Bolens 13AN683G163, 13AG683G163, 13AG683H163, 660, 688 Operator's Manual

SINCE-1850
Operator's Manual
Transmatic Lawn Tractor
Models 660 - 688
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered,
brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark attester 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 laws
apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A. FORM NO. 769-00565
(11/2002)
TABLEOFCONTENTS
Content Page
Important Safe Operation Practices ........................................................................ 3
Slope Gauge ........................................................................................................... 7
Tractor Set-up ......................................................................................................... 8
Know Your Lawn Tractor ......................................................................................... 11
Operating Your Lawn Tractor .................................................................................. 13
Making Adjustments ................................................................................................ 16
Service .................................................................................................................... 20
Maintaining your Lawn Tractor ................................................................................ 22
Off-Season Storage ................................................................................................. 27
Troubleshooting ...................................................................................................... 28
Attachments & Accessories ..................................................................................... 27
FINDINGMODELNUMBER
This Operator's Manual isan important part of your new lawn tractor. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what itsays.
Before you start assembling your new equipment, please locate the model plate on the equipment and copy the informationfrom itin the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an
authorized dealer.
You can locate the model number by looking beneath the seat. A sample model plate isexplained below. For
future reference, please copy the model number and the serial number of the equipment in the space below.
Copy the model number here:
TROY_BILT LLC
O. BOX 361131
CLEVELAND, OH44136
www.bolens.com 330-558-7220
866-840-6483
Copy the serial number here:
ENGINEINFORMATION
The engine manufacturer isresponsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed separately with your unit for more information.
CALLINGCUSTOMERSUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.
Call 1- (330) 558-7220 or 1-(866) 846-6483 to reach a Customer Support representative. Please have your unit's model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.
SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol points out important safety instructionswhich, if not followed, could endanger
the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructionsmay result inpersonal injury. When you see this symbol--heed itswarning.
DANGER: This machine was built to be operated according to the rules for safe operation inthis man-
ual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury.This machine is capable of amputating hands and feet and throwing objects. Failure to
observe the following safety instructionscould result in serious injury or death.
_, WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm.
GENERAL OPERATION
1. Read, understand, and follow all instructionson the machine and inthe manual(s) before attempting to
assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.
2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.
3. Never allow children under 14 years old to operate this machine. Children 14 years old and over should read and understand the operation instructionsand safety rules inthis manual and should be trained and supervised by a parent.
4. Never allow adults to operate this machine without proper instruction.
5. To help avoid blade contact or a thrown object injury, keep bystanders, helpers, children and pets
at least 75 feet from the machine while itis in operation. Stop machine if anyone enters the area.
6. Thoroughly inspectthe area where the equipment isto be used. Remove all stones, sticks, wire,
bones, toys, and other foreign objects which could be picked up and thrown by the blade(s). Thrown objects can cause serious personal injury.
7. Plan your mowing pattern to avoid discharge of material toward roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator.
8. Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injuryto the eyes.
9. Wear sturdy, rough-soled work shoes and close- fitting slacks and shirts. Loose fitting clothes and jewelry can be caught in movable parts. Never operate this machine in bare feet or sandals.
10. Be aware of the mower and attachment discharge direction and do not point it at anyone. Do not operate the mower without the discharge cover or entire grass catcher in its proper place.
11. Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade(s) can amputate hands and feet.
12. A missing or damaged discharge cover can cause blade contact or thrown object injuries.
13. Stop the blade(s) when crossing gravel drives, walks, or roads and while not cutting grass.
14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on any public roadway.
15. Do not operate the machine while under the influence of alcohol or drugs.
16. Mow only indaylight or good artificial light.
17. Never carry passengers.
18. Disengage blade(s) before shifting into reverse. Back up slowly. Always look down and behind before and while backing to avoid a back-over
accident.
19. Slow down before turning. Operate the machine smoothly. Avoid erratic operation and excessive speed.
20. Disengage blade(s), set parking brake, stop engine and wait until the blade(s) come to acomplete stop before removing grass catcher, emptying grass, unclogging chute, removing any grass or debris, or making any adjustments.
21. Never leave a running machine unattended. Always turn off blade(s), place transmission in neutral, set parking brake, stop engine and remove key before dismounting.
22. Use extra care when loading or unloading the machine into a trailer or truck. This unit should not
be driven up or down ramp(s), because the unit could tip over, causing serious personal injury.The unit must be pushed manually on ramp(s) to load or unload properly.
23.Mufflerandenginebecomehotandcancausea burn.Donottouch.
24.Checkoverheadclearancescarefullybeforedriving underlowhangingtreebranches,wires,door
openingsetc.,wheretheoperatormaybestruckor pulledfromtheunit,whichcouldresultinserious
injury.
25.Disengageallattachmentclutches,depressthe brakepedalcompletelyandshiftintoneutralbefore
attemptingtostartengine.
26.Yourmachineisdesignedtocutnormalresidential grassofaheightnomorethan10".Donotattempt tomowthroughunusuallytall,drygrass(e.g., pasture)orpilesofdryleaves.Drygrassorleaves maycontacttheengineexhaustand/orbuildupon themowerdeckpresentingapotentialfirehazard.
27.Useonlyaccessoriesandattachmentsapproved forthismachinebythemachinemanufacturer.
Read,understandandfollowallinstructions
providedwiththeapprovedaccessoryor attachment.
28.Dataindicatesthat operators, age 60 years and
above, are involved ina 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.
29. If situations occur which are not covered in this manual, use care and good judgment. Contact your
customer service representative for assistance.
SLOPE OPERATION
Slopes are a major factor related to loss of control and tip-over accidents which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or ifyou feel uneasy on it, do not mow
it.
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 degrees as shown on the slope gauge, do not
operate this unit on that area or serious injury could
result.
DO:
1,
2,
Mow up and down slopes, not across. Exercise extreme caution when changing direction on slopes.
Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
3. Use slow speed. Choose a low enough speed setting so that you will not have to stop or shift while
on the slope. Tires may lose traction on slopes even though the brakes are functioning properly.
Always keep machine ingear when going down slopes to take advantage of engine braking action.
4. Follow the manufacturer's recommendations for wheel weights or counterweights to improve
stability.
5. Use extra care with grass catchers or other attachments. These can change the stability of the
machine.
6. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Rapid engagement or braking could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury.
7. Avoid starting or stopping on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.
DO NOT:
1. Do not turn on slopes unless necessary; then, turn slowly and gradually downhill, if possible.
2. Do not mow near drop-offs, ditches or embankments. The mower could suddenly turn
over if a wheel is over the edge of a cliff, ditch, or if an edge caves in.
3. Do not try to stabilize the machine by putting your foot on the ground.
4. Do not use a grass catcher on steep slopes.
5. Do not mow on wet grass. Reduced traction could cause sliding.
6. Do not shift to neutral and coast downhill. Over- speeding may cause the operator to lose control of
the machine resulting in serious injury or death.
7. Do not tow heavy pull behind attachments (e.g. loaded dump cart, lawn roller, etc.) on slopes greater than 5 degrees. When going down hill, the extra weight tends to push the tractor and may cause you to loose control. (e.g. tractor may speed up, braking and steering ability are reduced, attachment may jack-knife and cause tractor to overturn).
CHILDREN
1,
Tragic accidents can occur ifthe operator is not alert to the presence of children. Children are often
attracted to the machine and the mowing activity. They do not understand the dangers. Never
assume that children will remain where you last saw them.
a. Keep children out of the mowing area and in
watchful care of a responsible adult other than the operator.
b. Be alert and turn machine off if a child enters
the area.
c. Beforeandwhilebacking,lookbehindand
downforsmallchildren.
d. Nevercarrychildren,evenwiththeblade(s)
shutoff.Theymayfalloffandbeseriously injuredorinterferewithsafemachine operation.
e. Useextremecarewhenapproachingblind
corners,doorways,shrubs,treesorother objectsthatmayblockyourvisionofachild whomayrunintothemachine.
f. Disengagethecuttingblade(s)before
shiftinginreverse.The"No-Cut-InReverse"
featureisaremindernottocutinreverseand tohelpavoidbackoveraccidents.Donot
defeatit.
g. Keepchildrenawayfromhotorrunning
engines.Theycansufferburnsfromahot muffler.
h. Removekeywhenmachineisunattendedto
preventunauthorizedoperation.
Neverallowchildrenunder14yearsoldtooperate themachine.Children14yearsoldandovershould readandunderstandtheoperationinstructionsand safetyrulesinthismanualandshouldbetrained andsupervisedbyaparent.
g,
TOWING
1. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except
at the hitch point.
2. Follow the manufacturers recommendation for weight limits for towed equipment and towing on
slopes.
3. Never allow children or others in or on towed equipment.
4. On slopes, the weight of the towed equipment may cause loss of traction and loss of control.
5. Travel slowly and allow extra distance to stop.
6. Do not shift to neutral and coast downhill.
SERVICE
SAFE HANDLING OF GASOLINE:
1,
To avoid personal injury or property damage use extreme care inhandling gasoline. Gasoline is
extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is
spilled on yourself or your clothes which can ignite. Wash your skin and change clothes immediately.
a. Use only an approved gasoline container. b. Never fill containers inside avehicle oron a
truck or trailer bed with a plastic liner. Always
place containers on the ground away from
your vehicle before filling.
c. When practical, remove gas-powered
equipment from the truck or trailer and refuel
iton the ground. If this isnot possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser nozzle.
d. Keep the nozzle in contact with the rim of the
fuel tank or container opening at all times
until fueling is complete. Do not use a nozzle lock-open device.
e. Extinguish all cigarettes, cigars, pipes and
other sources of ignition.
f. Never fuel machine indoors. g. Never remove gas cap or add fuel while the
engine is hot or running. Allow engine to cool at least two minutes before refueling.
h. Never over fill fuel tank. Fill tank to no more
than Y2inch below bottom of filler neck to allow space for fuel expansion.
i. Replace gasoline cap and tighten securely.
j. Ifgasoline is spilled, wipe it off the engine
and equipment. Move unit to another area. Wait 5 minutes before starting the engine.
k. To reduce fire hazards, keep machine free of
grass, leaves, or other debris build-up. Clean
up oil or fuel spillage and remove any fuel
soaked debris.
I. Never store the machine or fuel container
inside where there is an open flame, spark or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.
m. Allow a machine to cool at least five minutes
before storing.
GENERAL SERVICE:
1. Never run an engine indoors or ina poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless, and deadly gas.
2. Before cleaning, repairing, or inspecting, make certain the blade(s) and all moving parts have
stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended
starting.
3. Periodically check to make sure the blades come to complete stop within approximately (5) five seconds after operating the blade disengagement control. If the blades do not stop within the this time frame, your unit should be serviced professionally by an authorized service dealer.
4. Check brake operation frequently as itis subjected to wear during normal operation. Adjust and service as required.
5. Check the blade(s) and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade(s) for damage (e.g., excessive wear, bent, cracked).
Replacetheblade(s)withtheoriginalequipment
manufacturer's(O.E.M.)blade(s)only,listedinthis manual."Useofpartswhichdonotmeetthe
originalequipmentspecificationsmayleadto improperperformanceandcompromisesafety!"
6. Mowerbladesaresharp.Wrapthebladeorwear gloves,anduseextracautionwhenservicingthem.
7. Keepallnuts,bolts,andscrewstighttobesurethe equipmentisinsafeworkingcondition.
8. Nevertamperwiththesafetyinterlocksystemor othersafetydevices.Checktheirproperoperation
regularly.
9. Afterstrikingaforeignobject,stoptheengine, disconnectthesparkplugwire(s)andground
againsttheengine.Thoroughlyinspectthe machineforanydamage.Repairthedamage
beforestartingandoperating.
10.Neverattempttomakeadjustmentsorrepairsto themachinewhiletheengineisrunning.
11.Grasscatchercomponentsandthedischarge coveraresubjecttowearanddamagewhichcould
exposemovingpartsorallowobjectstobethrown. Forsafetyprotection,frequentlycheckcomponents
andreplaceimmediatelywithoriginalequipment manufacturer's(O.E.M.)partsonly,listedinthis
manual."Useofpartswhichdonotmeetthe originalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
12.Donotchangetheenginegovernorsettingsor over-speedtheengine.Thegovernorcontrolsthe
maximumsafeoperatingspeedoftheengine.
13.Maintainorreplacesafetyandinstructionlabels,as necessary.
14.Observeproperdisposallawsandregulationsfor gas,oil,etc.toprotecttheenvironment.
WARNING: YOUR RESPONSIBILITY- Restrict the use of this power machine to persons who
read, understand and follow the warnings and instructions in this manual and on the machine.
TO AVOID SERIOUS
INJURY OR DEATH
GOUPADDDOWNSLOPES,NOTACROSS.
AVOIDSUDDENTURNS.
DONOTOPERATETHEUMT WHEREIT
COULDSLIPORTIP+
IFMACHINESTOPSGOINGUPHILL,STOP BLADE(S)ADDRACKDOWNHILLSLOWLY.
DONOTMOWWHENCHILDREN OROTHERSAREAROUND.
NEVERCARRYCHILDRENEVENWITH BLADESOFF+
LOOKDOWN& BEHINDBEFOREAND WHILEBACKING.
KEEPSAFETYDEVICES(GUARDS, SHIELDS,ADDSWITCHES,ETC.)
INPLACEANOWORKING.
REMOVEOBJECTSTHATCOULD BETHROWN8Y THEBLARE(S).
KNOWLDCATMNARDFUNCTIONOFALL CONTROLS.
BESUREBLARE(S)ANOENGINEARE STOPPED8EFOREPLACINGHANGS
ORFEETREAR8LAHE(S).
BEFORELEAVINGOPERATOR'SPOSITION, DISENGAGEBLAHE(S),PLACETHECONTROL LEVERIN NEUTRAL,ENGAGEPARKING BRAKE,SHUTOFFANDREMOVEKEY.
READ OPERATOR'S
MANUAL
J
I
'4 SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE |
I '.,I
A POWER POLE
A CORNER OF A BUILDING
15°
W
..J
WARN,.G
€.3
W
GO
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 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.
SECTION3: TRACTORSET-UP
IMPORTANT:Your tractor is shipped with motor oil in the engine. However, you MUST check the oil level before
starting the engine and operating. Refer to the separate Briggs & Stratton Operator/Owner Manual (or Tecumseh eng ne s Owner s Manua ) packed w th your tractor. Read nstruct ons carefu y.
NOTE: Reference to right or left hand side of the unit
is observed from the driver's seat, facing forward.
ToolsRequiredForAssembly
(1) 1/2" socket wrench (for steering wheel) (1) 9/16" wrench or socket wrench (for seat)
(2) 7/16" wrenches or socket wrenches (for battery)
AttachingtheBatteryCables
NOTE: The positive battery terminal is marked Pos.
(+). The negative battery terminal is marked Neg. (-).
The positive cable (heavy red wire) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from
corrosion.
Remove the hex bolt and wing nut from the negative cable.
Remove the black plastic cover, if present, from the negative battery terminal and attach the negative cable (heavy black wire) to the negative battery terminal (-) with the bolt and wing nut.
Make certain the hold-down rod is in position over the battery, securing it in place. See Figure 1.
W
Rubber
Boot
z
d-
vii
Hex Bolt
Figure 1
NOTE: If the battery is put into service after the date
shown on top of battery, charge the battery as instructed on page 24 of this manual prior to operating
the tractor.
AttachingTheSteeringWheel
The hardware for attaching the steering wheel has been packed within the steering wheel, beneath steering wheel cap. Carefully pry off the steering wheel cap and remove the hardware.
NOTE: There are two different styles of steering
wheel cap. See Figure 2. Styles vary by model
Remove the steering bellow from itspackaged location on the deck engagement/lift lever (found on the right hand side of tractor). NOTE: Tractor
models 668 & 688 do NOT require a steering bellow and do NOT come equipped with one.
On models so equipped, place the steering bellow over the steering shaft extending through the dash. See Figure 2.
NOTE: If the openings on each end of the steering
bellow are two different sizes, the smaller end goes down, against the dash of the lawn tractor.
With the wheels of the tractor pointing straight
forward, place the steering wheel over the steering shaft.
Place the washer (with the cupped side down) over the steering shaft and secure with the hex bolt. See Figure 2.
Place the steering wheel cap over the center of the steering wheel and push downward until it "clicks" into place.
Steering
Wheel Cap _
j& Washer
"sl;°'ngff \
<
Figure 2
AttachingTheSeat
Seat styles vary by tractor model and there are three different styles available:
Standard Adjustment
Quick Adjustment &
Knob Adjustment Refer to Figure 3, Figure 4 and Figure 5 to identify
which your tractor's seat style and follow applicable
instructionsbelow.
NOTE: For shipping reasons, seats are either
fastened to the tractor seat's pivot bracket with aplastic tie, or mounted backward to the pivot bracket. In either case, free the seat form its shipping position and remove the two hex screws (or knobs, on models so equipped) from the bottom of seat before proceeding with applicable instructions below.
StandardAdjustmentSeat
1. Position the shoulder screws (found on the base of
the seat) inside the slot openings inthe seat pivot bracket. Figure 3.
2. Slide the seat slightly rearward in the seat pivot
bracket, lining up the rear slots in the pivot bracket with the remaining two holes in the seat's base.
3. Select desired position for the seat, and secure with
the two hex screws removed earlier. See Figure 3.
QuickAdjustmentSeat
NOTE: If your seat was shipped mounted backwards
on the seat pivot bracket, pull out the tab found on the seat stop and hold it open while sliding the seat off the seat pivot bracket. See Figure 4.
1. Line up the plastic seat spacers with the slots in
seat pivot bracket.
2. Slide seat in until front seat spacer engages the
seat stop. See Figure 4.
,_ WARNING: Before operating this machine,
make sure the seat is engaged in the seat stop, stand behind the machine and pull back on seat until fully engaged into stop.
KnobAdjustmentSeat
1. Position the shoulder screws (found on the base of
the seat) inside the slot openings inthe seat pivot bracket. Figure 5.
2. Slide the seat slightly rearward in the seat pivot
bracket, lining up the rear slots in the pivot bracket with the remaining two holes in the seat's base.
3. Select desired position for the seat, and secure with
the two knobs removed earlier. See Figure 5.
StandardAdjustment
HexScrew_
Shoulder
oS:r::s
in Slot _
Figure 3
QuickAdjustment
Seat Stop
\
)
Pivot Bracket
Figure 4
KnobAdjustment
Figure 5
GasandOilFill-up
The gasoline tank is located under the hood and has a capacity of either two or three gallons. Do not overfill.
,_ WARNING: Use extreme care when ,_.
handling gasoline. Gasoline is extremely flammable and the vapors are explosive.
Never fuel machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes, and other sources of
ignition.
Service the engine with gasoline and oil as instructed in the separate Briggs & Stratton Operator/Owner Manual
(or Tecumseh engine's Owner's Manual) packed with
your tractor. Read instructions carefully.
IMPORTANT:Your tractor is shipped with motor oil in the engine. However, you MUST check the oil level before operating. Be careful not to overfill.
ShippingBraceRemoval
_, WARNING: Make sure the riding mower's
engine is off, remove the ignition key, and set the parking brake before removing the shipping brace.
Locate the shipping brace and accompanying warning tag found on the right side of the mower, between the discharge chute and the cutting deck. See Figure 6.
Warning'rag
Figure 6
While holding the discharge chute with your left hand, remove the shipping brace with your right
hand by grasping it between your thumb and index finger and rotating it clockwise.
WARNING: The shipping brace, used for
packaging purposes only, must be removed and discarded before operating your riding
mower.
WARNING: The mowing deck is capable of
throwing objects. Failure to operate the riding mower without the discharge cover in the proper operating position could result in serious personal injury and/or property damage.
Identifyingthe MulchPlug(if soequipped)
On tractor models with 38- and 42-inch decks so equipped, a mulch plug can be found within the cutting
deck's discharge opening.
NOTE: Refer to Mulchingon page 15 for more detailed
information.
if you'd prefer to operate the cutting deck without mulching, simply remove the mulch plug by unthreading the plastic wing nut which fastens it to the cutting deck. This will allow the clippings to discharge out of the discharge opening during operation. See Figure 7.
@
Plastic Wing Nut Mulch Plug
Figure 7
TirePressure
WARNING: Maximum tire pressure under
any circumstances is 30 psi. Equal tire pressure should be maintained at all times.
The tires on your unit may be over-inflated for shipping purposes. Reduce the tire pressure before operating
the tractor. Recommended operating tire pressure is approximately 10 p.s.i for the rear tires & 14 p.s.i, for
the front tires. Check sidewall of tire for maximum p.s.i.
10
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