Toro 30180 Operator's Manual

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Page 1

FORM NO. 3317–980GB

ProLine Mid-Size

16 HP

Traction Unit

Model No. 30180 – 590001 thru 690001 & 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.

Page 2

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.

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.

1. Model and Serial Number Plate

For your convenience, write the product model and serial numbers in the space below.

Model No:

Serial No.

2149

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.

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

The Toro Comany – 1995

Page 3

Contents

Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operation Practices for Ride-on (riding)

Rotary Lawnmower Machines 2. . . . . . . . .

Slope Chart 5. . . . . . . . . . . . . . . . . . . . . . . . .

Symbols Glossary 7. . . . . . . . . . . . . . . . . . .

Gasoline and Oil 10. . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 10. . . . . . . . . . . . . . .

Stabilizer/Conditioner 10. . . . . . . . . . . . . . . .

Filling the Fuel Tank 10. . . . . . . . . . . . . . . . .

Check Engine Oil Level 10. . . . . . . . . . . . . . .

Set-up 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 11. . . . . . . . . . . . . . . . . . . . . . . . .

Mount Control Panel and Fuel Tank 13. . . . .

Install Shift Lever 13. . . . . . . . . . . . . . . . . . . .

Install Upper Handle 14. . . . . . . . . . . . . . . . .

Connect Throttle Cable 14. . . . . . . . . . . . . . .

Connect Choke Cable 15. . . . . . . . . . . . . . . . .

Connect Wire Harness 15. . . . . . . . . . . . . . . .

Install Control Rods 16. . . . . . . . . . . . . . . . . .

Install the Battery 17. . . . . . . . . . . . . . . . . . . .

Activate the Battery 18. . . . . . . . . . . . . . . . . .

Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 20. . . . . . . . . . . . . . . . . . .

Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

Parking Brake 21. . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 22. . . . . . .

Operating Mower Blade Control (PTO) 23. .

The Safety Interlock System 23. . . . . . . . . . .

Driving Forward or Backward 24. . . . . . . . . .

Stopping the Machine 24. . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 25. . . . . . . . . . . . . . . .

Air Cleaner 26. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 27. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug 29. . . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 30. . . . . . . . . . . . . .

Tire Pressure 30. . . . . . . . . . . . . . . . . . . . . . . .

Brake 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 32. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 33. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Drive Belt 33. . . . . . . . . . . . . .

Cleaning the Cooling System 33. . . . . . . . . .

Replacing the Traction Belt 34. . . . . . . . . . . .

Adjusting the Electric Clutch 34. . . . . . . . . . .

Battery 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 36. . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 37. . . . . . . . . . . . . . . . .

Troubleshooting 38. . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

Safety

Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines

Training

1. Read the instructions carefully. Be familiar with

the controls and the proper use of the equipment.

2. Never allow children or people unfamiliar with

these instructions to use the lawnmower. Local regulations may restrict the age of the operator.

3. Never mow while people, especially children, or

pets are nearby.

4. Keep in mind that the operator or user is

responsible for accidents or hazards occurring to other people or their property.

5. Do not carry passengers.

6. All drivers should seek and obtain professional

and practical instruction. Such instruction should emphasize:

Preparation

1. While mowing, always wear substantial

footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

2. Thoroughly inspect the area where the

equipment is to be used and remove all objects which may be thrown by the machine.

3. WARNING – Petrol is highly flammable.

• Store fuel in containers specifically

designed for this purpose.

• Refuel outdoors only and do not smoke

while refuelling.

• Add fuel before starting the engine. Never

remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.

• If petrol is spilled, do not attempt to start

the engine but move the machine away from the area of spillage and avoid creating any source of ignition until petrol vapors have dissipated.

• the need for care and concentration when

working with ride-on machines;

• control of a ride-on machine sliding on a

slope will not be regained by the application of the brake. The main reasons for loss of control are:

insufficient wheel grip; being driven too fast; inadequate braking; the type of machine is unsuitable for its

task; lack of awareness of the effects of

ground conditions, especially slopes; incorrect hitching and load distribution.

• Replace all fuel tanks and container caps

securely.

4. Replace faulty silencers.

5. Before using, always visually inspect to see that

the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

6. On multi–bladed machines, take care as rotating

one blade can cause other blades to rotate.

Page 5

Safety

Operation

1. Do not operate the engine in a confined space

where dangerous carbon monoxide fumes can collect.

2. Mow only in daylight or in good artificial light.

3. Before attempting to start the engine, disengage

all blade attachment clutches and shift into neutral.

4. Do not use on slopes of more than:

• Never mow side hills over 5

• Never mow uphill over 10

• Never mow downhill over 15

Note: Slope angle is calculated as in

5.4.2.3.2.

5. Remember there is no such thing as a “safe”

slope. Travel on grass slopes requires particular care. To guard against overturning:

• do not stop or start suddenly when going up

or downhill;

• engage clutch slowly, always keep machine

in gear, especially when travelling downhill;

• machine speeds should be kept low on

slopes and during tight turns;

• stay alert for bumps and hollows and other

hidden hazards;

• never mow across the face of the slope,

unless the lawnmower is designed for this purpose.

6. Use care when pulling loads or using heavy

equipment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely control.

• Do not turn sharply. Use care when

reversing.

7. Watch out for traffic when crossing or near

roadways.

8. Stop the blades rotating before crossing surfaces

other than grass.

9. When using any attachments, never direct

discharge of material toward bystanders nor allow anyone near the machine while in operation.

10. Never operate the lawnmower with defective

guards, shields or without safety protective devices in place.

11. Do not change the engine governor settings or

overspeed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury.

12. Before leaving the operator’s position:

• disengage the power take-off and lower the

attachments;

• change into neutral and set the parking

brake;

• stop the engine and remove the key.

13. Disengage drive to attachments, stop the engine,

and disconnect the spark plug wire(s) or remove the ignition key

• before cleaning blockages or unclogging

chute;

• before checking, cleaning or working on the

lawnmower;

• after striking a foreign object. Inspect the

lawnmower for damage and make repairs before restarting and operating the equipment;

• if the machine starts to vibrate abnormally

(check immediately).

14. Disengage drive to attachments when

transporting or not in use.

• Use counterweight(s) or wheel weights

when suggested in the instruction handbook.

Page 6

Safety

15. Stop the engine and disengage drive to

attachment

• before refuelling;

• before removing the grass catcher;

• before making height adjustment unless

adjustment can be made from the operator’s position.

16. Reduce the throttle setting during engine run-out

and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

Maintenance and Storage

1. Keep all nuts, bolts and screws tight to be sure

the equipment is in safe working condition.

2. Never store the equipment with petrol in the tank

inside a building where fumes may reach an open flame or spark.

Sound Pressure

This unit has an equivalent continous A-weighted sound pressure at the operator ear of: 100 dB(A), based on measurements of identical machines per ANSI B71.5–1984 procedure.

Sound Power

This unit has a power level of: 100 dB(A)/1pW, based on measurements of identical machines per Directive 84/538/EEC and amendments.

Vibration Level

This unit has a maximum hand-arm vibration level of

6.44 m/s machines per ISO 5349 procedures.

, based on measurements of identical

3. Allow the engine to cool before storing in any

enclosure.

4. To reduce the fire hazard, keep the engine,

silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease.

5. Check the grass catcher frequently for wear or

deterioration.

6. Replace worn or damaged parts for safety.

7. If the fuel tank has to be drained, this should be

done outdoors.

8. On multi-bladed machines, take care as rotating

one blade can cause other blades to rotate.

9. When machine is to be parked, stored or left

unattended, lower the cutting means unless a positive mechanical lock is used.

Page 7

Slope Chart

Read all safety instructions on pages 2–9.

Safety

Page 8

Page 9

Symbols Glossary

Safety

Safety alert triangle– symbol within triangle indicates a hazard

Safety alert symbol

Read operator’s manual

Consult technical manual for proper service procedures

Shut off engine & remove key before preforming maintenance or repair work

Fire, open light & smoking prohibited

Fire or open flame

Explosion

Do not dispose of lead battery in garbage

Stay a safe distance from the machine

Caustic liquids, chemical burns to fingers or hand

Caution, toxic risk

Eye protection must be worn

First aid, flush with water

Stay safe distance from machine

Keep children away

from battery

Page 10

Safety

Symbols Glossary

Do not open or remove safety shields while engine is running

Thrown or flying objects,

whole body exposure

Thrown or flying objects,

whole body exposure

Keep guards and safety shields in place

Severing of toes & fingers, rotary mower blade

Machine rollover, riding mower

To operate machine on a slope, use with 16kg weight kit & operate with deck lowered

Stop engine before leaving operator position

Machine being transported

Blade cutting elementheight adjustment

(mm)

Severing of fingers or hand,

mower blade

Severing of toes or foot, mower blade

Cutting of fingers or hand

Cutting of foot

Hot surface, burns to fingers or hands

Blade engagement control operation

Discharge door lever operation

Fuel shut off control operation

Blade retaining bolts must be

Torqued to 115–149 N.m

Page 11

Symbols Glossary

Fast

Safety

Power take off (PTO)

Slow

Decreasing/Increasing

On/Run

Off/stop

Engine start

Engine stop

Engage

Disengage

Traction drive

Forward

Reverse

Choke

Brake system

Parking brake

Battery

Fuel

Neutral

First gear

Second gear

Third gear

Fourth gear

Page 12

Gasoline and Oil

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AVOID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.

Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and

stay away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container

and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

Stabilizer/Conditioner

Add the correct amount of gas stabilizer/conditioner to the gas.

• Keeps gasoline fresh during storage

• Cleans the engine while it runs

• Eliminates gum-like buildup in the fuel system,

which causes hard starting

IMPORTANT: Never use fuel additives containing methanol or ethanol.

Filling the Fuel Tank

1. Shut the engine off.

2. Clean around the fuel tank cap and remove the

cap. Use a funnel and add unleaded regular gasoline to the fuel tank, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.

3. Install the fuel tank cap securely. Wipe up any

gasoline that may have spilled.

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 28.

Page 13

Set-up

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

DESCRIPTION QTY. USE

Upper Handle Flanged bolt 3/8–16 x 1” (26 mm) Flange nut 3/8–16

R-clamp 1 Secure throttle and choke cables Shift lever

Shift lever mounting bracket Washer 1/4” Bolt 1/4–28 x 2” (51 mm)

Rod fitting Clevis pin Washer Hairpin cotter

Fuel tank Control panel Bolt 5/16–18 x 7/8” (22.5 mm) Lock washer 5/16” Washer 5/16”

1 4 4

1 1 1 1

2 2 2 2

1 1 4 4 4

Install upper handle to frame

Install shift lever to transmission

Install control rods

Install fuel tank and control panel

Hose clamp Lock nut 1/4–20

Cable tie Wire tie 1 Retain wire harness Lock nut 5/16–18

Lock nut 1/4–20

2 1

1 1

Install wire harness

Secure negative battery cable to engine bolt Secure positive battery cable to solenoid

Page 14

Set-Up

DESCRIPTION USEQTY.

Battery Battery holder Bolt 3/8–16 x 1-3/4” (44 mm) Lock nut 3/8–16 Battery strap Support rod Lock nut 1/4–20 Battery pad Carriage bolt 5/16–18 x 3/4” (19 mm) Lock nut 5/16–18 Red battery cable-positive Terminal boot-red Black battery cable-negative Terminal boot-black

Operator’s Manual Parts catalog Registration card

1 2 2 2 1 2 2 2 2 2 1 1 1 1

1 1 1

Install battery

Read before operating machine

Fill out and return to Toro

Page 15

Set-Up

Mount Control Panel and Fuel Tank

1. Position control panel under bottom of rear

frame (Fig. 1). Align fuel tank to top of rear frame (Fig. 1).

Figure 1

1. Rear frame

2. Control panel

3. Fuel tank

1716

Install Shift Lever

1. Align mounting block with flats of shaft on top

of transmission and slide onto shaft (Fig. 3). Note: DO NOT remove rubber washer on

transmission shaft.

2. Slide shift lever through control panel and align

mounting hole in lever with mounting block on transmission. Secure lever to transmission with 51 mm bolt and washer. Torque bolt to 115 in. lb. (155 N.m).

2. Secure control panel and fuel tank to rear frame

with (4) 7/8 in. (22.5 mm) bolts, lock washers and washers (Fig. 2).

3. Slide hose clamp onto fuel line (Fig. 2). Push

fuel line onto fuel tank fitting and secure with hose clamp (Fig. 2).

1. Bolt 5/8–18 x 7/8” (22.5 mm)

2. Lock washer

3. Washer

Figure 2

4. Fuel line

5. Hose clamp

6. Fuel fitting

1717

1. Mounting block

2. Shift lever

1718

Figure 3

3. Bolt 1/4–28 x 2” (51 mm)

4. Washer

Page 16

Set-Up

Install Upper Handle

1. Align upper handle mounting holes with desired

mounting holes in rear frame (upper or lower set of holes)

2. Secure each side with (2) 3/8 –16 x 1” (26mm)

flange bolts and flange nuts (Fig. 4). Torque bolts to 25 ft. lbs. (34 N.m).

3. Route cables and wire harness inside of frame

(Fig. 4)

1719

1. Upper handle

2. Rear frame

3. Flange bolt 3/8 x 16–1” (26mm)

Figure 4

4. Flange nut 3/8

5. Wires and cables

Connect Throttle Cable

1. Route throttle cable under fuel tank supports and

around right side of engine (Fig. 5).

2. Move remote throttle control lever forward until

there is approximately 1/8 in. (3.5 mm) between lever and front end of slot in control base.

2135

Figure 5

1. Throttle cable

2. Choke cable

3. Hook wire Z–bend into top hole of governor arm

(Fig. 6).

4. Loosen cable clamp screw allowing cable

installation, but do not tighten (Fig. 6).

3. Cable clamp

5. Pull throttle cable firmly until governor arm

contacts stop and tighten cable clamp screw to lock adjustment in place (Fig. 6).

Figure 6

1. Governor arm

2. Throttle cable

3. Cable clamp screw

2136

Page 17

Set-Up

Connect Choke Cable

1. Route choke cable around right side of engine

(Fig. 5).

2. Move remote choke control into full choke

position.

3. Hook cable Z-bend into hole in carburetor choke

lever (Fig. 7).

4. Loosen cable clamping screw allowing cable

installation, but do not tighten (Fig. 7).

5. Pull firmly on choke cable and tighten cable

clamp screw (Fig. 7).

6. Secure choke and throttle cables to right side of

engine with cable clamp and engine cover mounting bolt (Fig. 5).

3. Remove lock nut from left rear engine mounting

bolt. Secure negative, black, battery cable and ring terminal wire from clutch connector to left rear engine mounting bolt. Secure with lock nut removed (Fig. 8).

4. Secure remaining gray ring terminal wire from

wire harness and positive, red battery cable to rear terminal of starter solenoid with a 1/4–20 lock nut (Fig. 8).

5. Push yellow and black wire terminals onto spade

terminals on starter solenoid.

2137

Figure 7

1. Choke cable

2. Choke lever

3. Cable clamp screw

4. Connectors

Connect Wire Harness

1. Route harness around left side of engine and

plug into connector at front of engine (Fig. 7).

Figure 8

1. Clutch wire connector

2. Starter solenoid

3. Ring terminal wire

4. Negative battery cable

5. Engine mounting bolt

6. Gray wire

7. Positive battery cable

8. Black wire

9. Yellow wire

6. Secure wire harness to fuel line with cable tie

(Fig. 9).

2138

2139

2. At left side of engine, secure clutch connectors

(Fig. 8).

Figure 9

1. Cable ti e

Page 18

Set-Up

Install Control Rods

1. Thread a rod fitting onto each control rod

approximately 2 in. (51 mm) (Fig. 10) or until upper control bar (Fig. 11) is approximately perpendicular to the ground.

2. Mount rod fitting ends to mounting holes in idler

brackets (from outside) with clevis pins, washers and hairpin cotters (Fig. 10).

1. Control rod and fitting

2. 2 in. (51 mm)

3. Idler bracket

2073

Figure 10

4. Clevis pin, washer and hairpin cotter

6. If an adjustment to brake rods is required,

remove hairpin cotter and washer securing brake rod fitting to idler bracket (Fig. 12).

Figure 11

1. Control r o d

2. Inside control bar

3. Parking brake lever

7. Adjust wing nut up or down on brake rod and

resecure to idler bracket (Fig. 12). Check adjustment and readjust if necessary.

Note: Make sure brake rod is installed in

forward (“F”) mounting hole in idler bracket.

1720

3. Check gap between upper control bar and upper

handle when fully engaging wheel belts. Gap should be approximately 1 to 1-1/4 in. (25–32 mm) (Fig. 11).

Note: The control bar and upper handle must

be parallel when in relaxed drive and brake positions.

4. Check operation. If adjustment is required,

remove hairpin cotter and washer securing end of control rod to upper control bar, thread rod into or out of rod fitting to proper position and reinstall to upper control bar with washer and hairpin cotter.

5. Brake rods should be adjusted so parking brake

lever can be swung into a snug position against the inside control bar while pulling back on upper control bar (Fig. 11).

8. Repeat procedure on opposite side if adjustment

is required.

2073

Figure 12

1. Idler bracket

2. Brake rod fitting

3. Hairpin cotter and washer

4. Wing nut

Page 19

Install the Battery

1. Mount battery holders to left rear corner or

cutting unit carrier frame with (2) 3/8–16 x 1–3/4” bolts and lock nuts.

2. Peel off backing from battery pads and affix pads

to battery holder, positioning as shown (Fig. 13).

Set-Up

2145

Figure 13

1. Battery holder 2. Battery pad

IMPORTANT: Activate battery with electrolyte and charge before installing.

3. Position battery onto holder with terminal posts

toward engine (Fig. 14).

4. Slide the red terminal boot onto the red battery

cable and the black terminal boot onto the the black battery cable (Fig. 14).

5. Install the positive battery cable to positive (+)

battery terminal and the negative battery cable to the negative (–) battery terminal and secure with carriage bolts and lock nuts.

6. Mount battery to holders with (2) support rods,

battery clamp and (2) lock nuts. Position support rods in mounting holes as shown in (Fig. 14). Tighten lock nuts so battery is held securely in position and will not slide.

2146

1. Battery holder

2. Battery pad

3. Battery terminal boot

4. Negative battery cable

Figure 14

5. Positive battery cable

6. Battery support rod

7. Battery clamp

Note: DO NOT OVERTIGHTEN.

Page 20

Set-Up

Activate the Battery

Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet.

1. If already installed, remove the battery from the

holder.

POTENTIAL HAZARD

• Battery electrolyte contains sulfuric acid

which is a deadly poison and it causes severe burns.

WHAT CAN HAPPEN

• If you carelessly drink electrolyte you could

die or if it gets onto your skin you will be burned.

HOW TO AVOID THE HAZARD

• Do not drink electrolyte and avoid contact

with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

Figure 15

1. Filler caps

2. Electrolyte

3. Lower part of the tube

3. Leave the covers off and connect a 3 to 4 amp

battery charger to the battery posts (Fig. 16). Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts).

1262

2. Remove filler caps from the battery. Slowly pour

electrolyte into each cell until the electrolyte level is up to the lower part of the tube (Fig. 15).

1. Positive post

2. Negative post

1254

Figure 16

3. Charger red (+) wire

4. Charger black (–) wire

Page 21

POTENTIAL HAZARD

• Charging battery produces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AVOID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. When the battery is fully charged, disconnect the

charger from the electrical outlet then from the negative and positive battery posts (Fig. 16).

