MODEL NO. AG15538A 15.5 HP 38 INCH LAWN TRACTOR · Assembly · Operation · Maintenance · Service and Adjustments · Storage · Troubleshooting · Repair Parts For Parts and Service, contact our authorized distributor: call 1-800-849-1297 For Technical Assistance: call 1-800-829-5886 190287 Rev. 1 7.28.04 RD/MH PRINTED IN U.S.A. TABLE OF CONTENTS Warranty ................................................ 2 Safety Rules .......................................... 3 Product Specifications ........................... 6 Assembly/Pre-Operation ....................... 8 Operation............................................. 11 Maintenance Schedule ........................ 17 Maintenance ........................................ 17 Service and Adjustments..................... 21 Storage ................................................ 27 Troubleshooting ................................... 28 Repair Parts......................................... 32 WARRANTY The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in materials and workmanship. For a period of two (2) years from date of purchase by the original consumer purchaser, we will repair or replace, at our option, without charge for parts or labor incurred in replacing parts, any part which we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions. 1. This warranty does not apply to the engine, other than EHP manufactured transaxle/ transmission components, battery (except as noted below) or components parts thereof. Please refer to the applicable manufacturer's warranty on these items. 2. Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser. Transportation charges for any parts submitted for replacement under this warranty must be paid by the purchaser unless such return is requested by Electrolux Home Products. 3. Battery Warranty: On products equipped with a Battery, we will replace, without charge to you, any battery which we find to be defective in manufacture, during the first ninety (90) days of ownership. After ninety (90) days, we will exchange the Battery, charging you 1/12 of the price of a new Battery for each full month from the date of the original sale. Battery must be maintained in accordance with the instructions furnished. 4. The Warranty period for any products used for rental or commercial purposes is limited to 90 days from the date of original purchase. 5. This Warranty applies only to products which have been properly assembled, adjusted, operated, and maintained in accordance with the instructions furnished. This Warranty does not apply to any product which has been subjected to alteration, misuse, abuse, improper assembly or installation, delivery damage, or to normal wear of the product. 6. Exclusions: Excluded from this Warranty are belts, blades, blade adapters, normal wear, normal adjustments, standard hardware and normal maintenance. 7. In the event you have a claim under this Warranty, you must return the product to an authorized service dealer. Should you have any unanswered questions concerning this Warranty, please contact: Electrolux Home Products, Inc. Outdoor Products Customer Service Dept. 250 Bobby Jones Expressway Augusta, GA 30909 USA In Canada contact: Electrolux Canada Corp. 7075 Ordan Drive Mississauga, Ontario L5T 1K6 LIMITED WARRANTY giving the model number, serial number and date of purchase of your product and the name and address of the authorized dealer from whom it was purchased. THIS WARRANTY DOES NOT APPLY TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR OUR EXPRESSED WARRANTIES. Some areas do not allow the limitation of consequential damages or limitations of how long an implied Warranty may last, so the above limitations or exclusions may not apply to you. This Warranty gives you specific legal rights, and you may have other rights which vary from locale to locale. This is a limited Warranty within the meaning of that term as defined in the MagnusonMoss Act of 1975. 2 SAFETY RULES IMPORTANT: This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. WARNING: In order to prevent accidental starting when setting up, transporting, adjusting or making repairs, always disconnect spark plug wire and place wire where it cannot contact spark plug. WARNING: Do not coast down a hill in neutral, you may lose control of the tractor. WARNING: Tow only the attachments that are recommended by and comply with specifications of the manufacturer of your tractor. Use common sense when towing. Operate only at the lowest possible speed when on a slope. Too heavy of a load, while on a slope, is dangerous. Tires can lose traction with the ground and cause you to lose control of your tractor. WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. · 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. · Stop engine before removing grass catcher or unclogging 