Toro 430 Garden Tractor, 420 Garden Tractor User manual

Toro 430 Garden Tractor, 420 Garden Tractor User manual
Form No. 3353-250
420 and 430 Garden Tractor
Model No. 72211—Serial No. 250000001 and Up
Model No. 72212—Serial No. 250000001 and Up
Register your product at www.Toro.com
Original Instructions (EN)
This spark ignition system complies with Canadian
ICES-002
Servicing the Spark Plug......................... 30
Fuel System Maintenance .............................. 31
Draining The Fuel Tank ......................... 31
Servicing the Fuel Filter ......................... 31
Electrical System Maintenance ....................... 32
Servicing the Fuses................................ 32
Servicing the Headlights......................... 32
Servicing the Battery.............................. 33
Drive System Maintenance ............................ 36
Checking the Tire Pressure ..................... 36
Servicing the Front Wheel Toe-In ............ 36
Transaxle Fluid ..................................... 36
Cooling System Maintenance ......................... 37
Cleaning the Cooling System................... 37
Brake Maintenance ...................................... 37
Servicing the Brake................................ 37
Storage .............................................................. 38
Cleaning and Storage ............................. 38
Troubleshooting ................................................. 39
Schematics ......................................................... 41
Contents
Introduction ......................................................... 2
Safety .................................................................. 4
Safe Operating Practices........................... 4
Toro Riding Mower Safety ........................ 5
Slope Chart ........................................... 6
Safety and Instructional Decals ................. 7
Setup ................................................................. 10
1 Installing the Steering Wheel ................ 11
2 Installing the Seat................................ 11
3 Activating and Installing the
Battery .................................. 12
4 Installing the Front Tires...................... 13
5 Installing the Rear Wheels .................... 13
6 Checking the Tire Pressure and
Tractor Lubrication................. 14
7 Reading the Manual and Viewing the
Safety Video .......................... 14
8 Checking the Safety System .................. 14
9 Test Drive the Tractor ......................... 14
Product Overview ............................................... 16
Controls .............................................. 17
Operation .......................................................... 19
Recommended Gasoline ........................ 19
Check Engine Oil Level.......................... 20
Think Safety First.................................. 20
Operating the Parking Brake ................... 20
Starting and Stopping the Engine............. 20
Operating the Power Take Off
(PTO)................................... 21
The Safety Interlock System.................... 21
Driving Forward or Backward ................. 23
Stopping the Machine ............................ 23
Operating the Attachment Lift
Lever .................................... 24
Using the Attachment Power Lift............. 24
Positioning the Seat ............................... 24
Using the Headlights ............................. 25
Positioning the Tilt Steering
Wheel ................................... 25
Pushing the Machine by Hand ................. 25
Using the Cruise Control........................ 26
Maintenance ....................................................... 27
Recommended Maintenance
Schedule(s) ................................... 27
Lubrication ................................................. 27
Greasing and Lubrication ....................... 27
Engine Maintenance .................................... 28
Servicing the Engine Oil......................... 28
Servicing the Air Cleaner ........................ 29
© 2004—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Introduction
Read this information carefully to learn how to operate
and maintain your product properly and to avoid injury
and product damage. You are responsible for operating
the product properly and safely.
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a
dealer, or to register your product.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model
and serial numbers of your product ready. Figure 1
identifies the location of the model and serial numbers
on the product. Write the numbers in the space
provided.
Figure 1
1.
2
Model and serial number plate
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
Model No.
Serial No.
This manual identifies potential hazards and has
safety messages identified by the safety alert symbol
(Figure 2 ), which signals a hazard that may cause
serious injury or death if you do not follow the
recommended precautions.
Figure 2
1. Safety alert symbol.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes general
information worthy of special attention.
3
Safety
• Watch for traffic when operating near or crossing
roadways.
Use extra care when loading or unloading the
machine into a trailer or truck.
Always wear safety goggles or safety glasses with
side shields when operating mower.
Data indicates that operators, age 60 years and
above, are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower
safely enough to protect themselves and others
from serious injury.
This machine meets or exceeds the B71.1-1998
specifications of the American National Standards
Institute, in effect at the time of production. However,
improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER-“personal
safety instruction." Failure to comply with the
instruction may result in personal injury or death.
•
Safe Operating Practices
Slope Operation
The following instructions are from ANSI standard
B71.1-1998.
Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or
death. All slopes require extra caution. If you cannot
back up the slope or if you feel uneasy on it, do not
mow it.
• Mow up and down slopes, not across.
• Remove obstacles such as rocks, tree limbs, etc.
• Watch for holes, ruts or bumps. Uneven terrain
could overturn the machine. Tall grass can hide
obstacles.
• Use slow speed. Choose a low gear so that you will
not have to stop or shift while on the slope.
• Follow Toro’s recommendations for wheel weight
or counterweights to improve stability.
• Use extra care with grass catchers or other
attachments. These can change the stability of the
machine.
• Keep all movement on slopes slow and gradual.
Do not make sudden changes in speed or direction.
• Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades and proceed slowly
straight down the slope.
• Do not turn on slopes unless necessary, and then,
turn slowly and gradually downhill, if possible.
• Do not mow near drop-offs, ditches, or
embankments. The machine could suddenly turn
over if a wheel goes over the edge of a cliff or
ditch, or if an edge caves in.
• Do not mow on wet grass. Reduced traction could
cause sliding.
• Do not try to stabilize the machine by putting your
foot on the ground.
• Do not use a grass catcher on steep slopes.
•
•
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
General Operation
• Read, understand, and follow all instructions in
•
•
•
•
•
•
•
•
•
•
•
•
the operator’s manual and on the machine before
starting.
Allow only responsible adults who are familiar with
the instructions to operate the machine.
Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up and thrown by the
blade.
Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
Never carry passengers.
Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
backing.
Be aware of the mower discharge direction and do
not point it at anyone. Do not operate the mower
without either the entire grass catcher or the guard
in place.
Slow down before turning.
Never leave a running machine unattended. Always
turn off blades, set parking brake, stop engine, and
remove keys before dismounting.
Turn off blades when not mowing.
Stop the engine before removing the grass catcher
or unclogging the chute.
Mow only in daylight or good artificial light.
Do not operate the machine while under the
influence of alcohol or drugs.
Children
Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted
4
Toro Riding Mower Safety
to the machine and the mowing activity. Never assume
that children will remain where you last saw them.
The following list contains safety information specific
to Toro products or other safety information that you
must know that is not included in the ANSI standards.
• Keep children out of the mowing area and under
the watchful care of another responsible adult.
• Be alert and turn the machine off if children enter
the area.
• Before and while backing, look behind and down
Engine exhaust contains carbon monoxide,
which is an odorless, deadly poison that can kill
you. It is also known to the State of California
to cause birth defects.
for small children.
• Never carry children, even with the blades off.
They may fall off and be seriously injured or
interfere with safe machine operation.
Do not run engine indoors or in an enclosed
area.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners,
• Stop the engine, disconnect spark plug wire(s) and
shrubs, trees, the end of a fence or other objects
that may obscure vision.
Service
• Use extra care when handling gasoline and other
•
•
fuels. They are flammable and vapors are explosive.
– Use only an approved container.
– Never remove the gas cap or add fuel when
the engine is running. Allow the engine to cool
before refueling. Do not smoke.
•
– Never refuel the machine indoors.
•
– Never store the machine or fuel container
inside where there is an open flame, such as
near a water heater or furnace.
•
• Never run a machine inside a closed area.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
•
• Never tamper with safety devices. Check their
proper operation regularly.
•
• Keep the machine free of grass, leaves, or other
debris build-up. Clean up oil or fuel spillage. Allow
the machine to cool before storing.
•
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
•
•
•
•
• Grass catcher components are subject to wear,
damage and deterioration, which could expose
moving parts or allow objects to be thrown.
Frequently check components and replace
with manufacturer’s recommended parts, when
necessary.
• Mower blades are sharp and can cut. Wrap the
•
blade(s) or wear gloves, and use extra caution when
servicing them.
•
• Use only genuine Toro replacement parts to ensure
that original standards are maintained.
5
remove key before performing any service, repairs,
maintenance or adjustments.
Slow down before turning. Sharp turns on any
terrain may cause loss of control.
Never leave a running machine unattended. Always
turn off blades, set parking brake, stop engine, and
remove the ignition and KeyChoice® keys before
dismounting.
Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and
any moving parts while engine is running.
Do not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect
your face, eyes and clothing when working with
a battery.
Battery gases can explode. Keep cigarettes, sparks
and flames away from battery.
Use only genuine replacement parts to ensure that
original standards are maintained.
Use only Toro approved attachments. Warranty
may be voided if used with unapproved
attachments.
Do not mow across slopes greater than 5 degrees.
Do not mow down slopes greater than 15 degrees.
Do not mow up slopes greater than 10 degrees.
If a steep slope must be ascended, back up the
hill, and drive forward down the hill, keeping the
machine in gear.
Avoid turning on slopes. If you must turn, turn
slowly and gradually downhill, if possible.
Do not use a grass catcher on steep slopes. Heavy
grass bags could cause loss of control or overturn
the machine.
Slope Chart
6
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of
potential danger. Replace any decal that is damaged or lost.
92-6727
1. Fuel levels
2.
Fuel
93-7255
1.
2.
3.
4.
5.
92-7090
1. Push the lever in to ride on 3.
the machine.
2. Pull the lever out to push
the machine.
Do not tow the machine
7
Throttle
Fast
Slow
Continuous variable setting
Ignition
6.
7.
8.
9.
Stop
Lights
Run
Start
99-2986
1.
Crushing/dismemberment hazard of bystanders—do not
turn the key while children are present; keep children a safe
distance from the machine.
99-5340
1.
KeyChoice—turn to enable reverse mowing.
93-7256
1.
Choke
4.
2.
On
5.
3.
Off
6.
Pull the knob out to start
PTO.
Pull the knob out to stop
PTO.
PTO
99-8036
Model 420
1.
2.
Lift
Up
3.
Engine oil pressure
Power Take-off (PTO)
104-7628
93-7323
1.
2.
Mowing in reverse enabled. 3.
Battery
4.
1.
Down
Read the Operator’s Manual.
106-9871
Model 430
1.
2.
3.
8
Cruise control, locked
4.
5.
Power Take-off (PTO)
Battery discharge indicator 6.
Engine oil pressure
Fuel level
Mowing in reverse enabled.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
6.
2. No re, open ame, or
smoking.
7.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
8.
5. Read the Operator’s
Manual.
9.
10.
Keep bystanders a safe
distance from the battery.
Wear eye protection;
explosive gases can cause
blindness and other injuries
Battery acid can cause
blindness or severe burns.
Flush eyes immediately
with water and get medical
help fast.
Contains lead; do not
discard.
93-7313
5. Cutting/dismemberment hazard of
9.
hand or foot, mower blade—stay away
from moving parts.
2. Tipping hazard—do not drive across
6. To drive the machine forward, press the 10.
slopes greater than 5 degrees, up slopes
ground speed selector forward.
greater than 10 degrees, or down slopes
greater than 15 degrees.
3. Thrown objects hazard—keep
7. To drive the machine in reverse, press
bystanders a safe distance from the
the ground speed selector rearward.
machine.
4. Thrown objects hazard, mower—keep 8. To brake, press the brake pedal.
the deector in place.
1. Warning-read the Operator’s Manual.
9
To engage the parking brake, press the
beaked pedal and move the parking
brake lever to the On position.
To disengage the parking brake, press
and release the brake pedal.
Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Step
1
2
3
4
5
6
7
8
9
Use
Qty.
Description
Steering Wheel
Lock Washer, 1/2 inch
Nut, 1/2 inch
Logo Cover
Seat
Spacer, large inside diameter
Spacer, small inside diameter
Shoulder bolt
Knob
Flat washer, 11/32 inch
Bolt, 1/4 x 3/4 inch
Hex Nut, 1/4 inch
Front tires
Cotter pin
Shim washers
Washers, thick
Washers
Cap
Rear tires
Lug nuts
1
1
1
1
1
2
2
2
2
2
2
2
2
2
4
2
2
2
2
10
No parts required
–
Check the Tire Pressure and Tractor
Lubrication.
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Safety Video
Registration Card
Oil drain hose
1
1
1
1
1
1
Read the Operator’s Manual and watch
the video before operating the machine.
No parts required
–
Check the safety system.
No parts required
–
Test drive the tractor.
Install the steering wheel.
Install the seat.
Activate and install the battery.
Install the front tires.
Install the rear tires.
Note: Determine the left and right sides of the machine from the normal operating position.
10
Step
Step
1
2
Installing the Steering
Wheel
Installing the Seat
Parts needed for this step:
Parts needed for this step:
1
1
1
1
1
2
2
2
2
2
Steering Wheel
Lock Washer, 1/2 inch
Nut, 1/2 inch
Logo Cover
Seat
Spacer, large inside diameter
Spacer, small inside diameter
Shoulder bolt
Knob
Flat washer, 11/32 inch
Procedure
Procedure
1. Position the front wheels straight ahead.
1. Install the large inside diameter spacer and the
2 shoulder bolts into the rear holes of the seat
(Figure 4 ).
2. Remove the logo cover by releasing the 3 latches
from the back side with a screwdriver.
3. Line up the center spoke toward the seat and
position the steering wheel onto the shaft spline
(Figure 3 ).
Figure 3
1. Center spoke
2. Shaft spline
3. Lock washer, 1/2 inch
4.
5.
Figure 4
Nut, 1/2 inch
Logo cover
1.
2.
3.
4.
5.
4. Secure the steering wheel with a lockwasher
(1/2 inch) and nut (1/2 inch) (Figure 3 ).
Seat
Spacer-small ID
Spacer-large ID
Shoulder bolt
Knob
6.
7.
8.
9.
Wire and connector
Wire harness connector
Wire clip
Flat washer, 11/32 inch
2. Position the seat onto the seat base by inserting the
2 shoulder bolts through the key hole openings at
the end of both slots (Figure 4 ).
3. Locate the small inside diameter spacer between
the seat and the seat base, thread the 2 knobs and
2 flat washers (11/32 inch) into the front holes in
the seat (Figure 4 ). Adjust the seat and tighten
the knobs.
5. Torque the steering wheel nut to 50 ft-lb (37 N.m).
6. Snap the logo cover into place (Figure 3 ).
11
4. Route the seat switch wire and connector through
the center opening in the seat base. Push the
seat switch connector fully into the wire harness
connector (Figure 4 ).
5. Secure the seat switch wire cable to the fender
opening (Figure 4 ).
Step
3
Activating and Installing the
Battery
Figure 5
1.
2.
Parts needed for this step:
2
2
Bolt, 1/4 x 3/4 inch
Hex Nut, 1/4 inch
Filler caps
Upper line
3.
Lower line
4. Slowly pour electrolyte into each battery cell until
the level is up to the upper line on the battery case
(Figure 5 ).
Procedure
Important: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
Bulk electrolyte with 1.265 specific gravity must be
purchased from a local battery supply outlet.
5. Wait five to ten minutes after filling the battery cells.
Add electrolyte, if necessary, until the electrolyte
level is up to the upper line on the battery case
(Figure 5 ).
Battery electrolyte contains sulfuric acid which
is a deadly poison and causes severe burns.
6. Install the battery filler caps.
• Do not drink electrolyte and avoid contact
with skin, eyes or clothing. Wear safety
glasses to shield your eyes and robber gloves
to protect your hands.
Charging the battery produces gasses that
can explode.
• Fill the battery where clean water is always
available for flushing the skin.
Never smoke near the battery and keep
sparks and flames away from battery.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
Note: Make sure the vent caps are installed in
the battery.
1. Remove the battery from the tractor.
7. Charge the battery for 1 hour at 10 amps or 2 hours
at 5 amps.
2. Clean the top of the battery with a paper towel.
Note: Never fill the battery with electrolyte while
the battery installed in the tractor. Electrolyte could
be spilled on other parts and cause corrosion.
8. When the battery is fully charged, unplug the
charger from the electrical outlet, then disconnect
the charger leads from the battery posts (Figure 6 ).
3. Remove the vent caps from the battery (Figure 5 ).
12
Figure 7
1.
2.
3.
4.
Figure 6
1. Positive Battery Post
2. Negative Battery Post
3.
4.
5.
6.
7.
Cap
Cotterpin
Thin Washer, 3/4 inch
3. Slide wheel onto axle with valve stem in (Figure 7 ).
Red (+) Charger Lead
Black (-) Charger Lead
4. Wheel end play should be 0 to 0.015 inch
(0 to 0.4 mm). Install the shim washers (as
required) and thick flat washer (3/4 inch) for
spacing on the axle.
9. Install the battery in the tractor and connect the
battery cables. Refer to the Installing the Battery in
Electrical System Maintenance, page 32 .
5. Insert cotter pin through the axle and bend the
ends of the pin open (Figure 7 ).
Note: Do not run the tractor with the battery
disconnected, electrical damage may occur.
6. Push the cap onto the end of the axle so it snaps
over washer (Figure 7 ).
Step
7. Repeat steps 2-6 on opposite side.
4
8. Grease the wheel bearings.
Step
5
Installing the Front Tires
Parts needed for this step:
2
2
4
2
2
2
Front wheel
Axle
Shim washer
Thick washer, 3/4 inch
Installing the Rear Wheels
Front tires
Cotter pin
Shim washers
Washers, thick
Washers
Cap
Parts needed for this step:
2
10
Rear tires
Lug nuts
Procedure
Procedure
1. Remove the tires from the crate (Figure 7 ).
1. Install the rear wheel onto the wheel hub with the
valve stem to the inside (Figure 8 ).
2. Install a thin washer (3/4 inch) onto the axle
(Figure 7 ).
2. Torque the wheel bolts to 75-80 ft-lb (105-112
N·m).
13
Step
7
Reading the Manual and
Viewing the Safety Video
Parts needed for this step:
1
1
1
1
1
1
Figure 8
1.
2.
Rear wheel
Wheel bolts
3.
Wheel hub
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Safety Video
Registration Card
Oil drain hose
Procedure
• Read the Operator’s Manual.
Refer to Checking the Safety Interlock System in
Operation, page 19.
• Learn how to operate the tractor. Read the
Operation section in this manual.
• View the safety video.
Step
6
• Fill out the registration card.
• Use the oil drain hose when changing the engine
oil.
Checking the Tire Pressure
and Tractor Lubrication
Step
8
No Parts Required
Procedure
Checking the Safety System
Check the front and rear tire pressure. Refer to
Checking the Tire Pressure in the Maintenance Section.
No Parts Required
Important: The tractor is shipped from the
factory with oil in the engine crank case.
Procedure
Check the engine oil and add only enough oil to raise
the level to the full mark on the dipstick. Refer to
Checking the Engine Oil in the Maintenance Section.
If safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
Check the tractor to ensure it is lubricated. Refer to
Greasing and Lubrication in the Maintenance Section.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches
before operating the machine.
14
Step
9
Test Drive the Tractor
No Parts Required
Procedure
1. Fill the tank with unleaded regular gasoline;
Gasoline and Oil in Operation, page 19. Open
the fuel shutoff valve and check the fuel hose and
fittings for leaks.
2. As applicable, check and test the operation of the
following:
• Engine, choke and throttle controls
• Headlights
• Indicator lights
• PTO clutch and brake
• Lift system
• Parking brake
• Steering
• Tractor operation in forward and reverse
15
Product Overview
Figure 9
1.
2.
Steering wheel
Ignition switch
5.
6.
Ground speed selector
Throttle lever
9.
10.
3.
4.
Brake pedal
Parking brake lever
7.
8.
Choke lever
Power take off (PTO)
11.
12.
16
Cruise control switch
Indicator control
module/Hourmeter
Tilt wheel lever
Hood opening
13.
Attachment lift
Controls
Become familiar with all the controls (Figure 10 for
model 420 or Figure 11 for model 430) before you
start the engine and operate the machine.
Figure 11
Model 430
Figure 10
Model 420
1. Steering wheel
2. Ignition switch
3. Brake pedal
8.
9.
10.
4.
5.
6.
7.
11.
12.
13.
Parking brake lever
Ground speed selector
Throttle lever
Choke lever
Power take off (PTO)
Cruise control switch
Indicator control
module/Hourmeter
Tilt wheel lever
Hood opening
Attachment lift
1.
2.
3.
Steering wheel
Ignition switch
Brake pedal
8.
9.
10.
4.
5.
6.
7.
Parking brake lever
Ground speed selector
Throttle lever
Choke lever
11.
12.
13.
Power take off (PTO)
Cruise control switch
Indicator control
module/Hourmeter
Attachment lift switch
Tilt wheel lever
Hood opening
Indicator Control Module
The indicator control module (Figure 12 and
Figure 13 ) contains lights for:
• Operating in reverse
• Power take off (PTO)
• Battery
• Oil pressure
• Hourmeter (LED)
• Cruise control (Model 430 only)
• Fuel level (Model 430 only)
17
light is on it is a reminder; the starter will not crank
and turn off the PTO before getting off.
• 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.
Figure 12
1.
2.
3.
Power take off (PTO)
Battery
Hourmeter
4.
5.
Oil pressure
Operating-in-Reverse
Figure 13
1.
2.
3.
4.
Power take off (PTO)
Cruise control
Battery
Hourmeter
5.
6.
7.
Fuel level
Oil Pressure
Operating-in-Reverse
Following are the conditions when indicator lights will
be on. At other times the lights should be off.
• Battery
The battery light will be on when the ignition key is
in the run or lights positions if the battery voltage
is below 11.2 volts. When this light comes on it
is important to have your battery and electrical
system checked and the problem corrected.
• Fuel Level
The fuel level light will be on when the ignition key
is in the run or lights positions and the fuel level is
low, approximately one pint remaining.
• Oil
The oil light will be on when the ignition 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.
• PTO (Power Take Off)
The PTO (power take off) light will be on when
the ignition key is in the run or lights positions and
the PTO (power take off) is engaged on. When this
18
Operation
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
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.
• Fill the fuel tank outdoors, in an open
area, when the engine is cold. Wipe up any
gasoline that spills.
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.
• Never fill the fuel tank inside an enclosed
trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4
to 1/2 inch (6 to 13 mm) below the bottom of
the filler neck. This empty space in the tank
allows gasoline to expand.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors can cause serious
injury and illness.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by a spark.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
• Store gasoline in an approved container and
conditioner opening.
keep it out of the reach of children. Never
buy more than a 30 day supply of gasoline.
• Keep gas away from eyes and skin.
• 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.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
• Keeps gasoline fresh during storage of 90 days or
less. For longer storage it is recommended that the
fuel tank be drained.
19
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
Important: Do not use fuel additives
containing methanol or ethanol.
Add the correct amount of gas
stabilizer/conditioner to the gas.
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline. To
minimize the chance of varnish deposits in the fuel
system, use fuel stabilizer at all times.
Filling the Fuel Tank
Figure 14
1. Shut the engine off and set the parking brake.
1.
2. Clean around fuel tank cap and remove the cap.
Add unleaded regular gasoline to fuel tank, until
the level is 1/4 to 1/2 inch (6 to 13 mm) below the
bottom of the filler neck. This space in the tank
allows gasoline to expand. Do not fill the fuel tank
completely full.
Brake pedal
2.
Parking brake lever
2. Lift the parking brake lever (Figure 14 ) forward
and gradually take your foot off the brake pedal.
The brake pedal should stay in the depressed
(locked) position.
Releasing the Parking Brake
3. Install fuel tank cap securely. Wipe up any gasoline
that may have spilled.
1. Push down on the brake pedal (Figure 14 ). The
parking brake lever should release.
Check Engine Oil Level
2. Gradually release the brake pedal.
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking
the Engine Oil Level inEngine Maintenance, page 28 .
Starting and Stopping the
Engine
Think Safety First
Starting the Engine
Please carefully read all the safety instructions.
Knowing this information could help you, your family,
pets or bystanders avoid injury.
1. Sit down on the seat.
2. Set the parking brake; refer to Setting the Parking
Brake in Brake Maintenance, page 37.
Operating the Parking
Brake
Note: The engine will not start unless you set the
parking brake or fully depress the brake pedal.
3. Push the PTO (power take off) to the off position
(Figure 15 ).
Always set the parking brake when you stop the
machine or leave it unattended.
4. Move the choke lever to the on position
(Figure 15 ).
Setting the Parking Brake
Note: An engine that has been running and is
warm may not require step 4.
1. Push the brake pedal (Figure 14 ) down and hold it
in the depressed position.
20
2. Move the throttle lever between half and full
throttle (Figure 15 ).
3. Turn the ignition key to off (Figure 16 ).
Operating the Power Take
Off (PTO)
The power take off (PTO) engages and disengages
power to the electric clutch.
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 PTO before getting off.
Figure 15
1. PTO-Off
2. Choke-On
3. Choke-Off
4.
5.
6.
Throttle lever
Fast
Slow
Engaging the Power Take Off (PTO)
5. Move throttle lever to the fast position (Figure 15 ).
Pull the power take off (PTO) to on (Figure 17 ).
6. Turn the ignition key and hold it in the start
position (Figure 16 ). When the engine starts,
release the key.
Important: If the engine does not start
after 10 seconds of continuous cranking,
turn the ignition key to off and let the
starter motor cool for 60 seconds; refer to
Troubleshooting Troubleshooting, page 39.
7. After the engine starts, move the choke lever to off
(Figure 15 ). 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.
Figure 17
1.
Off-disengaged
2.
On-engaged
Disengaging the Power Take Off
(PTO)
Push the power take off (PTO) to off (Figure 17 ).
The Safety Interlock System
Figure 16
1. Off
2. Lights
3.
4.
Run
Start
If safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
• Do not tamper with the interlock switches.
Stopping the Engine
• Check the operation of the interlock switches
1. Push the PTO (power take off) to off (Figure 15 ).
daily and replace any damaged switches
before operating the machine.
21
Understanding the Safety Interlock
System
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 KeyChoice® 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.
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 hydro control pedal is in the neutral position.
•
•
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.
Setting the KeyChoice® Switch to
Operate in Reverse
An interlock feature on the tractor prevents the power
take off (PTO) from operating when backing up. If
you shift into reverse with the PTO engaged (i.e.,
with mower blades or other attachment running), the
PTO will disengage. Do not mow in reverse unless
absolutely necessary.
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.
Testing the Safety Interlock System
If you need to use the PTO while backing up, you can
turn off this interlock feature using the KeyChoice®
switch located near the seat bracket (Figure 18 ).
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 the On position. Now turn the ignition
key to start while sitting on the seat; the engine
should not crank.
2. Push the power take off (PTO) to the off position
and release the parking brake. Now turn the
ignition key to the Start position while sitting on
the seat; the engine should not crank.
3. Set the parking brake and move the power take
off (PTO) to the Off position. Rise from the seat
and turn the ignition key to the Start position; the
engine should not crank.
4. Set the parking brake and move the power take off
(PTO) to the Off position. While sitting in the
seat, 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 move the power take off
(PTO) to the Off position. While sitting in the seat,
start the engine. While the engine is running, move
the power take off (PTO) to the On position and
rise slightly from the seat; the engine should stop.
6. With the parking brake released, turn the ignition
key to the run position 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
You could back over a child or bystander while
the mower blade(s) or other attachment is
engaged and cause serious injury or death.
• Do not mow in reverse unless absolutely
necessary.
• Do not insert the KeyChoice® key unless it
is absolutely necessary.
• Always look backward and down before
backing up.
• Use the KeyChoice® switch only if you are
certain no children or other bystanders will
enter the mowing area.
• Be very observant after deactivating the
interlock because the sound of the engine
may prevent you from noticing that a child
or bystander has entered the work area.
• Always remove both the ignition and
KeyChoice® keys and put them in a
safe place out of the reach of children or
unauthorized users when leaving the unit
unattended.
1. Engage the PTO.
2. Insert the KeyChoice® key into the switch
(Figure 18 ).
22
To go forward or backward, release the parking
brake: refer to Releasing the Parking Brake in
Brake Maintenance, page 37 . 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
(Figure 21 ). 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 KeyChoice® switch located on the seat bracket
on the right hand side just below the seat.
Figure 18
1. KeyChoice® switch
To slow down, release the pressure on the traction
control pedal.
3. Turn the KeyChoice® key.
Important: To avoid transmission damage,
always release the parking brake before moving
the traction control pedal.
A red light on the front console (Figure 19 and
Figure 20 ) turns on, indicating that the interlock
is disabled.
Figure 19
1. Operating-in-reverse light-Model 72202
Figure 21
1.
Forward
2.
Backward
Figure 20
1. Operating-in-reverse light-Model 72201
Stopping the Machine
4. Shift into reverse and complete your task.
5. Stop the PTO, which will turn off the red light on
the console, to activate the interlock.
6. Remove the KeyChoice® key and put it in a safe
place out of reach of children.
To stop the machine, release the traction control
pedal, disengage the power take off (PTO), and turn
the ignition key to off. Also set the parking brake if
you leave the machine unattended; refer to Setting
the Parking Brake in Brake Maintenance, page 37 .
Remember to remove the key from the ignition switch.
Driving Forward or
Backward
The throttle control regulates the engine speed as
measured in RPM (revolutions per minute). Place
the throttle control in the fast position for best
performance.
23
Raising Attachments
1. Turn key to the on or run position (Figure 23 ).
Children or bystanders may be injured if they
move or attempt to operate the tractor while it
is unattended.
2. Push the lift switch in the up direction to raise the
attachment lift (Figure 23 ).
This will lift and hold the attachment in the up, or
raised position.
Always remove the ignition and KeyChoice®
keys and set the parking brake when leaving
the machine unattended, even if just for a few
minutes.
Lowering Attachments
1. Turn key to the on or run position (Figure 23 ).
Operating the Attachment
Lift Lever
2. Push the lift switch in the down direction to lower
the attachment lift (Figure 23 ).
This will lower the attachment lift.
The attachment lift lever (Figure 22 ) is used to raise
and lower various attachments.
Raising an Attachment
Pull attachment lift lever rearward until latch locks. In
this position the lift will hold the attachment in the up,
or raised position.
Lowering an Attachment
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.
Figure 23
1.
2.
Key
Lift switch -up
3.
Lift switch -down
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.
Figure 22
1.
Lift lever
2.
1. Raise the seat and loosen the adjustment knobs
(Figure 24 ).
Button
2. Slide the seat to the desired position and tighten
the knobs.
Using the Attachment Power
Lift
The attachment power lift (Figure 23 ) is used to raise
and lower attachments.
24
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 (Figure 26 ).
2. Move the steering wheel to a comfortable position;
then release the lever to lock.
Figure 24
1. Adjustment knob
Using the Headlights
Figure 26
The headlights are turned on with a separate position,
lights, of the ignition switch (Figure 25 ). 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
or discharging the battery.
1.
Tilt lever
2.
Steering wheel
Pushing the Machine by
Hand
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.
2. Move the drive control rod to the push position.
This disengages the drive system and allows the
wheels to turn freely (Figure 27 ).
To Operate the Machine
Figure 25
1. Lights
Move the drive control rod to the operate position
(Figure 27 ).
Note: The machine will not drive unless the drive
control rod is in the operate position.
25
Figure 27
1.
2.
Operate position
Push position
3.
Drive control rod
Figure 28
1.
Using the Cruise Control
Lock-Set
2.
Unlock-Off
2. 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.
A three position switch, located on the dash
(Figure 28 ), with the functions of: Lock-Set (spring
loaded), On and Unlock-Off 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.
Disengaging the Cruise Control
1. While holding your foot steady on the traction
control, move the cruise control switch (Figure 28 )
to the unlock-off position.
Engaging the Cruise Control
2. This unlocks the traction control and your foot
then operates the traction control.
1. Begin driving tractor: Refer to Driving Forward or
Backward in Operation Operation, page 19 . While
holding your foot steady on the traction control,
push the cruise control switch (Figure 28 ) to the
lock-set position.
3. For quick stops, just press on the brake pedal. This
automatically disengages the cruise control and
applies the brake at the same time.
26
Maintenance
Recommended Maintenance Schedule(s)
Maintenance
Service Interval
Maintenance Procedure
After the rst use
• Change the engine oil.
Before each use or
daily
•
•
•
•
•
Check the safety interlock system.
Check the engine oil level.
Check the battery electrolyte.
Clean the air intake screen.
Check the brake.
Every 25 hours
• Clean the foam air cleaner element (more often in dusty dirty
conditions).
• Check the tire pressure.
Every 50 hours
• Grease the front wheels and spindles (more often in dirty or dusty
conditions).
• Clean the paper air cleaner element.
Every 100 hours
•
•
•
•
Every 200 hours
• Change the oil lter (more often in dirty or dusty conditions).
• Replace the paper air cleaner element.
Before storage
•
•
•
•
Change the engine oil (more often in dirty or dusty conditions).
Check the spark plug(s).
Replace the fuel lter.
Clean the cooling ns and engine shrouds.
Drain the fuel.
Charge the battery and disconnect the cables.
Check the toe-in.
Perform all maintenance procedures listed above before storage.
Important: Refer to your engine operator’s manual for additional maintenance procedures.
If you leave the key in the ignition switch, someone could accidently start the engine and seriously
injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug before you do any
maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Lubrication
How to Grease
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to off.
Remove the ignition key.
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.
4. Wipe up any excess grease.
Greasing and Lubrication
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.
27
Where to Add Grease
2. Clean around the oil dipstick (Figure 31 ) so that
dirt cannot fall into the filler hole and damage the
engine.
1. Lubricate the front wheels and spindles until grease
begins to ooze out of the bearings (Figure 29 ).
3. Unscrew the oil dipstick and wipe the metal end
clean (Figure 31 ).
2. Lubricate the front axle pivot (Figure 29 ).
4. Slide the oil dipstick fully into the filler tube, but
do not thread it onto the tube (Figure 31 ). Pull
the dipstick out and look at the metal end. If the
oil level is low, slowly pour only enough oil into
the filler tube to raise the level to the full mark on
the dipstick.
Important: Do not overfill the crankcase
with oil because the engine may be damaged.
Figure 29
Engine Maintenance
Servicing the Engine Oil
Change the oil after the first 8 operating hours and
every 100 operating hours thereafter.
Figure 31
Oil Type: Detergent oil (API service SF, SG, SH or SJ)
1.
2.
Crankcase Capacity:
• when the oil filter is not removed, 51 ounces (1.5 l)
• when the oil filter is removed, 58 ounces (1.7 l)
Oil dipstick
Filler tube
3.
Dipstick end
Changing and Draining the Oil
Viscosity: See the table below.
1. Start the engine and let it run for five minutes. This
warms the oil so that it drains better.
2. Park the machine so that the drain side is slightly
lower than the opposite side to ensure that the oil
drains completely. Then disengage the PTO, set the
parking brake, stop the engine, and remove the key.
3. Place a pan below the oil drain. Use either a flat
screw driver, 3/8 inch (10 mm) wrench to open
valve (Figure 32 ).
4. Rotate valve end counterclockwise to open valve
(Figure 32 ).
5. When oil has drained completely, rotate valve end
clockwise to close the valve (Figure 32 ).
Figure 30
Note: Dispose of the used oil at a certified
recycling center.
Checking the Engine Oil Level
1. Park the machine on a level surface, disengage the
PTO, stop the engine, and remove the key.
28
4. Install the replacement oil filter to the adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 3/4 turn (Figure 33 ).
5. Fill the crankcase with the proper type of new oil;
refer to Changing and Draining the Engine Oil in
Engine Maintenance, page 28 .
Servicing the Air Cleaner
Foam Element: Clean and oil after every 25 operating
hours.
Figure 32
Paper Element: Clean after every 50 operating hours.
Replace after every 200 operating hours or yearly,
whichever comes first.
1. Oil drain
6. Clean around the oil dipstick and unscrew the cap
(Figure 31 ).
7. Slowly pour approximately 80% of the specified oil
into the filler cap (Figure 31 ). Refer to Servicing
the Engine Oil in Engine Maintenance, page 28 .
8. Check the oil level; refer to Checking the Engine
Oil Level in Engine Maintenance, page 28 .
9. Slowly add additional oil to bring it to the full mark.
Note: Service the air cleaner more frequently (every
few hours) if operating conditions are extremely dusty
or sandy.
Removing the Foam and Paper
Elements
1. Disengage the PTO and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Changing the Oil Filter
Replace the oil filter every 200 hours or every other
oil change.
3. Clean around the air cleaner to prevent dirt from
getting into the engine and causing damage.
Unlatch the two side latches and remove the air
cleaner cover (Figure 34 ).
Note: Change the oil filter more frequently when
operating conditions are extremely dusty or sandy.
1. Drain the oil from the engine; refer to Changing and
Draining the Engine Oil in Engine Maintenance,
page 28 .
2. Remove the old filter (Figure 33 ).
3. Apply a thin coat of new oil to the rubber gasket
on the replacement filter.
Figure 34
1.
2.
3.
Cover
Foam element
Paper element
4.
5.
6.
Wing nut
Air cleaner base
Latches
4. Carefully remove the foam element from the paper
element (Figure 34 ).
Figure 33
5. Unscrew the wing nut and remove the paper
element (Figure 34 ).
1. Oil lter
29
Cleaning the Foam Element
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. Install a new
spark plug(s) if necessary.
1. Wash the foam element in liquid soap and warm
water (Figure 34 ). When the element is clean, rinse
it thoroughly.
2. Dry the element by squeezing it in a clean cloth (do
not wring). Allow the element to air dry.
Type: Champion RCJ8Y (or equivalent)
Important: Replace the foam element if it is
torn or worn.
Air Gap: 0.030 inch (0.75 mm)
Removing the Spark Plug(s)
Cleaning the Paper Element
1. Disengage the PTO and set the parking brake.
1. Lightly tap the element on a flat surface to remove
dust and dirt (Figure 35 ).
2. Inspect the element for tears, an oily film, and
damage to the rubber seal.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
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.
3. Pull the wire(s) off of the spark plug(s) (Figure 36 ).
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.
Figure 36
Figure 35
1.
Paper element
2.
1.
Rubber seal
Spark plug wire installed
2.
Spark plug
Checking the Spark Plug
Installing the Foam and Paper
Elements
1. Look at the center of the spark plug(s) (Figure 37 ).
If you see light brown or gray on the insulator, the
engine is operating properly. A black coating on
the insulator usually means the air cleaner is dirty.
Important: To prevent engine damage, always
operate the engine with the complete foam and
paper air cleaner assembly installed.
1. Carefully slide the foam element into the paper air
cleaner element (Figure 34 ).
2. Place the air cleaner assembly onto the air cleaner
base and install the wing nut (Figure 34 ).
3. Install the air cleaner cover and latch it (Figure 34 ).
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 (Figure 37 ). Bend the side electrode
(Figure 37 ) if the gap is not correct.
Servicing the Spark Plug
Check the spark plug(s) after every 100 operating
hours. Make sure the air gap between the center and
30
Figure 37
1. Center electrode insulator
2. Side electrode
3.
Figure 38
Air gap (not to scale)
1.
Fuel shut-off valve
4. Open the hood.
Installing the Spark Plug(s)
5. Squeeze the ends of the hose clamp together
and slide it up the fuel line toward the fuel tank
(Figure 39 ).
1. Install the spark plug(s). Make sure that the air gap
is set correctly.
2. Tighten the spark plug(s) to 16 ft-lb (22 N·m).
3. Push the wire(s) onto the spark plug(s) (Figure 36 ).
Fuel System
Maintenance
Draining The Fuel Tank
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
Figure 39
• Drain gasoline from the fuel tank when the
1.
2.
engine is cold. Do this outdoors in an open
area. Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and
Hose clamp
Fuel line
3.
Filter
6. Pull the fuel line off the filter (Figure 39 ). Open
fuel shut-off valve and allow gasoline to drain into
an approved gas can.
stay away from an open flame or where a
spark may ignite the gasoline fumes.
Note: Now is the best time to install a new fuel
filter because the fuel tank is empty.
1. Park the machine on a level surface, to ensure the
fuel tank drains completely. Disengage the PTO
and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
7. 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 in
Fuel System Maintenance, page 31 .
3. Close the fuel shut-off valve at the fuel tank
(Figure 38 ).
Servicing the Fuel Filter
Replace the fuel filter after every 100 operating hours
or yearly, whichever occurs first.
31
Never install a dirty filter if it is removed from the fuel
line.
1. Disengage the PTO and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Close fuel shut-off valve at fuel tank (Figure 38 ).
4. Open the hood.
5. Squeeze the ends of the hose clamps together and
slide them away from the filter (Figure 39 ).
Figure 40
6. Remove the filter from the fuel lines.
7. Install a new filter and move the hose clamps close
to the filter.
8. Open fuel shut-off valve at fuel tank (Figure 38 ).
1.
2.
Main-30 amp
Alternator-25 amp
3.
Dash/Hour meter-10 amp
4.
5.
Head lights-10 amp
Power attachment
lift-25 amp (Model 72202
only)
9. Close the hood.
Servicing the Headlights
Electrical System
Maintenance
Specification: Bulb #1156 Automotive Type
Removing the Bulb
Servicing the Fuses
1. Disengage the PTO and set the parking brake.
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 (Figure 40 ) to remove
or replace it.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Fuses:
4. Rotate the bulb holder 1/4 turn counterclockwise
and remove it from the reflector (Figure 41 ).
3. Open the hood. Pull wire connectors off both bulb
holder terminals.
• Main/Starter F1-30 amp, blade-type
5. Push and rotate the bulb counterclockwise until it
stops (approximately a 1/4 turn) and remove bulb
from the bulb holder (Figure 41 ).
• Alternator F2-25 amp, blade-type
• Dash/Hour meter F3-10 amp, blade-type
• Head lights F4-10 amp, blade-type
• Power attachment lift F5-25 amp, blade-type
(Model 430 only)
•
32
Servicing the Battery
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
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.
Figure 41
1. Bulb holder
2. Reector
3. Tabs
4.
5.
Slots
Terminals
Voltage: 12 v, 260 Cold Cranking Amps
Removing the Battery
Installing the Bulb
1. The bulb has metal pins on the side of its base.
Align the pins with the slots in the bulb holder and
insert the base into the holder (Figure 42 ). Push
and rotate the bulb clockwise until it stops.
Battery terminals or metal tools could short
against metal tractor components causing
sparks. Sparks can cause the battery gasses to
explode, resulting in personal injury.
• When removing or installing the battery, do
not allow the battery terminals to touch any
metal parts of the tractor.
• Do not allow metal tools to short between
the battery terminals and metal parts of the
tractor.
Incorrect battery cable routing could damage
the tractor and cables causing sparks. Sparks
can cause the battery gasses to explode,
resulting in personal injury.
Figure 42
1. Bulb
2. Metal pins
3.
4.
• Always disconnect the negative (black)
Bulb holder
Slots
battery cable before disconnecting the
positive (red) cable.
• Always reconnect the positive (red) battery
2. The bulb holder has two tabs (Figure 41 ). 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.
cable before reconnecting the negative
(black) cable.
1. Disengage the PTO and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Open the hood and locate the battery.
3. Push the wire connectors onto the terminals on
the bulb holder.
33
4. Remove the right side panel for clearance when
removing battery Figure 43 ).
3. Using the bolt and nut, connect the positive
(red cover) cable to the positive (+) battery post
(Figure 44 ). Slide the rubber cover over the battery
post.
Remove the screws and lift up the panel to clear the
pin and slide panel tabs out from the steering tower.
4. Using the bolt and nut, connect the negative (black)
cable to the negative (-) battery post (Figure 44 ).
5. Install the right side panel by sliding tabs into
steering tower and inserting pin into flange of
footrest. Secure with screws (Figure 43 ).
Checking the Electrolyte Level
1. With the engine off, open the hood to locate the
battery.
2. Look at the side of the battery. The electrolyte
must be up to the upper line. Do not allow the
electrolyte to get below the lower line (Figure 45 ).
Figure 43
1.
2.
3.
Battery
Side panel tabs
Screw
4.
5.
Pin
Right side panel
5. Disconnect the negative (black) ground cable from
the battery post (Figure 44 ).
Figure 45
1.
2.
Filler caps
Upper line
3.
Lower line
3. If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery in .
Figure 44
1.
2.
3.
Negative cable
Nut
Bolt
4.
5.
6.
Battery electrolyte contains sulfuric acid
which is a deadly poison and causes severe
burns.
Rubber cover (red)
Positive cable
Battery hold down strap
• Do not drink electrolyte and avoid
6. Lift the red cover up from the positive cable.
Disconnect the positive cable (red cover) from the
battery post (Figure 44 ).
contact with skin, eyes or clothing. Wear
safety glasses to shield your eyes and
robber gloves to protect your hands.
7. Remove the battery hold down strap (Figure 44 ).
Remove battery from the tractor.
• Fill the battery where clean water is
Installing the Battery
• Follow all instructions and comply with
always available for flushing the skin.
all safety messages on the electrolyte
container.
1. Install the battery into the tractor (Figure 43 ).
2. Secure battery with hold down strap (Figure 44 ).
34
Adding Water to the Battery
Important: Always keep the battery fully
charged (1.265 specific gravity). This is especially
important to prevent battery damage when the
temperature is below 32°F (0°C).
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. Remove the battery from the chassis; refer to
Removing the Battery.
1. Remove the battery from the tractor.
2. Clean the top of the battery with a paper towel.
2. Check the electrolyte level; refer to Checking
Electrolyte Level.
Note: Never fill the battery with distilled water
while the battery installed in the tractor. Electrolyte
could be spilled on other parts and cause corrosion.
3. Make sure the filler caps are installed in battery.
Charge battery for a minimum of 6 to 10 amps for
one hour. If the battery is in the fully discharged
condition, then the charging requirement is 3 amps
for 6 hours.
3. Remove the vent caps from the battery (Figure 46 ).
Important: Never over charge the battery.
Excessive charging will shorten the battery life.
4. When the battery is fully charged, unplug the
charger from the electrical outlet, then disconnect
the charger leads from the battery posts (Figure 47 ).
Figure 46
1. Filler caps
2. Upper line
3.
Lower line
4. Slowly pour distilled water into each battery cell
until the level is up to the upper line (Figure 46 )
on the battery case.
Important: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
5. Wait five to ten minutes after filling the battery
cells. Add distilled water, if necessary, until the
electrolyte level is up to the upper line (Figure 46 )
on the battery case.
Figure 47
1.
2.
6. Reinstall battery vent caps.
Positive Battery Post
Negative Battery Post
3.
4.
Red (+) Charger Lead
Black (-) Charger Lead
5. Install the battery in the tractor and connect the
battery cables; refer to Installing the Battery.
Charging the Battery
Note: Do not run the tractor with the battery
disconnected, electrical damage may occur.
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks
and flames away from battery.
35
Drive System
Maintenance
Checking the Tire Pressure
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 (Figure 48 ). Check the tires when they are cold to
get the most accurate pressure reading.
Pressure: 20 psi (138 kPa) front and rear tires
Figure 49
1.
2.
Figure 48
1.
Measure here
Flats
3.
4.
Jam nut
Steering lever
5. The front measurement should be less than the
rear, as specified.
Valve stem
Adjusting the Toe-In
Servicing the Front Wheel
Toe-In
1. Check the toe-in before you adjust it; refer to
Measuring Toe-In.
2. Remove ball joint from one steering lever
(Figure 49 ).
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 (Figure 49 ).
5. Install ball joint to steering lever and check the
toe-in; refer to Measuring Toe-In.
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 every
year before storage.
Specification: 1/8-1/4 inch (3-6 mm) toe-in on front
wheels.
Measuring the Toe-in
Important: If more than one turn is required
to meet specifications, alternate between left
and right steering rods to maintain steering
wheel alignment.
1. Disengage the PTO and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Transaxle Fluid
3. Push front tires out, at front, to remove normal
looseness in the linkage.
The transaxle is a sealed system and no checking or
changing of the fluid is required.
4. Measure, between the rims, at spindle level, in the
front and rear of the wheels (Figure 49 ).
Important: If any transaxle problems arise,
contact your local Authorized Service Dealer for
help and service.
36
Cooling System
Maintenance
1. Disengage the PTO, set the parking brake, stop the
engine, and remove the key.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. 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.
4. Release the brake and move the drive control rod
to the push position; refer to Pushing the Machine
by Hand in Operation, page 19. Wheels should
rotate freely.
5. If both conditions are met no adjustment is
required.
2. Remove the air intake screen, cylinder covers, and
fan housing (Figure 50 ).
Adjusting the Brake
Cleaning the Cooling System
Clean the air intake screen from grass and debris before
each use.
Clean the cooling fins and engine shrouds every 100
hours.
1. Check the brake before you adjust it; refer to
Checking the Brake.
2. Release the parking brake; refer to Releasing the
Parking Brake in Operation, page 19
3. To adjust the brake remove the cotter pin and
loosen the brake adjusting nut slightly (Figure 51 ).
Figure 50
1. Air intake screen
2. Fan housing
3.
4.
Cylinder cover
Cylinder cover
Figure 51
1.
2.
3. Clean debris and grass from the parts.
4. Install the air intake screen, cylinder covers, and
fan housing.
Brake adjusting nut
Cotter pin
3.
Right Front of Transaxle
4. Carefully insert a 0.015 inch (0.38 mm) feeler
gauge between the outer brake pad and rotor disk
(Figure 51 ).
5. Tighten the brake adjusting nut until slight
resistance is felt on the feeler gauge when sliding it
in and out. Install the cotter pin.
6. Check the brake operation again; refer to Checking
the Brake.
Brake Maintenance
Servicing the 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.
Important: With the parking brake released,
the rear wheels must rotate freely when you
push the mower. If the 0.015 inch (0.38 mm)
clearance and free wheel rotation cannot
be achieved contact your service dealer
immediately.
Checking the Brake
1. Park the machine on a level surface, disengage the
PTO, and set the parking brake.
37
Storage
Important: Do not store
stabilizer/conditioned gasoline over
90 days.
Cleaning and Storage
9. Remove the spark plug(s) and check its
condition; refer to Servicing the Spark Plug in
Engine Maintenance, page 28 . 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 30 ft-lb (40 N·m).
Do not install the wire on the spark plug(s).
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to off.
Remove the ignition and KeyChoice® 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. Avoid excessive use of
water, especially near the control panel, lights,
engine, and the battery.
10. Disconnect the negative battery cable. Clean the
battery and battery terminals. Check the electrolyte
level and charge it fully; refer to Servicing the
Battery in Electrical System Maintenance, page 32 .
Leave the negative battery cable disconnected from
the battery during storage.
3. Check the brake; refer to Servicing the Brake in
Brake Maintenance, page 37
Important: The battery must be fully
charged to prevent it from freezing and being
damaged at temperatures below 32°F (0°C). A
fully charged battery can be stored one winter
season without recharging.
4. Service the air cleaner; refer to Servicing the Air
Cleaner in Engine Maintenance, page 28.
5. Grease the chassis; refer to Greasing and
Lubrication in Lubrication, page 27.
11. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
6. Change the crankcase oil and filter; refer to
Servicing the Engine Oil in Engine Maintenance,
page 28 .
12. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
7. Check the tire pressure; refer to Checking the Tire
Pressure in Drive System Maintenance, page 36.
13. Store the machine in a clean, dry garage or storage
area. Remove the keys from the ignition and
KeyChoice® switches and keep it in a memorable
place. Cover the machine to protect it and keep
it clean.
8. Prepare the machine for storage when non-use
occurs over 30 days. Prepare machine for storage
as follows.
A. Add a petroleum based stabilizer/conditioner
to fuel in the tank. Follow mixing instructions
from stabilizer manufacture. Do not use an
alcohol based stabilizer (ethanol or methanol).
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and
used at all times.
B. Run engine to distribute conditioned fuel
through the fuel system (5 minutes).
C. Stop engine, allow to cool and drain the fuel
tank; refer to Servicing the Fuel Tank in
Fuel System Maintenance, page 31.
D. Restart engine and run it until it stops.
E. Choke or prime the engine. Start and run
engine until it will not start. Operate primer, if
equipped on machine, several times to ensure
fuel remains in primer system.
F. Dispose of fuel properly. Recycle as per local
codes.
38
Troubleshooting
Problem
Starter does not crank
Possible Cause
1. Blade control (PTO) is
engaged.
1. Move the blade control
(PTO) to disengaged.
2.
3.
4.
5.
2.
3.
4.
5.
Parking brake is not on.
Operator is not seated.
Battery is dead.
Electrical connections are
corroded or loose.
6. Fuse is blown.
7. Relay or switch is defective.
Engine will not start, starts
hard, or fails to keep running.
Set the parking brake.
Sit on the seat.
Charge the battery.
Check the electrical
connections for good
contact.
6. Replace the fuse.
7. Contact an Authorized
Service Dealer.
1. Fuel tank is empty.
1. Fill fuel tank with gasoline.
2. Choke is not on.
2. Move the throttle lever to
choke position.
3. Clean or replace the air
cleaner element.
4. Install wire on spark plug.
3. Air cleaner is dirty.
4. Spark plug wire is loose or
disconnected.
5. Spark plug is pitted, fouled,
or the gap is incorrect.
6. Dirt in the fuel lter.
7. Dirt, water, or stale fuel is
in the fuel system.
Engine loses power.
Corrective Action
5. Install a new, correctly
gapped spark plug.
6. Replace the fuel lter.
7. Contact an Authorized
Service Dealer.
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
2. Clean the air cleaner
element.
3. Add oil to the crankcase.
3. Oil level in the crankcase is
low.
4. Cooling ns and air
passages under the
engine blower housing
are plugged.
5. Spark plug is pitted, fouled,
or the gap is incorrect.
6. Vent hole in the fuel cap is
plugged.
7. Dirt in the fuel lter.
8. Dirt, water, or stale fuel is
in the fuel system.
39
4. Remove the obstruction
from the cooling ns and
air passages.
5. Install a new, correctly
gapped spark plug.
6. Clean or replace the fuel
cap.
7. Replace the fuel lter.
8. Contact an Authorized
Service Dealer.
Problem
Engine overheats.
Abnormal vibration.
Machine does not drive.
Possible Cause
Corrective Action
1. Engine load is excessive.
1. Reduce the ground speed.
2. Oil level in the crankcase is
low.
3. Cooling ns and air
passages under the
engine blower housing
are plugged.
2. Add oil to the crankcase.
1. Engine mounting bolts are
loose.
1. Tighten the engine
mounting bolts.
2. Loose engine pulley, idler
pulley, or blade pulley.
3. Engine pulley is damaged.
2. Tighten the appropriate
pulley.
3. Contact an Authorized
Service Dealer.
1. Drive control is in the push
position.
1. Move the drive control to
the operate position.
2. Traction belt is worn, loose
or broken.
3. Traction belt is off the
pulley.
2. Contact and Authorized
Service Dealer.
3. Contact an Authorized
Service Dealer.
40
3. Remove the obstruction
from the cooling ns and
air passages.
Schematics
Wiring Schematic (Model 420) (Rev. A)
41
Wiring Schematic (Model 430) (Rev. A)
42
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