Craftsman ZTS 6000 User Manual

Operator's anual

T °

ZTS

Zero-Turn Rear Engine Riders with

Model No.

107.289860 (21HP Briggs & Stratton Engine with 42" Mower)

Electric Start

CAUTION: Before using this product, read the manual and follow all its Safety Rules and Operating Instructions,

Sears, Roebuck and Co., Hoffman Estates, IL 60179

Visit our Craftsman website: www.sears.com/craftsman

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 traducci6n en espaSol de este Manual

del Operador puede encontrarse en la pagina 37.

U.S.A.

7103147

Revision D

Rev. Date 04/2009

Warranty Statement ..................................................... 3

Safety Rules & Information ......................................... 4

Identification Numbers ................................................ 9

Assembly .................................................................... 10

Pre-Operation ............................................................. 13

Operation .................................................................... 14

Maintenance ............................................................... 21

Service & Adjustments ............................................. 30

Storage ....................................................................... 34

Specifications ............................................................ 34

Troubleshooting ......................................................... 35

Spanish Operator's Manual ...................................... 37

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

Hardware and Torque Specifictions ................. PTS-39

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

Service Numbers ........................................ Back Cover

NOTE: In this manual, "left" and "right" are

CRAFTSMAN FULL WARRANTY

When operated and maintained according to all supplied instructions, if any non-expendable part of this riding equip- ment fails due to a defect in material or workmanship within two years from the date or purchase, call 1-800-659-5917

to arrange for free in-home repair.

The frame and front axle will be repaired free of charge for five years from the date of purchase if defective in material or workmanship.

All of the above warranty coverage applies for only 90 days from the date of purchase if this riding equipment is ever used for commercial or rental purposes.

In all cases, if repair proves impossible, the riding equipment will be replaced free of charge with the same or an equivalent model.

The battery will be replaced free of charge for 90 days from the date of purchase if defective in material or workman- ship (our testing proves that it will not hold a charge).

This warranty covers ONLY defects in material and workmanship. Sears will NOT pay for:

• Expendable items that 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.

• Tire or wheel replacement or repair resulting from normal wear, accident, or improper operation or maintenance.

• 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 riding equipment according to the instructions contained in the opera-

tor's manual.

referred to as seen from the operating position.

• 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 finishes, or product label replacement.

This 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., Hoffman Estates, IL 60179

Readthesesafetyrulesandfollowthemclosely.Failuretoobeytheserulescouldresultinlossofcontrol

ofunit,severepersonalinjuryordeathtoyou,orbystanders,ordamagetopropertyorequipment.

This mowing deck is capable of amputating hands and feet and throwing objects. The triangle _ 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. Alwa.ys 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 and operational.

10. Slow down before turning.

11. Never leave a running unit unattended. Always disen- gage the blades (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 unclogging 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 power

equipment-related injuries. These operators should evaluate their ability to operate the equipment 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.

24. Disengage attachments before: refueling, 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 (if equipped), disengage

the blades (PTO), stop the engne, 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-covered, or grass-covered

land unless the exhaust system is equipped with a

spark attester meeting any applicable local or state

laws. Other states or federal areas may have similar laws.

29. OSHA regulations may require the use of hearing protection when exposed to sound levels greater than

85 dBA for an 8 hour time period.

CAUTION

1_ This machine produces sound levels in

Wear hearing protection when operating this

machine.

excess of 85 dBA at the operator's ear and

can cause hearing loss though extended

periods of exposure.

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 unit 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.

4. Always follow the engine manual instructions for storage preparations before storing the unit for both

short and long term periods.

5. Always follow the engine manual instructions for proper start-up procedures when returning the unit to

service.

6. 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-controland tip- over accidents, which can result in severe injury or death• Operation on all slopes requires extra caution• Ifyou cannot back up the slope or if you feel uneasy on it, do not operate

on it. Control of a walk-behind or 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 conditions, incorrect hitching and load distri- bution•

. Mow across slopes, not up and down.

• 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 loose traction•

5. Never mow down slopes•

6. Avoid starting, stopping, or turning on a slope• If tires

lose traction (i.e. machne stops forward motion on a slope), disengage the blade(s) (PTO) and drive slow

off the slope•

7. Keep all movement on slopes slow andgradual. 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 attachments; they can affect the

stability of the unit. Do not use on steeps slopes•

9. Do not try to stabilize the machine by putting your foot on the ground (ride-on units)•

10. Do not mow near drop-offs, ditches, or embank- ments• The mower could suddenly turn over if a

wheel !s 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 if you cannot back up them.

13. See your authorized dealer/retailer for recommenda-

tions 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 uphill, if possible. Never

mow down slopes•

TOWED EQUIPMENT (RIDE-ON UNITS)

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. See attaching a trailer under OPERATION.

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.

,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 slope.

Use extra caution when operating on slopes with rear- mounted grass catchers.

Mow across the face of slopes, not up and down,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. i'_everallow children to operate the unit.

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

vision.

EMISSIONS

1. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth

defects, or other reproductive harm.

2. 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 standard ICES-O02.

SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION

ONLY RiDE UP AND DOWN HILL,

NOT ACROSS HiLL

10 DEGREES MAX.

WARNING: To avoid serious injury, operate your unit up and down the face of slopes, never across the face. Do not operate on slopes greater than 10 degrees. Make turns gradually to

prevent tipping or loss of control. Exercise extreme caution

when changing direction on slopes. Braking may be affected by attachments. Reduce speed on slopes.

1. Fold this page along dotted line indicated above.

2. Hold page before you so that its [eft edge is vertically parallel to a tree trunk or other upright structure.

3. Sight across the fold in the direction of hill slope you want to measure.

4. Compare the angle of the fold with the slope of the hill.

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

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

3. Never tamper with safety devices. Check their proper

operation regularly and make necessary repairs if they are not functioning properly.

4. Keep unit free of grass, leaves, or other debris build- up. Clean up oil or fuel spillage, and remove any fuel-

soaked debris. Allow machine to cool before storage.

5. If you strike an object, stop and inspect the machine. Repair, if necessary, before restarting.

6. Never make adjustments or repairs with the engine running.

7. Check grass catcher components and the discharge guard frequently and replace with manufacturer's rec-

ommended parts, when necessary.

8. Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

9. Check brake operation frequently. Adjust and service

as required.

10. Maintain or replace safety and instructions labels, as necessary.

11. 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.

12. 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.

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

14. Replace faulty silencers/mufflers.

15. Maintain or replace safety and instruction labels as

necessary.

16. Use only fac!ory authorized replacement parts when

making repairs.

17.Always comply with factory specifications on all set- tings and adjustments.

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

19. 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.

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

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

22. 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.

23. 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).

24. 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 awayfrom 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 your authorized dealer.

25. WARNING: Stored energy device. Improper release of springs can result in serious personal injury.

Springs should be removed by an authorized techni- cian.

26. 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.

All DANGER, WARNING, CAUTION and instructional

messages on your rider and mower should be carefully

Decal - Tracking Adjustment

Part No. 1726638SJVl Decal - Ground

Speed Lever Part No. 7102576YP

Decal - Amputation and

Thrown Objects Hazard

Part No. 1704277SlVI

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.

Decal - Control Panel Part No. 7103082YP

Decal - Cutting Height Switch

Part No. 1734276SlVl

Decal - Hot Surfaces Part No. 1734273SM (Located on RH side)

z::_ Thrown Objects Hazard ,_;'

DecaJ - Operation, U Part No. 7102575YP

A_p_I_0_h_za,_ ,%-_ll-0_e,h_zat_

Decal - Operation, Lower Part No. 7103185YP

!i?'!'!!_?.;,';':,,,L

Decal - Cutting Hazard Part No. 1734672SlVl

(Located on rear frame)

Decal - Transmission Release Part No. 1734532SM

(Located on rear frame)

Decal - Ground Speed Lever

Part No. 1734270SlVl

Decal - Parking Brake

Part No. 7102578YP

Decal - Cutting Height

indicator

Part No. 1734335SlVl

_(\_\_' CRAFTSMAN _

When contacting the service center for replacement

parts, service, or information you MUST have these numbers.

