BOLENS Lawn, Tractor Manual L0904580
User Manual: BOLENS BOLENS Lawn, Tractor Manual BOLENS Lawn, Tractor Owner's Manual, BOLENS Lawn, Tractor installation guides
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Balenmo Owner/Operator Manual RidingMower Models 13000 8 HP 28"sidedischarge 13O01 8.5 HP 28"sidedischarge 13002 8.5 HP 28"sidedischarge(Export) 13003 12.5 HP33" mulcher 13004 12.5HP (Australia) 13005 12.5HP 36"sidedischarge 13OO612.5HP 36"sidedischarge(Export) 13007 12.5HP 33"mulcher(Export) 13055 8 HP28" sidedischarge 13057 8.5 HP28"sidedischarge 13O67 12.5HP 33"mulcher 13O68 12.5HP 33"mulcher(Export ©1993 Garden Way Inc. FORM1768445(8/93) SupersedesFORM1763980Rev.B (10/92) INTRODUCTION Thank you for purchasing available. this Bolens ® riding mower. We feel you now own one of the finest pieces of equipment This is a safety, operation, and general maintenance manual which does not attempt to cover major repairs. Bolens ® equipment is carefully designed, engineered and manufactured to give good performance if properly operated and maintained. Review this manual to familiarize yourself with the unit, its features, and its operation. All Bolens ® mowers have passed rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory. Your Warranty Statement is included, on the back cover of this manual. Please read it carefully. Also please return the completed postpaid owner registration card which is included with this manual. Proper registration is required for all warranty claims. IDENTIFICATION For prompt servicewhen repairs or adjustments are required, your authorized Bolens_ dealer must have the identification numbers of your riding mower. Pleasefill in the identification numbers in the spaces below for future reference. Your identification numbers are located under the seat as shown to the right. NUMBERS Model/Serial Number Date of Purchase: Mower Serial Number: Transmission Model/Serial Number: Engine Model/Serial/Spec. Numbers: AND WARNINGRIDING TO ALL CALIFORNIA OTHER MOWER OPERATORS Under California law, and under the laws of several other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest covered, brush covered, or grass covered land, or on land covered with grain, hay, or other flammable agricultural crop, without an engine spark arrester in continuous effective working order. The engine on your riding mower, like most outdoor power equipment, is an internal combustion engine that burns gasoline, a hydrocarbon fuel. Therefore, your riding mower must be equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Failure of the owner/operator of the riding mower to comply with this regulation is a misdemeanor under California law, and may also be a violation of other state and/or federal regulations, laws, ordinances, or codes. Contact your local fire marshal or forest service for specific information about what regulations apply in your area. TABLE OF CONTENTS SAFETY..............................................................i ........... ATrACHMENTSAND KITS............................................. 3 6 SPECIFICATIONS .......... ................................................. 6 ASSEMBLY.................................................................... HITCH.......................................................................... COLUMNSUPPORT..................................................... BATTERY...................................................................... SEAT............................................................................ ENGINEOIL.................................................................. SPARKPLUG............................................................... MOWERDECKINSTALLATION.................................... CONTROLSAND OPERATIONi....................................... CONTROLS.................................................................. EngineSpeed Lever.................................................... BrakePedal................................................................ Parking Brake ............................................................ IgnitionKeyswitch...................................................... Drive Pedal................................................................. Mower BladeDriveLever........................................... Mower HeightAdjustingKnob................................... TransmissionShift Lever........................................... Mower Lift Lever........................................................ OPERATION................................................................. Pre-StartingChecklist................................................ Filling FuelTank......................................................... 8 8 8 8 9 9 9 9-16 18 17 17 17 17 17 17 17 17 17 18 18 18 19 Starting....................................................................... 19 InterlockSystem Test................................................ 20 Mowing...................................................................... 20 TestingHeightof Cut ................................................. 21 GageWheelAdjustment............................................. 21 Stopping .................................................................... 22 Parking....................................................................... 22 MowingTips.............................................................. 22 SpecialPatternEffects............................................... 22 MAINTENANCE.............................................................. 23 TRACTORMAINTENANCE ............................................ 23 Engine........................................................................ 23 BrakeAdjustment....................................................... 23 TransmissionDriveBeltAdjustment.......................... 23 Battery........................................................................ 24 MOWERDECKMAINTENANCE.................................... 25 Mower DriveBeltReplacement.................................. 25 Mower DriveBeltAdjustment ..................................... 27 Mower DeckBrakeAdjustment.................................. 28 BladeMaintenance..................................................... 29 STORAGE ..................................................................... 31 MAINTENANCECHART.................................................. 32 TROUBLESHOOTING CHART......................................... 32 WIRING DIAGRAM......................................................... 35 WARRANTY...................................................... BACKCOVER SAFETY IMPORTANT! Safe Operation Practices This is a safety alert symbol. It is used in this Manual and on riding mower decals to alert you to potential hazards. TRAINING for Riding Mowers Wheneveryou see this symbol, read and obey the safety messagethat follows it. Failureto obey the safety message could resultin personalinjuryor propertydamage. 1. Beforeoperatingthe unit: a. Readthis owner/operator manual, the separate engine owner'smanual, and any other literature you may have received. PREVENTINGACCIDENTSIS THE RESPONSIBILITYOF EVERYEQUIPMENT OPERATOR.THE OPERATORIS b. Be thoroughly familiar with the RESPONSIBLEFOR ACCIDENTSOR controls and proper use of theunit. HAZARDSOCCURRINGTO OTHER c. Readall literature furnished with any PEOPLEORTHEIR PROPERTY. THE attachments used on the unit. FOLLOWINGGENERALSAFETY d. Knowhow to stop the unit and PRECAUTIONSMUST BEFULLY disengage its controls quickly in case UNDERSTOODAND FOLLOWEDWHEN of an emergency. OPERATINGYOUR RIDING MOWER. REVIEWTHEM FREQUENTLYAND NEVER 2. NEVERallow children to operatethe unit. Localregulations may restrict the TAKECHANCES. BECAREFULBEFORE, age of the operator. DURINGAND IMMEDIATELYAFTERUSE OFANY POWEREDEQUIPMENT. 3. Do not allow adults to operatethe unit ACCIDENTSCANBE PREVENTED. without proper instruction. 4. Neverallow irresponsible adults to operatethe unit. 5. Keep thearea of operation clear of all persons (particularly small children) and pets. GENERAL , OPERATION Thoroughlyinspect the area wherethe unit will be used: a. Removeall stones, sticks, wires, bones, and other foreignobjects. Tall grass can hide obstacles. b. Inspect the area for holes, ruts, or bumps. Uneven terrain could overturn the unit. 2. Wear proper clothing before operating the unit: SAFETY (Cont.) a. Do not operate the unit when barefoot or wearing open sandals. Always wear substantial footwear. b. Always wear long trousers. c. Do not wear loose-fitting clothing or jewelry that could get caught in moving parts. d. Be aware that vines, branches, etc., ('an snag loose-fitting clothing or jewelry. 3. Before attempting to start the engine: a. Apply the parking brake. b. Disengagethe mower blade drive. c. Shift into neutral. . Mow only in daylight or in good artificial light. . Never operate the unit in wet grass-reduced traction could cause sliding. Always maintain proper traction. Keep a firm grip on the steering wheel. Neverattempt to stabilize the unit by putting your foot on the ground. . a. Apply the parking brake. b. Disengagethe mower blade drive. c. Shift into neutral. 12. Do not changethe engine governor settings or over-speedthe engine. Operatingan engineat excessivespeed may increasethe hazardof personal injury. 13.Do not put hands or feet near or under rotating parts. Keepclearof the dischargeopeningat all times. Beaware of the mower dischargedirectionand do not point it at anyone. Do not operatethe unit without eitherthe entireoptional baggingattachmentor thedischarge chute in place. 14.Watch for traffic when operatingnear,or when crossingroadways. 15. Disengagethe mower blade drive and wait for the mower blades to come to a stop when crossing gravel drives, walks, or roads. b. Limit loads to those you can safely control. 16.Nter striking a foreign object: d. Use optional counterweight(s) or wheel weights when using attachments which affect the balance of the unit. . 11. Beforeattempting to start the engine: Use carewhen pulling loads or using heavy equipment: a. Use only approved drawbar hitch points. c. Do not turn sharply. Slow down before turning. Use care when backing up. . 10. Use extra care when loadingor unloading the unit into a trailer or truck. Never attempt to defeat the purpose of guards or other safety devices installed on the unit. Never operate the unit with defective guards or shields, or without safety devices in place. Before use, always visually inspect the mower blade(s) and blade bolts and replaceif they are worn or damaged. Replaceworn or damaged blades and bolts in sets to maintain proper balance. Torque the blade bolts to the correct troque values indicated in this manual. 9. If the unit has a two bladedeck,usecare whenrotatingonebladebecausethis can causethe other blade to rotate. a. Disengagethe mower blade drive. b. Stop the engine. c. Wait for all moving parts to come to a complete stop. d. Removethe wire from the spark plug. e. Keepthe wire away from the plug to prevent accidental starting. f. Thoroughly inspect the unit for any damage, and repair the damage before re-starting and operating the unit. 17. If the unit should start to vibrate abnormally, stop the engine and check immediately for the cause; Vibration is generallya warning of trouble. 18. Before cleaning the mower deck housing, before cleaning the unit and before making any repairs or inspections: a. Disengagethe mower blade drive. b. Stop the engine. C. Wait for all moving parts to come to a complete stop. d. Removethe wire from the spark plug. e. Keepthe wire away from the plug to prevent accidental starting. 19.Stop the engine whenever you leave the unit. 20. Do not run the engine indoors. Exhaust gases contain carbon monoxide, a deadly gas that is odorless and colorless. Always run the engine outdoors and make sure there is adequateventilation. 21 .Stop the blade (move the mower blade drive lever to its disengaged position) whenever you are approached by any child, inattentive person, or pet. 22. Disengagethe mower blade drive when you are not mowing. 23. Do not touch engine parts which may be hot from operation. Allow the engine to cool before inspecting, cleaning, or repairing the unit. 24. Do not operate the unit while under the influence of alcohol or drugs. 25.Use low throttle settings when engaging the drive pedal, especially in high gears. 26. Never attempt to carry any passengers on the unit. They could fall off and be seriously injured, or they could interfere with the safe operation of the unit. 27. Use extra care when approaching blind corners, shrubs, trees, and any other object that may obscure vision. 28. When using any attachments, never direct the discharge of material toward bystanders. 29.There is a safety interlock switch which should shut down the engine within a few seconds after the operator leaves the seat. If this switch fails to operate, get the unit serviced immediately by an authorized Bolens® dealer. Severe injury could result from not following this instruction. 30.Never leavea running machine unattended. Always disengagethe mower blade drive, set the parking brake, stop the engine and remove the keys before dismounting. SAFETY SLOPE OPERATION 1. MOWup and downthe face of a slope--Never across. SERVICE 1, Handlegasoline with care -- it is highly flammable: a. Use an approved gasoline container. 2. Keepall movement on a slope slow and gradual. Do not make sudden changes in speed or direction. Do not turn on slopes unless necessary,and then, turn slowly and gradually downhill, if possible. Use slow speed. Choose a low gear so you will not have to stop or shift while on the slope. , ; Do notstop or start suddenly on a slope. If the tires loose traction, disengagethe mower blade drive and proceed slowly straight down the slope. b. Never remove the fuel cap of, or add gasoline to, a running or hot engine or to an engine that has not been allowedto cool for several minutes after running. Never store the unit or fuel container inside where there is an open flame, such as in a water heater. c. Keepsmoking materials,sparks, and flame away from the gas tank and the fuel container. 2. Checkthe fuel before starting the engine: Do not mow steep slopes. a. Do not fill the gasoline tank indoors, when the engine is running or until the engine has been allowed to cool for several minutes after operating. 5. Do not mow near drop-offs, ditches, or embankments. If a wheel goes over the edge, or if the edge caves in, the unit could overturn. 1 Use extra care while using the optional model 6028 or 6036 grass collection attachments. These can changethe stability of the unit. Use wheel- and/or counter-weights when using these attachments. Do not use them on steep slopes. CHILDREN 1. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Neverassume that children will remain where you last saw them. Keep children out of the mowing area. Keep them under the watchful eye of an adult other than the person operating the unit. Be alert and turn unit off if children enter the area. b. Cleanoff any spilled gasoline before starting the engine. 3. Replaceany worn or damaged parts. 4. Checkthe blade and the engine mounting bolts at frequent intervals for proper tightness. 5. Never store the unit with gasoline in the fuel tank inside a building where gasolinefumes could reach an open flame or spark. 6. When storing gasoline: 2. Before backing up: a. Look behind you and on the ground immediately behind the unit before backing up and while running in reverse. b. Be sure to look down and behind you for small children. A large percentage of accidents involving children occur while backing up. c. Disengagethe mower blade drive before backing up. , 11. Use only original-equipment replacement parts. Parts manufactured by others could present safety hazards even thoughthey mayfit on theunit. 12. Beforeinspecting, cleaning, adjusting, or repairing the unit: a. Disengagethe mower blade drive. b. Stop the engine. c. Wait for all moving parts to come to a complete stoP. d. Removethe wire from the spark plug. e. Keepthe wire away from the plug to prevent accidental starting. f. Allow the engine to cool. 13.Keepall nuts, bolts, and screws tight to be sure the unit is in safe working condition. 14. Replacea wornor faulty muffler. 15. Do not allow children to be near you when you are serviceing this unit. 16. Removethe battery, drain the fuel tank and drain the engine oil if it becomes necessary to tip the unit up on its end or on its side. Fluids can leak from the unit if it is tipped over. 17;Chock the wheels (place blocks of wood on both sidesof the wheels) whenever you haveto performany maintenancethat requires the parking brake to be off. a. Store gasoline in a cool, wellventilated area,safely away from any spark- or flame-producing equipment. 18.Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. b. Store gasoline in an approved container, safely out of the reachof children. 19.Checkbrake operation frequently. Adjust and service as required (See page 23). 7. If the fuel tank has to be drained, drain it outdoors. , (Cont.) Allow the engine to cool before storing this unit in any enclosure. To reduce fire hazard, keepthe engine free of grass, leaves,or excessive grease. 18,Checkthe (optional)grass catching bag. Under normal use, the bag's material is subject to deterioration and wear. It should be checkedfrequently and replacedwhen necessary. Use onlya genuine Bolens®replacement bag. DECALS For your personal safety and the safety of others,safety messagedecals have been placed on your riding mower. Make sure these decals are in place, clean and legible at all times. Refer to the separate parts catalog for decal locations, part numbers, and ordering instructions. ATTACHMENTS AND KiTS Below is a list of attachments and kits that are available for your unit, The information is the most current at the time this manual was printed. Check with your nearest Bolens ® dealer for up-to-date information. Kit Number 6O28 6036 6957 6958 Description Power packer Bagging Power packer Bagging Storage Stand (Stands Wheel Weights, 701bs. Attachment for 28" decks Attachment for 36"" decks unit up on rear end for storage/maintenance,) (pair) SPECIFICATIONS Bolens ® reserves the right to make changes in specifications shown herein, add improvements manufactured product at any time without notice or obligation. Models 13000, 13001,13002, 13055 & 13057 Engine ........................... Models 13000 & 13055--Briggs& Stratton Mode_195707 Verticalshaft8 He (seeenginemanualforfurtherdetails) Models 13001, 13002 & 13057--Briggs& Stratton Model196707 Verticalshaft8.5HP (seeenginemanualfor furtherdetails) FuelCapacity. ................1 U,S,Gal,(3.7 Liters) ElectricalSystem..........12v./160cca Speed............................ HighGear:4.0 MPH(6.5 Km/Hr). LowGear:1.2MPH(1,9 Km/Hr) Reverse:1.5 MPH(2.4 Km/Hr) Tires.............................. Models 13000 & 13055 Front:4.10/3.50x 8 Rear:4,80/4,00x 8 Models 13001, 13002 & 13057 Front:11.00x 4.00x 5.00 Rear:16 x 6.50x 8 TurningRadius.............23"(58,4cm) Height........................... 38.5"(98 cm) Width (at reartires) ......32"(81 cm) CuttingWidth................28"(71 cm), sidedischargemowerdeck No.of Blades................1 Cuttingheightrange.....1"to 3"(2,5 cm to 7.5 cm) Weight.......................... 340 Ibs (154 Kilos) Modets 13003,13007, 13067 & 13068 Engine ........................... Bfiggs & Stratton Model286707 Verticalshaft12,5HP (seeenginemanualfor further details) FuelCapacity .................1 U,S.Gal.(3.7 Liters) ElectricalSystem..........12v./160cca Speed............................ HighGear:4.0M£H (6.5Krn/Hr) LowGear:1.2MPH(1.9 Km/Hr) Reverse:1,5MPH(2.4 Km/Hr) 6 or 6iscontint_e the Tires.............................. Front:11.00x 4.00x 5.00 Rear:16 x 6.50x 8.00 TurningRadius.............23"(58.4cm) Height........................... 38.5"(98 cm) Width (atreartires) ......32"(81 cm) CuttingWidth................ 33"(84 cm_.mu{_h{n9m_'_ _c_, No.of Blades................ 2 Cuttingheightrange.....1"to 3"(2,5 cmto 7,5 cm) Weight.......................... 350 Ibs(159 Kilos) Model 13004 Engine ............................ Briggs& Stratton Model286707 Verticalshaft12.5HP (seeenginemanual for _urtherdetails) FuelCapacity. ................1 U,S,Ga),(3,7 Liters) ElectricalSystem..........12v./160cca Speed............................ HighGear:4,0 MPR(6.5Km/Hr) LowGear:12 MPH(1,9 Km/Hr) Reverse: 1.5MPH(2.4 Km/Hr) Tires.............................. Front:11,00x 4,00x 5.00 Rear:16 x 6,50x 8.00 TurningRadius.............23"(58.4cm) Height........................... 38.5"(98 cm) Width(at reartires)......32"(81 cm) CuttingWidth(s)...........28"(71 cm), sidedischarge;33"(84 cm),mulching mower; 36"(91 cm) sidedischarge No. ofBlades ................1 (28"),2 (33"& 36") Cuttingheightrange.....1"to 3.25"(2.5cmto 8.3 cm) Weight.......................... 340 Ibs(154 Kilos)to 360Ibs [163_,ilos) Models 13005 & 13006 Engine ........................... Briggs&Stratton Model286707 Verticalshaft12.5HP (seeenginemanualfor further details) SPECIFICATIONS FuelCapacity ................. 1 U.S.Gal.(3.7Liters) Electrical System..........12v./160cca Speed ............................ HighGear:4°0 MPH(6.5 Km/Hr) LowGear:1.2MPH(1.9Km/Hr) Reverse: 1.5 MPH(2.4Km/Hr) Tires.............................. Front:11x 5.00x 5.00 Rear:16 x 6.50x 8 (Cont.) TurningRadius............. 23"(56.4cm) Height........................... 38.5"(98 cm) Width(at reartires)......32"(81 cm) CuttingWidth................ 36' (91 cm),sidedischarge mowerdeck No. ofBlades ................2 Cuttingheightrange.....1' to3' (2.5 cmto7.5 cm) Weight.......................... 360 Ibs(163 Kilos) ASSEMBLY Hitch Assembly 1. Cut the ties holding the hitch to the ignitionkey (No hitchon Model 13000). Secure the hitch (A, Fig. 1) to the rear of theframe with two 1/2-13 x 1 hex screws, lock washersand hex nuts(B). Installthe washersand nuts on the insideof the frame. Column Support Assembly 1. Removethe three bolts(C, Fig. 2) from the bottomof the columnsupport. 2. Secure the columnsupportto the forward end of the frame with bolts removedin Step 1. NOTE:Thecolumnsupportshownin Fig.2 is oneof two different supports. Yourun#mayhavea differentstyleof columnsupport. 3. Attach the rod end assembly (D, Fig. 2) on the bottom of the steering columnto the tie rod (E) as follows: A. Removethe top cotter pin (F) and all but one flat washer from the tie rod. B. Placethe rodend assembly(D) over outdoorpowerequipmentshop,battery the tie rod. store or servicestation. OONOTUSEAN TYPEBATTERY CHARGER OR C. Re-installthe remaining flat washers AUTOMOTIVEELSE TI-IE BATTERY COULO BEOAMAGEO! (G). Re-instaUthe cotterpin, Battery 1. Lift seat supportand disconnect first the negative(-) andthenthe positive (+) cablesfrom the battery terminals. 3. Removetwo lock nutsand washers from the two "L" boltsand remove battery. 4. Fill batterywith electrolyteto the level indicatedon the batterycase. 5. Chargebattery usinga trickletype charger. If a trickle type chargeris not available,havethe batteryinitially chargedat an 'G D E A \ B \ \ Fio.1 Fio.2 \ ASSEMBLY (Cont.) 6. Re-install battery after servicing,with negative (-) terminal to the left. Re-install battery hold-down clamps and secure. It may be necessary to hold "L"-Bolts up against the underside of frame, so nuts can be threaded onto the tops of the "L"bolts. BA'I'rERYELECTROLYTECANCAUSE SEVEREBURNSAND BLINDNESS. I J H WEAREYE PROTECTIONAND PROTECTIVECLOTHINGWHENWORKING NEARA BATTERY. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY OR PROPERTY DAMAGE. IN THE EVENTOFAN ACCIDENT, FLUSHWITH WATERAND CALLA PHYSICIANIMMEDIATELY. 7. Re-connect first the positive(+) cable to the positive (+) battery terminal and then the negative (-) cable to the negative (-) battery terminal. Seat 5. LEFT SIDE OF AXLE: 2. Attach front of seat to seat support using two shoulder bolts (H), nylon washer (I) and wave washer (J). Position nylon washer between wave washer and seat support. Add one 1-1/4" steel washer (K) between seat and seat support on each bolt (H). Secure rear of seat with two flat washers and hand knobs (L). Adjustment The seat can be adjusted forward and backward by loosening hand knobs (L). Re-tighten after seat is in desired position. YOURUNIT HAS BEENSHIPPED WITHOUT 01LIN THE ENGINE. DO NOT STARTTHE ENGINEWITHOUT FIRST CHECKINGTHE ENGINE01L LEVEL. THE ENGINEWILL BE SEVERELYDAMAGEDIF IT IS STARTEDWITHOUT 01LIN THE CRANKCASE. Spark Oil Refer to the Engine Owner's Manual supplied for engine oil specifications. washers(X) on the axleas required. Place spacerand shims to eliminateplay without restrictingwheel movement. Securewith retainingring(V). 7. Attach protector caps (V) to both sides of axle. Front Wheels 1. Place one 1-1/4" washer(Q) and two 13/8" washers(S) ontofront axle. Place wheel on front axle. Plug Unplug spark plug wire from spark plug and keepwire well away from plug until you are readyto use your riding mower. This will help prevent accidentalstarting. 3. Placetwo 1-3/8" washers(U) on axle as requiredto eliminatefree playwithout restricting movement. WHEEL ASSEMBLY required) Rear Wheels 5. Attachprotectorcaps(R) to bothsides of axle. (If 1. Greaseaxle (Never Seize). 2. Placespacer (Z, Fig.4) onto eachside of rearaxle. 3. Placetwo 1-1/4" flat washerS (Y) on each side of rear axleand install wheels. 5. RIGHT SIDE OF AXLE: Engine Placetwo 1- 1/4"washers(P) and secondspacer(Z) on leftaxle. Addtwo or three 1-1/2" shim Assembly 1. Locate wiring harness (F, Fig. 3) under seat support and connect to seat interlock switch (G). Seat Fig. 3 Placetwo 1-1/4"washers(P) and secondspacer(Z) on rightaxle. Placetwo 1-1/2" shim washers(X) on the rightaxleand secure with retainingring (W). 4. Secure wheel& washerswith retaining ring (T). ASSEMBLY FRONT REAR WHEELS (Cont.) 3. Attach s_ouider bolts(Z) to lift plates. Insert boltfrom the inside. Secure with nut. WHEELS Z GAGE WHEEL ASSEMBLY (If required) 1, Slide a spacer,a gage wheel, and a 1/2 fiat washeronto a 9age wheet axle. Securewith a cotterpin. Repeat on the ott_erside, x *t MOWER Fi0.4 DECK IHSIrALLATtOH 28" Mower Deck Installation The 28" mower deckis shipped assembled on your riding mower, with the discharge chuteremoved(this dischargechute MUST bs _nstalled on the deckbefore using the mower), Some adjustmentof the mower deck may alsobe required(See page 14). z %jl & TO HELPPREVENTPERSONALINJURY FROMOBJECTS"THROWN BYTHE MOWERDECKBLADE,THE DISCHARGECHUTEMUST BE INSTALLEDONTHE OECK. Fig.5 33"Deck .... FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURYOR PROPERTY DAMAGE. MOWER DEGK LIFT PLATE ASSEMBLY (if required] 1. 33" DECKS: PlaceI(ft _(ate(() on Inside of bracket on mower deck(See M FJa. 28" & 36" DECKS: Placelift plate (I) on inside of bracketon mower deck (See Fig. 5). / / N Fi0,6 NOTE:FOR SHIPPINGPURPOSES ONLY,A TEMPORARY SHIELDHAS BEENII_TALLEDtN THEDISCHARGE OPENING ONTHEMOWER_ECK 1. Remove boltsholding temporary shield in d{sc_arge opening. Removeshield and discard. 2. Secure withflange screws & nuts at (J,_ 2. Loosely attachends of dischargechute & (K). Nuts should face toward the (M, Fig. 6) inside discharge opening with inside of frame. two 5/16-18 x 3/4 flange screwsand 51163. 33" & 36" DECKS: Placepivot(M) 1B _ange nuts (N). The nuts should be on intodesired height setf_nghole in lift plate top. (1)and secure wit/7washerand spring pin. See GAGE WHEEL ADJUSTMENT to determine properheight. 9 ASSEMBLY (Cont.) 3. Looselyattachtop of dischargechute with two 5116-18 x 3/4 carriageboltsand two 5116-18 flange nuts (0). The nuts shouldbe to the outside. 4. Tightenall four nutsand boltsinstalled in Steps 2 and 3. 33" & 36" Inch Mower Installation Deck 1. Lifttractor up and slide mowerdeck undertractorwith gage wheelstowardthe rear. 2. Connect lift rods (D, Fig. 7) to mower decksand securewith springpins (L). 3. Connect pivot rods(E, Fig.7) to lift plates (F) on mower deck. Secure with springpins (X). 4. Connectfront of rodend (U, Fig. 6) to tractorand securewith clevispin (V) and springpin (W). P ( Fig. 7 5. Removebelt guide (P, Fig. 7). TOPVIEW--33' MOWERDECK 6. Routemower drivebelt over sheave (Y). It may be necessaryto rotate differentialto assemblebelt. u 7. Re-installbelt guide (P) as farto the front as possible. Re-tightenbelt guide. Checkclearancebetweenguide(P) and bolt headon differential.A 1/8" minimum gap shouldexist. 8. Install mower bladedrive cable(S, Figs.8, 9 & 10) from tractor, ontocable support(0), as shownin Figs.8, 9 & 10. 9. With the mower blade drive lever (F, page 17, Fig.23) in the disengaged (DOWN) position. Adjustnuts (R, Fig.10 so all slackhas beentaken up in cable (S). Tightennuts (R). 36" Discharge Chute Assembly 1. Securedischargechute (T, Fig. 11) over dischargeopeningwith two 3/8-16 x 3/4 carriageboltsand 3/8-16 top lock nuts (N). Installso the nuts are on top. 10 Fig.8 V ASSEMBLY (Cont.) TOPVIEW--36' MOWERDECK TO HELPPREVENTPERSONALINJURY FROMOBJECTSTHROWNBYTHE MOWERDECKBLADE,THE DISCHARGECHUTEMUST BE INSTALLEDONTHE DECK. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY ORPROPERTY DAMAGE. Cablefrom Tractor Fig.9 NUTS(R) CaLE(S) N WASHERS CABLJESUPPORT(Q_)I Fig. 10 Fig.11 11 ASSEMBLY (Cont.) RIDER PREPARATION FOR DIFFERENT SIZED DECKS U 28"and 36"decksrequirea differentsetup ofthe ridingmower than the 33" deck. Set-upfor the twoconfigurationsis describedbelow. A C Remove Seat 1. Lift seat. Support Cover 2. Unscrewand removeshift knob. 3. Removescrews(B, Fig. 12) and removeshift quadrant. B 4. Unplugseat switch. 5. Removescrews(U) and pull seat supportfrom seat supportcover. 6. Removeremaining3 screws(A) securingseat supportcover. Remove2 screws(C) securinggas tankto seat supportcover. Removeseat support cover. Install Cable Mower Blade Fig.12 / Drive 1. Threadnut (D, Fig. 13) downwardon cablethreads until it stops. 2. Threadnut (H) and washer (I) upward and off cableassembly. Front Slot ° / J 33" 3. 28" & 36" DECKS ONLY: Insert cable,nut (H) and washer (I) upward throughrear slot (E) in frame. E Rear Slot 281'& 36" 33" DECKS ONLY: Insert cable,nut (H) and washer (I) upwardthroughfront slot (F) in frame. 4. Placenut (H) and washer (I) at top of slot and screwdowntightly,securing cableassemblyto frame. 5. Connect cable to the mower bladedrive (PT0) lever (G). Fastencable to the right sideof PTOlever whenfacing towardfront of rider. Securewith screw(J) and nut as shownin Fig. 13. Tightenscrew, but allow someplay so cable may pivot. 12 D Fig. 13 Connect (Left Assembly Side) 28" & 36" Decks Link to Lift Only 1. If swivel(J, Fig. 14) is not attachedto OUTERlift arm, removehairpinand washer. Attachswivelto the OUTER lift arm. Swivelloopshouldface to the outsde(left), overthe OUTER slot. Place washer and attachhair pin. Hairpin shouldbe on the inside(right) of lift arm. 2. Slidelink (K) upward,through the OUTER slot on theframe. Slidelink throughswivel(J). Thread nut (L) onto link. The position of the nut will determine the heightof the mower when set in transportposition. See instructionsin the DECK ADJUSTMENTS, on page 14. ASSEMBLY Test Outer Lift Arm /28" J & 36" W /33" Interlock (Cont.) System Beforeoperatingunit, perform the interlock system test outlined in the CONTROLS AND OPERA TION on page 20. A Inner Lift Arm_ Fi0.14 3. To install mower deck, Seethe DECK INSTALLATION on page 9. Replace Seat, Seat Support Cover and Seat Switch 33" Decks 1. Position seatsupportcoverin position as shown in Fig. 12. Thread 2 screws (C) into gas tank, but do not tighten. Thread screws (A) into the sides of seat support cover. Tighten all hardware. Only 1. If swivel (V, Fig. 14) is not attachedto INNER lift arm, remove hair pin and washer. Attach swivel to the INNERlift arm. Swivel loop should face to the inside (right), over the INNER slot. Placewasher and attachhair pin. Hair pin should be on the outside (left) of lift arm. 2. Slide link (U) upward, through the INNER slot on the frame. Slide link through swivel (V). Thread nut (W) onto link. The position of nut will determine the height of the mower when set in transport postions. See instructions in the DECK ADJUSTMENTSon page 14. THE SAFETYINTERLOCKSWITCH SHOULDSHUT DOWNTHE ENGINE WITHIN A FEW SECONDSAFTERTHE OPERATORLEAVESTHE SEAT. IF THIS SWITCHFAILSTO OPERATE, HAVETHE MOWERSERVICED IMMEDIATELYBY AN AUTHORIZED BOLENS ® DEALER. SEVEREINJURY COULDRESULTFROM NOT FOLLOWINGTHIS INSTRUCTION. 2. Positionseatsupporton seatsupport coveras shownin Fig.12. Secureseat supportwith screws(U). 3. Plugin seat switch. 4. Positionshift quadrant (Q) as shown. Securewith screws(B, Fig. 11). 5. Secureshift knobontoend of shift lever. 6. Lower seat. 13 ASSEMBLY (Cont.) 33" DECKSHOWN-OTHERSSIMILAR D \ Fig. 15 Fig. 16 DECK ADJUSTMENTS All mower decksshouldbe checkedand re-adjusted,if necessary,beforeusingthe ridingmower. 36"decksshouldbe checkedafter assemblyand installationfor proper adjustment. All DecksmTransport Adjustment Height A 1/2" socketwrenchwith an extension and a universaljoint is recommended for this adjustment. When mower lift lever (See page 18, Item I)is in the raised(UP) position,there shouldbe a gap of no more than 1/8" betweenshoulderbolts(J, Fig. 16) on the mower deckliftingplates and frame. If adjustmentis necessary,lift seat and seat support. Removelift rodfrom mower deckand push lift rod up through frameso nuts (D, Fig15) areaccessible. Turn nuts (D) with the socketwrench, reattachmower deck,and check. Repeatas necessary. 28" Decks_Mower Tension Adjustment Drive Belt Check distance (K, Fig. 17), between center of pivot block and center of pivot. Normal distanceshouldbe7-1/2" (7-1/4" for36" Decks). NOTE'AFTER THEMOWER HASBEENUSEDFORA WHILE,THEMOWER DRIVEBELTCANSTRETCH ANDBEGIN 14 Fig. 17 SLIPPING.MOVEDECKFORWARD BY ROTATING PIVOT(E) TOTHEREARONROOS (F) TOPROVIDE ADDEDBELTTENSION. READJUSTFRONTLINKTOLEVELMOWER. (SEEPAGE25,MOWERDRIVEBELT REPLACEMENTFORADOITIONAL DRIVE BELTADJUSTMENT INFORMA TION). 33" & 36" Decks-Mower Belt Tension Adjustment Drive Belttensionis controlledby positionof idler (M, Figs.19 & 21) and pivot rods(F, Fig. 17). Distance(K, Fig. 17) shouldbe 7-1/2' for 33" decks7-1/4" for 36"decks. Adjustpositionof idler (M, Figs.19 & 21) by movingit along the slot. If further adjustmentis necessary,adjustdistance (K, Fig. 17) by rotatingpivot(E) to the rear. Re-adjustfrontcenter linkto level mower. NOTE'AFTER THEMOWB_HAS ASSEMBLY (Cont.) BEENUSEDFORA WHILE,THEMOWER DRIVEBELTCANSTRETCH ANDBEGIN SLIPPING.MOVEDECKFORWARD BY RELOCATING PIVOT(E)ONPIVOTRODS(F) TOADDBELTTENSION.RE-ADJUST FRONT CENTER LINKTOLEVELMOWER. TOP VlEW--2r MOWERDECK (SEEPAGE25,MOWERDRIVE BELT REPLACEMENTFORADOITIONAL DRIVE BELTADJUSTMENT INFORMATION). S 28" & 36" Decks--Mower Spring Connection Adjustment With mower lift lever(See page18, Item I) in the disengagedposition, adjustcable (S, Figs.18, 20, & 21) at nuts (R, Fig. 20) untilall slackin cablehas beentakenup. WHEN ADJUSTED, SPRING (T) SHOULD NOT BE UNDER TENSION. Fig. 18 Cablefrom Tractor TOPVIEW--33'MOWERDECK 33" Decks--Mower Spring Connection Adjustment With mower lift lever (See page 18, Item I) in the disengaged position, adjustcable (S, Figs.19 & 21) at nuts (R, Fig.21) so there is a slight slackin cable. WHEN ADJUSTED, SPRING (T) SHOULD NOT BE UNDER TENSION. MOWER DECK LEVELING Park the riding mower on a hard, level surface. Fig. 19 TOPVIEW--36' MOWERDECK NUTS(_ CaLE(S) WASHERS CMLE SUPPORT(Q_) I Fig.20 Fig.21 Cablefrom Tractor 15 ASSEMBLY (Cont.) Tire Pressure 1. Usean automotive-typetire gaugeto checkthe air pressurein all four tires. Fronttires .........from 12 to 15 PSI (82 to 103 kPa) equallyinflated. Rear tires..........from 8 to 10 PSI (55 to 68 kPa) equallyinflated. D DO NOT OVER-INFLATE. Front to Rear Leveling 1. Checktire pressureas explainedabove. 2. Place mower lift lever (I, page 18) to the lower(DOWN) position so deckis in cuttingposition. 3. Adjustmower height adjustingknob (G, Fig.23) so the mower bladesare approximately2-1/2" from the ground. 4. Aligna cuttingbladeso tips point to the front and rear of the unit. Measure distancefrom ground to tips of blade. (R, Fig. 22). Bothtips shouldbethe same distancefrom the ground. If they are not, adjustfront rod (A, Fig. 22) as necessary. Place mower lift leverinto the raised(UP) positionto adjust. Lowermower againto recheck level. R 1 Fig. 22 Side to Side Leveling 1. Aligna cuttingbladeso tips pointfrom side to side of the unit. 2. Measuredistancefrom groundto tips of blade. Bothtips shouldbe the same distancefrom the ground. If theyare not, remove lift rodfrom mower deckand push lift rod up throughframe so nuts (D, Fig 22) are accessible.Adjust nuts (D) as necessary. Re-attachlift rodsand rechecklevel. Repeatas necessary. Other Deck Information Additional mower deck informationcan be found in MOWER DECK MAINTENANCE, beginningon page 25. 16 Fig. 23 A CONTROLS AND OPERATION E way up places the engine in CHOKE. For best performance, always run the engine at full throttle. USECHOKEPOSITIONFOR STARTINGONLY; Fig. 24 B-- BRAKEPEDAL. Stops the forward or rearwardmotionof the mower. IT DOES NOTSTOPTHE ROTATIONOFTHE MOWERBLADES. C-- PARKINGBRAKE(BRAKELOCK). Pushthe brakepedal (B) all the way down and push brakelock (C, Fig.26) to the rightto applythe parkingbrake.To disengage, push the brake pedal downand release. D D IGNITIONKEYSWlTCH.The keyswitch has three positions - OFF,RUN, and START. E -- DRIVEPEDAL. Engagesthe forward or rearward motionof the riding mower. G F-- MOWER BLADEDRIVELEVER. Engagesdrive to the mower deck blade(s). To engage,lift lever and move it to the left into the detent. To disengage, lift lever, push it to the right, and slowly release. NOTE:DISENGAGEMOWERBLADE DRIVEWHENEVERTHE CUTTINGBLADES ARENOT IN USE. Fig. 25 CONTROLS Know the riding mower before you operate it. Carefully review this manual and become thoroughly familiar with the operatingprocedures and safety precautions. Figures 24, 25, 26, 27 & 28 show you the location of all primary controls on your riding mower. See below for descriptions. A-- ENGINESPEEDLEVER. Controlsthe engine speed. Downdecreasesengine speed,up increases enginespeed,all the G -- MOWERHEIGHTADJUSTINGKNOB. This knob allows you to select infinitely variable cutting heights for the mower deck. Twisting clockwise raises mower, counter-clockwise lowers mower. H --TRANSMISSION SHIFT LEVER. Allows you to select eitherreverse, 17 CONTROLS AND OPERATION (Cont.) neutral,or one of five forward gears. (See SPECIFICATIONS on page 6 for average speeds in some of these gears). Until you become familiar with the riding mower, use onlythe lower gears either 1, 2, or 3. See Fig. 27 for detailed shifting pattern. I-- MOWER LIFT LEVER.(Fig. 28) While in the UP position, the mower deck is in transport position. In the DOWN position, the mower deck is in the mowing position. The Mower Lift Lever should be in the UP position wheneverthe riding mower is not actually mowing. NOTE: THISRIDINGMOWERHAS INTERLOCK SWITCHES A T THEBRAKE, MOWERCLUTCH,ANDSEAT. THE UNITWILLNOTSTARTUNLESSTHE BRAKEPEDAL IS DEPRESSED (ORTHE PARKING BRAKEISSET),ANDTHE MOWERBLADEDRIVELEVERISIN THE DISENGAGED POSITION. Fig. 27 VIEW OF SHIFT PATTERN DECAL FROM OPERATOR_POSITION THEENGINE WILLAUTOMATICALLY STOPIF THEOPERATOR LEAVESTHE SEAT WHENEITHER THEMOWERBLADE ISENGAGED ORTHEBRAKE PEDALIS NOTDEPRESSED. THE SAFETYINTERLOCKSWITCH SHOULDSHUT DOWNTHE ENGINE WITHIN A FEW SECONDSAFTERTHE OPERATORLEAVESTHE SEAT. IF THIS SWITCH FAILSTO OPERATE,HAVETHE MOWER SERVICEDIMMEDIATELYBYAN AUTHORIZEDBOLENS®DEALER. SEVEREINJURY COULDRESULT FROM NOT FOLLOWINGTHIS INSTRUCTION. II III Fig. 28 OPERATION Pre-Start Checklist [] 1. ReviewSection 1: SAFETY. [] 2. Checkthe engineoil level. [] 3. Fillthe fuel tank. (See Filling Fuel Tank, below.) 18 r-14. 1-15. a. Checkthe unitfor any loose or missing hardware. Tighten or replaceas necessary. Inspect the batteryfor: Proper electrolyte level. Cleancablesand battery terminals. Cleanany debrisoff engine flywheelscreen. CONTROLS _7. AND OPERATION (Cont.) Checktire inflation: Fronttires:from 12 to 15 PSI (82 to 103 kPa) equallyinflated. Rear tires:from 8 to 10 PSi (55 to 68 kPa) equallyinflated. DO NOT OVER-INFLATE, Re-connect spark plug,_ireto spark plug. Make sure mowerdischarge deflectorshieldis securely fastened to the right-handside of mowerdeck (28 & 36 inch decks). O10. Adjustseat to a comfortable position. (See page 8, Seat Adjustment. [311. Ct_eckarea to be _o_. e,_,_ anydebrisfrom this area. [] 12. Set parkingbrake. [] 13 Place transmission shift lever (rite N (Neutral) (Fig. 2_'). Filling 8. Do not completelyflit thefuel tank. Allowat least 1/4-inch of space at the top of the tank. This allowsfor fuel expansion. Fuel Tank 1. Disengagemowerblade drive. 2. Shut offengine 3. Set parking brake. 3. Allow engine to coolfor at least two minutes before filling fuel tank. 4. Move transmission shift lever into 4th or 5th gear to allow accessto fuel tank filler cap. 5. Tilt seat and seat support (P, Fio. 29) forward and upward. 6. SLOWLY unscrew fuel tank filler cap (o). 7. Use a good grade of clean,fresh, unleaded gasoline. SLOWLYpour gas into tank. Usea funnel if necessary (make sure that it is clean). Frequentlystop and check the level of fuel in tank white_illing. GASOUNEIS HIGHLYFLAMMABLE AND ITS VAPORSAREEXPLOSIVE,, OQNOT ADDGASOLINETO THETARK WHILETHEENGINEIS RUNNING. IF THE ENGINEHASBEENRUNNING, ALLOWITTO COOLFOR SEVERAL MINUTES. DONOT ALLOWOPENFLAMES, SPARKS,MATCHES,ORSMOKING NEARBYWHENREFUELLING. F|LLTHE GASTANKOUTDOORSIN A WELL-VENTILATEDAREA. WIPE UP Ally SPILLSMiD MOVETHE RIDING MOWERAWAYFROMGASOLINE FUMES BEFORESTARTINGTHE ENGINE. NEVERBRINGA GASOLINECANNEAR THE BATTERYPOSTS. A SHORT CIRCUITCAUSEDBY TOUCHINGTHE POSITIVE(+) POSTANDANY METAL COULDCAUSEANEXPLOSIONOF GASOLINEOR BATTERYGASES. 9. Re-instal} fuel tank fillercap and the cap on the fuel container. 10. Wipe up any spilledgasoline, 11. Tilt seatand seatsupportrearward and downward. Starting 1. PerformPre-Start Checklist _scribed earlier. 2. Set parkingbrake(C, Fig. 26, page17). The enginewill not startunless the brake pe_l is down. 3. When startinga cord engine,m_ enginespeed I_v_r (A, Fi_.2_,, pa_e17} all the way up to theCHOKE position. Whenstarting a warm engine,set throttle at 3/4 full position. 4. Move mower blade drivelever (See F, page 17) art the way (lownto its disengaged position. (The enginewill not start if the mower bladedrive is engaged.) 5. Sit in the operator'sseat. 6. Move the transmission shift lever(See Fig. 27, page 18) to N (Neutral). 7. Belore starting engine,make sure there are no childrennearby. 19 CONTROLS AND OPERATION 8. Place ignitionkey in keyswitch and turn key to the START position. Releasekey as soon as the enginestarts. (Cont.) POSITIONOFCONTROLSIN TRANSPORTPOSITION 9. To manuallystart engine:(all models except 13000 [2027]) A. Place ignitionkey in keyswitch and turn key to the RUN position. f B. Slowly pull recoilstarter rope (A, Fig. 31) outward until you feel some resistance from engine compression-then rapidly pull rope outward. C. Allow starterrope to gradually rewind rope. Do not releaseropeand allow it to snap back. D. RepeatSteps9B and 9C untilthe engine starts. Fig.30 10. Move enginespeedlever (A, page 17) to the FAST position. 11. Allow engineto warm up for a few minutes before you mow. Interlock System Test 1. Before working with the riding mower, always perform an operational check of the riding mower's interlocksystem as follows: A. Parkthe unit on a level surface so it does not roll when you releasethe brake. B. Sit in operator's seat and start the engine. (See Starting on the previous page) Depressbrake pedal and check to make sure mower blade drive is disengaged. C. Releasebrake. Raise yourself several inches off the seat. The engine should stop. If it does, go on to the next step. If it does not, havethe interlock system adjusted or repaired. DONOTOPERATE THEUNIT! D. Depress brake pedalagain. Re-start engine. Raise mower blade drive lever to its engaged position. IF THE INTERLOCKSYSTEMDOESNOT FUNCTIONPROPERLY,SHUTTHE ENGINEOFF,APPLYTHE PARKING BRAKE,ALLOWTHE ENGINETO COOL, DISCONNECTTHE SPARKPLUGWIRE AND PREVENTIT FROMTOUCHING THE SPARKPLUG,AND REMOVETHE KEYFROMTHE KEYSWITCH.DO NOT USETHE RIDING MOWERUNTILTHE INTERLOCKSYSTEMIS REPAIRED. FAILURETO FOLLOWTHIS WARNING COULDRESULTIN PERSONALINJURY OR PROPERTYDAMAGE. I IIII IIIIII E. Again,raise yourself severalinches off the seat. The engineshouldstop. If it does not, have the interlock system adjusted or repaired. DONOTOPERATE THEUNIT! Mowing 1. After performing the interlock system test on you ridingmower,you are now readyto beginactualmowing. Put mower lift lever (B, Fig.30) up intothe raised position,and put themower bladedrive lever (C) down into the disengaged positionwhile transportingyour riding mower to the work area. A Fig.31 2. Onceyou have arrived at the work area, releasethe drive pedal and stop the unit. Make sure the throttle lever is in the FAST position. 3. Select cutting height(See Testing height of Cut, next page.) 4. Make sure that no one is in the path of discharge or close to the mower. Slowly engagethe mower bladeby moving the mower blade drive lever (C, Fig. 32) up to its ENGAGED position. NOTE:THEMOWERBLADEDRIVECANBE DISENGAGED ATANYTIMEBY MOVING THEMOWERBLADEDRIVELEVER DOWN TOITSDISENGAGEO POSITION. 5. Lower mower lift lever (B, Fig. 32) to the lowest (DOWN) position, to position mower deck for cutting. 6. Select the gearyou want by moving the transmission shift lever(Z, Fig.32) to the 20 CONTROLS AND OPERATION (Cont.) POSITIONOF CONTROLSIN MOWINGPOSITION P Fig.32 desiredgear. Do not mow in R (Reverse). Here are somegeneralgear selection guidelines: 1st gear: Goingup or down moderatehills,travellingon slippery surfaces, highgrass. 2nd/3rd gear: Levelterrainto mild slopes,normalgrass. 4th gear: Levelterrain,light mowing. 5th gear: Travelfrom storagesite to work location. Reverse: Movingout of storage site, maneuveringin tightareas. 7. Slowly depressthe drive pedal(E, page 17) to beginmoving. NOTE:AFTERYOUBEGINMOVING, YOUCANSHIFTTOANYOFTHE HIGHERORLOWERGEARS"ONTHE GO". YOUDONOTHAVETOCOMETO A COMPLETESTOP--ALLYOUHAVE TOO0 IS LETUPONTHEORIVEPEOAL WHENYOUSHIFI_.HOWEVER, YOU MUSTCOMETOA COMPLETE STOP WHENEVER YOUSHIFTFROMA FORWARO GEARTOREVERSE OR FROMREVERSE TOA FORWARO GEAR. Testing Height of Cut After mowing a small area, it is recommended thatthe mower be stopped, the parkingbrakeset, and the height of the cuttingarea inspected(Make surethere are no small childrenor inattentive persons aroundyou when this is done). The area can be inspectedfrom the operator'sposition. If you wish to leave Fig. 33 the operator'sposition, disengagemower blade drive and stopenginebefore doing so (See Stopping, on next page). Twist the mowerheightadjustingknob(D, Fig.32) or clockwiseto raisethemower (highercut), counter-clockwise to lower the mower(shortercut). A goodcutting heightto beginwith is 2-1/2". Generally,if the mower is set too low, the grasstends to mat and clump. (This can also happen if the grass is wet. See Mowing Tips, on the following page.) If this doeshappen,raisethe mowerabout 1/4"and test the cutagain. Repeatuntila cleancut isachieved. If you havea unit equippedwith a 33" mulching deck, cuttingheight is a very importantfactor in mulchingperformance. Set the cuttingheighthighenoughsothat the deckis not overloaded.Too much grassin the cutting chamberat one time limitstheamountof circulationinsidethe deckand impairsmulchingaction. An "overloaded"deckwill leavegrassclumps. Generally,a mulchingdeckthatis setat a slightlyhighercutting heightwill give betterperformancethan one thatis settoo low. (See also Mowing Tips, on the following page.) GAGE WHEEL ADJUSTMENT The gagewheelsare primarilyan antiscalpdevice. Adjustsothey arejust off theground. If severalcuttingheightswill be usedduringa cuttingsession,set the gagewheelswhilethe mower deckis in the lowestcuttingpositionthat will be used. While mowingextremelyrough, uneven or hilly terrain, it is best to allow the mower deckto ridedirectlyon the gage wheels. In this case, set the gagewheels so they contactthe groundwhen the mower deckheight has beenselected. Rear Gage Wheel 28" Decks Adjustment, Removethe nuts securingthe gage wheels. Placethe gagewheels in the desiredposition (P, Fig.33) and secure with nuts. Set both gagewheelsto the same height. 33"& 36"Decks Removespring pin and washerand position swivel(M, Fig.34, following page) into desiredhole. Replacespring pin. Set bothgage wheelsto the same position. Nter proper cuttingheight has been set, the mower deck gagewheels should be adjusted as well. Before doing this, stop the tractor. (See Stopping, Next page.) 21 CONTROLS AND OPERATION (Cont.) from weekto week. Alternatemowingthe lawnfrom northto southandfrom east to west. Thiswill helppreventmattingand grainingof the grass. 33" Forbest results,alwaysmow with the enginespeedlever in its FAST position. Makesure the mower deckis level. If the deckis not level itwill cut unevenly. Fig.34 Front Anti.Scalp Wheel Adjustment, 33" Decks If you are not usingan optionalbagging attachment,directthe dischargetowards the cut portionof the lawn. Thiswill best dispersethe clippings. (See also Testing Heightof Cut,on the previouspage.) Fi0. 35 5. Move transmissionshiftleverout of the N (Neutral) position. Keepthe insideof the mowingdeckclean and free from grass buildup.(See STORING YOUR RIDING MOWER, page 31.) 6. Removekeyfrom key-switchand store it out of the reachof children. Special 4. Set parkingbrake. only Removethe nuts securingwheels. Place wheel in the desiredposition (Q, Fig. 35) and securewith nuts removedearlier. Set bothwheelsto the same height. Normally, the lowerhole shouldbe used. Stopping (See pages 17 & 18 for description of controls) 1. Removeyour foot from drivepedal. 2. Depressbrakepedal. 3. Move mower blade drivelever downto the disengagedposition. 7. Do not parkthe ridingmower on a slope. Blockthewheels(place blocks of wood on both sides Of the wheels) to prevent it from rolling. 8. Disconnectsparkplug wirefrom spark plug. Preventspark plug wire from touchingsparkplug. This will prevent accidentalstarting. 4. Move enginespeed leverto the slow position. Mowing 5. Movetransmissionshift lever out of the N (Neutral) position. The besttime to mowyour lawn is in the earlyafternoon. Thisis usuallywhen the grass is mostdry. Avoidcuttingthe lawn when it is wet--wet grasstendsto form clumps. Also, thesensitivenewlycut areaswill not be exposed to directsun. 6. Shut engineoff byturning the ignition keyto the OFF position. 7. Set parking brake byfully depressing brakepedaland moving brakelock to the right. 8. Lowermower lift lever to the lowest (DOWN) position. Thiswill restthe mowerdeck on the ground. (Also see Parking, below.) Parking 1. Parkthe riding mower in a clean,level spot. 2. Park the mower out of the reachof children. 3. If possible, park the ridingmower insidea dry enclosure,afterthe unit has cooled. 22 Tips Never mow in R (Reverse). Forbest performance,alwayskeepthe mower deckblade(s)sharp. A dull blade tendsto tear grass,not cut it. Do not cut the grasstoo short, especially in hotweather.Thiscankill the grassand mayallow weedsto gain a foothold. We recommenda cutting height of 2-1/2". Forbestresults, adjust mower deckheight so the bladecutsoff onlythetop third (or less) of the grass. If the lawnis overgrown,or if you must usethe mower on extremely uneven terrain,use thehighestcuttingheight setting. Unlessa specialpatterneffectis desired (next column), varyyourcuttingpattern Pattern Effects It is possibleto createpatternsin your lawnby mowing in specificdirections. You can"train"your lawn to "grain"in a specificway by mowing in the same pattern everytime. Some patterns are listedbelow. To producea patternof contrasting stripes. Mow the lawn in parallel strips that run in oppositedirectionsto each other. (ForexampleNorth to South and then Southto North.) To produce a "diamond" or "checkerboard" pattern,first mow the lawnin parallel strips. Then, withina coupleof days, mowyour lawnagain in parallel stripsbut at right anglesto thefirst mowing. (For example:The first mowingis doneeast to west and/orwest to east. The second mowingisthen donenorthto .south and/or southto north.) MAINTENANCE TRACTOR MAINTENANCE Engine I FORSPECIFIC ENGINE MAINTENANCE INSTRUCTIONS, REFERTOENGINE OWNER'S MANUALSUPPLIEO WITHTHERIOING MOWER.THEENGINE OWNER'S MANUAL INCLUBESINSTRUCTIONS FORCHECKING ENGINE OILLEVEL,CHANGING ENGINE OIL, INSPECTING ANOCLEANING ENGINE AIR FILTER,IGNITION SYSTEMMAINTENANCE, ANOOTHERIMPORTANT ENGINE MAINTENANCE INFORMATION. FOR FURTHER REPAIRS, CONTACTYOURLOCAL BOLENS _ OEALER. I I n --.== ,,=,..= L ,.._= _% _"'= ./% !_ __ _ '=""== r----..._ 3/16.,_1/4. \ (5-6 mm) Lubrication Refer to MaintenanceChart on Page 32 for lubrication instructions. Interlock System Test This riding mower is equippedwith an interlocksystem. Thissystempreventsthe operatorfrom startingthe engine,if: Fig. 36 Brake Adjustment 1.) ...thereis no one in theseat. 2.) ...the brake pedal is not depressed. 3.) ...the mower bladedrivelever is in the engagedposition. IF THE INTERLOCKSYSTEM DOESNOT FUNCTIONPROPERLY,SHUTTHE ENGINEOFF, APPLYTHE PARKING BRAKE,ALLOWTHE ENGINETO COOL, DISCONNECTTHE SPARKPLUGWIRE AND PREVENTIT FROMTOUCHING THE SPARKPLUG, AND REMOVETHE KEYFROMTHE KEYSWITCH.DO NOT USETHE RIDING MOWERUNTILTHE INTERLOCKSYSTEM IS REPAIRED. FAILURETO FOLLOWTHIS WARNING COULDRESULTIN PERSONALINJURY OR PROPERTYDAMAGE. See Interlock System Test on page 20, in the CONTROLS AND OPERATION section to perform this test. BEFOREADJUSTINGTHE BRAKE, SHUTTHE ENGINEOFF, BLOCKTHE WHEELS,ALLOWTHE ENGINETO COOL,DISCONNECTTHE SPARKPLUG WIRE ANDPREVENTIT FROM TOUCHINGTHE SPARKPLUG,AND REMOVETHE KEYFROMTHE KEYSWITCH. FAILURETO FOLLOWTHIS WARNING COULDRESULTIN PERSONALINJURY OR PROPERTYDAMAGE. 1. Lift seat and seat support up to gain access to the side of transmission. 2. Turn hex nuts (C, Fig. 36) holding brake lever to left-hand side of transmission to remove any play from the brake system. 3. Havean assistant push firmly on brake pedal. Adjust until a gap of 3/16" (5 mm) to 1/4" (6 mrn) exists between front edge of brake lever (B) and forward edge of slot in frame the brake lever goes down through. NOTE." DONOTOVER-TIGHTEN NUTS (C)ORTHEBRAKEWILLORAG ANO OVERHEAT Transmission Replacement Drive Belt BEFOREREMOVINGTHE TRANSMISSION DRIVEBELT, SHUTTHE ENGINE OFF, BLOCKTHE RIDING MOWER'S WHEELS,ALLOWTHE ENGINETO COOL,DISCONNECTTHE SPARKPLUG WIREAND PREVENTIT FROM TOUCHINGTHE SPARKPLUG,AND REMOVETHE KEYFROMTHE KEYSWITCH. FAILURETO FOLLOWTHIS WARNING COULDRESULTIN PERSONALINJURY OR PROPERTYDAMAGE. 1. Remove mower deck. See Mower Deck Removal, page 25. 2. Move transmission shift lever to N (Neutral). 3. Remove old transmission drive belt. and discard. 23 MAINTENANCE (Cont.) 4. Removebelt guide (C, Fig. 37) behind enginepulley. 5. To installnew belt: A. Placebelt intosheave(F). It may be necessaryto rotatedifferentialto assemble. B. Loosentransmissionpulleybelt guides (G). \ C. Loosenidler pulley (H). D. Placeforward portion of belt onto transmissionpulley (I). E. Placebelt betweenidler pulley (H) and belt guide. Fig.37 D / F. Re-tightenidler pulley. G. Re-tightenbelt guides (G) 1/8" (.32 cm) awayfrom sheave(F). 6. Re-installand re-tightenbelt guide(C). Positionguideas far forward as possible. After assembly,checkclearancebetween guide (C) and bolt headson differential. A 1/8" minimumclearanceshouldexist. Transmission Adjustments Drive A Belt Guide 1. Pushdrive pedal all the way forward. 2. Loosenand adjust beltguide (C) so there is a 1/8" (3.1 mm) to 3/16" (4.7 mm) gap betweenupperguide and belt. Retighten. Fig.38 Battery / Maintenance 3. RepeatStep 2 for forward belt guide (G). Drive Chain BATTERYELECTROLYTE CANCAUSE SEVEREBURNSANDBLINDNESS. Adjustment If drivechainappearsto haveexcessive slack,adjustto prevent it from coming off sprockets. To adjust: 1. Liftseat and seat supportup. 2. LoosenchaintightenerLA,Fig.38). 3. Slidethe chaintighteneruntil excess slackis removed. WEAREYEPROTECTIONAND PROTECTIVE CLOTHINGWHENWORKING NEARA BATTERY. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY OR PROPERTY DAMAGE. IN THE EVENTOFAN ACCIDENT, FLUSHWITH WATERAND CALLA PHYSICIANIMMEDIATELY. 4. Re-tighten the chaintightener. Keepbattery terminals cleanand free of corrosion. After cleaningterminals, apply petroleum jelly on them to help prevent corrosion. 24 BATTERIESCANGIVE,OFFHIGHLY FLAMMABLEHYDROGENGASTHAT IS EASILYIGNITED. • NEVERALLOWA SPARKOR OPEN FLAME NEARTHE BATTERY. • DO NOTLAYTOOLSACROSSTHE BATTERYTERMINALS. • DO NOTTOUCHATOOL FROMTHE POSITIVE(+) BATTERYTERMINALTO THE FRAMEOFTHE RIDINGMOWER. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY OR PROPERTY DAMAGE. Regularly checkelectrolytelevel in battery. Keepelectrolyte within level indicatedon batterycase. Addonly distilledwaterto bringelectrolyteto properlevel. MAINTENANCE MOWER Mower DECK Deck MAINTENANCE (Cont.) 33" DECKSHOWN--OTHERSSIMILAR Removal BEFOREREMOVINGOR REINSTALLINGTHE MOWER DECK,SHUT THE ENGINEOFF, APPLYTHE PARKINGBRAKE,ALLOWTHE ENGINE TO COOL,DISCONNECTTHE SPARK PLUG WIRE ANDPREVENTIT FROM TOUCHINGTHE SPARKPLUG, AND REMOVETHE KEYFROM THE KEYSWITCH. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY ORPROPERTY DAMAGE. 1. Removebelt guide (P, Fig. 39) 2. Move mower lift lever (I, page 16) downward to set mower in the lowest position. 3. Removethe belt from the engine pulley (B). It may be necessary to turn the differential to remove belt. 4. Removehitchpins(C) anddisconnect lift rods(D). 5. Remove hitch pins and disconnect pivot rods (F) from lift plate. 6. Disconnectmower drivecable cable (S, Figs. 41,42 & 43 on the following pages) from spring (H). Loosen nuts securing cableto cable support (See Fig. 40). Removecable from deck. 7. Remove clevis pin from the front of rod end (E, Fig. 39), releasing mower. 8. Slide mower out from under the tractor. Swing the lift rods (D) forward or backward to allow for easy removal. Fig.39 MOWER BELT REPLACEMENT NUTS(It) BEFOREREPLACINGTHE MOWER DECKBELT,SHUTTHE ENGINEOFF, MOVETHE MOWERBLADECLUTCH LEVERDOWNTO ITS DISENGAGED POSITION,APPLYTHE PARKING BRAKE,ALLOWTHE ENGINETO COOL, DISCONNECTTHE SPARKPLUGWIRE ANDPREVENTIT FROMTOUCHING THE SPARKPLUG,ANDREMOVETHE KEYFROMTHE KEYSWITCH. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURYOR PROPERTY DAMAGE. 28" Mower Drive Belt Replacement 1. Remove belt guide (P, Fig. 39) and loosenguides (Y & H, Fig.41 on following page). 2. Rotate idler arm (B, Fig. 41) away from mower sheave and remove old belt. 3. Install new belt (Z) under belt guide (Y) on pulley (X), WASHERS CULE SUPPORT(Q_) I Fig.40 4. Re-tighten idler pulley bolt (T). Make sure guide(Y) is in approximate position as shown. 5. Assemble belt ontoenginesheaveand slidebelt guide (P, Fig. 39) as far forward as possible. Re-tighten guide (P). NOTE: It may be necessary to rotate differential to assemble. Check clearance between guide (P) and bolt heads on differential. A gap of 1/8" should exist. 6. Lift mower blade drive lever (F, page 15) to engagedrive. 25 MAINTENANCE (Cont.) 7. Re-tighten beltguide(H) 1/16' (.15 cm) awayfrom drivebelt. H 8. With the mower in the highestsetting, checkclearancebetweenbelt at point (AA). If there is not at least a 1' (2.5 cm) gap, move mower ahead by adjusting pivot location on lift arms (E, Fig. 45). It may be necessaryto adjust rod (A, Fig. 45) to level mower. 9. With mowerbladedriveengaged,belt guide (Y) should not contactdrive belt. 10. Checkto see if mower is leveland adjustif necessary(See page 16). 33" Mower Drive Replacement Belt Fig. 41 Y 1. Loosen belt guides (A & B Fig. 42 and (P, Fig. 45). 2. Rotate idler arm (C) away from pulley (R). Replace belt (Z) with new belt. 3. Route belt betweenidler (Q) and belt guide (A). Place guide(A) in approximate position shownand secure. 4. Placenew belt into groove of stationary idler (E) and secure belt guide(B) in rear of slot as shown. 5. Placenew belt into groove of engine pulley and assemblebelt guide (P, Fig.45) as far forward as possible. Re-tighten guide (P). Check clearance between guide (P) and bolt heads on differential. A gap of 1/8" should exist S A Fig.42 6. Lift mower bladedrive lever (F, page 17) to engagedrive. f \ 7. With the mower in the highest setting, checkclearance between belt at point (AA, Fig. 44) If there is not at least a 1" (2.5 cm) gap, move mower ahead by adjusting pivot location on lift arms (E Fig. 45). / \ I 8. Checkto see if mower is level and adjust if necessary(See MOWER DECK LEVELING, page 16). \ / 33" Mower Blade Belt Replacement Mowerdrive belt must first be removed (as describedearlier) beforedoingthis repair. BLADESSHOULD BEPERPENDICULAR TO EACHOTHER / Fig. 43 26 MAINTENANCE J (Cont.) 3. Replacebelt (Z) with new belt. Place new belt aroundpulleys,betweenidlers and beltguides(J & S) as shownin Fig. 44. S 4, Secure belt guide(S) and idler in rear of slot as shown. 6. Positionguide (J) throughholein bottomof plateand securein place. 7. Placenewbelt intogrooveof engine pulley and slidebelt guide(P, Fig.45) as far forward as possible. Re-tightenguide (P). It may be necessaryto rotate differentialto assemblebelt. After assembly,checkclearancebetweenguide (P) and bolt headsof differential.A gap of 1/8"shouldexist. C Fig. 44 8. Lift mowerblade drivelever (F, page 17) to engagedrive. 33" DECKSHOWN-OTHERSSIMILAR 9. With the mower in the highestsetting, checkclearancebetweenbelt at point (AA) If there is not at leasta 1"(2.5 cm) gap, relocateidler (X) as far ahead as possible. If moreadjustmentis needed,move moweraheadbyadjustingpivot location on lift arms (E, Fig. 45). 10. Checktosee if mower is level and adjustif necessary(See MOWER DECK LEVELING, page 16), Mower \ pivot arm (G) back in position so it is applying pressure on pulley (W). Secure mounting bolts (K). Make sure there is clearance between the right-hand mower blade and the deck on the right side. 3. Slide pulley (W) toward the center. 4. Replacebelt (L) with new belt. IMPORTANT._--cutting blades MUSTbe perpendicular to each other as shown in Fig. 43. 5. Slide pulley(W) to the right. Rotate Drive Belt Adjustment Start the riding mower. Engageand disengagethe mower blade drivelever (Item F, page 17) while having an assistant watch the mower drive belt. The belt should not move when the mower blade clutch lever is in the disengaged position. Fig.45 2. Loosenfour mountingbolts(K) securingpulley (W). Re-installation Follow instructions startingon page 9, Mower Deck Installation to re-install the mower deck. Mower Check 1. Loosen screw (F, Fig. 42) and rotate arm (G) 90° to the rear. Deck 36" Mower Drive Replacement Belt 1. Loosenbelt guides (J & S, Fig.44 and P, Fig. 45). If the belt does move when you perform this check,shut the engine off and adjust as follows: 28" Decks Adjustthe mower ddve cableend (S, Fig.42 and S, Fig. 48 on the followingpage)or move mower backby adjustingpivotlocationon lift arms (E, Fig. 45). Repeat.thistest until belt does not move. Checkmower levelingafter adjustingpivot(E). 2. Rotateidlerarm(B, Fig.44) andbrake arm(C),and removebelt(Z). 27 MAINTENANCE (Cont.) 33" & 36" Decks Adjustthe mower drivecableend (S, Figs.42 & 44 and S, Fig.48 on thefollowing page) or relocate theadjustablepulley(B, Fig. 42 or X, Fig. 44) within its slot on the idler support bracket. If further adjustmentis necessary,move mower aheadby adjustingpivot locationon lift arms (E, Fig.45). Repeatthis test until belt does not move. Checkmower levelingafter adjustingpivots (E). MOWER DECK BRAKE ADJUSTMENTS If the mower deck pulleys do not stop rotatingwithin 5 seconds after placingthe mowerblade drivelever(F, page 17) into the disengaged(DOWN) position, adjust as follows: BEFOREADJUSTINGTHE MOWER DECKBLADEBRAKE,SHUTTHE ENGINEOFF,APPLYTHE PARKING BRAKE,ALLOWTHE ENGINETO COOL, DISCONNECTTHE SPARKPLUG WIRE AND PREVENTIT FROMTOUCHING THE SPARKPLUG, ANDREMOVETHE KEYFROMTHE KEYSWITCH. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY OR PROPERTY DAMAGE. 28" Mower Adjustment Deck Brake 1. Move mower bladedrive leverto the disengaged(DOWN) position. 2. Adjustcableand spring(K, Figs.46 & 48) at nuts (R, Figs.46 & 48) until all slackin spring(K, Fig. 46) has beentaken up. WHEN ADJUSTED, SPRING (K) SHOULD NOT BE UNDER TENSION 3. If brakepad (A, Fig. 46) is not centered in pulley(B), Adjustidlerarm pivot(D) as necessary,by re-locatingwashersat pivot. 4. If bladestill does not stop within5 secondsafter the mower drivehas been disengaged,replacebrake pad (A). Fig.46 33" Mower Deck Brake Adjustment 1. Move mower bladedrivelever to the disengaged(DOWN) position. NUTS(_ cuue_ (s) t._ __ WASHERS T Fig.47 28 CABLESUPPORT(Q_) i Fi0.48 \\\\\_\\\\\\\\\_ MAINTENANCE 2. If brakepad (A, Fig. 47) doesnot squarelycontactbothtop and bottom surfacesof pulley (B), re-positionpulley (B) as follows: (Cont.) B Pulley(B) hasone washeron top and on bottom. To raise pulleyup, removescrew (C), placebothwasherson bottomand reinstallscrew(C). To drop pulley down, removescrew (C), place bothwasherson top and re-installscrew(C). 3. Adjust cable (S, Figs. 48 & 49) at nuts (R, Fig.47 & 48) so there is a slight slack in spring(T, Fig. 47). WHEN ADJUSTED, SPR/NG (T) SHOULD NOT BE UNDER TENSION 4. If bladestilldoes not stop within 5 secondsafter the mower drivehas been disengaged,replacebrakepad (A, Fig.47). 36" Mower Adjustment Deck Brake Fig.49 1. Move mower blade drive lever to the disengaged(DOWN) position. adjustingbarrel to tractor. Secure cable end to the right-hand side of mower blade drive lever (M) with screw and nut (P & 0). Re-attach cable to mower deck. 2. Adjustbrakepad (A, Fig. 49) so it squarelycontactspulley (B). Blade Maintenance 3. Adjustnut (E, Fig.49) until the leg on brakearm (C) contactsbelt. 3. Adjustcable(S, Figs.48 & 49) at nuts (R, Fig. 48) sothere isa slightslackin spring(T, Fig.44). WHEN ADJUSTED, SPR/NG (T) SHOULD NOT BE UNDER TENS/ON 4. If blade still does not stop within 5 seconds afterthe mower drive has been disengaged, replace brake pad (A, Fig. 49). Other Deck Adjustments Information about otherdeck adjustments can be found in DECK ADJUSTMENT,. MOWER DRIVE REPLACEMENT CABLE WHENEVERYOU INSPECTORWORK ONTHE MOWERBLADE(S), DISCONNECTTHE MOWERBLADE DRIVE, SHUTTHE ENGINEOFF, BLOCK THE RIDING MOWER'SWHEELS, ALLOWTHE ENGINETO COOL, DISCONNECTTHE SPARKPLUGWIRE AND PREVENTIT FROMTOUCHING THE SPARKPLUG,ANDREMOVETHE KEYFROMTHE KEYSWITCH. Blade Inspection Periodicallyexamineends of mower blade(s) and area between turned-up and flat portions on the top of blade. When mowinggrassin dry or sandy conditions,abrasiveparticleswear away the metalconnectingtheseportions of the blade.(A, Fig. 51.on thefollowingpage) If a separationstartsformingin the blade as shownin (B, Fig. 51), you must replace the blade. If this wear is allowedto continue,the separation will enlargeand eventually allow a portion of the blade to break off. For best results, always keep blade(s) sharp. A sharp blade will cleanly cut grass. A dull blade tends to tear it. See next pagefor blade sharpening information. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURYOR PROPERTY DAMAGE. 1. Unhook cable from mower deck and remove screw and nut (P & O, Fig. 50) securing cable to mower blade drive lever. 2. Loosen nuts (Q) securing cable adjusting barrel to tractor. Remove cable. 3. Route new cable up into tractor. 28" and 36" deck cablesare routed through front hole (T) 33" deck cable is routed through back hole (U). Secure cable Fig. 50 29 MAINTENANCE Mower Deck Replacement (Cont.) Blade NEW BLADE ,__ BEFOREREPLACINGTHE MOWER BLADE(S),DISCONNECTTHE MOWER BLADEDRIVE, SHUTTHE ENGINEOFF, CHOCKTHE RIDING MOWER'S WHEELS,ALLOWTHE ENGINETO COOL,DISCONNECTTHE SPARKPLUG WIRE AND PREVENTIT FROM TOUCHINGTHE SPARKPLUG, AND REMOVETHE KEYFROMTHE KEYSWITCH. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY OR PROPERTY DAMAGE. BLADE REMOVAL 28" Blade EARLY BLADE WEAR BLADE WEAR DANGEROUS Fig. 51 28" (except Models 13055 & 13057) Removal 1. Wrap heavy rags around blade (or wear heavy leather gloves). Hold blade to prevent it from turning. 2. Before removing blade, note position: the raised corners of the blade point up. 33" A B 3. Removetwo screws (A, Fig. 52) and lock washers (B) securing plate (C), and blade (D) to the spindle assembly (E). 36"(and Models 13068 13055, 13057, 13067 Models 13055 & 13057) & 1. Wrap heavy rags around blade (or wear heavy leather gloves). Hold blade to prevent it from turning. 2. Removeblade bolt (F, Fig. 52), spring washer (G), and spindle washer (I) securing blade (H) to bottom of blade adapter (J). Fig.52 F G 3. Remove blade. 3. Loosen center bolt (K). Removetwo outer bolts and nuts (L). Removecenter bolt (K). 33" Blade 36" Blade Removal Removal 3. Removebladebolt (F, Fig.52), spring washer(G), and spindlewasher(I) securingblade(H) to bottomof blade adapter(J). 1. Wrap heavy rags around blade (or wear heavy leather gloves). Hold blade to prevent it from turning. 1. Wrap heavy ragsaroundblade(or wear heavy leathergloves). Hold blade to preventit from turning. 4. Removeblade. 2. Before removing blade, note position: the raised corners of the blade point up. 2. Beforeremovingblade, noteposition: the raisedcornersof the bladepoint up. 28" Blade 3O BLADE INSTALLATION Installation 1. Re-p0siti0nblade in place. MAINTENANCE 2. Re-position plate (C) on bottom of blade (D). Secure blade and plate with two new blade screws (A) and new lock washers (B) to bottom of spindle assembly (E). Torque screws (A) 25 -30 foot-pounds. Models 13068 13055, 13057, 13067 & STORING MOWER YOUR RIDING When storingtheriding mowerfor more than 30 days: 2. Install two newouter bolts and nuts (L). 3. Install newcenter bolt (K). 4. Torque bolts (L & K) to 30 footpounds. 5. Make sure the blades are 90° from each other (See Fig. 43, page 26). 36" Blade Installation 1. Re-position blade in blade adapter (J). 2. Secure with newblade bolt (F), spring washer (G) and spindle washer (I). Torque blade bolt (F) from 50 to 70 footpounds. 2. Afterengine hascooled,storeunitin a dry, protected place. 5. Re-installspark plug. Leavespark plug wire disconnected. 6. Fullychargebatteryoncea month duringstorageusing onlya trickle charger (not an automotive-typecharger,which could ruin the battery). Thiswill ensure peak battery power. 7. Cleanundersideof the mowerdeck. Usea hose,a wire brushor a scraperto removeanygrassbuildup. (Heavygrass buildupcanseriouslyeffectthe performanceof any mowingdeck, especiallythe 33"mulchingdeck.) To cleandeck,removeit, usethe optional Model 6957 storagestand(see page 6), availablefrom your localBolens dealer, or set thefront ofyour uniton jackstands. Mower Deck Blade Re. sharpening and Balancing The deck blade(s) can be sharpenedwith a file or a grinder. A localsharpening service can also sharpen them. To sharpen: 1. Remove equal amounts of metal from both ends of bladesalong cutting edges. Sharpen cutting edgesat a 25-30 ° angle. 2. Check balance of blade(s) by inserting a nail or screwdriver through center hole. Hold nail level with ground so blade can rotate on it. Grind or file off heavierend, as required, to balance blade. An unbalanced blade will cause vibration and undue wear on component parts. 11. Blockall four wheels. (Placewooden blockson bothsidesof wheels.) This helps preventany accidentalmovement. 1. Move unitoutsideand runengineuntil it stopsfrom lackof fuel. 3. Remove,clean,and re-gapsparkplug. 1. Re-position blade on bottom of spindle. See Engine Owner's Manual supplied 2. Secure with newblade bolt (F), spring with theunit, for thecorrectgap. washer (G) and spindle washer (I). 4. Pourone ounceof engineoil through Torque blade bolt (F) from 35 footsparkplug holeinto engine. Placea clean pounds. rag overspark plug holeand crankengine severalrevolutionsto distributeoil on cylinderwalls. 33" Blade Installation 1. Re-position blade in place. (Cont.) JACKSTANDSMUST BEUSEDWITH EXTREMECAUTION. ALWAYSSET THE PARKINGBRAKEAND SECURELY BLOCKTHE REARWHEELSWHENEVER JACKSTANDSARE USED. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURYOR PROPERTY DAMAGE. ELECTROLYTE CANLEAKOUT OFTHE BATTERYVENTTUBEIF THE MOWER IS TIPPEDUP ON END ORON ITS SIDE. REMOVETHE BATrERYBEFORE TIPPINGTHE MOWERON ITS END OR ONITS SIDE. DRAIN FUELTANK BFORETIPPING THE MOWERON ITS END OR ON ITS SIDE. GASOLINEIS HIGHLYFLAMMABLE AND ITS VAPORSARE EXPLOSIVE. DO NOTADDGASOLINETOTHE TANK WHILETHE ENGINEIS RUNNING. IF THE ENGINEHAS BEENRUNNING, ALLOWIT TO COOLFORSEVERAL MINUTES. DO NOTALLOWOPENFLAMES, SPARKS,MATCHES,ORSMOKING NEARBYWHENWORKINGWITH GASOLINE. DRAINTHE FUELTANK OUTDOORSIN A WELL-VENTILATED AREA. WIPE UP ANY SPILLSBEFORESTORINGTHE UNIT. NEVERBRINGA GASOLINECANNEAR THE BATTERYPOSTS. A SHORT CIRCUITCAUSEDBYTOUCHINGTHE POSITIVE(+) POSTAND ANY METAL COULDCAUSEAN EXPLOSIONOF GASOLINEOR BATTERYGASES. FAILURETO FOLLOWTHIS INSTRUCTIONCOULDRESULTIN PERSONALINJURY ORPROPERTY DAMAGE. 8. Thoroughlyexamineentireunit for loose hardware or any damagedor worn parts. Replaceor repair as needed. 9. Sandand re-paint any rusted areas. 10. Cover yourunitwith a breathable cover. 31 MAINTENANCE (Cont.) Maintenace Chart BeforeEach Use Checkfor looseor missingfasteners v' Checkengineoil level i,, Cleanmower deck After Each Use Every25 Hours Every40 Hours Every50 Hours Monthly Each Season v' Changeengineoil i,,' Cleanair cleaner element i/ Greaserearaxle bearingsand front spindle vs Checkmower blade(s) for balance, straightness,& sharpness. Serviceif necessary v' Check, clean & re-gap sparkplug Check chaintension. Adjustif necessary 11 Lightlyoil steeringpivot linkand rod, brake and clutchpivot brackets(4) and idler pivots v' Greasefrontwheel bearings v' Troubleshooting Chart Before performingand of the correctionsIn this TroubleshootingChart, refer to the appropriateinformationcontainedin this manual for the correctsafety precautionsand operatingor maintenance procedures. ENGINEPROBLEMS PROBLEM Enginedoesnotstart 32 POSSIBLECAUSE CORRECTION Nofuelintank(8HPenginesmaystillhavea small amountintankandstillnotstart) Checkfuellevel.Addifnecessary Blown15 ampfuse(in wiringharness beneath seat) Replace fuse Sparkplugwirenotconnected Connectsparkplugwire Throttlenotin CHOKEposition Movethrottleto CHOKEposition MAINTENANCE (Cont.) ENGINEPROBLEMS(Cont.) PROBLEM Enginedoesnotstart (Cont.) Enginerunspoorly Engineoverheats POSSIBLECAUSE CORRECTION Interlock switchinactivated, parking brakenotset and/ormowerbladedriveactivated Operator mustbeontheseat,thebrakepedalmustbe depressed, andthemowerbladedrive mustbe desengaged ortheinterlock systemwillprevent engine from starting Batterydischarged ordead.Poorbatterylead connection Charge/replace battery.Check, cleanandtighten batteryleadsas necessary Loose,brokenor corroded interlock, ignitionor starter wires Findand repair Badsparkplug Cleanor replaceandre-gapas necessary Fueltankventplugged Clearventinfueltankcap Malfunctioning startermotor Haveunitserviced byauthorized dealer Malfunctioning engine Haveunitserviced byauthorized dealer Waterinfuel. Stalefuel Drainfueltank. Re-fillwithfreshfuel. Malfunctioning startersolenoid Replace solenoid Badsparkplug Cleanor replace andre-gapas necessary Clogged aircleaner Cleanor replaceasnecessary Throttleoutofadjustment Referto engineowner'smanual Waterinfuel. Stalefuel Drainfuel tank. Re-fillwithfreshfuel. Carburetor outof adjustment Referto engineowner'smanual Enginelugsdown(overloaded) Raisecuttingheight Loosesparkplug Tightensparkplug Lowoillevel Addoilas necessary Engiineover-filled withoil Removeoilas necessary Engineairscreenand/orcoolingfinsclogged with debris Cleandebrisfrom engine Carburetor outofadjustment Seeengineowner'smanual MOWERDECKPROBLEMS PROBLEM Bladewillnotengage POSSIBLECAUSE CORRECTION Mowerbladedrivenotactivated Liftmowerbladedriveleverintoengagedposition Loosebelt(s) Tightenbelt(s) Wornor brokenbelt Replace belt Missingor looseidlerpulley Replace/tighten Brakeridingagainstdeckpulley Adjustbrake 33 MAINTENANCE (Cont.) MOWERDECKPROBLEMS(Cont.) PROBLEM Bladewillnotengage (Cont.) Deckcutspoorly Deckgivesslopingcut POSSIBLECAUSE CORRECTION Brokenor missingwoodruffkeyin enginepulley Replace woodruffkey Brokenor missingwoodruffkeyin mowerbladespindle shaft(s)(Models13000,13001,13002& 13004only) Replace woodruffkey(s) Broken, wornor maladjusted mowerbladedrivecable Replace/adjust cable Dullblade(s) Sharpenor replaceblade(s)asnecessary Loosebelt(s) Tightenbelt(s) Brakeridingagainstdeckpulley Adjustbrake Deckheightimproperly setordecknotlevel Adjustdeck Loosebladebolt(s) Tightenbladebolt(s) Gagewheelssetincorrectly Adjustgagewheels Blade(s)installed upside-down Installblade(s)withbentcornersfacingup Deckisnotlevel Adjustdeck Tiresarenotevenlyinflated Checktire pressure.Adjustas necessary RIDINGMOWERPROBLEMS PROBLEM Drivedoesnotengage Driveisengagedallthe time Brakedoesnotfunction Steeringwheeldoesnot turnwheels 34 POSSIBLECAUSE CORRECTION Wornor brokenbelt Replace andadjustbelt Beltbrakeimproperly adjusted Adjustbrake Drivechainhasjumpedsprocket Re-install chainandadjust Broken,wornor maladjusted mowerbladedrivecable Replace/adjust cable Brokenor missingwoodruffkeyinenginepulley Replace woodruffkey Loosebelt(s) Tighten/replace beltas necessary Transmission malfunction Haveunitserviced byauthorized dealer. Beltimproperly adjusted Adjustbelt Transmission malfunction Haveunitserviced byauthorized dealer Beltguidesimproperly adjusted Adjustbeltguides Swivelat rearofbrakerodis improperly adjusted Adjustswivel Disconnected brakerod Re-connect brakerod Transmission malfunction Haveunitserviced byauthorized dealer Missingrollpin from baseofsteeringwheel Re-install rollpin Linkarmnotconnected tosteeringshaft Re-connect. Replace hardware if necessary MAINTENANCE (Cont.) RIDINGMOWERPROBLEMS(Cont.) PROBLEM Steeringwheeldoesnot turnwheels(Cont,) Steeringisroughor loose POSSIBLECAUSE CORRECTION link armnotconnected to spindle arm Re-connect. Replace hardware if necessary Tierodnotconnected Re-connect. Replace hardware if necessary Fronttiresunder-inflated Inflatetiresto correctpressure(Seepg.16) Wornsteeringbearings attopand/orbottomofsteering Replace bearings shaft Unitvibratesor is excessively noisy Unitspullsto oneside whendrivenonlevel ground Looseorwornsteering parts suchasfront wheel spindles, front wheelbushings, axle pivot bolt, front axle assembly, tie rodorsteering shaft connections Replace wornparts/tighten looseconnections Looseengine mounting bolts Tightenhardware Looseengine pulley Tightenpulleyhardware Mowerdeckblades outofbalance and/or loose. Balance and/ortightenblades Wornmowerblade spindle bearings Replace bearings Onefront tire isunderinflated Inflatefronttiresevenly(Seepg.16) BLACK , FUSE WIRING DIAGRAM 15A LL = __.._ BLUE/BLACK REDHELLOW BRAKE SWITCH (OFF) MOWERDRIVE SWITCH OF F RUN REAR VIEW OF IGNITION START SWITCH j STARTER SEAT SWITCH (OFF) ;NITION SWITCH BLUE RED/YELL0W 35 LIMITED I. PRDDUCTS This WARRANTY CDVERED warranty applies tO all Bolens'_ brandeq, equLpment. Troy-Bill _ branded gas and electric sprayers, and all W-W Grinder*o branded eclu_pment all Troy-Bilt_ branded equipment sold as a commercial - instttutlonal II. PRODUCT All WARRANTY: new Bolens,, original period warranty: _ The Belts. workmanship items Seats. equipment are not Batteries. which WARRANTY: L|MITED THREE YEAR LIMITED specified a_ove is warranted in material mowers, snow and workmanship, casters, accessories application.. and WARRANTY by Garden under normS) Way, Inc. to the use and service for a covered Blades. are normally COMMERCIAL under Knives. replaced -- the second Tines. Fibers, through and third Tires, penod=c INSTITUTIONAl. year Wheels, of this extended Paint home and Appearance use limited Items, Light maintenance. -- INDUSTRIAL _ RENTAL _ DEMONSTRATOR: ONE: WARRANTY Institutional, Industrial w_tt be for a period and thetr Engines 1ollowing items The Commercial, units Grinder_ only, to be free from defects from date of purchase. Hoses. and similar PRODUCT YEAR and W-W RESlDEHTIAL; mulching manufactured by Briggs & Stratton. Koh}e[ and Tecumsen or transmissions manufactured by Peerless will also f_ th_s t_ree year warranty pedo_, _._o_9_ _,e a_t_,orize_ Tepa_t stations of their respective manufacturers. EXCLU,_IDN_ Bulbs. COMMERCIAL Troy-Bilt_'_. [e,.ta=[purchaser of three (-3) years Engines b,_'_te_ IlL NON tractors, to include their attachments and/or - m_lustrial ° rental or demonstrator manufactured manufactured also be warranted manufacturers. Rental of one !f) attachments. Dy Briggs Kohler warranty Limited date of purchase This warranty & Stratton. for thiS one (1) year and Demonstrator year. from applies to the original and Tecumsel_, perlo_l througr_ Warranty covering on all BoJens_, purchaser and transmissions the authorized defects Troy-Bilt_ on material and W-W only. manufactured repair an_ Grinder_ stations by Peerless of their will respective IV. GENERAL INFORMATION Garden Way, Inc. 's obligation under this warranty Garden Way equipment dealer, of any part found and labor. In order to obtain • 1) Providing 2) Informing (Charges This warranty warranty proof service, of purchase the owner is limited to the repair or replacement, at its option, to be defective in material or workmanship, without is responsible documentati6n, does not cover defects, malfunctions or failures or attachments. 2) Lack of re,_sonable 3) Misuse, accidents and necessary or norma\ wear. maintenance OF CONSEQUENTIAL CIRCUMSTANCF.S INCLUDING BUT SERVICES IMPLIED DAMAGES: FOR ANY INCIDENTAL NOT LIMITED TO COST TO PERFORM LIMITATION _'egi,stration or copy ot bill of sale. any authorized Garden Way equipment dealer ot the de_ec _, an_ m_,_g for pick-up, delivery and service carts are not covered by this warranty.) accessories DISCLAIMER for: o_ner_hi1_ 1) Use of unauthorized ]'ASKS OF IMPLIED WARRANTY caused as specified GARDEN WAY, t_,e 9rO_,_ct aY_\&b_ lot r_,a_r. by: in the "Operation and Safety INC. BE LIABLE SHALL NOT Instructions". UNDER ANY OR CONSEQUENTIAL DAMAGES OR EXPENSE OF ANY KIND, OF EQUIPMENT RENTAL, LOSS OF PROFITS OR COST OF HIRING NORMALLY WARRANTIES: by an authorized charge for parts PERFORMED ANY OF MERCHANTABILITY IMPLIED BY THE EQUIPMENT. WARRANTIES, OR FITNESS FOR INCLUDING A PARTICULAR WITHOUT PURPOSE, LIMITATION SHALL ANY BE LIMITED IN DURATION TO A PERIOD OF THREE YEARS (1 YEAR IF PRODUCT IS PURCHASED FOR COMMERCIAL, INSTITUTIONAL, INDUSTRIAL, RENTAL (DR DEMONSTRATOR USE) FROM THE DATE OF SALE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION DAMAGES, OR L_MITATIONS ON HOW LONG IMPLIED WARRANTY OR EXCLUSION This warranty M,tO " NOT gives you APPLY specific TO YOU. legal rights, and you may also have other Garden Way, Inc, 102nd & 9th Avenue _- "!['_o_jNe_ York 12180. OF INCIDENTAL OR CONSEQUENTIAL LASTS. THEREFORE, THE ABOVE LIMITATION PHONE: _ FAX: (414) 284~5521 (414) 284-3_g65 rights which vary from state to state. Printed in the U.S.A,
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