Toro 72115 Operator's Manual

Download

Page 1

FORM NO. 3321–860



Wheel

Horse

270HE

Lawn & Garden

Tractor

Model No. 72115 – 9900001 & 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.

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.

1. Model

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

Model No:

Serial No.

and Serial Number Plate

(under the seat)

1202

CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.

Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.

The left and right side of the machine is determined by sitting on the seat in the normal operator’s position.

The Toro Company – 1998

Page 3

Contents

Page

Safety 2.

Gasoline and Oil 10

Operation 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operation Practices for Ride-on (riding)

Rotary Lawnmower Machines2. . . . . . . .

Safe Operating Practices 2 Sound Pressure Level 4 Sound Power Level 4 Vibration Level 4 Slope Chart 5

Symbols Glossary7. . . . . . . . . . . . . . . . . . .

Symbols Glossary8. . . . . . . . . . . . . . . . . . .

Symbols Glossary9. . . . . . . . . . . . . . . . . . .

Recommended Gasoline10. . . . . . . . . . . . . .

Stabilizer/Conditioner 11 Filling the Fuel Tank 11 Check Engine Oil Level 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 12 Controls 12 Key Choice Switch 12 Parking Brake 12 Starting and Stopping

the Engine 13

Operating the

Power Take Off (PTO) 14 The Safety Interlock System 15 Operating–in–Reverse 15 Indicator Control Module 17 Driving Forward or Backward 18 Stopping the Machine 18 Attachment Power Lift 19 Adjusting Dial-A-Height 19

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

Page

Positioning the Seat 19 Headlights 20 Positioning the

Tilt Steering Wheel 20 Using the Cruise Control 20 Pushing the Machine by Hand 21

Maintenance 22

Service Interval Chart 22 Air Cleaner 23 Engine Oil 25 Spark Plug 27 Greasing and Lubrication 28 Tire Pressure 28 Brake 29 Fuel Tank 30 Fuel Filter 31 Power Lift 31 Front Wheel Toe-In 32 Transaxle Fluid 32 Fuse 33 Headlights 33 Battery 34 Wiring Diagram 37 Cleaning and Storage 39

Troubleshooting 40

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

Page 4

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.

Safe

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

symbol, which means CAUTION,

Operating Practices

6. 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 effects of

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

Preparation

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.

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 – Fuel 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 fuel while the engine is running or when the engine is hot.

Page 5

Safety

• If fuel 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.

• Replace all fuel tanks and container caps

securely.

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.

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.

7. When using any attachments, never direct

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

8. Never operate the lawnmower with damaged

guards or without safety protective devices in place.

9. Do not change the engine governor settings or

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

10. 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.

11. Disengage drive to attachments, stop the engine,

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

3. Before attempting to start the engine, disengage

all blade attachment clutches and shift into neutral.

4. 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.

5. Watch out for traffic when crossing or near

roadways.

6. Stop the blades before crossing surfaces other

than grass.

• 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).

12. Disengage drive to attachments when

transporting or not in use.

13. Stop the engine and disengage drive to

attachment

• before refuelling;

• before removing the grass catcher;

Page 6

Safety

• before making height adjustment unless

adjustment can be made from the operator’s position.

14. 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.

Slope Operation

1. For operation on slopes:

• Never mow side hills over 5

• Never mow uphill over 10

• Never mow downhill over 15

2. 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

•

in gear, especially when travelling downhill;

, always keep machine

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.

Sound

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 90 dB(A), based on measurements of identical machines per Directive 84/538/EEC and amendments.

Pressure Level

• 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.

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 fuel in the tank

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

3. Allow the engine to cool before storing in any

enclosure.

Sound

This unit has a sound power level of: 105 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments.

Vibration

This unit has a maximum hand-arm vibration level of

3.0 m/s2 and whole body vibration level of 0.3 m/s2, based on measurements of identical machines per EN 1033 and EN 1032.

Power Level

Level

Page 7

Safety

Slope

Read all safety instructions on pages 2–NO TAG.

Chart

Page 8

Page 9

Safety

Symbols

Safety alert symbol

Read operator’s manual

Consult Technical Manual for proper service procedures

Thrown or flying objects– Whole body exposure

Glossary

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

Thrown or flying objects– Rotary side-mounted mower

Keep deflector shield in place

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 side hill

Machine rollover up hill

Machine rollover down hill

Machine rollover

Operating in reverse not allowed unless deactivated by Key Choice switch

Page 10

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

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

’s view is not hindered

Stay a safe distance from the snowthrower

ractors 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

Page 11

Symbols Glossary

Safety

Fast

Slow Decreasing/Increasing

On/Run

Off/Stop

Engine

Engine start

Engine stop

Fuel

Fuel level

olume empty

olume 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

O (Power T

Engage

Disengage

Unlock

Lock

ake Off)

Page 12

Gasoline and Oil

Recommended

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

Gasoline

• 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 AV

OID 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 AV

OID 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, r

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

emove gas–power

• 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.

