Rover 405606x108A User Manual

Owner s Manual model 405606x108A

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F 050760L

TABLE OF CONTENTS

WARRANTY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESPONSIBILITY OF THE OWNER 3. . . . . . . . . . . . . . . . . .

SAFETY RULES 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTERNATIONAL PICTORIALS 9. . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS BAG CONTENTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO INSTALL THE FRONT WHEELS 11. . . . . . . . . . . . . . . . .

HOW TO INSTALL THE SEAT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO ASSEMBLE THE STEERING WHEEL 12. . . . . . . . . . . .

MAINTENANCE FREE BATTERY 13. . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO INSTALL THE BATTERY CABLES 13. . . . . . . . . . . . . . .

IMPORTANT! BEFORE YOU START MOWING 14. . . . . . . . . . . .

HOW TO PREPARE THE ENGINE 14. . . . . . . . . . . . . . . . . . . . . . . .

CHECK THE LEVEL OF THE MOWER HOUSING 14. . . . . . . . . .

CHECK THE TIRES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION OF CONTROLS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATTACHMENTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THE THROTTLE CONTROL 16. . . . . . . . . . . . . . . .

HOW TO USE THE BLADE ROTATION CONTROL 16. . . . . . . . .

HOW TO USE THE SPEED CONTROL PEDAL 17. . . . . . . . . . . . .

HOW TO DISCONNECT THE TRANSMISSION 17. . . . . . . . . . . . .

HOW TO SET THE PARKING BRAKE 18. . . . . . . . . . . . . . . . . . . . .

HOW TO CHANGE THE CUTTING HEIGHT 18. . . . . . . . . . . . . . . .

HOW TO STOP THE UNIT 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO TRANSPORT THE UNIT 18. . . . . . . . . . . . . . . . . . . . . . . .

HOW TO OPERATE WITH THE MOWER HOUSING 19. . . . . . . .

HOW TO OPERATE THE UNIT ON HILLS 19. . . . . . . . . . . . . . . . .

BEFORE STARTING THE ENGINE 20. . . . . . . . . . . . . . . . . . . . . . .

HOW TO START THE ENGINE 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING TIPS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOWING AND BAGGING TIPS 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE CHART 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO CHECK THE MUFFLER 22. . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO REMOVE AND INSTALL THE BLADE 23. . . . . . . . . . . .

HOW TO SHARPEN THE BLADE 23. . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO ADJUST THE BLADE ROTATION CONTROL 24. . . . .

HOW TO CHECK AND ADJUST THE MOTION DRIVE BELT 25.

HOW TO CHECK AND ADJUST THE DRIVE BRAKE 26. . . . . . .

MAINTENANCE FREE BATTERY 26. . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO CHARGE THE BATTERY 26. . . . . . . . . . . . . . . . . . . . . . .

WHERE TO LUBRICATE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO CHECK THE FUEL FILTER 27. . . . . . . . . . . . . . . . . . . . . .

CHECK THE TIRES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO REMOVE THE MOWER HOUSING 28. . . . . . . . . . . . . . .

HOW TO INSTALL THE MOWER HOUSING 28. . . . . . . . . . . . . . .

HOW TO LEVEL THE MOWER HOUSING 29. . . . . . . . . . . . . . . . .

HOW TO REPLACE THE MOTION DRIVE BELT 30. . . . . . . . . . . .

HOW TO REPLACE THE MOWER DRIVE BELT 31. . . . . . . . . . . .

HOW TO INSTALL THE WHEELS 32. . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO REPLACE THE FUSE 33. . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO REPLACE THE LIGHT BULB 33. . . . . . . . . . . . . . . . . . . .

HOW TO CLEAN THE MOWER HOUSING 33. . . . . . . . . . . . . . . . .

STORAGE (OVER 30 DAYS) 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLE SHOOTING CHART 34. . . . . . . . . . . . . . . . . . . . . .

SLOPE GUIDE 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

General

Rover Mowers Limited warrant this machine or accessory is free of defects in material and workmanship. Claims are limited to making good or replacing any part found defective by the manufacturer or his agent. The warranty period shall apply from the date of purchase for a period of 12 months for domestic use or 90 days for commercial use. Warranty applies to Australia and New Zealand only. Contact any Rover Mowers Limited authorised service dealer or Rover Agent.

Extended warranty: For domestic use only, a 24 months extended warranty applies. It requires the customer to complete the 2 Year warranty registration card , and forward along with a copy of the cash register receipt to !Warranty, Rover Mowers Limited". Normal warranty exclusions as listed still apply.

Exclusions: Following is a list of conditions excluded from warranty; all engines, parts that are considered suffering from wear and tear, parts that are damaged due to abuse or misuse, parts that can be subjected to use beyond their normal intended working capacity Eg; blades, blade bolts, v-belts and spark plugs. If repairs or alterations have been made without the manufacturer s written authority. Any transport costs involved in the repair or replacement of and defective parts. If it is found that parts other than genuine have been used on the machine.

NOTE: This warranty does not exclude any conditions or warranty implied by the Trade Practices Act 1974 or any other relevant legislation. Engine warranty is covered by the engine manufacturer and could differ from the warranty of the rest of the machine. Refer to the engine manual (if included) or consult the nearest engine service dealer.

Proof of date of purchase should be retained as it needs to be presented if warranty is to be claimed. Fill out the details on previous page as a record for warranty purposes.

Rover Mowers Limited reserves the right to make changes and add improvements to its products at any time without notice or obligation. Rover Mowers Limited reserves the right to discontinue manufacture of any product any any time at its discretion.

Rover Mowers Limited PO Box 1235 Eagle Fram Queensland 4009 AUSTRALIA

ABN 11 000 257 303

Rover Mowers Limited East Tamaki Auckland NEW ZEALAND

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OWNER S INFORMATION

This instruction book is for several different models. The instructions are written for a person with some mechanical ability. Like most service books, not all the steps are described. Steps on how to loosen or tighten fasteners are steps anyone can follow with some mechanical ability. Read and follow these instructions before you use the unit.

Know your product: If you understand the unit and how the unit operates, you will get the best performance. As you read this manual, compare the illustrations to the unit. Learn the location and the function of the controls. To help prevent an accident, follow the operating instructions and the safety rules. Keep this manual for future reference.

IMPORTANT: Many units are not assembled and are sold in car- tons. It is the responsibility of the owner to make sure the assembly instructions in this manual are exactly followed. Other units are purchased in an assembled condition. On assembled units, it is the responsibility of the owner to make sure the unit is correctly assembled. The owner must carefully check the unit according to the instructions in this manual before it is first used.

RESPONSIBILITY OF THE OWNER

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1. Carefully read and follow the rules for safe operation.

2. Follow all the assembly instructions.

3. Inspect the unit.

4. Make sure that the operator of the unit knows how to correctly use all standard and accessory equipment.

5. Operate the unit only with guards, shields, and other safety items in place and working correctly.

6. Correctly adjust the unit.

7. Service the unit only with authorized or approved replacement parts.

8. Complete all maintenance on the unit.

Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

Environmental Awareness

Do not fill the engine s fuel tank completely full.

Drain fuel for off season storage.

Use only unleaded gasoline.

Service the air cleaner regularly.

Change oil regularly. Use 10W 30 oil in summer.

Tune up the engine regularly.

Keep equipment in efficient operating condition.

Dispose of used engine oil properly.

SAFETY RULES

Safe Operation Practices for Ride on Mowers

WARNING: This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

I. General operation

1. Read, understand and follow all instructions in the Instruction Book, on the machine, the engine and with any attachments before starting.

2. Only allow responsible adults, who are familiar with the instructions, to operate the machine.

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

4. Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area.

5. Never carry passengers.

6. Turn off power to the blades or any attachments before backing up. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.

7. Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass bagger or the mower guard in place.

8. Slow down before turning.

9. Never leave a machine unattended with the engine running. Always turn off the blade(s), set the parking brake, stop the engine and remove the key before dismounting.

10. Turn off power to attachment(s) when transporting or not in use. Turn off the blade(s) when not mowing.

11. Stop the engine before removing the grass bagger or unclogging the chute.

12. Mow only in daylight or good artificial light.

13. Do not operate the machine while under the influence of alcohol or drugs or when very tired.

14. Watch for traffic when operating near or crossing roadways.

15. Use extra caution when loading or unloading the machine into a trailer or truck.

16. Turn off all attachment clutches before attempting to start the engine.

17. Always wear goggles, safety glasses, or an eye shield when you operate the unit to protect your eyes from foreign objects that can be thrown from the unit. Always wear eye protection when you make an adjustment or repair to the machine.

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

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OWNER S INFORMATION

b. Limit loads to those you can safely control. c. Do not turn sharply. Use care when backing. d. Use counterweights or wheel weights when suggested in the Instruction Book.

19. Do not operate this machine if you are taking drugs or other medication which can cause drowsiness or affect your ability to operate this machine.

20. Do not use this machine if you are mentally or physically unable to operate this machine safely.

21. 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 a riding mower safely enough to protect themselves and others from serious injury.

II. Slope operation

Slopes and rough terrain are major factors related to loss of control and tip over accidents, which can result in severe injury or death. ALL slopes require extra caution. If you cannot back up the slope or if you feel uneasy on the slope, do not mow it. See the !Slope Guide" in the back of this book to check for safe operation.

1. Mow up and down slopes, not across.

2. Remove obstacles such as rocks, limbs, etc...

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

4. Use slow speed on slopes. Do not make sudden speed changes.

5.Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability.

6. Use extra care with grass baggers or other attachments, they can change the stability of the machine.

7. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.

8. Avoid starting or stopping on a slope. If tires lose traction, turn off the blades and proceed slowly straight down the slope.

DO NOT

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

2. Do not mow drop offs, ditches or embankments. A wheel over the edge or an edge caving in could cause a sudden overturn and an injury or death.

3. Do not mow on wet grass. Reduced traction could cause sliding.

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

5. Do not use a grass bagger or other rear mounted accessories on steep slopes (greater than 10 degrees).

III. Children

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

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

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

3. Before and when backing, look behind and down for small children.

4. Never carry children or any passengers, even with the blades off. They may fall off and be seriously injured or interfere with the safe operation of the machine.

5. Never allow children to operate the machine. Instruct children in the potential dangers of the machine.

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

IV. Service

1. Use extra care when handling gasoline and other fuels. Fuels are flammable and the vapors are explosive. a. Use only an approved container. b. Never remove the gas cap or add fuel with the engine running. Allow the engine to cool for several minutes before refueling. Do not smoke. c. Never refuel the machine indoors. d. Never store the machine with fuel in the tank or fuel container inside where there is an open flame, such as a water heater.

2. Never start or run the engine inside a closed area.

3. Keep all nuts and bolts, especially the blade attachment nuts tight. Frequently check the blade(s) for wear or damage such as cracks and nicks. A blade that is bent or damaged must be immediately replaced with an original equipment blade from an authorized service dealer. For safety, replace the blade every two years. Keep the equipment in good condition.

4. Never tamper with the safety devices. Check their proper operation regularly.

5. To reduce fire hazards, keep the machine free of grass, leaves or other debris build up. Clean up oil or fuel spills. Allow the machine to cool before storing.

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

7. Never make adjustments or repairs with the engine running. The carburetor can be adjusted with the engine running. Do not change the engine governor settings or over speed the engine.

8. Grass bagger components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. For storage, always make sure the grass bag is empty. Frequently check components and replace with manufacturer s recommended parts when necessary.

9. Mower blade(s) are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them or the blade housing area.

10. Check the brake operation frequently. Adjust and service as required.

11. Wait for all movement to stop before servicing any part of the unit.

Look for this symbol to indicate important safety precautions. This symbol indicates: !Attention! Become Alert! Your Safety Is At Risk."

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Each person that operates power equipment must learn to use correct and safe mowing procedures. To help you

learn, carefully read the following pages. Most of the time the operator was

not correctly shown or did not read the instructions on the unit or in the Instruction Book before using the unit. Also, some operators do not have enough experience. The result is unsafe use, endangering the operator, bystanders and the equipment. Another result can be a poor appearance of the area mowed.

Read this book. Read the instructions on the unit. Operate the mower according to the Safe Mowing Guide. Follow all safety rules, cautions or warnings in this book and on the unit. Make sure anyone that uses the unit reads the instructions and is told how to safely operate the mower.

SAFE MOWING GUIDE

controls and how they work. In an emergency, how fast you can stop the blade is important. Learn how to control the mower at all times.

Many engines are started by hand. When you use a pull start or rope start, place your feet apart and away from the blade(s). Hold the rope handle tight. Never wrap the rope around your arm or fingers for a !better grip". To start the engine, follow the instructions on the mower, in this book and in the engine operating instructions.

For electric start engines, sit in the seat to start the engine. The battery can be dangerous. Follow the instructions on the battery, the acid container, and in this book when working with the battery. Even small batteries have enough voltage to cause an injury. Always be careful.

The mower is designed to be operated by one person. Never let another person ride with you on the unit or on any accessories. A passenger will make the unit harder to control, block the visibility or distract the operator and is dangerous to the operator, the passenger and the equipment. Without a passenger seat, the passenger can fall from the mower or contact dangerous parts. A mower is not a toy for showing off or for giving rides.

The blade of a power mower rotates very fast. It can discharge rocks and other objects over a long distance which can be dangerous. The force of the objects can break windows, cause injuries or even put an eye out. Most of the time the injury is to a person, like a child. Keep every person completely away from the area to be mowed. Make sure the grass is not discharged toward anyone. Planning your mowing pattern has a double advantage. It can decrease the possibility of an injury and make the clean up after mowing easier.

The mower will give you good service and durability, if operated in normal conditions. If the mower is not correctly serviced or is used where the terrain is rough or unsuitable, product performance and safety will be decreased.

Correct clothing is an important part of safe mowing. Safety glasses will protect the eyes from objects discharged by the mower. Safety shoes with steel plates can protect a foot from injury by the blade. For protection from objects discharged from the mower, wear clothing that will cover the arms and legs.

Before you start cutting the grass, practice using the mower in a large open and level area. Learn the location of the controls on the mower. Know the purpose of the

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Never cut a wet lawn. Wet grass can cause an accident, affect mower performance and can cause problems with future lawn growth and appearance. Wet grass is slippery and can cause the mower to slip. Someone can get injured by touching the blade(s). Wet grass tends to clog the mower, causing poor discharge. Cut wet grass will collect on the lawn, retarding the growth of the grass. Also, getting the mower wet will cause parts to rust and decrease the life of the unit.

When you look over the lawn, remember obstacles that cannot be removed, like pipes, stumps or rocks. Keep away from these obstacles that can cause damage to the mower or injury to the operator or a person near the mower. Clear the area of rocks, toys, wire or other loose objects. These items can damage the mower or can be discharged by the mower blade.

Check the terrain of the area to be mowed. Mow in a pattern that will keep you away from dangerous areas. Check the distance you need to stop and the distance available to turn. Slopes and rough terrain must be mowed carefully and some areas must not be mowed at all. With riding mowers, mow up and down the hill. When you must mow rough terrain or on slopes, drive slowly and stop in these areas only in an emergency. Before you ride up or down a slope, try to back straight up the slope. Do not ride up or down a slope that is too steep to back straight up. See the !Guide" in the back of this Instruction Book to check any slopes.

Before you start cutting, make sure the mower was completely assembled according to the Instruction Book. If the mower was completely assembled at the

store, you must still check the mower according to the assembly instructions. Make sure the mower is correctly assembled and that all fasteners are tight. Make sure the engine has the correct amount of oil. Check these items often during the life of the mower.

Your mower has a gasoline engine. Gasoline is a dangerous fuel. Keep gasoline only in an approved safety gasoline container. Do not keep large amounts of gasoline. When you add gasoline to the fuel tank, do not smoke. Store the gasoline container and the mower in an area that has good ventilation. Also, keep the gasoline away from any flames like the pilot light of a furnace or any other source of ignition. If the mower is to be stored for more than a few weeks, remove the gasoline from the fuel tank. When inside an enclosure, do not add gasoline to the fuel tank. Before you add gasoline, move the mower outside and add gasoline carefully. Before you start the engine, remove any gasoline from the outside of the fuel tank or from the mower. Warm gasoline will expand. Leave some space in the fuel tank for the gasoline to expand. Also, the fuel cap has a vent hole for fuel vapors. Always use the correct fuel cap. Failure to follow safety rules about gasoline will cause fires and explosions, injury to you and damage to the equipment and other property.

SAFE MOWING GUIDE

engine and transmission cool before servicing the mower. Remember, exhaust fumes are dangerous. Never operate the engine inside a building.

When you get a new mower, it can be a new experience for the family. Tell each person how a mower can be dangerous. Remember, a mower is not a toy. A mower is not to be used by children or anyone not old enough, strong enough or that does not have experience.

If the mower is not correctly assembled, not operated correctly, or not regularly serviced, the mower can be dangerous. The most important rule to follow is always use good judgement and common sense. Mow safely and carefully.

Your mower will easily cut thick grass. Fingers, feet and other parts can also be cut by the blade. Injuries occur when the operator does not think and reaches into the chute opening. Always operate the mower as if the blade is rotating. Do not service or make an adjustment, except to the carburetor, while the engine is running.

When you mow, remember that children are attracted to the mower. Always use caution when mowing around obstacles like trees or shrubs or when moving backward. Only mow in a forward direction if possible. Your visibility is decreased when you mow backward. Also, the blades are made to cut while the unit is moving forward. If you mow backward, the cutting performance decreases.

Before you leave the mower, stop the engine. Remove the key. Disengage and lower any attachment. Set the parking brake. Never mount or dismount from the seat while the engine is running. An accident can occur if you touch the brake, speed control pedal, throttle, or blade control while the engine is running. Mount and dismount from the seat on the side of the unit that is marked ENTER EXIT.

If you add gasoline to an engine that is running or hot, the result can be an explosion. Before you add gasoline, stop the engine and let the engine cool for several minutes. Remove dry grass and other debris from the mower. Keep the mower clean to improve the performance, help the engine and transmission run cooler, extend the life of moving parts, and decrease the danger of a fire.

Fires and explosions are not the only dangers when working around a mower. The engine, transmission, and the muffler will get hot in several minutes when the engine is running. Do not touch these parts of the mower. Stop the engine. Let the

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Use only accessories that are factory approved for your mower. The wrong accessory can decrease the safety of the mower and can even damage the unit. Read and follow the instructions included with the accessory and the mower.

Use only original equipment or replacement parts that are factory approved for service. If you need service, select an Authorized Service Center for your mower. If you do the work on the unit, follow the instructions in the Instruction Book.

Make sure you are in good condition when you mow. When you mow for several hours your reflexes will decrease and your mind will not be as alert. Take a short break or an accident can occur. If the temperature is hot, use caution to prevent dehydration. If you are tired, angry or not completely alert, do not operate the mower. If you use alcohol, medication or drugs, do not use the mower or any type of power equipment.

Engine speed is a key to safe mowing and to a good looking lawn. The maximum speed of the engine was set at the factory. Do not change the setting of the engine governor.

Select the maximum engine and ground speed that is right for the terrain and the height of the grass. The blade cuts best when the engine is operating at maximum speed. The engine and transmission will also run cooler at maximum engine speed.

Also, the grass bagger will function better when the engine is operating at maximum speed. On slopes, decrease the ground speed and use care making sure the mower feels safe to operate.

If the weather conditions are bad, do not mow. If weather conditions become bad, stop cutting and finish later. It is dangerous to cut grass in the rain. Always find protection in an electrical storm. If the weather conditions are extra dry, protect your eyes with safety glasses from the dust and from the objects discharged by the mower. Also, a dust or a pollen mask can help.

Your mower is equipped with a number of safety devices which are important to the safety of the operator and bystanders and must never be changed or removed from the mower. If a safety device is lost, damaged or no longer functions, repair or replace the device before you operate the mower.

It is best to mow during the day. If you must mow at night, make sure there is enough light for safe operation.

Your mower will require regular maintenance and service. The maintenance schedule depends on the hours of use. Also, mowing conditions can change the schedule. Check the Instruction Book for more information. Correct maintenance will help the mower function safely.

Do not service the mower (except for the carburetor adjustment) while the engine is running. Before you service the unit, even with the engine stopped, always disconnect the wire from the spark plug to prevent the engine from starting.

If you hit a large object during operation, stop the engine. Remove the wire from the spark plug. Carefully inspect the mower for damage. Before you start the engine again, make the necessary repairs. If you

SAFE MOWING GUIDE

feel new or excessive vibration, immediately stop the engine and check for the problem. Vibration can be a warning of a problem. Keep all nuts, bolts and screws tight.

The blade is the most dangerous part of the mower. Frequently check the blade and the blade mounting fasteners. Keep the fasteners tight. If the blade hits a solid object, stop the engine. Remove the wire from the spark plug. Check for a blade that is bent, cracked or for other damages. Before you start the engine, replace a damaged blade(s). For safety, replace the blade every two years.

A sharp blade decreases the workload on the engine and more evenly cuts grass. Frequently sharpen the blade for a better looking cut. Use the left side of the mower housing to trim near an object.

A grass bagger is a good accessory for your mower. For best performance and safety, make sure the grass bagger is approved for use with your mower. Follow the assembly and operation instructions included with the grass bagger.

Some grass baggers require a special blade for best performance. Before you attach, check, or empty the grass bagger, always stop the engine. Before each use of the grass bagger, check for cracks, wear or deterioration. Before you use the grass bagger, replace a damaged part with a replacement part approved by the factory.

For you to have a good green lawn, follow the mowing procedures below. Do not cut the grass too short. If you cut the grass too short you can cause the grass to become yellow or make the lawn look brown. Use a lower height of cut in cool months when the grass is thicker. Raise the height of cut in hot dry periods. If you cut the grass with

a blade that is not sharp or at a slow engine speed you can damage the grass. Move the throttle control to the FAST position when mowing and using the grass bagger. Also, use a slower ground speed when using the grass bagger.

If you change the direction or pattern of cut slightly every time you mow will make the grass grow stronger and thicker. Do not add oil or gasoline to the mower while on the lawn. Spilled oil or gasoline can kill the grass. In high or thick grass, do not try to cut all the grass the first time. Raise the height of cut on the first cutting and lower the height for the next cutting. Another way is to cut only part of the width of the mower and decrease your ground speed (not the engine) to move more slowly so that the mower can discharge the grass as it moves forward.

Understand the controls and how they work. Learn the ground speed(s) of your mower. Check the stopping distance required at different travel speeds. Check the turning radius of the mower. The controls on your riding mower are different from an automobile. The throttle is operated by hand and holds the engine speed constant until it is changed. The location of the travel speed control is different from that of an automobile. Also, the brake and clutch systems are different. Remember the procedures to follow in an emergency. Remember, turning off the engine ignition switch will stop the blade and the drive mechanism. If the traction of the wheels is lost or does not feel safe, disengage all systems and stop the engine. Dismount from the mower. Push the unit to a safe place before you begin mowing again.

Your unit has an electrical system that includes an operator presence switch in the seat. The operator presence switch detects if the operator is sitting on the seat. The engine will stop if the operator leaves the seat when the blade engagement control is engaged. This operator presence switch is a safety device only. It must not regularly be used to stop the engine or the blade. There are other control systems on the mower for this purpose. Always keep the operator presence switch and other safety devices and controls in place and operating for your protection.

Remember, your mower is a tool that can be dangerous if it is not correctly used. Follow the instructions in this Instruction Book. Safe and careful use of the mower will give you many safe hours of problem free use.

F 050760L

STEPS TO FOLLOW

BEFORE MOWING

Be sure to dress correctly. Wear hard shoes, not sandals or tennis shoes.

Examine the blade. A blade that is bent, cracked, or damaged must be replaced with a factory replacement blade.

Fill the fuel tank outside. Clean off spilled fuel.

Read and follow the Owner s Manual, the instructions with the engine, and the instructions with any attachments. Owner s Manual instructions are for your safety and the safety of others.

Exhaust fumes are dangerous. Start the engine outside.

Make sure all safety devices are in place and working correctly.

Operation of the mower is only for a person that has experience.

Wet grass can be dangerous. Let the grass dry.

Instruct children and others to keep away from the work area.

Never cut the grass without good light.

Pick up loose objects. Remove them from the mowing area.

WHILE MOWING

Watch for fixed objects and avoid them. They can damage the mower or cause injury.

A hot engine, muffler, and transmission will cause a burn. Do not touch.

Inclines and slopes must be carefully mowed. See the !Guide" in the back of this book to check a slope.

Lack of daylight or good artificial light is cause to stop mowing.

Examine the mower, the blade, and other parts for damage after hitting a foreign object or if the unit vibrates excessively.

Do not make adjustments or repairs without stopping the engine. Disconnect the spark plug wire.

On or near roads, watch out for traffic. Direct discharge away from roads.

When mowing, avoid areas where traction is unsure. Look back before changing direction of travel.

In heavy grass, raise the cutting height. Cut slower. Stop the engine to remove clogged grass from the mower.

Never remove any safety related parts.

Do not pour gasoline into a engine that is hot or running.

AFTER MOWING

Always let the mower cool before storing in an enclosed area.

Foreign material on the mower is dangerous. Clean off grass, leaves, grease and oil before storing.

Tighten all loose nuts, bolts and screws before you use the unit.

Empty and clean any grass catcher or other accessory.

Remove the key or disconnect the spark plug wire to prevent unauthorized use.

Make sure the mower is not kept near a source of ignition. Gas fumes can cause an explosion.

Only original parts or factory approved substitutes can be used to service the mower.

When storing the mower for an extended period, remove the fuel from the fuel tank.

Instruct children to leave the mower alone. It is not a toy.

Never keep gasoline near a source of ignition. Always use an approved container. Keep gasoline away from children.

Lubricate according to the Instruction Book. See !Lubrication".

IMPORTANT Read the Instruction Book. Keep this book for future use and reference.

WARNING: Look for this symbol to point out important safety precautions. It means: !Attention! Become Alert! Your Safety Is Involved."

F 050760L

INTERNATIONAL PICTORIALS

IMPORTANT: Some of the following pictorials are located on your unit or on literature supplied with the product. Before you operate the unit, learn and understand the purpose for each pictorial.

Safety Warning Pictorials

1 Warning 2 Shield Eyes. Explosive Gases Can

Cause Blindness Or Injury.

3 No Sparks, Flames or Smoking. 4 Sulphuric Acid Can Cause Blindness

Or Severe Burns

12 í 546

5 Flush Eyes Immediately With Water.

Get Medical Help Fast.

6 IMPORTANT: Read Owner s Manual

Before Operating This Machine.

7 WARNING: Thrown Objects. Keep

Bystanders Away. Read User Instructions Before Operating This Machine.

8 WARNING: Do Not Use This Machine

On Slopes Greater Than 15 Degrees.

9 DANGER: Keep People, Especially

Children, Away From Unit.

10 DANGER: No Step.

11 DANGER: Keep Feet And Hands

Away From Rotating Blade.

12 DANGER: Keep Hands Away From

Rotating Blade.

13 DANGER: Disconnect Spark Plug

Wire Before Servicing Unit.

14 WARNING: Hot Surface.

15 WARNING: Use Caution When

Connecting Or Disconnecting Accessories.

16 WARNING: Crushed Fingers.

Control And Operating Pictorials

1 Engine Start

2 Lights

3 Engine Off

4 Engine On

6 Brake

7 Parking Brake

8 Clutch

9 Slow

10 Fast

467

УЯИ зрТхУЯИ плрТ

11 Choke

12 Oil

13 Blade Rotation Control

14 Raise

15 Fuel

101112

9F 050760L

ASSEMBLY

Read and follow the assembly and adjustment instructions for your mower. All fasteners are in the parts bag. Do not discard any parts

WARNING: Before doing any assembly or maintenance to the mower, remove the wire from the spark plug.

or material until the unit is assembled.

NOTE: In this instruction book, left and right describe the location of a part with the operator on the seat.

PARTS BAG CONTENTS

The fasteners and other loose parts are shown below. The fasteners are shown full size. The quantity is shown in brackets ( ).

2x82

(2) Carriage Bolt

14x79

(2) Wing Nut

25x3

(1) Bolt

17x146

(1) Washer

1001054 (2) Knob

17x195

(2) Washer

17x47

(2) Washer

17x192

(2) Washer

(2) Cotter Pin

94618

(2) Hub Cap

30x49

20729

(1) Keys & Ring

690604

(1) Terminal Cover

10F 050760L

ASSEMBLY

HOW TO INSTALL THE FRONT WHEELS

Use a knife and cut the four sides of the container. Install the front wheels in the container.

NOTE: Use a piece of wood about 4 feet (1.25 meters) long to raise the front of the tractor. If a piece of wood cannot be found, get another person to help lift the tractor. Be careful, do not let the tractor fall.

1. Raise the front of the tractor. Set a support (block of wood) under the tractor.

Cotter Pin

Hub Cap

2. Make sure the valve stem is to the outside of the tractor. Slide the front wheel on the spindle.

3. Fasten each front wheel with washer, washer and cotter pin. Bend the ends of the cotter pin appart to keep the front wheel on the spindle.

4. After the front wheels are installed, lift the tractor from the support. Roll the tractor off of the container.

5. If your tractor has hub caps, install the hub caps. Make sure the washers hold the hub caps in place.

Washer (17x195)

Washer (17x192)

Black Cable

Valve Stem

Spindle

Front Wheel

Figure 1

11F 050760L

ASSEMBLY

HOW TO INSTALL THE SEAT

1. Carefully remove the plastic bag from the seat.

Use the fasteners shown below to install the seat. The fasteners are shown at full size.

(A)

1001054

NOTE: Fasteners may be attached to seat for shipping purposes, if so remove fasteners before proceeding.

2. Align the holes in the seat hinge to the holes in the seat (Figure 2). Fasten the seat to the seat hinge with the fasteners as shown.

(B)

17x47

3. Check the operating position of the seat. If the seat needs to be adjusted, loosen the two wing bolts. Slide the seat forward or backward along the seat adjusting holes as shown. Tighten the wing bolts (A).

Seat

Seat Hinge

Seat

Adjusting Hole

Figure 2

HOW TO ASSEMBLE THE STEERING WHEEL

Tools Required: 3/8" Socket Wrench

Attach the steering wheel as follows:

(A)

25x3

(C)

17x146

1. Make sure the front wheels point forward.

2. Slide the bellows over the steering post (Figure 3).

NOTE: Before attachment of the steering wheel, make sure that the front wheels point forward and are straight. For proper alignment of the steering wheel, see Figure 3.

3. Slide the steering wheel onto the steering post.

4. Use the fasteners shown above to secure the steering wheel. The fasteners are shown at full size. Tighten the screw until snug and then add 1/4 turn. DO NOT over tighten.

5. Attach the cover to the steering wheel.

Decal (Optional)

Cover

Steering Wheel

Bellows

Steering Post

Straight

6. Some models have an optional decal in the parts bag. Attach the decal to the center of the steering wheel as shown.

Figure 3

12F 050760L

ASSEMBLY

MAINTENANCE FREE BATTERY

IMPORTANT: Before you attach the battery cables to the battery, check the battery date. The battery date tells if the battery must be charged.

1. Check the top of the battery for the location of the battery date (Figure 4).

2. If the battery is put into service before the battery date, the battery cables can be attached without charging the battery. See !How To Install The Battery Cables".

3. If the battery is put into service after the battery date, the battery must be charged. See !How To Charge The Maintenance Free Battery".

HOW TO CHARGE THE MAINTENANCE FREE BATTERY

WARNING: When you charge the battery, do not smoke. Keep the battery away from any sparks. The fumes from the battery acid can cause an explosion.

1. Remove the battery and battery tray.

2. Remove the protective caps from the battery terminals.

3. Use a 12 volt battery charger to charge the battery. Charge at a rate of 6 amperes for one hour. If you do not have a battery charger, have an authorized service center charge the battery.

4. Install thebattery and battery tray. Make sure the positive (+)

terminal is on the left side.

HOW TO INSTALL THE BATTERY CABLES

WARNING: To prevent sparks, fasten the red cable to the positive (+) terminal before you connect the black cable.

Use the fasteners shown below to install the battery cables. The fasteners are shown at full size.

(A)

2x82

1. Remove the protective caps from the battery terminals.

2. Fasten the red cable and terminal cover (if equipped) to the positive (+) terminal with the fasteners as shown (Figure 4).

3. Fasten the black cable to the negative ( ) terminal with the fasteners as shown.

(B)

14x79

Black Cable

Positive (+)

Terminal

Red Cable

Battery

Terminal Cover

Battery Tray

Figure 4

13F 050760L

ASSEMBLY

IMPORTANT! BEFORE YOU START MOWING

Check the engine oil.

Fill the fuel tank with gasoline.

Check the level of the mower housing.

Check the air pressure of the tires.

Make sure the battery cables are attached.

HOW TO PREPARE THE ENGINE

NOTE: The engine was shipped from the factory filled with oil. Check the level of the oil. Add oil as needed.

See the engine manufacturer s instructions for the type of gasoline and oil to use. Before you use the unit, read the information on safety, operation, maintenance, and storage.

WARNING: Follow the engine manufacturer s instructions for the type of gasoline and oil to use. Always use a safety gasoline container. Do not smoke when adding gasoline to the engine. When inside an enclosure, do not fill with gasoline. Before you add gasoline, stop the engine. Let the engine cool for several minutes.

IMPORTANT: This unit is equipped with an internal combustion engine and must not be used on or near any unimproved

WARNING: Before doing any assembly or maintenance to the mower, remove the wire from the spark plug.

NOTE: In this instruction book, left and right describe the location of a part with the operator on the seat.

forest covered, brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it must 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. See an Authorized Service Center for a spark arrester for the muffler.

In some areas, local law requires the use of a resistor spark plug to control the ignition signals. See an Authorized Service Center for a resistor spark plug for the engine.

NOTE: Actual sustained horsepower will likely be lower due to operating limitations and environmental factors.

CHECK THE LEVEL OF THE MOWER HOUSING

Make sure the level of cut is still correct. After you mow a short distance, look at the area that was cut. If the mower housing does not cut level, see the instructions on !How To Level The Mower Housing" in the Maintenance section of this instruction book.

CHECK THE TIRES

Check the air pressure in the tires. Tires with too much air pressure will cause the unit to ride rough. Also, the wrong air pressure will keep the mower housing from cutting level. The correct air pressure (PSI) is 14 PSI (1 BAR). The tires were over inflated for shipment.

14F 050760L

Throttle Control

Lever

Brake Pedal

OPERATION

Blade Rotation

Control

Speed Control

Pedal

Lift

Lever

LOCATION OF CONTROLS

BLADE ROTATION CONTROL: Use the blade rotation

control to start and stop the rotation of the blade.

BRAKE PEDAL: Use the brake pedal to quickly stop.

HEADLIGHT SWITCH: The headlight switch is the first part

of the ignition switch. To use the lights with the engine running, turn the key to the position for the lights.

Figure 5

AUTOMATIC DRIVE DISCONNECT: Use the auto -

matic drive disconnect, located under the seat, to disengage the transmission.

LIFT LEVER: Use the lift lever to change the height of cut.

PARKING BRAKE LEVER: Use the parking brake lever

to engage the brake when you leave the unit.

SPEED CONTROL PEDAL: Use the speed control lever

to change the speed and the direction of the unit.

IGNITION SWITCH: Use the ignition switch to start and stop

the engine.

THROTTLE CONTROL LEVER: Use the throttle control

lever to increase or decrease the speed of the engine.

15F 050760L

OPERATION

ATTACHMENTS

This unit can use many different attachments. See the attachment page in this book. This unit can pull attachments like a lawn sweeper, a lawn aerator, a hopper spreader or a small trailer. This unit can not use attachments that engage the ground like a plow, a disk harrow, or a cultivator.

For all pull behind attachments or trailers, the maximum gross weight is 250 pounds. Gross weight is the weight of the attachment or trailer and any load that might be on or in it.

Do not operate on a slope that is greater than 10 degrees when using a pull behind attachment or trailer. We have included a slope guide in this book to help you determine the slope on which you will be operating your unit. Never allow someone to stand or ride on or in an attachment or trailer.

HOW TO USE THE THROTTLE CONTROL

Use the throttle control to increase or decrease the speed of the engine.

CAUTION: Always operate the engine with the throttle control in the FAST position. If the engine runs for several minutes at slower than the FAST position, the engine and transmission will overheat and can be damaged.

1. The FAST position is marked with a detent. For normal operation and when using a grass bagger, move the throttle control to the FAST position. For maximum charging of the battery and for a cooler running engine and transmission, operate the engine in the FAST position.

2. For transport and to tow pull behind attachments, control the ground speed with the speed control pedal.

3. The engine governor is set at the factory for maximum performance. Do not adjust the governor to increase the speed of the engine.

ШСЙ МС ЛНЫ МШЫ ЮФЯЬЫ ОСМЯМЧСТ ЭСТМОСФ

The blade rotation control is next to the steering wheel (Figure 6). Use the blade rotation control to engage the blade(s) or to operate a snow thrower attachment.

1. Before you start the engine, make sure the blade rotation con- trol is in the DISENGAGE position.

2. Move the blade rotation control to the ENGAGE position to rotate the blade(s).

Note: If the engine stops when you engage the blade(s), the seat switch is not activated. Make sure you sit in the middle of the seat. Also, make sure the wire is connected to the seat switch.

3. Move theblade rotation control to the DISENGAGE position to stop the blade(s). Before you leave the operator s position, make sure the blade(s) has stopped rotating.

4. Before you ride the unit across a sidewalk or a road, move the

blade rotation control to the DISENGAGE position.

WARNING: Always keep your hands and feet away from the blade, deflector opening, and the mower housing when the engine runs.

Disengage

Position

Blade Rotation Control

Engage Position

Figure 6

16F 050760L

OPERATION

CHOKE

HOW TO USE THE SPEED CONTROL PEDAL

The drive system uses a Hydrostatic Automatic Drive transmission. The Hydrostatic transmission is very easy to operate. This type of drive system does not require a shift lever or a clutch pedal.

The speed and direction of travel is controlled by a single speed control pedal operated with your right foot. Do not use the left brake pedal in normal operation. Only use the left brake pedal to quickly stop in an emergency.

HOW TO DRIVE FORWARD

1. The automatic drive disconnect must be in the DRIVE position (Figure 8).

2. Slowly release your left foot from the brake pedal.

3. Move the throttle control to the FAST position.

4. Slowly push the speed control pedal forward to the desired speed (Figure 7).

5. To increase forward speed, slowly move the speed control

pedal forward. To reduce forward speed, slowly release the speed control pedal until the unit slows to the desired speed.

HOW TO DRIVE IN REVERSE

1. Look to the rear.

2. Slowly push the speed control pedal to the REVERSE position.

HOW TO CHANGE DIRECTIONS

CAUTION: To change directions, do not use the left brake pedal. Use only the speed control pedal.

1. Slowly remove your foot from the speed control pedal. The speed control pedal will automatically return to the NEUTRAL

position.

2. When the unit stops, slowly move the speed control pedal to the desired direction.

SPEED CONTROL PEDAL POSITIONS

The forward speed is controlled by the position of the speed control pedal. The following chart provides functions along with the pedal positions. Always operate the engine with the throttle control in the FAST position.

FUNCTION РЫЬЯФ

РСНЧМЧСТ

Trimming Snow Thrower

1/3

THROTTLE

Speed Control

Pedal

Figure 7

HOW TO DISCONNECT THE TRANSMISSION

To push the unit, use the automatic drive disconnect to release the transmission. The automatic drive disconnect is under the seat.

1. The engine must be off.

2. Raise the seat. The automatic drive disconnect is under the seat.

3. Move and latch the automatic drive disconnect in the PUSH position (Figure 8). The transmission is now released and the unit can be pushed.

NOTE: In cold weather, the heavy viscosity oil in the transmission will make the unit difficult to push.

4. To engage the transmission, unlatch the automatic drive disconnect. The transmission is now connected and ready to op-

erate.

Bagging Grass 1/3 to 1/2

Normal Mowing 1/2 to 2/3

Easy Mowing Snow Blade

Transport FULL

Pull Behind Attachments

Automatic Drive Disconnect

PUSH POSITION

17F 050760L

1/2 to 3/4

1/3 to 1/2

FAST

CHOKE

FAST

SLOW

THROTTLE

Seat

Automatic Drive Disconnect

DRIVE POSITION

Figure 8

OPERATION

HOW TO SET THE PARKING BRAKE

1. Completely push the brake pedal forward.

2. Lift the parking brake lever (Figure 9).

3. Remove your foot from the brake pedal and then release the parking brake lever. Make sure the parking brake will hold the unit.

4. To release the parking brake, completely push the brake pedal forward. The parking brake will automatically release.

WARNING: Before you leave the operator s position, move the shift lever to the neutral (N) position. Set the parking brake. Move the blade rotation control to the DISENGAGE position. Stop the engine and remove the ignition key.

Parking

Brake

Figure 9

HOW TO CHANGE THE CUTTING HEIGHT

To change the cutting height, raise or lower the lift lever as follows.

1. Move the lift lever forward to lower the mower housing and back to raise the mower housing (Figure 10).

2. When you ride on a sidewalk or road, move the lift lever to the highest position and move the blade rotation control to the DISENGAGE position.

HOW TO STOP THE UNIT

1. Slowly remove your foot from the speed control pedal. The speed control pedal will automatically return to the NEUTRAL position and the unit will stop.

2. Move the blade rotation control to the DISENGAGE position.

3. Set the parking brake.

Lift Lever

Figure 10

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

4. Move the throttle control to the SLOW position.

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

HOW TO TRANSPORT THE UNIT

To transport the unit, follow the steps below.

1. Move the blade rotation control to the DISENGAGE position

2. Raise the lift lever to the highest position.

3. Move the throttle control to the FAST position.

4. Slowly push the speed control pedal forward to the desired speed.

18F 050760L

OPERATION

ШСЙ МС СРЫОЯМЫ ЙЧМШ МШЫ УСЙЫО ШСЛНЧТЩ

WARNING: The deflector is a safety device. Do not remove the deflector. The deflector forces the discharged material toward the ground. Always keep the deflector in the down position. If the deflector is damaged, replace the deflector with an original equipment part from an authorized service center.

1. Start the engine.

2. Release the parking brake.

3. Move the lift lever to a height of cut position. In high or thick grass, cut the grass in the highest position first and then lower the mower housing to a lower position.

CAUTION: Do not operate with the mower housing in the LEVEL ADJUSTMENT position. If you operate in the LEVEL ADJUSTMENT position, the mower housing and blades can be damaged.

HOW TO OPERATE THE UNIT ON HILLS

4. Move the throttle control to the SLOW position.

5. Move the blade rotation control to the ENGAGE position.

6. Move the throttle control to the FAST position.

7. Slowly push the speed control pedal to the desired speed.

NOTE: When you mow in heavy grass or mow with a grass bagger, use a slow forward speed.

8. Make sure the level of cut set at the factory is still correct. After you mow a short distance, look at the area that was cut. If the mower housing does not cut level, see the instructions on !How To Level The Mower Housing" in the Maintenance section.

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

WARNING: Do not ride up or down slopes that are too steep to back straight up. Never ride the unit across a slope. See the !Slope Guide" in the back of this book for information on how to check slopes.

HOW TO OPERATE ON A HILL

1. Control the speed only with the speed control pedal. Do not use the brake pedal on a hill.

2. To help prevent an accident, slowly move the speed control pedal. Avoid sudden turns or changes in speed.

3. To reduce forward speed when going down a hill, slowly release the speed control pedal until the unit slows to the desired speed.

HOW TO STOP ON A HILL

1. Avoid stopping on a hill. If you must quickly stop in an emergency, remove your right foot from the speed control pedal and quickly depress the left brake pedal.

2. Set the parking brake.

3. Before you dismount from the seat, move the throttle control to SLOW position, move the blade rotation control to the DISENGAGED position, turn off the engine and set the parking brake.

HOW TO START OPERATION ON A HILL

1. Start the engine

2. Move the blade rotation control to the ENGAGED position.

3. Move the throttle control to the FAST position.

4. Depress the brake pedal and release the parking brake. As you release the parking brake, push the speed control pedal to the desired speed.

WARNING: Slowly push the speed control pedal as you release the parking brake. The parking brake must be disengaged before the speed control pedal is able to engage the transmission.

19F 050760L

OPERATION

BEFORE STARTING THE ENGINE

CHECK THE OIL

NOTE: The engine was shipped from the factory filled with oil. Check the level of the oil. Add oil as needed. See the engine manufacturer s instructions for the type of gasoline and oil to use.

1. Make sure the unit is level.

NOTE: Do not check the level of the oil while the engine runs.

2. Check the oil. Follow the procedure in the engine manufacturer s instructions.

3. If necessary, add oil until the oil reaches the FULL mark on the dipstick. The quantity of oil needed from ADD to FULL is shown on the dipstick. Do not add too much oil.

ADD GASOLINE

WARNING: Always use a safety gasoline container. Do not smoke when adding gasoline to the fuel tank. Do not add gasoline when you are inside an enclosure. Before you add gasoline, stop the engine and let the engine cool for several minutes.

Fill the fuel tank with regular unleaded gasoline. Do not use premium unleaded gasoline. Make sure the gasoline is fresh and clean. Leaded gasoline will increase deposits and shorten the life of the valves.

Full

Fuel Tank

CAUTION: A mixture of alcohol (ethanol or methanol) and gasoline (called gasohol), will attract moisture and cause acid deposits during storage. While the unit is in storage, the acids in the fuel can damage the fuel system.

To prevent engine problems with the fuel system, empty the fuel system before storage of 30 days or longer as follows.

1. Drain the fuel tank.

2. Start the engine. Let the engine run until the fuel lines and the carburetor are empty.

3. After storage, make sure you use fresh fuel. See the storage instructions for additional information.

4. Never use engine cleaner or carburetor cleaner in the fuel tank or permanent damage can occur.

CARBURETOR

The factory settings for the carburetor are for most conditions. If the engine is operated under the following conditions, you can adjust the carburetor mixture. To adjust the carburetor, see the engine manufacturer s instructions.

1. The engine has a loss of power or does not run smooth.

2. A change from summer to winter operation.

3. A 40 degree change in the operation temperature. The carburetor was adjusted at 80 degrees at the factory.

4. The engine is operated above 4,000 feet.

HOW TO START THE ENGINE

WARNING: The electrical system has an operator presence system that includes a sensor switch for the seat. These components tell the electrical system if the operator is sitting on the seat. This system will stop the engine when the operator leaves the seat. For your protection, always make sure this system operates correctly.

NOTE: The engine will not start unless you depress the brake pedal or engage the parking brake and move the blade rotation control to the DISENGAGE position.

1. Push the brake pedal completely forward. Keep your foot on the pedal.

2. Make sure the blade rotation control is in the DISENGAGE position.

3. Move the throttle control completely forward to the CHOKE or FAST position. Some models have a separate choke knob. Pull the choke knob to the full CHOKE position.

4. Turn the ignition key to the START position. Release the key when the engine starts.

NOTE: If the engine does not start after four or five tries, see the TROUBLE SHOOTING CHART.

5. Slowly move the throttle control to the SLOW position.

6. Let a cold engine run for several minutes. Begin work when the engine is warm. To start a hot engine, move the throttle control to a position between FAST and SLOW.

20F 050760L

OPERATING TIPS

OPERATION

1. Check the blade rotation control for correct adjustment. For the blade(s) to disengage correctly, the adjustment must be correct.

2. Before you use the unit, check the oil in the engine and add oil if necessary.

3. If the engine will not start, first make sure the wire is attached to the spark plug.

4. Make sure all the belts are inside all the belt guides. See the instructions on how to remove and install the motion drive and mower drive belts.

MOWING AND BAGGING TIPS

1. For a lawn to look better, check the cutting level of the mower housing. See !How To Level The Mower Housing" in the Maintenance section.

2. For the mower housing to cut level, make sure the tires have the correct amount of air pressure.

3. Every time you use the unit, check the blade. If the blade is bent or damaged, immediately replace the blade. Also, make sure the nut for the blade is tight.

4. Keep the blade(s) sharpened. Worn blades will cause the ends of the grass to turn brown.

5. Before you make an inspection, adjustment (except for the carburetor) or repair, make sure the wire from the spark plug is disconnected.

6. For longer life of the battery on electric start models, charge the battery every three months.

7. Use the speed control pedal to change the ground speed, not the throttle control.

8. Belt noise can occur when the blade is engaged. This noise is normal and does not affect the operation of the unit.

10. For better engine performance and an even discharge of the cut grass, always operate the engine with the throttle in FAST position.

11. When you use a bagger, operate the engine with the throttle in FAST position and the speed control pedal pushed 1/3 forward.

12. For better cutting performance and a quality cut, mow with the speed control pedal pushed 1/3 to 1/2 forward.

13. After each use, clean the bottom and top of the mower housing for better performance. Also, a clean mower housing will help prevent a fire.

5. Do not cut or bag grass that is wet. Wet grass will not discharge correctly. Let the grass dry before cutting.

6. Use the left side of the mower housing to trim near an object.

7. Discharge the cut grass onto the mowed area. The result is a more even discharge of cut grass.

8. When you mow large areas, start by turning to the right so that the cut grass will discharge away from shrubs, fences, driveways, etc. After one or two rounds, mow in the opposite direction making left turns until finished (Figure 11).

9. If the grass is very high, cut two times to decrease the load on the engine. First cut with the mower housing in the highest position and then lower the mower housing for the second cut.

Figure 11

21F 050760L

MAINTENANCE

MAINTENANCE CHART

FREQUENCY MAINTENANCE REQUIRED COMMENTS

Daily or before each use

After completion of first 5 hours

After 25 hours Maintenance engine. Refer to the Engine Owner s Manual.

Before storage of 30 days or more

Maintenance engine. Refer to the Engine Owner s Manual.

Examine blade(s). Check for cracks, wear, and excessive

damage.

Remove debris from unit and mowing area.

Examine all rotating and sliding parts.

Check tire inflation. Refer to the Maintenance section.

Verify that the mower housing is level. Refer to the Maintenance section.

Examine V belts. Check for cracks, wear, and excessive

damage.

Check brake operation. Refer to the Operation and Maintenance

sections.

Change oil. Refer to the Engine Owner s Manual.

Remove, examine, sharpen, and balance

Refer to Maintenance section.

blade(s).

Check adjustments:

Refer to Maintenance section. a. Blade Rotation Control b. Brake c. Clutch d. Steering

Lubricate chassis and mower housing. Refer to Where to Lubricate instructions.

Check the muffler:

Refer to Maintenance section. a. Torque b. For wear or burn out c. Condition of spark arrestor, (if applicable).

Prepare engine for storage. Refer to the Engine Owner s Manual.

Drain fuel system. Refer to warnings in the Owner s Manual.

Add fuel stabilizer. Refer to the Engine Owner s Manual.

Prepare battery for storage: a. Remove from unit. b. Fully charge. c. Move to cool dry place.

GENERAL RECOMMENDATIONS

1.The owner s responsibility is to maintain this product. This will extend the life of the product and is also necessary to maintain warranty coverage.

2. Check the spark plug, drive brake, lubricate the unit, and clean the air filter once a year.

3. Check the fasteners. Make sure all fasteners are tight.

4. Follow the Maintenance section to keep the unit in good operating condition.

WARNING: Before you make an inspection, adjustment, or repair to the unit, disconnect the wire to the spark plug. Remove the wire from the spark plug to prevent the engine from starting by accident.

NOTE: Torque is measured in foot pounds (metric Nm). This measurement describes how tight a nut or bolt must be. The torque is measured with a torque wrench.

HOW TO CHECK THE MUFFLER

Check the muffler every 50 hours. Make sure the muffler is correctly mounted and is not loose. If the muffler is worn or burnt, replace with a new muffler. A worn muffler is a fire hazard and can also damage the engine.

If you mount a spark arrester to the muffler, also check the spark arrester when you check the muffler. If the spark arrester is worn or damaged, replace it with a new spark arrester. See your nearest authorized service center for a spark arrester.

22F 050760L

MAINTENANCE

INSPECT BLADE

WARNING: Before you inspect or remove the blade, disconnect the wire to the spark plug. If the blade hits an object, stop the engine. Check the unit for damage. The blade has sharp edges. When you hold the blade, use gloves or cloth material to protect your hands.

If you keep the blade sharp and inspect the blade for damage, the blade will cut better and be more safe to operate. Frequently check the blade for excessive wear, cracks, or other damage. Frequently check the nut that holds the blade. Keep the nut tight. If the blade hits an object, stop the engine. Disconnect the wire to the spark plug. See if the blade is bent or damaged. Check the blade adapter for damage. Before you operate the unit, replace damaged parts with original equipment parts. See the authorized service center in your area. Every three years, have an authorized service person inspect the blade or replace the old blade with an original equipment part.

HOW TO REMOVE AND INSTALL THE BLADE

1.Remove the mower housing. See the instructions on !How To Remove The Mower Housing".

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

3. Remove the nut that holds the blade (Figure 12).

Hi Lift

Edge Up

Mandrel

Blade Adapter

Blade

Belleville Washer

Washer

Nut

4. Check the blade and the blade adapter according to the instructions for !Inspect Blade". Replace a badly worn or damaged blade with an original equipment blade. See an authorized service center in your area.

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

6. Mount the blade and blade adapter on the mandrel (Figure 12).

7. Mount the blade so that the hi lift edges are up. If the blade is upside down, the blade will not cut correctly and can cause an accident.

8. Fasten the blade with the original washers and nut. Make sure the outside rim of the Belleville washer is against the blade (Figure 13).

WARNING: Always keep the nut tight that holds the blade. A loose nut or blade can cause an accident.

Figure 12

9. Tighten the nut that holds the blade to a torque of 35 foot pounds (47,5 N m).

10.Install the mower housing. See !How To Install The Mower Housing".

Blade Adapter

Blade

Washer

Belleville Washer

(Outside rim must be

against the blade.)

Nut

Figure 13

HOW TO SHARPEN THE BLADE

WARNING: Vibration can be caused if the blade is not correctly balanced or if the blade is damaged. A blade that is damaged with cracks can break and cause an accident.

Keep a sharp edge on the blade. A blade that is not sharp will cause the tips of the grass to become brown.

1. Sharpen the blade two times a year or every 25 hours.

2. Remove the blade according to the instructions in !How To Remove And Install The Blade".

3. Clean the blade with a brush, soap and water. Check the blade. Look for cracks , nicks, or other damage. Replace a badly worn or damaged blade with an original equipment blade. See an authorized service center in your area.

4. Sharpen the blade with a file (Figure 14). Make sure you keep the original bevel angle.

5. Make sure the blade is balanced. Use a screwdriver and hold the blade parallel to the ground (Figure 14). A blade that is balanced will stay parallel to the ground. If the blade is not bal- anced, the heavy end will rotate toward the ground. Sharpen the heavy end until the blade is balanced.

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

7. Assemble the blade according to the instructions !How To Remove And Install The Blade".

Blade

Screwdriver

Blade is balanced

when parallel to the ground.

Ground

23F 050760L

Figure 14

File

MAINTENANCE

ШСЙ МС ЯЬЦЛНМ МШЫ ЮФЯЬЫ ОСМЯМЧСТ ЭСТМОСФ

WARNING: To prevent an injury, the blade rotation control must operate correctly.

In normal usage, the blade rotation control will not require an adjustment. However, if the cutting performance decreases or the quality of cut is poor, make the following changes.

1. When you mow, make sure the throttle control in in the FAST position.

2. Move theblade rotation control to the DISENGAGE position (Figure 15).

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

Disengage

Position

Blade Rotation Control

Engage Position

6. Attach the wire to the spark plug. Mow for a short distance and again check the quality of cut. If necessary, move the blade drive spring to the bottom hole.

7. Again check the quality of cut. If the quality of cut has not improved, replace the mower drive belt. See !How To Replace The Mower Drive Belt". If replacing the belt does not correct the problem, take the unit to an authorized service center.

8. Move the blade rotation control to the DISENGAGE posi- tion. Stop the engine. Disconnect the wire from the spark plug. Check the operation of the blade brake. Rotate the pulleys with your hand. Make sure the brake pads are pressed tightly against the pulleys (Figure 17).

WARNING: If the brake pads do not press tightly against the pulleys, take the unit to an authorized service center.

Blade Brake

Brake Pad

Against Pulley

Figure 15

4. Check the blade(s). Keep a sharp edge on the blade(s). A blade that is not sharp will cause the tips of the grass to become brown.

5. Disconnect the blade drive spring from the blade control rod. Move the blade drive spring to the middle hole (Figure 16). This will increase the tension on the mower drive

belt.

DISENGAGE POSITION

Blade

Control Rod

Top Hole (New Belt)

Middle Hole

Bottom Hole

Figure 17

9. Move the blade rotation control to the ENGAGE position. Check the pads for the blade brake. If the pads are excessively worn or damaged, replace the brake pad assemblies. Correct replacement parts and assistance are available from an authorized service center.

10. Attach the wire to the spark plug. Mow for a short distance and again check the operation of the blade rotation control.

11. When you move the blade rotation control to the DISENGAGE position, all movement will stop within five seconds. If there is movement of the belt or the blades continue to rotate, engage and disengage the blade rotation control five times to remove any excess rubber from a new mower drive belt. If you need assistance, take the unit to an authorized service center.

Blade Drive Spring

Figure 16

12. If you replace the mower drive belt, move the blade drive spring to the top hole (Figure 16).

24F 050760L

MAINTENANCE

HOW TO CHECK AND ADJUST THE MOTION DRIVE BELT

If the motion drive belt is loose, the belt will slip when; (1) going up a hill, (2) pulling a heavy load, or (3) the unit will not move forward. Adjust the belt as follows.

WARNING: Before you make an inspection, adjustment, or repair to the unit, disconnect the wire to the spark plug. Remove the wire from the spark plug to prevent the engine from starting by accident.

1. Check the routing of the motion drive belt. Make sure the belt is installed correctly and is inside all the belt guides.

2. Disconnect the clutch link from the idler arm (Figure 18).

3. Align the hole in the brake lever with the hole in the frame. Hold the brake lever in place with a 1/4 inch (6 mm) pin or bolt (Figure 19).

4. Rotate theclutch link until the mounting hole in the clutch link is aligned with the hole in the idler arm as shown in Figure 18.

5. Connect the clutch link to the idler arm (Figure 18).

6. Remove the 1/4 inch (6 mm) pin or bolt (Figure 19).

7. If the belt still slips after the belt has been adjusted, then the motion drive belt is worn or damaged and must be replaced. See !How To Replace The Motion Drive Belt".

Clutch Rod

Clutch Link

Idler Arm

Mounting

Holes

Figure 18

Clutch Link

Idler Arm

1/4" (6mm)

Pin or Bolt

Idler Spring

Belt Guide

Brake Lever

Motion Drive Belt

Figure 19

25F 050760L

MAINTENANCE

ШСЙ МС ЭШЫЭХ ЯТЬ ЯЬЦЛНМ МШЫ ЬОЧКЫ ЮОЯХЫ

Completely push the brake pedal forward. Set the parking brake. Move the automatic drive disconnect to the PUSH position. Push the unit. If the rear wheels rotate, adjust or replace the brake pads. Adjust the drive brake as follows.

1. The location of the drive brake is on the right side of the gearbox (Figure 20).

2. Make sure the parking brake is set and the automatic drive disconnect is in the PUSH position. Turn the hex nut in a clockwise direction until the rear wheels do not turn when the unit is pushed forward.

3. Release the parking brake and push the unit. If the unit does not roll, turn the hex nut in a counterclockwise direction until the unit rolls.

4. Set the parking brake. Push the unit. If the rear wheels do not turn, the drive brake is correctly adjusted. Release the parking brake.

WARNING: If you cannot correctly adjust the drive brake, replace the brake pads. Correct replacement parts and assistance are available from an authorized service center.

MAINTENANCE FREE BATTERY

Drive Brake

Hex Nut

Gearbox

Figure 20

HOW TO REMOVE THE BATTERY

To charge or clean the battery, remove the battery from the unit as follows.

WARNING: To prevent sparks, disconnect the black battery cable from the negative ( ) terminal before you disconnect the red cable. WARNING: The battery contains sulfuric acid which is harmful to the skin, eyes and clothing. If the acid gets on the body or clothing, wash with water.

1. Disconnect the black cable from the negative ( ) terminal (Figure 21).

2. Disconnect the red cable from the positive (+) terminal.

3. Lift the battery tray and the battery out of the unit.

HOW TO CLEAN THE BATTERY

1. Remove the battery.

2. Wash the battery with a solution of one gallon of water and four tablespoons of baking soda (sodium bicarbonate). Make sure the solution does not get into the battery cells.

3. Clean the terminals and the ends of the cables with a wire brush.

4. Install the battery.

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

1. Before you charge the battery, remove the battery.

2. To charge the battery, use a 12 volt battery charger. Charge at a rate of 6 amperes for 1 hour.

3. Install the battery.

WARNING: To prevent sparks, fasten the red cable to the positive (+) terminal before you connect the black cable.

4. Fasten the red cable and terminal cover (if equipped) to the positive (+) terminal with the fasteners as shown.

5. Fasten theblack cable to the negative ( ) terminal with the fasteners as shown.

Positive (+)

Terminal

Wing Nut

Red Cable

Carriage Bolt

HOW TO CHARGE THE BATTERY

WARNING: When you charge the battery, do not smoke. Keep the battery away from any sparks. The fumes from the battery acid can cause an explosion.

Terminal

Black Cable

Carriage Bolt

26F 050760L

Battery Tray

Cover

Battery

Figure 21

MAINTENANCE

WHERE TO LUBRICATE

Apply grease with a brush to the areas shown.

Lubricate the areas shown with engine oil.

NOTE: Apply grease to the steering gear assembly. CAUTION: If the unit is operated in dry areas that have sand, use a dry graphite spray to lubricate the unit.

HOW TO CHECK THE FUEL FILTER

NOTE: Before you replace the fuel filter or the fuel line, the fuel tank must be empty.

If the fuel filter is dirty, the engine will run rough and have less performance. Remove the old filter (Figure 23). Replace the old filter with a new filter. Use an original equipment part. See an authorized service dealer in your area.

CHECK THE TIRES

Figure 22

Clips

Fuel Line

Fuel Filter

Figure 23

27F 050760L

MAINTENANCE

HOW TO REMOVE THE MOWER HOUSING

1. Move the blade rotation control to the DISENGAGE position.

2. Move the lift lever to the level adjustment position (Figure 24).

WARNING: The lift lever is spring loaded. Make sure the lift lever is locked in the LEVEL ADJUSTMENT position.

3. Remove the hair pins and the washers from the adjuster arms (Figure 25). See illustrations !C" and !D" .

4. Remove the hair pins and washers from the suspension links. See illustrations !A" and !B".

5. Disconnect the extension spring from the blade control rod. See illustration !E".

6. Disconnect the front hanger from the axle support. See illustration !F".

7. Remove the mower drive belt from the stack pulley.

8. Pull the mower housing away from the right side of the unit.

9. To operate without the mower housing, move the lift lever to the TOP position.

Suspension

Link

Level Adjustment

Position Figure 24

Lift Lever

Blade Rotation

Control

HOW TO INSTALL THE MOWER HOUSING

1. Push the mower housing under the right side of the unit.

2. Put the mower drive belt around the stack pulley. Make sure the !V" side of the mower drive belt is against the stack pulley. Also, make sure the mower drive belt is not twisted.

3. Attach the front hanger to the axle support with the hanger rod. Fasten with the fasteners as shown. See illustration !F".

4. Make sure the mower drive belt is between the stack pulley and the two belt guides. See illustration !G".

5. Attach the suspension links to the lifter assembly. Fasten with the washers and hair pins. See illustrations !A" and !B".

6. Attach the right and the left adjuster arms to the suspension brackets. Fasten with the washers and hair pins. See illustrations !C" and !D" .

7. Attach the extension spring to the blade control rod. See illustration !E".

8. Move the blade rotation control to the ENGAGE position. Make sure the mower drive belt is inside all the belt guides.

9. Make sure the mower housing is level. See the instructions on !How To Level The Mower Housing".

10. Check the operation of the blade rotation control. See the instructions on !How To Adjust The Blade Rotation Control".

Stack Pulley

Adjuster

Arm

Suspension

Link

Lifter

Assembly

Belt

Guide

Mower Drive Belt

Extension

Spring

Belt

Guide

Adjuster Arm

Blade

Control Rod

Mower Drive Belt

28F 050760L

Hanger Rod

Front Hanger

Figure 25

MAINTENANCE

HOW TO LEVEL THE MOWER HOUSING

If the mower housing is level, the blade will cut easier and the lawn will look better.

WARNING: Before you make an inspection, adjustment, or repair to the unit, disconnect the wire to the spark plug. Remove the spark plug wire to prevent the engine from starting by accident.

1. Make sure the unit is on a hard flat surface.

Lift Lever

2. Check the air pressure in the tires. If the air pressure is incorrect, the mower housing will not cut level. Make sure the tires are inflated to 14 PSI. (1 BAR).

IMPORTANT: On models equipped with gauge wheels, the gauge wheels must be removed to correctly adjust the level of the mower housing.

3. Some models have gauge wheels on the mower housing. If equipped, remove the gauge wheels.

4. Move the lift lever to the LEVEL ADJUSTMENT position (Figure 26).

WARNING: The lift lever is spring loaded. Make sure the lift lever is locked in the LEVEL ADJUSTMENT position.

5. Loosen the left and right adjuster knobs (Figure 27). Push down on each side of the mower housing. Make sure both sides of the mower housing are setting on a flat surface. Also, make sure the lift links are loose and can easily move up or down.

6. Push down on the lift links and tighten the left and right adjust- er knobs (Figure 27). Make sure the adjuster knobs are tight. If necessary, use a wrench to tighten the adjuster knobs. For plasticadjuster knobs, tighten to a torque of 7 foot pounds (9,5 N m). For metal adjuster knobs, tighten to a torque of 10 foot pounds (13,5 N m).

Cutting Height Positions

Level Adjustment Position

Figure 26

Lift Link

Adjuster Knobs

Lift Lever

Figure 27

7. Raise the lift lever from the LEVEL ADJUSTMENT position to a CUTTING HEIGHT position (Figure 28).

8. If equipped, install the gauge wheels.

9. Mow for a short distance. If the height of cut is not level, repeat the above steps.

CAUTION: Do not operate with the mower housing in the LEVEL ADJUSTMENT position. If you operate in the LEVEL ADJUSTMENT position, the mower housing and blades can be damaged.

Cutting Height Positions

Figure 28

29F 050760L

MAINTENANCE

HOW TO REPLACE THE MOTION DRIVE BELT

REMOVAL

1.Remove the mower housing. See the instructions on !How To Remove The Mower Housing".

2. Remove the mid idler pulley.

3. Disconnect the idler spring (Figure 31).

4. Remove the idler pulley and spacer (Figure 31).

5. Remove the V idler pulley and spacer.

6. Remove the motion drive belt from the drive pulley (Figure 31).

7. To remove the motion drive belt from the stack pulley, pull the front end of the belt under the stack pulley and then back between the stack pulley and the steering plate (Figure 29).

8. Remove the access panel (Figure 30).

9. Remove the two screws that attach the steering shaft

assembly (Figure 30). Raise the steering wheel and steering shaft assembly. Pull the motion drive belt under the steering shaft assembly.

10. Remove the motion drive belt. A correct replacement part or assistance is available from an Authorized Service Center in your area.

INSTALLATION

1. Slide the motion drive belt between the stack pulley and the belt guides (Figure 29). Install the motion drive belt on the

top pulley of the stack pulley. Make sure the !V" side of the belt is against the pulley.

2. Push the motion drive belt through the opening between the steering plate and the engine plate.

3. Install the end of the motion drive belt around the drive pulley (Figure 31).

4. Put the motion drive belt around the V idler pulley. Install the motion drive belt, V idler pulley and spacer.

5. Put the belt around the idler pulley. Fasten the idler pulley and spacer with the hex nut. Make sure the flat side of the belt is against the idler pulley. Also, make sure the belt is not twisted.

6. Connect the idler spring (Figure 31).

7. Install the mid idler pulley.

8. Check the routing of the motion drive belt (Figure 31). Make sure the motion drive belt is installed correctly on the idler pulleys and inside all belt guides.

9. Attach the steering shaft assembly to the steering plate with two screws (Figure 30).

10. Attach the access panel (Figure 30).

11. Before you use the unit, check the adjustment of the clutch. See the instructions !How To Check And Adjust The Clutch".

12. Install the mower housing. See the instructions !How To Install The Mower Housing".

FRONT

Stack Pulley

Motion

Drive

Belt Figure 29

Screw

Steering Shaft

Assembly

Motion Drive

Belt

Access Panel

Steering

Plate

Belt Guides

Figure 30

Idler Pulley

Spacer

V Idler Pulley

Drive Pulley

Idler Spring

Spacer

V Idler Pulley

Idler Spring

30F 050760L

Mid Idler Pulley

Motion Drive Belt

Belt Guide

Stack Pulley

Figure 31

MAINTENANCE

HOW TO REPLACE THE MOWER DRIVE BELT

1.Remove the mower housing. See the instructions on !How To Remove The Mower Housing".

2. Pull the belt retainer away from the idler pulley and remove the mower drive belt (Figure 32).

3. Pull the belt retainer away from the right mandrel pulley and remove the mower drive belt.

4. Pull the belt retainer away from the left mandrel pulley and remove the mower drive belt.

NOTE: Replace the mower drive belt with an original equipment belt from an authorized service center.

5. Install the new mower drive belt. Pull the belt retainer away from the right mandrel pulley. Put the belt around the right

mandrel pulley.

6. Pull the belt retainer away from the left mandrel pulley. Put the belt around the left mandrel pulley.

7. Pull the belt retainer away from the idler pulley. Put the flat side of the mower drive belt around the idler pulley.

8.Make sure the !V" side of the mower drive belt is against the mandrel pulleys as shown.

9.Install the mower housing. See the instructions on !How To Install The Mower Housing".

10. Before you mow, check the blade rotation control. See the instructions on !How To Adjust The Blade Rotation Control".

Right Mandrel Pulley

Belt Retainer

Left Mandrel Pulley

Belt Retainer

Idler Pulley

Mower Drive Belt

Figure 32

31F 050760L

MAINTENANCE

HOW TO INSTALL THE WHEELS

If the wheels must be removed for service, make sure they are installed as follows.

Front Wheel

1. Make sure the valve stem is to the outside of the tractor. Slide the front wheel on the spindle (See Figure 33).

2. Fasten the front wheel with washer and cotter pin. Bend the ends of the cotter pin apart to keep the front wheel on the

spindle.

3. If your model has hub caps, install the hub caps. Make sure the washer hold the hub caps in place.

Hub Cap

Valve Stem

Cotter Pin

Washer

Spindle

Front Wheel

Figure 33

Rear Wheel

1. Install the washers and spacer onto the axle as shown in Figure 34.

2. Mount the square key in the key slot (See Figure 34).

3. Make sure the valve stem is to the outside of the tractor. Align the slot in the rear wheel with the square key. Slide the rear wheel on the axle.

4. Fasten the rear wheel with washer and e ring.

5. If your model has hub caps, install the hub caps. Make sure the washer hold the hub caps in place.

Rear Wheel

Hub Cap

E Ring

Washer

Valve Stem

Square Key

Key Slot

Washer

Axle

Spacer

Figure 34

32F 050760L

MAINTENANCE

HOW TO REPLACE THE FUSE

If the fuse is blown, the engine will not start. The location of the fuse is next to the battery. Remove the fuse and replace with a automotive fuse (Figure 35).

Automotive Fuse

Figure 35

HOW TO REPLACE THE LIGHT BULB

1. Raise the tractor hood.

2. Turn the light socket until the tabs on the socket align with the notches in the bezel (Figure 36). Remove the light socket. Turn the light bulb and remove the bulb.

HOW TO CLEAN THE MOWER HOUSING

WARNING: Before you clean the mower housing, stop the engine and disconnect the wire to the spark plug.

Grass and other debris on top of the mower housing can keep the belt from working correctly. For safety and correct operation, frequently clean the top of the mower housing. Remove grass and debris from around the pulleys and other moving parts.

3. Install a new light bulb. Align the light socket with the notches in the bezel and turn the light socket to lock in position.

Bezel

Light Bulb

Light Socket

1. Move the lever for the blade rotation control to the ENGAGE position.

2. Clean the top of the mower housing.

3. Move the lever for the blade rotation control to the DISENGAGE position.

4. Again clean the top of the mower housing.

5. After you cut the grass, clean the bottom of the mower housing.

Figure 36

STORAGE (over 30 days)

At the end of each year, prepare the unit for storage as follows.

THE ENGINE

For storage information, see the the engine manufacturer s instructions.

THE BATTERY

1. Remove the battery.

2. Clean the battery terminals of any deposits.

3.Charge the battery. See the instructions on !How To Prepare And Charge The Battery".

4. Store the battery in a cool, dry place.

NOTE: After a long time in storage, charge the battery.

THE FUEL SYSTEM

WARNING: Do not drain the gasoline inside a building or near a fire. Do not smoke because the fumes from the fuel can cause an explosion.

1. Start the engine.

2. Run the engine until the fuel tank and the carburetor are out of fuel and the engine stops.

3. After storage, make sure you use fresh fuel.

CLEAN THE UNIT

1. Clean the dirt and grass from the engine.

2. Clean the mower housing.

LUBRICATE THE UNIT

See the !Lubrication" instructions in this book.

33F 050760L

TROUBLE SHOOTING CHART

PROBLEM: The engine will not start.

1.Follow the steps, !How To Start The Engine" in this book.

2. Electric Start Models: Clean the battery terminals. Tighten the cables.

3. Drain the fuel tank. Clean the fuel line. Replace the fuel filter.

4. Remove the spark plug(s). Move the throttle to the SLOW position. Turn the ignition key to the ON position. Try to start the engine several times. Install the spark plug.

5. Replace the spark plug.

6. Adjust the carburetor.

PROBLEM: The engine will not turn over.

1.Follow the steps, !How To Start The Engine" in this book.

2. Electric Start Models: Check the level of the acid in the battery. If needed, add water. Charge the battery.

3. Replace the fuse.

4. Check the wiring harness for damage or a loose connection. Repair the damaged wire.

5. Electric Start Models: replace the solenoid. Recoil Start Models: replace the module.

PROBLEM: The engine is difficult to start.

1. Adjust the carburetor.

2. Replace the spark plug.

3. Replace the fuel filter.

PROBLEM: The engine does not run smooth or has a loss of power.

1. Check the oil.

2. Clean the air filter.

3. Clean the air screen.

4. Replace the spark plug.

5. The engine is working too hard. Use a lower gear.

6. Adjust the carburetor.

7. Replace the fuel filter.

PROBLEM: The engine does not run smooth at fast speed.

1. Replace the spark plug.

2. Adjust the throttle control.

3. Clean the air filter.

4. Replace the fuel filter.

PROBLEM: The engine stops when the blades are engaged.

1. To activate the seat sensor, always sit in the middle of the seat.

2. Check the wiring harness for damage or a loose connection. Repair the damaged wire.

PROBLEM: On slopes, the engine stops.

1. Mow up and down slopes. Never mow across a slope.

2. To activate the seat sensor, always sit in the middle of the seat.

PROBLEM: The engine will not idle.

1. Replace the spark plug.

2. Clean the air filter.

3. Adjust the carburetor.

4. Adjust the throttle control.

5. Drain the fuel tank. Clean the fuel line. Replace the fuel filter.

PROBLEM: A hot engine causes a decrease in power.

1. Clean the air screen.

2. Check the oil.

3. Adjust the carburetor.

4. Replace the fuel filter.

PROBLEM: Excessive vibration.

1. Replace the blade.

2. Check for loose engine bolts.

3. Decrease the air pressure in the tires.

4. Adjust the carburetor.

5. Check for a damaged belt or damaged pulley. Replace the damaged parts.

PROBLEM: The grass does not discharge correctly.

1. Stop the engine . Clean the mower housing.

2. Raise the height of cut.

3. Replace or sharpen the blade(s).

4. Move the shift lever to a slower speed.

5. Move the throttle control to the FAST position.

6. Replace the spring for the blade idler.

PROBLEM: The mower housing does not cut level.

1. Check the air pressure in the tires.

2. Adjust the level of the mower housing.

3. Check the front axle. If the front axle does not freely pivot, loosen the axle bolt(s).

PROBLEM: The mower blades will not rotate.

1. Check the mower drive belt. Make sure the belt is installed correctly.

2. Replace the mower drive belt.

PROBLEM: The unit will not move when the brake is released and the speed control pedal is depressed.

1. Check the motion drive belt. Make sure the belt is installed correctly.

2. Adjust the clutch.

3. Replace the motion drive belt.

4. Release the Automatic Drive Disconnect under the seat.

PROBLEM: The unit moves slower or stops when the speed control pedal is depressed.

1. Adjust the clutch.

2. Replace the motion drive belt.

PROBLEM: When the brake pedal is released, belt noise can be heard.

1. Temporary belt noise does not change the operation of the unit. If belt noise is continuous, check the routing of the belt. Make sure the belt is inside all belt guides.

2. If the noise is continuous, adjust the clutch.

PROBLEM: The rear wheels spin over uneven terrain.

1. Check the front axle. If the front axle does not freely pivot, loosen the axle bolt(s).

34F 050760L

NOTES

35F 050760L

REPAIR PARTSMODEL 405606x108A

CHASSIS & HOOD

3 4

36F 050760L

REPAIR PARTSMODEL 405606x108A

CHASSIS & HOOD

Key

No. Part No. Description

1690566 Seat

2028x23 Cap, Push 0n

3094057 Spring

426x229 Screw

51001054 Bolt, Wing

6017x47 ZWasher

7009x56 Bolt, Shoulder

8094154E701 Support, Seat

9094156 ZRod, Pivot

101001648E700 Bracket, Pivot

11001x45 Bolt

12015x89 Nut

13009x55 Bolt, Shoulder

14094155 ZWasher

Key

No. Part No. Description

3126x270 Screw

3226x238 Screw

331001491 Bearing, Steering

341001584E701 Dash

3526x201 Screw

36093007E701 Panel, Access

37095318E701 Support, Dash

381001270E701 Bracket, Rear Hanger

39094083E700 Support, Left Grille

40094007E701 Axle, Hanger

41094082E700 Support, Right Grille

42009x58 Bolt, Shoulder

431001928E701 Frame, Right

441001927E701 Frame, Left

15164x31 Spring

1626x249 Screw

1726x263 Screw

18164x30 Spring

191001559E285 Deck, Seat

2015x123 Nut

21094829E701 Plate, Index

22009x47 Screw

231001582 Mat, Left

241001578 Mat, Right

251001797E285 Hood, W1

261001798E285 Grille

271001806 Lens

281001805 Housing, Headlamp

291001799E701 Bracket, Lower Pivot

30690482E701 Support , Battery

45690424 Container, Battery

461001002E701 Plate, Hitch

47690434E700 Panel, Rear

49015x81 Nut

5026x277 Screw

5115x124 Nut

531001802 Insert, Center Grille

541001803 Insert, Left Grille

551001804 Insert, Right Grille

561001800 Insert, Left Hood

571001801 Insert, Right Hood

591001755 Grommet, Parking Brake

600193x1 Fastener, Panel

701001542 Holder, Cup

1002050 Parts Bag, Assembly

F 050760LInstruction Book & Parts List

37F 050760L

REPAIR PARTSMODEL 405606x108A

DRIVE ASSEMBLY

2827

38F 050760L

REPAIR PARTSMODEL 405606x108A

DRIVE ASSEMBLY

Key

No. Part No. Description

126x249 Screw

2091079 Grip, Parking Brake

41001245 ZRod, Parking Brake

5094008E701 Bracket, Left Transaxle

61001013 ZRod, Clutch

7094045 ZLatch, Parking Brake

837x106 V Belt, Drive

9015x79 Nut, Flange

10021544 Pedal, Brake/Clutch

111001011 E701 Assembly, Brake Pedal

12094384 Screw, Guide

14002x53 Bolt, Carriage

15017x57 Washer

160031x4 Pin , Hair

Key

No. Part No. Description

30092132 ZNut, Adjusting

31015x84 Nut, Centerlock

32030x20 Pin, Cotter

33017x48 Washer

34165x92 Spring, Extension

3517x148 Washer

361001086 ZArm, Disconnect

3706x105 Capscrew

38165x150 Spring, Brake

39015x98 Locknut, Flange

40690409 Pulley, Idler

41690369 Spacer

421001097E701 Bracket, Idler Assembly

43009x49 Bolt, Shoulder

17095121E701 Pedal Assembly, Hydro

18092294 601Wheel & Tire Ass y, Rear

091914 Tire ONLY *

407049 Tube ONLY

1917x160 Washer

20690554 ZSpacer

21024373 Stem, Valve

2217x195 Washer

230011 x3 E Ring

24094618 Cap, Hub

25015x88 Nut, Centerlock

26 ** Transaxle, Peerless Hydro

271001085E701 Strap, Torque

2826x216 Screw

291001234 ZRod, Control

441001007 ZLink, Clutch

451001014 Nut, Tee

46690410 Pulley, Idler

471001012 Bushing, Pivot

481001018 ZArm Assembly, Idler

49094008E701 Bracket, Right Transaxle

5001x155 Bolt, Hex

511001214 ZBracket, Dump Valve

521001215 ZRod, Roll Release

531001108E701 Bracket, Idler Pivot

54002x92 Bolt, Carriage

55002x78 Bolt, Carriage

56165x155 Spring, Clutch

57017x38 Washer

58021553Key, Square 3/16"

* When you order a tire, make sure to give the brand name of the tire so that the tread pattern on the tire will match.

** For information on Replacement Parts for this transaxle contact the manufacturer.

39F 050760L

REPAIR PARTSMODEL 405606x108A

STEERING

40F 050760L

REPAIR PARTSMODEL 405606x108A

STEERING

Key

No. Part No. Description

11001980 Wheel, Steering

2690625 Post, Steering

31001982 Cover, Steering Wheel

4094124Bearing #

515x111Nut, Flange #

6009x57 Bolt, Shoulder

71001893Gear, Pinion #

8011x25Ring, Snap #

9094121 Gear, Sector

10094123 Bearing

11001x84 Bolt

121001121E701 Plate, Steering

Key

No. Part No. Description

2317x104 Washer

24017x53 ZWasher

25015x84 Nut, Flange

261001460E701 Axle Assembly

27095329E701 Drag Link, Left

28094575E701 Spindle Assembly, Right

29095328E701 Drag Link, Right

3026x249 Screw

31091334 Bearing, Wheel

32024373 Stem, Valve

33024380 Tire *

407924 Tube

13094006E700 Plate, Engine

14015x88 Nut, Flange

1515x118 Nut, Flange

161001270E700 Bracket, Hanger

1794007E701 Axle, Hanger

1801x146 Bolt

19030x49 Pin, Cotter

20690150 Bearing

21094576E701 Spindle Assembly, Left

2201x111 Bolt

* When you order a tire , make sure to give the brand name of the tire so that the tread pattern on the tire will match.

# These parts are included when ordering Key number 2.

34094581 601 Wheel andTire Assembly

3517x195 Washer

3617x192 Washer

3717x113 Washer

38094618 Hub Cap

3926x267 Screw

40092059 Bellows

410025x3 Bolt

4317x146 Washer

41F 050760L

MOWER HOUSING SUSPENSION

2424

REPAIR PARTSMODEL 405606x108A

42F 050760L

REPAIR PARTSMODEL 405606x108A

MOWER HOUSING SUSPENSION

Key

No. Part No. Description

1092698 Grip

2094157 ZHandle, PTO

3094022 ZPad, Switch

40025x3 Bolt

5092697 Grip

6166x40 Spring

717x103 Washer

8690533 Handle, Lift

9094017 ZLever, PTO

10009x39 Bolt, Shoulder

11030x20 Pin, Cotter

12017x57 Washer

Key

No. Part No. Description

2217x168 Washer

23017x57 Washer

240031x4 Pin , Hair

25017x91 Washer

26002x85 Bolt, Carriage

271001111E 700 Lever Assembly, Lift

30094067 Pin

31094055E701 Bracket, Rear Suspension

32690151 Spacer, Lifter

33009x53 Bolt, Shoulder

34094015E700 Bracket, Pivot

3617x191 Washer

13094004 ZLink, PTO

14015x84 Nut, Flange

1526x249 Screw

16166x39 Spring

17094018E701 Bracket, PTO

18165x118 Spring, PTO

19690394E701 Crank, PTO

20690212E701 Link, Lift

21690122 ZLink, Lift Handle

37015x84 Nut, Flange

38165x131 Spring

39015x68 Nut, Flange

40094005E701 Bracket, PTO

41094027E701 Hanger, Left Deck

42094026E700 Hanger, Right Deck

43094158 ZRod, Hanger

44690539E701 Bracket, Suspension

451001098E701 Plate, Stiffening

43F 050760L

REPAIR PARTSMODEL 405606x108A

MOWER HOUSING

3029

547

44F 050760L

39 40

REPAIR PARTSMODEL 405606x108A

MOWER HOUSING

Key

No. Part No. Description

1092851 Pulley, Jackshaft

215x140 Nut, Hex

3037x62 Belt, Mower Drive

4690387 Pulley, Idler

5015x84 Nut, Flange

8690212E701 Link, Lift

9094137 Pad, Friction

10009x52 Bolt, Shoulder

11094055E701 Bracket, Suspension

12094049E701 Pad Assembly, Left Brake

13094068 Knob

14009x51 Bolt, Shoulder

15094128E700 Plate, Suspension

Key

No. Part No. Description

30094142E700 Bracket, Suspension

31091770E700 Plate

32015x88 Nut, Flange

33002x53 Bolt, Carriage

341001200 Mandrell

35690539E701 Bracket, Suspension

36690411 Adapter, Blade

37095103E701 Blade

3817x166 Washer

3917x165 Washer

4015x100 Nut

410166x4 Spring

42028x23 Cap, Push On

16166x43 Spring

17015x79 Nut, Flange

18094143E700 Bracket, Suspension

19095194 Pin, Hanger

20017x91 Washer

210031x4 Pin , Cotter

220025x7 Bolt

23094051E701 Cover, Pulley

24009x39 Bolt, Shoulder

25690408E701 Arm, Idler

26166x41 Spring

27094047E701 Pad Assembly, Right Brake

28094145E701 Bracket Assembly, Brake

29166x42 Spring

* Includes Key No. 17, 18, 30, 31, 32, 33, 45, 46, 47 and 51.

43094957 ZRod, Pivot

44094707 Deflector Assembly

45094956E701 Bracket, Deflector

46094144E700 Bracket, Front Hanger

47017x45 ZWasher

48094781 Guide, Belt

50094681E700 Bracket, Support

5126x249 Screw

52165x119 Spring, Extension

53690369 Spacer

54094141E701 Housing, Blade *

55015x98 Nut, Flange

1 557601044 Complete Mower Housing Assy

45F 050760L

REPAIR PARTSMODEL 405606x108A

ENGINE MOUNT

46F 050760L

Key

No. Part No. Description

1092317Fuel Cap #

2690280 Fuel Tank

3095197Hose Clamp #

47601033Fuel Line (Must cut to length) #

5095197Hose Clamp #

626x201 Screw

7094006E700 Plate, Engine

8092371 Throttle Control

9 * Engine, BRIGGS & STRATTON

9a 1001717 Muffler

9b 091309 Gasket, Muffler

REPAIR PARTSMODEL 405606x108A

ENGINE MOUNT

9c 095207 Adapter, Muffler

9d 06x103 Screw, Adapter

9e 009x59 Bolt, Muffler

9f 092378 Lock, Screw

100025x7 Bolt, Engine Mount

11690439 ZStack Pulley Assembly

12019x35 Lockwasher

1301x140 Bolt, Hex

1417x170 Washer

1526x249 Screw

21094384 Guide, Belt

22015x79 ZNut, Flange

23094066 Guide, Belt

2626x253 Screw

301001897 Shield, Heat

3126x263 Screw

3206x104 Screw

* For information on Replacement Parts contact the engine manufacturer.

# These parts are included with Key number 2.

47F 050760L

REPAIR PARTSMODEL 405606x108A

ELECTRICAL SYSTEM

MAIN HARNESS: 250x112

SEAT: 250x67; LIGHT : 250x92

48F 050760L

Key

No. Part No. Description

1250x92 Harness, Light Wire

1001716 Socket, Light

090084 Bulb, Light

2250x112 Harness, Chassis Wire

3092556 Switch, Ignition

1001304 Key, Ignition

091489 Nut, Hex

091488 Cap, Ignition

41001575 Switch, Limit

5302031 Fuse

407078 Holder, Fuse

REPAIR PARTSMODEL 405606x108A

ELECTRICAL SYSTEM

61002004 Solenoid

26x229 Screw, Mounting

15x116 Locknut

7024x32 Cable, Battery Ground

26x229 Screw, Ground Cable

8021075 Battery

002x82 Bolt, Carriage

014x79 Wingnut

690604 Boot, Battery Positive

9250x67 Harness, Seat Switch Wire

10094159 Switch, Seat Sensor

11024x31 Cable

49F 050760L

50F 050760L

INDEX

Adjustments

Blade Rotation Control, 24 Clutch, 25 Drive Brake, 26 Mower Housing, Level, 29

Assembly

Battery, 13 Front Wheel, 11 Seat, 12 Steering Wheel, 12

Attachments, 16

Automatic Drive Disconnect,

Operation, 17

Battery

Charge, 26 Check, 13 Clean, 26 Install, 13 Removal, 26 Storage, 33

Belt

Motion Drive

Adjust, 25 Replace, 30

Mower Drive

Adjust, 24 Replace, 31

Blade

Inspect, 23 Remove And Install, 23 Sharpen, 23

Blade Rotation Control

Adjust, 24 Location, 15 Operation, 16

Brake Pedal, Location, 15

Clutch

Adjust, 25

Check, 25 Controls, Location, 15 Cutting Height

Adjust, 29

Change, 18

Drive Brake

Adjust, 26

Check, 26

Engine

Fuel, 14, 20

Oil, 14, 20

Preparation, 14

F 040740L

Spark Arrester, 14, 22 Starting, 20 Storage, 33 Throttle Control, 16

Filter, Fuel, 27

Front Wheel, Assembly, 11 Fuel, Type, 20

Fuse, 33

Headlight, Replace Light Bulb, 33 Headlight Switch, Location, 15

Ignition Switch, Location, 15

Lift Lever

Location, 15 Operation, 18

Lubrication, Mower, 27

Maintenance

Battery

Charge, 26 Clean, 26

Belt

Motion Drive, 30

Mower Drive, 31 Blade, 23 Blade Rotation Control, 24 Clutch, 25 Drive Brake, 26 Filter, Fuel, 27 Fuse, 33 Headlight, 33 Install, Wheels, 32 Lubrication, 27 Mower Housing

Clean, 33

Install, 28

Level, 29

Remove, 28 Muffler, 22 Storage, 33

Maintenance Chart, 22

Motion Drive Belt

Adjust, 25 Replace, 30

Mower Drive Belt

Adjust, 24 Replace, 31

Mower Housing

Clean, 33 Cutting Height, 18 Install, 28

Level Adjustment, 29 Operation, 19 Remove, 28

Muffler, 22

Spark Arrester, 22

Oil

Check, 20 Type, 20

Operation

Attachments, 16 Automatic Drive Disconnect, 17 Blade Rotation Control, 15, 16 Brake Pedal, 15 Headlight Switch, 15 Ignition Switch, 15 Lift Lever, 15, 18 Location Of Controls, 15 Mower Housing, 19 Mowing And Bagging, 21 Operate On Hills, 19 Parking Brake, 15, 18 Speed Control Pedal, 15, 17 Start The Engine, 20 Stop The Unit, 18 Throttle Control, 15, 16 Transport, 18

Parking Brake

Location, 15 Operation, 18

Parts Bag, 10

Safety Rules

American National Standard

Institute, 3$4

Safe Mowing Guide, 5$7 Seat, Install, 12 Seat Switch, Operation, 20 Slope Guide, 50

Spark Arrester, 14, 22 Speed Control Pedal

Location, 15

Operation, 17 Steering Wheel, 12

Storage, 33

Throttle Control

Location, 15

Operation, 16 Tire Pressure, 14, 27

Trouble Shooting Chart, 34

Warranty, 2

52F 040740L

Rover 405606x108A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual