Bolens 140-990A User Manual

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ASSEMBLY OPERATION MAINTENANCE PARTS LIST

IMPORTANT:

Read Safety Rules

and Instructions

.50

MODEL NUMBER 140-990A

16 H.P.

HYDROSTATIC

GARDEN

TRACTOR

NOTE

OPTIONAL 50" DECK MODEL 190-992A AVAILABLE

PRINTED IN U.S.A.

FORM N0.770-0253

INDEX

Safe Operation Practices......................................

3

Optional Tiller Attachment Instructions

...............26

Know YourTractor.................................................

4

Optional Cultivator Instructions ..........................

27

Assembly Instructions...........................................

5

Optional Disc Instructions...................................

28

Operating Instructions...........................................

9

Electrical System..............................................

29

Maintenance ......................................................

13

Transaxle Parts............................................

30&31

Trouble Shooting Chart.................................

20 & 21

Hydrostatic Pump Parts...............................

32&33

Hydrostatic Trouble Shooting Chart...................

22

Tractor Repair Parts...............................

34 thru 46

Optional 12" Plow Instructions............................

23

Parts Information...................................

Back Cover

t

 

LIMITED WARRANTY

 

For one year from the date of original retail purchase, 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 material or workmanship. Transportation charges for any parts submitted for replacement under this warranty must be paid by the purchaser

unless such return is requested by MTD PRODUCTS INC.

This warranty will not apply to any part which has become inoperative due to misuse,

excessive use, accident, neglect, improper maintenance, 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 applicable manufacturer’s warranty on these items.

This warranty will not apply where the 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

Department of MTD.

The return of a complete unit will not be accepted by the factory unless prior written

permission has been extended by MTD.

This warrany gives you specific legal rights. You may also have other rights which vary

from state to state.

 

TO PURCHASERS

OF INTERNAL COMBUSTION ENGINE EQUIPPED

MACHINERY OR DEVICES IN THE STATE OF CALIFORNIA

>

The equipment which you have just purchased does not have a spark arrester. If this equipment is used on any forest covered land, brush covered land, or grass covered unimproved land in the State of California, before using on such land, the California law requires that a spark arrester be provided. In addition, spark arrester is required by law to be in effective working order. The spark arrester must be attached to the exhaust system and comply with Section 4442 of the California Public Resources Code.

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.

This unit 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 per­ sons, 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 ob­ jects, 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 operating position.

8.Disengage power to attachment(s) and stop engine before making any repairs or ad­ justments. Disconnect the spark plug wire and keep the wire away from the plug to pre­ vent accidental starting.

9.Before attempting to unclog the mower or discharge chute, stop the engine and be sure the blade(s) have stopped completely. Discon­ nect the spark plug wire and keep the wire away from the plug to prevent accidental start­ ing.

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, stop­

ping 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 ex­ treme 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 back­ ing.

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 flam­ mable.

A.Use approved gasoline container.

B.Never remove cap or add gasoline to a run­ ning or hot engine or fill fuel tank indoors. Wipe up spilled gasoline.

C.Open doors if engine is run in garage. Ex­ haust fumes are dangerous. Do not run engine indoors.

19.Keep the vehicle and attachments in good operating condition, and keep safety devices

in place. Use guards as instructed in owner’s manual.

20.Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condi­ tion.

21.Never store the equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow engine to cool before storing in any enclosure.

22.To reduce fire hazard, keep engine free of grass, leaves or excessive grease.

23.The vehicle and attachments should be stop­ ped and inspected for damage after striking a foreign object. The damage should be repaired before restarting and operating the equipment.

24.Do not change the engine governor settings or overspeed the engine.

25.When using the vehicle with mower, proceed 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 equipment specifications.

27.Look behind to make sure the area is clear before placing the transmission in reverse and backing up.

KNOW YOUR TRACTOR

Power Take-Off Handle

Start/Park Lever

16 H.P. Cast Iron

Engine

Rear Axle Range

Hydraulic

Lift Valve

/■x

'

Cast Aluminum

Grille

27 X 9.50 Rear Wheels

16 X 6.50

Front Wheels

FIGURE 1.

Hex Lock-Htrt (F)__ V2" W jiich

Belleville

Steerlnr/mie

FIGURE 2.

ASSEMBLY

The Garden Tractor is packed and shipped in one container and is fully assembled except for the steering wheel, seat, battery and mounting the three point hitch.

NOTE

Reference to left or right side of machine is from the operator’s position in the seat facing forward.

-Contents of Hardware Pack

(See figure 1.)

A (1) Battery Hold Down

B (2) Battery Hold Down Rods

C (2) Fiat Washers

D (2) Wing Nuts

E (1) Steering Wheel Cap

F (1) Hex Lock Nut 5/16-18Thread

G (1) Belleville (Curved) Washer

H (1) Hex Bolt 1/2-13x1.00" Long

I (1) Lock Washer 1/2" I.D.

ATTACHING STEERING WHEEL

1. Place the steering wheel over the steerng column extending through the dash. Line up the flats on the steering column with the flats

------in the steering wheel. (See figure 2.)

2.Place the belleville (curved) washer (G) with the cupped side down over the steering col­ umn and secure with hex lock nut (F).

3.Place the steering wheel cap (E) over the center of the steering wheel and seat it with your hand.

ATTACHING THE SEAT

Select one of four seat positions on the tractor -seat spring. Secure seat to seat spring with hex bolt (H) and lock washer (I). (See figure 3.)

BATTERY INFORMATION

^WARNIN^

A.Battery acid must be handled with great care as it will blister the skin and damage clothing. It is advisabie to wear goggies, rubber gloves, and a protective apron when working with it.

B.Neutraiize acid spiiled on clothing with dilute ammonia water or a water soiution 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 con­ tinues.

D.Since battery acid is corrosive to metals, do not pour into any sink or drain. Rinse empty electroiyte containers and mutilate before discarding.

^DANGER \

BATTERIES CONTAIN SULFURIC ACID AND MAY CONTAIN EXPLO­ SIVE 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.

ACTIVATING THE BATTERY

NOTE

If your battery is activated (elec­ trolyte in the battery) and installed in the tractor, go directly to step 9.

1.Place the battery to be filled on a workbench. Never activate a battery in the unit.

2.Remove the fill caps from all cells.

3.Fill each cell carefully using 1.265 specific gravity electrolyte. Fill each cell to the top of the separators. Do not overfill.

4.Let the battery sit for 20 minutes for the chemical reaction to take place.

5.Charge the battery at a MAXIMUM RATE OF 5 AMPS until the specific gravity reads 1.265. Use a hydrometer to check the specific gravi­ ty.

A CAUTION

An excessive rate of charge will damage the battery.

6.Check the level of electrolyte. Adjust level to bottom of split ring if necessary with elec­ trolyte.

7.Replace fill caps.

8.Once the battery has been activated never add anything except distilled water or a good grade of drinking water.

9.If your battery has been installed in your unit at the factory:

A.Use a hydrometer to check the specific gravity. The specific gravity should be 1.265 at 80° F.

B.If it is less, remove the fill caps and use a battery charger to bring the specific gravi­ ty up to 1.265. NEVER CHARGE AT MORE THAN 5 AMPS.

C.Replace the fill caps.

D.The positive cable has been attached to the positive terminal of the battery at the factory. You only have to attach the negative cable (grounded) to the negative (Neg, N or -) terminal of the battery with a hex head bolt, lock washer and nut.

INSTALLING THE BATTERY

NOTE

The positive battery terminal is marked Pos. (-t-). The negative bat­ tery terminal is marked Neg. (-).

1. Place the battery in the battery case with the Negative (-) terminal to the front.

^I^NOTE

Do not push the battery back all the way.

FIGURE 4.

Pull Rod

11

Clevis End

321/2

2.Attach the positive battery cable (which has two wires) to the positive battery terminai.

(See figure 4.)

3.Attach the negative battery cable (grounded, single wire) to the negative battery terminal.

4.Assemble the hold down rods (B) and hold down (A) before you place It over the battery (see figure 5) using wing nuts (D) and flat washers (C).

5.Place the battery hold down assembly over the battery and slide the battery into place. (See figure 4.)

\ WARNING {

Place the hold down on the side op­ posite the terminals.

6.Hook the hold down rods into the battery case and tighten fingertight. (Do not overtighten.)

ASSEMBLING THE THREE POINT HITCH

NOTE

Use the three point hitch only for the rear attachments such as the moldboard plow, disc and cultivator.

If you are using the mowing deck, snow blade or snow thrower it is not necessary to attach the three point hitch.

 

1. Adjust the clevis ends on both pull rods so

FIGURES.

that they measure 32Va inches. (See figures.)

2. Assemble each draft bar to the axle brackets using the longest clevis pins, two large washers, and secure with a cotter hairpin.

—(See figures 7 and 8.)

NOTE

Refer to figure 9 to determine which is the right and left draft bars.

3. Attach the flat end of the pull rod to the top hole in the draft bar with the shorter clevis pin, flat washer cotter hairpin. (See figure 7.)

4. Assemble the draw bar to the draft bars and FIGURE?. secure each end with a cotter hairpin. (See

figure 9.)

5. Screw one hex nut all the way on to each of hook bolts.

FIGURES.

6. Place a lock washer next to the hex nut and in­

 

sert the hook bolt through the inside of the

 

draft bar. Secure using a second nut. Do not

 

tighten. (See figure 9.)

 

7. Fasten the chains to the hooks welded on the

 

draft bars. Cross the chains over and attach to

 

the opposite hook bolts.

 

NOTE

 

Pull the chains to make them as

■■■*:•> 7:-^: VN

tight as possible.

h - ................- d

8. Tighten the outside nuts on the hook bolts un­

 

til there is approximately one inch of play in

 

the center of the chains.

FIGURES.

9. Tighten the inside nuts on the hook bolts.

TIRE PRESSURE

Reduce the rear wheel tire pressure to 15 p.s.i. for operation. The tires have been over-inflated for shipping. Equal tire pressure should be main­ tained on all tires. Maximum tire pressure is 30 p.s.i.

HYDROSTATIC TRANSMISSION

See the maintenance section of this manual for correct lubrication and level for the oil in the hydrostatic transmission.

OPERATION

CAUTION

1.KEEP ALL SHIELDS & GUARDS IN PLACE

2.BEFORE LEAVING OPERATOR’S POSITION: SHIFT CONTROLS INTO NEUTRAL SET PARKING BRAKE

DISENGAGE ATTACHMENT DRIVE SHUT ENGINE OFF

REMOVE IGNITION KEY

3.WAIT FOR ALL MOVEMENT TO STOP BEFORE SERVICING MACHINE

4.KEEP PEOPLE & PETS A SAFE DISTANCE AWAY FROM MACHINE

Your garden tractor is equipped with a chute deflector and internal baffle on the (optional) cut­ ting deck. The tractor must not be operated without these pieces in their proper place.

CAUTION

DO NOT OPERATE

M O W E R U N L E S S

GUARD IS IN ITS

PROPER PLACE.

10.Assemble and adjust the two halves of the center adjustment arm until it is 12 inches long. (See figure 10.)

11.Assemble the flat end of the center adjust­ ment arm to the upper hole in the center hitch bracket with a clevis pin, two flat washers and a cotter hairpin. (See figure 9.)

Before starting the engine fill the crankcase with oil. Refer to the Engine Operation and Maintenance manual.

Throttle Control

The throttle control is located on the right side of the dashboard and is used to regulate the engine speed. (See figure 11.) The engine should be operated from 3/4 to full throttle “FAST” when operating any equipment that uses the tractor engine as a source of power such as the cutting deck, snow thrower or rotary tiller.

Choke Control (See figure 11.)

Pull the choke knob all the way out. Set throttle in the “FAST” position. A warm engine requires less choking.

Ignition Switch (See figure 11.)

The ignition switch is located on the left side of the dashboard. Turn the key to the “START” posi­ tion to start the engine. When the engine is run­ ning leave the key in the “ON” position. To stop the engine turn the key to the “OFF” position.

I WARNING I

Remove the key from the tractor when the tractor is not in use to pre­ vent accidental starting.

Light Switch (See figure 11.)

The head lamps are operated by a toggle light switch located on the dashboard. The head lamps will only operate when the engine is running. Flip the toggle switch up to turn on lights and down for off.

Ammeter (See figure 11.)

The ammeter registers the rate of battery charge or discharge. The ammeter should register on the plus ( + ) side when the engine is running in the “FAST” position until the battery is completely charged.

With a fully charged battery or with the engine id­ ling, the ammeter may not show a charge.

FIGURE 11.

Power Take Off Operation (PTO)

There are two PTO’s on your tractor. The front PTO is a pulley located behind the grille and is used to operate the snow thrower. This PTO is directly connected to the engine and operates whenever the engine is running.

The rear PTO is located under the tractor and is used to operate the grass cutting deck and rotary tiller. (See figure 12.)

H-:;- '

Power Take Off

(PTO)

■t.

FIGURE 12.

-f-

\t ■'

f : -

”i<■.‘•^-'■V'-íí“'-'!

‘4

' i

FIGUREIS.

The rear PTO is operated by the PTO lever. (See figure 13.)

■^NOTE

The PTO lever must be in the DISENGAGED position to start the engine.

High/Low Axle Range

Your tractor is equipped with a two speed rear ax­ le for greater versatility. (See figure 14.) The LOW range is used when operating the rotary tiller, moldboard plow and should also be used when ex­ tra power is required.

HIGH range operation is for normal loads, grass cutting and normal use.

LOW Range (0-4 mph)

HIGH Range (0-8 mph)

The Axle Range Lever must be in either the HIGH or LOW range position. The tractor will not move if it is in the center position.

NOTE

When pushing the tractor by hand with the engine shut off, place the Axle Range Lever between the HIGH and LOW position. The hydro­ static pump will not rotate and the tractor will be easier to push.

10

FIGURE 14.

Hydraulic Lift Lever

The hydraulic lift lever is used to raise or lower all of the tractor attachments. Move the lever forward to raise the attachment and move the lever backwards to lower the attachment. (See figure 14.)

Brake Pedal

The brake pedal is located on the right side of the tractor. Depressing the brake pedal operates the brake. It is used for emergency stopping only. When you depress the brake pedal the control lever will return close to the neutral position. The control lever is used for normal stopping. (See figure 15.)

Parking Brake

To set the parking brake, depress the brake pedal, pull up the parking brake knob and release the brake pedal. It will stay in the raised position. To release the parking brake, depress and release the brake pedal. (See figures 14 and 15.)

Control Lever (Hydrostatic)

The control lever is used to regulate the ground speed of the tractor. Moving the control lever to its extreme position makes the tractor travel faster. Moving the control lever forward (F) moves the tractor forward, moving the control lever backwards (R) reverses the tractor. The control lever is used to regulate the ground speed of the tractor. (See figure 15.)

FIGURE 15.

To increase rear wheel torque (pulling power) move the control lever towards the neutral posi­ tion. The tractor responds similar to shifting to a lower gear with a gear type transmission.

The control lever is used for normal slowing down and stopping by moving the control lever towards neutral (N). It is especially useful when rotary till­ ing hard or rough ground. Additional braking may be obtained by moving the control lever gradually in the opposite direction of your travel.

Deck Adjuster

The deck adjuster is located on the left side of the tractor and is used in conjunction with the mow­ ing deck wheels to set the cutting height of the mowing deck. To operate the deck adjuster, depress the thumb button and move the deck ad­ juster forward to lower the cutting height and move it towards the rear to raise the cutting height.

The deck adjuster and the wheels on the mowing deck must be adjusted so the deck is parallel to the ground. (See figure 16.)

The deck is designed to raise and float over ground irregularities to prevent scaiping.

11

FIGURE 16.

Carriage Locks

The carriage locks hold the quick disconnect frame in the raised position when the rear at­ tachments are used.

Remove the carriage locks, raise the quick discon­ nect frame by hand and reassemble the carriage locks to the inside so they hold the quick disonnect frame up. (See figure 17.)

Carriage

Lock

FIGURE 17.

Seat Adjustment

The seat is adjustable to four positions. Remove the bolt holding the seat to the spring to change positions. (See figure 18.)

Rear Wheel Width

The rear wheels can be reversed to increase or decrease the width. To reverse the wheels, raise the back of the tractor and block it well. Remove the four lug bolts holding the rim to the rear axle hub. Reverse the wheel and reassemble. (See figure 19.)

FIGURE 19.

Operating the Tractor

1. Start the engine as outlined in the Engine Operating and Maintenance manual.

12

2.The engine should be run with the throttle control in the “FAST” position to obtain the maximum efficiency. The sound you may hear when you accelerate is the normal operating sound of the hydrostatic transmission. The faster you push the control lever forward or backward, the louder the sound.

3.Release the brake and move the control lever into either the forward (F) or reverse (R) posi­ tion.

4.The brake pedal is used for emergency stop­ ping only. Normal stopping is done by using

the control lever. When the brake pedal is depressed the control lever will return close to the neutral position so the tractor brake will stop the tractor, however, the tractor may creep either forward or backward when the brake pedal is released.

Maintenance and adjustments for the engine are covered in the Engine Operating and Maintenance Instructions manual.

MAINTENANCE

Lubrication

Item numbers 1 through 4 must be lubricated once a year with multi-purpose automotive grease.

1.Steering Gear—(See figure 20.)

2.King Pin—(See figure 21.)

3.Pivot Bolt—(See figure 21.)

4.Deck Linkage—Oil with SAE 30 oil on all pivot points once a season. (See figure 22.)

FIGURE 20.

FIGURE 21.

FIGURE 22.

5. Hydrostatic Transmission

(See figure 23.) The dipstick for the hydrostatic transmission is located behind the seat. This dipstick checks the oil level in the hydrostatic transmission, transaxle and hydraulic lift system.

The oil level should be maintained to the FULL mark on the dipstick. Check the oil level every 8 hours of operation.

Use 20 weight oil with a zinc additive package of .07% minimum. The following list of oils meet these specifications:

13

Rykon Industrial Oil #31

Amoco 300, 20 wt.

Rotella, 20 wt.

Rimula Series 3, 20 wt.

X100 Motor Oil, 20 wt.

Havoline Motor Oil, 20 wt.

Ursa, Extra Heavy, 20 wt.

NOTE

If the above oils cannot be obtained, SAE 20 motor oil with a SE rating may be substituted.

FIGURE 23.

The capacity of the unit is 5 quarts. However, because the oil will not completely drain from the lift system and hydrostatic transmission, you will only drain approximately 3 quarts. To drain, remove the plug from the bottom of the transaxle. (See figure 24.)

FIGURE 24.

6. Oil Filter

(See figure 25.) A full flow replaceable oil filter, located under the left side of the frame, should be replaced initially after twenty hours of operation and thereafter every 100 hours for commercial or industrial applications and yearly for normal usage. It can be removed by turning it counterclockwise by hand. Use Fram filter PH-16 or equivalent.

FIGURE 25.

7.Hydrostatic Control—Lubricate between the control slide and the control adjustment plate. (See figure 35.)

Disc Brake Adjustment

Disc Brake

k'-

■ A

 

 

Disc

FIGURE 26.

14

The disc brake is iocated on the ieft side of the transaxle. To adjust, tighten the lock nut. (See figure 26.) (Wheel is removed for clarity.) The lock nut should be tightened just enough to stop the tractor when the brake pedal is depressed, allow­ ing the disc to turn freely between the brake pads when the pedal is relased.

PTO Belt Removal

1.Place the PTO Lever in the disengaged posi­ tion.

2.Remove the lower belt guard. (See figure 27.)

FIGURE 27.

3.Loosen the set screw in the universal joint. (See figure 28.)

4.Drive out the roll pin in the universal joint. (See figure 28.)

5.Slide the universal joint towards the rear of the tractor.

FIGURE 28.

6.Remove the PTO belts. (See figure 29.)

7.Reassemble in reverse order using matched belts.

NOTE

PTO belts must be replaced using matched sets.

FIGURE 29.

15

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