Page 13

Gasoline and Oil

Stabilizer/Conditioner

Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine:

• Keeps gasoline fresh during storage of 90 days

or less. For longer storage it is recommended that the fuel tank be drained.

• 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

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

2. Clean around each fuel tank cap and remove the

3. Install fuel tank caps securely. Wipe up any

4. Fuel gauge is located in right side tank.

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 25.

the Fuel T

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.

gasoline that may have spilled.

ank

Engine Oil Level

Page 14

Operation

Think

Safety First

Please carefully read all the safety instructions on pages 2–9. 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.

Key

Choice Switch

A turn and release switch used for deactivating the “Operating–In–Reverse” interlock feature. Located on the seat bracket on the right hand just below the seat (Fig. 2).

m–4220

1. “Key

Choice” switch

Figure 2

1. Steering

wheel Ignition switch Brake pedal Parking brake lever Ground speed selector Throttle lever Choke lever Power take of

f (PT

Figure 1

Cruise control switch

10.

Indicator control module/Hourmeter

11.

Attachment lift switch

12. T

ilt wheel lever

13.

Hood opening

14.

Dial-a-height knob

Parking Brake

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

While the ignition key is in the “RUN” or “LIGHTS” positions and the Parking Brake is engaged, the light, in the Indicator Module, will be lit.

2332

Setting the Parking Brake

1. Push the brake pedal (Fig. 3) down and hold it in

the depressed position.

2. Lift the parking brake lever (Fig. 3) up and

gradually take your foot off the brake pedal. The brake pedal should stay in the depressed (locked) position.

Page 15

Operation

Releasing the Parking Brake

1. Push down on the brake pedal (Fig. 3). The

parking brake lever should release.

2. Gradually release the brake pedal.

Figure 3

1. Brake

pedal

Parking brake lever

2333

5. Move throttle lever to “FAST” (Fig. 5).

6. Turn the ignition key clockwise and hold it in

the “START” position (Fig. 6). When the engine starts, release the key.

IMPORTANT: If the engine does not start after 30 seconds of continuous cranking, turn the ignition key to “OFF” and let the starter motor cool; refer to Troubleshooting, page 40.

7. After the engine starts, move the choke lever to

“OFF” (Fig. 5). If the engine stalls or hesitates, move the choke lever back to “ON” for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.

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. Note: The engine will not start unless you set

the parking brake or fully depress the brake pedal.

3. Push the PTO (power take off) to “OFF”

(Fig. 4).

4. Move the choke lever to “ON” (Fig. 4). Note: An engine that has been running and is

warm may not require step 4.

Figure 4

1. PTO—Off

2. Choke–On

3. Choke–Off

1. Off

2. Lights

1206

Figure 5

1. Fast

2. Slow

Figure 6

3. Run

4. Start

1207

1208

Page 16

Operation

Stopping

1. Move the throttle lever to “SLOW” (Fig. 5).

2. Turn the ignition key to “OFF” (Fig. 6). Note: If the engine has been working hard or

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.”

Operating Power T

The power take off (PT power to the electric clutch.

While the ignition key is in “RUN” or “LIGHTS” position and the power take off (PTO) is engaged “ON”, the PTO light, in the Indicator Module, will be “ON”. When this light is “ON” it is a reminder; the starter will not crank and to turn the off PTO before getting off.

the

ake Off (PT

O) engages and disengages

Engaging the Power Take Off (PTO)

1. Depress the brake pedal to stop the machine.

2. Pull the power take off (PTO) to “ON” (Fig. 7).

1206

Figure 7

1. Off-Disengaged 2. On-Engaged

Disengaging the Power Take Off (PTO)

1. Depress the brake pedal to stop the machine.

2. Push the power take off (PTO) to “OFF”

(Fig. 7).

Page 17

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 brake pedal is depressed

• The power take off (PTO) is “OFF”

The safety interlock system is designed to stop the engine if:

• You rise from the seat when the brake pedal is

released

• You rise from the seat when the power take off

(PTO) is “ON”or gear selector is not in “N” neutral.

The safety interlock system is designed to stop the power take off (PTO) if:

• You shift into reverse with the power take off

(PTO) engaged.

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 PTO will stop.

Do not mow while backing up unless it is absolutely necessary

reverse gear or use other PTO driven attachments (such as a snowthrower or tiller), this operating–in–reverse interlock feature may be temporarily deactivated.

. If you need to mow while in

Before deactivating this feature, 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 feature 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 operating–in–reverse interlock feature by turning the “Key Choice” switch (Fig. 8), 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. 9) will turn on as a reminder that the 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 18

Operation

POTENTIAL HAZARD

• A child or bystander could be backed over

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

1. Set the parking brake. Move the power take off

(PTO) to “ON”. Now turn the ignition key to “START”; the engine should not crank.

