Toro 72200 Operator's Manual

Download

410 Garden Tractor

Model No. 72200—Serial No. 250000001 and Up

Form No. 3353–241

Operator ’s Manual

Original Instructions (EN)

Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important The engine in this product is not equipped

with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126. Other states or federal areas may have similar laws.

The enclosed Engine Owner ’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner ’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

This spark ignition system complies with Canadian ICES–002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB–002 du Canada.

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .

Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . .

Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 12. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 12. . . . . . . . . . . . . . . . . . . .

Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 13. . . . . . . . . . . . . . . . .

Activating and Installing the Battery 13. . . . . . . . . .

Checking the Engine Oil 14. . . . . . . . . . . . . . . . . . .

 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Checking the Tractor Lubrication 14. . . . . . . . . . . .

Learn to Operate the Tractor 14. . . . . . . . . . . . . . . .

Test Driving the Tractor 14. . . . . . . . . . . . . . . . . . . .

Checking the Safety System 14. . . . . . . . . . . . . . . .

Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 15. . . . . . . . . . . . . . . . . . . . . . . .

Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 15. . . . . . . . . . . . . . . .

Starting and Stopping the Engine 15. . . . . . . . . . . .

Operating the Power Take Off (PTO) 16. . . . . . . . .

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

Indicator Control Module 18. . . . . . . . . . . . . . . . . .

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

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

Operating the Attachment Lift Lever 19. . . . . . . . .

Positioning the Seat 19. . . . . . . . . . . . . . . . . . . . . . .

Headlights 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Tilt Steering Wheel 20. . . . . . . . . . .

Pushing the Machine by Hand 20. . . . . . . . . . . . . . .

Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 21. . . . . . . .

Servicing the Engine Oil 22. . . . . . . . . . . . . . . . . . .

Servicing the Air Cleaner 23. . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 25. . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 25. . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 26. . . . . . . . . . . . . . . . .

Servicing the Brake 26. . . . . . . . . . . . . . . . . . . . . . .

Servicing the Fuel Tank 27. . . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 27. . . . . . . . . . . . . . . . . . .

Servicing the Front Wheel Toe-In 28. . . . . . . . . . . .

Transaxle Fluid 28. . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Fuses 28. . . . . . . . . . . . . . . . . . . . . . .

Servicing the Headlights 28. . . . . . . . . . . . . . . . . . .

Servicing the Battery 29. . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 32. . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 33. . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 36. . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and

Printed in the USA

Page

serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

Safe Operating Practices

The following instructions are from ANSI standard B71.1—2003.

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

m–2345

Figure 1

1. Location o f the model and serial numbers

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and 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 you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

General Operation

• Read, understand, and follow all instructions in the

operator ’s manual and on the machine before starting.

• Do not place hands or feet near rotating parts or under

the machine. Keep clear of the discharge opening at all times.

• Allow only responsible adults who are familiar with

the instructions to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc.,

which could be picked up and thrown by the blade.

• Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing up.

• Never direct discharged material toward anyone.

Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blade(s) when crossing gravel surfaces.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general

information worthy of special attention.

Safety

This machine meets or exceeds the B71.1–2003 specifications of the American National Standards Institute, in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay

• Do not operate the mower without either the entire

grass catcher, discharge guard or other safety devices in place and working.

• Slow down before turning.

• Never leave a running machine unattended. Always

turn off blades, set parking brake, stop engine, and remove key before dismounting.

• Disengage blades when not mowing. Stop the engine

and what for all parts to come to a complete stop before cleaning the machine, removing the grass catcher or unclogging the discharge chute.

• Operate the machine only in daylight or good artificial

light.

• Do not operate the machine while under the influence

of alcohol or drugs.

• Watch for traffic when operating near or crossing

roadways.

• Keep children out of the mowing area and under the

watchful care of a responsible adult, not the operator.

• Use extra care when loading or unloading the machine

into a trailer or truck.

• Always wear safety goggles or safety glasses with side

shields when operating mower.

• Data indicates that operators, age 60 years and above,

are involved in a large percentage of riding mower–related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

• Always follow the recommendations for wheel weights

or counterweights.

Slope Operation

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• Mow up and down slopes, not across.

• Watch for holes, ruts, bumps, rocks or other hidden

obstacles. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Choose a low ground speed so you will not have to

stop or shift while on a slope.

• Do not mow on wet grass. Tires may lose traction.

• Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.

• Avoid starting, stopping or turning on a slope. If tires

lose traction, disengage the blades and proceed slowly straight down the slope.

• Be alert and turn the machine off if children enter the

area.

• Before and while backing or changing direction, look

behind, down, and side–to–side for small children.

• Never carry children, even with the blades off. They

may fall off and be seriously injured or interfere with

safe machine operation.

• Children who have been given rides in the past may

suddenly appear in the mowing area for another ride

and be run over or backed over by the mower.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners,

shrubs, trees, or other objects that may block your

view of a child.

Towing

• Tow only with a machine that has a hitch designed for

towing. Do not attached towed equipment except at

the hitch point.

• This product has a limited towing capacity for small

attachments, such as leaf sweepers, rollers or carts.

The combined weight of the attachment and load

should not exceed the weight of the tractor. Use of

these types of attachments should be limited to flat

ground.

• Never allow children or others in or on towed

equipment.

• On slopes, the weight of towed equipment may cause a

loss of traction and control.

• Travel slowly and allow extra distance to stop.

• Keep all movement on slopes slow and gradual. Do

not make sudden changes in speed or direction, which could cause the machine to roll over.

• Use extra care while operating mower with grass

catchers or other attachments; they can affect the stability of the machine. Do not use on steep slopes.

• Do not try to stabilize the machine by putting your

foot on the ground.

• Do not mow near drop-offs, ditches, or embankments.

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

Service

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes and other

sources of ignition.

• Use only an approved gasoline container.

• Never remove the gas cap or add fuel when the

engine is running. Allow the engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where

there is an open flame, spark, or pilot light such as a water heater or other appliances.

• Never fill containers inside a vehicle or on a truck

or trailer with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Never leave a running machine unattended. Always

turn off blades, set parking brake, stop engine, and remove the ignition and KeyChoice keys before dismounting.

• Remove gas-powered equipment from the truck or

trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel

tank or container opening at all times until the fueling is complete. Do not use a nozzle lock-open device.

• If fuel is spilled on clothing, change clothing

immediately.

• Never overfill the fuel tank. Replace gas cap and

tighten securely.

• Never run a machine inside a closed area.

• Keep nuts and bolts tight to be sure the equipment is in

safe working condition.

• Never tamper with safety devices. Check their proper

operation regularly.

• Keep the machine free of grass, leaves, or other debris

build-up. Clean up oil or fuel spillage fuel soaked debris. Allow the machine to cool before storing.

• If you strike a foreign object, stop and inspect the

mower. Repair, if necessary, before restarting.

• Keep hands, feet, hair and loose clothing away from

attachment discharge area, underside of mower and any moving parts while engine is running.

• Do not touch equipment or attachment parts which

may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Battery acid is poisonous and can cause burns. Avoid

contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks and

flames away from battery.

• Use only Toro approved attachments. Warranty may be

voided if used with unapproved attachments.

• Do not mow across slopes exceeding 5 degrees.

• Do not mow up slopes exceeding 10 degrees.

• Do not mow down slopes exceeding 15 degrees.

• If a steep slope must be ascended, back up the hill, and

drive forward down the hill, keeping the machine in gear.

• Use only genuine Toro replacement parts to ensure that

original standards are maintained.

• Never make any adjustments or repairs with the engine

running.

• Check grass catcher components and the discharge

guard frequently and replace with manufacturer’s recommended parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s)

or wear gloves, and use extra caution when servicing them.

• Check brake operation frequently. Adjust and service

as required.

• Maintain or replace safety and instruction decals as

necessary.

Toro Riding Mower Safety

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards.

• Stop the engine, disconnect spark plug wire(s) and

remove key before performing any service, repairs, maintenance or adjustments.

Slope Chart

Example: Compare

slope with folded

edge.

Fold along appropriate line

Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.)

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

83-6620

99-2985

99-5339

93-0302

92-6726

112168

1. Mowing in reverse enabled.

99-8038

2. Power Take-off (PTO)

92-6721

1. Pull the knob out to start the PTO.

92-6720

2. Push the knob in to stop the PTO.

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

Manual.

Operator’s

distance from the battery.

Battery Symbols

Some or all of these symbols are on your battery.

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection; explosive gases can cause blindness and other injuries

5. Wear eye protection

6. Read the

Manual.

7. Keep bystanders a safe distance from the battery.

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

Operator’s

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.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Fill the fuel tank outdoors, in an open area,

when the engine is cold. Wipe up any gasoline that spills.

• Never fill the fuel tank inside an enclosed

trailer.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 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.

• 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 ground.

• 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.

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

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 it is recommended that the fuel tank be drained.

• 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 fuel tank cap and remove the cap. Add

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

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

that may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 22.

Setup

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

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

Description Qty. Use

Bolt, 1/4 x 3/4 inch Hex Nut, 1/4 inch

Key 1 Use in ignition switch. Operator’s Manual

Riding Mower Safety Video

Checking the Tire Pressure

Refer to Checking the Tire Pressure on page 26. Check the front and rear tire pressure. The recommended front and rear tire pressure is 20 psi (83 kPa).

Activating and Installing the Battery

Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.

2 2

1 1

Activating and installing the battery

Read before operating tractor View before operating tractor

4. Slowly pour electrolyte into each battery cell until the

level is up to the upper line on the battery case (Fig. 2).

Important Do not overfill the battery because

electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.

