Dealer Setup & Adjustment Instructions

Transcription

1 ealer Setup & djustment Instructions Regent & LT Series Tractors and Mowers Refer to the ealer Setup & djustment binder Index for a complete listing of products covered by this document. Mfg. No. escription Tractors & Mower ombinations Regent, 18HP & 38 Mower eck Regent, 20HP & 38 Mower eck Regent, 22HP & 44 Mower eck Regent, 24HP & 50 Mower eck LT18538, 18.5HP & 38 Mower eck LT2042, 20HP & 42 Mower eck LT2044, 20HP & 44 Mower eck LT2250, 22HP & 50 Mower eck , 24HP & 50 Mower eck , 22HP & 44 Mower eck , 20HP & 38 Mower eck , 24HP & 50 Mower eck , 22HP & 44 Mower eck , 20HP & 38 Mower eck , 18HP & 38 Mower eck , 18HP & 38 Mower eck Regent, 20HP Regent, 22HP Regent, 24HP LT18500, 18.5HP Regent, 18HP & 38 Mower eck LT2042, 20HP & 42 Mower eck ttention Setup Personal: The safety warnings provided in this guide and in the operator's manual included with the unit contain important information that must be obeyed when assembling, setting-up, operating, servicing, transporting, or storing the unit. These warnings are highlighted by the safety alert triangle symbol shown above, which signifies that an important safety message is being provided. You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all times while working on or around this unit and all other outdoor power equipment. Sections and items denoted by the Setup symbol provide the information necessary to fully assemble, test, and prepare the units described above for delivery to your customers. dditional information concerning functional tests, general adjustment procedures, and the location of normal lubrication points are included in these instructions. TLE OF ONTENTS: SFETY RULES...2 SETUP PROEURES Quick Setup List...3 Uncrating...4 attery harging & Installation...4 Mower ssembly...5 Install eflector (50 Models)...5 Install Idler Spring (50 Models)...5 Install rank (Free Floating Mowers)...5 heck Fluid levels...7 heck Transmission Oil Level...7 Fill and heck Engine Oil...7 Perform Safety hecks...8 Functional Tests...8 Mower lade Stopping heck...8 Seat Switch onnection...8 Safety Interlock System...8 Torque Mower lades...9 urnishing the Electric PTO lutch...9 Reduce and heck Tire Pressure...9 Lubrication...10 Hourmeter...11 Mower djustments & ssembly...12 Mower eck Removal & Installation - Free Floating...12 Side-to-Side Leveling - Free Floating...13 Front-to-ack Leveling - Free Floating...13 Mower eck Removal & Installation - Frame Hung...14 Side-to-Side Leveling - Frame Hung...15 Front-to-ack Leveling - Frame Hung...15 JUSTMENT PROEURES djust Gauge Wheels...16 Electric PTO lutch djustment...16 Internal Neutral djustment...17 Seat Slide djustment...17 Reverse Mow Option (RMO) Switch djustment...18 SERVIE PROEURES Hood Removal and Installation...19 Fuse Replacement...19 Oil rain Operation...20 hange Engine Oil...20 hange Engine Oil & Filter...20 ir Filter & Pre-leaner Service (riggs & Stratton)...21 ir Filter Replacement (Kohler)...23 Spark Plug Replacement...24 Transmission Maintenance...25 heck Transmission Oil Level...25 Purge Transmission...25 heck Transmission Oil Level...26 Transmission rive elt Replacement...26 Mower elt Replacement...28 Form No / TP RG-SMN

2 Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of equipment, severe personal injury or death to you, yourself or bystanders, or damage to property or equipment. This mowing deck is capable of amputating hands and feet and throwing objects. The triangle in text signifies important cautions or warnings which must be followed. IMPORTNT Safe operation practices for riding mowers. I. General operation 1. Read, understand, and follow all instructions in the manual and on the unit before starting. 2. Only allow responsible adults, who are familiar with the instructions, to operate the unit. 3. lear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade(s). 4. e sure the area is clear of other people before mowing. Stop the unit if anyone enters the area. 5. Never carry passengers. 6. o not mow in reverse unless absolutely necessary. lways look down and behind before and while backing. 7. e aware of the mower discharge direction and do not point it at anyone. o not operate the mower without either the entire grass catcher or the guard in place. 8. Slow down before turning. 9. Never leave a running unit unattended. lways turn off blades, set parking brake, stop engine, and remove keys before dismounting. 10. Turn off blades when not mowing. 11. Stop engine before removing grass catcher or unclogging chute. 12. Mow only in daylight or good artificial light. 13. o not operate the unit while under the influence of alcohol or drugs. 14. Watch for traffic when operating near or crossing roadways. 15. Use extra care when loading or unloading the unit into a trailer or truck. II. Slope operation Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. ll slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it. WRNING SLOPE OPERTION Never operate on slopes greater than 17.6 percent (10 ) which is a rise of 3-1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally. When operating on slopes that are greater than 15 percent (8.5 ) but less than 30 percent use front counterweights and rear wheel weights (see your dealer). Select slow ground speed before driving onto slope. In addition to front and rear weights, use extra caution when operating on slopes with rear-mounted grass catcher. Mow UP and OWN the slope, never across the face, use caution when changing directions and O NOT STRT OR STOP ON SLOPE. O See your authorized dealer for recommendations of wheel weights or counterweights to improve stability. Mow up and down slopes, not across. Remove obstacles such as rocks, tree limbs, etc. Watch for holes, ruts, or bumps. Uneven terrain could overturn the unit. Tall grass can hide obstacles. Use slow ground speed so that you will not have to stop or change speeds while on the slope. Use extra care with grass catchers or other attachments. These can change the stability of the unit. SFETY RULES Keep all movement on the slopes slow and gradual. o not make sudden changes in speed or direction. void starting or stopping on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope. O NOT o not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible. o not mow near drop-offs, ditches, or embankments. The unit could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in. o not mow on wet grass. Reduced traction could cause sliding. o not try to stabilize the unit by putting your foot on the ground. o not use grass catcher on steep slopes. III. hildren Tragic accidents can occur if the operator is not alert to the presence of children. hildren are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. e alert and turn unit off if children enter the area. 3. efore and when backing, look behind and down for small children. 4. Never carry children. They may fall off and be seriously injured or interfere with safe unit operation. 5. Never allow children to operate the unit. 6. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. IV. Service 1. Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. a) Use only an approved container. b) Never remove gas cap or add fuel with the engine running. llow engine to cool before refueling. o not smoke. c) Never refuel the unit indoors. d) Never store the unit or fuel container inside where there is an open flame, such as a water heater. d) lean up oil and fuel spills immediately. 2. Never run a unit inside a closed area. 3. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. 4. Never tamper with safety devices. heck their proper operation regularly. 5. Keep equipment free of grass, leaves, or other debris build-up. 6. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. 7. Never make adjustments or repairs with the engine running. 8. Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace, when necessary, with manufacturer s recommended parts. 9. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. 10. heck brake operation frequently. djust and service as required. 11. llow the unit to cool before storing. TP RG-SMN 2 1/2006

3 Quick Setup List Page Setup Procedure Steps to Perform 4 Uncrating o Remove rate & anding. o Place Transmission Release Lever in PUSH position & Roll Tractor forward off skid. 4 attery harging & o harge the attery (Note: proceed with other setup steps Installation while battery is charging). o Install attery. 5 heck Fluid Levels o heck Transmission fluid level. o Fill & check Engine oil level. 6 SFETY HEKS o heck for LOOSE HRWRE. o heck all OPERTOR ONTROLS. o Test PRKING RKE. o Perform MOWER LE STOPPING HEK. (lade must stop within 5 seconds!) o heck the Seat Switch connection. o Perform SFETY INTERLOK SYSTEM HEK. 7 Torque Mower lades o Torque mower blades. 7 urnish Electric lutch o urnish Electric lutch (run for 15 seconds, repeat 10 times). 7 Reduce & heck Tire Pressure o Reduce & check Tire Pressure. (Front Tires psi, Rear tires psi) 8 Lubrication o Lubricate all grease & oil points. 10 Mower ssembly o Install Mower eck onto Tractor and ttach elt (select models). o Level Mower eck (Side-to-side & Front-to-back). 14 djustment Procedures o Gauge Wheels (select models). 1/ TP RG-SMN

4 Uncrating Using a reciprocating utility saw or equivalent, cut crate away from bottom skid. Remove crate. Remove shrinkwrap plastic. 2. ut banding from front and rear tractor axles. ut banding from mower rollers. Remove mower from bottom skid. IMPORTNT NOTE When cutting crate from bottom skid, use caution around tractor tires and mower rollers. 3. Hold brake pedal down (, Figure 1) and push down on parking brake knob () to release parking brake. 4. Place hydro release lever in the PUSH position by pulling the release lever handle (located on the back of the tractor, Figure 49) back until it locks in the released position. 5. e sure there are no nails or sharp objects on bottom skid to puncture the tractor s tires. Roll the tractor forward off the skid. Figure 1. Engaging the Parking rake. Ground Speed Pedals. rake Pedal. Parking rake Knob attery harging & Installation WRNING TTERY SFETY RULES attery acid causes severe burns. void contact with skin. Wear eye protection while handling the battery. To avoid an explosion, keep flames and sparks away from battery, especially while charging. When installing battery cables, ONNET THE POSITIVE (+) LE FIRST and negative (-) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool. harge attery 1. Open the tractor hood to access the battery (E, Figure 2). 2. Loosen the wingnut & washer (). 3. Pivot the hold-down rod () up and away from battery and secure. 4. Remove the battery (E). Figure 2. attery Maintenance. Negative ables. Positive ables & over. Hold-own Rod. Wingnut & Washer E. attery E 2. To charge the battery, follow the instructions provided by the battery charger manufacturer as well as all warnings included in the safety rules section of this document. harge the battery until fully charged. o not charge at a rate higher than 10 amps. Install attery 1. Reinstall the battery (E) in the battery compartment, and secure with the battery hold-down rod () and wingnut & washer (). 2. Reattach the battery cables, positive cables first () then the negative cables (). 3. oat the cable ends and battery terminals with petroleum jelly or non-conducting grease. TP RG-SMN 4 1/2006

5 Mower ssembly Install eflector (50 Models) WRNING For your personal safety, do not handle the sharp mower blades with bare hands. areless or improper handling of blades may result in serious injury. 1. Remove and retain the hardware securing the deflector (I, Figure 3) to to the mower deck. 2. Secure the rod () to the mower deck as shown using one 1/4-20 x 7/8 carriage bolt (H), one 1/4 push nut (), one 1/4 flat washer (), and one 1/4-20 locknut (). 3. Install the spring (E) in the center notch of the deflector (I). 4. Install the deflector (I), spring (E), 5/16 washer (F), and clamp (G) on rod (). 5. Wind the spring (E) 1/2 turn so that the legs will force the deflector down in to the operating position. Secure using one 1/4-20 x 7/8 carriage bolt (H), one 1/4 push nut (), one 1/4 flat washer (), and one 1/4-20 locknut (). G I F H Figure 3. eflector Installation (50 Models). Locknuts, 1/4-20. Washers, Flat, 1/4. Rod. Push Nuts, 1/4 E. Spring F. Washer, Flat, 5/16 G. lamp H. arriage olts, 1/4-20 x 7/8 I. eflector E 1/ TP RG-SMN

6 Install Idler Spring (50 Models) 1. onnect one end of spring (, Figure 4) to the exposed capscrew & nut () which is located under idler pulley (E). 2. onnect the other end of idler spring () to the exposed capscrew () which is behind arbor cover (). Install Mower rank (Free Floating Models) 1. pply a small amount of grease to the crank assembly (, Figure 5) threads. 2. Insert the crank handle () into the threaded trunion (F) and turn clockwise. 3. Install the spacer () and flat washer () onto crank assembly () as shown. 4. Insert the crank handle () through the non-threaded trunion (G). 5. Install the the wave washer () onto crank assembly () and roll pin into crank assembly () as shown. E F G E Figure 4. Idler Spring Installation (50 Models). Idler Spring. apscrew. rbor over, LH. Exposed apscrew E. Idler Pulley Figure 5. rank Handle Installation (Free Floating Models). rank ssembly. Spacer. Flat Washer. Wave Washer E. Roll Pin F. Threaded Trunion, Upper G. Non-Threaded Trunion, Lower TP RG-SMN 6 1/2006

7 heck Fluid Levels heck Transmission Oil Level The K46 transmission is a sealed unit that is shipped with the correct oil level. However if a transmission s oil level is suspect it can be checked. See Transmission Maintenance. Fill & heck Engine Oil Service Interval: efore each use, and every 8 hours. 1. Turn the engine off, and set the parking brake to PRK. 2. lean the area around the dip stick (, Figure 6, 7, or 8). 3. Remove the dip stick () and clean it with a paper towel. 4. Insert the dip stick () back into the engine. riggs & Stratton Models, thread the cap back onto the tube. Kohler Models, push cap () firmly into place. 5. Remove the dip stick and read the oil level. The oil level should be between the FULL and marks (). If not, add oil according to the oil recommendations chart (Figure 39 or 40). Figure 7. riggs & Stratton two cylinder Models. Oil rain Valve. Oil Filter. ip Stick. hecking Oil Level Figure 6. riggs & Stratton single cylinder Models. Oil rain Valve. Oil Filter. ip Stick. hecking Oil Level Figure 8. Kohler Models. Oil rain Valve. Oil Filter. ip Stick. hecking Oil Level 1/ TP RG-SMN

8 Perform Safety hecks WRNING isengage the PTO, stop the engine, set the parking brake, and wait for moving parts to stop before leaving operator's position for any reason. If the tractor does not pass the test, do not operate tractor. Under no circumstance should you attempt to defeat the purpose of the safety system. Functional Tests 1. heck the tractor for loose bolts, screws, nuts, etc. 2. Start the engine and check all controls for proper operation: ground speed control pedals, clutch/brake pedal, parking brake, throttle and choke cables, electric PTO clutch, headlight switch, steering, attachment lift, etc. 3. Stop the engine and check for fluid leaks: oil, gasoline, or transmission oil. 4. If any control fails to operate properly during testing or seems to be out of adjustment, check and readjust it according to the following djustments section. Mower lade Stopping heck Mower blades and mower drive belt should come to a complete stop within five seconds after the electric clutch switch is turned off. With the tractor in neutral, the electric clutch switch disengaged, and an operator in the seat, start the tractor engine. Run the engine at full throttle. Engage the electric PTO clutch switch and wait several seconds. isengage electric clutch switch and check the time it takes for the mower drive belt to stop. If the mower drive belt does not stop within five seconds, adjust the PTO clutch according to the instructions in the Electric lutch djustment section. Seat Switch onnection heck that the seat switch (, Figure 9) is connected to the seat switch wire harness (). Safety Interlock System Tests This unit is equipped with safety interlock switches and other safety devices. These safety systems are present for your safety: do not attempt to bypass safety switches, and never tamper with safety devices. heck their operation regularly. Operational SFETY hecks Your unit is equipped with a seat switch safety system. heck the seat switch operation every fall and spring with the following tests. Test 1 Engine should NOT crank if: PTO switch is ON, OR rake pedal is NOT fully depressed (parking brake OFF), Test 2 Engine SHOUL crank if: PTO switch is OFF, N rake pedal is fully depressed (parking brake ON) Test 3 Engine should SHUT OFF if: Operator rises off seat with PTO engaged, OR Operator rises off seat with brake pedal NOT fully depressed (parking brake OFF). Test 4 lade rake heck Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned OFF (or operator rises off seat). If mower drive belt does not stop within five seconds, re-adjust the PTO clutch as described in the JUSTMENTS section or see your dealer. Test 5 Reverse Mow Option (RMO) heck Engine should shut off if: PTO is engaged N RMO is not activated N reverse pedal is depressed. RMO light should illuminate if: RMO is engaged N PTO switch is activated. NOTE: Once the engine has stopped, the PTO switch must be turned off after the operator returns to the seat in order to start the engine. WRNING If the unit does not pass a safety test, do not operate it. See RMO Switch djustment. Under no circumstance should you attempt to defeat the purpose of the safety interlock system. Figure 9. Seat Switch. Seat Switch. Wiring Harness TP RG-SMN 8 1/2006

9 Torque Mower lades WRNING For your personal safety, do not handle the sharp mower blades with bare hands. areless or improper handling of blades may result in serious injury. WRNING For your personal safety, blade mounting capscrews must each be installed with two spring washers or a hex washer and spring washer, then securely tightened. Torque blade mounting nut to ft. lbs. ( Nm). Torque blade mounting capscrew to ft. lbs. (61-75 Nm). FRME HUNG 38 & 42 MOELS 1. heck that blades are installed with the tabs pointing up toward deck as shown in Figure 10. Secure the large washer (), spring washers (), and nut (). Use a wooden block () to prevent blade rotation while tightening the nut () to ft. lbs. ( Nm). FREE FLOTING 38 & LL 44, 50 MOELS 1. Secure the hex washer (, Figure 11), spring washer () and capscew (). Use a wooden block () to prevent blade rotation while tightening the blade bolt () to ft. lbs. (61-75 Nm). urnishing the Electric PTO lutch 1. Select a safe area to operate the mower deck. With the drive in neutral, the PTO switch disengaged, and an operator in the seat, start the tractor engine. Run the engine at full throttle. 2. Engage the PTO switch and run the deck for fifteen seconds. isengage the PTO switch and wait for the mower drive belt to stop. 3. Repeat step 2 above ten times, and then re-check the mower blade stopping time. (Stopping time must be five seconds or less.) Reduce & heck Tire Pressures The tires are over-inflated for shipping purposes. Inflate to the pressures shown. Note that these pressures may differ slightly from the Max Inflation stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire life. Figure 10. lade Torque. 4x4 Wood lock. Large Washer. Spring Washer. lade Nut Figure 11. lade Torque. 4x4 Wood lock. Spline or Hex Washer. Spring Washer. lade olt Size PSI bar 22 x ,68-,82 20 x ,68-,82 15 x ,82-1,0 Figure 12. Tire Pressure 1/ TP RG-SMN

10 Lubrication Lubricate the unit at the locations shown in Figures as well as the lubrication points listed. Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Wipe surfaces clean before and after lubrication. Grease: steering linkage mower linkage front axle shafts (remove wheel hubs) rear axle shafts (remove wheel hubs) Use grease fittings when present. utomotive lithium grease is recommended. Oil: foot pedal rods & brackets seat adjustment assembly draglink mower deck height adjustment linkage manual lift lever transmission idler assembly Figure 13. Lubricating TP RG-SMN 10 1/2006

11 Hourmeter HOURMETER MOELS The hour meter measures the number of hours the key has been in the RUN position. This hourmeter can not be reset and does not have a maintenance reminder. HOURS 1/10 Figure 14. Mower Lubrication Points Figure 17. Hourmeter - Select Models Figure 15. Mower Lubrication Points Figure 16. rbor Lubrication Point 1/ TP RG-SMN

12 Mower djustments & ssembly Mower eck Removal & Installation WRNING Engage parking brake, disengage PTO, stop engine and remove key before attempting to install or remove the mower. Removing the Mower eck - Free Floating Mowers 1. Park tractor on a hard, level surface such as a concrete floor. Turn off PTO switch and engine, remove the key and apply parking brake. 2. Place mower in the lowest cutting position using the mower height adjuster. 3. Place the attachment lift in the lowest position. 4. Move idler arm (, Figure 19) to relieve belt tension. Remove belt from PTO pulley (). 5. Remove hair pin (, Figure 18) and washer (). isconnect the lift cable & pin () from the lift holes (). Re-install washer () and hair pin () to prevent loss. UTION The muffler and surrounding areas may be hot. 6. Turn wheels straight ahead. Pull back on springloaded lever (, Figure 20) and lift mower hitch off of the tractor brackets. 7. Turn wheels fully left, and slide mower deck out right side of tractor. Installing the Mower eck 1. Park tractor, shut off PTO and engine, remove the key and apply parking brake. Turn the wheels fully to the left. 2. Place mower height adjuster in the lowest cutting position. Place the mower lift lever in the lowest position, also. Slide mower deck under right side of tractor so that mower hitch is aligned with the front tractor hitch. 3. Turn wheels straight. Pull back on the spring-loaded lever (, Figure 20) while lifting up on the mower hitch. Install mower hitch onto tractor hitch brackets (). When properly installed, the spring-loaded lever should seat fully underneath the brackets. 4. onnect the lift cable & pin (, Figure 18) to the Figure 18. Lift Rod (Viewed from underneath right side of tractor). Lift Holes, 11/32 (8.7mm). Washer. Hair Pin. Lift able & Pin Figure 19. Removing & Installing elt. Idler rm. PTO Pulley Figure 20. Mower Hitch. Tractor Hitch rackets. Spring-Loaded Lever tractor lift holes () using the flat washer () and hair pin (). Note: Use the same hole (upper, center or lower) on each side to keep deck level. 5. Move idler arm (, Figure 19) to relieve belt tension. Install belt onto the PTO pulley (). TP RG-SMN 12 1/2006

13 WRNING efore checking mower, shut off PTO and engine, remove the key, and allow all moving parts to stop. Leveling The Mower - Free Floating Mowers If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut. Make sure tire pressure is correct as specified in hecking Tire Pressure. SIE-TO-SIE LEVELING 1. With the mower installed, place the tractor on a smooth, level surface such as a concrete floor. Turn the front wheels straight forward. 2. heck for bent blades and replace if necessary. 3. Place the mower in mid-cut position. rrange the outside mower blades so that they are pointing from side-to-side. 4. Measure the distance between the outside tips of each blade and the ground. If there is more than 1/8 (3mm) difference between the measurements on each side, proceed to step 5. If the difference is 1/8 (3mm) or less, proceed to step See Figure 21. Loosen the outside nut (). Turn the eccentric nut () to raise or lower left-hand side of mower. When mower is level, hold the eccentric nut while tightening the outside nut. FRONT-TO-K LEVELING 6. rrange the blades so they face front-to-back. 7. Measure the distance from the ground to the front tip of the center blade, and from the ground to rear tips of left-hand and right-hand blades. Front tip of the center blade should be 1/4" (6mm) higher than rear tips of left-hand and right-hand blades. If not, proceed with steps To raise front of mower deck, loosen front nut () and turn rear nut (, Figure 22) against bracket. To lower front of mower deck, loosen rear nut () and the bracket will move backwards to lengthen rod. 9. Re-check the blade measurement then tighten the front nut () against the bracket to secure. Figure 21. Leveling The Mower Side-to-Side. Outside Nut. Eccentric Nut Figure 22. Front to ack Leveling (Lift bracket and hardware removed for clarity). Rear Nut. Front Nut 1/ TP RG-SMN

14 Mower eck Removal & Installation WRNING Engage parking brake, disengage PTO, stop engine and remove key before attempting to install or remove the mower. Removing the Mower eck - Frame Hung Mowers 1. Park tractor on a hard, level surface such as a concrete floor. Turn off PTO switch and engine, remove the key and apply parking brake. 2. Place wood blocks under the mower deck. Place the attachment lift in the lowest position. UTION Stored energy device. 44 & 50 mowers have spring lift assist. Lift lever must be in lowest cutting position and mower on support blocks to avoid injury when removing or installing mower mounting hardware. 3. Move idler arm (, Figure 24) to relieve belt tension. Remove belt from PTO pulley (). 4. Remove hair pin (, Figure 23) and washer (). isconnect the mower lift channels () from the tractor lift arms (). Re-install washers () and hair pins () to prevent loss. UTION The muffler and surrounding areas may be hot. 5. Turn wheels straight ahead. Support the mower hanger (, Figure 25). Remove safety clip () and rod (). Lower the mower hanger (). 6. Turn wheels fully left, and slide mower deck out right side of tractor. Installing the Mower eck 1. Park tractor, shut off PTO and engine, remove the key and apply parking brake. Turn the wheels fully to the left. 2. Place mower height adjuster in the lowest cutting position. Place the mower lift lever in the lowest position, also. Slide mower deck under right side of tractor so that mower hitch is aligned with the front tractor hitch. 3. Turn wheels straight. Lift the mower hanger (, Figure 25). Insert rod () through mower hanger () and tractor brackets (). Secure with safety clip (). Figure 23. Lift rms (Viewed from underneath right side of tractor). Mower Lift hannels. Washer. Tractor Lift rm. Hair Pin Figure 24. Removing & Installing elt. Idler rm. PTO Pulley Figure 25. Mower Hitch. Safety lip. Mower Hanger. Rod. Tractor rackets 4. onnect the mower lift channels (, Figure 23) to the tractor lift arms (). Install washers () and hair pins (). 5. Move idler arm (, Figure 24) to relieve belt tension. Install belt onto the PTO pulley (). TP RG-SMN 14 1/2006

15 WRNING efore checking mower, shut off PTO and engine, remove the key, and allow all moving parts to stop. Leveling The Mower - Frame Hung Mowers If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut. Make sure tire pressure is correct as specified in hecking Tire Pressure. SIE-TO-SIE LEVELING 1. With the mower installed, place the tractor on a smooth, level surface such as a concrete floor. Turn the front wheels straight forward. 2. heck for bent blades and replace if necessary. 3. Place the mower in mid-cut position. rrange the outside mower blades so that they are pointing from side-to-side. 4. Measure the distance between the outside tips of each blade and the ground. If there is more than 1/8 (3mm) difference between the measurements on each side, proceed to step 5. If the difference is 1/8 (3mm) or less, proceed to step Turn the locknut (, Figure 26) to raise or lower that side of the mower. FRONT-TO-K LEVELING 6. rrange the blades so they face front-to-back. 7. Measure the distance from the ground to the front tip of the center blade, and from the ground to rear tips of left-hand and right-hand blades. 44 & 50 MOWER EKS - Front tip of the center blade should be 1/4" (6mm) higher than rear tips of left-hand and right-hand blades. If not, proceed with step & 42 MOWER EKS - front to back deck height variance of 1/8 (3mm) and side to side variance of 1/8 (3mm) is acceptable. If not, proceed with step 8. Front tip of the center blade should be 1/4" (6mm) higher than rear tips of left-hand and right-hand blades. If not, proceed with steps To raise front of mower deck, tighten locknuts (, Figure 27) and against spacers (). To lower front of mower deck, loosen locknuts (). Locknuts must be turned evenly on both sides to keep deck level. Figure 26. Leveling The Mower Side-to-Side. Lift Rod. Locknut Figure 27. Leveling The Mower Side-to-Side. Locknuts. Spacers 1/ TP RG-SMN

16 djustment Procedures Gauge Wheels (Select Models) WRNING efore checking mower, shut off PTO and engine, remove the key, and allow all moving parts to stop. NOTIE O NOT remove the mower deck baffles. The baffles help prevent grass clippings from becoming airborne and plugging up the engine cooling fins. The mower gauge wheels can be placed in several positions depending on the height of cut. When using higher cutting heights, set the wheels in the lower position. When using lower cutting heights, set the wheels in the upper position. To adjust: 1. Remove the locknut (, Figure 28), gauge wheel (), washer (), and shoulder bolt (E). hange position of gauge wheel to desired height. 2. Insert shoulder bolt (E) through washers () gauge wheel (), and gauge wheel bracket (). Secure with locknut (). Repeat steps 1 & 2 for all gauge wheels. Electric PTO lutch djustment heck the PTO clutch adjustment after 250 hours of operation. lso perform the following procedure if the clutch is slipping or will not engage. 1. Remove key from ignition switch and disconnect spark plug wires to prevent the possibility of accidental starting while the PTO is being adjusted. 2. See Figure 29. Note the position of the 3 adjustment windows () in the side of the brake plate and the nylock adjustment nuts (). 3. Insert a.012 feeler gauge through each window, positioning the gauge between the rotor face and the armature face as shown in Figure lternately tighten the adjustment nuts (, Figure 29) until the rotor face and armature face just contacts the gauge. 5. heck the windows for an equal amount of tension when the gauge is inserted and removed, and make any necessary adjustments by tightening or loosening the adjustment nuts. Figure 29. PTO lutch djustment. djustment Window (Qty. 3, one shown). djustment Nuts Window.012 Feeler Gauge (3) Places Required Figure 30. Feeler Gauge Position Figure 28. Fixed racket Gauge Wheel djustment. Gauge Wheel racket. Washer. Locknut E. Shoulder olt. Gauge Wheel E djustment Nut TP RG-SMN 16 1/2006

17 NOTE: The actual air gap between the rotor and armature may vary even after performing the adjustment procedure. This is due to dimensional variations on component parts, and is an acceptable condition. 6. heck the mower blade stopping time. The mower blades and mower drive belt should come to a complete stop within five seconds after the electric PTO switch is turned off (see MOWER LE RKE HEK, Page 8). Internal Neutral djustment The neutral gate of the Tuff Torq K46 is established internally and should not need to be adjusted. If the tractor creeps forward or backward with the ground speed control pedal at rest (neutral position) while the engine is running, perform the following adjustment: 1. lock the front tires. 2. Using an overhead chain hoist or hydraulic floor jack, elevate the rear end of the tractor so that the wheels do not contract the ground. Position jackstands under the rear frame. 3. Remove the clip ring and washer securing the right rear wheel. Remove the wheel. 4. Using a 17 mm wrench loosen the neutral adjustment jam nut (, Figure 31). 5. ctivate the seat switch, depress the clutch / brake pedal, and start the engine. 6. Release the clutch / brake pedal. 7. Using an 8 mm wrench adjust neutral by turning the eccentric (). 8. Once neutral has been established, hold the eccentric () in place and secure in position with the jam nut (). 9. Fully depress the ground speed pedal in both direction and check that it returns to neutral and the rear wheels do not creep. 10. fter adjustments have been completed, shut off the engine, replace the right rear wheel, and lower the tractor. Seat djustment Figure 31. Neutral djustment. Jam Nut. Eccentric Seat Slide djustment The seat can be adjusted forward and back. Move the lever (, Figure 32), position the seat as desired, and release the lever to lock the seat into position. Figure 32. Seat djustment. Seat djustment Lever 1/ TP RG-SMN

18 RMO Switch djustment RMO Switch Inspection Perform the inspection procedures listed below. If necessary, perform the RMO switch adjustments. The RMO switch position will need to be adjusted if under the following set of conditions: Engine running RMO deactivated PTO on The engine kills if the reverse pedal is depressed. The unit may creep backward with the pedal slightly depressed, but not faster than 1 foot per second. The RMO switch position will need to be adjusted if under the following set of conditions: Engine running RMO deactivated Ground speed control pedal in neutral or forward The engine kills when the PTO is engaged. Perform adjustment if unit fails either of these checks. Figure 33. Switch djustment.. Switch racket. Locknuts. ontrol ssembly Reference Mark RMO Switch djustment Perform the inspection procedures listed above to determine if the RMO switch needs to be adjusted. 1. Using a grease pencil, make a starting reference line on the switch bracket (, Figure 33) and the control assembly (). 2. Loosen locknuts (). 3. djust the switch bracket (). Sliding the switch bracket up reduces the allowed reverse ground speed (with RMO off and PTO on). Sliding the switch bracket down increases the allowed reverse ground speed (with RMO off and PTO on). If the engine kills with the ground speed pedal in neutral or forward (when PTO is turned on, RMO is off), slide the switch bracket down. 4. Tighten capscrews (). 5. heck RMO system to see the unit does not exceed 1 foot per second in reverse with the PTO on. If so repeat steps 2-4. TP RG-SMN 18 1/2006

19 Service Procedures Hood Removal and Installation HOO REMOVL 1. Open the hood. 2. Remove the socket and bulbs (, Figure 34) by twisting the socket counterclockwise and pulling it out of the bezel (). Repeat on other side. 3. Rock the hood back slightly and lift hood (, Figure 35) off pivot posts(). Set hood on a clean and flat surface. HOO INSTLLTION 1. Set hinge posts (, Figure 35) onto pivot posts (). 2. Roll the hood forward until it reaches the stops (). 3. Install the socket and bulb () by pushing it into the bezel () twisting the socket and bulb clockwise. Repeat on other side. 4. lose the hood. Figure 35. Hood Removal and Installation. Hinge Post. Pivot Post. Hood. Stop Figure 34. Head Light. Socket and ulb. ezel Fuse Replacement The fuse is a 20-amp blade type automotive fuse located behind the battery on the steering tower. Replace only with the same rated fuse, 20-amp. To replace the fuse: 1. Open the hood and locate the fuse holder (, Figure 36) and fuse (). ttached to the steering tower. 2. Hold the fuse holder () and pull out the fuse (). 3. Inspect the fuse for a broken connection. See Figure 37. Replace fuse if connection is broken. If you are not sure if connection is broken replace fuse. 4. Hold the fuse holder () and insert new fuse () until it is seated properly. Figure 36. Fuse. Fuse, 20-amp. Fuse Holder Solid Fusible Link roken Fusible Link Figure 37. lade Type Fuse. Good Fuse with solid Fusible link. Failed Fuse with broken Fusible link 1/ TP RG-SMN

20 Oil rain Valve Operation 1. Place a suitable container with a 4 quart capacity under the oil drain valve (, Figure 6, 7, or 8). 2. Loosen or remove the dip stick (, Figure 6, 7, or 8). 3. Wipe oil drain valve (, Figure 38) and cover () with paper towel or rag. NOTE: Sliding a hose with a 1/2 (12.5 mm) inside diameter tube over the valve nipple may aid in guiding the draining oil. 4. Rotate the drain valve () counter clockwise and pull out 1/4 (6.35 mm) for engine oil to drain. llow ample time for complete drainage. 5. fter all the oil has drained, close the oil drain valve () by pushing in and rotating clockwise to close. 6. Wipe the nipple () with paper towel or rag. Install the cover () over nipple (). hange Engine Oil RIGGS & STRTTON MOELS Service Interval: 50 hours or once per season. Oil apacity: pproximately 1-7/8 quarts (1.8L) without filter change. NOTE: hange engine oil while the engine is warm. Run the engine for a few minutes, then shut the engine off and allow it to cool from hot to warm. 1. lean the area around the dip stick (, Figure 6 or 7) and oil drain valve (). 2. rain engine oil. See OIL RIN VLVE OPERTION above. 3. Fill the crankcase with oil. See HEK ENGINE OIL LEVEL. hange Engine Oil & Filter RIGGS & STRTTON MOELS Service Interval: 100 hours or once per season. Oil apacity: pproximately 2 quarts (1.9L) with oil filter change. NOTE: hange engine oil while the engine is warm. Run the engine for a few minutes, then shut the engine off and allow it to cool from hot to warm. 1. lean the area around the dip stick (, Figure 6 or 7) and oil drain valve (). 2. rain engine oil. See OIL RIN VLVE OPERTION above. 3. Remove the oil filter (). iscard the filter. Valve losed Figure 38. Oil rain Valve. Engine lock / Valve ase. Oil rain Valve. over. Nipple Figure 39. Recommended Engine Oil - riggs & Stratton Models Use oil classified PI Service lass SF, SG, SH, SJ or better with SE Viscosity: 5W-30 10W-30 onventional* Valve Open F *UTION: ir cooled engines run hotter than automotive engines. The use of non-synthetic multi-viscosity oils (5W-30, 10W-30, etc.) in temperatures above 40º F (4º) will result in higher than normal oil consumption. When using a multi-viscosity oil, check oil level more frequently. **UTION: SE 30 oil, if used below 40º F (4º), will result in hard starting and possible engine bore damage due to inadequate lubrication. 30 onventional** Synthetic 5W-30, 10W Using a drop of oil on your finger tip, wet the rubber gasket on the bottom of the new filter. 5. Turn the filter clockwise until the rubber gasket meets the filter base. Then turn 1/2 to 3/4 turn more. 6. Fill the crankcase with oil. See HEK ENGINE OIL LEVEL. 7. Test run the engine to check for leaks. Stop the engine for 1 minute, then recheck the oil level. TP RG-SMN 20 1/2006

21 hange Engine Oil & Filter KOHLER MOELS Service Interval: 100 Hours. Oil apacity: 1.6 Quarts (1.5L) with oil filter change. Note: hange engine oil while the engine is warm. Run the engine for a few minutes, then shut the engine off and allow it to cool. 1. lean the area around the dip stick (, Figure 8) and oil drain valve (). 2. rain engine oil. See OIL RIN VLVE OPERTION above. 3. Remove the oil filter (, Figure 8). iscard the filter. 4. Turn the new filter upside down and fill with fresh engine oil. llow the oil to seep into the new filter for two minutes. 5. Using a drop of oil on your finger tip, wet the rubber gasket on the bottom of the new filter. 6. ump the oil out of the filter and install the filter on the filter base. Turn the filter clockwise until the rubber gasket meets the filter base. Then turn 2/3 to 1 full turn more. 7. Fill the crankcase with oil. See HEK ENGINE OIL LEVEL. 8. Test run the engine to check for leaks. Stop the engine for 1 minute, then recheck the oil level. Use oil classified PI Service lass SG, SH, SJ or better with SE Viscosity: 5W-20, 5W-30 onventional 5W-20, 5W-30 Synthetic* F *Recommended: Synthetic oils provide better starting below -10 F. Figure 40. Recommended Engine Oil - Kohler Models 10W-30, 30 onventional Or Synthetic ir Filter & Pre-leaner Service RIGGS & STRTTON TWO YLINER MOELS Service Interval: Pre-leaner: Every 25 hours or as required. ir Filter: Every 50 hours or as required. Replacement Interval: Pre-leaner: s required. ir Filter: Every 200 hours or once per season. ir Filter Removal & Installation 1. Unscrew the four knobs (, Figure 41) by turning counter clockwise. 2. Remove the cover (). Remove the filter () and pre-cleaner (). 3. Install the pre-cleaner () with the mesh side up. Install the filter () as shown. 4. Install the cover () making sure the tabs are inserted into their slots. Secure by turning screws clockwise until snug. Figure 41. ir Filter ssembly - riggs & Stratton Twin ylinder Models. Knobs. ir Filter over. ir Filter. Pre-leaner 1/ TP RG-SMN

22 Pre-leaner Service NOTE: Replace a worn or damaged pre-cleaner. 1. Figure 42. Wash the pre-cleaner in liquid detergent and water. 2. Squeeze the pre-cleaner dry and saturate with engine oil. Remove all excess oil by squeezing the precleaner in an absorbent cloth. ir Filter Service NOTE: Replace a worn or damaged air filter. 1. Figure 42. If stamped Washable, the filter can be washed with warm water and mild soap. 2. Rinse with tap water with the screen side UP allowing dirt and debris to filter out. 3. llow the filter to dry overnight before reinstalling. ir Filter & Pre-leaner Service Pre-leaner Figure 42. ir Filter Service ir Filter RIGGS & STRTTON SINGLE YLINER MOELS Service Interval: Pre-leaner: Every 25 hours or as required. ir Filter: Every 50 hours or as required. Replacement Interval: Pre-leaner: s required. ir Filter: Every 200 hours or once per season. ir Filter Removal & Installation 1. Lift up on the air filter latch (, Figure 43). 2. Rotate the air filter latch () to the inside. 3. Pull air filter cover () out and off. 4. Lift air cleaner (, Figure 45) and pre cleaner () if equipped, from blower housing) 5. Install the pre-cleaner () with the mesh side up. Install the filter () as shown. 6. Install the cover () making sure the tabs are inserted into their slots. Secure with the latch (). Pre-leaner Service NOTE: Replace a worn or damaged pre-cleaner. 1. Figure 44. Wash the pre-cleaner in liquid detergent and water. 2. Squeeze the pre-cleaner dry. o not oil precleaner. ir Filter Service NOTE: Replace a worn or damaged air filter. 1. Figure 44. If stamped Washable, the filter can be washed with warm water and mild soap. 2. Rinse with tap water with the screen side UP allowing dirt and debris to filter out. 3. llow the filter to dry overnight before reinstalling Figure 43. ir Filter ssembly - riggs & Stratton Single ylinder Models. ir Filter Latch. ir Filter over 2. TP RG-SMN 22 1/2006

23 Pre-leaner ir Filter Figure 44. ir Filter Service Figure 45. ir Filter Service - riggs & Stratton Single ylinder Models. ir Filter Latch. ir Filter over. ir Filter. Pre-leaner Replace ir Filter KOHLER MOELS Service Interval: Every 25 hours or two months, or as required. 1. Loosen the air filter cover knobs (, Figure 46) and remove the cover (). lean out any debris from around the air filter. Inspect the condition of the sealing surfaces of the air filter element () and filter base (). Replace any damaged parts. 2. Remove the air filter element (). 3. Install the new air filter element with the pleated side out and seat it onto the edges of the air cleaner base (). 4. Reinstall the air filter cover () and secure with the two knobs (). Figure 46. ir Filter ssembly - Kohler Models. ir Filter over Knobs. over. ir Filter. ase 1/ TP RG-SMN

24 Replace Spark Plug Service Interval: Yearly Spark Plug Gap:.030 (.76mm) Replacement Spark Plug Resistor Spark Plug, hampion R12Y 1. Stop the engine and allow it to cool. 2. See Figures 47, 48, or 49. lean the area around the spark plug. 3. Remove the spark plug. 4. heck the spark plug gap. It should be.030 (see Figure 47, 48, or 49). 5. Reinstall the plug into the cylinder head. Torque the plug to 180 in. lbs (20 N.m.). Figure 48. Spark Plug Gapping Figure 47. Spark Plug Gapping Figure 49. Spark Plug Gapping TP RG-SMN 24 1/2006

25 Transmission Maintenance K46 Maintenance o not allow dirt, water, or other debris to enter the expansion chamber or transmission. Even a small amount of dirt can damage the transmission The K46 is a sealed unit and does not require regular maintenance. The transmission oil level can be checked at the vent located on top of the transmission (see Figure 51). heck Transmission Oil Level The K46 oil level may be checked by removing the vent plug and cover and measuring the oil level. Note: Removing the vent plug cover and vent plug may result in damage to the vent plug and vent plug and cover. If parts are damaged during removal replace with new parts. 1. Using a long flat bladed screwdriver or similar tool through the access hole see Figure 50, and pry the vent plug cover (, Figure 51) and vent plug off () transmission (). 2. Using an allen wrench, piece of wire or similar item measure the distance from the top of the vent hole to the top of the oil. The distance should be 1-1/4 to 1-5/8. TRNSMISSION INFORMTION Transmission Oil apacity: px. 2.6 qt (1,8L). Transmission Oil Type: SE 10W-30 with a minimum PI rating of SG/. ccess Opening Figure 50. Vent Plug ccess Hole Figure 51. Vent Plug. Vent Plug over. Vent Plug. Transmission ccess Hole Purge Transmission Perform the following purging procedure if the unit is excessively noisy or lacks drive in forward or reverse. 1. Elevate the rear end of the tractor using a chain hoist or floor jack. Support the rear of the unit using jackstands. Elevate the unit just high enough for the rear wheels to clear the ground. 2. ctivate the seat switch, depress the clutch / brake pedal, and start the engine. fter the engine has started, set throttle to ILE. 3. Release the brake pedal and fully depress the forward ground speed pedal. 4. While holding the ground speed control in forward Figure 52. Transmission Release Lever. Transmission Release Lever position, engage and disengage the transmission release valve lever (, Figure 52) several times. 5. Fully depress the reverse ground speed pedal. 6. While holding the ground speed control in reverse, engage and disengage the transmission release valve lever () several times. 7. Engage the transmission release valve lever and stroke the transmission from full forward to full reverse several times. 8. Lower the tractor and test run for several minutes. 1/ TP RG-SMN

26 Transmission rive elt Replacement REMOVE THE OL ELT 1. Turn off the PTO, stop the engine, block the tires, and engage the parking brake. 2. Remove the mower deck. 3. Remove the hood. See Hood Removal and Installation. 4. Remove cap (, Figure 53), nut () and washer (). Remove and discard nut (). o not reuse nylock type nuts on critical components such as steering. 5. Remove steering wheel (F) from steering shaft (). THis may require a tap with a soft faced hammer from underneath. 6. Squeeze together the base of shaft cover (E) to remove it from holes (G) in dash. 7. lock rear wheels and raise the front of the tractor. 8. Hold or support steering shaft (, Figures 53 & 54) from the under side of the tractor. 9. Remove clip (, Figure 54) and washer(s) (). 10. Slide steering shaft (, Figure 54) out. Remove washer(s) () and bushing (). 11. Unplug the PTO clutch plug (, Figure 55). Remove the capscrew (F) and related hardware securing the PTO clutch to the crankshaft. Remove the clutch. 12. Remove the drive belt from the engine pulley (, Figure 58), idler pulleys (), and transmission input pulley (). INSTLL THE NEW ELT 1. Install a new drive belt on the transmission input pulley (, Figure 58) and engine drive pulley (). 2. Install the PTO clutch using the original hardware as shown in Figure 55. e sure the engine pulley key () is installed as shown in the inset. Torque the crankshaft bolt (F) to ft lbs (61-67Nm). 3. Install the drive belt in the idler assembly pulleys (, Figure 55). Tighten the pulley hardware. 4. Set bushing (, Figure 54) into tower dash hole (E). oth flat edges must be in line for proper fit. See Figure Slide washer (, Figure 54) and bushing () onto steering shaft (). 6. Slide shaft () with washer () and bushing () through lower bracket (F). 7. Guide shaft () through tower (E) and bushing (). 8. Guide bushing () through bracket (F). oth flat edges must be in line for proper fit. See Figure 56. E Figure 53. Transmission rive elt Replacement. ap E. Shaft over. Nut F. Steering Wheel. Washer G. Holes. Steering Shaft E F G Figure 54. Steering Shaft. lip. Steering Shaft. Washer(s) as required E. Tower & ash Hole. ushings F. Lower racket G F TP RG-SMN 26 1/2006