2. Push the power take off (PTO) to “OFF” and

release the parking brake. Now turn the ignition key to “START”; the engine should not crank.

WHAT CAN HAPPEN

• Blade contact will cause serious personal

injury or death.

HOW TO AV

• Do not mow in r

OID THE HAZARD

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

emove both the ignition and “Key

3. Set the parking brake and move the power take

off (PTO) to “OFF”(On gear drive models the speed selector lever must be in “N” neutral). Now start the engine. While the engine is running, release the parking brake and rise slightly from the seat; the engine should stop.

4. With the parking brake released, turn the ignition

key to RUN without starting the engine. Pull the PTO switch to ON. You should hear an audible click indicating the PTO is activated and the PTO light will illuminate. Move the foot pedal to reverse. You should hear an audible click indicating the PTO is deactivated and the PTO light should turn off.

5. With the parking brake released, turn the ignition

m–4220

Figure 8

1. “Key

Choice” switch

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

6. With the parking brake released, turn the ignition

switch to RUN without starting the engine. Pull the PTO switch to ON. Turn the “Key Choice” key and release. The Operating–in–Reverse warning light should illuminate. Move the foot pedal to reverse. The PTO and PTO light on the dash should remain on. Push the PTO switch to OFF. The PTO light and the Operating–in–Reverse warning light should turn off.

Page 19

Operation

Indicator

Control Module

The indicator control module (Fig. 9) contains lights for:

• Operating–in–Reverse

• Power take off (PTO)

• Battery

• Hourmeter

• Oil pressure

• Fuel level

7531 42 6

Figure 9

1. Power

2. Temperature

3. Battery

4. Hourmeter

take of

f (PT

Fuel Level

6. Oil

7. Operating–in–Reverse

PTO (Power Take Off)

The PTO (power take off) light will be “ON” when the key is in the “RUN” or “LIGHTS” positions and the PTO (power take off) is engaged “ON”. When this light is “ON” it is a reminder; the starter will not crank and turn off the PTO before getting off.

Hourmeter

The hourmeter records the number of hours the engine has operated (Fig. 9). It is turned on when the ignition switch is in the “RUN” or “LIGHTS” positions. Use the times for scheduling regular maintenance.

Battery

The battery light will be “ON” when the key is in the “RUN” or “LIGHTS” positions if the battery voltage is below 12.6 volts or when the engine is running and the alternator output is above 14.8 volts. When this light comes on it is important to have your battery and electrical system checked and the problem corrected.

Fuel Level

Following are the conditions when indicator lights will be “ON”. At other times the lights should be off.

Operating–in–Reverse

The Operating–in–Reverse light will illuminate whenever the “key choice” switch is used to deactivate the operating–in–reverse interlock. It is a reminder that the interlock system is deactivated. The light goes out whenever the power take off (PTO) is disengaged or the engine is shut off.

The fuel level light will be “ON” when the key is in the “RUN” or “LIGHTS” positions and the fuel level is low, approximately one pint remaining.

Oil

The oil light will be “ON” when the key is in the “RUN” or “LIGHTS” positions and the engine is not running, after the engine is started the light should go out. When the engine is running if the oil pressure drops below a safe operating level the light comes “ON”. When the light comes on while the engine is running, Stop engine immediately and correct the

cause of low oil pressure.

Page 20

Operation

Driving

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the “FAST” position for best performance.

Forward or Backward

Temperature

The temperature light will be “ON” when the key is in the “RUN” or “LIGHTS” positions and the engine temperature exceeds proper operating limits. Stop

engine immediately and correct the cause of high temperature.

To go forward or backward, release the parking brake: refer to Releasing the Parking Brake, page 13. 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. 10). The farther you move the traction control pedal in either direction, the faster the machine will move in that direction.

Note: For reverse motion, with the PTO

engaged, the operating–in–reverse interlock must be deactivated by the “Key Choice” switch located on the seat bracket on the right hand side just below the seat.

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.

1210

Figure 10

1. Forward 2. Backward

Stopping

To stop the machine, release the traction control pedal, disengage the power take off (PTO), and turn the ignition key to “OFF” to stop the engine. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 12. Remember to remove the key from the ignition switch.

POTENTIAL HAZARD

the Machine

• 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 AV

•

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

OID THE HAZARD

emove the ignition and “Key

Page 21

Operation

Attachment

Power Lift

The attachment power lift (Fig. 11) is used to raise and lower attachments.

Raising Attachments

1. Turn key to the “ON” or “RUN” position

(Fig. 11).

2. Push the lift switch in the “UP” direction to raise

the attachment lift (Fig. 11). This will lift and hold the attachment in the up, or raised position.

Lowering Attachments

1. Turn key to the “ON” or “RUN” position

(Fig. 11).

