Bolens 138-784-401 User Manual
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18 H P
$1.00
HYDROSTATIC
LAWN TRACTOR
Model Number
138-784-401
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Thank you for purchasing an American-built product.
Important:
Read Safety Rules and Instructions Carefully
FORM NO. 770-63620
INDEX
Slope Gauge
Contents of Hardware Pack............................................ 4
Rules for Safe Operation Practices
Assembly Instructions
Controls
Operation................................................................... 12
Adjustments................................................................ 13
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INSTRUCTIONS GIVEN WITH THIS SYM
BOL ^RE FOR PERSONAL SAFETY. BE
A.
SURE TO FOLLOW THEM.
LIMITED WARRANTY
For two years from the date of original etail purchase, SENTAR/MTD PRODUCTS INC will either
repair or replace, at its option, free of charge, F.O.B. factory or authorized service firm, any part
or parts found to be defective in mateiial or workmanship. Transportation charges for the move
ment of any power equipment unit or attachment are the responsibility of the purchaser. Transpor
tation charges for any parts submitted for replacement under this warranty must be paid by the
purchaser unless such return is requissted by SENTAR/MTD PRODUCTS INC.
This warranty will not apply to any par: which has become inoperative due to misuse, excessive
use, accident, neglect, improper main enance, alterations, or unless the unit has been operated
and maintained in accordance with the instructions furnished. This warranty does not apply to
the engine, motor, battery, battery charger or component parts thereof. Please refer to the ap
plicable manufacturer’s warranty on tiese items.
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3
5
Lubrication......................................................................15
Maintenance.................................................................. 16
Off-Season Storage........................................................19
Trouble Shooting Charts
Electrical System .......................................................... 22
Illustrated Parts for Lawn Tractor
Parts Information.... ...... Back Cover
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20-22
23-35
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This warranty will not apply where tho unit has been used commercially.
Warranty service is available through your local authorized service dealer or distributor. If you
do not know the dealer or distributor in your area, please write to the Customer Service Depart
ment of SENTAR/MTD.
The return of a complete unit will not t’e accepted by the factory unless prior written permission
has been extended by SENTAR/MTD
This warranty gives you specific legal rights. You may also have other rights which vary from state
to state.
V
WARNING: This unit is equipped with an interral combustion engine and should not be used on or near any unim
proved forest-covered, brush-covered or grass covered land unless the engine’s exhaust system is equipped with
a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained
in effective working order by the operator.
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 lav\ s apply on federal lands. A spark arrester for the muffler is available
through your nearest engine authorized servi ;e center.
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USE THIS SHEET AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.
■ SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
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^-----------------------------------A CORNER OF A BUILDING
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A POWER POLE
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OR A FENCE POST
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AC WARNING ^
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2V2 feet every 10 feet). A
riding mower could overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is
extremely difficult to maintain your footing and you could slip, resulting in serious injury.
Operate RIDING mowers up and down slopes, never across the face of slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
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CONTENTS OF HARDWARE PACK
Remove this sheet from your owner’s manual
Refer to the separate deck manual for any info
which is on the reverse side of this sheet fo
(Hardware pack may contain extra items which are not used on your unit.)
and lay the hardware on the illustration for identification purposes,
•mation concerning the deck. After assembly, keep the Slope Gauge
future use.
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INCHES
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IMPORTANT
RULES FOR SAFE OPERATION
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED, COULD EN
DANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL
INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE YOUR UNIT. FAILURE TO COMPLY WITH
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WHEN YOU SEE THIS SYMBOL— A HEED ITS
WARNING.
DANGER
AC
Your unit was built to be operated according to the rules for safe operation in this manual.
As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. If you violate any of these rules, you may cause serious injury to yourself
or others.
A
READ THIS OWNER’S MANUAL carefully in its entirety
1.
before attempting to assemble or operate this unit. Keep
this manual in a safe place for future and regular
reference and for ordering replacement parts.
This unit is a precision piece of power equipment, not
2.
a plaything. Therefore exercise extreme caution at all
times.
Know the controls and how to stop the machine quickly.
Do not allow children to operate vehicle. Do not allow
adults to operate it without proper instruction. Only per
sons well acquainted with these rules of safe operation
should be allowed to use your mower.
Wear sturdy, rough-soled work shoes and close-fitting
slacks and shirts to avoid entanglement in the moving
parts. Never operate a unit in bare feet, sandals, or
sneakers.
To prevent injury, do not carry passengers or give rides.
6.
Keep children, pets and bystanders out of the area while
mowing. Only the operator should ride on the unit and
only ride in the seat.
Check overhead clearance carefully before driving under
7.
power lines, guy wires, bridges or low hanging tree
branches, before entering or leaving buildings, or in any
other situation where the operator may be struck or pulled
from the unit, which could result in serious injury.
To maintain control of the unit and reduce the possibil
8.
ity of upset or collision, operate the tractor smoothly.
Avoid erratic operation and excessive speed.
Keep the area of operation clear of all persons, particular
9.
ly small children and pets. Stop engine when they are
in the vicinity of your mower. Although the area of opera
tion should be completely cleared of foreign objects, a
small object may have been overlooked and could be
accidently thrown by the mower in any direction and
cause injury to you or a bystander.
Stop the blade(s) when crossing gravel drives, walks or
10.
roads.
Disengage all attachment clutches and shift into neutral
11.
before attempting to start engine.
Disengage power to attachment(s) and stop engine
12.
before leaving operating position.
Do not put hands or feet near or under rotating parts.
13.
Keep clear of the discharge opening at all times as the
rotating blade(s) can cause injury.
Disengage power to attachment(s) and stop engine
14.
before making any repairs or adjustments. Disconnect
the spark plug wire and keep the wire away from the plug
to prevent accidental starting.
15. Before attempting to unclog the mower or discharge
chute, stop the engine. The mower blade(s) may con
tinue to rotate for a few seconds after the engine is shut
off. Therefore, be sure the blade(s) have stopped com
pletely. Disconnect the spark plug wire and keep the wire
away from the plug to prevent accidental starting.
16. Disengage power to attachment(s) when transporting or
not in use.
17. Take all possible precautions when leaving vehicle un
attended such as disengaging power take-off, lowering
attachments, shifting into neutral, setting parking brake,
stopping engine and removing key.
18. For your safety, use the slope gauge included as part
of this manual to measure slopes before operating this
unit on a sloped or hilly area. If the slope is greater than
15° as shown on the slope gauge, do not operate this
unit on that area or seriotts injury could result.
19. Do not stop or start suddenly when going uphill or
downhill. Mow up and down face of steep slopes; never
across the face. Use extreme caution if it is necessary
to drive the tractor up an incline or back the tractor down
an incline because the front of the tractor could lift and
rapidly flip over backward which could cause serious
injury.
20. Reduce speed on slopes and in sharp turns to prevent
tipping or loss of control. Always keep the tractor in gear
when going down steep hills to take advantage of engine
braking action.
21. Stay alert for holes in terrain and other hidden hazards
which may cause the unit to tip over.
22. 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 sug
gested in owner’s manual.
23. Watch out for traffic when crossing or near roadways.
24. When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near vehicle
while in operation.
25. 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.
Rules for Safe Operation (continued)
26. Keep the vehicle and attachments in good operating con
dition, and keep safety devices in place. Use gi ards as
instructed in operator’s manual.
27. Keep all nuts, bolts, and screws tight to be sure th 3 equip
ment is in safe working condition.
28. Never store the machine with fuel in the fuel tank inside
a building where ignition sources are present, such as
hot water and space heaters, clothes dryers, and the like.
Allow the engine to cool before storing in any en closure.
29. To reduce fire hazard, keep engine free of grass, leaves
or excessive grease.
30. The vehicle and attachments should be stoppée and in
spected for damage after striking a foreign object. The
damage should be repaired before restart! ig and
operating the equipment.
31. Do not change the engine governor settings or ov jrspeed
the engine.
32. When using the vehicle with mower, proceed as follows:
(1) Mow only in daylight or in good artificial li jht.
IMPORTANT: This unit is shipped WITHOUT GASOLINE or OIL; however, a small amount of oil may
be present from the fact ory. Do not overfill. After assembly, service engine with gasoline
and oil as instructed ir the separate engine manual packed with your unit.
(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.
33. Check grass catcher bags frequently for wear or
deterioration. For safety protection, replace only with new
bag meeting original equipment specifications.
34. Look behind to make sure the area is clear before plac
ing the transmission in reverse and continue looking
behind while backing up. Disengage blades before shift
ing into reverse and backing up.
35. This unit should not be driven up a ramp onto a trailer
or truck under power, because the unit could tip over,
causing serious personal injury. The unit must be pushed
manually to load properly.
NOTE: Reference to right or left hand side of the unit is observed from the driver’s seat, fac
ing forward. Refer to th(» separate deck manual for all information concerning the deck.
ASSEMBLY
UNPACKING
1. Remove the carton from the tractor as follow vs. Cut
and remove the bands around the carton, Open
the top flaps and remove all carton inserts. Lift the
carton off the tractor. Roll the tractor off the skid.
Make certain all parts and literature havj been
removed from the carton before the carton is
discarded.
2. Remove page four from this manual and lay the
contents of the hardware pack on the illustration
for identification.
BATTERY INFORMATION
t WARNING i
A. Battery acid must be handled with great care as
contact with it can burn and blister the skin. I; is also
advisable to wear protective clothing (goggles, rub
ber gloves and apron) when working with it.*
A
B. Should battery acid accidentally splatter into the
eyes or onto the face, rinse the affected area im
mediately with clean, cold water. If there is any
further discomfort, seek prompt medical attention.
C. If acid spills on clothing, first dilute it with clean
water, then neutralize with a solution of ammonia/
water or baking soda/water.
D. Since battery acid is corrosive, do not pour it into
any sink or drain. Before discarding empty elec
trolyte containers, rinse them with a neutralizing
solution.
E. NEVER connect or disconnect charger clips to bat
tery while charger is turned on as it can cause
sparks.
F. Keep all lighted materials (cigarettes, matches,
lighters) away from the battery as the hydrogen gas
generated during charging can be combustible.
G. As a further precaution, only charge the battery in
a well-ventilated area.
*Always shield eyes, protect skin and clothing
when working near batteries.
Fill Caps
Vent
Elbow
Clear Plastic
Drain Tube
FIGURE 1.
FIGURE 2.
DANGER
Ai
Battery contains sulfuric acid. Refer to warning on
page 6. Antidote: EXTERNAL—Flush with water.
INTERNAL—Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg or vegetable
oil. Seek prompt medical attention. EYES: Flush with
cool water for at least 15 minutes, then seek immediate
medical attention.
Since batteries produce explosive gases, keep ail
lighted materials (cigarettes, lighters, matches, etc.)
away. Be sure to charge battery only in well-ventilated
areas.
KEEP BATTERIES
OUT OF THE REACH OF CHILDREN!
ACTIVATING THE BATTERY
Do not activate battery (fill with battery acid) until
battery is actually placed in service. Be certain to
read previous warnings before activating the
battery.
1. Open the battery pack. Be careful not to puncture
the box. It contains the battery with a long plastic
tube attached, battery fluid (acid) in a cardboard
container and one cone.
2. Place the battery on a table or workbench. Make
certain the long plastic drain tube is in place on
the vent elbow.
3. Remove the six fill caps from the top of the bat
tery with a screwdriver. Be careful not to damage
the fill caps. See figure 1.
4. Cut off the tip of the cone for use as a funnel.
5. Place the battery fluid container upright on the
table or workbench. Carefully remove the flap on
the box, and pull out the plastic tube. Cut off the
tip of the plastic tube. Do not squeeze the container
when cutting the tip.
6. Fill each battery cell slowly and carefully to the split
ring at the bottom of the well. See figure 2. Use
caution as the acid level will rise rapidly after the
bottom of the cell is filled. DO NOT OVERFILL.
7. Allow battery to stand for 30 minutes with the fill
caps removed, while the plates absorb acid.
8. If acid level has fallen after the 30 minute standing
period, refill each cell with battery acid to the split
ring. Replace the fill caps.
9. Before discarding the empty container, neutralize
any residue with baking soda and rinse container
with water. Puncture container several times
before discarding.
10. Charge the battery after the 30 minute standing
period. SLOW CHARGE THE BATTERY (DO NOT
FAST CHARGE) at a maximum bench rate of 5
amperes until the specific gravity reading is 1.265
(approximately 30 minutes).
■^NOTE
After battery has been in service, add
only distilled water to replace norrnal
loss. Do not add acid.
■^NOTE
This engine is equipped with an
alternator. The current for the bat
tery charger alternator is unregu
lated. During normal operation, it is
only necessary to charge the battery:
1. When it is activated for the first
time.
2. Before winter storage.
3. Before using the tractor after winter
storage.
SEAT ASSEMBLY (Hardware A)
1.
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Place the seat in position against the seat brackets.
Secure each side of seat with shoulder bolts, lock
washer and hex nut. Crown side of washers should
be against the head of the bolt and the nut. See
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figure 3.
2.
----
Plug the wire lead which is in the wire harness
beneath the seat into the plug on the wire lead ex
tending from the right hand side of the seat. Make
certain to route the wire in front of the right hand
seat bracket so the wire is not pinched when rais-
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ing and lowering the seat. See figure 4.
STEERING WHEEL INSTALLATION (Hardware B)
Your unit is equipped with indicator lights, located in
the steering wheel. The steering wheel must be
assembled as follows for proper operation of the in
dicator lights.
1. Open the hood of the tractor.
2. Place the larger end of the steering bellow over the
wire harness extending through the steering wheel
(bellow must fit over the four tabs on the steering
-------
wheel). See figure 5.
3. Insert the ends of the wire harness down through
the hole in the dash. Then slide the wires through
the slot into the smaller hole in the dash to the stop
(tape) on the harness as shown in figure 5. Only
about 6" of wire will extend beneath the dash.
4. Plug the three connectors on the wire harness in
to the corresponding connectors on the tractor.
FIGURE 6.
Black
Negative (-)
Cable
5. Slide the upper steering column through the hole
in the dash, over the lower steering column. Insert
hex bolt through upper and lower column to secure
temporarily in any one of the four hole locations.
6. Position the front wheels of the tractor so they are
pointing straight forward.
7. Slide the steering bellow over the steering column.
Hold the wires out of the way as shown. See figure
-----------
6.
8. Place the steering wheel over the steering column,
positioning steering wheel as shown (slot for the
wires is toward the front of the tractor).
9. Place the washer with the cupped side down over
the steering column. Secure with 5/16" hex lock
nut.
10. Attach the steering wheel insert to the steering
wheel as follows.
a. Position the steering wheel insert so the lights
are toward the bottom.
b. Place the two prongs on one side of the insert
over two of the spokes on the steering wheel.
Press into place.
c. Take the slack out of the wires by pulling
through the steering wheel.
d. Press the prongs on the other side of the insert
over the other two spokes on the steering
wheel.
11. Remove the hex bolt which is holding the upper
and lower steering columns. Turn steering wheel
three full revolutions clockwise.
12. The four holes in the upper steering column pro
vide four height positions for the steering wheel.
See figure 6, inset. Select desired position, and
secure with hex bolt and hex lock nut. Tighten
securely.
13. If any excess wire is beneath the steering wheel,
insert it inside the steering bellow. Pull bellow up
against the bottom of the steering wheel.
INSTALLING THE BATTERY (Hardware C)
FIGURE 7.
,Red / /
Positive ( + )
Cable /
//
•NOTE
The positive battery terminal • is
marked Pos. (-h). The negative bat
tery terminal is marked Neg. (-).
1. Place the battery on the battery plate with the ter
minals towards the rear of the tractor.
2. Attach the positive cable (heavy red wire) and the
small red wire (from the circuit breaker) to the
positive battery terminal (-i-) with hex bolt 5/8"
------long, 1/4" lock washer and hex nut. See figure 7.
3. Attach the negative cable (heavy black wire) to the
negative battery terminal (-) with the other hex
bolt 5/8" long, 1/4" lock washer and hex nut.
FIGURE 8.
4. Attach one push nut to each of the battery hold-
-down rods as shown in figure 8, inset.
5. Hook one hold-down rod into the hole in battery
plate beside the battery. Slide the push nut to the
bottom of the hold-down rod. See figure 8. Place
the black plastic battery cover in position over the
hold-down rod. Secure with wing nut. Attach other
hold-down rod to the other side of battery cover in
the same manner.
Push
Nuts
6. Route the battery drain tube down beside the oil
drain pipe on the right side of the tractor. Slip the
end of the drain tube into the mounting clamp pro
vided in hardware pack. Secure the mounting
clamp to the tractor by placing the clamp over the
hex bolt and nut which hold the engine pulley belt
guard to the frame. Secure in place with hex lock
■nut. See figure 9.
FIGURE 9.
NOTE
The vented battery allows any gases
or liquid from the battery to be
drained onto the ground.
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. Recommended operating tire
pressure should be 10 p.s.i.
Check sidewall of tire for manufacturer’s maximum tire
pressure. If this information does not appear on your
tire, maximum tire pressure under any circumstances
is 30 p.s.i. Equal tire pressure should be maintained
on all tires.
10
CONTROLS
IGNITION SWITCH
The ignition switch is located on the dashboard. Turn
the key to the START position to start the engine. When
the engine is running, leave the key in the ON posi
tion. To stop the engine, turn the key to the OFF posi
tion. See figure 10.
WARNING
Ac
Remove the key from the tractor
when the tractor is not in use to pre
vent accidental starting.
the opposite side (charging) when the engine is run
ning in 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
10.
GASOLINE TANK
The gasoline tank is located under the tractor seat. Tip
the seat forward to fill the tank. Refer to figure 3. Be
careful not to pinch the wire lead to the seat switch
when raising and lowering the seat.
THROTTLE CONTROL
The throttle control is located on the left side of the
dashboard and is used to regulate the engine speed.
See figure 10. The engine should be operated from %
to full throttle (FAST) when operating any equipment
that uses the tractor engine as a source of power such
as the mowing deck, snow thrower or rotary tiller.
CHOKE CONTROL
The choke control is located on the right side of the
dashboard and is operated manually. Details for the
choke operation are covered in the separate engine
manual packed with your unit. See figure 10.
HYDROSTATIC CONTROL LEVER
A single control lever connected to the hydrostatic
transmission controls both the speed and direction of
the tractor. Infinite speed control is achieved by mov
ing the control lever forward or backward. The farther
forward or backward you move the control lever, the
faster you will travel. Pulling the control lever into
neutral (N) area will stop the tractor. To increase rear
wheel torque (pulling power), move the control lever
towards neutral (N) position. The lawn tractor responds
similar to shifting to a lower gear with a gear type
transmission. See figure 11.
LIGHT SWITCH
The head lamps are operated by pushing the light
switch located on the dashboard. The head lamps will
only operate when the engine is running. See figure 10.
AMMETER
The ammeter registers the rate of battery charge or
discharge. The ammeter will register on the discharg
ing side with starting the engine. It should register on
CLUTCH-BRAKE PEDAL
The clutch-brake pedal is located on the right side of
the tractor. See figure 12. Depressing the pedal
disengages the engine from the hydrostatic transmis
sion and applies the brake. You can release the clutch
pedal and resume the same speed without moving the
hydrostatic control lever. See figure 12.
11
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