Craftsman 502254152 Owner’s Manual

owners

a a

Model No.

502.2541 52

CAUTION:

Read And Follow

All Safety Rules And Instructions Before

Operating This Equipment.

11 P. LECTRIC START

8 SPEED = 30" MOWER

EA ENG! I

® Assembly

® Operation

• Maintenance o Repair and Adjustment

® Repair Parts

F-88516 Sears, Roebuck and Co., Chicago, IL. 60684 U.S.A.

• PrTnted fn U,S,A.

SAFETY RULES

Safe Operation Practices for Riding Vehicles

As Recommended by American National Standards Institute

1. Know the controls and how to stop quickly, READ THIS INSTRUCTION BOOK and any instructions furnished with

attachments.

2. Do not allow children to operate the machine. Do not allow adults to operate tt without proper instruction.

3, Clear the work area of objects (wire, rocks, etc.) which might

be discharged by the machine,

4. Handle gasoline with care, It is highly flammable. a. Use an approved gasoline container. b. Never remove the fuel cap or add gasoline to a running orhot engine oran engine that has not been allowed to cool

for several minutes after running, Never fill the fuel tank

indoors. Clean up spilled gasoline.

c. Do not run the engine indoors. Exhaust fumes are dangerous,

5. Always wear safety glasses or a eye shield when you operate

the unit to protect your eyes from foreign objects that can be thrown from the unit, Always wear eye protection when you

make an adjustment or repairs to the unit.

6. Keep all nuts, bolts, and screws tight to be sure the equip-

ment is in safe working condition.

7, Disengage all attachment clutches and shift into neutral

before attempting to start the engine,

8. Disengage power attachment(s) when transporting or not in use.

9, Do not stop or start suddenly when going uphil] ordownhill,

Mow upand down the face of steep slopes;never across the face, See the "Guide" in the back this book to check for

safe operation,

1O, Reduce speed and exercise extreme caution on slopes and in

sharpturns to prevent tipping or loss of control. Beespecially cautious when changing directions on slopes.

11, Stay alert for holes, rocks, roots in the terrain, and other

hidden hazards, Keep away from drop-offs,

12. Use care when pulling loads or using heavy equipment. a. Use only approved drawbar hitch points.

b. Limit loads to those you can safety control.

c, Do not turn sharply. Use care when baektng, d, Use counterweight(s) or wheel weights when suggested

in the instruction book.

13. Watch out for traffic when crossing or near roadways.

14. When using any atiachments, never direct discharge of material toward bystanders or allow anyone near the unit while in operation.

15. Disengage power to attachment(s) and stop the engine before 1eaving the operator's position.

16. To reduce fire hazards, keep the engine free of grass, leaves,

or excessive grease.

17, The vehicle and attachments must bestopped and inspected

for damage after striking a foreign object, All damage must be repaired before restarting and operating the equipment.

18, Donot change the engine governorsettings oroverspeed the

engine.

19. When using the vehicle with a mower, proceed as follows: a. Mow only in daylight or tn good a_ifieiat light2

b, Never make a cutting height adjustment while the engine is running if the operator must dismount. c. Stop the engine before removing a grass catcher or unclogging the chute, d. Check the blade(s) and mounting nut(s) for proper tight- ness at frequent intervals, Frequently check the blade for

wear or damage such as cracks and nicks, A blade that is

bent or damaged must be immediately replaced with a

factory replacement blade. For safety, replace the blade

every two years, Frequently check the nut(s) that hold the blade(s). Replace damaged nuts and tighten loose nuts, ,'

20. Disengage power to the mower before backing up. Do not mow in reverse unless absolutely necessary and then only

after careful observation of the entire area behind the

mower.

21. Under normal usage, the grass catcher bag material" is

subject to deterioration and wear. It should be checked frequently for bag replacement. Replacement bags should be checked to ensure compliance with the original manufac- turers recommendations or specifications.

22. Donot operate the mowerwithout either the grass catcher or

guards in place, Read the instructions provided with the grass catcher.

23, Do not carry passengers, Do not mow when children and

others are present.

24. Never store the equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark.

Allow the engine to cool before storing in any enclosure.

25. Take atl possible precautions when leaving the vehicle

unattended, such as disengaging the blade engagement _ control lever, lowering the attachment(s), shifting into neutral,

setting the parking brake, stopping the engine, and removing the key.

26, Keep the vehicle and attachments in good operating condi-

tion, and keep safety devices in place and working,

27. Disengage power to attachment(s) and stop the engine before making any repairs or adjustments, The carburetor can be adjusted with the engine running.

28, Wa!!; for all movement to stopbefore servicing any part ofthe

29, ;:;Read and follow the instructions in this book concern ng

safety, and op§ration of the mower.