5. Slowly pour electrolyte into each cell until the

level is up to the lower part of the tube (Fig. 15) and install covers.

Set-Up

6. Install the battery into the holder.

Page 22

Operation

Think Safety First

Please carefully read all the safety instructions and symbols in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

Controls

Become familiar with all the controls (Fig. 17) before you start the engine and operate the machine.

Throttle Control – The throttle control has three positions: CHOKE, FAST and SLOW.

Blade Control Bail – Control bail used in conjunction with deck engagement switch (PTO) to release blade brake and engage clutch to drive mower blades. Release bail to disengage mower blades.

Blade Control Switch (PTO) – Rocker switch used in conjunction with control bail to release blade brake and engage clutch to drive mower blades.

Recoil Starter – Pull recoil Starter handle to start engine.

Fuel Shut–off Valve – (Under fuel tank) Close fuel shut–off valve when transporting or storing mower.

Gear Shift Lever – Transmission has four forward speeds, neutral and reverse, and has an in-line shift pattern. Do not shift while unit is moving, as transmission damage may occur.

Upper Control Bar – Shift to desired gear and push forward on control bar to engage forward traction operation and pull back to brake. Pull right side of control bar to turn right and left side to turn left.

Lower Control Bar – Shift transmission to reverse and pull rearward on lower control bar to engage rearward traction operation.

Parking Brake Lever – Pull back on upper control bar and swing brake lever up against the upper handle.

Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: RUN and OFF.

1. Throttle control

2. Blade control bail

3. Blade control switch (PTO)

4. Gear shift lever

2150

Figure 17

5. Upper control bar

6. Lower control bar

7. Parking brake lever

8. Ignition switch

Page 23

Parking Brake

Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

1. Pull the upper control bar (Fig. 18) rearward and

hold it in this position.

2. Lift the parking brake lock (Fig. 18) up and

gradually release the upper control bar. The brake lock should stay in the set (locked) position.

Releasing the Parking Brake

1. Pull rearward on the upper control bar (Fig. 18).

Lower the parking brake lock to the released position.

Operation

2. Gradually release the upper control bar.

Figure 18

1. Upper control bar 2. Parking brake lock

2130

Page 24

Operation

Starting and Stopping the Engine

Starting

1. Make sure spark plug wire(s) are installed on

spark plug(s) and fuel valve is open.

2. Move the shift lever to neutral, set the parking

brake and turn ignition key to RUN.

3. Move the throttle control to CHOKE position

before starting a cold engine. Note: A warm or hot engine usually does not

require any choking. To start a warm engine, move throttle control to FAST position.

4. Grasp recoil starter handle firmly and pull out

until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly.

IMPORTANT: Do not pull recoil rope to its limit or let go of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged.

2130

Figure 19

1. Throttle lever 2. Ignition key

3. Set the parking brake.

4. Pull wire off spark plug(s) to prevent possibility

of accidental starting before storing machine.

5. Close fuel shut off valve before storing machine.

IMPORTANT: Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur.

Stopping

1. Move the throttle lever to “SLOW” (Fig. 19). Note: If the engine has been working hard or

is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.”

2. Turn the ignition key to “OFF” (Fig. 19).

Page 25

Operation

Operating Mower Blade Control (PTO)

The blade control switch (PTO) in conjunction with the blade control bail engages and disengages power to the electric clutch and mower blades.

Engaging the Mower Blades (PTO)

1. Pull on the upper control bar to stop the machine

(Fig. 20).

2. To engage blade, squeeze blade control bail

against upper control bar

3. Press rocker switch forward “ON”. Hold blade

control bail against control bar while operating.

4. Repeat procedure to engage mower blades if

blade control bail is released.

The Safety Interlock System

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the mower blades from rotating unless:

• The control bail is depressed

• The blade control switch (PTO) is pressed “ON”

The safety interlock system is designed to stop the mower blades if you release the blade control bail.

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 and start the engine :refer

to Starting and Stopping the Engine, page 22

2130

Figure 20

1. Upper control bar

2. Blade control bail

3. Blade control switch (PTO)

Disengaging the Mower Blades (PTO)

1. Releasing blade control bail to disengage blades

(PTO) (Fig. 20).

2. Or push the blade control switch (PTO) to the

“OFF”position (Fig. 20).

2. Squeeze the blade control bail against upper

control bar. The blades should not rotate.

3. Then continue holding the blade control bail and

press the rocker switch forward. The clutch should engage and the mower blades begin rotating.

4. Release the blade control bail. The blades should

stop rotating.

5. Then push the blade control switch (PTO) to

“ON” without holding the blade control bail. The blades should not rotate.

Page 26

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.

Forward

1. To go forward, move the shift lever to a forward

gear.

2. Release the parking brake: refer to Releasing the

Parking Brake, page 21.

3. Slowly press on the upper control bar to move

forward (Fig. 21).

To go straight, apply equal pressure to both ends of the upper control bar (Fig. 21).

To turn, release pressure on the upper control bar side away from the direction you want to turn (Fig. 21).

Backward

1. To go backward, move the shift lever to reverse

gear.

2. Release the parking brake: refer to Releasing the

Parking Brake, page 21.

3. Slowly pull on the lower control bar to move

rearward (Fig. 21).

To go straight, apply equal pressure to both ends of the lower control bar (Fig. 21).

To turn, release pressure on the lower control bar side in the direction you want to turn (Fig. 21).

Stopping the Machine

To stop the machine, pull back on the upper control bar, release the blade control bail (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 21. Remember to remove the key from the ignition switch.

Figure 21

1. Upper control bar 2. Lower control bar

2130

POTENTIAL HAZARD

• Someone could move or attempt to operate

the machine while it is unattended.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the machine.

HOW TO AVOID THE HAZARD

• Always remove the ignition key and set the

parking brake when leaving the machine unattended, even if just for a few minutes.

Page 27

Maintenance

Service Interval Chart

Each

Service Operation

Oil—check level X X Oil—change* Initial X X Safety System—check X X Brake—check X X X Wheel Bearings—grease* X X Transmission Couplings—grease* X X Foam Air Cleaner—service* X X Paper Air Cleaner—replace* X X Spark Plug(s)—check X X X Belts—check for wear/cracks X X Gasoline—drain X Engine—clean outside X X X Fuel Filter—replace X X Battery–Check electrolyte level X X Tires—check pressure X X Chipped Surfaces—paint X

Use8Hours25Hours50Hours

100

Hours

250

Hours

Storage

Service

* More often in dusty, dirty conditions

POTENTIAL HAZARD

• If you leave the key in the ignition switch, someone could start the engine.

WHAT CAN HAPPEN

• Accidental starting of the engine could seriously injure you or other bystanders.

HOW TO AVOID THE HAZARD

• Remove the key from the ignition switch and pull the wire(s) off the spark plug(s)

before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

Page 28

Maintenance

Air Cleaner

Service Interval/Specification

Foam Element: Clean and re-oil after every 25 operating hours.

Paper Element: Replace after every 100 operating hours.

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. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unscrew the cover nut(s) and remove the air cleaner cover.

3. Remove the cover seal, element cover and air

cleaner assembly (Fig. 22).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and

warm water. When the element is clean, rinse it thoroughly.

B. Dry the element by squeezing it in a clean

cloth.

C. Put one or two ounces of oil on the element

(Fig. 23). Squeeze the element to distribute the oil.

IMPORTANT: Replace the foam element if it is torn or worn.

1213

Figure 23

1. Foam element 2. Oil

4. Carefully slide the foam element off the paper

element (Fig. 22).

2142

Figure 22

1. Foam element

2. Paper element

3. Cover seal

4. Element cover

Page 29

Maintenance

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 24).

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.

Engine Oil

Service Interval/Specification

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when

operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SF, SE/CC, CD or SE)

Crankcase Capacity: w/filter, 1.9 l (64 oz.) w/o filter

1.4 l (48 oz.).

Viscosity: See table below

USE THESE SAE VISCOSITY OILS

1213

Figure 24

1. Paper element 2. Rubber seal

Installing the Foam and Paper Elements

1. Installing the Foam and Paper Elements IMPORTANT: To prevent engine damage,

always operate the engine with the complete foam and paper air cleaner assembly installed.

1. Carefully slide the foam element onto the paper

air cleaner element (Fig. 22).

2. Place the air cleaner assembly onto the air cleaner base and install element cover and cover seal (Fig. 22).

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

3. Install the air cleaner cover and secure with wing nut(s).

Page 30

Maintenance

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.

2. Clean around the oil dipstick (Fig. 25) so dirt

cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end

clean (Fig. 25).

4. Slide the oil dipstick fully into the filler tube

(Fig. 25). 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.

Changing/Draining Oil

1. Start the engine and let it run five minutes. This

warms the oil so it drains better.

2. Park the machine so that the 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. Place a pan below the oil drain. Remove the oil

drain plug (Fig. 26).

4. When oil has drained completely, install the oil

drain plug. Note: Dispose of the used oil at a certified

recycling center.

2140

Figure 25

1. Oil dipstick 2. Metal end

2143

Figure 26

1. Oil drain plug

5. Slowly pour approximately 80% of the specified

amount of oil into the filler tube (Fig. 25). Now check the oil level; refer to Checking Oil Level, page 28. Slowly add additional oil to bring to “FULL” mark on dipstick.

Page 31

Maintenance

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. Install a new spark plug(s) if necessary.

Type: Champion RV 15YC (or equivalent) Air Gap: 0.635 mm (0.025 in.)

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. Pull the wire(s) off the spark plug(s) (Fig. 27). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 28).

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.

2. Check the gap between the center and side

electrodes (Fig. 28). Bend the side electrode (Fig. 28) if the gap is not correct.

0.635 m m (0.025 in.)

3. Remove the spark plug(s) and metal washer.

Figure 27

1. Spark plug wire 2. Spark plug

m-2442

Figure 28

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

1. Install the spark plug(s) and metal washer. Make

sure the air gap is set correctly.

2. Tighten the spark plug(s) to 17 N.m (12 ft. lb).

3. Push the wire(s) onto the spark plug(s) (Fig. 27).

Page 32

Maintenance

Greasing and Lubrication

Service Interval/Specification

Grease the wheel bearings every 8 operating hours and the transmission couplers every 250 operating hours. Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose grease.

2155

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.

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.

Where to Add Grease

1. Lubricate the wheel bearings and front spindles

until grease begins to ooze out of the bearings (Fig. 29).

Figure 30

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 50 operating hours or monthly, whichever occurs first (Fig. 31). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: .103 kPa (15 psi) front and rear

Figure 29

2. Lubricate the transmission couplers (Fig. 30).

Figure 31

1. Valve stem

2147

Page 33

Maintenance

Brake

Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.

Checking the Brake

1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Rear wheels must lock when you try to push the machine forward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 31.

3. Release the brake, wheels should rotate freely.

4. If both conditions are met no adjustment is

required.

Adjusting the Brake

The brake lever is on the upper control bar (Fig. 17). If the parking brake does not hold securely, an adjustment is required.

1. Check the brake before you adjust it; refer to

Checking the Brake, page 31.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 21.

3. Remove the belt cover (Fig. 32) (3) bolts.

4. To adjust the brake remove the cotter pin and

washer from the brake lever (Fig. 32).

5. Rotate the trunnion so it smoothly slides into

brake lever (Fig. 32). Tighten wing nut.

6. Secure trunnion to brake lever with washer and

cotter pin (Fig. 32). Replace the belt cover.

7. Check the brake operation again; refer to

Checking the Brake, page 31.

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.

Figure 32

1. Hairpin cotter and washer

2. Trunnion

3. Brake lever

4. Wing nut

2156

Page 34

Maintenance

Fuel Tank

Draining The Fuel Tank

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AVOID THE HAZARD

• Drain gasoline from the fuel tank when the

engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never drain gasoline near an open flame or

where gasoline fumes may be ignited by a spark.

• Never smoke a cigarette, cigar or pipe.

1717

Figure 33

1. Fuel shut-off valve 2. Clamp

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.

2. Close fuel shut–off valve at fuel tank (Fig. 33).

3. Squeeze the ends of the hose clamp together and

slide it up the fuel line away from valve (Fig. 33).

4. Pull the fuel line off the valve (Fig. 33). Open

fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new

fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 33.

5. Install the fuel line onto the valve. Slide the hose

clamp close to the valve to secure the fuel line.

Page 35

Maintenance

Fuel Filter

Service Interval/Specification

Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first.

Replacing the Fuel Filter

Never install a dirty filter if it is removed from the fuel line.

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 33).

3. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 34).

4. Remove the filter from the fuel lines.

Replacing the Drive Belt

1. Remove belt guard, not shown for clarity.

2. Remove top capscrew securing idler support and

idler bracket to rear frame (Fig. 35).

3. Loosen bottom two mounting screws enough to

allow belt to pass between drive pulley and idler support (Fig. 35).

4. Raise wheel off ground enough to allow belt

removal.

5. Install new belt, secure bolts and install belt

cover.

5. Install a new filter, if the filter has an arrow, install with arrow pointing toward the carburetor. Move the hose clamps close to the filter.

6. Open fuel shut-off valve at fuel tank (Fig. 33).

2139

1. Hose clamp

2. Fuel line

Figure 34

3. Filter

1722

Figure 35

1. Top capscrew

2. Idler bracket

3. Idler support

4. Bottom capscrew

Cleaning the Cooling System

Service Interval/Specification

Before each use, check and clean engine cooling system. Remove any build–up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor–governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.

Page 36

Maintenance

Replacing the Traction Belt

1. Raise the front of the machine and hold with

jack stands. Remove lower shield (4) bolts.

2. Disconnect in–line wire connector from wire

harness to electric clutch.

3. Remove left front engine mounting bolt securing

clutch retainer to frame (Fig. 36). Unhook retainer from clutch and remove retainer.

4. Unhook tension spring from side of frame

(Fig. 36).

5. Loosen pivot bolt enough to remove traction belt

from the drive pulley and clutch.

6. Install new belt around clutch and drive pulley.

7. Torque pivot bolt to 47-54 N.m (35-40 ft. lb.)

Install tension spring between idler arm and frame bracket (Fig. 36).

Adjusting the Electric Clutch

The clutch is adjustable to ensure proper engagement and proper braking

1. To adjust clutch, tighten or loosen adjusting nuts

(Fig. 36).

2. Check adjustment by inserting feeler gauge thru

slots next to studs.

3. The proper disengaged clearance between the

clutch plates is 0.30-0.45 mm (.012–.018 in.). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

8. Hook clutch retainer into clutch and secure to

frame with engine mounting bolt. Torque engine mounting bolt to 19-24 N.m (170-220 in. lb.)

9. Connect clutch in–line wire connector to wire

harness.

10. Install lower shield.

5. Tension spring

6. Adjusting nut

7. Pivot bolt

1. Lower shield

2. Traction belt

3. Idler pulley

4. Clutch retainer

Figure 36

2148

Page 37

Maintenance

Battery

Service Interval/Specification

Check the electrolyte level in the battery every 50 hours. 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

Checking Electrolyte Level

1. With the engine off, open the covers to see into the cells. The electrolyte must be up to the lower part of the tube (Fig. 37). Do not allow the electrolyte to get below the plates. (Fig. 37).

2. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 35.

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 37).

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 0°C (32°F).

1. Remove the battery from the holder.

2. Check the electrolyte level; refer to Checking

Electrolyte Level.

3. Remove the filler caps from the battery and

connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery is fully charged.

1. Filler caps

2. Lower part of tube

Figure 37

3. Plates

1262

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. 37).

POTENTIAL HAZARD

• Charging the battery produces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AVOID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. Install the battery into the holder.

Page 38

Maintenance

Wiring Diagram

c2323

Page 39

Maintenance

Cleaning and Storage

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing.

IMPORTANT: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, and engine.

3. Check the brake; refer to Brake, page 31.

4. Service the air cleaner; refer to Air Cleaner,

page 26.

5. Grease the machine; refer to Greasing and Lubrication, page 30.

IMPORTANT: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 0° C (32° F). A fully charged battery maintains its charge for about 50 days at temperatures lower than 4° C (40° F). If temperatures will be above 4° C (40° F), check the electrolyte level in the battery and charge every 30 days.

9. Check the tire pressure; refer to Tire Pressure,

page 30.

10. During long-term storage, either drain gasoline

from the fuel tank (step 11) or add a fuel stabilizer/conditioner additive to a full tank of gasoline (step A).

11. Drain gasoline from the fuel tank; refer to Fuel

Tank, page 32. After fuel is drained, start the engine and let it idle until all gasoline is 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 is in the fuel system.

6. Change the crankcase oil; refer to Engine Oil, page 27.

7. Remove the spark plug(s) and check its condition; refer to Spark Plug, page 29. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

8. Remove the battery from the chassis, check the electrolyte level, and charge fully; refer to Battery, page 35. Do not connect the battery cables to the battery posts during storage.

A. 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.

12. Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is damaged or defective.

13. Paint all scratched or bare metal surfaces. Paint

is available from your Authorized Service Dealer.

14. 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.

Page 40

Troubleshooting

g,,

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Starter does not rotate

Engine will not start, starts hard, or fails to keep running.

1. Blade control (PTO) is ENGAGED.

2. Electrical connections are corroded or loose.

3. Fuse is blown.

4. Battery is dead.

5. Relay or switch is defective. 5. Contact Authorized Service

1. Fuel tank is empty. 1. Fill fuel tank with gasoline.

2. Choke is not ON. 2. Move choke lever to ON.

3. Air cleaner is dirty. 3. Clean or replace air cleaner

4. Spark plug wire is loose or disconnected.

5. Spark plug is pitted, fouled, or gap is incorrect.

6. Dirt in fuel filter. 6. Replace fuel filter.

7. Dirt, water, or stale fuel is in fuel system.

1. Move blade control (PTO) to DISENGAGED.

2. Check electrical connections for good contact.

3. Replace fuse.

4. Charge battery.

Dealer.

element.

4. Install wire on spark plug.

5. Install new, correctly gapped spark plug.

7. Contact Authorized Service Dealer.

Engine loses power.

1. Engine load is excessive. 1. Reduce ground speed.

2. Air cleaner is dirty. 2. Clean air cleaner element.

3. Oil level in crankcase is low. 3. Add oil to crankcase.

4. Cooling fins and air passages under engine blower housing are plugged.

5. Spark plug is pitted, fouled, or gap is incorrect.

6. Vent hole in fuel cap is plugged.

7. Dirt in fuel filter. 7. Replace fuel filter.

8. Dirt, water, or stale fuel is in fuel system.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

Page 41

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Troubleshooting

Engine overheats.

Abnormal vibration.

Machine does not drive.

1. Engine load is excessive. 1. Reduce ground speed.

2. Oil level in crankcase is low. 2. Add oil to crankcase.

3. Cooling fins and air passages under engine blower housing are plugged.

1. Engine mounting bolts are loose.

2. Loose engine pulley, idler pulley, or blade pulley.

3. Engine pulley is damaged. 3. Contact Authorized Service

1. Shift lever is in NEUTRAL. 1. Move shift lever to a drive

2. Traction belt is worn, loose or broken.

3. Wheel belt(s) are worn, loose or broken.

4. Traction belt is off pulley. 4. Contact Authorized Service

3. Remove obstruction from cooling fins and air passages.

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

gear position.

2. Contact Authorized Service Dealer.

3. Contact Authorized Service Dealer.

Dealer.

Page 42

Page 43

Page 44

Toro 30180 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual