Bolens 137-465A User Manual
ASSEMBLY
OPERATION
TEN CENTS
MANUAL
Model Nos.
137-460A
MAINTENANCE
PARTS LIST
Important:
Read Safety Rules and
Instructions Carefully
137-465A
137-460-300
137-465-300
RIDING
MOWERS
PRINTED IN U.S.A.
34”
FORM NO. 770-6697
IMPORTANT
It is suggested that this manual be read in its entirety before attempting to assemble or operate. Keep this
manual in a safe place for future reference and for ordering replacement parts.
This unit is shipped WITHOUT GASOLINE or OIL. After assembly, see operating section of this manual for
proper fuel and amount.
Your rotary mower is a precision piece of power equipment, not a plaything. Therefore exercise extreme
caution at all times.
SAFE OPERATION PRACTICES FOR RIDING VEHICLES
1. Know the controls and how to stop quickly
READ THE OWNER’S MANUAL.
2. Do not allow children to operate vehicle. Do
not allow adults to operate it without proper
instruction. Only persons well acquainted
with these rules of safe operation should be
allowed to use your mower.
3. Do not carry passengers.
4. Keep the area of operation clear of all
persons, particularly small children and pets.
Stop engine when they are in the vicinity of
your mower. Although the area of operation
should be completely cleared of foreign
objects, a small object may have been over
looked and could be accidently thrown by the
mower in any direction.
5. Clear work area of objects which might be
picked up and thrown by the mower in any
direction.
6. Disengage all attachment clutches and shift
into neutral before attempting to start engine.
7. Disengage power to attachment(s) and stop
engine before leaving operator position.
8. Disengage power to attachment(s) and stop
engine before making any repairs or adjust
ments. Disconnect the spark plug wire and
keep the wire away from the plug to prevent
accidental starting.
9. Before attempting to unclog the mower or
discharge chute, stop the engine and be sure
the blade(s) have stopped completely. Dis
connect the spark plug wire and keep the wire
away from the plug to prevent accidental
starting.
10. Disengage power to attachment(s) when
transporting or not in use.
11. Take all possible precautions when leaving
vehicle unattended such as disengaging
power-take-off, lowering attachments, shift
ing into neutral, setting parking brake,
stopping engine and removing key.
12. Do not stop or start suddenly when going
uphill or downhill. Mow up and down face of
steep slopes; never across the face.
13. Reduce speed on slopes and in sharp turns to
prevent tipping or loss of control. Exercise
extreme caution when changing direction on
slopes.
14. Stay alert for holes in terrain and other hidden
hazards.
15. Use care when pulling loads or using heavy
equipment.
A. Use only approved drawbar hitch points.
B. Limit loads to those you can safely
control.
C. Do not turn sharply. Use care when
backing.
D. Use counterweight(s) or wheel weights
when suggested in owner’s manual.
16. Watch out for traffic when crossing or near
roadways.
17. When using any attachments never direct dis
charge of material toward bystanders nor
allow anyone near vehicle while in operation.
18. Handle gasoline with care—it is highly
flammable.
A. Use approved gasoline container.
B. Never remove cap or add gasoline to a
running or hot engine or fill fuel tank
indoors. Wipe up spilled gasoline.
C. Open doors if engine is run in garage-
exhaust fumes are dangerous. Do not run
engine indoors.
Keep the vehicle and attachments in good
19.
operating condition, and keep safety devices
in place. Use guards as instructed in owner’s
manual.
Keep all nuts, bolts, and screws tight to be
20.
sure the equipment is in safe working condi
tion.
Never store the equipment with gasoline in
21.
the tank inside a building where fumes may
reach an open flame or spark. Allow engine to
cool before storing in any enclosure.
To reduce fire hazard keep engine free of
22.
grass, leaves or excessive grease.
The vehicle and attachments should be
23.
stopped and inspected for damage after
striking a foreign object, and the damage
should be repaired before restarting and
operating the equipment.
Do not change the engine governor settings or
24.
overspeed the engine.
When using the vehicle with mower, proceed
25.
as follows:
(1) Mow only in daylight or in good artificial
light.
(2) Never make a cutting height adjustment
while engine is running if operator must
dismount to do so.
(3) Shut the engine off and wait until the
blade comes to a complete stop before
removing the grass catcher.
(4) Check blade mounting bolts for proper
tightness at frequent intervals.
26. Check grass catcher bags frequently for wear
or deterioration. For safety protection replace
only with new bag meeting original equip
ment specifications.
27. Look behind to make sure the area is clear
before placing the transmission in reverse and
backing up.
INDEX
Safe Operation Practices..............................................2
Index and Assembly
Battery Information
Controls......................................................................... 6
Operating Instructions..................................................9
Lubrication...................................................................10
Adjustment...................................................................12
Belt Removal............................................................... 13
Off-Season Storage.....................................................16
Trouble Shooting Chart (Recoil Model)
GRASS CATCHER Model No. 197-015A is
available as optional equipment for the mowers
shown in this manual.
The mower should not be operated
without the entire grass catcher or
chute deflector in place.
.....................................................
.......................................................
....................
WARNING
i
3
4
17
NOTE
Under normal usage bag material is
subject to wear, and should be
checked periodically. Be sure any
replacement bag complies with the
mower manufacturer’s recommen
dations.
For replacement bags, use only fac
tory authorized replacement bag No.
764-0121.
Trouble Shooting Chart (Electric Model)
Schemat for Electrical System (Recoil Start)... 19
Schematic for Electrical System (Electric Start).20
Differential Breakdown
Transmission Breakdown...........................................22
Deck Linkage
Illustrated Parts for Rider
Parts List for Rider
Parts Information
...............................................................
A.
Installation of tire to rim :
1. Lubricate tire beads and rim flanges.
2. Do not exceed 30 P.S.I. when seating
beads.
3. Adjust to recommended pressure after
beads are sealed.
..............................................
.......................
...................................
.......................................
jCAUTION
................
24, 26, 28, 30
25, 27, 29, 31
Back Cover
.18
21
23
NOTE
Reference to right-hand or left-hand
side of machine is from the driver’s
seat facing forward.
IMPORTANT
After striking a foreign object, stop
the engine (motor). Remove wire
from spark plug, thoroughly inspect
the mower for any damage, and re
pair the damage before restarting
and operating the mower.
The steering wheel and seat, with the necessary
hardware, are easily assembled to the machine.
On the electric starter models, the battery must be
activated and installed as outlined in this section.
TIRE PRESSURE
FOR SHIPPING PURPOSES, THE TIRES ON
YOUR UNIT MAY BE OVER-INFLATED. TIRE
PRESSURE SHOULD BE REDUCED BEFORE
UNIT IS PUT INTO OPERATION. PRESSURE
SHOULD BE APPROXIMATELY 15 P.S.I. EQUAL
TIRE PRESSURE SHOULD BE MAINTAINED ON
ALL TIRES. MAXIMUM TIRE PRESSURE IS 30
P.S.I.
Hex Nut
Lock Washer 1 /4”
Hex Bolt
1/4-20
H
1/4-20x5/8
oi
Hex Lock Nut
3/8-16
FIGURE 1. HARDWARE SUPPLIED
Step 1. Remove the lawn mower and all parts
from the carton. Make certain that all
loose parts and literature have been
removed before the carton is discarded.
Step 2. Place steering wheel over steering shaft.
Belleville Washer 3/8”
step 3. Secure with Belleville washer and hex
nut. See figure 2.
Step 4. Press the cap on the steering wheel by
hand. See figure 2.
BATTERY INFORMATION
\ WARNING I
Steering Wheel Ca
FIGURE 2. STEERING WHEEL ASSEMBLY
Step 5. Your molded seat comes with the
mounting bolt molded in the seat.
A. Seiect one of three hole locations on
seat spring.
B. Piace seat on spring and secure with
lockwasher (A) and hex nut (B). See
figures 1 and 3.
A.
Battery acid must be handled with great care
as it will blister the skin and damage clothing.
It is advisable to wear goggles, rubber gloves,
and a protective apron when working with it.
B.
Neutralize acid spilled on clothing with dilute
ammonia water or a water solution of baking
soda. If acid gets on clothes, dilute it with
clean water first, then neutralize.
C.
If for any reason acid should be spattered in
the eyes, wash it out immediately with clean
cold water. Seek medical aid if discomfort
continues.
D. Since battery acid is corrosive to metals, do
not pour into any sink or drain. Rinse empty
electrolyte containers and mutilate before
discarding.
DANGER
t
(D
BATTERIES CONTAIN SULFURIC ACID AND MAY
CONTAIN EXPLOSIVE GASES (when electrolyte
has been added)
A. Keep sparks, flame, cigarettes away.
B. Hydrogen gas is generated during charging
and discharging.
C. Ventilate when charging or using in enclosed
space.
D. When using a charger—to avoid sparks,
NEVER connect or disconnect charger clips to
battery while charger is turned on.
E. Always shield eyes, protect skin and clothing
when working near batteries.
FIGURE 3. SEAT ASSEMBLY
NOTE
Check ALL nuts and boits for correct
tightness.
A. ACTIVATING THE BATTERY
1. Place battery to be filled on bench or work
bench. NEVER activate battery in unit.
Remove vent caps from all cells.
2. Fill each cell carefully using battery grade
1.250-1.265 specific gravity. Sulfuric acid to
be 3/8” above the top of the separators or to
the split ring.
3. Allow battery to set for 20 minutes to Vz hour.
Add additional acid if necessary to bring it up
to the proper level.
4. Replace the vent caps.
The battery can now be charged after the 20
5.
minutes setting period. Battery can be SLOW
CHARGED (DO NOT FAST CHARGE) at a
maximum bench rate of 4-5 amperes until the
specific gravity reading is 1.265-1.275. A
charging rate in excess of this will buckle and
warp the positive plates and perforate the
separators. If electrolyte bubbles violently
while charging, reduce charging rate until
excessive bubbling action subsides, then
continue charging until specific gravity is
reached.
CAUTION
After battery has been in service,
add only approved water. DO NOT
ADD ACID.
B.
TO INSTALL BATTERY
To install the battery in this unit, refer to
next column.
C. MAINTENANCE
1. Check periodically (every two weeks or before
and after charging) to be sure electrolyte
level is 9/16” above separator plates. Add
only distilled water or good quality drinking
water. NEVER add additional acid or other
chemicals to battery after initial activation.
2. The battery should be checked with a
hydrometer after every 25 hours of operation.
If the specific gravity is less than 1.225
remove battery and recharge.
3. Coat the terminals and exposed wiring with a
thin coat of grease or petroleum jelly for
longer service and protection against electro
lyte corrosion.
4. The battery should be kept clean. Any
deposits of acid should be neutralized with
soda and water. Be careful not to get this
solution in the cells.
3. Recharge battery whenever the specific
gravity is less than 1.225 before returning to
service or every two months, whichever
occurs first.
E.
COMMON CAUSES FOR BATTERY FAILURE
ARE:
1. Overcharging
2. Undercharging
3. Lack of water
4. Loose hold downs and/or corroded
connections
5. Excessive loads
6. Battery electrolyte substitutes
7. Freezing of electrolyte
'NOTE
THESE FAILURES DO NOT CON
STITUTE WARRANTY.
LIMITED WARRANTY
For ninety (90) days of original retail purchase, the
battery carries a limited warranty against faulty
material or workmanship by the battery manufac
turer.
INSTALLING THE BATTERY
1. Open the hood of the riding mower.
2. Place the battery in the battery case with the
terminal to the front. See figure 4.
D. STORAGE
1. Charge battery usihg normal methods.
NEVER store discharged battery as it will not
recover.
2. Store in cold, dry place.
3. Recharge battery whenever the specific
gravity is less than 1.225 before returning to
service or every two months, whichever
occurs first.
FIGURE 4.
3. Cut the black rubber tubing approximately 4
inches long.
4. Push the rubber tubing into the manifold of
the battery and place the other end into the
drain tube. See figures 4 and 5.
NOTE
The vented battery allows any gases
or liquid from the battery to be car
ried to the rear of the mower through
the drain tube.
5. Hook the hold down rods under the battery
case and place the hold down over the
manifold of the battery as shown in figure 6.
6. Secure the hold down with the wing nuts.
7. Attach the positive cable (from the starter
solenoid) and the small wire (from the
ammeter) to the positive battery terminal with
the bolt, lockwasher and nut in the assembly
pack.
8. Attach the negative cable, grounded, to the
negative battery terminal with the bolt,
lockwasher and nut in the assembly pack.
CONTROLS
The controls on both models may be considered
as the Drive Control and the Cutting Control as
follows:
FIGURES.
a. Throttle Control. The throttle control is used to
regulate the engine speed and choke the engine.
The engine should be operated from % to full
throttle when operating the cutting deck or snow
thrower (optional). See figure 7.
Throttle Control
i^Aminet
Ignition Switch
Uii
Clutch
Light Switch
■■
Loctout -t. ..= ^
Gea» Shift'lever
FIGUREZ. CONTROLS
FIGURES.
b. Gearshift Lever. The gear shift lever is used to
shift into one of four Forward Gears, NEUTRAL or
REVERSE. See figures 7 and 8.
c. Brake. The brake pedal is located on the right
hand side of the mower and is operated by
depressing it with your right foot. See figure 9.
d. Brake Lock. The brake lock is located on the
right hand side of the mower. To lock the brake,
depress the brake pedal and lift up the lock
button. The pedal will stay depressed. To release,
depress the pedal. See figure 9.
e. Clutch Pedal. The clutch pedal is used to
disengage the drive mechanism. Depressing _die
clutch pedal at any time will reduce mower speed.
Trdep'ressed all the way,TTwTn stopTheHmow^.
''SeeTtgurn^O:
f. Clutch Lockout. When the clutch pedal Isl
depressed all the way it can be locked by placing'
the clutch lockout in the START position as
shown in figure 10. The clutch locknut must be in |
this position before the engine will start.
g. Stop Lever. The stop lever allows you to
regulate the maximum ground speed of the riding
mower by setting the stop lever in any one of the
five settings. The farther forward the stop lever is
set, the faster the ground speed. See figure 10.
h. Ammeter. (Electric Start Model Only) The
ammeter registers the rate of battery charge or
discharge. The ammeter should register on the
plus side ( +) when the engine is running the fast
position until the battery is completely charged.
With a fully charged battery or with the engine
idling the ammeter will not show a charge. See
figure 7.
---------
------------—-------------
i. Light Switch. (Eiectric Start Oniy) Pull the light
switch out to turn on the lights. The lights will
only operate when the engine is running. See
figure?.
j. Ignition Switch. The ignition switch is located
on the right side of the dashboard.
Recoii Model. See figure 11. Turn the key to the
ON position when starting the engine. To stop the
engine turn the key to the left to the OFF position
and remove the key to prevent accidental starting.
Electric Start. See figure 7. Turn the key to the
START position to start the engine. When the
engine is running, let the key return to the ON
position. To stop the engine, turn the key to the
left to the OFF position and remove it to prevent
accidental starting.
NOTE
The engine will not start unless the
clutch lockout is in the START posi
tion and the lift lever is in the DIS
ENGAGED position.
Lift and Disengagement
Lever (Shown Disengaged)
C
OO
il
3 c
<ra
FIGURE 8. SHIFT PATTERN
FIGURE 9. RIGHT HAND CONTROLS
Clutch Lockout
(Shown in the Start Position)
•av:
FIGURE 10. LEFT HAND CONTROLS
^ R'ocoil Starter
I (Shown Locked)
FIGURE 11. RECOIL STARTER
k. Recoil Starter. The recoil starter is located on
the right side of the dashboard. The recoil starter
can either be pulled while seated on the rider or
pulled while standing behind the rider. The
ignition key must be on before the engine will
start. After the engine starts, the recoil starter
handle must be returned and locked into the
dashboard before the blades or clutch are
engaged. The engine will stop if you do not follow
these instructions. See figure 11.
Wheel Height Adjuster. See figure 13. Move the
lever towards the wheel and set it in the desired
cutting height.
FIGURE 13. WHEEL HEIGHT ADJUSTER
l. Lift and Disengagement Lever. It is used to
raise the cutting deck. Pulling it all the way back
and locking it disengages the blades. The engine
will not start unless the lift and disengagement
lever is in the disengaged position. See figure 9.
m. Cutting Controls. The cutting controls consist
of the height of cut stop and the wheel height
adjusters.
Height of Cut Stop. See figure 12. Lift the stop
and set it at the desired cutting height.
The cutting height of the mower can be set in two
different ways; FULL FLOAT position where the
deck folows the contour of the ground, and the
SUSPENDED position where the deck hangs from
the frame of the rider. The suspended position is
normally used for cutting rough uneven ground.
To set the cutting deck in the full float position,
set the wheel height adjusters in the desired cut
ting height as indicated in figure 13. Set height of
cut stop in the 1 Va position. See figure 12.
To set the cutting deck in the suspended position,
set the height of cut stop in the desired cutting
height and then set the deck wheel so they just
clear the ground.
CAUTION
A
Parking Brake MUST be disengaged
before unit is put into motion.
Heighi of Cut Stop
FIGURE 12. HEIGHT OF CUT SETTINGS
NOTE
Unit is equipped with separate brake
and clutch pedals. To efficiently
stop, it is necessary to disengage
clutch when applying brakes.
OPERATING
INSTRUCTIONS
STARTING THE ENGINE
Be sure to follow the instructions for the oil and
gasoline as described in the engine manual.
Step 1. Be sure the fuel shut-off valve is open.
See figure 14.
Step 2. Place the clutch lockout in the START
position. See figure 10.
Step 3. Place the lift and disengagement lever in
the DISENGAGED position. See figure 9.
Electric Start
See figures 17 and 19. Turn the ignition
key to the START position. When the
engine is running, let the key return to
the ON position.
S T A R T
1
FIGURE 16. STARTER SWITCH
To stop either model, turn the key to the left to the
OFF position and remove the key to prevent
accidental starting.
NOTE
A brief break-in period is essential
to ensure maximum engine and
mower life. This consists of running
the engine at half speed for a period
of time required to use one tank of
gasoline. It is also recommended to
change crankcase oil after the first 2
hours of operation.
Step 4. Set the throttle control in the CHOKE
position. See figure 7.
Step 5. Recoil Starter.
a. Turn the ignition key to the ON
position. See figure 15.
b. Grasp the recoil starter, unlock it by
twisting it Va turn and pull it out
sharply and hold it in the out position.
c. Slowly release the recoil starter and
lock it into the dashboard as shown in
figures 15 and 17.
FIGURE 15. RECOIL STARTER
STOPPING THE ENGINE
Turn the ignition key to the left to the OFF
position and remove the key to prevent accidental
starting.
OPERATING THE MOWER
Step 1. Set the desired cutting height.
Step 2. Start the engine as outlined on page 6.
Step 3. Select gear and shift.
NOTE
As you become familiar with the
operation of the mower you can
move the stop lever to a faster posi
tion.
Step 4. While holding down the clutch pedal,
move the clutch lockout lever forward.
Step 5. Put the gear shift lever into either
FORWARD or REVERSE.
NOTE
DO NOT force the gear shift lever! If
the lever cannot be moved from
NEUTRAL to one of the drive posi
tions, release the clutch pedal slow
ly, depress it again, and then move
the gear shift lèveras required.
Step 6. Once the machine is in motion, remove
foot from the pedal. The mower will
now move ahead or to the rear, and the
use of the steering wheel will provide
directional control.
Step 7 .The mower is brought to a stop by
pressing your right foot against the brake
pedal and your left foot against the
clutch pedal. The drive belt will be
disengaged and the brake will be applied.
CAUTION
A
Gear changing should be done only
after the mower has been brought to
full stop. If the mower is not to be
used for a long period, place the
gear shift lever in NEUTRAL and
stop the engine. DO NOT leave the
machine on an incline.
OPERATING THE CUTTER BLADE
The cutting blades may be engaged while the
mower is moving or standing still. DO NOT
engage the cutting blades abruptly as the sudden
belt tension on the pulley may cause the engine to
stall.
WARNING
t
When The blade drive is engaged,
keep feet and hands away from the
discharge opening and from the
blade.
To stop the blades, move the lift and
disengagement lever (figure 9) into the DISEN
GAGED position. This raises the deck and
disengages the blades.
NOTE
When the machine is used for other
than mowing operations the blade
drive should be disengaged.
t
crankcase with new oil; thereafter change the oil
every 25 hours of operation. This procedure
ensures for minimum wear of engine parts and
provides for virtually trouble-free operation. To
change the oil, proceed as follows;
Step 1. With the machine on level ground, place
a suitable metal container under the oil
drain plug, then remove the drain plug.
See figure 17.
Step 2. After the oil has been drained completely
from the crankcase, replace the drain
plug and tighten.
Step 3. Refill crankcase with 2V4 pints of good
quality, type MS, Engine oil into the
crankcase. Summer use SAE 30; Winter
(Below 40°F) use SAE 5W-20 or SAE
10W.
LUBRICATION
Lubricate the wheel bearings (2 per wheel) and the
upper and lower spindle bearings with SAE 30 oil
once a season. See figure 18.
CRANKCASE OIL
To ensure maximum engine performance, perform
the following periodic maintenance:
Oil Check
Check the oil level in the crankcase before each
use of the machine and after every five hours of
operation. Oil should be kept between the add and
full marks on the dipstick.
After the first five hours of operating a new
engine, drain the oil (See figure 17.) from the
crankcase while engine is still hot and refill
\vi ym
FIGURE 18. WHEEL AND SPINDLE BEARINGS
10
Loading...