SECTION 1 TROUBLESHOOTING STEERINGPROBLEMS PROBLEM Hard Steering REMEDY CAUSE Low Tire Pressure Check Pressure Chapter I1 Section 1 Lack of Lubricant Lubricate Chapter I1 Section 1 Bearings and/or Bushings worn Steering Disassembly and Inspection Chapter I1 Section 2 Tie Rods Bent Straighten o r Replace Chapter I1 Section 2 Steering Gear Broken Disassembly and Replacement Chapter I1 Section 2 MOWER PAN AND BLADEPROBLEMS PROBLEM CAUSE REMEDY Belt Off Pulleys Replace Chapter Section 3 I1 Be
ONLY MODELS 9301,9302,9302E,9303E,9600,9601 MOWER .PAN AND BLADECont.
MODELS 9301,9302,9302E,9303E,9600,9601ONLY DRIVEPROBLEMSCont. PROBLEM Mower Will Not Propel Cont. CAUSE REMEDY Rubber Drive Roller Worn o r Damaged Replace Chapter Section 4 Chain Loose Adjust Chain Broken Repair o r Replace, Chapter I1 Section 4 Transmission Rod(s) Bent Repair o r Replace, Chapter I1 Section 4 Differential Broken Repair o r Replace, Chapter I1 Section 4 Sprocket Worn o r Broken Replace Chapter Section 4 Will Not Drive In Check Reverse Booster Spring o r Disc.
MODELS 9301, 9302, 9302E, 9303E, '9600, 9601 ONLY FUEL PROBLEMS Cont. ~- Engine slows down and stops REMEDIES CAUSES TROUBLES a. Unplug hole a. Vent hole in fuel tank cap plugged i b. Clean out fuel line o r b. Fuel line or strainer clogged strainer c. Refill tank c. Fuel tank runs dry IGNITION PROBLEMS SPARK PLUG TROUBLE CHART PLUG CONDITION Black carbon o r sooty deposit CAUSES RECOMMENDATION a. Breaker points dirty or out of adjustment a. Clean and adjust gap b. Weak condenser b.
Disc MODELS 9301,9302,9302E,9303E,9600,9601 ONLY SPECIFICATIONS LUBRICATION SPECIFICATIONS Boy “A” Grease or Multiple Purpose, Automotive Grease Lawn-Boy“A” Grease or Multiple purpoSe,Automotive Grease “A” Grease or Multiple purpoSe, Automotive Grease #30 Weight Oil Grease For Front Axle& King Pin Spindle Front Wheel Bearings Differential Lawn-Boy Hexshaft Drive Roller BOLT AND N U T TORQUES Bolt King Pin to Tie Rod Nuts 135 inch pounds Steering Casting Bolts.
;9600, 9601 ONLY MODELS 9301,9302,9302E,9303E, TIRE SPECIFICATIONS 4.10/3.50~4 15-17 P.S.I. 480/400x8 22-25 P.S.I. Front Size. Pressure Rear Size Pressure 10x5/4.50-4 15-17 P.S.I. 16~5.50-8 22-25 P.S.I.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY SECTION 2 HOW TO REPAIR AND REPLACE STEERING To insure trouble-free operation, use a grease gun and apply a good quality automotive chassis lubricant to the five zerk fittings. (Figure 2-1). Or Lawn-Boy “A” grease. A positive type steering system is employed. The steer- ing arm is keyed to the steering shaft and secured with a setscrew. The steering gear is linked to the left side spindle and kingpin arm. A tie rod connects the wheels.
MODELS 9301,9302,9302E,9303E,i9600,9601 FIGURE 2-3 ONLY 04238 11-24 SERVICE BULLETIN REFERENCES REVISED 1977
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY STEERINGDISASSEMBLY SPINDLE A N D / O R KING PIN REMOVAL Disconnect the spark plug lead. Remove thebattery,(electric start models only.) Stand mower on tilt (knurfing) bar. Remove front wheel. Remove tie rods from kingpin arm.Drive out roll pin. Remove spindlefromsteeringcasting. See Figures 2-3 and 2-4. NOTE FIGURE 2-4 RIGHT 94193 King pin a r m s a r e not identical (Figure 2-4). Care should betakento reinstall them properly.
n MODELS 9301,9302, 9302E, 9303E, 9600, 9601ONLY FIGURE 2-6 94173 \ STEERING WHEEL ALIGNMENT ! If steering wheel does not line up properly with frontwheels, it canbealigned as follows: 2. Loosen ,jam nut at ball joint socket 1. Remove nut securingballjoint pin arm. 3. Assemble ball jointto nut. to king and turn ball joint on o r off rod until steering wheel is aligned with front wheels. (Figure 2-6.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY SECTION 3 ADJUSTMENTS POWERFORDRIVING To effect transmission of motivepower to the cuttingblade, two V-belts a r e used. The primary drive pulley which is located above the drive disc is keyed to the engine crankshaft. A short V-belt runsfromthis primary pulley totheupper pulleyon the intermediate spindle. A' longer V-beltconnectsthelower pulleyonthe intermediate spindle to thebladepulley on theblade shaft, driving the cutting blade.
04242 SERVICE BULLETIN REFERENCES 11-28 REVISED 1977
MODELS 9301, 9302, 9302E,9303E.9600, 9601 ONLY MOWER PAN DISASSEMBLY PANREMOVAL Remove belt, and bell arm shoulder bolts. Remove front pan suspension bar shoulder bolts. Pan can now be removed frommower. FRONT BELT REMOVAL Disconnect spark plug lead. NOTE 1 I REAR BELT REMOVAL Use a rope as shown on Figure 2-10 when removing idler spring. Remove belt. Disconnect spark plug lead. Remove battery, (electric start models only). Remove rear cover.
MODELS 9301,9302,9302E,9303E,'9600,9601ONLY BLADE BRAKEADJUSTMENT When the blade control lever is placed in the “off” position, an adjustable leaf spring connected to the bell a r m and hub assembly is forced against the drive belt preventing the blade from rotating. SAFETY WARNING BLADE NUT MUSTBETIGHT BEFORE ADJUSTING BLADE BRAKE TENSION. SECURE MOWER TO PREVENT TIPPING OR FALLING.
MODELS 9301,9302,9302E, 9303E, 9600,9601 ONLY PAN TILT ADJUSTMENT- 26” & 30’’ MODELS 1. Locate the mower on a flat level surface such as driveway, a sidewalk, garage floor, etc. 2. Place the height adjustment lever in the middle setting. 3. Rotatethebladeuntilthecuttingedge is facing the front of the mower and measure the distance from the ground to the tip of thecuttingedge of the blade. See Figure 2- 13. 180º and measure (from r e a r of pan) the distance’ from theground 4.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY SECTION 4 THEORY OF OPERATION INTRODUCTION The Lawn-Boy Riding Mower is powered by a verticalshaftfour-cyclegasolineengine mounted on the rear of the machine. The vertical crankshaft of the engine drives both the wheels and the cutting blade, with the speed of the forward motion determined by the Speed Selector Lever which provides three forward speeds, a reverse, and a neutral position.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY shown, Figure 2-15, is nearest the center and is theslowestspeed, or First. Thesecond position shown, Figure 2-16, produces a higherspeed, o r Second, and the third position, Figure 2-17, near the rim of the disc produces the highest speed, or Third. In third position, the Rider will travel at approximately 6 mph.
MODELS 9301,9302,9302E, 9303E,'9600, 9601 ONLY Inherent in the driving system of disc and drive roller making sudden contact is a tendency to lurch or buck when the machine is started from a dead stop. To make smoother starts possible, a series of sprockets and chains transmits the motive power from the drive roller to the wheels.
MODELS 9301,9302,9302E,9303E,9600,9601ONLY driveshaft. The sprocket on that shaft, in turn drives an intermediate chain which drives a sprocket on the final drive spindle. The dual sprocket on the final drive spindle drives a final drive chain on the big sprocket mounted on the wheel axle to move the wheels. This combination of sprockets and chainsreducesstartingtorqueandabsorbstheshockand lurching of starting.
MODELS 9301,9302,9302E,9303E, '9600, 9601 ONLY To eliminatedriverollerslippage and to assure smooth starts, a system of two disc compression springs is employed. When the speed selector lever is placed in gear, the primarydisccompressionspringcreates initial drive roller pressure against the drive disc. Momentarily, the driveroller is allowed toslip,eliminating quick "jumpy" starts. The secondary disc compression spring thengoesintoeffectsupplying additional disc pressuretopropel the unit.
MODELS 9302,9302E,9303E,9600,9601ONLY NOTE 9303.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY PRIMARY DRIVE SERVICING DISC COMPRESSION SPRING REMOVAL _- Disconnect spark plug lead; remove battery, (electric start models only). Remove r e a r cover. Remove both disc compression springs. Models9301, 9302, 93023,and single disc compression spring. 9600 have The springsare not identical--tag a s outside. one as inside;theother Remove the springs with a rope. (See Figure 2-24.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY DRIVE ASSEMBLY ADJUSTMENTS DRIVE ROLLER TRAVEL HORIZONTAL Disconnect spark plug lead; remove battery, (electric start models only,) stand mower on tilt (knurfing) bar. The cast iron bearing carrier of the drive roller assembly must be in contact with the extended threaded ends of the screws holding the hex shaft bearing retainers to the drive bracket with theshiftlever placed in the fullreverseposition(Figure 2-26.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY FIGURE 2-27 94332 DRIVE ROLLER ADJUSTMENTVERTICAL ALIGNMENT When the speed selector lever is placed in neutral position, the drive roller disengages from the drive disc by use of various linkages. Proper clearance betweendrive disc anddriveroller is 1/16 inch with speed selector lever in neutral. See Figure 2-27. Thisassures the operator of a positive neutralposition and performs a secondary brakingaction by haltingthechain movement to the rear wheels.
MODELS 9301,9302,9302E,9600 ONLY
MODELS 9303,9303E, 9601, ONLY 3. Tighten upper reverseboosterspring nut until spring is compressed 1 1/2". See Figure 2-30. 4. Tighten orloosen uppernuton, speed controlclutchrodto obtain 1/16inch clearance between roller and disc. 5. Tighten remaining jam nuts.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY DRIVE ROLLER ADJUSTMENT- SPRING TENSION A. Primary (inside) Disc Compression lbs., pressure andthe driveroller contact breaks disc.drive with the See Figure 2-31. Adjustment Spring 1. Place mower inhorizontalposition and remove rear cover. 5. Replacesecondarydisccompression spring. 2. Place speed selector lever in second gear. Do not depress clutchpedal. B. Secondary(Outside) DiscCompression Spring Adjustment (Figure 2-32). 3.
MODELS 9301,9302,9302E,9303E,i9600,9601 ONLY 15 to 17 lbs., pressure and the drive rollerbreakscontact with thedrive disc. in neutral position and re-checkthe 1/16 inch clearance between drive disc and, drive roller. 2. Place speed selector lever NOTE If drive roller slippage is observed, slightlyincreasethespringtension on thesecondary(outside)spring. If quick "jumpy" starts are observed, decrease spring tension on the primary (inside) spring.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY BRAKE ROD\ BRAKE BAND.
MODELS 9301,9302,9302E,9303E, '9600, 9601ONLY SECONDARY .DRIVE SERVICING Remove brake band from chasis. Remove secondary chain (Figure 2-35.) Remove bearing retainer plates fromchasis. Remove bearings and driveshaft. Replaceintermediatedriveshaftand reassembleinreverseorder of disassembly. Loosen nylon chain guide eccentric nut slightly and rotate into or away from chain to attain proper chain tension. Correct chaintension is 1/4 inchdeflection with light thumb pressure.
MODELS 9301,9302,9302E,9303E,9600,9601 FIGURE 2-38 FIGURE 2-39 ONLY 1A 0 7 9 04247
MODELS FINALDRIVE REMOVAL ‘9600, 9601 ONLY 9301,9302,9302E,9303E, DISASSEMBLY DIFFERENTIAL Disconnect spark plug lead; remove battery (electric start models only). SAFETY WARNING WHEN STANDINGMOWER ON END, ALWAYSANCHOR IT TO PREVENT FROM TIPPING ORFALLING.ALSO PLACE THROTTLE IN “STOP” POSITION AND DISCONNECT SPARK PLUG LEAD. Stand moweron tilt (knurfing) bar. Remove r e a r belt. ! Remove rods from carrier bracket and disc compression springs. Lower bracket to floor. Removechain, ings.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY ENGINEREMOVAL Disconnect spark plug lead and throttle linkage. Remove rear drive belt. For Model 9601 alsoremove head bolts attached tosupport plate (Figure 2-40.) 2 cylinder mounting Remove engine mounting bolts and lift engine from mounting frame. NOTE Do not tip engine on its side without removing oil and fuel. DRIVE DISC REMOVAL Remove engine. Remove four allen screws securing disc to drive pulley. head DRIVEPULLEYREMOVAL Remove engine and drive disc.
MODELS 9302E,9303E ONLY SECTION 5 ELECTRICAL SERVICING L FIGURE 2-41 Follow these procedures to remove battery. 1. Remove two wing screws and remove battery cover. 2. Disconnect battery leads. 3. Remove four nuts securingbatterycarrier to batteryframe and remove battery.SeeFigure 2-41. SAFETY WARNING DO NOT ALLOW BATTERY TERMINALS TO MAKE CONTACT WITH THE BATTERY FRAME. THIS COULD RESULT IN FIRE OR PERSONAL INJURY (BURNS). SEE FIGURE 2-42.
MODELS 9302E, 9303E ONLY DIODE GROOVED END I DIODE OF FIGURE 2-43 FRONT MOWER 94256 INSTALLING NEW DIODES 1. Remove diode cover. 2. Insert newdiodes into springclips. DO NOT FORCE. The groove inthe one endof the diode matches a ridge in the clip.See Figure 2-43. INSTALLINGREPLACEMENT FUSE AG AMP 250 Volt Fuse is inserted into clip receptacle in vertical position either end up.
MODELS 9301,9302,9302E,9303E,9600,9601 ONLY SECTION 6 PREVENTIVE MAINTENANCE To obtain peak performance and long life fromthe enginethe aircleanermustbe servicedregularly. Under normal conditionsan air cleaner should beserviced every 10 hours of operation,oftener, if under dusty condition. To service air cleaner, pour old oil from bowl. Wash elementthoroughly in solvent and dry.Clean bowl and refill with same type of oil used incrankcase.See engineOwner’s Manual.
MODELS 9301,9302,9302E,-9303E,9600,9601 ONLY FRICTION DRIVE Check rubberdriverollerdrivedisc clearance every 30 hours. BLADE SAFETY WARNING DISCONNECT THE SPARK PLUG WIRE AND PLACE THE BLADE IN THE "OFF" CONTROL LEVER POSITION. Always keep blade sharp and balanced. A bent blade will cause vibration and loss of power. See Figure 2-44. Check balance and grind heavy end until proper balance is at- FIGURE 2-44 681717 BLADEREMOVAL 1. Disconnect spark plug. 2. Lift mower on end. 3.
MODELS 9301,9302,9303E, 9302E, 9600,9601 BENT BLADE Tilt the mower up on the knurfing bar and place a straightedge (yardstick) across the bottom of the pan. Rotate the blade until one end is aligned with the straightedge and measure the gap between the blade and the straightedge. Rotate the blade until the other end is under the samepoint of the straightedge and measure this gap. If the gaps are not within 1/4” of eachother, the blade,blade spindle, bladeadaptor or deck maybe damaged or distorted.