2. Push the lift switch in the “DOWN” direction to

lower the attachment lift (Fig. 11). This will lower the attachment lift.

Adjusting

Dial-A-Height

The Dial-A-Height control (Fig. 11) is used to limit the downward travel of the attachment. The Dial-A-Height knob is rotated to change the location of this stop, up or down.

1. Raise the attachment lift lever: Refer to Raising

Attachments. In the raised position the Dial-A-Height knob (Fig. 11) can be rotated to change the stop location. Turn clockwise to raise and counterclockwise to lower the height of the attachment.

2. The Dial-A-Height indicator (Fig. 11) will show

the change, high to low, in attachment lift height as adjustment is made.

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. Key

2. Lift

switch UP

Lift switch DOWN

Raise the seat and loosen the adjustment knobs (Fig. 12).

2. Slide the seat to the desired position and tighten

the knobs.

2266



Figure 12

1. Adjustment

knob

Figure 1

Dial-A-Height knob

Dial-A-Height indicator

Page 22

Operation

Headlights

The headlights are turned on with a separate position, “LIGHTS”, of the ignition switch (Fig. 13). The lights are on while the ignition switch is in the “LIGHTS” position even with the engine off. Remove the key when the machine is left unattended so lights can not be turned on discharging the battery.

1208

Figure 13

1. Lights

Using

the Cruise Control

A three position switch, located on the dash (Fig.15), with the functions of: Lock–Set (spring loaded), On and Unlock–Off controls the engagement. Cruise control maintains the traction control position without foot pressure. Cruise control is intended for operation in the forward direction only. Do not use cruise control in reverse.

Engaging the Cruise Control

1. Begin driving tractor: Refer to Driving Forward

or Backward, Page 18. While holding your foot steady on the traction control, push the cruise control switch (Fig. 15) to the “Lock–Set” position.

Positioning T

ilt Steering Wheel

the

The steering wheel has four tilt locations. Position the steering wheel where you have the best control of the machine and are most comfortable.

1. Lift the tilt lever to release the lock (Fig. 14).

2. Move the steering wheel to a comfortable

position; then release the lever to lock.

1203b

Figure 14

1. Tilt

lever

Steering wheel

1238

Figure 15

1. Lock–Set 2. Unlock–Off

2. This locks the traction control in position and

your foot can then be removed from the traction control. A constant ground speed will be maintained.

Disengaging the Cruise Control

1. While holding your foot steady on the traction

control, move the cruise control switch (Fig. 15) to the “Unlock–Off” position.

2. This unlocks the traction control and your foot

then operates the traction control.

3. For quick stops, just press on the brake pedal.

This automatically disengages the cruise control and applies the brake at the same time.

Page 23

Operation

Pushing

the Machine by Hand

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

To Push the Machine

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

ignition key to “OFF” to stop the engine.

2. Move the drive control rod to the “PUSH”

position. This disengages the drive system and allows the wheels to turn freely (Fig. 16).

IMPORTANT: Drive control rod moves to the “OPERATE” position when the brake is applied.

To Operate the Machine

1. Apply the brake, this moves the drive control rod

to “OPERATE” and engages the drive system, or move the drive control rod to the “OPERATE” position (Fig. 16).

Note: The machine will not drive unless the

drive control rod is in the “OPERATE” position.

Figure 16

1. Operate

position

Push position

1209

Page 24

Maintenance

Service

Oil—check level Oil—change* Initial X Oil Filter—change* (200 hours, every

other oil change or yearly) Safety System—check Brake—check X X X X Chassis—grease* X X Foam Air Cleaner—service* Paper Air Cleaner—replace* Spark Plug(s)—check 200 hours Belts—check for wear/cracks Gasoline—drain X Engine—clean outside Chipped Surfaces—paint Battery—check electrolyte Battery—charge, disconnect cables Fuel Filter—replace T

ires—check pressure Front Wheels–check toe-in Power Lift–check fluid T

ransaxle Fluid–check level

Interval Chart

Operation

Each

Use5Hours25Hours50Hours

X X

X X X

X X X X

X X X X X X X X

100

Hours

Storage Service

X X

X X X

Spring

Service

More often in dusty

, dirty conditions

Page 25

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.

Maintenance

HOW TO AV

OID THE HAZARD

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

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

Air

Cleaner

Service Interval/Specification

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

Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first.

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. Air

cleaner cover

2. Latches

Cover nut

4. Cover

Figure 17

Foam element Paper element Rubber seal Air cleaner base

1213

1. Disengage the power take off (PTO), set the

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

2. Open the hood.

3. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unhook latches and remove the air cleaner cover (Fig. 17).

4. Carefully slide the foam element off the paper

element (Fig. 17).

5. Unscrew the cover nut and remove the cover and

paper element (Fig. 17).

Page 26

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

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

1213

Figure 19

1. Paper

element

Rubber seal

Installing the Foam and Paper Elements

Figure 18

1. Foam

element

2. Oil

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 19).

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 or cannot be cleaned thoroughly.

1213

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. 17).

2. Slide the air cleaner assembly and cover onto the

long rod. Now screw the cover nut finger-tight against the cover (Fig. 17).

Note: Make sure the rubber seal is flat

against the air cleaner base and cover.

3. Install the air cleaner cover and hook latches

(Fig. 17).

4. Close the hood.

Page 27

Maintenance

Engine

Oil

Service Interval/Specification

Change oil:

• After the first 5 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when

operating conditions are extremely

dusty or sandy. Oil Type: Detergent oil (API service SF or SG) Crankcase Capacity: w/filter, 4 pints (1.9 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

Checking Oil Level

1. Park the machine on a level surface, disengage

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

2. Open the hood.

3. Clean around the oil dipstick (Fig. 20) so dirt

cannot fall into the filler hole and damage the engine.

4. Unscrew the oil dipstick and wipe the metal end

clean (Fig. 20).

5. Slide the oil dipstick fully into the filler tube, do

not thread onto tube (Fig. 20). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark.

IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged.

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

1. Oil

Metal end

dipstick

Figure 20

Filler tube

Page 28

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 drain side is slightly

lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Open the hood.

4. Slide a piece of hose over oil drain to direct oil.

5. Place a pan below the oil drain. Open the drain

by turning counterclockwise, 1/8 turn. and pull out (Fig. 21).

6. When oil has drained completely, close the drain

by pushing in and turning clockwise, 1/8 turn. Note: Dispose of the used oil at a certified

recycling center.

Change Oil Filter Service Interval/Specification

Replace the oil filter every 200 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 26.

2. Remove the old filter and wipe the filter adapter

(Fig. 22) gasket surface.

3. Apply a thin coat of new oil to the rubber gasket

on the replacement filter (Fig. 22).

1241

Figure 21

1. Oil

drain

2. Hose

7. Slowly pour approximately 80% of the specified

amount of oil into the filler tube (Fig. 20). Now check the oil level; refer to Checking Oil Level, page 25. Slowly add additional oil to bring to “FULL” mark on dipstick.

Figure 22

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. 22).

5. Fill the crankcase with the proper type of new

oil; refer to Changing/Draining Oil, page 26.

1256

Page 29

Maintenance

Spark

Plug

Service Interval/Specification

Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap.

Type: Champion RC–12YC (or equivalent) Air Gap: 0.040” (1.02 mm)

Removing the Spark Plug(s)

1. Disengage the power take off (PTO), set the

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

2. Open the hood.

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

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

Checking the Spark Plug

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

eplace the spark plug(s) when it has:

0.040” mm)

(1.02

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

Figure 23

1. Spark

plug wire

Spark plug

1215

Air gap (not to scale)

1. Center

Side electrode

Figure

electrode insulator

Installing the Spark Plug(s)

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

sure the air gap is set correctly.

2. Tighten the spark plug(s) to 20 ft-lb (27 Nm).

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

4. Close the hood.

Page 30

Maintenance

Greasing

and Lubrication

Service Interval/Specification

Grease the machine after every 50 operating hours or yearly, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose grease.

How to Grease

1. Disengage the power take off (PTO), set the

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

2. Clean the grease fittings with a rag. Make sure to

scrape any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease

into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Where to Add Grease

1. Lubricate the front wheels and spindles until

grease begins to ooze out of the bearings (Fig. 25).

3. Lubricate the traction control pedal on

hydrostatic models (or brake and clutch pedals on gear drive models) where they pivot on mounting shaft (Fig. 26).

1264

Figure 26

Tire

Pressure

Service Interval/Specification

Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 25 operating hours or monthly, whichever occurs first (Fig. 27). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 20 psi (138 kPa) front and rear

2. Lubricate the front axle pivot (Fig. 25).

Figure 25

1211

Figure 27

1. Valve

stem

2323

Page 31

Maintenance

Brake

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

Checking the Brake

1. Park the machine on a level surface, disengage

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

2. Rear wheels must lock and skid when you try to

push the tractor forward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 29.

3. Move the drive control rod to the “PUSH”

position; refer to Pushing the Machine by Hand, page 21. Wheels should rotate freely.

Adjusting the Brake

The brake lever is on top of the transaxle (Fig. 28). If the parking brake does not hold securely, an adjustment is required.

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

Checking the Brake, page 29.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 13.

3. To adjust the brake remove the cotter pin and

washer from the brake lever (Fig. 28).

4. Rotate the trunnion so it smoothly slides into

brake lever (Fig. 28).

5. Secure trunnion to brake lever with washer and

cotter pin (Fig. 28).

6. Check the brake operation again; refer to

Checking the Brake, page 29.

4. If both conditions are met no adjustment is

required.

IMPORTANT: Drive control rod moves to the “OPERATE” position when the brake is applied.

IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately.

Figure 28

1. Cotter

2. Trunnion

pin and washer

Brake lever

1245

Page 32

Maintenance

Fuel Tank

Draining The Fuel Tank

POTENTIAL

• 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 AV

• 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.

HAZARD

OID THE HAZARD

4. Squeeze the ends of the hose clamp together and

slide it up the fuel line toward the fuel tank (Fig. 30).

5. Pull the fuel line off the filter (Fig. 30). Open

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

Note: Now is the best time to install a new

fuel filter because the fuel tank is empty.

6. Install the fuel line onto the filter. Slide the hose

clamp close to the filter to secure the fuel line and filter. Refer to Replacing the Fuel Filter; page 31.

1. Park the machine on a level surface, to assure

fuel tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut-off valve at fuel tank (Fig. 29).

1263

Figure 29

1. Fuel

shut-of

f valve

1. Hose

Fuel line

clamp

Figure 30

3. Filter

1217

3. Open the hood.

Page 33

Maintenance

Fuel

Filter

Service Interval/Specification

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

Replacing the Fuel Filter

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

1. Disengage the power take off (PTO), set the

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

2. Close fuel shut–off valve at fuel tank (Fig. 29).

3. Open the hood.

4. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 31).

5. Remove the filter from the fuel lines.

Power

Lift

Service Interval/Specification

Check fluid level in power lift after every 25 operating hours or yearly, whichever occurs first. Fill with Dexron Type II or Type III automatic transmission fluid.

Checking Fluid Level

1. Raise attachment lift to the full “UP” position.

Refer to: Raising Attachments page .

2. Disengage the power take off (PTO), set the

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

3. Open the hood.

4. Remove the plug on top of the power lift pump

(Fig. 32). Fluid should be level with the bottom of the hole.

5. If fluid is below bottom of the hole fill with

Dexron Type II or Type III automatic transmission fluid.

Figure 31

1. Hose

clamp

Fuel line

3. Filter

6. Install a new filter and move the hose clamps

close to the filter.

7. Open fuel shut-off valve at fuel tank (Fig. 29).

8. Close the hood.

1217

1. Power

lift pump

2350

Figure 32

2. Plug

Page 34

Maintenance

Front

Wheel T

oe-In

Service Interval/Specification

Maintain toe-in of the front wheels as specified. If uneven tire wear, lawn scuffing or hard steering develop adjustment may be required. Check the toe-in after every 100 operating hours or yearly, whichever occurs first (Fig. 33).

Specification: 1/8–1/4 inch toe-in on front wheels.

Measuring Toe-in

1. Disengage the power take off (PTO), set the

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

2. Push front tires out, at front, to remove normal

looseness in the linkage.

3. Measure, between the rims, at spindle level, in

the front and rear of the wheels (Fig. 33).

4. The front measurement should be less than the

rear, as specified.

Adjusting Toe-In

1. Check the toe-in before you adjust it; refer to

Measuring Toe-In, Page 32.

2. Remove ball joint from one steering lever

(Fig. 33).

3. Loosen jam nut securing ball joint to steering

rod. Rotate ball joint one turn, clockwise to increase or counter clockwise to decrease toe-in.

4. Hold flats on ball joint to align with flats on tie

rod and tighten jam nut.

5. Install ball joint to steering lever and check the

toe-in; refer to Measuring Toe-In, Page 32.

IMPORTANT: If more than one turn is required to meet specifications, alternate between left and right steering rods to maintain steering wheel alignment.

Transaxle

Fluid

Service Interval/Specification

1. Measure

Ball joint flats

here

Figure 33

Jam nut Steering lever

1261

Check fluid level after every 100 hours or yearly whichever comes first. Always keep the fluid level at the full level when the transaxle is cold. The transaxle is a sealed system and no changing of the fluid is required.

Fluid Type: SAE 10W–30 Detergent oil (API service SF or SG)

Checking Fluid Level

1. Park the machine on a level surface, disengage

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

2. Open the hood.

3. Clean around the fluid reservoir (Fig. 34) so

level is clearly visible and so dirt cannot fall into the reservoir if fluid is added.

Page 35

4. When transaxle is cold add oil to “Full Cold”

line on reservoir (Fig. 34).

Maintenance

IMPORTANT: Do not fill above the full cold line as fluid may overflow.

1243

Figure 34

1. Fluid

reservoir

Full cold level

Fuse

Service Interval/Specification

The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. To replace fuses pull up on the fuse (Fig. 35) to remove or replace it.

Fuse: F1–30 amp, blade-type, Main/Starter

F2–25 amp, blade-type, Regulator F3–10 amp, blade-type, Dash F4–10 amp, blade-type, Headlights F5–25 amp, blade-type, Lift

4 3 2

2337

1. Dash

and Cruise control

-10

Amp

Head lights-10 amp

Figure 35

Regulator-25 amp Main-30 amp Lift 25 amp

Headlights

Specification: Bulb # 1156 Automotive Type

Removing the Bulb

1. Disengage the power take off (PTO), set the

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

2. Open the hood. Pull wire connectors off both

bulb holder terminals.

3. Rotate the bulb holder 1/4 turn counterclockwise

and remove it from the reflector (Fig. 36).

4. Push and rotate the bulb counterclockwise until

it stops (approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 37).

Page 36

Maintenance

2. The bulb holder has two tabs (Fig. 36). 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.

Battery

Figure 36

1. Bulb

holder

2. Reflector

3. Tabs

4. Slots

5. Terminals

Installing the Bulb

1. The bulb has metal pins on the side of its base.

Align the pins with the slots in the bulb holder and insert the base into the holder (Fig. 37). Push and rotate the bulb clockwise until it stops.

Service Interval/Specification

Check the electrolyte level in the battery before each use. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Voltage: 12 v, 280 Cold Cranking Amps

Removing the Battery

1. Disengage the power take off (PTO), set the

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

2. Open the hood to see the battery.

3. Remove side panels for clearance when

removing battery (Fig. 39). Remove the wing nuts and screws and lift up to clear pin and slide panel tabs out from steering tower.

1. Bulb

2. Metal

pins

Figure 37

4. Slots

Bulb holder

4. Disconnect the negative (black) ground cable

from the battery post (Fig. 38).

5. Lift the rubber cover up on the positive (red)

cable. Disconnect the positive (red) cable from the battery post (Fig. 38).

6. Remove the battery hold down rods (Fig. 38).

Page 37

Maintenance

1219

Figure 38

1. Negative

Rubber cover

Positive cable (red)

cable (black)

Bolt and wing nut

Hold down rod and wing nut

Installing the Battery

7. Install the battery into the chassis (Fig. 39).

8. Secure battery in chassis with hold down rods.

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

(red) cable to the positive (+) battery post (Fig. 38). Slide the rubber cover over the battery post.

1260

Figure 39

1. Battery

2. Side

3. Screw

panel tabs

Wing nut

5. Pin

Checking Electrolyte Level

1. With the engine off, open the hood to see the

battery.

2. Open covers to see into the cells. The electrolyte

must be up to the lower part of the tube (Fig. 40). Do not allow the electrolyte to get below the plates. (Fig. 40).

10. Using the bolt and wing nut, connect the

negative (black) cable to the negative (–) battery post (Fig. 38).

11. Install side panels by sliding tabs into steering

tower and inserting pin into flange of footrest. Secure with screws and wing nuts (Fig. 39).

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

of distilled water; refer to Adding Water to the Battery, page 35.

1262

Figure 40

1. Filler

caps

Lower part of tube

3. Plates

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.

Page 38

Maintenance

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

2. Lift off the filler caps (Fig. 40).

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 40).

IMPORTANT: Do not overfill the battery because electr sever

e corr

4. Press the filler caps onto the battery.

olyte (sulfuric acid) can cause

osion and damage to the chassis.

Charging the Battery

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

1. Remove the battery from the chassis; refer to

Removing the Battery, page 34.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 35, steps 2–3.

3. Remove the filler caps from the battery and

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

POTENTIAL HAZARD

• Charging the battery pr

WHAT CAN HAPPEN

oduces gasses.

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. Install the battery in the chassis; refer to

Installing the Battery, page 35.

Page 39

Maintenance

Wiring

Diagram

CRUISE SWITCH OPERATION OFF NO CONNECTION

ON 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED

SW7

CRUISE SWITCH

(MOMENTARY)

SW8

(CRUISE DISENGAGE SWITCH)

SWITCH OPENS WHEN

BRAKE IS DEPRESSED

(CRUISE RELAY)

354

CRUISE MAGNET

SW10

3 4

(LIFT SWITCH)

LIFT

PUMP

270 HYDRO

HEADLIGHT HARNESS

BK OR

PK W

PTO CLUTCH

SW3

(PTO SWITCH)

PTO SWITCH IS SHOWN IN OFF POSITION

BUBU

2328

WARNING LIGHT HARNESS

#194 LAMP

PTO

OIL

LOW FUEL

#194 LAMP

OVER RIDE

TEMP

#194 LAMPBATTERY

B+

VOLTAGE COMPARATOR

BATTERY LIGHT MODULE

PK PK

W W

Y Y

GNGN

OR OR

BK BK

HOUR

METER

GYGYGY

C2C1

SW9

(LOW FUEL)

CLUTCH

NMIR

MODULE

SW5

(REVERSE SWITCH)

SWITCH OPENS WHEN

HYDRO PEDAL IS MOVED

TO REVERSE

BKGN T

(KEY OVER RIDE)

SWITCH CLOSES

WHEN KEY IS

TURNED

SW6

Page 40

Maintenance

270 HYDRO

SW4

(IGNITION SWITCH)

OFF-----------NO CONNECTION RUN/LIGHTS----------B I R L RUN---------------B I R START--------------B I R S

1S5

PKOR

10A

25A

4L3

PKBU

10A

(INTERLOCK RELAY)

SW2

(BRAKE SWITCH)

IS DEPRESSED

CLOSES WHEN BRAKE

BRAKE SWITCH

SW1

(SEAT SWITCH)

SEAT SWITCH IS CLOSED

WHEN OPERATOR IS IN

THE SEAT

WIRE COLOR CODES

30A

VIO

GN BU W

F2 25A

BLACK

BROWN

BLUE

GREEN

GREY

ORANGE

REG

OIL

START

MAG

B+

VIOBN R

IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.

OR BN

(START RELAY)

354

PINK

RED

TAN

VIOLET

VIO

WHITE

YELLOW

SPARK PLUG SPARK PLUG

IGNITION MODULES

SOLINOID

SHIFT OIL SWITCH

CLOSES WITH PRESSURE

STARTER

FUEL SOLINIOD

(TEMP. SWITCH)

SWITCH OPEN WITH HIGH TEMPERATURE

354

(KILL RELAY)

GND

Page 41

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 W Pressure washing may damage the electrical system or wash away necessary gr 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 29.

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

page 23.

5. Grease the chassis; refer to Greasing and

Lubrication, page 28.

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

page 25.

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

condition; refer to Spark Plug, page 27. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the electric starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s) and tighten it to 15 ft–lb (20.4 Nm). Do not install the wire on the spark plug(s).

8. Remove the battery from the chassis, check the

electrolyte level, and charge it fully; refer to Battery, page 34. Do not connect the battery cables to the battery posts during storage.

ASH THE MACHINE.

ease at

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 28.

10. For long-term storage (more than 90 days) add

stabilizer/conditioner additive to fuel in the tank (1 oz. per gallon) (8 ml per liter) and proceed as follows:

A. Run the engine to distribute conditioned

fuel through the fuel system (5 minutes).

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

the fuel tank; refer to Fuel Tank, page 30, or operate engine until it stops.

C. Restart the engine and run until it stops.

Repeat, with the “CHOKE” on, until the engine will not restart.

D. Dispose of fuel properly or use within 90

days for other applications. Recycle in accordance with local codes.

Note: 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.

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 ignition and “Key Choice” keys and keep them in a memorable place. Cover the machine to protect it and keep it clean.

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

Page 42

Troubleshooting

g,,

PROBLEM

Starter does not crank

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

POSSIBLE CAUSES

Blade control (PT ENGAGED.

Parking brake is not on.

Operator is not seated.

Battery is dead.

Electrical connections are corroded or loose.

Fuse is blown.

Relay or switch is defective.

Fuel tank is empty

Choke is not ON.

Air cleaner is dirty

Spark plug wire is loose or disconnected.

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

O) is

. 1.

. 3.

CORRECTIVE ACTION

Move blade control (PT DISENGAGED.

Set parking brake.

Sit on the seat.

Charge the battery

Check electrical connections for good contact.

Replace fuse.

Contact Authorized Service Dealer.

Fill fuel tank with gasoline.

Move choke lever to ON. Clean or replace air cleaner

element.

Install wire on spark plug.

Install new spark plug.

, correctly gapped

O) to

Engine loses power

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Air cleaner is dirty

Oil level in crankcase is low

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

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

6. V

ent hole in fuel cap is

plugged.

Dirt in fuel filter

Dirt, water fuel system.

. 6.

, or stale fuel is in

. 2.

. 7.

, or stale fuel is in

. 3.

Replace fuel filter

Contact Authorized Service Dealer.

Reduce ground speed. Clean air cleaner element. Add oil to crankcase.

Remove obstruction from cooling fins and air passages.

Install new spark plug.

Clean or replace the fuel cap.

Replace fuel filter

Contact Authorized Service Dealer.

, correctly gapped

Page 43

Troubleshooting

PROBLEM

Engine overheats.

Abnormal vibration.

Machine does not drive.

POSSIBLE CAUSES

Engine load is excessive.

Oil level in crankcase is low

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

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

Drive control is in “PUSH” position.

2. T

raction belt is worn, loose or

broken.

3. T

raction belt is of

f pulley

, idler

. 3.

. 2.

CORRECTIVE ACTION

Reduce ground speed. Add oil to crankcase.

Remove obstruction from cooling fins and air passages.

1. T

ighten engine mounting

bolts.

2. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Move drive control to “OPERA

Contact Authorized Service Dealer.

TE” position.

Page 44