02139 GTH2548 Owner's Manual SAFETY RULES SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS 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. 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. I. GENERAL OPERATION • • • • • • • • • • • • • • • • • Read, understand, and follow all instructions in the manual and on the machine before starting. Only allow responsible adults, who are familiar with the instructions, to operate the machine. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade. Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. Never carry passengers. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing. Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place. Slow down before turning. Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting. Turn off blades when not mowing. Stop engine before removing grass catcher or unclogging chute. Mow only in daylight or good artificial light. Do not operate the machine while under the influence of alcohol or drugs. Watch for traffic when operating near or crossing roadways. Use extra care when loading or unloading the machine into a trailer or truck. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury. Keep machine free of grass , leaves or other debris build-up which can touch hot exhaust / engine parts and burn. Do not allow the mower deck to plow leaves or other debris which can cause build-up to occur. Clean any oil or fuel spillage before operating or storing the machine. Allow machine to cool before storage. III. CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. • Keep children out of the mowing area and under the watchful care of another responsible adult. • Be alert and turn machine off if children enter the area. • Before and when backing, look behind and down for small children. • Never carry children. They may fall off and be seriously injured or interfere with safe machine operation. • Never allow children to operate the machine. • Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. IV. SERVICE • • • II. SLOPE OPERATION Slopes are a major factor related to loss-of-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. • • • • • 2 Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. - Use only an approved container. - Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not smoke. - Never refuel the machine indoors. - Never store the machine or fuel container inside where there is an open flame, such as a water heater. Never run a machine inside a closed area. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. Never tamper with safety devices. Check their proper operation regularly. Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage. Allow machine to cool before storing. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. Never make adjustments or repairs with the engine running. Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer's recommended parts, when necessary. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. Check brake operation frequently. Adjust and service as required. SAFETY RULES SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS • • • • • • • • • • • • • • Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. Never carry passengers or children even with the blades off. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing. Never carry children.They may fall off and be seriously injured or interfere with safe machine operation. Keep children out of the mowing area and under the watchful care of another responsible adult. Be alert and turn machine off if children enter the area. Before and when backing, look behind and down for small children. Mow up and down slopes (15° Max), not across. Remove obstacles such as rocks, tree limbs, etc. Watch for holes, ruts, or bumps. Uneven terrain could over turn 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. WARNING: In order to prevent accidental starting when setting up, transporting, adjusting or making repairs, always disconnect spark plug wire and place wire where it cannot contact spark plug. WARNING: Do not coast down a hill in neutral, you may lose control of the tractor. WARNING: Tow only the attachments that are recommended by and comply with specifications of the manufacturer of your tractor. Use common sense when towing. Operate only at the lowest possible speed when on a slope. Too heavy of a load, while on a slope, is dangerous. Tires can lose traction with the ground and cause you to lose control of your tractor. WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. 3 PRODUCT SPECIFICATIONS CUSTOMER RESPONSIBILITIES Gasoline Capacity and type: 5 Gallons Unleaded Regular • • Oil Type (API-SG-SL): SAE 10W30 (above 32°F) SAE 5W-30 (below 32°F) • Oil Capacity: W/Filter: 4.0 Pints W/O Filter: 3.5 Pints Spark Plug: (Gap: .030") Champion RC12YC Ground Speed (MPH): Forward: Reverse: Tire Pressure: Front: 14 PSI Rear: 10 PSI WARNING: This tractor is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. A spark arrester for the muffler is available through your nearest authorized service centre/department (See REPAIR PARTS section of this manual). 0 – 5.8 0 – 2.1 Charging System: 15 AMPS @ 3600 RPM Battery: AMP/HR: MIN. CCA: CASE SIZE: Blade Bolt Torque: 45–55 FT. LBS. 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. 35 280 U1R CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manufactured to give you the best possible dependability and performance. Should you experience any problem you cannot easily remedy, please contact your nearest authorized service center/ department We have competent, well-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”. TABLE OF CONTENTS MAINTENANCE ...................................................... 16-19 SERVICE AND ADJUSTMENTS ............................ 20-26 STORAGE .................................................................... 27 TROUBLESHOOTING ............................................ 28-29 REPAIR PARTS - TRACTOR .................................. 32-45 SAFETY RULES ......................................................... 2-3 PRODUCT SPECIFICATIONS ....................................... 4 CUSTOMER RESPONSIBILITIES................................. 4 ASSEMBLY ................................................................. 6-9 OPERATION ........................................................... 10-15 MAINTENANCE SCHEDULE ...................................... 16 4 UNASSEMBLED PARTS Gauge Wheel Steering Wheel (4) Adjusting Bar Steering Sleeve (4) Clevis Pins (4) Wheels Steering Wheel Adapter (4) Retainer Springs (double loop) Steering Sleeve Extension (4) Washers 3/8 x 3/4 x 14 Ga. Steering Wheel Insert Seat (4) Locknut 3/8-16 (4) Shoulder Bolt Nose Roller Rod (4) Lockwasher Nose Roller (4) Hex Bolts 5/16-18 x 3/4 Mower Nose Roller Brackets (2) Hex Bolts 5/16-18 x 1 (5) Retainer Springs (double loop) Retainer Spring (2) Locknuts 5/16-18 (2) Retainer Springs (single loop) (2)Flanged Pins (1) Oil Drain Tube For Future Use Keys (1)Front Plate Assembly (2) Keys 5 Slope Sheet ASSEMBLY 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. STEERING WHEEL INSERT LOCK NUT TOOLS REQUIRED FOR ASSEMBLY A socket wrench set will make assembly easier. Standard wrench sizes are listed. (1) Pliers (1) Tire pressure gauge (2) 9/16" wrench (1) Utility knife (1) 1/2" wrench (1) 3/4" socket w/drive ratchet LARGE FLAT WASHER STEERING WHEEL STEERING WHEEL ADAPTOR When right or left hand is mentioned in this manual, it means when you are in the operating position (seated behind the steering wheel). TABS TO REMOVE TRACTOR FROM CARTON STEERING WHEEL EXTENTION UNPACK CARTON • • • • STEERING SHAFT Remove all accessible loose parts and parts cartons from carton . Cut along dotted lines on all four panels of carton. Remove end panels and lay side panels flat. Remove mower and packing materials. Check for any additional loose parts or cartons and remove. STEERING SLEEVE 43 021 FIG. 1 BEFORE REMOVING TRACTOR FROM SKID HOW TO SET UP YOUR TRACTOR CHECK BATTERY (See Fig. 2) ATTACH STEERING WHEEL (See Fig. 1) • • • • • • • • • • Remove locknut and large flat washer from steering shaft. Position front wheels of the tractor so they are pointing straight forward. Slide the steering sleeve over the steering shaft. Align tabs and press steering sleeve extension into bottom of steering wheel. Position steering wheel so cross bars are horizontal (left to right) and slide onto steering wheel adapter. Secure steering wheel to steering shaft with locknut and large flat washer previously removed. Tighten securely. Snap steering wheel insert into center of steering wheel. Remove protective materials from tractor hood and grill. 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 the Maintenance section of this manual for charging instructions). LABEL 02 17 3 FIG. 2 INSTALL SEAT (See Fig. 3) IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES IN SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR IS TO ROLL OFF SKID. 6 Seat position should be adjusted forward or backward so that the operator can comfortably reach clutch/brake pedal and safely operate the tractor. • Remove the two (2) bolts and flat washers securing the seat to cardboard packing. Keep the two (2) bolts only and place them with the two (2) identical bolts and four (4) washers in the parts bag. Discard the flat washers and cardboard packing. • Release L.H. seat slide on seat pan by pulling out on adjustment handle and sliding it to the rear position exposing seat mounting holes from bottom. Slide R.H. slide to same rear position. ASSEMBLY • • • • • 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 "STOP" position. Continue with the instructions that follow. Mount rear of seat on slides using mounting bolts and lock washers as shown. Pull out on adjustment handle and slide seat all the way forward. Install front mounting bolts and lock washers. Tighten all mounting bolts securely. Lower seat into operating position and sit on seat. Press clutch/brake pedal all the way down. If operating position is not comfortable, adjust seat. To adjust seat: Grasp adjustment handle and pull out, slide seat to desired position and release adjustment handle. L.H. SEAT SLIDE ASSEMBLE GAUGE WHEELS TO MOWER DECK (See Fig. 4) The gauge wheels are designed to keep the mower deck in proper position when operating mower. Be sure they are properly adjusted to ensure optimum mower performance. • Slide gauge wheel bar down into bracket channel, Be sure that gauge wheel bar aligning holes are on top. Assemble gauge wheels as shown using shoulder bolts, 3/8 washers and 3/8-16 center locknuts and tighten securely. • For ease of mower to tractor assembly, raise gauge wheels to highest position and retain with clevis pins and spring retainers. • Adjust gauge wheels before operating mower. See “TO ADJUST GAUGE WHEELS” in the Operation section of this manual. SEAT ADJUSTMENT SEAT HANDLE PAN LOCK WASHERS 02521 R.H. SEAT SLIDE MOUNTING BOLTS FIG. 3 NOTE: You may now roll or drive your tractor off the skid. Follow the appropriate instruction below to remove the tractor from the skid. RETAINER SPRING TO ROLL TRACTOR OFF SKID (See Operation section for location and function of controls) • • • • PIN SHOULDER BOLT Press lift lever plunger and raise attachment lift lever to its highest position. Release parking brake by depressing brake pedal. Place freewheel control in "transmission disengaged position" (See “TO TRANSPORT” in the Operation section of this manual). Roll tractor forward off skid. ADJUSTING BAR GAUGE WHEEL 3/8-16 CENTER LOCKNUT 3/8 WASHER FIG. 4 TO DRIVE TRACTOR OFF SKID (See Operation section for location and function of controls) TO ATTACH NOSE ROLLER (See Fig. 5) • Assemble brackets "A" and "B" to the inside of mower mounting brackets as shown. Tighten securely. NOTE: Be sure bracket tabs are positioned in tab holes in mower brackets. • Position nose roller between brackets and install rod and retainer spring. WARNING: Before starting, read, understand and follow all instructions in the Operation section of this manual. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other people and objects. • 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 (see "TO TRANSPORT" in Operation section of this manual). • Sit on seat in operating position, depress 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. LOCK NUT HEX BOLT ROD "B" BRACKET TAB HOLE "A" BRACKET NOSE ROLLER 02612 RETAINER SPRING 7 FIG. 5 ASSEMBLY NOTE: To assist in locating hole in flanged pin, the hole in pin is inline with notch on head of pin. If necessary, move mower side-to-side to give space between plate and mower brackets. IMPORTANT: Check belt for proper routing in all mower pulley grooves. • Engage belt tension rod by pushing rod into locking bracket. INSTALL MOWER AND DRIVE BELT (See Figs. 6 and 7) Be sure tractor is on level surface and mower suspension arms are raised with attachment lift control. Engage parking brake. • Cut and remove ties securing anti-sway bar and belts. Swing anti-sway bar to left side of mower deck. • Slide mower under tractor with deflector shield to right side of tractor. IMPORTANT: Check belt for proper routing in all mower pulley grooves. • If equipped, turn height adjustment knob counterclockwise until it stops. • Lower mower linkage with attachment lift control. • Be sure belt tension rod is in disengaged position. • Install belt into electric clutch pulley groove. • Place the suspension arms on outward pointing deck pins. Retain with double loop retainer spring with loops up as shown. • Install front plate assembly to tractor suspension brackets and retain with single loop retainer springs as shown. • Position front plate assembly between front mower brackets. Raise deck and plate assembly to align holes and insert flanged pins. Secure pins with double loop retainer springs between the plate assembly and mower brackets. CAUTION: Belt tension rod is spring loaded. Have a tight grip on rod and engage slowly. • • • • Connect anti-sway bar to chassis bracket under left footrest and retain with double loop retainer spring. If equipped, turn height adjustment knob clockwise to remove slack from mower suspension. Raise deck to highest position. Adjust gauge wheels before operating mower as shown in the Operation section of this manual. LOCK BRACKET BELT TENSION ROD (DISENGAGED POSITION) FRONT SUSPENSION BRACKETS FRONT MOWER BRACKET ELECTRIC CLUTCH PULLEY DOUBLE LOOP RETAINER SPRING CHASSIS BRACKET FRONT PLATE ASSEMBLY SINGLE LOOP RETAINER SPRINGS GAUGE WHEEL FLANGED PIN DOUBLE LOOP RETAINER SPRING ANTI-SWAY BAR USE PLIERS FOR RETAINER SPRINGS SUSPENSION ARMS DOUBLE LOOP RETAINER SPRING (OUTWARD POINTING DECK PINS) 025 10 DEFLECTOR SHIELD LOOP UP FIG. 6 8 ASSEMBLY ✓ CHECKLIST 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. BEFORE YOU OPERATE AND ENJOY YOUR NEW TRACTOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT. PLEASE REVIEW THE FOLLOWING CHECKLIST: ✓ All assembly instructions have been completed. ✓ No remaining loose parts in carton. ✓ Battery is properly prepared and charged. (Minimum 1 hour at 6 amps). ✓ Seat is adjusted comfortably and tightened securely. ✓ All tires are properly inflated. (For shipping purposes, the tires were overinflated at the factory). ✓ Be sure mower deck is properly leveled side-to-side/ front-to-rear for best cutting results. (Tires must be properly inflated for leveling). ✓ Check mower and drive belts. Be sure they are routed properly around pulleys and inside all belt keepers. ✓ Check wiring. See that all connections are still secure and wires are properly clamped. ✓ Before driving tractor, be sure freewheel control is in drive position. WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS: ✓ Engine oil is at proper level. ✓ Fuel tank is filled with fresh, clean, regular unleaded gasoline. ✓ Become familiar with all controls - their location and function. Operate them before you start the engine. ✓ Be sure brake system is in safe operating condition. ✓ It is important to purge the transmission before operating your tractor for the first time. Follow proper starting and transmission purging instructions (See “TO START ENGINE” and “PURGE TRANSMISSION” in the Operation section of this manual). CHECK MOWER LEVELNESS For best cutting results, mower 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, mower drive, 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. 9 OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning. REVERSE NEUTRAL HIGH LOW CHOKE FAST SLOW IGNITION P ENGINE OFF LIGHTS ON OVER TEMP LIGHT FUEL ENGINE ON OIL PRESSURE ENGINE START BATTERY PARKING BRAKE REVERSE FORWARD PARKING BRAKE LOCKED MOWER HEIGHT PARKING BRAKE UNLOCKED MOWER LIFT 15 ATTACHMENT CLUTCH ENGAGED ATTACHMENT CLUTCH DISENGAGED DANGER, KEEP HANDS AND FEET AWAY 15 SLOPE HAZARDS KEEP AREA CLEAR (SEE SAFETY RULES SECTION) DANGER indicates a hazard which, if not avoided, will result in death or serious injury. FREE WHEEL (Automatic Models only) Failure to follow instructions could result in serious injury or death. The safety alert symbol is used to identify safety information about hazards which can result in death, serious injury and/or property damage. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION when used without the alert symbol, indicates a situation that could result in damage to the tractor and/or engine. HOT SURFACES indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage. FIRE indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage. 10 OPERATION KNOW YOUR TRACTOR READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR. Compare the illustrations with your tractor to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference. LIGHT SWITCH AMMETER HOURMETER LIFT LEVER PLUNGER THROTTLE CONTROL 0 60 LIFT LEVER 60 AMPS TECH BRAKE PEDAL ATTACHMENT CLUTCH SWITCH CHOKE CONTROL HEIGHT ADJUSTMENT KNOB MOTION DRIVE BELT TENSION HANDLE IGNITION SWITCH MOTION CONTROL LEVER PARKING BRAKE LEVER 02711 FREE WHEEL CONTROL FIG. 7 Our tractors conform to the safety standards of the American National Standards Institute. ATTACHMENT CLUTCH SWITCH - Used to engage mower blades or other attachments mounted to your tractor. LIFT LEVER - Used to raise and lower mower deck or other attachments mounted to your tractor. LIFT LEVER PLUNGER - Used to release attachment lift lever when changing its position. BRAKE PEDAL - Used for braking the tractor and starting the engine. MOTION CONTROL LEVER- Selects the speed and direction of tractor. CHOKE CONTROL - Used when starting a cold engine. AMMETER - Indocates charging (+) or discharging (-) of battery. LIGHT SWITCH POSITION - Turns the headlights on and off. THROTTLE CONTROL - Used to control engine speed. FREEWHEEL CONTROL - Disengages transmission for pushing or slowly towing the tractor with the engine off. IGNITION SWITCH - Used to start and stop the engine. HOURMETER - Indicates hours of operation. PARKING BRAKE LEVER - Locks brake pedal into the brake position. HEIGHT ADJUSTMENT KNOB - Used to adjust the mower height. MOTION DRIVE BELT TENSION HANDLE- Used when changing motion drive belt and, if necessary, starting engine under extremely cold conditions. 11 OPERATION 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. 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. HOW TO USE YOUR TRACTOR TO SET PARKING BRAKE (See Fig. 8) 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 brake pedal into full “BRAKE” position and hold. • Place parking brake lever in “ENGAGED” position and release pressure from brake pedal. Pedal should remain in “BRAKE” position. Make sure parking brake will hold tractor secure. CAUTION: Always stop tractor completely, as described above, before leaving the operator's position; to empty grass catcher, etc. TO USE THROTTLE CONTROL (See Fig. 8) Always operate engine at full throttle. • Operating engine at less than full throttle reduces the battery charging rate. • Full throttle offers the best mower performance. ATTACHMENT CLUTCH SWITCH PULL OUT TO “ENGAGE” PUSH IN TO “DISENGAGE” CHOKE CONTROL TO USE CHOKE CONTROL (See Fig. 8) 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. THROTTLE CONTROL LEVER BRAKE PEDAL “BRAKE” POSITION TO MOVE FORWARD AND BACKWARD (See Fig. 8) 02149 IGNITION KEY CAUTION: Do not attempt to operate motion control lever when the parking brake is set or when the brake pedal is depressed. Doing so may result in misadjustment to the drive control system. MOTION “DRIVE” “DISENGAGED” CONTROL LEVER POSITION HEIGHT ADJUSTMENT POSITION PARKING BRAKE KNOB “ENGAGED” POSITION FIG. 8 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. • Slowly move motion control lever to desired position. STOPPING (See Fig. 8) MOWER BLADES • To stop mower blades,move attachment clutch switch 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. TO ADJUST MOWER CUTTING HEIGHT (See Fig. 8) The cutting height is controlled by turning the height adjustment knob in desired direction. ) to raise cutting height. • Turn knob clockwise ( ) to lower cutting • Turn knob counterclockwise ( height. The cutting height range is approximately 1-1/2" to 4-1/2". The heights are measured from the ground to the blade tip with the engine not running. These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed. • 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. IMPORTANT: THE MOTION CONTROL LEVER DOES NOT RETURN TO NEUTRAL (N) POSITION WHEN THE CLUTCH/ BRAKE PEDAL IS DEPRESSED. ENGINE • Move throttle control between half and full speed (fast) position. NOTE: Failure to move throttle control between half and full speed (fast) position, before stopping may cause engine to “backfire”. • Turn ignition key to “OFF” position and remove key. Always remove key when leaving tractor to prevent unauthorized use. • 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). 12 OPERATION TO ADJUST GAUGE WHEELS (See Fig. 9) TO OPERATE ON HILLS 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. NOTE: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). • Remove retainer spring and clevis pin which secure each gauge wheel bar. • Lower gauge wheels to ground. Raise gauge wheels slightly to align holes in bracket and gauge wheel bar and insert clevis pin. Gauge wheels should be slightly off the ground. • Replace retainer spring into clevis pin. • Be sure all gauge wheels are in the same setting. WARNING: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope. • • • IMPORTANT: THE MOTION CONTROL LEVER RETURNS TO NEUTRAL (N) POSITION WHEN THE BRAKE PEDAL IS FULLY DEPRESSED. • • • IMPORTANT: BE SURE TO READJUST GAUGE WHEELS IFYOU CHANGE THE CUTTING HEIGHT OF THE MOWER DECK. RETAINER SPRING 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 position with attachment lift control. • Pull freewheel control out and 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.). 7 CLEVIS PIN FIG. 9 TO OPERATE MOWER (See Fig. 10) Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. You must remain fully and centrally positioned in the seat to prevent the engine from hesitating or cutting off when operating your equipment on rough, rolling terrain or hills. • Select desired height of cut. • Lower mower with attachment lift control. • Start mower blades by engaging attachment clutch control. • TO STOP MOWER BLADES - disengage attachment clutch control. CAUTION: Do not operate the mower without either the entire grass catcher, on mowers so equipped, or the deflector shield in place. 02219 FIG. 11 LIFT LEVER HIGEST POSITION TOWING CARTS AND OTHER AT TACH MENTS 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. LOWEST POSITION PUSH IN TO “DISENGAGE” DEFLECTOR SHIELD 02 14 FIG. 10 To restart movement, slowly release parking brake and brake pedal. Slowly move motion control lever to slowest setting. Make all turns slowly. TO TRANSPORT (See Figs. 7 and 11) 01 97 ATTACHMENT CLUTCH SWITCH PULL OUT TO “ENGAGE” Choose the slowest speed before starting up or down hills. Avoid stopping or changing speed on hills. If stopping is absolutely necessary, push brake pedal quickly to brake position and engage parking brake. 2 13 OPERATION NOTE: Before starting, read the warm and cold starting procedures below. • 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. BEFORE STARTING THE ENGINE CHECK ENGINE OIL LEVEL The engine in your tractor has been shipped, from the factory, already filled with summer weight oil. • Check engine oil with tractor on level ground. • Unthread and remove oil fill cap/dipstick; wipe oil off. Reinsert the dipstick into the tube and rest oil fill cap on the tube. Do not thread the cap onto the tube. 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. 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. ADD GASOLINE • Fill fuel tank to bottom of filler neck. Do not overfill. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. (Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. 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. NOTE: In extreme cold conditions, if engine will not start, you may need to disengage the motion drive belt as follows: • Be sure parking brake is engaged. • Remove retainer spring from the drive belt tension handle to relieve belt tension. • Start engine and allow it to warm up for three (3) minutes. • Shut-off engine and engage parking brake. • Engage drive belt tension handle and replace the retainer spring. CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. IMPORTANT: WHEN OPERATING IN TEMPERATURES BELOW32°F(0°C), USE FRESH, CLEAN WINTER GRADE GAS O LINE TO HELP INSURE GOOD COLD WEATHER STARTING. CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. 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 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 warmup 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. TO START ENGINE (See Fig. 8) 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 brake pedal and set parking brake. • 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. 14 OPERATION PURGE TRANSMISSION MOWING TIPS • CAUTION: Never engage or disengage freewheel lever while 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. Disengage parking brake • 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. Shutoff 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. Disengage parking brake. • 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 transmission is now purged and now ready for normal operation. Tire chains cannot be used when the mower housing is attached to tractor. Mower should be properly leveled for best mowing performance. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual. The left hand side of mower should be used for trimming. Drive so that clippings are discharged onto the area that has 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 (See Fig. 12). 00272 FIG. 12 • • • • 15 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. MAINTENANCE MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE E E RS S AG RS RS US OU SON OR UR OU HOU H T O H A 0 S H SE RE 25 10 50 EE Y 8 R RY ERY ERY ERY FO OR E E F BE SERVICE EV EV EV EV EV BE H AC DATES Check Brake Operation Check Tire Pressure T R A C T 0 R Check Operator Presence and Interlock Systems Check for Loose Fasteners 5 Sharpen/Replace Mower Blades 3 Lubrication Chart Check Battery Level 4 Clean Battery and Terminals Check Transaxle Cooling Check V-Belts Check Engine Oil Level Change Engine Oil (with oil filter) 1,2 Clean Air Filter 2 Clean Air Screen 2 Inspect Muffler/Spark Arrester Replace Oil Filter (If equipped) 1, 2 Clean Engine Cooling Fins maint_sch-tractore.new1 E N G I N E 1,2 Change Engine Oil (without oil filter) 2 Replace Spark Plug Replace Air Filter Paper Cartridge 2 Replace Fuel Filter 3 - Replace blades more often when mowing in sandy soil. 4 - Not required if equipped with maintenance-free battery. 5 - Tighten front axle pivot bolt to 35 ft.-lbs. maximum. Do not overtighten. 1 - Change more often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty or dusty conditions. LUBRICATION CHART GENERAL RECOMMENDATIONS The warranty on this tractor does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain tractor as instructed in this manual. Some adjustments will need to be made periodically to properly maintain your tractor. At least once a season, check to see if you should make any of the adjustments described in the Service and Adjustments section of this manual. • At least once a year you should replace the spark plug, clean or replace air filter, and check blades and belts for wear. A new spark plug and clean air filter assure proper air-fuel mixture and help your engine run better and last longer. ➀ SPINDLE ZERK ➀ FRONT WHEEL BEARING ZERK • ➀ FRONT WHEEL BEARING ZERK ➀ STEERING ➁ ENGINE SECTOR GEAR TEETH ➀ MANDREL ZERKS BEFORE EACH USE • • • • ➀ SPINDLE ZERK 02501 Check engine oil level. Check brake operation. Check tire pressure. Check operator presence and interlock systems for proper operation. Check for loose fasteners. ➀ ➁ GENERAL PURPOSE GREASE REFER TO MAINTENANCE“ENGINE” SECTION IMPORTANT: DO NOT OIL OR GREASE THE PIVOT POINTS WHICH HAVE SPECIAL NYLON BEARINGS. VISCOUS LUBRICANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELF-LUBRICATING BEARINGS. IF YOU FEEL THEY MUST BE LUBRICATED, USE ONLY A DRY, POWDERED GRAPHITE TYPE LUBRICANT SPARINGLY. 16 MAINTENANCE TRACTOR MANDREL ASSEMBLY Always observe safety rules when performing any maintenance. BLADE CENTER HOLE 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). BLADE BOLT (SPECIAL) 02 54 4 STAR 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. FIG. 13 TO SHARPEN BLADE (See Fig. 14) 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 cone 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. 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 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.. CENTER HOLE BLADE CARE For best results mower blades must be kept sharp. Replace bent or damaged blades. BLADE BLADE REMOVAL (See Fig. 13) 5/8" BOLT OR PIN • Raise mower to highest position to allow access to blades. NOTE: Protect your hands with gloves and/or wrap blade with heavy cloth. • Remove blade bolt by turning counterclockwise. • Install new or resharpened blade with stamped "THIS SIDE UP" facing deck and mandrel assembly. FIG. 14 BATTERY Your tractor has a battery charging system 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. • 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. IMPORTANT: TO ENSURE PROPER ASSEMBLY, CENTER HOLE IN BLADE MUST ALIGN WITH STAR ON MANDREL ASSEMBLY. • Install and tighten blade bolt securely (45-55 Ft. Lbs. torque). IMPORTANT: SPECIAL BLADE BOLT HEAT TREATED. 17 MAINTENANCE TO CHANGE ENGINE OIL (See Figs. 15 and 16) Determine temperature range expected before oil change. All oil must meet API service classification SG-SL. • Be sure tractor is on level surface. • Oil will drain more freely when warm. • Catch oil in a suitable container. • Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil. • Remove yellow cap from bottom fitting of drain valve and install the drain tube onto the fitting. 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). OIL DRAIN VALVE 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. YELLOW CAP 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 compressed air or high pressure sprayer to clean cooling fins. • • 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 ser vice center/department. • • ENGINE LUBRICATION • Only use high quality detergent oil rated with API service classification SG-SL. Select the oil’s SAE viscosity grade according to your expected operating temperature SAE VISCOSITY GRADES C -30 0 -20 30 -10 32 40 0 60 10 To insure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Every 100 hours of operation (more often under extremely dusty, dirty conditions), remove the blower housing and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. NOTE: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed will cause engine damage due to overheating. 100 80 20 Unlock drain valve by pushing inward and turning counterclockwise. To open, pull out on the drain valve. After oil has drained completely, close and lock the drain valve by pushing inward and turning clockwise until the pin is in the locked position as shown. Remove the drain tube and replace the cap onto to the bottom fitting of the drain valve. 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. Insert dipstick into the tube and rest the oil fill cap on the tube. Do not thread the cap onto the tube when taking reading. Keep oil at “FULL” line on dipstick. Tighten cap onto the tube securely when finished. CLEAN AIR INTAKE/COOLING AREAS 10W30 5W-30 -20 CLOSED AND LOCKED POSITION FIG. 16 TRANSAXLE PUMP FLUID F 9 45 02 DRAIN TUBE 30 40 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE oil_visc_chart4_e FIG. 15 Change the oil after every 50 hours of operation or at least once a year if the tractor is not used for 50 hours in one year. Check the crankcase oil level before starting the engine and after each eight (8) hours of operation. 18 MAINTENANCE CLEAN AIR SCREEN IN-LINE FUEL FILTER (See Fig. 17) 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. See engine manual. 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. AIR FILTER Your engine will not run properly using a dirty air filter. Service air cleaner more often under dusty conditions. See engine manual. ENGINE OIL FILTER Replace the engine oil filter every season or every other oil change if the tractor is used more than 100 hours in one year. See engine manual. CLAMP MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. 00667 CLAMP FUEL FILTER SPARK PLUGS FIG. 17 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. CLEANING • Clean engine, battery, seat, finish, etc. of all foreign matter. • Keep finished surfaces and wheels free of all gasoline, oil, etc. • Protect painted surfaces with automotive type wax. We do not recommend using a garden hose or pressure washer to clean your tractor unless the engine and transmission are covered to keep water out. Water in engine or transmission will shorten the useful life of your tractor. Use compressed air or a leaf blower to remove grass, leaves and trash from tractor and mower. 19 SERVICE AND ADJUSTMENTS WARNING: TO AVOID SERIOUS INJURY, BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS: • Depress brake pedal fully and set parking brake. • Place attachment clutch in “DISENGAGED” position. • Turn ignition key to “STOP” 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. TO INSTALL MOWER TRACTOR Be sure tractor is on level surface and mower suspension arms are raised with attachment lift control. Engage parking brake. • Swing anti-sway bar to left side of mower deck. • Slide mower under tractor with deflector shield to right side of tractor. TO REMOVE MOWER (See Fig. 18) • • • • Place attachment clutch in “DISENGAGED” position. If equipped, turn height adjustment knob to lowest setting. Lower mower to its lowest position. Disengage belt tension rod from lock bracket. IMPORTANT: CHECK BELT FOR PROPER ROUTING IN ALL MOWER PULLEY GROOVES. CAUTION: Rod is spring loaded. Have a tight grip on rod and release slowly. • • • • • • • • • • • Remove retainer spring holding anti-swaybar to chassis bracket and disengage anti-swaybar from bracket. Remove four retainer springs from front plate assembly and remove plate. Remove retainer springs from suspension arms at deck and disengage arms from deck. Raise attachment lift to its highest position. Slide mower forward and remove belt from electric clutch pulley. Slide mower out from under right side of tractor. • If equipped, turn height adjustment knob counterclockwise until it stops. Lower mower linkage with attachment lift control. Be sure belt tension rod is in disengaged position. Install belt into electric clutch pulley groove. Place the suspension arms on outward pointing deck pins. Retain with double loop retainer spring with loops up as shown. Install front plate assembly to tractor suspension brackets and retain with single loop retainer springs as shown. LOCK BRACKET SUSPENSION ARMS FRONT MOWER BRACKET BELT TENSION ROD (DISENGAGED POSITION) ELECTRIC CLUTCH PULLEY FRONT PLATE ASSEMBLY DOUBLE LOOP RETAINER SPRING CHASSIS BRACKET SINGLE LOOP RETAINER SPRING RETAINER SPRING USE PLIERS FOR RETAINER SPRINGS LOOP UP FLANGED PIN ANTI-SWAY BAR DEFLECTOR SHIELD SUSPENSION ARMS DOUBLE LOOP RETAINER SPRINGS (Outward pointing deck pins) FIG. 18 20 02565 SERVICE AND ADJUSTMENTS • Position front plate assembly between front mower brackets. Raise deck and plate assembly to align holes and insert flanged pins. Secure pins with double loop retainer springs between the plate assembly and mower brackets. NOTE: To assist in locating hole in flanged pin, the hole in pin is inline with notch on head of pin. If necessary, move mower side-to-side to give space between plate and mower brackets. SUSPENSION ARM 01553 LIFT LINK ADJUSTMENT NUT FIG. 20 IMPORTANT: CHECK BELT FOR PROPER ROUTING IN ALL MOWER PULLEY GROOVES. • Engage belt tension rod by pushing rod into locking bracket. FRONT-TO-BACK ADJUSTMENT (See Figs. 21 and 22) 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. CAUTION: Belt tension rod is spring loaded. Have a tight grip on rod and engage slowly. • • • To obtain the best cutting results, the mower blades should be adjusted so the front tip is approximately 1/8" to 1/2" lower than the rear tip when the mower is in its highest position. Connect anti-sway bar to chassis bracket under left footrest and retain with double loop retainer spring. If equipped, turn height adjustment knob clockwise to remove slack from mower suspension. Raise deck to highest position. CAUTION: Blades are sharp. Protect your hands with gloves and/or wrap blade with heavy cloth. TO LEVEL MOWER HOUSING Check adjustment on right side of tractor. Position any blade so the tip is pointing straight forward. Measure distance "B" at front and rear tip of the blade. • Before making any necessary adjustments, check that both front plate links are equal in length. • If links are not equal in length, adjust one link to same length as other link. • To lower front of blade, loosen nut “C” on both front links an equal number of turns. NOTE: Each full turn of nut “C” will change distance. “B” by approximately 3/16". • When distance “B” is 1/8" to 1/2" lower at front than rear, tighten nut “D” against trunnion on both front links. • To raise front of blade, loosen nut “D” from trunnion on both front links. Tighten nut “C” on both front links an equal number of turns. The two front links must remain equal in length. • When distance “B” is 1/8" to 1/2" lower at front than rear, tighten nut “D” against trunnion on both front links. • Recheck side-to-side adjustment. 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 (See Figs. 19 and 20) • Raise mower to its highest position. • Measure height from bottom edge of mower to ground level at front corners of mower. Distance “A” on both sides of mower should be the same. • 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, loosen lift link adjustment nut on that side. NOTE: Each full turn of adjustment nut will change mower height about 3/16". • Recheck measurements after adjusting. BOTTOM EDGE OF MOWER TO GROUND A BOTTOM EDGE OF MOWER TO GROUND 00598 GROUND LINE BLADE 02548 A “B” FIG. 19 “B” FIG. 21 21 SERVICE AND ADJUSTMENTS BOTH FRONT PLATE LINKS MUST BE EQUAL IN LENGTH BELT TENSION ROD (DISENGAGED POSITION) RH SUSPENSION ARM RH MANDREL COVER IDLER PULLEY 02 51 6 ELECTRIC CLUTCH PULLEY IDLER PULLEY NUT “C” NUT “D” SPRING ARM 0251 7 PRIMARY IDLER ARM TRUNNION FRONT PLATE ASSEMBLY R.H. MANDREL 025 13 FIG. 23 FIG. 22 TO REPLACE MOWER DRIVE BELT TO REPLACE MOWER BLADE (SECONDARY) DRIVE BELT (See Fig. 24) MOWER DRIVE BELT REMOVAL (See Fig. 23) • Park tractor on a level surface. Engage parking brake. • Lower mower to its lowest position. • Disengage belt tention rod from lock bracket. Park the tractor on level surface. Engage parking brake. • Remove mower (See “TO REMOVE MOWER” in this section of manual). • Remove screws from R.H. and L.H. mandrel covers and remove covers. REMOVE MOWER DRIVE BELT (Refer to “TO REMOVE MOWER DRIVE BELT” illustration in this section of manual). • Carefully roll belt over the top of R.H. mandrel pulley. • Remove belt from idler pulleys. • Check primary idler arm and two idlers to see that they rotate freely. • Be sure spring is securely hooked to primary idler arm and spring arm. CAUTION: Rod is spring loaded. Have a tight grip on rod and release slowly. • Remove screws from R.H. mandrel cover and remove cover. • Remove any dirt or grass clippings which may have accumulated around mandrels and entire upper deck surface. • Disconnect R.H. suspension arm from rear deck bracket by removing retainer spring. • Roll belt over the top of R.H. mandrel pulley carefully. • Remove belt from electric clutch pulley. • Remove belt from idler pulleys. • Check primary idler arm and two idlers to see that they rotate freely. • Be sure spring is securely hooked to primary idler arm and spring arm. MOWER DRIVE BELT INSTALLATION (See Fig. 23) • Install belt in both idlers. • Install new belt onto electric clutch pulley. • Roll belt into upper groove of R.H. mandrel pulley carefully. • Carefully check belt routing making sure belt is in the grooves correctly. • Reconnect R.H. suspension arm to rear deck bracket with retainer spring. • Reassemble R.H. mandrel cover. • Engage belt tension rod by pushing rod into locking bracket. REMOVE MOWER BLADE (SECONDARY) DRIVE BELT • Carefully roll belt off L.H. mandrel pulley. • Remove belt from center mandrel pulley, idler pulley, and R.H. mandrel pulley. • Remove any dirt or grass which may have accumulated around mandrels and entire upper deck surface. • Check secondary idler arm and idler pulley to see that they rotate freely. • Be sure spring is hooked in secondary idler arm and secondary spring arm. INSTALL NEW MOWER BLADE (SECONDARY) DRIVE BELT • Install new belt in lower groove of R.H. mandrel pulley, idler pulley, and center mandrel pulley as shown. • Carefully roll belt over L.H. mandrel pulley. Make sure belt is in all grooves properly. REINSTALL MOWER DRIVE BELT (Refer to “TO REMOVE MOWER DRIVE BELT” illustration in this section of manual). • Install belt into upper groove of R.H. mandrel pulley and around both idlers. Pull belt to front of mower to remove slack. 22 SERVICE AND ADJUSTMENTS • • • • Disengage transmission by placing freewheel control in “transmission disengaged” position. Pull freewheel control out and into the slot and release so it is held in the disengaged position. The rear wheels must lock and skid when you try to manually push the tractor forward. If the rear wheels rotate, the brake needs to be adjusted or the pads need to be replaced. Reinstall mandrel covers and securely tighten all screws. Carefully check belt routing making sure belt is in all grooves correctly. Reinstall mower to tractor (See “TO INSTALL MOWER” in this section of manual). L.H. MANDREL SECONDARY IDLER ARM IDLER PULLEY TO ADJUST BRAKE/REPLACE PADS Contact a qualified service center. SPRING SECONDARY SPRING ARM TO REPLACE MOTION DRIVE BELT (See Fig. 26) Park the tractor on level surface. Engage parking brake. For ease of service there is a belt installation guide decal on bottom of left footrest. • Remove mower (See “TO REMOVE MOWER” in this section of this manual.) BELT REMOVAL • Create slack in belt by removing retainer spring from drive belt tension handle. • Remove belt from all idler pulleys, transaxle pulley and then from engine pulley. BELT INSTALLATION • Install new belt around engine pulley first, then around transaxle pulley and lastly into all the idler pulleys. • Check to be sure belt is positioned correctly and is on proper side of all belt keepers. • Engage the drive belt tension handle and replace the retainer spring. • Reinstall mower. CENTER MANDREL R.H. MANDREL COVER 025 15 FIG. 24 TO ADJUST ATTACHMENT CLUTCH (See Fig. 25) The electric clutch should provide years of service. The clutch has a built-in brake that stops the pulley within 5 seconds. Eventually, the internal brake will wear which may cause the mower blades to not engage, or, to not stop as required. Adjustments should be made by your nearest authorized service center/department. • Make sure attachment clutch and ignition switches are in “OFF” position. • Adjust the three nylon locknuts until space between clutch plate and rotor measures .012" at all three slot locations cut in side of brake plate. NOTE: After installing a new electric clutch, run tractor at full throttle and engage and disengage electric clutch 10 cycles to wear in clutch plate. ROTOR RETAINER SPRING CLUTCH PLATE 00751 DRIVE BELT TENSION HANDLE .012" NYLON LOCKNUT (3) 02504 TRANSAXLE PULLEY ENGINE PULLEY BELT KEEPER FLAT IDLER SLOT (3) BRAKE PLATE FIG. 25 TO CHECK AND ADJUST BRAKE BELT KEEPER If tractor requires more than five (5) feet to stop at highest speed in highest gear on a level, dry concrete or paved surface, then brake must be checked and adjusted. 2498 V-IDLER BELT CLUTCHING CLUTCHING KEEPER IDLER FLAT IDLER FIG. 26 TO CHECK BRAKE • Park tractor on a level, dry concrete or paved surface, depress clutch/brake pedal all the way down and engage parking brake. 23 BELT KEEPER SERVICE AND ADJUSTMENTS TRANSAXLE MOTION CONTROL LEVER NEUTRAL ADJUSTMENT (See Fig. 27) TO REMOVE WHEEL FOR REPAIRS FRONT WHEEL (See Fig. 28) • Block up axle securely. • Remove axle cover, retaining ring and washers to allow wheel removal. • Repair tire and reassemble. • Replace washers and snap retaining ring securely in axle groove. • Replace axle cover. The motion control lever has been preset at the factory and adjustment should not be necessary. • Park tractor on level surface. Stop tractor by turning ignition key to “OFF” position and engage parking brake. • Loosen the adjustment bolt in front of the right rear wheel. • Move motion control lever to the neutral position (N). • Tighten the adjustment bolt. REAR WHEEL • Block rear axle securely. • Remove five (5) hub bolts to allow wheel removal. • Repair tire and reassemble. Replace and tighten hub bolts securely. 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. 02508 ADJUSTMENT BOLT FIG. 27 TRANSMISSION REMOVAL/REPLACEMENT WASHERS 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. RETAINING RING AXLE COVER TO AD JUST STEER ING WHEEL ALIGNMENT q 63s 006 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. FIG. 28 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. 24 SERVICE AND ADJUSTMENTS TO START ENGINE WITH A WEAK BATTERY (See Fig. 29) REPLACING BATTERY (See Fig. 30) WARNING: 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. WARNING: 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 SYSTEM. THE OTHER VEHICLE MUST ALSO BE A 12 VOLT SYSTEM. DO NOT USE YOUR TRACTOR BATTERY TO START OTHER VEHICLES. • • • TO ATTACH JUMPER CABLES • Connect one end of the RED cable to the POSITIVE (+) terminal of each battery(A-B), taking care not to short against tractor chassis. • Connect one end of the BLACK cable to the NEGATIVE (-) terminal (C) of fully charged battery. • Connect the other end of the BLACK cable (D) 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. 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 NUT TERMINAL ACCESS DOOR HEX BOLT POSITIVE (RED) CABLE TERMINAL GUARD 02614 WEAK OR DEAD BATTERY 02 17 9 NEGATIVE (BLACK) CABLE FIG. 30 FULLY CHARGED BATTERY FIG. 29 25 SERVICE AND ADJUSTMENTS 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. HOOD INTERLOCKS AND RELAYS HEADLIGHT WIRE CONNECTOR Loose or damaged wiring may cause your tractor to run poorly, stop running, or prevent it from starting. • Check wiring. See electrical wiring diagram in the Repair Parts section of this manual. 02491 TO REPLACE FUSE Replace with 30 amp automotive-type plug-in fuse. The fuse holder is located behind the dash. TO REMOVE HOOD AND GRILL ASSEMBLY (See Fig. 31) • • • • FIG. 31 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. ENGINE TO ADJUST THROTTLE CONTROL CABLE The throttle control has been preset at the factory and adjustment should not be necessary. If adjustment is necessary, see engine manual. TO ADJUST CHOKE CONTROL The choke control has been preset at the factory and adjustment should not be necessary. If adjustment is necessary, see engne manual. TO ADJUST CARBURETOR Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your tractor to an authorized service center for repair and/or adjustment. 26 STORAGE 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. ENGINE FUEL SYSTEM IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK DURING STORAGE. ALSO, 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. WARNING: 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 • Empty the fuel tank by starting the engine and let it run until the fuel lines and carburetor are empty. • Never use engine or carburetor cleaner 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 empty the gas tank and carburetor if using fuel stabilizer. 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. ENGINE OIL Drain oil (with engine warm) and replace with clean engine oil. (See “ENGINE” in the Maintenance section of this manual). BATTERY • • • • • CYLINDER(S) 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. • • • • 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. 27 TROUBLESHOOTING POINTS PROBLEM Will not start CAUSE 1. 2. 3. 4. 5. 6. 7. Out of fuel. Engine not “CHOKED” properly. Engine flooded. Bad spark plug. Dirty air filter. Dirty fuel filter. Water in fuel. 1. 2. 3. 4. 5. 6. 7. 8. 9. Loose or damaged wiring. Carburetor out of adjustment. 8. 9. 10. 11. Hard to start CORRECTION Engine valves out of adjustment. Extreme cold conditions. 10. 11. Fill fuel tank. See “TO START ENGINE” in Operation section. Wait several minutes before attempting to start. Replace spark plug. Clean/replace air filter. Replace fuel filter. Empty fuel tank and carburetor, refill tank with fresh gasoline and replace fuel filter. Check all wiring. See “To Adjust Carburetor” in Service Adjustments section. Contact an authorized service center/department. See "To start engine" in operation section 1. 2. 3. 4. 5. 6. 7. Dirty air filter. Bad spark plug. Weak or dead battery. Dirty fuel filter. Stale or dirty fuel. Loose or damaged wiring. Carburetor out of adjustment. 1. 2. 3. 4. 5. 6. 7. 8. Engine valves out of adjustment. 8. Clean/replace air filter. Replace spark plug. Recharge or replace battery. Replace fuel filter. Empty fuel tank and refill tank with fresh, clean gasoline. Check all wiring. See “To Adjust Carburetor” in Service Adjustments section. Contact an authorized service center/department. Engine will not turn over 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake pedal not depressed. Attachment clutch is engaged. Weak or dead battery. Blown fuse. Corroded battery terminals. Loose or damaged wiring. Faulty ignition switch. Faulty solenoid or starter. Faulty operator presence switch(es). 1. 2. 3. 4. 5. 6. 7. 8. 9. Depress brake pedal. Disengage attachment clutch. Recharge or replace battery. Replace fuse. Clean battery terminals. Check all wiring. Check/replace ignition switch. Check/replace solenoid or starter. Contact an authorized service center/department. Engine clicks but will not start 1. 2. 3. 4. Weak or dead battery. Corroded battery terminals. Loose or damaged wiring. Faulty solenoid or starter. 1. 2. 3. 4. Recharge or replace battery. Clean battery terminals. Check all wiring. Check/replace solenoid or starter. Loss of power 1. 2. 3. 4. 5. 6. 7. 8. 9. Cutting too much grass/too fast. Throttle in “CHOKE” position. Build-up of grass, leaves and trash under mower. Dirty air filter. Low oil level/dirty oil. Faulty spark plug. Dirty fuel filter. Stale or dirty fuel. Water in fuel. 1. 2. 3. 4. 5. 6. 7. 8. 9. Raise cutting height/reduce speed. Adjust throttle control. Clean underside of mower housing. Clean/replace air filter. Check oil level/change oil. Clean and regap or change spark plug. Replace fuel filter. Empty fuel tank and refill tank with fresh, clean gasoline. Empty fuel tank and carburetor, refill tank with fresh gasoline and replace fuel filter. Connect and tighten spark plug wire. Clean engine air screen/fins. Clean/replace muffler. Check all wiring. See “To Adjust Carburetor” in Service Adjustments section. Contact an authorized service center/department. Excessive vibration 10. 11. 12. 13. 14. Spark plug wire loose. Dirty engine air screen/fins. Dirty/clogged muffler. Loose or damaged wiring. Carburetor out of adjustment. 10. 11. 12. 13. 14. 15. Engine valves out of adjustment. 15. 1. 2. 3. Worn, bent or loose blade. Bent blade mandrel. Loose/damaged part(s). 1. 2. 3. 28 Replace blade. Tighten blade bolt. Replace blade mandrel. Tighten loose part(s). Replace damaged parts. TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine continues to run when operator leaves seat with attachment clutch engaged 1. Faulty operator-safety presence control system. 1. Check wiring, switches and connections. If not corrected, contact an authorized service center/ department. Poor cut - uneven 1. 2. 3. 4. 5. Worn, bent or loose blade. Mower deck not level. Buildup of grass, leaves, and trash under mower. Bent blade mandrel. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels. 1. 2. 3. 4. 5. Replace blade. Tighten blade bolt. Level mower deck. Clean underside of mower housing. Replace blade mandrel. Clean around mandrels to open vent holes. Mower blades will not rotate 1. 2. 3. 4. Obstruction in clutch mechanism. Worn/damaged mower drive belt. Frozen idler pulley. Frozen blade mandrel. 1. 2. 3. 4. Remove obstruction. Replace mower drive belt. Replace idler pulley. Replace blade mandrel. Poor grass discharge 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine speed too slow. Travel speed too fast. Wet grass. Mower deck not level. Low/uneven tire air pressure. Worn, bent or loose blade. Buildup of grass, leaves and trash under mower. Mower drive belt worn. Blades improperly installed. Improper blades used. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Place throttle control in “FAST” position. Shift to slower speed. Allow grass to dry before mowing. Level mower deck. Check tires for proper air pressure. Replace/sharpen blade. Tighten blade bolt. Clean underside of mower housing. Replace mower drive belt. Reinstall blades sharp edge down. Replace with blades listed in this manual. Clean around mandrels to open vent holes. Headlight(s) not working (if so equipped) 1. 2. 3. 4. 5. Switch is “OFF”. Bulb(s) or lamp(s) burned out. Faulty light switch. Loose or damaged wiring. Blown fuse. 1. 2. 3. 4. 5. Turn switch “ON”. Replace bulb(s) or lamp(s). Check/replace light switch. Check wiring and connections. Replace fuse. Battery will not charge 1. 2. 3. 4. Bad battery cell(s). Poor cable connections. Faulty regulator (if so equipped). Faulty alternator. 1. 2. 3. 4. Replace battery. Check/clean all connections. Replace regulator. Replace alternator. Loss of drive 1. 2. 3. Freewheel control in “disengaged” position. Motion drive belt worn, damaged, or broken. Air trapped in transmission during shipment or servicing. 1. 2. 3. Place freewheel control in “engaged” position. Replace motion drive belt. Purge transmission. Engine “backfires” when turning engine “OFF” 1. Engine throttle control not set between half and full speed (fast) position before stopping engine. 1. Move throttle control between half and full speed (fast) position before stopping engine. 29 SERVICE NOTES 30 TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 SCHEMATIC BLACK RED BATTERY SOLENOID RED RED A AMMETER (OPTIONAL) STARTER WHITE C WHITE M RED FUSE BLACK G RED WHITE BLACK M G A2 A1 RED IGNITION SWITCH BLACK ELECTRIC CLUTCH H B A E CLUTCH / BRAKE (PEDAL UP) RED SEAT SWITCH (NOT OCCUPIED) D ORANGE BROWN BLACK L F BLACK B S PTO (DISENGAGED) BLACK GROUNDING CONNECTOR HOUR METER BLUE BLACK (OPTIONAL) RED FUEL LINE SPARK PLUGS GAP (2 PLUGS ON TWIN CYL. ENGINES) IGNITION UNIT CHARGING SYSTEM OUTPUT 15 AMP DC @ 3600 RPM FUEL SHUT-OFF SOLENOID 28 VOLTS AC @ 3600 RPM (REGULATOR DISCONNECTED) REGULATOR RED ALTERNATOR BROWN PTO SWITCH IGNITION SWITCH POSITION CIRCUIT OFF M + G + A1 ON + LIGHTS B + A1 ON START B + A1 B + S + A1 “MAKE” POSITION CIRCUIT OFF ON C + G, B + H C + F, B + E, A + D NONE L + A2 HEADLIGHTS G F C H NONE NONE WIRING INSULATED CLIPS NOTE: IF WIRING INSULATED CLIPS WERE REMOVED FOR SERVICING OF UNIT, THEY SHOULD BE REPLACED TO PROPERLY SECURE YOUR WIRING. BLACK REMOVABLE CONNECTIONS NON-REMOVABLE CONNECTIONS 31 E B D A PTO SWITCH CONNECTOR REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 ELECTRICAL 22 79 21 42 40 81 33 30 25 0 60 46 A M P 6 S 0 45 50 26 16 10 11 29 27 12 2 28 1 8 12 32 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 ELECTRICAL KEY PART NO. NO. DESCRIPTION 1 2 8 10 11 12 16 21 22 25 26 27 28 29 30 33 40 42 45 46 50 79 81 Battery Bolt Hex Head 1/4-20 x 3/4 Tray, Battery Bolt, Battery Front 1/4-20 x 7.5 Zinc Holddown Battery Front Mount Nut, Push Nylon 1.4" Battery Front Switch Interlock Push-In Harness Socket Light w/4152J Bulb Cable, Battery Fuse Nut Keps Hex 1/4-20 Cable, Ground Switch, Plunger NC Gray Switch, Ign Key Harness Ign. Cover, Terminal Red Ammeter Hourmeter Switch, PTO Socket Assembly Bulb Relay Asm. 532 14 49-27 874 76 04-12 532 12 48-86 532 14 52-11 532 15 01-09 532 14 57-69 532 17 61-38 532 17 56-88 532 00 41-52 532 18 54-56 532 10 88-24 873 51 04-00 532 17 06-97 532 12 13-05 532 17 55-66 532 14 04-01 532 18 80-34 532 15 43-36 532 17 75-00 532 17 75-01 532 17 46-51 532 17 52-42 532 10 97-48 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 33 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 CHASSIS AND ENCLOSURES 15 25 14 153 130 148 161 5 158 130 37 68 35 162 17 18 31 122 130 150 165 17 47 122 138 58 167 8 146 7 17 144 143 6 7 156 156 159 7 130 152 156 30 43 139 17 32 17 34 28 139 33 16 17 21 142 17 130 50 47 91 56 36 1 17 36 19 17 44 17 17 45 17 17 20 99 17 2 24 166 86 17 39 17 47 chassis-stealth_44 34 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 CHASSIS AND ENCLOSURES KEY PART NO. NO. DESCRIPTION 1 532 18 03-75 Rail, Frame RH 2 532 17 52-82 Drawbar, Gt 5 532 18 56-04 Dash, Plastic 6 532 15 78-82 Dash, 1PCS, Lower 7 817 72 04-08 Screw, Thd Cut 1/4-20 x 1/2 8 532 18 46-68 Support, Battery 14 532 19 00-55 Hood Asm., Pnt 15 532 16 18-41 Lens LH 16 532 12 17-94 Cover, Access 17 817 00 06-12 Screw, 3/8-16 x 3/4 18 532 18 28-73 Grille 19 819 13 13-12 Washer 13/32 x 13/16 x 12 Ga. 20 874 78 06-16 Bolt, Fin Hex 3/8-16 x 1 21 873 80 06-00 Nut, Crownlock 3/8-16 24 532 18 10-58 Footrest, RH 25 532 16 18-42 Lens RH 28 532 18 10-57 Footrest, LH 30 532 14 50-52 Saddle 31 532 16 14-19 Bracket Supt 1-pc Vgt Steering 32 532 16 13-27 Bracket, Frame Pivot Lh 33 532 16 13-26 Bracket, Frame Pivot Rh 34 532 17 70-18 Plate Asm Engine Chassis 35 819 11 11-16 Washer 11/32 x 11/16 x 16 Ga. 36 817 06 05-12 Screw 5/16-18 x 3/4 37 532 18 17-20 Fender, Pnt. 39 532 17 52-78 Bracket, Axle Front 43 532 13 69-39 Bracket, Spnsn Front Lh 44 532 13 69-40 Bracket, Spnsn Front Rh 45 532 17 60-18 Bracket Asm., Susp Chassis Rh 47 817 49 06-08 Screw Thdrol 3/8-16 x 1/2 50 532 17 54-76 Bracket, Chassis Front 56 532 17 60-16 Bracket Asm., Susp Chassis Lh 58 532 18 35-69 Bracket Asm., Fender 68 817 49 05-08 Screw, 5/16-18 x 1/2 86 874 78 07-20 Bolt, Fin Hex 7/16-14 unc x 1-1/4 91 532 18 03-74 Rail, Frame Lh 99 532 17 71-43 Rod Asm. Bypass 122 532 16 14-64 Screw Hex WSHD 8-18 x 7/8 130 532 17 18-75 Screw Hw Hd Hi-Lo #13-16 x 3/4 138 532 18 17-98 Cupholder 139 532 17 18-73 Bolt Shoulder 5/16-18 142 532 16 18-97 Bracket Dash Stealth RH 143 532 17 75-86 Skirt Grille RH 144 532 16 19-00 Bracket Dash Stealth LH 146 532 17 75-87 Skirt Grille LH 148 532 16 46-55 Extrusion Bumper 150 532 19 03-09 Duct Heat Hood 152 532 17 79-56 Shield, Browning 153 532 18 82-12 Light Box Asm. w/Lens 156 817 00 05-12 Screw 5/16-18 x 3/4 158 817 67 06-08 Screw 3/8-16 x 1/2 159 817 00 06-12 Screw 3/8-16 x 3/4 161 532 18 17-87 Console Fuel Window 162 532 14 24-32 Screw Hex 1/4-1/2 unc 165 532 18 35-54 Bracket Support Tank 166 873 68 07-00 Nut, Crown Lock 7/16-14 unc 167 532 18 46-72 Bushing Snap NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 35 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 GROUND DRIVE 42 39 40 41 70 89 38 132 6 46 37 68 36 77 74 64 35 37 65 127 120 128 34 55 117 117 52 50 56 38 29 131 129 48 153 48 142 130 151 135 137 143 122 120 121 114 117 152 58 20 133 77 120 89 147 114 73 111 120 23 98 146 9 89 123 7 126 94 61 69 22 2 33 3 94 145 2 3 106 107 drive_6-vgt 138 145 1 108 36 112 69 33 125 124 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 GROUND DRIVE KEY PART NO. NO. 1 ------- 2 3 6 7 9 20 22 23 29 33 34 35 36 37 38 39 40 41 42 46 48 50 52 55 56 58 61 64 65 68 69 70 73 74 532 00 70-70 532 00 75-63 876 02 04-12 532 14 05-07 532 14 00-80 873 94 08-00 532 18 02-35 532 14 08-45 532 17 66-00 812 00 00-53 532 07 16-73 532 13 76-48 532 14 94-12 532 12 17-49 532 15 00-35 874 32 10-16 532 17 85-75 873 93 10-00 532 12 48-72 532 14 51-70 872 11 06-14 532 13 14-94 532 12 77-83 532 10 57-06 532 16 15-97 874 76 07-24 532 14 39-95 532 17 66-01 532 17 96-13 532 00 51-42 532 12 38-00 532 18 17-88 874 49 05-48 532 14 24-32 DESCRIPTION Transaxle Hydro Gear 331-3000 (Order Parts From Transaxle Manufacturer) Key Sq. 1/4 x 2.5 Washer Pin, Cotter Wheel, Hub Assembly Bolt, Hub Nut Lever Asm Shift Knob Brake, Rod Ring E Cap, Parking Brake Rod, Parking Brake Spring, Drive Ground Washer 25/32 x 1-1/4 x 16 Ga. Nyliner Screw, Fin. #10-24 x 1 Actuator, Interlock VGT Nut Centerlock 10-24 unc Cover, Pedal Retainer, Spring Bolt Rdhd 3/8-16 x 1-3/4 Gr. 5 Pulley, Idler, Flat Pulley, Idler, Grooved Bearing, Idler V-Belt Bolt Fin Hex 7/16-14 x 1-1/2 Pulley, Transaxle Shaft, Brake Pedal Bolt, Shoulder Pin, Roll Washer Console Automatic YT/GT Bolt Hex Flghd 5/16-18 x 3 Gr. 5 Screw Hex Wsh. Hi-Lo 1/4-1/2 KEY PART NO. NO. DESCRIPTION 77 89 94 98 106 107 108 111 112 114 117 120 121 122 123 124 125 126 127 128 129 130 131 132 133 135 137 138 142 143 145 146 147 151 152 153 Bolt Fin Hex 7/16-14 x 1 Nut Crownlock 7/16-14 unc Fastener Christmas Tree Bracket Shift O-Ring Asm Hydro Gear Line Fuel Hydro 15” VGT Cap Asm Vent Hydro Gear Spacer Shift Lever VGTH Washer Nylon High Temp Nut Lock Hex W/Ins 5/16-18 unc Nut, Lock Flg. 3/8-16 Screw 3/8-16 x .75 Bracket Strap Torque Bolt RDHDSQ 5/16-18 unc x 2-1/2 Rod Shift Bolt Shoulder 5/16-18 x .561 Screw 5/16-18 x 5/8 Washer SRRTD 5/16 ID x 1 x .125 Link Control Clutch Spring Drive GRND Bracket Asm Idler Tensioning Washer 13/32 x 5/8 x 16 Ga. Pin Cotter 3/32 x 3/4 Bracket Mtg Hydro 3500 LH VGT Bracket Mtg Hydro 3500 RH VGT Link Asm Control Hydro 3500 Nut Lock 5/16-18 NC Thd. Washer Thrust 5/8 x 1.10 x 1/32 Strap Torque HG-3500 Screw Thdrol 5/16-18 x 3/4 Washer Axle Flange HG-3000 Fan 7" Hydro Washer Bolt Hex 5/16-18 x 7/8 Bolt Hex 5/16 x 1 W/Patch Spring, Retainer 874 78 07-16 873 68 07-00 532 13 38-35 532 14 10-04 532 14 29-18 532 15 47-39 532 14 29-17 532 15 62-40 532 17 85-58 873 80 05-00 873 90 06-00 817 00 06-12 532 17 56-11 872 01 05-20 532 18 32-54 532 16 54-92 817 49 05-10 532 16 60-02 532 17 73-62 532 17 66-24 532 17 94-73 819 13 10-16 876 02 03-12 532 17 54-67 532 17 54-68 532 17 73-64 532 12 49-49 532 00 13-70 532 17 54-69 817 06 05-12 532 16 31-68 532 14 04-62 532 14 13-22 874 76 05-14 532 17 87-05 532 12 47-88 NOTE: All component dimensions given in U. S. inches 1 inch = 25.4 mm 37 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 STEERING ASSEMBLY 9 8 7 26 51 3 2 45 1 6 9 8 12 4 3 7 11 44 15 14 10 21 6 14 15 20 23 5 22 13 34 14 15 36 13 31 33 32 6 41 13 29 27 53 42 19 28 27 47 28 6 49 16 46 50 52 15 14 35 18 steering_13-vgt 38 8 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 STEERING ASSEMBLY KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 26 27 28 29 31 32 33 34 35 36 41 42 44 45 46 47 49 50 51 52 53 Wheel, Steering Axle Asm., Front Fitting, Grease Spindle Asm, LH Spindle Asm., RH Bearing, Race Thrust Harden Washer 25/32 x 1-5/8 x 16 Ga. Ring, Klip #T5304-75 Cap, Spindle Bolt, Fin Hex 5/8-11 x 2-3/4 Spacer Brg Axle Front 1.570 Nut, Lock Flange 5/8-11 unc Washer 25/32 x 1-1/4 x 16 Ga. Washer, Lock Hvy Hlcl Spr 3/8 Nut 3/8-24 Shaft Asm., Steering Draglink, Ball Joint Solid Vgt Support Asm., Steering Vgt Boot Steering Adapter, Wheel Steering Bushing, Strg. Screw Cap , Wheel Steering Bearing, Col. Strg. Screw 3/8-16 x 3/4 Bearing, Flange Bushing, Nyliner Snap Washer 11/32 x 1 x 10 Ga. Washer, Lock Hvy Hlcl Spr 5/16 Bolt, Hex Hd 5/16-18 x 3/4 Gear, Sector Steering Tie Rod Bracket Switch Inerlock VGT97 Screw 5/16-18 x 1/2 Extension Steering Premium Washer 13/32 x 1-1/20 x 11 Ga. Washer Flat 13/32 x 1 x 10 Ga. Bracket Asm. Idler Pulley Idler Flat Nut Lock Flg 3/8-16 unc Nut Hex Jam Toplock 1/2-20 unc Clip Steering Washer Harden 532 16 66-27 532 17 85-57 532 18 32-26 532 16 18-49 532 16 18-48 532 12 49-31 532 12 17-48 812 00 00-29 532 12 12-32 874 78 10-44 532 13 65-18 873 90 10-00 532 12 17-49 810 04 06-00 873 54 06-00 532 18 68-14 532 17 55-72 532 15 60-11 532 17 75-92 532 15 99-45 532 15 51-05 532 15 29-27 532 16 66-26 532 12 49-37 817 00 06-12 532 10 42-39 532 13 81-36 819 11 16-10 810 04 05-00 874 78 05-12 532 18 70-39 532 18 67-99 532 15 52-46 817 49 05-08 532 17 75-93 819 18 24-11 819 13 16-10 532 17 94-71 532 17 58-20 873 90 06-00 873 94 08-00 532 17 55-53 532 18 89-67 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 39 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 ENGINE 1 83 22 25 62 69 21 20 80 70 71 84 84 86 82 12 18 41 42 15 43 10 37 47 9 28 29 31 26 2 81 11 27 8 37 39 SPARK ARRESTER KIT 40 engine-kawasaki_1 vgt KEY PART NO. NO. 1 ------- 2 8 9 10 11 12 15 18 20 21 22 25 26 27 28 29 31 37 39 40 41 532 14 97-23 532 12 13-61 532 17 77-48 532 17 52-87 532 17 93-35 532 14 39-96 532 17 91-15 532 18 18-03 532 18 29-37 532 17 18-75 532 17 81-48 873 92 06-00 532 00 36-45 532 13 92-77 532 00 78-34 532 13 71-80 532 14 50-06 532 12 34-87 817 49 06-36 817 49 06-64 532 12 61-97 KEY PART NO. NO. DESCRIPTION Engine Kohler, Model No. CV730 (Order parts from engine manufacturer) Muffler Side Pulley V-Idler Keeper Asm. Belt Engine VGT Bushing Clutch Electric Pulley Engine VGT Elect Clutch Tank Fuel 5.0 Cap Fuel Control Throttle Screw HWHD Hi-Lo #13-16 x 3/4 Control Choke Nut Keps 3/8-24 unf Bushing Stem Tank Fuel Fuel Line Spark Arrester Kit Clip Push-In Clamp Hose Screw TT 3/8-16 x 2-1/4 unc Screw TT 3/8-16 x 4 unc Washer 1-1/2 OD x 15/32 ID x .250 40 42 43 47 62 69 810 04 07-00 532 17 99-53 532 17 52-88 532 14 66-29 -------- 70 71 80 81 82 532 17 55-46 532 17 55-45 532 16 33-05 532 14 84-56 -------- 83 84 86 532 17 18-77 817 06 06-24 532 18 43-62 DESCRIPTION Washer Lock 7/16 Bolt Hex 7/16-20 x 3.75 Ga 5 Bushing Shield Heat Muffler Gasket (Order from Enigne Manufacturer) Tube Exhaust RH Tube Exhaust LH Nut Flange M8-1.25 Tube Drain Oil Easy Plug Oil Drain ((Order parts from engine manufacturer) Bolt 5/16-18unc x 1-3/4 W/Sems Screw 3/8-16 x 1-1/2 Nut Hex Flange Toplock M8-1.25 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm For engine service and replacement parts, call the toll free number for your engine manufacturer listed below: Briggs & Stratton 1-800-233-3723 Kohler Co. 1-800-544-2444 Tecumseh Products 1-800-558-5402 Honda Engines 1-800-426-7701 Kawasaki 1-949-460-5688 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 LIFT ASSEMBLY 40 35 73 43 38 34 7 32 8 9 10 31 30 39 42 1 70 3 29 4 5 23 72 5 33 4 11 2 6 11 23 70 79 77 41 41 23 74 70 12 76 26 24 78 75 23 lift_rh_11 76 KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 23 24 26 29 30 31 32 33 Rod Asm., Lever Shaft Asm., Lift Vgt Lever Asm., Lift Rh E-Ring Truarc #5133-87 Washer 29/32 x 1-1/4 x 16 Ga. Bolt, Fin Hex 3/8-16 x 1-1/2 Grip, Handle Button Plunger Plunger, Lever Lift Spring Link Lift Retainer, Spring Retainer, Spring Nut, Jam Hex 1/2-13 unc Nut Crownlock 1/2-13 unc Trunnion Infin Height Nut, Special Washer 13/32 x 5/8 x 16 Ga. Spring, Compression Inf Hgt Pin, Cotter 3/32 x 1/2 532 12 10-06 532 18 00-45 532 15 91-89 812 00 00-22 819 29 20-16 871 11 06-24 532 12 56-31 532 12 45-26 532 12 23-64 532 18 38-94 532 17 53-75 532 16 35-52 532 12 46-70 873 35 08-00 873 80 08-00 532 15 02-33 532 11 08-07 819 13 10-16 532 13 71-50 876 02 03-08 KEY PART NO. NO. DESCRIPTION 34 35 38 39 40 41 42 43 70 72 73 74 75 76 77 78 79 Rod, Adj Lift Knob, Inf 3/8-16 Unc Pointer Height Indicator Plug, Hole Blk. 1.485/1.515 Dia. Screw 5/16-18 x 1 Nut, Lift Link Washer 11/32 x 1-1/2 x 10 Ga. Scale, Indicator Height Nut Hex Flange Lock Nut Push Phos & Oil Nut, Hex Jam 3/8-16 unc Arm, Suspension Rear RH Plate, Asm, Susp, Front Pin Flange Trunnion Susp. Arm Trunnion, Front, Susp Arm, Suspension Rear LH 532 13 71-67 532 13 80-57 532 15 50-97 532 12 39-35 817 06 05-16 532 17 59-94 819 11 24-10 532 12 39-34 532 14 52-12 532 11 04-52 873 35 06-00 532 17 58-02 532 17 58-05 532 17 55-60 532 17 62-05 532 17 56-89 532 17 53-78 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 41 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 SEAT ASSEMBLY 1 20 35 20 8 8 24 7 25 7 14 10 28 33 26 22 5 5 6 16 37 15 21 2 13 17 12 3 seat_10-vgt KEY PART NO. NO. DESCRIPTION 1 2 3 5 6 7 8 10 12 13 14 15 16 Seat Bracket, Pivot Seat Strap asm Fender Clip, Push In Hinged Nut, Crownlock 3/8-16 Spring, Seat Cprsn Bolt 5/16-18 unc x 3/4 Pan, Seat Bracket, Mounting Switch Bushing, Snap Bolt, Carriage 1/4-20 x 1-1/2 Spacer, Split Spring, Cprsn 532 18 87-15 532 14 05-51 532 14 06-75 532 14 50-06 873 80 06-00 532 12 41-81 532 17 18-77 532 18 24-93 532 12 12-46 532 12 12-48 872 05 04-12 532 12 12-49 532 12 37-40 KEY PART NO. NO. DESCRIPTION 17 20 21 24 25 26 28 33 35 37 Nut, Lock 1/4 Lge Flg Gr. 5 Cap, Spring Seat Bolt, Shoulder 5/16-18 Track Slide Seat LH Track Slide Seat RH Washer 11/32 x 5/8 x 12 Ga. Washer Split Bolt Fin Hex 5/16-18 unc x 3/4 Cap Vinyl 1 x .34 Red Nut, Crownlock 5/16-18 532 12 39-76 532 12 42-38 532 17 18-52 532 17 79-46 532 17 79-47 819 11 10-12 810 01 05-00 874 78 05-12 532 17 84-26 873 80 05-00 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 42 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 DECALS 1 15 3 4 7 10 5 5 27 24 6 23 17 14 23 11 12 KEY PART NO. NO. DESCRIPTION 1 3 4 5 6 7 8 10 11 12 Decal, Final Decal, Hood, RH Decal, Hood, LH Decal, Side Panel Decal, Warning Decal, Hood Cust. Resp. Decal, Mower Heavy Duty Decal, Danger Decal, Foot Rest Decal, Deck Caution 532 18 97-22 532 18 89-47 532 18 89-48 532 18 97-08 532 17 05-63 532 18 09-41 532 17 84-82 532 15 71-40 532 18 12-53 532 17 85-02 8 KEY PART NO. NO. WHEELS & TIRES 11 3 4 7 10 5 6 532 17 52-91 532 18 89-25 532 18 28-54 532 10 62-02 532 14 50-05 532 16 69-60 532 18 19-16 532 18 19-17 532 18 99-42 KEY NO. 1 2 3 4 5 6 7 PART NO. 532 05 91-92 532 06 51-39 532 14 45-09 532 00 81-34 532 10 62-30 532 12 49-57 532 12 49-59 Decal, V-Belt Schematic Decal, Ins. Strg Whl Decal, Saddle Oper. Reflector, Taillight Decal, Btry Dngr/Psn Decal, Drawbar Pad Footrest LH Pad Footrest RH Manual, Owner’s (English) DESCRIPTION Cap, Valve, Tire Stem, Valve Rim Assembly, Front Tube, Front (Service Item Only) Tire, Front Fitting, Grease Bearing, Flange (Front Wheel Only) 8 532 17 50-39 Cap, Hub 9 532 10 55-88 Tire, Rear 10 532 00 71-54 Tube, Rear (Service Item Only) 11 532 14 45-10 Rim Assembly, Rear 12 532 12 48-60 Fitting, Grease -532 14 43-34 Sealant, Tire (10 oz. Tube) NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 1 2 14 15 17 23 24 27 ---- DESCRIPTION 9 8 12 wheel_art_1-vgt 43 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 MOWER DECB 46 132 95 182 45 49 49 33 33 31 30 43 49 121 99 126 49 114 os 183 e_ roll er 91 132 97 30 45 30 39 98 42 _n 52 130 42 21 48 46 37 32 112 94 32 42 50 47 115 97 122 31 50 110 5 57 116 117 56 21 113 184 100 118 119 24 25 21 1 26 17 3 29 16 6 28 27 5 15 18 19 14 20 13 18 48 11 8 mower_deck.48prem_2 44 REPAIR PARTS TRACTOR - MODEL NO. GTH2548 (GTH2548A), PRODUCT NO. 954 57 20-04 MOWER DECK KEY PART NO. NO. 1 3 5 6 8 532 18 18-48 532 17 89-15 532 12 46-70 532 17 80-24 532 17 43-65 11 532 17 39-21 -- 532 18 00-54 13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 37 39 42 43 45 46 47 48 49 532 17 43-60 532 17 43-58 532 11 04-85 532 17 44-93 872 11 06-10 872 14 05-05 532 13 28-27 532 17 43-78 873 68 05-00 532 10 53-04 532 17 81-02 532 11 04-52 532 18 17-07 819 11 10-16 532 13 14-91 532 17 39-84 532 18 76-90 532 17 78-65 532 17 83-42 532 17 79-68 532 17 43-75 532 12 20-52 532 17 43-73 532 18 08-06 532 13 77-29 532 18 08-08 532 17 43-68 873 90 06-00 KEY PART NO. NO. DESCRIPTION Deck Weldment Mower 48 Bracket Asm., Sway Bar Retainer Spring Sway Bar Deck Bolt 7/16 Asm. Blade (The following blades are available) Blade, 48" Mulching (For mulching mowers only) Blade, 48" Hi-Lift (For bagging and discharging) Shaft Asm. w/Lower Bearing Mandrel Asm. Bearing, Ball, Mandrel Stripper Mandrel Deck Bolt RDHD Sq Neck 3/8-16 x 1.25 Bolt, Carriage 5/16-18 x 5/8 Bolt, Hex Hd, Shoulder 5/16-18 Baffle, Vortex Mower Nut, Crownlock 5/16-18 Unc Cap, Sleeve Spring, Torsion Nut, Push Deflector Shield Washer 11/32 x 5/8 x 16 Ga. Rod, Hinge Screw, Thdroll Washer Head Washer, Spacer Mandrel Pulley, Mandrel Nut, Flg. Top Lock Cntr. 9/16 Pulley, Idler, Flat Pulley, Idler, Driven Spacer, Retainer Arm, Idler Secondary Cover, Mandrel Deck Screw, Thdroll. 1/4-20 x 5/8 V-Belt, Mower, Secondary V-Belt, Mower, Primary Nut Lock Flg. 3/8-16 Unc 50 52 56 57 91 94 95 97 98 99 100 110 112 113 114 115 116 117 118 119 121 122 126 130 132 182 183 184 -- 872 11 06-12 532 17 58-20 532 15 59-86 532 15 69-41 532 18 05-35 532 17 60-66 532 18 05-34 532 17 85-15 532 17 94-79 532 18 40-58 872 11 06-16 532 17 50-16 532 17 43-87 872 11 05-06 532 17 43-84 532 17 46-09 532 18 42-19 532 13 39-57 873 93 06-00 819 12 14-14 532 17 43-71 532 17 46-06 532 17 43-72 817 00 06-16 817 00 06-12 532 17 91-27 532 16 35-52 532 17 39-79 532 17 43-56 -- 532 18 15-91 DESCRIPTION Bolt, Carr. 3/8-16 x 1-1/2 Gr. 5 Pulley Idler Flat Bar Pnt Adj. Pin Head Rivet Bracket Asm N Roller RH Roller Nose 48" Bracket Asm N Roller LH Washer Hardened Spring Primary Drive Pulley Idler"V" Bolt RDHD Sqnk 3/8-16 Unc x 2 Arm Spring Secondary Link Tension Relief Lever Bolt Carr. 5/16-18 x 3/4 Tension Asm. Relief Lever Arm Spring Tension Relief Bolt, Shoulder Gauge Wheel Nut, Centerlock 3/8-16 Unc Washer 3/8 x 7/8 x 14 Ga. Spring Secondary Drive Bushing Pivot Tension Relief Arm, Idler, Primary Deck Screw 3/8-16 x 1.0 Screw 3/8-16 x .75 Rod Roller Nose Retainer Spring Keeper Belt Idler Mandrel Asm. Service (Includes Key Nos. 13-15 and 33) Replacement Mower, Complete (Std. Deck-Order separately nose roller components Key Nos. 91 - 95 and 132, 182, 183.) NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 45 WARRANTY STATEMENT SECTION 1: LIMITED WARRANTY Husqvarna Forest & Garden Company (“Husqvarna”) warrants Husqvarna product to the original purchaser to be free from defects in material and workmanship from the date of purchase for the “Warranty Period” of the product as set forth below: Lifetime Warranty: All tiller tines against breakage, trimmer shafts, ignition coils and modules on hand held product. 3 Year Warranty: Spindles (on Zero Turn Riders and Commercial Walk-Behinds) 2 Year COMMERCIAL-Warranty: Husqvarna Commercial Turf Equipment—zero turn riders, wide area walks, and ground engaging commercial equipment. 2 Year NON-COMMERCIAL Warranty: Automatic Mower, Riding lawn mowers, yard and garden tractors, walk behind mowers, tillers, chain saws, trimmers, brushcutters, clearing saws, snow blowers, handheld blowers, backpack blowers, hedge trimmers, electrical products and power-assist collection systems for noncommercial, nonprofessional, noninstitutional or nonincome producing use, except as herein stated. Emission control system components necessary to comply with CARB-TIER-II and EPA regulations, except for those components which are part of engine systems manufactured by third party engine manufacturers for which the purchaser has received a separate warranty with product information supplied at time of purchase. 1 Year Warranty: Power cutters, stump grinder, pole pruners and pole saws for non-commercial, non-professional, non-institutional or non-income producing use. All trimmers, brushcutters, clearing saws, hovering trimmers, stick edgers, backpack blowers, hand held blowers, hedge trimmers, power-assist collection systems used for commercial, institutional, professional or income producing purposes or use. 46 Batteries have a one-year prorated limited warranty with 100% replacement during the first 6 months. 90 Day Warranty: Automatic Mower, Chain saws, power cutters, stump grinders, pole saws, pole pruners, snow throwers, model series 580 & 600 walk-behind mowers and commercial turf equipment or any Husqvarna product used for commercial, institutional, professional, or income producing purposes or use except as otherwise provided herein. Husqvarna Safety Apparel carries a 90-day warranty from the date of the customer’s original purchase for defects in material and workmanship. Normal wear, tear or abuse is not covered under warranty. Product must be returned to Charlotte with a warranty claim form. All care and maintenance instructions must be followed as stated by the manufacturer on the care label. The fit of the protective apparel/boot is not covered under warranty. 30 Day Warranty: Replacement parts, accessories including bars and chains, tools and display items. SECTION 2: HUSQVARNA’S OBLIGATIONS UNDER THE WARRANTY Husqvarna will repair or replace defective components without charge for parts or labor if a component fails because of a defect in material or workmanship during the warranty period. SECTION 3: ITEMS NOT COVERED BY THIS WARRANTY The following items are not covered by this warranty: (1)Normal customer maintenance items which become worn through normal regular use, including, but not limited to, belts, blades, blade adapters, bulbs, filters, guide bars, lubricants, rewind springs, saw chain, spark plugs, starter ropes and tines; (2)Natural discoloration of material due to ultraviolet light; (3)Engine and drive systems not manufactured by Husqvarna; these items are covered by the respective manufacturer’s warranty as provided in writing with the product information supplied at the time of purchase; all claims must be sent to the appropriate manufacturer; (4)Lawn and garden attachments are covered by a third party which gives a warranty, all claims for warranty should be sent to the manufacturer; and (5)Emission Control System components necessary to comply with CARB-TIER-II and EPA regulations which are manufactured by third party engine manufacturer. SECTION 4: EXCEPTIONS AND LIMITATIONS This warranty shall be inapplicable to defects resulting from the following: (1)Accident, abuse, misuse, negligence and neglect, including stale fuel, dirt, abrasives, moisture, rust, corrosion, or any adverse reaction due to incorrect storage or use habits; (2)Failure to operate or maintain the unit in accordance with the Owner’s/Operator’s manual or instruction sheet furnished by Husqvarna; (3)Alterations or modifications that change the intended use of the product or affects the product’s performance, operation, safety, or durability, or causes the product to fail to comply with any applicable laws; or: (4)Additional damage to parts or components due to continued use occurring after any of the above. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. HUSQVARNA SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THESE PRODUCTS EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THESE PRODUCTS IS LIMITED IN DURATION TO THE WARRANTY PERIOD AS DEFINED IN THE LIMITED WARRANTY STATEMENT. HUSQVARNA RESERVES THE RIGHT TO CHANGE OR IMPROVE THE DESIGN OF THE PRODUCT WITHOUT NOTICE, AND DOES NOT ASSUME OBLIGATION TO UPDATE PREVIOUSLY M A N U F A CTURED PRODUCTS. Some states do not allow the exclusion of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. SECTION 5: CUSTOMER RESPONSIBILITIES The product must exhibit reasonable care, maintenance, operation, storage and general upkeep as written in the maintenance section of the Owner’s/Operator’s manual. Should an operational problem or failure occur, the product should not be used, but delivered as is to an authorized Husqvarna dealer for evaluation. Proof of purchase, as explained in section 6, rests solely with the customer. SECTION 6: PROCEDURE TO OBTAIN WARRANTY CONSIDERATION It is the Owner’s and Dealer’s responsibility to make certain that the Warranty Registration Card is properly filled out and mailed to Husqvarna Forest & Garden Company. This card should be mailed within ten (10) days from the date of purchase in order to confirm the warranty and to facilitate post-sale service. Proof of purchase must be presented to the authorized Husqvarna dealer in order to obtain warranty service. This proof must include date purchased, model number, serial number, and complete name and address of the selling dealer. To obtain the benefit of this warranty, the product believed to be defective must be delivered to an authorized Husqvarna dealer in a timely manner, no later than thirty (30) days from date of the operational problem or failure. The product must be delivered at the owner’s expense. Pick-up and delivery charges are not covered by this warranty. An authorized Husqvarna dealer can be normally located through the “Yellow Pages” of the local telephone directory or by calling 1-800-HUSKY62 for a dealer in your area. HUSQVARNA 7349 Statesville Road Charlotte, NC 28269 531 83 81-23 2002 SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION FOL D AL ONG THIS DOT IS A TED 15 D LINE EGR EE S LOP E 47 ONLY RIDE UP AND DOWN HILL, NOT ACROSS HILL 15 DEGREES MAX. WARNING: To avoid serious injury, operate your tractor up and down the face of slopes, never across the face. Do not mow slopes greater than 15 degrees. Make turns gradually to prevent tipping or loss of control. Exercise extreme caution when changing direction on slopes. 1. Fold this page along dotted line indicated above. 2. Hold page before you so that its left edge is vertically parallel to a tree trunk or other upright structure. 3. Sight across the fold in the direction of hill slope you want to measure. 4. Compare the angle of the fold with the slope of the hill. 532 18 99-42 Rev. 1 5.25.04 TR/MH Printed in U.S.A.