5. Wait five to ten minutes after filling the battery cells.

Add electrolyte, if necessary, until the electrolyte level is up to the upper line on the battery case (Fig. 2).

6. Install the battery filler caps.

Danger

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

1. Filler caps

2. Upper line

2 3

m–5004

Figure 2

3. Lower line

1. Remove the battery from the tractor.

2. Clean the top of the battery with a paper towel. Note: Never fill the battery with electrolyte while the

battery installed in the tractor. Electrolyte could be spilled on other parts and cause corrosion.

3. Remove the vent caps from the battery (Fig. 2).

Warning

Charging the battery produces gasses that can explode.

Never smoke near the battery and keep sparks and flames away from battery.

Note: Make sure the vent caps are installed in the battery.

7. Charge the battery for 1 hour at 10 amps or 2 hours at

5 amps.

8. When the battery is fully charged, unplug the charger

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 3).

3 1

Learn to Operate the Tractor

Learn how to operate the tractor. Read the Operation section starting on page 15.

Test Driving the Tractor

1. Fill the tank with unleaded regular gasoline; Gasoline

and Oil, page 12. Open the fuel shutoff valve and check the fuel hose and fittings for leaks.

2. As applicable, check and test the operation of the

following:

• Engine, choke and throttle controls

• Headlights

• Indicator lights

m–4970

Figure 3

1. Positive Battery Post

2. Negative Battery Post

9. Install the battery in the tractor and connect the battery

cables. Refer to the Installing the Battery on page 30.

Note: Do not run the tractor with the battery disconnected, electrical damage may occur.

3. Red (+) Charger Lead

4. Black (–) Charger Lead

Checking the Engine Oil

Important The tractor is shipped from the factory with

oil in the engine crankcase Check the oil level and add only enough oil to raise the

level to the full mark on the dipstick. Refer to Checking the Engine Oil on page 22.

Checking the Tractor Lubrication

Check the tractor to ensure it is lubricated. Refer to Greasing and Lubrication on page 25.

• PTO clutch and brake

• Lift system

• Parking brake

• Steering

• Tractor operation in forward and reverse

Checking the Safety System

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Refer to Checking the Safety Interlock System on page 16.

Operation

2. Lift the parking brake lever (Fig. 2) forward and

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

Think Safety First

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

Controls

Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine.

Releasing the Parking Brake

1. Push down on the brake pedal (Fig. 2). The parking

brake lever should release.

2. Gradually release the brake pedal.

Figure 2

1. Brake pedal 2. Parking brake lever

m–6516

m–6514

Figure 1

1. Steering wheel

2. Ignition switch

3. Brake pedal

4. Parking brake lever

5. Ground speed selector

6. Throttle lever

7. Choke lever

8. Power take off (PTO)

9. Cruise control switch

10. Indicator control module/Hourmeter

11. Tilt wheel lever

12. Hood opening

13. Attachment lift

Operating the Parking Brake

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

Setting the Parking Brake

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

depressed position.

Starting and Stopping the Engine

Starting the Engine

1. Sit down on the seat.

2. Set the parking brake; refer to Setting the Parking

Brake, page 15.

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 the off position

(Fig. 3).

4. Move the choke lever to the on position (Fig. 3). Note: An engine that has been running and is warm may

not require step 4.

5. Move throttle lever to the fast position (Fig. 3).

6. Turn the ignition key and hold it in the start position

(Fig. 4). When the engine starts, release the key.

Important If the engine does not start after 10 seconds

of continuous cranking, turn the ignition key to off and let the starter motor cool for 60 seconds; refer to Troubleshooting, page 34.

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

(Fig. 3). 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.

Operating the Power Take Off (PTO)

The power take off (PTO) engages and disengages power to the electric clutch.

1. PTO—Off

2. Choke–On

3. Choke–Off

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.

Engaging the Power Take Off (PTO)

1. Pull the power take off (PTO) to on (Fig. 5).

m–6523

Figure 3

4. Throttle lever

5. Fast

6. Slow

1. Off—disengaged 2. On—engaged

Figure 5

m–6524

Figure 4

1. Off

2. Lights

3. Run

4. Start

Stopping the Engine

1. Push the PTO (power take off) to off (Fig. 3).

2. Move the throttle lever between half and full throttle

(Fig. 3).

3. Turn the ignition key to off (Fig. 4).

1208

Disengaging the Power Take Off (PTO)

1. Push the power take off (PTO) to off (Fig. 5).

The Safety Interlock System

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

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 hydro control pedal is in the neutral position.

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

• You rise from the seat when the brake pedal is released

6. With the parking brake released, turn the ignition key

to the RUN run position 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.

7. With the parking brake released, turn the ignition

switch to RUN without starting the engine. Pull the PTO switch to on. Turn the KeyChoice 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.

• You rise from the seat when the power take off (PTO)

is on.

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.

Testing the Safety Interlock System

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

1. Set the parking brake. Move the power take off (PTO)

to the On position. Now turn the ignition key to start while sitting on the seat; the engine should not crank.

