Toro 73542, 73561 Operator's Manual

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520xi and 522xi

Wheel Horse Garden Tractor

Model No. 73542 and 73561—220000001 and Up

Form No. 3326-686

Operator ’s Manual

Domestic English (EN)

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 This engine 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. Other states or federal areas may have similar laws.

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.

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.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Slope Chart 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 7. . . . . . . . . . . . . . .

Check Before Operating 8. . . . . . . . . . . . . . . . . . . . . .

Opening the Hood 8. . . . . . . . . . . . . . . . . . . . . . . .

Closing the Hood 8. . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Side Panels 8. . . . . . . . . . . . . . . . . .

Adding Fuel 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 9. . . . . . . . . . . . . .

Check for Debris 10. . . . . . . . . . . . . . . . . . . . . . . . .

Check the Safety Interlock System 11. . . . . . . . . . .

Check the Brake 11. . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 11. . . . . . . . . . . . . . . . . . . . . . . .

Controls 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Parking Brake 11. . . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 12. . . . . . . . . . . .

Page

Operating the Power Take Off (PTO) 12. . . . . . . . .

The Safety Interlock System 13. . . . . . . . . . . . . . . .

Gauges and Indicator Lights 14. . . . . . . . . . . . . . . .

Driving Forward or Backward 15. . . . . . . . . . . . . . .

Stopping the Machine 16. . . . . . . . . . . . . . . . . . . . .

Using the Cruise Control 16. . . . . . . . . . . . . . . . . . .

Raising and Lowering Attachments 16. . . . . . . . . . .

Positioning the Seat 17. . . . . . . . . . . . . . . . . . . . . . .

Lights 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Tilt Steering Wheel 18. . . . . . . . . . .

Centering the Steering Wheel (Power Steering

Models) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Smart Turnt Steering Feature 18. . . . . . . . . . . .

Pushing the Machine by Hand 18. . . . . . . . . . . . . . .

Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 19. . . . . . . .

Servicing the Air Cleaner 20. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 21. . . . . . . . . . . . . . . . . . .

Changing Spark Plugs 22. . . . . . . . . . . . . . . . . . . . .

Greasing the Tractor 23. . . . . . . . . . . . . . . . . . . . . .

Maintaining the Tire Pressure 24. . . . . . . . . . . . . . .

Servicing the Brake 24. . . . . . . . . . . . . . . . . . . . . . .

Draining the Fuel Tank 25. . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 26. . . . . . . . . . . . . . . . . . .

Servicing the Front Wheel Toe-In 26. . . . . . . . . . . .

Changing Transaxle Fluid 27. . . . . . . . . . . . . . . . . .

Cleaning the Power Steering Filter (Power Steering

Models Only) 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Fuses 29. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Headlights 29. . . . . . . . . . . . . . . . . . . . . .

Replacing Taillights 29. . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 30. . . . . . . . . . . . . . . . . . . . . .

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

Wiring Diagram 34. . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Front Wheel Toe-in 40. . . . . . . . . . . . . . .

Ensuring that the Steering Linkage is Centered 40.

Checking Tire Pressure 40. . . . . . . . . . . . . . . . . . . .

Activating the Battery 41. . . . . . . . . . . . . . . . . . . . .

Installing the Drawbar Hitch Pin 42. . . . . . . . . . . . .

Checking the Wiring and Fasteners 42. . . . . . . . . . .

Test Driving the Tractor 42. . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 44. . . . . . . . . . . . .

 2000 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

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 at the location shown in Figure 1.

m–3605

Figure 1

1. Model and serial number plate

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.

Determine the left and right side of the machine from the normal operating position.

Safety

This machine meets or exceeds the B71.1-1998 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 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

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

Model No:

Serial No.

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.

The following instructions are from ANSI standard B71.1—1998.

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

General Operation

• Read, understand, and follow all instructions in the

operator ’s manual and on the machine before starting.

• 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.

• Be aware of the mower discharge direction and do not

point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning.

• Never leave a running machine unattended. Always

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

• Turn off blades when not mowing.

• Do not mow on wet grass. Reduced traction could

cause sliding.

• Do not try to stabilize the machine by putting your

foot on the ground.

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow 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.

• 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.

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.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts or bumps. Uneven terrain could

overturn the machine. Tall grass can hide obstacles.

• Use slow speed. Choose a low gear so that you will not

have to stop or shift while on the slope.

• Follow Toro’s recommendations for wheel weight or

counterweights to improve stability.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual. Do

not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose

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

• Do not turn on slopes unless necessary, and then, turn

slowly and gradually downhill, if possible.

• 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.

• Do not use a grass catcher on steep slopes.

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.

• Keep children out of the mowing area and under the

watchful care of another responsible adult.

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

area.

• Before and while backing, look behind and down 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.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners,

shrubs, trees, the end of a fence or other objects that may obscure vision.

Service

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive. – Use only an approved container. – Never remove the gas cap or add fuel when the

engine is running. Allow the engine to cool before

refueling. Do not smoke. – Never refuel the machine indoors. – Never store the machine or fuel container inside

where there is an open flame, such as near a water

heater or furnace.

• Never run a machine inside a closed area.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good 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. Allow the machine to cool before storing.

• Stop and inspect the equipment if you strike an object.

Repair, if necessary, before restarting.

• Grass catcher components are subject to wear, damage

and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components 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.

• Use only genuine Toro replacement parts to ensure that

original standards are maintained.

Toro Riding Mower Safety

• Mow up and down slopes greater than 5°, not across.

• Mow downhill only on slopes above 10°, never mow

uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear.

• Do not operate machine on hillsides or slopes exceeding 15°.

• Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible.

• Do not use a grass catcher on steep slopes. Heavy grass bags could cause loss of control or overturn the machine.

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 standard.

Warning

Engine exhaust contains carbon monoxide, an odorless, deadly poison that can kill you.

Do not run the engine indoors or in an enclosed area.

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

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

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Never leave a running machine unattended. Always

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

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

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

• Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments.

• Do not touch equipment or attachment parts which

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

• Remove obstacles such as rocks, tree limbs, etc. from

the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles.

• 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 genuine replacement parts to ensure that

original standards are maintained.

Slope Chart

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.

On the drive shaft cover

(Part No. 99-6090)

(2) Under the side shield

(Part No. 98-5014)

On the front of the

seat bracket

(Part No. 99-2985)

Under the hood

(Part No. 100-7304)

On the battery strap

(Part No. 93-1265)

On the drive shaft tunnel

(Part No. 80-8760)

On the Battery

(Part No. 104-4163)

On the engine bulkhead

(Part No. 98-5012)

On the Battery

(Part No. 104-4164)

On the front of the

seat bracket

(Part No. 99-5339)

Check Before Operating

Closing the Hood

The hood catch is located at the left hand corner of the grill.

Each time before operating your tractor, check the following:

• Fuel level

• Engine oil level

• Debris on the air-intake screens

• Debris in the engine area

• Debris on the rear transaxle cover

• The safety interlock system

• The brake

Some of these steps will require that you open the hood or remove the side panels on the tractor.

Opening the Hood

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

power take off (PTO), set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

2. Push the hood latch to the left (Fig. 2).

1. Press rearward on the hood catch as you begin to lower

the hood.

2. Push the hood down until the latch closes.

Front of tractor

Figure 3

1. Hood catch 2. Hood hinges

M4227

Removing the Side Panels

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

PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

Figure 2

1. Hood latch

3. Raise the hood to full height.

Caution

Components under the hood will be hot if the tractor has been running. If you touch hot components you may be burned.

Allow the tractor to cool before performing maintenance or touching components under the hood.

m–3314

2. Raise the hood.

3. Lift up and twist each of the two side panel latches

until they line up with the open slot (Fig. 4).

Figure 4

1. Side panel latch 2. Open slot

4. Pull the top of the side panel toward you until the side

panel latches pass through the open slot.

5. Lift the side panel from the tractor.

m–3318

Adding Fuel

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 Do not 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

• 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 fuel stabilizer/conditioner to

the gasoline, as directed by the manufacturer. Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline.

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.

• Do not fill the fuel tank completely full. Add

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

Filling the Fuel Tank

1. Park the machine on a level surface, disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

Note: When filling the tank, make sure that the machine is on a level surface so that adequate air space is allowed.

2. Clean around the fuel tank cap and remove the cap.

3. Add fuel until the fuel level is 1/4 to 1/2 in. (6 mm to

13 mm) below the bottom of the filler neck. This space in the tank allows for expansion of the fuel.

Do not fill the fuel tank completely.

4. Install the fuel tank cap securely.

5. Wipe up any gasoline that may have spilled.

Checking the Engine Oil Level

1. Park the machine on a level surface, disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

2. Open the hood.

3. Clean around the oil dipstick (Fig. 5) so dirt cannot

fall into the dipstick tube and damage the engine.

Using Stabilizer/Conditioner

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

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage, drain the fuel tank.

m–3246

Figure 5

1. Dipstick 2. Oil filler

4. Pull out the oil dipstick and wipe the metal end clean

(Fig. 6).

m–3219

Figure 6

1. Metal en d

m–3412

Figure 7

Arrows show air intake and exhaust path

1. Air intake screens (1 of 3 shown)

5. Slide the oil dipstick fully into the dipstick tube

(Fig. 5).

6. Pull the dipstick out and look at the metal end (Fig. 6).

If the oil level is low (near the L mark), add oil; refer to Engine Oil, page 21.

Important Do not overfill the crankcase with oil

because this may result in engine damage.

Check for Debris

Important Operating the engine with a blocked grass

screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating.

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

PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

2. Check for debris on the air-intake screens (Fig. 7).

3. Wipe away debris before each use and/or during use, if

required.

4. Wipe away any accumulated debris from the rotating air-intake screen (Fig. 8).

Danger

The rotating air-intake screen and drive shaft can catch fingers, hands, and loose clothing, causing amputation or other severe injury when moving.

• Do not operate the tractor without the side

panels and hood in place.

• Keep fingers, hands and clothing clear of the

rotating air-intake screen and drive shaft.

• Stop the engine and remove the ignition key

before performing maintenance.

m–3617

Figure 8

1. Rotating air intake screen

5. Clean any debris build-up from the engine area with a brush or blower.

Important If possible, blow dirt out (Fig. 9), rather

than washing it out. If water is used, keep it away from electrical items.

Operation

Think Safety First

Please carefully read all the safety instructions on pages 3 through 7. Knowing this information could help you, your family, pets, or bystanders avoid injury.

Controls

m–3615

Figure 9

Important Do not clean the machine using pressurized

water. High-pressure washing can damage the electrical system or deplete grease.

6. Clean debris from the rear transaxle cover (Fig. 10). Note: The rear transaxle cover is an air-intake area for

cooling the transaxle.

m–3436

Figure 10

1. Rear transaxle cover

Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine.

8 6

16 10

Check the Safety Interlock System

Always check the interlock system before operating the tractor. Instructions for checking the interlock system are found in the Operation section, page 13.

Check the Brake

Refer to Checking and Adjusting the Brake, page 24.

Figure 11

1. Throttle

2. Choke

3. PTO switch

4. Seat adjustment lever

5. Engine water temperature gauge

6. Attachment lift lever

7. Indicator lights

8. Fuel gauge

9. Hour meter

10. Ignition switch

11. Brake pedal

12. Parking brake lever

13. High–Low range lever

14. Cruise control switch

15. Steering wheel tilt lever

16. Traction control pedal

Using the Parking Brake

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

m–3597

Setting the Parking Brake

1. Push the brake pedal (Fig. NO TAG) down and hold it.

2. Lift the parking brake lever (Fig. NO TAG) up and

gradually take your foot off the brake pedal. The brake pedal should stay down.

Releasing the Parking Brake

1. Push down on the brake pedal (Fig. NO TAG).

The parking brake lever should release.

2. Release the brake pedal.

Starting and Stopping the Engine

Starting

1. Sit down on the seat.

2. Push the brake pedal down. Note: The engine will not start unless you push the brake

pedal down fully.

3. Push the PTO switch to the off position (Fig. 12).

m–3312

Figure 13

1. Stop

2. Run with lights

7. When the engine starts, release the key.

Important Do not crank the engine continuously for

more than 10 seconds at a time. If the engine does not start, allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter.

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

position (Fig. 12). If the engine stalls or hesitates, move the choke lever

back to the on position for a few seconds. Then, move the throttle lever to the desired setting. Repeat this as required.

3. Run

4. Start

m–3257

Figure 12

1. Throttle

2. Choke

4. Move the choke lever to the on position (if the engine

is cold) (Fig. 12).

5. Move the throttle lever halfway to the fast position

(Fig. 12).

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

position (Fig. 13).

3. PTO switch

9. Allow the engine to warm up before using it.

Stopping

1. Move the throttle lever to the slow position (Fig. 12).

2. Allow the engine to run for a short time to cool down.

3. Turn the ignition key to the stop position (Fig. 13).

4. Remove both the ignition and KeyChoice keys when

the equipment is not in use or unattended.

Operating the Power Take Off (PTO)

The power take off (PTO) runs the various powered attachments such as mowers, snowthrowers, and tillers.

If the ignition key is in the run or lights position and the PTO is engaged, the PTO indicator light will be on. When this light is on, it is a reminder: the implement is being powered and the starter will not crank while the PTO is engaged. Always turn off the PTO before getting off the seat.

Engaging the PTO

Operating in Reverse

1. Press the brake pedal to stop the machine.

2. Move the throttle lever to the fast position.

Important For best performance, always use full

throttle when the PTO is on.

3. Pull the PTO switch to the on position (Fig. 14).

Figure 14

1. Push (off-disengaged) 2. Pull (on-engaged)

m–3264

Disengaging the PTO

Push the PTO switch to the off position.

The Safety Interlock System

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the engine from starting unless the following conditions are met:

• You are sitting on the seat

• The brake pedal is depressed

• The PTO is in the off position

The safety interlock system is designed to stop the engine when you do the following:

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

• You rise from the seat when the PTO is in the on

position.

The safety interlock system is designed to stop the PTO when you shift into reverse with the power take off (PTO) engaged.

The tractor has an interlock feature that prevents mowers, snowthrowers, and other PTO powered attachments from operating while the tractor is traveling in reverse. If you shift into reverse with the PTO engaged, the PTO will stop.

If you need to mow or use other PTO powered attachments while in reverse gear, you can temporarily deactivate this interlock. Do not mow while backing up

unless it is absolutely necessary.

Danger

A child or bystander could be backed over by a riding mower with blades engaged and cause serious personal injury or death.

• Do not mow in reverse unless 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 appear in the mowing 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.

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

If you are certain that you can safely mow or operate an attachment in reverse, complete the following procedure:

1. Engage the PTO.

2. Insert the KeyChoice key into the KeyChoice switch

(Fig. 15).

Note: Do not insert the KeyChoice key unless it is absolutely necessary to mow or operate an attachment in reverse. Always remove both the ignition and the KeyChoice keys and put them in a safe place out of the reach of children when leaving the unit unattended.

9. Fully press the brake pedal, set the parking brake, push

the PTO switch to the Off position, and start the engine.

10.Pull the PTO switch to the On position and rise

slightly from the seat; the engine should stop.

m–4260

Figure 15

1. Reverse interlock key

3. Turn the KeyChoice key clockwise until it stops and

release it. A red light illuminates on the front console (Fig.

