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  9. Sears 502.254152 User manual

Sears 502.254152 User manual

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owners
a a
Model No.
502.2541 52
CAUTION:
Read And Follow
All Safety Rules
And Instructions Before
Operating This
Equipment.
11 P. LECTRIC START
8 SPEED =30" MOWER
EA ENG! I
®Assembly
®Operation
•Maintenance
oRepair and Adjustment
®Repair Parts
F-88516 Sears, Roebuck and Co., Chicago, IL. 60684 U.S.A. •PrTnted fn U,S,A.
SAFETY RULES
Safe Operation Practices for Riding Vehicles
As Recommended by American National Standards Institute
1. Know the controls and how to stop quickly, READ THIS
INSTRUCTION BOOK and any instructions furnished with
attachments.
2. Do not allow children to operate the machine. Do not allow
adults to operate tt without proper instruction.
3, Clear the work area of objects (wire, rocks, etc.) which might
be discharged by the machine,
4. Handle gasoline with care, It is highly flammable.
a. Use an approved gasoline container.
b. Never remove the fuel cap or add gasoline to a running
orhot engine oran engine that has not been allowed to cool
for several minutes after running, Never fill the fuel tank
indoors. Clean up spilled gasoline.
c. Do not run the engine indoors. Exhaust fumes are
dangerous,
5. Always wear safety glasses or a eye shield when you operate
the unit to protect your eyes from foreign objects that can be
thrown from the unit, Always wear eye protection when you
make an adjustment or repairs to the unit.
6. Keep all nuts, bolts, and screws tight to be sure the equip-
ment is in safe working condition.
7, Disengage all attachment clutches and shift into neutral
before attempting to start the engine,
8. Disengage power attachment(s) when transporting or not
in use.
9, Do not stop or start suddenly when going uphil] ordownhill,
Mow upand down the face of steep slopes;never across the
face, See the "Guide" in the back this book to check for
safe operation,
1O, Reduce speed and exercise extreme caution on slopes and in
sharpturns to prevent tipping or loss of control. Beespecially
cautious when changing directions on slopes.
11, Stay alert for holes, rocks, roots in the terrain, and other
hidden hazards, Keep away from drop-offs,
12. Use care when pulling loads or using heavy equipment.
a. Use only approved drawbar hitch points.
b. Limit loads to those you can safety control.
c, Do not turn sharply. Use care when baektng,
d, Use counterweight(s) or wheel weights when suggested
in the instruction book.
13. Watch out for traffic when crossing or near roadways.
14. When using any atiachments, never direct discharge of
material toward bystanders or allow anyone near the unit
while in operation.
15. Disengage power to attachment(s) and stop the engine
before 1eaving the operator's position.
16. To reduce fire hazards, keep the engine free of grass, leaves,
or excessive grease.
17, The vehicle and attachments must bestopped and inspected
for damage after striking a foreign object, All damage must
be repaired before restarting and operating the equipment.
18, Donot change the engine governorsettings oroverspeed the
engine.
19. When using the vehicle with a mower, proceed as follows:
a. Mow only in daylight or tn good a_ifieiat light2
b, Never make a cutting height adjustment while the
engine is running if the operator must dismount.
c. Stop the engine before removing agrass catcher or
unclogging the chute,
d. Check the blade(s) and mounting nut(s) for proper tight-
ness at frequent intervals, Frequently check the blade for
wear or damage such as cracks and nicks, A blade that is
bent or damaged must be immediately replaced with a
factory replacement blade. For safety, replace the blade
every two years, Frequently check the nut(s) that hold the
blade(s). Replace damaged nuts and tighten loose nuts, ,'
20. Disengage power to the mower before backing up. Do not
mow in reverse unless absolutely necessary and then only
after careful observation of the entire area behind the
mower.
21. Under normal usage, the grass catcher bag material" is
subject to deterioration and wear. It should be checked
frequently for bag replacement. Replacement bags should be
checked to ensure compliance with the original manufac-
turers recommendations or specifications.
22. Donot operate the mowerwithout either the grass catcher or
guards in place, Read the instructions provided with the
grass catcher.
23, Do not carry passengers, Do not mow when children and
others are present.
24. Never store the equipment with gasoline in the tank inside a
building where fumes may reach an open flame or spark.
Allow the engine to cool before storing in any enclosure.
25. Take atl possible precautions when leaving the vehicle
unattended, such as disengaging the blade engagement _
control lever, lowering the attachment(s), shifting into neutral,
setting the parking brake, stopping the engine, and removing
the key.
26, Keep the vehicle and attachments in good operating condi-
tion, and keep safety devices in place and working,
27. Disengage power to attachment(s) and stop the engine
before making any repairs or adjustments, The carburetor
can be adjusted with the engine running.
28, Wa!!; for all movement to stopbeforeservicing any part of the
29, ;:;Read and follow the instructions in this book concern ng
safety, and op§ration of the mower.
WARNING: This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest-covered,
brush-covered or grass-covered land unless the engine's exhaust system isequipped with aspark arrester meeting applicable local or state
laws (if any), If a spark arrester is used, it must be maintained in effect!re working order by the operator,
In the State of California the above is required by law (Section 4442 of the California Public Resources Code), Other states may have similar
laws, Federal laws apply on federal lands, See an Authorized Service Center for a spark attester for the muffler,
Look for this symbol to point out important safety
precautions. It means: "Attentionl Become Alertl
Your Safety Is Involved/p
F-88516
This product is made to give you many hours of performance and
safe operation. To keep the unit in good condition, you must
correctly service the unit. For safety and performance, follow the
ASSEMBLY, OPERATION, and MAINTENANCE instructions. If you
can not correct a problem, see the nearest Sears Service Center.
CUSTOMER RESPONSIBILITIES
Follow all the assembly instructions. Correctly adjust the unit.
Carefully read and foltow the rules for safe operation. Inspect the
unit, Complete all maintenance on the unit, Know how to operate
all standard and accessory equipment on the unit, Make sure that
the operator can correctly operate the unit. Operate the unit only
with guards, shields, and other safety items in place and working
correctly. Service the unit only with authorized or approved
replacement parts,
RIDING LAWN MOWER
Record inthe space below the serial number and the date
of purchase of this unit.
The model number and serial number are found under the
seat on a plate attached to the seat support.
Serial Number:
Date of Purchase:
Keep these numbers for future reference,
REAR ENGINE RIDER FEATURES
Craftsman Engine Air cooled and long life with solid state
ignition.
All Gear Transmission Eight forward speeds and one reverse
to let you select the correct speed for your type of yard. A drive
chain connects the transmission to an automotive type
differential.
Tilt Seat The seat tilts forward for easy access to the battery
and the engine,
Side Panels The side panels can be easily removed for access
to the engine. •
Mower Housing The full-floating suspensionand single blade
give an even cut. The lift lever has an eight position height
adjustment.
ATTACHMENTS
This unit can useattachments available at the nearest Sears Store.
This unit can pull attachments like a lawn sweeper, a lawn aerator,
or a hopper spreader, This unit can not use attachments that
engage the ground like a plow, a disk harrow, or a cultivator.
MAINTENANCE AGREEMENT
ASears Maintenance Agreement Isavailable on this unit. See the
nearest Sears Store for information.
LIMITED TWO YEAR WARRANTY ON ELECTRIC START RIDING EQUIPMENT
Fortwo years fromthe date ofpurchase,when thisriding equipment is maintained, lubricated, and tuned upaccordingto the operating
and maintenance instructions in the Owner's Manual, Sears will repair free of charge any defect in material or workmanship in this
electric start riding equipment.
Thiswarranty excludesblade(s),blade adapter(s}, sparkplug(s),air cleaner, and belt(s),which are expendableand becomeworn during
normal use.