2. Push the power take off (PTO) to the off position and

release the parking brake. Now turn the ignition key to the Start position while sitting on the seat; the engine

should not crank.

3. Set the parking brake and move the power take off

(PTO) to the Off position. Rise from the seat and turn the ignition key to the Start position; the engine

should not crank.

4. Set the parking brake and move the power take off

(PTO) to the Off position. While sitting in the seat, start the engine. While the engine is running, release the parking brake and rise slightly from the seat; the

engine should stop.

5. Set the parking brake and move the power take off

(PTO) to the Off position. While sitting in the seat, start the engine. While the engine is running, move the power take off (PTO) to the On position and rise slightly from the seat; the engine should stop.

Setting the KeyChoice Switch to Operate in Reverse

An interlock feature on the tractor prevents the power take off (PTO) from operating when backing up. If you shift into reverse with the PTO engaged (i.e., with mower blades or other attachment running), the PTO will disengage. Do not mow in reverse unless absolutely

necessary.

If you need to use the PTO while backing up, you can turn off this interlock feature using the KeyChoice switch located near the seat bracket (Fig. 6).

Danger

You could back over a child or bystander while the mower blade(s) or other attachment is engaged and cause serious injury or death.

• Do not mow in reverse unless absolutely

necessary.

• Do not insert the KeyChoice key unless it is

absolutely necessary.

• Always look backward and down before

backing up.

• Use the KeyChoice switch only if you are

certain no children or other bystanders will enter the mowing area.

• Be very observant after deactivating the

interlock because the sound of the engine may prevent you from noticing that a child or bystander has entered the work area.

• Always remove both the ignition and

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

1. Engage the PTO.

2. Insert the KeyChoice key into the switch (Fig. 6).

1. Power take off (PT O)

2. Hourmeter

21 3

m–6519

Figure 8

3. Operating-in-Reverse

m–4220

Figure 6

1. KeyChoice switch

3. Turn the KeyChoice key.

A red light on the front console (Fig. 7) turns on, indicating that the interlock is disabled.

m–6519

Figure 7

1. Operating-in-reverse light

4. Shift into reverse and complete your task.

5. Stop the PTO, which will turn off the red light on the

console, to activate the interlock.

6. Remove the KeyChoice key and put it in a safe place

out of reach of children.

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 KeyChoice 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.

PTO (Power Take Off)

The PTO (power take off) light will be on when the ignition 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. 8). It is turned on when the ignition switch is in the run or lights positions. Use the times for scheduling regular maintenance.

Indicator Control Module

The indicator control module (Fig. 8) contains lights for:

• Operating in reverse

• Power take off (PTO)

• Hourmeter

Driving Forward or Backward

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

To go forward or backward, release the parking brake: refer to Releasing the Parking Brake, page 15. 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. 9). 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 KeyChoice 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 9

1. Forward 2. Backward

Raising an Attachment

1. Pull attachment lift lever rearward until latch locks. In

this position the lift will hold the attachment in the up, or raised position.

Lowering an Attachment

1. Pull attachment lift lever rearward, to release lift

pressure, and push the button on top to release the latch. Move lift lever forward to lower attachment.

Stopping the Machine

To stop the machine, release the traction control pedal, disengage the power take off (PTO), and turn the ignition key to off. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 15. Remember to remove the key from the ignition switch.

Caution

Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended.

Always remove the ignition and KeyChoice keys and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Operating the Attachment Lift Lever

The attachment lift lever (Fig. 10) is used to raise and lower various attachments.

m–6531

Figure 10

1. Lift lever 2. Button

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 knobs

(Fig. 11).

2. Slide the seat to the desired position and tighten the

knobs.

m–4982

Figure 11

1. Adjustment knob

Headlights

The headlights are turned on with a separate position, lights, of the ignition switch (Fig. 12). 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 or discharging the battery.

To Push the Machine

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

ignition key to off.

2. Move the drive control rod to the push position. This

disengages the drive system and allows the wheels to turn freely (Fig. 14).

Figure 12

1. Lights

Positioning the Tilt Steering Wheel

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. 13).

2. Move the steering wheel to a comfortable position;

then release the lever to lock.

1208

To Operate the Machine

1. Move the drive control rod to the operate position

(Fig. 14).

Note: The machine will not drive unless the drive control rod is in the operate position.

1. Operate position

2. Push position

Figure 14

3. Drive control rod

M–4566

1203b

Figure 13

1. Tilt lever 2. Steering wheel

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because transaxle damage may occur.

Maintenance

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

Every 25 Hours

Every 50 Hours

Every 100 Hours

Every 200 Hours

Before Storage

Maintenance Procedure

• Check oil level

• Check safety system

• Check brake

• Clean air intake screen

• Check battery electrolyte

• Check air cleaner

• Service foam air cleaner

• Check tire pressure

• Grease chassis

• Check belts for wear/cracks

• Change oil

• Replace fuel filter

• Clean outside of engine

• Replace paper air cleaner

• Check spark plug(s)

• Change oil filter

• Perform all maintenance procedures listed above before storage

• Drain gasoline

• Paint chipped surfaces

• Charge battery and disconnect cables

• Check front wheel toe-in

• Check safety system

• Check brake

After Storage

More often in dusty, dirty conditions

Important Refer to your engine operator’s manual for additional maintenance procedures.

• Check spark plug(s)

• Check battery electrolyte

• Check tire pressure

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.

Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Servicing the Engine Oil

Change the oil after every 100 operating hours. Oil Type: Detergent oil (API service SG, SH, SJ, or

higher) Crankcase Capacity: w/filter, 64 oz. (1.9 l) Viscosity: See the table below.

USE THESE SAE VISCOSITY OILS

3 1

10W–30

5W–20, 5W–30

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

Checking the Engine Oil Level

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

PTO, stop the engine, and remove the key.

2. Clean around the oil dipstick (Fig. 15) so that dirt

cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean

(Fig. 15).

4. Slide the oil dipstick fully into the filler tube, but do

not thread it onto the tube (Fig. 15). Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to, but not over, the F mark on the dipstick.

1. Oil dipstick

2. Filler tube

Figure 15

3. Metal end

m–6532

Changing and Draining the Engine Oil

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

warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly

lower than the opposite side to ensure that the oil drains completely.

3. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

4. Locate a piece of 1/2 inch (13 mm) tubing or hose

long enough to extend past the frame. Slide the tubing or drain hose over the drain valve (Fig. 16).

5. Place a pan below the drain hose. Rotate the oil drain

valve to allow the oil to drain (Fig. 16).

6. When oil has drained completely, close the drain

valve.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

7. Remove the drain hose (Fig. 16). Note: Dispose of the used oil at a recycling center.

1 1216

Figure 16

1. Oil drain cap 2. Drain hose

8. Change the oil filter, if necessary (Fig. 17).

9. Clean around the oil dipstick and unscrew the cap

(Fig. 15).

10.Slowly pour approximately 80% of the specified oil

into the filler tube (Fig. 15). Refer to Servicing the Engine Oil, page 22.

11. Check the oil level; refer to Checking the Engine Oil

Level, page 22.

12.Slowly add additional oil to bring it to the full mark.

3. Place the new filter, open end up, in a shallow pan.

Pour new oil of the proper type in through the center hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by the filter material.

4. Apply a thin coat of clean oil to the rubber gasket on

the replacement filter (Fig. 17).

m–1256

Figure 17

1. Oil filter

2. Gasket

3. Adapter

5. 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 2/3 to 1 turn (Fig. 17).

6. Fill the crankcase with the proper type of new oil;

refer to Changing and Draining the Oil, page 22.

Changing the Engine Oil Filter

Replace the oil filter every 200 hours or every other oil change.

Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to Changing and

Draining the Oil, page 22.

2. Remove the old filter and wipe the filter adapter

(Fig. 17) gasket surface.

Servicing the Air Cleaner

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

Paper Element: Replace after every 100 operating hours. Note: Service the air cleaner more frequently (every few

hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper Elements

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. 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. 18).

m–5117

1. Knob

2. Air cleaner cover

3. Foam element

4. Wing nut

Figure 18

5. Paper element

6. Stud

7. Air cleaner base

m–5115

Figure 19

1. Foam element 2. Oil

Cleaning the Paper Element

1. Lightly tap the element on a flat surface to remove

dust and dirt (Fig. 20).

2. 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.

Figure 20

1. Paper element 2. Rubber seal

m–5118

3. Remove the wing nut and slide the foam and paper air

cleaner assembly off of the stud (Fig. 18).

4. Carefully slide the foam element off of the paper

element (Fig. 18).

Cleaning the Foam Element

1. Wash the foam element in liquid soap and warm water.

When the element is clean, rinse it thoroughly.

2. Dry the element by squeezing it in a clean cloth (do

not wring). Allow the element to air dry.

3. Put oil on the element (Fig. 19). Squeeze the element

to distribute the oil.

Important Replace the foam element if it is torn or

worn.

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. 18).

2. Place the air cleaner assembly onto the air cleaner base

(Fig. 18).

3. Install the air cleaner cover and secure it with the

cover nut (Fig. 18).

Servicing the Spark Plug

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

Type: Champion RC12YC (or equivalent) Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug(s)

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Open the hood.

3. Pull the wire(s) off the spark plug(s) (Fig. 21). Clean

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

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

2. Check the gap between the center and side electrodes

(Fig. 22). Bend the side electrode (Fig. 22) if the gap is not correct.

1. Center electrode insulator

2. Side electrode

Figure 22

3. Air gap (not to scale)

0.030 in.

(0.76 mm)

m–3215

Installing the Spark Plug(s)

1. Install the spark plug(s). Make sure that the air gap is

set correctly.

1218

Figure 21

1. Spark plug wire 2. Spark plug

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 22). If you

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

Important Never clean the spark plug(s). Always

replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

2. Tighten the spark plug(s) to 30 ft-lb (41 N⋅m).

3. Push the wire(s) onto the spark plug(s) (Fig. 21).

Greasing and Lubrication

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. Remove the ignition 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. 23).

2. Lubricate the front axle pivot (Fig. 23).

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. 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 26.

4. Release the brake and move the drive control rod to

the push position; refer to Pushing the Machine by Hand, page 20. Wheels should rotate freely.

5. If both conditions are met no adjustment is required.

Adjusting the Brake

m–6522

Figure 23

Checking the Tire Pressure

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. 24). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 20 psi (138 kPa) front and rear tires

2323

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

the Brake, page 26.

2. Release the parking brake; refer to Releasing the

Parking Brake, page 15.

3. To adjust the brake remove the cotter pin and loosen

the brake adjusting nut slightly (Fig. 25).

4. Carefully insert a 0.015 inch (0.38 mm) feeler gauge

between the outer brake pad and rotor disk (Fig. 25).

5. Tighten the brake adjusting nut until slight resistance

is felt on the feeler gauge when sliding it in and out. Install the cotter pin.

6. Check the brake operation again; refer to Checking the

Brake, page 26.

Important With the parking brake released, the rear

wheels must rotate freely when you push the mower. If the

0.015 inch (0.38 mm) clearance and free wheel rotation cannot be achieved contact your service dealer immediately.

Figure 24

1. Valve stem

Servicing the 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

PTO, and set the parking brake.

0.015in. (0.38 mm)

1. Brake adjusting nut

2. Cotter pin

Figure 25

3. Right Front of Transaxle

M–4567

Servicing the Fuel Tank

Draining The Fuel Tank

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• 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 smoke when draining gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine on a level surface, to ensure the fuel

tank drains completely. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Close fuel shut–off valve at fuel tank (Fig. 26).

1. Hose clamp

2. Fuel line

Figure 27

3. Filter

Servicing the Fuel Filter

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.

1218

Figure 26

1. Fuel shut-off valve

4. Open the hood.

5. Squeeze the ends of the hose clamp together and slide

it up the fuel line toward the fuel tank (Fig. 27).

6. Pull the fuel line off the filter (Fig. 27). Open fuel

shut-off valve and allow gasoline to drain into an approved gas can.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

7. 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 27.

1263

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Close fuel shut–off valve at fuel tank (Fig. 26).

4. Open the hood.

5. Squeeze the ends of the hose clamps together and slide

them away from the filter (Fig. 27).

6. Remove the filter from the fuel lines.

7. Install a new filter and move the hose clamps close to

the filter.

8. Open fuel shut-off valve at fuel tank (Fig. 26).

9. Close the hood.

Servicing the Front Wheel Toe-In

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 every year before storage (Fig. 28).

Specification: 1/8–1/4 inch (3–6mm) toe-in on front wheels.

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

Measuring the Toe-in

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

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

looseness in the linkage.

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

front and rear of the wheels (Fig. 28).

5. The front measurement should be less than the rear, as

specified.

The transaxle is a sealed system and no checking or changing of the fluid is required.

Important If any transaxle problems arise, contact

your local Authorized Service Dealer for help and service.

Servicing the Fuses

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. 29) to remove or replace it.

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

Alternator F2—25 amp, blade-type Dash/Hour meter F3—10 amp, blade-type Head lights F4—10 amp, blade-type

m–1261

1. Measure here

2. Flats

Figure 28

3. Jam nut

4. Steering lever

Adjusting the Toe-In

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

Measuring Toe-In, page 28.

2. Remove ball joint from one steering lever (Fig. 28).

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 (Fig. 28).

4 3 2 1

Figure 29

1. Main—30 amp

2. Alternator—25 amp

3. Dash/Hour meter—10 amp

4. Head lights—10 amp

Servicing the Headlights

Specification: Bulb #1156 Automotive Type

Removing the Bulb

1. Disengage the PTO and set the parking brake.

m–6533

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Open the hood. Pull wire connectors off both bulb

holder terminals.

4. Rotate the bulb holder 1/4 turn counterclockwise and

remove it from the reflector (Fig. 30).

5. Push and rotate the bulb counterclockwise until it stops

(approx. 1/4 turn) and remove bulb from the bulb holder (Fig. 31).

Figure 30

1. Bulb holder

2. Reflector

3. Tabs

4. Slots

5. Terminals

Figure 31

1. Bulb

2. Metal pins

3. Bulb holder

4. Slots

2. The bulb holder has two tabs (Fig. 30). 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.

Servicing the Battery

Warning

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

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after

handling.

Service Interval/Specification

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, 260 Cold Cranking Amps

Removing the Battery

Warning

Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the tractor.

• Do not allow metal tools to short between the

battery terminals and metal parts of the tractor.

Warning

Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always reconnect the positive (red) battery

cable before reconnecting the negative (black) cable.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Open the hood and locate the battery.

m–4972

Figure 32

1. Negative cable

2. Nut, 5/16 inch

3. Bolt, 5/16 inch

4. Rubber cover (red)

5. Positive cable

6. Battery Hold Down Strap

Installing the Battery

1. Install the battery into the tractor (Fig. 33).

2. Secure battery with hold down strap (Fig. 33).

3. Using the bolt and nut, connect the positive (red cover)

cable to the positive (+) battery post (Fig. 32). Slide the rubber cover over the battery post.

4. Using the bolt and nut, connect the negative (black)

cable to the negative (–) battery post (Fig. 32).

5. Install the right side panel by sliding tabs into steering

tower and inserting pin into flange of footrest. Secure with screws (Fig. 33).

4. Remove the right side panel for clearance when

removing battery (Fig. 32). Remove the screws and lift up the panel to clear the pin and slide panel tabs out from the steering tower.

5. Disconnect the negative (black) ground cable from the

battery post (Fig. 32).

6. Lift the red cover up from the positive cable.

Disconnect the positive cable (red cover) from the battery post (Fig. 32).

7. Remove the battery hold down strap (Fig. 32). Remove

battery from the tractor.

1. Battery

2. Side panel tabs

3. Screw

m–4973

Figure 33

4. Pin

5. Right side panel

Checking the Electrolyte Level

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

battery.

2. Look at the side of the battery. The electrolyte must be up to the upper line (Fig. 34). Do not allow the electrolyte to get below the lower line (Fig. 34).

3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 31.

Important Do not overfill the battery because

electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.

5. Wait five to ten minutes after filling the battery cells.

Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 34) on the battery case.

6. Reinstall battery vent caps.

Charging the Battery

1 2 3

Figure 34

1. Filler caps

2. Upper line

3. Lower line

Danger

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

Adding Water to the Battery

m–5004

Warning

Charging the battery produces gasses that can explode.

Never smoke near the battery and keep sparks and flames away from battery.

Important Always keep the battery fully charged

(1.265 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 30.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 31.

3. Make sure the filler caps are installed in battery.

Charge battery for a minimum of 6 to 10 amps for one hour. If the battery is in the fully discharged condition, then the charging requirement is 3 amps for 6 hours.

Important Never over charge the battery. Excessive

charging will shorten the battery life.

4. When the battery is fully charged, unplug the charger

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 35).

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. Remove the battery from the tractor.

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

Note: Never fill the battery with distilled water while the

battery installed in the tractor. Electrolyte could be spilled on other parts and cause corrosion.

3. Remove the vent caps from the battery (Fig. 34).

4. Slowly pour distilled water into each battery cell until

the level is up to the upper line (Fig. 34) on the battery case.

1. Positive Battery Post

2. Negative Battery Post

m–4970

Figure 35

3. Red (+) Charger Lead

4. Black (–) Charger Lead

5. Install the battery in the tractor and connect the battery

cables; refer to Installing the Battery, page 30.

Note: Do not run the tractor with the battery disconnected, electrical damage may occur.

Cleaning and Storage

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

brake, and turn the ignition key to off. Remove the ignition and KeyChoice keys.

2. Remove grass clippings, dirt, and grime from the

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

Important You can wash the machine with mild

detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, lights, engine, and the battery.

3. Check the brake; refer to Servicing the Brake, page 26.

4. Service the air cleaner; refer to Servicing the Air

Cleaner, page 23.

5. Grease the chassis; refer to Greasing and Lubrication,

page 25.

6. Change the crankcase oil and filter; refer to Servicing

the Engine Oil, page 22.

9. Remove the spark plug(s) and check its condition;

refer to Servicing the Spark Plug, page 25. 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 30 ft-lb (40 Nm). Do not install the wire on the spark plug(s).

10.Disconnect the negative battery cable. Clean the

battery and battery terminals. Check the electrolyte level and charge it fully; refer to Servicing the Battery on page 29. Leave the negative battery cable disconnected from the battery during storage.

Important The battery must be fully charged to

prevent it from freezing and being damaged at temperatures below 32°F (0°C). A fully charged battery can be stored one winter season without recharging.

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

replace any part that is damaged.

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 keys from the ignition and KeyChoice switches and keep it in a memorable place. Cover the machine to protect it and keep it clean.

7. Check the tire pressure; refer to Checking the Tire

Pressure, page 26.

8. Prepare the machine for storage when non–use occurs

over 30 days. Prepare machine for storage as follows. A. Add a petroleum based stabilizer/conditioner to

fuel in the tank. Follow mixing instructions from stabilizer manufacture. 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 engine to distribute conditioned fuel through

the fuel system (5 minutes).

C. Stop engine, allow to cool and drain the fuel tank;

refer to Servicing the Fuel Tank, page 27. D. Restart engine and run it until it stops. E. Choke or prime the engine. Start and run engine

until it will not start. Operate primer, if equipped

on machine, several times to ensure fuel remains in

primer system. F. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

Wiring Diagram

PINK

RED

WIRE COLOR CODES

BLACK

BROWN

KEY SWITCH P/N 92–6785

R B

SW4

S I

(IGNITION SWITCH)

OFF–––––––––––NO CONNECTION

RUN/LIGHTS––––––––––B I R L

RUN–––––––––––––––B I R

START––––––––––––––B I R S

YELLOW

TAN

VIOLET

WHITE

VIO

ORANGE

BLUE

GREEN

GREY

BUBNGN

IGNITION SWITCH TERMINAL

LOCATIONS VEIWED FROM BACK.

VIO

5 1

10A

SOLENOID

MAG

FUEL

(KILL RELAY)

235

GND

IGNITION

MODULE

STARTER

+–

B+

25A

VIO

30A

(INTERLOCK RELAY)

235

ORBN

SPARK PLUG

START

SW2

(BRAKE SWITCH)

BRAKE SWITCH

CLOSES WHEN BRAKE

IS DEPRESSED

REG

VIO

SOLENOID

SW1

(SEAT SWITCH)

THE SEAT

SEAT SWITCH IS CLOSED

WHEN OPERATOR IS IN

416XT HYDRO

HEADLIGHT HARNESS

SW3

(PTO SWITCH)

PTO SWITCH IS

SHOWN IN OFF

POSITION

BU BU

PK W

PTO

CLUTCH

WBU

4 2

TGN

NMIR

CLUTCH

MODULE

WARNING LIGHT HARNESS

#194 LAMP

PTO

CPKB

#194 LAMP

OVER RIDE

SW6

SW5

SWITCH CLOSES

WHEN KEY IS

TURNED

(KEY OVER RIDE)

(REVERSE SWITCH)

SWITCH OPENS WHEN

HYDRO PEDAL IS MOVED

TO REVERSE

METER

HOUR

–

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. Operator is not seated. 3. Sit on the seat.

4. Battery is dead. 4. Charge the battery.

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

7. Relay or switch is defective. 7. Contact Authorized Service

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

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

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

4. Spark plug wire is loose or disconnected.

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

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

1. Move blade control (PTO) to DISENGAGED.

5. Check electrical connections for good contact.

Dealer.

element.

4. Install wire on spark plug.

5. Install new, correctly gapped spark plug.

Engine loses power.

Engine overheats.

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

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

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

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

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

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

6. Vent hole in fuel cap is plugged.

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

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

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

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

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

7. Contact Authorized Service Dealer.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

Problem Corrective ActionPossible Causes

Abnormal vibration.

Machine does not drive.

1. Engine mounting bolts are loose.

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

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

1. Drive control is in the push position.

2. Traction belt is worn, loose or broken.

3. Traction belt is off pulley. 3. Contact Authorized Service

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

1. Move drive control to the operate position.

2. Contact Authorized Service Dealer.

Dealer.

Consumer Lawn Tractors and Lawn & Garden Tractors

The Toro Total Coverage Guarantee

A Two-Year Full Warranty

(Limited Warranty for Commercial Use)

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products and Attachments 2 year full warranty

• 300, 400XT, and 5xi Series:

Frame 5 year full warranty Front Axle 5 year full warranty Drive Shaft (5xi Series Only) 5 year full warranty

• All Batteries 1 year full warranty

This warranty covers both the cost of parts and labor, and transportation within a fifteen mile radius of the servicing dealer.

This warranty applies to all consumer Lawn Tractors, Lawn and Garden Tractors, and their attachments.

* Normal residential purposes means use of the product on the

same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply.

Warranty Period

Limited Warranty for Commercial Use

Toro Consumer Products and attachments used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for the following time periods from the date of purchase:

Products

• 300, 400XT, and 5xi Series: Liquid Cooled Gas Engines 1 year limited warranty Air Cooled Gas and Diesel

Engines All other items 1 year limited warranty

• All other Lawn Tractors and

Lawn & Garden Tractors

Warranty Period

2 year limited warranty

90 day limited warranty

Instructions for Obtaining Warranty Service

If you think that your T oro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Y ellow Pages of your telephone directory (look under “Lawn Mowers”) or access our website at www.Toro.com. U.S. Customers may also call toll free: 866–854–9035 to use our 24-hour Toro dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Customer Care Department, Consumer Division Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 Toll Free: 866–854–8930 (U.S. customers) Toll Free: 866–854–9033 (Canada customers)

Owner Responsibilities

You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover:

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

• Pickup and delivery charges for distances beyond a fifteen mile radius from an Authorized Toro Service Dealer.

All repairs covered by this warranty must be performed by an Authorized T oro Service Dealer using Toro approved replacement parts.

General Conditions

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0045 Rev. B

Toro 72200 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual