Western Auto AYP9187B89 User Manual WIZARD LAWN TRACTOR Manuals And Guides 98080197
WESTERN AUTO Lawn, Tractor Manual 98080197 WESTERN AUTO Lawn, Tractor Owner's Manual, WESTERN AUTO Lawn, Tractor installation guides
User Manual: Western Auto AYP9187B89 AYP9187B89 WESTERN AUTO WIZARD LAWN TRACTOR - Manuals and Guides View the owners manual for your WESTERN AUTO WIZARD LAWN TRACTOR #AYP9187B89. Home:Lawn & Garden Parts:Western Auto Parts:Western Auto WIZARD LAWN TRACTOR Manual
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Western Auto Operation and Service Instructions Wizard Lawn Tractor Stock Number 93-9187-1 Model Number AYPS187B89: p _ Dr. Factory Number 9187B89 Thank you for purchasing an American-built product. A SAFE Safe Operation PracticesRULES for Ride-On Mowers A IMPORTANT: 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. • • • • • • • __ -• • • • • • • • II. GENERAL:OPERATION Read, understand,and followall instructionsin the manual and on the machine beforestarling. Only allow responsibleadults, who are familiar with the instructions,to operatethe machine. Clear the area of objects such as rocks,toys, wire, etc., which couldbe pickedup and thrownbythe blade. Besurethearea isclearofotherpeoplebeforamowing.Stop machineif anyone entersthe area. Never carry passengers. Do notmowin reverseunlessabsolutelynecessary.Always lookdownand behindbeforeand whilebacking. Be aware ofthe mowerdischargedirectionand do notpoint it at anyone. Do not operatethe mower withouteitherthe entiregrasscatcheror the guardin place. _low downbefore turning. Never leave a runningmachineunattended.Alwaysturnoff blades, set parkingbrake, stop engine, and remove keys beforedismounting. Turn off bladeswhen not mowing. Stop engine before removinggrass catcher or unclogging chute. Mow onlyin daylightor good artificiallight. Do not operatethe machinewhile under the influenceof alcoholor drugs. Watch fortrafficwhen operating near or crossingroadways. Use extracare when loadingor unloadingthe machineinto a traileror truck. III. CHILDREN Tragic accidentscan 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. • Keepchildrenoutofthe mowingarea and underthewatchful careof another responses adult. • Be alert andturnmachineoffif childrenenter the area. • Beforeand when backing,lookbehindand downfor small children. • Never carry children. They may fall off and be seriously injuredor intederewithsafe machineoperation. • Never allowchildrento operate the machine. • Use extra care when approachingblind comers, shrubs, trees, or otherobjectsthatmay obscurevision. IV. SERVICE • Useextracarein handlinggasolineand otherfuels.Theyare flammableand vaporsare explosive. - Use onlyan approvedcontainer. Never remove gas cap or add fuel with the engine running.Alloweng=neto coolbeforerefueling. Do not smoke. Neverrefuelthe machineindoors. Neverstorethe machineor fuel containerinsidewhere there is anopenflame, suchas a waterheater. • Never runa machineinsidea closedarea. • Keepnutsandbolts,especiallyblade attachmentbolts,tight and keepequipmentin goodcondition. • Never tamper with safety devices. Check their prope operationregularly. • Keepmachinefree ofgrass,leaves,orotherdebrisbuild-up. Clean oil or fuel spillage. Allow machine to cool before storing. • Stop and inspectthe equipmentif you strike an object. Repair,ifnecessary,beforerestarting. • Nevermakeadjustmentsor repairswiththeenginerunning. • Grasscatchercomponentsaresubjecttowear, damage,and deterioration,which could expose moving paris or allow objectsto be thrown. Frequentlycheck componentsand replacewithmanufacturer's recommendedparis,when necessary. • Mowerbladesare sharpand cancut. Wrap theblade(s)or wear gloves,and use extracautionwhen servicingthem. • Check brakeoperationfrequently. Adjust and service as required. SLOPE OPERATION Slopes are a major factor related to loss-of-control and tipover 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 it, do not mow it. DO: • Mow up and downslopes,not-across. • Remove obstaclessuch as rocks,tree limbs,etc. • Watch for holes, ruts, or bumps. Uneven terrain could overturnthe machine. Tallgrass can hideobstacles. • Useslowspeed. Choosea low gearsothatyouwillnothave to stop or shittwhileon the slope. • Follow the manufacturer's recommendationsfor wheel weightsor counterweightsto improvestability. -_ Use extra care with grass catchersor other attachments. _Thes_ Canchangethe st-'=,bility of the machine. • Keep all movementonthe slopesslowand gradual. Do not make sudden changesin speed or direction. =• Avoid startingor stoppingon a slope. If tires losetraction, disengagethe bladesand proceedslowlystraightdownthe slope. DO NOT: Do not turnonslopesunlessnecessary,andthen,tumslowly and graduallydoV_12_ill, if possible. • Do notmow near drop-offs,ditches,or embankments.The mowercouldsuddenlytum over ifa wheel is overthe edge of a cliffor ditch,or if an edge caves in. • Do not mow on wet grass. Reduced tractioncould cause sliding. • Donottrytostabilizethemachinebypuffingyourfootonthe ground. • Do not usegrass catcheron steep slopes. I I & A safety precautions. It means CAUTIONIII BECOME ALERTII! YOUR Lookforthissymboltopointoutimportant SAFETY IS INVOLVED. wire and place wire where it,candot contact spark plug in order to pre,Tent accidental starting setting up, transporting, CAUTION:when Always disconnect spark plug adjusting or making repairs. A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 2 CONGRATULATIONS :.on ypur purch_6i_a new Tm(_' ! tor. It has been designed, erlgineered and manufactured _ to give you the best poss_le dependability and performance. MODEL • _ _ , NUMBER " AYP9187B89 SERIAL NUMBER Should you e'_pedence any problem you cannot easily remedy, please contact your nearest authorized service center. We have competent, well-trained techntdans and the proper tools to service Or repair this tractor. Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor properly. Always observe the •SAFETY RULES'. DATE OF PURCHASE THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON A PLATEUNDER THE SEAT. YOU SHOULD RECORD BOTH SERIAL NUMBER AND DATE OF PURCHASEAND KEE° IN A SAFE PLACE FOR FUTURE REFERENCE. PRODUCT SPECIFICATIONS CUSTOMER RESPONSIBILITIES HORSEPOWER: 18.0 • Read and observe the safety rules. GASOLINE CAPACITY AND TYPE: OIL TYPE (API-SF/SG/SH): 3.5 GALLONS UNLEADED REGULAR • Follow a regular schedule in maintaining, caring for and using your tractor. • Follow the instructions under the "Customer Responsibilities" and "Storage • sections of this owner's manual. OIL CAPACITY: W/FILTER: 3.5 PINTS W/O FILTER: 3.0 PINTS SPARK PLUG: (GAP: .030") CHAMPION RJ19LM VALVE CLEARANCE: INTAKE: .004" - .006" EXHAUST: .007" - .009" GROUND SPEED (MPH): Forward: Reverse TIRE PRESSURE: FRONT: REAR: CHARGING SYSTEM: 3 AMPS Battery 5 AMPS Battery BATTERY: AMP/HR: MIN. CCA: CASE SIZE: BLADE BOLT TORQUE: 27-35 FT. LBS. See "ENGINE" in Customer Responsibilities Section WARNING: This tractor is equipped with an internal combustion engine and should notbe used on or near any unimproved forestcovered, brush-covered or grass-covered land unlessthe engine's exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark attester is used, it should be maintained in effective working order by the operator. In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Otherstates may have similar laws. Federal laws apply on federal lands. 0-5.7 0-2.5 14 PSI 10 PSI 30 240 UIR 3 TABLE.OF CONTENTS:" SERVICE AND ADJUSTMENTS ............................ 20-25 STORAGE ................................................................. 2€ TROUBLESHOOTING ............................................ 27-28 REPAIR PARTS - TRACTOR ................................. 30-47 REPAIR PARTS - ENGINE .................................... 48-54 PARTS ORDERING/SERVICE ................ BACK COVER SAFETY RULES ......................................... -.................. 2 PRODUCT SPECIFICATIONS .................................... 3 CUSTOMER R_SPONSlBILmES ..................... 3, 15-19 WARRANTY. ........................ •........................ ,............ 4 ASSEMBLY ............... •........... •.................................... 5-8 OPERATION ............................................................. 9-14 MAINTENANCE SCHEDULE ...................................... 15 WESTERN AUTO TRACTOR LIMITED WARRANTY AYP9187B89 Westem AutoSupplyCompanyWarrantstothe originalretailpurchaserthatthisproductisfree fromdefectsin materialor workmanshipand agrees to repair this productfree of chargewithinthesetimeperiodsfromthe date of purchase: • 2 years, if the productis usedfor personal,family, or householduse; • 90 days, if the productis usedfor any otherpurposesuchas commercialor rentaluse. Excludedfrom this warrantyare normalwear, maintenance,or mechanicaladjustmentswhichare not due to defectsin materialorworkmanship.Consultyourowner'smanualforhelpto maintainyourproductormakemechanicaladjustments.Products whichhavebeen altered,misused,abused,orrepairedbyotherthana WesternAuto-authorized ocmanufacturer-authorized service facility are also excluded. A rider or tractorbatterywhichprovesdefectivewithin90 dayswill be replacedwithoutcharge. After 90 daysbutwithin1 year from the date of purchase,WesternAutowill replacethe batteryfor a chargeof 1/12 of the currentretailpriceof the battery for each full monthbetweenthe date ofpurchaseand the dateof return. Enginesor transaxlesare warrantedby the engine or transaxlemanufacturerwhichgives its own 2 year warrantyand providesservicethroughitsauthorizedservicefacilities.See theengineortransaxlewarrantyfordetails. Repair maybe arranged throughparticipatingWestern Autostores. Forrepairserviceretum thisproductwithproofofpurchasedate to a participating WestemAutostore.Thiswarrantygives you specificlegalrightsandyou may haveotherrightsthatvaryfrom stateto state. Ifdifficulty is encounteredinhavingthis warranty honored,contact: WesternAutoSupplyCompany ConsumerAffairsSectionof the GeneralServiceDepartment 2107 GrandAvenue,KansasCity,Missouri 64108 Telephone: 816 346-4411 4 :_i_. :_ _ -_. : - : 4¸ , ,..L. _: :... _ .... CONTENTS _ • _ . • OF HARDWARE PACK o. Parts B_agcontents shown full size Parts packed separately in carton (1) Hex Bolt 3/8-16 x I © Seat Mulcher (1) Large Flat Washer Steering Wheel (1) Lockwasher 3/8 Q (1) Hex Bolt 5/16-18 x 1-1/4 | (1) Locknut 5/16-18 (1) Shoulder Bolt 5/16-18 Plate Steering Boot (1) Hex Bolt 1/2-13 x I i Manual Pads Bag Parts bag contents not shown full size (_ (1) Lock Washer 1_/2 (2) Shoulder Bolts (2)Washers x 7/8 x 14 Gauge 3/8 12)Gauge _ Wheels _ (2) Centerlock Nuts (1) Washer 17/32 x 1-3/16 x 12 Gauge I /_(2) Shrews #10 x 5/8 _ (2) Weld Nuts #10 _'_ I lllltitltltltlililtltlti (2) Lock Washers #10 I I Steering Wheel Adapter ) Wast_ers Steering Extension Shaft m Steering Wheel Insert 3/16 x 3/4 x 16 Gauge (2) Keys (2) Hex Bolts 1/4-20 x 314 €, ,,_------. _ U (2) Latch Hook Assemblies Washers (2) Hex Nuts (2) 1/4-20 Lock 1/4 Slope Sheet ._2) L_/ashers 9/32 x 5/8 x 16 Gauge 5 ASSEMBLY Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes. To ensure safe arKt prOper operation of your tractor all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to insure proper tightness. TOOLS REQUIRED FOR ASSEMBLY '_ A socket wrench set will make assembly easier. Standard wrench sizes are listed. 3/8HEX (1) 3/4" Socket w/drive rachet Utility knife (2) 7116" wrenches Tire pressure gauge (2) 112"wrenches Phillips Screwdriver (1) 9/16" wrench When right or left hand is mentioned in this manual, it means when you are in the operating position (seated behindthe steering wheel). • • • (_ WASHER LARGE FLAT WASHER STEERING WHEEL STEERING BOOT CARTON Remove all accessible loose parts and parts cartons from carton (See page 5). Cut, from top to bottom, along lines on all four comers of carton, and lay panels flat. Check for any additional loose parts or cartons and remove. ADAPTER BEFORE ROLLING TRACTOR OFF SKID A'I-rACH BOLT 3/8LOCK TO REMOVE TRACTOR FROM CARTON UNPACK --INSERT STEERING WHEEL _ _,_. . (See Fig. 1) EXTENSION SHAFT ____ 5/16 HEX BOLT ASSEMBLE EXTENSION SHAFT AND BOOT 5/16 LOCKNUT • Slide extension shaft onto lower steering shaft. Align mounting holes in extension and lower shafts and install 5/16 hex bolt and Iocknut. Tighten securely. IMPORTANT: TIGHTEN BOLT AND NUT SECURELY TO 18-22 FT. LBS TORQUE. • /" - I" _ ._._.. I/. LOWER ,,,_l= STEERING 17 .. _ "', _ _ ' I ,' , ; I Place tabs of steering boot over tab slots in dash and push down to secure. INSTALL STEERING WHEEL • FIG. 1 Position front wheels of the tractor so they are pointing straight forward. Slide steering wheel adapter onto steering shaft extension. -- TO ROLL TRACTOR OFF SKID (See tion section for location and function Position steering wheel So cross bars are horizontal (left to right) and slide inside boot and onto adapter. • Assemble large flat washer, 3/8 lock washer, 3/8 hex " bolt and tighten securely. • Snap steering wheel insert into center of steering wheel. _ _;i Operaof con- trols) • Remove protectivematerials from tractor hood and grill. .IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES IN SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR IS TO ROLL OFF SKID. • Press lift lever plunger and raise attachment liftleverto its highest position. • Release parking brake by depressing clutch/brake pedal. • Place freewheel control in freewheeling position to disengage transmission (See "TO TRANSPORT" in the Operation section of this manualp. Roll tractor forward off skid. • • 6 Remove banding holding discharge guard up against tractor. ASSEMBLY HOW TO SET UP YOUR TRACTOR CONNECT BATTERY CAUTION: INSTALL SEAT (See Fig. 3) Adjust seat before tightening adjustment boll • Remove cardboard packing on seat pan. • Place seat on seat pan and assemble shoulder bolt. Tighten shoulder bolt securely. • Assemble adjustment bolt, Iockwasher and flat washer loosely. Do not tighten. • Lower seat into operating position and sit on seat. • Slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down. (See Fig. 2) Do not short battery terml- object contact aboth terminals the nals bytoallowing wrench or any at other same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc. Positive terminal must be connected first to prevent sparking from accidental grounding. • • Get off seat without moving its adjusted position. Raise seat and tighten adjustment bolt securely. I- T_ifthood to raised position. Open terminal access doors, remove terminal protective caps and discard. • If this battery is put into service after month and year indicated on label (label located between terminals) charge battery for minimum of one hour at 6-10 amps. • First connect RED battery cable to positive (+) battery terminal with hex bolt, flat washer, lockwasher and hex nut as shown. Tighten securely. • Connect BLACKgrounding cable to negative (-) battery terminal with remaining hex bolt, flat washer, lock washer and hex nut. Tighten securely. • Close terminal access doors. Use terminal access doors for:. • • • • • SEAT PAN SHOULDER BOLT _._.. _.. LARGE FLAT WASHER ADJUSTMENT FIG. 3 Inspection for secure connections (to tighten hardware). Inspection for corrosion. Testing battery. Jumping (if required). Periodic charging. HEX NUT LOCK WASHER ASSEMBLE GAUGE WHEELS TO MOWER DECK (See Fig. 4) The gauge wheels are designed to keep the mower deck in proper position when operating mower. Be sure they are properly adjusted to ensure optimum mower performance. • Assemble gauge wheels with tractor on a flat level surface. • Adjust mower to desired cutting height (See =TO ADJUST MOWER CUTTING HEIGHT" in the Operation section of this manual). • With mower in desired height of cut position, gauge wheels shouldbe assembled so they are slightlyoffthe ground. Install gauge wheel in appropriate hole with shoulder bolt, 3/8 washer, and 3/8-16 Iocknut and tighten securely. • Repeat for opposite side installing gauge wheel in same adjustment hole. FLAT WASHER HEX BOLT PROTECTIVE CAPS DISCARD TERMINAL LOCK WASHER BOLT POSITIVE (RED) CABLE GAUGE WHEEL MOUNTING BRACKET \ NEGATIVE (BLACK) CABLE FIG. 2 3/8-16 LOCKNUT GAUGE WHEEL 7 FIG. 4 iii ASSEMBLY Ii CHECK TIRE PRESSURE INSTALL MULCHER PLATE (See FKjs.5 and 6) • Install two latchhooks to mulcher plate using screw, washer, lock washer, and weld nut as shown. NOTE: Pre-assemble weld nut to latch hook by inserting The tires on your tractorwere ovednflated at the factory for shipping purposes. Correct tire pressure is important for best cuffing performance. weld nut from the top with hook pointing down. • Tighten hardware securely. Raise and hold deflector shield in upright position. • Place front of mulcher plate over front of mower deck • • • CAUTION: Do not remove discharge guard from mower. Raise and hold guard when attaching mulcher plate and allow it to rest on plate while in ! _ operation. TO CONVERT DISCHARGING . CHECK DECK LEVELNESS For best cutting results, mower housing should be properly leveled. See =TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. opening and slide into place, as shown. Hook front latch into hole On front of mower deck. Hook rear latch into hole on back of mower deck. | a= I _ I --J_J_ I _ TO BAGGING CHECK POSITION OF ALL See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments section of this manual. Verify that the belts are muted correctly. CHECK BRAKE SYSTEM After you learn how to operate your tractor, check to see that the brake is properly adjusted. See =TO ADJUST BRAKE" in the Service and Adjustments section of this manual. Simply remove mulcher plate and store in a safe place. Your mower is now ready for discharging or installationof optional grass catcher accessory. NOTE: It is not necessary to change blades. The mulcher blades are designed for discharging and bagging also. ,/CHECKLIST BEFORE YOU OPERATE AND ENJOY YOUR NEW TRACTOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCEAND SATISFACTION FROM THIS QUALITY PRODUCT. PLEASE REVIEW THE FOLLOWING CHECKLIST: ,/ All assembly instructionshave been completed. ,/ No remaining loose parts in carton. ,/ Battery is properly prepared and charged. (Minimum 1 hour at 6 amps). HOOK POINTS DOWN LOCK ,/ Seat is adjusted comfortably and tightened securely. ,/ All tires are properly inflated. (For shipping purposes, the tires "::ereovednflated at the factory). / Be sure mower deck is properly leveled side-to-side/ front-to-rear for best cutting results. (Tires must be properly inflated for leveling). ,/ Check mower and drive belts. Be sure they are routed properly around pulleys and inside all belt keepers. "_......-'SCREW / Check wiring. See that all connections are still secure and wires are properly clamped. FIG. 5 / HOOK HOOK LOCK WASHER WELD. NUT WASHER WASHER MULCHERpLATE FOR PROPER BELTS OR WELD NUT Reduce tire pressure to PSI shown in =PRODUCT SPECIFICATIONS on page 2 of this manual. Before driving tractor, be sure freewheel control is in drive position. WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS: DEFLECTOR SHIELD p°. / ,f ,/ LATCH HOOKS FIG. 6 8 Engine oil is at proper level. Fuel tank is filled with fresh, clean, r_gular unleaded gasoline. Become familiar with all controls - their location and function. Operate them before you start the engine. / Be sure brake system is in safe operating condition. •/ It is importantto purge the transmission before operating your tractorfor the first time. Follow proper starting and transmissionpurginginstructions(See =TOSTART ENGINE" and =PURGE TRANSMISSION" in Operation section of this manual). • _ OPERATION These symbols may appear on your tractor or in IRerature supplied with the product. Learn and undemtand their meaning. BATTERY CAUTION OR WARNING REVERSE FORWARD FAST SLOW ENGINE ON ENGINE OFF OIL PRESSURE CLUTCH LIGHTS ON OVER TEMP LIGHT " CHOKE MOWER HEIGHT DIFFERENTIAL PARKING BRAKE UNLOCKED ° LOCK I Ill LOCKED R N H L REVERSE NEUTRAL HIGH LOW PARKING BRAKE MOWER LIFT ATTACH MENT CLUTCH ENGAGED ATTACH MENT CLUTCH DISENGAGED KEEP AREA CLEAR SLOPE HAZARDS (SEE SAFETY RULES SECTION) IGNITION DANGER, KEEP HANDS AND FEET AWAY FREE WHEEL (Automatic Models only) 9 ii OPERATION KNOW YOUR TRACTOR READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR Compare the illustrationswith your tractor to familiarize yourself with the locationsof various controlsand adjustments. Save this manual for future reference. UGHT SWITCH AMMETER CHOKE THROTTLE CONTROL ----_ 4 CONTROL . - .... "" _. "" •• LIFT LEVER PLUNGER D -t BRAKE CLUTCH/ PEDAL LIFT LEVER "0 IGNITION SWITCH FREEWHEEL PARKING BRAKE CONTROL MOTION CONTROL LEVER HEIGHT ADJUSTMENT KNOB FIG. 7 _'_ -'- Our tractors conform to the safety standards of the American National Standards Institute. LIFT LEVER PLUNGER: Used to release attachment lift lever when changing its position. ATTACHMENT CLUTCH SWITCH: Used to engage the rr_wer blades, or other attachments mounted to your tractor. IGNITION SWITCH: engine. LIGHT SWITCH: ;Turns the headlights on and off. :. THROTTLE FREEWHEEL CONTROL: Disengages trans_missionfor pushing or slowly towing the tractor with'1_e engine off. CONTROJ.: Used to control engine speed. CLUTCH/BRAKE PED'_L: Used for declutchingand braking the tractor and starting the engine. PARKING BRAKE: brake position. MOTION CONTROL direction of tractor. HEIGHT ADJUSTMENT KNOB: Used to adjustthe mower height. Locks clutch/brake pedal into the LEVER: Used for starting and stopping the AMMETER: battery. Selects the speed and Indicates charging (+) or discharging (-) of CHOKE CONTROL: Used when starting a cold engine. ATTACHMENT UFT LEVER: Used to raise and lowerthe mower deck or other attachments mounted to your tractor. 10 e 8 OPERATION The operation of any tractor can result in foreign objects thrown into the eyes, which can m;esult in severe eye damage. Always wear safety glasses or eye shields while o_mting your tractor or performing any adjustments or repairs. We recommend a wide vmion safety mask over the spectacles or standard safety glasses. HOW TO USE YOUR TRACTOR NOTE: Under certain conditions when tractor is standing idlewith the engine running,hot engine exhaust gases may cause =browning" of grass. To eliminate this possibility, always stop engine when stopping tractor on grass areas. TO SET PARKING BRAKE (See Fig. 8) Your tractor isequipped with an operator presence sensing switch. When engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine. • -Depress clutch/brake pedal into full "BRAKE" position and hold. • pletely, as described above, before leavCAUTION: Always position; stop tractor coming the operator's to empty grass catcher, etc. Place parking brake lever in •ENGAGED • position and release pressure from clutch/brake pedal. Pedal should remain in •BRAKE • position. Make sure parking brake will hold tractor secure. CONTROL \ CONTROL / / _ _ _l II _'_._,._/ \"_\_ _/ __,'_ PUSH.INTO "1 TO USE USE I;H CHOKE CONTROL . _ ',,_'_\" \\\/_ ,, PARKINGBRAKE • Tc,eng;lge To engage choke control, pull knob out. Slowly push kr ob in to disengage. knob "1 MOVE TO IVIOVI"F FORWARD I _ "_,"_ / r '" CLUTCH/BRAKE PEDAL ':DRIVE" POSITION _ MOTION.CONTROL i LEVER The direction and speed of movement is controlled by the motion control lever. • "DISENGAGED" POSITION • • FIG. 8 STOPPING HEIGHT (See The cutting height is controlled by tuming the height adjustment knob in desired direction. Mo--_attachment clutch lever to •DISENGAGED • position. GROUND DRIVE •• • Start tractor with motion control lever in neutral (N) position. Release parking brake and clutch/brake pedal. Slowly move motion control lever to desired position. TO ADJUST MOWER CUTTING Fig. 7) (See Fig. 8) MOWER BLADES • AND BACKWARD (See Fig. 8) OSITION .)_...,,_ (See Fig. 8) I. ct _okecon' Use choke controlwhenever you are starting a cold engine. [Do not _o:use Io,'start a warm engine. use to _/"DISENGAGE POSmON CONTROL (See Fig. 8) o Ak,ays operate engine at full throttle. • Operating engine at less than full throttle reduces the battery charging rate. • Full throttle offers the best bagging and mower perform_lnce. mance. ATTACHMENT CLUTCH SWITCH PULL-OUT TO "ENGAGE" THROTTLE CHOKE TO USE THROTTIE Depress clutch/brake pedal intofull •BRAKE • position. Move motion control lever to neutral (N) position. • Turn knob clockwise (F_) to raise cuffing height. • Turn knob counterclockwise (P-_)to height. lower cutting IMPORTANT:_ THE MOTION CONTROL LEVEP_IDOES NOT RETURN TO NEUTRAL (N) POSITION WHEN THE CLUTCH/BRAKE P'E_-DAL IS DEPRESSED. ENGINE - The cuttingheight range is approximately 1-1/2" to 4". The heights are measured from the ground to the blade tip with the engine not running. These heigl-Csare approximate and may vary depending upon soil ce_nditions,height of grass and types of grass being mowed. • • The average lawn shouldbe cut to approximately2-1/2 inches dudng the cool season and to over 3 inches during hot months. For healthier and better looking lawns, mow often and after moderate growth. • For best cutting performance, grass over 6 inches in height should be mowed twice. Make the first cut relatively high; the second to desired height. Move throttle control to slow position. NOTE: Failure to move throttle controlto slow position and allowing engine to idle before stopping may cause engine to •backfire•. • Tum Ignition key to •OFF" position and remove key. Always remove key when leaving tractor to prevent unauthodzed use. N_yer use choke to stop engine. 11 OPERATION TO OPERATE:_MOWER (See Fig. 9) Your tractor isequipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine• • Select desired height of cut. • Lower mower with attachment lift cor_ml. • Start mower blades by engaging attachment clutch control. TO STOP MOWER BLADES - disengage attachment clutch control. • I _ | ALA I--JIMIL -_1 / • Raise attachment lift to highest position with attachment lift control. • Pull freewheel control knob out and hold in position by inserting retainer spdng intoforward hole of control rod. • Do not push or tow tractor at more than two (2) MPH. • To reengage transmission, reverse above procedure. NOTE: To protect hood from damage when transporting your tractoron a truck ora trailer, be sure hood isclosed and secured totractor• Use an appropriate means oftying hood to tractor (rope, cord, etc.). CAUTION: Do not operate the mower without either the entire grass catcher, on mowers so equlpped, or the discharge guard in place. FIG. 10 BEFORE STARTING THE ENGINE CHECK • • • FIG. 9 TO OPERATE • ON HILLS • 4Bk i _ hills with slopes greater than 15 ° and CAUTION: not drive up or down do not drive Do across any slope. ADD GASOLINE • _=:3. Choose the slowest speed before starting up or down hills.-'Avoid stopping or changing speed on hills. • if slowing is necessary, move throttle control lever to _ slower position. • if stopping is absolutely necessary, push clutch/brake pedal quickly to brake position and engage pa.._ing brake • Move motion cont,r.0.1 lever to neutral (N) position. IMPORTANT: THE I_!_TION CONTROL LEVER DOES NOT RETURN TO NEUTRAL (N) POSITION WHEN THE CLUTCH/BRAKE PEDAL IS DEPRESSED. • To restart movement, slowly release parking brake and clutch/brake pedal. • Slowly move motion control lever to slowest setting. • Make all tums slowly. TO TRANSPORT (See Fig. 10) When pushing or towing your tractor, be sure to disengage t_is_on by placing freewheel control in freewheeling p'_tton.'_=ree wheel control is located at the rear drawbar of tractor. 12 ENGINE OIL LEVEL (See Fig. 15) The engine inyourtractor has been shipped, from the factory, already filled with summer weight oil. Check engine oil with tractor on level ground. Remove oil fill cap/dipstick and wipe clean, reinsertthe dipstick and screw cap tight, wantfor a few seconds, remove and read oil level. If necessary, add oil until "FULL" mark on dipstick i_ reached. Do not overfill. For cold weather operation you should change oil for easier starting (See =OIL VISCOSITY CHART" in the Customer Responsibilities section of this manual). To change engine oil, see the Customer Responsibilities section in this manual. Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. (Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. IMPORTANT: WHEN OPERATING IN TEMPERATURES BELOW 32°F(0°C), USE FRESH, CLEAN WINTER GRADE GASOLINE TO HELP INSURE GOOD COLD WEATHER STARTING. WARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol o1"m_thanol) can attract moisture which leads to separation-and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before stop age of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine ol carburetor cleaner products in the fuel tank or permanenl damage may occur. OPERATION I& fill6i' neck. Do not overfill..Wipe off any •spilled oil or fuel. Do not store, spill or CAUTION: to bottom gas tank use gasoline Fill near an open of flame. TO START ENGINE (See I I Fig. 8) NOTE: If at a high altitude (above 3000 feet) or in cold temperatures (below 32 F)the carburetor fuel mixture may need to be adjusted for best engine performance. See '1"O ADJUST CARBURETOR" in the Service and Adjustments section of this manual. PURGE TRANSMISSION When starting the engine for the first time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine. • Be sure freewheel control is in the transmission engaged position. • Sit on seat in operating position, depress clutch/brake pedal and set parking brake. ":Place motion control lever in neutral (N) position. Move attachment clutch to =DISENGAGED • position. Move throttle control to fast position Pull choke control out for a cold engine start attempt. For a warm engine start attempt the choke control may not be needed. NOTE: Before starting, read the warm and cold starting procedures below. • Insertkeyinto ignitionand turnkey clockwiseto =START" position and release key as soon as engine starts. Do not run starter continuously for more than fifteen seconds per minute. If the engine does not start after several attempts, push choke control in, wait a few minutes and try again. Ifengine stilldoes not start, pull the choke control out and retry. WARM WEATHER STARTING (50 ° F and above) • • When engine, starts,,slowi,vpush choke control in until the engine begins to run smoothly. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly. The attachments and ground drive can now be used. If the engine does not accept the load, restart the engine and allow itto warm up for one minute using the choke as described above. COLD WEATHER STARTING (50° F and below) • When engine starts, slowly push choke control in until the engine begins to run smoothly. Continue to push the-_oke control in small steps allowing the engine to accept small changes in speed and load, until the choke control is fully in. If the engine starts to run roughly, pull the choke control out slightly for a few seconds and then continue to push the control in slowly. This may require an engine warm-up period from several seconds to several minutes, depending on the tem_perature. '_. AUTOMATIC TRAN.LSMISSlON WARM UP • Before driving fife unit incold weather, the transmission should be warmed up as follows: • Be sure the tractor is on level ground. • Place the motion control lever in neutral. Release the parking brake and let the clutch/brake slowly retum to operating position. • Allow one minute for transmission to warm up. This can be done during the engine warm up period. The attachments can be used duringthe engine warm: Ul_l_eriodafter the transmission has been warmed up and may require the choke controlbe pulledout slightly. 13 freewheel while the engine is runCAUTION: lever Never engage or disengage ning. To ensure proper operation and performance, it is recommended that the transmission be purged before operating tractor for the first time. This procedure will remove any trapped air inside the transmission which may have developed during shipping of your tractor. IMPORTANT: SHOULD YOUR TRANSMISSION REQUI'RE REMOVAL FOR SERVICE OR REPLACEMENT, I:r SHOULD BE PURGED AFTER REINSTALLATION BEFORE OPERATING THE TRACTOR. • Place tractorsafely on level surface with engine off and parking brake set. • Disengage transmission by placing freewheel control in freewheeling position (See =TO TRANSPORT" in this section of manual). • Sitting in the tractor seat, start engine. After the eng!ne is running, move throttle control to slow position. With motion control lever in neutral (N) position, slowly disengage clutch/brake pedal. Move motion control lever to full forward position and hold for five (5) seconds. Move lever to full reverse position and hold for five (5) seconds. Repeat this procedure three (3) times. • NOTE: During this procedure there will be no movement of drive wheels. The air is being removed from hydraulic drive system. • • • • • Muve motion controlleverto neutral (N) position. Shutoff engine and set parking brake. Engage transmission by placing freewheel control in driving position(See =TOTRANSPORT" in this section of manual). Sitting in thetractor seat, start engine. Afterthe engine is running, move throttle control to half (1/2) speed. With motion control lever in neutral (N) position, slowly disengage clutch/brake pedal. Slowly move motion control lever forward, after the tractor moves approximately five (5) feet, slowly move motion control lever to reverse position. After the tractor moves approximately five (5) feet retum the motion control lever to the neutral LN) position. Repeat this procedure with the motion co=trol lever three (3) times. Your tractor is now purged and now ready for normal operation. OPERATION MOWING T S. MULCHING MOWING TIPS • Tire chains cannot be used when the mower housing is attached to tractor. • Mower should be properly leveled for best mowing performance. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. The left hand side of mower should be used for trimming. IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER HOUSING FREE OF BUILT-UP GRASS AND TRASH. CLEAN AFTER EACH USE. • • The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades. Drive so that clippings are discharged onto the area that has been cut. Have the cut area to the rightof the machine. This will result in a more even distributionof clippings and more uniform cutting. • • When mowing large areas, start by turning to the right ---- so---that clippings will discharge away from shrubs, fences, driveways, etc. After one or two rounds, mow in the opposite direction making left hand tums until finished (See Fig. 11 ). Avoid cutting your lawn when it iswet. Wet grass tends to form clumps and interferes with the mulching action. The bast time to mow your lawn is the early afternoon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. • Forbest results, adjustthe mower cutting height so that the mower cuts off only the top one-third of the grass ° blades (See Fig. 12). For extremely heavy mulching, reduce your widthof cuton each pass and mow slowly. • Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mow across or perpendicular to the first cut path. Change your cuttingpattern from week to week. Mow northto southone week then change to east towest the next week. This willhelp prevent matting and graining of the lawn. • If grass is extremely tall, it should be mowed twice to reduce load and possible fire hazard from dried clippings. Make first cut reiatively high; the second to the desired height. • Do not mow grass when it is wet. Wet grass will plug mower and leave undesirable clumps. Allow grass to dry before mowing. • Always operate engine at full throttle when mowing to assure better mowing performance and proper discharge of material. Regulate ground speed by selecting a low enough gear to give the mower cutting performance as well as the quality of cut desired. • When operating attachments, select a ground speed that will suit the terrain and give best performance of the attachment being used. • MAX 1/3 FIG. 12 iI _ FIG. 11 14 ' CUSTOMERRESPONSIBILITIES Check Brake Operation V' Check Tire Pressure _ V' Check Operator Presence and T Interlock Check forSystems Loose Fasteners A Sharpen/Rep lace M°wer Blades Lubrication Chart _'= Check Battery and LevelTerminals/Recharge Clean Battery V_6 V' T _V' V'7 V' Check Transexle Cooling V' i ll_ Adjust Blade Belt(s) Tension V's Adjust Motion Drive Belt(s) Tension I,i's Check Engine Oil Level Change Engine V' Oil V p V_1.2.3 E Clean Clean Air Air Filter Screen (_ Inspect Muffler/Spark N Replace Oil Filter (If equipped) Clean Engine Cooling Fins I_., if2 Replace Spark Plug V' Replace Air Filter Paper Cartridge V'2 V'= V'2 Arrester V r Replace Fuel Filter 12 3 4 - 5 - If equipped with adjustable system. 6 - Not required if equipped wi_ maintenance-free battery. 7 - Tighten front axle pivot bolt to 35 ft.-Ibs, maximum. Do not overtighten. LUBRICATION CHART RECOMMENDATIONS The warranty on this tractor does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain tractor as instructed in this manual. V _ _/ Change more often when operating under a heavy load _ in high ambient temperatures. Service more often when operating in dirty or dusty conditions. If equipped with oil filter, change oll every 50 hours. Replace blades more often when mowing in sandy soiL GENERAL (_t SPINDLE ZERK ---------I_(_-'-"_ (_l FRONT WHEEL'_.'_"_--'-- Some adjustments will need to be made periodically to ipropedy-rnaintain your tractor. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. • V' BEARING ZERK "t_..:_ll_ ..... ..... _1"-'_ SPINDLE ZERK (_) __'Jr" FRONT WHEEL (_) "_ BEARING ZERK "ENGINE" SECTION Once a year you should replace the spark plug, clean or replace air filter, and check blades and belts for wear. A new spark plug and clean air filter.assure proper air-'fuelmixture and help your engine runbetter and last longer:... BEFORE EACH USE • Check engine oil level. • Check brake operation. • • Check tire pressure. Check for loose fasteners. (_ SAE 30 OR 10W30 MOTOR OIL (_ GENERAL PURPOSE GREASE (_) REFER TO CUSTOMER RESPONSIBILmES IMPORTANT: DO NOT OIL OR GREASE THE PIVOT POINTS WHICH HAVE SPECIAL NYLON BEARINGS. VISCOUS LUBRICANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELF-LUBRICATING BEARINGS. IF YOU FEEL THEY MUST BE LUBRICATED, USE ONLY A DRY, POWDERED GRAPHITE TYPE LUBRICANT SPARINGLY. 15 i L ;CUSTOMERi. RESPONSIBILITIES II TRACTOR .... • TO SHARPEN BLADE (See Fig. 14) Care should be taken to keep the blade balanced. An unbalanced blade willcause excessive vibration and eventual damage to mower and engine. Always observe safe_ _rules when performing any maintenance. BRAKE OPERATION If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. (See "TO ADJUST BRAKE" in the Service and Adjustments section of this manual). TIRES • • The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. • To check blade balance, you will need a 5/8" diameter steel bolt, pin, or a cone balancer. (When using a cone balancer, follow the instructions supplied with balancer). • Slide blade on to an unthreaded portion of the steel bolt or pin and hold the bolt or pin parallel with the ground. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. Maintain proper air pre,s,surein all tires (See =PRODUCT SPECIFICATIONS on page 3 of this manual). • =:,Keep_tiresfree of gasoline, oil, or insect control chemicals which can harm rubber. • NOTE: Do not use a nailfor balancing blade. The lobes of the center hole may appear to be'centered, but are not. Avoid stumps, stones, deep ruts,_sharp objects and other hazards that may cause tire damage. NOTE: To seal tire punctures and prevent flat tires due to "- slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and corrosion. CENTER HOLE BLADE CARE 5/8" BoLT__ / / __ BLADE For best results mower blades must be kept sharp. Replace bent or damaged blades. BLADE REMOVAL (See Fig. 13) • ORF,l i Raise mower to highest position to allow access to blades. FIG. 14 Remove hex bolt, lockwasher and flat washer securing blade. BATTERY Install new or resharpened blade with trailing edge up towards deck as shown. IMPORTANT: TO ENSURE PROPER ASSEMBLY, CENTER HOLE IN BALDE MUST ALIGN WaTH STAR ON MANDREL ASSEMBLY. Your tractor has a battery charging system which is sufficient for normal use. However, periodic charging of the battery with _n automotive charger will extend its life. • Reassemble hex bolt, lock washer and flat washer in exact order as shown, • Keep battery and terminals clean. • Keep battery boltstight. • Tighten bolt securely (27-35 Ft. Lbs, torque). _IMEORTAN.T-: BLADE BOLT IS GRADE 8 HEATTREATED. -N61[e: We dohot recomme_ndsharpening blade - but ifyou do, be sure the blade is balanced. •• MANDREL • Corrosion and dirton the battery and terminals can cause the battery to =leak"power. ASSEMBLY / R _EX _LOCK • Remove terminal guard. • Disconnect BLACK batten/ cable first then RED battery cable and remove battery from tractor. • Rinse the battery with plain water and dry: • Clean terminals and battery cable ends=withwire brush until bright. • Coat terminals with grease or petroleum jelly. • Reinstall battery (See "CONNECT BATTERY' in the Assembly section of this manual). HOLE FLAT WASH! WASHER '_ I \ "_ BOLT (GRADE 8) ° *A GRADE 8 HEAT TREATED BOLT CAN BE -_IlJIENTIRED BY SIX UNES ON THE BOLT HEAD. FIG. 13 Recharge at 6-10 amperes for I hour. TO CLEAN BATTERY AND TERMINALS TRAILING EDGE UP _CENTER BLADE Keep small vent holes open. 16 iiii CBSTOMER RESPONSIBILITIES V-BELTS TO CHANGE ENGINE OIL (See Fig. 15) Check V-belts fb'rdeterioration and wear after 100 hours of operation and replace if necessary, 1"he belts are not adjustable. Replace belts if they begin to slip from wear. Determine temperature range expected before oil change. All oil must meet API service classification SF, SG or SH. • Be sure tractor is on level surface. TRANSAXLE • • Oil will drain more freely when warm. Catch oil in a suitable container. COOLING The fan and cooling fins of transmission should be kept clean to assure proper cooling. • Do not attempt to clean fan or transmission while engine is running or while the transmission is hot. Remove oil fillcap/dipstick. Be careful not to allow dirt to enter the engine when changing oil. • Remove drain plug. • Inspect cooling fan to be sure fan blades are intact and clean. • After oil has drained completely, replace oil drain plug and tighten securely. Inspect cooling fins for dirt, grass clippings and other 7-matedals. To prevent damage to seals, do not use compressed air or high pressure sprayer to clean cooling fins. • Refill engine with oil through oil fill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see =PRODUCT SPECIFICATIONS" on page 2 of this manual. • Use gauge on oilfill cap/dipstick for checking level. Be sure dipstick cap is tightened securely for acc'urat_ reading. Keep oil at =FULL" line on dipstick. ° TRANSAXLE PUMP FLUID The transaxle was sealed at the factory and fluid maintenance is not required for the lifeof the transaxle. Should the transaxle ever leak or require servicing, contact your nearest authorized service center/department. AIR SCREEN ENGINE LUBRICATION Only use high quality detergent oil rated with API service classification SF, SG or SH. Select the oil's SAE viscosity grade according to your expected operating temperature. OIL RLL CAW DIPSTSICK SAE VISCOSITY GRADES OIL DRAIN PLUG *F -20" 0, 30" 32" 40" 60, 80" 100" FIG. 15 °c _ -_ -lo" o10" _ _ _T_P_TURE _'_GE_rncIF'ATEO eEFORe,t_"O,.C._QS " Air cooled engine/run hotter than automotive engine. Use of multi-vtsco¢,_ o_s (10W-30_et_) a=b_t_ " 40"F(4"C)willresultInhighoil¢onstaq)Uon andposs_kD engl_-_age, che_ o_kwe!more frequenUy Ues_gZhees typesofoh. - "SAE 30 oll, tf used below 40"F(4°C)__will result in hard star_ and possible engine born damage due to inadequate lubrication. Change the oil after every 50 hours of operation or at least once a year if the tractor is not used for 50 hours in one year. Check the crankcase oil level before starting the.engine and after each eight (8) hours of operation. Tight_n oil fill cap/dipstick secure_ each time you check the oil level. 17 "CUSTOMERRESPONSIBILITIES AIR FILTER (See Fig. 16) CLEAN Your engine will fibt run properly using a dirty air filter. Clean the foam pre-cleaner after every 25 hours of operation or every season. Service paper cartridge every 100 hours of operation or every season, whichever occursfirst. AIR SCREEN (See Fig. 17) Air screen must be kept free of dirt and chaff to prevent engine damage from overheating. Clean with a wire brush or compressed airto remove dirt and stubborn dried gum fibers. Service air cleaner more often under dusty conditions. • AIR SCREEN Remove knobs and cover. TO SERVICE PRE-CLEANER • Wash it in liquid detergent and water. • Squeeze it dry in a clean cloth. • Saturate it in engine oil. Wrap it in clean, absorbent cloth and squeeze to remove excess oil. -= If_ery dirty or damaged, replace pre-cleaner. TO SERVICE CARTRIDGE • Clean cartridge by tapping gently on flat surface. Ifvery dirty or damaged, replace cartridge. • Reinstall precleaner cartridge cover and secure with knobs. FIG. 17 CLEAN AIR INTAKF.JCOOLING IMPORTANT: PETROLEUM SOLVENTS, SUCH AS KEROSENE, ARE NOT TO BE USED TO CLEAN THE CARTRIDGE. THEY MAY CAUSE DETERIORATION OF THE CARTRIDGE. DO NOT OIL CARTRIDGE. DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE. KNOB AREAS To insure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Every 100 hours of operation (more often under extremely dusty, dirty conditions), remove the blower housing and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. NOTE: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed will cause engine damage due to overheating. _COVER CARTRIDGE MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. SPARK PLUGS Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in =PRODUCT SPECIFICATIONS" on page 2 of this manual. FIG. 16 18 ...... CUSTOMER'RESPONSIBILITIES IN-LINE FUEL FILTER (See Fig. 19) ENGINE OIL-RLTER (See Fig. 18) Replace the engine oil filter every season or every other oil change if the tractor is used*more than 100 hours m one year. • Unscrew old filter by turning counterclockwise. Use a suitable container to catch oil. • • Apply a thin coating of new engine oil to rubber gasket on replacement oil filter. Install replacement oil filter by tuming clockwise until rubber gasket contacts mounting surface, then tighten filter an additional 1/2 to 3/4 tum. The fuel filter should be replaced once each season, ff fuel filter becomes clogged, obstructingfuel flow to carburetor, replacement is required. • With engine cool, remove filter and plug fuel line sections. • Place new fuel filter in position it, :uel line with arrow pointing towards carburetor. • Be sure there are no fuel line leaks and clamps are properly positioned. • Immediately wipe up any spilled gasoline. Fill crankca..sewith new oil (See "TO CHANGE ENGINE OIL in this section of this manual). For approxi-mate capacity see =PRODUCT SPECIFICATIONS • on page 3 of this manual. • CLAMP CLAMP Start engine and check for oil leaks. Correct any leaks before placing engine into full operation. FUEL FILTER FIG. 19 OIL RLTER CLEANING '0 • Clean engine, battery, seat, finish, etc. of all foreign matter. • Keep finished surfaces and wheels free of all gasoline, oil, etc. • Protect painted surfaces with automotive type wax. We do not recommend using a garden hose to clean your tractor unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in a shortened engine life. FIG. 18 19 ERVIG CAU:FION: BEFORE • • • • • • AN D USTMENTS PERI:ORMING ANY SERVICE OR ADJUSTMENTS: Depress clutch/brake pedal fully and set parking brake. Place motion control lever in neutral (N) position. Place attachment clutch in =DISENGAGED" position. Turn ignition key "OFF" and remove key. Make sure the blades and all moving parts have completely stopped. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. TRACTOR CLUTCH LEVER TO REMOVE MOWER (See Fig. 20) CLUTCHI M_ ower willbe easier to remove from the right side of tractor. • • • • • • • • SUSPENSION ARMS Place attachment clutch in "DISENGAGED" position. Move attachment lift lever forward to lower mower to its lowest position. Roll belt off engine pulley, Disconnect clutch rod from clutch lever by removing retainer spring. Disconnect anti-sway, bar from Chassis bracket by removing retainer spnng. Disconnect suspension arms from rear deck brackets by removing retainer springs. Disconnect front linksfrom deck by removing retainer springs. Raise lift lever to raise suspension arms. Slide mower out from under tractor. RETAINER SPRING AN_-SWAY IMPORTANT: IF AN ATTACHMENT OTHER THAN THE MOWER DECK IS TO BE MOUNTED ON THE TRACTOR, REMOVE THE FRONT LINKS. TO INSTALL MOWER Raise attachment lift lever to its highest position. Slide mower under tractorwith discharge guard to right side of tractor. • • Lower lift lever to its lowest position. Install mower in reverse order of removal instructions. RET_NER SPRINGS (BOTH SIDES) FIG. 20 (See Fig. 20) • • BAR 2O r- ! 'sERVi TO LEVEL MOWER cE!AND; ADJUSTMENTS HOUSING FRONT-TO-BACK ADJUSTMENT (See Rgs. 23 and 24) IMPORTANT: DECK MUST BE LEVEL SIDE-TO-SIDE. IF THE FOLLOWING FRONT-TO-BACK ADJUSTMENT IS NECESSARY, BE SURE TO ADJUST BOTH FRONT LINKS EQUALLY SO MOWER WILL STAY LEVEL SIDE-TOSIDE. Adjust the m0T_se r While tractor isparked on level ground or driveway. Make sure tires are properly inflated (See =PRODUCT SPECIFICATIONS" on page 2 ofthis manual). If tires are over or underinflated, you willnot properlyadjust your mower. SIDE-TO-SIDE To obtain the best cutting results, the mower housing should be adjusted so that the front isapproximately 1/8" to 1/2" lower than the rear when the mower is in its highest position. ADJUSTMENT (See Figs. 21 and 22) • Raise mower to its highest position. • At the midpoint of both sides of mower, measure height from bottom edge of mower to ground. Distance"A"on both sides of mower should be the same or within 1/4" of each other. • If adjustment is necessary, make adjustment on one _ side of mower only. • Check adjustment on right side of tractor. Measure distance "D" directly in frontand behind the mandrel at bottom edge of mower housing as shown. • To raise one side of mower, tighten lift link adjustment nut on that side. Before makingany necessary adjustments, checkthat bothfront linksare equal in length. Bothlinks shouldbe approximately 10-3/8". • To lower one side of mower, loosen lift linkadjustment nut on that side. • NOTE: Three full turns of adjustment nut will change mower height about 1/8". • Recheck measurements after adjusting. If links are not equal in length, adjust one link to sa.rne length as other link. To lower front of mower loosen nut "E" on both'fror_t links an equal number of turns. • When distance =D" is 1/8" to 1/2" lower at front than rear, tighten nuts "F" against trunnion on both front links. • To raise frontof mower, loosen nut"F_from trunnion on both front links. Tighten nut "E" on both front links an equal number of turns. When distance "D" is 1/8" to 1/2" lower at front than rear, tighten nut"F" against trunnionon bothfront links. • BOTTOM EDGE OF MOWER TO BOTTOM EDGE OF MOWER TO • Recheck side-to-side adjustment. o ot MANDREL FIG. 21 SUSPENSION ARM "D" FIG. 23 BOTH FRONT MNKS MUST BE EQUAL IN LENGTH _UNK ADJUSTMENT NUT FIG. 22 NUT "E" NUT FRONT UNKS 21 TRUNNION FIG. 24 SERVlCEi;AN D ADJ USTMENTS TO REPLACE MOWER BLADE DRIVE BELT (See Fig. 25)::_ WITH PARKINGBRAKE "ENGAGED" NUT"A" The mower blade drive belt may be replaced without tools. Park the tractor on level surface, Engage parking brake. BELT REMOVAL • Remove mower from tractor (See "TO REMOVE MOWER • in this section of this manual). • Work belt off both mandrel pulleys and idler pulleys. • Pull belt away from mower. BELT INSTALLATION • Install new belt in reverse order of removal. • Make sure belt is in all pulley grooves and inside all belt guides. Install mower in reverse order of removal instructions. -- "_i _, ARM w MANDREL PULLEY_ DO NOT TOUCH THIS NUT. IF FURTHER BRAKE ADJUSTMENT IS NECESSARY CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER/DEPARTMENT iDLER PULLEYS FIG. 26 TO REPLACE MOTION DRIVE BELT (See Fig. X) Park the tractor on level surface. Engage parking brake. For assistance, there is a belt installation guide decal on bottom side of left footrest. MANDREL PULLEY • Remove mower (See "TO REMOVE MOWER" in this section of this manual.) • Remove belt from stationary idler and clutching idler. • Pull belt slack toward rear of tractor. Carefully remove belt upwards from transmission input pulley and over cooling fan blades. Pull belt toward front of tractor and remove downward from around engine pulley. • FIG. 25 • TO ADJUST BRAKE Install new belt by reversing above procedure. (See Fig. 26) Your tractor is equipped with an adjustable brake system which is mounted on the side of the transaxle. If tractor requires more than six (6) feet stopping distance - at'highspe_'d.inhighest gear, .thenbrake must be adjusted. • - Depressclutch/brake pedal and engage parkingbrake. • Measure distance between brake operating arm and nut "A" on brake rod. If distance is other than 1-9/16", loosen jam nut and turn nut"A" un=tildistance becomes 1-9/16". Retighten jam nut agair_st nut "A". Road test tractor fo_,_)roperstopping distance as stated above. Readjust if-necessary. If stopping distance is still greater than six (6) feet in highest gear, further maintenance is necessary. Contact your nearest authorized service center/department. FIG. 27 22 ............... oi SERVICEANDADJUSTMENTS TO ADJUST MOTION CONTROL LEVER TO CHECK TOE-IN (See Fig. 29) (See Fig. 28) The motion control lever has been preset at the factory and adjustment should not be necessary. • • If for any reason the motion control lever will not hold its positionwhile at a selected speed, it may be adjusted at the fdction pack located on the right side of transmission. • • • Park tractor on level surface. Stop tractor by tuming ignition key to "OFF" position, and engage parking brake. Adjust motion control lever by tightening adjustment Iocknut one half (1/2) turn. NOTE: If for any reason the effort to move the motion control lever becomes too excessive, reverse the above adjustment procedure by loosening Iocknut 1/4 to 1/2 turn. Road test tractor after adjustment and repeat procedure if necessary. Position front wheels straight ahead. Measure distance between wheels at front and rear of tires (dimensions "A" and "B"). Front dimension =A"shouldbe 118"to 1/4" lessthan rear dimension =B'. TO ADJUST TOE-IN (See Figs. 29 and 30) • Loosen jam nuts at adjustment sleeves on tie rod. • Adjust tie rod untildimension =A"is 1/8" to 114"less than dimension =B_. • Tighten jam nuts securely. FRONT WHEEL CAMBER The front wheel camber is not adjustable on your tractor. If damage has occurred to affect the front wheel camber, contact your nearest authorized service center/depart, ment. B A FIG. 29 ADJUSTMENT LOCKNUT FIG. 28 _TRAN-SMISSION REMOVAL/REPLACEMENT Should your transmission require removal for service or replacement, itshould be purged after reinstallationbefore operating the tractor. See =PURGE TRANSMISSION" in Operation section of this manual. TO ADJUST STEERING WHEEL ALIGNMENT If steering wheel crg_sbars are not horizontal (left to right) when wheels are positionedstraightforward, remove steering wheel and reassemble per instructionsin the Assembly section of this manual. FRONT WHEEL TOE-IN ADJUSTMENT Front wheel toe-in isrequired for proper steering operation. Toe-in was set at the factory and adjustment should not be necessary, if parts in the front axle or steering mechanism have been replaced or damaged, check toe-in and adjust -_-nec=lbssary. TO REMOVE WHEEL FOR REPAIRS (See Fig. 31) • • Block up axle securely. Remove axle cover, retaining ring a,ndwashers to allow wheel removal (rear wheel contain_ a square key - Do not lose). • Repair tire and reassemble. • On rear wheels only: align grooves in rear wheel hub and axle. Insert square key. • Replace washers and snap retaining ring securely in axle groove. • Replace axle cover. NOTE: To seal tire punctures and prevent flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and 23 corrosion. S ERV I Nb ;ADj UST MENTS IERS RETAINING RING "POSITIVE" (+) - (-) LH. PANEL BOLT AXLE COVER -- "NEGATIVE" FIG. 31 TO START ENGINE WITH A WEAK BATTERY (See Fig. 32) CAUTION: Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. ° FIG. 32 TO REPLACE HEADLIGHT BULB • Raise hood. If your battery is too weak to start the engine, it should be recharged. If "jumper cables • are used for emergency starting, follow this procedure: IMPORTANT: YOUR TRACTOR IS EQUIPPED WITH A 12 VOLT NEGATIVE GROUNDED SYSTEM. THE OTHER VEHICLE MUST ALSO BE A 12 VOLT NEGATIVE GROUNDED SYSTEM. DO NOT USE YOUR TRACTOR BATTERY TO START OTHER VEHICLES. • Pull bulb holder out of the hole in the backside of the grill. • Replace bulb in holder and push bulb holder securely back into the hole in the backside of the grill. Close hood. TO A'I-rACH JUMPER CABLES • Connect each end of the RED cable to the POSITIVE (+) terminal of each battery, taking care not to short against chassis. • Connect one end of the BLACK cable to the NEGATIVE (-) terminal of fully charged battery. Loose or damaged wiring may cause your tractor to run poorly, stop running, or prevent it from starting. • Replace with 30 amp automotive-type plug-in fuse. The fuse holder is located behind the dash. • INTERLOCKS • ~ TO REMOVE CABLES, REVERSE ORDER - FUSE TO REMOVE HOOD AND GRILL ASSEMBLY (See Fig. 33) •"'- BLACK-_.able first from chassis and then from the fully charged battery. • Check wiring. See electrical wiring diagram in the Repair Parts section of this mar.ual. TO REPLACE Connect the other end of the BLACK cable to good CHASSIS GROUND, away from fuel tank and battery. AND RELAYS RED cable last from both batteries. 24 • Raise hood. • Unsnap headlight wire connector. • Standinfrontoftractor. Grasphoodatsides, tilttoward engine and lift off of tractor. • To replace, reverse above procedure. SERVICE ANDADJUSTMENTS IMPORTANT: NEVER TAMPER WITH THE ENGINE GOVERNOR, WHICH IS FACTORY SET FOR PROPER ENGINE SPEED. OVERSPEEDING THE ENGINE ABOVE THE FACTORY HIGH SPEED SETTING CAN BE DANGEROUS. IF YOU THINKTHE ENGINE-GOVERNED HIGH SPEED NEEDS ADJUSTING, CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER/ DEPARTMENT, WHICH HAS PROPER EQUIPMENT AND EXPERIENCE TO MAKE ANY NECESSARY ADJUSTMENTS. HOOD STOP HEADUGHT WIRE CONNECTOR FIG. 33 SWIVEL ENGINE TO ADJUST THROTTLE CLAMP SCREW CONTROL CABLE FIG. 34 (See Fig. 34) The throttle control has been preset at the factory and adjustment should notbe necessary. Checkadjustment as described below before loosening cable. If adjustment is necessary, proceed as follows: • With engine not running, move throttle control lever to fast position. Check that swivel is against stop. If it is not, loosen cable clamp screw and pull cable back until swivel is against stop. Tighten cable clamp screw securely. • TO ADJUST CHOKE CONTROL (See Fig. 35) The choke control has been preset at the factory and adjustment should not be necessary. Check adjustment as described below before loosening cable. If adjustment is ._necessa_'y, proceed as follows: ....• With-engine not running, move choke control (located on dash panel) to full choke position. • Loosen knob and remove cover assembly from air cleaner. • Choke should be closed. If it is not, loosen casing clamp screw and move choke cable until c h0ke is completely closed. Tighten casing clamp screw securely. Replace air clea'_er cover assembly and tighten knob. " • TO ADJUST CLAMP SCREW FIG. 35 CARBURETOR Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your tractor to an authorized service center for repair and/or adjustment. High speed stop is factory adjusted. damaqe may result. Do not adjust - 25 STORAGE Immediately prepare your tractor for storage at the end of the season or if the tractor will not be used for 30 days or ENGINE mora. FUEL SYSTEM CAUTION: Never store the tractor with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. TRACTOR Remove mower from tractor for winter storage. When :mower is to be stored for a period of time, clean it thor5ughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. • Clean entire tractor (See'CLEANING" inthe Customer Responsibilities section of this manual). • Inspect and replace belts, if necessary (See belt replacement instructions inthe Service and Adjustments section of this manual). • Lubricate as shown in the Customer Responsibilities section of this manual. • Be sure that all nuts, bolts and screws are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. • Touch up all rusted or chipped paint surfaces; sand lightlybefore painting. IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK DURING STORAGE. ALSO, EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS (CALLED GASOHOL OR USING ETHANOL OR METHANOL) CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION AND FORMATION OF ACIDS DURING STORAGE. ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE. • Drain the fuel tank. • Start the engine and let it run until the fuel lines and carburetor are empty. • Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. Use iresh fuel next season. • NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer. ENGINE Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Customer Responsibilities section of this manual). BATrERY • Fully charge the battery for storage. • After a period of time in storage, battery may require recharging. • • CYLINDER(S) To help prevent corrosion and power leakage during long periods of storage, battery cabl=.s should be disconnected and battery cleaned thoroughly (see "TO CLEAN BATTERY AND TERMINALS" in the Customer Responsibilities section of this manual). % •- After cleaning, leave cables disconnected and place cables where they cannot come in contact with battery termk]aJs. Be sure-battery drain tube is securely attached. • . If battery is removed from tractor for storage, do not store battery directly on concrete or damp surfaces. OIL • Remove spark plug(s). • Pour one ounce of oil through spark plug hole(s) into cylinder(s). • Turn ignitionkeyto"START" position for a few seconds to distribute oil. • . Replace with new spark plug(s). OTHER • Do not store gasoline from one season to another. • Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. • If possible, store your tractor indoors and cover it to give protection from dust and .dirt. • Cover your tractorwith a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensati0h to form and will cause your tractor to rust. IMPORTANT: NEVER COVER TRACTOR WHILE ENGINE AND EXHAUST AREAS ARE STILL WARM. 26 TROUBLESHOOTING PROBLEM Will not start CORRECTION CAUSE 1. 2. 3. 4. 5. 6. 7. Out of fuel. Enginenot'CHOKED" properly. Engine flooded. Bad sparkplug. Dirtyair filter. Dirty fuelfilter. Waterin fuel. 8. 9. Looseor damagedwiring. Carburetoroutof adjustmanL 10. POINTS 1. 2. 3. 4. 5. 6. 7. Fillfueltank. See .T') START ENGINE"in Operationsec'don. Wait several minutesbeforea"_mptingto start. Replacesparkplug. Clean/replaceair filter. Replacefuel filter. Drainfuel tankandcarburetor,refilltankwith fresh gasolineand replacefuelfilter, 8. Checkallwiring. 9. See "ToAdjustCarburetor"in ServiceAdj_nts section. 10. Contactan authorizedservicecenter/deparlment. Engine valves out of edjustmenL I Hard to start Engine will not tum over Engine clicks but will not start . Loss o_fpower Excessive vibmtlon 1. 2. 3. 4. 5. 6. 7. Dirty air filter. Bad spark plug. Weak or dead battery. Dirty fuel filter. Stale or dirty fuel. Loose or damaged wiring. Carburetor out of adjustment. 1. 2. 3. 4. 5. 6. 7. Clean/replace air filter. Replace spark plug. Recharge or replace battery. Replace fuel filter. Drain fuel tank and refill with fresh gasoline. Check all wiring. See "To Adjust Carburetor" in Service Adjustments secfion. 8. Engine valves out of adjustment. 8. Contact an authorized service center/department. 1. 2. 3. 4. 5. 6. 7. 8. 9. Clutch/brakepedalnot depressed. Attachmentclutchis engaged. Weak or deed battery. Blownfuse. Corrodedbatteryterminals. Looseor damagedwiring. Faultyignitionswitch. Faultysolenoidor starter. Faultyoperatorpresenceswitch(es). 1. 2. 3. 4. 5. 6. Depress dutch/brake pedal. Disengage attachment dutch. Recharge or replace battery. Replace fuse. Clean battery terminals. Check all wiring. 7. 8. 9. Check/replace ignition switch. Check/replace solenoid or starter. Contact an authorized service center/department. 1. 2. 3. 4. Weak or dead battery. Corroded battery terminals. Loose or damaged widng. Faulty solenoid or starter. 1. 2. 3. 4. Rechargeor replacebattery. Clean batteryterminals. Checkall wiring. Check/replacesolenoidor starter. 1. 2. Cutting too much graseitoo fast. Throttle in "CHOKE" position. 3. 4. 5. 6. 7. 8. 9. Build-up of grass, leaves and trash under mower. Dirty air filter. Low oil level/dirty oil. Faulty spark plug. Dirty fuel filter. Stale or dirty fuel. Water In fuel. "'" 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Spark plug wire loose. Dirty eng!ne air screen/fins. Dirty/dogged muffler. Loose or damaged wiring. Carburetor out of edjustmanL 10. 11. 12. 13. 14. 15. Engine valves out of adjustment. 15. Set in"HigherCut"position/reducespeed. Adjustthrot'decontrol. Cleanundersideof mowerhousing. Clean/replaceair filter. Checkoillavel/changa oil. Cleanandregapor change sparkplug. Replacefuel filter. Drainfuel tank and refillwithfresh gasoline. Drainfueltank and carb(Jretor,refilltankwith fresh gasolineand replacefuelfilter. Connectandtightensparkplugwire_ Cleanengineairscreen/fins. " Clean/replacemuffler. Checkall wiring. See"ToAdjustCarburetor"in Service Adjustments section. Contactan authorizedservice centerldepartment. 1. 2. 3. 1. 2. 3. Worn, bent or loose blade. Bent blade mandrel. Loose/damaged part(s). 27 Replace blade. Tighten blade boll Replace blade mandrel. Tighten loose part(s). Replace damaged parts. r : PROBLEM TROU B LESH OOTIN G POINTS ::_ Engine continues to run when operator leaves seat with attachment clutch CORRECTION CAUSE 1. Faulty operator-sefety presence control system. 1. Check wiring, switches and connections. If not corrected, contact an authodzad service canted departmenL 1. 2. Wom, bent or loose blade. Mower deck not level. 1. 2. Replace blade. Tighten blade bolL Level mower deck. 3. 4. Buildup of grass, leaves, and trash under mower. Bent blade mandrel. 5. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels. 3. 4. 5. Clean underside of mower housing. Replace blade mandrel. Clean around mandrels to open vent holes. 1. 2. 3. 4. Obstruction in clutch mechanism. Wom/damagad mower drive belt. Frozen idler pulley. Frozen blade mandrel. 1. Remove obstruction. 2. 3. 4. Replace mower drive belt. Replace idler pulley. Replace blade mandrel. 1. Engine speed too slow. Travel speed too fasL Wet grass. Mower deck not level. Low/uneven Ura air pressure. Worn, bent or loose blade. Buildup of grass, leaves and trash under mower. Mower dave belt worn. Blades improperly installed. Improper blades used. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels. engaged Poor cut-uneven Mower blades will not rotate Poor grass discharge 2. 3. 4. 5. 6. 7, 8. 9. 10. 11. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Place throttlecontrolin "FAST"position. Shifttoslowerspeed. Allowgrassto drybeforemowing. Levelmower deck. Checktires for properair pressure. Replace/sharpenblade. Tighten blade boll Clean undersideof mowerhousing. Replacemower davebell Reinstallbladessharpedge down. Replacewithbladeslistedin this manual. Cleanaroundmandrels to openvent holes. Headlight(s) not working (if so equipped) 1. 2. 3. 4. 5. Switch is "OFF'. Bulb(s) bumed out. Faulty light switch. Loose or damaged widng. Blown fuse. 1. 2. 3. 4. 5. Tum switch "ON". Replace bulb(s). Chack/replace light switch. Check widng and connections. Replace fuse. Battery will not charge 1. 2. 3. 4. Bad battery cell(s). Poor cable connections. 1. 2. Replace battery. Check/clean all connections. Faulty regulator (if so equipped). •Faulty alternator. 3. 4. Replace regulator. Replace alternator. i Loss of dr_e Engine "backfires" _ when turning engine "OFF" 1. 2. 3. Freewheelcontrolin "disengaged'position. Motiondrive beltworn,damaged,or broken. Air trappedin transmissiondudngshipment or servicing. 1. 2. 3. Place freewheel control in "engaged" position. Replace motion drive bell Purge transmission. 1. Engine throttle control not set'at =SLOW" position for 30 seconds before stopping engine. 1. Move throttle control to "SLOW" position and allow to idle for 30 seconds before stol_ging engine. 28 TRACTOR .... SCHEMATIC - - MODEL NUMBER AYP9187B89°: 11 _, "* RED BLACK BATrERY RED RED i) FUSE 30 AMP. WHn_ ) G , t I I I STARTER , '©:O' BLACK qF I SOLENOID CLUTCH / BRAKE (PEDAL UP) Lq WHITE SEAT SWITCH (NOT OCCUPIED) IGNITION SWITCH WHITE |_-_l .... I _1 I ' I I I I l BLACK I- I BLACK GROUNDING CONNECTOR I (CLUTCH OFF) METER HOUR _) d SPARK (OPTIONAL) d IGNITION UNIT • I GAP PLUG _ PLUGS ON _ TWIN CYL. ENGINES) . • • CHARGING SYSTEM OUTPUT 3 AMP DC Q 3600 RPM I ORANGE BLUE [ SYSTEM OUTPUT SAMPACO3SOo_IODE _'14 YOUR TRACTOR IS EQUIPPED WITH A SPECIAL ALTERNATOR SYSTEM. THE LIGHTS ARE NOT CONNECTED TO THE BATTERY, BUT HAVE THEIR OWN ELECTRICAL SOURCE. BECAUSE OF THIS, THE BRIGHTNESS OF THE LIGHTS WILL CHANGE WITH ENGINE SPEED. AT IDLE THE LIGHTS CIRCUIT OFF G + M+ L RUN/LIGHT B+ L RUN B+ L START B+ L + S "MAKE" NONE A+ Y NONE NONE ;ALTERNATOR UGHTING NOTE PosmoN F 3600 RPM DISCONNECTED) j FUEL SHUT-OFF SOLENOID IGNITION SWITCH 28 VOLTS AC MIN. • (CHARGING SYSTEM F VOLTS AC MIN, 0 3600 RPM (LIGHTS I OFF) BROWN HEADLIGHTS m A WILL DIM. AS THE ENGINE IS NON-REMOVABLE SPEEDED UP, THE LIGHTS CONNECTIONS WILL BECOME THEIR BRIGHTEST. ---O-REMOVABLE CONNECTIONS WIRING INSULATED CLIPS NOTE: IF WIRING INSULATED CLIPS WERE REMOVED FOR SERVICING OF UNIT, THEY SHOULD BE REPLACED TO PROPERLY SECURE YOUR WIRING. 29 I', _-. ,_ REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 ELECTRICAL \ 21 / I \ I 1 1 I I 41 " i ii I! \1 26 | I 19 I 2O I r-- I I _j_\| I \'4 I ! | 25 | | t | I | ! I % \ I I 29 30 REPAIR. PARTS TRACTOR - - MODEL NUMBER AYP9187B89 ELECTRICAL KEY PART NO. NO. 1 2 3 4 6 8 10 11 12 16 19 20 21 22 24 25 26 28 29 30 31 32 33 40 41 42 43 44 45 52 55 70 163465 74760412 19091016 10040400 73220400 7603J 145211 150109 145769 153664 10090400 73350400 136850 4152J 4799J 146148 108824X 145491 121305X 140301 124211X 141226 122147X 156442 71110408 131563 145673 73640400 121433X 141940 17490508 140422 DESCRIPTION Battery 12 Volt 28 Amp w/acid Bolt Hex Hd 1/4-20unc X 3/4 Washer 9/32 X 5/8 X 16 Ga Washer Lock Hvy Helical 1/4 Nut Fin Hex 1/4-20 Unc Tray Battery Bolt Batry. Front Hold Down Battery Front Nut Push Nylon 1/4" Switch Interlock Push-In Washer Lock 1/4 Nut Jam Hex 1/4-20 Unc Harness Socket Light w/4152J Bulb, Light # 1156 Cable Battery 6ga 11" Red Cable Battery 6 Ga Red w/16 wire Fuse 30 Amp Auto Green Cable Ground 6ga 21"black Switch Plunger Nc Gray Switch Ign 4 Pos W/L P/I. Nut Ignition Cover Sw Key Key Ign Molded Generic Harness Ign Bolt Fin Hex 1/4-20uncx 1/2 Cover Terminal Red Solenoid Nut Keps BIk 1/4-20 Unc Ammeter Rectangular 6 Amp Protection Loop Screw Thrdol. 5/16-18 x 7.5 Harness Eng B&S 14 OHV Dual NOTE: All component dimensions given in UoS. inches 1 inch = 25.4 mm 31 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 CHASSIS AND ENCLOSURES 29 12 28 53 52 31 55 57 37 54 20 23 37 14 14 60 37 y_3 3 74 / 14 3 38_ 39 32 REPAIR PARTS. TRACTOR - - MODEL NUMBER AYP9187B89 CHASSIS AND ENCLOSURES KEY NO. 1 2 3 4 5 9 10 11 12 13 14 17 18 20 23 25 26 28 29 30 31 37 38 39 51 52 53 54 55 57 58 60 64 74 140 142 143 144 145 PART NO. 160392 140356 17490612 19131216 155272 161917X012 72140608 155927 145660 155936 17490608 159639X418 126938X 156437 124028X 19131312 73800600 157428 146654 151287X418 139976 17490508 139886 139887 73800400 19091416 144697 161464 144696 74780412 162266 72140606 154798 73680600 158418 156095 154966 154207 156524 DESCRIPTION Chassis Assembly Drawbar Screw Thdrol. 3/8-16 x 3/4 Ty-Tt Washer 13/32 x 3/4 x 16 Ga. Bumper Hood/Dash Dash Bolt Carriage 3/8-16 x 3/4 Panel Asm. Dash Lh Private label Clip Tinnerman Grile P/L Panel Dash Rh Lt Private label Screw Thdrol. 3/8-16 x 112Ty-Tt Hood Pnt Steel Private Label Bumper Hood Plate Mtg Battery/Fuel Tank Bushing Snap Nyl. BIk Fuel Line Washer 13/32 x 13116 x 12 Ga. Nut Lock Hex w/Insert 3/8-16 UNC Grill Private Lable Euro Lens Grille Private label Euro Fender/Footrest Bracket Fender Support Screw Thdrol. 5/16-18 x 112Tyt Bracket Asm. Pvt. Lh Mwr. Rear Bracket Asm. Pvt. Rh Mwr. Rear Nut Lock Hex W/Ins. 1/4-20 Washer 9/32 x 718 x 16 Ga. Lh Grille Bracket Screw Hex 8-18 x 7/8 Bracket, Grill Rh Bolt Fin Hex 1/4-20 x .75 Air Duct Intake B&S Intek Twin Bolt, Rdhd Sqnk 3/8-16 UNC x 314 Dash Lower STLT Nut Crownlock 3/8-16 unc Bracket Suspension Front Plate Reinforcement STLT Bracket Swaybar Chassis Bracket Pnt Footrest STLT Rod Pivot Chassis/Hood NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 33 REPAIR PARTS TRACTOR " - MODEL NUMBER AYP9187B89 DRIVE 59 32 30 / _ 97 36 16 95 _ ._ 30 61 16 27 22 24 77 O6 26 105 100 34 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 DRIVE KEY NO. 1 2 3 8 10 16 18-_ 19 21 22 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 42 47 48 49 50 51 52 53 55 56 57 59 61 62 63 PART NO. 150071 142431 143995 154792 76020416 73800500 74780616 73800600 106933X 145627 73350600 106888X 19131316 76020412 145204 124236X 130807 74760512 155071 120183X 19211616 1572H 123674X 74760644 4470J 154777 19131312 127783 154407 123205X 74760624 73680600 73680500 105710X 105709X 74760620 140294 149312 17490612 8883R 140186 DESCRIPTION KEY NO. PART NO. Transaxle (See Breakdown) Hydro Gear Model 319-0650 Spring, Retum, Brake Pulley, Transaxle Rod Shift Hydro LT Pin Cotter 1/8 x I CAD Nut Lock Hex W/Ins 5/16-18 Unc P Bolt Fin Hex 3/8-16 Unc x I Gr. 5 Nut Lock Hex W/Wsh 3/8-16 Unc Knob, Round 1/2-13 Rod, Brake Hydro Nut Spring, Brake Rod Washer Pin Cotter 1/8 x3/4 CAD. Rod, Parking Brake Cap, Parking Brake Red Bracket, Transaxle Bolt Hex Hd 5/16-18 Unc x 3/4 Shaft, Foot Pedal Bearing, Nylon Washer Pin, Roll Pulley, Idler, Flat Bolt Spacer, Split Keeper, Belt Idler Washer 13/32 x13/16 x12 Gauge Pulley, Idler, V-Groove Bellcrank Clutch Retainer, Belt Bolt Nut Crownlock 3/8-16 UNC Nut Crownlock 5/16-18 UNC Link, Clutch Spring, Return, Clutch Bolt Fin Hex 3/8-16 UNC x 1-1/4 V-Belt, Ground Drive Keeper, Center Span ScrewThdrol. 3/8-16x3/4Ty.TT Cover, Pedal Pulley, Engine 64 65 66 70 71 72 73 74 75 76 77 7R. 81 82 83 84 86 87 88 89 90 93 94 95 96 97 98 100 102 103 104 105 106 116 144 145 146 147 148 149 150 151 71170764 10040700 154778 134683 140158 19132012 156347 121199X 121749X 12000001 123583× 121748X 156046 123782X 19171216 161901 157480 19212016 12000008 158388 124346X 142564 140462 144643 4497H 140469 73510600 19111216 141322 73940800 140156 71070516 74780520 72110610 19111016 74490540 74490536 74490524 159103 122052X 150935 19133210 DESCRIPTION Bolt, Hex Washer Keeper Belt Engine Keeper Belt Engine Strap Torque Lh Hydro Washer 13/32 x 1-1/4 x 12 Gauge Strap Torque Rh Hydro Spacer, Split Washer 25/32 x 1-1/4 x 16 Gauge E-Ring Key, Square Washer 25/32 x 1-5/8 x 16 Gauge. Shaft Asm. Cross Hydro Spring Torsion T/A Washer 17/32 x 3/4 x 16 Ga. Rod, Tie Bushing Washer 21/32 x 1-1/4 x 16 Ga. Ring Klip #5304-62 Console, Hydro Nut Self Thd Wshd 114 Line Fuel Hydro 4" Fan, Hydro 7" Contro/Asm Bypass Hydro Retainer Spring 1" Zinc/Cad Keeper Belt Rh Hydro 0750. 18/20" Nut Keps Hex 3/8-16 Unc Washer 11/32 x 3/4 x 16 Ga. Washer Beliville .501D x 1.50D Nut, Hex, Jam Toplock 1/2-20 UNF Arm, Control Hydro Screw Cap Hex 5116 x 18 x 1 Bolt Fin Hex 5/16-18 Unc x 1-114 Bolt Rdhd Sq Neck 3/8-16 x 1.25 Washer Bolt Hex Flghd 5/16-18 x Gr. 5 Bolt Hex Flghd Bolt Hex Flghd Spacer Spacer Retainer Bushing Nylon Collered Nut Self Thd Wshd NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 35 REPAIR PARTS TRACTOR -- MODEL NUMBER AYP9187B89 STEERING ASSEMBLY €- -_p o • 39 • • ,= -. - -_-.-_?-.-;.. )-'I ' i -,''''--42 • I ;Y"""_a7 I 62 44 4O \ 25 \ 36 REPAIR PARTS TRACTORSTEERING - MODEL NUMBER AYP9187B89 ASSEMBLY KEY NO. 1 2 3 4 5 6 7 8 10 11 13 15 17 18 19 20 22 23 25 27 29 32 36 37 38 39 40 41 42 43 44 46 47 51 54 62 63 65 66 67 68 74 75 76 77 78 PART NO. 140044 137094 157479 157478 6266H 121748X 19272016 12000029 154432 10040600 154779 73901000 156546 57079 124035X 126684X 71200410 127501 154406 136874 17490612 137347 155099 152927 140045 19133808 781 OH 100711L 145054 121749X 153720 121232X 6855M 73800500 74780520 156594 74780616 154780 154404 74781044 154429 109850 109851 137156 73700600 73360600 .... DESCRIPTION Wheel Steering Ayp/keich BIk Axle Front Cast Spindle Asm LH Spindle Asm RH Bearing Race Thrust Harden Washer 25/32 X 1-5/8 X 16 Ga Washer 27/32 X 1-1/4 X 16 Ga Ring Klip #t5304-75 Link Drag Extended Cast Washer. Lock Hvy Hlcl Spr 3/8 Spacer.Bearing Axle Front Nut Lock Flange 5/8-11 Unc Shaft Asm Strg Washer Thrust 515x 750x 033 Support Shaft Washer Shim 114 X 5/8 X 062 Screw Hex Socket 1/4-20 x 518 Shaft Asm Pittman Bracket Steering Gear Sector 22 Teeth Screw Thdrol 3/8-16x3/4 Ty-tt Rod Asm Tie Ball Jt Adj Bushing Steering Screw Cap Wheel Steer Ayp Washer 13/32 x 2-3/8 x 8 Ga Nut Lock Center 3/8-24 Unf Adapter Wheel Strg .640/.635 Boot Shaft Steering Washer 25/32 X 1 1/4 X 16 Ga Shaft Extension Steering Non Adjust. Cap Spindle Fr Top BIk Fitting Grease Nut Lock Hex W/Ins. 5/16-18 Unc P Bolt Fin Hex 5/16-18 Uric P Kit, Steering Assembly Bolt Fin Hex 3/8-16unc x 1 Spacer Axle Bearing Arm Pittman Bolt Fin Hex 5/8-11 Unc x 2-3/4 Brace Axle Joint Asm Ball Rh Joint Asm Ball Lh Rod Tie Ball J Adj Nut Hex Jam 3/8-24 Unf Lh Nut Hex Jam 3/8-24 Unf NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 37 REPAIR PARTS TRACTOR - -MODEL NUMBER AYP9187B89 SEAT ASSEMBLY +.._ 14 I i I i I ! J i I i I i I 26 23 KEY NO. 1 2 3 4 5 6 7 8 9 10 12 13 PART NO. 140117 140551 _ 74760616 19131610 145006 73800600 124181X 17490616 19131614 155925 121246X 121248X KEY NO. DESCRIPTION Seat Bracket Pivot Seat 8 720 ': Bolt Fin Hex 3/8-16 Unc x 1 V_sher Flat 13/32 x 1 x 10 Ga Clip Push In Hinged Nut Crownlock 3/8-16 Unc Spring Seat Cprsn 2 250 BIk Zi Screw Thdrol 3/8-16 X 1 Ty-tt Washer 13/32 X 1 X 14 Ga Pan Seat Bracket Mounting Switch Bushing Snap BIk Nyl 50 Id 14 15 16 17 21 22 23 24 25 26 PART NO. 72050412 134300 121250X 123976X 153236 73800500 74780814 19171912 127018X 10040800 DESCRIPTION Bolt Carriage 1/4-20x1-1/2 Spacer Split 28x 96 Yel Zinc Spring Cprsn 1 27 BIk Pnt Nut Lock 1/4 Lge F"r_q Gr-5 Zinc Bolt Shoulder 5116-18 Unc Blkz Nut Lock Hex w/Ins 5/16-18 Unc Bolt Fin Hex 1/2-13 X 718 Gr 5 Washer 17/32 X 1-3/16 X 12 Ga Bolt Shoulder 5/16-18 X 62 Washer Lock Hvy Hlcl Spr 1/2 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 38 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 DECALS : ...d 9 -13 2 3 18 12 12 18 10 4 20 11 8 13 5 15 14 7 KEY NO. 1 2 3 4 5 6 7 8 9 PART NO. 156811 143470 141579 141580 273727 141583 162700 141517 127520 WHEELS 6 KEY NO. DESCRIPTION Decal, Decal, Decal, Decal, Decal, Decal, Decal, Decal, Decal, 10 11 12 13 14 15 18 20 ----- Oper. Instr. Fend STLTH Insert Strg Wizard Plus Hood, R.H. Hood, L.H. HP Engine Deck Mulching Wizard Plus Fender Auto Rad Wiz Mower Vented Wizard Plus USA White AND TIRES 4,10 11 PART NO. 157002 150218 162550 143349 160396 142341 143388 145005 138311 154515 154516 165113 KEY NO. PART NO. 1 2 3 4 5 6 7 8 9 10 11 -- 59192 65139 106222X 59904 106732X427 278H 9040H 106108X427 122082X 7152J 104757X 144334 DESCRIPTION Decal, Fender Danger Decal, Lens Logo Decal, Pnl Sd B&S Intek 18 Wiz Decal, Wiz Hyd 42" Decal, V-Belt Schematic Decal, Drawbar Control Mvt Hyd Name plate Hood Wizard Large Decal, Battery Dngr/Psn PI Sym Decal, Lift Handle Pad Footrest LH STLT Pad Footrest RH STLT Owner's Manual DESCRIPTION Cap Valve Tire Stem Valve Tire F Ts 15 X 6 0 - 6 Service Tube Front (Service Item Only) Rim Asm 6" front White Service Fitting Grease/_Front Wheel Only) Bearing Flange.(.Front Wheel Only) Rim Asm 8" rear White Service Tire R Ts 20 X 10-8 C Service Tube Rear (Service Item Only) Cap Axle BIk I 50 X 1 00 Sealant, Tire (10 oz. Tube) NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 39 RqPAI R PARTS ,_. TRACTOR - - MODEL NUMBER AYP9187B89 EN(_INE 2 1_ 15 14 I I 81 31 39 29 23 / OPTIONAL EQUIPMENT Spark Arrester 40 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 ERGINE KEY NO. PART NO. 1 2 148875 17720410 4 5 6 8 10 13 14 15 16 17 23 25 26 29 31 32 33 34 35 37 38 149723 160589 159955 150176 162797 273485 132803,3,, 13200300 11050600 17490624 159880 145996 73920600 137180 157103 140527 123487X 106082X 17490512 8543R ...... 39 62 72 61 109227X 10040500 71070512 128861 NOTE: DESCRIPTION Control Throt 36 LH Flag Screw Hex Thd Cut 1/4-20x5/8'T Engine, Briggs Model No. 407777 Muffler Asm Twin Lo-Tone • Exhaust Asm RH B&S 20 HP Vert Intek Exhaust Asm LH B&S 20 HP Vert Intek Bolt 5/16-18 UNC x 314 w/Sems Shield Heat Gasket Muffler Nipple Pipe 4-i/2" Elbow Std 90 Degree 3/8-18 Npt Washer Lock Ext Tooth 3/8 Screw Thdrol 3/8-16 X 1-1/2 Tt Shield Browning Control Choke Nut Keps 3/8-24 Unf Kit Spark Arrestor Tank Fuel Cap Asm Fuel Clamp Hose BIk Pad Spacer Screw Thdrol 5/16-18 x 3/4 Line Fuel 54" Plug Oil Drain (Order From Engine Manufacturer) Pad Idler Washer Lock Hvy Helical 5/16 Screw Hex Hd Cap Nut Flange 1/4-20 Starter Nut All component dimensions given in U. S. inches 1 inch = 25.4 mm 41 'REPAIR PARTS .,i TRACTOR - - MODEL NUMBER AYP9187B89 LIFT 7 ° ° \ / / 49 37 ,/ 3O 38 4O 1 3 26 4 6 6 2 11 5 4 12 13 19 13 2O i I 718 15 o.r i 20 15 31 _ 19 32 42 20 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 LIFT KEY NO. 1 2 3 4 5 6 7 8 11 12 13 15 16 17 18 19 20 23 24 25 26 27 28 29 30 31 32 36 37 38 40 41 49 50 PART NO. 159460 159471 105767X 12000002 19211621 120183X 125631X 122365X 139865 139866 4939M 127218 73350800 130171 73680800 139868 163552 110807X 19131016 2876H 76020308 126971X 73350600 138057 150233 140302 73540600 155097 123935X 17490512 19112410 155096 145212 110452X DESCRIPTION Wire Asm Inner W/Plunger Shaft Asm Lft RH Pin Groove E-dng Truarc #5133-62 Washer Pltd 21/32 X 1 X 21 Ga Bearing Nylon Grip Handle Fluted Button Plunger Red Link Lift LH Link Lift RH Retainer Soring Link Front Nut Jam Hex 1/2-13 Unc Trunnion BIk Zinc Nut Crownlock 1/2-13 Unc Arm Suspension Rear Retainer Spring Nut Special Washer 13/32 X 5/8 X 16 Ga Spring 2-1/8" Pin Cotter 3/32 X 1/2 Rod Adj Lift Zinc 7.49 Wrk Lg Nut Hex Jam 3/8-16 Unc Knob Inf 3/8-16 Unc BIk W/sym Trunnion Dp Stop Dbl Thds PLT Bearing Pvt. Lift Spherical Nut Crownlock 3/8-24 Pointer Height Indicator Plug Hole BIk 1.485 / 1.515 Dia. Screw Thdrol 5/16-18 x 3/4 Washer 11/32 x 1-1/2 x 10 Ga. Indicator Height STLT Nut Hex Flange Lock Nut Push Phos & Oil NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 43 REPAIR PARTS TRACTOR MOWER -- MODEL NUMBER AYP9187B89 DECK 102 103 34 I I I I 105 / ,33 32 31 106 101 21 22 113 111 _[_23 24 ! \ 2 119 16 118 28 29 18 5 6 21 27 REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 MOWER DECK KEY NO. 1 2 3 4 5 6 8 9-_ 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 40 41 43 -44 45 46 48 49 50 51 52 53 54 55 56 PART NO. 164961 72140506 138017 138440 4939M 130832 850857 10030600 140296 134149 129895 137645 128774 110485X 140329 72110610 72140505 132827 159770 73680500 134753 131267 105304X 123713X 110452X 130968 19111016 131491 157722 129963 153535 137266 72110614 133835 131494 19131316 73680600 133551 149083 140088 4497H 137729 133944 155066 131340 _ 69180 , 139888 131845 133943 155046 122052X KEY NO. DESCRIPTION PART NO. DESCRIPTION Spring Torsion Brakes 42" Guard TUV Idler Knob Rd V-Belt Mower Rod Clutch Primary 38/42 Spring Return Arm Clutch Secondary Washer 25/32 X 1-5/8 X 16 Ga Ring Klip #15304-75 Bolt Shoulder 3/8-16 Unc 1 44 Keeper Spring 4 060 Lever Asm Clutch Primary P/LBushing 747 Od X 794 Lg Brass Spr;l_gClutch Mower 2 750 Zinc Nut Hex Jam 3/8-16 Unc Trunnion Adj Washer Sintered Keeper Belt Idler Bolt Carriage 3/8-16 x 2-1/2 Nut Lock Hex w/Ins 3/8-16 Unc Cover Mulching 42" Black Screw Washer #10 Washer Lock #10 Latch Asm Bagger Nut Weld Bracket Gauge Wheel LH 42" deck Bracket Gauge Wheel RH 42" deck Screw Thdrol 5/16,18 X 3/4 Tyt Nut Keps 5/16-18 Unc Bolt Carr 5/16-unc X 1/2 Bolt Shoulder Wheel Gage Nut Crownlock 3/8-16 Unc Washer 12/32 x 14/16 x 12 Ga. Bracket Extruded Gauge Wheel Washer, Felt Washer 13/32 x 13116 x 12 Ga. Bolt Fin Hex 3/8-16 UNC x I Gr. 5 Bolt, RdHd Sqnk 3/8-16 UNC x 1 Washer 13/32 x 1-3/8 x 3 Ga. Washer Thrust .75 x 1.230 Mandrel Asm Service (Includes Key Nos. 8-10, 12-15, 31 and 33) Mower Deck Complete (Std. Deck - - 164963 Order seperately Mulcher Plate and Gauge Wheel cojnponents and mulch components, Key Nos. 101106 and 111-121.) NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm Mower Housing Bolt Rdhd Sqnk 5/16-18unc X 3/4 Bracket Asm Fr Sway Bar 38/42 Bracket Asm Deck 42" sway Bar Retainer Spring Arm Suspension Rear Bolt 3/8-24 X 1 114 Washer Lock Hvy 3/8 Washer Hard Blade Mower Vented Blade Mulching 42" Bearing Ball Shaft Asm W/lower Bearing Housing Mandrel Vented Bearing Ball Mandrel Stripper Mower Vented Bolt Rdhd Sqnk 3/8-16 X 1-1/4 Bolt Rdhd Sqnk 5/16-18 X 5/8 Bolt Shoulder Baffle Vortex 42 Nut Crownlock 5/16-18 UNC Stiffener Bracket 42" deck Bracket Deflector Mower42" Cap Sleeve 80x 112 BIk Mower Spring Torsion Deflector 2 52 Nut Push Phos & Oil Shield Deflector Mower 42" BIk Washer11/32 X 5/8 X16 Ga Rod Hinge 42" 6 75 Wig Screw Thdrol Washer Head Washer Spacer Mower Vented Pulley Mandrel42" Nut 9/16 Top Lock Flng Bolt Rdhd 3/8-16uncx1-3/4Gr5 Fastner Christmas Tree Pulleyldler Flat 3 060 Washer 13/32x 13/16x 16 Ga Nut Crownlock 3/8-16 UNC Rod PivotW/nibs Rod Clutch Secondary W/nibs Guard Mandrel LH Black Spring Retainer 1" Zinc/cad Screw Hex Thd Cut Washer Hardened Smaller Roller Asm Cam Follower 42" dec Bolt Shldr 10-24 Zinc Gr 5 42" Nut Lock #10-24 Unc --_Bolt Shoulder 5/16-18 Unc Blkz ,..Arm Asm Pad Brake Washer Hardened Arm Idler 42" mower LT/YT Spacer Retainer Pm Mower 58 59 67 68 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 92 101 102 103 104 105 106 111 112 113 114 115 116 117 118 119 121 128 129 130 131 132 141 -- 45 140086 141043 162132 144200 142427 131870 127847 121748X 12000029 128903 127845 160570 127498 153701 73350600 142028 120958X 156084 72140620 73800600 136420 71161010 19061216 10071000 160793 2029J 155197 155198 17490512 73510500 72110504 137644 133957 73930600 19121414 143723 153390 19131312 74780616 72140608 19132203 6266H 130794 REPAIR PARTS TRACTOR-" MODEL NUMBER AYP9187B89 HYDRO TRANSAXLE - MODEL NUMBER319-0650 58 26 23 ! 19 90 53 52 91 -36 35 46 REPAIR PARTS TRACTOR HYDRO TRANSAXLE KEY PART NO. NO. 1 2 3 4 5 6 7_ 8 9 13 14 15 17 18 19 23 24 25 26 27 28 29 30 34 35 36 37 38 39 40 41 142930 142931 142932 142928 142933 142934 142935 150771 142937 142938 142939 142940 142941 150772 150773 142944 142945 142946 150774 142948 142949 142950 150787 142951 142952 142953 142964 142955 150777 150778 142958 - - MODEL NUMBER AYP9187B89 - MODEL NUMBER 319-0650 DESCRIPTION Housing, Lower Assembly, Upper Housing Seal, Lip Ring, Wire Retaining Ring, Retaining Bearing, Shaft Ball Bearing, Cradle Bearing, Thrust 30 x 52 x 13 Swashplate, Variable Block, Cylinder Assembly Arm, Trunnion Seal, Lip Guide, Slot Shaft, Motor Bearing, Thrust 42 x 68 x 16 Block, Cylinder Assembly Seal, Lip 10 x 25 x 7 Actuator, Bypass Center Section Assembly Kit Seal, Lip 26 x 42 x 8 Ring, Retaining Washer 26 x 35 x 1 Plate, Bypass Oil Filter Element Arm, Bypass Ring, Retaining Arm, Actuating Pin, Actuating Bolt 5/16-24 x 1-3/4 Locknut, Hex 5/16-24 UNJC Brake Rotor/Stator Kit KEY PART NO. NO. DESCRIPTION 43 44 52 53 56 58 59 62 63 64 68 69 83 85 88 89 90 91 92 93 113 114 119 134 135 139 140 Washer 7116 x 7/8 x .060 Differential Assembly Washer 3/4 x 1.5 x .13 Seal .75 x 1.25 x .250 Shaft, Input Bolt 114-20 x 1.38 Pin .50D x .43 ID x .750 Arm, Control Puck, Dampener Set Screw Spring Stud 5/16-24 Jackshaft Assembly Jackshaft Screw, Cap Washer 7/16 x 1 x 1/2 Sleeve Bearing Seal, Wiper Spring, Block Washer, Block Thrust Cap, Vent Assembly Fitting, O-Ring Assembly Spacer Nut, Castle 5/16-24 Pin, Cotter Spring, Compression Nut, Hex 5/16-24 142884 150829 142991 142961 142963 142964 142965 142966 142967. 142920 142969 144610 142971 150806 142973 142974 142975 142976 142977 142978 142917 142918 142980 144607 144608 150775 150776 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 47 REPAIR PARTS ' TRACTOR BRIGGS & S.TRA'I-I'ON - - MODEL NUMBER ENGINE - MODEL NUMBER AYP9187B89 407777, TYPE NUMBER 0119-E1 12 15Q]I 823T 11_11_ '_"REQUIRES SPECIAL TOOLS TO INSTALL. SEE REPAIR INSTRUCTION MANUAL 592 s 87 E) IB! 195 20_ 190 46 146 26 741 7 -'__ o 27 48 REPAIR PARTS TRACTOR BRIGGS &.STRATFON - - MODEL NUMBER AYP9187B89 ENGINE - MODEL NUMBER 407777, TYPE NUMBER 0119-E1 5'1 * TO ReOUmes INSTALL SEE REPAIR _k REQUIRES SPECIAL TOOLS TO INSTALL SEE REPAIR INSTRUCTION MANUAL INSTRUCTION MANUAL 51 \ 7 1022 lo=S I 1022 211 loe 615A 615 _:_ 6340 87 -O 351 216 49 REPAIR PARTS " TRACTOR BRIGGS & ST.RATrON ENGINE - - MODEL NUMBER AYP9187B89 - MODEL NUMBER 407777, TYPE NUMBER 0119-E1 iiii, 119! 881 1411 t 95 t 823 102 823 108_ 222 265 351 3O5 3O5 1005 .:=, 163 7s 865B 188 1006 5O _'_ _ REPAIR PARTS TRACTOR- - MODEL NUMBER AYP9187B89 BRIGGS &oSTRATTON ENGINE - MODEL NUMBER 407777, TYPE NUMBER 0119-E1 802 783 i 10901 615B 31 8O3 544 i I i i _482 51 592A REPAIR PARTS TRACTOR BRIGGS & STRATTON - - MODEL NUMBER AYP9187B89 ENGINE - MODEL NUMBER 407777, TYPE NUMBER 0119-E1 523 116C % __ iii 1035 _. 1027 52_ 788 116D ,1,'977 CARBURETOR GASKET SET . s_ . 358 GASKET-SET 20@ " ______ 355 lo, _ 1soi_ 98T 116_ 116A_ - CAR'BURETOR 'e121 51 _'_ 633 @ s_ SlAL©_©J sss_ .= KIT' 117_ -- i., A-103,3 VALVE OVERHAUL KIT .- ' _ - 1oo +,o+= ! ,_o_ J_l 116 _:_ 355 _ 116A _ 987 (_ _J 868 _ 633 @ 52 I0",_ REPAIR PARTS TRACTOR BRIGGS KEY PART NO. NO. 1 2 3 4 5 5A 6 7 8 91011 12 13 15 16 20 22 23 24 25 26 27 28 29 32 33 34 35 40 42 45 46 50 51 -51A 53 73 75 78 97 89 95 98 102 104 105 108 110 &.STRATrON ENGINE - - MODEL NUMBER AYP9187B89 - MODEL NUMBER 407777, TYPE KEY PART NO. NO. DESCRIPTION 499584 Cylinder Assembly 499585 Bushing, Cylinder 690926 * Seal, Oil 690069 Sump, Engine 499587 Head, Cylinder No. 1 499595 Head, Cylinder No. 2 690097 Washer, Flat 690962 _* Gasket, Cylinder Head 499601 Breather Assembly 690937 * Gasket, Breather 691003 Screw, Hex 690942 Tube, Breather 690945 * Gasket, Crankcase 690360 Screw, Cylinder Head (3-9/16") 690946 Plug, Oil Drain 691046 Crankshaft 690947 * Seal, Oil 690308 Screw, Crankcase Cover 691054 Flywheel 690974 Key, Flywheel 499588 Piston Assembly (Std.) 499589 Piston Assembly (.010" O.S.) 499590 Piston Assembly (.020" O.S.) 499591 Piston Assembly (.030" O.S.) 499604 Ring Set, Piston (Std.) 499605 Ring Set, Piston (.010* O.S.) 499606 Ring Set, Piston (.020" O.S. 499607 Ring Set, Piston (.030" O.S. 690975 Lock, Piston Pin 499582 Pin Assembly, Piston 499583 Rod Assembly, Connecting 690976 Screw, Connecting Rod 499596 Valve, Exhaust 499597 Valve, Intake 690963 Spring, Valve 690964 Retainer, Valve 499586 Keeper Valve 690977 Tappet, Valve 690978 Gear, Cam 690948 Manifold, Intake 690949 *.O Gasket, Carb. Mounting 690950 *.• Gasl(et, Intake Manifold 690951 Stud, Carb. Mounting 691055 Screen, Rotating 691056 Washer, Spring 691057 Screw, Torx 690657 * Seal, Governor Shaft 690238 _ Plug, Oil _ZI 690718 Screw, Slotted 499802 _---Screw, Idle Speed 690234 0- Gasket, Plate 690984 ° Pin, Float Hinge 690985 • Valve, Needle 690986 Valve, Choke 691261 Washer NUMBER 0119-E1 DESCRIPTION 116 690987 116A 690988 116B 690589 116C 691031 116D 691032 117 690232 119 690990 119A 690991 119B 690992 119C 690720 121 499811 0. O-Ring, Solenoid Retainer 0. O-Ring, Fuel Transfer Tube * Seal, O-Ring (Oil Pump Cover) * Seal, O-Ring (Dipstick) * Seal, O-Ring (Oil Fill Tube) Jet, Main (Standard) • Screw, Phillips Screw, Phillips Screw, Phillips Screw, Phillips Carburetor Overhaul Kit 122 125 130 131 133 135 137 141 142 146 150 160 163 176 187 Spacer, Carburetor Carburetor Valve, Throttle Shaft, Throttle Floa[, Carburetor Tube, Fuel Transfer 0.Gasket, Float Bowl Shaft, Choke ° Nozzle, Carburetor Key, Timing 0-Gasket, Nozzle Retainer, Solenoid O'Gasket, AirCleaner Screw, T-30 Line, Fuel (Cut To Required Length) Line, Fuel Screw, He){ Screw, Torx Hex Adjuster, Rocker Arm Nipple, Oil Filter Spring.Governor Spring, Governed Idle Link, Throttle Bracket, Choke Control Link, Choke Gear, Governor Washer, Thrust Plate, Governor Control Lever Assembly, Governor 690952 499804 690993 499805 499806 499803 690994 499807 499808 94388 281767 690996 691001 691033 691050 187A 691049 188 691058 190 690953 192 690083 195 690954 209 690018 211 690019 212 691020 213 691021 216 691022 219 394348 220 690412 222 691023 227 691048 * • 0 O Included in Gasket Set, Part Number 499889 Included in Carburetor Lit, Part Number 499811 Included in Carburetor Gasket Set, Part Number 499890 Included in Valve Overhaul Gasket Set, Part Number 499890 i NOTE: All component dimensions giv'_nin-U.S, inches 1 inch = 25.4 mm 41 • 53 o o REPAIR PARTS TRACTOR - - MODEL NUMBER AYP9187B89 BRIGGS & ST.RATTON ENGINE - MODEL NUMBER 407777, TYPE NUMBER 0119-E1 KEY PART NO. NO. 240 252 256 258 265 277 304 305 309 310 311 332 333 334 337 351 355 358 363 383 387 445 467 474 482 510 523 525 544 DESCRIPTION 691035 690956 690957 691003 691024 691029 691004 691005 691262 691263 691264 690059 691060 691061 690965 691044 690997 499889 691062 690966 691034 691007 691008 691063 691183 497606 691036 691037 Filter, Fuel Element, Breather Retainer, Element Screw, Hex Clamp, Casing Nut, Hex Housing, Blower Screw, Hex Motor, Starter Screw, Hex Brush Set Nut, Flywheel Armature, Magneto Screw, Armature Mounting Spark Plug Screw, Hex .*(_ Washer, Seal Gasket Set Flywheel, Puller Wrench, Spark Plug Pump, Fuel Cartridge, Air Cleaner Nut, Air Cleaner Altemator Screw, Hex Drive, Starter Dipstick, Oil Tube, Oil Fill Armature, Starter (Service with 499529 Starter Motor) 552 690552 Bushing, Governor Crank 552A 690553 Bushing, Governor Crank 556 690967 Screw, Hex 562 690311 Bolt, Carriage 573 691009 Plate, Black 592 690958 Nut, Hex 592A 691029 Nut, Hex 601 691038 Clamp, Fuel Line 615 690328 Retainer, Govemor 615A 690317 Retainer, Govemor 615B 6912_65 Retainer 6t-6 .691045 Crank, Governor 633 690998 .0 Seal, Choke Shaft 634 690442 Washer, Flat 635 691210 Boot, Spark Plug 668 691215 Spacer 703 690010 Clip, Hose 718 690959 Dowel, Sleeve 726 499612 Gear, Ring 728 690372 _'ew, Torx_ 741 690980 G_ar, Timing 783 691280 Gear, Starter 788 691039 Bracket, Pump 789 691220 Hamess, Wiring 801 691283 Cap, Drive 802 691286 Cap, End 803 Housing, Starter (Service with 499529 Starter Motor) KEY PART NO. NO. DESCRIPTION 823 690960 847 499602 851 691234 855 691011 865 691012 865A 691013 865B 691015 Screw, Hex Dipstick/Tube Assembly Terminal, Ignition Cable Adapter, Air Cover, Air Guide Cover, Air Guide Cover, Air Guide "21Seal, Valve 868 690968 871 690969 Bushing, Guide 878 691237 Wire, Aitemator Plate, Cover 881 690999 "21Gasket, Exhaust 883 690970 918 691040 Hose, Vacuum Solenoid, Fuel 947 499809 965 499613 Cover, Oil Pump 967 691016 Filter, Pre-Cleaner 968 499788 Cover, Air Cleaner Bowl, Float 975 499810 Gasket Set, Carburetor 977 499812 987 691000 .0 Seal, Throttle Shaft 1005 691243 Fan, Flywheel 1006 691247 Retainer, Fan 1017 690770 Screen, Oil Pump Label Kit 1019 690103 1022 690971 *21Gasket, Rocker Cover 1023 499599 Cover, Rocker (Cyl. No. 1) 1023A 499600 Cover, Rocker (Cyl. No. 2) 1024 499054 Pump, Oil 1026 690981 Rod, Push (Steel) 1026A 690982 Rod, Push (Aluminum) 1027 690041 Filter, Oil 1029 690972 Arm, Rocker Valve Overhaul Kit 1033 499890 1035 691042 Shaft, Oil Pump 1036 499783 Label Kit, Emission Owner's Manual 1058 273694 Retainer, Brush 1090 691293 1100 690973 Pivot, Rocker Arm 2500 407777,0027 Replacement Engine RPM Settings: Low: 1750-1950 High: 3200-3400 * . 0 Included in Gasket Set, Part Number 499889 Included in Carburetor Lit, Part Number 499811 Included in Carburetor Gasket Set, Part Number 499890 21 Included in Valve Ovgrhaul Ga_sketSet.Part Number 499890 -NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm 54 SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION ONLY RIDE UP AND DOWN HILL, NOT ACROSS HILL SIGHTING _" _ .,.CUT OU'.. SIGHT AND HOLD THIS LEVEL WITH SKY LINE OR TREE. 15 ° MAX. l& greater than 15°), never across the face. Make turns gradually to prevent tipping or loss of control. Exercise extreme erate when your Tractor and downonthe face of slopes (not caution changingup direction slopes. HOW AND WHERE TO ORDER PARTS Jr 1. 2. 3. You can identify your product correctly by looking at its model number label which is located under the seat. A. Name the product that needs a part, for example: tractor. B. State the product's model numberand factory number. These numbers appear on a label on the product. List the description and part numberofthe partyou want. This manual shows drawings, descriptions, and part numbers. You may order from a participating Westem Auto store. If you cannot do that, please order direct from: Telephone: 1-800-633-8434 Western Auto National Parts Center 2107 Grand Avenue Kansas City, MO 64108 1_13:'_ctEV.1 04.20.98 PRINTED IN U.S.A. SJ
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