NO TAG) to serve as a reminder that the interlock has been deactivated.

4. Remove the KeyChoice key. Once you deactivate the interlock, it stays in this

mode—with your mower blade or PTO powered attachment operating whenever you back up—and the console light stays on until you either disengage the PTO or turn off the engine.

Testing the Safety Interlock System

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

1. Fully press the brake pedal. Pull the PTO switch to the

On position.

2. Turn the ignition key to the Start position. The starter

should not crank.

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

to the Run position without starting the engine.

12.Pull the PTO switch to the On position; you should

hear an audible click indicating that the PTO is activated and the PTO light should illuminate.

13.Move the foot pedal to reverse; you should hear an

audible click, indicating that the PTO is deactivated, and the PTO light should turn off.

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

to the Run position without starting the engine.

15.Pull the PTO switch to the On position.

16.Turn the KeyChoice key and release it. The

Operating–in–Reverse warning light should illuminate.

17.Move the foot pedal to reverse; the PTO and PTO light

on the dash should remain on.

18.Push the PTO switch to the Off position; the PTO light

and the Operating–in–Reverse warning light should turn off.

Gauges and Indicator Lights

The indicator lights (Fig. 16) illuminate when certain controls are activated and when major malfunctions occur that need immediate attention.

1 2 3 4 5 6

3. Push the PTO switch to the Off position and release

the brake pedal.

4. Turn the ignition key to the Start position. The starter

should not crank.

5. Fully press the brake pedal and set the parking brake.

Push the PTO switch to the Off position and rise from the seat.

6. Turn the ignition key to the Start position. The starter

should not crank.

7. Fully press the brake pedal and set the parking brake.

Push the PTO switch to the Off position and start the engine.

8. With the engine running, release the parking brake and

rise slightly from the seat; the engine should stop.

1. Parking brake light

2. PTO (power take off) light

3. Battery light

4. Operating–in–Reverse warning light

m–3317

Figure 16

5. Oil pressure light

6. Cruise control light

7. Engine oil temperature gauge

8. Fuel gauge

Parking Brake Light

Fuel Level Gauge

When the parking brake light is on, it indicates the parking brake is set. The machine will not drive while the parking brake is set.

PTO Light

When the PTO light is on, it indicates the implement is being powered. The PTO clutch must be disengaged before the engine will start.

Battery Light

The battery light will be on when the key is in the run or lights positions if the battery voltage is below 12.1 volts or above 15.0 volts. If the light comes on at a higher RPM, it is important to have your battery and electrical system checked and the problem corrected.

Operating–in–Reverse Warning Light

The Operating–in–Reverse warning light will illuminate whenever the KeyChoice key 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 PTO is disengaged or the engine is shut off.

When the light is on, look behind and use extra caution when backing. Be especially watchful for children and pets.

Oil Pressure Light

When the oil light is on, it indicates the engine oil pressure is low. After the engine starts the light should go out. When the engine is running, the light comes on if the oil pressure drops below a safe operating level. If the light comes on while the engine is running, stop the engine

immediately and correct the cause of low oil pressure.

This gauge shows the level of fuel remaining.

Hour Meter

The hour meter (Fig. NO TAG) records the amount of time the engine has run. Use it to schedule regular maintenance.

Driving Forward or Backward

1. Stop the tractor.

Important Do not shift gears with the tractor in

motion. Internal transmission damage may result.

Important Do not force the shift lever. Applying

slight pressure to the traction control pedal while shifting will help the gears engage.

2. Shift into high (H) or low (L) forward speed with the

High-Low lever (Fig. NO TAG).

Note: Use low for best mowing performance and smoothest operation with all attachments. Use high for transporting or where conditions permit higher speed.

Danger

Driving with excessive speed on slopes can cause you to rollover or lose control, resulting in serious injury or death to you or bystanders.

• Do not shift into neutral while moving.

• Do not allow the tractor to roll freely in neutral

on slopes.

• Read, understand, and follow all instructions in

the Operator’s Manual and on the machine before starting.

Cruise Control Light

The cruise control light indicates that the cruise control system is activated.

Engine Oil Temperature Gauge

This gauge shows the oil temperature in the engine. If the gauge enters the red zone, disengage the PTO and allow the engine to cool while continuing to run the engine.

If the gauge does not show temperatures dropping, stop

the engine immediately, clean the air intake screens, and/or correct the cause of high temperature.

3. Place the throttle control in the fast position for best

performance. (The throttle control regulates engine revolutions per minute.)

4. Place your foot on the traction control pedal and

slowly press on the top of the pedal to move forward, or on the bottom of the pedal to move backward (Fig.

17).

Note: The farther you move the pedal in either direction, the faster the machine will move in that direction.

Figure 17

1. Traction control pedal

2. Brake pedal

5. To slow down, release the pressure on the traction

control pedal and step on the brake pedal.

3. Forward

4. Backward

m–3258

Stopping the Machine

1. Release the traction control pedal.

2. Step on the brake pedal.

3. Disengage the PTO.

4. Lower the attachment lift.

5. Turn the ignition key to the stop position to stop the

engine.

6. Set the parking brake before getting off; refer to

Setting the Parking Brake, page 12.

7. Remove the ignition and KeyChoice keys from the

switches.

m–3313

Figure 18

1. Cruise control

Engaging the Cruise Control

1. Drive the tractor forward and obtain the desired speed.

2. While holding your foot steady on the traction control

pedal, push the cruise control switch (Fig. 18) to the set position.

This locks the traction control in position.

3. Remove your foot from the traction control. Note: If you initially set the cruise control to any speed

other than full speed, you can speed up with your foot on the traction pedal for as needed. When you release the traction pedal, the cruise speed you set previously resumes automatically.

Important If you accidentally press the cruise control

while the engine is running and you are not moving, the machine will subsequently operate at partial speed in forward and will not operate in reverse. To correct this situation, move the cruise control switch to the off position or press the brake pedal to disengage the cruise control.

Disengaging the Cruise Control

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.

Using the Cruise Control

The cruise control is a switch (Fig. 18) on the right fender that maintains a set traction control position without foot pressure. The cruise control only operates when moving forward.

To disengage the cruise control, complete one of the following steps:

• While holding your foot steady on the traction control,

move the cruise control switch to the off position (Fig. 18).

• Press the brake pedal.

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

Raising and Lowering Attachments

Raise and lower attachments using the attachment power lift lever. This lever is located to the right of the steering wheel (Fig. 19).

m–3258

Figure 19

1. Attachment power lift lever

Raising Attachments

1. Start the tractor.

2. Pull the lift lever up to raise the attachment (Fig. 20).

Lowering Attachments

1. Start the tractor.

2. Push the lift lever down to lower the attachment

(Fig. 20).

Positioning the Seat

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

1. Move the adjustment lever sideways to unlock seat

(Fig. 21).

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

lever to lock the seat into position.

Important Ensure that the seat is locked in position

before operating.

m–3315

Figure 20

1. Lift lever, Up 2. Lift lever, Down

3. Release the lever when the attachment has reached the

desired height. The attachment will remain in the raised position until

you lower it again.

Warning

When the engine is off, attachments in the raised position may gradually lower, possibly pinning or injuring you or a bystander.

Figure 21

1. Adjustment lever

M3320

Lights

The lights turn on whenever you turn the ignition key to or past the lights position (Fig. 22). You can turn then on even if the engine is not running; therefore remove the ignition key when leaving the machine unattended so that no one can accidentally turn on the lights and discharge the battery.

Lower the attachment lift before stopping the engine.

3. Continue turning the steering wheel by the degree to

which it is off center.

m–3312

Figure 22

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. 23).

2. Move the steering wheel to a comfortable position;

then release the lever to lock it in place.

4. Turn the steering wheel in the other direction until the

front wheels aim straight ahead. The steering wheel should now be centered.

The Smart Turn Steering Feature

The Smart Turn Steering feature automatically lowers the speed of the tractor in tight turns. The decrease in speed is directly proportional to the sharpness of the turn, up to a maximum speed reduction of 40 percent. This allows you to make turns at higher speeds without having to change the speed control position. After the turn, the original speed is automatically restored.

The Smart Turn Steering feature does not affect engine speed.

This system was set at the factory and should not need adjustment.

Danger

Driving with excessive speed while turning can cause you to rollover, resulting in serious injury or death to you or bystanders.

m–3259

Figure 23

1. Tilt lever 2. Steering wheel

Centering the Steering Wheel (Power Steering Models)

The power steering may not always return the steering wheel to the centered position when you turn the wheels straight forward. If this happens, center the steering wheel using the following procedure:

1. Note the degree to which the steering wheel is out of

center.

2. Turn the steering wheel all the way in the opposite

direction until the front wheels no longer turn.

• Do not rely on the Smart Turn steering feature

to avoid accidents while turning.

• Read, understand, and follow all instructions in

the Operator’s Manual and on the machine before starting.

Pushing the Machine by Hand

Important Do not tow the machine because

transmission damage may occur. Always push the machine by hand.

1. Disengage the PTO and stop the engine.

2. Move the High-Low range lever to the neutral position

(N). This allows the rear wheels to turn freely.

3. Push the machine to the desired location.

4. Place the lever high or low after moving the machine,

and set the parking brake.

Maintenance

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

25 Hours

50 Hours

100 Hours

200 Hours

Maintenance Procedure

• Engine oil—check level

• Brakes—check

• Safety System—check

• Air-intake screens—clean

• Engine area—clean

• Rear transaxle cover—clean

• Engine air precleaner—clean

• Tires—check pressure

• Battery—check electrolyte level

• Transaxle—check oil level

• Grease fittings—grease

• Power take off (PTO) belt—check tension

• Engine oil—change

• Engine air filter—replace

• Fuel filter—replace

• Engine oil filter—change

• Transaxle oil and oil filter—change

• Power steering filter—have it cleaned by your Authorized Service Dealer

• Spark plugs—change

• Chipped surfaces—paint

• Brakes—check

• Safety System—check

• Air-intake screens—clean

• Rear transaxle cover—clean

• Engine air precleaner—clean

• Tires—check pressure

Yearly/Storage Service

• Battery—check electrolyte level

• Grease fittings—grease

• Power take off (PTO) belt—check tension

• Engine oil—change

• Engine air filter—replace

• Fuel filter—replace

• Engine oil filter—change

• Transaxle oil and oil filter—change

• Spark plugs—change

More often in dusty, dirty conditions

Initially, perform this operation after 5 hours

Initially, perform this operation after 50 hours

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

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 Air Cleaner

Foam Element: Clean and 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. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

2. Open the hood.

3. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage (Fig. 24).

m–3214

Figure 24

1. Air cleaner cover

2. Knob

3. Cover nut

4. Cover

5. Foam element

6. Paper element

7. Rubber seal

8. Air cleaner base

4. Loosen the knob on the air cleaner cover and remove

the cover (Fig. 24).

5. Carefully slide the foam element off the paper element

(Fig. 24).

6. Unscrew the cover nut and remove the cover and paper

element (Fig. 24).

Cleaning the Foam Element

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

2. When the element is clean, rinse it thoroughly.

3. Dry the element by squeezing it in a clean cloth.

4. Put one or two ounces of oil on the element (Fig. 25).

Important Replace the foam element if it is torn or

worn.

Servicing the Engine Oil

Change oil after the first 5 operating hours and then after every 100 operating hours. Change the oil filter every 200 hours of operation or every other oil change.

Oil Type: Detergent oil (API service SG or SH)

m–3247

Figure 25

1. Foam element 2. Oil

5. Squeeze the element to distribute the oil.

Checking the Paper Element

Inspect the element for tears, an oily film, damage to the rubber seal, excessive dirt, or other damage (Fig. 26). If any of these conditions exit, replace the filter.

Important Do not clean the paper element with

pressurized air or liquids, such as solvent, gas, or kerosene.

m–3248

Figure 26

1. Paper element 2. Rubber seal

Crankcase Capacity: w/filter, 2.1 qts. (2.0 l) Viscosity: Refer to the following table.

USE THESE SAE VISCOSITY OILS

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

Changing the Engine Oil

1. Start the engine and let it run for 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 ensure that the oil drains completely.

3. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

Important To prevent engine damage, always operate

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

Installing the Foam and Paper Elements

1. Carefully slide the foam element onto the paper air

cleaner element (Fig. 24).

2. Slide the air cleaner assembly and cover onto the long

rod.

3. Install the cover nut finger-tight against the cover (Fig.

24).

Note: Ensure that the rubber seal is flat against the air cleaner base and cover.

4. Install the air cleaner cover and knob (Fig. 24).

5. Close the hood.

4. Open the hood.

Caution

Components under the hood will be hot if the tractor has been running. If you touch hot components you may be burned.

Allow the tractor to cool before performing maintenance or touching components under the hood.

5. Place a pan below the oil drain.

6. Open the drain by turning it counterclockwise 1/8 turn

and pulling out on it (Fig. 27).

m–3262

Figure 27

1. Oil drain

7. When the oil has drained completely, close the drain

by pushing it in and turning it clockwise, 1/8 turn.

8. Dispose of the used oil at a certified recycling center.

9. Slowly pour approximately 80% of the specified

amount of oil into the oil filler tube (Fig. 28).

m–3246

Figure 28

1. Oil filler tube

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

Level, page 9.

11. Slowly add additional oil to bring the oil level to the

full mark on the dipstick.

1256

Figure 29

1. Oil filter

2. Gasket

3. Adapter

3. Wipe the filter adapter gasket surface (Fig. 29).

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

the replacement filter (Fig. 29).

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 1/2 turn (Fig. 29).

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

refer to Changing Oil, page 21, steps 9 through 11.

7. Dispose of the used oil filter at a certified recycling

center.

Changing Spark Plugs

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

Type: Champion RC-12YC (or equivalent) Air Gap: 0.030” (0.76 mm)

Important Overfilling the crankcase with oil may

cause engine damage.

Changing the Engine Oil Filter

1. Drain the oil from the engine; refer to Changing Oil,

page 21, steps 1 through 8.

2. Remove the old filter (Fig. 29).

Removing the Spark Plug

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

attachment lift, stop the engine, and remove the ignition key.

2. Open the hood.

3. Pull the wires off the spark plugs (Fig. 30).

4. Clean around the spark plugs to prevent dirt from

falling into the engine and potentially causing damage.

5. Remove the spark plugs and metal washers.

Installing the Spark Plugs

1. Install the spark plugs and metal washers.

2. Ensure that the air gap is set correctly.

3. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to

29.8 Nm).

4. Push the wires onto the spark plugs (Fig. 30).

5. Close the hood.

m–3246

Figure 30

1. Spark plug wire 2. Spark plug

Checking the Spark Plugs

1. Look at the center of the spark plugs (Fig. 31).

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 Do not clean the spark plugs. Always

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

2. Check the gap between the center and side electrodes

(Fig. 31) and bend the side electrode, if the gap is not correct.

Greasing the Tractor

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 Add Grease

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

attachment lift, stop the engine, and remove the ignition key.

2. Clean the grease fittings with a cloth.

3. Scrape off any paint from the fittings.

4. Connect a grease gun to each fitting in turn.

5. Pump grease into the fittings until grease begins to

ooze out of the bearings.

6. Wipe up any excess grease.

Where to Add Grease

1. Lubricate the left-hand and right-hand spindles until

grease begins to ooze out of the bearings (Fig. 32).

2. Lubricate the front axle pivot (Fig. 32).

1. Center electrode insulator

2. Side electrode

Figure 31

3. Air gap (not to scale)

0.030”

(0.76 mm )

m–3215

m–3240

Figure 32

3. Open the drive shaft maintenance cover on the tractor

tunnel near the seat by unscrewing the two screws securing it, then raising it (Fig. 33).

m–3422

Figure 33

1. Drive shaft maintenance cover

Danger

The rotating, cooling fan and drive shaft can catch fingers, hands, feet, hair, and loose clothing, causing amputation or other severe injury.

• Do not operate the tractor without the drive

shaft cover in place.

• Keep fingers, hands and clothing clear of the

rotating, fan and drive shaft.

• Stop the engine and remove the ignition key

before performing maintenance.

m–3420

Figure 35

7. If your tractor has manual steering, put one pump of

grease into the steering housing (from underneath the frame) (Fig. 36).

m–3409

Figure 36

Maintaining the Tire Pressure

4. Lubricate the three grease fittings (Fig. 34).

m–4224

Figure 34

5. Replace and secure the cover.

6. Grease the fitting on the brake pedal (Fig. 35).

Check the pressure at the valve stem after every 25 operating hours or monthly, whichever occurs first (Fig. 37). Check the tires when they are cold to get the most accurate pressure reading. If the tire pressure is low, fill the tire to the following pressure:

Pressure: 20 psi (138 kPa) front and rear

m–3319

Figure 37

1. Valve stem

Servicing the Brake

Check the parking brake before each use. If the parking brake does not hold securely, adjust it.

Checking the Brake

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

PTO, put the High-Low range lever in the neutral position.

Important With the parking brake released, the rear

wheels must rotate freely when you push the tractor. If brake action and free wheel rotation cannot be achieved, contact your Authorized Service Dealer immediately.

2. Set the parking brake, stop the engine, and remove the

ignition key.

3. Push the tractor forward.

The rear wheels must lock and skid. If the wheels turn and do not lock, adjust the brake; refer to Adjusting the Brake.

Adjusting the Brake

1. Place the transmission in neutral.

2. Depress the brake pedal.

There should be 2 in. (51 mm) of free travel (Fig. 38) before the brake begins to engage.

2”

m–3418

Figure 38

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 that the

fuel tank drains completely.

2. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

3. Close the fuel shut-off valve at the fuel tank (Fig. 40

& 41).

3. Turn the brake adjustment nut at the rear of the tractor

(Fig. 39) until there is 2 in. (51 mm) of free travel.

m–3417

Figure 39

1. Brake adjustment nut

Important Do not overtighten the adjustment nut.

m–3263

Figure 40

1. Fuel shut-off valve

5. Remove the filter from the fuel lines.

m–2487

Figure 41

1. Hose clamp

2. Fuel line

3. Fuel shut-off valve

4. Loosen the hose clamp and slide it up the fuel line away from the fuel shut-off valve (Fig. 41).

5. Pull the fuel line off the fuel shut-off valve (Fig. 41).

Note: Some fuel will flow out from the hose as it is

disconnected from the valve.

6. Attach a 5/16 in. internal diameter hose to the valve to help drain the fuel into the container.

7. Open the valve and allow gasoline to drain into a gas can or drain pan.

Important Do not turn or unscrew the fuel shut-off

valve.

8. Remove the drain hose.

9. Install the fuel line onto the fuel shut-off valve.

10.Slide the hose clamp close to the valve to secure the

fuel line (Fig. 41).

Note: The fuel shut-off valve should normally be left open, except for service on the fuel system or when the tractor is transported on a trailer.

m–3365

Figure 42

1. Hose clamp

2. Fuel line

3. Filter

4. Flow direction arrow

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

the filter. Ensure that the flow direction arrow points toward the

engine.

7. Open the fuel shut-off valve at the fuel tank (Fig. 40

& 41).

8. Replace the side panels and close the hood.

Servicing the Front Wheel Toe-In

Maintaining correct front wheel toe-in is important for safety, Smart Turn steering operation, and ease of use. If uneven tire wear, lawn scuffing, or hard steering develop, you may need to adjust the toe-in of the front wheels. Check the toe-in after every 100 operating hours or once a year, whichever occurs first.

Maintain the following specification: 1/8–1/4 inch (3.5–6.5 mm) toe-in on the front wheels.

Replacing the Fuel Filter

Replace the fuel filter after every 100 operating hours.

1. Disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

2. Close the fuel shut-off valve at the fuel tank (Fig. 40 & 41).

3. Open the hood and remove the side panels.

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

them away from the filter (Fig. 42).

Measuring Toe-In

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

attachment lift, stop the engine, and remove the ignition key.

2. Turn the wheels straight ahead.

3. Push the front of the tires out to remove normal

looseness in the linkage.

4. Measure the distance between both of the front tires at

spindle level (at the front and rear of the wheels) (Fig.

43).

The front measurement should be 1/8 to 1/4 in. (3 to 6 mm) less than the rear measurement. If adjustment is needed, refer to Adjusting Toe-In.

m–3421

Figure 43

Adjusting Toe-In

1. Loosen the jam nuts at the ends of the steering rods

(Fig. 44).

Changing Transaxle Fluid

Check the fluid level every 25 hours. Always keep the fluid level in the correct operating range on the dipstick when the transaxle is cold.

Replace the transaxle fluid and filter at 50 hours initially, then every 200 hours thereafter.

Fluid Type: SAE 10W-30 Detergent oil (API service SG, SH or above)

Transaxle Capacity:

Total system capacity: 6.0 qts. Approximate refill capacity: 4.5 qts.

Fluid Type: SAE 10W-30 Detergent oil (API service SG, SH or above)

Checking the Transaxle Oil

1. Park the machine on a level surface.

m–3397

Figure 44

1. Jam nut 2. Steering rod

2. Rotate both steering rods equal amounts to adjust the

toe-in to 1/8 to 1/4 in. (3 to 6 mm).

3. Hold each tie rod end with one wrench and tighten the

jam nut with a second wrench.

Important Ensure that the flat surface on the top of

the front tie rod ends is parallel to the bottom of the steering arm (Fig. 45).

2. Disengage the PTO, set the parking brake, lower the

attachment lift, stop the engine, and remove the ignition key.

3. Tilt the seat up.

4. Clean around the transmission dipstick (Fig. 46) so dirt

cannot fall into the filler hole and damage the transaxle.

m–3260

Figure 46

1. Transmission dipstick and filler tube

m–3583

Figure 45

View from front of tractor looking at end of tie rod

1. This 2. Not this

4. Check the toe-in; refer to Measuring Toe-In.

5. Pull out the transmission dipstick and wipe the metal

end clean (Fig. 46).

6. Slide the dipstick fully into the filler tube (Fig. 46).

7. Pull the dipstick out and look at the metal end (Fig.

47). When the transaxle is cold, oil should be in the

operating range, below the full line on the dipstick.

m–2467

Figure 47

1. Operating range 2. FULL line

8. If the oil level is low, slowly pour only enough SAE 10W-30 detergent oil into the filler tube to raise the level to the full line.

Important Do not fill above the full line because the

fluid may overflow.

Draining the Transaxle Oil

1. Warm up the transaxle oil by driving the tractor.

2. Park the machine on a level surface to ensure that the

oil drains completely.

3. Turn off the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key.

4. Place a pan below the transaxle drain.

5. Open the drain by removing the plug (Fig. 48).

Figure 49

1. Transaxle filter

2. Gasket

2. Wipe the filter adapter gasket surface (Fig. 49).

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

the replacement filter (Fig. 49).

4. Install the replacement transaxle filter to the filter

adapter. Turn the filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 49).

3. Adapter

1256

Filling the Transaxle Oil

1. Slowly pour the specified refill capacity of oil into the

filler tube (Fig. 46).

2. Start the engine, let it run for 30 seconds at high idle,

and cycle the steering wheel several times (power steering models only) to fill the filter and hydraulic lines.

m–3322

Figure 48

1. Transaxle drain plug

6. When the oil has drained completely, wipe the plug clean, apply pipe sealant to the plug, and install it.

7. Dispose of the used oil at a certified recycling center.

Changing the Transaxle Filter

1. Remove the transaxle filter (Fig. 49).

3. Stop the engine.

4. Check the fluid level; refer to Checking Transaxle

Fluid Level, page 27.

5. Slowly add additional oil to bring the oil level to the

full mark on the dipstick.

Cleaning the Power Steering Filter (Power Steering Models Only)

Have the power steering filter cleaned after the first 50 hours; then every 200 hours. Please have your Authorized Service Dealer clean the filter.

Replacing Fuses

The electrical system is protected by fuses. They require no maintenance. However, if a fuse blows, check the component and circuit for a malfunction or short.

To replace a fuse, pull it out of the fuse box and insert a new fuse of the same type and size that you removed (Fig.

50).

1 2 3 4

m–3316

Figure 50

1. F1; main-30 amp

2. F2; regulator-25 amp

3. F3; dash, interlock-10 amp

4. F4; headlights-10 amp

Replacing Headlights

Specification: Bulb # 1156 Automotive Type

Removing the Bulb

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

attachment lift, stop the engine, and remove the ignition key.

2. Open the hood.

3. Pull the wire connectors off both bulb holder

terminals.

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

remove it from the reflector (Fig. 51).

5. Push and rotate the bulb counterclockwise until it stops

(approx. 1/4 turn) and remove the bulb from the bulb holder (Fig. 52).

Figure 52

1. Bulb

2. Metal pins

3. Bulb holder

4. Slots

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

2. Align the two tabs on the bulb holder with the slots in

the reflector and insert the bulb holder into the reflector (Fig. 51).

3. Rotate it 1/4 turn clockwise until it stops.

4. Push the wire connectors onto the terminals on the

bulb holder.

5. Close the hood.

Replacing Taillights

Specification: Bulb GE 194

1. Bulb holder

2. Reflector

3. Tabs

1 4

Removing the Bulb

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

attachment lift, stop the engine, and remove the ignition key.

2. Remove the two screws securing the lens (Fig. 53).

Figure 51

4. Slots

5. Terminals

Removing the Battery

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

attachment lift, stop the engine, and remove the ignition key.

Figure 53

1. Lens

2. Screws

3. Bulb

4. Socket

3. Pull the lens out far enough so you can remove the bulb socket (Fig. 53).

4. Pull the bulb from the socket (Fig. 53).

Installing the Bulb

1. Push a new bulb into the socket (Fig. 53).

2. Install the bulb socket in the lens and push the lens

into the tractor (Fig. 53).

3. Secure the lens with the two screws removed previously (Fig. 53).

m–3321

2. Remove the front grill by pulling it outward toward

you.

3. Remove the battery shield (Fig. 54).

m–5073

Figure 54

1. Negative cable (black)

2. Positive cable (red)

3. Bolt (2)

4. Washer (2)

5. Locknut (2)

6. Battery shield

7. Hold–down rod

8. Wire tie

Servicing the Battery

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.

Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Battery size: 12 v, 380 Cold Cranking Amps

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

Danger

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 connect the positive (red) battery cable

before connecting the negative (black) cable .

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

battery post (Fig. 54).

Important Always disconnect the negative (black)

cable first.

5. Disconnect the positive (red) cable from the battery

post (Fig. 54).

6. Remove the battery by lifting it up, then pulling it out

(directly toward you) from the tractor.

Important Always hold the battery vertical to avoid

spilling battery acid.

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. 55). Do not allow the electrolyte to fall below the Lower line (Fig. 55).

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

distilled water; refer to Adding Water to the Battery

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.

Adding Water to the Battery

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

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

3. Remove the vent caps from the battery (Fig. 55).

4. Slowly pour distilled water into each battery cell until

the electrolyte level is up to the Upper line (Fig. 55) on the battery case.

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. 55) on the battery case.

1. Vent caps

2. Upper line

6. Reinstall the battery vent caps.

Charging the Battery

Charging the battery produces gasses that can explode.

m5004

Figure 55

3. Lower line

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).

Warning

1. Remove the battery from the chassis; refer to Removing the Battery, page 30.

2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 31.

3. Make sure the vent caps are installed in the battery. Charge the battery for 1 hour at 25 to 30 amps or 6 hours at 4 to 6 amps. Do not overcharge the battery.

4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 56).

m4970

Figure 56

1. Positive Battery Post

2. Negative Battery Post

3. Red (+) Charger Lead

4. Black (–) Charger Lead

Cleaning and Storage

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

engine, and remove the ignition and KeyChoice keys.

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

external parts of the entire machine, especially the engine.

3. Clean dirt and chaff from the outside of the engine’s

cylinder head fins and blower housing; refer to Check for Debris, page 10.

Important You can wash the machine with mild

detergent and water. Do not use high pressure water to wash the machine. Pressure washing may damage the electrical system or wash away necessary grease at friction points. Avoid excessive use of water, especially near the control panel, lights, engine, and the battery.

4. Check the brake; refer to Servicing the Brake, page 24.

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

Cleaner, page 20.

6. Grease the chassis; refer to Greasing the Tractor,

page 23.

7. Change the crankcase oil; refer to Servicing Engine

Oil, page 21.

8. Check the tire pressure; refer to Maintaining the Tire

Pressure, page 24.

5. Install the battery in the tractor and connect the battery cables; refer to Installing the Battery

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

Installing the Battery

1. Place the battery onto the chassis (Fig. 54).

Important Always connect the positive (red) cable

first.

2. Using the bolt, washer and locknut, connect the positive (red) cable to the positive (+) battery post (Fig. 54).

3. Using the bolt, washer and locknut, connect the negative (black) cable to the negative (–) battery post (Fig. 54).

4. Replace the battery shield and secure to the chassis with the hold-down rods and wing nuts.

Important Keep the battery shield in place to protect

the battery from heat.

5. Replace the grill.

9. For storage over 30 days, prepare the tractor as

follows: A. Add a petroleum based stabilizer/conditioner to

fuel in the tank. Follow mixing instructions from stabilizer

manufacturer. (1 oz. per gallon). Do not use an

alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective

when mixed with fresh gasoline and used at all times. B. Run the engine to distribute conditioned fuel

through the fuel system (5 minutes).

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

tank; refer to Draining the Fuel Tank, page 25. D. Restart the engine and run it until it stops. E. Choke the engine. F. Start and run the engine until it will not start again. G. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned

gasoline over 90 days.

10.Remove the spark plugs and check their condition;

refer to Changing Spark Plugs, page 22.

11. With the spark plugs removed from the engine, pour

two tablespoons of engine oil into the spark plug hole.

12.Use the electric starter to crank the engine and

distribute the oil inside the cylinder.

13.Install the spark plugs and tighten to recommended

torque; refer to Changing Spark Plugs, page 22.

Note: Do not install the wire on the spark plug(s).

14.Remove the battery from the chassis, check the

electrolyte level, and charge it fully; refer to Servicing the Battery, page 30.

Note: Do not connect the battery cables to the battery posts during storage.

Important The battery must be fully charged to

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

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

replace any part that is damaged.

16.Paint all scratched or bare metal surfaces.

Paint is available from your Authorized Service Dealer.

17.Store the machine in a clean, dry garage or storage

area.

18.Remove both the ignition and KeyChoice keys and put

them in a safe place place out of the reach of children.

19.Cover the machine to protect it and keep it clean.

Wiring Diagram

RED

PINK

RTPK

WIRE COLOR CODES

BROWN

BLACK

BKBNBU

SW4

RUN---------------B I R

RUN/LIGHTS----------B I R L

OFF-----------NO CONNECTION

(IGNITION SWITCH)

START--------------B I R S

TAN

BLUE

VIOLET

WHITE

YELLOW

VIO

GREY

ORANGE

GREEN

IGNITION SWITCH TERMINAL

OR VIORBN

LOCATIONS VEIWED FROM BACK.

10A

VIO

FUEL

SOLINIOD

SPARK PLUG

SHIFT

SOLINOID

OIL

START

STARTER

PRESSURE

OIL

SWITCH

CLOSES WITH

B+

MAG

(KILL RELAY)

GND

235

MODULES

IGNITION

SPARK PLUG

REG

25A

VIO

30A

235

OR BN

(INTERLOCK RELAY)

235

SW2

WHEN BRAKE IS

DEPRESSED

BRAKE SWITCH CLOSES

(BRAKE SWITCH)

SW1

(SEAT SWITCH)

THE SEAT

SEAT SWITCH IS CLOSED

WHEN OPERATOR IS IN

(START RELAY)

532

VIO

20/22 Kohler

ORBK

HEADLIGHT HARNESS

REAR HARNESS

TAIL LIGHTS

ORBK

VIO

SW7

PKPK

DCE

SW8

356

CRUISE SWITCH

SW3

PTO SWITCH IS

SHOWN IN OFF

(PTO SWITCH)

PTO

CLUTCH

BRAKE IS DEPRESSED

SWITCH OPENS WHEN

(CRUISE DISENGAGE SWITCH)

CRUISE MAGNET

BN BN

Cruise Module

(MOMENTARY)

CRUISE SWITCH OPERATION

OFF NO CONNECTION

ON 3 AND 2 CONNECTED

MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED

POSITION

BU BU

VIO

1N4004

47uF

TEMP.

GAUGE

FUEL

SW9

SW5

HOUR

#194

CLUTCH

NMIR

MODULE

SWITCH CLOSES

WHEN KEY IS

TURNED

(KEY OVER RIDE)

SWITCH OPENS WHEN

HYDRO PEDAL IS MOVED

TO REVERSE

(REVERSE SWITCH)

METER

SENDER

TEMP.

LAMP

FUEL

SENDER

LAMP

#194

GND

SW6

PARK BRAKE IS ENGAGED

(PARK SWITCH)

AKJ

#194 LAMP

PTO

SWITCH CLOSES WHEN

#194 LAMP

PARK

BATTERY

FAD

VOLTAGE

COMPARATOR

B+

BATTERY LIGHT MODULE

5 3

GNGNPKWW

VIOVIO

#194 LAMP

OIL

WARNING LIGHT HARNESS

CRUISE

OVER RIDE

Troubleshooting

Problem Possible Causes Corrective Action

The starter does not crank.

The engine cranks, but will not start.

1. The PTO is on. 1. Move the PTO to the off position.

2. The brake is not depressed or

the parking brake is not on.

3. The operator is not seated. 3. Sit on the seat.

4. The electrical connections are

corroded or loose.

5. A fuse is blown or loose. 5. Correct or replace fuse.

6. The relay or switch is broken. 6. Contact Authorized Service

7. The battery is discharged. 7. Charge or replace the battery.

8. The safety interlock system is

malfunctioning.

9. A broken starter or starter

solenoid.

10.Seized internal engine

components.

1. Incorrect starting procedure. 1. Refer to Starting and Stopping

2. Set the parking brake.

4. Check the electrical connections for good contact.

Dealer.

8. Contact your Authorized Service Dealer.

9. Contact your Authorized Service Dealer.

10.Contact your Authorized Service Dealer.

the Engine, page 12.

2. The fuel tank is empty. 2. Fill with fresh fuel.

3. The fuel shut-off valve is closed.

4. Dirt, water, or stale fuel is in the fuel system.

5. Clogged fuel line. 5. Clean or replace.

6. The spark plug lead is disconnected.

7. The kill relay is not energized. 7. Contact your Authorized

8. A spark plug is damaged or dirty.

9. The ignition is broken. 9. Contact your Authorized

3. Open the fuel shut-off valve.

4. Drain and flush the fuel system; add fresh fuel.

6. Reconnect the spark plug.

Service Dealer.

8. Replace the spark plug.

Service Dealer.

Problem Corrective ActionPossible Causes

The engine starts, but does not keep running

The engine runs, but knocks or misses.

1. Misadjusted or broken choke or throttle control cable.

2. The fuel tank vent is restricted. 2. Contact your Authorized

3. Dirt or water in the fuel system. 3. Drain and flush the fuel system;

4. The fuel filter is clogged. 4. Replace the fuel filter.

5. The fuel pump is broken. 5. Contact your Authorized

6. The carburetor is broken. 6. Contact your Authorized

7. Loose wires or poor connections.

8. The cylinder head gasket is broken.

9. A fuse is blown or loose. 9. Correct or replace fuse.

1. Dirt, water, or stale fuel is in the fuel system.

2. A spark plug lead is loose. 2. Reconnect the spark plug lead.

1. Contact your Authorized Service Dealer.

Service Dealer.

add fresh fuel.

Service Dealer.

7. Check and tighten wire connections.

8. Contact your Authorized Service Dealer.

1. Drain and flush the fuel system; add fresh fuel.

The engine will not idle.

3. A spark plug is broken. 3. Replace the spark plug.

4. Loose wires or poor connections.

5. Engine overheating. 5. See Engine Overheats.

1. The fuel tank vent is restricted. 1. Contact your Authorized

2. Dirt, water, or stale fuel is in the fuel system.

3. A spark plug is damaged or broken.

4. Carburetor idle passages are plugged.

5. The idle speed adjusting screw is incorrectly set.

6. The fuel pump is broken. 6. Contact your Authorized

7. Low compression. 7. Contact your Authorized

8. The air cleaner element is dirty. 8. Clean or replace.

4. Check and tighten wire connections.

Service Dealer.

2. Drain and flush the fuel system; add fresh fuel.

3. Replace the spark plug.

4. Contact your Authorized Service Dealer.

5. Contact your Authorized Service Dealer.

Service Dealer.

Problem Corrective ActionPossible Causes

The engine overheats.

The engine loses power.

1. The crankcase oil level is incorrect.

2. The fuel mixture is lean. 2. Contact your Authorized

3. Excessive loading. 3. Reduce load; use lower ground

4. The air intake screens are dirty. 4. Clean with every use.

5. The cooling fins and air passages under the engine blower housing and/or the rotating air intake screen are plugged.

1. The crankcase oil level is incorrect.

2. The air cleaner element is dirty. 2. Clean or replace.

3. Dirt, water, or stale fuel is in the fuel system.

4. The engine is overheated. 4. See Engine Overheats.

5. A spark plug is damaged or dirty.

1. Fill or drain to the full mark.

Service Dealer.

speed.

5. Clean with every use.

1. Fill or drain to the full mark.

3. Drain and flush the fuel system; add fresh fuel.

5. Replace the spark plug.

The tractor will not operate in either direction because the engine bogs down or stalls.

The tractor goes forward only at partial speed and is slow or does not operate in reverse.

6. Low compression. 6. Contact your Authorized Service Dealer.

7. The vent hole in the fuel tank

vent fitting is plugged.

8. The engine load is excessive. 8. Reduce ground speed.

1. The brake is sticking. 1. Contact your Authorized

1. The engine is running at partial

speed.

2. The linkage is out of

adjustment.

