944.607840 Sears Craftsman Tractor Parts Manual

944.607840 Sears Craftsman Tractor Parts and Manual
AYP (American Yard Products) Parts   |   AYP Parts Lookup   |   Sears Craftsman Parts

OWNER’S MANUAL

MODEL NO. 944.607840

Important:

Read and follow all Safety Rules and Instructions Before Operating This Equipment

22.0HP ELECTRIC START 46" MOWER AUTOMATIC LAWN TRACTOR

Assembly

Operation

Maintenance

Service and Adjustments

Repair Parts

Sears Canada, Inc., Toronto, Ontario M5B 2B8

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

DANGER: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

WARNING: In order to prevent ac- cidental starting when setting up, transporting, adjusting or making re- pairs, always disconnect spark plug wire and place wire where it cannot contact spark plug.

WARNING: Do not coast down a hill in neutral, you may lose control of the tractor.

WARNING: Tow only the attachments that are recommended by and com- ply with specifications of the manu- facturer of your tractor. Use common sense when towing. Operate only at the lowest possible speed when on a slope. Too heavy of a load, while on a slope, is dangerous. Tires can lose traction with the ground and cause you to lose control of your tractor.

I. GENERAL OPERATION

Read, understand, and follow all instructions on the machine and in the manual before starting.

Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

Only allow responsible adults, who are familiar with the instructions, to operate the machine.

Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades.

Be sure the area is clear of bystanders before operat- ing. Stop machine if anyone enters the area.

Never carry passengers.

Do not mow in reverse unless absolutely necessary. Always look down and behind before and while back- ing.

Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Ma- terial may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working.

Slow down before turning.

Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.

Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard.

Operate machine only in daylight or good artificial light.

Do not operate the machine while under the influence of alcohol or drugs.

Watch for traffic when operating near or crossing road- ways.

Use extra care when loading or unloading the machine into a trailer or truck.

Always wear eye protection when operating ma- chine.

2

Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-re- lated injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

Follow the manufacturer's recommendation for wheel weights or counterweights.

Keep machine free of grass , leaves or other debris build-up which can touch hot exhaust / engine parts and burn. Do not allow the mower deck to plow leaves or other debris which can cause build-up to occur. Clean any oil or fuel spillage before operating or storing the machine. Allow machine to cool before storage.

II. SLOPE OPERATION

Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

Mow up and down slopes, not across.

Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

Choose a low ground speed so that you will not have to stop or shift while on the slope.

Do not mow on wet grass. Tires may lose traction. Always keep the machine in gear when going down slopes. Do not shift to neutral and coast downhill.

Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause the machine to roll over.

Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine. Do no use on steep slopes.

Do not try to stabilize the machine by putting your foot on the ground.

Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.

III. CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

• Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

• Be alert and turn machine off if a child enters the area.

• Before and while backing, look behind and down for small children.

• Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs, trees, or other objects that may block your view of a child.

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

IV. TOWING

Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

Follow the manufacturer's recommendation for weight limits for towed equipment and towing on slopes.

Never allow children or others in or on towed equip- ment.

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.

Never make any adjustments or repairs with the engine running.

Check grass catcher components and the discharge guard frequently and replace with manufacturer's rec- ommended parts, when necessary.

Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

Check brake operation frequently. Adjust and service as required.

Maintain or replace safety and instruction labels, as necessary.

V. SERVICE

SAFE HANDLING OF GASOLINE

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

Use only approved gasoline container.

Never remove gas cap or add fuel with the engine run- ning. Allow engine to cool before refueling.

Never fuel the machine indoors.

Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or other appliances.

Never fill containers inside a vehicle or on a truck or trailer bed with plastic liner. Always place containers on the ground away from your vehicle when 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 with a portable container, rather than from a gasoline dispenser nozzle.

Keep the 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 immedi- ately.

Never overfill fuel tank. Replace gas cap and tighten securely.

GENERAL SERVICE

Never operate machine in a closed area.

Keep all nuts and bolts tight to be sure the equipment is in safe working condition.

Never tamper with safety devices. Check their proper operation regularly.

Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage and remove any fuel- soaked debris. Allow machine to cool before storing.

If you strike a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.

Be sure the area is clear of bystanders before operat- ing. Stop machine if anyone enters the area.

Never carry passengers.

Do not mow in reverse unless absolutely necessary. Always look down and behind before and while back- ing.

Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

Be alert and turn machine off if a child enters the area.

Before and while backing, look behind and down for small children.

Mow up and down slopes (15° Max), not across.

Choose a low ground speed so that you will not have to stop or shift while on the slope.

Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

If machine stops while going uphill, disengage blades, shift into reverse and back down slowly.

Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.

TABLE OF CONTENTS

SAFETY RULES

2-3

PRODUCT SPECIFICATIONS

4

CUSTOMER RESPONSIBILITIES

4

WARRANTY

4

ASSEMBLY

5-7

OPERATION

8-14

MAINTENANCE SCHEDULE

15

MAINTENANCE

15-18

SERVICE AND ADJUSTMENTS

19-24

STORAGE

25

TROUBLESHOOTING

26-27

REPAIR PARTS - TRACTOR

28-43

REPAIR PARTS - ENGINE

44-50

PARTS ORDERING/SERVICE

BACK COVER

3

PRODUCT SPECIFICATIONS

Gasoline Capacity

3.0 Gallons

and type:

Unleaded Regular

Oil Type

SAE 30 (above 32°F)

(API-SG-SL):

SAE 5W-30 (below 32°F)

 

Synthetic (below 0°F)

Your tractor was shipped from the factory with non-synthetic SAE 10W30 motor oil

Oil Capacity:

W/Filter:

64 oz

 

W/O Filter: 60 oz

Spark Plug:

Champion QC12YC

(Gap: .040")

 

 

Ground Speed (MPH):

Forward: 0-5.5

 

Reverse: 0-2.4

Charging System:

3 Amps Battery

5 Amps Headlights

 

 

Battery:

AMP/HR:

35

 

Min. CCA:

280

 

Case Size:

U1R

Blade Bolt Torque:

45-55 FT. LBS.

MAINTENANCE AGREEMENT

A Maintenance Agreement is available on this product. Contact your nearest Sears store for details.

CUSTOMER RESPONSIBILITIES

Read and observe the safety rules.

Follow a regular schedule in maintaining, caring for and using your tractor.

Follow the instructions under “Maintenance” and “Stor- age” sections of this owner’s manual.

WARNING: This tractor is equipped with an internal com- bustion engine and should not be used on or near any unimprovedforest-covered,brush-coveredorgrass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.

A spark arrester for the muffler is available through your nearest authorized service center/department (See REPAIR PARTS section of this manual).

CONGRATULATIONS on your purchase of a new Tractor. It has been designed, engineered and manufactured to give you the best possible dependability and performance.

Should you experience any problem you cannot easily remedy, please contact your nearest authorized service center/department. We have competent, well-trained representatives and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor properly. Always observe the “SAFETY RULES”.

LIMITED TWO (2) YEAR WARRANTY ON CRAFTSMAN TRACTOR (RIDING EQUIPMENT)

For two (2) years from date of purchase Sears Canada, Inc. will repair or replace at Sears option free of charge parts which are defective as a result of material or workmanship.

FULL ONE (1) YEAR WARRANTY ON BATTERY

For one (1) year from date of purchase, if any battery included with this riding equipment proves defective in material or workman- ship and our testing determines the battery will not hold a charge, Sears will replace the battery at no charge.

COMMERCIAL OR RENTAL USE

Warranty on Riding Equipment used for commercial or rental purposes is limited to ninety (90) days.

This Warranty does NOT cover:

1.Pre-delivery set-up.

2.Tire replacement or repair caused by punctures from outside objects (such as nails, thorns, stumps, or glass).

3.Expendable items which become worn during normal use, such as blades, spark plug, air cleaners and belts.

4.Repairs necessary because of operator abuse or negligence, including damaged jackshaft or mandrel and the failure to operate and maintain the equipment according to the instructions contained in the Owner’s Manual.

Warranty service is available by returning the Craftsman Riding Equipment to the nearest Sears Service Centre/Department in Canada. This warranty applies only while this product is in use in Canada.

This warranty is in addition to any statutory warranty and does not exclude or limit legal rights you may have but shall run concur- rently with applicable provincial legislation. Furthermore, some provinces do NOT allow limitation on how long an implied warranty will last so the above limitations may not apply to you.

SEARS CANADA, INC., TORONTO, ONTARIO M5B 2B8

4

UNASSEMBLED PARTS

Battery

(2) Hex Bolts 1/4-20 x 3/4

(2) Keps Nut 1/4-20

Slope Sheet

(1) Oil Drain Tube

Key

(2) Keys

ASSEMBLY

Your new tractor has been assembled at the factory with the exception of those parts left unassembled for shipping puposes.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Standard wrench sizes are listed.

(2) 7/16" wrenches

When right or left hand is mentioned in this manual, it means when you are in the operating position (seated behind the steering wheel).

TO REMOVE TRACTOR FROM CARTON

UNPACK CARTON

Cut along dashed lines on all four panels of carton. Remove end panels and lay side panels flat.

Check for any additional loose parts or cartons and remove.

CONNECT BATTERY (See Fig. 1)

CAUTION: Do not short battery termi- nals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.

Positive terminal must be connected first to prevent sparking from accidental grounding.

Lift hood to raised position.

Remove terminal protective caps and discard.

NOTE: If this battery is put into service after month and year indicated on label (L) (label located between terminals) charge battery for minimum of one hour at 6-10 amps.

First connect RED battery cable to positive (+) terminal with hex bolt and keps nut.

Connect BLACK grounding cable to negative (-) ter- minal with remaining hex bolt and keps nut. Tighten securely.

5

L

02954

FIG. 1

ADJUST SEAT (See Fig. 2)

Sit in seat.

Lift up adjustment lever (A) and slide seat until a com- fortable position is reached which allows you to press clutch/brake pedal all the way down.

Release lever to lock seat in position.

A

FIG. 2

ASSEMBLY

NOTE: You may now roll or drive your tractor off the skid. Follow the appropriate instruction below to remove the tractor from the skid.

WARNING: Before starting, read, understand and follow all instructions in the Operation section of this manual. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other people and objects.

TO ROLL TRACTOR OFF SKID (See Op- eration section for location and function of controls)

Raise attachment lift lever to its highest position.

Release parking brake by depressing clutch/brake pedal.

Place freewheel control in "transmission disengaged position" (See “TO TRANSPORT” in the Operation section of this manual).

Roll tractor forward off skid.

Remove banding holding the deflector shield up against tractor.

TO DRIVE TRACTOR OFF SKID (See Op- eration section for location and function of controls)

WARNING: Before starting, read, understand and follow all instructions in the Operation section of this manual. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other people and objects.

Be sure all the above assembly steps have been com- pleted.

Check engine oil level and fill fuel tank with gasoline.

Place freewheel control in "transmission engaged" position (see "TO TRANSPORT" in Operation section of this manual).

Sit on seat in operating position, depress clutch/brake pedal and set the parking brake.

Place motion control lever in neutral (N) position.

Press lift lever plunger and raise attachment lift lever to its highest position.

Remove key from bag and start the engine (see "TO START ENGINE" in the Operation section of this man- ual). After engine has started, move throttle control to idle (slow) position.

Release parking brake.

Slowly move the motion control lever forward and slowly drive tractor off skid.

Apply brake to stop tractor, set parking brake and place motion control lever in neutral position.

Turn ignition key to "STOP" position.

Continue with the instructions that follow.

INSTALL MULCHER PLATE (See Fig. 3) (If previously removed)

Raise and hold deflector shield in upright position.

Place slot in mulcher plate over tab on mower and position plate over mower opening as shown.

Hook front latch into hole on front of mower deck.

Hook rear latch into hole on back of mower deck.

CAUTION: Do not remove deflector shield from mower.

TO CONVERT TO BAGGING OR

DISCHARGING

Simply remove mulcher plate and store in a safe place. Your mower is now ready for discharging or installation of optional grass catcher accessory.

NOTE: It is not necessary to change blades. The mulcher blades are designed for discharging and bagging also.

DEFLECTOR

SHIELD

TAB

MULCHER

PLATE

LATCH

HOOKS

FIG. 3

6

ASSEMBLY

CHECK TIRE PRESSURE

The tires on your tractor were overinflated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance.

Reduce tire pressure to PSI shown on tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly leveled. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL BELTS

See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments section of this manual. Verify that the belts are routed correctly.

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that the brake is operating properly. See “TO CHECK BRAKE” in the Service and Adjustments section of this manual.

CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRACTOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PER- FORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

All assembly instructions have been completed.

No remaining loose parts in carton. Battery is properly prepared and charged.

Seat is adjusted comfortably and tightened securely.

All tires are properly inflated. (For shipping purposes, the tires were overinflated at the factory).

Be sure mower deck is properly leveled side-to-side/ front-to-rear for best cutting results. (Tires must be properly inflated for leveling).

Check mower and drive belts. Be sure they are routed properly around pulleys and inside all belt keepers.

Check wiring. See that all connections are still secure and wires are properly clamped.

Before driving tractor, be sure freewheel control is in “transmission engaged” position (see “TO TRANS- PORT” in the Operation section of this manual).

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS:

Engine oil is at proper level.

Fuel tank is filled with fresh, clean, regular unleaded gasoline.

Become familiar with all controls, their location and function. Operate them before you start the engine.

Be sure brake system is in safe operating condition.

Be sure Operator Presence System and Reverse Op- eration System (ROS) are working properly (See the Operation and Maintenance sections in this manual).

It is important to purge the transmission before op- erating your tractor for the first time. Follow proper starting and transmission purging instructions (See “TO START ENGINE” and “PURGE TRANSMISSION” in the Operation section of this manual).

7

OPERATION

These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their mean- ing.

REVERSE

NEUTRAL

HIGH

 

LOW

 

CHOKE

FAST

SLOW

IGNITION SWITCH

 

 

 

 

 

 

 

 

 

 

ENGINE OFF

REVERSE

ENGINE ON

ENGINE START

PARKING BRAKE MOWER HEIGHT

MOWER LIFT

 

OPERATION

 

 

 

 

 

 

 

 

 

SYSTEM (ROS)

 

 

 

 

 

 

 

 

LIGHTS ON

FUEL

BATTERY

REVERSE

FORWARD

CRUISE CONTROL

 

CLUTCH/BRAKE

 

PEDAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

15

 

 

 

 

 

 

 

 

 

 

ATTACHMENT

ATTACHMENT

 

DANGER, KEEP HANDS

KEEP AREA CLEAR

SLOPE HAZARDS

CLUTCH DISENGAGED

CLUTCH ENGAGED

AND FEET AWAY

(SEE SAFETY RULES SECTION)

FREE WHEEL (Automatic Models only)

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury.

CAUTION when used without the alert symbol, indicates a situation that could result in damage to the tractor and/or engine.

Failure to follow instructions could result in serious injury or death. The safety alert symbol is used to identify safety inform- ation about hazards which can result in death, serious injury and/or property damage.

HOT SURFACES indicates a hazard which,

if not avoided, could result in death, serious injury and/or property damage.

FIRE indicates a hazard which, if not avoided, could result in death, serious injury and/or property damage.

8

OPERATION

KNOW YOUR TRACTOR

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR

Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

DP

H

E

N

B

FG

CJ

A

M

FIG. 4

Our tractors conform to the applicable safety standards of the American National Standards Institute.

(A)ATTACHMENT LIFT LEVER - Used to raise, lower, and adjust the mower deck or other attachments mounted to your tractor.

(B)CLUTCH/BRAKE PEDAL - Used for declutching and braking the tractor and starting the engine.

(C)PARKING BRAKE - Locks clutch/brake pedal into the brake position.

(D)THROTTLE CONTROL - Used to control engine speed.

(E)ATTACHMENT CLUTCH LEVER - Used to engage the mower blades, or other attachments mounted to your tractor.

(F)IGNITION SWITCH - Used for starting and stopping the engine.

(G)REVERSE OPERATION SYSTEM (ROS) “ON” POSI- TION - Allows operation of mower deck or other powered attachment while in reverse.

(H)LIGHT SWITCH - Turns the headlights on and off.

(J)MOTION CONTROL LEVER – Selects the speed and direction of tractor.

(M)FREEWHEEL CONTROL – Disengages transmission for pushing or slowly towing the tractor with the engine off.

(N)CHOKE CONTROL - Used when starting a cold en- gine.

(P)SERVICEREMINDER/HOURMETER– Indicates when service is required for the engine and mower.

9

OPERATION

The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your tractor or performing any adjustments or repairs. We recommend standard safety glasses or a wide vision safety mask worn over spectacles.

HOW TO USE YOUR TRACTOR

TO SET PARKING BRAKE (See Fig. 5)

Your tractor is equipped with an operator presence sens- ing switch. When engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine.

1.Depress clutch/brake pedal (B) all the way down and hold.

2.Pull parking brake lever (C) up and hold, release pres- sure from clutch/brake pedal (B), then release parking brake lever. Pedal should remain in brake position. Make sure parking brake will hold tractor secure.

B

C

FIG. 5

STOPPING

MOWER BLADES -

To stop mower blades, move attachment clutch lever to disengaged position ( ).

J

(

) Attachment

FIG. 6

(

) Disengaged

 

 

Clutch

 

 

Position

 

Engage Position

 

 

NOTE: Failure to move throttle control between half and full speed (fast) position, before stopping, may cause en- gine to “backfire”.

Turn ignition key (F) to “STOP” position and remove key. Always remove key when leaving tractor to prevent unauthorized use.

Never use choke to stop engine.

IMPORTANT: Leaving the ignition switch in any position other than "STOP" will cause the battery to discharge and go dead.

NOTE: Under certain conditions when tractor is standing idle with the engine running, hot engine exhaust gases may cause “browning” of grass. To eliminate this possibility, al- ways stop engine when stopping tractor on grass areas.

CAUTION: Always stop tractor com- pletely, as described above, before leaving the operator's position.

D

N

F

FIG. 7

TO USE THROTTLE CONTROL - D (See Fig. 7)

Always operate engine at full speed (fast).

Operating engine at less than full speed (fast) reduces engines operating efficiency.

Full speed (fast) offers the best bagging and mower performance.

TO USE CHOKE CONTROL - N (See Fig. 7)

Use choke control whenever you are starting a cold engine. Do not use to start a warm engine.

To engage choke control, pull knob out. Slowly push knob in to disengage.

GROUND DRIVE -

To stop ground drive, depress clutch/brake pedal all the way down.

Move motion control lever (J) to neutral position.

ENGINE -

Move throttle control (D) between half and full speed (fast) position.

10