has four tilt locations. Position the steering wheel where you have the best control of the machine and are most comfortable. 1. Lift the tilt lever to release the lock (Fig. 14). 2. Move the steering wheel to a comfortable position; then release the lever to lock. 2 m-4223 Figure 12 1 1. Adjustment knob 1203b Figure 14 1. Tilt lever 2. Steering wheel 19 Operation Using the Cruise Control Pushing the Machine by Hand The cruise control is optional on some models. A three position Set-Lock (spring loaded), On and Off-Unlock dash switch (Fig. 15) controls the engagement. Cruise control maintains the traction control position without foot pressure. Cruise control is intended for operation in the forward direction only. Do not use cruise control in reverse. Engaging the Cruise Control 1. Begin driving tractor: Refer to Driving Forward or Backward, Page 17. While holding your foot steady on the traction control, push the cruise control switch (Fig. 15) to the “SET”–“LOCK” position. IMPORTANT: Always push the machine by hand. Never tow the machine because transaxle damage may occur. To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. 2. Move the drive control rod to the “PUSH” position. This disengages the drive system and allows the wheels to turn freely (Fig. 16). To Operate the Machine 1. Move the drive control rod to the “OPERATE” position (Fig. 16). Note: 1 2 The machine will not drive unless the drive control rod is in the “OPERATE” position. 1 1641t 3 2 Figure 15 1. Lock-Set 2. 2. Unlock-Off This locks the traction control in position and your foot can then be removed from the traction control. A constant ground speed will be maintained. M-4566 Figure 16 Disengaging the Cruise Control 1. While holding your foot steady on the traction control, move the cruise control switch (Fig. 15) to the “OFF”–”UNLOCK” position. 2. This unlocks the traction control and your foot then operates the traction control. 3. For quick stops, just press on the brake pedal. This automatically disengages the cruise control and applies the brake at the same time. 20 1. Operate position 2. Push position 3. Drive Control Rod Maintenance Service Interval Chart Service Operation Oil—check level Each Use 5 Hours 25 Hours 50 Hours 100 Hours Initial X Oil Filter—change* (200 hours, every other oil change or yearly) X Safety System—check X Brake—check X X X X X Chassis—grease* X Foam Air Cleaner—service* X X Spark Plug(s)—check 200 hours X X Belts—check for wear/cracks X X X Paper Air Cleaner—replace* X X X Gasoline—drain X X X X Chipped Surfaces—paint Battery—check electrolyte Spring Service X Oil—change* Engine—clean outside Storage Service X X X X Battery—charge, disconnect cables X X Fuel Filter—replace X X Tires—check pressure X X Front Wheels–check toe-in X X X * More often in dusty, dirty conditions 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(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s). 21 Maintenance Air Cleaner 4. Carefully slide the foam element off the paper element (Fig. 17). Service Interval/Specification 5. Unscrew the cover nut and remove the cover and paper element (Fig. 17). Foam Element: Clean and re-oil after every 25 operating hours, or yearly, whichever occurs first. Cleaning the Foam and Paper Elements Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first. Note: 1. Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Foam Element A. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. B. Dry the element by squeezing it in a clean cloth. C. Put one or two ounces of oil on the element (Fig. 18). Squeeze the element to distribute the oil. Removing the Foam and Paper Elements 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2. Open the hood. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Remove knob and the air cleaner cover (Fig. 17). IMPORTANT: Replace the foam element if it is torn or worn. 2 1 2 1 4 3 1213 Figure 18 6 7 5 8 Figure 17 1. 2. 3. 4. 22 Air cleaner cover Knob Cover nut Cover 1. Foam element 5. 6. 7. 8. Foam element Paper element Rubber seal Air cleaner base 1214 2. Oil Maintenance 2. Installing the Foam and Paper Elements Paper Element A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 19). B. IMPORTANT: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 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. 1. Carefully slide the foam element onto the paper air cleaner element (Fig. 17). 2. Slide the air cleaner assembly and cover onto the long rod. Now screw the cover nut finger-tight against the cover (Fig. 17). Note: 1 Make sure the rubber seal is flat against the air cleaner base and cover. 3. Install the air cleaner cover (Fig. 17). 4. Close the hood. 2 1213 Figure 19 1. Paper element 2. Rubber seal 23 Maintenance Engine Oil Checking Oil Level Service Interval/Specification 1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2. Open the hood. 3. Clean around the oil dipstick (Fig. 20) so dirt cannot fall into the filler hole and damage the engine. 4. Unscrew the oil dipstick and wipe the metal end clean (Fig. 20). 5. Slide the oil dipstick fully into the filler tube do not thread onto tube (Fig. 20). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark. Change oil: • After the first 5 operating hours. • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF or SG) Crankcase Capacity: w/filter, 4 pints (1.9 l) Viscosity: See table below USE THESE SAE VISCOSITY OILS IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged. 1 –20 °F 0 –30 °C –20 20 –10 32 40 0 80 60 10 2 100 3 20 30 40 Figure 20 1. Oil dipstick 2. Metal end 24 3. Filler tube Maintenance Changing/Draining Oil Change Oil Filter 1. Start the engine and let it run five minutes. This warms the oil so it drains better. Service Interval/Specification 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 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 25. Slide a piece of hose over oil drain to direct oil. 2. Remove the old filter and wipe the filter adapter (Fig. 22) gasket surface. Place a pan below the oil drain. Open the drain by turning counterclockwise, 1/8 turn and pull out (Fig. 21). 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 22). 3. Open the hood. 4. 5. 6. Replace the oil filter every 200 hours or every other oil change. When oil has drained completely, close the drain by pushing in and turning clockwise, 1/8 turn. Note: 3 Dispose of the used oil at a certified recycling center. 2 1 1256 Figure 22 1. Oil filter 2. Gasket 2 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. 22). 5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 25. 1 1216 Figure 21 1. Oil drain 7. 3. Adapter 2. Hose Slowly pour approximately 80% of the specified amount of oil into the filler tube (Fig. 20). Now check the oil level; refer to Checking Oil Level, page 24. Slowly add additional oil to bring to “FULL” mark on dipstick. 25 Maintenance Spark Plug Checking the Spark Plug 1. Service Interval/Specification Look at the center of the spark plug(s) (Fig. 24). 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. Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Type: Champion RJ–12YC (or equivalent) Air Gap: 0.040” (0.102 mm) IMPORTANT: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Fig. 24). Bend the side electrode (Fig. 24) if the gap is not correct. Removing the Spark Plug(s) 1. 2 Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 3 1 2. Open the hood. 3. Pull the wire(s) off the spark plug(s) (Fig. 23). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 4. Remove the spark plug(s) and metal washer. 0.040” (0.102 mm) Figure 24 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) 2 Installing the Spark Plug(s) 1 1. Install the spark plug(s) and metal washer. Make sure the air gap is set correctly. 2. Tighten the spark plug(s) to 20 ft-lb (27 Nm). 3. Push the wire(s) onto the spark plug(s) (Fig. 23). 4. Close the hood. 1218 Figure 23 1. Spark plug wire 26 2. Spark plug Maintenance Greasing and Lubrication 3. Service Interval/Specification Grease the machine after every 50 operating hours or yearly, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy. Lubricate the traction control pedal on hydrostatic models (or brake and clutch pedals on gear drive models) where they pivot on mounting shaft (Fig. 26). Grease Type: General-purpose grease. How to Grease 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the ignition and “key choice” keys. 1264 Figure 26 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 until grease begins to ooze out of the bearings. Tire Pressure Wipe up any excess grease. Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 25 operating hours or monthly, whichever occurs first (Fig. 27). Check the tires when they are cold to get the most accurate pressure reading. 4. Where to Add Grease 1. 2. Lubricate the front wheels and spindles until grease begins to ooze out of the bearings (Fig. 25). Service Interval/Specification Pressure: 20 psi (138 kPa) front and rear Lubricate the front axle pivot (Fig. 25). 1 2323 Figure 27 1. Valve stem 1211 Figure 25 27 Maintenance Brake Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. Checking the Brake 1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2. Rear wheels must lock and skid when you try to push the tractor forward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 28. 3. Release the brake and move the drive control rod to the “PUSH” position; refer to Pushing the Machine by Hand, page 20. Wheels should rotate freely. 4. If both conditions are met no adjustment is required. Adjusting the Brake 1. Check the brake before you adjust it; refer to Checking the Brake, page 28. 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. 28). 4. Carefully insert a 0.020” (.51 mm) feeler gauge between the outer brake pad and rotor disk (Fig. 28). 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 28. IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the mower. If the 0.020” (.51 mm) clearance and free wheel rotation cannot be achieved contact your service dealer immediately. 3 0.020” (.51 mm) 2 1 M-4567 Figure 28 1. Brake adjusting nut 2. Cotter pin 28 3. Right Front of Transaxle Maintenance Fuel Tank 5. Draining The Fuel Tank Pull the fuel line off the filter (Fig. 30). Open fuel shut-off valve and allow gasoline to drain into an approved gas can. Note: 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 • 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. 1. 2. Park the machine on a level surface, to assure fuel tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 6. 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. Refer to Replacing the Fuel Filter; page 30. 3 2 1 1218 Figure 30 1. Hose clamp 2. Fuel line 3. Filter Close fuel shut–off valve at fuel tank (Fig. 29). 1 1263 Figure 29 1. Fuel shut-off valve 3. Open the hood. 4. Squeeze the ends of the hose clamp together and slide it up the fuel line toward the fuel tank (Fig. 30). 29 Maintenance Fuel Filter Front Wheel Toe-In Service Interval/Specification Service Interval/Specification Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first. Maintain toe-in of the front wheels as specified. If uneven tire wear, lawn scuffing or hard steering develop adjustment may be required. Check the toe-in after every 100 operating hours or yearly, whichever occurs first (Fig. 32). Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. Specification: 1/8–1/4 inch toe-in on front wheels. 1. Measuring Toe-in Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 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. Close fuel shut–off valve at fuel tank (Fig. 29). 3. Open the hood. 2. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 31). Push front tires out, at front, to remove normal looseness in the linkage. 3. Measure, between the rims, at spindle level, in the front and rear of the wheels (Fig. 32). 4. The front measurement should be less than the rear, as specified. 5. Remove the filter from the fuel lines. 3 1 4 2 3 1 1217 Figure 31 1. Hose clamp 2. Fuel line 3. Filter 2 Figure 32 6. Install a new filter and move the hose clamps close to the filter. 7. Open fuel shut-off valve at fuel tank (Fig. 29). 8. Close the hood. 30 1. Measure here 2. Ball joint flats 3. Jam nut 4. Steering lever 1261 Maintenance Adjusting Toe-In 1. Check the toe-in before you adjust it; refer to Measuring Toe-In, Page 30. 2. Remove ball joint from one steering lever (Fig. 32). 3. Loosen jam nut securing ball joint to steering rod. Rotate ball joint one turn, clockwise to increase or counter clockwise to decrease toe-in. 4. Hold flats on ball joint to align with flats on tie rod and tighten jam nut (Fig. 32). 5. Install ball joint to steering lever and check the toe-in; refer to Measuring Toe-In, Page 30. Fuse Service Interval/Specification The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. To replace fuses pull up on the fuse (Fig. 33) to remove or replace it. Fuse: Main/Starter F1–30 amp, blade-type Regulator F2–25 amp, blade-type Dash F3–10 amp, blade-type Head lights F4–10 amp, blade-type IMPORTANT: If more than one turn is required to meet specifications, alternate between left and right steering rods to maintain steering wheel alignment. 