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. · 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. · Keep machine free of grass , leaves or other debris build-up which can touch hot exhaust / engine parts and burn . Do not allow the mower deck to plow leaves or other debris which can cause buildup to occur. Clean any oil or fuel spillage before operating or storing the machine . Allow machine to cool before storage. I. GENERAL OPERATION · Read, understand, and follow all instructions in the manual and on the machine before starting. · Only allow 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 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. II. SLOPE OPERATION Slopes are a major factor related to lossof-control and tipover 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. DO: · Mow up and down slopes, not across. · Remove obstacles such as rocks, tree limbs, etc. 3 SAFETY RULES · 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 the manufacturer's recommendations for wheel weights 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 the 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: · 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 mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in. · 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. · Do not use grass catcher on steep slopes. · Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. IV. SERVICE · Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. - Use only an approved container. - Never remove gas cap or add fuel with the engine running. Allow 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 a water heater. · Never run a machine inside a closed area. · Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. · Never tamper with safety devices. Check their proper operation regularly. · Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage. Allow machine to cool before storing. · Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. · Never make adjustments or repairs with the engine running. · 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. · Check brake operation frequently. Adjust and service as required. III. 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 machine off if children enter the area. · Before and when backing, look behind and down for small children. · Never carry children. They may fall off and be seriously injured or interfere with safe machine operation. · Never allow children to operate the machine. 4 SAFETY RULES · Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. · Never carry passengers or children even with the blades off. · Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing. · Never carry children. They may fall off and be seriously injured or interfere with safe machine operation. · Keep children out of the mowing area and under the watchful care of another responsible adult. · Be alert and turn machine off if children enter the area. · Before and when backing, look behind and down for small children. · Mow up and down slopes (15° Max), 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. · Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly straight down the slope. · If machine stops while going uphill, disengage blades, shift into reverse and back down slowly. · Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible. 5 PRODUCT SPECIFICATIONS GASOLINE 1.25 CAPACITY AND UNLEADED TYPE: REGULAR OIL TYPE SAE 30 (ABOVE 32°F) (API-SG-SL): SAE 5W-30 (BELOW 32°F) OIL CAPACITY: 3 PINTS SPARK PLUG: CHAMPION RC12YC (GAP: .030") GROUND SPEED (MPH): FORWARD: 1ST 1.1 2ND 2.2 3RD 3.3 4TH 4.4 5TH 4.9 REVERSE: 1.4 TIRE PRESSURE: FRONT:14 PSI REAR: 12 PSI CHARGING 3 AMPS BATTERY SYSTEM: 5 AMPS HEADLIGHTS BATTERY: AMP/HR: 28 MIN. CCA: 230 CASE SIZE: U1R BLADE BOLT TORQUE: 27-35 FT. LBS. CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manufactured to give you the best possible dependability and performance. Should you experience any problem you cannot easily remedy, please contact your nearest authorized service center/ department We have competent, welltrained technicians and the proper tools to service or repair this tractor. Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor properly. Always observe the "SAFETY RULES". CUSTOMER RESPONSIBILITIES · Read and observe the safety rules. · Follow a regular schedule in maintaining, caring for and using your tractor. · Follow the instructions under "Maintenance" and "Storage" sections of this owner's manual. WARNING: This tractor is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest authorized service center/department (See REPAIR PARTS section of this manual). 6 UNASSEMBLED PARTS Steering Wheel Steering Wheel Insert (1) Hex nut 1/2-20 (1) Large Flat Washer (1) Hex Bolt 1/4-28 x 1-1/4 (1) Locknut 1/4-28 Steering Wheel Adapter Steering Boot Steering Extension Shaft Seat (1) Washer 17/32 x 1-3/16 x 12 Gauge (1) Lock Washer 1/2 (1) Bolt Slope Sheet (1) Oil Drain Tube For Future Use Keys (2) Keys 7 ASSEMBLY/PRE-OPERATION Your new tractor has been assembled at the factory with the exception of those parts left unassembled for shipping purposes. To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to insure proper tightness. Review the video cassette before you begin. TOOLS REQUIRED FOR ASSEMBLY A socket wrench set will make assembly easier. Standard wrench sizes you need are listed below. (1) 3/4" wrench (1) Pliers (2) 7/16" wrench (1) Utility knife (1) Tire pressure gauge When right or left hand is mentioned in this manual, it means, from your point of view, when you are in the operating position (seated behind the steering wheel). 1/2 Hex Nut Insert Large Flat Washer Steering Wheel Steering Boot Tabs Adapter 1/4 Locknut Extension Shaft 1/4 Hex Bolt TO REMOVE TRACTOR FROM CARTON UNPACK CARTON 1. Remove all accessible loose parts and parts boxes from carton. 2. Cut along dotted lines on all four panels of carton. Remove end panels and lay side panels flat. 3. Check for any additional loose parts or cartons and remove. BEFORE REMOVING TRACTOR FROM SKID ATTACH STEERING WHEEL ASSEMBLE EXTENSION SHAFT AND BOOT 1. Slide extension shaft onto lower steering shaft. Align mounting holes in extension and lower shafts and install 1/4 hex bolt and locknut. Tighten securely. IMPORTANT: Tighten bolt and nut securely to 10-12 ft. lbs torque. 2. Place tabs of steering boot over tab slots in dash and push down to secure. INSTALL STEERING WHEEL 3. Position front wheels of the tractor so they are pointing straight forward. 4. Remove steering wheel adapter from steering wheel and slide adapter onto steering shaft extension. 5. Position steering wheel so cross bars are horizontal (left to right) and slide inside boot and onto adapter. 6. Assemble large flat washer, 1/2 hex nut and tighten securely. Lower Steering Shaft Tab Slots 7. Snap steering wheel insert into center of steering wheel. 8. Remove protective materials from tractor hood and grill. IMPORTANT: Check for and remove any staples in skid that may puncture tires where tractor is to roll off skid. HOW TO SET UP YOUR TRACTOR INSTALL SEAT Adjust seat before tightening adjustment bolt. 1. Remove adjustment bolt, lock washer and flat washer securing seat to cardboard packing and set aside for assembly of seat to tractor. 2. Pivot seat upward and remove from the cardboard packing. Remove the cardboard packing and discard. 3. Place seat on seat pan so head of shoulder bolt is positioned over large slotted hole in pan. 8 4. Push down on seat to engage shoulder bolt in slot and pull seat towards rear of tractor. 5. Pivot seat and pan forward and assemble adjustment bolt, lockwasher and flat washer loosely. Do not tighten. 6. Lower seat into operating position and sit in seat. 7. Slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down. 8. Get off seat without moving its adjusted position. 9. Raise seat and tighten adjustment bolt securely. Seat NOTE: You may now roll or drive your tractor off the skid. Follow the appropriate instruction below to remove the tractor from the skid. TO ROLL TRACTOR OFF SKID (See Operation section for location and function of controls) 1. Press lift lever plunger and raise attachment lift lever to its highest position. 2. Release parking brake by depressing clutch/brake pedal. 3. Place gearshift lever in neutral (N) position. 4. Roll tractor forward off skid. 5. Remove banding holding deflector shield guard up against tractor. Seat Pan Shoulder Bolt TO DRIVE TRACTOR OFF SKID (See Operation section for location and function of controls) WARNING: Before starting, read, understand and follow all instructions in the Operation section of this manual. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other people and objects. 1. Be sure all the above assembly steps have been completed. 2. Check engine oil level and fill fuel tank with gasoline. 3. Sit on seat in operating position, depress clutch/brake pedal and set the parking brake. 4. Place gear shift lever in neutral (N) position. 5. Press lift lever plunger and raise attachment lift lever to its highest position. 6. Start the engine. After engine has started, move throttle control to idle position. 7. Depress clutch/brake pedal into full "BRAKE" position and hold. Move gearshift lever to 1st gear. 8. Slowly release clutch/brake pedal and slowly drive tractor off skid. 9. Apply brake to stop tractor, set parking brake and place gearshift lever in neutral position. 10. Turn ignition key to "STOP" position. Continue with the instructions that follow. Flat Washer Lock Washer Adjustment Bolt CHECK BATTERY 1. Lift seat pan to raised position. NOTE: If this battery is put into service after month and year indicated on label (label located between terminals) charge battery for minimum of one hour at 6-10 amps. (See "BATTERY" in Maintenance section of this manual for charging instructions). Seat pan Label Terminal Terminal 9 CHECK TIRE PRESSURE The tires on your tractor were overinflated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance. · Reduce tire pressure to PSI shown in "PRODUCT SPECIFICATIONS" section of this manual. CHECKLIST Before you operate your new tractor, we wish to assure that you receive the best performance and satisfaction from this Quality Product. Please review the following checklist: All assembly instructions have been completed. No remaining loose parts in carton. Battery is properly prepared and charged. (Minimum 1 hour at 6 amps). Seat is adjusted comfortably and tightened securely. All tires are properly inflated. (For shipping purposes, the tires were overinflated at the factory). Be sure mower deck is properly leveled side-to-side/front-to-rear for best cutting results. (Tires must be properly inflated for leveling). Check mower and drive belts. Be sure they are routed properly around pulleys and inside all belt keepers. Check wiring. See that all connections are still secure and wires are properly clamped. While learning how to use your tractor, pay extra attention to the following important items: Engine oil is at proper level. Fuel tank is filled with fresh, clean, regular unleaded gasoline. Become familiar with all controls, their location and function. Operate them before you start the engine. Be sure brake system is in safe operating condition. CHECK FOR PROPER POSITION OF ALL BELTS See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments section of this manual. Verify that the belts are routed correctly. CHECK DECK LEVELNESS For best cutting results, mower housing should be properly leveled. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. CHECK BRAKE SYSTEM After you learn how to operate your tractor, check to see that the brake is properly adjusted. See "TO ADJUST BRAKE" in the Service and Adjustments section of this manual. 10 OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning. REVERSE NEUTRAL HIGH LOW CHOKE FAST SLOW IGNITION P ENGINE OFF LIGHTS ON ENGINE ON ENGINE START PARKING BRAKE PARKING BRAKE LOCKED PARKING BRAKE UNLOCKED OVER TEMP LIGHT FUEL OIL PRESSURE BATTERY REVERSE FORWARD MOWER HEIGHT MOWER LIFT 15 15 ATTACHMENT CLUTCH ENGAGED ATTACHMENT CLUTCH DISENGAGED DANGER, KEEP HANDS AND FEET AWAY SLOPE HAZARDS KEEP AREA CLEAR (SEE SAFETY RULES SECTION) DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION when used without the alert symbol, indicates a situation that could result in damage to the tractor and/or engine. HOT SURFACES indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage. FIRE indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage. FREE WHEEL (Automatic Models only) Failure to follow instructions could result in serious injury or death. The safety alert symbol is used to identify safety information about hazards which can result in death, serious injury and/or property damage. 11 KNOW YOUR TRACTOR READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference. Attachment Clutch Lever Ignition Switch Light Switch Position Lift Lever Plunger Throttle/Choke Control Attachment Lift Lever Clutch/Brake Pedal Height Adjustment Indicator Parking Brake Lever Gearshift Lever Our tractors conform to the safety standards of the American National Standards Institute. ATTACHMENT CLUTCH LEVER - Used to engage the mower blades, or other attachments mounted to your tractor. ATTACHMENT LIFT LEVER - Used to raise, lower, and adjust the mower deck or other attachments mounted to your tractor. CLUTCH/BRAKE PEDAL - Used for declutching and braking the tractor and starting the engine. GEARSHIFT LEVER - Selects the speed and direction of tractor. IGNITION SWITCH - Used for starting and stopping the engine. LIFT LEVER PLUNGER - Used to release attachment lift lever when changing its position. LIGHT SWITCH POSITION - Turns the headlights on and off. PARKING BRAKE LEVER - Locks clutch/ brake pedal into the brake position. THROTTLE/CHOKE CONTROL - Used for starting and controlling engine speed. 12 The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your tractor or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. HOW TO USE YOUR TRACTOR TO SET PARKING BRAKE Your tractor is equipped with an operator presence sensing switch. When engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine. 1. Depress clutch/brake pedal all the way down and hold. 2. Pull parking brake lever up and release pressure from clutch/brake pedal. Pedal should remain in brake position. Make sure parking brake will hold tractor secure. Throttle/Choke Control Attachment Clutch Lever "Engaged" Position Ignition Key Clutch/ Brake Pedal "Disengaged" Position Parking Brake "Engaged" Position · Never use choke to stop engine. IMPORTANT: Leaving the ignition switch in any position other than "STOP" will cause the battery to discharge and go dead. NOTE: Under certain conditions when tractor is standing idle with the engine running, hot engine exhaust gases may cause "browning" of grass. To eliminate this possibility, always stop engine when stopping tractor on grass areas. CAUTION: Always stop tractor completely, as described above, before leaving the operator's position. TO USE THROTTLE CONTROL Always operate engine at full throttle. · Operating engine at less than full throttle reduces the battery charging rate. · Full throttle offers the best bagging and mower performance. TO MOVE FORWARD AND BACKWARD The direction and speed of movement is controlled by the gearshift lever. 1. Start tractor with clutch/brake pedal depressed and gearshift lever in neutral (N) position. 2. Move gearshift lever to desired position. 3. Slowly release clutch/brake pedal to start movement. IMPORTANT: Bring tractor to a complete stop before shifting or changing gears. Failure to do so will shorten the useful life of your transaxle. TO ADJUST MOWER CUTTING HEIGHT The position of the attachment lift lever determines the cutting height. · Grasp lift lever. · Press plunger with thumb and move lever to desired position. The cutting height range is approximately 1-1/2 to 4". The heights are measured from the ground to the blade tip with the engine not running. These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed. "Brake" Position "Disengaged" Position Gearshift Lever STOPPING MOWER BLADES · To stop mower blades, move attachment clutch lever to disengaged position. GROUND DRIVE · To stop ground drive, depress clutch/ brake pedal all the way down. · Move gearshift lever to neutral (N) position. ENGINE · Move throttle control to slow position. NOTE: Failure to move throttle control to slow position to allow engine to idle before stopping may cause engine to "backfire". · Turn ignition key to "STOP" position and remove key. Always remove key when leaving tractor to prevent unauthorized use. 13 · The average lawn should be cut to approximately 2-1/2 inches during the cool season and to over 3 inches during hot months. For healthier and better looking lawns, mow often and after moderate growth. · For best cutting performance, grass over 6 inches in height should be mowed twice. Make the first cut relatively high; the second to desired height. TO OPERATE MOWER Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. You must remain fully and centrally positioned in the seat to prevent the engine from hesitating or cutting off when operating your equipment on rough, rolling terrain or hills. 1. Select desired height of cut. 2. Start mower blades by engaging attachment clutch control. TO STOP MOWER BLADES disengage attachment clutch control. CAUTION: Do not operate the mower without either the entire grass catcher, on mowers so equipped, or the deflector shield in place. Attachment Clutch Lever "Engaged" Position Attachemnt Lift Lever High Position Low Position "Disengaged" Position · If stopping is absolutely necessary, push clutch/brake pedal quickly to brake position and engage parking brake. · Move gearshift lever to 1st gear. Be sure you have allowed room for tractor to roll slightly as you restart movement. · To restart movement, slowly release parking brake and clutch/brake pedal. · Make all turns slowly. TO TRANSPORT · Raise attachment lift to highest position with attachment lift control. · When pushing or towing your tractor, be sure gearshift lever is in neutral (N) position. · Do not push or tow tractor at more than five (5) MPH. NOTE: To protect hood from damage when transporting your tractor on a truck or a trailer, be sure hood is closed and secured to tractor. Use an appropriate means of tying hood to tractor (rope, cord, etc.). TOWING CARTS AND OTHER ATTACHMENTS Tow only the attachments that are recommended by and comply with specifications of the manufacturer of your tractor. Use common sense when towing. Too heavy of a load, while on a slope, is dangerous. Tires can lose traction with the ground and cause you to lose control of your tractor. BEFORE STARTING THE ENGINE CHECK ENGINE OIL LEVEL The engine in your tractor has been shipped, from the factory, already filled with summer weight oil. 1. Check engine oil with tractor on level ground. 2. Remove oil fill cap/dipstick and wipe clean, reinsert the dipstick and screw cap tight, wait for a few seconds, remove and read oil level. If necessary, add oil until "FULL" mark on dipstick is reached. Do not overfill. · For cold weather operation you should change oil for easier starting (See "OIL VISCOSITY CHART" in the Maintenance section of this manual). · To change engine oil, see the Maintenance section in this manual. Deflector Shield TO OPERATE ON HILLS WARNING: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope. Use the slope guide provided at the back of this manual. · Choose the slowest speed before starting up or down hills. · Avoid stopping or changing speed on hills. · If slowing is necessary, move throttle control lever to slower position. 14 ADD GASOLINE · Fill fuel tank to bottom of filler neck. Do not overfill. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. (Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. IMPORTANT: When operating in temperatures below32°F(0°C), use fresh, clean winter grade gasoline to help insure good cold weather starting. CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. 5. Insert key into ignition and turn key clockwise to start position and release key as soon as engine starts. Do not run starter continuously for more than fifteen seconds per minute. If the engine does not start after several attempts, move throttle control to fast position, wait a few minutes and try again. If engine still does not start, move the throttle control back to the choke position and retry. WARM WEATHER STARTING (50° F and above) 6. When engine starts, move the throttle control to the fast position. · The attachments and ground drive can now be used. If the engine does not accept the load, restart the engine and allow it to warm up for one minute using the choke as described above. COLD WEATHER STARTING ( 50° F and below) 6. When engine starts, leave throttle control in choke position until engine warms up and begins to run roughly. Once rough running begins, immediately move the throttle control to the fast position. Engine warm-up may take from several seconds to several minutes (the colder the temperature, the longer the warm-up). · The attachments can also be used during the engine warm-up period. NOTE: If at a high altitude (above 3000 feet) or in cold temperatures (below 32 F) the carburetor fuel mixture may need to be adjusted for best engine performance (see "TO ADJUST CARBURETOR" in the Service and Adjustments section of this manual). TO START ENGINE When starting the engine for the first time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine. 1. Sit on seat in operating position, depress clutch/brake pedal and set parking brake. 2. Place gear shift lever in neutral (N) position. 3. Move attachment clutch to disengaged position. 4. Move throttle control to choke position. NOTE: Before starting, read the warm and cold starting procedures below. 15 MOWING TIPS · Tire chains cannot be used when the mower housing is attached to tractor. · Mower should be properly leveled for best mowing performance. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. · The left hand side of mower should be used for trimming. · Drive so that clippings are discharged onto the area that has already been cut. Have the cut area to the right of the tractor. This will result in a more even distribution of clippings and more uniform cutting. · When mowing large areas, start by turning to the right so that clippings will discharge away from shrubs, fences, driveways, etc. After one or two rounds, mow in the opposite direction making left hand turns until finished. · If grass is extremely tall, it should be mowed twice to reduce load and possible fire hazard from dried clippings. Make first cut relatively high; the second to the desired height. · Do not mow grass when it is wet. Wet grass will plug mower and leave undesirable clumps. Allow grass to dry before mowing. · Always operate engine at full throttle when mowing to assure better mowing performance and proper discharge of material. Regulate ground speed by selecting a low enough gear to give the mower cutting performance as well as the quality of cut desired. · When operating attachments, select a ground speed that will suit the terrain and give best performance of the attachment being used. 16 MAINTENANCE MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE Check Brake Operation Check Tire Pressure Check Operator Presence and Interlock Systems Check for Loose Fasteners Sharpen/Replace Mower Blades Lubrication Chart Check Battery Level Clean Battery and Terminals Check Transaxle Cooling Check V-Belts Check Engine Oil Level Change Engine Oil (with oil filter) 1,2 1,2 2 2 4 3 5 S E GE S RS RS US UR N RA UR OU HOU HO ASO TO CH O H 0 S EA 8H SE RE 25 50 10 Y Y Y Y Y RE ER VER VER VER VER EFO FO B SERVICE E EV E E E BE DATES T R A C T 0 R E N G I N E Change Engine Oil (without oil filter) Clean Air Filter Clean Air Screen Inspect Muffler/Spark Arrester Replace Oil Filter (If equipped) Clean Engine Cooling Fins Replace Spark Plug Replace Air Filter Paper Cartridge Replace Fuel Filter 1, 2 2 2 1 - Change more often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty or dusty conditions. 3 - Replace blades more often when mowing in sandy soil. 4 - Not required if equipped with maintenance-free battery. 5 - Tighten front axle pivot bolt to 35 ft.-lbs. maximum. Do not overtighten. GENERAL RECOMMENDATIONS The warranty on this tractor does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain tractor as instructed in this manual. Some adjustments will need to be made periodically to properly maintain your tractor. At least once a season, check to see if you should make any of the adjustments described in the Service and Adjustments section of this manual. · At least once a year you should replace the spark plug, clean or replace air filter, and check blades and belts for wear. A new spark plug and clean air filter assure proper air-fuel mixture and help your engine run better and last longer. Zerk LUBRICATION CHART Spindle Spindle Zerk Front Wheel Bearing Zerk Front Wheel Bearing Zerk Engine General Purpose Grease Refer to Maintenance "Engine" Section IMPORTANT: Do not oil or grease the pivot points which have special nylon bearings. Viscous lubricants will attract dust and dirt that will shorten the life of the self-lubricating bearings. If you feel they must be lubricated, use only a dry, powdered graphite type lubricant sparingly. BEFORE EACH USE 1. 2. 3. 4. Check engine oil level. Check brake operation. Check tire pressure. Check operator presence and interlock systems for proper operation. 5. Check for loose fasteners. 17 4. Reassemble blade bolt, lock washer and flat washer in exact order as Always observe safety rules when pershown. forming any maintenance. 5. Tighten blade bolt securely (27-35 Ft. BRAKE OPERATION Lbs. torque). If tractor requires more than five (5) feet IMPORTANT: Blade bolt is heat treated. to stop at highest speed in highest gear If bolt needs replacing, replace only with on a level, dry concrete or paved surface, then brake must be checked and adjusted. approve bolt shown in the Repair Parts. (See "TO ADJUST BRAKE" in the Service Mandrel Trailing and Adjustments section of this manual). Assembly Edge Up Blade TIRES Flat · Maintain proper air pressure in all tires Washer (See "PRODUCT SPECIFICATIONS" Lock section of this manual). Washer · Keep tires free of gasoline, oil, or insect Star control chemicals which can harm rubBlade Bolt Center Hole ber. · Avoid stumps, stones, deep ruts, sharp TO SHARPEN BLADE objects and other hazards that may NOTE: We do not recommend sharpcause tire damage. ening blade - but if you do, be sure the NOTE: To seal tire punctures and prevent blade is balanced. flat tires due to slow leaks, tire sealant Care should be taken to keep the blade may be purchased from your local parts balanced. An unbalanced blade will cause dealer. Tire sealant also prevents tire dry excessive vibration and eventual damage rot and corrosion. to mower and engine. OPERATOR PRESENCE SYSTEM · The blade can be sharpened with a file or on a grinding wheel. Do not attempt Be sure operator presence and interlock to sharpen while on the mower. systems are working properly. If your trac· To check blade balance, you will need a tor does not function as described, repair 5/8" diameter steel bolt, pin, or a cone the problem immediately. balancer. (When using a cone balancer, · The engine should not start unless follow the instructions supplied with the brake pedal is fully depressed and balancer.) attachement clutch control is in the NOTE: Do not use a nail for balancing disengaged position. blade. The lobes of the center hole may · When the engine is running, any atappear to be centered, but are not. tempt by the operator to leave the seat · Slide blade on to an unthreaded portion without first setting the parking brake of the steel bolt or pin and hold the should shut off the engine. bolt or pin parallel with the ground. If · When the engine is running and the blade is balanced, it should remain in a attachment clutch is engaged, any athorizontal position. If either end of the tempt by the operator to leave the seat blade moves downward, sharpen the should shut off the engine. heavy end until the blade is balanced. · The attachment clutch should never operate unless the operator is in the seat. BLADE CARE Center Hole For best results mower blades must be 5/8" Bolt kept sharp. Replace bent or damaged Blade or Pin blades. BLADE REMOVAL 1. Raise mower to highest position to alBATTERY low access to blades. Your tractor has a battery charging system 2. Remove blade bolt, lock washer and which is sufficient for normal use. Howflat washer securing blade. ever, periodic charging of the battery with 3. Install new or resharpened blade with trailing edge up towards deck as shown. an automotive charger will extend its life. · Keep battery and terminals clean. IMPORTANT: To ensure proper assembly, · Keep battery bolts tight. center hole in blade must align with star on mandrel assembly. 18 TRACTOR · Keep small vent holes open. · Recharge at 6-10 amperes for 1 hour. NOTE: The original equipment battery on your tractor is maintenance free. Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary. TO CLEAN BATTERY AND TERMINALS Corrosion and dirt on the battery and terminals can cause the battery to "leak" power. 1. Disconnect BLACK battery cable first then RED battery cable and remove battery from tractor. 2. Rinse the battery with plain water and dry. 3. Clean terminals and battery cable ends with wire brush until bright. 4. Coat terminals with grease or petroleum jelly. 5. Reinstall battery (See "REPLACING BATTERY" in the SERVICE AND ADJUSTMENTS section of this manual). TRANSAXLE COOLING Keep transaxle free from build-up of dirt and chaff which can restrict cooling. V-BELTS Check V-belts for deterioration and wear after 100 hours of operation and replace if necessary. The belts are not adjustable. Replace belts if they begin to slip from wear. Check the crankcase oil level before starting the engine and after each eight (8) hours of operation. Tighten oil fill cap/ dipstick securely each time you check the oil level. TO CHANGE ENGINE OIL Determine temperature range expected before oil change. All oil must meet API service classification SG-SL. · Be sure tractor is on level surface. · Oil will drain more freely when warm. · Catch oil in a suitable container. 1. Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil. 2. Remove yellow cap from end of drain valve and install the drain tube onto the fitting. Oil Drain Valve Closed and Locked Position Yellow Cap Drain Tube ENGINE LUBRICATION Only use high quality detergent oil rated with API service classification SG-SL. Select the oil's SAE viscosity grade according to your expected operating temperature. SAE VISCOSITY GRADES SAE 30 5W-30 F C -30 -20 -20 0 -10 30 32 0 40 10 60 20 80 30 100 40 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, they will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the tractor is not used for 25 hours in one year. 3. Unlock drain valve by pushing inward slightly and turning counterclockwise. 4. To open, pull out on the drain valve. 5. After oil has drained completely, close and lock the drain valve by pushing inward and turning clockwise until the pin is in the locked position as shown. 6. Remove the drain tube and replace the cap onto the end of the drain valve. 7. Refill engine with oil through oil fill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see "PRODUCT SPECIFICATIONS" section of this manual. 8. Use gauge on oil fill cap/dipstick for checking level. For accurate reading, tighten dipstick cap securely onto the tube before removing dipstick. Keep oil at "FULL" line on dipstick. Tighten cap onto the tube securely when finished. CLEAN AIR SCREEN Air screen must be kept free of dirt and chaff to prevent engine damage from overheating. Clean with a wire brush or compressed air to remove dirt and stubborn dried gum fibers. 19 AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter. Remove cartridge every 25 hours and tap gently to clean. Replace paper cartridge once a year or after every 100 hours of operation, more often if used in very dusty, dirty conditions. 1. Remove knobs and cover. 2. Remove cartridge nut and clean or replace cartridge. 3. Reassemble and tighten securely. NOTE: Do not attempt to oil the paper cartridge. See engine manual. MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. SPARK PLUG(S) Replace spark plug(s) at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in "PRODUCT SPECIFICATIONS" section of this manual. IN-LINE FUEL FILTER The fuel filter should be replaced once each season. If fuel filter becomes clogged, obstructing fuel flow to carburetor, replacement is required. 1. With engine cool, remove filter and plug fuel line sections. 2. Place new fuel filter in position in fuel line with arrow pointing towards carburetor. 3. Be sure there are no fuel line leaks and clamps are properly positioned. 4. Immediately wipe up any spilled gasoline. Clamp Fuel Filter Clamp CLEANING · Clean engine, battery, seat, finish, etc. of all foreign matter. · Keep finished surfaces and wheels free of all gasoline, oil, etc. · Protect painted surfaces with automotive type wax. We do not recommend using a garden hose or pressure washer to clean your tractor unless the engine and transmission are covered to keep water out. Water in engine or transmission will shorten the useful life of your tractor. Use compressed air or a leaf blower to remove grass, leaves and trash from tractor and mower. 20