Toro 268-H Lawn and Garden Tractor User manual

Toro 268-H Lawn and Garden Tractor User manual
FORM NO. 3321–854
Wheel Horse
268HE

Lawn & Garden
Tractor
Model No. 72105 – 9900001 & Up
Operator’s Manual
IMPORTANT: Read this manual carefully. It contains information about your
safety and the safety of others. Also become familiar with the controls and
their proper use before you operate the product.
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 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
The left and right side of the machine is determined
by sitting on the seat in the normal operator’s
position.
1. Model and Serial Number Plate (under the seat)
For your convenience, write the product model and
serial numbers in the space below.
Model No:
Serial No.
Read this manual carefully to learn how to operate
and maintain your product correctly. Reading this
manual will help you and others avoid personal injury
and damage to the product. Although 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 Comany – 1998
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 . . . . . . . . . .
18
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
19
19
20
20
20
21
21
22
22
23
25
27
28
28
29
30
31
31
32
33
34
35
38
40
41
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 2–9.
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.
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
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.
• 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
•
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
•
•
•
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 25.
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 hand 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
7
m–4220
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.
While the ignition key is in the “RUN” or “LIGHTS”
positions and the Parking Brake is engaged, the light,
in the Indicator Module, will be lit.
1640t
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
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.
Operation
Releasing the Parking Brake
5.
Move throttle lever to “FAST” (Fig. 5).
1.
Push down on the brake pedal (Fig. 3). The
parking brake lever should release.
6.
Turn the ignition key clockwise and hold it in
the “START” position (Fig. 6). When the engine
starts, release the key.
2.
Gradually release the brake pedal.
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 41.
1
7.
After the engine starts, move the choke lever to
“OFF” (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 desired
setting. Repeat this as required.
2
2
1
1201
3
Figure 3
1. Brake pedal
2. Parking brake lever
1
Starting and Stopping
the Engine
Starting
1.
Sit down on the seat.
2.
Set the parking brake; refer to Setting the
Parking Brake, page 12.
Note:
3.
4.
2
1207
1206
Figure 4
Figure 5
1. PTO—Off
2. Choke–On
3. Choke–Off
1. Fast
2. Slow
1
2
3
The engine will not start unless you set
the parking brake or fully depress the
brake pedal.
4
Push the PTO (power take off) to “OFF”
(Fig. 4).
1208
Figure 6
Move the choke lever to “ON” (Fig. 4).
Note:
An engine that has been running and is
warm may not require step 4.
1. Off
2. Lights
3. Run
4. Start
13
Operation
Stopping
Engaging the Power Take Off (PTO)
1.
Move the throttle lever to “SLOW” (Fig. 5).
1.
Depress the brake pedal to stop the machine.
2.
Turn the ignition key to “OFF” (Fig. 6).
2.
Pull the power take off (PTO) to “ON” (Fig. 7).
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.”
2
1
Operating the
Power Take Off (PTO)
1206
Figure 7
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; the
starter will not crank and to turn the off before getting
off.
14
1. Off-Disengaged
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).
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 power take off (PTO) is “OFF”
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 power take off
(PTO) is “ON”.
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.
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
operating–in–reverse interlock feature 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 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.
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
operating–in–reverse interlock feature may be
temporarily deactivated.
Before deactivating this feature, 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 feature because the sound of
15
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
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 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.
4.
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.
5.
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.
6.
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.
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–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.
16
Operation
Indicator Control Module
Oil
The indicator control module (Fig. 9) contains lights
for:
•
Operating–in–Reverse
•
Power take off (PTO)
•
Low oil pressure
•
Low alternator output
1
2
Battery
3
4
5
Figure 9
1. Operating–in–Reverse
2. Battery
3. Hourmeter
The oil light will be “ON” when the key is in the
“RUN” or “LIGHTS” positions and the engine is not
running, after the engine is started the light should go
out. When the engine is running if the oil pressure
drops below a safe operating level the light comes
“ON”. When the light comes on while the engine is
running, Stop engine immediately and correct the
cause of low oil pressure.
4. Oil
5. PTO (power take off)
The following are the conditions when the indicator
lights will be “ON”. At other times the lights should
be off.
The battery light will be “ON” when the key is in the
“RUN” or “LIGHTS” positions if the battery voltage
is below 12.6 volts or when the engine is running and
the alternator output is above 14.8 volts. When this
light comes on it is important to have your battery
and electrical system checked and the problem
corrected.
Hourmeter
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.
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.
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.
17
Operation
Driving Forward or Backward
Stopping the Machine
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 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 ignition switch.
To go forward or backward, release the parking brake:
refer to Releasing the Parking Brake, page 13. 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:
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.
IMPORTANT: To avoid transmission
damage, always release the parking brake
before moving the traction control pedal.
1
2
1210
Figure 10
18
2. Backward
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.
To slow down, release the pressure on the traction
control pedal.
1. Forward
POTENTIAL HAZARD
• Someone could move or attempt to operate
the tractor while it is unattended.
Operation
Attachment Lift Lever
Adjusting Dial-A-Height
The attachment lift lever (Fig. 11) is used to raise and
lower various attachments.
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.
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.
1.
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.
2.
The Dial-A-Height indicator (Fig. 11) will show
the change, high to low, in attachment lift height
as adjustment is made.
2
1
3
5
4
6
1205
Figure 11
1. Lift lever
2. Button
3. Dial-A-Height
4. Indicator
5. High
6. Mounting position
19
Operation
Positioning the Seat
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
1.
2.
Raise the seat and loosen the adjustment knobs
(Fig. 12).
Slide the seat to the desired position and tighten
the knobs.
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.
1
2
1
1203b
Figure 12
Figure 14
1. Adjustment
knobs
1. Tilt lever
Headlights
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
1208
Figure 13
1. Lights
20
2. Steering wheel
Operation
Using the Cruise Control
Pushing the Machine by Hand
The cruise control is optional on some models. A
three position Lock–Set (spring loaded), On and
Unlock–Off 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.
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).
Begin driving tractor: Refer to Driving Forward
or Backward, page 18. While holding your foot
steady on the traction control, push the cruise
control switch (Fig. 15) to the “LOCK-SET”
position.
IMPORTANT: Drive control rod moves to the
“OPERATE” position when the brake is
applied.
To Operate the Machine
1
1.
2
1641t
Figure 15
1. Lock-Set
2.
Apply the brake, this moves the drive control rod
to “OPERATE” and engages the drive system, or
move the drive control rod to the “OPERATE”
position (Fig. 16).
Note:
The machine will not drive unless the
drive control rod is in the “OPERATE”
position.
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.
1
2
Disengaging the Cruise Control
1.
While holding your foot steady on the traction
control, move the cruise control switch (Fig. 15)
to the “UNLOCK–OFF” 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.
1209
Figure 16
1. Operate position
2. Push position
21
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 200 hours
X
X
X
X
X
Chassis—grease*
X
Foam Air Cleaner—service*
X
X
Spark Plug(s)—check
X
Belts—check for wear/cracks
X
X
X
X
X
X
X
Chipped Surfaces—paint
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
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).
22
X
X
Gasoline—drain
Transaxle Fluid–check level
X
X
X
Paper Air Cleaner—replace*
Battery—check electrolyte
Spring
Service
X
Oil—change*
Engine—clean outside
Storage
Service
X
X
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.
Unhook latches and remove the air cleaner cover
(Fig. 17).
IMPORTANT: Replace the foam element if it
is torn or worn.
2
1
7
1
1213
4
Figure 18
8
1. Foam element
2. Oil
6
5
3
2
1213
Figure 17
1.
2.
3.
4.
Air cleaner cover
Latches
Cover nut
Cover
5.
6.
7.
8.
Foam element
Paper element
Rubber seal
Air cleaner base
23
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
2
1213
Figure 19
1. Paper element
24
2. Rubber seal
Make sure the rubber seal is flat
against the air cleaner base and cover.
3.
Install the air cleaner cover and hook latches
(Fig. 17).
4.
Close the hood.
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
3. Filler tube
25
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.
Replace the oil filter every 200 hours or every other
oil change.
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 26.
Slide a piece of hose over oil drain to direct oil
out over the frame.
2.
Remove the old filter and wipe the filter adapter
(Fig. 22) gasket surface.
5.
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).
6.
When oil has drained completely, close the drain
by pushing in and turning clockwise, 1/8 turn.
3.
Open the hood.
4.
Note:
3
Dispose of the used oil at a certified
recycling center.
2
1
1256
Figure 22
1
1. Oil filter
2. Gasket
3. Adapter
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 26.
1241
Figure 21
1. Oil drain
7.
26
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 25. Slowly add additional oil to bring to
“FULL” mark on dipstick.
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
2
3. Air gap (not to scale)
Installing the Spark Plug(s)
1
Figure 23
1. Spark plug wire
2. Spark plug
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.
1215
27
Maintenance
Greasing and Lubrication
3.
Service Interval/Specification
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 the machine after every 50 operating hours or
yearly, whichever occurs first. Grease more frequently
when operating conditions are extremely dusty or
sandy.
Grease Type: General-purpose grease.
How to Grease
1.
Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
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
28
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.
Adjusting the Brake
The brake lever is on top of the transaxle (Fig. 28). If
the parking brake does not hold securely, an
adjustment is required.
1.
Check the brake before you adjust it; refer to
Checking the Brake, page 29.
2.
Release the parking brake; refer to Releasing the
Parking Brake, page 13.
3.
To adjust the brake remove the cotter pin and
washer from the brake lever (Fig. 28).
4.
Rotate the trunnion so it smoothly slides into
brake lever (Fig. 28).
5.
Secure trunnion to brake lever with washer and
cotter pin (Fig. 28).
6.
Check the brake operation again; refer to
Checking the Brake, page 29.
Checking the Brake
1.
2.
3.
4.
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.
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 29.
Release the brake and move the drive control rod
to the “PUSH” position; refer to Pushing the
Machine by Hand, page 21. Wheels should
rotate freely.
If both conditions are met no adjustment is
required.
IMPORTANT: Drive control rod moves to the
“OPERATE” position when the brake is
applied.
IMPORTANT: With the parking brake
released, the rear wheels must rotate freely
when you push the mower. If brake action
and free wheel rotation cannot be achieved
contact your service dealer immediately.
2
3
1
1245
Figure 28
1. Cotter pin and washer
2. Trunnion
3. Brake lever
29
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 a gas can or drain pan.
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.
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 31.
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
3
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.
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).
30
Figure 30
1. Hose clamp
2. Fuel line
3. Filter
1217
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.
1
1
2
4
3
3
1217
Figure 31
1. Hose clamp
2. Fuel line
3. Filter
2
1261
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.
1. Measure here
2. Ball joint flats
3. Jam nut
4. Steering lever
31
Maintenance
Adjusting Toe-In
1.
Check the toe-in before you adjust it; refer to
Measuring Toe-In, Page 31.
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, Page31.
IMPORTANT: If more than one turn is
required to meet specifications, alternate
between left and right steering rods to
maintain steering wheel alignment.
Transaxle Fluid
Service Interval/Specification
Check fluid level after every 100 hours or yearly
whichever comes first. Always keep the fluid level at
the full level when the transaxle is cold. The transaxle
is a sealed system and no changing of the fluid is
required.
Fluid Type: SAE 10W–30 Detergent oil (API service
SF or SG)
Checking Fluid Level
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 fluid reservoir (Fig. 33) so
level is clearly visible and so dirt cannot fall into
the reservoir if fluid is added.
4.
When transaxle is cold add oil to “Full Cold”
line on reservoir (Fig. 33).
IMPORTANT: Do not fill above the full cold
line as fluid may overflow.
1
2
1243
Figure 33
1. Fluid reservoir
32
2. Full cold level
Maintenance
Fuse
Service Interval/Specification
4
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. 34) 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
3
2
1
2344
Figure 34
1. Dash-10 Amp
2. Head lights-10 amp
3. Regulator-25 amp
4. Main-30 amp
33
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. 36).
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. 35).
4.
Push and rotate the bulb counterclockwise until
it stops (approx. 1/4 turn) and remove bulb from
the bulb holder (Fig. 36).
1
2
3
4
Figure 36
1. Bulb
2. Metal pins
1
2.
The bulb holder has two tabs (Fig. 35). 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 35
34
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
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.
2
3
5
1
1219
Figure 37
Voltage: 12 v, 280 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. 38). Remove the wing
nuts and screws and lift up to clear pin and slide
panel tabs out from steering tower.
4.
Disconnect the negative (black) ground cable
from the battery post (Fig. 37).
5.
Lift the rubber cover up on the positive (red)
cable. Disconnect the positive (red) cable from
the battery post (Fig. 37).
6.
Remove the battery hold down rods (Fig. 37).
1. Negative cable (black)
2. Rubber cover
3. Positive cable (red)
4. Bolt and wing nut
5. Hold down rod and wing
nut
35
Maintenance
Installing the Battery
Checking Electrolyte Level
7.
Install the battery into the chassis (Fig. 38).
1.
With the engine off, open the hood to see the
battery.
8.
Secure battery in chassis with hold down rods.
2.
9.
Using the bolt and wing nut, connect the positive
(red) cable to the positive (+) battery post
(Fig. 37). Slide the rubber cover over the battery
post.
Open covers to see into the cells. The electrolyte
must be up to the lower part of the tube
(Fig. 39). Do not allow the electrolyte to get
below the plates. (Fig. 39).
3.
If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery, page 36.
10. Using the bolt and wing nut, connect the
negative (black) cable to the negative (–) battery
post (Fig. 37).
1
11. Install side panels by sliding tabs into steering
tower and inserting pin into flange of footrest.
Secure with screws and wing nuts (Fig. 38).
2
4
3
1
1262
Figure 39
1. Filler caps
2. Lower part of tube
4
2
3. Plates
Adding Water to the Battery
3
5
Figure 38
1. Battery
2. Side panel tabs
3. Screw
4. Wing nut
5. Pin
1260
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.
Lift off the filler caps (Fig. 39).
3.
Slowly pour distilled water into each battery cell
until the level is up to the lower part of the tube
(Fig. 39).
IMPORTANT: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
4.
36
Press the filler caps onto the battery.
Maintenance
Charging the Battery
IMPORTANT: Always keep the battery fully
charged (1.260 specific gravity). This is
especially important to prevent battery
damage when the temperature is below 32°F
(0°C).
1.
Remove the battery from the chassis; refer to
Removing the Battery, page 35.
2.
Check the electrolyte level; refer to Checking
Electrolyte Level, page 36, 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.
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 36.
37
Maintenance
Wiring Diagram
268 HYDRO
HEADLIGHT HARNESS
BK
OR
BK
OR
OR
PK
CRUISE SWITCH OPERATION
BU
BK
T
BU
2
8
SW3
(PTO SWITCH)
5
(CRUISE RELAY)
K4
PTO
CLUTCH
PTO SWITCH IS
SHOWN IN OFF
POSITION
2
7
5
8
BU
1
5
(MOMENTARY)
PK GYW
BN
BN
3
6
Y
2
PK
2
1
3
PK
4
T
GY
5 AND 6 CONNECTED
7
SW7
CRUISE SWITCH
4
OFF
NO CONNECTION
ON
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
BU BU
BK
SW8
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
1
CRUISE MAGNET
BK
BK
6
2
4
PK BU W
WARNING LIGHT HARNESS
A
PK
#194 LAMP
B
W
PTO
OVER RIDE #194 LAMP
C
T
#194 LAMP
GN
OIL
BATTERY
D
BK
W
T
GN
OR
BK F
BK
GN
SW5
(REVERSE SWITCH)
SWITCH OPENS WHEN
HYDRO PEDAL IS MOVED
TO REVERSE
B+
OR
D
PK
A
BK
T
SW6
(KEY OVER RIDE)
SWITCH CLOSES
WHEN KEY IS
TURNED
BK
HOUR
METER
-
+
PK
F
3
GN T BK
PK
#194 LAMP
E
OR
VOLTAGE
COMPARATOR
5
1
CLUTCH
NMIR
MODULE
BK
BK
BK
BATTERY LIGHT MODULE
GN
38
Maintenance
SW4
(IGNITION SWITCH)
268 HYDRO
WIRE COLOR CODES
OFF-----------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN---------------B I R
START--------------B I R S
L
I
4
S
3
1
OR PK
OR
B
5
S
R
2
BN R VIO
R
B
I
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
BK
BLACK
PK
PINK
BN
BROWN
R
RED
BU
BLUE
T
TAN
GN
GREEN
VIO
VIOLET
GY
GREY
W
WHITE
OR
ORANGE
Y
YELLOW
F4
10A
PK
F3
10A
PK
GY
R
VIO
F1
30A
PK
F2
25A
3
Y
2
IS DEPRESSED
CLOSES WHEN BRAKE
BRAKE SWITCH
K3
(START RELAY)
3
BK
1
5
4
T
SW2
(BRAKE SWITCH)
5
1
VIO
SPARK PLUG
4
GY
R
K2
(INTERLOCK RELAY) OR BN
2
1
3
ORBN
GN
BU
T
SW1
(SEAT SWITCH)
SPARK PLUG
IGNITION
MODULES
VIO
5
GN
BU
W
AC
REG
3
OIL
2
START
1
MAG
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
AC
OIL
SWITCH
Y
R
B+
SOLINOID
SHIFT
STARTER
FUEL
SOLINIOD
CLOSES WITH
PRESSURE
-
+
BK
3
4
GN
W
K1
(KILL RELAY)
1
2
5
Y
BK BK
BK
GND
GN
39
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 ignition
and “key choice” keys.
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 29.
4.
Service the air cleaner; refer to Air Cleaner,
page 23.
5.
Grease the chassis; refer to Greasing and
Lubrication, page 28.
6.
Change the crankcase oil; refer to Engine Oil,
page 25.
7.
8.
40
Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 27. 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).
Remove the battery from the chassis, check the
electrolyte level, and charge it fully; refer to
Battery, page 35. 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 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 28.
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 30, 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 keys from the ignition
and “key choice” switches and keep them 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
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.
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 choke 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.
41
Troubleshooting
PROBLEM
Engine
g
overheats.
Abnormal vibration.
Machine does not drive.
42
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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