4 3 2 Transaxle Fluid 1 2344 Figure 33 Service Interval/Specification 1. Dash-10 Amp 2. Head lights-10 amp 3. Regulator-25 amp 4. Main-30 amp The transaxle is a sealed system and no checking or changing of the fluid is required. IMPORTANT: If any transaxle problems arise, contact your local Authorized Service Dealer for help and service. 31 Maintenance Headlights Installing the Bulb Specification: Bulb # 1156 Automotive Type 1. Removing 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. 35). Push and rotate the bulb clockwise until it stops. 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. 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. 34). 4. Push and rotate the bulb counterclockwise until it stops (approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 35). 1 2 3 4 Figure 35 1. Bulb 2. Metal pins 1 2. The bulb holder has two tabs (Fig. 34). 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. 3 4 2 4 Figure 34 32 3. Bulb holder 4. Slots 5 5 1. Bulb holder 2. Reflector 3. Tabs 2 4 4. Slots 5. Terminals Maintenance Battery 4 Service Interval/Specification 2 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 case. 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. 3 5 1 1219 Figure 36 Voltage: 12 v, 240 Cold Cranking Amps Removing the Battery 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. Open the hood to see the battery. 3. Remove side panels for clearance when removing battery (Fig. 37). Remove the wing nuts and screws and lift up to clear pin and slide panel tabs out from steering tower. 4. 5. 6. Disconnect the negative (black) ground cable from the battery post (Fig. 36). Lift the rubber cover up on the positive (red) cable. Disconnect the positive (red) cable from the battery post (Fig. 36). Remove the battery hold down rods (Fig. 36). 1. Negative cable (black) 2. Rubber cover 3. Positive cable (red) 4. Bolt and wing nut 5. Hold down rod and wing nut Installing the Battery 7. Install the battery into the chassis (Fig. 37). 8. Secure battery in chassis with hold down rods. 9. Using the bolt and wing nut, connect the positive (red) cable to the positive (+) battery post (Fig. 36). Slide the rubber cover over the battery post. 10. Using the bolt and wing nut, connect the negative (black) cable to the negative (–) battery post (Fig. 36). 11. Install side panels by sliding tabs into steering tower and inserting pin into flange of footrest. Secure with screws and wing nuts (Fig. 37). 33 Maintenance 4 1 1. Clean the top of the battery with a paper towel. 2. Lift off the filler caps (Fig. 38). 3. Slowly pour distilled water into each battery cell until the level is up to the lower part of the tube (Fig. 38). 4 2 3 IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. 5 1260 4. Figure 37 1. Battery 2. Side panel tabs 3. Screw 4. Wing nut 5. Pin Charging the Battery IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). Checking Electrolyte Level 1. Open the hood to see the battery. 2. Open covers to see into the cells. The electrolyte must be up to the lower part of the tube (Fig. 38). Do not allow the electrolyte to get below the plates. (Fig. 38). 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 34. 1. Remove the battery from the chassis; refer to Removing the Battery, page 33. 2. Check the electrolyte level; refer to Checking Electrolyte Level, page 34, steps 2–3. 3. Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery is fully charged. 1 2 Press the filler caps onto the battery. 3 1262 POTENTIAL HAZARD • Charging the battery produces gasses. Figure 38 1. Filler caps 2. Lower part of tube 3. Plates WHAT CAN HAPPEN • Battery gasses can explode. HOW TO AVOID THE HAZARD • Keep cigarettes, sparks and flames away from battery. 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. 34 4. Install the battery in the chassis; refer to Installing the Battery, page 33. A B+D F BK PK OR OR E BK F GN BK OR BATTERY LIGHT MODULE VOLTAGE COMPARATOR W PK C T #194 LAMP OIL GN D BATTERY#194 LAMP T OVER RIDE #194 LAMP PTO PK A W B #194 LAMP PK BK - HOUR METER OR BK BN PK GYW BU BU PKBUW CLUTCH NMIR MODULE 2 TURNED GN T BK GN SW3 BK HYDRO PEDAL IS MOVED TO REVERSE SW2 BK PK F3 10A SW1 (SEAT SWITCH) 4 2 VIO 3 1 OR Y F1 30A R SW9 1 OR GN OR Y SWITCH IS OPEN WHEN IN PARK 3 GN W (PARK SWITCH) T BK T OR SEAT SWITCH IS CLOSED WHEN OPERATOR ISIN THE SEAT SW8 (NEUT. SWITCH) OR BN PK IS DEPRESSED CLOSES WHEN BRAKE BRAKE SWITCH S GND BK VIO K1 (KILL RELAY) SOLINOID VIO F2 25A VIO GN W 3 1 5 OIL MAG REG START B+ STARTER - AC AC OIL PRESSURE SWITCH IGNITION MODULE SPARK PLUG + PK PINK R RED T TAN VIO VIOLET W WHITE Y YELLOW WIRE COLOR CODES BLACK BROWN BLUE GREEN GREY ORANGE R BK R B BN L I BU GN GY IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. OR R K2 (INTERLOCK RELAY) OR PK BN R VIO (BRAKE SWITCH) VIO 3 4 GY F4 10A SWITCH IS CLOSED WHEN IN NEUTRAL T PTO SWITCH IS SHOWN IN OFF POSITION (PTO SWITCH) OR SW6 1 (KEY OVER RIDE) (REVERSE SWITCH) SWITCH CLOSES SWITCH OPENS WHEN 2 WHEN KEY IS SW5 BK PTO CLUTCH BN OR BK 2 7 4 8 5 1 4 1 6 3 3 4 1 5 2 HEADLIGHT HARNESS 4 3 1 WARNING LIGHT HARNESS + 5 2 5 SW4 (IGNITION SWITCH) OFF-----------NO CONNECTION RUN/LIGHTS----------B I R L RUN---------------B I R START--------------B I R S L 3I S B R 4 1 5 2 Maintenance Wiring Diagram 35 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. 3. Check the brake; refer to Brake, page 28. 4. Service the air cleaner; refer to Air Cleaner, page 22. 5. Grease the chassis; refer to Greasing and Lubrication, page 27. 6. Change the crankcase oil; refer to Engine Oil, page 24. 7. Remove the spark plug(s) and check its condition; refer to Spark Plug, page 26. 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) and tighten it to 15 ft–lb (20.4 Nm). 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 33. Do not connect the battery cables to the battery posts during storage. IMPORTANT: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32°F (0°C). A 36 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 27. 10. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank (1 oz. per gallon) (8 ml per liter) and proceed as follows: A. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). B. Stop the engine, allow it to cool and drain the fuel tank; refer to Fuel Tank, page 29, or operate engine until it stops. C. Restart the engine and run until it stops. Repeat, with the “CHOKE” on, until the engine will not restart. D. Dispose of fuel properly or use within 90 days for other applications. Recycle in accordance with local codes. Note: 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. 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. Troubleshooting PROBLEM Starter does not crank Engine g will not start, starts hard, or f il to keep fails k running. i Engine g loses power. 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. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5. Check electrical connections for good contact. 6. Fuse is blown. 6. Replace fuse. 7. Relay or switch is defective. 7. Contact Authorized Service Dealer. 1. Fuel tank is empty. 1. Fill fuel tank with gasoline. 2. Choke is not ON. 2. Move chike lever to ON. 3. Air cleaner is dirty. 3. Clean or replace air cleaner element. 4. Spark plug wire is loose or disconnected. 4. Install wire on spark plug. 5. Spark plug is pitted, fouled, or gap is incorrect. 5. Install new, correctly gapped spark plug. 6. Dirt in fuel filter. 6. Replace fuel filter. 7. Dirt, water, or stale fuel is in fuel system. 7. Contact Authorized Service Dealer. 1. Engine load is excessive. 1. Reduce ground speed. 2. Air cleaner is dirty. 2. Clean air cleaner element. 3. Oil level in crankcase is low. 3. Add oil to crankcase. 4. Cooling fins and air passages under engine blower housing are plugged. 4. Remove obstruction from cooling fins and air passages. 5. Spark plug is pitted, fouled, or gap is incorrect. 5. Install new, correctly gapped spark plug. 6. Vent hole in fuel cap is plugged. 6. Clean or replace the fuel cap. 7. Dirt in fuel filter. 7. Replace fuel filter. 8. Dirt, water, or stale fuel is in fuel system. 8. Contact Authorized Service Dealer. 37 Troubleshooting PROBLEM Engine g over heats. Abnormal vibration. Machine does not drive. 38 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. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Loose engine pulley, idler pulley, or blade pulley. 2. Tighten the appropriate pulley. 3. Engine pulley is damaged. 3. Contact Authorized Service Dealer. 1. Drive control is in “PUSH” postion. 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.
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