WARNING: This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest-covered,

brush-covered or grass-covered land unless the engine's exhaust system isequipped with a spark arrester meeting applicable local or state laws (if any), If a spark arrester is used, it must be maintained in effect!re working order by the operator,

In the State of California the above is required by law (Section 4442 of the California Public Resources Code), Other states may have similar

laws, Federal laws apply on federal lands, See an Authorized Service Center for a spark attester for the muffler,

precautions. It means: "Attentionl Become Alertl Look for this symbol to point out important safety

Your Safety Is Involved/p

F-88516

This product is made to give you many hours of performance and safe operation. To keep the unit in good condition, you must

correctly service the unit. For safety and performance, follow the ASSEMBLY, OPERATION, and MAINTENANCE instructions. If you

can not correct a problem, see the nearest Sears Service Center.

CUSTOMER RESPONSIBILITIES

Follow all the assembly instructions. Correctly adjust the unit. Carefully read and foltow the rules for safe operation. Inspect the unit, Complete all maintenance on the unit, Know how to operate

all standard and accessory equipment on the unit, Make sure that the operator can correctly operate the unit. Operate the unit only

with guards, shields, and other safety items in place and working

correctly. Service the unit only with authorized or approved replacement parts,

RIDING LAWN MOWER

Record inthe space below the serial number and the date

of purchase of this unit.

The model number and serial number are found under the seat on a plate attached to the seat support.

REAR ENGINE RIDER FEATURES

Craftsman Engine Air cooled and long life with solid state ignition.

All Gear Transmission Eight forward speeds and one reverse

to let you select the correct speed for your type of yard. A drive

chain connects the transmission to an automotive type

differential.

Tilt Seat The seat tilts forward for easy access to the battery and the engine,

Side Panels The side panels can be easily removed for access

to the engine. •

Mower Housing The full-floating suspension and single blade give an even cut. The lift lever has an eight position height adjustment.

ATTACHMENTS

This unit can useattachments available at the nearest Sears Store. This unit can pull attachments like a lawn sweeper, a lawn aerator,

or a hopper spreader, This unit can not use attachments that engage the ground like a plow, a disk harrow, or a cultivator.

Serial Number:

Date of Purchase:

Keep these numbers for future reference,

MAINTENANCE AGREEMENT

A Sears Maintenance Agreement Isavailable on this unit. See the

nearest Sears Store for information.

LIMITED TWO YEAR WARRANTY ON ELECTRIC START RIDING EQUIPMENT

Fortwo years fromthe dateof purchase,when thisridingequipment is maintained, lubricated, and tuned up accordingto the operating and maintenance instructions in the Owner's Manual, Sears will repair free of charge any defect in material or workmanship in this

electric start riding equipment.

Thiswarranty excludesblade(s),blade adapter(s}, sparkplug(s),air cleaner, and belt(s),which are expendableand become worn during normal use.

This warranty does not cover:

- tire replacement or repair caused by punctures from outside objects (such as nails, thorns, stumps, or glass);and

- repairs necessary because of operator abuse or negligence, including the failure to maintain the equipment according to

instructions contained in the Owner's Manual; and

- riding equipment used for commercial or rental purposes.

FULL 90-DAY WARRANTY ON BATTERY

For 90 days from the 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 th_ battery at no charge,

WARRANTY SERVICE IS AVAILABLE BY CONTACTING THE NEAREST SEARS SERVICE CENTEP_'DEPARTMENT IN THE UNITED STATES. This warranty applies only while this product is in use in the United States.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Sears, Roebuckand Co,, D/698-731A, Sears Tower, Chicago,tL 60684

F-88516 3

INDEX

Adjustments:

Blade Engagement Control .............. 15

Brake, Drive .........................................25

Carburetor ...........................................29

Chain, Front Drive ..............................26

Chain, Rear Drive ...............................27

Mower Housing, Level ......................22

Throttle Control Cable .......................29

Assembly ..........................................5 - 10

Attachments ...............................................3

Battery:

Charge ....................................................7

Clean and Check ................................ 18

Emergency Start ................................30

Install ....................................................10

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

Belt;

Motion Drive, Replace .......................21

Mower Drive, Adjust .......................... 15

Mower Drive, Replace .......................21

Blade, Remove and Install ..................... 16

Blade, Sharpen .........................................17

Blade Engagement Control'.

Adjust ...................................................15

Operation .............................................11

Brake Pedal, Operation ........................... 11

Carburetor, Adjust ...................................29

Chains, Check and Adjust ............... 26, 27

Charge Battery ...........................................7

Clutch/Brake Pedal 11

Controls ..............................................11, 1'2

Engine:

Carburetor ...........................................29

Oil, Change ..................................14, t9

Oil Level, Check .................................. 14

Oil, Type ...............................................14

Operation Speed Chart ..................... I2

Starting ................................................12

Stopping ..............................................12

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

Throttle Control ........................... 11, 29

Trouble Shooting Chart .................... 31

Filter, Air ................................................... t 9

Fuel ............................................................12

Fuel System, Storage .............................30

Fuse ..................._................................32, 33

Lubrication ................................................18

Maintenance .................................. t3 - 19

Air Filter ................................................19

Battery ..................................................18

Blade .............................................16, 17

Blade Engagement Control .............. 15

Drive Brake ..........................................25

Drive Chains .................................26, 27

Engine Oil ..................................... 14, 19

Lubrication .......................................... 18

Muffler

Check ...................................................18

Spark Arrester ................................2, 18

Spark Plug ................................................18

Tires ...........................................................17

Mower Housing

Level .....................................................22

Remove and Install ............................20

Oil:

Check ...................................................14

Change .................................................19

Operation .......................................11 - 13

Mower Housing ..................................13

Operate On Hills .................................13

Operate The Unit ................................ t3

Start Engine ........................................t2

Stop The Unit ..................................... 12

Parts Bag " 6

Repair and Adjustment ................20 - 30

Mower Drive Belt ............................... 22

Carburetor ...........................................29

Drive Chains .................................26, 27

Level Mower Housing .......................22

Motion Drive Belt ...............................21

Mower Housing, Install ..................... 20

Mower Housing, Remove ................. 20

Safety Rules ................................................2

Seat ...........................................,..................9

Sharpen, Blade ......................................... 17

Shift Lever ................................................ 12

Side Panel, Remove ................................ 13

Slope Guide ..........;................................... 51

Spark Plug ................................................ 18

Speed Control Chart ............................... 12

Start Engine ..............................................12

Steering Wheel ..........................................8

Stop, Riding Mower ................................ 12

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

Throttle Control Cable, Adjust ..............29

Tire Pressure ..................................... 10, 17

Transmission, Friction Drive ......... 23 - 28

Trouble Shooting Chart .......................... 31

Warranty ......................................................3

Wiring Schematic ....................................32

F-88516 4

ASSEMBLY

SET UP

Your unit was carefully inspected and put in a carton for protection from damage. The unit is assembled except for the items shown on this page.

These items are in the carton with a bag of fasteners and loose parts needed for assembly. Find and remove these items, The

fasteners and roose parts are shown on the next page.

HOW TO REMOVE FROM THE CARTON

To remove the riding mower from the carton, follow the instruc- tions below.

I. Open the top of the carton,

2. The items shown at the right are in a small box. Remove and check each item. Remove the small box.

3. Cut each corner of the carton from the top to the bottom with a knife.

4. Move the shift lever to the NEUTRAL position.

5. Make sure the parking brake is disengaged,

6. Move the lift lever to the HIGH position,

7. Carefully push the riding mower backwards off the wood frame,

TOOLS YOU NEED TO ASSEMBLE THE UNIT

I. Adjustable wrench

2. Open end wrench 1/2" - 9/16"

3. Open end wrench 7/16"- 1/2" 4, Blade type screwdriver

5, Phillips screwdriver

6. Low Tire pressure gauge

7. Knife

D-4656-2

I. Seat " 5. Parts Bag 9. Battery Acid

2. Bezel 6. Owner's Manual 10. Bellows

3, Steering VVhee| 7. Battery 11. Upper Console

4. Steering Post 8, Battery Tray 12. Cover

F-88516 5

PARTS BAG - contents

The fasteners and loose parts are shown beiow. The fasteners are shown full size with the quantities in brackets ().

(4) Hex Bolt

5/16" x 5/8"

For Seat

STD523106

26x161

(2) Screw #10xl/2" Type BT For Console Cover

(1) Hex Bolt 6x90 (I) Hex Bolt

5/16" x 1-1/2" (1) Bolt 3/8" x 3/4"

For Adapter 5/16" x 1-1/4" For Steering Wheel

STD5231 t5 For Steering Post STD523707

(2) Hex Bolt

1/4" -20 x 5/8"

For Battery Cables

STD522506

(2) Screw 15x66

For Bearing (2) Locknut (1) Locknut

STD611005 I/4"-20 5/16"- 18

For Battery Cables For Adapter

STD541425 STD541431

(4) Washer (2) Locknut Notsi_OwnfutIsize

(4) Lockwasher I,D. 1!/3Z _ 5/16"-18 20094Z

I,D, 5116" For Seat For Steering Post (1) (1) Washer

For Seat STD551031 For Batter/Clamp (1) I.D. 13/32"

STD551131 STD54I 431 For Steering Wheel

19x39

(1) Lockwasher

I.D.3/8"

For Steering Wheel

STD551237

F-88516

55804

(1) Cover

ForBattery Clamp

Not shown fuilsize

55253Z

(1} Clamp, Battery

For Battery

91275

(2) Key

For Ignition

Not shown full size Not shown fullsize Not shown ful! size

24582 20107 56022

(4) Hub Cap (2) Seat Spring Cap (1) Bearing

For Wheels For Seat Springs For Steering Post "

t 7xl 32

(t) Washer

I,D, .328"

For Steering Post

Not shown full size

Not shown futl size Not shown full size 55705

55919 55911 (1) Tube, Oll Drain (I) Cap (I} Adapter For Engine

For Steering Wheel For Steering WheeI

54148

(t) Cable Cover

For Red Battery Cable

ASSEMBLY

HOW TO PREPARE AND CHARGE THE BATTERY

IMPORTANT: Before you install the battery, add the battery acid, (Electrolyte) to the battery, Battery acid wilt damage paint and parts,

WARNING: Read the instructions included with the battery acid container, Protect your hands

and eyes from the battery acid. Use clothing that will protect you,

I. Ifnot Tnstalledon the battery, removethe vent capsfrom the

plastic bag, Read the instructions included with the vent caps,

2. If medal tape covers the vents, remove the metal tape from

the vents. Discard the metal tape.

3. Pour battery acid into each battery cell until the battery acid

touches the bottom of the vent as shown. Do not add the battery acid above the bottom of the vent. If you add too

much battery acid, the excessive battery acid will flow from

the battery when you charge the battery.

4. Wait 20 to 30 mTnutesbefore you put the vent caps on the battery. The level ofthe battery acid can drop below the vent described in step 3. Add more battery acid until the correct battery acid level is reached, Install the vent caps, Wash the top of the battery with water to remove any battery acid,

5. Discard the battery acid container and any battery acid that was not used asfollows. Fillthe container halffull with water.

Add baking soda and mix together using a piece of wood, Add more baking soda until the solution does not foam, Dis- cardthe solution and wash the container with water. Destroy

the container.

Remove and discard the metal tape, ,

Ve n]

Correct

Liquid Level

WARNING: Whenyou charge the battery, do not smoke. Keep the battery away from any sparks,

The fumes from the battery acid can cause an explosion.

Use a 12 volt battery charger to charge the battery. Charge at a rate of 2 amperes for 3 to 4 hours, After the battery is

charged, check the level ofthe battery acid. If the level of the battery acid falls, add water. Do not add battery acid to a

charged battery or the result can be an explosion.

0-5468

DANGER _.,_,./,°"",,,,,,,

BATTERY ACID WILL "Z'=_,_____-

.... i'r,

<!° ",_

CAUSE SEVERE BURNS V" °'°

Containssufphuricacid. Donotletthebatteryacidcomeincontactwith theskin,theeyes,orthe

clothing,

To prevent accidents, neutralize the battery acid that was not used. To neutralize, fill the container half futl with water, Add baking soda and mix using a piece of wood until the solution does not foam, Discard the solution and wash the container with water. Destroy the container.

ANTIDOTE:

External - Wash the area with water, then wash with a solution of water and sodium bicarbonate,

Internal - Drink large amounts of water, milk, or milk of magnesia, Drink water mixed with the whites of eggs. Call a Doctor

immediately. Eyes - Flush with water for 15 minutes and then get immediate

medical help.

POIStON

KEEP AWAY FROM CHILDREN -

D-5213

F-88516 7

ASSEMBLY

HOW TO INSTALL THE STEERING WHEEL

Attach the steering wheel with the fasteners shown full size

below.

Bearing

g Post

Control Panel

1. Lookat the hole in the upper steering shaft. Turn the front tiresto the left untilthe hole inthe upper steering shaft points toward the front.

2. Slide the steering postthrough the control panel and onthe

upper steering shaft as shown. Fasten with the fasteners as shown in the illustration.

3. Turnthe front wheels until a 1/2" wrench will fit onthe lock- nut. Make sure the head of the bolt fits around the steering

post. Tighten the Iocknut to a torque of 18 foot pounds.

4. Slide the bearing on the steering post. Align the holesin the bearing with the holes in the top of the control panel Fasten the bearing with the screws as shown.

Control Panel

D-4584-t

Upper Steering

Shaft

,, IIIH

B C

bearing is correctly installed, if the bearing becomes loose or is damaged, replace

WARNING: For safe operation, make sure the

immediately.

5. Attach the steering panel to the control panel as follows. Attach the front tab intothe control panel. Move the steering

panelback.Put the two tabsofthe steeringpanelinthe control panel as shown.

6. To assemble thecover, putthetab inthe control panel.Fasten the top of the cover with the two screws as shown.

7. Slide the bellows over the steering post. Make sure the collar ofthe bellows isontop. Push on the top of the bellows.Fasten

the adapter to the steering post with the fasteners as

shown.

8. Fastenthe adapter to the steering post with the bolt and nut as shown. Tighten to a torque of 18 foot pounds.

Steering Panel

•

ASSEMBLY

9, Make sure the front wheels point to the front. Attach the

steering wheel to the adapter. Fasten the steering wheel with the large Washer, the lockwasher washer, and the bolt

shown in the illustration.

10. Attach the steering wheel cap to the steering wheel.

11. Connect the ends of the wires for the headlight. Before the bezel can be assembled, the two screws at the front of the

control panel must be removed. Put the bezel in position on the end of the control panel.Fasten the bezel with the screws

that were removed,

NOTE: if you do not follow the above assembly instructions correctly, the steering system will feel loose and the unit will

not steer correctly.

HOW TO INSTALL THE TILT SEAT

Assemble the seat with the fasteners shown full size below.

I. Align the four long holes inthe seat support to the four holes

in the seat. Make sure the wire from the seat switch sensor

goes through the large hole in the seat support, Fasten the seat to the seat support with the fasteners as shown, Do not tighten.

2. Move the seat to the best position for operating the unit. Tighten the hex bolts.

3, Connect the wire from the seat switch sensor to the wire

harness. Make sure the tab part of the connector, from the seat switch sensor, locks into the latch of the wire harness

connector,

Adapter

Post

D-4583

SteeringWheel Cap=.....__

Steering _'¢heel

WARNING: For correct and safe operation of the

unit, you must connect the wire from the seat

switch sensor to the wire harness.

4. Some models have two seat spring caps in the parts bag, Mount the caps on the seat springs as shown.

Wire from

Seat Spring

Cape

Strap

Sensor"

D-4591-1

Bezel

Control Panel

F-88516

D-4677

ASSEMBLY

CHECK THE TIRES

Check the airpressureinthe tires. Tires with too much air pressure wilt cause the unit to ride rough,Also, the wrong air pressurewill

keep the mower housing from cutting level. The correct air pressureisshown on the side of the tires. If the air pressure_ not

shown, inflate the tires from 10 to 12 PS1 (0,7 to 0.85 kg!_m2).

HOW TO CHECK THE MOWER HOUSING

Make surethe levelofcutset at the factory isstillcorrect. After you

mow a short distance, look at the area that was cut, If the mower housing does not cut level, see the instructionson "How To Level The Mower Housing" in the maintenancesection of this instruction

book.

HOW TO ATTACH THE HUB CAPS

Push each hub cap onto the center hub of each wheel. Make sure the washer holds the hub cap in place.

FINAL ASSEMBLY

1. The engine isfilled with oil. Check the oil. See"HowTo Check

The Ot(" in the Maintenance sectton.

2. Make sure alI the fasteners are tight.

'3. Read and follow the instructions in the Operation section.

Know the location and purpose of all the controls.

0-4606-2

Plastic Sleeve

Battery

BatteryTray

HOW TO INSTALL THE BA'r-rERY

Usethe fasteners shown below to installthe battery. The fasteners

are shown full size.

A C

1. Check the level of the acid. If the acid has fallen below the correct level, add water to the correct level.

2. Install the battery and the battery tray as shown in the illus- tration. Make sure the positive (+) terminal is toward the

front of the unit.

3. Slide the plastic sleeve over the end of the battery clamp.

Fasten the battery withthe battery clamp as shown.

4. Slide the cover for the positive term inaI on to the red battery cable as shown.

WARNING: To prevent sparks, {asten the red •

5. Fasten the red battery cable to the positive (+) terminal with

the nut and bolt as shown in the illustration.

6. Slide the cover on to the positive (+) terminal.

7o Fasten the black battery cable to the negative (-) terminal

with the nut and bolt as shown in the illustration.

8. To prevent corrosion, apply grease to the battery terminals.

cable to the positive (+) terminal before you connect the black cable to the negative (-)

terminal.

0-4653-3

Cover

BLACK

RED

F-885t 6

Clutch/Brake

Pedal

OPERATION

_4757

KNOW THE PRODUCT

Before you operate the unit, read this instruction book. If you understand the unit and how the unit operates, youwill get thebest

performance, When you read this instruction book, compare the illustrations to the unit. Learnthe location of the controls, To help

prevent an accident, follow the operating instructions and the safety rules. Keep this instruction book for future reference.

THE BLADE ENGAGEMENT CONTROL

See the location of the btade engagement control in the illustra- tion. Use the blade engagement control to start and stop the rotary blade.

1. Before you start the engine, make sure the control leverisin the DISENGAGE position.

2, Move the control lever to the ENGAGE position to rotate

the blade,

3. Move the control tever to the DISENGAGE position to step the rotary blade. Before you leave the operator's position,

make sure the blade has stopped rotating.

4. Before you ride the unit on a sidewalk or a road, move the control fever to the DISENGAGE position.

WARNING: Always keep your hands and feet

away from the blade, deflector opening, and the

mower housing when the engine runs.

F-88516

HOW TO USE THE CLUTCH/BRAKE PEDAL

This unit has only one pedal that is located on the left side of the unit, The pedal hastwo functions. The first function isa clutch. The

second function is a brake. Push the pedal completely forward to stop the unit,

HOW TO USE THE LIFT LEVER

The lift leveris on the rightside of the unit,To change the height of

cut, raise or lower the lift lever, When you ride on a sidewalk or a road, move the lift fever to the HI position.

HOW TO SET THE PARKING BRAKE

1. Push the clutch/brake pedal completely forward. Hold the

clutclVbrakepedalin the down position.Toengagethe parking brake, raise the parking brake lever and then release the clutch/brake pedal.

2. To release the parking brake, depress the clutch/brake pedal.

The parking brake .will automatically disengage.

WARNING: Before you leave the operator's position, move the shift lever to the neutral (N)

position. Set the parking brake. Move the blade engagement control to the DISENGAGE

position. Stop the engine and remove the ignition key.

HOW TO USE THE THROTTLE CONTROL

Use the throttle control to increase or decrease the speed of the engine. Tostart a cold engine, move thetever tothe left and intothe START or CHOKE position. For normal operations, move the fever to the FAST position, The engine governoris set at the factory for

maximum performance. Do not adjust the governor to increasethe speed of the engine.

OPERATION

HOW TO USE THE SHIFT LEVER

To change the forward speed or the direction of the unit, follow the

steps below:

t. Fully apply the clutch/brake pedal.

out of NEUTRAL or REVERSE, fully apply the

WARNING: Before you move the shift lever ir_or clutch/brake pedal.

Move the shift lever to FIRST or to REVERSE.

Slowly release the clutch!brake pedal, Do not ride with your

foot on the c[utchibrake pedal,

While the unit moves forward, you can select any forward

speed, Just move the shift lever to the next faster or next slower speed. You do not have to use the clutch/brake pedal.

The shift lever positionsfor operation of your unit are shown

in the chart below.

Shift

Lever

FUNC IONj S.IFTLEVER

Trimming 1

o0 ,oolor2

Normal mowing

Light mowing

Transpo_

Pull Behind 3or4

Attachments

3or4

5or6

7or8

THROTTLE

==z

FAST

SLOW-FAST

HOW TO STOP THE UNIT

1. Push the pedal completely forward to stop the unit, Keep

your foot on the pedal.

2. Move the blade engagement control to the DISENGAGE

position.

3. Move the shift lever to the NEUTRAL position. 4, Set the perking brake.

WARNING: Make sure the parking brake will hold the unit.

F-88516

5. Move the throttle control to the SLOW position.

6. To stop the engine, turn the ignition key to the OFF position.

Remove the key.

HOW TO START THE ENGINE

WARNING: The electrical system has an operator presence system that includes a sensor switch mounted in the seat, These components

on the seat, For your protection, always make tell the electrical system ifthe operator is sitting

sure this system operates correctly, This system will stop the engine when the operator leaves the seat if the blade engagement control is

engaged,

1. Check the oil.

2. Fillthe fuel tank with regular unleaded gasoline. Make sure

the gasoline is clean. Leaded gasoline will increasedeposits and shorten the life of the valves.

NOTE: Do not use gasbhol or methanol. Do not use premium unleaded gasoline.

WARNING: Always use a safety gasoline container, Do not smoke when adding gasoline

not add gasoline. Before you add gasoline, stop

to the fuel tank, When inside an enclosure, do the engine and let the engine coot for several

minutes,

3. Sit in the seat. Push the clutch/_orake pedal completely for-

ward. Keep your foot on the pedal.

4, Move the shift lever to the neutral (N) position.

5. Make sure the blade engagement control is in the DIS- ENGAGE position.

6. Move the throttle control to the CHOKE position.

7, Turn the ignition key to the START position. Release the key

when the engine starts.

NOTE: If the engine does not start after four or five tries, move the throttle control to the FAST position. Again try

to start the engine, if the engine w!!! not start, see the TROUBLE SHOOTING CHART,

8, Slowly move the throttle control to the SLOW position,

9. Let acold engine run for several minutes. Begin work when

the engine iswarm. To start ahot engine, move the throttle

control to a position between FAST and SLOW.

OPERATION

HOW TO OPERATE WITH

THE MOWER HOUSING

, WARNING: The deflector is a safety device. Do

not remove the deflector. The deflector forces the discharged material toward the ground.

Always keep the deflector in the down position. If the deflector is damaged, replace it with a factory replacement part.

1. Start the engine.

2. Move the lift leverto a height of cut position, in high or thick grass, cut the grass in the high position first and then lower

the lift lever to a lower position,

3. Move the throttle control to the SLOW position.

4, Move the blade engagement controlto the ENGAGE position.

5. Push the clutch/brake pedal completely forward.

6. Move the shift lever to the first speed setting.

IMPORTANT: When you mow in heavy grass or mow

with a bagger, put the shift lever in the slowest speed.

7, Slowly release the clutch/brake pedal.

8. Move the throttle controlto the FAST position, if you need to

go faster or slower, move the shift lever to another speed setting.

HOW TO OPERATE THE UNIT ON HILLS

WARNING; Do not ride up or down slopes that are too steep to back straight up. Never ride the

unit across a slope, See the "Slope Guide" inthe back of this book for information on how to check slopes.

1. Before you ride up or down a hill, move the shift lever to the

slowest speed,

2. Do not stop or change speed settings on a hill. If you must stop, quicklypushthe clutch/brake pedalforward and set the parking brake.

3. To start again, make sure the shift feveristhe slowest speed. Move the throttle control to the SLOW position. Slowly

release the pedal,

4. ifyou must stop or start on a hilt, always have enough space for the unit to roll when you release the brake and engage

the clutch.

5. Bevery careful when you change directions on a hill.To help prevent an accident, move the throttle control to the slow

position on a slope and in a turn,

WARNING: For better control of the unit, always select a safe speed,

MAINTENANCE

Use the following maintenance section to keep your unit in good operating condition,

WARNING: Before you make an inspection, adjustment (except carburetor), or repair, dis-

connect the wire from the spark plug.

HOW TO REMOVE THE SIDE PANEL

To help service and clean the engine or the transmission, the rear side panels can be easily removed.

t, Remove the large screws that hold the' front of the side

panel.

2. Slide the side panel back app,__.ximately one inch, Remove the side panel,

i lilt, i,i .....

Slide Backto Remove

O-461 t-_

F-885t6

MAINTENANCE

FIRST 2 HOURS (after 2 mowings)

HOW TO CHANGE THE OIL

NOTE: Drain the oil when the engine is warm. Be careful, do not get oil on the belts, ap

1. Put the plastic drain tube into the otI drain valve, Put the other end of the drain tube into a container as shown. Turn

the oil drain valve counterclockwise to open the valve. Drain the oil completely from the engine. Turn the oil drain valve

clockwise to close the valve. Remove the plastic drain tube.

2. UseaSD, SE,orSFdetergentgradeoi!.Detergentollhelpsto clean the engine. Nothing must be added to the oil.

3, Before you change the oil, use the temperature chart below

to select the viscosity grade of the oit to use.

Temperature range before the next oil change. All oils must be A,P,I. service grade SD, SE, or SF,

Recommended SAE viscosity grades

-20 ° 0° 32° 40 ° 60° 80° 100°

CAUTION: To protect the starting system, use SAE 5W30 oil

when the temperature is below 32 °F.

4. Clean the area around the dipstick. Remove the dipstick, Slowly pour approximately 3 pints (1,4 liters) of oil into the oil extension tube.

5. insert the dipstick into the oil extension tube, Turn the

dipstick in a clockwise direction until it is tight. Remove the dipstick, Check the oil level on the dipstick. The oil level must

reach the FULL mark on the dipstick.

EVERY 5 HOURS (every 5 mowings)

HOW TO CHECK THE OIL

IMPORTANT: Do not check the level of the oil when the

engine runs.

1. Stop the engine. Wait several minutes to let the oil drain,

Make sure the unit is level,

2. Clean the area around the dipstick. Remove the dipstick, Wipe the oil from the dipstick,

3, Insert the dipstickinto the oil fill tube, Turn the dipstick clock-

wise until it is tight. Remove the dipstick. Check the oil level

on the dipstick. The oil level must reach the FULL mark on the dipstick.

4. tf necessary, add oil until the oil reaches the FULL mark on the dipstick. Do not add too much oil

Plastic Tube

Container

\.,

Dipstick

OIL

F-88S_6 14

MAINTENANCE

EVERY 25 HOURS (twice a year)

HOW TO CHECK AND ADJUST

THE BLADE ENGAGEMENT CONTROL

WARNING: To prevent an injury, the blade

engagement control must operate correctly.

1. Stop the engine. Disconnect the wire from the spark plug.

2. Before you adjust the blade engagement control lever, check and level the mower housing, See "How To Level The

Mower Housing".

3, Set the height ofthe mower housing in the lowest position.

4. Move the blade engagement control to the DISENGAGE

position.

5, Check the blade engagement control lever. Before the blade

engagement control engages, there must be I/8" to 3/8"

(3mm to 9ram) of free movement.

6, If an adjustment is needed, disconnect the clevis from the

pivot rodand bracket assembly. Turn the clevis clockwiseto decrease the free movement of the blade engagement

control. Turn the clevis counterclockwise to increase the free movement.

7, Connect the clevis to the pivot rod and bracket assembly.

Move the blade engagement control to the DISENGAGE position. Check the free movement of the blade engagement

control,

i i,i i1_ ii¸ i,, . ....

Position ' +;_.

L% -Oom.,o.o,y

To .

Disengaged

Position

D4s_o _1/8" (3ram)- 3/8" (9,re,m) .....

Pivot Rod

And Bracket Assembly

D-4755

8, Check the operation of the blade brake. Rotate the pulley

with your hand. Make sure that the blade brake pad presses tightly against the pulley.

9. Move the blade engagement control to the ENGAGE posi- tion, Check the blade brake pad. If the blade brake pad is

excessively worn or damaged, replace the blade brake pad assembly. Correct replacement parts and assistance are

available from an authorized service center,

10. Mow for a short distance and again check the operation of

the blade engagement control.

11, When you move the blade engagement control to the DIS-

ENGAGE position, all movement will stop within five

seconds if the adjustment is correct. If all movement does not stop, again adjust the blade engagement control begin-

ning with the first step, If you need assistance, take the unit to an authorized service center.

12. Ifyou replace the mower drive belt, adjust the blade engage-

ment control lever,

F_88516

Clevis

Clockwise

PadAgainstPulley With BladeControl in DfSENGAGE

D-5298

BrakePad

Away From Pulley

With Blade Control

! i i In ENGAGEposition

ill

I i II

........ :==::___ j

MAINTENANCE

SVERV2S

BLADE SERVICE

connect the wire to the spark plug. if the blade

_[b WARNING: Before you inspect the blade, dis-

Frequently check the blade for excessive wear. cracks, or other

damage, Frequently check the nut that holds the blade. Keep the

nut tight. Ifthe blade hits an object, stop the engine, Disconnect the

wire to the spark plug. See if the blade isbent or damaged. Before you operate the unit, replace damaged parts with factory replace-

ment parts. Every three years, have an authorized Service person inspect the blade or replace the old blade with a factory replace-

ment blade, Keep a sharp edge on the blade. A blade that is not sharp will cause

the ends of the grass to become brown.

hits an object, stop the engine. Disconnect the wire to the spark plug. Check the unit for

damage,

HOURS (twice a year)

HOW TO REMOVE AND INSTALL THE BLADE

Mandrel

Blade

Hi-Lift Edge Up

D-4607-t

WARNING: Before you remove the blade, dis- connect the wire to the spark plug. The blade

has sharp edges. When you hold the blade, use gloves or cloth material to protect your hands.

1. Remove the mower housing. See the instructions on "How

To Remove The Mower Housing".

2. Use a piece of wood to keep the blade from rotating.

3. Remove the nut that holds the blade.

4. Check the blade according to the "Blade Service" instruc-

tions. Replacea badlyworn or damaged bladewith a factory

replacement blade,

5. Clean the top and bottom of the mower housing. Remove nil the grass and debris.

6. Mount the blade so that the hi-lift edges are up as shown, If the blade is upside down, the blade will not cut correctly and

can cause an accident.

7, Fasten the blade with the original washers and nut, Make

sure the outside rim of the belleville washer is against the blade as shown,

8. Tighten the nut that holds the blade to a torque of 30 foot pounds (41,5Nm),

WARNING: Always keep the nut tight that holds

the blade, A loose nut or blade can cause an accident.

F-88516 16

MAINTENANCE

EVERY HOURS (twice a year)

HOW TO SHARPEN THE BLADE

WARNING: Vibration can be caused if tile blade is not correctly balanced or if the blade is

damaged. A blade that is damaged with cracks can break and cause an accident,

1. Sharpen the blade two times a year or every 25 hours. 2, Remove the blade according to the instructions in "HowTo

Remove The Blade",

3, Clean the blade with a brush, soap, and water. Check the

blade. Look for cracks, nicks, or other damage. If the blade is bent, badly worn, or damaged, replace with a factory replacement blade.

4, Sharpen the blade with afile. Make su reyou keep the original

bevel angle.

5. Make sure the blade isbalanced. Use ascrewdriver and hold the blade parallel to the ground as shown. A blade that is

balanced will stay parallel to the ground, If the blade is not balanced, the heavy end will rotate toward the ground.Sharpen

the heaw end until the blade is balanced,

6. A new blade will cut batter than a badly worn blade. Every three years, have an authorized service person inspect the blade or replace the old blade with a factory replacement

blade.

D-3509-1

CHECK THE TIRES

Check the air pressure inthe tires,Tires with too much air pressure will cause the unitto ride rough. Also, the wrong air pressure wil!

keep the mower housing from cutting level. The correct air

• pressure isshown on the side of the tiles. If the air pressure is not

shown, inflate the tires from t0 to 12 PSI (0.7 to 0.85 kg/cm2).

O-4169-1

Ground

F-88516

+ 39 hidden pages