Toro 71226 Operator's Manual

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Page 1

Form No. 3323-529

Wheel Horse



16-38 XLE Lawn Tractor

71226—200000001 & Up

Operator ’s Manual

International English (GB)

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.

m–1856

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.

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

The Toro Company – 1999

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Contents

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

Safe Operating Practices for Ride–on (riding)

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

Safe Operating Practices 2. . . . . . . . . . . . . .

Sound Pressure Level 4. . . . . . . . . . . . . . . . .

Sound Power Level 4. . . . . . . . . . . . . . . . . .

Vibration Level 4. . . . . . . . . . . . . . . . . . . . . .

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

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

Symbols Glossary 8. . . . . . . . . . . . . . . . . . .

Symbols Glossary 9. . . . . . . . . . . . . . . . . . .

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

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

Using Stabilizer/Conditioner 11. . . . . . . . . . .

Filling the Fuel Tank 11. . . . . . . . . . . . . . . . .

Check Engine Oil Level 11. . . . . . . . . . . . . . .

Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 12. . . . . . . . . . . . . . . . . . .

Controls 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake 12. . . . . . . . . . . . . . . . . . . . . . .

Positioning the Seat 13. . . . . . . . . . . . . . . . . .

Headlights 13. . . . . . . . . . . . . . . . . . . . . . . . .

Using the Blade Control (PTO) 13. . . . . . . . .

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

Adjusting Mower Wheels 14. . . . . . . . . . . . .

Starting and Stopping the Engine 14. . . . . . .

The Safety Interlock System 16. . . . . . . . . . .

Operating-in-Reverse 16. . . . . . . . . . . . . . . . .

Testing the Safety System 18. . . . . . . . . . . . .

Page

Driving Forward or Backward 18. . . . . . . . . .

Selecting Ground Speeds 19. . . . . . . . . . . . . .

Stopping the Machine 19. . . . . . . . . . . . . . . .

Side Discharge or Mulch Grass 20. . . . . . . . .

Installing the Discharge Cover 20. . . . . . . . . .

Tips for Mowing Grass 21. . . . . . . . . . . . . . .

Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 22. . . . . . . . . . . . . . . .

Greasing and Lubrication 23. . . . . . . . . . . . . .

Tire Pressure 23. . . . . . . . . . . . . . . . . . . . . . . .

Brake 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 25. . . . . . . . . . . . . . . . . . . . .

Fuse 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Headlights 26. . . . . . . . . . . . . . . . . . . . . . . . .

Battery 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug 30. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 31. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 31. . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 32. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 34. . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Blade 35. . . . . . . . . . . . . . . . . . . . . . .

Removing the Mower 37. . . . . . . . . . . . . . . . .

Installing the Mower 39. . . . . . . . . . . . . . . . .

Blade Drive Belt 41. . . . . . . . . . . . . . . . . . . . .

Side-to-Side Mower Leveling 42. . . . . . . . . .

Front-to-Rear Blade Slope 43. . . . . . . . . . . . .

Washing Underside of Mower 45. . . . . . . . . .

Cleaning and Storage 46. . . . . . . . . . . . . . . . .

Troubleshooting 48. . . . . . . . . . . . . . . . . . . . . . . . .

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Safety

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

This machine meets or exceeds European Standards in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

symbol, which means CAUTION,

Safe Operating Practices

The following instructions are from the CEN standard EN 836:1997.

• All drivers should seek and obtain professional

and practical instruction. Such instruction should emphasize:

• the need for care and concentration when

working with ride-on machines;

• control of a ride-on machine sliding on a

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

• insufficient wheel grip;

• being driven too fast;

• inadequate braking;

• the type of machine is unsuitable for

its task;

• lack of awareness of the effect of

ground conditions, especially slopes;

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Training

• Read the instructions carefully. Be familiar with

the controls and the proper use of the equipment.

• Never allow children or people unfamiliar with

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

• Never mow while people, especially children, or

pets are nearby.

• Keep in mind that the operator or user is

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

• Do not carry passengers.

• incorrect hitching and load

distribution.

Preparation

• While mowing, always wear substantial

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

• Thoroughly inspect the area where the

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

• WARNING – Petrol is highly flammable.

• Store fuel in containers specifically

designed for this purpose.

• Refuel outdoors only and do not smoke

while refuelling.

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Safety

• 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.

• Replace all fuel tanks and container caps

securely.

• Replace faulty silencers.

• 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.

• On multi-bladed machines, take care as rotating

one blade can cause other blades to rotate.

Operation

• 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 humps and hollows and other

hidden hazards;

• never mow across the face of the slope,

unless the lawnmower is designed for this purpose.

• Use care when pulling loads or using heavy

equipment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely control.

• Do not turn sharply. Use care when

reversing.

• Use counterweight(s) or wheel weights

when suggested in the instruction handbook.

• Do not operate the engine in a confined space

where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage

all blade attachment clutches and shift into neutral.

• Do not use on slopes of more than

• 5 when mowing on side hills;

• 10 when mowing uphill;

• 15 when mowing downhill.

• 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;

• Watch out for traffic when crossing or near

roadways.

• Stop the blades rotating before crossing surfaces

other than grass.

• When using any attachments, never direct

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

• Never operate the machine with defective guards

or without safety protective devices in place.

• Do not change the engine governor settings or

overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

• Before leaving the operator’s position:

• disengage the power take-off and lower the

attachments;

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Safety

• change into neutral and set the parking

brake;

• stop the engine and remove the key.

• Disengage drive to attachments, stop the engine,

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

• before clearing 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

transporting or not in use.

• Stop the engine and disengage drive to

attachment

• before refuelling;

• Allow the engine to cool before storing in any

enclosure.

• To reduce the fire hazard, keep the engine,

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

• Check the grass catcher frequently for wear or

deterioration.

• Replace worn or damaged parts for safety.

• If the fuel tank has to be drained, this should be

done outdoors.

• On multi-bladed machines, take care as rotating

one blade can cause other blades to rotate.

• When machine is to be parked, stored or left

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

Sound Pressure Level

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 87 dB(A), based on measurements of identical machines per Directive 84/538/EEC.

• before removing the grass catcher;

• before making height adjustment unless

adjustment can be made from the operator’s position.

• 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

• Keep all nuts, bolts and screws tight to be sure

the equipment is in safe working condition.

• Never store the equipment with petrol in the tank

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

Sound Power Level

This unit has a sound power level of: 100 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments.

Vibration Level

This unit has a maximum hand-arm vibration level of

5.39 m/s2 and whole body vibration level of

0.27 m/s2, based on measurements of identical machines per EN 1033 and EN 1032.

Page 7

Slope Chart

Read all safety instructions on pages 2–8.

Safety

Page 8

Page 9

Symbols Glossary

Safety

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

Operating in reverse not allowed unless deactivated by Key Choice switch

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Safety

Symbols Glossary

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

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Symbols Glossary

Safety

Fast

Slow Decreasing/Increasing

On/Run

Off/Stop

Engine

Engine start

Engine stop

Fuel

Fuel level

Volume empty

Volume full

Battery charging conditin

Head lights– Main/high beam

Brake system

Choke

Engine temperature

Engine lubricating

oil pressure

Engine lubricating oil level

Key Choice Switch

Parking brake

Clutch

PTO (Power Take Off)

Engage

Disengage

Unlock

Lock

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.

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

• Always place gasoline containers on the

ground away from your vehicle before filling.

• Do not fill gasoline containers inside a

vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas–powered

equipment from the truck or trailer and refuel the equipment with its wheels on the round.

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used,

keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

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Gasoline and Oil

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days

or less. For longer storage, drain the fuel tank.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel

system, which causes hard starting

IMPORTANT: Do not use fuel additives containing methanol or ethanol.

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

Note: A fuel stabilizer/conditioner is most

effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

1. Shut the engine off and set the parking brake.

2. Clean around each fuel tank cap and remove the

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

3. Install fuel tank caps securely. Wipe up any

gasoline that may have spilled.

4. Fuel gauge is located in right side tank.

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 34.

Page 14

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. 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 clutch/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 clutch/brake pedal. The clutch/brake pedal should stay in the depressed (locked) position.

Releasing the Parking Brake

1. Push down on the clutch/brake pedal (Fig. 2).

The parking brake lever should release.

2. Gradually release the clutch/brake pedal.

1. Steering wheel

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

3. Ignition switch

4. Clutch/brake pedal

5. Blade control (PTO)

6. Ground speed selector

Figure 1

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

8. Parking brake lever

9. Throttle lever

10. Hood opening

11. Operating-in-Reverse light

12. Key Choice switch

m–1880

Figure 2

1. Clutch/brake pedal 2. Parking brake lever

Page 15

Operation

Positioning the Seat

The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

1. Raise the seat and loosen the adjustment knob

(Fig. 3).

2. Move the seat to the desired position and tighten

the knob.

m–1862

Figure 3

1. Adjustment knob

Headlights

Using the Blade Control (PTO)

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

Engaging the Blade(s)

1. Depress the clutch/brake pedal to stop the

machine.

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

(Fig. 4).

1. Disengaged

2. Engaged

Figure 4

3. Blade control (PT O)

m–1852

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.”

Disengaging the Blade(s)

1. Depress the clutch/brake pedal to stop the

machine.

2. Move the blade control (PTO) to

“DISENGAGED” (Fig. 4).

Page 16

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 (25 to 102 mm).

2. Pull on the height-of-cut lever (deck lift) and move it to the desired position (Fig. 5).

m–1881

Figure 5

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)

Figure 6

1. Wheel

2. Wheel Bracket

3. Locknut

4. Wheel Bolt

Starting and Stopping the Engine

Starting

1. Sit down on the seat.

2. Set the parking brake; refer to Setting the

Parking Brake, page 12.

1505

Adjusting Mower Wheels

The mower front wheels are to guide the mower over uneven ground. The front wheel height can be changed to more closely match the selected height-of-cut selected for the mower.

1. To change the height of the mower front wheels, remove the wheel mounting bolt and change the hole into which the wheel is mounted (Fig. 6).

2. Use the top hole for lowest cut height, and the bottom hole for higher cut heights (Fig. 6).

Note: The engine will not start unless you set

the parking brake or fully depress the clutch/brake pedal.

3. Move the ground speed selector into neutral “N”

(Fig. 7).

4. Move the blade control (PTO) to

“DISENGAGED” (Fig. 8).

5. Move the throttle lever to “CHOKE” (Fig. 9). Note: An engine that has been running and is

warm may not require step 5.

6. Turn the ignition key clockwise and hold it in the “START” position (Fig. 10). 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 48.

Page 17

7. After the engine starts, slowly move the throttle

lever to “FAST” (Fig. 9). 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.

m–1893

1. Start

2. On

Operation

Figure 10

3. Off

1. Ground speed selector

1. Disengaged

2. Engaged

Figure 7

Figure 8

3. Blade control (PT O)

m–1852

Stopping

1. Move the throttle lever to “FAST” (Fig. 9).

2. Turn the ignition key to “OFF” and remove the

key (Fig. 10). 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.”

1. Choke

2. Fast

m–1859

Figure 9

3. Slow

Page 18

Operation

The Safety Interlock System

Understanding the Safety Interlock System

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

• You are sitting on the seat

• The clutch/brake pedal is depressed

• The blade control (PTO) is “DISENGAGED”

The safety system is designed to stop the engine if:

• You rise from the seat when the clutch/brake

pedal is released.