3. There is internal hydro wear. 3. Contact your Authorized

7. Contact your Authorized Service Dealer.

Service Dealer.

1. Move the throttle to the fast position.

2. Contact your Authorized Service Dealer.

Service Dealer.

Problem Corrective ActionPossible Causes

The tractor will not operate in either direction.

The tractor operates erratically.

1. The High-Low range lever is in neutral (N).

2. The transmission oil is low. 2. Fill to the full mark on the

3. The transmission is broken. 3. Contact your Authorized

4. The control linkage needs adjustment or replacement.

5. The parking brake was not released or the parking brake is not releasing.

6. The drive shaft or wheel hub key has been damaged.

1. The transmission oil level is low.

2. The transmission control linkage needs adjustment or replacement.

1. Move the High-Low range lever to L or H.

transmission oil dipstick when the transmission is cold.

Service Dealer.

4. Contact your Authorized Service Dealer.

5. Release the parking brake or check the linkage.

6. Contact your Authorized Service Dealer.

1. Fill to the full mark on the transmission oil dipstick when the transmission is cold.

2. Contact your Authorized Service Dealer.

The tractor operates in both directions, but with a loss of power. This condition becomes worse as the transmission becomes hot.

Abnormal vibration or noise.

3. The transmission is broken. 3. Contact your Authorized Service Dealer.

1. The transmission oil level is

low.

2. The transmission shows signs

of overheating or water contamination.

3. The cooling fan and/or

transmission cooling fins are faulty or dirty.

4. The engine is not operating at

full throttle

1. The engine mounting bolts are

loose.

2. The idler pulley or cutter deck

blade is loose.

3. The transaxle cooling fan is

loose.

4. There is a problem with the

electric clutch

1. Fill to the full mark on the transmission oil dipstick when the transmission is cold.

2. Replace the transmission oil and filter.

3. Clean the transmission and/or replace the fan (contact your Authorized Service Dealer).

4. Increase the engine speed to full throttle.

1. Tighten the engine mounting bolts.

2. Tighten the appropriate pulley.

3. Contact your Authorized Service Dealer.

4. Contact your Authorized Service Dealer.

Problem Corrective ActionPossible Causes

PTO belt comes off of pulleys, slips, or fails.

1. Belt tension is incorrect. 1. Refer to the attachment operator’s manual.

2. Mower level is incorrect 2. Refer to the attachment operator’s manual.

3. Blade slope in transport is

incorrect.

4. Cutter deck belt guide is loose

or incorrectly adjusted.

5. Belt is worn or damaged. 5. Refer to the attachment

6. A pulley is damaged. 6. Contact your Authorized

7. The engine is not at full throttle.

8. The PTO is being engaged

when cutter deck is in tall uncut grass or weeds.

9. The mower is overloaded

because mulching or bagging requires more power.

3. Refer to the attachment operator’s manual.

4. Adjust and tighten belt guide.

operator’s manual.

Service Dealer.

7. Always operate engine powered attachments at full throttle.

8. Engage PTO only in shorter or previously cut grass.

9. Reduce ground speed when mulching or bagging.

10.The mower is overloaded because too much grass is being cut at a time.

11.The mower is overloaded because deck is clogged with grass clippings.

12.The attachment is overloaded because tractor is mowing too fast for conditions.

10.Cut tall grass and weeds with mower in its highest position, making a second pass cutting at height desired.

11.Clean the mower.

12.Reduce ground speed.

Setup

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Bolt, 1/4-20 x 0.88 in. Washer, 1/4 in. Hex Nut, 1/4-20 in.

Hitch Pin Hairpin Cotter Flat Washer, 0.50 in inside diameter

Key 2 Use in ignition and KeyChoice switches Operator’s Manual

Engine Operator’s Manual Riding Mower Safety Video

2 2 2

1 1 1

Attaching the battery cables

Installing the drawbar hitch pin

Read before operating the tractor Read before operating the tractor Watch before operating the tractor

Checking Front Wheel Toe-in

With the tractor on a level surface, check to make sure the front wheel toe-in is between 1/8 and 1/4 in. For instructions on adjusting toe-in, refer to Servicing the Front Wheel Toe-in, page 26.

Ensuring that the Steering Linkage is Centered

1. With the tractor on a level surface, turn the steering

wheel fully to the left and check the clearance of the left hand spindle stop to the stop on the front axle.

There should be a slight clearance between the stops (Fig. 57).

1. Left hand spindle stop

2. Axle stop

Front of Tractor

Figure 57

3. Clearance

m–4265

2. Repeat for the right front tire in a right turn.

3. If the stops on one side hit, and on the other side have

clearance, shorten the tie rod on the side that hits, and equally lengthen the tie rod on the opposite side until both sides have clearance.

4. Check the toe-in adjustment.

Checking Tire Pressure

Check front and rear tire pressure. The correct front and rear tire pressure is 20 psi (138 kPa).

Activating the Battery

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.

Purchase bulk electrolyte with 1.265 specific gravity battery supply outlet.

Danger

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

m-5004

Figure 58

1. Filler caps

2. Upper line

3. Lower line

7. Charge the battery for 10 to 15 minutes at 25 to

30 amps or 30 minutes at 4 to 6 amps.

• 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.

1. Remove the battery from the tractor; refer to

Removing the Battery, page 30.

Note: Never fill the battery with electorlyte while the battery installed in the tractor. Electrolyte could be spilled on other parts and cause corrosion.

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

3. Remove the vent caps from the battery (Fig. 58).

4. Slowly pour electrolyte into each battery cell until the

level is up to the upper line (Fig. 58) on the battery case.

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 (Fig. 58) on the battery case.

6. Install battery filler caps.

Warning

Charging the battery produces gasses that can explode.

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

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

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 59).

1. Positive Battery Post

2. Negative Battery Post

Figure 59

3. Red (+) Charger Lead

4. Black (–) Charger Lead

m-4970

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

cables; refer to Installing the Battery, page 32.

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

Installing the Drawbar Hitch Pin

Insert the drawbar hitch pin into the drawbar hitch and secure it with a 0.50 in. inside diameter flat washer and hairpin cotter (Fig. 60).

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

following:

• Engine, choke and throttle controls

• Gauges

• Headlights and taillights

• Indicator lights

• PTO clutch and brake

• Lift system

• Service and parking brakes

• Transmission controls

• Steering

1. Drawbar hitch pin

2. Drawbar hitch

2 4

Figure 60

3. .50” Flat washer

4. Hairpin cotter

m–2481

Checking the Wiring and Fasteners

• Inspect the tractor for any loose electrical connections

and secure them as required.

• Check the wire routing to make sure moving parts do

not interfere with wires and cause a short.

• Ensure that all fasteners are tight.

Test Driving the Tractor

• Tractor operation in forward and reverse

7. Test the operation of the safety interlock system, refer

to Testing the Safety Interlock System, page 14.

1. Check the oil level in the crankcase, refer to Checking

the Engine Oil, page 9.

2. Check the oil level in the transaxle, refer to Checking

the Transaxle Oil, page 27.

3. Grease the tractor, refer to Greasing the Tractor,

page 23.

4. Fill the tank with unleaded regular gasoline with an

octane rating of at least 85.

5. Open the fuel shutoff valve and check the fuel hose

and fittings for leaks.

Consumer Riding Products

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 2 year full warranty

• 300 and 5xi Series Tractors:

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 riding products 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 and 5xi Series Tractors Liquid Cooled Gas Engines 1 year limited warranty Air Cooled Gas and Diesel

Engines All other items 1 year limited warranty

• All other Riding Products 90 day limited warranty

Warranty Period

2 year 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 800-421-9684 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 800-348-2424 (U.S. customers) 877-484-9255 (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. –

Toro 73542, 73561 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual