User manual CRAFTSMAN 917.270940

Owner's Manual ICRAFTSMAN'J 20.0 HP ELECTRIC START 42" MOWER AUTOMATIC LAWN TRACTO Model No. 917.270940 · · · · Safety Assembly Operation Maintenance · Repair Parts differently from previously built engines. which operates the enThis product has a low emission engine Before you start gine, read and understand this Owner's Manual, CAUTION: Read and follow all Safety Rules and Instructions before operating this equipment, For answers to your questions about this product, Call: 1-800-659-5917 Sears Craftsman Help Line 5 am - 5 pro, Mon- Sat Sears, Roebuck and Co., Hoffman Estates, II 60179 Visit our Craftsman website:www.sears.com/craftsman Warranty ............................................... 2 Safety Rules ......................................... 3 Product Specifications .......................... 5 Assembly .............................................. 7 Operation ............................................ 11 Maintenance Schedule ...................... 18 Maintenance ....................................... 18 Service and Adjustments .................... 22 Storage ............................................... 29 Troubleshooting ................................. 30 Repair Parts ........................................ 34 Parts Ordering ..................... Back Cover LIMITED TWO YEAR WARRANTY ON CRAFTSMAN RIDING EQUIPMENT PARTS For two (2) years from the date of purchase, if this Craftsman Riding Equipment is maintained, lubricated and tuned up according to the instructions in the owner's manual, Sears will repair or replace, free of charge, any parts found to be defective in material or workmanship. Warranty service is available free of charge by taking your Craftsman riding equipment to your nearest Sears Service Center. In-home warranty service is available but a trip charge will apply. This warranty applies only while this product is in the United States. This Warranty does not cover: · Expendable items which become worn during normal use, such as blades, spark plugs, air cleaners, belts and oil filters. · Tire replacement or repair caused by punctures from outside objects, such as nails, thorns, stumps, or glass. · Repairs necessary because of operator abuse, including but not limited to, damage caused by towing objects beyond the capability of the riding equipment, impacting objects that bend the frame or crankshaft, or over speeding the engine. · Repairs necessary because of operator negligence, including but not limited to, electrical and mechanical damage caused by improper storage, failure to use the proper grade and amount of engine oil, failure to keep the deck clear of flammable debris, or the failure to maintain the equipment according to the instructions contained in the owner's manual. · Engine (fuel system) cleaning or repairs caused by fuel determined to be contaminated or oxidized (stale). In general, fuel should be used within thirty (30) days of its purchase date. · Riding equipment used for commercial or rental purposes. LIMITED 90 DAY WARRANTY ON BATTERY For ninety (90) days from date of purchase, if any battery included with this riding equipment proves defective in material or workmanship and our testing determines the battery will not hold a charge, Sears will replace the battery at no charge. Warranty service is available free of charge by taking your Craftsman riding equipment to your nearest Sears Service Center. In-home warranty service is available but a trip charge will apply. This warranty applies only while this product is in the United States. To locate the nearest sears service center or to schedule in-home warranty service, simply contact sears at 1-800-4-my-home This Warranty gives you specific legal rights, and you may also have other rights which may vary from state to state. Sears, Roebuck and Co., D/817 WA, Hoffman Estates, IL 60179 2 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. 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. · 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 mowerrelated injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury. SLOPEOPERATION 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. · 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. 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. 3 · 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. · Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. 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 area. inside a closed · 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. · 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. 4 · 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. A(_Look for this symbol to point out important safety precautions. It means CAUTION!H BECOMEAWARE!!! YOUR _FETY IS INVOLVED. CAUTION: In order to prevent accidental starting when setting up, transporting, adjusting or making repairs always disconnect spark plug wire and place wire _ere it cannot contact spark plug. CAUTION; Do not coast down a hill in neutral, you may lose control of the tractor. _CAUTION: 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 ,_YwOU tractor. r ARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. We have competent, wel!-trained 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". REPAIR AGREEMENT A Repair Agreement is available on this product. Contact your nearest Sears store for details. 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, brushcovered 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). PRODUCT GASOLINE CAPACITY AND TYPE: SPECIFICATIONS 3.5 GALLONS UNLEADED REGULAR SAE 30 (ABOVE 32°F) SAE 5W-30 (BELOW 32°F) 3.0PINTS CHAMPION RJ19LM OR J19LM INTAKE: .004"-.006" EXHAUST: .007"-.009" FORWARD: 5.5 REVERSE: 2.4 FRONT: REAR: 14 PSI 10 PSI OILTYPE API-SF/SG/SH): OIL CAPACITY: SPARK PLUG: GAP: .030") VALVE ADJUSTMENT GROUND SPEED(MPH): TIRE PRESSURE: CHARGING SYSTEM: BATTERY: 3AMPS BATTERY 5 AMPS HEADLIGHTS AMP/HR: 30 MIN. CCA: 240 CASE SIZE:U1R 27-35 FT. LBS BLADE BOLT TORQUE: 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. 5 Steering Wheel _ P Steering Sleeve Steering Wheel Adapter /> Steering Wheel Insert I Steering Extension Shaft (1) Hex Bolt 3/8-16 x 1 (1) Lock washer 3/8 (1) Hex Bolt (1) Large Flat Washer (1) Locknut 5/16-18 Seat @ (1) Washer 17/32 x 1-3/16 (1) Knob x 12 Gauge (_ Keys Videq Cassette Slope Sheet (2) Keys 6 Your new tractor has been assembled at the factory with 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. TOOLS REQUIRED FOR ASSEMBLY A socket wrench set will make assembly easier. Standard wrench sizes you need are listed below. (1) 9/16" wrench (1) Pliers (2) 1/2" 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). · Assemble large flat washer, 3/8 lock washer, 3/8 hex bolt and tighten securely. · Snap steering wheel insert into center of steering wheel. · 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. / Steering Wheel Insert Hex Bolt _Lock _-- - ---i Washer Large Flat TO REMOVE TRACTOR CARTON UNPACK CARTON FROM _ · Remove all accessible loose parts and parts boxes from shipping carton. · Cut, from top to bottom, along lines on all four corners of shipping carton, and lay panels flat. · Check for any additional loose parts or boxes and remove. BEFORE REMOVING TRACTOR FROM SKID ATTACH STEERING WHEEL ASSEMBLE EXTENSION SHAFT AND BOOT · Slide extension shaft onto lower steering shaft. Align mounting holes in extension and lower shafts and install 5/16 hex bolt and Iocknut. Tighten securely. · Place tabs of steering boot over tab slots in dash and push down to secure. INSTALL STEERING WHEEL · Position front wheels of the tractor so they are pointing straight forward. · Remove steering wheel adapter from steering wheel and slide adapter onto steering shaft extension. · Position steering wheel so cross bars are horizontal (left to right) and slide inside boot and onto adapter. 7 HOW TO SET UP YOUR TRACTOR CHECK BATTERY · Lift hood to raised position. · 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). NOTE: You may now roll or drive you 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) · Press lift lever plunger and raise attachment lift lever to its highest position. · Release parking brake by depressing clutch/brake pedal. · Place freewheel control in freewheeling position to disengage transmission (See "TO TRANSPORT" in the Operation section of this manual). · Roll tractor forward off skid. · Remove banding holding discharge guard up against tractor. Label INSTALL SEAT Adjust seat before tightening adjustment knob. · Remove adjustment knob and flat washer securing seat to cardboard packing and set aside for assembly of seat to tractor. · Pivot seat upward and remove from the cardboard packing. Remove the cardboard packing and discard. · Place seat on seat pan and assemble shoulder bolt. Tighten shoulder bolt securely. · Assemble adjustment knob and flat washer loosely. Do not tighten. · Lower seat into operating position and sit on seat. · Slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down. · Get off seat without moving its adjusted position. · Raise seat and tighten adjustment knob securely. Seat Seat Pan Shoulder Bolt __ TO DRIVE TRACTOR OFF SKID (See Operation section for location and function of controls) _WARNING: Before starting read, understand and fo ow 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. · Be sure all the above assembly steps have been completed. · Check engine oil level and fill fuel tank with gasoline. · Place freewheel control in "transmission engaged" position. · Sit on seat in operating position, depress clutch/brake pedal and set the parking brake. · Place motion control lever in neutral (N) position. · Press lift lever plunger and raise attachment lift lever to its highest position. · Start the engine. After engine has started, move throttle control to idle position. · Release parking brake. · Slowly move the motion control lever forward and slowly drive tractor off skid. · Apply brake to stop tractor, set parking brake and place motion control lever in neutral position. · Turn ignition key to "OFF" position. Continue with the instructions that follow. Adjustment Knob Flat Washer 8 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. 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 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 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. INSTALL MULCHER PLATE (If previously removed) · Raise and hold deflector shield in upright position. · Place front of mulcher plate over front of mower deck opening and slide into place, as shown. · Hook front latch into hole on front of mower deck. · Hook rear latch into hole on back of mower deck. _kCAUTION: Do not remove deflector shield from mower. Raise and hold shield when attaching mulcher plate and allow it to rest on plate while in operation. Deflector-_-_ Shield Mulcher Latch Hooks TO CONVERT DISCHARGING TO BAGGING OR Simply remove mulcher plate and store in a safe place. Your mower is now ready for discharging or installation of optional grass catcher accessory. NOTE: It is not necessary to change blades. The mulcher blades are designed for discharging and bagging also. 9 _ CHECKLIST BEFORE YOU OPERATE AND ENJOY YOUR NEW TRACTOR, WE W_SH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT. PLEASE REVIEWTHE FOLLOWING CHECKLIST: ,I 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. J Al_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. ,/Before driving tractor, be sure freewheel control is in drive position. WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRAATTENTION 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 - thei, location and function. Operate them before you start the engine. ·/ Be sure brake system is in safe operating condition. ,/It is important to purge the transmissiol before operating your tractor for the fir,' time. Follow proper starting and transmission purging instructions (Se_ "TO START ENGINE" and "PURGE TRANSMISSION" in the Operation section of this manual). 10 These symbols may appear on your tractor or in literature Learn and understand their meaning. supplied with the product. BATTERY CAUTION WARNING OR REVERSE FORWARD FAST SLOW ENGINE ON ENGINE OFF OIL PRESSURE LIGHTS ON OVER TEMP LIGHT ! MOWER LIFT FUEL CHOKE MOWER HEIGHT PARKING BRAKE LOCKED UNLOCKED RNHL ATTACHMENT CLUTCH ENGAGED REVERSE NEUTRAL HIGH LOW PARKING BRAKE ATTACHMENT IGNITION CLUTCH DISENGAGED KEEP AREA CLEAR (SEE SAFETY SLOPE HAZARDS RULES SECTION) DANGER, KEEP HANDS AND FEET AWAY FREE WHEEL (Automatic Models only) 11 KNOWYOUR TRACTOR MANUAL AND SAFETY RULES BEFORE OPERATING READ THIS OWNER'S 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. Light Switch Attachment Clutch Lever Ignition Switch Ammeter Choke Control X'_/;i"" ·- - , " "- --" Lever Plunger _nt Lift Lever Throttle Control Clutch/ Brake Pedal Height Adjustment Indicator Free Wheel Control g Brake Lever _Motion Control Lever Our tractors conform to the safety standards of the American Institute. AMMETER - Indicates charging (+) or discharging (-) of battery. 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. CHOKE CONTROL - Used when starting a cold engine. CLUTCH/BRAKE PEDAL - Used for declutching and braking the tractor and starting the engine. MOTION CONTROL LEVER - Selects the speed and direction of tractor. National Standards FREEWHEEL CONTROL - Disengages transmission for pushing or slowly towing the tractor with the engine off. IGNITION SWITCH - Used for starting and stopping the engine. LIFT LEVER PLUNGER - Used to release attachment lift lever when changing its position. LIGHT SWITCH - Turns the headlights on and off. PARKING BRAKE LEVER - Locks clutch/ brake pedal into the brake position. THROTTLE CONTROL - Used to control 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. · Depress clutch/brake pedal into full "BRAKE" position and hold. · Place parking brake lever in "ENGAGED" position and release pressure from clutch/brake pedal. Pedal should remain in "BRAKE" position. Make sure parking brake will hold tractor secure. Attachment Clutch Lever Choke "Engaged" Position Key gaged" Throttle Control Clutch/ , Parking Position Brake · Never use choke to stop engine. IMPORTANT: Leaving the ignition switch in any position other than "OFF" will cause the battery to be discharged, (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 empty grass catcher, etc. TO USE THRO'n'LE 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 USE CHOKE CONTROL Use choke control whenever you are starting a cold engine. Do not use to start a warm engine. · To engage choke control, pull knob out. Slowly push knob in to disengage. TO MOVE FORWARD AND BACKWARD The direction and speed of movement is controlled by the motion control lever. · Start tractor with motion control lever in neutral (N) position. · Release parking brake and clutch/ brake pedal. · Slowly move motion control lever to desired position. "Disengaged" Position STOPPING "Brake" Position Motion Control Lever MOWER BLADES · To stop mower blades,move attachment clutch lever to "DISENGAGED" position. GROUND DRIVE - · To stop ground drive, depress clutch/ brake pedal into full "BRAKE" position. · Move motion control lever to neutral (N) position. IMPORTANT: The motion control lever TO ADJUST MOWER CUTTING does not return to neutral (N) position HEIGHT when the clutch/brake pedal is deThe position of the attachment lift lever pressed. determines the cutting height. ENGINE · Grasp lift lever. · Move throttle control to slow position. · Press plunger with thumb and move NOTE: Failure to move throttle control to lever to desired position. slow position and allowing engine to idle The cutting height range is approxibefore stopping may cause engine to "backfire". mately 1-1/2 to 4". The heights are · Turn ignition key to "OFF" position and measured from the ground to the blade remove key. Always remove key when tip with the engine not running. leaving tractor to prevent unauthorized use. 13 These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed. · 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 ADJUST GAUGE WHEELS Gauge wheels are properly adjusted when they are slightly off the ground when mower is at the desired cutting height in operating position. Gauge wheels then keep the deck in proper position to help prevent scalping in most terrain conditions. · Adjust gauge wheels with tractor on a flat level surface. · Adjust mower to desired cutting height (See "TO ADJUST MOWER CUTTING HEIGHT" in the Operation section of this manual). · With mower in desired height of cut position, gauge wheels should be assembled so they are slightly off the ground. Install gauge wheel in appropriate hole with shoulder bolt, 3/8 washer, and 3/8-16 Iocknut and tighten securely. · Repeat for opposite side installing gauge wheel in same adjustment hole. · TO STOP MOWER BLADES - disengage attachment clutch control. _CAUTIONDo not operate the mower without either the entire grass catcher, on mowers so equipped, or the deflector shield in place. Attachment Clutch Lever "Engaged" Attachemnt Lift Lever High _ Position Position it ' _ LOW Position i _ _{ / ._ Deflector Shield TO OPERATE ON HILLS 3/8-16 Gauge Wheel Mounting Bracket 3/8 Gauge Wheel Bolt _,CAUTION: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope. · 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. · If stopping is absolutely necessary, push clutch/brake pedal quickly to brake position and engage parking brake. · Move motion control lever to neutral (N) position. IMPORTANT: The motion control lever does not return to neutral (N) position when the clutch/brake pedal is depressed. · To restart movement, slowly release parking brake and clutch/brake pedal. · Slowly move motion control lever to slowest setting. · Make all turns slowly. TO TRANSPORT When pushing or towing your tractor, be sure to disengage transmission by placing freewheel control in freewheeling position. Free wheel control is located at the rear drawbar of tractor. · Raise attachment lift to highest with attachment lift control. position 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. · Select desired height of cut. · Start mower blades by engaging attachment clutch control. 14 · Pull freewheel control out and down into the slot and release so it is held in the disengaged position. · Do not push or tow tractor at more than two (2) MPH. · To reengage transmission, reverse above procedure. 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.). ADD GASOLINE · Fill fuel tank. 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. IMPORTANT: When operating in temperatures below 32°F(0°C), use fresh clean winter grade gasoline to help insure good cold weather starting. _,WARNING: Experience indicates that 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 fo_ additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. _CAUTIONj Fillto bo!tom of gas tank tiller neck. uo no[ overrill. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. 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. · Be sure freewheel control is in the transmission engaged position. · Sit on seat in operating position, depress clutch/brake pedal and set parking brake. · Place motion control lever in neutral (N) position. · Move attachment clutch to "DISENGAGED" position. · Move throttle control to fast position · Pull choke control out for a cold engine start attempt. For a warm engine start attempt the choke control may not be needed. NOTE: Before starting, read the warm and cold starting procedures below. TOWING CARTS AND OTHER ATrACHMENTS 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 ENIGNE CHECK ENGINE OIL LEVEL · The engine in your tractor has been shipped, from the factory, already filled with summer weight oil. · Check engine oil with tractor on level ground. · 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. 15 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, push choke control in, wait a few minutes and try again. If engine still does not start, pull the choke control out and retry. WARM WEATHER STARTING (50 ° F and above) · When engine starts, slowly push choke control in until the engine begins to run smoothly. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly. · 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) · When engine starts, slowly push choke control in until the engine begins to run smoothly. Continue to push the choke control in small steps allowing the engine to accept small changes in speed and load, until the choke control is fully in. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly. This may require an engine warm-up period from several seconds to several minutes, depending on the temperature. AUTOMATIC TRANSMISSION WARM UP · Before driving the unit in cold weather, the transmission should be warmed up as follows: · Be sure the tractor is on level ground. · Place the motion control lever in neutral. Release the parking brake and let the clutch/brake slowly return to operating position. · Allow one minute for transmission to warm up. This can be done during the engine warm up period. · The attachments can be used during the engine warm-up period after the transmission has been warmed up and may require the choke control be pulled out slightly. 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. PURGETRANSMISSION ,_CAUTION: Never engage or disengage freewheel lever willie the engine is running. To ensure proper operation and performance, it is recommended that the transmission be purged before operating tractor for the first time. This procedure will remove any trapped air inside the transmission which may have developed during shipping of your tractor. IMPORTANT: Should your transmission require removal for service or replacement, it should be purged after reinstallation before operating the tractor. · Place tractor safely on level surface with engine off and parking brake set. · Disengage transmission by placing freewheel control in freewheeling position (See "TO TRANSPORT" in this section of manual). · Sitting in the tractor seat, start engine. After the engine is running, move throttle control to slow position. With motion control lever in neutral (N) position, slowly disengage clutch/brake pedal. · Move motion control lever to full forward position and hold for five (5) seconds. Move lever to full reverse position and hold for five (5) seconds. Repeat this procedure three (3) times. NOTE: During this procedure there will be no movement of drive wheels. The air is being removed from hydraulic drive system. · Move motion control lever to neutral (N) position. Shut- off engine and set parking brake. · Engage transmission by placing freewheel control in driving position (See "TO TRANSPORT" in this section of manual). · Sitting in the tractor seat, start engine. After the engine is running, move throttle control to half (1/2) speed. With motion control lever in neutral (N) position, slowly disengage clutch/brake pedal. 16 · Slowly move motion control lever forward, after the tractor moves approximately five (5) feet, slowly move motion control lever to reverse position. After the tractor moves approximately five (5) feet return the motion control lever to the neutral (N) position. Repeat this procedure with the motion control lever three (3) times. · Your tractor is now purged and now ready for normal operation. MOWING TIPS · 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 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. /- 1 · MULCHING MOWING TIPS ) IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. Clean after each use. · The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades. · Avoid cutting your lawn when it is wet. Wet grass tends to form clumps and interferes with the mulching action. The best time to mow your lawn is the early afternoon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. · For best results, adjust the mower cutting height so that the mower cuts off only the top one-third of the grass blades. For extremely heavy mulching, reduce your width of cut on each pass and mow slowly. · Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mow across or perpendicular to the first cut path. · Change your cutting pattern from week to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and graining of the lawn. Max 1/3" 17 F,LL,NOATES AS COMPLETE REGULAR SERVICE Check Tire Pressure Check Brake Operation _ f" SERVICE DATES Check Operator T Presence and li_ V'7 If InterlockforSystems Fasteners Check Loose T cA a Lubrication Chart Check Battery Sharpen/Replace Level Mower Blades Clean Battery and Terminals Check Transaxle Cooling _4 Vw V' I_ V's II/s I/ V' 1_123 I_ Adjust Blade Belt(s) Tension Adjust Motion Drive Belt(s) Tension Check Change Engine Engine Oil Level Oil E U CleanAirFilter Clean Air Screen Inspect Muffler/Spark Arrester Fins _Vj: i/ N Clean Engine Replace Replace Replace Cooling Spark Plug Oil Filter (If equipped) Air Filter Paper Cartridge Fuel Filter often when operating under a heavy load or in high ambient temperatures, _i V'2 V' V' 5 - If equipped with adiustable system. 6 - Not required if equipped with maintenance-free battery 7 - Tighten front axle pivot bolt to 35 fb-lbs maximum, Do not overtighten. 1 - Change more 2 - Service more often when operating in dirty or dusty conditions. 3 - If equipped with oil filter, change oil every 50 hours, 4 - Replace blades more often when mowing in sandy soil GENERAL RECOMMENDATIONS LUBRICATION CHART Zerk 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. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. · 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. BEFORE EACH USE Check engine oil level. Check brake operation. Check tire pressure. Check operator presence and interlock systems for proper operation. · Check for loose fasteners. · · · · _Front Wheel Bearing Zerk i Beading Zerk i OGeneral 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. 18 TRACTOR Always observe safety rules when performing any maintenance. BRAKE OPERATION If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. (See "TO ADJUST BRAKE" in the Service and Adjustments section of this manual). TIRES · Maintain proper air pressure in all tires (See "PRODUCT SPECIFICATIONS" section of this manual). · Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. · Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. NOTE: To seal tire punctures and prevent flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and corrosion. OPERATOR PRESENCE SYSTEM Be sure operator presence and interlock systems are working properly. If your tractor does not function as described, repair the problem immediately. · The engine should not start unless the clutch/brake pedal is fully depressed and attachement clutch control is in the disengaged position. · When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake should shut off the engine. · When the engine is running and the attachment clutch is engaged, any attempt by the operator to leave the seat should shut off the engine. · The attachment clutch should never operate unless the operator is in the seat. BLADE CARE For best results mower blades must be kept sharp. Replace bent or damaged blades. BLADE REMOVAL · Raise mower to highest position to allow access to blades. · Remove hex bolt, lock washer and flat washer securing blade. · Install new or resharpened blade with trailing edge up towards deck as shown. IMPORTANT" To ensure proper assembly, center hole in blade must align with star on mandrel assembly. · Reassemble flat washer · Tighten hex bolt, lock washer an_ in exact order as shown. (27-35 Mandrel Center Hole Ft. Lbs. Assembly bolt securely torque). lrailing Edge Up \. Blade / _?_ Flat Washer\ Lock Washer _--Hex Bolt (Grade) *A Grade 8 heat treated bolt can be identified by six lines on the bolt head. IMPORTANT: Blade bolt is Grade 8 heat treated. TO SHARPEN BLADE NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause excessive vibration and eventual damage to mower and engine. · The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. · To check blade balance, you will need a 5/8" diameter steel bolt, pin, or a con_ balancer. (When using a cone balancer, follow the instructions supplied with balancer.) NOTE: Do not use a nail for balancing blade. The lobes of the center hole may appear to be centered, but are not. · Slide blade on to an unthreaded portion of the steel bolt or pin and hold the bolt or pin parallel with the ground. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. o / BATrERY Your tractor has a battery charging systen which is sufficient for normal use. However, periodic charging of the battery with an automotive charger will extend its life. · Keep battery and terminals clean. Keep battery bolts tight. · Keep small vent holes open. 19 ° 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. · Remove terminal guard. · Disconnect BLACK battery cable first then RED battery cable and remove battery from tractor. · Rinse the battery with plain water and dry. · Clean terminals and battery cable ends with wire brush until bright. · Coat terminals with grease or petroleum jelly. · Reinstall battery (See "REPLACING BATTERY" in the SERVICE AND ADJUSTMENTS section of this manual). 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. TRANSAXLE COOLING The transmission fan and cooling fins should be kept clean to assure proper cooling. Do not attempt to clean fan or transmission while engine is running or while the transmission is hot. To prevent possible damage to seals, do not use high pressure water or steam to clean transaxle. · Inspect cooling fan to be sure fan blades are intact and clean. · Inspect cooling fins for dirt, grass clippings and other materials. To prevent damage to seals, do not use cetnpressed air or high pressure sprayer to clean cooling fins. TRANSAXLE PUMP FLUID The transaxle was sealed at the factory and fluid maintenance is not required for the life of the transaxle. Should the transaxle ever leak or require servicing, contact your nearest authorized service center/department. NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage4rom 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. 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 SF, SG or SH. · Be sure tractor is on level surface. · Oil will drain more freely when warm. · Catch oil in a suitable container. · Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil. · Remove drain plug. · After oil has drained completely, replace oil drain plug and tighten securely. · Refill engine with oil through oil fill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see "PRODUCT SPECIFICATIONS" section of this manual. · Use gauge on oil fill cap/dipstick for checking level. Be sure dipstick cap is tightened securely for accurate reading. Keep oil at "FULL" line on dipstick. Oil Drain _ _ _': _ J, _ _ P,uo Screen 'ti Air OIL Fill Cap/ Dipstsick _ _lr[! _: ENGINE LUBRICATION Only use high quality detergent oil rated with API service classification SF, SG, or SH. Select the oil's SAE viscosity grade according to your expected operating temperature. 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. 20 ENGINE COOLING FINS Remove any dust, dirt or oil from engine cooling fins to prevent engine damage from overheating. Air guide covers must be removed. Remove side panels and hood (See "TO REMOVE HOOD AND GRILL ASSEMBLY" in the Service and Adjustments section of this manual). Cover Top Air _ Engine Cooling Fins _ '_ "_ ,,o IMPORTANT: Petroleum solvents, such as kerosene, are not to be used to clean the cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use.pressurized air to clean or dq cartridge. 45 Cover Knob Wing Foam PreCartridge Air Screen dge Air Guide Cover 6 MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. (Both Sides) AIR FILTER Your engine will not run properly using a dirty air filter. Clean the foam pre-cleaner after every 25 hours of operation or every season. Service paper cartridge every 100 hours of operation or every season, whichever occurs first. Service air cleaner more often under dusty conditions. · Remove knob(s) and cover. TO SERVICE · · · · PRE-CLEANER Slide foam pre-cleaner off cartridge. Wash it in liquid detergent and water. Squeeze it dry in a clean cloth. Saturate it in engine oil. Wrap it in clean, absorbent cloth and squeeze to remove excess oil. · If very dirty or damaged, replace precleaner. · Reinstall pre-cleaner over cartridge. · Reinstall cover and secure with knob(s). TO SERVICE CARTRIDGE · Remove wing nuts and cartridge plate. · Carefully remove cartridge to prevent debris from entering carburetor. · Clean cartridge by tapping gently on flat surface. If very dirty or damaged, replace cartridge. · Reinstall cartridge plate, wing nuts, precleaner, cover and secure with knob(s). SPARK PLUGS Replace spark plugs 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. · With engine cool, remove filter and plug fuel line sections. · Place new fuel filter in position in fuel line with arrow pointing towards carburetor. · Be sure there are no fuel line leaks and clamps are properly positioned. · Immediately wipe up any spilled gasoline. 21 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 to clean your tractor unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in a shortened engine life. CAUTION: Before performing any service or adjustments: · Depress clutch/brake pedal fully and set parking brake. · Place motion control lever in neutral (N) position. · Place attachment clutch in "DISENGAGED" position. · Turn ignition key "OFF" and remove key. · Make sure the blades and all moving parts have completely stopped. · Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. TRACTOR TO REMOVE MOWER Mower will be easier to remove from the right side of tractor, · Place attachment clutch in "DISENGAGED" position. · Move attachment lift lever forward to lower mower to its lowest position. · Roll belt off engine pulley. · Remove small retainer spring, and lift clutch spring off pulley bolt. · Remove large retainer spring, slide collar off and push housing guide out of bracket. · Disconnect anti-swaybar from chassis bracket by removing retainer spring. · Disconnect suspension arms from rear deck brackets by removing retainer springs. · Disconnect front links from deck by removing retainer springs. · Raise lift lever to raise suspension arms. Slide mower out from under tractor. IMPORTANT: If an attachment other than the mower deck is to be mounted on the tractor, remove the front links and hook the clutch spring Into square hole in frame. TO INSTALL MOWER · Raise attachment lift lever to its highest position. · Slide mower under tractor with discharge guard to right side of tractor. · Lower lift lever to its lowest position. · Install mower in reverse order of removal instructions. Small Retainer Spring Clutch Spring Retainer Spring -_ Anti-Sway ine Pulley Collar -- Housing Guide Large Retainer Spring 22 TO LEVEL MOWER HOUSING Adjust the mower while tractor is parked on level ground or driveway. Make sure tires are properly inflated (See "PRODUCT SPECIFICATIONS" section of this manual). If tires are over or underinflated, you will not properly adjust your mower. SIDE-TO-SIDE ADJUSTMENT · Raise mower to its highest position. · At the midpoint of both sides of mower, measure height from bottom edge of mower to ground. Distance "A" on both sides of mower should be the same or within 1/4" of each other. · If adjustment is necessary, make adjustment on one side of mower only. · To raise one side of mower, tighten lift link adjustment nut on that side. · To lower one side of mower, _oosen ift link adjustment nut on that side. NOTE:Each full turn of adjustment nut will change mower height about 1/8". · Recheck measurements after adjusting. Bottom edge of Bottom edge of · Before making any necessary adjustments, check that both front links are equal in length. Both links should be approximately 10-3/8". · If links are not equal in length, adjust one link to same length as other link. · To lower front of mower loosen nut "E" on both front links an equal number of turns. · When distance "D" is 1/8" to 1/2" lower at front than rear, tighten nuts "F" against trunnion on both front links. · To raise front of mower, loosen nut "F" from trunnion on both front links. Tighten nut "E" on both front links an equal number of turns. · When distance "D" is 1/8" to 1/2" lower at front than rear, tighten nut "F" agains trunnion on both front links. · Recheck side-to-side adjustment. m°we_ °und Both Front Links Should be Equal in Length (_ Suspension Nut Lift Link Adjustment Nut FRONT-TO-BACK ADJUSTMENT IMPORTANT: Deck must be level side-to side. If the following front-to-back adjustment is necessary, be sure to adjust both front links equally so mower will stay level side-to-side. To obtain the best cutting results, the mower housing should be adjusted so that the front is approximately 1/8" to 1/2" lower than the rear when the mower is in its highest position. Check adjustment on right side of tractor. Measure distance "D" directly in front and behind the mandrel at bottom edge of mower housing as shown. Front Links 23 TO REPLACE MOWER BLADE DRIVE BELT The mower blade drive belt may be replaced without tools. Park the tractor on level surface. Engage parking brake. BELT REMOVAL· Remove mower from tractor (See "TO REMOVE MOWER" in this section of this manual). · Work belt off both mandrel pulleys and idler pulleys. · Pull belt away from mower. BELT INSTALLATION · Install new belt in reverse order of removal. · Make sure belt is in all pulley grooves and inside all belt guides. · Install mower in reverse order of removal instructions. Mandrel With Parking Brake "Engaged" Nut "A" Jam Nut L // )erating Arm Do not touch this nut. If further brake adjustment is necessary contact your nearest authorized service center/department TO REPLACE MOTION DRIVE BELT Pulley :_== / ,_-f_:-_i" 2 _/_ Idler Pulleys j,,,,,,_ /Pulley I . -, \ _._,f TO ADJUST BRAKE Your tractor is equipped with an adjustable brake system which is mounted on the side of the transaxle. If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. · Depress clutch/brake pedal and engage parking brake. · Measure distance between brake operating arm and nut "A" on brake rod. · If distance is other than 1-9/16", loosen jam nut and turn nut "A" until distance becomes 1-9/16". Retighten jam nut against nut "A". · Road test tractor for proper stopping distance as stated above. Readjust if necessary. If stopping distance is still greater than six (6) feet in highest gear, further maintenance is necessary. Contact your nearest authorized service center/department. Park the tractor on level surface. Engage parking brake. For assistance, there is a belt installation guide decal on bottom side of left footrest. · Remove mower (See "TO REMOVE MOWER" in this section of this manual.) · Remove belt from stationary idler and clutching idler. · Pull belt slack toward rear of tractor. Carefully remove belt upwards from transmission input pulley and over cooling fan blades. · Pull belt toward front of tractor and remove downward from around engine pulley. · Install new belt by reversing above procedure. Engine Pulley-- Clutching Stationary Idler / Idler _ Transmission Input Pulley _ 24 TRANSAXLE MOTION CONTROL LEVER NEUTRAL ADJUSTMENT The motion control lever has been preset at the factory and adjustment should not be necessary. · Loosen adjustment bolt in front of the right rear wheel, and lightly tighten. · Start engine and move motion control lever until tractor does not move forward or backward. · Hold motion control lever in that position and turn engine off. · While holding motion control lever in place, loosen the adjustment bolt. · Move motion control lever to the neutral (N) (lock gate) position. · Tighten adjustment bolt securely. NOTE; If additional clearance is needed to get to adjustment bolt, move mower deck height to the lowest position. After above adjustment is made, if the tractor still creeps forward or backward while motion control lever is in neutral position, follow these steps: · Loosen the adjustment bolt. · Move the motion control lever 1/4 to 1/2 inch in the direction it is trying to creep. · Tighten adjustment bolt securely. · Start engine and test. · If tractor still creeps, repeat above steps until satisfied. Motion Control Lever Neutral Lock Gate TO ADJUST STEERING MENT WHEEL ALIGN If steering wheel crossbars are not horizontal (left to right) when wheels are positioned straight forward, remove steering wheel and reassemble per instructions in the Assembly section of this manual. FRONT WHEEL TOE-IN/CAMBER The front wheel toe-in and camber are not adjustable on your tractor. If damage has occurred to affect the front wheel toe in or camber, contact your nearest authorized service center/department. TO REMOVE WHEEL FOR REPAIRS · Block up axle securely. · Remove axle cover, retaining ring and washers to allow wheel removal (rear wheel contains a square key - Do not lose). · Repair tire and reassemble. · On rear wheels only: align grooves in rear wheel hub and axle. Insert square key. · Replace washers and snap retaining ring securely in axle groove. · Replace axle cover. NOTE: To seal tire punctures and preven' flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and corrosion. Retaining Ring Washers Axle Cover Adjustment Bolt t TRANSMISSION MENT REMOVAL/REPLACE- Square Key (Rear Wheel Only) Should your transmission require removal for service or replacement, it should be purged after reinstallation and before operating the tractor. See "PURGE TRANSMISSION" in the Operation section of this manual. 25 TO START ENGINE WITH AWEAK BAI-I'ERY CAUTION: Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. If your battery is too weak to start the engine, it should be recharged. (See "BATTERY" in the MAINTENANCE section of this manual). If "jumper cables" are used for emergency starting, follow this procedure: IMPORTANT: Your tractor is equipped with a 12 volt negative grounded system. The other vehicle must also be a 12 volt negative grounded system. Do not use your tractor battery to start other vehicles. TO ATTACH JUMPER CABLES · Connect each end of the RED cable to the POSITIVE (+) terminal of each battery, taking care not to short against chassis. · Connect one end of the BLACK cable to the NEGATIVE (-) terminal of fully charged battery. · Connect the other end of the BLACK cable to good CHASSIS GROUND, away from fuel tank and battery. TO REMOVE CABLES, REVERSE ORDER · BLACK cable first from chassis and then from the fully charged battery. · RED cable last from both batteries. REPLACING BA'n'ERY ACAUTION: Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands,rings,etc. Positive terminal must be connected first to prevent sparking from accidental grounding. · Lift hood to raised position. · Remove terminal guard. · Disconnect BLACK battery cable then RED battery cable and carefully remove battery from tractor. · Install new battery with terminals in same position as old battery. · Reinstall terminal guard. · First connect RED battery cable to positive (+) battery terminal with hex bolt and keps nut as shown. Tighten securely. · Connect BLACK grounding cable to negative (-) battery terminal with remaining hex bolt and keps nut. Tighten securely · Close terminal access doors. · Close hood. Keps Terminal Access _;:; ;' Door_ ' ·! , -Negative Cable (Red) Cable (Black) Hex Bolt q "Positive" (+) o L.H. Panel Bolt P "Negative" (-) Guard TO REPLACE HEADLIGHT BULB · Raise hood. · Pull bulb holder out of the hole in the backside of the grill. · Replace bulb in holder and push bulb holder securely back into the hole in the backside of the grill. · Close hood. INTERLOCKS AND RELAYS cause running, or wiring section. Loose or damaged wiring may your tractor to run poorly, stop prevent it from starting. · Check wiring. See electrical diagram in the Repair Parts TO REPLACE FUSE Replace with 15 amp automotive-type plug-in fuse. The fuse holder is located 26 TO REMOVE HOODAND ASSEMBLY GRILL TO ADJUST CHOKE CONTROL The choke control has been preset at the factory and adjustment should not be necessary. Check adjustment as described below before loosening cable. If adjustment is necessary, proceed as follows: · With engine not running, move choke control (located on dash panel) to full choke position. · Remove air cleaner cover, filter and cartridge plate to expose carburetor choke (see "AIR FILTER" in the Maintenance section of this manual). · Choke should be closed. If it is not, loosen casing clamp screw and move choke cable until choke is completely closed. Tighten casing clamp screw securely. · Reassemble air cleaner. Choke Closed · Raise hood. · Unsnap headlight wire connector. · Stand in front of tractor. Grasp hood at sides, tilt toward engine and lift off of tractor. · To replace, reverse above procedure. \ ,\ Headlight Wire Connector ENGINE Maintenance, repair, or replacement of the emission control devices and systems, w_ich are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized engine manufacturer's service outlet. TO ADJUST THROTTLE CONTROL CABLE The throttle control has been preset at the factory and adjustment should not be necessary. Check adjustment as described below before loosening cable. If adjustment is necessary, proceed as follows: · With engine not running, move throttle control lever to fast position. · Check that swivel is against side of quarter circle. If it is not, loosen cable clamp screw and pull cable back until swivel is against quarter circle. Tighten cable clamp screw securely. Clamp Screw Quarter Circle _ Lever Casing Clamp Screw TO ADJUST CARBU RETOR The carburetor has been preset at the factory and adjustment should not be necessary. However, minor adjustment may be required to compensate for differences in fuel, temperature, altitude or load. If the carburetor does need adjustment, proceed as follows: In general, turning the mixture screw in (clockwise) decreases the supply of fuel to the engine giving a leaner fuel/air mixture. Turning the mixture screw out (counterclockwise) increases the supply of fuel to the engine giving a richer fuel/ air mixture. IMPORTANT: Damage to the needles and the seats in carburetor may result if screw is turned in too tight. PRELIMINARY SETTING · Be sure you have a clean air filter, and the throttle control cable and choke are adjusted properly (see above). \ Swivel 27 · With engine off turn idle mixture screw in (clockwise) closing it finger tight and then turn out (counterclockwise) 1-1/4 to 1-1/2 turns. FINAL SETTING · Start engine and allow to warm for five minutes. Make final adjustments with engine running and shift/motion control lever in neutral (N) position. · With throttle control lever in slow position, hold throttle lever against idle speed screw and adjust idle speed screw to obtain 1200 to 1400 RPM. · While still holding throttle lever against idle speed screw, turn idle mixture screw in (clockwise) until engine begins to die and then turn out (counterclockwise) until engine runs rough. Turn screw to a point midway between those two positions. · Continue to hold throttle lever against idle speed screw and adjust idle speed screw to obtain 900 to 1200 RPM. Release throttle lever. ACCELERATION TEST · Move throttle control lever from slow to fast position. If engine hesitates or dies, turn idle mixture screw out (counterclockwise) t/8 turn. Repeat test and continue to adjust, if necessary, until engine accelerates smoothly. High speed stop is factory adjusted. Do not adjust - damage may result. IMPORTANT" Never tamper with the engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous. If you think the engine-governed high speed needs adjusting, contact your nearest authorized service center/department, which has proper equipment and experience to make any necessary adjustments. __ "_,_ _Throttle .,, ..Idle Speed Screw _ _.._ --.--Jdle Mixture Screw Lever Idle Speed_ Screw__ Throttle Le ve r ""-"---_ _ _---------_ldle _ixt u re Screw _ 28 Immediately prepare your tractor for storage at the end of the season or if the tractor will not be used for 30 days or more. CAUTION: Never store the tractor with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. TRACTOR Remove mower from tractor for winter storage. When mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. · Clean entire tractor (See "CLEANING" in the Maintenance section of this manual). · Inspect and replace belts, if necessary (See belt replacement instructions in the Service and Adjustments section of this manual). · Lubricate as shown in the Maintenance section of this manual. · Be sure that all nuts, bolts and screws are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. · Touch up all rusted or chipped paint surfaces; sand lightly before painting. 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. · Drain the fuel tank. · Start the engine and let it run until the fuel lines and carburetor are empty. · Never use engine or carburetor cleane_ products in the fuel tank or permanent damage may occur. · Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer. ENGINEOIL Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER(S) · Remove spark plug(s). · Pour one ounce of oil through spark plug hole(s) into cylinder(s). · Turn ignition key to "START" position for a few seconds to distribute oil. · Replace with new spark plug(s). OTHER · Do not store gasoline from one season to another. · Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. · If possible, store your tractor indoors and cover it to give protection from dust and dirt. · Cover your tractor with a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensation to form and will cause your tractor to rust. IMPORTANT: Never cover tractor while engine and exhaust areas are still warm. BATI'ERY · Fully charge the battery for storage. · After a period of time in storage, battery may require recharging. · To help prevent corrosion and power leakage during long periods of storage, battery cables should be disconnected and battery cleaned thoroughly (see "TO CLEAN BATTERY AND TERMINALS" in the Maintenance section of this manual). · After cleaning, leave cables disconnected and place cables where they cannot come in contact with battery terminals. · If battery is removed from tractor for storage, do not store battery directly on concrete or damp surfaces. ENGINE FUEL SYSTEM IMPORTANT: It is important to prevent puUmdeposits from forming in essential el system parts such as carburetor, fuel filter, fuel hose, or tank during storage. Also, experience indicates that alcohol blended fuels called gasohol or using 29