• You rise from the seat when the blade control

(PTO) is “ENGAGED.”

• You shift into reverse with the power take off

(PTO) engaged and the operating-in-reverse interlock activated.

Operating-in-Reverse

An interlock feature is provided that prevents the Power Take Off (PTO) from operating while the tractor is traveling in reverse. If the unit is shifted into reverse while the mower blade or other PTO driven attachment is engaged, the engine will stop.

Do not mow while backing up unless it is absolutely necessary. If you need to mow while in

reverse gear or use other PTO driven attachments (such as a snowthrower or tiller), this no operating-in-reverse interlock may be temporarily deactivated.

Before deactivating this interlock, be sure there are no children present on or near the property where you are using the tractor, and that none are likely to appear while you are mowing or operating an attachment. Be extra observant after you have chosen to deactivate the interlock because the sound of the tractor’s engine might prevent you from being aware that a child or a bystander has entered the area where you are operating the tractor.

If you are certain that you can safely mow in reverse or operate an attachment, deactivate the no operating-in-reverse interlock by turning the Key Choice switch (Fig. 11), located on the seat bracket on the right hand side just below the seat, after engaging the blade (PTO). A red light on the front console (Fig. 12) will turn on as a reminder that the no operating-in-reverse interlock has been deactivated. Once the interlock is deactivated it stays in this mode—with your mower blade or PTO-driven attachment operating whenever you back up—and the console light stays on until either the blade (PTO) is disengaged, or the engine is turned off.

Note: Do not insert the “Key Choice” key

unless it is absolutely necessary to mow in reverse or operate an attachment. The “Key Choice” key should also be removed from the unit if it will be operated by someone other than a responsible, experienced operator. This will prevent the unit from operating in reverse with the mower blade or other PTO attachment engaged. Always remove both the ignition and the “Key Choice” keys and put them in a safe place out of the reach of children when leaving the unit unattended.

Page 19

POTENTIAL HAZARD

• A child or bystander could be backed over

by a riding mower with its blade(s) engaged.

WHAT CAN HAPPEN

• Blade contact will cause serious personal

injury or death.

HOW TO AVOID THE HAZARD

• Do not mow in reverse unless absolutely

necessary.

• Always look backward and down before

backing up.

• Use “Key Choice” switch only if you are

certain no children or other bystanders will appear in the mowing area.

• Always remove both the ignition and Key

Choice keys and put them in a safe place out of the reach of children or unauthorized users when leaving the unit unattended.

Figure 12

1. Operating–in–Reverse light

Operation

m–1863

1. “Key Choice” switch

Figure 11

Page 20

Operation

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. While setting in the seat, perform the following checks.

1. Move the ground speed selector into neutral “N.”

Set the parking brake. Move the blade control (PTO) to “ENGAGED.” Now turn the ignition key to “START”; the engine should not crank.

2. With the ground speed selector in neutral “N,”

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

3. With the ground speed selector in neutral “N,”

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.

4. Put the PTO lever in the “disengage” position

and the ground speed selector in neutral. Start the engine. While the engine is running, move the PTO lever to the “engage” position, push in the clutch and put the ground speed selector in reverse. The engine should stop.

5. Put the PTO lever in the “disengage” position

and the ground speed selector in neutral. Start the engine. Move the PTO lever to the “engage” position and turn the Key Choice key and release. The Operating-in-Reverse warning light should illuminate. Move the PTO lever to the “disengage” position and the Operating-in-Reverse warning light should turn off.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute).

To go forward or backward, depress the clutch/brake pedal. Move the ground speed selector to the desired forward speed or reverse. As you slowly release the pedal, the machine will begin to move. Steer the machine with the steering wheel.

Note: For reverse motion, with the PTO

engaged, the operating-in-reverse interlock must be deactivated by the key choice switch located in front of and below the seat.

POTENTIAL HAZARD

• If you release the clutch/brake pedal too

quickly when the ground speed selector is in gear, you could suddenly put the machine in motion.

WHAT CAN HAPPEN

• Sudden engagement of the machine’s drive

system could cause you to lose control.

HOW TO AVOID THE HAZARD

• Always release the clutch/brake pedal

slowly when starting the machine in motion (forward or reverse).

Page 21

Operation

Selecting Ground Speeds

IMPORTANT: To avoid transmission damage, always depress the clutch/brake pedal before shifting into or out of reverse.

Always start the machine in motion by depressing the clutch/brake pedal and shifting into the desired speed. Once the machine is in motion, you can shift into any forward speed without depressing the clutch/brake pedal. In most conditions, the machine is powerful enough to move out in any speed. If it will not move out in a selected speed (i.e., #5) due to a heavy load, use a lower speed (i.e., #2).

IMPORTANT: Do not shift on slopes. Choose a slow speed so that you will not have to stop or shift while on the slope.

Stopping the Machine

To stop the machine, depress the clutch/brake pedal, shift into neutral, 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 12. Remember to remove the keys from the ignition and Key Choice switches.

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 and “Key

Choice” keys and set the parking brake when leaving the machine unattended, even if just for a few minutes.

IMPORTANT: Do not “Ride the Brakes”. Shift to a lower speed for slower ground speed. Choose a slow speed so that you will not have to stop or shift while on the slope.

Page 22

Operation

Side Discharge or Mulch Grass

POTENTIAL HAZARD

• Without the grass deflector, discharge

cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.

WHAT CAN HAPPEN

• Contact with rotating mower blade(s) and

thrown debris will cause injury or death.

HOW TO AVOID THE HAZARD

• NEVER remove the grass deflector from

the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the

mower.

