Craftsman 107.277700 User Manual

Operator’s Manual

ZT 7000

ZerO“Turn Rear Engine Rider

18 HP, 50” Mower

Electric Start

Mode! No.

107.277700

CAUTION: Before using this product, read

the manual and follow all its Safety Rules and Operating Instructions.

For answers to your questions about this product, call:

1-800-659-5917

Sears Craftsman Help Line 5 am - 5 pm, Mon - Sat

Nota: Una traducción en español de este Manual del Operador puede encontrarse en la página 33.

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

Visit our Craftsman website: www. sears, co m/c rafts man

TP 199-3928-07-CZ-C

1726431-07

TABLE OF CONTENTS

Nota: Una traducción en español de este Manual del Operador puede encontrarse en la página 33.

Warranty Statement

Safety Rules & information.......................................3

Identification Numbers..............................................7

Optional Accessories

Literature Package Contents....................................8

Pre-Operation.............................................................9

Operation..

.........................................................

..............................................

...........................................

Maintenance

Service & Adjustments............................................26

Storage......................................................................30

Troubleshooting. Spanish Operator’s Manual

Repair Parts.......................................................PTS-1

Repair Protection Agreement........Inside Back Cover

....................................................

............................................... ..31

....................................

..17

NOTE: In this manual, “left"and “right"are referred to as seen from the operating position.

WARRANTY

LIMITED WARRANTY ON CRAFTSMAN RIDING EQUIPMENT For two (2) years from the date of purchase, if this Craftsman riding equipment is maintained, lubricated and tuned up

according to the instructions in the owner's manual. Sears will repair or replace free of charge any parts that are found to be defective in material or workmanship according to the guidelines of coverage listed below. Sears will also provide free labor for these applicable warrantied parts for the two full years. During the first 30 days of purchase, there will be no charges to service the product at your home for issues covered by this warranty. (See exclusions below). For your convenience, IN HOME warranty service will still be available after the first 30 days of purchase, but a trip charge will apply. This charge will be waived if the Craftsman product is dropped off at an authorized Sears loca tion. For the nearest authorized Sears location, please call 1-800-MY-HOME. This warranty applies only while this product is within the United States.

THIS WARRANTY DOES NOT COVER:

• Expendable items which become worn during normal use, including but not limited to blades, spark plugs, air cleaners, belts, and oil filters.

• Standard maintenance servicing, oil changes, or tune-ups.

• Tire replacement or repair caused by punctures from outside objects, such as nails, thorns, stumps, or glass.

• Repairs necessary because of operator abuse, including but not limited to, damage caused by towing objects beyond the capability of the riding equipment, impacting objects that bend the frame or crankshaft, or over-speeding the engine.

Repairs necessary because of operator negligence,

including but not limited to, electrical and mechanical damage caused by improper storage, failure to use the proper grade and amount of engine oil, failure to keep the deck clear of flammable debris, or failure to maintain the equipment according to the instructions contained in the owner's manual.

Engine (fuel system) cleaning or repairs caused by fuel determined to be contaminated or oxidized (stale). In general, fuel should be used within 30 days of its purchase date.

Normal deterioration and wear of the exterior of the exterior finishes, or product label replacement.

Riding equipment used for commercial or rental pur poses.

LIMITED WARRANTY ON BATTERY For ninety (90) days from date of purchase, if any battery included with this riding equipment proves defective in

material or workmanship and our testing determines the battery will not hold a charge. Sears will replace the battery at no charge. During the first 30 days of purchase, there will be no charges to replace the battery at your HOME. After first 30 days, for your convenience, IN-HOME warranty service will still be available but a trip charge will apply. This charge will be waived if the Craftsman product is dropped off at an authorized Sears location. FOR THE NEAREST AUTHORIZED LOCATION, PLEASE CALL 1-800-4-MY-HOME. This battery warranty applies only while this product is within the United States.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Sears, Roebuck and Co., Dept. 81 TWA, Hoffman Estates, IL 60179

SAFETY RULES

Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control

of unit, severe personal injury or death to you, or bystanders, or damage to property or equipment.

This mowing deck is capable of amputating hands and feet and throwing objects.

The triangle A in text signifies important cautions or warnings which must be followed.

GENERAL OPERATION

1. Read, understand, and follow all instructions in the manual and on the unit before starting.

2. Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

3. Only allow responsible adults, who are familiar with the instructions, to operate the unit (local regulations can restrict operator age).

4. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade(s).

5. Be sure the area is clear of other people before mow ing. Stop the unit if anyone enters the area.

6. Never carry passengers.

7. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while travel ling in reverse.

8. Never direct discharge material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blade(s) when crossing gravel surfaces.

9. Do not operate the machine without the entire grass catcher, discharge guard (deflector), or other safety devices in place.

10. Slow down before turning.

11. Never leave a running unit unattended. Always disen gage the PTO, set parking brake, stop engine, and remove keys before dismounting.

12. Disengage blades (PTO) when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unciogging the discharge guard.

13. Operate the machine only in daylight or good artificial light.

14. Do not operate the unit while under the influence of alcohol or drugs.

15 Watch for traffic when operating near or crossing

roadways.

16. Use extra care when loading or unloading the unit into a trailer or truck.

17. Always wear eye protection when operating this unit.

18. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should eval uate their ability to operate the riding mower safely enough to protect themselves and others from injury.

19. Follow the manufacturer’s recommendations for wheel weights or counterweights.

20. Keep in mind the operator is responsible for accidents occurring to other people or property.

21. All drivers should seek and obtain professional and practical instruction.

22. Always wear substantial footwear and trousers.

Never operate when barefoot or wearing sandals.

23. Before using, always visually check that the blades and blade hardware are present, intact, and secure. Replace worn or damaged parts.

■ ‘ ' fore: refuelinc '24. Disengage attachments bef removing an attachment, making adjustments (unless the adjustment can be made from the operator’s posi tion).

25. When the machine is parked, stored, or left unattend ed, lower the cutting means unless a positive mechanical lock is used.

26. Before leaving the operator’s position for any reason, engage the parking brake, disengage the PTO, stop the engine, and remove the key.

27. To reduce fire hazard, keep the unit free of grass, leaves, & excess oil. Do not stop or park over dry leaves, grass, or combustible materials.

28. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on or near any forest-covered, brush-cove red, or grass-covered land unless the exhaust system is equipped with a spark arrester meeting any applicable local or state laws. Other states or federal areas may have similar laws.

TRANSPORTING AND STORAGE

1. When transporting the unit on an open trailer, make sure it is facing forward, in the direction of travel. If the unit is facing backwards, wind lift could damage the unit.

2. Always observe safe refueling and fuel handling prac tices when refueling the tractor after transportation or storage.

3. Never store the unit (with fuel) in an enclosed poorly ventilated structure. Fuel vapors can travel to an igni tion source (such as a furnace, water heater, etc.) and cause an explosion. Fuel vapor is also toxic to humans and animals.

TP 600-2459-06-UV-SMA

Always follow the operator’s manual instructions for storage preparations before storing the tractor for both short and long term periods. Always follow the engine manual instructions for proper start-up procedures when returning the unit to service. Never store the unit or fuel container inside where there is an open flame or pilot light, such as in a water heater. Allow unit to cool before storing.

SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tip over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, do not operate on it.

Control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are: insufficient tire grip on the ground, speed too fast, inadequate braking, the type of machine is unsuitable for its task, lack of awareness of the ground con ditions, incorrect hitching and load distribution.

1. Mow up and down slopes, not across.

2. Watch for holes, ruts, or bumps. Uneven terrain could overturn the unit. Tall grass can hide obstacles.

3. Choose a slow speed so that you will not have to stop or change speeds while on the slope.

4. Do not mow on wet grass. Tires may lose traction.

5. Always keep unit in gear especially when traveling down slopes. Do not shift to neutral and coast down hill.

6. Avoid starting, stopping, or turning on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.

7. Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause the machine to rollover.

8. Use extra care while operating machines with grass catchers or other attachment; they can affect the sta bility of the unit.

9. Do not try to stabilize the machine by putting your foot on the ground.

10. Do not mow near drop-offs, ditches, or embank ments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

11. Do not use grass catchers on steep slopes.

12. Do not mow slopes you cannot back up.

13. See your authorized retailer for recommendations of wheel weights or counterweights to improve stability.

14. Remove obstacles such as rocks, tree limbs, etc.

15. Use slow speed. Tires may lose traction on slopes even through the brakes are functioning properly.

16. Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.

TOWED EQUIPMENT

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 manufacturer’s recommendations for weight limit for towed equipment and towing on slopes.

3. Never allow children or others in or on towed equip ment.

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 down hill.

A WARNING

Never operate on slopes greater than 17.6 percent (10°) which is a rise of 3-1/2 feet (106 cm) vertically in

20 feet {607 cm) horizontally. When operating on slopes use additional wheel

weights or counterweights. See your retailer to determine which weights are available and appropriate for your unit.

Select slow ground speed before driving onto slope.

In addition to front and rear weights, use extra caution when operating on slopes with rear-mounted grass catcher.

Mow UP and DOWN the slope, never across the face, use caution when changing directions and DO NOT START OR STOP ON SLOPE.

CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them.

1. Keep children out of the mowing area and under the watchful care of another responsible adult.

2. Be alert and turn unit off if children enter the area.

3. Before and during reverse operation, look behind and down for small children.

4. Never carry children, even with the blade(s) off. They may fall off and be seriously injured or interfere with safe unit operation. Children who have been given

rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

5. Never allow children to operate the unit.

6. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

EMISSIONS

Engine exhaust from this product contains chemicals

known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

Look for the relevant Emissions Durability Period and

Air Index information on the engine emissions label.

IGNITION SYSTEM

1. This spark ignition system complies with Canadian

ICES-002.

SERVICE AND MAINTENANCE

Safe Handling of Gasoline

1. Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

2. Use only approved gasoline containers.

3. Never remove the gas cap or add fuel with the engine running. Allow the engine to cool before refueling.

4. Never fuel the machine indoors.

5. Never store the machine or fuel container where there is an open flame, spark, or pilot light such as near a water heater or other appliance.

6. Never fill containers inside a vehicle or on a truck bed with a plastic bed liner. Always place containers on the ground away from your vehicle before filling.

7. Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possi ble, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dis penser nozzle.

8. Keep nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is com plete. Do not use a nozzle lock-open device.

9. If fuel is spilled on clothing, change clothing immedi ately.

10. Never over fill the fuel tank. Replace gas cap and tighten securely.

11. Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.

12. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

13. Replace all fuel tank caps and fuel container caps securely.

Service & Maintenance

1. Maintain or replace safety and instruction labels as necessary.

2. Never run the unit in an enclosed area where carbon monoxide fumes may collect.

3. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition.

4. Never tamper with safety devices. Check their proper operation regularly and make necessary repairs if they are not functioning properly.

5. Keep unit free of grass, leaves, or other debris build up. Clean up oil or fuel spillage.

6. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

7. Never make adjustments or repairs with the engine running unless specified otherwise in the owner’s manual.

8. Do not remove the fuel filter when the engine is hot as spilled gasoline may ignite. Do not spread fuel line clamps further than necessary. Ensure clamps grip hoses firmly over the filter after installation.

9. Do not use gasoline containing METHANOL, gasohol containing more than 10% ETHANOL, gasoline addi tives, or white gas because engine/fuel system dam age could result.

10. If the fuel tank must be drained, it should be drained outdoors.

11. Replace faulty silencers/mufflers.

12. Grass catcher components are subject to wear, dam age, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recom mended parts, when necessary.

13. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.

14. Check brake operation frequently. Adjust and service as required.

15. Use only factory authorized replacement parts when making repairs.

16. Always comply with factory specifications on all set tings and adjustments.

17. Only authorized service locations should be utilized for major service and repair requirements.

18. Never attempt to make major repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturer’s warranty.

19. On multiple blade mowers, take care as rotating one blade can cause other blades to rotate.

20. Do not change engine governor settings or over speed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

21. Disengage drive attachments, stop the engine, remove the key, and disconnect the spark plug wire(s) before: clearing attachment blockages and chutes, performing service work, striking an object, or if the unit vibrates abnormally. After striking an object, inspect the machine for damage and make repairs before restarting and operating the equipment.

22. Never place hands near the moving parts, such as a hydro pump cooling fan, when the tractor is running. (Hydro pump cooling fans are typically located on top of the transaxle).

23. Units with hydraulic pumps, hoses, or motors: WARN ING: Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause seri ous injury. If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Keep body and hands away from from pin holes or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, and not hands, to search for leaks. Make sure all hydraulic fluid con nections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. If leaks occur, have the unit serviced imme diately by an authorized service center.

24. WARNING: Stored energy device. Improper release of springs can result in serious personal injury. Springs should only be removed by an authorized service center.

25. Models equipped with an engine radiator: WARNING: Stored energy device. To prevent serious bodily injury from hot coolant or steam blow-out, never attempt to remove the radiator cap while the engine is running. Stop the engine and wait until it is cool. Even then, use extreme care when removing the cap.

SAFETY & OPERATION DECALS

This unit has been designed and manufactured to pro vide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing.

Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effec tively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit.

Decal - Ignition Switch Part No. 1726526

Decal - Operation, Upper Part No. 1726429

All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important! The safety decals below are on your rider and mower.

If any of these decals are lost or damaged, replace them at once. Contact a Sears Parts & Service Center for replacements.

These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation.

DO NOT OPEN RESERVOIRS!

LattWhael . .

Decal - Sealed Hydraulic System Part No. 1726525

'('pg'SHPwItmft Shewn) . -

' Controls Located -

' ' Beneath Hitch' '

Decal -Transmission Release Valve Part No. 1726834

ROTATING BLADES CUT OFF ARMS AND LEGS

STOfN«« CHIIOSEK ÄßE HEAß

ik DANGER 1

QPERATIRGOM SLOPES GAR BE OAMGEROUS. tEtePERArOfi'SMAALIAL

AHILL 60 HOtDmVE ANA EkONATOFERATE SNSlOßES

Decal - Danger/Warning, Lower Part No. 1726430

Decal - Cutting Height Adjustment Part No. 1721197

Decal - Parking Brake Part No. 1726529

Decal - Danger, Rotating Blades Part No. 1704277

Decal - Ground Speed Control - LH/RH Part No. 1725671 / 1725670

ROTATING CUTTING BLADE\

Oo not put hands

under mower

blade is

Decal - Danger, Rotating Blades Part No. 1704276

detk while

rotating.

or teet

IDENTIFICATION NUMBERS

For Paris & Service

CRR$^rinN

Model No.:

' vv vv vv

I234I

Sears, Roebuck and Co. 3333 Beverly Road Hoffman Esiate.s, IL 60179

When contacting the service center for replacement parts, service, or information you MUST have these numbers.

Record your model name/number, manufacturer’s identi

fication numbers, and engine serial numbers in the space provided for easy access.

The identification tag is located on the underside of the seat deck. Tilt the seat deck forward to access the ID

tag.

For answers to your questions about this product, call: 1-800-659-5917

Sears Craftsman Help Line, 5 am - 5 pm,

Monday-Saturday.

Call 1-SOO-4MY-HOME www.sears.com

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PRODUCT REFERENCE DATA

Model Description Name/Number

Stock Number Unit Serial Number

Date Purchased

................................................................................................................\

Engine Make

Engine Type/Spec Engine Code/Serial Number

El igiric'; Mcv:|;;í|

’Twin Bag Grass Catcher

’ Headlight Kit ’ Bumper Kit ’ Wheel Weights

LITERATURE PACKAGE CONTENTS

OPTIONAL ACCESSORIES

Setup Instructions ■ English

Keys

Setup Instructions ■ Spanish

Operator’s Manual & Parts Book - English/Spanish

PRE-OPERATION

Read The Operator’s Mariual

• Read the operator’s manual. You should always read and follow

the instructions in the Operator’s manual. Proper care, performance tips, and safety information is located in this important document.

Always Check the Oil

Level

• Check the engine oil level. The engine in your tractor has been

shipped, from the factory, already filled with 10W-30 weight oil for use during the engine break-in period. Always check the oil level before starting the engine.

Fill-Up with FRESH

Gasoline

• Fill the tank with fresh fuel.

The single most common service

issue is stale or contaminated fuel!

Fuel should not be more than 30 days old. Use fuel stabilizer to extend the life of your fuel, and always store fuel in an approved, sealed, plastic gas can. Stale fuel clean-out is not covered under your war

ranty.

Charge The Battery

• Lift the seat deck to access the battery. If the unit is put into service after the month and year indicated on the battery date tag (located on

top of battery) charge the battery for one hour at 6-10 amps. Refer to the SERVICE & ADJUSTMENTS section of the operator’s manual for battery charging information.

Check Tire Pressure

Push Unit Off Crate

To push the unit off the crate:

• Set both transmission release levers to PUSH position by pulling the levers back (levers are located under the trail er hitch).

• Cut the steel banding securing rider to pallet (6 bands).

• Set the parking brake to DRIVE position.

• Set the mower cutting height to its highest setting.

• Fold the cardboard used to crate the unit in half, and place it under the front wheels of the unit.

• Push the unit forward off the crate.

• Set the transmission release valve levers back to DRIVE positions (levers pushed in).

Start The Engine

To start the engine:

•While sitting in the operator’s seat, set the parking brake to PARK. Make sure the yellow PTO switch is OFF and the ground speed control levers are locked in PARK positions.

• Move the engine throttle control fully forward to CHOKE.

NOTE: A warm engine may not require choking. In this case, set the throttle control to FAST.

• Insert the key into the ignition switch and turn it to START.

• After the engine starts, gradually move the throttle con trol back to FAST position (choke open). Warm the engine by running it for at least a minute before turning on the PTO switch, or driving the unit.

• After warming the engine, ALWAYS operate the unit

with the throttle set to FAST position when mowing.

• See the OPERATION section driving information.

• Reduce the tire pressures to the pressures shown below. Tires are over-inflated for shipping purposes, and must be set to the correct pres

sures for optimum traction. Rear Tire Pressure: 10-12 PS! Front Tire Pressure: 18-20 PSI

OPERATION

The information below briefly describes the function of individual controls. Starting, stopping, driving, and mowing require the combined use of several controls applied in specific sequences. To learn what combination and sequence of controls to use for various tasks please read the entire section.

Ground Speed Levers

These levers control the ground speed of the rider. The left lever controls the left rear drive wheel and the right lever controls the right rear drive wheel.

Pushing the levers out, away from the operator’s lap locks them in PARK positions (inset, Figure 1). Pulling the levers in across the operator’s lap puts them in DRIVE positions.

From DRIVE position, moving a lever forward increases the FORWARD speed of the associated wheel. Pulling back on a lever increases the REVERSE speed. The fur ther a lever is pushed, the faster the drive wheel will turn.

See the DRIVING PRACTICE for steering instructions.

The throttle controls engine speed. Always operate at FULL throttle when mowing. Move the lever forward to the detent for FULL throttle (FAST). Move the throttle back to decrease engine speed to IDLE (SLOW).

Close the choke for cold starting. Open the choke once the engine starts. A warm engine may not require chok ing. Move the lever forward past the FULL throttle detent to close the choke. Move the lever back to the detent to open the choke.

Throttle Control

Choke

Mower Height of Cut Adjustment

To adjust cutting height, rotate the turn crank clockwise to raise the mower deck and counterclockwise to lower the mower deck.

Ignition Switch

The ignition switch starts and stops the engine; it has three positions:

OFF Stops the engine and shuts off the

electrical system.

RUN Allows the engine to run and powers the

electrical system.

START Cranks the engine for starting.

NOTE: Never leave the ignition switch in the RUN posi tion with the engine stopped. This drains the battery.

Hour Meter

The hour meter measures the number of hours the key has been in the RUN position. The hour meter will flash an oil change indicator at 5 hours, and a lubrication

reminder every 50 hours. These reminders will automati

cally reset themselves.

NOTE: The hour meter wiii register the passage of time when the key is in the RUN position, even if the engine is not running.

PTO Switch

The PTO (Power Take-Off) switch engages and disen gages an electric clutch attached to the engine crank shaft. This electric clutch drives and stops the mower deck. To turn the mower on, pull the switch UP. Push the switch DOWN to turn the mower off. Note that the opera tor must be seated firmly in the rider seat for the PTO to function.

Transmission Release Levers

The transmission release levers deactivate the transmis sions so that the unit can be pushed by hand. See

PUSHING THE UNIT BY HAND for operational informa

tion.

I Seat Adjustment Knob

The seat can be adjusted forward and backward. Tip the seat forward, loosen the adjustment knob, slide the seat to the desired position, and tighten the knob.

Fuel Tank

To remove the cap, turn counterclockwise.

Parking Brake

DRIVE Releases the parking brake. PARK Locks the parking brake.

GENERAL OPERATING SAFETY

Before first time operation:

• Be sure to read all information in the Safety and Operation sections before attempting to operate this rider and mower.

• Become familiar with all of the controls and how to stop the unit.

• Drive in an open area without mowing to become accus tomed to driving the unit.

Pull the parking brake lever up to engage the parking brake (PARK position). Move the lever fully down to dis engage the parking brake (DRIVE position).

NOTE: To start the unit the parking brake must be in

PARK position.

Awarning

If you do not understand how a specific control

functions, or have not yet thoroughly read the CONTROL FUNCTIONS section, do so now.

Do NOT attempt to operate the rider without first

becoming familiar with the location and function of ALL controls.

CHECKS BEFORE STARTING

• Check that the crankcase oil is filled to full mark on dipstick.

• Adjust the seat position and make certain you can reach all controls.

• Fill the fuel tank with fresh fuel.

FUEL RECOMMENDATIONS

For daily operation: Use only unleaded gasoline with a pump sticker octane rating of 87 or higher. Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel. Methyl Teriary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel. No other gasoline/alcohol or gasoline/ether blends are approved. Do not use fuel additives other than fuel stabilizer.

For storage: CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract mois ture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage.

To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start the engine, and let it run until the fuel lines and carburetor are empty (see STORAGE for fuel draining procedure). Use fresh fuel next season. See STORAGE instructions for additional information.

Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. To add fuel:

1. Remove the fuel cap (B, Figure 2).

2. Fill the tank. Do not overfill. Leave room in the tank for fuel expansion.

3. Install and hand tighten the fuel cap.

Awarning

Never allow passengers to ride on the unit. Before leaving the operator’s position for any

reason, engage the parking brake, disengage the PTO, stop the engine and remove the key.

To reduce fire hazard, keep the engine, rider and mower free of grass, leaves and excess grease. Do not stop or park rider over dry leaves, grass or combustible materials.

Gasoline is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills.

Figure 2. Pre-Start Checks A. Seat Adjustment Knob B. Fuel Tank Cap

A WARNING

Never operate on slopes greater than 17.6 percent (10°) which is a rise of 3-1/2 feet (106 cm)

vertically in 20 feet (607 cm) horizontally. Select slow ground speed before driving onto a

slope. Use extra caution when operating on slopes with a rear-mounted grass catcher.

Mow UP and DOWN the slope, never across the face. Use caution when changing directions and

DO NOT START OR STOP ON A SLOPE.

A WARNING - TRAILERS

Do not load this zero-turn rider on a trailer or truck using two separate ramps. Only use a single ramp that is at least one foot wider than the width of the rear wheels of this rider. This

rider has a zero turning radius and the wheels could fall off the ramps, or the rider could tip over

injuring the operator or bystanders.

EMERGENCY STOPPING

In the event of an emergency the engine can be stopped by simply turning the ignition switch to STOP. Use this method only in emergency situations. For normal engine shut down follow the procedure given in STOPPING THE

RIDER AND ENGINE.

8. Begin mowing. See DRIVING PRACTICE.

9. When finished, turn the PTO switch OFF.

10. Stop the engine (see STOPPING THE RIDER AND ENGINE).

PUSHING THE RIDER BY HAND

STOPPING THE RIDER & ENGINE

1. Returning the ground speed control levers to PARK positions will stop rider movement.

2. Stop the mower by pushing down on the PTO switch.

3. Move the parking brake lever to PARK position.

4. Move the throttle control to FAST position and turn the ignition key to OFF. Remove the key.

STARTING THE ENGINE

1. While sitting in the operator’s seat, set the parking brake to PARK. Make sure the PTO switch is OFF and the ground speed control levers are locked in PARK positions.

2. Move the engine throttle control fully forward to CHOKE.

NOTE: A warm engine may not require choking. In this case, set the throttle control to FAST.

3. Insert the key into the ignition switch and turn it to START.

4. After the engine starts, gradually move the throttle control back to FAST position (choke open). Warm the engine by running it tor at least a minute before turning on the PTO switch, or driving the unit.

5. After warming the engine, ALWAYS operate the

unit with the throttle set to FAST position when mowing.

1. Turn the PTO switch OFF, set the parking brake to PARK, turn the ignition switch OFF, remove the key, and wait for all moving parts to stop.

2. Locate the transmission release levers (A & B, Figure

3) at the rear of the unit.

3. Pull both levers back and down to release the trans missions (position B, Figure 3).

4. Set the parking brake to DRIVE. The rider can now be pushed by hand.

5. After moving the rider, set the parking brake to PARK and move the transmission release levers up and in to re-engage the transmissions (position A, Figure 3).

DO NOT TOW RIDER

Towing the unit will cause transmission dam

age. Do not use another vehicle to push or pull this unit.

MOWING

1. Place the parking brake lever in PARK position. Make sure the PTO switch is OFF, the ground speed control levers are locked in their PARK positions, and the operator is in the seat.

2. Set the mower cutting height to the desired setting.

3. Start the engine (see STARTING THE ENGINE).

4. Set the throttle to FAST.

5. Turn the PTO switch ON to engage the mower deck.

6. Move the parking brake lever to DRIVE position.

7. Move the ground speed control levers from PARK positions to drive positions (levers in across the oper ator’s lap).

Figure 3. Transmission Release Levers

A. Drive Position

B. Push Position

DRIVING PRACTICE -

BASIC DRIVING

WARNING: Never operate on slopes greater than 17.6% (10°). See SLOPE OPERATION in the safety section. Zero turn riders operate differently from other four wheeled vehicles. The drive wheels are also your steer ing wheels. If you cannot drive the unit on a hill, you will not be able to steer the unit on it. Operating zero turn units on slopes requires extra caution.

The lever controls of the zero turn rider are very respon sive, and learning to gain a smooth and efficient control of the rider’s forward, reverse, and turning movements will take some practice.

Spend some time going through the following maneuvers and becoming familiar with how the unit accelerates, travels, and steers — before you begin mowing —is absolutely essential to getting the most out of the zero turn rider.

Locate a smooth, flat area of your lawn — one with plenty of room to maneuver. (Clear the area of objects, people and animals before you begin.) Operate the unit at mid-throttle during this practice session (ALWAYS operate at full throttle when mowing), and turn slowly to prevent tire slippage and damage to your lawn.

Smooth Travel

The lever controls of the zero turn rider are highly responsive.

The BEST method of handling the ground speed control levers is in three steps — as shown in Figure 4.

FIRST place your hands onto the levers as shown.

SECOND, to go forward gradually push the levers forward with your palms.

THIRD, to speed up move the levers farther forward. To slow down smoothly, slowly move the levers back toward neutral.

Figure 4. Move Control Levers Gradually

We suggest you begin with the Smooth Travel procedure to the right, and then advance through the forward, reverse, and turning maneuvers.

You must set the parking brake to DRIVE prior to moving the control levers out of park position.

A WARNING

Do not mow in reverse unless absolutely necessary. Always look down and behind before and while travelling in reverse.

Forward Travel

Forward Travel Practice

Gradually move both ground speed control levers evenly FORWARD from neutral. Slow down and repeat.

Reverse Travel Practice

LOOK DOWN & BEHIND, then gradually move both ground speed control levers evenly BACK from neutral. Slow down and repeat.

NOTE: Practice backing up for several minutes before attempting to do so near objects. The rider turns as sharply in reverse as when going forward, and backing up straight takes practice.

Reverse Travel

Figure 5. Forward Travel

Practice Turning Around a Corner

Practice Turning In Place

While traveling forward allow one handle to gradually

return back toward neutral. Practice several times before

mowing.

NOTE: To prevent pivoting directly on the tire tread, it is

best to keep both wheels going at least slightly forward.

Executing Turns

ADVANCED DRIVING

To “zero turn” means to turn in place. To turn in place, gradually move one ground speed control lever forward from neutral and one lever back from neutral simultane ously. Repeat several times.

Turning In Place

Figure 8. Turning in Place

Executing an End-Of-Row Zero

Turn

Your zero turn rider’s unique ability to turn in place allows you to turn around at the end of a cutting row rather than having to stop and make a Y-turn before starting a new row.

For example, to execute a right end-of row

zero turn:

1. Slow down at the end of the row.

2. Move the LEFT ground speed control lever forward slightly while moving the RIGHT ground speed control lever back to center and then slightly back from center.

3. Begin mowing forward again.

This technique turns the rider RIGHT and slightly overlaps the row just cut —eliminating the need to back up and re-cut missed grass.

>4s you become more familiar and experi

enced with operating the zero turn rider, you will learn more maneuvers that will make your mowing time easier and more enjoyable.

Remember, the more you practice, the bet

ter your controi of the rider will be!

Figure 9. Executing an End-Of-RowTurn

MOWER DECK REMOVAL & INSTALLATION

NOTE: Perform mower removal and installation on a hard, level surface such as a concrete floor.

A WARNING

Engage parking brake, disengage PTO, stop engine and remove key before attempting to install or remove the mower.

Removing the Mower Deck

1. Turn the PTO off, set the parking brake to PARK, turn the ignition OFF, remove the key, and wait for ali mov ing parts to stop.

2. Pivot the rider’s front wheels forward.

3. Place the cutting height adjustment crank (D, Figure f 0) in the lowest cutting position.

4. Release tension on the drive belt using the mower belt release lever (E, Figure 10) and remove the drive belt from the engine pulley.

5. Disconnect the front hitch by removing the hitch rod and clip (A, Figures 10 & 11), and lifting the mower hitch (B) up and off the rider hitch bracket (D).

6. Slide the mower deck forward until the rear mower supports (C) disengage the frame of the rider.

7. Slide the mower deck out from under the right side of the rider.

Installing the Mower Deck

1. Pivot the rider’s front wheels forward.

2. Place the cutting height adjustment crank (D, Figure 10) in the lowest cutting position.

3. Slide the mower deck under the right side of the rider. Slide the mower backwards making sure that the rear mower supports (C, Figure 11) slide up the ramps on the frame. The rear of the mower is supported by these frame ramps. Hang the mower hitch (B, Figure 11) on the rider

4. hitch bracket (D) and secure with the hitch rod and clip (A). Use the mower belt release lever (E, Figure 12) to

5. release tension on the mower idler pulley, and install the drive belt as shown In Figure 12.

Figure 10. Mower Components A. Hitch Rod and Clip B. Mower Hitch C. Rear Mower Supports D. Cutting Height Adjustment Crank E. Mower Belt Release Lever

Figure 11. Mower Hitch Components A. Hitch Rod and Clip B. Mower Hitch C. Rear Mower Supports D. Rider Hitch Bracket

Figure 12. Mower Belt Routing A. Engine Pulley B. Mower Drive Belt C. Back-Side Idler Pulley D. V-ldler Pulley E. Mower Belt Release Lever F. Mower Drive Pulley

MAINTENANCE

MAINTENANCE SCHEDULE

The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by observing the elapsed time recorded by the hour meter.

RIDER MAINTENANCE ITEMS

Clean Debris from Rider and Engine Compartment *

Clean Debris from Engine Cooling Areas & Air Filter *

Check Tire Pressure Lubricate Rider & Mower * Clean Deck & Check/Replace Mower

Blades Clean Battery & Cables

Check Rider Safety System ** Check / Adjust PTC Clutch

ENGINE MAINTENANCE ITEMS

Check Engine Oil Level Service Air Filter Pre-Cleaner * Replace Air Filter * Change Engine Oil * Replace Spark Plug Replace Fuel Filter Change Engine Oil & Filter *

Before

Each Use

•

Every Spring

&Falf

• •

m •

Hours25Hours

•

100 Hours

•

200 Hours

•

* More often in hot (over 85“ F: 30“ C) weather or dusty operating conditions.

** Check the function of the safety system after the unit has been stored for 30 days or longer.

Rider Maintenance Items

CLEAN DEBRIS FROM RIDER AND ENGINE COMPARTMENT

Service interval: Before each use. CAUTION: If debris is not removed from the engine

compartment and other hot surfaces, it creates a fire hazard. Before starting the unit at the beginning of the

mowing session, remove any grass clippings, dirt, leaves, or other debris from the unit. Also clean out the engine compartment.

CLEAN DEBRIS FROM ENGINE COOLING AREAS AND AIR FILTER

Service Interval: Before each use. CAUTION: If debris is not removed from the engine

compartment and other hot surfaces, it creates a fire hazard. Before starting the unit at the beginning of the

mowing session, lift the seat deck and clean any debris from the intake screen on top of the engine (A, Figure

13), exposed engine cooling fins, and around the air filter assembly. Also open the air filter cover (B) and remove any debris that has accumulated in the air filter compart ment.

B. Air Filter Cover

CHECKTIRE PRESSURE

Service Interval: 25 Hours. Tire pressure should be checked periodically, and main

tained at the levels shown in Figure 14. Note that these pressures may differ slightly from the “Max Inflation” stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire life.

Tire Pressure

Front 18-20 psi (1,24-1,38 bar)

Rear 10-12 psi (,69-,83 bar)

Figure 14. Tire Pressures

LUBRICATION

Service Interval: 25 hours.

Lubricate the unit at the locations shown in Figures 15

through 17 as well as the following lubrication points.

Grease:

front wheel grease fittings

■ front wheel bushings

■ mower pivots

■ mower arbors

Use grease fittings when present. Not all greases are compatible. Use automotive-type lithi

um grease.

Oil:

■ rear frame assembly pivot

■ hydro linkage

■ seat adjustment assembly

■ brake linkage

■ frame pivot points

■ mower deck height adjustment linkage

Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Remember to wipe fittings and sur faces clean both before and after lubrication.

Figure 16. Lubricating Rider

Figure 17. Arbor Lubrication

CLEAN DECK &

CHECK ! REPLACE MOWER BLADES

Service Interval: 25 hours or as required.

A WARNING

For your personal safety, do not handle the sharp mower blades with bare hands. Careless or improper handling of blades may result in serious injury.

----------------------

A WARNING

For your personal safety, blade mounting capscrews must each be installed with a hex/spline washer and spring washer, then securely tightened. Torque blade mounting capscrew to 45 - 55 ft. lbs. (61 - 75 N.m.)

1. Remove mower deck (see “Mower Deck Removal” in the OPERATION section).

2. See Figure 18. Remove blade to inspect it or to safe ly access the underside of the mower deck. Use a block of wood to prevent blade rotation while loosen ing the capscrew by turning it counterclockwise.

3. Remove the capscrew (D, Figure 20), spring washer (C) , hex washer (B), and blade.

4. Clean the underside of the mower deck.

5. Inspect the blades for nicks or dull edges. Use a file to sharpen blade to a fine edge. If the blade is dam aged, it must be replaced.

6. Balance the blade as shown in Figure 19. Center the blade’s hole on a nail lubricated with a drop of oil. A balanced blade will remain level. If the blade is not balanced, continue to sharpen the heavy side until it balances.

7. Reinstall the blade with the lift wings (E, Figure 20) pointing up toward the mower deck as shown.

8. Reinstall the hex washer (B, Figure 20), spring wash er (C) and capscrew (D). Use a wooden block (A) to prevent blade rotation while tightening the capscrew (D) to 45-55 ft. lbs. (61-75 N.m). Turn capscrew clockwise to tighten.

Figure 18. Blade Removal

Figure 20. Blade Installation A. 4x4 Wood Block B. Hex Washer C. Spring Washer D. Blade Capscrew E. Lift Wings

CLEANING THE BATTERY AND CABLES

^WARNING

Be careful when handling the battery. Avoid

spilling electrolyte. Keep flames and sparks away from the battery. When removing or instaliing battery cables, disconnect the negative cable FIRST and reconnect

it LAST. If not done in this order, the positive

terminal can be shorted to the frame by a tool. Always wear safety glasses and gloves when

handling batteries.

Service Interval: 200 Hours

1. Disconnect the cables from the battery, negative cable first (B, Figure 21).

2. Remove the rubber strap securing the battery, and remove the battery.

3. Clean the battery and battery compartment with a solution of baking soda and water.

4. Clean the battery terminals and cable ends with a wire brush until shiny.

5. Reinstall the battery and secure with the rubber strap.

6. Reattach the battery cables: first attach the positive cable (see A, Figure 21), then attach the negative cable (B).

7. Coat the cable ends and battery terminals with petro leum jelly or non-conducting grease.

CHECK RIDER SAFETY

Service interval: 200 Hours & Every Spring/Fall

This unit is equipped with safety interlock switches. These safety systems are present for your safety. Do not attempt to bypass safety switches, and never tamp er with safety devices. Check their operation regularly.

Operational SAFETY Checks

TEST 1 — ENGINE SHOULD NOT CRANK IF:

• PTO switch is ON, OR

• Parking brake is in DRIVE position, OR

• Ground speed control levers are not in their PARK positions.

TEST 2 — ENGINE SHOULD CRANK IF:

• PTO switch is OFF, AND

• Parking brake is in PARK position, AND

• Ground speed control levers are locked in their PARK positions.

TEST 3 — ENGINE SHOULD SHUT OFF IF:

• Operator rises off seat with the PTO ON, OR

• Operator rises off seat with the parking brake in DRIVE position, OR

• Operator moves the ground speed control levers out of their PARK positions before setting the park ing brake to DRIVE.

TEST 4 — BLADE BRAKE CHECK

The mower blades and mower drive belt should come to a complete stop within five seconds after the PTO switch is turned OFF. If mower drive belt does not stop within five seconds, contact a Sears Parts & Repair Center.

SYSTEM

B. Negative (-) Battery Cable

NOTE: Once the engine has stopped, the PTO switch must be turned OFF, parking brake must be set to PARK, and the ground speed control levers must be locked in their PARK positions in order to start the engine.

A WARNING

If the unit does not pass a safety test, do not operate it. See a Sears Parts & Repair Center. Under no circumstance should you attempt to defeat the purpose of the safety interlock system.

CHECK / ADJUST PTO CLUTCH

A WARNING

To avoid serious injury, perform adjustments oniy with engine stopped, key removed and tractor on level ground.

Service Interval: 200 Hours.

The PTO clutch is engaged and disengaged by the PTO switch. The clutch powers and brakes the mower blades. Check the PTO clutch adjustment every 200 hours of operation. Also perform the following procedure if the clutch is slipping, will not engage, or if a new clutch has been installed.

1. Remove key from ignition switch and disconnect spark plug wires to prevent the possibility of acciden tal starting while the PTO is being adjusted.

2. See Figure 22. Note the position of the 3 adjustment windows (A) in the side of the brake plate and the nylock adjustment nuts (B).

3. Insert a .012”-.015” (2,5-4mm) feeler gauge (0) through each window, positioning the gauge between the rotor face and the armature face as shown in Figure 23.

4. Alternately tighten the adjustment nuts (B, Figure 22) until the rotor face and armature face just contacts the gauge.

5. Check the windows for an equal amount of tension when the gauge is inserted and removed, and make any necessary adjustments by tightening or loosen ing the adjustment nuts.

NOTE: The actual air gap between the rotor and arma ture may vary even after performing the adjustment pro cedure. This is due to dimensional variations on compo nent parts, and is an acceptable condition.

6. Check the mower blade stopping time. The mower blades and mower drive belt should come to a com plete stop within five seconds after the electric PTO switch is turned off. If adjustment does not stop a mower braking problem, replace the electric PTO clutch.

----------------

Figure 22. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut

Figure 23. Adjust PTO Clutch A. Window

B. Adjustment Nut C. Feeler Gauge

Engine IVlaintenance items

CHECK ENGINE OIL LEVEL

Service Interval: Before each use, and every 8 hours.

1. Turn the engine off, and set the parking brake to PARK.

2. Clean the area around the dip stick (C, Figure 25).

3. Remove the dip stick (C) and clean it with a paper towel.

4. Insert the dip stick back into the engine, but do not thread the cap back onto the tube (D).

5. Remove the dip stick and read the oil level. The oil level should be between the “F” and “L” marks (D). If not, add oil according to the oil recommendations chart (Figure 24).

CHANGE ENGINE OIL

Service Interval: 100 Hours. Oil Capacity: .95 Quarts with oil filter change.

Note: Change engine oil while the engine is warm. Run the engine for a few minutes, then shut the engine off

and aliow it to cool from hoi to warm.

1. Clean the area around the dip stick (C, Figure 25) and oil drain tube (A).

2. Remove the oil drain plug (A) from the end of the oil drain tube. Remove the dip stick (C). Allow ample time for complete drainage.

3. Reinstall the oil drain plug (A).

4. Fill the crankcase with oil. See CHECK ENGINE OIL LEVEL above.

Use oil classified API Service Class SG,

SH,

or better with SAE Viscosity:

10W-30 Conventional Or Synthetic

20 32 40 60 80

°C -30 -18 -7 0 4 16 27 38

•Recommended: Synthetic oils provide better starting below -10"F.

Figure 24. Recommended Engine Oil

100

CHANGE ENGINE OIL & FILTER

Service interval: 200 Hours. Oil Capacity: .95 Quarts with oil filter change.

Note: Change engine oil while the engine is warm. Run the engine for a few minutes, then shut the engine off

and aliow it to cool from hoi to warm.

1. Clean the area around the dip stick (C, Figure 25) and oil drain (A).

2. Remove the oil drain plug (A) and and dip stick (C). Allow ample time for complete drainage.

3. Remove the oil filter (B). Discard the filter.

4. Turn the new filter upside down and fill with fresh engine oil. Allow the oil to seep into the new filter for two minutes.

5. Using a drop of oil on your finger tip, wet the rubber gasket on the bottom of the new filter.

Figure 25. Oil Change

A. Oil Drain Tube

B. Oil Filter

C. Dip Stick

D. Checking Oil Level

6. Dump the oil out of the filter and install the filter on the filter base. Turn the filter clockwise until the rub ber gasket meets the filter base. Then turn 2/3 to 1 full turn more.

7. Reinstall the oil drain plug (A).

8. Fill the crankcase with oil. See CHECK ENGINE OIL LEVEL above.

9. Test run the engine to check for leaks. Stop the engine for 1 minute, then recheck the oil level.

SERVICE AIR FILTER PRE-CLEANER

Service interval: 25 Hours or as required.

1. Loosen the air filter cover knob and remove the cover (A, Figure 26). Clean out any debris from around the air filter. Inspect the condition of the sealing surfaces of the air filter element (D) and filter base. Replace any damaged parts.

2. Remove the foam pre-cleaner (B) from the air filter element (D).

3. Wash the pre-cleaner (B) with warm water and deter gent. Rinse thoroughly. Squeeze out all excess water. DO NOT wring out. Allow the pre-cleaner to air dry.

4. Saturate the pre-cleaner with new engine oil. Squeeze out the excess oil. DO NOT wring out. Squeeze the pre-cleaner in a paper towel until all excess oil has been removed.

5. Reinstall the pre-cleaner (B) over the air filter (D).

6. Reinstall the air cleaner cover (A).

REPLACE AIR FILTER

Service Interval: 100 Hours or as required.

1. Loosen the air filter cover knob and remove the cover (A, Figure 26). Clean out any debris from around the air filter. Inspect the condition of the sealing surfaces of the air filter (D) and filter base. Replace any dam aged parts.

2. Remove the foam pre-cleaner (B) from the air filter element. Service the pre-cleaner as described in SERVICE AIR FILTER PRE-CLEANER above.

3. Remove the wing nut (C). Remove and replace the air filter (D).

4. Reinstall the wingnut (C) and pre-cleaner (B).

5. Reinstall the air cleaner cover (A).

Figure 26. Air Filter Assembly A. Air Filter Cover & Knob B. Foam Pre-Cleaner C. Wingnut with Locking Material D. Air Filter E. Rubber Seal F. Stud

REPLACE SPARK PLUG

Service Interval: 200 Hours.

Replacement Spark Plug: Champion RC12YC or equiv

alent Spark Plug Gap: .040” (1mm)

1. Stop the engine and allow it to cool.

2. Clean the area around the spark plug (A, Figure 28).

3. Remove the spark plug and inspect it. If at all dam aged or worn, replace it.

4. Check the spark plug gap. The gap (new or used plug) should be .040” (see Figure 27).

5. Reinstall the plug into the cylinder head (Figure 28). Torque the plug to 28-32 ft. lbs. (38-43 N.m.).

REPLACE FUEL FILTER

.040"

Figure 27. Spark Plug Gapping

A WARNING

Gasoline is highly flammable and must be

handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills.

Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. DO NOT spread hose clamps further than necessary. Ensure clamps grip hoses firmly over filter after installation.

Service interval: 200 Hours.

The fuel filter is located in the fuel line between fuel tank and carburetor. If the filter is dirty or clogged, replace as follows:

1. Stop the engine and allow the unit to cool .

2. Disconnect the negative battery cable from the nega tive battery terminal (C, Figure 28).

3. Using locking pliers, clamp off the fuel line on both sides of the fuel filter (B).

4. Place a suitable container under the fuel filter to catch spilled fuel.

5. Spread the fuel filter clamps only far enough to remove the clamps. Move the clamps away from the fuel filter.

6. Remove and replace the fuel filter.

7. Secure the fuel filter with the original clamps and remove the locking pliers.

8. Reconnect the negative battery cable (C) when fin ished.

--------

Figure 28. Engine Compartment

A. Spark Plug

B. Fuel Filter

C. Negative Battery Terminal & Cable

SERVICE & ADJUSTMENTS

Figure 29. Seat Adjustment A. Seat Adjustment Knob (Underside of Seat Deck)

SEAT ADJUSTMENTS

The seat and ground speed control levers should be adjusted so the ground speed control levers can be moved through their full range of motion.

Figure 30. Control Lever Adjustment A. Jam Nut B. Carriage Bolt C. Forward Slot D. Mount Bolts E. Knob

The seat can be adjusted forward and back. Loosen the adjustment knob (A, Figure 29) located on the underside of the seat deck, move the seat to the desired position, then tighten the knob.

GROUND SPEED CONTROL LEVER ADJUSTMENT

The control levers have three adjustments: To Adjust Control Lever Height: Pull the levers in

across the operator’s lap to their DRIVE positions. Loosen the mount bolts (D, Figure 30) and raise or lower the levers to the desired position. Tighten the mounting bolts.(D).

To Adjust Control Lever End Gap: The control lever end gap should be adjusted so that the levers do not contact each other when placed in DRIVE positions. Loosen the jam nut (A, Figure 30) and adjust the length of the carriage bolt (B) so that the levers do not contact each other. Repeat on the opposite side. Tighten the

jam nut (A) to lock the carriage bolt in position.

To Adjust Operator Clearance: The space between the operator and the control levers can be increase by removing the upper mounting bolt (D, Figure 30), pivoting the lever forward, and reinstalling the capscrew through the control lever and forward slot (C). Repeat with the other ground speed lever.

SPEED BALANCING ADJUSTMENT

If the rider veers to the right or left when the ground speed control levers are in the maximum forward posi tion, the top speed of the right lever can be balanced by turning the adjustment knob (E, Figure 30). Turn the knob COUNTERCLOCKWISE to increase speed or CLOCKWISE to decrease speed

CUTTING HEIGHT ADJUSTMENT

Turn the cutting height adjustment crank (A, Figure 31) clockwise to raise the mower deck and counterclockwise to lower it. If the crank is difficult to turn, thoroughly clean and lubricate it.

PTO CLUTCH ADJUSTMENT

See CHECK / ADJUST PTO CLUTCH in the

Maintenance Section.

BRAKE ADJUSTMENT

1. Lift up the seat deck.

2. Set the parking brake to DRIVE.

3. Push the brake lever (C, Figure 32) forward and pull the brake rod (A) back. There should be an approxi mately 5/8” -1/2” gap between the adjustment nut (B) and brake lever. If not, adjust the nut (B) until 1/8” is achieved.

4. Repeat on both sides.

BATTERY CHARGING

Figure 31. Cutting Height Adjustment

A. Cutting Height Adjustment Crank

A WARNING----------------------

Keep open flames and sparks away from the battery; the gasses coming from it are highly

explosive. Ventilate the battery well during charging.

A dead battery or one too weak to start the engine may be the result of a defect in the charging system or other electrical component. If there is any doubt about the cause of the problem, contact a Sears Parts & Repair Center. If you need to replace the battery, follow the steps under Cleaning the Battery & Cables in the

Regular Maintenance Section.

To charge the battery, follow the instructions provided by the battery charger manufacturer as well as all warnings included in the safety rules sections of this book. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte tem perature is at least 60° F). Do not charge at a rate higher than 10 amps.

ENGINE ADJUSTMENTS

The carburetor is designed to deliver the correct fuel-toair mixture to the engine under all operating conditions. The main fuel jet is calibrated at the factory and is not adjustable. The low idle fuel adjusting needle is also set at the factory and normally does not need adjustment.

A. Brake Rod

B. Adjustment Nut

C. Brake Lever

To ensure proper operation at altitudes above 5000 feet, it may be necessary to have an authorized Kohler dealer install a special high-altitude jet kit in the carburetor. If a high-altitude kit as been installed, the engine must be converted back to the original jet size before it is operat ed at lower altitudes. If not, overheating and engine damage can result.

MOWER DECK LEVELING ADJUSTMENTS

A WARNING

Before checking mower, shut off PTO and engine. Allow all moving parts to stop. Remove ignition key, then disconnect the spark plug wire and fasten it away from the spark plug.

If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut. See CHECK TIRE PRESSURE.

Side to Side Leveling

1. With the mower installed, place the rider on a smooth, level surface such as a concrete floor. Turn the front wheels straight forward. Turn the engine off, set the parking brake to PARK, and wait for all mov ing parts to stop.

2. Check for bent blades and replace if necessary.

3. Check the tire pressures. See CHECK TIRE PRES SURE.

4. Set the cutting height to mid position. Arrange the mower blades so that they are pointing from side-toside (Figure 34).

5. Measure the distance between the tips of the outside blades and the ground (Figures 33 & 34). If there is more than 1/8" (3mm) difference between the meas urements on each side, proceed to step 6. If the dif ference is 1/8" (3mm) or less, proceed to Front To Back Leveling.

6. See Figure 35. Loosen the outside nut (A) and taptite screw (C), then turn the eccentric nut (B) to raise or lower the left side of the deck. When the mower deck is level, hold the eccentric nut while tightening the outside nut. Tighten the taptite screw (C).

Figure 33. Measure Blade Tips to Ground A. Mower Deck B. Blade Tip C. Level Ground

A. Outside Nut B. Eccentric Nut C. Taptite Screw

Figure 36. Orient Blades Front-to-Back

Front To Back Leveling

1. Turn the blades front-to-back as shown in Figure 36. Measure the distance from the ground to front tip of center blade, and from ground to rear tips of left hand and right hand blades (Figures 33 & 36). Front tips should be 1/8"-1/4" (3-6 mm) higher than rear tips. If not, proceed to step 2.

2. To raise front of mower deck, loosen front nut (A, Figure 40 inset) and turn rear nut (B) against bracket (C) to shorten rod (D).

3. To lower the front of mower deck, loosen rear nut (B) and bracket (C) will move back to lengthen rod (D).

4. Recheck measurement before tightening front nut (A) against bracket.

MOWER BELT REPLACEMENT

Mower Drive Belt Replacement

1. Park the rider on a level surface. Disengage the PTO, turn off the engine and set the parking brake. Remove the key.

2. Use the idler pulley arm (K, Figure 38) to release belt tension and remove the mower drive belt (F) from the PTO pulley (G).

3. Remove the belt from the remaining deck pulleys. Note: It is not necessary to remove the mower deck.

4. Install the new belt (F) as shown in Figure 38.

Figure 37. Front-to-Back Leveling

A. Front Nut

B. Rear Nut

C. Mower Bracket

D. Adjustment Rod

Arbor Drive Belt Replacement

Contact a Sears Parts & Repair Center for replacement of the arbor drive belt (A, Figure 38).

Figure 38. PTO Belt Routing

A. Arbor Drive Beit

B. Right Arbor Pulley

C. Arbor Idler Pulley

D. Center Arbor Pulley E. Left Arbor Pulley F. Mower Drive Beit

G. Engine PTO Pulley

H. Mower Drive Pulley I. Mower idler Pulley J. Backside Idler Pulley

K. Idler Pulley Arm

STORAGE

Before you store your unit for the off-season, read the Maintenance and Storage instructions in the Safety Rules section, then perform the following steps:

• Disengage the PTO, set the parking brake, & remove the key.

• Check all fluid levels. Check all maintenance items.

• Battery life will be increased if it is removed, put in a cool, dry place and fully charged about once a month. If the battery is left in the unit, disconnect the negative cable.

It is important to prevent gum deposits from forming in the essential fuel system parts such as the carburetor, fuel filter, fuel line, and fuel tank during storage. Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to the sepa ration and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in stor age.

To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Follow these instructions;

1. Stop the engine, remove the key, and allow the engine to cool.

2. Place a suitable container below the fuel filter (A, Figure 39') to catch spilled fuel, and place a contain er suitable to hold the contents of the fuel tank next to the unit.

3. Using locking pliers, clamp the fuel line between the fuel filter (A) and fuel tank.

4. Spread the clamp on the fuel filter only far enough to slide the clamp away from the filter.

5. Disconnect the fuel line from the fuel filter.

6. Route the fuel line into a suitable container, remove the locking pliers, and drain the fuel tank.

7. Reconnect the fuel filter, and secure with the clamp.

8. Start and run the unit until all fuel is consumed.

Before starting the unit after it has been stored:

• Check all fluid levels. Check all maintenance items. » Fill with FRESH fuel.

• After starting, allow the engine to warm before oper ating.

A WARNING

Never store the unit {with fuel) in an enciosed, poorly ventilated structure. Fuel vapors can travel to an ignition source (such as a furnace, water heater, etc.) and cause an explosion.

Fuel vapor is also toxic to humans and animals.

Figure 39. Engine Compartment A. Fuel Filter

Awarning

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