Operator's Manual CRAFTSMAN ° LAW TRACTOR 21.0 HR* 42" Mower Electric Start Automatic Transmission Model No. 917.25480 I This product has a low emission engine which operates I differently from previously built engines. Before you start the engine, read and understand this Owner's Manual. I IMPORTANT: Read and follow all Safety Rules and Instructions before operating this equipment. SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179 U.S.A. Visit our Craftsman website:www.sears.com/craftsman 433231 *As rated by the engine manufacturer Warranty .................................................. Safety Rules ............................................ Product Specifications ............................. Assembly/Pre-Operation ......................... Operation ................................................. CRAFTSMAN Maintenance Schedule .......................... Maintenance .......................................... Service and Adjustments ....................... Storage .................................................. Troubleshooting ..................................... 2 3 6 7 9 16 16 21 27 28 FULL WARRANTY TWO YEARS ON RIDING EQUIPMENT Also, when operated and maintained according to all supplied instructions, Warranty wilt also cover defects in material and workmanship of the Frame and Front Axle for five years from the date of purchase This warranty covers ONLY defects pay for: • • • • • • • • in material and workmanship. Sears will NOT Expendable items that become worn during normal use, including but not limited to blades, spark plugs, air cleaners, belts, and oil filters. Standard maintenance servicing, oil changes, or tune-ups. Tire replacement or repair caused by punctures from outside objects, such as nails, thorns, stumps, or glass. Tire or wheel replacement or repair resulting from normal wear, accident, or improper operation or maintenance. Repairs necessary because of operator abuse, including but not limited to damage caused by towing objects beyond the capability of the riding equipment, impacting objects that bend the frame or crankshaft, or over-speeding the engine. Repairs necessary because of operator negligence, including but not timited to, electrical and mechanical damage caused by improper storage, failure to use the proper grade and amount of engine oil, failure to keep the deck clear of flammable debris, or failure to maintain the riding equipment according to the instructions contained in the operator's manual. Engine (fuel system) cleaning or repairs caused by fuel determined to be contaminated or oxidized (stale). In general, fuel should be used within 30 days of its purchase date. Normal deterioration and wear of the exterior finishes, or product label replacement. All riding equipment and battery warranty coverage is void if this product is ever used for commercial or rental purposes. This warranty applies only while this product is within the United States. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Sears, Roebuck and Co., Hoffman Estates, IL 60179 2 _DANGER: 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. _IWARNING: 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. _IbWARNING: Do not coast down a hill in neutral, you may lose control of the tractor. _IWARNING: 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. _IWARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of Californiato 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. I. GENERAL OPERATION * Read, understand, and follow all instructions on the machine and in the manual before starting. * Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times. * 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 blades. * Be sure the area is clear of bystanders before operating. 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. Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces. Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working. Stow down before turning. Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting. Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard. Operate machine 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. Always wear eye protection when operating machine. 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. Follow the manufacturer's recommendation for wheel weights or counterweights. 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 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. II.SLOPEOPERATION Slopes area majorfactorrelated totossof control andtip-over accidents, whichcan resultinsevere injuryordeath.Operation onallslopesrequires extra caution. If you cannot back up the slope or if you feet uneasy on it, do not mow it. * Mow up and down slopes, not across. * Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles. * Choose a low ground speed so that you will not have to stop or shift while on the slope. * Do not mow on wet grass. Tires maylose traction. Always keep the machine in gear when going down slopes. Do not shift to neutral and coast downhill. * Avoid starting, stopping, or turning on a slope. Ifthetireslosetraction, disengage the blades and proceed slowly straight down the slope. * Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause the machine to roll over. * Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine. Do no use on steep slopes. * Do not try to stabilize the machine by putting your foot on the ground. * Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over ira wheel is over the edge or if the edge caves in. Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine. Never allow children to operate the machine. Use extra care when approaching blind corners, shrubs, trees, or other objects that may block your view of a child. IV. TOWING * * * * * Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point. Followthemanufacturer'srecommendation for weight limits for towed equipment and towing on slopes. Never allow children or others in or on towed equipment. On slopes,the weight ofthetowed equipment may cause loss of traction and toss of control. Travel slowly and allow extra distance to stop. V. SERVICE SAFE HANDLING OF GASOLINE To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. * Extinguish all cigarettes, cigars, pipes, and other sources of ignition. * Use only approved gasoline container. * Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. * Never fuel the machine indoors. * Neverstorethemachineorfuetcontainer where there is an open flame, spark, or pilot light such as on a water heater or other appliances. * Never fill containers inside a vehicle or on a truck or trailer bed with plastic liner. Always place containers on the ground away from your vehicle when filling. Ill. 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 in the watchful care of a responsible adult other than the operator. * Be alert and turn machine off if a child enters the area. * Before and while backing, look behind and down for small children. 4 Remove gas-powered equipment from thetruckor trailerandrefuelit onthe ground. Ifthisisnotpossible, thenrefuel suchequipment withaportable container, ratherthanfroma gasoline dispenser nozzle. Keepthenozzleincontact withtherim ofthefueltankorcontainer opening at alltimesuntilfueling iscomplete. Donot usea nozzle lock-open device. Iffuelisspilled onclothing, change clothingimmediately. * Never overfill fueltank.Replace gascap andtighten securely. GENERAL SERVICE . Never operate machine in a closed area. Keep all nuts and bolts tightto be sure the equipment is in safe working condition. Never tamper with safety devices. Check their proper operation regularly. Be sure the area is clear of bystanders before operating. 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. Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine. Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator. Be alert and turn machine off if a child enters the area. Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing. If you strike a foreign object, stop and inspectthe machine. Repair, if necessary, before restarting. Never make any adjustments or repairs with the engine running. Check grass catcher components and the discharge guard frequently and replace with manufacturer's recommended parts, when necessary. Mower blades are sharp. Wrapthe blade or wear gloves, and use extra caution when servicing them. Check brake operation frequently. Adjust and service as required. Maintain or replace safety and instruction labels, as necessary. Before and while backing, look behind and down for small children. Mow up and down slopes (15 ° Max), not across. Choose a low ground speed so that you will not have to stop or shift while on the slope. Avoid starting, stopping, or turning on a slope. Ifthetires Iosetraction, 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. PRODUCT SPECIFiCATiONS Gasoline Capacity and Type: 2.50 Gallons Unleaded Regular Oil Type API-SG-SL): SAE 30 (above 32°F) SAE 5W30 (below 32°F Oil Capacity: W/Filter: 56 oz. W/O Filter: 48 oz. Spark Plug: Champion RC12YC (Gap: .030") Ground Speed Forward: Reverse: Charging System: 3 Amps Battery 5 Amps Headlights Battery: Amp/Hr: 28 Min. CCA: 230 Case size: 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 can not easily remedy, please contact a Sears or other qualified service center. We have competent, well-trained representatives 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". 0- 5.2 0- 2.9 CUSTOMER RESPONSIBILiTiES • Read and observe the safety rules. • Follow a regular schedule in maintaining, caring for and using your tractor. • Follow the instructions under "Maintenance" and "Storage" sections of this owner's manual. Blade Bolt Torque: 45-55 Ft. Lbs. _IbWARN[NG: This tractor is equipped with an internal combustion engine and should not be used on or near any unimproved forestcovered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting applicable local or state taws (if any). [f a spark arrester is used, it should be maintained in effective working order by the operator. In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest Sears service center (See REPAIR PARTS manual). 6 Keys Slope Sheet (2) Keys Your new tractor has been assembled unassembled for shipping purposes. at the factory with exception of those parts left TOOLS REQUIRED FOR ASSEMBLY Label A socket wrench set will make assembly easier. Standard wrench sizes are listed. (1) 1/2" wrench (2) 7/16" wrenches Tire pressure gauge Utility knife Pliers When right or left hand is mentioned in this manual, it meanswhen you arein the operating position (seated behind the steering wheel). TO REMOVE TRACTOR FROM CARTON UNPACK CARTON * 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. Check for any additional loose parts or cartons and remove. BEFORE REMOVING FROM SKID TRACTOR TO CHECK BATTERY 1. Lift seat to raised position. NOTE: If this battery is put into service after month and year indicated on label (label is located between terminals) charge battery for minimum of one hour at 6-10 amps. (See "BATTERY" in Maintenance section of this manual for charging instructions). * For batteryand battery cable installation see "REPLACING BATTERY" in the "Service and Adjustments" section in this manual. ADJUST SEAT * Sit in seat. * Lift up adjustment lever (A) and slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down. * Release lever to lock seat in position. NOTE:Youmaynowrollyourtractoroff theskid.Follow theappropriate instruction _CHECKLIST below toremove thetractor fromtheskid. Before you operate your new tractor, we _WARNING:Beforestarting, read, wish to assure that you receive the best understand andfollowallinstructions inthe performance and satisfaction from this 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. TO ROLL TRACTOR OFF SKID (See Operation section for location and function of controls) 1. Raise attachment lift lever to its highest position. 2. Release parking brake by depressing clutch/brake pedal. 3. Place freewheel control in "transmission disengaged position" (See "TO TRANSPORT" inOperation section ofthis manual). 4. Roll tractor forward off skid. 5. Remove banding holding the deflector shield up against tractor. Continue with the instructions that follow. 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. _" Seat is adjusted comfortably and tightened securely. J" All tires are properly inflated. (For shipping purposes, thetires were overinftated 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. J" Check wiring. See that all connections are still secure and wires are properly clamped. J" Before driving tractor, be sure freewheel control is in "transmission engaged" position (see "TO TRANSPORT" in the Operation section of this manual). CHECK TIRE PRESSURE The tires on your tractor were overinftated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance. • Reduce tire pressure to PSI shown on tires. CHECK DECK LEVELNESS For best cutting results, mower housing should be properly leveled. See "TO LEVEL MOWER" in the Service and Adjustments section of this manual. While learning how to use your tractor, pay extra attention to the following important items: J" Engine oil is at proper level. J" Fuel tank is filled with fresh, clean, regular unleaded gasoline. J" Become familiar with all controls, their location and function. Operate them before you start the engine. J" Be sure brake system is in safe operating condition. J" Be sure Operator Presence System and Reverse Operation System (ROS) are working properly (See the Operation and Maintenance sections in this manual). J" 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 FOR PROPER POSITION OF ALL BELTS See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments section of this manual. Verifythat the belts are routed correctly. CHECK BRAKE SYSTEM After you learn how to operate your tractor, check to see that the brake is operating properly. See "TO CHECK BRAKE" in the Service and Adjustments section of this manual. 8 These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning. R N REVERSE G I'.,I H NEUTRAL HIGH LOW CHOKE FAST SLOW IGNITION ENGINE OFF REVERSE OPERATION ENGINE ON ENGINE START PARKING BRAKE MOWER SWITCH MOWER LIFT HEIGHT SYSTEM(ROS) LIGHTS ON FUEL BATTERY REVERSE FORWARD CRUISE CLUTCH/BRAKE PEDAL CONTROL ®@@@@ m ATTACHMENT CLUTCH DISENGAGED ATTACHMENT CLUTCH ENGAGED DANGER, KEEP HANDS AND FEET AWAY KEEP AREA (SEE CLEAR SLOPE SAFETY RULES HAZARDS SECTION) DANGER indicates a hazard which, if not avoided, will result in death or serious injury. FREE (Automatic WARNING hazard which, if not avoided, could result indicates in death a or serious injury. WHEEL Models only) 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. 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 and/or property damage. injury ,Jl_llIll/l_lll,, HOT SURFACES indicates if not avoided, could result and/or property damage. a hazard which, in death, serious FIRE indicates a hazard which, could result in death, serious property damage. if not avoided, injury and/or injury KNOW YOUR TRACTOR READ THiS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference. 03078 Our tractors conform to the applicable safety standards of the American National Standards institute. (F) IGNITION SWITCH - Used for starting and stopping the engine. (G) REVERSE OPERATION SYSTEM (ROS) "ON" POSITION - Allows operation of mower or other powered attachment while in reverse. (H) LIGHT SWITCH - Turns the headlights on and off. (J) MOTION CONTROL LEVER - Selects the speed and direction of tractor. (M) FREEWHEELCONTROLDisengages transmission for pushing or slowly towing the tractor with the engine off. (A) ATTACHMENT LIFT LEVER - Used to raise and lower the mower or other attachments mounted to your tractor. (B) CLUTCH/BRAKE PEDALUsed for dectutching and braking the tractor and starting the engine. (C) PAR KIN G BRAKE - Locks clutch/brake pedal into the brake position. (B) THROTTLE/CHOKE CONTROL- Used for starting and controlling engine speed. (E) ATTACH MENT C LUTC H LEVER - Used to engage the mower btades, or other attachments mounted to your tractor. 10 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 standard safety glasses or a wide vision safety mask worn over spectacles. HOW TO USE YOUR TRACTOR TO SET PARKING BRAKE Your tractor is equipped with an operator presence sensing switch. When engine is running, any attempt bythe operator to leave the seat without first setting the parking brake will shut off the engine. 1. Depress clutch/brake pedal (B) all the way down and hold. 2. Putt parking brake lever (C) up and hold, release pressure from clutch/brake pedal (B), then release parking brake lever. Pedal should remain in brake position. Make sure parking brake will hold tractor secure. • Turn ignition key (F) to "STOP" position and remove key. Always remove key when leaving tractor to prevent unauthorized use. IMPORTANT." Leaving the ignition switch in any position other than "STOP" will cause the battery to discharge and go dead. NOTE: Undercertain conditionswhentractor is standing idle with the engine running, hot engine exhaust gases may cause "browning" of grass. To eliminate this possibility, always stop engine when stopping tractor on grass areas. CAUTION: Always stop tractor completely, as described above, and set parking brake before leaving the operator's position. TO USE THROTTLE CONTROL (D) Always operate engine at full speed (fast). • Operating engine at less than full speed (fast) reduces engine's operating efficiency. • Full speed (fast) offers the best mower performance. STOPPING MOWER BLADES • To stop mower blades, move attachment clutch clutch lever to disengaged position (r_). TO MOVE FORWARD AND BACKWARD The direction and speed of movement is controlled by the motion control lever. (J) (1_1) Attachment Clutch Engage Position (1"_1) Disengaged Position GROUND DRIVE • To stop ground drive, depress clutch/brake pedal (B) all the way down. • Move motion control lever (J) to neutral position. ENGINE • Move throttle control (D) 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". 1. Start tractor with motion control lever in neutral position. 2. Release parking brake. 3. Slowly move motion control lever to desired position. 11 TO ADJUST MOWER CUTTING HEIGHT TO OPERATE MOWER The position of the attachment determines the cutting height. Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. You must remain fully and centrally positioned in the seat to prevent the engine from hesitating or cutting off when operating your equipment on rough, rolling terrain or hills. 1. Select desired height of cut with attachment lift lever. 2. Start mower blades by engaging attachment clutch control. TO STOP MOWER BLADES Disengage attachment clutch control. lift lever (A) Put attachment lift lever in desired cutting height slot. The cutting height range is approximately 1"to 4". The heights are measured from the ground to the blade tip with the engine not running. These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed. The average lawn should be cutto approximately 2-1/2" during the cool season and to over 3" 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 shoutd be mowed twice. Make the first cut relatively high; the second to desired height. TO ADJUST GAUGE WHEELS Gauge wheels are properly adjusted when they are slightly off the ground when mower is at the desired cutting height in operating position. Gauge wheels then keep the deck in proper position to help prevent scalping in most terrain conditions. NOTE: Adjust gauge wheels with tractor on a flat level surface. 1. Adjust mower to desired cutting height (See "TO ADJUST MOWER CUTTING HEIGHT" in this section of manual). 2. With mower in desired height of cut position, gauge wheels should be assembled so they are slightly off the ground. Install gauge wheel in appropriate hole. Tighten securely. 3. Repeat for all, installing gauge wheel in same adjustment hole. _ICAUTION: Do not operate the mower without either the entire grass catcher, on mowers so equipped, or the deflector shield (S) in place. TO OPERATE ON HILLS ,_I, WARNING: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope. Use the slope guide provided at the back of this manual. • Choose the slowest speed before starting up or down hills. • Avoid stopping or changing speed on hills. • If stopping is absolutely necessary, push clutch/brake pedal quickly to brake position and engage parking brake. • Move motion control lever to neutral position. IMPORTANT: The motion control lever does not return to neutral position when the clutch/ brake pedal is depressed. • To restart movement, slowly release parking brake and clutch/brake pedal. • Slowly move motion control lever to slowest setting. • Make all turns slowly. 12 TO TRANSPORT REVERSE OPERATION SYSTEM (ROS) Your tractor is equipped with a Reverse Operation System (ROS). Any attempt by the operator to travel in the reverse direction with the attachment clutch engaged will shut off the engine unless ignition key is placed in the ROS "ON" position. When pushing or towing your tractor, be sure to disengage transmission by placing freewheel control in freewheeling position. Freewheel control is located at the rear drawbar of tractor. 1. Raise attachment lift lever to its highest position. 2. Pull freewheel control out and intothe slot and release so it isheld in the disengaged position. + Do not push or tow tractor at more than two (2) MPH. + To re-engage transmission, reverse above procedure. ,_WARNING: Backing up with the attachment clutch engaged while mowing is strongly discouraged. Turning the ROS "ON", to allow reverse operation with the attachment clutch engaged, should only be done when the operator decides it is necessary to reposition the machine with the attachment engaged. Do not mow in reverse unless absolutely necessary. TRANSMiSSiON USING THE REVERSE OPERATION SYSTEM Only use if you are certain no children or other bystanders will enter the mowing area. 1. Move motion control lever to neutral position. 2. With engine running, turn ignition key counterclockwise to ROS "ON" position. 3. Look down and behind before and while backing. 4. Slowly move motion control lever to reverse (R) position to start movement. 5. When use ofthe ROS isno longer needed, turn the ignition key clockwise to engine "ON" position. ROS "ON" Position TRANSMiSSiON ENGAGED DISENGAGED 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.). Engine ;'ON" Position (Normal Operating) TOWING CARTS AND OTHER ATTACHMENTS Tow only the attachments that are recommended by and comply with specifications of the manufacturer of your tractor. Use common sense when towing. Too heavy of a load, while on a slope, isdangerous. Tires can lose traction with the ground and cause you to lose control of your tractor. 13 3. Place motion control lever in neutral position. 4. Move attachment clutch to disengaged position. 5. Move throttle control to choke position. NOTE: Before starting, read the warm and cold starting procedures below. 6. Insert key into ignition and turn key clockwise to start position and release key as soon as engine starts. Do not run starter continuously for more than fifteen seconds per minute. If the engine does not start after several attempts, move throttle control to fast position, wait a few minutes and try again. If engine still does not start, move the throttle control back to the choke position and retry. BEFORE STARTING THE ENGINE CHECK ENGINE OIL LEVEL The engine in your tractor has been shipped, from the factory, already filled with summer weight oil. 1. Check engine oil with tractor on level ground. 2. Remove oil fill cap/dipstick and wipe clean, reinsert the dipstick and screw cap tight, wait for a few seconds, remove and read oil level. If necessary, add oil until "FULL' mark on dipstick is reached. Do not overfill. • For cold weather operation you should change oil for easier starting (See the oil viscosity chart in the Maintenance section of this manual). • To change engine oil, seethe Maintenance section in this manual. WARM WEATHER STARTING (50° F and above) 7. When engine starts, move the throttle control to the fast position. • The attachments and ground drive can now be used. Ifthe 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. Usefresh, 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 ensure fuel freshness. _I,CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. IMPORTANT: When operating in temperatures below 32°F(0°C), use fresh, clean winter grade gasoline to help ensure 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 fuet 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 inthe fuel tank or permanent damage may occur. TO START ENGINE When starting the engine for the first time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine. 1. Be sure freewheel control is in the transmission engaged position. 2. Siton seat in operating position, depress clutch/brake pedal and set parking brake. COLD WEATHER STARTING (50 ° F and below) 7. When enginestarts, leavethrottle control in choke position until engine warms up and begins to run roughly. Once rough running begins, immediately move the throttle control to the fast position. Engine warm-up may take from several seconds to several minutes (the colder the temperature, the longer the warm-up). AUTOMATIC TRANSMISSION WARM UP Before driving the unit in cold weather, the transmission should be warmed up as follows: 1. Be sure the tractor is on level ground. 2. Placethe motion control lever in neutral. Release the parking brake and let the clutch/brake slowly return to operating position. 3. Allow one minute for transmission to warm up. This can be done during the engine warm up period. • The attachments can also be used during the engine warm-up period after the transmission has been warmed up. 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 CARBU R ETO R" in the Service and Adjustments section of this manual). 14 PURGE TRANSMiSSiON MOWING TIPS • Tire chains cannot be used when the mower housing is attached to tractor. Mower should be properly leveled for best mowing performance. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. The left hand side of mower should be used for trimming. Drive so that clippings are discharged onto the area that has already been cut. Have the cut area to the right of the tractor. This will result in a more even distribution of clippings and more uniform cutting. When mowing large areas, start byturning 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. _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. 1. Place tractor safely on a level surface that is clear of objects and open - with engine off and parking brake set. 2. Disengage transmission by placing freewheel control in disengaged position (See "TO TRANSPORT" in this section of manual). 3. Sitting in the tractor seat, start engine. After the engine is running, move throttle control to slow position. With motion control lever in neutral position, slowly disengage clutch/brake pedal. _IiCAUTION: At any time, during step 4, there may be movement of the drive wheels. 4. 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. 5. Move motion control lever to neutral position. Shutoff engine and set parking brake. 6. Engage transmission by placing freewheel control in engaged position (See "TO TRANSPORT" in this section of manual). 7. Sitting in the tractor seat, start engine. After the engine is running, move throttle control to half (1/2) speed. With motion control lever in neutral position, slowly disengage clutch/brake pedal. 8. Slowly move motion control leverforward, 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 position. Repeat this procedure with the motion control lever three (3) times. Your transmission is now purged and now ready for normal operation. 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 ensure better mowing performance and proper discharge of material. Regulate ground speed by selecting a low enough speed 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. 15 MAINTENANCE SCHEDULE w Check Brake Operation BEFORE EACH EVERY 8 USE EVERY 2S EVERY EVERY 100 EVERY SEASON HOURS .OURS HOURS HOURS BEFORE STORAGE _ Check Tire Pressure T Check Operator Presence A Check for L.... Fast ..... & ROS Systems C Check/Replace T Lubrication Chart _ 0 Check Battery Level _4 R Clean Battery and Terminals _ if Mower Blades Clean Debris Off Steering Check Transaxle Ks if Plate _#' _s Cooling Check Mower Levelness Check V-Belts _f Check Enqine Oil Level Change Change Engine Oil (with oil filter) Engine NE Clean Air G Oil (without _1,2 oil tilter) _2 Filter 1_4_'2 N Replace E Clean Engine Cooling Replace Replace _lace Arrester Oil Filter (If equipped) _,2 Fins _ Spark Plug Air Filter _t" 1_'1,2 Clean Air Screen Inspect Muffler/Spark __ _ Paper 2 _ Cartridge _4" _,_2 Fuel Filter _4' 1 Cha_lgemofeoftenwheno#eratir_gunderaheawloado[inhighambieflttemperatures 3 Re#Faoeb_adesmofeofter_whel_mowi_lginsandy8oil 2 Se,v_cemo,edt_w_no_rat_g_ndJrlyo, 4 No_requ_red_qu_p_edw_hma_ntenancef,eebatt_,y du_ycondJt_ons LUBRICATION 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. BEFORE EACH USE (_S Zerk (_Front Wheel Bearing zerk @ Sector Gear Teeth 5 SeeC_eani_lgJnMaintenanceSectior_ CHART Spindle Zerk Front Wheel Bearing zerk Engine _General Purpose Grease @Refer to Maintenance "ENGINE" Section 1. 2. 3. 4. Check engine oil level. Check brake operation. Check tire pressure. Check operator presence and ROS systems for proper operation. 5. Check for loose fasteners. 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. Ifyou feet they must be lubricated, use only a dry, powdered graphite type lubricant sparingly. 16 TRACTOR Always observe safety rules when performing any maintenance. BRAKE OPERATION 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 serviced. (See "TO CHECK BRAKE" in the Service and Adjustments section of this manual). TIRES • Maintain proper air pressure in all tires (See the sides of tires for proper PSI). • 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. CHECK REVERSE OPERATION (ROS) SYSTEM • When the engine is running with the ignition switch in the engine "ON" position and the attachment clutch engaged, any attempt by the operator to drive in reverse should shut off the engine. • When the engine is running with the ignition switch in the ROS "ON" position and the attachment clutch engaged, any attempt by the operator to drive in reverse should NOT shut off the engine. BLADE CARE For best results mower blades must be sharp. Replace worn, bent or damaged blades. _, CAUTION: Use only a replacement blade approved by the manufacturer of your tractor. Using a blade not approved by the manufacturer of your tractor is hazardous, could damage your tractor and void your warranty. BLADE REMOVAL 1. Raise mower to highest position to allow access to blades. NOTE: Protect your hands with gloves and/ or wrap blade with heavy cloth. 2. Remove blade bolt by turning counterclockwise. 3. install new blade with stamped "GRASS SIDE" facing the ground. IMPORTANT: To ensure proper assembly, center hole in blade must align with star on mandrel assembly. 4. install and tighten blade bolt securely (45-55 Ft. Lbs. torque). IMPORTANT: Special blade bolt is heat treated. OPERATOR PRESENCE SYSTEM AND REVERSE OPERATION SYSTEM (ROS) Be sure operator presence and reverse operation 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 the attachment clutch control is in the disengaged position. CHECK OPERATOR PRESENCE SYSTEM • 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. Star Center Hole Blade Bolt (Special) ------._<_ __ Mandrel Assembly Blade 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. ROS "ON" Position Engine "ON" Position (Normal Operating) 17 BATTERY Your tractor has a battery charging system which is sufficient for normal use. However, periodic charging of the battery with an automotive charger wilt 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. TO CLEAN BATTERY AND TERMINALS Corrosion and dirt on the battery and terminals can cause the battery to "leak" power. 1. Disconnect BLACK battery cable first then RED battery cable and remove battery from tractor. 2. Rinsethe batterywith plain waterand dry. 3. Clean terminals and battery cable ends with wire brush until bright. 4. Coatterminals with grease or petroleum jelly. 5. Reinstall battery (See "REPLACING BATTERY" in the SERVICE AND ADJUSTMENTS section of this manual). TRANSAXLE COOLING The transmission fan and cooling fins should be kept clean to ensure 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. TRANSAXLE PUMP FLUID The transaxle was sealed at the factory and fluid maintenance is not required for the life of the transaxle. Should the transaxle ever leak or require servicing, contact you r nearest Sears or other qualified service center. ENGINE LUBRiCATiON Only use high quality detergent oil rated with API service classification SG-SL Selectthe oil's SAE viscosity grade according to your expected operating temperature. NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, they will result in increased oil consumption when used above 32°R Check your engine oil level more frequently to avoid possible engine damage from running low on oil. SAE VISCOSITY C _30 _20 TEMPERATURE _10 0 RANGE ANTICIPATED GRADES 10 20 30 BEFORE NEXT OIL CHANGE 40 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. Checkthe crankcase oil level before starting the engine and after each eight (8) hours of operation. Tighten oil fill cap/dipstick securely each time you check the oil level. TO CHANGE ENGINE OiL Determine temperature range expected before oil change. All oil must meet API service classification SG-SL. ® Be sure tractor is on level surface. ® Oil will drain more freely when warm. Catch oil in a suitable container. ® 1. Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil. 2. Slide oil drain extension from the docking position on the engine blower housing and extend outward from engine. Docking Position Oil Drain Extension Cap 3. To open, twist cap counter-clockwise 4. After oil is drained completely, replace cap and twist clockwise until it stops. 5. Re-attach oil drain extension to engine blower housing. 6. Refill enginewith oitthrough oilfill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see "PRODUCT SPECIFICATIONS" section of this manual. 7. Use gauge on oil fill cap/dipstick for checking level. For accurate reading, tighten dipstick cap securely onto the tube before removing dipstick. Keep oil at "FULL' line on dipstick. Tighten cap onto the tube securely when finished. 18 ENGINE OIL FILTER MUFFLER inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. Replace the engine oil filter every season or every other oil change if the tractor is used more than 100 hours in one year. SPARK PLUG(S) Replace spark plug(s) atthe beginning of each mowing season or after every 100 hours of operation, whichever occursfirst. Spark plug type and gap setting are shown in "PRO DUCT SPECIFICATIONS" section of this manual. AIR FILTER Your engine will not run properly using a dirty air filter. Service paper cartridge every 100 hours of operation or every season, whichever occurs first. Service air cleaner more often under dusty conditions. 1. Remove cover. 2. Carefully remove air filter cartridge and pre-cleaner from base. 3. Clean base carefully to prevent debris from falling into carburetor. Knobs IN=LINE FUEL FILTER The fuel filter should be replaced once each season. If fuel filter becomes clogged, obstructing fuel flow to carburetor, replacement is required. 1. With engine cool, remove filter and plug fuel line sections. Ca_ridge 2. Place newfuelfilter in position in fuel line with arrow pointing towards carburetor. 3. Be sure there are no fuel line leaks and clamps are properly positioned. 4. Immediately wipe up any spilled gasoline. Clamp NOTE: If very dirty or damaged, replace cartridge. 4. Place new pre-cleaner and cartridge firmly in base. 5. Replace cover. IMPORTANT: Petroleum solvents, such as kerosene, are not to be used to clean the cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean cartridge. ENGINE COOLING SYSTEM Debris may clog the engine's air cooling system. Remove blower housing and clean area shown to prevent overheating and engine damage. Air Scree Clean out chaff r_. and debris CLEAN AIR SCREEN Air screen must be kept free of dirt and chaff to prevent engine damage from overheating. Clean with a wire brush or compressed airto remove dirt and stubborn dried gum fibers. 19 CLEANING • Clean engine, battery, seat, finish, etc. of all foreign matter. • Clean debris from steering plate. Debris can restrict clutch/brake pedal shaft movement, causing belt slip and loss of drive. IMPORTANT: Tug hose ensuring connection is secure. 5. Turn the water on. 6. While sitting in the operator's position on the tractor, re-start the engine and place the throttle lever in the Fast ",_" position. A CAUTION: Avoid all pinch points and movable parts Clutch/brake Nozzle Ada pedal Washout Port Clean Steering \ Steering System, Dash, Fender and Mower N_otShown CAUTION: _ Pinch _ Points IMPORTANT: Recheck the area making certain the area is clear. 7. Move the tractor's attachment clutch control to the "Engaged" position. Remain in the operator's position with the cutting deck engaged until the deck is cleaned. 8. Move the tractor's attachment clutch control to the "DISENGAGED" position. Turn the ignition key to the STOP position to turn the tractor's engine off. Turn the water off. 9. Pull back the lock collar of the nozzle adapter to disconnect the adapter from the nozzle washout port. 10. Move the tractor to a dry area, preferably a concrete or paved area. Place the attachment clutch control in the "Engaged" position to remove excess water and to help dry before putting the tractor away. _,WARNING: A broken or missing washout fitting could expose you or others to thrown objects from contact with the blade. Replace broken or missing washout fitting immediately, prior to using mower again. Plug any holes in mower with bolts and Ioeknuts, • 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. DECK WASHOUT PORT Your tractor's deck is equipped with a washout port on its surface as part of its deck wash system. It should be utilized after each use. 1. Drive the tractor to a level, clear spot on your lawn, near enough to a water spigot for your garden hose to reach. IMPORTANT: Make certain the tractor's discharge chute is directed AWAY from your house, garage, parked cars, etc. Remove bagger chute or mulch cover if attached. 2. Make sure the attachment clutch controt is in the "DISENGAGED" position, set the parking brake, and stop the engine. 3. Thread the nozzle adapter (packaged with your tractor's Operator's Manual) onto the end of your garden hose. 4. Pull back the lock collar of the nozzle adapter and push the adapter onto the deck washout port at the left end of the mower deck. Release the lock collar to lock the adapter on the nozzle. 20 SERVICE ORTO ADJUSTMENTS: WARNING: AVOID SERIOUS iNJURY, BEFORE PERFORMING ANY 1. Depress clutch/brake pedal fully and set parking brake. 2. Place motion control lever in neutral position. 3. Place attachment clutch in "DISENGAGED" position. 4. Turn ignition key to "STOP" and remove key. 5. Make sure the blades and all moving parts have completely stopped. 6. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. TO REMOVE MOWER 1. Place attachment clutch in "DISENGAGED" position. 2. Lower attachment lift lever to its lowest position. 3. Roll belt off engine pulley (M) and belt keepers (G). 4. Remove retainer spring (K), slide collar (L) off and push housing guide (P) out of bracket. 5. Remove clutch cable spring (Q) from idler arm (R). 6. Disconnect front link (E) from mower remove retainer spring and washer. 7. Go to either side of mower and disconnect mower suspension arm (A) from chassis pin (B) and rear lift link (C) from rear mower bracket (D) - remove retainer springs and washers. _f_ CAUTION: After rear lift links are disconnected, the attachment lift lever will be spring loaded. Have a tight grip on lift lever when changing position of the lever. 8. Slide mower out from under right side of tractor. IMPORTANT: If an attachment other than the mower is to be mounted on the tractor, remove the front link (E) and rear lift liks (C) from tractor and hook the clutch spring (Q) into the cable guide on front edge of lower dash. TO iNSTALL MOWER Be sure tractor is on level surface and engage parking brake. 1. Lower attachment lift lever to its lowest position. CAUTION: Lift lever is spring loaded. Have a tight grip on lift lever, lower it slowly and engage in lowest position. NOTE: Be sure mower side suspension arms (A) are pointing forward before sliding mower under tractor. 2. Slide mower under tractor until it is centered under tractor. 03042tex 21 3. ATTACH MOWER SIDE SUSPENSION ARMS (A) TO CHASSIS - Position hole in arm over pin (B) on outside of tractor chassis and secure with retainer spring. 4. Repeat on opposite side of tractor. 5, ATTACH REAR LIFT LINKS (C) - Lift rear corner of mower and position slot in link assembly over pin (D) on rear mower bracket and secure with washer and retainer spring. 6, ATTACH FRONT LINK (E) - Work from left side of tractor. Insert rod end of link assembly through front hole in tractor front suspension bracket (F). 7. Insert end of link (E) into hole in front mower bracket (H) and secure with washer and retainer spring (J). 8. Hook end of clutch cable spring (Q) into hole in idler arm (R). 9. Push clutch cable housing guide (P) into bracket, slide collar (L) onto guide and secure with retainer spring (K). 10. Install belt onto engine pulley (M) and belt keepers (G). IMPORTANT: Check belt for proper routing in all mower pulley grooves. 11.Raise attachment lift lever to highest position. 12. If necessary, adjust gauge wheels before operating mower as shown in the Operation section of this manual. % 03042rex 22 TO LEVEL MOWER Make sure tires are properly inflated to the PSI shown on tires. If tires are over or under inflated, it may affect the appearance of your lawn and lead you to think the mower is not adjusted properly. VISUAL SIDE=TO-SIDE ADJUSTMENT 1. With all tires properly inflated and if your lawn appears unevenly cut, determine which side of mower is cutting lower. 2. With a 3/4" or adjustable wrench, turn lift link adjustment nut (A) to the left to lower LH side of mower, or, to the right to raise LH side of mower. NOTE: Each full turn of adjustment nut will change mower height about 3/16". Turn nut rig to raise mower FRONT-TO-BACK IMPORTANT: to-side. Deck must be level side- To obtain the best cutting results, the mower blades should be adjusted so the front tip is 1/8" to 1/2" lower than the rear tip when the ower is in its highest position. CAUTION: Blades are sharp. Protect your hands with gloves and/or wrap blade with heavy cloth. • Raise mower to highest position. Position any blade so the tip is pointing straight forward. Measure distance (B) to the ground at front and rear tip of the blade. If front tip of blade is not 1/8" to 1/2" lower than the rear tip, go to the front of tractor. • With an 11/16" or adjustable wrench, loosen jam nut A several turns to clear adjustment nut B. With a 3/4" or adjustable front link adjustment nut (tighten) to raise the front counterclockwise (loosen) front mower. Turn nut left to lower mower 3. Test your adjustment by mowing some uncut grass and visually checking the appearance. Readjust, if necessary, until you are satisfied with the results. PRECISION SIDE=TO=SIDE ADJUSTMENT 1. With alttires properly inflated, parktractor on level ground or driveway. _iL CAUTION: Blades are sharp. Protect your hands with gloves and/or wrap blade with heavy cloth. 2. Raise mower to its highest position. 3. At both sides of mower, position blade at side and measure the distance (A) from bottom edge of blade to the ground. The distance should be the same on both sides. 4. If adjustment is necessary, see step 2 in Visual Adjustment instructions above. 5. Recheckmeasurements, adjustifnecessary until both sides are equal. AI L' hJ ADJUSTMENT Tighten adjust nut B to raise mower wrench, turn (B) clockwise of mower, or, to lower the Loosen adjust nut B to lower mower Loosen jam nut A first NOTE: Each full turn of the adjustment nut will change mower height about 1/8". • Recheck measurements, adjust if necessary until front tip of blade is 1/8" to 1/2" lower than the rear tip. • Hold adjustment nut in position with wrench and tighten jam nut securely against adjustment nut. W IA 23 TO REPLACE MOWER BLADE DRIVE BELT BELT INSTALLATION 1. install new belt from tractor rear to front, over the steering plate (F) and above clutch brake pedal shaft (G). 2. Pull belt toward front of tractor and roll belt onto engine pulley (E). 3. Pull belt toward rear of tractor. Carefully work belt down around transmission cooling fan and onto the input pulley (D). Be sure belt is inside the belt keeper. 4. Install belt on centerspan idler (C). 5. Install belt through stationary idler (A) and clutching idler (B). 6. Make sure belt is in all pulley grooves and inside all belt guides and keepers. 7. Install mower (See "TO INSTALL MOWER" in this section of manual). The mower blade drive belt may be replaced without tools. Park the tractor on level surface. Engage parking brake. BELT REMOVAL 1. Removemowerfromtractor (See"TO REMOVE MOWER"inthissectionofmanual). 2. Work belt off both mandrel pulleys and idler pulleys. 3. Putt belt away from mower. BELT INSTALLATION 1. Work belt around both mandrel pulleys and idler pulleys 2. Make sure belt is in all pulley grooves and inside all belt guides. 3. Install mower (See "To Install Mower" in this section of this manual). Mandrel Idler Pulle_ Pulle, Mandrel TO REPLACE MOTION DRIVE BELT Park the tractor on level surface. Engage parking brake. For assistance, there is a belt installation guide decal on bottom side of left footrest. TO REMOVE WHEEL 1. Block up axle securely. 2. Remove axle cover, retaining ring and washers to allow wheel removal (rear wheels have a square key- Do not lose). 3. Repair tire and reassemble. NOTE: On rear wheels only: align grooves in rear wheel hub and axle. Insert square key. 4. Replace washers and snap retaining ring securely in axle groove. 5. Replace axle cover. NOTE: To seal tire punctures and prevent flat tires due to stow leaks, purchase and use tire sealant from Sears. Tire sealant also prevents tire dry rot and corrosion. BELT REMOVAL 1. Remove mower (See "TO REMOVE MOWER" in this section of manual). NOTE: Observe entire motion drive belt and position of all belt guides and keepers. 2. Remove bettfrom stationary idler (A) and clutching idler (B). 3. Remove belt from centerspan idler (C). 6. Pull belt slack toward rear of tractor. Carefully remove belt upwards from transmission input pulley and over cooling fan blades (D). 4. Remove belt downward from engine pulley (E). 5. Slide belt toward rear of tractor, off the steering plate (F) and remove from tractor. Washers Retaining Axle Cover, Ring\ \ Square_ Key ___ (Rear Wheel Only) 24 _ TO CHECK BRAKE FRONT WHEEL TOE=IN/CAMBER Your new tractor front wheel toe-in and camber is set at the factory and is normal. The front wheel toe-in and camber are not adjustable. If damage has occurred to affect the factory set front wheel toe-in or camber, contact a Sears or other qualified service center. 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 serviced. You may also check brake by: 1. Park tractor on a level, dry concrete or paved surface, depress brake pedal all the way down and engage parking brake. 2. 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, then the brake needs to be serviced. Contact a Sears or other qualified service center. TO START ENGINE WiTH WEAK BATTERY AGL, WARNING: Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. ifyour battery istoo 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. TRANSAXLE MOTION CONTROL LEVER NEUTRAL ADJUSTMENT The motion control lever has been presetatthe factory; adjustment should not be necessary. 1. Loosen adjustment bolt in front of the right rear wheel, and lightly tighten. 2. Start engine and move motion control lever until tractor does not move forward or backward. 3. Hold motion control lever in that position and turn engine off. 4. While holding motion control lever in place, loosen the adjustment bolt. 5. Move motion control lever to the neutral (lock gate) position. 6. Tighten adjustment bolt securely. Motion Lever Neutral Lock Gate ...... Adjustment Bolt NOTE: If additional clearance is needed to get to adjustment bolt, move mower deck height to the lowest position. After above adjustment is made, if the tractor still creeps forward or backward while motion control lever is in neutral position, follow these steps: TO ATTACH JUMPER CABLES 1. Connect one end of the RED cable to the POSITIVE (+) terminal of each battery(AB), taking care notto short against tractor chassis. 2. Connect one end of the BLACK cable to the NEGATIVE (-)terminal (C) of fully charged battery. 3. Connect the other end of the BLACK cable (D) to good chassis ground, away from fuel tank and battery. 1. Loosen the adjustment bolt. 2. Movethe motion control lever 1/4 to 1/2 inch in the direction it is trying to creep. 3. Tighten adjustment bolt securely. 4. Start engine and test. 5. If tractor still creeps, repeat above steps until satisfied. TO REMOVE CABLES, REVERSE ORDER 1. BLACK cable first from chassis and then from the fully charged battery. 2. RED cable last from both batteries. Weak or I__ Dead _[_ Battery 25 "_1_ Fully L_JCharged Battery REPLACING BATTERY TO REPLACE termin_asWARNING: not short by allowing aDo wrench or anybattery 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. 1. Lift seat pan to raised position. 2. Disconnect BLACK battery cable first then RED battery cable and carefully remove battery from tractor. 3. Install new battery with terminals in same position as old battery. 4. First connect RED battery cable to positive (+) terminal with hex bolt and keps nut as shown. Tighten securely. Slide terminal cover over terminal 5. Connect BLACK grounding cable to negative (-) terminal with remaining hex bolt and keps nut. Tighten securely. Replace with 20 amp automotive-type plug-in fuse. The fuse holder is located behind the dash. TO 1. 2. 3. REMOVE HOOD & GRILLASSEMBLY Raise hood. Unsnap headlight wire connector. Stand in front of tractor. Grasp hood at sides, tilt toward engine and lift off of tractor. 4. When replacing hood, be sure to reconnect the headlight wire connector. Headlight Connector . Keps / Nut "-_. Hex Bolt ENGINE TO ADJUST THROTTLE Positive (Red) Cable Wire TRANSMISSION REMOVAL/REPLACE= MENT 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. Terminal Cover FUSE Negative (Black) Cable HEADLIGHT BULB TO REPLACE 1. Raise hood. 2. Remove bulb holder from the hole in the backside of the grill. 3. Replace bulb in holder and install bulb holder securely back into the hole in the backside of the grill. 4. Close hood. INTERLOCKS AND RELAYS Loose or damaged wiring may cause your tractor to run poorly, stop running, or prevent it from starting. Check wiring. CONTROL The throttle control has been preset at the factory and adjustment should not be necessary Check adjustment as described below before loosening cable. If adjustment is necessary, see engtne 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 engine manual. TO ADJUST CARBURETOR Your carburetor has been preset atthe factory and adjustment should not be necessary. However, minor adjustment may be required to compensate for differences in fuel, temperature, altitude or load. If the engine does need adjustment, see engine manual. 26 ENGINE FUEL SYSTEM IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts such as carburetor, fuel hose, or tank during storage. Also, alcohol blended fuels (called gasohot 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. * Empty the fuel tank by starting the engine and letting 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. ENGINE OiL Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER(S) 1. Remove spark plug(s). 2. Pour one ounce of oil through spark plug hole(s) into cylinder(s). 3. Turn ignition key to "START" position for a few seconds to distribute oil. 4. Replace with new spark plug(s). 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. 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 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. 1. Clean entire tractor (See "CLEANING" in the Maintenance section of this manual). 2. Inspect and replace belts, if necessary (See belt replacement instructions in the Service and Adjustments section of this manual). 3. Lubricate as shown in the Maintenance section of this manual. 4. Be sure that all nuts, bolts and screws are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. 5. Touch up all rusted or chipped paint surfaces; sand lightly before painting. BATTERY * 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. 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 itto 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 CHART: See appropriate section in manual unless directed to Sears service center CAUSE PROBLEM Will not start 1 Out of fuel. 1 Fill fuel tank. 2 Engine not "CHOKED" 2 See "TO START ENGINE" Operation section. 3 Engine flooded. 3 Wait several minutes attempting to start. 4 Bad spark 4 Replace 5 6 Dirty air filter. 5 Clean/replace Dirty fuel filter. 6 Replace 7 Water in fuel. 7 Empty fuel tank and carburetor, refill tank with fresh gasoline and replace fuel filter. 8 Loose or damaged 8 Check all wiring. 9 Carburetor 9 See "To Adjust Carburetor" in Service and Adjustments section. 10 Contact a Sears or other qualified service center. 10 Hard to start Engine will not turn over Engine clicks but will not start CORRECTION Engine properly. plug. wiring. out of adjustment. valves out of adjustment. in before spark plug. air filter. fuel filter. 1 Dirty air filter. 1 Clean/replace 2 Bad spark 2 Replace 3 Weak or dead battery. 3 Recharge 4 Dirty fuel filter. 4 Replace 5 Stale or dirty fuel. 5 Empty fuel tank and refill tank with fresh, clean gasoline. 6 Loose or damaged 6 Check all wiring. 7 Carburetor 7 See "To Adjust Carburetor" in Service and Adjustments section. 8 Engine out of adjustment. 8 Contact a Sears or other qualified service center. 1 Clutch/brake pedal not depressed. 1 Depress 2 Attachment 2 Disengage 3 Weak or dead battery. 3 Recharge 4 Blown fuse. 5 Corroded 6 Loose or damaged 7 Faulty ignition 8 Faulty solenoid 9 Faulty operator switch(es). 1 2 3 Loose or damaged 4 Faulty solenoid plug. wiring. out of adjustment. valves clutch is engaged. air filter. spark plug. or replace battery. fuel filter. clutch/brake pedal. attachment or replace clutch. battery. 4 Replace terminals. 5 Clean wiring. 6 Check all wiring. 7 Check/replace ignition or starter. 8 Check/replace solenoid presence 9 Contact a Sears or other qualified service center. Weak or dead battery. 1 Recharge Corroded terminals. 2 Clean wiring. 3 Check all wiring. or starter. 4 Check/replace battery switch. battery 28 fuse. battery terminals. or replace battery switch. or starter. battery. terminals. solenoid or starter. TROUBLESHOOTING CHART: See appropriate section in manual unless directed to Sears service center CAUSE PROBLEM Loss of power Excessive vibration CORRECTION 1 Cutting too much grass/too 2 Throttle in "CHOKE" and 1 Raise cutting height/reducespeed 2 Adjust 3 Clean underside housing. 4 Clean/replace throttle control. of mower 3 Build-up of grass, leaves trash under mower. 4 Dirty air filter. 5 Low oil level/dirty 5 Check oil level/change 6 Faulty spark plug. 6 Clean ®ap 7 Dirty fuel filter. 7 Replace 8 Stale or dirty fuel. 8 Empty fuel tank and refill tank wigfresh, clean gasoline. 9 Water 9 Empty fuel tank and carburetor, refill tank with fresh gasoline and replace fuel filter. oil. in fuel. 10 Spark plug wire 11 Dirty engine 12 Dirty/clogged 13 Loose or damaged 14 Carburetor 15 Engine air filter. oil. or changespark plug fuel filter. loose. 10 Connect air screen/fins. 11 Clean 12 Clean/replace 13 Check all wiring. out of adjustment. 14 See "To Adjust Carburetor" in Service and Adjustments section. valves out of adjustment. 15 Contact a Sears service center muffler. wiring. 1 Worn, 2 Bent blade 3 Loose/damaged Engine continues to run when operator leaves seat with attachment clutch engaged 1 Faulty operator-safety control system. Poor cut = uneven cutting 1 Worn, 2 Mower deck not level. 3 4 Mower blades will not rotate fast. position. bent or loose blade. & tighten spark plug wire engine air screen/fins. muffler. or other qualified 1 Replace 2 Contact a Sears service center 3 Tighten loose part(s). Replace damaged parts. 1 Check wiring, switches and connections. If not corrected, contact a Sears or other 1 Replace 2 Level mower Buildup of grass, leaves, and trash under mower. 3 Clean underside housing. of mower Bent blade mandrel. 4 Contact a Sears qualified service or other center. Clogged mower deck vent from build-up of grass, leaves, and trash around mandrels. 5 Clean around mandrels open vent holes. 1 Obstruction 1 Remove obstruction. 2 Worn/damaged 2 Replace mower 3 Frozen idler pulley. 3 Replace idler pulley. 4 Frozen blade mandrel. 4 Contact a Sears qualified service mandrel. part(s). presence bent or loose blade. in clutch mechanism. mower 29 drive belt blade. Tighten blade bolt or other qualified blade. Tighten blade deck. to drive belt. or other center. bolt TROUBLESHOOTING CHART: See appropriate section in rnanual unless directed to Sears service center CAUSE PROBLEM Poor grass discharge Headlight(s) not working (if so equipped) Battery will not charge Loss of drive 1 Engine 2 CORRECTION speed too slow. 1 Place throttle position. control Travel speed too fast. 2 Shift to slower speed. 3 Wet grass. 4 Mower 5 Low/uneven 6 Worn, bent or loose blade. 7 in "FAST" 3 Allow grass not level. 4 Level mower tire air pressure. 5 Check tires for proper 6 Replace/sharpen blade bolt. Buildup of grass, leaves and trash under mower, 7 Clean underside housing. 8 Mower drive belt worn. 8 Replace mower drive belt. 9 Blades improperly 9 Reinstall blades sharp edge down. deck installed. blades used. 10 to dry before PSI. blade. Tighten of mower 10 Improper 11 Clogged mower deck vent holes 11 from buildup of grass, leaves, and trash around mandrels. Clean around mandrels open vent holes. 1 Light switch 1 Turn light switch "ON". 2 Bulb(s) 2 Replace 3 Faulty light switch. 3 Check/replace 4 Loose or damaged 4 Check wiring 5 Blown fuse. 5 Replace fuse. 1 Bad battery 1 Replace battery. 2 Poor cable connections. 2 Check/clean 3 Faulty regulator 3 Replace regulator. alternator. is "OFF". or lamp(s) burned out. wiring. cell(s). (if so equipped). mowing. deck. Replace with blades this manual. bulb(s) listed in to or lamp(s). light switch. and connections. all connections. 4 Faulty alternator. 4 Replace 1 Freewheel control in "DISENGAGED" position. 1 Place freewheel control in "ENGAGED" position. 2 Debris on steering equipped), 2 See "CLEANING" in the maintenance section. 3 Motion drive belt worn, damaged, or broken. 3 Replace 4 Purge transmission. 5 Install axle key at rear wheel. See "TO REMOVE WHEEL" in the Service and Adjustments section. plate (if 4 I Air trapped in transmission shipment or servicing. 5 I Axle during key missing. Engine "backfires" when turning engine "OFF" Engine between position Engine dies when tractor is shifted into reverse Reverse operation system (ROS) is not "ON" while mower or other attachment is engaged. throttle control not sel half and full speed (fast) before stopping engine. 30 motion drive belt. Move throttle control between half and full speed (fast) position before stopping engine. Turn ignition key to ROS "ON" position. See Operation section. SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION o3 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. 4o Compare the angle of the fold with the slope of the hill 11.25.09 CL JCRI_FTSMI:IWJ Printed in the U.S.A.