• Never try to clear discharge area or mower

blades unless you move the blade control (PTO) to “DISENGAGED” and rotate the ignition key to “OFF.” Also remove the key and pull the wire off the spark plug.

Installing the Discharge Cover

To convert from side discharge to a mulching mower, install the discharge cover into the opening at the side of the mower.

1. Shut the engine off and remove the ignition key.

2. Lift the grass deflector and slide the tabs on top

of the discharge cover under the grass deflector retaining rod. Rotate the discharge cover down over the opening, and onto the lower lip of the mower (Fig. 13).

3. Secure the discharge cover to the lower lip of the mower with bolts and nuts (Fig. 13).

Note: Do not over-tighten nuts, distorting

cover causing blade contact.

1. The mower has a hinged grass deflector that

disperses clippings to the side and down toward the turf.

2. To mulch grass clippings you must install the

discharge cover (optional on some models) into the opening in the side of the mower; refer to Installing the Discharge Cover, page 20.

1. Grass deflector

2. Tabs under rod

3. Discharge cover

Figure 13

4. Lower lip

5. Bolt

6. Nut

4. To convert back to a side discharge mower, remove the discharge cover and lower the grass deflector over the discharge opening.

m–1883

Page 23

Operation

Tips for Mowing Grass

Fast Throttle Setting

For best mowing and maximum air circulation, operate the engine at “FAST.” Air is required to thoroughly cut grass clippings, so do not set the height-of-cut too low or totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.

Using the mower for the First Time

Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to assure an acceptable quality-of-cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended, unless grass is sparse or it is late fall when grass grows more slowly.

Avoid Cutting Too Low

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height one notch to ensure uneven turf is not cut too short.

Long Grass

If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting.

When Stopping

If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this:

1. With the blade(s) “ENGAGED,” move onto a

previously cut area.

2. To disperse the clippings evenly, raise the mower

one or two height-of-cut settings while driving forward with the blade(s) “ENGAGED.”

Keep the Underside of the Mower Clean

Mowing Direction

Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

Mow at Correct Intervals

Normally, mow every 4 days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again 2 days later at a lower height setting.

Use the washout port to clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

Blade Maintenance

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Every 30 days, check the cutter blade(s) for sharpness and file down any nicks.

Page 24

Maintenance

More often in

Service Interval Chart

Each

Service Operation

Oil—initial change X Oil—periodic change (50 hours or once

each season) Oil—check level X Safety System—check X X X X Cutter Blade—check X X X Brake—check X X X X Chassis—grease X X Foam Air Cleaner—service X X Paper Air Cleaner—replace X Spark Plug—check X X X Belts—check for wear/cracks X Gasoline—drain X Engine—clean outside X X Mower Housing—clean X X X

Use5Hours25Hours

Storage

Service

Spring

Service

Notes

dusty, dirty conditions

Chipped Surfaces—paint X Battery—check electrolyte X X X X X Battery—charge, disconnect cables X Fuel Filter—replace X Tires—check pressure X X X

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 off the spark plug before

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

Page 25

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), shift into

neutral, 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.

Where to Add Grease

Tire Pressure

Service Interval/Specification

Maintain the air pressure in the front and rear tires at 20 psi (138 kPa). Check the pressure at the valve stem after every 25 operating hours or yearly, whichever occurs first. Check the tires when they are cold to get the most accurate pressure reading.

m–1872

Figure 15

1. Valve stem

1. Lubricate the front wheels and steering spindles

until grease begins to ooze out the bearings (Fig. 14).

m–2346

Figure 14

Page 26

Maintenance

Brake

The brake is on the right side of the rear axle, inside the rear tire (Fig. 16). If the brake does not hold securely or stopping power is insufficient, an adjustment is required.

Checking the Brake

1. Park the machine on a level surface, disengage

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

2. 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 24.

Adjusting the Brake

1. Check the brake before you adjust it; refer to Checking the Brake, page 24.

2. To increase braking resistance, tighten the brake adjusting nut (Fig. 16) 1/8 turn clockwise; then check the brake again. Continue this adjusting and checking process until the brake is set properly.

3. Push down on the clutch/brake pedal to release the parking brake.

IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If the brake seems to “drag,” loosen the adjusting nut slightly until the wheels rotate freely. If both conditions cannot be achieved, contact an authorized service dealer immediately.

m–1895

Figure 16

1. Brake adjusting nut

Page 27

Wiring Diagram

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Page 28

Maintenance

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. 17) to remove from the socket. Push down to insert.

Fuses: 10 amp, blade-type

Figure 18

1. Bulb holder

2. Reflector

3. Tabs

Installing the Bulb

m–1874

4. Slots

5. Terminals

m–1672

Figure 17

1. Fuse (removed) 2. Socket

Headlights

Specification: Bulb # 1156, automotive type.

Removing the Bulb

1. Disengage the blade control (PTO), shift into

neutral, 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. 18).

4. Push and rotate the bulb counterclockwise until

it stops (approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 19).

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. 19). Push and rotate the bulb clockwise until it stops.

1. Bulb

2. Metal pins

Figure 19

3. Bulb holder

4. Slots

m–1875

2. The bulb holder has two tabs (Fig. 18). 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.

Page 29

Battery

Maintenance

Service Interval/Specification

Check the electrolyte level in the battery before each use. Always keep the battery clean and fully charged. Use a paper towel to clean the battery 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), shift into

neutral, 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. 20).

4. Slide the rubber cover up the positive (red)

cable. Disconnect the positive (red) cable from the battery post (Fig. 20).

5. Remove the battery box, battery, and long vent

tube from the chassis (Fig. 21).

1. Negative cable (black)

2. Rubber cover

3. Positive cable (red)

Figure 20

4. Battery box

5. Bolt and wing nut

m–1876

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. 21).

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. 21). Always install the long battery vent tube through the holes to prevent battery acid from corroding the tractor and mower.

Page 30

Maintenance

Checking Electrolyte Level

m–2347

Figure 21

1. Battery

2. Battery box

3. Vent tube

4. Slot in battery box

5. Holes in frame

2. Install the battery box and battery into the

chassis (Fig. 21). Make sure to slide the end of the vent tube through the holes in the frame (Fig. 21).

3. Using the bolt and wing nut, connect the positive

(red) cable to the positive (+) battery post (Fig. 20). Slide the rubber cover over the battery post.

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. 22). Do not allow the electrolyte to get below the “LOWER” line (Fig. 22).

3. If the electrolyte is low, add the required amount

of distilled water; refer to Adding Water to the Battery, page 29.

1. Filler caps

2. UPPER line

Figure 22

3. LOWER line

m–1878

4. Using the bolt and wing nut, connect the

negative (black) cable to the negative (–) battery post (Fig. 20).

Page 31

Maintenance

Adding Water to the Battery

The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution.

1. Clean the top of the battery with a paper towel.

2. Unscrew the filler caps (Fig. 22).

3. Slowly pour distilled water into each battery cell

until the level is up to the “UPPER” line (Fig. 22) on the battery case.

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

4. Screw the filler caps onto the battery.

Charging the Battery

IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C).

1. Remove the battery from the chassis; refer to

Removing the Battery, page 27.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 28, steps 2–3.

3. Remove the filler caps from the battery and

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

POTENTIAL HAZARD

• Charging the battery produces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AVOID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. Install the battery in the chassis; refer to

Installing the Battery, page 27.

Page 32

Maintenance

Spark Plug

Service Interval/Specification

Install a new spark plug after every 100 operating hours. Check the spark plug after every 25 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 RJ–19LM (or equivalent) Air Gap: 0.030” (0.762 mm)

Removing the Spark Plug

1. Disengage the blade control (PTO), shift into

neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2. Open the hood.

Checking the Spark Plug

1. Look at the center of the spark plug (Fig. 24). If

you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

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. 24). Bend the side electrode (Fig. 24) if the gap is not correct.

0.030”

(0.762 m m )

3. Pull the wire off the spark plug (Fig. 23). 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.

m–1884

Figure 23

1. Spark plug wire

m–1870

Figure 24

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

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).

3. Push the wire onto the spark plug (Fig. 23).

4. Close the hood.

Page 33

Fuel Tank

Draining The Fuel Tank

Maintenance

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), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine.

m–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 yearly, 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.

2. Open the hood.

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), shift into

neutral, 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.

Page 34

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 or yearly, 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), shift into

neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine.

m–1864

Figure 27

1. Foam element 2. Paper element

5. Unscrew the rubber nut and remove the paper

element (Fig. 28).

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. 26).

m–1884

Figure 26

1. Knob 2. Air cleaner cover

m–1865

Figure 28

1. Rubber nu t 2. Paper element

4. Carefully slide the foam element off the paper

element (Fig. 27).

Page 35

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.

Maintenance

B. Dry the element by squeezing it in a clean

cloth.

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

(Fig. 29). Squeeze the element to distribute the oil.

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

Figure 29

1. Foam element 2. Oil

m–1867

Figure 30

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. 27).

m–1866

2. Slide the air cleaner assembly onto the long rod.

Screw the rubber nut finger-tight against the air cleaner (Fig. 28).

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 30).

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.

Note: Make sure the rubber seal is flat

against the air cleaner base.

3. Install the air cleaner cover and knob (Fig. 26).

Tighten the knob snugly.

4. Close the hood.

Page 36

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 SF, SG or SH) Crankcase Capacity: 48 oz/1–1/2 qt (1400 cc/1.4 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

5. Screw the oil dipstick fully onto the filler tube

(Fig. 31). 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.

1. Oil dipstick

2. Metal end

m–1868

Figure 31

3. Filler tube

–20 0 20 40 60 80 100

–30°–20 –10 0 10 20 30 40

Checking Oil Level

1. Park the machine on a level surface, disengage

the blade control (PTO), shift into neutral, 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. 31) so dirt

cannot fall into the filler hole and damage the engine.

4. Unscrew the oil dipstick and wipe the metal end

clean (Fig. 31).

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), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Open the hood.

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

remove the drain plug (Fig. 32).

5. When oil has drained completely, install the

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

recycling center.

Page 37

Maintenance

6. Slowly pour approximately 80% of the specified

amount of oil into the filler tube (Fig. 31). Check the oil level; refer to Checking Oil Level, page 34, steps 4–5.

m–1869

Figure 32

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

Cutting Blade

To assure a superior quality of cut, keep the blade(s) sharp. For convenient sharpening and replacement, you may want to have an extra blade(s).

POTENTIAL HAZARD

• A blade that is worn or damaged could

break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AVOID THE HAZARD

• Periodically inspect the blade for wear and

damage. Immediately install a new blade if it is worn or damaged.

Inspecting the Blade(s)

1. Remove the mower; refer to Removing the

Mower, page 37.

2. Inspect the cutting edges (Fig. 33). If the edges

are not sharp or have nicks, remove the blade(s) and sharpen them; refer to Sharpening the Blade(s), page 36.

3. Inspect the blade(s), especially the curved area

(Fig. 33). If you notice any damage, wear, or a slot forming in this area (Fig. 33), immediately install a new blade.

Page 38

Maintenance

1. Cutting edge

2. Curved area

Figure 33

3. Wear/slot forming

Sharpening the Blade(s)

1. Use a file to sharpen the cutting edge at both

ends of the blade (Fig. 35). Maintain the original angle. The blade retains its balance if the same

m–151

amount of material is removed from both cutting edges.

m–1854

Figure 35

1. Sharpen a t original angle

Removing the Blade

1. Remove the mower; refer to Removing the

Mower, page 37.

2. Carefully tip the mower over.

3. Remove the bolt (5/8” wrench), curved washer,

retainer and blade (Fig. 34). A block of wood may be wedged between the blade and the mower to lock the blade when you are removing the bolt.

4. Inspect all parts. If damage is noticed, install

new parts.

2. Check the balance of the blade by putting it on a

blade balancer (Fig. 36). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the back side of the blade. Repeat this procedure until the blade is balanced.

m–1855

Figure 36

1. Blade 2. Balancer

Installing the Blade(s)

1. Install the blade, blade retainer, curved washer

(cupped side toward blade), and the blade bolt (Fig. 34).

1. Bolt

2. Retainer

3. Blade

Figure 34

4. Spindle

5. Curved washer

m–1886

IMPORTANT: The curved part of the blade must be pointing toward the inside of the mower to assure proper cutting.

2. Tighten the blade bolt to 45–60 ft-lb

(61–81 Nm).

Page 39

Removing the Mower

Maintenance

1. Park the machine on a level surface, disengage

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

2. Remove the key from the ignition switch and

pull the wire off the spark plug.

3. Move the height-of-cut lever (deck lift) into the

“D” notch.

4. Remove the height-of-cut lift assist spring from

the retaining bolt (Fig. 37), using the spring tool provided with the machine. The spring is between the frame and the right rear wheel.

POTENTIAL HAZARD

• The height-of-cut lever (deck lift) is

spring-tensioned.

WHAT CAN HAPPEN

• When the mower is being removed, this

spring-loaded mechanism could suddenly release and injure you or someone else.

HOW TO AVOID THE HAZARD

• Move the height-of-cut lever (deck lift) to

the “D” position and remove the height-of-cut lift assist spring to release the spring tension.

5. Move the height-of-cut lever (deck lift) into the

“A” notch.

6. Unhook the blade control (PTO) cable ring end

from the idler spring (Fig. 38).

7. Remove jam nut from blade control (PTO) cable

at mounting bracket. Slide the cable from the bracket (Fig. 38).

1. Spring

2. Bolt

Figure 37

3. Spring tool

8. Move the cable out of the way and lay inside

frame rail so it cannot get caught in drive belts or pulleys.

Page 40

Maintenance

Figure 38

1. Blade control (PT O) cable

2. Ring end

3. Idler spring

4. Jam nut

5. Mounting bracket

9. Remove the bolts and lock nuts and pull the two

mower pivot mount brackets down from the front axle (Fig. 39).

11. Remove the hair pin cotter and washer at the

mower leveling bracket (Fig. 40). Slide the bracket off the mounting pin. Re-install the washer and hairpin cotter for storage.

12. Rotate the leveling bracket up, toward the frame,

and hook the long rod into one of the holes to store. Secure long rod with washer and hairpin cotter. Repeat for opposite side of the mower.

13. Move the height-of-cut lever (deck lift) into the

“D” notch. Hook lift assist spring onto retaining bolt for storage (Fig. 37).

m–4630

Figure 39

1. Pivot mount bracket

2. Bolt 5/16–18 x 2-1/2”

3. Lock nut

10. Remove the hair pin cotter and washer from the

end of the long rod (Fig. 40). Slide the rod out of the mower mount.

m–1805

Figure 40

1. Hair pin cotter and washer

2. Long rod

3. Leveling bracket

4. Mower mount

14. Remove the mower belt from the lower engine

pulley (Fig. 41). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to remove the belt. If it is too difficult to remove the belt, loosen the bolts and nuts securing the belt guides.

IMPORTANT: Do not bend the belt guide(s) away from the pulley because the belt will not operate properly when the mower is installed later.

Page 41

Maintenance

Figure 41

Top View

1. Mower belt

2. Engine pulley

m–1890

3. Belt guides

15. Turn the front wheels fully to the left. Slide the

mower out to the right to complete removal.

Installing the Mower

1. Park the machine on a level surface, disengage

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

2. Remove the key from the ignition switch and

pull the wire off the spark plug.

3. Turn the front wheels fully to the left. Slide the

mower under the chassis from the right side.

4. Install mower belt onto the lower engine pulley

(Fig. 41). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to install the belt. If it is too difficult to install the belt, loosen the bolts and nuts securing the belt guides.

IMPORTANT: Do not bend the belt guides away from the pulley. There must be a maximum 1/8” (3.175 mm) between the belt guide and the edge of the pulley to keep the belt on the pulley during operation. If the space is more than 1/8” (3.175 mm), adjust the belt guide(s) and tighten them securely. The belt guide must not contact the pulley.

5. Install the mower pivot mount brackets to the

front axle with bolts and lock nuts (Fig. 42).

1. Pivot mount bracket

2. Bolt 5/16–18 x 2-1/2”

Figure 42

3. Lock nut

m–4630

6. Move the height-of-cut lever (deck lift) into the

“A” notch.

Page 42

Maintenance

7. Slide the end of the long rod through the hole in

the mower mount (Fig. 43). Install the washer and hair pin cotter to secure the rod in place. Repeat this step on the opposite side of the mower.

8. Mount the slotted mower leveling bracket onto

the pin on the height-of-cut arm (Fig. 43). Install the washer and hair pin cotter to secure the mower. Repeat this step on the opposite side of the mower.

m–1805

Figure 43

1. Rod

2. Hair pin cotter and washer

3. Leveling bracket

4. Mower mount

9. Look under tractor and take down blade control

(PTO) cable nested inside frame rail.

10. Remove first jam nut and thread second jam nut

onto the blade control (PTO) cable all the way. Rout cable through slot in deck bracket and thread second jam nut onto cable (Fig. 44).

m–2384

Figure 44

1. Blade control cable

2. Mounting bracket slot

3. Cable ring end

4. Idler spring

5. Jam nut

12. Engage blade control (PTO) lever on dash.

Measure distance between hook ends of idler spring (Fig. 45). Adjust jam nuts so 6” (150 mm) dimension is obtained (Fig. 45).

13. Tighten jam nuts securely and disengage blade

control (PTO).

11. Hook end of blade control (PTO) cable onto

idler spring (Fig. 44).

1. Blade control cable

2. Idler spring

m–2385

Figure 45

3. Jam nut

4. 6” (150 mm) Engaged

Page 43

Maintenance

14. Move the height-of-cut lever (deck lift) into the

“D” notch to make it easier to install the height-of-cut lift assist spring.

15. Hook the height-of-cut lift assist spring onto the

retaining bolt (Fig. 46), using the spring tool provided with the machine.

m–1851

Figure 46

1. Spring

2. Bolt

3. Spring tool

Installing the Blade Drive Belt

1. Install the new belt around the blade pulleys and

under the belt guide on the idler pulley.

2. Position the idler pulley belt guide so it points

toward the left, 90° to the idler arm (Fig. 47). Tighten the mounting bolt and lock nut securing the idler pulley and belt guide.

3. Install the left and right pulley covers with the

mounting screws (Fig. 47).

4. Install the mower; refer to Installing the Mower,

page 39.

16. Check side-to-side blade level; refer to

Side-to-Side Mower Leveling, page 42.

Blade Drive Belt

Removing the Blade Drive Belt

1. Remove the mower; refer to Removing the

Mower, page 37.

2. Remove the pulley cover mounting screws and

pulley covers from both blade pulleys (Fig. 47).

3. Loosen, but do not remove the bolt and nut

securing the idler pulley and belt guide (Fig. 47).

4. Remove the belt from the pulleys.

1. Pulley cover

2. Idler pulley belt guide position

m–1890

Figure 47

Top View

3. Mower belt

Page 44

Maintenance

Side-to-Side Mower Leveling

The mower blades must be level from side to side. Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn. Before you level the mower, set the air pressure in the front and rear tires to the recommended inflation. Refer to “Tire Pressure” (page 21) in the Maintenance Section.

1. Park the machine on a level surface, disengage

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

2. Remove the key from the ignition switch and

pull the wire off the spark plug.

3. Carefully rotate blade(s) side to side (Fig. 48).

Measure between the outside cutting edges and the flat surface (Fig. 48). If both measurements are not within 3/16” (5 mm), an adjustment is required; refer to steps 4 and 5.

4. Remove the hair pin cotter and washer from the

leveling bracket (Fig. 49). To level the blade(s), reposition the leveling bracket in a different hole and install the washer and hair pin cotter. (Fig. 49). A front hole lowers the blade height and a rear hole raises its height. Repeat this procedure on the opposite side.

m–1889

Figure 49

1. Hair pin cotter and washer

2. Leveling bracket

3. Front hole

4. Rear hole

1. Blades side to side

2. Outside cutting edges

Figure 48

3. Measure here

5. Now check the front-to-rear blade slope; refer to

Front-to-Rear Blade Slope, page 43.

m–1891

Page 45

Maintenance

Front-to-Rear Blade Slope

Check the front-to-rear blade slope any time you install the mower. Before you check the slope, set the air pressure in the front and rear tires to the recommended inflation. Refer “Tire Pressure” (page 21) in the Maintenance Section. If the front of the mower is not within a range of 1/8”–3/8” (3.5 mm–10.5 mm) lower than the rear of the mower, adjust the blade slope using the following instructions:

1. Park the machine on a level surface, disengage

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

2. Remove the key from the ignition switch and

pull the wire off the spark plug.

3. Check and adjust side-to-side blade level if you

have not checked the setting; refer to Side-to-Side Mower Leveling, page 42.

4. Move the height-of-cut lever (deck lift) into the

“C” notch.

(16 mm)

5/8”

1805

Figure 50

1. Adjusting block

2. Long rod

3. Hairpin cotter and washer

4. Mower mount

6. Check the front to rear slope by measuring

between the bottom of the mower (front center and rear center) and the flat surface (Fig. 51). If the front is not within a range of 1/8”–3/8” (3.5mm–10.5mm) lower than the rear, an adjustment is required.

5. Measure the length of the rod extending out the

front of the adjusting block on the sides of the chassis (Fig. 50). If the rod length is not 5/8” (16 mm), remove the hair pin cotter and washer from the end of the rod (Fig. 50), and turn the rod until the 5/8” (16 mm) dimension is obtained. Then install the end of the rod into the hole in the mower mount and secure in place with washer and hair pin cotter. Repeat this procedure on the opposite side of the mower.

Page 46

Maintenance

1. Pivot mounting bolt 2. Eyebolt locknut



Figure 52

11. When front-to-rear blade slope is correct,

recheck the side-to-side level of the mower; refer to Side-to-Side Mower Leveling, page 42.

m–1892

Figure 51

1. Measure front center 2. Measure rear center

7. To adjust front-to-rear blade slope loosen front

pivot plate mounting bolts slightly (Fig. 52).

8. Rotate lock nuts on eyebolts to change

adjustment (Fig. 52).To raise the front of the mower tighten the eyebolt lock nuts. To lower the front of the mower loosen the eyebolt lock nuts.

9. After adjusting both eyebolt lock nuts evenly,

check the front-to-rear slope again. Continue adjusting eyebolts until the front blade tip is 0-3/8” (0-9.2 mm) lower than the rear blade tip (Fig. 51).

10. When front-to-rear slope is correct, tighten the

pivot plate mounting bolts (Fig. 52).

Page 47

Washing Underside of Mower

Maintenance

After each use wash the underside of the mower to prevent grass build-up for improved mulch action and clipping dispersal.

1. Park the machine on a hard, level surface,

disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine.

2. Screw coupling to the end of a garden hose,

attach coupling to mower washout fitting and turn water on high (Fig. 53).

Note: Spread petroleum jelly on washout

fitting o-ring to make coupling slide on easier and protect o-ring.

3. Lower the mower to the lowest height-of-cut.

4. Sit on the seat and start the engine. Engage

power take off (PTO) and let mower run for one to three minutes.

5. Disengage the power take off (PTO) and turn the

ignition key to “OFF” to stop the engine.

POTENTIAL HAZARD

• A broken or missing washout fitting could

expose you and others to thrown objects or blade contact.

WHAT CAN HAPPEN

• Contact with thrown debris or blade

contact will cause injury or death.

HOW TO AVOID THE HAZARD

• Replace broken or missing washout fitting

immediately, before using mower again.

• Plug any hole(s) in mower with bolts and

locknuts.

• Never put your hands or feet under the

mower or through openings in the mower.

6. Turn the water off, remove coupling from the

washout fitting and hose.

7. Run mower again for one to three minutes to

remove excess water.

m–2755

Figure 53

1. Washout fitting

2. Coupling (not included)

3. Hose

Page 48

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. Pressure washing may damage the electrical system or wash away necessary grease at friction points. Avoid excessive use of water, especially near the control panel, lights, engine, and the battery.

3. Check the brake; refer to Brake, page 23.

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

page 32.

5. Grease the chassis; refer to Greasing and

Lubrication, page 23.

A fully charged battery maintains its charge for about 50 days at temperatures lower than 40°F (4°C). If the temperatures will be above 40°F (4°C), check the water level in the battery and charge it every 30 days.

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

page 23.

10. For storage over 30 days, prepare the traction

unit as follows. A. Add a petroleum based

stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacturer. (1 oz. per gallon). Do not use

an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most

effective when mixed with fresh gasoline and used at all times.

B. Run the engine to distribute conditioned

fuel through the fuel system (5 minutes).

C. Stop the engine, allow it to cool and drain

the fuel tank; refer to Draining Fuel Tank, page 31.

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

page 34.

7. Remove the spark plug(s) and check its

condition; refer to Spark Plug, page 30. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the electric starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s); refer to Spark Plug, page 30. Do not install the wire on the spark plug(s).

8. Remove the battery from the chassis, check the

electrolyte level, and charge it fully; refer to Battery, page 27. Do not connect the battery cables to the battery posts during storage.

IMPORTANT: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32°F (0°C).

D. Restart the engine and run it until it stops. E. Choke or prime the engine. F. Start and run the engine until it will not

start again. Use the primer, if equipped on machine, several times to ensure no fuel remains in primer system.

G. Dispose of fuel properly. Recycle as per

local codes.

IMPORTANT: Do not store stabilizer/conditioned gasoline over 90 days.

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

Repair or replace any part that is damaged or defective.

Page 49

12. Paint all scratched or bare metal surfaces. Paint

is available from your Authorized Service Dealer.

13. Store the machine in a clean, dry garage or

storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

Maintenance

Page 50

Troubleshooting

g,,

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Starter does not crank

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

1. Blade control (PTO) is ENGAGED.

2. Parking brake is not on. 2. Set parking brake.

3. Battery is dead. 3. Charge the battery.

4. Electrical connections are corroded or loose.

5. Fuse is blown. 5. Replace fuse.

6. Relay or switch is defective. 6. Contact Authorized Service

1. Operator is not seated. 1. Sit on the seat.

2. Fuel tank is empty. 2. Fill fuel tank with gasoline.

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. Choke is not closing. 6. Adjust throttle cable.

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

1. Move blade control (PTO) to DISENGAGED.

4. Check electrical connections for good contact.

Dealer.

element.

4. Install wire on spark plug.

5. Install new, correctly gapped spark plug.

Engine loses power.

8. Idle speed is too low or mixture is incorrect.

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

1. Engine load is excessive. 1. Shift into lower gear to reduce

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.

8. Adjust carburetor idle speed and idle mixture.

9. Contact Authorized Service Dealer.

ground speed.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plug.

Page 51

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Troubleshooting

Engine loses power (continued).

Engine overheats.

Abnormal vibration.

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.

1. Engine load is excessive. 1. Shift into lower gear to reduce

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. Cutting blade(s) is bent or unbalanced.

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Engine mounting bolts are loose.

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

5. Engine pulley is damaged. 5. Contact Authorized Service

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

ground speed.

3. Remove obstruction from cooling fins and air passages.

1. Install new cutting blade(s).

3. Tighten engine mounting bolts.

4. Tighten the appropriate pulley.

Dealer.

Blade(s) does not rotate.

Machine does not drive.

Uneven cutting height.

1. Blade drive belt is worn, loose or broken.

2. Blade drive belt is off pulley. 2. Install blade drive belt and

1. Traction belt is worn, loose or broken.

2. Traction belt is off pulley. 2. Contact Authorized Service

3. Transmission does not shift. 3. Contact Authorized Service

1. Tire pressure is incorrect. 1. Set tire pressure.

2. Mower is not level. 2. Level mower from

3. Underside of mower is dirty. 3. Clean the underside of the

1. Install new blade drive belt.

check idler pulley and belt guides for correct position.

1. Contact Authorized Service Dealer.

Dealer.

side-to-side and front-to-rear.

mower.

Page 52