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Operators Manuals

Body - 50 lbs brilliant white offset or equivalent Cover - on pre-printed two tone Swash stock. Press: Body - 1 color, 2-sided Cover - 1 color, 1 sided Bindery: Covers: Saddle stitch, face trim *if too thick for saddle stitch, tape bind

FRONT COVER is present at the beginning of the file. BACK COVER is the page immediately after the front cover. The part number for this manual (typically a 172_____ number) is located on the front cover. This file may contain several manual which differ only by their covers. See the part number at the bottom of the cover page. .

Body:

The body for all manuals is identical regardless of the cover. Odd number pages are always right hand pages, even number pages are always left hand pages.

General:

This instruction sheet is NOT part of the manual and must not be printed. Pages labeled THIS PAGE INTENSIONALLY BLANK are placement pages and should NOT be printed.

THIS PAGE INTENTIONALLY BLANK (FOR PLACEMENT ONLY - DO NOT PRINT)

OPERATORS MANUAL

Regent / 500 / 2500 Series

16HP Hydro Tractors
Mfg. No. 1693915 1693925 1693935 1693948 1694185 1694200 1694309 1694313 1694316 1694343 Description Regent, 16HP Hydro Regent, 16HP Hydro (Export) 516H, 16HP Hydro 2516H, 16HP Hydro 2516H, 16HP Hydro Regent, 16HP Hydro 2526H, 16HP Hydro Regent, 16HP Hydro (Export) Regent, 16HP Hydro (Export) 2526H, 16HP Hydro (Export)

38 Mower Decks
Mfg. No. 1693792 1693794 1693930 1693960 1693963 Description 38 Mower Deck 38 Mower Deck (Export) 38 Mower Deck (Export) 38 Mower Deck 38 Mower Deck (Export)

40 Mower Decks
Mfg. No. 1693554 1693557 1693962 1693964 1694377 Description 40 Mower Deck 40 Mower Deck (Export) 40 Mower Deck 40 Mower Deck (Export) 40 Mower Deck (Export)

17HP Hydro Tractors

Mfg. No. 1693918 1693928 1693938 1693951 1693957 1694376 Description Regent, 17HP Hydro Regent, 17HP Hydro (Export) 517H, 17HP Hydro 2517H, 17HP Hydro 2517H, 17HP Hydro (Export) 2005 Rapid, 17HP Hydro (Export)

44 Mower Decks
Mfg. No. 1693795 1693885 1693961 Description 44 Mower Deck 44 Mower Deck (Export) 44 Mower Deck

1722563-09 Superceeds 1722706 Rev 2/2003 TP 100-2501-09-RG-SMA

MANUFACTURING, INC. 500 N Spring Street / PO Box 997 Port Washington, WI 53074-0997 [Link] Copyright 2003 Simplicity Manufacturing, Inc. All Rights Reserved. Printed in USA.

Table of Contents
Safety Rules .........................................................2
General Operation ..................................................2 Towing ....................................................................2 Slope Operation ......................................................3 Transportation & Storage ........................................3 Emissions................................................................3 Service & Maintenance ...........................................4 Battery Maintenance .............................................19 Cleaning the Battery and Cables ....................19 Servicing the Mower Blades .................................20 Check Mower Blade Timing - 40 Mowers ............21 Check Mower Belt Tension - 40 Mowers .............22

Troubleshooting, Adjustment, & Service ........24

Chart - Troubleshooting The Tractor.....................24 Chart - Troubleshooting The Mower .....................25 Battery Charging ...................................................26 Seat Adjustment....................................................26 Steering Gear Adjustment.....................................26 Brake & Brake Spring Adjustment ........................27 PTO Clutch Adjustment ........................................27 Mower Adjustments ..............................................28 Leveling The Mower......................................28 Blade Brake Check .......................................29 38 & 44Mower Belt Replacement .......................29 40 Mower Belt Replacement................................30 40 Mower Arbor Drive Belt Replacement.............31 Tractor Drive Belt Replacement ............................32 Transmission Purging ...........................................32

Identification Numbers........................................5
Decals .....................................................................5 CE Safety Icons ......................................................6

Features, Controls, & Operation ........................8

Control Functions ....................................................8 Parking Brake .........................................................9 Safety Interlock System ........................................10 General Operation Safety .....................................10 Adding Fuel ...........................................................10 Starting The Engine ..............................................10 Stopping The Tractor & Engine.............................11 Driving The Ttractor ..............................................10 Mowing..................................................................10 Pushing the Tractor by Hand ...............................11 Using A Munching Mower .....................................12 Mower Installation & Removal ..............................13 Adjusting Mower Height and Gauge Wheels 38 & 44 .....................................13 Adjusting Mower Height 40 ..................................14 Storage .................................................................14

Specifications ....................................................33 Parts & Accessories..........................................34

Replacement Parts ...............................................34 Maintenance Items................................................34 Optional Accessories ............................................34

Regular Maintenance ........................................15

Schedule ...............................................................15 Tire Pressure ........................................................15 Raising the Hood & Seat ......................................16 Checking the Fuel Filter ........................................16 Safety Interlock System Check .............................16 Blade Brake Check ...............................................16 PTO Clutch Adjustment Check .............................16 Engine Maintance .................................................16 Lubrication ............................................................17 Lubricating Rear Axle Shafts ................................18 Transmission Identification ...................................19 Transmission Service............................................19

Lawn Care & Mowing Information ....................................LC1 International Symbols ................................LC8 Technical Literature ....................................LC8
NOTE: In this manual, left and right are referred to as seen from the operating position.

WARNING
Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

Safety Rules & Information

Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of unit, severe personal injury or death to you, 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. GENERAL OPERATION Read, understand, and follow all instructions in the manual and on the unit before starting. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. Only allow responsible adults, who are familiar with the instructions, to operate the unit (local regulations can restrict operator age). Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade(s). Be sure the area is clear of other people before mowing. Stop unit if anyone enters the area. Never carry passengers. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while travelling in reverse. Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the deflector in place. Slow down before turning. Never leave a running unit unattended. Always disengage the PTO, set parking brake, stop engine, and remove keys before dismounting. Turn off the PTO switch to disengage the blades when not mowing. Stop engine before removing grass catcher or unclogging chute. Mow only in daylight or good artificial light. Do not operate the unit 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 unit into a trailer or truck. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from injury. Keep in mind the operator is responsible for accidents occurring to other people or property. All drivers should seek and obtain professional and practical instruction. Always wear substantial footwear and trousers. Never operate when barefoot or wearing sandals. Before using, always visually check that the blades and blade hardware are present, intact, and secure. Replace worn or damaged parts. Never operate the machine with defective guards, or without safety protective devices in place. Disengage attachments before: refueling, removing an attachment, making adjustments (unless the adjustment can be made from the operators position). When the machine is parked, stored, or left unattended, lower the cutting means unless a positive mechanical lock is used. Follow the manufacturers recommendation for wheel weights or counterweights. Before leaving the operators position for any reason, engage the parking brake, disengage the PTO, stop the engine, and remove the key. To reduce fire hazard, keep the unit free of grass, leaves, & excess oil. Do not stop or park over dry leaves, grass, or combustible materials.

TRANSPORTING AND STORAGE

When transporting the unit on an open trailer, make sure it is facing forward, in the direction of travel. If the unit is facing backwards, wind lift could damage the hood. Always observe safe refueling and fuel handling practices when refueling the tractor after transportation or storage. Never store the unit (with fuel) in an enclosed poorly ventilated structure. Fuel vapors can travel to an ignition source (such as a furnace, water heater, etc.) and cause an explosion. Fuel vapor is also toxic to humans and animals. Always follow the engine manual instructions for storage preparations before storing the tractor for both short and long term periods. Always follow the engine manual instructions for proper start-up procedures when returning the unit to service. Never store the unit or fuel container inside where there is an open flame or pilot light, such as in a water heater. Allow unit to cool before storing.

TP 600-2459-03-UV-SMA 2

Safety Rules and Information

SLOPE OPERATION
Slopes are a major factor related to loss-of-control and tipover accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not operate on it. Control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are: insufficient tire grip on the ground, speed too fast, inadequate braking, the type of machine is unsuitable for its task, lack of awareness of the ground conditions, incorrect hitching and load distribution. Do 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 speed. Tires may lose traction on slopes even through the brakes are functioning properly. Choose a low gear so that you will not have to stop or shift while on the slope. Use extra care with grass catchers or other attachments. These can change the stability of the unit. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Always keep unit in gear especially when traveling downhill. When clutching, release clutch slowly. Do Not Do not start or stop on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope. Do not turn on slopes unless necessary, and 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 unit by putting your foot on the ground. Do not use grass catchers on steep slopes. Do not mow slopes you cannot back up. Do not shift to neutral and coast down hill.

WARNING
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 use additional wheel weights or counterweights. See your dealer to determine which weights are available and appropriate for your unit. 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 DOWN the slope, never across the face, use caution when changing directions and DO NOT START OR STOP ON SLOPE. Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them. Keep children out of the mowing area and under the watchful care of another responsible adult. Be alert and turn unit off if children enter the area. Before and during reverse operation, look behind and down for small children. Never carry children. They may fall off and be seriously injured or interfere with safe unit operation. Never allow children to operate the unit. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

TOWED EQUIPMENT
Never allow children or others in or on towed equipment. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point. Follow the manufacturers recommendations for weight limit for towed equipment and towing on slopes. On slopes, the weight of the towed equipment may cause loss of traction and loss of control. Travel slowly and allow extra distance to stop. Do not shift to neutral and coast down hill.

EMISSIONS
Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. Look for the relevant Emissions Durability Period and Air Index information on the engine emissions label.

Safety Rules & Information

SERVICE AND MAINTENANCE
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. Allow engine to cool before refueling. Do not smoke. c) Never refuel the unit indoors. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated. Replace all fuel tank caps and fuel container caps securely. Never fill containers inside a vehicle or on a truck bed with a plastic bed liner. Always place containers on the ground away from your vehicle before filling. Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle. Keep nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. If fuel is spilled on clothing, change clothing immediately. Maintain or replace safety and instruction labels as necessary. Never run the unit in an enclosed area where carbon monoxide fumes may collect. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. Never tamper with safety devices. Check their proper operation regularly and make necessary repairs if they are not functioning properly. Keep unit free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. Never make adjustments or repairs with the engine running unless specified otherwise in the engine manufacturers manual. Do not remove the fuel filter when the engine is hot as spilled gasoline may ignite. Do not spread fuel line clamps further than necessary. Ensure clamps grip hoses firmly over the filter after installation. Do not use gasoline containing METHANOL, gasohol containing more than 10% ETHANOL, gasoline additives, or white gas because engine/fuel system damage could result. If the fuel tank must be drained, it should be drained outdoors. Replace faulty silencers/mufflers. 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 with manufacturers recommended parts, when necessary. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. Check brake operation frequently. Adjust and service as required. Use only factory authorized replacement parts when making repairs. Always comply with factory specifications on all settings and adjustments. Only authorized service locations should be utilized for major service and repair requirements. Never attempt to make major repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturers warranty. On multiple blade mowers, take care as rotating one blade can cause other blades to rotate. Do not change engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury. Disengage drive attachments, stop the engine, remove the key, and disconnect the spark plug wire(s) before: clearing attachment blockages and chutes, performing service work, striking an object, or if the unit vibrates abnormally. After striking an object, inspect the machine for damage and make repairs before restarting and operating the equipment. Never place hands near the hydro pump cooling fan when the tractor is running. Cooling fan is located on top of the transaxle.

Identification Numbers

Identification Numbers
SA SA M M PL PL E E
Mfg. No.: 169XXXX
2002
dB(A)

North American Models

Mower ID Tag

Tractor ID Tag

Serial No.: XXXXX kW: XXX Engine RPM XXXX LpA: XXX dB(A) Vibration @ Wheel: XXX m/s Vibration @ Seat: XXX m/s

Simplicity Mfg. Inc. Port Washington, WI USA 53074-0997

When contacting your authorized dealer for replacement parts, service, or information you MUST have these numbers. Record your model name/number, manufacturers identification numbers, and engine serial numbers in the space provided for easy access. These numbers can be found in the locations shown.

NOTE: For location of engine identification numbers, refer to the engine owners manual.
CE Models: Place the extra copy of the identification tag in the manual

CE IDENTIFICATION TAG MARKINGS

A. B. C. D. E. F. G. H. I. J. K. L. Manufacturers Identification Number Manufacturers Serial Number Power Rating in Kilowatts Maximum Engine Speed in Rotations per Minute Manufacturers Address Year of Manufacture CE Compliance Logo Mass of Unit in Kilograms Sound Power in Decibels *** Sound Pressure at Operators Position in Decibels ** Vibration at the Steering Wheel * Vibration at the Seat *
C D J K

This unit complies with European Harmonized Lawn Mower Standard EN 836, European Machinery Directive 98/37/EC, and European EMC Directive 89/336/EC * Tested according to EN 836:1997/A2:2001, EN 1032: 1996, EN 1033:1995 ** Tested according to EN836:1997/A2:2001 *** Tested according to 2000/14/EC

SA SA

CE Models

PRODUCT
Model Description Name/Number

REFERENCE

DATA

M M

PL PL

Unit MFG Number

Unit SERIAL Number

E E
5

Mower Deck MFG Number

Mower Deck SERIAL Number

Dealer Name

Date Purchased

ENGINE REFERENCE DATA

Engine Make Engine Model

Engine Type/Spec

Engine Code/Serial Number

A
Mfg. No.:

F
169XXXX

G I
2002
dB(A)

Serial No.: XXXXX kW: XXX Engine RPM XXXX LpA: XXX dB(A) Vibration @ Wheel: XXX m/s Vibration @ Seat: XXX m/s

L E

Simplicity Mfg. Inc. Port Washington, WI USA 53074-0997

CE Models: Place copy of Identification Tag here.

Safety Decals
SAFETY DECALS
This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing. Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit. All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important! The safety decals below are on your rider and mower. If any of these decals are lost or damaged, replace them at once. See your local dealer for replacements. These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation.

NORTH AMERICAN MODEL DECALS

Decal - Control Locations Part No. 1723731

CE MODEL DECALS
Decal - Control Locations Part No. 1723731

1723731 1723731

DANGER

WARNING
AVOID SERIOUS INJURY OR DEATH
READ OPERATOR'S MANUAL(S). KNOW LOCATION AND FUNCTION OF ALL CONTROLS. KEEP SAFETY DEVICES (GUARDS, SHIELDS, SWITCHES, ETC.) IN PLACE AND WORKING. REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE. DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND. NEVER CARRY CHILDREN EVEN WITH BLADES OFF. LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING. AVOID SUDDEN TURNS. IF YOU CANNOT BACK UP A HILL, DO NOT OPERATE ON IT. GO UP AND DOWN SLOPES, NOT ACROSS. IF MACHINE STOPS GOING UPHILL, STOP BLADE AND BACK DOWN SLOWLY. BE SURE BLADE(S) AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET NEAR BLADE(S). WHEN LEAVING MACHINE, SHUT OFF ENGINE, REMOVE KEY, AND SET PARKING BRAKE.

DANGER

OPERATING ON SLOPES CAN BE DANGEROUS

SEE OPERATOR'S MANUAL. IF YOU CANNOT BACK-UP A HILL, DO NOT DRIVE ON IT.
DO NOT TOW TRACTOR! Damage may result to transmission

ROTATING BLADES CUT OFF ARMS AND LEGS

STOP MOWER WHEN CHILDREN ARE NEAR. NO RIDERS THEY FALL OFF.
1723175

Decal - North American Operating Instructions Part No. 1716530

1722814-00

Decal - North American Safety Instructions Part No. 1722814

Decal - CE Operating Instructions Part No. 1722561

Decal - CE Safety Instructions Part No. 1723175

Decal - Danger Part No. 1704276

Decal - Danger Part No. 1704277

Decal - Danger, Rotating Blades Part No. 1720389

ALL MODELS

DANGER
ROTATING CUTTING BLADE
Do not put hands or feet under mower deck while blade is rotating.
1720660

Decal - Danger, Mulching Models Part No. 1720389

Decal - Hydro Release Valve Part No. 1719635

1723470
1723847

Decal - Cutting Height Part No. 1723470 6

Decal - Cutting Height Part No. 1723847

CE Safety Icons / Directive Compliance

SAFETY ICONS
Warning: Read Operators Manual. Read and understand the Operators Manual before using this machine. Danger: Thrown Objects. This machine is capable of throwing objects and debris. Keep bystanders away. Danger: Dismemberment. This machine can amputate limbs. Keep bystanders and children away when engine is running. Danger: Dismemberment. This mower deck can amputate limbs. Keep hands and feet away from blades. Danger: Remove Key & Read Manual Before Servicing Danger: Machine Rollover. Do not use this machine on slopes greater than 10. Remove the key and read the operators manual before performing service procedures involving components in this area.
1723824

Features & Controls

Please take a moment and familiarize yourself with the name, location, and function of these controls so that you will better understand the safety and operating instructions provided in this manual.

Trans. Release Lever on Rear Of Tractor

CONTROL FUNCTIONS
The information below briefly describes the function of individual controls. Starting, stopping, driving, and mowing require the combined use of several controls applied in specific sequences. To learn what combination and sequence of controls to use for various tasks see the OPERATION section.

Throttle/Choke Control
(Single Lever Models) The throttle/choke lever controls engine speed and choke. Move the throttle forward to increase engine speed and back to decrease engine speed. Always operate at FULL throttle. Move the control fully forward (past the detent) to close the choke. Close the choke for cold starting. Open the choke once the engine starts. A warm engine may not require choking.

Headlights
The light switch turns the tractor headlights on and off.

PTO Switch
The PTO (Power Take-Off) switch engages and disengages attachments that use the PTO. To engage the PTO, pull UP on the switch. Push DOWN to disengage. Note that the operator must be seated firmly in the tractor seat for the PTO to function.

Throttle Control
(Twin Lever Models) The throttle controls engine speed. Move the throttle forward to increase engine speed and back to decrease engine speed. Always operate at FULL throttle.

Ignition Switch
The ignition switch starts and stops the engine, it has three positions: OFF Stops the engine and shuts off the electrical system. Allows the engine to run and powers the electrical system.

Choke
(Twin Lever Models) Close the choke for cold starting. Open the choke once the engine starts. A warm engine may not require choking. Move the lever forward to close the choke.

RUN

START Cranks the engine for starting. NOTE: Never leave the ignition switch in the RUN position with the engine stoppedthis drains the battery. 8

Operation
Brake Pedal
Depressing the brake pedal applies the tractor brake.

Cutting Height Fine Tuning Adjustment (40 Mower Decks Only)

The cutting height fine tuning adjustment is used to set the mower cutting height between two of the preset cutting positions.

Ground Speed Pedals

The tractors forward ground speed is controlled by the forward ground speed control pedal. The tractors reverse ground speed is controlled by the reverse ground speed control pedal. Depressing either pedal will increase ground speed. Note that the further down the pedal is depressed, the faster the tractor will travel.

Seat Adjustment Lever

The seat can be adjusted forward and back. Move the lever, position the seat as desired, and release the lever to lock the seat into position.

Transmission Release Valve Lever Parking Brake

The parking brake knob is used to lock the parking brake when the tractor is stopped. Fully depressing the brake pedal and pulling up on the knob engages the parking brake. Refer to page 10 for a full explanation of parking brake functions. The transmission release valve lever deactivates the transmission so that the tractor can be pushed by hand. See PUSHING THE TRACTOR BY HAND for operational information.

Fuel Tank
To remove the cap, turn counterclockwise. On models with a dashboard display, the fuel gauge is part of the dashboard. Model without a dashboard display have a fuel gauge located under the seat.

Mower Height of Cut Adjustment

38 & 44 MOWER DECKS

The cutting height adjustment knob controls the mower cutting height. The cutting height is infinitely adjustable between 1 and 3-5/8.
40 MOWER DECKS

Attachment Lift Control Lever

When using the mower deck, lift the deck off the ground while transporting to and from the job site. DO NOT cut with the mower in the raised, transport position. The attachment lift control lever raises and lowers attachments that utilize the tractors manual lift linkage. To lower an attachment: pull the lever back slightly, depress the release button, and push the lever forward until it locks in the lowered position. To raise an attachment: push the lever forward slightly, depress the release button, then pull the lever back until it locks in the raised position.

The cutting height adjustment lever controls the mower cutting height. Push down on the button to release the lever, move to the desired cutting height, and release the button to lock. The cutting height is infinitely adjustable between 1 and 3-5/8.

PARKING BRAKE FUNCTION

Applying the Parking Brake - See Figure 1. To lock the parking brake, release the ground speed pedals (A), fully depress the brake pedal (B), pull UP on the parking brake knob (C), and then release brake pedal. Releasing the Parking Brake - See Figure 1. To release the parking brake, fully depress the brake pedal (B) and push the parking brake knob (C) DOWN.
B

C
A

IMPORTANT NOTE: The tractors hydraulic attachment lift will not work when the parking brake is engaged.

Figure 1. Engaging the Parking Brake A. Ground Speed Pedals B. Brake Pedal C. Parking Brake Knob 9

Operation
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. Check their operation regularly.

GENERAL OPERATING SAFETY

Be sure to read all information in the Safety and Operation sections before attempting to operate this unit. Become familiar with all of the controls and how to stop the unit.

ADDING FUEL
To add fuel: 1. Remove the fuel cap. 2. Fill the tank. Do not overfill. Leave room in the tank for fuel expansion. Refer to your engine manual for specific fuel recommendations. 3. Install and hand tighten the fuel cap.

Operational SAFETY Checks

Your unit is equipped with a seat switch safety system. Check the seat switch operation every fall and spring with the following tests. Test 1 Engine should NOT crank if: PTO switch is ON, OR Brake pedal is NOT fully depressed (parking brake OFF), OR The cruise control lever is NOT in NEUTRAL. Test 2 Engine SHOULD crank if: PTO switch is OFF, AND Brake pedal is fully depressed (parking brake ON), AND The cruise control lever is in NEUTRAL. 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 Blade Brake Check 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, readjust the PTO clutch as described in the ADJUSTMENTS section or see your dealer.

STARTING THE ENGINE

Do not use gasoline containing METHANOL, gasohol containing more than 10% ETHANOL, gasoline additives, or white gas because engine/fuel system damage could result.

WARNING
Gasoline is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills. [Link] sitting in the operators seat, fully depress the brake pedal or set the parking brake. 2. Make sure that your feet are not depressing the ground speed control pedals and that the cruise control lever is in neutral. 3. Disengage the PTO clutch. 4. Set the throttle to FULL. 5. Close the choke. NOTE: A warm engine may not require choking. 6. Insert the ignition key and turn it to START. 7. After the engine starts, move the engine throttle control to SLOW. Warm up the engine by running it for at least a minute. 8. Set throttle to FULL. NOTE: In the event of an emergency the engine can be stopped by simply turning the ignition switch to STOP. Use this method only in emergency situations. For normal engine shut down follow the procedure given in STOPPING THE TRACTOR.

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.

WARNING
If the unit does not pass a safety test, do not operate it. See your authorized dealer. Under no circumstance should you attempt to defeat the purpose of the safety interlock system.

10

STOPPING THE TRACTOR & ENGINE

1. Return the ground speed control(s) to neutral. 2. Disengage the PTO and wait for all moving parts to stop. 3. Place the throttle control in the position specified in the engine owners manual provided in the operator's packet shipped with your tractor. Follow any recommended stopping procedures. 4. Turn the ignition switch to OFF. Remove the key.

MOWING

Operation

DRIVING THE TRACTOR

1. Sit in the seat and adjust the seat so that you can comfortably reach all the controls and see the dashboard display. 2. Engage the parking brake. 3. Make sure the PTO switch is disengaged. 4. Start the engine (see STARTING THE ENGINE). 5. Disengage the parking brake and release the brake pedal. 6. Depress the forward ground speed control pedal to travel forward. Release the pedal to stop. Note that the further down the pedal is depressed the faster the tractor will travel. 7. Stop the tractor by releasing the ground speed control pedals, setting the parking brake, and stopping the engine (see STOPPING THE TRACTOR AND ENGINE).

1. Set the mower cutting height to the desired level and set the gauge wheels to the appropriate position (if equipped). 2. Engage the parking brake. Make sure the PTO switch is disengaged. 3. Start the engine (see STARTING THE ENGINE). 4. Fully lower the mower using the attachment lift lever. 5. Set the throttle to FULL. 6. Engage the PTO (Mower Deck). 7. Begin mowing. See Section C for tips on mowing patterns, lawn care, and troubleshooting information. 8. When finished, shut off the PTO and raise the mower using the attachment lift control lever. 9. Stop the engine (see STOPPING THE TRACTOR AND ENGINE).

PUSHING THE TRACTOR BY HAND

1. Disengage the PTO and turn the engine off. 2. Pull the transmission release back approximately 21/2 (6 cm) to lock into released position (Figure 2). 3. The tractor can now be pushed by hand.

DO NOT TOW TRACTOR

Towing the unit will cause transmission damage. Do not use another vehicle to push or pull this unit. Do not actuate the transmission release valve lever while the engine is running.

Release Lever

Figure 2. Release Lever - Hydro Models 11

Operation
USING A MULCHING MOWER
Benefits of Proper Mulching
Mulching consists of a mower deck which cuts and recuts clippings into tiny particles and then blows them down into the lawn. These tiny particles decompose rapidly into by-products that your lawn can use. Under proper conditions your mulching mower virtually eliminate noticeable clippings on the lawn surface.
B

Limitations of Mulching Decks

Mulching mowers cannot function properly if the grass is wet, or if the grass is simply too high. Even more than normal mowing, mulching requires that the grass be dry and no more than 1/3 of the height is cut. Do not use the mower as a mulching mower during the first two or three cuttings in the spring. The long grass blades, quick growth, and often wetter conditions are more suitable for broadcasting (side-discharging).

Figure 3. Installing the Side Discharge Deflector A. Side Discharge Deflector B. Mulching Cover

Correct Ground Speed & Engine Speed

Use full engine throttle to maximize mower blade tip speed matched with a slow ground speed so that clippings will be finely cut. Ground speed while mulching should be half the speed used when broadcasting (sidedischarging) under similar conditions. Since mulching requires more horse power that broadcasting, using a slower ground speed is vitally important for proper mulching operation.

Using the Side Discharge Deflector

When to use the side discharge deflector: If youve been on vacation or missed a mowing and the grass has gotten very long, do not try to mulch at your normal cutting height. To handle these situations your mulching mower is equipped with a side discharge deflector. Installing the side discharge deflector allows you to broadcast clippings. Broadcasting, or side-discharging, disperses fine clippings evenly over the entire lawn. Many golf courses use this method. Your mower has a deep dish deck to allow freer circulation of clippings so they are broadcast evenly over the lawn. Always operate the engine at full throttle. Use an appropriate ground speed for the thickness and height of grass you are cutting. If you hear the engine slowing down, you are mowing too fast, use a slower ground speed. Mow when the grass is 3-5long. Do not cut off more than 1 in a single pass.

Correct Cutting Height

Cutting off too much at one time shocks the plants growth system and weakens the grass plants. A good rule of thumb is the 1/3 rule: to cut no more than one third of the grass height, and never more than 1 inch at a time. The best mulching action typically results from cutting only the top 1/2 to 3/4 of the grass blade. This provides short clippings which decompose properly (much more quickly than longer clippings). The ideal cutting height will vary with climate, time of year, and quality of your lawn. We recommend that you experiment with both the cutting height and ground speed to achieve the best cut. Start with a high cutting height and use progressively lower heights until you find a cutting height that is matched to your mowing conditions and preferences. For best results, overlapping is recommended.

WARNING
Never operate the mower deck without either the discharge chute or mulching deflector in place. To install the side discharge chute: 1. Lift up the mulching cover (B, Figure 3). 2. Install the side discharge deflector (A) under the mulching cover. The side discharge deflector hooks onto the mulching cover hinge rod, and is held in place by the mulching cover. 3. Release the mulching cover.

12

Operation
MOWER INSTALLATION & REMOVAL

WARNING
Engage parking brake, disengage PTO, stop engine and remove key before attempting to install or remove the mower.

NOTE: Perform mower removal and installation on a hard, level surface such as a concrete floor.
1. Turn the front wheels of the tractor full left. 2. Place the mower in lowest cutting position. 3. Move lever (C, Figure 5) to release belt tension, then slide belt off of PTO pulley. 4. Remove clip (B, Figure 5) from the rod (A), and remove the rod. 5. Disconnect the front hitch by pulling out on the release rod (B, Figure 4) and lifting the mower hitch off the tractor hitch (A). Slide the mower deck out from under the right side of the tractor. 6. Install the mower in reverse order of removal.
C

B Figure 4. Front Hitch A. Hitch

B. Release Rod
A D

NOTE: When installing rod (A, Figure 5), turning the front wheels slightly left or right helps to align the holes.
B

Figure 5. Mower Deck - Left Side (38 Deck Shown) A. Rod C. Lever B. Clip D. U-Bracket

ADJUSTING MOWER CUTTING HEIGHT & GAUGE WHEELS - 38 & 44

NOTE: Perform adjustment on a hard, level surface such as a concrete floor.
1. Set the mower height adjustment lever (B, Figure 6) to the desired cutting height. 2. Remove the pin & clip (A, Figure 6) from each mower deck front gauge wheel. 3. Adjust the gauge wheels to achieve the appropriate mower deck-to-ground clearance, as shown in Figure 6. Reinstall pin & clip to each wheel. Between 3/4"- 1" with Height Adjuster Lever in lower 3 slots, 2" with Height Adjuster Lever in upper 3 slots
B

Figure 6. Mower Deck - Right Side A. Pin & Clip B. Height Adjustment Lever 13

Operation
ADJUSTING MOWER CUTTING HEIGHT 40
The cutting height adjustment lever (A, Figure 7) controls the mower cutting height and has five positions. The highest cutting position should be used when transporting to and from the work site (do not cut with the lever in the highest position). The lower four positions are used when mowing. Set this lever so that the deck is cutting off 1/3 the height of the grass or less. If the desired cutting height falls between two notches, use the cutting height fine tuning adjuster (B) to achieve the correct height. Figure 7. Mower Cutting Height Adjustment A. Cutting Height Lever B. Fine Tuning Adjustment
A B

STORAGE

WARNING
Never store the unit (with fuel) in an enclosed, poorly ventilated structure. Fuel vapors can travel to an ignition source (such as a furnace, water heater, etc.) and cause an explosion. Fuel vapor is also toxic to humans and animals. Before you store your unit for the off-season, read the Maintenance and Storage instructions in the Safety Rules section, then perform the following steps: Disengage the PTO, set the parking brake, & remove the key. Perform engine maintenance and storage measures listed in the engine owners manual. This includes draining the fuel system, or adding stabilizer to the fuel (do not store a fueled unit in an enclosed structure - see above). Battery life will be increased if it is removed, put in a cool, dry place and fully charged about once a month. If the battery is left in the unit, disconnect the negative cable. Before starting the unit after it has been stored: Check all fluid levels. Check all maintenance items. Perform all recommended check and procedures found in the engine owners manual. Allow the engine to warm up for several minutes before use.

14

Operation

Regular Maintenance

MAINTENANCE SCHEDULE
The following schedule should be followed for normal care of your tractor and mower. Use the hour meter to determine your operating time. Before Each Use Every 5 Hours Every Every Every 25 Hours 100 Hours 250 Hours Spring & Fall Before Each Use Every 5 Hours *** Yearly *** Yearly Yearly Before Each Use Every 5 Hours Every Every Every 25 Hours 100 Hours 250 Hours Spring & Fall Every Every Every 25 Hours 100 Hours 250 Hours Spring & Fall

SAFETY ITEMS Check Safety Interlock System Check Tractor Brakes Check Mower Blade Stopping Time TRACTOR MAINTENANCE ITEMS Check Tractor/Mower for loose hardware Check / Clean Cooling Fins Check / Adjust PTO Clutch Lubricate Tractor & Mower ** Lubricate Rear Axle Shafts Clean Battery & Cables Check Tire Pressure Clean Deck & Check/Replace Mower Blades ** Perform Transmission Maint. (Varies by Model) Check Mower Blade Timing (40 Mowers) Check Arbor Drive Belt Tension (40 Mowers) ENGINE MAINTENANCE ITEMS Check Engine Oil Level Check / Change Engine Air Filter Change Engine Oil & Filter * Inspect Spark Plug(s) Check / Replace Fuel Filter

These procedures and their service intervals can be found in the engine manufacturers owners manual. Always refer to the engine manual for engine-related information.

* Change original engine oil after initial break-in period. Refer to engine owners manual. ** More often in hot (over 85 F: 30 C) weather or dusty operating conditions. *** Service after the first 25 hours of operation, then every 250 hours of operation.

TIRE PRESSURE
Tire pressure should be checked periodically, and maintained at the levels shown in the chart at right. Note that these pressures differ slightly from the Max Inflation stamped on the side-wall of the tires. The pressures shown in the chart provide proper traction, improved cut quality, and extended tire life.

Tire
Front Rear

Pressure
12 - 15 psi (82 - 103 kPa) 10 - 12 psi (56 - 82 kPa)

15

Regular Maintenance
RAISING THE HOOD & SEAT
1. To raise the hood, grasp the hood recess (Figure 8) on top, then pivot the hood up and forward. 2. To raise the seat for battery access, tilt the seat forward.
Hood recess

CAUTION
Do not run the engine with the hood raised. Engine heat will cause damage to the headlight bezel and hood. Figure 8. Gas Tank Located Under Hood

CHECKING FUEL FILTER

WARNING
Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. DO NOT spread hose clamps further than necessary. Ensure clamps grip hoses firmly over filter after installation. The fuel filter (C, Figure 9) is located in fuel line between fuel tank and carburetor. If filter is dirty or clogged, replace as follows. Place a container below filter to catch spilled gasoline. 1. Using a pliers, open and slide hose clamps from fuel filter. 2. Remove hoses from filter. 3. Install new filter in proper flow direction in fuel line. Secure with hose clamps. See warning at beginning of procedure.

C E

SAFETY INTERLOCK SYSTEM CHECK

Service Interval: Every Fall & Spring Check the function of the safety interlock system using the test procedure found on page 10 of this manual. If the tractor fails any of the tests, see your dealer.

BLADE BRAKE CHECK

Service Interval: Every 100 Hours or Fall & Spring Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned off. 1. With tractor in neutral, PTO disengaged and operator in seat, start the engine. 2. Look over the left-hand footrest at the mower drive belt. Engage the PTO and wait several seconds. Disengage the PTO and check the amount of time it takes for the mower drive belt to stop. 3. If mower drive belt does not stop within five seconds, re-adjust the clutch or see your dealer. 16

Figure 9. Engine Compartment A. Oil Fill D. Air Filter B. Gas Tank E. Spark Plug C. Fuel Filter

PTO CLUTCH ADJUSTMENT CHECK

Service Interval: After 25 Hrs, Then Every 250 Hrs Check the PTO clutch adjustment after the initial 25 hour break-in period and then after every 250 hours of operationor if the clutch starts slipping or will not engage. Check and adjust the clutch using the procedure outlined in the Adjustments section of this manual.

ENGINE MAINTENANCE
Refer to the engine owners manual for all engine maintenance procedures and recommendations.

Regular Maintenance
LUBRICATION
Service Interval: Every 25 Hours Lubricate the unit at the locations shown in Figures 1012 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 foot pedal mower linkage transmission idler assembly pivot rear axle shafts (remove wheel hubs) Use grease fittings when present. Automotive lithium grease is recommended. Oil: control linkage seat adjustment assembly brake linkage mower deck height adjustment linkage manual lift lever

Grease Axle Shafts Yearly Figure 11. Lubricating Tractor

Figure 10. Lubricate Deck Linkage (38 shown)

Figure 12. Arbor Lubrication Points 17

Regular Maintenance
LUBRICATE REAR AXLE SHAFTS
A B

WARNING
PREVENT SERIOUS INJURY OR DEATH FROM FALLING UNIT Always use a properly working lifting device with a capacity suitable for the weight of the unit being serviced. Always use a jack stand to support the unit while performing service, and chock remaining wheels to prevent the unit from rolling off the supports. Never work under or around an elevated unit that is not properly supported and secured in position with wheel chocks. Service Interval: Yearly We recommend removing the rear wheel hubs and lubricating the axle shafts yearly. This prevents the wheel hubs from seizing onto the axle shaft and makes future service easier. 1. Turn off the ignition, turn off the PTO, engage the parking brake, and block the front tires. 2. Using a jack or chain hoist positioned at the center of the rear frame, carefully jack the unit up until the rear tires are approximately 1" - 2" (2.5-5cm) off the ground.
C

x3
F G

B E

Figure 13. Rear Wheel (Models with Axle Caps) A. Key E. Small Washer (A.R.) B. Large Washers F. E-Ring C. Spacer G. Hub Cap D. Wheel Assembly

NOTE: For overall unit stability during service, do not jack rear end higher than required for wheel removal.
3. Support the rear of the unit on jackstands positioned under the rear frame.

NOTE: Your axle assembly may differ slightly from the assembly pictured: the quantity of washers is adjusted on a tractor by tractor basis during assembly to allow a small amount of axle end-play.
4. Remove the hardware retaining the wheel assembly to the axle and lubricate the axle shaft using antiseize compound or lithium grease. 5. Reinstall the components in reverse order of disassembly and lower the unit. Be sure the key (A, Figure 13) is in place in the axle keyway.

18

Regular Maintenance
TRANSMISSION IDENTIFICATION
Several service procedures within this book are identified by, and vary by, transmission type. To determine what transmission is in your tractor, check the identification tag attached to the axle of the transmission (Figure 14), or check your tractors parts book.
TUFF TORQ K61 10010101 10010101010

TRANSMISSION MAINTENANCE
K46 Maintenance
The K46 is a sealed unit and does not require regular maintenance. If the transmission lacks drive or is excessively noisy, it may need to be purged. See TRANSMISSION PURGING in the Troubleshooting, Adjustments, & Service Section. ID Tag Figure 14. Transmission ID Tag Location

BATTERY MAINTENANCE

WARNING
When removing or installing battery cables, disconnect the negative cable FIRST and reconnect it LAST. If not done in this order, the positive terminal can be shorted to the frame by a tool.

Cleaning the Battery and Cables

1. Disconnect the cables from the battery, negative cable first (A, Figure 15). 2. Remove the battery and clean the compartment with a solution of baking soda and water. 3. Clean the battery terminals and cable ends with a wire brush until shiny. 4. Reinstall the battery and reattach the battery cables, positive first. 5. Coat the cable ends and battery terminals with grease or petroleum jelly.
A

FRONT

Figure 15. Battery A. Negative Cable B. Positive Cable & Cover

19

Regular Maintenance WARNING

For your personal safety, do not handle the sharp mower blades with bare hands. Careless or improper handling of blades may result in serious injury.

WARNING
For your personal safety, blade mounting capscrews must each be installed with a hex/spline washer and spring washer, then securely tightened. Torque blade mounting capscrew to 45 - 55 ft. lbs. (61 - 75 N.m.)

Figure 16. Blade Removal

SERVICING THE MOWER BLADES

Service Interval: Every 100 Hours or As Required

Workbench

NOTE: Mower blades must be timed perpendicular to each other.

1. Remove mower deck (see Mower Deck Removal). 2. See Figure 16. To remove blade for sharpening, use a block of wood to prevent blade rotation while loosening the capscrew. 3. 38 & 44 Mowers: Remove the capscrew (D, Figure 18), spring washer (C), hex washer (B), and blade. 40 Mowers: Remove the capscrew (A, Figure 19), spring washer (F), spline washer (G), alignment pin (E) and blade (D). Do not remove the blade adapter (C). 4. Use a file to sharpen blade to a fine edge. If blade is severely damaged, it must be replaced. 5. Balance the blade as shown in Figure 17. Center the blades hole on a nail lubricated with a drop of oil. A balanced blade will remain level. 6. Reinstall the blade (Figures 18 & 19) with the tabs pointing up toward the mower deck as shown. Reinstall the alignment pin (E). 7. 38 & 44 Mowers: Reinstall the hex washer (B, Figure 18), spring washer (C) and capscrew (D). Use a wooden block (A) to prevent blade rotation while tightening the capscrew (D) to 61-75 N.m (45-55 ft. lbs.). 40 Mowers: Be sure the blades are positioned perpendicular to each other as shown in Figure 19. If not, perform the Mower Blade Timing procedure found in this section. Reinstall the spline washer (G), spring washer (F) and capscrew (A). Use a wooden 20
A B C

Nail

Figure 17. Balancing The Blade

TIGHTEN

Figure 18. Installing The Blade - 38 & 44 Models A. 4x4 Wood Block C. Spring Washer B. Hex Washer D. Blade Bolt

block (B) to prevent blade rotation while tightening the capscrew (A) to 61-75 N.m (45-55 ft. lbs.).

Regular Maintenance
CHECK MOWER BLADE TIMING 40 MOWERS
Service Interval: Yearly 1. Turn the PTO to the off position, engage the parking brake, turn the engine off, and remove the key. Remove the mower deck (see Mower deck removal). 2. Turn the mower deck over and check the position of the blades. The blades must be positioned perpendicular to each other as shown in Figure 20. If not, proceed to step 3. 3. Use a block of wood (B, Figure 19) to prevent blade rotation while loosening the capscrew. 4. Remove the capscrew (A, Figure 19), spring washer (F), and spline washer (G). 5. Remove the alignment pin (E, Figure 19). Rotate the blade (D) manually until the blades are perpendicular to each other as shown in Figure 20. It may be necessary to remove and rotate the blade adapter (C) to align the blade hole and adapter hole. 6. Reinstall the alignment pin (E), spline washer (G), spring washer (F) and capscrew (A). Use a wooden block (B) to prevent blade rotation while tightening the capscrew (A) to 61-75 N.m (45-55 ft. lbs.). Figure 19. Blade Installation & Hardware A. Blade Mounting Capscrew B. 4x4 Wood Block C. Blade Adapter D. Blade E. Alignment Pin F. Spring Washer G. Spline Washer
A B C D E G F A

Figure 20. Check Blade Timing

21

Regular Maintenance
CHECK MOWER BELT TENSION 40 MOWERS

WARNING
Mower blades are sharp. For your personal safety, do not handle mower blades with bare hands. Careless or improper handling of blades may result in serious injury. Service Interval: Yearly 1. Turn the PTO to the off position, engage the parking brake, turn the engine off, and remove the key. Remove the mower deck (see Mower deck Removal). 2. Remove the screws securing the belt covers. Remove the belt covers. 3. Loosen the idler assembly capscrew (A, Figure 21). 4. Using a 3/8" drive ratchet and extension (Figure 22), insert the square end of the extension into the square hole (D) and rotate the spring-loaded idler assembly (B, Figure 21) to relieve tension on the belt (C). . 5. Remove the belt (C) and inspect it for cracks, missing teeth and wear. Replace belt if worn or damaged. 6. Reinstall the belt (C). Releasing the idler assembly (B) allows the spring to automatically tension the cogged belt. 7. Tighten the idler assembly capscrew (A) and reinstall the belt covers. 8. Check the mower blade timing.
A C

D B A

Figure 21. Mulching Deck (Belt Covers Removed)

A. B. C. D. Idler Assembly Capscrew Spring-Loaded Idler Assembly Belt Square Hole

Figure 22. Release Cogged Belt Tension

A. 3/8 Ratchet and Extension

22

Notes

23

Troubleshooting, Adjustment, & Service

TROUBLESHOOTING
While normal care and regular maintenance will extend the life of your equipment, prolonged or constant use may eventually require that service be performed to allow it to continue operating properly. The troubleshooting guide below lists the most common problems, their causes and remedies. See the information on the following pages for instructions on how to perform most of these minor adjustments and service repairs yourself. If you prefer, all of these procedures can be performed for you by your local authorized dealer.

WARNING
To avoid serious injury, perform maintenance on the tractor or mower only when the engine is stopped and the parking brake engaged. Always remove the ignition key, disconnect the spark plug wire and fasten it away from the plug before beginning the maintenance, to prevent accidental starting of the engine.

TROUBLESHOOTING THE TRACTOR

PROBLEM
Engine will not turnover or start.

CAUSE
1. 2. 3. 4. 5. 6. 7. 8. 9. Brake pedal not depressed. PTO (electric clutch) switch in ON position. Cruise control engaged. Out of fuel. Engine flooded. Circuit breaker tripped. Battery terminals require cleaning. Battery discharged or dead. Wiring loose or broken.

REMEDY
Fully depress brake pedal. Place in OFF position. Move lever to Neutral position. If engine is hot, allow it to cool, then refill the fuel tank. Disengage choke. Wait one minute for automatic reset. Replace if defective. See Battery Maintenance Section. Recharge or replace. Visually check wiring & replace broken or frayed wires. Tighten loose connections. See your dealer. See your dealer. Clean and gap or replace. See engine manual. Drain fuel & refill with fresh fuel. Replace fuel filter. Drain fuel & refill with fresh fuel. Replace fuel filter. Clean air filter. Check choke adjustment Clean and gap or replace. See engine manual. Check/add oil as required. See engine manual. Clean engine fins, blower screen and air cleaner. Clean radiator screen. See engine manual. Drain excess oil. Replace air filter. See engine manual. Open choke. Depress pedals. Move into drive position. See Drive Belt Replacement. See cause and remedy below. Disengage parking brake.

Engine starts hard or runs poorly.

Engine knocks. Excessive oil consumption.

10. Solenoid or starter motor faulty. 11. Safety interlock switch faulty 12. Spark plug(s) faulty, fouled or incorrectly gapped. 13. Water in fuel. 14. Gas is old or stale. 1. Fuel mixture too rich. 2. Spark plug(s) faulty, fouled, or incorrectly gapped. 1. Low oil level. 2. Using wrong grade oil. 1. Engine running too hot. 2. 3. 1. 2. 1. 2. 3. 4. 5. Using wrong weight oil. Too much oil in crankcase. Dirty air filter. Choke closed. Ground speed control pedals not depressed. Transmission release lever in push position. Drive belt is broken. Drive belt slips. Parking brake is engaged.

Engine exhaust is black. Engine runs, but tractor will not drive.

24

Troubleshooting, Adjustment, & Service

Tractor Troubleshooting Cont.
Tractor drive belt slips. 1. 2. 3. 4. Clutch/brake is out of adjustment. Pulleys or belt greasy or oily. Belt stretched or worn. Idler pulley pivot bracket frozen in declutched position. 1. Brake is incorrectly adjusted. 2. Internal brake worn. 1. Steering linkage is loose. 2. 3. Improper tire inflation. Front wheel spindle bearings dry. See Adjustments Section. Clean as required. Replace with new belt. Remove idler pulley bracket, clean and lubricate. See Brake Adjustment. See your dealer. Check and tighten any loose connections. See Steering Gear Adjustment. Check and correct. Grease spindles. See Lubricating the Tractor.

Brake will not hold. Tractor steers hard or handles poorly.

TROUBLESHOOTING THE MOWER

PROBLEM
Mower will not raise.

CAUSE
1. 2. 3. 1. 2. 1. 2. 3. 4. 5. 6. Lift linkage not properly attached or damaged. Dirt in hydraulic lines. Brake pedal depressed. Mower not leveled properly. Tractor tires not inflated equally or properly. Engine speed too slow. Ground speed too fast. Blades are dull. Mower drive belt slipping because it is oily or worn. Check PTO (Electric Clutch) Adjustment. Blades not properly fastened to arbors. Engine speed too slow. Ground speed too fast. Carburetor improperly adjusted. Cutting height set too low. Discharge chute jamming with cut grass. Engine not up to operating temperature. Starting mower in tall grass. Blade mounting screws are loose. Mower blades, arbors, or pulleys are bent. Mower blades are out of balance. Belt installed incorrectly. Bent or rough pulleys. Using incorrect belt. Idler pulley spring broken or not properly attached. Belt stops out of adjustment. Mower drive belt broken. PTO clutch out of adjustment. Blade shear pin broken.

REMEDY
Attach or repair. Change hydraulic system filter. Release brake pedal to power transmission. See Mower Adjustment. See Maintenance Section. Set to full throttle. Slow down. Sharpen or replace blades. See Mower Blade Service. Clean or replace belt as necessary. See Adjustments Section. See Servicing the Mower Blades. Set to full throttle. Slow down. See Engine Manual. Cut tall grass at maximum cutting height during first pass. Cut grass with discharge pointing toward previously cut area. Run engine for several minutes to warm-up. Start the mower in a cleared area. Tighten to 45-55 [Link]. (61-75 N.m.). Check and replace as necessary. Remove, sharpen, and balance blades. See Servicing the Mower Blades. Reinstall Correctly. Repair or replace. Replace with correct belt. Repair or replace as needed. Check belt stops. Replace drive belt. Adjust PTO clutch. Replace shear pin.

Mower cut is uneven.

Mower cut is rough looking.

Engine stalls easily with mower engaged.

1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 1. 2. 1.

Excessive mower vibration.

Excessive belt wear or breakage. Mower drive belt slips or fails to drive.

2. 3. 4. Mower blades collide (40 Mower). 1.

25

Troubleshooting, Adjustment, & Service

BATTERY CHARGING

WARNING
Keep open flames and sparks away from the battery; the gasses coming from it are highly explosive. Ventilate the battery well during charging. A dead battery or one too weak to start the engine may be the result of a defect in the charging system or other electrical component. If there is any doubt about the cause of the problem, see your dealer. If you need to replace the battery, follow the steps under Cleaning the Battery & Cables in the Regular Maintenance Section. To charge the battery, follow the instructions provided by the battery charger manufacturer as well as all warnings included in the safety rules sections of this book. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60 F). Do not charge at a rate higher than 10 amps.

Figure 23. Seat Adjustment A. Seat Adjustment Lever

WARNING
To avoid serious injury, perform adjustments only with engine stopped, key removed and tractor on level ground.
A

SEAT ADJUSTMENT
The seat can be moved forward and back by moving the lever (A, Figure 23) underneath the front of the seat, then positioning the seat as desired.

STEERING GEAR ADJUSTMENT

If there is excessive slack in the steering system, the steering gear backlash can be removed. 1. See Figure 24. Locate the steering gear assembly on the underside of the tractor. Loosen the two nuts and adjust the bracket so the gear teeth are closely meshed. 2. Tighten nuts (A, Figure 24) to 36-44 ft. lbs. (49-59 Nm) after adjustment.

Figure 24. Steering Gear Adjustment A. Nuts

26

Troubleshooting, Adjustment, & Service

BRAKE & BRAKE SPRING ADJUSTMENT
1. Disengage the PTO, stop the engine, block the wheels, remove the ignition key, and engage the parking brake. 2. Remove the mower deck (see Mower Deck Removal). 3. Locate the brake spring (A, Figure 25) and adjustment nut (B). 4. With the parking brake engaged, measure the compressed spring length. The spring should be 1-11/16 - 1-3/4 (4.2cm - 4.4 cm) when compressed. If the spring is not within this range, turn the adjustment nut (B, Figure 25) to compress or release the spring. If this adjustment does not correct a braking problem, see your dealer.
A B

Spring Length 1-11/16 to 1-3/4

Figure 25. Brake Spring Adjustment B. Nut A. Spring

PTO CLUTCH ADJUSTMENT

Check the PTO clutch adjustment after the initial 25 hour break-in period and then after every 250 hours of operation. Also perform the following procedure if the clutch is slipping or will not engage, or if a new clutch has been installed. 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 26. Note the position of the 3 adjustment windows (A) in the side of the brake plate and the nylock adjustment nuts (B). 3. Insert a .012-.015 (2,5-4mm) feeler gauge (C) through each window, positioning the gauge between the rotor face and the armature face as shown in Figure 27. 4. Alternately tighten the adjustment nuts (B, Figure 26) until the rotor face and armature face just contacts the gauge. 5. Check 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. 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. Check 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. 7. Perform the BLADE BRAKE CHECK found in the 01 27
B

Figure 26. Adjust PTO Clutch A. Window B. Adjustment Nut

B

Figure 27. Adjust PTO Clutch A. Window B. Adjustment Nut C. Feeler Gauge MAINTENANCE Section. Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned off.

Troubleshooting, Adjustment, & Service WARNING

Before checking mower, shut off PTO and engine. Allow all moving parts to stop. Remove ignition key, then disconnect the spark plug wire and fasten it away from the spark plug.
B

MOWER ADJUSTMENTS
Leveling The Mower
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 Checking Tire Pressure.
ALL MODELS

Figure 28. Side-to-Side Adjustment A. Outside Nut C. Taptite Screw B. Eccentric Nut

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. Check for bent blades and replace if necessary. 3. Disengage the PTO. Place the mower in mid-cut position. Arrange one of the mower blades so that it is 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 6. 5. See Figure 28. Loosen the outside nut (A). Turn the eccentric nut (B) to raise or lower left-hand side of mower. When mower is level, hold the eccentric nut while tightening the outside nut. Figure 29. Front-to-Back Leveling Rod - 40
A. Front Nut B. Rear Nut

NOTE: When using a turbo collection system, raise the discharge side of the mower approximately 1/4 to compensate for turbo assembly weight. Check level of cut grass and adjust the 1/4 measurement if necessary for a smooth even cut.
40 MOWER

A B

6. Arrange the blades so they face front-to-back. 7. Measure the distance from the ground to front tip and rear tip of the left and right-hand blades. 8. Front tips should be 1/8-1/4 higher. If not, proceed with steps 8 - 10. 9. See Figure 29. To raise front of mower deck, loosen front nut (A) and turn rear nut (B) against bracket (C). 10. To lower front of mower deck, loosen rear nut (B) and bracket (C) will move backwards to lengthen rod. 11. Re-check measurement before tightening front nut (A) against bracket. 28
C

Figure 30. Front-to-Back Adjustment Nut - 38 & 44 A. Outside Nut C. Adjustment Nut B. Eccentric Nut

Troubleshooting, Adjustment, & Service

38 & 44 MOWERS

6. Arrange the blades so they face front-to-back 7. Measure the distance from the ground to the front and rear tips of each blade. The measurement should be equal for both blades. Front tips should be equal to rear tips or within 1/8" higher. If not, proceed to next step. [Link] Figure 30. Loosen the outside nut (A) and turn the eccentric nut (B) to raise or lower the rear of the deck. When the mower deck is level, hold the eccentric nut while tightening the outside nut.

Belt Covers not shown for clarity

NOTE: If mower handle drops out of cutting height quadrant, turn adjustment nut (C, Figure 30) clockwise to increase spring tension. DO NOT tighten nut all the way so that spring is solid.
A

MOWER BELT REPLACEMENT

38 Mowers
1. Park the tractor on a level surface. Disengage the PTO, turn off the engine and set the parking brake. Remove the key. 2. Remove the mower deck from the tractor. See Mower Installation & Removal in the Operation section. 3. Loosen the hardware securing the belt guides (A, Figure 31). Also loosen the idler pulley belt guide (B). 4. Remove the old belt and install the new belt over the pulleys as shown in Figure 31. 5. Tighten the belt guide hardware and idler pulley belt guide (B). The idler pulley belt guide should be at the mid-point of the belt wrap as shown.

Figure 31. Mower Deck Belt Routing - 38 Deck A. Belt Guides B. Idler Pulley Belt Guide

Belt Covers not shown for clarity

44 Mowers
1. Park the tractor on a level surface. Disengage the PTO, turn off the engine and set the parking brake. Remove the key. 2. Remove the mower deck from the tractor. See Mower Installation & Removal in the Operation section. 3. Remove both belt covers. 4. Loosen the idler pulley bolt. 5. Remove the old belt and install the new belt over the pulleys as shown in Figure 32. 6. Tighten the idler pulley bolt. 7. Reinstall both belt covers. Figure 32. Mower Deck Belt Routing - 44 Deck

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Troubleshooting, Adjustment, & Service

40 Mower PTO Belt Replacement
1. With the mower deck installed, park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, shut the engine off, and remove the key. 2. Remove the mower deck (see Mower deck removal). Remove the belt covers. 3. Note the position of the idler pulley belt guides (E & F, Figure 33) when installed. Loosen the idler pulley capscrews and remove the belt from the idler pulleys (D & G). 4. Install the new belt (B) as shown. When the mower deck is installed on the tractor, the belt wraps around the PTO clutch pulley (A), backside idler pulley (D), mower deck drive pulley (C), and v-idler pulley (G) . 5. Return the idler pulley belt guides (E & F) to their original positions and tighten the idler pulley capscrews.
G

Figure 33. PTO Belt Replacement A. Engine PTO Clutch Pulley B. PTO Belt C. Mower Deck Drive Pulley D. Backside Idler Pulley E. Belt Guide F. Belt Guide G. V-Idler Pulley

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Troubleshooting, Adjustment, & Service

A D C B A

Figure 35. Release Cogged Belt Tension A. 3/8 Ratchet and Extension Figure 34. Mulching Deck (Belt Covers Removed) A. Idler Assembly Capscrew B. Spring-Loaded Idler Assembly C. Belt D. Square Hole

40 Mower Arbor Drive Belt Replacement

1. With the mower deck installed, park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, shut the engine off, and remove the key. 2. Remove the mower deck (see Mower Deck Removal). Remove the belt covers. 3. Loosen the idler assembly capscrew (A, Figure 34). 4. Using a ratchet (A, Figure 35), insert the end of the extension into the square hole (D, Figure 34) and move the idler assembly (B, Figure 34) to relieve tension on the belt (C). 5. Remove the belt (C). 6. Install a new belt (C) on the pulleys as shown. Releasing the idler assembly (A) allows the spring to automatically tension the cogged belt. 7. Tighten the idler assembly capscrew (A). Reinstall the belt covers. 8. Check that the blades are positioned perpendicular to each other (see Figure 36). If not, perform the mower blade timing procedure found in the Regular Maintenance section. Figure 36. Mower Blade Timing

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Troubleshooting, Adjustment, & Service

TRACTOR DRIVE BELT REPLACEMENT
IMPORTANT NOTE
To avoid damaging belts, do not pry belts over pulleys. 1. Park the tractor on a level surface. Disengage the PTO, turn off the engine and set the parking brake. Remove the key. 2. Remove the mower deck from the tractor. See Mower Installation & Removal. 3. Unplug the wiring harness from the PTO clutch. Remove the PTO clutch as shown in Figure 37. 4. Remove the drag link rear hardware. When reassembling, apply thread locking compound to nut before tightening. 5. Loosen the belt stop on the transmission pulley. Belt stop hardware is located on the inside of RH frame. Move belt stop out of the way. Belt stop should be positioned 1/8" from belt when new belt is installed and hardware is tightened. 6. Carefully slide belt over transmission pulley and remove from other pulleys. 7. Install new belt as shown in Figure 38. 8. Reverse steps 1-5.
A B

C D

Figure 37. PTO (Electric Clutch) Assembly A. PTO C. Washer B. Sleeve D. Capscrew

TRANSMISSION PURGING
Purge the transmission 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 just high enough for the wheels to clear the ground. 2. Activate the seat switch, depress the clutch / brake pedal, and start the engine. After the engine has started, set throttle to IDLE. 3. Release the brake pedal and fully depress the forward ground speed pedal. 4. While holding the forward ground speed pedal down, engage and disengage the transmission release valve lever (A, Figure 39) several times. 5. Fully depress the reverse ground speed pedal. 6. While holding the reverse ground speed pedal down, engage and disengage the transmission release valve lever (A) 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. Figure 38. Drive Belt Routing - All Models A. Engine Pulley C. Idler Pulleys B. Transmission Pulley

Figure 39. Transmission Release Lever A. Transmission Release Lever

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Specifications
NOTE: Specifications are correct at time of printing and are subject to change without notice.

ENGINE:
16 HP Kohler Command
Make Model Horsepower Displacement Electrical System Oil Capacity Kohler CommandTM CV460 16 @ 3600 rpm 27.9 Cu. in (460 cc) 12 Volt, 15 amp. Alternator, Battery: 200 CCA 4.0 Pints w/Filter (1.9 L)

CHASSIS:
Fuel Tank Capacity Rear Wheels Front Wheels 2.0 Gallons (7.5 L) Tire Size: 20 x 8-8 Turf Type Inflation Pressure: 10-12 psi (82-103 kPa) Tire Size: 15 x 6.50-6 Inflation Press.: 12-15 psi (82-103 kPa) Bearings: Sintered Iron with Grease Fittings

16 HP Honda GXV
Make Model Horsepower Displacement Electrical System Oil Capacity Honda GXV530 16 @ 3600 rpm 32.3 Cu. in (530 cc) 12 Volt, 12 amp. Regulated, Battery: 200 CCA 1.37 Quarts w/Filter (1,05 L)

TRANSMISSION:
Type Hydraulic Fluid Speeds @ 3400 rpm Continuous Torque Output Drawbar Rating Maximum Weight on Axle Hydrostatic Tuff Torq K46 10w 30 Premium Engine Oil Forward: 0-5.6 MPH (9.0 km/h) Reverse: 0-3.0 MPH (4.6 km/h) 170 ft. lbs. 227 lbs. (103 Kg) 675 lbs.

17 HP
Make Model Horsepower Displacement Electrical System Oil Capacity Briggs & Stratton Intek 17 @ 3600 rpm 31 Cu. in (502 cc) 12 Volt, 9 amp. Alternator, Battery: 200 CCA 56 Oz. (1.6 L)

DIMENSIONS
Overall Length Overall Width Height Wheel Base Weight (approx.) Net 68 in (172 cm) 36 in (92 cm) At Steering Wheel: 41 in (104 cm) To Top of Engine Cover: 34 in (86 cm) 50 in (127 cm) 371 lbs. (168 kg) w/44 mower 463 lbs. (210 kg)

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Parts and Accessories

Replacement Parts
Replacement parts are available from your authorized dealer. Always use genuine Simplicity Service Parts.

Maintenance Items
Many convenient and helpful service and maintenance items are available from you authorized dealer. Some of these items include: Engine Oil Touch-Up Paint Grease Gun Kit 8 oz. Grease Tube Tire Sealant Degrimer/Degreaser Gas Stabilizer

Optional Accessories
Snowthrower Cab 42 & 36 Single Stage Snowthrowers 42" Dozer/Snow Blade Rear Wheel Weights Tire Chains Twin Bag Grass Catcher Dump Cart Hour Meter Kit Gas Cans

TECHNICAL MANUALS
Additional copies of this manual are available, as well as fully illustrated parts lists. These manuals show all of the products components in exploded views (3D illustrations which show the relationship of parts and how they go together) as well as part numbers and quantities used. Important assembly notes and and torque values are also included. For applicable manuals currently available for your model, contact our Customer Publications Department at 262-284-8519. Have the information listed in the box below available when phoning in your request. Technical manuals can be downloaded from [Link]

Model: Mfg. No.: Your Name: Address: City, State, Zip: Visa/Mastercard No.: Card Expiration Date:

34

Lawn Care & Mowing Information

HOW AND WHEN TO WATER, FERTILIZE & AERATE
Most lawns are watered too often, but with too little water. However too much water can allow development of diseases with your lawn. It is best to water the lawn only when necessary, and then to water it slowly, evenly, and deeplyimitating a slow, soaking rain.
WHEN TO WATER YOUR LAWN HOW TO WATER YOUR LAWN

The best method of watering a lawn is to imitate a slow, soaking rain, applying about 1 inch of water.
HOW TO FERTILIZE YOUR LAWN

Fertilizing with a slow-release fertilizer provides missing nutrients which help create slow, even growth. Remember that over-fertilizing can cause harm, and that most fertilizing should be applied in the spring so that it will release into the lawn through the summer.
AERATING YOUR LAWN

When the lawn begins to wilt, the grasss color dulls, or footprints stay compressed for more than a few seconds, the lawn is beginning to dry out, and needs additional moisture. The best time to water is early morning to allow the water to soak deeply into the lawn and reduce the amount that evaporates in the hot afternoon sun.

Consider aerating your lawn in spring. Using an aerator to remove cores of soil from the lawn increases the speed of clipping decomposition and encourages deeper root growth by opening up the soil and permitting greater movement of water, fertilizer and air.

HOW HIGH TO MOW THE GRASS

Cutting the grass too short causes weak, thin grass plants, which are easily damaged by dry periods and pests. Letting grass grow a bit longerespecially when it is hot and dryreduces heat build-up, preserves needed moisture and protects the grass from heat damage and other problems. Cutting off too much at one time shocks the plants growth system and weakens the grass plants. A good rule of thumb is the 1/3 rule: to cut no more than one third of the grass height, and never more than 1 inch at a time.

Cut less than

1/3

Optimal cutting point at less than 1/3 from top of grass blade

Cutting down to this area contributes to thatch problems

Cut Here On First Pass

Cut Here On Second Pass

Tall Grass Requires Incremental Cutting

For extremely tall grass, set the cutting height at maximum for the first pass, and then reset it to the desired height and mow a second or third time. Dont cover the grass surface with a heavy layer of clippings.

TP 600-2136-03-UV-SMA

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Lawn Care & Mowing Information

WHEN AND HOW OFTEN TO MOW
The time of day and condition of the grass greatly affect the results youll get when mowing. For the best results, follow these guidelines: G Mow when the grass is between 3-4 (7,5-10 cm) high. G Mow with sharp blades. Short clippings of grass one inch or shorter decompose more quickly than longer blades. Sharp mower blades cut grass cleanly and efficiently, preventing frayed edges which harm the grass. G Mow at time of day when the grass is cool and dry. Late afternoon or early evening often provide these ideal mowing conditions. G Avoid mowing after rain or even heavy dew, and never mulch when the grass is wet (moist grass does not mulch well, and clumps beneath the mower deck). Note: Always operate the engine at full throttle when mowing.

PROPER MOWING SPEED

ENGINE SPEED & GROUND SPEED

Always operate the engine at full throttle when mowing. If you hear the engine slowing down, you are mowing too fastmaintaining a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems. Select an appropriate ground speed for the thickness and height of the grass you are cutting (3rd gear or slower for manual gear models, or mid-range or slower for hydro models). If you hear the engine slowing down you are mowing too fast, use a slower ground speed.
HOW MUCH GRASS TO CUT OFF

Mow when the grass is 3-4 inches (7,5-10cm) long. Do not cut off more that 1 (2.5cm) of grass in a single pass.

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