Poulan 409631 User Manual

IMPORTANT MANUAL Do Not Throw Away

03090

OPERATOR'S MANUAL

WARNING:

MODEL:

Read this Man u al and follow all Warnings and Safety Instructions. Fail ure to do so can re sult in serious in ju ry.

PBGT26H54

LAWN TRACTOR

ALWAYS WEAR EYE PROTECTION DURING OPERATION Visit our website: www.poulan-pro.com

409631 Rev1 01.16.07 TH

Printed in U.S.A.

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

DANGER: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

WARNING: In order to prevent ac ci den tal starting when setting up, trans port ing, ad just ing or making repairs, al ways dis con nect spark plug wire and place wire where it can not contact spark plug.

WARNING: Do not coast down a hill in neutral, you may lose control of the tractor.

WARNING: Tow only the attachments that are rec om mend ed by and comply with spec i fi ca tions of the man u fac tur er of your tractor. Use common sense when towing. Operate only at the low est possible speed when on a slope. Too heavy of a load, while on a slope, is dan ger ous. Tires can lose trac tion with the ground and cause you to lose control of your tractor.

WARNING

Engine exhaust, some of its con stit u ents, and cer tain vehicle com po nents contain or emit chem i cals known to the State of Cal i for nia to cause can cer and birth de fects or oth er re pro duc tive harm.

• Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working.

• Slow down before turning.

• Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.

• Disengage blades 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.

• Operate machine only in daylight or good artificial light.

• Do not operate the machine while under the influence of alcohol or drugs.

• Watch for traffic when operating near or crossing road ways.

• Use extra care when loading or unloading the machine into a trailer or truck.

• Always wear eye protection when operating machine.

• Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect them selves and others from serious injury.

• Follow the manufacturer's recommendation for wheel weights or counterweights.

• Keep machine free of grass , leaves or other debris build-up which can touch hot exhaust / engine parts and burn. Do not allow the mower deck to plow leaves or other debris which can cause build-up to occur. Clean any oil or fuel spillage before operating or storing the machine. Allow machine to cool before storage.

WARNING

Battery posts, terminals and related ac ces so ries contain lead and lead compounds, chem i cals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm. Wash hands after handling.

I. GENERAL OPERATION

• Read, understand, and follow all instructions on the machine and in the manual before starting.

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

• Only allow responsible adults, who are familiar with the in struc tions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades.

• Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.

• Never carry passengers.

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

• Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

II. SLOPE OPERATION

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

• Mow up and down slopes, not across.

• Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Choose a low ground speed so that you will not have to stop or shift while on the slope.

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

Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.

• Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

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

• Use extra care while operating machine with grass catchers or other at tach ments; they can affect the stability of the machine. Do no use on steep slopes.

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

• Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

III. CHILDREN

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

• Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

• Be alert and turn machine off if a child enters the area.

• Before and while backing, look behind and down for small children.

• Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine 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.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs, trees, or other objects that may block your view of a child.

IV. TOWING

• Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

• Follow the manufacturer's recommendation for weight limits for towed equipment and towing on slopes.

• Never allow children or others in or on towed equipment.

• On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

• Travel slowly and allow extra distance to stop.

V. SERVICE

SAFE HANDLING OF GASOLINE

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

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

• Use only approved gasoline container.

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

• Never fuel the machine indoors.

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

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

• Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.

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

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace gas cap and tighten securely.

GENERAL SERVICE

• Never operate machine in a closed area.

• Keep all nuts and bolts tight to be sure the equipment is in safe working condition.

• Never tamper with safety devices. Check their proper operation regularly.

• Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage and remove any fuelsoaked debris. Allow machine to cool before storing.

• If you strike a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.

• Never make any adjustments or repairs with the engine run ning.

• Check grass catcher components and the discharge guard frequently and replace with manufacturer's recommended parts, when necessary.

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

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

• Maintain or replace safety and instruction labels, as necessary.

• Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary. Al ways look down and behind before and while backing.

• Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

• Be alert and turn machine off if a child enters the area.

• Before and while backing, look behind and down for small children.

• Mow up and down slopes (15° Max), not across.

• Choose a low ground speed so that you will not have to stop or shift while on the slope.

• Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

• If machine stops while going uphill, disengage blades, shift into reverse and back down slowly.

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

PRODUCT SPECIFICATIONS

Gasoline Capacity 4 Gallons and type: Unleaded Regular

Oil Type (API-SG-SL): SAE 30 (above 32°F) SAE 5W-30 (below 32°F)

Oil Capacity: W/ Filter: 64 oz W/O Filter: 60 oz

Spark Plug: Champion QC12YC (Gap: .040")

Ground Speed (MPH): Forward: 0 – 5.8 Reverse: 0 – 2.1

Charging System: 16 AMPS @ 3600 RPM Battery: AMP/HR: 35

MIN. CCA: 280 Case Size: U1R

Blade Bolt Torque: 45-55FT. LBS.

CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manu fac tured to give you the best possible dependability and performance.

Should you experience any problem you cannot easily remedy, please contact your nearest authorized servicecenter/ de part ment We have competent, well-trained tech ni cians and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor prop erly. Always observe the “SAFETY RULES”.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for and using your tractor.

• Follow the instructions under “Maintenance” and “Stor age” sec tions of this own er’s manual.

WARNING: This tractor is equipped with an internal com bus tion engine and should not be used on or near any un im proved forest-covered, brush-covered or grass-cov ered land unless the en gine’s exhaust system is equipped with a spark arrester meeting ap pli ca ble local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.

In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

A spark arrester for the muffler is available through your nearest authorized service center/department (See RE PAIR PARTS section of this manual).

TABLE OF CONTENTS

SAFETY RULES .........................................................2-3

PRODUCT SPECIFICATIONS ....................................... 4

CUSTOMER RESPONSIBILITIES ................................. 4

ASSEMBLY ................................................................. 6-9

OPERATION ...........................................................10-16

MAINTENANCE SCHEDULE ...................................... 17

MAINTENANCE ..................................................... 17-20

SERVICE AND AD JUST MENTS ............................ 21-25

STORAGE .................................................................... 26

TROU BLE SHOOT ING ............................................ 27-28

WARRANTY ................................................................. 30

UNASSEMBLED PARTS

(5) Large Retainer

Springs - 7/16

(2) Smaller Retainer

Springs - 5/16

Mower

(1) 3/4 O.D. Washers

(5) 1-3/16 O.D. Washers

Mower Front Wheel

(1) Wheel

(1) Shoulder Bolt

(1) Oil Drain Tube For Future Use

Keys

(1) 1-1/4 O.D. Washer

(1) Locknut

3/8-16

Slope Sheet

(1) Anti-Sway Bar

(2) Rear Lift Link

Assemblies

(2) Keys

ASSEMBLY

Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Stan dard wrench sizes are listed.

(1) 3/4" wrench (1) Utility knife (1) 9/16" wrench (1) Pliers (1) Tire Pressure Gauge When right or left hand is mentioned in this man ual, it

means from your point of view, when you are in the operating po si tion (seated be hind the steer ing wheel).

TO REMOVE TRACTOR FROM CARTON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons from carton .

• Cut along dashed lines on all four panels of carton. Remove end panels and lay side panels flat.

• Remove mower and packing materials.

• Check for any additional loose parts or cartons and remove.

FIG. 2

NOTE: You may now roll or drive your tractor off the skid.

Follow the ap pro pri ate instruction below to remove the tractor from the skid.

WARNING: Before start ing, read, un der stand and fol low all in struc tions in the Op er a tion section of this man u al. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other peo ple and objects.

CHECK BATTERY (See Fig. 1)

• Lift hood to raised position. NOTE: If this battery is put into service after month and year

indicated on label (L) (label is located between terminals) charge battery for minimum of one hour at 6-10 amps. (See "BATTERY" in Maintenance section of this manual for charging instructions).

02931

FIG. 1

ADJUST SEAT (See Fig. 2)

• Sit in seat.

• Lift up adjustment lever (A) and slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down.

• Release lever to lock seat in position.

TO ROLL TRACTOR OFF SKID (See Op er a tion section for location and function of con trols)

• Raise attachment lift lever to its highest po si tion.

• Release parking brake by de press ing brake ped al.

• Place freewheel control in dis en gaged po si tion to dis en gage trans mis sion (See “TO TRANS PORT” in the Op er a tion section of this manual).

• Roll tractor forward off skid.

TO DRIVE TRAC TOR OFF SKID (See Op er a tion section for location and function of con trols)

• Be sure all the above assembly steps have been completed.

• Check engine oil level and fill fuel tank with gasoline.

• Place freewheel control in "trans mis sion engaged" position (see "TO TRANSPORT" in Operation section of this manual).

• Sit on seat in operating position, depress brake pedal and set the parking brake.

• Raise attachment lift lever to its highest position.

• Remove key from bag and start the engine (see "TO START" in the Operation section of this manual). After engine has started, move throttle control to idle (slow) position.

• Release parking brake.

• Slowly depress forward drive pedal and drive tractor off skid.

• Apply brake to stop tractor and set park ing brake.

• Turn ignition key to "STOP" position.

Continue with the in struc tions that follow.

ASSEMBLY

0205

ASSEMBLE FRONT WHEEL TO MOWER (See Fig. 3)

• Using shoulder bolt, washer and locknut from parts bag, as sem ble front wheel to mower as shown. Tighten securely.

FIG. 5

FIG. 3

INSTALL MOWER AND DRIVE BELT

(See Figs. 4-12)

See MOWER AND DRIVE BELT ASSEMBLY Supplement Sheet for additional guidance on this assembly.

Be sure tractor is on level surface and engage park ing brake.

• Lower attachment lift lever to it's lowest position.

CAUTION: Lift lever is spring loaded. Have a tight grip on lift lever, lower it slowly and engage in lowest position.

• Turn steering wheel to the left as far as it will go and position mower on right side of tractor with deflector shield to the right.

NOTE: Be sure mower side suspension arms (A) are pointing forward before sliding mower under tractor.

• Slide mower under tractor until it is centered under tractor.

• FIRST INSTALL ANTI-SWAY BAR (S).

- From right side of mower, insert anti-sway bar into

hole in transmission bracket (T).

02995

FIG. 6

- Pivot bar towards you and insert other end of bar

into hole in rear mower bracket (D). Move mower as needed to insert bar.

- Secure with washer and retainer spring as shown

using small 5/16 retainer spring.

02965

FIG. 4

• Remove plastic tie securing belt, bring belt forward and check belt for proper routing in all mower pulley grooves.

02996

FIG. 7

ASSEMBLY

• ATTACH MOWER SIDE SUSPENSION ARMS (A) TO CHASSIS - Position hole in arm over pin (B) on outside of tractor chassis and secure with washer and retainer spring.

• Repeat on opposite side of tractor.

FIG. 8

• ATTACH REAR LIFT LINKS (C) - Insert rod end of lift link assembly into hole in tractor lift shaft suspension arm (L) and pivot link down to mower. Lift rear corner of mower and position slot in link assembly over pin on rear mower bracket (D) and secure with washer and retainer spring.

• Repeat on opposite side of tractor.

• Turn steering wheel to position wheels straight forward.

• ATTACH FRONT LINK (E) - Work from left side of tractor. Insert rod end of link assembly through front hole in tractor front suspension bracket (F) and secure with7/16 retainer spring (G) through hole in link located behind the bracket.

• Insert other end of link (E) into hole in front mower bracket (H) and secure with washer and 5/16 retainer spring (J).

5/16

7/16

FIG. 10

• Disengage belt tension rod (K) from locking bracket (L).

• Install belt onto engine clutch pulley (M).

IMPORTANT: Check belt for proper routing in all mower pulley grooves.

FIG. 9

FIG. 11

ASSEMBLY

FIG. 12

• Engage belt tension rod (K) on locking bracket (L).

CAUTION: Belt tension rod is spring loaded. Have a tight grip on rod and engage slowly.

• Raise attachment lift lever to highest position.

• If necessary, adjust gauge wheels before op er at ing mower as shown in the Operation section of this manual.

CHECK TIRE PRESSURE

The tires on your tractor were overinflated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance.

• Reduce tire pressure to PSI shown on tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly leveled. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL BELTS

See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments sec tion of this manual. Verify that the belts are routed cor rect ly.

✓CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRAC TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

✓ All assembly instructions have been com plet ed. ✓ No remaining loose parts in carton.

✓ Battery is properly prepared and charged. ✓ Seat is adjusted comfortably and tightened securely. ✓ All tires are properly inflated. (For shipping purposes,

the tires were overinflated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/

front-to-rear for best cutting results. (Tires must be properly inflated for leveling).

✓ Check mower and drive belts. Be sure they are routed

properly around pulleys and inside all belt keepers.

✓ Check wiring. See that all connections are still secure

and wires are properly clamped.

✓ Before driving tractor, be sure free wheel control is in

“transmission engaged” position (see “TO TRANS PORT” in the Operation section of this man u al).

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS:

✓ Engine oil is at proper level. ✓ Fuel tank is filled with fresh, clean, regular unleaded

gasoline.

✓ Become familiar with all controls, their location and

function. Operate them before you start the engine.

✓ Be sure brake system is in safe operating condition. ✓ Be sure Operator Presence System and Reverse Op-

eration System (ROS) are working properly (See the Operation and Maintenance sections in this manual).

✓ It is important to purge the transmission before op er -

at ing your tractor for the first time. Follow proper starting and transmission purging instructions (See “TO START EN GINE” and “PURGE TRANSMISSION” in the Op er a tion section of this manual).

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that the brake is operating properly. See “TO CHECK BRAKE” in the Service and Adjustments section of this manual.

OPERATION

These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.

REVERSE

ENGINE OFF

LIGHTS ON

ATTACHMENT

CLUTCH DISENGAGED

FREE WHEEL

(Automatic Models only)

NEUTRAL

REVERSE

OPERATION

SYSTEM (ROS)

FUEL

HIGH

ENGINE ON

BATTERY

ATTACHMENT

CLUTCH ENGAGED

REVERSE

LOW

ENGINE START

DANGER, KEEP HANDS

AND FEET AWAY

CHOKE

PARKING BRAKE

FORWARD

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury.

FAST

MOWER HEIGHT

CRUISE CONTROL

KEEP AREA CLEAR

(SEE SAFETY RULES SECTION)

SLOW

SLOPE HAZARDS

IGNITION SWITCH

MOWER LIFT

CLUTCH/BRAKE

PEDAL

Failure to follow instructions could result in serious injury or death. The safety alert symbol is used to identify safety information about hazards which can result in death, serious injury and/or property damage.

CAUTION when used without the alert symbol, indicates a situation that could result in damage

to the tractor and/or engine.

HOT SURFACES indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage.

FIRE indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage.

OPERATION

KNOW YOUR TRACTOR

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR

Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and ad just ments. Save this manual for future reference.

FIG. 13

Our tractors conform to the applicable safety standards of the American National Standards Institute.

(A) ATTACHMENT LIFT LEVER – Used to raise and lower the mower or other attachments mounted to your trac tor. (B) BRAKE PEDAL – Used for brak ing the tractor and start ing the engine. (C) PARKING BRAKE – Locks clutch/brake pedal into the brake position.

(D) THROTTLE CONTROL – Used to control engine speed. (E) ATTACHMENT CLUTCH SWITCH – Used to engage the

mow er blades, or other at tach ments mounted to your tractor. (F) IGNITION SWITCH – Used for starting and stopping the engine. (G) REVERSE OPERATION SYSTEM (ROS) "ON" POSITION – Allows operation of mower or other powered attachment while in reverse.

(H) LIGHT SWITCH – Turns the headlights on and off. (J) CRUISE CONTROL LEVER – Used to set forward

movement of tractor at desired speed without holding the forward drive pedal. (K) FORWARD DRIVE PEDAL – Used for forward movement of tractor. (L) REVERSE DRIVE PEDAL – Used for reverse movement of tractor. (M) FREEWHEEL CONTROL – Disengages transmission for pushing or slowly tow ing the trac tor with the engine off.

(N) CHOKE CONTROL – Used when starting a cold engine. (P) SERVICE REMINDER / HOUR METER – Indicates when

service is required for the engine and mower.

(Q) 12-VOLT POWER PORT – Used for 12-volt accessories.

OPERATION

The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye dam age. Always wear safety glass es or eye shields while operating your tractor or per form ing any ad just ments or repairs. We rec om mend standard safety glasses or a wide vision safety mask worn over spectacles.

HOW TO USE YOUR TRAC TOR

TO SET PARKING BRAKE(See Fig. 14)

Your tractor is equipped with an operator presence sens ing switch. When engine is running, any attempt by the op er a tor to leave the seat without first setting the parking brake will shut off the engine.

• Depress brake pedal (B) all the way down and hold.

• Pull parking brake lever (C) up and hold, re lease pres sure from brake pedal (B), then release parking brake lever. Pedal should re main in brake position. Make sure parking brake will hold tractor secure.

FIG. 14

STOPPING

MOWER BLADES

• To stop mower blades, push at tach ment clutch switch in to disengaged position (O).

IMPORTANT: Leaving the ignition switch in any position other than "STOP" will cause the battery to discharge and go dead.

NOTE: Under certain conditions when tractor is standing idle with the engine running, hot engine exhaust gases may cause “browning” of grass. To elim i nate this possibility, always stop en gine when stopping tractor on grass areas.

CAUTION: Always stop tractor com plete ly, as de scribed above, before leav ing the operator's position.

FIG. 16

TO USE THROTTLE CONTROL (See Fig. 16)

Always operate engine at full speed (fast).

• Operating engine at less than full speed (fast) reduces engines operating efficiency.

• Full speed (fast) of fers the best bagging and mower per for mance.

(I) Attachment Clutch Switch Pull Out To “Engage”

GROUND DRIVE -

• To stop ground drive, depress brake pedal all the way down.

ENGINE -

• Move throttle control (D) between half and full speed (fast) position.

NOTE: Failure to move throttle control between half and full speed (fast) position, before stopping, may cause engine to “backfire”.

• Turn ignition key (F) to “STOP” position and remove key. Always remove key when leaving tractor to prevent un au tho rized use.

• Never use choke (N) to stop engine.

(O) Push-In to “Dis en gaged”

FIG. 15

TO USE CHOKE CONTROL -D (See Fig. 16)

Use choke control whenever you are starting a cold engine. Do not use to start a warm engine.

• To engage choke control, pull knob out. Slowly push knob in to disengage.

TO MOVE FORWARD AND BACKWARD -N (See Fig. 17)

The direction and speed of movement is controlled by the forward and reverse drive pedals.

• Start tractor and release parking brake.

• Slowly depress forward (K) or reverse (L) drive pedal to begin movement. Ground speed increases the further down the pedal is depressed.

OPERATION

FIG. 17

TO USE CRUISE CONTROL -J (See Fig. 17)

The cruise control feature can be used for forward travel only.

SYSTEM CHARACTERISTICS The cruise control should only be used while mowing or

transporting on relatively smooth, straight surfaces. Other con di tions such as trimming at slow speeds may cause the cruise control to dis en gage. Do not use the cruise control on slopes, rough terrian or while trimmimg or turning.

• With forward drive pedal depressed to desired speed, pull cruise control lever (J) up and hold while lifting your foot off the pedal, then release the lever.

To disengage the cruise control, depress the brake pedal or tap on forward drive pedal.

• The average lawn should be cut to approximately 2-1/2 inches during the cool season and to over 3 inches during hot months. For healthier and better looking lawns, mow often and after moderate growth.

• For best cutting performance, grass over 6 inches in height should be mowed twice. Make the first cut relatively high; the second to de sired height.

TO ADJUST GAUGE WHEELS (See Fig. 19)

Gauge wheels are prop er ly ad just ed when they are slight ly off the ground when mower is at the desired cutting height in operating position. Gauge wheels then keep the deck in proper position to help prevent scalping in most terrain conditions.

NOTE: Adjust gauge wheels with tractor on a flat level surface.

• Adjust mower to desired cutting height (See “TO AD JUST MOWER CUT TING HEIGHT” in this sec tion of manual).

• With mower in desired height of cut po si tion, gauge wheels should be assembled so they are slightly off the ground. In stall gauge wheel in ap pro pri ate hole. Tighten se cure ly.

• Repeat for all, installing gauge wheel in same adjustment hole.

TO ADJUST MOWER CUT TING HEIGHT (See Fig. 18)

The po si tion of the at tach ment lift le ver (A) de ter mines the cut ting height.

FIG. 18

• Put attachment lift lever in desired cutting height slot.

• Slide pointer tab (T) to desired cutting height as a reminder for next time you mow.

The cutting height range is ap prox i mate ly 1" to 4". The heights are measured from the ground to the blade tip with the engine not running. These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed.

FIG.19

TO OPERATE MOWER

Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. You must remain fully and centrally positioned in the seat to prevent the engine from hesitating or cutting off when operating your equipment on rough, rolling terrain or hills.

1. Select desired height of cut with attachment lift lever.

2. Start mower blades by engaging at tach ment clutch control.

TO STOP MOWER BLADES disengage at tach ment clutch con trol.

CAUTION: Do not operate the mower without either the en tire grass catcher, on mowers so equipped, or the deflector shield (S) in place.

OPERATION

FIG. 20

REVERSE OPERATION SYSTEM (ROS)

Your tractor is equipped with a Reverse Operation System (ROS). Any attempt by the operator to travel in the reverse direction with the attachment clutch engaged will shut off the engine unless ignition key is placed in the ROS "ON" position.

WARNING: Backing up with the attachment clutch engaged while mowing is strongly discouraged. Turning the ROS "ON", to allow reverse operation with the attachment clutch engaged, should only be done when the operator decides it is necessary to reposition the machine with the attachment engaged. Do not mow in reverse unless absolutely necessary.

USING THE REVERSE OPERATION SYSTEM Only use if you are certain no children or other bystanders

will enter the mowing area.

• Depress brake pedal all the way down.

• With engine running, turn ignition key counterclockwise

to ROS "ON" position.

• Look down and behind before and while backing.

• Slowly depress reverse drive pedal to start move-

ment.

• When use of the ROS is no longer needed, turn the

ignition key clockwise to engine "ON" position.

ROS "ON" POSITION ENGINE "ON" POSITION

TO OPERATE ON HILLS

CAUTION: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope.

(NORMAL OPERATING)

• To restart movement, slowly release parking brake and brake pedal.

• Slowly depress appropriate drive pedal to slowest set ting.

• Make all turns slowly.

TO TRANSPORT (See Figs. 13 and 21)

When pushing or towing your tractor, be sure to disengage transmission by placing freewheel control in free wheel ing po si tion. Free wheel control is located at the rear drawbar of tractor.

• Raise attachment lift to highest position with at tach ment lift control.

• Pull freewheel control out and down into the slot and release so it is held in the disengaged position.

• Do not push or tow tractor at more than two (2) MPH.

• To reengage transmission, reverse above procedure.

NOTE: To protect hood from damage when transporting your tractor on a truck or a trailer, be sure hood is closed and secured to tractor. Use an appropriate means of tying hood to tractor (rope, cord, etc.).

Transmission Engaged

Transmission Disengaged

FIG. 21

SERVICE REMINDER/HOUR METER

Service reminder shows the total number of hours the engine has run and flashes to indicate that the engine or mower needs servicing. When service is required, the service reminder will flash for two hours. To service engine and mower, see the Maintenance section of this manual.

NOTE: Service reminder runs when the ignition key is in any position but "STOP". For accurate reading, be sure key remains in the "STOP" position when engine is not running.

TOWING CARTS AND OTHER AT TACH MENTS

Tow only the attachments that are recommended by and comply with specifications of the manufacturer of your tractor. Use common sense when towing. Too heavy of a load, while on a slope, is dangerous. Tires can lose traction with the ground and cause you to lose control of your tractor.

• Choose the slowest speed before starting up or down hills.

• Avoid stopping or changing speed on hills.

• If stopping is absolutely necessary, push brake pedal quickly to brake position and engage parking brake.

OPERATION

BEFORE STARTING THE ENGINE

CHECK ENGINE OIL LEVEL

The engine in your tractor has been shipped, from the factory, already filled with sum mer weight oil.

• Check engine oil with tractor on level ground.

• Remove oil fill cap/dipstick and wipe clean, reinsert the dipstick and screw cap tight, wait for a few seconds, remove and read oil level. If necessary, add oil until “FULL” mark on dipstick is reached. Do not overfill.

• For cold weather operation you should change oil for easier starting (See “OIL VISCOSITY CHART” in the Maintenance sec tion of this manual).

• To change engine oil, see the Maintenance section in this manual.

ADD GASOLINE

• Fill fuel tank to bottom of filler neck. Do not overfill. Use fresh, clean, regular un lead ed gasoline with a minimum of 87 octane. (Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quan ti ties that can be used within 30 days to assure fuel freshness.

CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame.

IMPORTANT: WHEN OPERATING IN TEMPERATURES

BELOW32°F(0°C), USE FRESH, CLEAN WINTER GRADE GAS O LINE TO HELP INSURE GOOD COLD WEATHER START ING.

CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to sep a ra tion and for ma tion of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before stor age of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage In struc tions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

• Insert key into ignition and turn key clockwise to “START” position and release key as soon as engine starts. Do not run starter continuously for more than fifteen sec onds per minute. If the engine does not start after several attempts, push choke control in, wait a few minutes and try again. If engine still does not start, pull the choke control out and retry.

WARM WEATHER STARTING (50° F and above)

• When engine starts, slowly push choke control in until the engine begins to run smoothly. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly.

• The attachments and ground drive can now be used. If the engine does not accept the load, restart the engine and allow it to warm up for one minute using the choke as described above.

COLD WEATHER STARTING (50° F and below)

• When engine starts, slowly push choke control in until the engine begins to run smoothly. Continue to push the choke control in small steps allowing the engine to accept small changes in speed and load, until the choke control is fully in. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly. This may require an engine warm-up period from several sec onds to several minutes, depending on the temperature.

AUTOMATIC TRANSMISSION WARM UP

• Before driving the unit in cold weather, the trans mis sion should be warmed up as follows:

• Be sure the tractor is on level ground.

• Release the parking brake and let the brake slowly return to operating po si tion.

• Allow one minute for transmission to warm up. This can be done during the engine warm up period.

• The attachments can be used during the engine warm-up period after the transmission has been warmed up and may require the choke con trol be pulled out slight ly.

NOTE: If at a high altitude (above 3000 feet) or in cold temperatures (below 32 F) the carburetor fuel mixture may need to be adjusted for best engine performance. See “TO ADJUST CARBURETOR” in the Service and Ad just ments section of this manual.

TO START ENGINE (See Fig. 13)

When starting the engine for the first time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine.

• Be sure freewheel control is in the transmission en gaged position.

• Sit on seat in operating position, depress brake pedal and set parking brake.

• Move attachment clutch to “DISENGAGED” position.

• Move throttle control to fast position

• Pull choke control out for a cold engine start attempt. For a warm engine start attempt the choke control may not be needed.

NOTE: Before starting, read the warm and cold starting procedures below.

PURGE TRANSMISSION

CAUTION: Never engage or disengage freewheel lever while the engine is run-

ning.

To ensure proper operation and performance, it is rec om mend ed that the transmission be purged before operating tractor for the first time. This procedure will remove any trapped air inside the transmission which may have de vel oped during shipping of your tractor.

IMPORTANT: SHOULD YOUR TRANSMISSION RE QUIRE REMOVAL FOR SERVICE OR REPLACEMENT, IT SHOULD BE PURGED AFTER REINSTALLATION BEFORE OPERATING THE TRACTOR.

• Place tractor safely on level surface with engine off and parking brake set.

OPERATION

• Disengage transmission by placing freewheel control in freewheeling position (See “TO TRANSPORT” in this section of manual).

• Sitting in the tractor seat, start engine. After the engine is running, move throttle control to slow position. Dis en gage parking brake

• Depress forward drive pedal to full forward position, hold for five (5) seconds and release pedal. Depress reverse drive pedal to full reverse position, hold for five (5) seconds and release pedal. Repeat this procedure three (3) times.

NOTE: During this procedure there will be no movement of drive wheels. The air is being removed from hydraulic drive system.

• Shut- off engine and set parking brake.

• Engage transmission by placing freewheel control in engaged position (See “TO TRANSPORT” in this sec tion of manual).

• Sitting in the tractor seat, start engine. After the engine is running, move throttle control to half (1/2) speed. Disengage parking brake.

• Drive tractor forward for approximately five feet then backwards for five feet. Repeat this driving procedure three times.

Your transmission is now purged and now ready for normal op er a tion.

FIG. 22

• If grass is extremely tall, it should be mowed twice to reduce load and possible fire hazard from dried clip pings. Make first cut relatively high; the second to the desired height.

• Do not mow grass when it is wet. Wet grass will plug mower and leave undesirable clumps. Allow grass to dry before mowing.

• Always operate engine at full throttle when mow- ing to assure better mowing performance and proper dis charge of material. Regulate ground speed by se lect ing a low enough gear to give the mower cut ting per for mance as well as the quality of cut desired.

• When operating attachments, select a ground speed that will suit the terrain and give best performance of the at tach ment being used.

MOWING TIPS

• Mower should be properly leveled for best mowing performance. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual.

• The left hand side of mower should be used for trim ming.

• Drive so that clippings are discharged onto the area that has been cut. Have the cut area to the right of the machine. This will result in a more even dis tri bu tion of clippings and more uniform cutting.

• When mowing large areas, start by turning to the right so that clippings will discharge away from shrubs, fences, driveways, etc. After one or two rounds, mow in the opposite direction making left hand turns until finished (See Fig. 22).

MAINTENANCE

SCHEDULE

Check Brake Operation

Check Tire Pressure

Check Operator Presence & ROS Systems

Check for Loose Fasteners

Check/Replace Mower Blades

Lubrication Chart

Check Battery Level

Clean Battery and Terminals

Check Transaxle Cooling

Check Mower Levelness

Check V-Belts

Check Engine Oil Level

Change Engine Oil (with oil filter)

Change Engine Oil (without oil filter)

Clean Air Filter

Clean Air Screen

Inspect Muffler/Spark Arrester

Replace Oil Filter (Ifequipped)

N E

Clean Engine Cooling Fins

Replace Spark Plug

Replace Air Filter Paper Cartridge

Replace Fuel Filter

1-Change more often when operating under a heavy load or

in high ambient temperatures.

2 - Service more often when operating in dirty or dusty conditions.

BEFORE

EACH

USE

EVERY

HOURS

EVERY

HOURS

3 - Replace blades more often when mowing in sandy soil. 4-Not required if equipped with maintenance-free battery.

1,2

EVERY

HOURS

1,2

EVERY

100

HOURS

EVERY

SEASON

BEFORE

STORAGE

maint_sch-tractore.ROS.e

GENERAL RECOMMENDATIONS

The warranty on this tractor does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must main tain tractor as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain your tractor.

At least once a season, check to see if you should make any of the adjustments described in the Service and Adjustments section of this manual.

• At least once a year you should replace the spark plug, clean or replace air filter, and check blades and belts for wear. A new spark plug and clean air filter assure proper air-fuel mixture and help your engine run better and last longer.

BEFORE EACH USE

• Check engine oil level.

• Check brake operation.

• Check tire pressure.

• Check operator presence and

ROS systems for proper operation.

• Check for loose fasteners.

LUBRICATION CHART

➀ SPINDLE ZERK

➀ FRONT

WHEEL BEARING ZERK

➀ SPINDLE ZERK

➀ FRONT

WHEEL BEARING ZERK

➁ ENGINE

➀ STEERING

SECTOR GEAR TEETH

➀ MANDREL

02956

ZERKS

➀ General Purpose Grease

➁ Refer to Maintenance “ENGINE” Section

IMPORTANT: DO NOT OIL OR GREASE THE PIVOT POINTS WHICH HAVE SPECIAL NYLON BEARINGS. VISCOUS LU BRI CANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORT EN THE LIFE OF THE SELF-LU BRI CAT ING BEARINGS. IF YOU FEEL THEY MUST BE LU BRI CAT ED, USE ONLY A DRY, POW DERED GRAPHITE TYPE LU BRI CANT SPARINGLY.

MAINTENANCE

TRACTOR

Always observe safety rules when per form ing any main te nance.

BRAKE OPERATION

If tractor requires more than five (5) feet to stop at highest speed in high est gear on a level, dry concrete or paved surface, then brake must be serviced. (See “TO CHECK BRAKE” in the Ser vice and Ad just ments section of this manual).

TIRES

• Maintain proper air pressure in all tires (See PSI on tires).

• Keep tires free of gasoline, oil, or insect control chemi cals which can harm rubber.

• Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage.

NOTE: To seal tire punctures and pre vent flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also pre vents tire dry rot and corrosion.

OPERATOR PRESENCE SYS TEM AND REVERSE OPERATION SYSTEM (ROS)

Be sure operator presence and reverse operation sys tems are work ing properly. If your tractor does not function as described, repair the problem immediately.

• The engine should not start unless the brake pedal is fully de pressed, and the attachment clutch con trol is in the dis en gaged position.

CHECK OPERATOR PRESENCE SYSTEM

• When the engine is running, any attempt by the op er a tor to leave the seat without first setting the parking brake should shut off the engine.

• When the engine is running and the at tach ment clutch is engaged, any attempt by the operator to leave the seat should shut off the engine.

• The attachment clutch should never operate unless the operator is in the seat.

ROS "ON" Position

CHECK REVERSE OPERATION (ROS) SYSTEM

• When the engine is running with the ignition switch in the engine "ON" position and the at tach ment clutch engaged, any attempt by the operator to shift into reverse should shut off the engine.

• When the engine is running with the ignition switch in the ROS "ON" position and the at tach ment clutch engaged, any attempt by the operator to shift into reverse should NOT shut off the engine.

Engine "ON" Position (Normal Operating)

BLADE CARE

For best results mower blades must be sharp. Re place worn, bent or damaged blades.

CAUTION: Use only a replacement

blade approved by the manufacturer of your tractor. Using a blade not approved by the manufacturer of your tractor is hazardous, could damage your tractor and void your warranty.

BLADE REMOVAL (See Fig. 23)

• Raise mower to highest position to allow access to blades.

NOTE: Protect your hands with gloves and/or wrap blade with heavy cloth.

• Remove blade bolt by turning coun ter clock wise.

• Install new blade with stamped "GRASS SIDE" facing the ground.

IMPORTANT: To ensure proper as sem bly, center hole in blade must align with star on mandrel assembly.

• Install and tighten blade bolt securely (45-55 Ft. Lbs. torque).

IMPORTANT: Special blade bolt is heat treated.

MANDREL ASSEMBLY

544

STAR

BLADE BOLT (SPECIAL)

BLADE

CENTER HOLE

FIG. 23

BATTERY

Your tractor has a battery charging system which is suf fi cient for normal use. However, periodic charging of the battery with an automotive charger will extend its life.

• Keep battery and terminals clean.

• Keep battery bolts tight.

• Keep small vent holes open.

• Recharge at 6-10 amperes for 1 hour.

NOTE: The original equipment battery on your tractor is maintenance free. Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary.

TO CLEAN BATTERY AND TERMINALS Corrosion and dirt on the battery and terminals can cause

the battery to “leak” power.

• Remove terminal guard.

• Disconnect BLACK battery cable first then RED bat tery cable and remove battery from tractor.

MAINTENANCE

• Rinse the battery with plain water and dry.

• Clean terminals and battery cable ends with wire brush until bright.

• Coat terminals with grease or petroleum jelly.

• Reinstall battery (See “REPLACING BATTERY" in the SERVICE AND ADJUSTMENTS section of this man u al).

V-BELTS

Check V-belts for deterioration and wear after 100 hours of operation and replace if necessary. The belts are not ad just able. Re place belts if they begin to slip from wear.

TRANSAXLE COOLING

The transmission fan and cooling fins should be kept clean to assure proper cooling.

Do not attempt to clean fan or transmission while engine is running or while the transmission is hot. To prevent pos si ble damage to seals, do not use high pressure water or steam to clean transaxle.

• Inspect cooling fan to be sure fan blades are intact and clean.

• Inspect cooling fins for dirt, grass clippings and other materials. To prevent damage to seals, do not use compressed air or high pressure sprayer to clean cooling fins.

TO CHANGE ENGINE OIL (See Figs. 24 and 25) Determine temperature range expected before oil change.

All oil must meet API service classification SG-SL.

• Be sure tractor is on level surface.

• Oil will drain more freely when warm.

• Catch oil in a suitable container.

• Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil.

• Remove yellow cap from end of drain valve and install the drain tube onto the fitting.

OIL DRAIN VALVE

463

CLOSED AND LOCKED POSITION

YEL LOW CAP

DRAIN TUBE

TRANSAXLE PUMP FLUID

The transaxle was sealed at the factory and fluid main te nance is not required for the life of the transaxle. Should the transaxle ever leak or require servicing, contact your near est au tho rized ser vice center/department.

ENGINE

LUBRICATION

Only use high quality detergent oil rated with API service classification SG-SL. Select the oil’s SAE viscosity grade according to your expected operating temperature.

SAEVISCOSITYGRADES

SAE 30

5W-30

-2003040

-30

TEMPERATURE RANGE ANTICIPATEDBEFORENEXTOIL CHANGE

-200

-10

203040

FIG. 24

NOTE: Although multi-viscosity oils (5W30, 10W30 etc.)

improve starting in cold weather, they will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil.

Change the oil after every 50 hours of operation or at least once a year if the tractor is not used for 50 hours in one year.

Check the crankcase oil level before starting the engine and after each eight (8) hours of operation. Tighten oil fill cap/dipstick securely each time you check the oil level.

oil_visc_chart1_e

100

FIG. 25

• Unlock drain valve by pushing inward and turning coun ter clock wise.

• To open, pull out on the drain valve.

• After oil has drained completely, close and lock the drain valve by pushing inward and turning clockwise until the pin is in the locked position as shown.

• Remove the drain tube and replace the cap onto to the bottom fitting of the drain valve.

• Refill engine with oil through oil fill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see “PRODUCT SPECIFICATIONS” section of this man u al.

• Use gauge on oil fill cap/dipstick for checking level. Be sure dipstick cap is tightened securely for accurate reading. Keep oil at “FULL” line on dipstick. Tighten cap onto the tube securely when finished.

CLEAN AIR SCREEN

Air screen must be kept free of dirt and chaff to prevent engine dam age from overheating. Clean with a wire brush or compressed air to re move dirt and stubborn dried gum fibers.

AIR FILTER

Your engine will not run properly using a dirty air filter. Service air cleaner more often under dusty conditions. See Engine Manual.

MAINTENANCE

ENGINE OIL FILTER

Replace the engine oil filter every season or every other oil change if the tractor is used more than 100 hours in one year.

MUFFLER

Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage.

SPARK PLUGS

Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in “PROD UCT SPECIFICATIONS” section of this manual.

IN-LINE FUEL FILTER (See Fig. 26)

The fuel filter should be replaced once each season. If fuel filter becomes clogged, ob struct ing fuel flow to car bu re tor, re place ment is re quired.

• With engine cool, remove filter and plug fuel line sec tions.

• Place new fuel filter in position in fuel line with arrow pointing towards carburetor.

• Be sure there are no fuel line leaks and clamps are properly positioned.

• Immediately wipe up any spilled gasoline.

CLAMP

FUEL FILTER

FIG. 26

CLEANING

• Clean engine, battery, seat, finish, etc. of all foreign matter.

• Keep finished surfaces and wheels free of all gasoline, oil, etc.

• Protect painted surfaces with automotive type wax.

We do not recommend using a garden hose or pressure washer to clean your tractor unless the engine and transmission are covered to keep water out. Water in engine or transmission will shorten the useful life of your tractor. Use compressed air or a leaf blower to remove grass, leaves and trash from tractor and mower.

+ 44 hidden pages