Form No. 3323-539 Wheel Horse 16–38 HXL Lawn Tractor 71241—200000001 & Up Operator’s Manual Para obtener una versión gratis de este manual en español, escriba a la dirección indicada más abajo. Asegúrese de indicar el modelo y el número de serie de su producto. Pour obtenir gratuitement une version en français de ce manuel, écrivez à l’adresse ci-dessous. N’oubliez pas d’indiquer les numéros de modèle et de série de votre produit. The Toro Company, Attn: Parts Dept.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine Toro replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines . . 2 Safe Operating Practices . . . . . . . . . . . . . . 2 Sound Pressure Level . . . . . . . . . . . . . . . . . 4 Sound Power Level . . . . . . . . . . . . . . . . . . 4 Vibration Level . . . . . . . . . . . . . . . . . . . . . . 4 Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5 Symbols Glossary . . . . . . . . . . . . . . . . .
Safety Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines • This machine meets or exceeds European Standards in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.
Safety • • • Add fuel before starting the engine. Never remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot. If petrol is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until petrol vapors have dissipated.
Safety • • change into neutral and set the parking brake; • Allow the engine to cool before storing in any enclosure. • stop the engine and remove the key. • To reduce the fire hazard, keep the engine, silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease. • Check the grass catcher frequently for wear or deterioration. • Replace worn or damaged parts for safety.
Safety Slope Chart Read all safety instructions on pages 2–8.
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Safety Symbols Glossary Safety alert symbol Dismemberment–Mower in rearward motion Safety alert symbol Stay a safe distance from the machine Read operator’s manual Consult Technical Manual for proper service procedures Thrown or flying objects– Whole body exposure Thrown or flying objects– Rotary side-mounted mower. Keep deflector shield in place Severing toes or foot– mower blade Severing fingers or hand– mower blade Rotating blade can cut off toes or fingers.
Safety Symbols Glossary Cutting element– basic symbol Riding on this machine is allowed only on a passenger seat & only if the driver’s view is not hindered Cutting element– height adjustment Cutting unit–lower Crushing of fingers or hands–Force applied from side Cutting unit-raised Kickback or upward motion–Stored energy Cutting or entanglement of foot–Rotating auger Severing of fingers or hand– impeller blade Keep a safe distance from snowthrower Stay a safe distance from the snowthrower Shut of
Safety Symbols Glossary Fast Slow Fuel Fuel level Decreasing/Increasing On/Run Volume empty Off/Stop Volume full Engine Battery charging conditin Engine start Head lights– Main/high beam Engine stop Brake system Choke Parking brake Engine temperature Clutch PTO (Power Take Off) Engine lubricating oil pressure Engage Disengage Engine lubricating oil level Unlock Lock Key Choice Switch 9
Gasoline and Oil Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive.
Gasoline and Oil Stabilizer/Conditioner Filling the Fuel Tank Using a stabilizer/conditioner in the machine: 1. Shut the engine off and set the parking brake. • Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained. 2. • Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Clean around each fuel tank cap and remove the cap.
Operation Think Safety First Parking Brake Please carefully read all the safety instructions and symbols in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury. Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake Controls Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine. 1. Push the brake pedal (Fig. 2) down and hold it in the depressed position.
Operation Positioning the Seat Using the Blade Control (PTO) The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. The blade control (PTO) engages and disengages power to the blade(s). 1. Engaging the Blade(s) 2. Raise the seat and loosen the adjustment knob (Fig. 3). Move the seat to the desired position and tighten the knob. 1. Depress the brake pedal to stop the machine. 2.
Operation Setting the Height-of-Cut 2 The height-of-cut lever (deck lift) is used to raise and lower the mower to the desired cutting height. 1. The cutting height may be set in one of seven positions from approximately 1 to 4 inches (25 to 102 mm). 2. Pull on the height-of-cut lever (deck lift) and move it to the desired position (Fig. 5). 4 1 3 1505 Figure 6 1. Wheel 2. Wheel bracket 3. Locknut 4.
Operation 6. After the engine starts, slowly move the throttle lever to “FAST” (Fig. 8). If the engine stalls or hesitates, move the throttle lever back to “CHOKE” for a few seconds. Then move the throttle lever to “FAST.” Repeat this as required. Stopping 1. Move the throttle lever to “SLOW” (Fig. 8). 2. Turn the ignition key to “OFF” (Fig. 9). Note: 2 1 If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.
Operation The Safety Interlock System Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless: • You are sitting on the seat • The brake pedal is depressed • The blade control (power take off/PTO) is “DISENGAGED” The safety interlock system is designed to stop the engine if: • • You rise from the seat when the brake pedal is released You rise from the seat when the blade control (PTO) is “ENGAGED”.
Operation POTENTIAL HAZARD • A child or bystander could be backed over by a riding mower with its blade(s) engaged. WHAT CAN HAPPEN • Blade contact will cause serious personal injury or death. HOW TO AVOID THE HAZARD • Do not mow in reverse unless absolutely necessary. • Always look backward and down before backing up. • Use “Key Choice” switch only if you are certain no children or other bystanders will appear in the mowing area.
Operation 5. Put the PTO lever in the “disengage” position and the foot pedal in neutral. Now start the engine. Move the PTO lever to the “engage” position and turn the “Key Choice” key and release. The Operating–in–Reverse warning light should illuminate. Move the PTO lever to the “disengage” position and the Operating–in–Reverse warning light should turn off. 2 1 Pushing the Machine by Hand IMPORTANT: Always push the machine by hand. Never tow the machine because transaxle damage may occur.
Operation 2 3 1 1861 Figure 13 1. Traction control pedal 2. Forward 3. Backward Stopping the Machine To stop the machine, release the traction control pedal, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 12. Remember to remove the key from the ignition switch. POTENTIAL HAZARD • Someone could move or attempt to operate the tractor while it is unattended.
Operation Side Discharge or Mulch Grass Installing the Discharge Cover To convert from side discharge to a mulching mower, install the discharge cover into the opening at the side of the mower. POTENTIAL HAZARD • Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. WHAT CAN HAPPEN • Contact with rotating mower blade(s) and thrown debris will cause injury or death.
Operation Tips for Mowing Grass Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at “FAST.” Air is required to thoroughly cut grass clippings, so do not set the height-of-cut too low or totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
Maintenance Service Interval Chart Service Operation Each Use Oil—initial change 5 Hours X X X Cutter Blade—check X X X Brake—check X X X Chassis—grease X X Foam Air Cleaner—service X X X Paper Air Cleaner—replace X X X Belts—check for wear/cracks X Gasoline—drain X Engine—clean outside X X X More often in dusty, d st dirty conditions X X X Chipped Surfaces—paint X X X X X Battery—charge, disconnect cables X Fuel Filter—replace X Tires—check pressure X X Spark P
Maintenance Greasing and Lubrication Tire Pressure Service Interval/Specification Service Interval/Specification Grease the machine after every 25 operating hours or once a year, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy. Maintain the air pressure in the front and rear tires at 20 psi (138 kPa). Check the pressure at the valve stem after every 25 operating hours or yearly, whichever occurs first (Fig. 16).
Maintenance Brake The brake is on the right side of the rear axle, inside the rear tire (Fig. 17). If the parking brake does not hold securely, an adjustment is required. Checking the Brake 1. 2. 3. Park the machine on a level surface, disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Move the drive control wire to the “PUSH” position; refer to Pushing the Machine by Hand, page 18.
Maintenance Wiring Diagram & $ ! ! % & $ ! ! % ! % & & $ " $ " " & & & & $ $ $ ! ! ! # # ! !! & $ $ ! ! ! & " " & ! ! ! ! $ ! !
Maintenance Fuse 5 5 Service Interval/Specification 1 3 The electrical system is protected by fuses. No maintenance is required, however, if a fuse blows check the circuit wiring for a short. To replace a fuse pull up (Fig. 18) to remove from the socket. Push down to insert. 4 2 Fuse: 10 amp, blade-type. 4 1 1874 Figure 19 2 1. Bulb holder 2. Reflector 3. Tabs 4. Slots 5. Terminals Installing the Bulb 1. 1672 Figure 18 1. Fuse (removed) 2.
Maintenance Battery 2 5 Service Interval/Specification Check the electrolyte level in the battery before each use. Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. 1 Voltage: 12 v, 160 Cold Cranking Amps 4 3 Removing the Battery 1.
Maintenance 1 2 2 3 3 4 1 1878 5 Figure 23 2347 1. Filler caps 2. UPPER line 3. LOWER line Figure 22 1. Battery 2. Battery box 3. Vent tube 2. 3. 4. 4. Slot in battery box 5. Hole in frame Install the battery box and battery into the chassis (Fig. 22). Make sure to slide the end of the vent tube through the hole in the frame (Fig. 22). Using the bolt and wing nut, connect the positive (red) cable to the positive (+) battery post (Fig. 21). Slide the rubber cover over the battery post.
Maintenance 3. Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery is fully charged. Removing the Spark Plug 1. Disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. 2. Open the hood. 3. Pull the wire off the spark plug (Fig. 24).
Maintenance Checking the Spark Plug 1. Fuel Tank Look at the center of the spark plug (Fig. 25). 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. Draining The Fuel Tank POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. IMPORTANT: Never clean the spark plug.
Maintenance Air Cleaner Service Interval/Specification Foam Element: Clean and re-oil after every 25 operating hours, or yearly, whichever occurs first. 1 Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first. 2 3 Note: 1873 Figure 26 1. Hose clamp 2. Fuel line Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 3. Filter Removing the Foam and Paper Elements 1.
Maintenance 4. Carefully slide the foam element off the paper element (Fig. 28). Cleaning the Foam and Paper Elements 1. Foam Element A. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 1 B. Dry the element by squeezing it in a clean cloth. C. Put one or two ounces of oil on the element (Fig. 30). Squeeze the element to distribute the oil. 2 IMPORTANT: Replace the foam element if it is torn or worn. 1864 Figure 28 1. Foam element 5. 2.
Maintenance Engine Oil Service Interval/Specification Change oil: 1 • After the first 5 operating hours. • After every 25 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. 2 1867 Figure 31 1. Paper element 2. Rubber seal Installing the Foam and Paper Elements IMPORTANT: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1.
Maintenance 5. Screw the oil dipstick fully onto the filler tube (Fig. 32). Unscrew the dipstick again and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark. 7. Slowly pour approximately 80% of the specified amount of oil into the filler tube (Fig. 32). Now check the oil level; refer to Checking Oil Level, page 33, steps 4–5. 2 IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged.
Maintenance Change Oil Filter—Service Interval/Specification Cutting Blade Replace the oil filter every 50 hours or every other oil change. To assure a superior quality of cut, keep the blade(s) sharp. For convenient sharpening and replacement, you may want to have an extra blade(s). Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 34. 2.
Maintenance Sharpening the Blade(s) 1. 2 1 Use a file to sharpen the cutting edge at both ends of the blade (Fig. 37). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 3 1 151 Figure 35 1. Cutting edge 2. Curved area 1854 3. Wear/slot forming Figure 37 1. Sharpen at original angle 2. 1. Remove the mower; refer to Removing the Mower, page 37. 2. Carefully tip the mower over.
Maintenance Removing the Mower 1. Park the machine on a level surface, disengage the blade control (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. POTENTIAL HAZARD • The height-of-cut lever (deck lift) is spring-tensioned. 2. Remove the key from the ignition switch and pull the wire off the spark plug. 3. Move the height-of-cut lever (deck lift) into the “D” notch.
Maintenance 11. Remove the hairpin cotter and washer at the mower leveling bracket (Fig. 42). Slide the bracket off the mounting pin. Re-install the washer and hairpin cotter for storage. 4 1 2 5 12. Rotate the leveling bracket up, toward the frame, and hook the long rod into one of the holes to store. Secure long rod with washer and hairpin cotter. Repeat for opposite side of the mower. 3 2384 13. Move the height-of-cut lever (deck lift) into the “D” notch.
Maintenance 3 2 1 3 install the belt. If it is too difficult to install the belt, loosen the bolts and nuts securing the belt guides. IMPORTANT: Do not bend the belt guide(s) away from the pulley. There must be a maximum 1/8” (3.2 mm) between the belt guide(s) and the edge of the pulley to keep the belt on the pulley during operation. If the space is more than 1/8” (3.2 mm), adjust the belt guide(s) and tighten them securely. The belt guide(s) must not contact the pulley. 1890 Figure 43 Top View 1.
Maintenance 8. Mount the slotted mower leveling bracket onto the pin on the height-of-cut arm (Fig. 45). Install the washer and hair pin cotter to secure the mower. Repeat this step on the opposite side of the mower. 2 4 1 2 5 3 1 2384 Figure 46 4 1 3 1. Blade control (PTO) cable 2. Ring end 3. Idler spring 4. Jam nut 5. Mounting bracket 1805 Figure 45 1. Hairpin cotter and washer 2. Long rod 9. 3. Leveling bracket 4.
Maintenance 15. Hook the height-of-cut lift assist spring onto the retaining bolt (Fig. 39), using the spring tool provided with the machine. 3 1 16. Check side-to-side blade level; refer to Side-to-Side Mower Leveling, page 41. 1 2 Blade Drive Belt 90° Removing the Blade Drive Belt 1. Remove the mower; refer to Removing the Mower, page 37. 1890 2. Remove the pulley cover mounting screws and pulley covers from both blade pulleys (Fig. 48). 3.
Maintenance 4. Carefully rotate blade(s) side to side (Fig. 49). Measure between the outside cutting edges and the flat surface (Fig. 49). If both measurements are not within 3/16” (4.8 mm), an adjustment is required; refer to steps 5 and 6. 1 6. Front-to-Rear Blade Slope Check the front-to-rear blade slope any time you install the mower. Before you check the slope, set the air pressure in the front and rear tires to the recommended inflation. Refer “Tire Pressure” (page 23) in the Maintenance Section.
Maintenance (15.875 mm) 8. Rotate lock nuts on eyebolts to change adjustment (Fig. 53). To raise the front of the mower, tighten the eyebolt lock nuts. To lower the front of the mower, loosen the eyebolt lock nuts. 9. After adjusting both eyebolt lock nuts evenly, check the front-to-rear slope again. Continue adjusting eyebolts until the front blade tip is 0–3/8” (0–9.2 mm) lower than the rear blade tip (Fig. 53). 5/8” 1 2 3 4 10.
Maintenance Washing Underside of Mower After each use wash the underside of the mower to prevent grass build-up for improved mulch action and clipping dispersal. 1. 2. Park the machine on a hard, level surface, disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Attach coupling (not supplied) to mower washout fitting and turn water on high (Fig. 54). 3. Lower the mower to the lowest height-of-cut. 4. Sit on the seat and start the engine.
Maintenance Cleaning and Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. IMPORTANT: You can wash the machine with mild detergent and water. DO NOT PRESSURE WASH THE MACHINE.
Maintenance 12. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 13. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.
Troubleshooting PROBLEM Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. p POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade control (PTO) is ENGAGED. 1. Move blade control (PTO) to DISENGAGED. 2. Parking brake is not on. 2. Set parking brake. 3. Battery is dead. 3. Charge the battery. 4. Electrical connections are corroded or loose. 4. Check electrical connections for good contact. 5. Fuse is blown. 5. Replace fuse.
Troubleshooting PROBLEM Engine g over heats. Abnormal vibration. Blade(s) does not rotate. Machine does not drive. Uneven cutting g height. g 48 POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine load is excessive. 1. Reduce ground speed. 2. Oil level in crankcase is low. 2. Add oil to crankcase. 3. Cooling fins and air passages under engine blower housing are plugged. 3. Remove obstruction from cooling fins and air passages. 1. Cutting blade(s) is bent or unbalanced. 1.
