Bolens 135N604F401 Owner's Manual
Contents
1. The only way to insure the performance of your product is to use original equi Mulching Blades 742 0537 19 38 N A 742 0538 21 2 Upper Mulching Blades 742 0539 12 5 N A 742 0539 12 5 Mulching Kit Complete 190 096 000 N A 190 097 000 Grass Collector Optional 190 063 000 190 103 000 190 063 000 Illustrated Parts Lists 770 95 3C 770 95 3C 770 95 3C pment parts and accessories which are designed and engineered to exacting specifications When you substitute you take a chance on quality reliability safety and performance Use original equipment parts See your local service dealer For Parts Accessories or Service Information MasterCard CALL NOW 1 800 800 7310 8 00 AM to 8 00 PM Eastern Time Monday through Saturday off season hours may vary2. QOCOOQOOOOOOOOOOOOOOQOOOO0O Copy the information from your model plate here TA 4p Have your model numb available when you ca HO000 YARD MAN cLEVELAND OHIO 44136 Model No Engine Oil SAE 30 737 0208 737 0208 737 0208 top bo You o er 754 0440 Lower Throttle Control Wire 746 0501 746 0634 746 0638 Battery 725 1633 725 1635 725 1635 Steering Wheel 731 0806A 731 0806A 731 0806A Steering Wheel Insert 731 0955 731 0955 731 0955 Steering Bellow 731 0954 731 0954 731 0954 Front Wheel Cover 2 734 1787 734 1787 734 1787 Rear Wheel Cover 2 734 1788 734 1788 734 1788 Front Wheel Bearings 2 per whi 741 0487A 741 0487A 741 0487A Fuse 7 5 Amp 725 1625 725 1625 725 1625 Headlight Bulbs 2 725 0963 725 0963 725 0963 Fuel Cap 751 0603 751 0603 751 0603 Deck Wheel 734 0973 734 0973 734 0973 Ignition Key 725 1663 725 1663 725 1663 Drive Belt 754 0349 754 0441 754 0441 Deck Belt 754 0329A 754 0439 Upper 754 0371A High Lift Blades 742 0543 Center 742 0473A 2 742 0542 Outer 2 742 0499 2
3. loosen the four self tapping screws on the bottom of the seat See figure 2 Slide the seat forward or backward as desired Retighten the self tapping screws HYDROSTATIC NEUTRAL CONTROL ADJUSTMENT The hydrostatic transmission control is in correct adjustment when the tractor does not move with the engine running the clutch engaged and the hydrostat ic control lever in the neutral position If adjustment is necessary follow these steps 1 Raise both rear wheels off the ground by placing blocks under the rear frame 2 Remove the transmission panel by removing the parking brake knob and truss machine screws 3 Loosen the hex jam nut on the speed selector adjusting rod See figure 12 Speed Selector Adjusting Rod Scissor Mounting Bracket Hex Jam Nut Loosen FIGURE 12 4 Loosen the hex nut on the scissor mounting bracket See figure 12 5 Start the engine and run at full throttle 6 Move the hydrostatic control lever until you find neutral rear wheels do not rotate in either direc tion my 7 Depress the clutch brake pedal all the way and set the parking brake 8 Shut off the engine 9 Tighten the hex nut on the scissor mounting bracket 10 Thread the speed selector rod in or out of the fer rule until the hydrostatic control lever lines up in the neutral position on the speed control index bracket WARNING Be careful of the cooling fan on the hydrostatic transmission 10 Thy
4. walks or roads Be sure the area is clear of other people before mowing Stop machine if anyone enters the area Never carry passengers Disengage blade s before shifting into reverse and backing up Always look down and behind before and while backing Be aware of the mower and attachment discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the chute guard in place Slow down before turning Operate the machine smoothly Avoid erratic operation and excessive speed Never leave a running machine unattended Always turn off blade s place transmission in neutral set park brake stop engine and remove key before dismounting Turn off blade s when not mowing Stop engine and wait until blade s comes to a complete stop before a removing grass catcher or unclogging chute or b making any repairs adjusting or removing any grass or debris Mow only in daylight or good artificial light Do not operate the machine while under the influence of alcohol or drugs Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck This unit should not be driven up or down a ramp onto a trailer or truck under power because the unit could tip over causing serious personal injury The unit must be pushed manually on a ramp to load or unload properly Never make a cutting height adjustmen
5. when working near batteries Wire Holder FIGURE 3 FIGURE 4 Cupped Washers ACTIVATING AND CHARGING THE BATTERY Do not activate battery fill with battery acid until battery is actually placed in service Be certain to read previous warnings before activating the battery 1 Lift the seat Remove the battery cover by press lt ing in on the sides and lifting up See figure 3 Remove the battery from the rear frame NOTE Some batteries are secured with a wire holder Do not remove this wire holder 2 Activate the battery as instructed in the Quick Start brochure included with the battery fluid Read instructions carefully NOTE You can continue assembling the lawn tractor while battery is standing for 30 minutes after filling with acid and later while you are charging the battery IMPORTANT To obtain the maximum life from your battery it MUST BE CHARGED prior to initial use CHARGE THE BATTERY after the 30 minute stand ing period Use a 12 volt automotive type battery charger to SLOW CHARGE THE BATTERY DO NOT FAST CHARGE DO NOT use a charger rated higher than 10 amps Charge the battery for a minimum of 2 hours or until battery is fully charged NOTE The information listed above is for initial charge Refer to the Maintenance section of this manual for battery care and charging instructions to obtain the maximum life from your battery IMPORTANT After the battery has been c
6. Dimension B unscrew tie rod from tie rod end Reassemble tie rod Check dimensions Readjust if necessary f Front ern i 1 8 Less Than A FIGURE 17 CUTTING BLADES A Removal for Sharpening or Replacement WARNING Be sure to disconnect and ground the spark plug wire and remove ignition key before working on the cutting blade to prevent accidental engine start ing Protect hands by using heavy gloves or a rag to grasp the cutting blades 1 Remove the large bolt and lock washer which holds the blade and adapter to the blade spindle 2 Remove the blade and adapter from the spindle 3 If the blade or blade adapter needs replacing remove the two small bolts lock washers and nuts which hold the blade to the adapter does not apply to all models B Sharpening Remove the cutting blades by following the directions of the preceding section When sharpening the blades follow the original angle of grind as a guide It is extremely important that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade An unbalanced blade will cause excessive vibration when rotating at high speeds may cause damage to the mower and could break causing personal injury The blade can be tested for balance by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly NOTE t is recommended that the blade always be removed from the adapter for the best t
7. NOTE The lift lever must be in the BLADES OFF position when starting the engine when shifting into reverse and if the operator leaves the seat See figure 1 B DECK LIFT INDICATOR The deck lift indicator marks the position being used for the lift lever Select the lift lever position desired press the indicator lever outward move it to the posi tion immediately below the lift lever and release the indicator lever See figure 11 C SETTING THE CUTTING HEIGHT 1 Select the position for the lift lever which gives the desired cutting height Move the deck lift indi cator so that the lift lever can be returned to the same position after it is raised 2 Move the deck wheels to the hole location so the wheels are 1 4 to 1 2 inch above the ground Lift Lever 4 FIGURE 11 OPERATION A WARNING AVOID SERIOUS INJURY OR DEATH GO UP AND DOWN SLOPES NOT ACROSS e AVOID SUDDEN TURNS DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP IF MACHINE STOPS GOING UPHILL STOP BLADE S AND BACK DOWNHILL SLOWLY DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND NEVER CARRY CHILDREN LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING KEEP SAFETY DEVICES GUARDS SHIELDS AND SWITCHES IN PLACE AND WORKING REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE S KNOW LOCATION AND FUNCTION OF ALL CONTROLS BE SURE BLADE S AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET NEAR BLADE S BEFORE LEAVING OPERATOR S POSITION DISE
8. activation undercharging overcharging corroded connections freezing These failures do not constitute warranty TIRES Recommended operating tire pressure is approxi mately 12 p s i check sidewall of tire for tire manu facturer s recommended pressure Maximum tire pressure under any circumstances is 30 p s i Equal tire pressure should be maintained on all tires When installing a tire to the rim be certain rim is clean and free of rust Lubricate both the tire and rim generously Never inflate to over 30 p s i to seat beads BELT REMOVAL AND REPLACEMENT zi NOTE Figures 18 and 20 are shown with the unit tipped up for clarity It is not necessary to tip the unit to remove the belts However if tipping the unit is desired remove the battery from the unit To prevent gasoline leakage drain the gasoline or remove the fuel tank cap place a thin piece of plastic over the neck of the fuel tank and screw on the cap Be certain to remove the plastic when finished changing the belts Block unit securely WARNING Failure to use this procedure could cause sparking and the gas in either battery could explode WARNING Excessive pressure over 30 p s i when seating beads may cause tire rim assembly to burst with force suf ficient to cause serious injury WARNING Disconnect the spark plug wire and ground it against the engine Block the wheels of the unit DECK BELT 1 Place the lift lever in the BLADES OFF po
9. area or serious injury could result Mow up and down slopes not across Remove obstacles such as rocks limbs etc Watch for holes ruts or bumps Uneven terrain could overturn the machine Tall grass can hide obstacles Use slow speed Choose a low enough gear so that you will not have to stop or shift while on the slope Always keep machine in gear when going down slopes to take advantage of engine braking action Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability Use extra care with grass catchers or other attachments These can change the stability of the machine Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Rapid engagement or brak ing could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury Avoid starting or stopping on a slope If tires lose traction disen gage the blade s and proceed slowly straight down the slope DO NOT Do not turn on slopes unless necessary then turn slowly and gradually downhill if possible Do not mow near drop offs ditches or embankments The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in Do not mow on wet grass Reduced traction could cause sliding Do not try to stabilize the machine by putting your foot on the ground Do not use grass catcher on steep slopes CHILDREN Tr
10. contact your local service dealer LINKAGE Once a season lubricate all the pivot points on the clutch brake and lift linkage with SAE 30 engine oil WHEELS The front wheels are provided with grease fittings The rear wheels must be removed from the axle for lubrication Lubricate at least once a season with automotive multi purpose grease PIVOT POINTS Lubricate all pivot points with light oil at least once a season BALL JOINTS The ball joints and drag link ends are permanently lubricated before performing any adjustments repairs or maintenance TROUBLE SHOOTING Refer to the chart on page 16 for trouble shooting engine problems HYDROSTATIC TRANSMISSION COOLING The hydrostatic transmission is cooled by the oil fan and fins If the hydrostatic transmission runs hot check to see if the fan is in operating condition the oil level is correct and the fins are clean NOTE DO NOT use high pressure water spray or steam to clean the hydrostatic transmission ENGINE Refer to the separate engine manual for engine maintenance instructions MAINTENANCE WARNING Disconnect the spark plug wire and ground against the engine Service air cleaner every 10 hours under normal con ditions Clean every few hours under extremely dusty conditions To service the air cleaner refer to the sep arate engine manual packed with your unit The spark plug s should be cleaned and the gap reset once a season Spark plug
11. or charging circuit where the insulation may have rubbed through and exposed the bare wire Replace the wire or repair with electrician s tape if the wire strands have not been damaged Note Look for a wire pinched between body panels burned by the exhaust pipe or muffler or rubbed against a moving part Engine ground wire loose Engine should have a black ground wire running from engine to frame or mounting bolt Engine cranks Throttle or choke not in Check owner s guide for correct position for throttle control and choke for starting but will not start Starting position No spark to spark plug Spark plug lead disconnected Connect lead Hold spark plug lead away from engine block about 1 8 Crank engine There should be a spark If not have engine repaired at authorized engine service dealer Faulty spark plug To test remove spark plug Attach spark plug lead to spark plug Ground the spark Plug body against the engine block Crank the engine The spark plug should fire at the electrode Replace if it does not No fuel to the carburetor Gasoline tank empty Fill Fuel line or in line fuel filter plugged Remove and clean fuel line Replace filter if necessary Air filter dirty If the air cleaner is dirty the engine may not start Clean or replace as recommended by the engine manufacturer Engine smokes Engine loses crankcase Dipstick not seated or broken Replace defective part vacuum Engine breather defective Replace Excessive
12. 125 Tighten hex jam nut against the ferrule Replace the transmission panel and parking brake knob Remove the blocks from under the frame and test the operation of the tractor DECK LEVELING ADJUSTMENT If an uneven cut is obtained the deck may be leveled by following instructions in Assembly section CUTTING DECK ENGAGEMENT ADJUSTMENT The cutting deck engagement may be adjusted to make certain deck is disengaged when lift lever is in the BLADES OFF position or to obtain more drive in the cutting positions Correct adjustment as follows 13 With the engine off place the lift lever in the highest cutting position first position Remove the cotter pin and flat washer which secure the disengagement rod to the stabilizer shaft assembly See figure 13 Shorten the rod by threading it in until the ferrule is against the back of the slot in the lift shaft assembly and the rod lines up with the hole in the stabilizer shaft For more belt tension the disengagement rod must be lengthened To decrease belt tension the disengagement rod must be shortened Check the adjustment by placing the lift lever in the BLADES OFF position The deck should move up and forward allowing the belt to become loose Start and test for disengagement Repeat procedure as necessary Disengagement Rod Stabilizer Shaft 7 Assembly FIGURE 13 BRAKE ADJUSTMENT See figure 14 The brake is located by the right rear wheel inside the frame Durin
13. Bent or damaged blade Stop engine immediately Check all pulleys blade adapters keys and bolts for tightness and vibration spindle damage Tighten or replace any damaged parts Stop engine immediately Replace damaged blade Only use original equipment blades Mower will not Engine speed low Throttle must be set at fuil throttle discharge Speed selection Use lower ground speed The slower your ground speed the better the quality of cut grass or leaves Blades short or dull Sharpen or replace blades uncut strip problem only uncut strips If the above steps fail to correct the problem take the unit to your local authorized service dealer for repair 16 USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY I Owed we SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE ho ant E A POWER POLE l a A CORNER OF A BUILDING 8 p i q OR A FENCE POST _ PYETET eg pry Arey P A 15 SLOPE GAUGE Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes Operate WALK BEHIND mowers across the face of slopes never u
14. ES Your lawn mower was built to be operated according to the rules for safe operation in this manual As with any type of power equipment carelessness or error on the part of the operator can result in injury This lawn mower is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death A ND o 10 11 12 13 14 15 16 17 18 19 Read understand and follow all instructions in the manual and on the machine before starting Keep this manual in a safe place for future and regular reference and for ordering replace ment parts Only allow responsible individuals familiar with the instructions to operate the machine Know controls and how to stop the machine quickly Do not put hands or feet under cutting deck or near rotating parts Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade A small object may have been overlooked and could be accidentally thrown by the mower in any direction and cause injury to you or a bystander To help avoid a thrown objects injury keep children bystanders and helpers at least 75 feet from the mower while it is in operation Always wear safety glasses or safety goggles during operation or while performing an adjustment or repair to protect eyes from foreign objects Stop the blade s when crossing gravel drives
15. NGAGE BLADE S PLACE THE SHIFT LEVER IN NEUTRAL ENGAGE BRAKE LOCK SHUT ENGINE OFF AND REMOVE KEY READ OPERATOR S MANUAL GAS AND OIL FILL UP Check the oil level and add if necessary Service the engine with gasoline as instructed in the separate engine manual packed with your tractor Read instructions carefully IMPORTANT Your tractor is shipped with oil however you must check the oil level before operating Be careful not to overfill WARNING Never fill fuel tank indoors with engine running or while engine is hot STARTING THE ENGINE IMPORTANT This unit is equipped with a safety interlock system for your protection The purpose of the safety interlock system is to prevent the engine from cranking or starting unless the clutch brake pedal is depressed and the lift lever is in the BLADES OFF position In addition the lift lever must be in the BLADES OFF position when the unit is put into reverse or the engine will shut off If the operator leaves the seat with the lift lever engaged and or with out setting the parking brake the engine will shut off WARNING Do not operate the tractor if A the interlock system is malfunctioning because it is a safety device designed for protection 1 Place the lift lever in the BLADES OFF position 2 Depress the clutch brake pedal and set the park ing brake 3 Place the hydrostatic control lever in the NEU TRAL N position 4 Set the throttle control
16. Season Storage To charge the battery Make certain fluid level in each cell is between LOWER LEVEL and UPPER LEVEL Use a 12 volt automotive charger which is rated less than 10 amps 13 H P Lawn Tractor Charge for 14 to 16 hours DO NOT CHARGE LONGER THAN 30 HOURS 15 and 19 H P Lawn Tractors Charge for a minimum of 3 hours and a maximum of 5 hours WARNING When removing or installing REMOVING INSTALLING JUMP STARTING the battery follow these instructions to prevent the screwdriver from shorting against the frame Removing the Battery Disconnect negative cable first then positive cable Installing the Battery Connect positive cable first then negative cable 13 Jump Starting 1 First connect end of one jumper cable to the posi tive terminal of the good battery then the other end to the positive terminal of the dead battery 2 Connect the other jumper cable to the negative terminal of the good battery then to the FRAME OF THE UNIT WITH THE DEAD BATTERY hs CLEAN THE BATTERY Clean the battery by removing it from the unit and washing with a baking soda and water solution If nec essary scrape the battery terminals with a wire brush to remove deposits Coat terminals and exposed wiring with grease or petroleum jelly to prevent corrosion BATTERY FAILURES Some common causes for battery failure are incor rect initial activation lack of water adding chemicals other than water after initial
17. YARD MANK Jpn pn OUTDOOR POWER EQUIPMENT HYDROSTATIC J LAWN O whner s TRACTORS M et n u ee J Thank you for purchasing an American built product e ASSEMBLY OPERATION e MAINTENANCE IMPORTANT Model Numbers Read Safety Rules and 135N604F401 13 HP Instructions Carefully 135V694H401 19 HP 135X694G401 15 HP WARNING This unit is equipped with an internal combustion engine and should not be used on or near ray unimproved for est covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of Califomia the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department P O Box 368022 Cleveland Ohio 44136 9722 PRINTED IN U S A FORM NO 770 8416K IMPORTANT THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSON AL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE YOUR UNIT WHEN YOU SEE THIS SYMBOL A HEED ITS WARNING A A DANGER SAFE OPERATION PRACTIC
18. agic accidents can occur if the operator is not alert to the pres ence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them _ Keep children out of the mowing area and in watchful care of an adult other than the operator Be alert and turn machine off if children enter the area Before and when backing look behind and down for small chil dren Never carry children They may fall off and be seriously injured or interfere with the safe machine operation Never allow children under 14 years old to operate the machine Children 14 years and over should only operate machine under close parental supervision and proper instruction 6 Use extra care when approaching blind corners shrubs trees or other objects that may obscure your vision of a child or other hazard 7 Remove key when machine is unattended to prevent unauthorized operation A SERVICE 1 Use extreme care in handling gasoline and other fuels They are extremely flammable and the vapors are explosive a Use only an approved container b Never remove fuel cap or add fuel with the engine running Allow engine to cool at least two minutes before refueling c Replace fuel cap securely and wipe off any spilled fuel before starting the engine as it may cause a fire or explosion d Extinguish all cigarettes cigars pipes and other sources of ignition e Never refue
19. ater INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable oil Call physician immediately EYES Flush with cool water for at least 15 minutes then get prompt medical attention Since batteries produce explosive gases keep all lighted materials cigarettes lighters match es etc away Be sure to charge battery only in well ventilated areas Make certain venting path of battery drain tube is always open KEEP BATTERIES OUT OF THE REACH OF CHILDREN ATTACHING THE STEERING WHEEL 1 19 H P only Raise the hood on the lawn tractor and remove the hex bolt and lock nut from the lower steering shaft Insert end with hole of upper shaft through the hole in dash panel and into the lower steering shaft Align the holes in the upper and lower steering shafts and secure with hex bolt and lock nut just removed See figure 1 inset 2 Remove the hex lock nut and cupped washer from the steering shaft Pry the steering insert off the center of the steering wheel 3 Position the front wheels of the tractor so they are pointing straight forward 4 Place the steering bellow then steering wheel over the steering shaft positioning steering wheel as desired 5 Place the washer with the cupped side down over the steering shaft Secure with hex lock nut See figure 1 6 Snap the steering insert over the four spokes of the steering wheel ASSEMBLING THE SEAT Remov
20. bottom edge of the center of the left side of deck to the ground Measure the same distance just behind the chute area on the right side of the deck Or place the blades in a straight line and measure the distance from the outside edge of the blade tips to the ground If adjustment is needed proceed as follows 1 Remove the hairpin clip and flat washer from the bottom of the adjustable lift link on the left side of the deck Hairpin clip and flat washer are on the inside of the lift link 2 Pull the adjustable lift link out of the deck hanger channel See figure 5 3 Turn the adjustable lift link up or down as necessary to level the deck Usually only one or two turns are needed 4 Insert the end of the adjustable lift link into the hole in the deck hanger channel Recheck the adjust ment Readjust if necessary 5 When deck is level secure end of adjustable lift link with flat washer and hairpin clip Negati Negative INSTALLING THE BATTERY 1 Raise the seat 2 Make certain the positive cable heavy red wire and negative cable heavy black wire are routed outside the battery opening 3 Place the battery inside the opening so that the positive terminal is toward the front of the unit See figure 6 Route the battery drain tube down beside the battery WARNING Always connect the positive cable first step 4 then the negative cable step 5 4 Remove the hex bolt from the positive terminal Place
21. ctor pull the hydrostatic control lever into NEUTRAL N or depress the clutch brake pedal Be sure that the lawn is clear of stones sticks wire or other objects which could damage lawn tractor or engine For best results and to insure more even grass distribution do not mow when lawn is exces sively wet WARNING Before leaving the operator s position for any reason disengage the blades place the hydrostatic control lever in neutral engage the parking brake shut engine off and remove the key When stopping the unit to empty a grass bag etc fol low the instructions above This procedure will also eliminate browning the grass which is caused by hot exhaust gases from a running engine GRASS COLLECTOR AVAILABLE Grass Collector Model 190 063 is available as optional equipment for the 38 and 42 decks Grass Collector Model 190 103 is available for 46 decks WARNING The mower should not be operated without the entire grass catcher or chute deflector in place NOTE Under normal usage bag material is subject to wear and should be checked periodically Be sure any replacement bag complies with the mower manu facturer s recommendations For replacement bags use only factory authorized replacement bag ADJUSTMENTS 1 WARNING Disconnect the spark plug wires and ground against the engine before performing any adjustments repairs or maintenance SEAT ADJUSTMENT To adjust the position of the seat
22. e the hex self tapping screws which secure the seat to the seat pivot bracket Turn the seat around and place in position against the seat pivot bracket lining up the slotted holes in the pivot bracket with the holes in the seat Select desired position for the seat and secure with hex self tapping screws See figure 2 BATTERY INFORMATION A WARNING A Battery acid must be handled with great care as contact with it can burn and blister the skin It is also advisable to wear protective clothing goggles rubber gloves and apron when working with it B Should battery acid accidentally splatter into the eyes or onto the face rinse the affected area immediately with clean cold water If there is any further discomfort seek prompt medical attention C If acid spills on clothing first dilute it with clean water then neutralize with a solution of ammonia water or baking soda water D Since battery acid is corrosive do not pour it into any sink or drain Before discarding empty elec trolyte containers rinse them with a neutralizing solution E NEVER connect or disconnect charger clips to battery while charger is turned on as it can cause sparks F Keep all lighted materials cigarettes matches lighters away from the battery as the hydrogen gas generated during charging can be combustible G As a further precaution only charge the battery in a well ventilated area Always shield eyes protect skin and clothing
23. echarge battery before returning to service or every two months whichever occurs first Store unit in a clean dry area Do not store next to corrosive materials such as fertilizer NOTE When storing any type of power equipment in an unventilated or metal storage shed care should be taken to rustproof the equipment Using a light oil or silicone coat the equipment especially any chains springs bearings and cables 15 TROUBLE SHOOTING GUIDE CORRECTIVE ACTION Engine will not Safety switch button There are two switches in the starting circuit of your unit the clutch pedal switch and the deck lift lever crank not depressed switch Make certain the actuator is fully depressing the buttons on each switch Battery installed The battery must be installed with negative terminal attached to black ground wire Negative terminal is incorrectly identified at the post by NEG N or The positive terminal identified by POS P or must be attached to the big red wire which goes to the solenoid Battery is dead or weak Check fluid level in battery If fluid is low fill to UPPER LEVEL line with water Charge with taper charger until fully charged Blown fuse or circuit Replace fuse with 7 1 2 amp automotive type fuse Fuses seldom fail without a reason The problem breaker must be corrected Check for loose connections in the fuse holder Replace fuse holder if necessary A dead short may be in the cranking
24. est of balance C Reassembly Before reassembling the blade and the blade adapter to the unit lubricate the spindle and the inner surface of the blade adapter with light oil or engine oil Lubricating the bolt holes bolts and inner surface of the nuts is also recommended When replacing blades be sure to install the blade with the side of the blade marked Bottom or with part number facing the ground when the mower is in the operating position Blade Mounting Torque 3 8 Dia Bolt 450 in Ib min 600 in Ib max 5 16 Dia Bolt if applicable 200 in Ib min 350 in Ib max To insure safe operation of your unit all nuts and bolts must be checked periodically for correct tightness BATTERY CARE AND MAINTENANCE CHECK FLUID LEVEL Check fluid level inside each cell of the battery every two weeks and before and after charging Always keep level between the LOWER LEVEL and UPPER LEVEL lines on battery Add only distilled water Never add additional acid or any other chemicals to the battery after initial acti vation NOTE After operating the lawn tractor for a long peri od of time check the fluid level in the battery as it can overheat and lose fluid CHARGING THE BATTERY The engine is equipped with an alternator which charges battery when tractor is operated Under nor mal conditions the battery only needs to be charged before during and after off season storage Follow the instructions under Off
25. f the United States of America its possessions and territories except those sold through YARD MAN S authorized chan nets of export distribution Other Warranties 1 The engine or component parts thereof carry separate warranties from their manufacturers Please refer to the applicable manufacturer s warranty on these items 2 Log splitter pumps valves and cylinders or com ponent parts thereof are covered by a one year warranty 3 Batteries are covered by a 90 day replacement warranty 4 All other warranties express or implied includ ing any implied warranty of merchantability or fitness for a particular purpose are hereby expressly disclaimed in their entirety 5 The as set forth in this warranty provide the sole and exclusive remedy of Y RD MAN S obligations arising from the sales of its products YARD MAN will not be liable for incidental or consequential loss or damage How state law relates to this warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Certain disclaimers are not allowed in some states and therefore they may not apply to you under all circumstances NOTE This warranty does not cover routine main tenance items such as lubricants filters blade sharpening and tune ups or such as brake adjustments clutch adjustments or deck Nor does this cover normal deterioration of the exterior finish due to use or exposure
26. g normal operation of this machine the brakes are subject to wear and will require periodic examination and adjustment WARNING Do not have the engine run ning when you adjust the brake To adjust the brake adjust the nut so the brake starts to engage when the brake lever is 1 4 to 5 16 away from the axle housing FIGURE 14 CARBURETOR ADJUSTMENTS WARNING If any adjustments are made to the engine while the engine is running e g carburetor disengage all clutches and blades Keep clear of all moving parts Be careful of heated surfaces and muffler Minor carburetor adjustments may be required to compensate for differences in fuel temperature altitude and load Refer to separate engine manual for carburetor adjustment information NOTE A dirty air cleaner will cause an engine to run rough Be certain air cleaner is clean and attached to the carburetor before adjusting carburetor LUBRICATION WARNING Always stop engine and dis connect spark plug wire before cleaning lubricating or doing any kind of work on lawn tractor STEERING GEARS Lubricate teeth of steering gears with automotive multi purpose grease after every 25 hours of opera tion or once a season See figure 15 STEERING SHAFT Lubricate steering shaft at least once a season with light oil 11 Steering Gears FIGURE 15 TRANSAXLE The transaxle is lubricated at the factory and does not require checking If repairs are needed
27. h the unit and which have not been subject to misuse abuse nance or alteration 000 00000 Normal wear parts or components thereof are subject to separate terms as noted below in the No Fault Ninety Day Consumer Warranty clause Two year consumer warranty on normal wear parts with ninety day no fault protection All normal wear part failures will be covered on this product for a period of 90 days regardiess of cause After 90 days but within the two year warranty period normal wear Parts failures will be covered if caused by defects in y material or workmanship of other component parts Normal wear parts are defined as belts blades blade adapters grass bags rider deck wheels seats and tires How to obtain service Warranty service is avail abie with proof of purchase through your local authorized service dealer To locate the dealer in your area please check the yellow pages or contact the Customer Service Department of YARD MAN P O Box 368022 Cleveland Ohio 44136 9722 Phone 1 800 YARD M N The return of a com plete unit will not be accepted by the factory unless A iy Transportation charges Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser OOOCOCCOCOCOCOCOCOCOCOOSCOCOSO MANUFACTURER S LIMITED WARRANTY Units exported out of the United States YARD MAN does not extend any warranty for products sold or exported outside o
28. harged add only distilled water DO NOT add acid ATTACHING THE CHUTE DEFLECTOR The chute deflector must be attached to the right side of the deck so that it covers the chute opening For 30 decks refer to the separate deck manual WARNING Do not operate your unit unless the chute deflector has been properly installed 1 Make certain deck is raised to its highest position lift lever pulled all the way back 2 Remove the truss machine screws cupped washers and hex nuts which are attached to the deck next to the chute opening 3 Place the chute deflector in position as shown in figure 4 Secure with hardware just removed Cupped side of washers goes against the chute deflector TIRE PRESSURE The tires on your unit may be over inflated for shipping purposes Reduce the tire pressure before operating the unit Recommended operating tire pressure is approximately 12 p s i check sidewall of tire for tire manufacturer s recommended pressure Deck Hanger gt Channel Adjustable iL Lift Link FIGURE 5 Cable U weave J i aia 4 Black Battery 3 Negative Terminal Battery Drain Tube FIGURE 6 Drain Transaxle Reinforcement Bracket FIGURE 7 WARNING Maximum tire pressure under any circumstances is 30 p s i Equal tire A pressure should be maintained on all tires LEVELING THE DECK With unit on hard level surface measure the distance from the
29. in the FAST position 5 Pull out the choke control a warm engine may not require choking 6 Turn the ignition key to the right to the START position After the engine starts release the key It will return to the ON position NOTE Protect the starter life by using short starting cycles of several seconds Cranking more than 15 seconds per minute can damage the starter motor 7 Push choke knob in gradually Move the throttle control to desired engine speed STOPPING THE ENGINE Turn the ignition key to the left to the OFF position Remove the key to prevent accidental starting IMPORTANT if you strike a foreign object stop the engine Remove wire from spark plug thoroughly inspect the unit for any damage and repair the dam age before restarting and operating the mower NOTE f any problems are encountered refer to the Trouble Shooting Guide on page 16 OPERATING THE LAWN TRACTOR 1 Set the desired cutting height 2 Start the engine as instructed previously 3 Move throttle control to full throttle to prevent strain on the engine and to operate the cutting blades 4 Depress the clutch brake pedal so the parking brake is released and then release the clutch brake pedal 5 Place the hydrostatic control lever in either the FORWARD or REVERSE position The farther forward you move the hydrostatic control lever the faster you will travel A WARNING Look to the rear before back ing up To stop the lawn tra
30. ine screws 5 Raise the seat Disconnect the battery cables Remove the battery and battery box from the unit 6 Disconnect the idler pulley spring which is attached to a bracket on the frame inside the left rear wheel Use a spring puller or other suitable tool 7 Remove the three self tapping screws from the cooling fan Remove the fan 8 Remove the four self tapping screws which hold the belt keeper assembly to the frame at the engine pulley Remove the belt keeper assembly 9 Roll the belt off of top sheave of engine pulley onto the pulley hub 10 Remove the belt from the transmission pulley and engine pulley and remove from the unit 11 Reassemble using a new belt following instruc tions in reverse order Belt Keeper Self Tapping Assembly FIGURE 20 OFF SEASON STORAGE If the machine is to be inoperative for a period longer than 30 days prepare for storage as follows 1 Ps 5 Clean the engine and the entire unit thoroughly Lubricate ali lubrication points Wipe the entire machine with an oiled rag to protect the surfaces Refer to the engine manual for correct engine storage instructions The engine must be com pletely drained of fuel to prevent gum deposits from forming on essential carburetor parts fuel lines and fuel tanks Charge battery fully The battery loses some of its charge each day when the unit is not used NEVER store battery without a full charge R
31. l the machine indoors because fuel vapors will accumulate in the area f Never store the fuel container or machine inside where there is an open flame or spark such as a gas hot water heater space heater or furnace 2 Never run a machine inside a closed area 3 To reduce fire hazard keep the machine free of grass leaves or other debris build up Clean up oil or fuel spillage Allow machine to cool at least 5 minutes before storing 4 Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting oo a wr 10 11 12 13 14 Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g excessive wear bent cracked Replace with blade which meets original equipment specifications Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly Use all guards as instructed in this manual After striking a foreign object stop the engine remove the wire from the spark plug and thoroughly inspect the mower for any damage Repair the damage before restarting and operating the mower Grass catcher components are subject to wear damage and deterioration which could expose moving parts or all
32. ow objects to be thrown For your safety protection frequently check components and replace with manufacturer s recommended parts when necessary Mower blades are sharp and can cut Wrap the biade s or wear gloves and use extra caution when servicing blade s Check brake operation frequently Adjust and service as required Muffler engine and belt guards become hot during operation and can cause a burn Allow to coo down before touching Do not change the engine governor settings or overspeed the engine Excessive engine speeds are dangerous Observe proper disposal laws and regulations Improper dis posal of fluids and materials can harm the environment and the ecology a Prior to disposal determine the proper method to dispose of waste from your local Environmental Protection Agency Recycling centers are established to properly dispose of materials in an environmentally safe fashion b Use proper containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Properly dispose of the containers immediately following the draining of fluids c DO NOT pour oil or other fluids into the ground down a Grain or into a stream pond lake or other body of water Observe Environmental Protection Agency regulations when disposing of oil fuel coolant brake fluid filters batteries tires and other harmful waste A WARNING your RESPONSIBILITY Restrict the use of
33. p and down slopes OPTIONAL EQUIPMENT At the time of manufacture of lawn tractor the following optional equipment is available NOTE These lawn tractors are not designed for ground engaging equipment tillers plows etc Description Model No 36 Single Stage Snow Thrower 190 491 000 42 Dozer Blade 190 485 000 Mulching Kit for 38 Deck 190 096 000 Mulching Kit for 42 Deck 190 097 000 Twin Bag Grass Collector for 38 and 42 Side Discharge Decks Twin Bag Grass Collector for 46 190 063 000 Side Discharge Decks 190 103 000 Front Counterweight 190 745 000 Tire Chains 18 x 8 5 190 754 000 18x 9 5 190 657 000 20x8 190 658 000 20x 10 190 915 000 31 Lb Wheel Weights 190 215 000 Gang Reel Set of three 45 0195 38 Lawn Sweeper 45 0222 Heavy Duty Lawn Roller 45 0179 Heavy Duty Dump Cart 45 0171 Tine De Thatcher 45 0186 Available through your local dealer or from Agri Fab Inc 303 W Raymond Street Sullivan Illinois 61951 18 we a Ww For TWO YEARS from the date of retail purchase within the United States of America its possessions and territories YARD MAN will at its option repair or replace for the original purchaser free of charge any part or parts found to be defective in material or workmanship This warranty covers units which have been operated and maintained in accordance with the owner s instructions furnished wit
34. plies the brake NOTE The clutch brake pedal must be depressed to start the engine PARKING BRAKE To set the parking brake depress the clutch brake pedal pull up the parking brake knob and release the clutch brake pedal It will stay in the raised position To release the parking brake depress and release the clutch brake pedal See figure 10 NOTE The parking brake must be set if the operator leaves the seat with the engine running Ne Parking Brake FIGURE 10 RELIEF VALVE A hydrostatic relief valve is provided so the unit can be moved without the engine running The lever which operates the relief valve is located on the console See figure 10 To operate the relief valve place the hydrostatic con trol lever in neutral release the parking brake push the lever forward and to the right to lock Be certain to release the lever by pushing it to the left before oper ating the engine INDICATOR LIGHTS Two or three indicator lights are located in the dash panel If a light illuminates when attempting to start the unit proceed as follows CLUTCH Depress the clutch pedal PTO Place lift lever in the DISENGAGED position Vanguard Engines Only OlL Check the crankcase oil level and add oil as required CUTTING CONTROLS A LIFT LEVER The lift lever is used to raise and lower the cutting deck and to engage and disengage the blades Pulling it all the way back and locking it disengages the blades
35. replacement is rec ommended at the start of each mowing season check engine manual for correct plug type and gap specifi cations Maintain engine oil as instructed in the separate engine manual packed with your unit Read and follow instructions carefully FUEL FILTER Your unit is equipped with a replaceable in line fuel filter Replace filter whenever contamination or discol oration is noticed Order replacement filter through your authorized engine service dealer CLEANING ENGINE AND DECK Any fuel or oil spilled on the machine should be wiped off promptly Grass leaves and other dirt must not be left to accumulate around the cooling fins of the engine or on any part of the machine Clean the underside of the deck after each mowing WHEEL ADJUSTMENT The caster forward slant of the king pin and the camber tilt of the wheels out at the top require no adjustment Automotive steering principles have been used to determine the caster and camber on the trac tor The front wheels should toe in 1 8 inch To adjust the toe in follow these steps 1 Remove the hex nut and lock washer and drop the end of the tie rod from the axle bracket See figure 16 2 Loosen the hex jam nut on tie rod 3 Adjust the tie rod assembly for correct toe in FIGURE 16 Dimension B should be approximately 1 8 less than Dimension A See figure 17 To increase Dimension B screw tie rod into tie rod end To decrease
36. sition 2 Remove the belt keeper pins from the engine pulley belt guard See figure 18 NOTE When reassembling make certain belt keeper pins are assembled in the same locations from which they were removed See figure 18 Belt Keeper Pins Engine Pulley FIGURE 18 3 Unhook the deck belt from the engine pulley 4 Place the lift lever in the BLADES ON all the way forward position 5 Disconnect the spring which is attached to a bracket on the transaxle inside the left rear wheel Use a spring puller or other suitable tool 6 Disconnect the six deck links by removing the hairpin clips and flat washers 7 Disconnect the stabilizer plate from the stabilizer shaft assembly by removing the hairpin clips and flat washers and sliding out the rod Refer to figure 13 8 Place the lift lever in the BLADES OFF position 9 Slide the deck from beneath the lawn tractor 10 Remove the belt guards at each deck pulley by removing the self tapping screws See figure 19 Stabilizer Plate Belt Guard poeck W SLI Belt Guard FIGURE 19 11 Remove and replace the belt reassemble follow ing the instructions in reverse order DRIVE BELT See Figure 20 1 Depress the clutch pedal and set the parking brake 2 Remove the deck from the lawn tractor 3 Raise and block the front wheels of the lawn tractor so you can work under it 4 Remove the transmission panel by removing the parking brake knob and truss mach
37. t while engine is running if operator must dismount to do so Wear sturdy rough soled work shoes and close fitting slacks and shirts Do not wear loose fitting clothes or jewelry They can be caught in moving parts Never operate a unit in bare feet sandals or sneakers Check overhead clearance carefully before driving under power lines wires bridges or low hanging tree branches before entering or leaving buildings or in any other situation where 20 21 the operator may be struck or pulled from the unit which could result in serious injury Disengage all attachment clutches thoroughly depress the brake pedal and shift into neutral before attempting to start engine Your mower is designed to cut normal residential grass of a height no more than 10 Do not attempt to mow through unusually tall dry grass e g pasture or piles of dry leaves Debris may build up on the mower deck or contact the engine exhaust presenting a potential fire hazard Ai SLOPE OPERATION Slopes are a major factor related to loss of contro and tip over accidents which can result in severe injury or death All slopes require extra caution If you cannot back up the slope or if you feel uneasy on it do not mow it For your safety use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area If the slope is greater than 15 as shown on the slope gauge do not operate this unit on that
38. the positive cable on the positive terminal See figure 6 Secure with hex bolt Be careful not to lose the nut inside the terminal 5 Secure the negative cable to the negative terminal in the same manner 6 Replace the battery cover over the positive terminal Refer to figure 3 Both the positive and negative cable must fit under the battery cover Lower the seat 7 Insert the drain tube through the cable tie which is attached to the transaxle reinforcement bracket on the right side of the unit See figure 7 Be certain drain tube is routed away from the wheel rim Pull on end of cable tie to tighten do not collapse drain tube Trim excess end of cable tie Trim excess end of drain tube if necessary about 4 should extend past the cable tie CONTROLS IGNITION SWITCH The ignition switch is located on the dashboard The engine is started by turning the key to the START position After the engine starts let the key return to the ON position To stop the engine turn the key to the left to the OFF position and remove it to prevent accidental starting See figure 8 THROTTLE CONTROL The throttle control is located on the dashboard and is used to regulate the engine speed See figure 8 To get maximum efficiency from cutting the throttle should be in the FAST position when operating the mower See figure 8 Ignition Switch Clutch Brake Pedal FIGURE 8 CHOKE CONTROL The choke control is located on
39. the right side of the dashboard and is operated manually Details for the choke operation are covered in the separate engine manual packed with your unit See figure 8 LIGHT SWITCH The head lamps are operated by pushing the light switch located on the dashboard The head lamps will only operate when the engine is running See figure 8 AMMETER The ammeter registers the rate of battery charge or discharge The ammeter will register on the discharg ing side with starting the engine It should register on the opposite side charging when the engine is running in the fast position until the battery is com pletely charged With a fully charged battery or with the engine idling the ammeter will not show a charge See figure 8 HYDROSTATIC CONTROL LEVER The hydrostatic control lever is located on top of the fender on the left side of the tractor This single con trol lever connected to the hydrostatic transmission controls both the speed and direction of the tractor Infinite speed control is achieved by moving the con trol lever forward or backward The farther forward or backward you move the control lever the faster you will travel Pulling the control lever into the neutral N area will stop the tractor See figure 9 Hydrostatic Control Lever FIGURE 9 CLUTCH BRAKE PEDAL The clutch brake pedal is located on the left side of the tractor See figure 8 Depressing the pedal returns the drive unit to neutral N and ap
40. this power machine to persons who read understand and follow the warnings and instructions in this manual and on the machine ASSEMBLY INSTRUCTIONS This owner s manual covers several models of lawn tractors Follow only those instructions which pertain to your model lawn tractor IMPORTANT After assembly service engine with gasoline and check oil level as instructed in the separate engine manual packed with your unit NOTE Reference to right or left hand side of the unit is observed from the driver s seat facing for ward UNPACKING 1 Remove the lawn tractor from the carton as follows Open the top flaps or cut top off carton Remove all carton inserts Cut the front comers of the carton Make certain brake is released raise the deck use the relief valve and push the unit out of the carton The seat has been mounted backward for shipping purposes The loose parts include the battery fluid steering wheel with steering cap attached and chute deflector are on the seat and wrapped in plastic Carefully cut and remove plastic wrap Remove loose parts from the seat 19 H P only The upper steering shaft is tied to the steering wheel for shipping Cut and remove the cable tie Steering Wheel Insert Steering fod Hex Lock Nut Bellow Cupped Washer Bracket gaa FIGURE 2 A DANGER Battery contains sulfuric acid Refer to warning at right Antidote EXTERNAL Flush with w
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