Craftsman EZ3 917.256524 Service manual

For Husqvarna Parts Call 606-678-9623 or 606-561-4983
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For Husqvarna Parts Call 606-678-9623 or 606-561-4983
NOTES
2
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Table of Contents
3
Seat Pan changed for easier assembly
4
Oil Drain
4
Solenoid / Fuse / PTO Switch
5
Solenoid Diagnostic Procedure
6
Electrical Components Quick List
7
Hydro Gear 0510 Service Information
8
Hydro Gear 0510 Neutral Adjustment for Lever LT
9
Lever Controlled Automatic LT Neutral Adjustment
10
Foot Controlled Automatic LT Speed Adjustment
11
Quick Attach Bagger
11
Cruise Control for Foot Pedal Operated LT Automatic
12
New GT Automatic Belt Replacement Procedure
13
New GT Automatic Starting Procedure for Extreme Cold
13
Hydro Gear 3000 for Garden Tractors Service Information
14
Hydro Gear 3500 Return to Neutral Adjustment for Trans
15
GT Automatic Speed Lever Neutral Adjustment for Tractor
16
GT Muffler changes
16
Blade Listing
17
New Front Suspension for Mowers
18
New Mandrel for 48” Mower
18
New 48” H.D. Mower
19
KOHLER Liquid Cooled V-Twin
20-21
New 21” Front Drive Mower
22-24
Touch-Up Paints
25
New Weed Trimmer
26-27
21" Rear Drive Adjustments
28-29
42" Mower Cable Clutch Kit # 175067
30
3
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Quick Attach Tractor Seat
Tractors will now be shipped with a quick attach seat that will have a quick install feature for the seat shoulder bolt. The seat will have the shoulder bolt mounted from the
factory. The customer will place the shoulder bolt over the front end of the slot and
push down. The head of the shoulder bolt will go through and is retained. The seat
knob and washer is then installed.
Quick Release Tractor Engine Oil Drain Valve
148456 Oil Drain Tube
162295 Elbow
148315 Oil Drain
A quick release oil drain valve will be on many 2001 tractor engines. The drain is
released with a slight push and a counterclockwise turn. There is a yellow cap on end
that will retain oil if the valve is not properly closed. Customers will be supplied a 10”
clear PVC tube to help drain the oil into a container. The tube is a 3/8” I.D. clear PVC
and can be purchased in bulk locally.
The valve has special threads that do not require pipe dope or teflon tape that is
needed for the brass elbow used on some twin cylinder engines.
4
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New Solenoid # 171141
Yellow Di-Chromate finish for improved corrosion resistance inside and out over previously
used zinc finish.
• Lowered Voltage contact surface pull in, as
low as 8.5 VDC.
• Coil Resistance is 3.8 to 4.3 Ohms. Previous
solenoids were 5.0 to 6.5 Ohms.
• The Solenoid Kit number will continue to be
146154.
•
Yellow
Di-Chromate
FUSE change on Lawn Tractors
A 20 AMP fuse part number 175158 will now
be used on lawn tractors. Lawn tractors made
in 1999 and 2000 with a 15 AMP fuse can also
use the 20 AMP fuse.
GTs will still use the 30 AMP fuse.
15
20
30
A 30 AMP FUSE SHOULD NEVER BE USED IN
PLACE OF A 15 OR 20 AMP FUSE.
PTO SWITCH CHANGE
The new PTO Switch will have 8 terminals instead of 7 terminals.
The switch with 8 terminals can be used for
product made before 2001.
C
Part numbers for the new and old switches are
on the page 5 electrical parts reference.
G
F
PTO SWITCH
H
B
POSITION
CIRCUIT
OFF
ON
C + G, B + H
C + F, B + E, A + D
E
There will be a new 175567 snap-in Ignition
Switch for tractors without headlights.
A
D
5
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Diagnosis of Starter Solenoids
• Remove the red cable from the engine starter motor before testing.
• Place digital meter selector on D.C. Voltage scale that includes 13 Volts.
Step # 1.
12.6
(-)
(+)
1. Place meter probes on battery terminals. If the
reading is 12.2 VDC or more, proceed to the next
step. If the reading is below 12.2 VDC, charge or
replace the battery with one that has at least
12.2 V DC.
A
Step # 2.
1.
Connect negative (black) meter lead to the battery
negative (-) terminal.
2. Connect the positive (red) meter lead to the ‘hot’
terminal of the solenoid.
3. Note the voltage reading.
A
B
Step # 3.
1. Keep the meter selector in the same position and
the negative meter lead connected to the battery
negative terminal.
2. Connect the positive (red) meter lead to the end of
the cable normally connected to the starter motor.
3. Engage the parking brake and turn the ignition
switch to the “START” position.
4. Note the voltage reading.
5. If the voltage drop is more than 0.50 VDC between
the two noted readings, the solenoid or the starter
cable is suspect. Replace the solenoid.
6. Re-install the red cable to the starter motor.
If the solenoid checks acceptable and the starter
does not crank, check for clean tight battery
connections and check the grounds for the
battery and the engine.
12.4
(-)
B
6
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The 0510 Automatic Transmission
from HYDRO-GEAR for Lawn Tractors
Oil should NOT be checked unless there is a complaint about the operation of the transmission.
There is a gold colored plug in the top of the transmission. Clean the underside of the frame and the
top of the transmission before checking the oil level. Contamination cannot be allowed to get into the
transmission. When the plug is removed, a 6 inch metal scale can be used to check the oil level.
When the transmission is cold, the oil level should be from .50 to 1.25 inches from the top of the
casting. 20W50 engine oil can be added to the level of the bottom thread for the oil plug. The oil
never needs to be changed for maintenance.
The 0510 transmission has an expansion tank. This allows for oil to expand into the tank
when the transmission is hot, and as the oil cools it is drawn back inside the transmission.
The expansion tank will be silver-gray in color and should not be opened.
If you are working on a tractor where the operator experiences transmission complaints:
• Check to see that the brake return spring is in position.
• Check the movement of the by pass valve and the freewheel control rod.
• Check the brake adjustments, if adjusted too tight, the transmission can overheat.
1-9/16"
Brake Rod Spring Adjustment
Brake Disc / Puck Clearance
8
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NEUTRAL ADJUSTMENT FOR LAWN TRACTORS
WITH LEVER CONTROL
1. Place the tractor on a smooth paved level surface.
2. Loosen Adjustment Bolt in front of the right rear wheel, and lightly tighten using a 1/2"
wrench.
3. Start Engine and move Lever until tractor does not move forward or backward.
Hold Control Lever in that position and do not move. Turn the engine off.
4. While holding the Control Lever to keep it from moving, loosen theAdjustment Bolt . Move the
Control Lever to the position indicated for Neutral on the fender. Tighten Adjustment
Bolt securely.
FINE TUNE THE NEUTRAL ADJUSTMENT ON AUTOMATIC DRIVE
1. Place the tractor on a smooth paved level surface.
2. Loosen the Adjustment Bolt using a 1/2" wrench. If the tractor is creeping forward, move the
Control Lever forward 1/4 to 1/2 inch. Move the Control Lever rearward 1/4 to 1/2 inch if the
tractor is creeping backwards. Tighten the Adjustment Bolt securely.
3. Start engine and test from both forward and reverse.
4. If tractor still creeps, repeat step # 2 until satisfied.
NOTE: If additional clearance is needed to get to adjustment bolt, move mower deck height to
the lowest position.
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RETURN TO NEUTRAL ADJUSTMENT Lawn Tractor
Hydro Gear 0510 Automatic Transmission
with Footpedal Control
WARNING: Potential for Serious Injury
Certain procedures require the engine to be operated and the tractor is raised off the ground.
To prevent possible injury to the technician or bystander, insure the tractor is properly
secured.
The return to neutral mechanism on the transmission is designed to go to the neutral position after
the operator’s foot is removed from the foot pedals.
Use illustration at the bottom of page.
1. Confirm the freewheel rod at the back of the tractor is in the position for the transaxle to move the
tractor. Raise the rear tires of the tractor off the ground to allow free rotation.
2. Remove the tractor footpedal linkage from the transmission control arm. NOTE: It may be necessary to remove the drawbar plate or the right rear wheel to remove the tractor footpedal
linkage.
3. Start the engine and raise the throttle to full speed.
4. Check for axle rotation. If the axles do not rotate, go to step 5. If the axles do rotate, go to
step 6.
5. Stop the engine. Reattach the footpedal linkage then recheck using steps 3 and 4. If the axles
do not turn, the adjustment is completed. Stop engine.
6. Note the direction of rear axle rotation of the right rear axle. Stop the engine. Loosen the adjusting puck screw until the puck can be rotated. Rotate the puck in the opposite direction of the
wheel rotation in 5 degree increments. Tighten the adjusting puck screw to 250 to 320 inch
pounds. Recheck using steps 3 and 4. Stop the engine. Continue to adjust the puck and test
until the rear axles do not rotate. Reattach the footpedal linkage then recheck using steps 3 and
4. If the axles do not turn, the adjustment is completed. Stop engine.
WARNING: Do not attempt to make
any adjustments with the engine running.
Use extreme caution while inspecting the
vehicle linkage.
10
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Forward Speed Adjustment for Footpedal Control
Lawn Tractors
Loosen indicated bolt under the footpad. Find the alignment mark in the metal at the base of the
forward foot pedal. Hold the pedal to align the mark with the edge of the footpad, and tighten the
bolt.
FORWARD
PEDAL
REVERSE
PEDAL
ALIGNMENT MARK
ADJUSTMENT BOLT
Three Bin Baggers with Quick Attach Improvements
Bagger Attachments with three bins
will have improvements to make
assembly easier.
The Bracket for lawn tractors will
have two shoulder bolts at the top
of each side of the drawbar plate.
The Bracket will fit over the shoulder
bolts and is secured with a Retainer Spring.
LT Bagger Mounting Bracket
The Bracket for garden tractors will
fit into two slots in the angled
drawbar plate. A Retainer Spring
will secure the bracket.
Brackets and chutes will be the
major differences between
baggers for 46” and 48” mowers.
GT Bagger Bracket
11
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CRUISE CONTROL FOR FOOT PEDAL OPERATED
AUTOMATIC LT
There will be an actuating rod for the cruise control with a knob on the right fender. The operator
uses the forward foot pedal to get the desired forward speed; then pushes forward on the knob to
engage the cruise control. This causes the teeth of the Cruise Pawl to engage the Cruise Sector
Gear, which will hold the transmission Control Arm in the position for that speed.
The operator can disengage the Cruise Control manually by pulling backwards on the fender Cruise
Knob or by using the forward speed pedal to go faster. This pulls the teeth of the cruise pawl out of
the sector gear and the tractor will slow to neutral unless the operator pushes on the pedal.
The brake rod can also disengage the Cruise Control. There is a locknut on the end of the brake rod
that will push on the Cruise Disengage Actuator Spring. This will push the Cruise Pawl away from the
Cruise Sector Gear and the automatic transmission will go to neutral and the transmission will not be
able to fight the operation of the brake.
Engaged
Disengaded
Cruise
Console
Knob
Lever
Cruise
Spring
Chassis
Attached toTransaxle
Pawl
Sector
Brake Rod
Arm
Actuator Spring
Brake Disengaging Cruise Pawl
* There is a Damper Cylinder in the system to smooth the tractor speed changes when the cruise
control is disengaged. If the operator complains that the tractor jerks or is not smooth, this part may
need to be replaced. You should correct for any loose fitting parts in the system and re-test before
replacing the damper cylinder.
12
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DRIVE BELT REPLACEMENT PROCEDURE
Garden Tractor with Hydro Gear 3000/3500 series
Automatic Transmission
•
•
•
•
•
•
Remove the mower deck from the tractor.
Remove the Retainer Spring from the Drive Belt Tension Handle located under the left footpad
near the rear tire.
Remove the old belt from the idler pulleys, transaxle pulley, and then from the engine pulley.
Start the new belt at the tractor front on the engine pulley, install on the transaxle pulley, and
last into the idlers. Check belt keeper positions.
Replace the Retainer Spring in the engaged Drive Belt Tension Handle.
Re-install the mower.
ENGINE
PULLEY
TRANSAXLE
PULLEY
BELT
KEEPER
FLAT IDLER
BELT
KEEPER
BELT
KEEPER
V-IDLER
BELT
KEEPER
CLUTCHING
V-IDLER
CLUTCHING
FLAT IDLER
Retainer Spring
Drive Belt Routing
Tension Handle
Drive Belt Tension Handle
PROCEDURE TO START ENGINE IN EXTREME COLD
Garden Tractor with Hydro Gear 3000/3500 series Automatic
If the engine will not start and the outside temperature is extremely cold, the operator may need to
perform this procedure.
• Depress the foot pedal and engage the parking brake rod. The parking brake must remain
engaged until this procedure is completed.
• Locate the handle under the left side footpad near the rear tire.
• Remove the Retainer Spring from the Drive Belt Tension Handle to relieve tension on the drive
belt.
• Start the engine and allow it to warm for 3 minutes.
• Engage the Drive Belt Tension Handle and replace the Retainer Spring.
CAUTION: If the Drive Belt Tension Handle is left in the disengaged position, the tractor will not
move without tension on the drive belt.
13
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The 3000 / 3500 AUTOMATIC TRANSMISSION from
HYDRO-GEAR for GARDEN TRACTORS
Speed Control Level
Adjustment
Control Arm
By-Pass Level
Opening for Oil fill
& Breather Tube
Brake Pull Rod
Oil Level Plug
Return Actuating
Arm
Adjusting Puck
Brake Return Spring
Brake Adjusting Nut
Oil should NOT be checked unless there is a complaint about the operation of the transmission. There is a gold colored plug in the right rear of the transmission case . Clean
the underside of the frame and the top of the transmission before checking the oil level.
Contamination cannot be allowed to get into the transmission. Place the tractor on a
level surface and remove the drawbar plate. When the plug is removed, the oil should
come to the bottom of the opening. 20W50 engine oil can be added to the level of the
bottom of the oil plug. The oil never needs to be changed for maintenance.
If you are working on a tractor where the operator experiences transmission complaints:
• Check to see that the neutral return adjustments for the transmission and the tractor
are correct. ( Both are elsewhere on this manual.)
• Check the movement of the by pass valve and the freewheel control rod.
(This is not an adjustment)
14
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RETURN TO NEUTRAL ADJUSTMENT GT
Hydro Gear 3000/3500 Automatic Transmission
with Hand Control
WARNING: Potential for Serious Injury
Certain procedures require the engine to be operated and the tractor is raised off the
ground. To prevent possible injury to the technician or bystander, insure the tractor is
properly secured.
The return to neutral mechanism on the transmission is designed to go to the neutral position after
the operator’s foot fully depresses the foot pedal .
1. Confirm the freewheel rod at the back of the tractor is in the position for the transaxle to move the
tractor. Raise the rear tires of the tractor off the ground to allow free rotation.
2. Remove the tractor linkage from the hand control from the transmission control arm. NOTE: It
may be necessary to remove the drawbar plate or the right rear wheel to remove the
linkage.
3. Remove the cotter pin and the washer securing the brake pull rod to the return actuating arm.
Remove the rod from the return actuating arm.
4. Push the tractor foot pedal down and lock the parking brake rod. Start the engine and raise the
throttle to full speed.
5. Check for axle rotation. If the axles do not rotate, go to step 6. If the axles do rotate, go to step
7.
6. Stop the engine. Reattach the hand control linkage then recheck using steps 4 and 5. If the
axles do not turn, the adjustment is completed. Stop engine. Re-install the brake pull rod in the
return actuating arm using the washer and a new cotter pin.
7. Note the direction of rear axle rotation of the right rear axle. Stop the engine. Loosen the adjusting puck screw until the puck can be rotated. Rotate the puck in the opposite direction of the
wheel rotation in 5 degree increments. Tighten the adjusting puck screw to 250 to 320 inch
pounds. Recheck using steps 4 and 5. Stop the engine. Continue to adjust the puck and test
until the rear axles do not rotate.
8. Reattach the hand control linkage then recheck using steps 4 and 5. If the axles turn, perform the
Neutral Adjustment for the tractor Automatic Speed Lever on page 14. Stop engine.Re-install
the brake pull rod in the return actuating arm using the washer and a new cotter pin.
WARNING: Do not attempt to make any adjustments with the engine running. Use extreme
caution while inspecting the vehicle linkage.
15
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Neutral Adjustment for GT Automatic Speed Lever
Garden Tractor with Hydro Gear 3000 series Automatic
•
•
•
•
Place the parking brake in the engaged
position.
Loosen the position bolt on the automatic
lever assembly, under the right fender.
Move the automatic speed lever into the
fender console neutral slot.
Tighten the position bolt on the lever
assembly.
If this procedure does not solve the problem, it
will be necessary to do the neutral adjustment on
the Hydro Gear 3000 or 3500 transaxle, before
doing this procedure again.
FRONT MUFFLERS ON 2001 GARDEN TRACTORS
GARDEN TRACTORS BEFORE 2001 HAD
THE MUFFLER BESIDE THE ENGINE
2001 GARDEN TRACTORS HAVE THE MUFFLER IN
FRONT OF THE ENGINE
KOHLER Command Twin cylinder engines will
have an integral solenoid shift starter in 2001.
The solenoid will be on the engine, not on the
tractor.
16
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* BLADE
LISTING *
* BLADE LISTING *
by RETAINER
HOLE CHARACTERISTICS
by RETAINER HOLE CHARACTERISTICS
PART
NUMBER
DECK
SIZE
CONSTRUCTION
TYPE
DECK
TYPE
145106
146749
701211
850972
20"
20"
20"
20"
REGULAR
PREMIUM
PREMIUM
REGULAR
MULCH
MULCH
STANDARD
STANDARD
154208
156716
20"
20"
ELECTRIC
ELECTRIC
MULCH
MULCH
159267
161541
165833
175064
176135
175052
21"
21"
21"
21”
21”
21”
REGULAR
REGULAR
REGULAR
REGULAR
PREMIUM
REGULAR
MULCH
REAR DRIVE
STANDARD
REAR DRIVE
MULCH
PUSH
MULCH / BAG FRONT GEAR
MULCH / BAG FRONT GEAR
MULCH ONLY FRONT GEAR
152202
157101
141114
141443
701213
850973
22"
22"
22"
22"
22"
22"
REGULAR
REGULAR
REGULAR
PREMIUM
PREMIUM
REGULAR
MULCH
MULCH
MULCH
MULCH
STANDARD
STANDARD
138970
138497
139774
134148
38"
38"
38"
38"
PREMIUM
REGULAR
PREMIUM
REGULAR
HI LIFT
HI LIFT
MULCH
MULCH
121263X
104418X
134998
38"
38"
38"
REGULAR
REGULAR
REGULAR
BAGGER
CROSS / BAGGER
MULCH
170037
170038
170039
170040
168720
168721
92 c.m.
92 c.m.
92 c.m.
92 c.m.
107 c.m.
107 c.m.
REGULAR
REGULAR
REGULAR
REGULAR
REGULAR
REGULAR
3 in One
3 in One
Super Bagger
Super Bagger
3 in One
3 in One
138971
138498
139775
134149
42"
42"
42"
42"
PREMIUM
REGULAR
PREMIUM
REGULAR
130652
25034
44"
44"
152443
176084
159705
173920
173921
137380
156468
CAST DECK
REAR DISCHARGE
SIDE DISC EZ3
REAR DISCHARGE
Left
Right
Left
Left
Left
Right
HOLE(S)
BLADE
BOLT(S)
RETAIL
NUMBER
3
3
3
3
1
1
1
1
71-33255
71-33271
71-33270
71-33233
3
1
3
3
3
3
3
3
3
1
1
1
1
1
1
71-33273
71-33274
3
3
3
1
1
1
1
71-33269
71-33256
71-33272
71-33223
71-33234
STAR
STAR
STAR
STAR
1
1
1
1
71-24651
71-24671
71-24654
71-24692
1
1
1
71-24673
3
3
Star 5
Star 6
Star 5
Star 6
Star 5
Star 6
1
1
1
1
1
1
HI LIFT
HI LIFT
MULCH
MULCH
STAR
STAR
STAR
STAR
1
1
1
71-24655
71-24676
PREMIUM
REGULAR
STANDARD
STANDARD
STAR
1
1
1
71-24678
71-24677
46"
46"
46"
48”
48”
PREMIUM
PREMIUM
PREMIUM
PREMIUM
PREMIUM
MULCH
2 in One
BAHIA
BAG/DISCHARGE
MULCH
STAR
STAR
STAR
STAR
STAR
1
1
1
1
1
71-24004
71-24015
50"
50"
PREMIUM
PREMIUM
STANDARD
STANDARD-THICK
STAR
STAR
1
1
71-24005
BLADE PART NUMBERS WITHIN SHADED AREAS ARE INTERCHANGABLE.
CONSTRUCTION - BLADES INDICATED AS PREMIUM ARE MADE OF BETTER STEEL WITH
A BETTER HEAT TREAT PROCESS TO RESIST SAND ABRASION.
17
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71-24652
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NEW Mandrel for NEW 48” Mower
Two Versions
• Greaseable Bearings
• Sealed Bearings
• Mounted at four points instead of
three on previous mandrels
• Dust Cup
• Blade easier to mount
• Repairable
• Larger 7/16” GR8 Blade Bolt
• Torque blade bolt to 40-50 FtLbs.
• Pulley Nut torqued 55 to 65 Ft.
Lbs.
New Front Mower Suspension for three blade Mowers
NEW GT Version Front Mower Suspension
Mower Suspension Links
176084 Blade for the 46” Mower will replace the 170698 Blade. It will be a thicker
.187” instead of .151”. The new blade will offer improved performance with longer life.
This blade is designed for the customer who does not want to mulch. It will give a
good quality of cut on a lawn or a rough yard without having to change blades.
18
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New 48” Heavy Duty Mower
• 10 gauge Heavy Duty Housing
• Heavier Lift Links
• New Front Mower Suspension
• Thicker Blades at .197” from .151”
• Shipped with 173920 Blade for bagging and discharging grass
• Mulching Kit with 173921 Blade optional
•
Premium version will have lever to tension the drive belt
Recessed Groove
Belleville Washer
7/16” Bolt
Grade 8
Fine Thread
19
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NEW KOHLER ENGINE - LIQUID COOLED TWIN
FEATURES
23 Horsepower V-Twin
Liquid Cooled
Solenoid Shift Starter
ENGINE REQUIREMENTS:
Regular Gasoline
SAE 10W30 Oil above 32degrees F
SAE 5W30 Oil below 32 degrees F
4 pints Engine Oil with new oil filter
3.5 pints Engine Oil w/o new filter
Ethelene Glycol Antifreeze
1.47 quarts Antifreeze Capacity
Antifreeze at 50% with water
Spark Plug Champion RC14YC
Spark Plug Gap 0.030” or 0.76mm
Spark Tester
25-455-01-S
Kohler Engine Service Manual # TP-2509
ENGINE OIL:
Select the SAE oil viscosity grade based on the
expected operation temperature.
Change the Oil every 50 hours of operation or
once a year.
Check the engine oil level before starting the
engine. Remove the dipstick and wipe oil with a
clean cloth. Do not thread the dipstick into the
tube before taking the reading.
ENGINE OIL FILTER:
Replace the engine oil filter once each season
or every other oil change (100 hours) if the oil is
changed more than once a year.
SPARK PLUGS:
Replace spark plugs once each season or
every 100 hours.
AIR FILTER:
Clean the engine pre-cleaner after every 25
hours of operation or at least once each season.
Use detergent and water to clean the precleaner. Squeeze it dry in a clean cloth. Work
clean engine oil into foam pre-cleaner and remove oil excess by squeezing in a clean dry
cloth.
Change the paper cartridge air filter once each
year or after every 100 hours of operation. DO
NOT wash the paper cartridge air filter.
DO NOT use pressurized air to ‘blow out’ the
filter as this will damage the paper element.
20
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BLOWER HOUSING AND AIR SCREEN
The air screen must be kept clean to prevent
engine damage from overheating. Clean with
compressed air or a brush to remove dirt and
stubborn dried gum fibers. The blower housing
is easily removed after unhooking four retaining
straps.
AIR INTAKE / COOLING
To ensure proper air circulation, make sure the
air intake screen, radiator, cooling fins, and other
external surfaces of the engine are kept clean.
Every 100 hours of operation remove the upper
blower housing assembly. Clean the cooling fins
of the radiator, external surfaces, and the air
intake screen in the blower housing assembly.
The screen assembly may be separated to
permit more thorough cleaning. Make sure all
parts are re-installed before starting the engine.
This may be needed more often in dusty or dirty
conditions.
Cleaning should be done with compressed air
or a soft brush. To avoid damaging the cooling
fins, DO NOT use a pressure washer.
NOTE: Operating the engine with a blocked
intake screen, dirty or plugged radiator cooling
fins, or cooling shrouds removed, will cause
engine damage due to overheating.
IN LINE FUEL FILTER
The fuel filter should be replaced each season.
If the fuel filter becomes clogged, obstructing the
fuel flow to the carburetor, replacement is required.
RADIATOR COOLANT
The coolant should be changed every 1000
hours. See the engine service manual for complete procedure on changing the coolant. Mix
equal parts of ethylene glycol antifreeze and
distilled water for the proper coolant concentration.
The condition of the hoses, clamps, and associated parts should be inspected when exposed
during engine servicing.
NOTE: Properly dispose of old coolant according
to local regulations.
21
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NEW 21” FRONT WHEEL GEAR DRIVE MOWER
• 21 inch cut
• Rear Discharge
• Side Discharge Deflector
• Mulcher Plug in rear door
• Welded Baffles
• Self Tapping screws
DRIVE SYSTEM COMPONENTS ARE LIKE 22’’ MODELS
BLADES for 21” Front Drive only
175064
176135
175052
REGULAR STEEL MULCH / BAG / DISCHARGE
PREMIUM STEEL MULCH / BAG / DISCHARGE
REGULAR STEEL MULCH only
22
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There will be extruded holes in reinforcing plates for self tapping screws used for the
Handle Brackets and the Rear Wheel Adjusters. The brackets will be pop riveted to
the housing to assist ease of assembly. Models with high wheels will use the wheel
adjuster bolt hole for another self tapping screw and additional support to the handle
bracket.
Extruded Holes
for wheel adjuster
bolt.
Pop Rivets
Extruded Hole for
Handle Bracket
Screws
• Rear door springs are easily replaceable
• A spring fits into each side of the rear door at the hinge.
• Install the bolt that holds the rear door to the handle brackets
• Use a hook to load the door springs against the handle bracket tabs.
23
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BELT COVER INSTALLATION
• Install the drive pulley .130” from
engine, place belt on pulley and
through opening in deck
• Insert Belt Cover into opening in
deck for belt #1
• Insert right tab beween housing
and engine #2
• Push left leg of belt cover so that
it is under edge of housing #3
#1
#2
#3
DRIVE COVER INSTALLATION
• Insert two tabs at end of cover
into housing belt opening
• Locating tabs on the front of the
Drive Cover will position over the
transmission opening
• Install screw to secure Drive
Cover
REAR WHEEL ADJUSTER IMPROVEMENTS
• Sector Plate formed into handle
brackets
• Belleville Washer eliminated with
form of selector lever
• Pal nut holds parts onto shoulder
bolt for easy assembly
• Recessed area in spacer washer
for pal nut
• Self tapping shoulder bolt eliminates nut inside housing
• Longer selector spring levers
24
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Touch - Up Paints for Lawn & Garden
PART No.
177392
175247
175246
169696
169695
169694
150131
150020
144401
136247
136246
130939
130937
161394
126967X
126966X
126965X
DESCRIPTION
PAINT CODE
RED LTX, Spray Paint
DESERT GOLD Spray Paint
STORM GRAY Spray Paint
ANTIQUE SAGE Spray Paint
ANNIVERSARY RED Spray Paint
FOREST GREEN Spray Paint
SATIN BLACK Spray Paint
POLO GREEN Spray Paint (SEARS)
GREEN Spray Paint
RED Spray Paint
BLUE (Dark) Spray Paint
GREEN ( POULAN ) Spray Paint
DOVER GRAY Spray Paint
HIGH GLOSS BLACK Spray Paint
NEW SEARS SILVER Spray Paint
GRAY Spray Paint( Husqvarna/WA)
ORANGE Spray Paint Husqvarna)
615
612
613
598
603
602
558
550
505, 506, 394, 423
510, 511
419
459, 478
428
417
410, 418
412, 422
NOTE: The paint code can be matched to the end of the part number for painted parts needing touch-up.
25
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WEED TRIMMER from ELECTROLUX Home Products
While servicing a weed trimmer, remove the wire
from the spark plug and secure the wire in a
position where it cannot contact the spark plug.
Adjusting
Trimmer
Head
There are two head assemblies used, one is
adjustable with from 1.5 to 3 inches of height and
the other is a fixed height. You will find a Locking
Plate Tab on the adjustable head. When the Tab
is depressed, the trimmer head can be moved to
the desired position.
Locking
Plate Tab
Use .155 inch diameter Trimmer Line that is cut
to 18 ¾ inches in length before installing.
To install, fold the trimmer line in half. Push the
folded end through the opening in the trimmer
plate and over the retainer clip. Pull the trimmer
line into the retainer clip to lock it in place. It is
important that after trimmer lines are installed,
that the length is checked or an unbalanced
condition may occur. The length of all lines must
not vary by more than one inch.
TRIMMER
LINE
There is a cover on the engine secured by one
knob for easy access. The screen inside the
cover as well as the engine air intake screen
should be cleaned during routine servicing.
There is a Skirt at the left front corner of the
Debris Shield. It should be replaced if damaged.
SKIRT
26
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BELT REPLACEMENT PROCEDURE
SHIELD
SCREW
HEAD
ASSEMBLY
COVER
SCREW
SHIELD
SCREW
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Remove the spark plug wire and secure away from the
spark plug
Remove the Cover Screw to access the belt at the
front pulley
Remove the Screw on each side holding the Shield by
the wheels
Place weed trimmer on side with air filter up.
Remove the two Shield Screws on underside by the
head
Pull Debris Shield toward the rear of the as shown by
arrow
Remove Drive Belt from Engine Pulley and Pulley on
the Head Assembly.
Remove the Return Spring from the chassis of the
weed trimmer
Remove the Cable Spring from the idler bracket
Remove shoulder bolt holding idler assembly and belt
to chassis. Move belt to get socket on the head of the
shoulder bolt. Hold Flange Nut of top of chassis while
loosening the shoulder bolt.
Install new Drive Belt in Idler Assembly
To reinstall Idler Assembly, place Shoulder Bolt
through Idler Assembly, Spacer, and Chassis. Loosely
attach Flange Nut on top of the chassis.
Install the Return Spring into the notch in Chassis side
Install the engagement cable Spring into the Idler
Assembly Bracket from the underside, so it is trapped
between the chassis and the bracket.
Tighten the Flange Nut and Shoulder Bolt.
Install the Drive Belt on the front Head Assembly Pulley
and then on the Engine Pulley.
Install the Debris Shield. Line up the tab on the chassis
side and the front edge between chassis and the head
assembly and push forward until the screw holes line
up. Install the two Shield Screws on underside.
Install Shield Screws either side of the chassis
Install the Screw in the front Cover
Replace the Wire on the Spark Plug
27
SHIELD
SCREWS
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21” Rear Wheel Gear Drive Adjustment and
Troubleshooting
Anytime the Speed Cable is disassembled or the drive pulley under the deck is disturbed, the adjustment procedure should be performed.
CAUTION: Disconnect the Spark Plug Wire before working on the mower.
Procedure to Adjust Speed Control Cable and to Install the Speed Control Cable.
1. Move the lever on the speed control cable to the slowest position before installing onto the handle.
2. Install the Cable End over the end of the Pivot Rod at the side of the engine. Snap the cable
Fitting into the housing Bracket. Do NOT lock in the Adjustment Tab.
3. Set the Speed Lever to one notch below the fastest speed.
4. Hold down the engine control bail and pull starter rope through to rotate engine several revolutions
to seat the drive belt under the deck.
DANGER: The BLADE is turning when this step is performed. The mower must be upright; and
care must be taken to keep any object from coming in contact with the blade, especially hands and
feet
Housing
Bracket
5. Pull all slack from the speed control fitting by
pushing lightly on the Pivot Rod, toward the
housing Bracket. Snap the Adjustment Tab into
place.
6. Return the speed lever to the low speed
position.
This is NOT CORRECT. If slack is found in the
cable, it is NOT properly adjusted. Repeat step
#5.
Cable End
NOTE: The Adjustment Tab at the side of the
cable is not yet locked in place. The cable
fitting is locked into the housing bracket.
Cable
Fitting
Adjustment
Tab
This shows the correct adjustment, with the
Adjustment Tab locked in and no slack in the
cable.
Adjustment
Spring
NOTE: The cable adjustment spring is not
necessarily collapsed after the adjustment.
Tab
28
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Gear Box
Pulley
Boot
7. The fitting on the Speed Control Cable End,
should be securely attached to this bracket.
Inspect the Belt Keeper Bracket, speed control
Cable Holding Arm to see if it is at a 90 degree
upright position. If the angle is other than 90
degrees, adjust this arm.
Brake
8. The rubber boot should be in this position
to protect the cable from debris and moisture.
Also check the condition of the cables at the
middle of the handle. If the cables have been
damaged, they may not be able to move into the
proper position.
Boot
9. Check the movement of the idler bracket. It
should travel from the deck tunnel to the engaged belt position. Check in both the fastest
and slowest speed positions. It may be necessary to loosen the flange nut slightly to get the
idler bracket to smoothly travel across the
needed range of movement.
Engagement
Cable
Flange Nut
10. It is difficult to tell if the speed has changed
as you move the speed lever, because the
speed differences are so small. It is best to
remove the cover over the idler pulleys while
evaluating the drive speeds. You should see a
different idler bracket position when you move
the speed lever.
Idler
Bracket
29
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PROBLEM: REPEATED PROBLEM WITH MOWER CABLE CLUTCH FAILURE AT CABLE SPRING
SOLUTION: INSTALL 42” MOWER CABLE CLUTCH REPLACEMENT KIT #175067
CLUTCH CABLE REPLACEMENT
KIT NO. 175067 FOR 42 INCH MOVER
KIT CONTENTS:
(1)
169676
Clutch Cable
(1)
173443
Carriage Bolt (Special)
(1)
7192J
Cable Tie
INSTALLATION INSTRUCTIONS
1. Remove the mower from tractor (See Tractor Owner's Manual for instructions).
2. Remove and discard clutch cable from tractor. Note the location of the cable tie.
3. Assemble new clutch cable to tractor. Secure cable to right side of chassis with the cable tie provided in kit.
REPLACE CLUTCHING IDLER CARRIAGE BOLT
4. Disconnect idler return spring from idler arm.
5. To access carriage bolt, remove nut and bolt "A" securing idler brackets to mower deck.
6. Remove and replace clutching idler carriage bolt "B" with carriage bolt supplied in kit.
7. Reassemble idler brackets to mower deck.
IMPORTANT: After tightening nut and bolt "A", the fixed idler bracket "C" must be tight and flush against mower hanger
bracket (Max. 1/16" clearance) and the clutching idler arm must move freely.
8. Reconnect idler return spring to idler arm.
9. Properly position belt on mower and install mower to tractor (See Tractor Owner's Manual for instructions).
FLUSH TO 1/16" MAX.
CLEARANCE
FIXED IDLER
BRACKET "C"
MOWER HANGER
BRACKET
REPLACE
CLUTCHING IDLER
CARRIAGE BOLT "B"
IDLER RETURN
SPRING
REMOVE
NUT AND BOLT "A"
AVAILABLE TECHNICAL INFORMATION
163578
163579
173699
174702
168695
169287
MANUAL, Tractor and Rear Tine Tiller
MANUAL, Mower and Front Tine Tiller
MANUAL, 2000 Sears Product Accessories
MANUAL, 2000 Sears Electrical Schematics
VIDEO, FHP Mower Leveling
VIDEO, FHP ‘Automatic’ Drive Servicing
30
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NOTES
31
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Printed in U.S.A.
177868
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12/21/00
VFH