Record your model name/number, manufacturer's identification numbers, and engine serial numbers in the space provided for easy access.

The identification tag is located on the underside of the seat. Tilt the seat 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.

Model Description Name/Number

Stock Number Unit Serial Number

Date Purchased

See your local Sears retailer to purchase the following accessories:

, Two Bin Grass Collector , Headlight Kit

, Front Bumper Kit

, Keys , Quick Start Guide

(English and Spanish)

, Operator's Manual & Parts Book

(English and Spanish)

Engine Make Engine Model

Engine Type/Spec Engine Code/Serial Number

INSTALLING THE SEAT

1. Raise the seat base (see Figure 1).

2. Align the holes in the seat bottom with the holes in the seat base.

3. Secure the seat to the seat base with two 5/16-18 x 3/4 serrated head bolts for the rear seat slots, and

two 5/16-18 x 3/4 shoulder bolts for the front slots.

4. Tighten to 14-19 ft-lbs (19-25 Nm).

5/16-18 x 3/4

19-25 Nm

14-19 ft-lbs

Figure 1. Installing the Seat

INSTALLING THE SEAT SAFETY SWITCH

1. Squeeze the side clips of the safety switch (A, Figure

2), and insert the switch into the slot (B) in the seat bottom. Be sure to slide the switch fully forward.

2. Connect the harness terminal housing (C) to the seat switch.

Loop the wire tie (D) around both the switch body and

the terminal housing.

Figure 2. Installing the Seat Safety Switch

SETTING UP THE GROUND SPEED

CONTROL LEVERS

1. Loosen (do not remove) the hardware securing the ground speed control levers to the lever bases.

2. Raise the levers, aligning the upper hole in each lever with the upper slotted hole in the lever base.

3. Install the hardware as shown in Figure 3. Tighten to 15-17 ft-lbs (20-23 Nm).

NOTE: Ground speed control levers must be adjusted prior to use. Refer to the "Ground Speed Control Adjustment" section.

_ 5/16-18

20-23 Nm

15-17 ftqbs

(_ (_ 5/16-18

x 1-3/4

Figure 3. Setting Up the Ground Speed Control Levers

Remove the Packaging Materials

Remove the cardboard from the crate. Remove any steel branding securing the

unit to the crate. Locate the manual packet.

........... i

Read the Operator's Manual

Locate the operator's manual in the manual packet. You should always read and follow the instructions in the operator's manual. Proper care, performance tips, and safety information are located in this important document.

Check the Tire Pressure

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

optimum traction. RearTire Pressure: 10-12 PSI

Front Tire Pressure: 18=20 PSi

Check Engine Oil Level

Fill=Up with FRESH Gasoline

Lift the seat deck to access the

Remove the fuel tank cap and fill fuel cap and tank.

the tank with fresh fuel. After

\, ,.,,_,',_//_ fueling, securely install the cap

and wipe up any fuel that may

have spilled. See the Operator's Manual for fuel recommendations.

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 warranty.

Fuel Tank Capacity: 4.0 Gallons (15,14 L)

Start the Engine and Drive the Unit Off the Crate

Refer to the STARTING THE ENGINE and DRIVING PRACTICE sections of this manual for information on

starting the unit and driving it off the crate.

Note: Engine is shipped with off. Add

FUI

10W-30 premium engine off if off level is

low. See MAINTENANCE for complete engine oil specifications and maintenance

requirements.

Lift the seat deck (Figure 15) to access the engine compartment.

Clean the area around the dip stick/oil fill tube. Remove the dip stick from the oil fill

tube and wipe the dip stick with a clean rag. Insert the dip stick into the oil fill tube (thread in or push

down completely). Remove and check the engine oil level. Oil level should

be between Full and Add marks. If necessary, add oil to the oil fill tube.

Replace and fully secure the dip stick.

Charge the Battery

Lift the seat deck to access the battery. If the unit is being 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 this manual for battery

charging information.

ParkinBrakeLever- .,=..._-

ENGAGEPositon _ F

Right

GroundSpeed

ControlLever

CONTROL FUNCTIONS

The information below briefly describes the

function of individual controls. Starting, stop- Transmission MowerBlade

ping, driving, and mowing require the combined ReleaseLevers Switch 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 to the side, away from the opera-

tor's lap (top inset, Figure 4), is the proper position for

starting the rider. Pulling the levers in across the opera-

tot's lap puts the levers 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 DRIVING PRACTICE for steering instructions.

Parking Brake Lever

Move the parking brake lever (bottom inset, Figure 4) up and across and into the locking notch to engage and lock the parking brake. Move the parking brake lever across and down to disengage the parking brake. The engine will not start unless the parking brake is engaged.

NOTE: The parking brake must be disengaged before operating the ground speed levers.

_r3_ Throttle/Choke Control (Choke-

The throttle/choke controls the engine speed and choke. Move the throttle/choke to the FAST position to increase engine speed and SLOW position to decrease engine speed. Always operate at full throttle. Move the throt- tle/choke control to the CHOKE position for starting a cold engine. A warm engine may not require choking.

O-Matic)

ignition

Switch

Figure 4. Controls

Mower Cutting Height Switch

To increase the mower cutting height (raise the mower deck), press the top of the yellow cutting height switch. To decrease mower cutting height (lower the mower deck), press the bottom of the switch. Mower cutting height range is approximately 3-3/4" to 1-1/2" (9,5 to 3,8 cm). The cutting height gauge indicates the position of the mower deck. The cutting height gauge is located on the front of the rider, just behind the driver's left leg.

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.

_ Mower Blade Switch

The yellow mower blade switch turns the mower blades on and off. To turn the mower blades ON, pull the switch up. To turn the mower blades OFF, push the switch down. Always set the engine speed control to FAST before turn- ing the mower blades ON, and while mowing.

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.

Fuel Tank

To remove the fuel tank cap, turn it counterclockwise.

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.

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.

• 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 gaso- line/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 always use fuel stabilizer, especially before storage of 30 days or longer. Use fresh

fuel next season. See STORAGE instructions for addi- tional 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 5).

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

3. Install and hand tighten the fuel cap.

Figure 5. Pre-Start Checks A. Fuel Tank Cap

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 across the face of slopes, not up and down.

Use caution when changing directions and DO

NOT START OR STOP ON A SLOPE.

A WARNING

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.

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.

STOPPING THE RIDER & ENGINE

1. Return the ground speed control levers to START/PARK positions to stop rider movement.

2. Engage the parking brake.

3. Turn off the mower blades by pushing the mower blade switch down to the OFF position.

4. Move the engine speed control to SLOW position and

turn the ignition switch to OFE Remove the key.

STARTING THE ENGINE

1. While sitting in the seat, make sure the mower blade switch is OFF, the ground speed control levers are locked in START/PARK positions, and the parking brake is engaged.

2. Move the throttle/choke control to the CHOKE posi- tion for starting a cold engine. A warm engine may

not require choking.

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

START to crank the engine.

4. After the engine starts, release the key. It will return to the RUN position.

5. Move the throttle/choke to the FAST position to

increase engine speed and SLOW position to

decrease engine speed. Always operate at full throt- tle.

6. Warm the engine by running it for at least a minute before turning on the mower blades, or driving the

unit.

ALWAYS operate the unit with the throttle/choke control set to FAST when mowing or driving,

NEVER engage the mower blades with the engine

speed set to SLOW,

PUSHING THE RIDER BY HAND

NOTE: Do not disengage the transmission if parked on a slope

Turn the mower blades OFF, push the ground speed control levers out to their START/PARK positions, engage the parking brake, turn the ignition switch OFF, remove the key, and wait for all moving parts to stop.

2. Locate the transmission release levers (C, Figure 6) at the rear of the unit.

Pull both levers back and down to release the trans- missions (position B, Figure 6).

Pull the ground speed control levers in to their DRIVE

positions, and disengage the parking brake. The rider can now be pushed by hand.

After moving the rider, set the ground speed control

levers to START/PARK, engage the parking brake,

and push both transmission release levers forward to

re-engage the transmissions (position A, Figure 6).

DO NOTTOW RIDER

Towing the unit will cause transmission dam- age. Do not use another vehicle to push or pull this unit. Do not use this unit to push or pull another vehicle or object.

MOWING

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

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

3. Set the engine speed control to FAST.

4. Turn the mower blades ON (pull switch up).

5. Disengage the parking brake.

6. Move the ground speed control levers in from START/PARK positions to drive positions (levers in

across the operator's lap).

7. Begin mowing. See DRIVING PRACTICE.

8. When finished, turn the mower blades OFF (push switch down).

9. Stop the rider and engine (see STOPPING THE RIDER AND ENGINE).

Figure 6, Transmission Release Levers A, Drive Position

B. Push Position C. Transmission Release Levers

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.

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

WARNING

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

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 7.

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 7. Move Control Levers Gradually

Forward Travel Practice

Gradually move both ground speed control levers evenly

FORWARD from neutral (see Figure 8). Slow down and

repeat.

Reverse Travel Practice

LOOK DOWN & BEHIND, then gradually move both ground speed control levers evenly BACK from neutral (see Figure 9). 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.

Forward Travel

Figure 8. Forward Travel

Reverse Travel

Figure 9. Reverse Travel

Practice Turning Around a Corner

While traveling forward allow one handle to gradually return back toward neutral (see Figure 10). Practice sev- eral times before mowing.

NOTE: To prevent damaging your lawn by pivoting direct- ly on the tire tread, it is best to keep both wheels going at least slightly forward.

Practice Turning In Place

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 (see Figure 11). Repeat several times.

Executing Turns

Figure 10. RightTurn

ADVANCED DRIVING

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:

Slow down at the end of the row.

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

(see Figure 12). Be sure to keep both

wheels moving to avoid turf damage.

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.

As 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 control of the rider will be!

Turning In Place

Figure 11. Turning in Place

Figure 12. Executing an End-Of-Row Turn

MOWER DECK REMOVAL & INSTALLATION

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

WARNING

After lowering the mower cutting height, engage parking brake, turn off the mower blades, turn the ignition switch to STOP, and remove key before attempting to install or remove the mower.

Removing the Mower Deck

1. Turn the mower blades OFF, put the ground speed control levers in START/PARK position, engage the

parking brake, turn the ignition OFF, and wait for all moving parts to stop.

2. Pivot the front wheels forward.

3. Use the mower belt release lever (D, Figure 13) to release belt tension. Remove the mower belt (B) from engine pulley (A).

4. Turn the ignition switch from OFF to RUN without starting the engine.

5. Use the mower cutting height switch to raise the mower deck.

6. Place 4x4 wood blocks under the front and rear lip of

the mower deck to securely support it.

7. Use the mower cutting height switch to fully lower the mower so that is it resting on the 4x4 wood blocks (A, Figure 14).

8. Turn the ignition switch to OFF and remove the key.

9. Remove the hair pin clip (B) securing the rear mower lift arm. Separate the lift arm from the mower deck. Repeat on both sides of the mower.

10. Remove the 3/8 -16 x 3/4 carriage bolts and flange nuts (C) that secure the front hitch rod, then remove

the hitch rod (D).

11. Slide the mower deck out from under the rider.

Installing

1. Slide the Slide the mower forward and hook the front hitch rod (D, Figure 14) to the front mower deck hooks.

2. Secure front hitch rod with two 3/8 -16 x 3/4 carriage bolts and flange nuts (C).

3. Slide the mower deck backwards and connect the rear lift arms to the mower deck. Secure with hair pin

clips (B).

4. Insert the key into the ignition switch. Turn the switch

from OFF to RUN without starting the engine.

5. Use the cutting height switch to raise the mower until it is no longer resting on the 4x4 wood blocks (A).

6. Turn the ignition switch OFF and remove the key. Remove the 4x4 blocks.

7. Use the mower belt release lever (D, Figure 13) to release mower belt tension, and install the belt as

shown.

the Mower Deck

mower deck under the right side of the rider.

Figure 13. Mower Belt Routing A. Engine Pulley B. Mower Belt

C. Idler Pulleys D. Mower Belt Release Lever

E. Arbor Pulleys

Figure 14. Mower Hitch Components A. 4x4 Wood Blocks

B. Hair Pin Clip C. 3/8-16 x 314 Carriage Bolt & Flange Nut

D. Front Hitch Rod

MAINTENANCE SCHEDULE

The following schedules should be followed for normal care of your rider and mower.

RIDER MAINTENANCE, All Models Before Spring 8 25 100 200 Yearly

Each Use & Fall Hours Hours Hours Hours

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 PTO Clutch •

ENGINE MAINTENANCE, 8 Hours or 25 Hours or 50 Hours or 100 Hours or Yearly

21HP Briggs & Stratton Daily Every Every Every

Check Engine Oil Level * • Service Air Pre-Cleaner * •

Season Season Season

Change Oil * • Service Air Filter * •

Change Oil & Filter * • Clean Cooling Fins * •

Replace Air Filter * • Replace Spark Plug •

Replace Fuel Filter 1 •

Check Valve Clearance 1" •

* 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.

1"These services should be performed by Sears or other qualified service dealer.

Rider Maintenance Items

WARNING

Move the ground speed levers to START/PARK positions, engage the parking brake, turn the mower blades OFF, turn the ignition switch OFF, and wait for all moving parts to stop before accessing the engine compartment or performing any maintenance procedures.

ACCESSING THE ENGINE COMPARTMENT

Lift up on the back edge of the seat deck to access the

engine compartment (see Figure 15).

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.

Figure 15. Accessing 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 unitat 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

16), 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.

CHECK TIRE PRESSURE

Service Interval: 25 Hours.

Tire pressure should be checked periodically, and main-

tained at the levels shown in Figure 17. 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.

Figure 16. Engine Compartment A. Intake Screen

B. Air Filter Cover

Tire Pressure

Front 18-20 psi (1,24-1,38 bar) Rear 10-12 psi (,69-,83 bar)

Figure 17. Tire Pressures

LUBRICATION

Service Interval: 25 hours. Lubricate the unit at the locations shown in Figures 18

through 22 as well as the following lubrication points.

Grease:

• front wheel bushings

• mower arbors

• front wheel grease fittings

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

um grease.

Oil:

• brake linkage

• hydro 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 20. Lubricating Rider

Figure 18. Mower Lubrication

t 4

_. x,_/" _

Figure 21. Lubricating Rider

i i7; " ;'_'_'<'_....

Figure 19. Arbor Lubrication (3-Blade Model Shown, All Models Similar)

Figure 22. Lubricating Mower Lift

CLEAN DECK & CHECK/REPLACE MOWER BLADES

Service Interval: 25 hours or as required.

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.

WARNING

For your personal safety, blade mounting capscrews must each be installed with two spring washers or a hex washer and spring washer, then securely tightened. Torque blade mounting nut to 80-90 ft-lbs (108-122 Nm).

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

2. Remove blade to inspect it or to safely access the underside of the mower deck (see Figure 23). Use a block of wood to prevent blade rotation while loosen- ing the capscrew by turning it counterclockwise.

3. Remove the nut (C, Figure 24), spring washers (B),

and blade.

Clean the underside of the mower deck.

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.

Balance the blade as shown in Figure 25. 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.

Reinstall the blade with the lift wings (D, Figure 24) pointing up toward the mower deck as shown.

Reinstall the spring washers (B, Figure 24) and nut (C). Use a wooden block (A) to prevent blade rotation

while tightening the nut (C) to 80-90 ft-lbs (108-122

Nm).

LOOSEN

Figure 23. Blade Removal

Figure 24. Blade Installation A. 4x4 Wood Block C. Blade Nut

B. Spring Washers D. Lift Wings

Workbench

Nail

Figure 25. Balancing The Blade

CLEANING THE BATTERY AND CABLES

WARNING

CHECK RIDER SAFETY SYSTEM

Corrosion hazard.

Batteries contain acid. Always keep the battery upright and do not spill the electrolyte. Avoid contact with skin and

eyes.

Explosion hazard. Changing the battery produces explosive

hydrogen gas. Only charge the battery in a well ventilated area, away from any ignition source such as a water heater, electric

motor, or a lit cigarette. Wear Protective Equipment

Always wear gloves and safety glasses when handling the battery and battery

cables.

Service Interval: 100 Hours

Disconnect the cables from the battery, negative

cable first (B, Figure 26).

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

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

Clean the battery terminals and cable ends with a

wire brush until shiny.

Reinstall the battery and secure with the rubber strap.

Reattach the battery cables: first attach the positive cable (see A, Figure 26), then attach the negative cable (B).

Coat the cable ends and battery terminals with petro-

leum jelly or non-conducting grease.

Service Interval: Every 100 hours, every spring/fall, and after storage of 30 days or longer.

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 -- ENGINESHOULD NOT CRANK IF:

• Mower blades switch is ON, OR

• Ground speed control levers are not intheir START/PARK positions, OR

• Parking brake lever is in DISENGAGE position.

TEST 2 -- ENGINESHOULD CRANK IF:

• Mower blade switch is OFE AND

• Ground speed control levers are in their START/PARK positions, AND

• Parking brake lever is in ENGAGE position.

TEST 3 -- ENGINESHOULD SHUT OFF IF:

• Operator rises off seat with the mower blade switch ON, OR

• Operator rises off seat with the ground speed levers in DRIVE positions, OR

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

• Operator moves the left and/or right ground speed

control lever out of its START/PARK position with the parking brake lever in ENGAGE position.

TEST 4 -- BLADE BRAKE CHECK The mower blades and mower drive belt should come

to a complete stop within five seconds after the mower

blade switch is turned OFE If mower drive belt does not stop within five seconds, contact your local author-

ized dealer.

Figure 26. Engine Compartment A. Positive (+) Battery Cable

B. Negative (-) Battery Cable

NOTE: Once the engine has stopped, the mower blade switch must be turned OFF, the ground speed control levers must be locked in their START/PARK positions, and the parking brake lever must be in the ENGAGE position in order to start the engine.

WARNING

If the unit does not pass a safety test, do not oper- ate it. See your local authorized dealer. Under no circumstance should you attempt to defeat the pur- pose of the safety interlock system.

CHECK / ADJUST PTO CLUTCH

WARNING

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

Service Interval: 200 Hours. The Power Take Off (PTO) clutch drives the mower

blades. The PTO clutch is engaged and disengaged by

the mower blade switch. Check the PTO clutch adjust-

ment every 200 hours of operation. Also perform the fol- lowing 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. Note the position of the 3 adjustment windows (A, Figure 27) in the side of the brake plate and the

nylock adjustment nuts (B).

3. Insert a .012"-.015" (2,5-4 mm) feeler gauge (C)

through each window, positioning the gauge between the rotor face and the armature face as shown in

Figure 28.

4. Alternately tighten the adjustment nuts (B, Figure 28) 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 27. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown)

B. Adjustment Nut

Figure 28. Adjust PTO Clutch A. Window

B. Adjustment Nut C. Feeler Gauge

Engine Maintenance Items

CHECK ENGINE OIL LEVEL

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

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

2. Clean the area around the dip stick (C, Figure 30).

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

4. Insert the dip stick back into the engine. Thread the cap back into the tube (D).

5. Remove the dip stick and read the oil level. The oil

level should be between the "FULl" and "ADD" marks (D). If not, add oil according to the oil recommenda-

tions chart (Figure 29).

CHANGE ENGINE OIL

Service Interval: 50 hours or once per season.

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

and allow it to cool from hot to warm.

Useoil classifiedAPIService ClassSF, SG,SH,SJor betterwith SAEViscosity:

! I 1! I ,

°F -20 0 20 32 40 60 80 100

°O -30 -18 -7 0 4 16 27 38

*CAUTION:Air cooled engines run hotter than automotive engines.

The useof non-synthetic multi-viscosity oils (5W-30, lOW-30, etc.)

in temperatures above 400 F(4°0) will result in higherthan normal oil consumption. When using a multi-viscosity oil, check oil level

more frequently.

**CAUTION: SAE30 oil, if usedbelow 400F (4°C),will result in hard

starting andpossible engine boredamage due to inadequate lubrication.

Figure 29. Recommended Engine Oil

1. Clean the area around the dip stick (C, Figure 30) 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) and route the hose

next to the engine.

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

LEVEL above.

5. Start and run the engine at SLOW speed for 30 sec- onds. Stop the engine and recheck the oil level.

CHANGE ENGINE OIL & FILTER

Service Interval: 100 hours or once per season.

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

and allow it to cool from hot to warm.

1. Clean the area around the dip stick (C, Figure 30) and oil drain (A).

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

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

4. Using a drop of oil on your finger tip, wet the rubber

gasket on the bottom of the new filter.

5. Turn the filter clockwise until the rubber gasket meets the filter base. Then turn 1/2 to 3/4 turn more.

Figure 30. Oil Change A. Oil Drain Tube

B. Oil Filter C. Dip Stick

6. Reinstall the oil drain plug (A).

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

8. Start and run the engine at SLOW speed for 30 sec-

onds. Stop the engine and recheck the oil level.

9. Test run the engine to check for leaks. Stop the

engine for 1 minute, then recheck the oil level.

AIR FILTER & PRE-CLEANER

Service Interval: Pre-Cleaner: Every 25 hours or as

required. Air Filter: Every 50 hours or as required. Replacement Interval: Pre-Cleaner: As required. Air

Filter: Every 200 hours or once per season.

Air Filter Removal & Installation

1. Lift up on the bottom of the latch (A, Figure 31 or 32) and flip the latch away from the cover (B).

2. Remove the cover (B). Remove the filter (C, Figure

31) and pre-cleaner (D).

3. Install the pre-cleaner (D) with the mesh side up. Install the filter (C) as shown.

4. Install the cover (B, Figure 32) making sure the tabs

are inserted into their slots.

5. Secure with the latch (A).

Figure 31. Air Filter Assembly A. Air Filter Latch

B. Air Filter Cover

Figure 32. Air Filter Service A. Air Filter Latch

B. Air Filter Cover C. Air Filter

D. Pre-Cleaner

REPLACE SPARK PLUG

Service Interval: Yearly Replacement Spark Plug: 491055S

Spark Plug Gap: .030" (.76 mm)

1. Stop the engine and allow it to cool.

2. Clean the area around the spark plug.

3. Remove the spark plug.

4. Check the spark plug gap. It should be .030" (see Figure 34).

5. Reinstall the plug into the cylinder head. Tighten the plug to 180 in-lbs (20 Nm).

.030" (.76 ram)

Figure 33. Spark Plug Gapping

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 34) and raise or lower the levers to the desired position. Tighten the mounting

bolts. 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 34) 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 lower mounting bolt (D, Figure 34), pivoting the lever forward, and reinstalling the capscrew through the control lever and forward slot (C). Repeat with the other ground speed lever.

Figure 34. Control Lever Adjustment A. Jam Nut

B. Carriage Bolt C. Forward Slot

D. Mount Bolts E. Knob

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 34). Loosen the jam nut and turn the knob COUNTERCLOCKWISE to increase speed or CLOCKWISE to decrease speed. Tighten the jam nut when complete.

CUTTING HEIGHT ADJUSTMENT

To increase the mower cutting height (raise the mower deck), press the top of the mower cutting height switch (A, Figure 35) To decrease mower cutting height (lower the mower deck), press the bottom of the switch. Mower cutting height range is 3-3/4" to 1-1/2" (9,5-3,8 cm). The cutting height gauge indicates the position of the mower deck. The cutting height gauge (B) is located on the front of the rider, just behind the driver's left leg.

PTO CLUTCH ADJUSTMENT

See CHECK / ADJUST PTO CLUTCH in the Maintenance Section.

Figure 35. Cutting Height Adjustment A. Cutting Height Adjustment Switch

B. Cutting Height Gauge

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