This warranty does not cover:
-tire replacement or repair caused by punctures from outside objects (such as nails, thorns, stumps, or glass);and
-repairs necessary because of operator abuse or negligence, including the failure to maintain the equipment according to
instructions contained in the Owner's Manual; and
- riding equipment used for commercial or rental purposes.
FULL 90-DAY WARRANTY ON BATTERY
For 90 days from the date of purchase, if any battery included with this riding equiPment proves defective in material or workmanship
and our testing determines the battery will not hold a charge, Sears will replace th_ battery at no charge,
WARRANTY SERVICE IS AVAILABLE BY CONTACTING THE NEAREST SEARS SERVICE CENTEP_'DEPARTMENT IN THE UNITED
STATES. This warranty applies only while this product is in use in the United States.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Sears, Roebuckand Co,, D/698-731A, Sears Tower, Chicago,tL 60684
F-88516 3
A
Adjustments:
Blade Engagement Control .............. 15
Brake, Drive .........................................25
Carburetor ...........................................29
Chain, Front Drive ..............................26
Chain, Rear Drive ...............................27
Mower Housing, Level ......................22
Throttle Control Cable .......................29
Assembly ..........................................5 - 10
Attachments ...............................................3
B
Battery:
Charge ....................................................7
Clean and Check ................................ 18
Emergency Start ................................30
Install ....................................................10
Storage ................................................30
Belt;
Motion Drive, Replace .......................21
Mower Drive, Adjust .......................... 15
Mower Drive, Replace .......................21
Blade, Remove and Install ..................... 16
Blade, Sharpen .........................................17
Blade Engagement Control'.
Adjust ...................................................15
Operation .............................................11
Brake Pedal, Operation ........................... 11
C
Carburetor, Adjust ...................................29
Chains, Check and Adjust ............... 26, 27
Charge Battery ...........................................7
Clutch/Brake Pedal 11
Controls ..............................................11, 1'2
Engine:
Carburetor ...........................................29
Oil, Change ..................................14, t9
Oil Level, Check ..................................14
Oil, Type ...............................................14
Operation Speed Chart ..................... I2
Starting ................................................12
Stopping ..............................................12
Storage ................................................30
Throttle Control ........................... 11, 29
Trouble Shooting Chart ....................31
INDEX
Filter, Air ................................................... t 9
Fuel ............................................................12
Fuel System, Storage .............................30
Fuse ..................._................................32, 33
Lubrication ................................................18
M
Maintenance ..................................t3 - 19
Air Filter ................................................19
Battery ..................................................18
Blade .............................................16, 17
Blade Engagement Control .............. 15
Drive Brake ..........................................25
Drive Chains .................................26, 27
Engine Oil ..................................... 14, 19
Lubrication ..........................................18
Muffler
Check ...................................................18
Spark Arrester ................................2, 18
Spark Plug ................................................18
Tires ...........................................................17
Mower Housing
Level .....................................................22
Remove and Install ............................20
O
Oil:Check ...................................................14
Change .................................................19
Operation .......................................11 - 13
Mower Housing ..................................13
Operate On Hills .................................13
Operate The Unit ................................ t3
Start Engine ........................................t2
Stop The Unit ..................................... 12
P
Parts Bag "6
R
Repair and Adjustment ................20 - 30
Mower Drive Belt ...............................22
Carburetor ...........................................29
Drive Chains .................................26, 27
Level Mower Housing .......................22
Motion Drive Belt ...............................21
Mower Housing, Install .....................20
Mower Housing, Remove ................. 20
S
Safety Rules ................................................2
Seat ...........................................,..................9
Sharpen, Blade ......................................... 17
Shift Lever ................................................ 12
Side Panel, Remove ................................ 13
Slope Guide ..........;................................... 51
Spark Plug ................................................ 18
Speed Control Chart ............................... 12
Start Engine .............................................. 12
Steering Wheel ..........................................8
Stop, Riding Mower ................................ 12
Storage ......................................................30
T
Throttle Control Cable, Adjust .............. 29
Tire Pressure ..................................... 10, 17
Transmission, Friction Drive ......... 23 - 28
Trouble Shooting Chart .......................... 31
W
Warranty ......................................................3
Wiring Schematic ....................................32
F-88516 4
ASSEMBLY
SET UP
Your unit was carefully inspected and put in acarton for protection
from damage.
The unit is assembled except for the items shown on this page.
These items are in the carton with a bag of fasteners and loose
parts needed for assembly. Find and remove these items, The
fasteners and roose parts are shown on the next page.
HOW TO REMOVE FROM THE CARTON
To remove the riding mower from the carton, follow the instruc-
tions below.
I. Open the top of the carton,
2. The items shown at the right are in asmall box. Remove and
check each item. Remove the small box.
3. Cut each corner of the carton from the top to the bottom with
aknife.
4. Move the shift lever to the NEUTRAL position.
5. Make sure the parking brake is disengaged,
6. Move the lift lever to the HIGH position,
7. Carefully push the riding mower backwards off the wood
frame,
TOOLS YOU NEED TO ASSEMBLE THE UNIT
I. Adjustable wrench
2. Open end wrench 1/2" - 9/16"
3. Open end wrench 7/16"- 1/2"
4, Blade type screwdriver
5, Phillips screwdriver
6. Low Tire pressure gauge
7. Knife
D-4656-2
12
11
I. Seat " 5. Parts Bag 9. Battery Acid
2. Bezel 6. Owner's Manual 10. Bellows
3, Steering VVhee| 7. Battery 11. Upper Console
4. Steering Post 8, Battery Tray 12. Cover
F-88516 5
PARTS BAG - contents
The fasteners and loose parts are shown beiow. The fasteners are shown full size with the quantities in brackets ().
(4) Hex Bolt
5/16" x 5/8"
For Seat
STD523106
(1) Hex Bolt 6x90 (I) Hex Bolt
5/16" x 1-1/2" (1) Bolt 3/8" x3/4"
For Adapter 5/16" x 1-1/4" For Steering Wheel
STD5231 t5 For Steering Post STD523707
(2) Hex Bolt
1/4" -20 x 5/8"
For Battery Cables
STD522506
26x161
(2) Screw
#10xl/2" Type BT
For Console Cover
(2) Screw 15x66
For Bearing (2) Locknut (1) Locknut
STD611005 I/4"-20 5/16"- 18
For Battery Cables For Adapter
STD541425 STD541431
@
19x39
(1) Lockwasher
I.D.3/8"
For Steering Wheel
STD551237
55804
(1) Cover
ForBattery Clamp
Not shown fuilsize
55253Z
(1} Clamp, Battery
For Battery
(4) Washer (2) Locknut Notsi_OwnfutIsize
(4) Lockwasher I,D. 1!/3Z _ 5/16"-18 20094Z
I,D, 5116" For Seat For Steering Post (1) (1) Washer
For Seat STD551031 For Batter/Clamp (1) I.D. 13/32"
STD551131 STD54I 431 For Steering Wheel
Not shown full size Not shown fullsize Not shown ful! size
24582 20107 56022
(4) Hub Cap (2) Seat Spring Cap (1) Bearing
For Wheels For Seat Springs For Steering Post "
Not shown full size
Not shown futl size Not shown full size 55705
55919 55911 (1) Tube, Oll Drain
(I) Cap (I} Adapter For Engine
For Steering Wheel For Steering WheeI
t 7xl 32
(t) Washer
I,D, .328"
For Steering Post
F-88516
91275
(2) Key
For Ignition
54148
(t) Cable Cover
For Red Battery Cable
ASSEMBLY
HOW TO PREPARE AND
CHARGE THE BATTERY
IMPORTANT: Before you install the battery, add the battery
acid, (Electrolyte) to the battery, Battery acid wilt damage paint
and parts,
WARNING: Read the instructions included with
the battery acid container, Protect your hands
and eyes from the battery acid. Use clothing that
will protect you,
I. Ifnot Tnstalledon the battery, remove the vent capsfrom the
plastic bag, Read the instructions included with the vent
caps,
2. If medal tape covers the vents, remove the metal tape from
the vents. Discard the metal tape.
3. Pour battery acid into each battery cell until the battery acid
touches the bottom of the vent as shown. Do not add the
battery acid above the bottom of the vent. If you add too
much battery acid, the excessivebattery acid will flow from
the battery when you charge the battery.
4. Wait 20 to 30 mTnutesbefore you put the vent caps on the
battery. The level of the battery acid candrop below the vent
described in step 3. Add more battery acid until the correct
battery acid level is reached, Install the vent caps, Wash the
top of the battery with water to remove any battery acid,
5. Discard the battery acid container and any battery acid that
was notusedasfollows. Fillthe container halffull with water.
Add baking soda and mix together using apiece of wood,
Add more baking sodauntil the solution does not foam, Dis-
cardthe solution and wash the container with water. Destroy
the container.
6,
WARNING: Whenyou charge the battery, do not
smoke. Keep the battery away from any sparks,
The fumes from the battery acid can cause an
explosion.
Use a 12 volt battery charger to charge the battery. Charge at
a rate of 2 amperes for 3to 4 hours, After the battery is
charged, check the level ofthe battery acid. If the level of the
battery acid falls, add water. Do not add battery acid to a
charged battery or the result can be an explosion.
Remove and discard
the metal tape, ,
Ve n]
0-5468
.... i'r,
Correct
Liquid
Level
A
DANGER _.,_,./,°"",,,,,,,
BATTERY ACID WILL "Z'=_,_____-
<!° ",_
CAUSE SEVERE BURNS V" °'°
Containssufphuricacid.
Donotletthebatteryacidcomeincontactwith theskin,theeyes,orthe
clothing,
To prevent accidents, neutralize the battery acid that was not used. To
neutralize, fill the container half futl with water, Add baking soda and
mix using a piece of wood until the solution does not foam, Discard the
solution and wash the container with water. Destroy the container.
ANTIDOTE:
External - Wash the area with water, then wash with a solution of
water and sodium bicarbonate,
Internal - Drink large amounts of water, milk, or milk of magnesia,
Drink water mixed with the whites of eggs. Call a Doctor
immediately.
Eyes -Flush with water for 15 minutes and then get immediate
medical help.
POIStON
KEEP AWAY FROM CHILDREN -D-5213
F-88516 7
ASSEMBLY
HOW TO INSTALL THE STEERING WHEEL
Attach the steering wheel with the fasteners shown full size
below.
Bearing
A
Upper Steering
Shaft
gPost
B C
Control Panel
1. Lookat the hole in the upper steering shaft. Turn the front
tiresto the left untilthe hole inthe upper steering shaft points
toward the front.
2. Slide the steering postthrough the control panel and onthe
upper steering shaft as shown. Fasten with the fasteners as
shown in the illustration.
3. Turnthe front wheels until a 1/2" wrench will fit onthe lock-
nut. Make sure the head of the bolt fits around the steering
post. Tighten the Iocknut to atorque of 18 foot pounds.
4. Slide the bearing on the steering post. Align the holesin the
bearing with the holes in the top of the control panel Fasten
the bearing with the screws as shown.
WARNING: For safe operation, make sure the
bearing is correctly installed, if the bearing
becomes loose or is damaged, replace
immediately.
5. Attach the steering panel to the control panel as follows.
Attach the front tab intothe control panel. Move the steering
panelback.Putthe two tabsof the steeringpanelinthe control
panel as shown.
6. To assemble thecover,putthetab inthe control panel.Fasten
the top of the cover with the two screws as shown.
7. Slide the bellows overthe steering post. Make surethe collar
ofthe bellows isontop. Push on the topofthe bellows.Fasten
the adapter to the steering post with the fasteners as
shown.
8. Fastenthe adapter to the steering post with the boltand nut
as shown. Tighten to atorque of 18 foot pounds.
Control Panel
D-4584-t
,, IIIH
Steering Panel
•
ASSEMBLY
9, Make sure the front wheels point to the front. Attach the
steering wheel to the adapter. Fasten the steering wheel
with the large Washer, the lockwasher washer, and the bolt
shown in the illustration.
10. Attach the steering wheel cap to the steering wheel.
11. Connect the ends of the wires for the headlight. Before the
bezel can be assembled, the two screws at the front of the
control panel must be removed. Put the bezel in position on
the end of the control panel.Fasten the bezel with the screws
that were removed,
NOTE: if you do not follow the above assembly instructions
correctly, the steering system will feel loose and the unit will
not steer correctly.
HOW TO INSTALL THE TILT SEAT
Assemble the seat with the fasteners shown full size below.
D-4583
Adapter
Post
D
I. Align the four long holes inthe seat support to the four holes
in the seat. Make sure the wire from the seat switch sensor
goes through the large hole in the seat support, Fasten the
seat to the seat support with the fasteners as shown, Do
not tighten.
2. Move the seat to the best position for operating the unit.
Tighten the hex bolts.
3, Connect the wire from the seat switch sensor to the wire
harness. Make sure the tab part of the connector, from the
seat switch sensor, locks into the latch of the wire harness
connector,
WARNING: Forcorrect and safe operation of the
unit, you must connect the wire from the seat
switch sensor to the wire harness.
SteeringWheel Cap=.....__
Steering _'¢heel
4. Some models have two seat spring caps in the parts bag, D-4591-1
Mount the caps on the seat springs as shown.
c
Wire from
Seat Spring
Cape
Strap
Sensor"
F-88516
Bezel
Control Panel
D-4677
9
CHECK THE TIRES ASSEMBLY
Check the airpressureinthe tires. Tires with too much air pressure
wilt cause the unit to ride rough,Also, the wrong air pressurewill
keep the mower housing from cutting level. The correct air
pressureisshown on the side of the tires. If the air pressure_not
shown, inflate the tires from 10 to 12 PS1 (0,7 to 0.85 kg!_m2).
HOW TO CHECK THE MOWER HOUSING
Make surethe levelof cutset at the factory is stillcorrect. After you
mow a short distance, look at the area that was cut, If the mower
housing does not cut level, see the instructionson "How To Level
The Mower Housing" in the maintenancesection of this instruction
book.
HOW TO ATTACH THE HUB CAPS
Push each hub cap onto the center hub of each wheel. Make sure
the washer holds the hub cap in place.
FINAL ASSEMBLY
1. The engine isfilled with oil. Check the oil. See"HowTo Check
The Ot(" in the Maintenance sectton.
2. Make sure alI the fasteners are tight.
'3. Read and follow the instructions in the Operation section.
Know the location and purpose of all the controls.
HOW TO INSTALL THE BA'r-rERY
Usethe fastenersshown below to installthe battery. The fasteners
are shown full size.
AC
1. Check the level of the acid. If the acid has fallen below the
correct level, add water to the correct level.
2. Install the battery and the battery tray as shown in the illus-
tration. Make sure the positive (+) terminal is toward the
front of the unit.
3. Slide the plastic sleeve over the end of the battery clamp.
Fasten the battery withthe battery clamp as shown.
4. Slide the cover for the positive term inaI on to the red battery
cable as shown.
AWARNING: To prevent sparks, {asten the red •
cable to the positive (+) terminal before you
connect the black cable to the negative (-)
terminal.
5. Fasten the red battery cable to the positive (+) terminal with
the nut and bolt as shown in the illustration.
6. Slide the cover on to the positive (+) terminal.
7o Fasten the black battery cable to the negative (-) terminal
with the nut and bolt as shown in the illustration.
8. To prevent corrosion, apply grease to the battery terminals.
0-4606-2
Plastic Sleeve
Battery
BatteryTray
/
0-4653-3
Cover
C
BLACK
RED
10
F-885t 6