Toro 71218 Operator's Manual

FORM NO. 3317–996GB

Wheel Horse

16–44 HXLE

Lawn Tractor

Model No. 71218 – 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.

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 Toro 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 Toro designs, produces and markets safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons who you allow to use the product about safe operation.

The Toro 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 (under the seat)

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

Model No:

Serial No.

1856

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.

Printed in USA

EThe Toro Company – 1995

Contents

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

Safe Operation Practices for Ride-on (riding)

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

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

Symbols Glossary 6. . . . . . . . . . . . . . . . . . .

Gasoline and Oil 9. . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 9. . . . . . . . . . . . . . .

Stabilizer/Conditioner 9. . . . . . . . . . . . . . . .

Filling the Fuel Tank 9. . . . . . . . . . . . . . . . .

Check Engine Oil Level 9. . . . . . . . . . . . . . .

Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 10. . . . . . . . . . . . . . . . . . .

Controls 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake 10. . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 11. . . . . . .

Using the Blade Control (PTO) 12. . . . . . . . .

The Safety System 12. . . . . . . . . . . . . . . . . . .

Driving Forward or Backward 13. . . . . . . . . .

Stopping the Machine 13. . . . . . . . . . . . . . . .

Setting the Height-of-Cut 14. . . . . . . . . . . . . .

Page

Positioning the Seat 14. . . . . . . . . . . . . . . . . .

Positioning the Tilt Steering Wheel 15. . . . . .

Headlights 15. . . . . . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 15. . . . . . . . . .

Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 16. . . . . . . . . . . . . . . .

Air Cleaner 17. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 19. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug 21. . . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 22. . . . . . . . . . . . . .

Tire Pressure 22. . . . . . . . . . . . . . . . . . . . . . . .

Brake 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 24. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 24. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Headlights 25. . . . . . . . . . . . . . . . . . . . . . . . .

Battery 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 28. . . . . . . . . . . . . . . . . . . . .

Storage 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 30. . . . . . . . . . . . . . . . . . . . . . . . .

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 are 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.

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).

Disengage drive to attachments when

14.

transporting or not in use.

• Use counterweight(s) or wheel weights when suggested in the instruction handbook.

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 Level

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

Sound Power Level

This unit has a sound power level of: 100 dB(A) / 1 pW, based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments. The test surface consisted of a surface of coconut mat surrounded by 2” grass.

Vibration Level

This unit has a maximum hand-arm vibration level of

4.80 m/s2 and whole body vibration level of

0.30 m/s2, based on measurements of identical machines per ISO 5349.

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.

Slope Chart

Read all safety instructions on pages 2–8.

Safety

Symbols Glossary

Safety alert symbol

Read operator’s manual

Consult Technical Manual for proper service procedures

Thrown or flying objects– Whole body exposure

Thrown or flying objects– Rotary side-mounted mower.

Keep deflector shield in place

Dismemberment–Mower in rearward motion

Stay a safe distance from the machine

Stay a safe distance from the mower

Keep children a safe distance from machine

Machine rollover side hill

Severing toes or foot– mower blade

Severing fingers or hand– mower blade

Rotating blade can cut off toes or fingers. Stay clear of blade as long as engine

is running

Do not open or remove safety shields while engine is running

Machine rollover up hill

Machine rollover down hill

Machine rollover ROPS

Symbols Glossary

Safety

Cutting element– basic symbol

Cutting element– height adjustment

Cutting unit–lower

Cutting unit-raised

Cutting or entanglement of foot–Rotating auger

Severing of fingers or hand– impeller blade

Keep a safe distance from snowthrower

Riding on this machine is allowed only on a passenger seat & only

if the driver’s view is not hindered

Crushing of fingers or hands–Force applied from side

Kickback or upward motion–Stored energy

Shut off engine & remove key before performing maintenance

or repair work

Machine travel direction– combined

Stay a safe distance from the snowthrower

Tractors must be equipped with 45kg rear wheel weight with this attachment installed

Machine rollover ROPS snowthrower

Severing of hand– Rotating knives

Severing of foot– Rotating knives

Low

High

Reverse

Neutral

First gear

Second gear

Third gear up to maximum # of forward gears

Safety

Symbols Glossary

Fast

Slow

Decreasing/Increasing

On/Run

Off/Stop

Engine

Engine start

Engine stop

Fuel

Fuel level

Volume empty

Volume full

Battery charging condition

Head lights– Main/high beam

Brake system

Choke

Engine temperature

Engine lubricating

oil pressure

Engine lubricating oil level

Parking brake

Clutch

PTO (Power Take Off)

Engage

Disengage

Unlock

Lock

Gasoline and Oil

Recommended Gasoline

Use fresh 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

Toro Stabilizer/Conditioner

Add the correct amount of Toro Gas Stabilizer/Conditioner to the gas. Using Toro Stabilizer/Conditioner or an isopropyl-based conditioner/stabilizer in the machine:

• 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 and open the hood.

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.

4. Close the hood.

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 19.

Operation

Think Safety First

Please carefully read all the safety instructions. 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.

Parking Brake

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

Setting the Parking Brake

1. Push the brake pedal (Fig. 2) down and hold it in the depressed position.

2. Lift the parking brake lever (Fig. 2) up 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.

1. Steering wheel

2. Light switch—on/off (selected models)

3. Ignition switch

4. Brake pedal

5. Blade control (PTO)

6. Traction control pedal

Figure 1

7. Height-of-cut lever (deck lift)

8. Parking brake lever

9. Tilt button (selected models)

10. Throttle lever

11. Hood opening

1857

1852

1858

Figure 2

1. Brake pedal 2. Parking brake lever

Operation

Starting and Stopping the Engine

Starting

1. Sit down on the seat.

2. Set the parking brake; refer to Setting the

Parking Brake, page 10.

Note: The engine will not start unless you set

the parking brake or fully depress the brake pedal.

3. Move the blade control (PTO) to “DISENGAGED” (Fig. 3).

4. Move the throttle lever to “CHOKE” (Fig. 4).

Note: An engine that has been running and is

warm may not require step 4.

5. Turn the ignition key clockwise and hold it in the “START” position (Fig. 5). 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 30.

1852

Figure 3

1. Disengaged

2. Engaged

3. Blade control (PTO)

Figure 5

1. Start

2. On

3. Off

Figure 4

1. Choke

2. Fast

3. Slow

1859

1860

6. After the engine starts, slowly move the throttle lever to “FAST” (Fig. 4). If the engine stalls or hesitates, move the throttle lever back to “CHOKE” for a few seconds. Then move the throttle lever to “FAST.” Repeat this as required.

Stopping

1. Move the throttle lever to “SLOW” (Fig. 4).

2. Turn the ignition key to “OFF” (Fig. 5).

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.”

Operation

Using the Blade Control (PTO)

The blade control (PTO) engages and disengages power to the blade(s).

Engaging the Blade(s)

1. Depress the brake pedal to stop the machine.

2. Move the blade control (PTO) to “ENGAGED”

(Fig. 6).

1852

Figure 6

1. Disengaged

2. Engaged

Disengaging the Blade(s)

3. Blade control (PTO)

The Safety System

Understanding the Safety System

The safety system is designed to prevent the engine from starting unless:

• You are sitting on the seat and

• The brake pedal is depressed and

• The blade control (PTO) is “DISENGAGED”

The safety system is designed to stop the engine if you rise from the seat when the brake pedal is released or the blade is “ENGAGED.”

Testing the Safety System

Test the safety 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 blade control (PTO) to “ENGAGED.” Now turn the ignition key to “START”; the engine should not crank.

2. Move the blade control (PTO) to “DISENGAGED” and release the parking brake. Now turn the ignition key to “START”; the engine should not crank.

1. Depress the brake pedal to stop the machine.

2. Move the blade control (PTO) to

“DISENGAGED” (Fig. 6).

3. Set the parking brake and move the blade control (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.

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.

To go forward or backward, release the parking brake: refer to Releasing the Parking Brake, page 10. Place your foot on the traction control pedal and slowly press on the top of the traction control pedal to move forward or on the bottom of the traction control pedal to move backward (Fig. 7). The farther you move the traction control pedal in either direction, the faster the machine will move in that direction.

To slow down release the pressure on the traction control pedal.

IMPORTANT: To avoid transmission damage, always release the parking brake before moving the traction control pedal.

Stopping the Machine

To stop the machine, release the traction control pedal, disengage the blade control (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 10. Remember to remove the key from the ignition switch.

POTENTIAL HAZARD

• Someone could move or attempt to operate

the tractor while it is unattended.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the tractor.

HOW TO AVOID THE HAZARD

• Always remove the ignition key and set the

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

1. Traction control pedal

2. Forward

1861

Figure 7

3. Backward

Operation

Setting the Height-of-Cut

The height-of-cut lever (deck lift) is used to raise and lower the mower to the desired cutting height.

1. The cutting height may be set in one of seven positions from approximately 1 to 4 inches (38 to 116 mm).

2. Pull on the height-of-cut lever (deck lift) and move it to the desired position (Fig. 8).

Approximately

1853

Figure 8

1. Height-of-cut lever (deck lift)

1” (25 mm) 1–1/2” (38 mm) 2” (51 mm) 2–1/2” (64 mm) 3” (76 mm) 3–1/2” (89 mm) 4” (102 mm)

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. Raise the seat and loosen the adjustment knob (Fig. 9).

2. Move the seat to the desired position and tighten the knob.

1862

Figure 9

1. Adjustment knob

Operation

Positioning the Tilt Steering Wheel

On select models the steering wheel tilts up and down. Position the steering wheel where you have the best control of the machine and are most comfortable.

1. Push in on the tilt button (Fig. 10).

2. Move the steering wheel to any of three

positions; then release the button.

1863

Figure 10

1. Tilt button 2. Steering wheel

Pushing the Machine by Hand

IMPORTANT: Always push the machine by hand. Never tow the machine because transaxle damage may occur.

To Push the Machine

1. Disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine.

2. Hook the drive control in the “PUSH” position. This disengages the drive system and allows the wheels to turn freely (Fig. 11).

To Operate the Machine

1. MOVE the drive control to the “OPERATE” position. This engages the drive system (Fig. 11).

Note: The machine will not drive unless the

drive control is in the “OPERATE” position.

Headlights

Headlights are optional on some models. A dash-mounted “ON/OFF” switch (Fig. 1) controls the headlights. The lights only shine while the engine is running and the switch is “ON.”

Figure 11

1. Operate position 2. Push position

1791

Maintenance

Service Interval Chart

Each

Service Operation

Oil—check level X

Oil—change* Initial X

Oil Filter—change* (100 hours or every other oil change)

Safety System—check X X

Brake—check X X X X

Chassis—grease* X X

Foam Air Cleaner—service* X X

Paper Air Cleaner—replace* X X

Spark Plug(s)—replace X X

Belts—check for wear/cracks X X

Gasoline—drain X

Engine—clean outside X X X

Chipped Surfaces—paint X

Battery—check electrolyte X X X

Battery—charge, disconnect cables X

Fuel Filter—replace X X

Tires—check pressure X X X

Use5Hours25Hours50Hours

100

Hours

X X

Storage

Service

Spring

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 by someone else could seriously injure you or other

bystanders.

HOW TO AVOID THE HAZARD

• Remove the key from the ignition switch and pull the wire off the spark plug before

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

Maintenance

Air Cleaner

Service Interval/Specification

Foam Element: Clean and re-oil after every 25 operating hours, or once a year, whichever occurs first.

Paper Element: Replace after every 100 operating hours or once a year, whichever occurs first.

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 blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood.

3. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unscrew the knob and remove the air cleaner cover (Fig. 12).

4. Carefully slide the foam element off the paper element (Fig. 13).

1864

Figure 13

1. Foam element 2. Paper element

5. Unscrew the rubber nut and remove the paper element (Fig. 14).

Figure 12

1. Knob 2. Air cleaner cover

1798

1865

Figure 14

1. Rubber nut 2. Paper element

Maintenance

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. 15). Squeeze the element to distribute the oil.

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

Figure 15

1. Foam element 2. Oil

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 16).

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.

1866

1867

Figure 16

1. Paper element 2. Rubber seal

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. 13).

2. Slide the air cleaner assembly onto the long rod. Now screw the rubber nut finger-tight against the air cleaner (Fig. 14).

Note: Make sure the rubber seal is flat

against the air cleaner base.

3. Install the air cleaner cover and knob (Fig. 12). Tighten the knob snugly.

4. Close the hood.

Maintenance

Engine Oil

Service Interval/Specification

Change oil:

• After the first 5 operating hours.

• After every 50 operating hours.

Note: Change oil more frequently when

operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SC, SD, SE, SF or SG)

Crankcase Capacity, with oil filter: 56 oz/1–3/4 qt (1700 cc/1.7 l)

Viscosity: See table below

USE THESE SAE VISCOSITY OILS

Checking Oil Level

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

2. Open the hood.

3. Clean around the oil dipstick (Fig. 17) so dirt

cannot fall into the filler hole and damage the engine.

4. Unscrew the oil dipstick and wipe the metal end clean (Fig. 17).

5. Screw the oil dipstick fully onto the filler tube (Fig. 17). Unscrew the dipstick again 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.

–20 0 20 40 60 80 100

–30°–20 –10 0 10 20 30 40

1. Oil dipstick

2. Metal end

1868

Figure 17

3. Filler tube

Maintenance

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 right front side is slightly lower than the left side to assure the oil drains completely. Then disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

3. Open the hood.

4. Place a pan below the oil dipstick/fill tube and

remove the drain plug (Fig. 18).

5. When oil has drained completely, install the drain plug.

Note: Dispose of the used oil at a certified

recycling center.

6. Slowly pour approximately 80% of the specified amount of oil into the filler tube (Fig. 17). Now check the oil level; refer to Checking Oil Level, page 19, steps 4–5.

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 20.

2. Remove the old filter and wipe the filter adapter (Fig. 19) gasket surface.

3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 19).

1869

Figure 18

1. Oil drain plug 2. Oil dipstick/fill tube

Figure 19

1. Oil filter

2. Gasket

3. Adapter

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. 19).

5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 20.

1256

Maintenance

Spark Plug

Service Interval/Specification

Install a new spark plug after every 100 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 and a gapping tool/feeler gauge to check and adjust the air gap.

Type: Champion RC–12YC (or equivalent) Air Gap: 0.030” (0.762 mm).

Removing the Spark Plug

1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood.

3. Pull the wire off the spark plug (Fig. 20). Now

clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage.

4. Remove the spark plug and metal washer.

Checking the Spark Plug

1. Look at the center of the spark plug (Fig. 21). 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. Always replace the spark plug when it has: a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side

electrodes (Fig. 21). Bend the side electrode (Fig. 21) if the gap is not correct.

1. Center electrode insulator

2. Side electrode

Figure 21

3. Air gap (not to scale)

0.030”

(0.762 mm)

1870

Figure 20

1. Spark plug wire 2. Spark plug

Installing the Spark Plug

1. Install the spark plug and metal washer. Make sure the air gap is set correctly.

2. Tighten the spark plug to 15 ft-lb (20.4 Nm).

1798

3. Push the wire onto the spark plug (Fig. 20).

4. Close the hood.

Maintenance

Greasing and Lubrication

Service Interval/Specification

Grease the machine after every 25 operating hours or once a year, 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 blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

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.

4. Wipe up any excess grease.

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 yearly, whichever occurs first (Fig. 23). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 12 psi (.85 kPa) front and rear

1872

Figure 23

1. Valve stem

Where to Add Grease

1. Lubricate the front wheels and steering spindles until grease begins to ooze out the bearings (Fig.

22).

2346

Figure 22

Maintenance

Brake

The brake is on the right side of the rear axle, inside the rear tire (Fig. 24). 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 blade control (PTO) and turn the ignition key to “OFF” to stop the engine.

2. Move the drive control wire to the “PUSH” position; refer to Pushing the Machine by Hand, page 15.

3. If the rear wheels lock and skid when you push the tractor forward, no adjustment is required. An adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 23.

IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the mower. If the 0.020” (5.08 mm) clearance and free wheel rotation cannot be achieved contact your service dealer immediately.

0.020” (5.08 mm)

Figure 24

1. Brake adjusting nut 2. Cotter pin

1 2

1674

Adjusting the Brake

(0.020” (5.08 mm) feeler gauge required)

1. Check the brake before you adjust it; refer to Checking the Brake, page 23.

2. Release the parking brake; refer to Releasing the Parking Brake, page 10.

3. To adjust the brake remove the cotter pin and loosen the brake adjusting nut slightly (Fig. 24).

4. Carefully insert a 0.020” (5.08 mm) feeler gauge between the two outer brake pads (Fig. 24).

5. Tighten the brake adjusting nut until slight resistance is felt on the feeler gauge when sliding it in and out. Install cotter pin.

6. Check the brake operation again; refer to Checking the Brake, page 23.

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.

1. Park the machine so that the left front side is slightly lower than the right side to assure fuel tank drains completely. Then disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood.

1873

1. Hose clamp

2. Fuel line

Figure 25

3. Filter

Fuel Filter

Service Interval/Specification

Replace the fuel filter after every 100 operating hours or once a year, whichever occurs first.

Replacing the Fuel Filter

The best time to replace the fuel filter (Fig. 25) is when the fuel tank is empty. Never install a dirty filter if it is removed from the fuel line.

3. Squeeze the ends of the hose clamp together and slide it up the fuel line toward the fuel tank (Fig. 25).

4. Pull the fuel line off the filter (Fig. 25) 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.

5. Install the fuel line onto the filter. Slide the hose clamp close to the filter to secure the fuel line and filter.

1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood.

3. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 25).

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps

close to the filter.

6. Close the hood.

Fuse

Service Interval/Specification

The electrical system is protected by fuses. No maintenance is required, however, if a fuse blows check the circuit wiring for a short. To replace a fuse pull up (Fig. 26) to remove from the socket. Push down to insert.

Fuse: 10 amp, blade-type.

Maintenance

Figure 27

1. Bulb holder

2. Reflector

3. Tabs

4. Slots

5. Terminals

1874

Installing the Bulb

1672

Figure 26

1. Fuse (removed)

2. Socket

Headlights

Specification: Bulb # 1156, automotive type.

Removing the Bulb

1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood. Pull wire connectors off both bulb holder terminals.

3. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the reflector (Fig. 27).

4. Push and rotate the bulb counterclockwise until it stops (approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 28).

1. The bulb has metal pins on the side of its base. Align the pins with the slots in the bulb holder and insert the base into the holder (Fig. 28). Push and rotate the bulb clockwise until it stops.

1. Bulb

2. Metal pins

Figure 28

3. Bulb holder

4. Slots

1875

2. The bulb holder has two tabs (Fig. 27). Align the tabs with the slots in the reflector, insert the bulb holder into the reflector and rotate it 1/4 turn clockwise until it stops.

3. Push the wire connectors onto the terminals on the bulb holder.

Maintenance

Battery

Service Interval/Specification

Check the electrolyte level in the battery after every 5 operating hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. 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, 160 Cold Cranking Amps

Removing the Battery

1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Tip the seat forward to see the battery.

3. Disconnect the negative (black) ground cable

from the battery post (Fig. 29).

Installing the Battery

1. Put the battery into the battery box and slide the vent tube into the channel and through the slot in the bottom of the box (Fig. 30).

IMPORTANT: Look down into the cut out area where the battery box fits into the chassis. Notice the holes at the end of the right frame member (Fig. 30). Always install the long battery vent tube through the holes to prevent battery acid from corroding the tractor and mower.

4. Slide the rubber cover up the positive (red) cable. Disconnect the positive (red) cable from the battery post (Fig. 29).

5. Remove the battery box, battery, and long vent tube from the chassis (Fig. 30).

1. Negative cable (black)

2. Rubber cover

3. Positive cable (red)

Figure 29

4. Battery box

5. Bolt and wing nut

1876

2347

Figure 30

1. Battery

2. Battery box

3. Vent tube

4. Slot in battery box

5. Hole in frame

2. Install the battery box and battery into the chassis (Fig. 30). Make sure to slide the end of the vent tube through the hole in the frame (Fig. 30).

3. Using the bolt and wing nut, connect the positive (red) cable to the positive (+) battery post (Fig. 29). Slide the rubber cover over the battery post.

4. Using the bolt and wing nut, connect the negative (black) cable to the negative (–) battery post (Fig. 29).

Maintenance

Checking Electrolyte Level

1. Tip the seat forward to see the battery.

2. Look at the side of the battery. The electrolyte

must be up to the “UPPER” line (Fig. 31). Do not allow the electrolyte to get below the “LOWER” line (Fig. 31).

3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 27.

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 26.

2. Check the electrolyte level; refer to Checking Electrolyte Level, page 27, steps 2–3.

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

1. Filler caps

2. UPPER line

Figure 31

3. LOWER line

1878

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. Unscrew the filler caps (Fig. 31).

3. Slowly pour distilled water into each battery cell

until the level is up to the “UPPER” line (Fig. 31) on the battery case.

IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.

POTENTIAL HAZARD

• Charging the battery produces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AVOID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. Install the battery in the chassis; refer to

Installing the Battery, page 26.

4. Screw the filler caps onto the battery.

Maintenance

Wiring Diagram

BLACK

GND

C-2186

FUSE

10 A.

SAFETY RELAY

SOLENOID

RED

BLACK

RED/WHT

N.0.

N.C.

BATTERY

COM

RED

FUSE

BLK/WHT

LIGHT BLUE

10 A.

RED

GRAY

SEAT SWITCH

N.O.

RED

ENGINE

MAGNETO

RED

ALT.

LIGHT

RED

COIL

STARTER

SOLENOID

FUEL

(Some Models)

BLACK BLACK

N.O.

PTO SWITCH

LIGHTS N.O.

BROWN

GREEN

WHITE

GRAY

DARK BLUE

YELLOW

KEY SWITCH

N.O.

NEUTRAL SWITCH

KEY SWITCH CIRCUIT LOGIC

LIGHTS CONNECTOR GND

NONE

NONE NONE

B+I+A X+Y

B+I+S

POSITION CIRCUIT "MAKE"

1. OFF

2. RUN

3. START

LIGHT HARNESS (NOT SHOWN)

+ 78 hidden pages