Toro 416-H Garden Tractor Riding Product Operator's Manual

FORM NO. 3318-501
A
(7
Wheel Horse”
416H
Garden Tractor
Model No. 73423 — 6900001 & 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.
A
À
NN
À
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.
A
m-2345
1. Model and Serial Number Plate
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 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.
The left and right side of the machine is determined
by sitting on the seat in the normal operator’s
position.
A WARNING: A
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
OThe Toro Company — 1996
All Rights Reserved
Contents
Safety .......oocoeeecococeaceaaao ee...
Safe Operating Practices ..............
SlopeChart .........................
Safety and Instruction Decals
Gasoline and Oil
Recommended Gasoline
Stabilizer/Conditioner ................
Filling the Fuel Tank ....... eee
Check Engine O1l Level ...............
Operation ........ _r—eñeccervecocrrereca,
Think Safety First
Controls ...........................
Parking Brake .......................
Starting and Stopping the Engine
Operating the Power Take Off (PTO) ....
The Safety Interlock System ...........
о аа ен вп пе т тя тв в вая я
+ + # + # u +
Indicator Lights .....................
Instruments ........ eee
Driving Forward or Backward ..........
Stopping the Machine
Attachment Lift Lever ................
Positioning the Seat ..................
Lights .............. iii...
Installing PTO Belt
a + + + +» & = + # + = 5 % = + a
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11
11
12
13
14
14
15
15
16
16
Page
Maintenance .........rÑ<—ereoscooorrrecoo 17
Service Interval Chart ................ 17
AirCleaner ..................... ‚ею. 19
Engine Oil ......................... 21
Spark Plug ............... oo. 23
Engine Breather ..................... 24
Greasing and Lubrication ...........e.. 23
Tire Pressure .......20000 0000 00e eau» 26
Brake ........... ii... 26
PTO (Power Take Off) Brake .......... 27
Front Wheel Toe-In .................. 28
Fuel Tank .......................... 29
FuelFilter .......................... 30
Transaxle Fluid ...................... 30
Headlights ......................... 32
Taillights... iit, 33
Battery ......... 1 0e a 0 eee 0 34
Fuse ......ooncorerorororeraeo, 2... 36
Wiring Diagram ..................... 37
Cleaning and Storage ................. 38
Troubleshooting ......................... 39
Warranty .............. iin... Back Cover
Safety
This machine meets or exceeds the B71.1-1990
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 À 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
This product is capable of amputating hands and feet
and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
POTENTIAL HAZARD
¢ Engine exhaust contains carbon monoxide,
which is an odorless, deadly poison.
WHAT CAN HAPPEN
e Carbon monoxide can kill you and is also
known to the State of California to cause
birth defects.
HOW TO AVOID THE HAZARD
* Do not run engine indoors or in an enclosed
area.
General Operation
1. Read, understand, and follow all instructions in
the operator’s manual and on the machine before
starting. |
2. Allow only responsible adults who are familiar
with the instructions to operate the machine.
3. Clear the area of objects such as rocks, toys,
wire, etc., Which could be picked up and thrown
by the blade.
4. Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
5. Never carry passengers.
6. Do not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing.
7. 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.
8. Slow down before turning. Sharp turns on any
terrain may cause loss of control.
9. Never leave a running machine unattended.
Always turn off blades, set parking brake, stop
engine, and remove key before dismounting.
10. Turn off blades when not mowing.
11. Keep hands, feet, hair and loose clothing away
from attachment discharge area, underside of
mower and any moving parts while engine 18
running.
12. Stop the engine before removing the grass
catcher or unclogging the chute.
13.
14.
15.
16.
17.
Mow only in daylight or good artificial light.
Do not operate the machine while under the
influence of alcohol or drugs.
Watch for traffic when operating near or crossing
roadways.
Use extra care when loading or unloading the
‘machine onto a trailer or truck.
Do not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
Slope Operation
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.
DO
Mow up and down slopes greater than 5°, not
across.
Mow downhill only on slopes above 10°, never
mow uphill. If a steep slope must be ascended,
back up the hill, and drive forward down the hill,
keeping the machine in gear.
Remove obstacles such as rocks, tree limbs, etc.
from the mowing area. Watch for holes, ruts or
bumps, as 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 the manufacturer’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.
Safety
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
Do not operate machine on hillsides or slopes
exceeding 15°,
Avoid turning on slopes. If you must turn, 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.
Heavy grass bags could cause loss of control or
overturn the machine.
Safety
Children
Tragic accidents can occur if the operator is not alert
to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain where you
last saw them. The following requirements must be
followed to prevent injury to children.
1.
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
for small children.
Never carry children. They may fall off and be
seriously injured or interfere with safe machine
operation.
Never allow children to operate the machine.
Use extra care when approaching blind corners,
shrubs, trees, the end of a fence or other objects
that may obscure vision.
Service
1.
3.
Stop the engine and disconnect spark plug
wire(s) before performing any service, repairs,
maintenance or adjustments.
Use extra care when handling gasoline and other
fuels, They are flammable and vapors are
explosive.
A. Use only an approved container.
B. 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.
D. 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.
10.
11.
12.
13.
Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
Never tamper with safety devices. Check safety
systems for proper operation before each use.
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 replacement parts to ensure
that original standards are maintained.
Check brake operation frequently. Adjust and
service as required.
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.
Safety
Slope Chart
Read all safety instructions on pages 2-4.
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, TT POLE ETC.)
TH;
$ is A 150 si
OPE
THIS IS A 10° SLOPE
THIS IS A 5° SLOPE
| a
IM ENT OU ETT
TE
Ho -
= Un T
FOLD ALONG APPROPRIATE LINE
CL
EXAMPLE: COM PARE
—— LOPE WITH FOLDED
EDGE,
Safety
Safety and Instruction Decals
ON DASH ABOVE STEERING WHEEL
(Part No. 92-9837)
A DANGER J
TO AVOID SERIOUS INJURY OR DEATH:
+ READ AND UNDERSTAND THE OPERATOR'S MANUAL.
+ KNOW LOCATION AND FUNCTION OF CONTROLS.
y + NEVER USE WHEN UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.
+ USE SAFELY; MACHINE IS NOT A TOY; NEVER LET CHILDREN OPERATE.
+ GO UP AND DOWN SLOPES, NOT ACROSS.
+ AVOID SHARP OR SUDDEN TURNS AND SLIPPERY OR STEEP AREAS.
+ IF MACHINE STOPS GOING UPHILL, STOP BLADE AND BACK SLOWLY DOWN.
wu * NEVER MOW WHEN CHILDREN OR OTHERS ARE IN THE MOWING AREA.
+ NEVER CARRY CHILDREN OR OTHER PASSENGERS.
+ LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING UP.
NY) + KEEP SAFETY DEVICES IN PLACE AND WORKING; CHECK BEFORE EACH USE.
BY - SAFETY INTERLOCKS CAN FAIL; NEVER ASSUME BLADE IS STOPPED.
‚ентом STOP ENGINE, SET PARKING BRAKE AND REMOVE KEY IF LEAVING MACHINE.
[posikiL oes - REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE. J
92937
ON FRAME PLATE UNDER
STEERING WHEEL
(Part No. 92-8946)
—
| ZU NDANGER
«ROTATING BLADES
CAN CUT OFF ARMS
AND LEGS.
* NEVER MOW WHEN
CHILDREN ARE NEAR.
- NEVER CARRY RIDERS;
THEY FALLOFF. — em.
UNDER CHOKE ON RIGHT SIDE
ON HOODSTAND OF TRANSAXLE
(Part No. 112168) (Part No. 88-2790)
2 у (A DANGER |
DOWN ROTATING PARTS WILL
= CUTFINGERS. ¢
LIFT KEEP HANDS AWAY. 3
UP
NS
UNDER SEAT INSIDE HOODSTAND
(Part No. 116446) NEXT TO BATTERY
(Part No. 111926)
HAND PUSH ONLY DO NOT OPERATE WITH
DO NOT TOW: BATTERY DISCONNECTED.
TRANSMISSION DAMAGE DAMAGE TO ELECTRICAL
MAY RESULT SYSTEM WILL RESULT.
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.
UNDER THROTTLE
ON HOODSTAND
(Part No. 78-9130)
ON RIGHT SIDE
OF FRAME PLATE
(Part No. 78-7300)
COLD
N START
CLUTCH
PULL TO | PULL
CHOKE UP TO
be DECLUTCH
ON LEFT SIDE OF UNDER THROTTLE
FRAME PLATE ON HOODSTAND
(Part No. 116445) (Part No. 111960)
7 7 Mn >
PARKING 7
| o ENGAGE ENGAGE
« DEPRESS PEDAL PTO
HOLD LEVER UP CLUTCH
» RELEASE PEDAL DISENGACE
TO DISENGAGE :
+ DEPRESS PEDAL e»
UNDER STEERING WHEEL
ON HOODSTAND
(Part No. 78-7190)
() SEAT SWITCH a ERATE |
- O
O PARKING BRAKE
O MOTION LEVER THROTTLE
() ProcLUTCH 0 AA A Q
() enaineon No / u
IDLE ЯВ
UNDER STEERING WHEEL
ON HOODSTAND
(Part No. 79-2470)
7
on ED OFF RUN
e e START
or D
LIGHTS IGNITION
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is
not available.
IMPORTANT: Never use methanol, gasoline
containing methanol, or gasohol containing
more than 10% ethanol because the fuel
system could be damaged. Do not mix oil with
gasoline.
E ONU
POTENTIAL HAZARD
e 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
e Use a funnel and fill the fuel tank outdoors,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
e 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.
e Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by a spark.
e 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.
Stabilizer/Conditioner
Add the correct amount of gas stabilizer/conditioner
to the gas. Using a stabilizer/conditioner in the
machine:
e Keeps gasoline fresh during storage
e (Cleans the engine while it runs _
e Eliminates gum-like buildup in the fuel system,
which causes hard starting
IMPORTANT: Never use fuel additives
containing methanol or ethanol. |
Filling the Fuel Tank
1. Shut the engine off and raise the seat.
2. Clean around the fuel tank cap and remove the
cap. Use a funne! and add unleaded regular
gasoline to the fuel tank, until the level 1s 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 tank
completely full.
3. Install the fuel tank cap securely. Wipe up any
gasoline that may have spilled.
4. Low fuel level is indicated on fuel gauge.
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 NO TAG.
Operation
Think Safety First
Please carefully read all the safety instructions on
pages 2-8. Knowing this information could help you,
your family, pets or bystanders avoid injury.
Controls
Become familiar with all the controls (Fig. 1) before
you start the engine and operate the machine.
8
3
m-2530
Figure 1
1. Ignition switch 8. Hydraulic lift lever
2. Brake pedal 9. Indicator lights
3. Parking brake lever 10. Test button
4. Ground speed selector 11. Light switch
5. Throttle lever 12. Voltmeter
6. Choke 13. Hour meter
7. Power take off (PTO)
Parking Brake
Always set the parking brake when you stop the
machine or leave it unattended.
While the ignition key is in the “RUN” position and
the Parking Brake is engaged, the light, in the
Indicator Module, will be lit.
Setting the Parking Brake
1. Push the brake pedal (Fig. 2) down and hold it in
the depressed position.
2. Move the parking brake lever (Fig. 2) back and
gradually take your foot off the brake pedal. The
brake pedal should stay in the depressed (locked)
position.
Releasing the Parking Brake
1. Push down on the brake pedal (Fig. 2). The
parking brake lever should release.
2. Gradually release the brake pedal.
m-2532
Figure 2
1. Brake pedal ‚ 2. Parking brake lever
Operation
Starting and Stopping
the Engine
Starting
1.
2.
Sit down on the seat.
Set the parking brake; refer to Setting the
Parking Brake, page 9.
Note: The engine will not start unless you set
the parking brake or fully depress the
brake pedal.
Move the PTO (power take off) to disengage
(Fig. 3).
Move the choke lever to “ON” (Fig. 3).
Note: An engine that has been running and is
warm may not require step 4.
Move throttle lever to “FAST” (Fig. 4).
Turn the ignition key clockwise and hold it in
the “START” position (Fig. 6). When the engine
starts, release the key.
IMPORTANT: If the engine does not start
after 30 seconds of continuous cranking, turn
the ignition key to “OFF” and let the starter
motor cool; refer to Troubleshooting, page 39.
After the engine starts, move the choke lever to
“OFF” (Fig. 4). 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.
10
+ 2
y
- 1
m-2533 m-2475
Figure 3 Figure 4
1. PTO—Disengaged 1. Choke-On
2. Choke—Off
O T 1
H
1—% E oFF 2
OPERATE Q RUN
IDLE Г 3
E START
IGNITION
m—2478 m-2477
Figure 5 Figure 6
1. Fast 1. Off
2. Slow 2. Run
3. Start
Stopping
1. Move the throttle lever to “SLOW?” (Fig. 5).
2. Turn the ignition key to “OFF” (Fig. 6).
Note: If the engine has been working hard or
1s 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.”
Operating the
Power Take Off (PTO)
The power take off (PTO) engages and disengages
power to the clutch.
While the ignition key is in “RUN” position and the
power take off (PTO) 1s engaged, the PTO light, in
the Indicator Module, will be “ON”. When this light
1s “ON” 1t 1s a reminder; the starter will not crank and
to turn off the PTO before getting off.
Engaging the Power Take Off (PTO)
1. Depress the clutch and brake pedals to stop the
machine.
2. Push the power take off (PTO) lever forward to
engage (Fig. 7).
m-2533
Figure 7
1. Engaged 2. Disengaged
Operation
Disengaging the Power Take Off (PTO)
1. Depress the clutch and brake pedals to stop the
machine.
2. Pull the power take off (PTO) lever back to
disengage (Fig. 7).
The Safety Interlock System
Understanding the Safety Interlock
System
The safety interlock system 1s designed to prevent the
engine from starting unless:
e You are sitting on the seat
e The brake pedal is depressed
e The power take off (PTO) is “OFF”
e The speed selector lever must be in “N” neutral.
The safety interlock system is designed to stop the
engine if you rise from the seat when the brake pedal
is released or the power take off (PTO) is engaged
and the traction control is not in neutral.
Testing the Safety Interlock System
Test the safety interlock system before you use the
machine each time. If the safety system does not
operate as described below, have an Authorized
Service Dealer repair the safety system immediately.
1. Set the parking brake. Move the power take off
(PTO) to engaged. Now turn the ignition key to
“START”; the engine should not crank.
2. Move the power take off (PTO) to disengaged
and release the parking brake. Now turn the
ignition key to “START”; the engine should not
crank. |
3. Set the parking brake and move the power take
off (PTO) to disengaged Now start the engine.
While the engine is running, release the parking
brake and rise slightly from the seat; the engine
should stop.
11
Operation
Indicator Lights
The indicator lights (Fig. 8) illuminate when certain
controls are activated and when major malfunctions
occur that need immediate attention.
Following are the conditions when indicator lights
will be “ON”. At other times the lights should be off.
All lights come on when the key 1s turned “ON” for a
two second test. |
TEST
Figure 8
4. PTO (power take off)
5. Oil Pressure
6. Testbutton
1. Seat switch
2. Parking brake
3. Clutch pedal
Seat Switch
The seat switch light comes “ON” when the seat 1s
unoccupied with the ignition switch in the “RUN” or
“START” positions.
Parking Brake
The parking brake light will be “ON” when the key 1s
in the “RUN” position and the parking brake is
secured with the parking brake lever raised. When
this light is “ON” it is a reminder; do not drive
machine with parking brake on and set parking brake
before getting off machine.
12
Motion Lever
The motion lever light comes “ON”, when the the key
is in the “RUN” position and the lever is not in
neutral.
PTO (Power Take Off)
The PTO (power take off) light will be “ON” when
the key is in the “RUN” position 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.
Oil Pressure
The oil light “BLINKS” when the key is “ON” and
the engine is not running, after the engine starts 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.
Test Button
The indicator lights come “ON” and the oil light
“BLINKS” when the test button is pressed to confirm
proper operation. |
Instruments
The gauges show conditions that need to be
monitored during tractor operation. Read them to
check operation immediately after starting the engine
and regularly during use.
m—2533
Figure 9
1. Hour meter 2. Voltmeter
Operation
Hour Meter
The hour meter records the number of hours the
engine has operated (Fig. 9). It is turned on when the
ignition switch is in the “RUN” position. Use these
times for scheduling regular maintenance.
Voltmeter
The voltmeter shows the electrical system battery
voltage (Fig. 9). When you turn the ignition key to
“RUN”, the gauge should read 12 volts or slightly
higher. After the engine starts, the gauge should read
between 12 and 15 volts. If the gauge reads less than
12 volts, the battery is discharging. If the gauge reads
15 volts for long periods of time, check the battery
water more often.
13
Operation
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. |
IMPORTANT: To avoid transmission
damage, always release the parking brake
before moving the traction control lever.
To go forward release the parking brake: refer to
Releasing the Parking Brake, page 9. Place your
hand on the traction control lever and slowly push on
the lever to move forward (Fig. 10).
To slow down, move the traction control toward
neutral.
To move backward push down and pull backward on
the traction control lever (Fig. 10).
The farther you move the traction control lever in
either direction, the faster the machine will move in
that direction.
For quick stops apply the brake. The traction control
lever will automatically return to neutral.
т-2533
Figure 10
2. Backward
1. Forward
14
Stopping the Machine
To stop the machine, move the traction control lever
to neutral, 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 9. Remember to remove the key from the
ignition switch.
Eee
POTENTIAL HAZARD
® Someone could move or attempt to operate
the tractor while it is unattended.
WHAT CAN HAPPEN
e Children or bystanders may be injured if
they use the tractor.
HOW TO AVOID THE HAZARD
e Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even if just for a few minutes.
Attachment Lift Lever
The attachment lift lever (Fig. 11) is used to raise and
lower various attachments.
Raising Attachments
1. Depress the clutch and brake pedals to stop the
machine.
2. Pull attachment lift lever rearward, to raise
attachments.
Lowering Attachments
1. Depress the clutch and brake pedals to stop the
machine.
2. Push lift lever forward to lower attachments.
\/
т-2532
Figure 11
1. Up 2. Down
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. To adjust move the lever sideways to unlock seat
(Fig. 12).
2. Slide the seat to the desired position and release
lever to lock in position.
m-2349
Figure 12
1. Adjustmentknob
15
Operation
Lights
The lights are turned on with a switch in the control
panel (Fig. 13). The lights are on while the ignition
switch 1s in the “Run” 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
ose
D m-2516
Figure 13
Light switch
16
Installing PTO Belt
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. Remove the belt cover.
3. Remove hairpin cotter and trunnion from power
take off PTO engagement plate (Fig. 14).
4. Unlatch and remove clevis pin that secures yoke
assembly to clutch shaft and pivot forward to
remove from engagement plate (Fig. 14).
5. Install belt from between clutch yoke and
engagement plate (Fig. 14).
Note: Install belt in inside pulley groove for
mowers and outside pulley groove for
tiller and snowthrower.
6. Assemble yoke and engagement plate and attach |
clevis pin, trunnion and hairpin cotter to secure
(Fig. 14).
3
1
7
6
1 m-2483
Figure 14
1. Hairpin cotter 5. Yoke
2. Trunnion 6. Clutch shaft
3. Engagement plate 7. Belt groove
4. Clevis pin
7. Install the belt cover.
Maintenance
Service Interval Chart
Service Operation
Each
Use
Hours
25
Hours
50
Hours
100
Hours
Storage
Service
Spring
Service
Oil—check level
Oil—change*
Initial
Oil Filter—change* (100 hours, every
other oil change or yearly)
Safety System—check
Brake—check
Foam Air Cieaner—service*
Paper Air Cleaner—replace*
Spark Plug(s)—check 200 hours
Chassis—grease*
Belts—check for wear/cracks
Gasoline—drain
Engine—clean outside
Chipped Surfaces—paint
Battery—check electrolyte
Battery—charge, disconnect cables
Fuel Filter—replace
PTO Brake-adjust
Tires—check pressure
Front Wheels—check toe-in
Transaxle Fluid—check level
> | >| >| >| >| >| >< | >| >| >< | XXX]
* More often in dusty, dirty conditions
17
Maintenance
18
ÁN CAUTION
POTENTIAL HAZARD
e If you leave the key in the ignition switch, someone could start the engine.
WHAT CAN HAPPEN
e 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).
Maintenance
Air Cleaner 4.
Service Interval/Specification 5
Foam Element: Clean and re-oil after every 25
operating hours, or yearly, whichever occurs first.
Paper Element: Replace after every 100 operating
hours or yearly, whichever occurs first. 1.
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 power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
2. Open the hood.
3. Clean around the air cleaner to prevent dirt from
getting into the engine and causing damage.
Remove the knob and air cleaner cover (Fig. 15).
Unscrew the nut and remove the cover, foam
element and paper element (Fig. 15).
Carefully slide the foam element off the paper
element (Fig. 15).
Cleaning the Foam and Paper Elements
Foam Element
A. Wash the foam element in liquid soap and
warm water. When the element 1s 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. 16). Squeeze the element to distribute
the oil.
IMPORTANT: Replace the foam element if it
is torn or worn.
1213
Figure 16
Foam element | 2. Oil
Figure 15
1. Knob 5. Foam element
2. Air cleaner cover 6. Paper element
3. Wing nut 7. Air cleaner base
4. Cover
19
Maintenance
2. Paper Element
A. Lightly tap the element on a flat surface to
remove dust and dirt (Fig. 17).
B. Inspect the element for tears, an oily film,
and damage to the rubber seal.
IMPORTANT: Never clean the paper element
with pressurized air or liquids, such as
solvent, gas, or kerosene. Replace the paper
element if it is damaged, defective, or cannot
be cleaned thoroughly.
р Zn
DD —
A \)
a: 7
1213
Figure 17
1. Paperelement 2. Rubber seal
20
Installing the Foam and Paper Elements
IMPORTANT: To prevent engine damage,
always operate the engine with the complete
foam and paper air cleaner assembly
installed. |
Carefully slide the foam element onto the paper
air cleaner element (Fig. 15).
Place the air cleaner assembly into air cleaner
base. Slide cover onto rod and secure with nut
(Fig. 15).
Install the air cleaner cover and secure with wing
nut (Fig. 15).
Close the hood.
Engine Oil
Service Interval/Specification
Change oil:
e After the first 25 operating hours.
e After every 50 operating hours.
Note: Change oil more frequently when
operating conditions are extremely
dusty or sandy.
O1l Type: Detergent oil (API service SF or SF/CC)
Crankcase Capacity: w/o filter, 2.5 quarts (2.4 1)
w/filter, 3.0 quarts (2.8 1)
Viscosity: See table below
USE THESE SAE VISCOSITY OILS
Maintenance
20 3240 60 80 100
-10 0 10 20 30
40
Checking Oil 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.
Open the hood.
Clean around the oil dipstick (Fig. 18) so dirt
cannot fall into the filler hole and damage the
engine.
Pull the oil dipstick out and wipe the metal end
clean (Fig. 18).
Push the oil dipstick fully into the filler tube
(Fig. 18). 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.
IMPORTANT: Do not overfill the crankcase
with oil because the engine may be damaged.
m-2451 m-2467
Figure 18
1. Oil dipstick 3. Filler tube
2. Metal end
21
Maintenance
Changing/Draining Oil
1. Start the engine and let 1t run five minutes. This
warms the oil so it drains better.
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.
3. Open the hood.
4. Place a pan below the oil drain. Open the drain
by removing the cap (Fig. 19).
5. When oil has drained completely, close the drain
by pushing in and turning clockwise, 1/8 turn.
Note: Dispose of the used oil at a certified
recycling center.
m-2448
Figure 19
1. Oil drain cap 2. Oil filter
6. Slowly pour approximately 80% of the specified
amount of oil into the filler tube (Fig. 18). Now
check the oil level; refer to Checking Oil Level,
page 21. Slowly add additional oil to bring to
“FULL” mark on dipstick.
22
Change Oil Filter
Service Interval/Specification
Replace the oil filter every 100 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 22.
2. Remove the old filter and wipe the filter adapter
(Fig. 20) gasket surface.
3. Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 20).
3
2
1256
Figure 20
1. Oil filter 3. Adapter
2. Gasket
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. 20).
5. Fill the crankcase with the proper type of new
oil; refer to Changing/Draining Oil, page 22.
Spark Plug
Service Interval/Specification
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 RS17YX (or equivalent)
Air Gap: 0.025” (.635 mm)
Removing the Spark Plug(s)
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. Pull the wire(s) off the spark plug(s) (Fig. 21).
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.
m-2442
Figure 21
1. Spark plug wire 2. Spark plug
Maintenance
Checking the Spark Plug
1.
1.
Center electrode insulator
Look at the center of the spark plug(s) (Fig. 22).
If you see light brown or gray on the insulator,
the engine is operating properly. A black coating
on the insulator usually means the air cleaner is
dirty.
IMPORTANT: Never clean the spark plug(s).
Always replace the spark plug(s) when it has:
a black coating, worn electrodes, an oily film,
or cracks.
Check the gap between the center and side
electrodes (Fig. 22). Bend the side electrode
(Fig. 22) if the gap is not correct.
E C3
| 0.025”
(.635 mm)
Figure 22
3. Air gap (not to scale)
2. Side electrode
Installing the Spark Plug(s)
1.
Install the spark plug(s) and metal washer. Make
sure the air gap is set correctly.
Tighten the spark plug(s) to 20 ft-1b (27 Nm).
Push the wire(s) onto the spark plug(s) (Fig. 21).
Close the hood.
23
Maintenance
En g ine Breather 4. Open breather clamp and remove screen and
baffle (Fig. ).
Service Interval/Specification 5. Clean screen and baffle in an approved solvent
Clean the engine breather after every 50 operating and dry in a paper towel.
hours or yearly, whichever occurs first. 6. Install baffle and screen and secure breather with
1. Disengage the power take off (PTO), set the clamp (Fig. ).
parking brake, and turn the ignition key to 7. Install air filter base and assemble air filter
“OFF” to stop the engine. Remove the key. (Fig. 23).
2. Remove the air filter; refer to Remove the Foam
and Paper elements page 19.
3. Remove the air filter base mounting bolts and
screws. Slide base off breather tube (Fig. 23).
m-2456
Figure 24
1. Clamp 2. Baffle
Figure 23
1. Air filter base 3. Screw
2. Bolt and washer 4, Breather tube
24
Greasing and Lubrication
Service Interval/Specification
Grease the machine after every 50 operating hours or
yearly, whichever occurs first. Grease more frequently
when operating conditions are extremely dusty or
sandy.
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.
Clean the grease fittings with a rag. Make sure to
scrape any paint off the front of the fitting(s).
Connect a grease gun to the fitting. Pump grease
into the fittings until grease begins to ooze out of
the bearings.
Wipe up any excess grease.
Where to Add Grease
1.
Lubricate the front wheels, spindles and tie-rod
ends until grease begins to ooze out of the
bearings (Fig. 25).
Lubricate the front axle pivot (Fig. 25).
DT
=
Figure 25
Maintenance
Lubricate the brake pedal where it pivots on
mounting shaft, steering shaft and spread grease
on steering sector teeth (Fig. 26).
m—2448
Figure 26
25
‘Maintenance
Tire Pressure
Service Interval/Specification
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.
Pressure: 12 psi (.85 kPa) front and rear
Ly
ANTES
(Ne
Vy
7
Ne,
M-—2488
Figure 27
1. Valve stem
26
Brake
Always set the parking brake when you stop the
machine or leave it unattended. If the parking brake
does not hold securely, an adjustment is required.
Checking the Brake
1.
Park the machine on a level surface, disengage
the power take off (PTO), set the parking brake,
and turn the ignition key to “OFF” to stop the
engine. Remove the key.
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 27.
Release the parking brake and move the the gear
shift lever to neutral. Wheels should rotate freely
without brake drag.
If both conditions are met no adjustment is
required.
Adjusting the Brake
The brake adjustment is behind the left side cover
(Fig. 28). If the parking brake does not hold securely,
an adjustment is required.
1.
1.
Check the brake before you adjust it; refer to
Checking the Brake, page 26.
Set parking brake so latch is in second notch. To
do this lift up on parking brake lever and slowly
depress brake pedal and feel when latch is in
second notch.
To adjust the brake tighten adjustment nut until
large spring 1s fully compressed, then back off
1/2 tum (Fig. 28).
Check the brake operation again; refer to
Checking the Brake, page 26.
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.
m-2484
Figure 28
Parking brake lever 3. Adjustment nut
2. Large spring
Maintenance
PTO (Power Take Off) Brake
Service Interval/Specification
Check adjustment of PTO brake after every 100
operating hours or yearly, whichever occurs first.
Adjusting PTO Brake
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. Engage PTO clutch.
3. Loosen (2) adjustment nuts (Fig. 29).
4. Place a 0.012 (0.3 mm) feeler gauge between
brake pad and clutch pulley (Fig. 29).
5. Holding brake pad against feeler gauge tighten
adjusting nuts. (Fig. 29). |
m-2480
Figure 29
1. Brake pad 3. 0.012 (0.3mm) feeler
2. Pulley gauge
4. Adjustment nut
27
Maintenance
Front Wheel Toe-In
Service Interval/Specification
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. 30).
Specification: 1/8—1/4 inch toe-in on front wheels.
Measuring Toe-in
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. 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. 30).
4. The front measurement should be less than the
rear, as specified.
1261
Figure 30
1. Measure here 3. Jamnut
2. Ball joint flats 4. Steering lever
28
Adjusting Toe-In
1.
Check the toe-in before you adjust it; refer to
Measuring Toe-In, Page 28.
Remove ball joint from one steering lever
(Fig. 30).
Loosen jam nut securing ball joint to steering
rod. Rotate ball joint one turn, clockwise to
increase or counter clockwise to decrease toe-in.
Hold flats on ball joint to align with flats on tie
rod and tighten jam nut (Fig. 30).
Install ball joint to steering lever and check the
toe-in; refer to Measuring Toe-In, Page 28.
IMPORTANT: If more than one turn is
required to meet specifications, alternate
between left and right steering rods to
maintain steering wheel alignment.
Maintenance
Fuel Tank 4. Pull the fuel line off fuel shut-off valve (Fig. 32).
Open fuel shut-off valve and allow gasoline to
Draining The Fuel Tank | drain into a gas can or drain pan.
| Note: Now is the best time to install a new
A DANGER | fuel filter because the fuel tank is
empty.
POTENTIAL HAZARD
5. Install the fuel line onto the fuel shut-off valve.
Slide the hose clamp close to the fuel shut-off
valve to secure the fuel line (Fig. 32).
® In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
* A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AVOID THE HAZARD
¢ Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open
area. Wipe up any gasoline that spills.
e Never drain gasoline near an open flame or |
Where gasoline fumes may be ignited by a Ph
spark.
e Never smoke a cigarette, cigar or pipe. 1
Figure 32
3
m—2487
1. 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.
1. Hose clamp 3. Fuel shut-off valve
2. Fuel line
2. Close fuel shut-off valve at fuel tank (Fig. 31).
m-2383
Figure 31
1. Fuel shut-off valve
3. Loosen the hose clamp and slide it up the fuel
line away from the fuel shut-off valve (Fig. 32).
29
Maintenance
Fuel Filter Transaxle Fluid
Service Interval/Specification | Service Interval/Specification
Replace the fuel filter after every 100 operating hours Check fluid level before every use. Always keep the
or yearly, whichever occurs first. fluid level at the full level when the transaxle 1s cold.
Fluid Type: SAE 10W-30 Detergent oil (API service
Replacing the Fuel Filter SF or SG) |
Never install a dirty filter if it is removed from the
fuel line. Checking Fluid Level
1. Disengage the power take off (PTO), set the 1. Park the machine on a level surface, disengage
parking brake, and turn the ignition key to the power take off (PTO), set the parking brake,
“OFF” to stop the engine. Remove the key. and turn the ignition key to “OFF” to stop the
engine. Remove the key.
2. Close fuel shut-off valve at fuel tank (Fig. 31).
2. Tilt the seat up.
3. Open the hood.
3. Clean around the transmission dipstick (Fig. 34)
4. Squeeze the ends of the hose clamps together so dirt cannot fall into the filler hole and damage
and slide them away from the filter (Fig. 33). the transaxle.
5. Remove the filter from the fuel lines.
lA ©
Ne
— O m-2449
Figure 34
1. Transmission dipstick
Figure 33
—
. Hose clamp 3. Filter
Fuel line
№
6. Install a new filter and move the hose clamps
close to the filter.
7. Open fuel shut-off valve at fuel tank (Fig. 31).
8. Close the hood.
30
Pull out the dipstick and wipe the metal end
clean (Fig. 34).
Slide the dipstick fully into the filler tube
(Fig. 18). Pull the dipstick out and look at the
metal end. When transaxle 1s cold oil should be
at the “Full” line on the dipstick (Fig. 34).
If oil level is low, slowly pour only enough oil
into the filler tube to raise the level to the
“FULL” mark.
IMPORTANT: Do not fill above the “Full”
line as fluid may overflow.
m-2467
Figure 35
. Full cold level
Maintenance
Changing/Draining Transaxle Fluid
Service Interval/Specification
Replace the transaxle fluid every 200 hours or once
per year.
Fluid Type: SAE 10W-30 Detergent oil (API service
SF or SG)
1.
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.
2. Place a pan below the transaxle drain. Open the
drain by removing the plug (Fig. 36).
3. When oil has drained completely, install the
plug.
Note: Dispose of the used oil at a certified
recycling center.
2
D
Lr 4
e
>
m-2464
Figure 36
1. Transaxle drain plug 2. Transaxle filter
4. Slowly pour approximately 80% of the specified
amount of oil into the filler tube (Fig. 34). Now
check the fluid level; refer to Checking
Transaxle Fluid Level, page 30. Slowly add
additional oil to bring to “FULL” mark on
dipstick.
31
Maintenance
Change Transaxle Filter
Service Interval/Specification
Replace the transaxle filter after the first 5 hours and
every 200 hours or once per year thereafter.
1. Drain the oil from the transaxle; refer to
Changing/Draining Transaxle Fluid, page 31.
2. Remove the transaxle filter and wipe the filter
adapter (Fig. 37) gasket surface.
3. Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 37).
3
2
1256
Figure 37
1. Transaxle filter 3. Adapter
N
Gasket
4. Install the replacement transaxle filter to the
filter adapter. Turn the filter clockwise until the
rubber gasket contacts the filter adapter, then
tighten the filter an additional 1/2 turn (Fig. 37).
5. Fill the transaxle with the proper type of new oil;
refer to Changing/Draining Transaxle Fluid,
page 31.
32
Headlights
Removing the Bulb
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. Pull wire connectors off light
terminals.
3. Remove screw securing retainer bracket
(Fig. 38).
4. Lift and twist bulb out of pocket (Fig. 38).
т-2485
Figure 38
1. Bulb 4, Screw
2. Retainer bracket 5. Terminals
3. Tabs
Installing the Bulb
1. Locate index boss horizontal and twist bulb
under tabs on left side of pocket (Fig. 38).
2. Hold bulb in socket with retainer bracket and
secure with screw (Fig. 38).
3. Push wire connectors onto bulb terminals
(Fig. 38).
Taillights
Removing the Bulb
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. Inserting a screwdriver into slot and twist to
- remove lens (Fig. 39).
3. Pull bulb out of socket
y
m-2486
Figure 39
1. Lens 3. Bulb
2. Slot 4. Socket
Maintenance
Installing the Bulb
1. Align the bulb base with socket and push into
position (Fig. 39).
2. Align and snap the lens onto the base (Fig. 39).
33
Maintenance
Battery
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.
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. Disconnect the negative (black) ground cable
from the battery post (Fig. 40).
4. Lift the rubber cover up on the positive (red)
cable. Disconnect the positive (red) cable from
the battery post (Fig. 40).
S. Remove the battery hold down rods (Fig. 40).
Lift battery from tractor
34
m-2474
Figure 40
1. Negative cable (black) 6. Rubber cover
2. Nut 7. Positive cable (red)
3. Lock washer 8. Battery clamp
4. Flat washer 9. Hold down rod
5. Bolt 10. Wing nut
Installing the Battery
6. Install the battery into the chassis (Fig. 40).
7. Secure battery in chassis with hold down rods,
washers and wing nuts (Fig. 40).
8. Using the bolt washers and nut, connect the
positive (red) cable to the positive (+) battery
post (Fig. 40). Slide the rubber cover over the
battery post.
9. Using the bolt, washer and nut, connect the
negative (black) cable to the negative (-) battery
post (Fig. 40).
Checking Electrolyte Level
1. With the engine off, open the hood to see the
battery.
2. Open covers to see into the cells. The electrolyte
must be up to the lower part of the tube
(Fig. 41). Do not allow the electrolyte to get
below the plates. (Fig. 41).
3. If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery, page 35.
1262
Figure 41
1. Filler caps 3. Plates
2. Lower part of tube
Maintenance
Adding Water to the Battery
The best time to add distilled water to the battery is
just before you operate the machine. This lets the
water mix thoroughly with the electrolyte solution.
1. Clean the top of the battery with a paper towel.
2. Lift off the filler caps (Fig. 41).
3. Slowly pour distilled water into each battery cell
until the level is up to the lower part of the tube
(Fig. 41).
IMPORTANT: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
4. Press the filler caps onto the battery.
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 34.
2. Check the electrolyte level; refer to Checking
Electrolyte Level, page 35, 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.
A WARNING
POTENTIAL HAZARD
e Charging the battery produces gasses.
WHAT CAN HAPPEN
e Battery gasses can explode.
HOW TO AVOID THE HAZARD
e Keep cigarettes, sparks and flames away
from battery.
4. Install the battery in the chassis; refer to
Installing the Battery, page 34.
35
Maintenance
Fuse
Service Interval/Specification
The electrical system is protected by fuses. It requires
no maintenance, however, if a fuse blows check
component/circuit for malfunction or short. To
replace fuses pull up on the fuse (Fig. 42) to remove
or replace it.
Fuse: Charging circuit F3-30 amp, blade-type
Main F4—25 amp, blade-type
Lights F2-15 amp, blade-type
m-2531
Figure 42
1. Charging circuit-30 amp 3. Lights-15 amp
2. Main-25 amp
36
Wiring Diagram
Maintenance
TAN
POSITION CIRCUIT REGULATOR 13
OFF G+M D
Oit LEVEL
RUN B+L MAG
START B+L+S ° ENGINE
Zl w
el E STARTER |
HOUR METER VOLT METER >
<
--
PINK < | START
+
| BLACK u SOLENOID
> | a
= 5 ΠLU +4)
< & ed ed o -
© | vie) 18 & | BATTERY
т ORANGE x [x 3
ouf | ® BLACK
— PARK BRAKE
acc} ke (NOT ENGAGED)
PLY 25A
PARK | YEL ef | a
BRAKE | OIL LEVEL ul
GND|_ — LT BLUE RELAY
NEUTRAL
I BROWN | BLACK
SEAT
TEST GRAY RED
L_ BLACK
POT FC We
AT TEST SWITCH | LM =
INDICATOR =
LIGHT TAN S G | GROUND
MODULE BLACK | SEAT SWITCH
KEY SWITCH (NO OPERATOR)
PINK
LT BLUE J —
wl] 15A L
< w
| PURPLE a 9
«С
o SEAT RELAY
NEUTRAL SWITCH anor WHITE
(OUT OF GEAR)
LT GREEN LT GREEN
DK BLUE
LT GREEN
+ = PTO SWITCHES
HEADLIGHTS | _. TAIL LIGHTS (PTO OFF)
5
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37
Maintenance
1.
38
Cleaning and Storage
Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
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.
Check the brake; refer to Brake, page 26.
Service the air cleaner; refer to Air Cleaner,
page 19.
Grease the chassis; refer to Greasing and
Lubrication, page 25.
Change the crankcase oil; refer to Engine Oil,
page 21.
Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 23. 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 34. 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
10.
11.
12.
13.
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.
Check the tire pressure; refer to Tire Pressure,
— page 26.
During long-term storage, either drain gasoline
from the fuel tank (step A) or add a fuel
stabilizer/conditioner additive to a full tank of
gasoline (step B).
A. Drain gasoline from the fuel tank; refer to
Fuel Tank, page 29. After fuel is drained,
start the engine and let it idle until all
gasoline 1s consumed and the engine stops.
This eliminates gum-like buildup in the fuel
system, which causes hard starting. Try to
start the engine two more times to assure
that no gasoline 15 1n the fuel system.
В. Add the correct amount of a fuel
stabilizer/conditioner to a full tank of
gasoline.
Note: Stabilizer/conditioners normally
preserve gasoline for six to eight
months.
Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged or
defective.
Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service
Dealer.
Store the machine in a clean, dry garage or
storage area. Remove the key from the ignition
switch and keep it in a memorable place. Cover
the machine to protect it and keep it clean.
Troubleshooting
Parking brake is not on.
Operator is not seated.
Speed selector not in “N”
neutral.
Battery is dead.
Electrical connections are
corroded or loose.
Fuse is blown.
Relay or switch is defective.
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
Starter does not crank Blade control (PTO) is Move blade control (PTO) to
ENGAGED. DISENGAGED.
Set parking brake.
Sit on the seat.
Move speed selector to “N”
neutral.
Charge the battery.
Check electrical connections
for good contact.
Replace fuse.
Contact Authorized Service
Dealer.
Engine will not start, starts hard, or
fails to keep running.
Fuel tank is empty.
Choke is not ON,
Air cleaner is dirty.
Spark plug wire is loose or
disconnected.
Spark plug is pitted, fouled, or
gap is incorrect.
Dirt in fuel filter.
Dirt, water, or stale fuel is in
fuel system.
Fill fuel tank with gasoline.
Move choke lever to ON.
Clean or replace air cleaner
element.
Install wire on spark plug.
Install new, correctly gapped
spark plug.
Replace fuel filter.
Contact Authorized Service
Dealer.
Engine loses power.
Engine load is excessive.
Air cleaner is dirty.
Qil level in crankcase is low.
. - Cooling fins and air passages
under engine biower housing
are plugged.
Spark plug is pitted, fouled, or
gap is incorrect.
Vent hole in fuel cap is
plugged.
Dirt in fuel filter.
Dirt, water, or stale fuel is in
fuel system.
Shift into lower gear to reduce
ground speed.
Clean air cleaner element.
Add oil to crankcase.
Remove obstruction from
cooling fins and air passages.
Install new, correctly gapped
spark plug.
Clean or replace the fuel cap.
Replace fuel filter.
Contact Authorized Service
Dealer.
39
Troubleshooting
PROBLEM
POSSIBLE CAUSES
CORRECTIVE ACTION
Engine overheats.
Engine load is excessive.
Qil level in crankcase is low.
Cooling fins and air passages
under engine blower housing
are plugged.
Shift into lower gear to reduce
ground speed.
Add oil to crankcase.
Remove obstruction from
cooling fins and air passages.
Abnormal vibration.
Engine mounting bolts are
loose.
Loose engine pulley, idler
pulley, or blade pulley.
Engine pulley is damaged.
Tighten engine mounting
bolts.
Tighten the appropriate
pulley.
Contact Authorized Service
Dealer.
Machine does not drive.
Traction belt is worn, loose or
broken.
Traction belt is off pulley.
Transmission does not shift.
Contact Authorized Service
Dealer.
Contact Authorized Service
Dealer.
Contact Authorized Service
Dealer.
40
Gas Powered
Consumer
Products
Except WPM
THE TORO TOTAL COVERAGE
GUARANTEE
A Full Two—Year Warranty
(Limited Warranty for Commercial Use)
What Is Covered By This Express Warranty?
The Toro Company promises to repair any TORO Product
used for normal residential purposes* if defective in materials
or workmanship for a period of two years from the date of
purchase. The cost of parts and labor is included, but the
customer pays the transportation costs.
Transportation within a 15 mile radius of the servicing dealer
is covered under this warranty for two-stage snowthrowers,
walk behind debris equipment and all TORO Wheel Horse
riding products. Single stage snowthrowers, and other prod-
ucts not specifically covered, are excluded from the transpor-
tation coverage provided by this warranty.
What Products Are Covered By This Warranty?
This warranty applies to all gasoline powered consumer prod-
ucts except walk power mowers. ProLine riding products,
wide area walk behind mowers and 18” and 21” mowers are
covered by separate warranty statements.
How About Commercial Use?
TORO Consumer Products used for commercial, institutional
or rental use are covered by a limited warranty for the follow-
ing time periods from the date of purchase:
Products Warranty Period
® 300, 400 and 500 Series Lawn and Garden Tractors
Chassis ....... 1 year limited warranty
Engine ....... 2 year limited warranty
e 260 Series Lawn and Garden Tractors, XL. Lawn Tractors,
Rear Engine Riders, Straight Shaft Trimmers,
and Backpack Blowers ..... 90 day limited warranty
e AllOthers ................. 45 day limited warranty
How Do You Get Warranty Service?
Should you feel your TORO Product contains a defect in ma-
terial or workmanship, contact the dealer who sold you the
product or any Authorized TORO Service Dealer or TORO
Master Service Dealer. The Yellow Pages of your telephone
directory is a good reference source. The dealer will either
arrange service at his/her dealership or recommend another
Authorized Service Dealer who may be more convenient. You
may need proof of purchase (copy of registration card, sales
receipt, etc.) for warranty validation.
If for any reason you are dissatisfied with the Service Dealer's
analysis of the defect in materials or workmanship or if you
need a referral to a TORO Service Dealer, please feel free to
contact us at the following address:
Toro Customer Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
612-888-8801
800-348-2424
What Must You Do To Keep The Warranty In Effect?
You must maintain your TORO Product by following the main-
tenance procedures described in the operator's manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
What Does This Warranty Not Cover?
and |
How Does Your State Law Relate To This Warranty?
There is no other express warranty except the TORO Starting
Guarantee on GTS Engines. This express warranty does not
cover:
e Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune—up parts, blade sharpening, brake and
clutch adjustments.
e Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance.
e Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non—use over three months.
e Pickup and delivery charges for distances beyond a 15 mile
radius from an Authorized TORO Service Dealer (covered
products only).
All repairs covered by this warranty must be performed by an
Authorized TORO Service Dealer using Toro approved replace-
ment parts.
Repair by an Authorized TORO Service Dealer is your sole
remedy under this warranty.
The Toro Company is not liable for indirect, incidental or
consequential damages in connection with the use of the
TORO Products covered by this warranty, including any
cost or expense of providing substitute equipment or ser-
vice during reasonable periods of malfunction or non—use
pending completion of repairs under this warranty. Some
states do not allow exclusions of incidental or consequen-
tial damages, so the above exclusion may not apply to
you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
* Normal residential purposes means mowing the lawn on the
same lot as your home. Use at more than one location is
considered commercial use and the commercial use war-
ranty would apply.
COUNTRIES OTHER THAN THE UNITED STATES OR CANADA
Customers who have purchased TORO Products exported from the United States or Canada should contact their TORO Dis-
tributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with
your Distributor's service or have difficulty obtaining guarantee information, contact the TORO importer. If all other remedies
fail, you may contact us at The Toro Company.