Sears CRAFTSMAN 944.604931 Owner'S Manual Download

Page: 1 / 56

16.5 HP
ELECTRIC START
42" MOWER
AUTOMATIC
LAWN TRACTOR

Important:
Read and fol low
all Safety Rules
and In struc tions
Be fore Op er at ing
This Equip ment

MODEL NO.

944.604931

OWNER’S

MANUAL

• Assembly
• Operation
• Maintenance
• Service and Adjustments
• Repair Parts

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

00011

02494

Summary of Contents for CRAFTSMAN 944.604931

Page 1: ...CTOR Important Read and follow all Safety Rules and Instructions Before Operating This Equipment MODEL NO 944 604931 OWNER S MANUAL Assembly Operation Maintenance Service and Adjustments Repair Parts Sears Canada Inc Toronto Ontario M5B 2B8 00011 02494 ...

Page 2: ...n changes in speed or direction Avoid starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly straight down the slope Safe Operation Practices for Ride On Mowers IMPORTANT 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 SAFETY RULES D...

Page 3: ...and turn machine off if children enter the area Before and when backing look behind and down for small children Mow up and down slopes 15 Max not across Remove obstacles such as rocks tree limbs etc Watchforholes ruts orbumps Uneventerraincouldoverturn the machine Tall grass can hide obstacles Use slow speed Choose a low gear so that you will not have to stop or shift while on the slope Avoid star...

Page 4: ...erator A spark arrester for the muffler is available through your nearestauthorizedservicecentre department SeeREPAIR PARTS section of this manual 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 YE...

Page 5: ...ing Extension Shaft Steering Wheel Adapter 1 Knob 1 Washer 17 32 x 1 3 16 x 12 Gauge Seat Battery 2 Keys Slope Sheet Keys 1 Oil Drain Tube 1 Hex Bolt 1 4 28 x 1 1 4 1 Locknut 1 4 28 1 Locknut 1 2 20 4 Washers 3 8 x 3 4 x 14 Ga 4 Wheels 4 Adjusting Bar 4 Retainer Springs double loop 4 Clevis Pins 4 Locknut 3 8 16 4 Shoulder Bolt Gauge Wheels ...

Page 6: ...TANT TIGHTEN BOLT AND NUT SECURELY TO 10 12 FT LBS TORQUE Place tabs of steering boot over tab slots in dash and push down to secure INSTALL STEERING WHEEL Position front wheels of the tractor so they are pointing straight forward Remove steering wheel adapter from steering wheel and slide adapter onto steering shaft extension Position steering wheel so cross bars are horizontal left to right and ...

Page 7: ...achment lift lever to its highest position Starttheengine Afterenginehasstarted movethrottle control to idle position Release parking brake Slowly depress forward drive pedal and drive tractor off skid Apply brake to stop tractor and set parking brake Turn ignition key to STOP position Continue with the instructions that follow 02466 02464 SEAT PAN SHOULDER BOLT ADJUSTMENT KNOB FLAT WASHER SEAT FI...

Page 8: ...on front of mower deck Hook rear latch into hole on back of mower deck CAUTION Donotremovedeflectorshield 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 baggin...

Page 9: ...ld 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 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...

Page 10: ...ition FREEWHEEL CONTROL Disengages transmission for pushing or slowly towing the tractor with the engine off AMMETER Indicates charging or discharging of battery LIFT LEVER PLUNGER ATTACHMENT LIFT LEVER PARKING BRAKE THROTTLE CONTROL AMMETER LIGHT SWITCH POSITION FORWARD DRIVE PEDAL BRAKE PEDAL FIG 5 FREE WHEEL CONTROL ATTACHMENT CLUTCH SWITCH CHOKE CONTROL REVERSE DRIVE PEDAL ATTACHMENT LIFT LEVE...

Page 11: ...ottle control to slow position NOTE Failure to move throttle control to slow position and allowing engine to idle before stopping may cause engine to backfire Turn ignition key to OFF 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 OFF WILL CAUSE THE BATTERY TO...

Page 12: ... tractor on a flat level surface Adjust mower to desired cutting height See TO AD JUST MOWER CUTTING HEIGHT in the Operation section of this manual Remove retainer spring and clevis pin which secure each gauge wheel bar Lower gauge wheels to ground Raise gauge wheels slightly to align holes in bracket and gauge wheel bar and insert clevis pin Gauge wheels should be slightly off the ground Replace ...

Page 13: ...eptsmallchangesinspeedandload untilthechoke control is fully in If the engine starts to run roughly pull the choke control out slightly for a few seconds and then continue to push the control in slowly This may requireanenginewarm upperiodfromseveralseconds to several minutes depending on the temperature ADD GASOLINE Fill fuel tank to bottom of filler neck Do not overfill Use fresh clean regular u...

Page 14: ...YOUR TRANSMISSION REQUIRE REMOVAL FOR SERVICE OR REPLACEMENT IT SHOULD BE PURGED AFTER REINSTALLATION BEFORE OPERATING THE TRACTOR Place tractor safely on level surface with engine off and parking brake set Disengage transmission by placing freewheel control infreewheelingposition See TOTRANSPORT inthis section of manual Sitting in the tractor seat start engine After the en gine is running move th...

Page 15: ...interferes with the mulching action The best time to mow your lawn is the early afternoon At this time the grass has dried the newly cut area will not be exposed to direct sunlight For best results adjust the mower cutting height so that the mower cuts off only the top one third of the grass blades See Fig 11 For extremely heavy mulch ing reduce your width of cut on each pass and mow slowly mulche...

Page 16: ...filter 1 2 GENERAL RECOMMENDATIONS The warranty on this tractor does not cover items that have beensubjectedtooperatorabuseornegligence Toreceive full value from the warranty operator must maintain tractor as instructed in this manual Some adjustments will need to be made periodically to properly maintain your tractor At least once a season check to see if you should make any of the adjustments de...

Page 17: ...d shut off the engine When the engine is running and the attachment clutch is engaged any attempt by the operator to leave the seat should shut off the engine The attachment clutch should never operate unless the operator is in the seat BLADE CARE Forbestresultsmowerbladesmustbekeptsharp Replace bent or damaged blades BLADE REMOVAL See Fig 12 Raise mower to highest position to allow access to blad...

Page 18: ...SAE viscosity grade according to your expected operating temperature Change the oil after every 50 hours of operation or at least once a year if the tractor is not used for 50 hours in one year SAE VISCOSITY GRADES SAE 10W 30 5W 30 Synthetic 5W 30 TEMP 10 30 20 10 0 10 20 30 0 20 40 60 80 100 F 40 C oil_visc_chart1_e honda TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE Check the crankcase oi...

Page 19: ... all foreign matter Keep finished surfaces and wheels free of all gasoline oil etc Protect painted surfaces with automotive type wax We do not recommend using a garden hose or pressure washer to clean your tractor unless the engine and trans mission are covered to keep water out Water in engine or transmission will shorten the useful life of your tractor Use compressed air or a leaf blower to remo...

Page 20: ...ition Roll belt off engine pulley Removesmallretainerspring andremoveclutchspring off pulley bolt Remove large retainer spring slide collar off and push housing guide out of bracket Disconnect anti swaybar from chassis bracket by re moving retainer spring Disconnect suspension arms from rear deck brackets by removing retainer springs Disconnect front links from deck by removing retainer springs Ra...

Page 21: ...qual number of turns When distance D is 1 8 to 1 2 lower at front than rear tighten nuts F against trunnion on both front links To raise front of mower loosen nut F from trunnion on both front links Tighten nut E on both front links an equal number of turns The two front links must remain equal in length Whendistance D is1 8 to1 2 loweratfrontthanrear tighten nut F against trunnion on both front l...

Page 22: ...at highest speed in highest gear on a level dry concrete or paved surface then brake must be checked and adjusted TO CHECK BRAKE Park tractor on a level dry concrete or paved surface depress brake pedal all the way down and engage parking brake Disengage transmission by placing freewheel control in transmission disengaged position Pull freewheel control out and into the slot and release so it is h...

Page 23: ...urchased from your local parts dealer Tire sealant also prevents tire dry rot and corrosion SERVICE AND ADJUSTMENTS FIG 26 RETAINING RING WASHERS SQUARE KEY REAR WHEEL ONLY AXLE COVER ENGINE PULLEY CLUTCHING IDLER STATIONARY IDLER TRANSMISSION INPUT PULLEY FIG 25 CENTER SPAN KEEPER TO REPLACE MOTION DRIVE BELT See Fig 25 Park the tractor on level surface Engage parking brake For assistance there i...

Page 24: ...oneendoftheBLACKcabletotheNEGATIVE terminal C of fully charged battery Connect the other end of the BLACK cable D to good chassis ground away from fuel tank and battery TO REMOVE CABLES REVERSE ORDER BLACK cable first from chassis and then from the fully charged battery RED cable last from both batteries TO REMOVE HOOD AND GRILL ASSEMBLY See Fig 28 Raise hood Unsnap headlight wire connector Stand ...

Page 25: ...gine does not operate properly due to suspected carburetor problems take your tractor to a Sears or other qualified service center for repair and or adjustment High speed stop is factory adjusted Do not adjust damage may result IMPORTANT NEVERTAMPERWITHTHEENGINEGOVERNOR WHICH IS FACTORY SET FOR PROPER ENGINE SPEED OVERSPEEDING THE ENGINE ABOVE THE FACTORY HIGH SPEED SETTING CAN BE DANGEROUS IF YOU...

Page 26: ...FUEL SYSTEM PARTS SUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALSO EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS CALLED GASOHOL OR USING ETHANOLORMETHANOL CANATTRACTMOISTUREWHICH LEADSTOSEPARATIONANDFORMATIONOFACIDSDURING STORAGE ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE Empty the fuel tank by starting the engine and let it run until the fuel lines a...

Page 27: ...aulty ignition switch 7 Check replace ignition switch 8 Faulty solenoid or starter 8 Check replace solenoid or starter 9 Faulty operator presence switch es 9 Contact an authorized service center department Engine clicks 1 Weak or dead battery 1 Recharge or replace battery but will not start 2 Corroded battery terminals 2 Clean battery terminals 3 Loose or damaged wiring 3 Check all wiring 4 Faulty...

Page 28: ...bolt 7 Buildup of grass leaves and trash under mower 7 Clean underside of mower housing 8 Mower drive belt worn 8 Replace mower drive belt 9 Blades improperly installed 9 Reinstall blades sharp edge down 10 Improper blades used 10 Replace with blades listed in this manual 11 Clogged mower deck vent holes from buildup of 11 Clean around mandrels to open vent holes grass leaves and trash around mand...

Page 29: ...E PEDAL UP SOLENOID BLACK WIRING INSULATED CLIPS NOTE IF WIRING INSULATED CLIPS WERE REMOVED FOR SERVICING OF UNIT THEY SHOULD BE REPLACED TO PROPERLY SECURE YOUR WIRING A AMMETER RED G B S M A1 A2 L HOUR METER OPTIONAL OPTIONAL SPARK PLUG GAP 2 PLUGS ON TWIN CYL ENGINES IGNITION SWITCH CIRCUIT POSITION OFF B A1 RUN LIGHT B S A1 START M G A1 B A1 RUN MAKE A2 L NONE NONE NONE REGULATOR ALTERNATOR 2...

Page 30: ...30 REPAIR PARTS TRACTOR MODEL NUMBER 944 604931 ELECTRICAL 28 29 26 25 40 33 30 42 90 187576B 52 D C AMPERES 45 Battery _27 8 1 91 2 27 55 16 22 21 16 ...

Page 31: ...09 Cable Battery 6 Ga Red 25 Intsole 26 175158 Fuse 27 73510400 Nut Keps Hex 1 4 20 Unc 28 145491 Cable Ground 6 Ga 21 black 29 121305X Switch Plunger Nc Gray 30 175566 Switch Ign 3 33 140403 Key Ign 40 187576 Harness Ign 42 154336 Cover Terminal Red 45 122822X Ammeter 52 141940 Protection Wire Loop Hourmeter 55 17490508 Screw Thdrol 5 16 18 x 1 2 90 180449 Cover Terminal 91 190270 Strap Battery M...

Page 32: ...IS AND ENCLOSURES 10 30 209 31 1 9 208 209 209 5 5 207 144 26 26 60 26 144 26 10 209 142 209 142 58 208 13 208 11 64 143 60 145 37 37 18 14 14 38 38 278 39 209 2 206 74 90 159 217 17 28 263 264 275 166 166 272 274 273 259 260 258 chassis Laser lt stlt_41 ...

Page 33: ...3707 Bolt Rdhd Sqnk 3 8 16unc x 3 4 64 154798 Dash Lower STLT 74 STD541437 Nut Crownlock 3 8 16 Unc 90 124346X Nut Self Thd Wsh Hd 1 4 142 175702 Plate Reinforcement STLT 143 186689 Bracket Swaybar Chassis 144 175582 Bracket Pnt Footrest STLT 145 156524 Rod Pivot Chassis Hood 159 179950X428 Cupholder 166 171875 Screw HWHD Hi Lo 13 16 x 3 4 206 170165 Bolt Shoulder 5 16 18 TT 207 17670508 Screw Thd...

Page 34: ... 26 76 78 75 74 27 26 59 19 219 221 221 220 222 221 19 51 51 271 19 19 6 231 239 33 239 238 52 237 233 240 232 241 235 242 221 274 224 225 223 223 223 223 226 226 234 236 227 218 217 244 96 254 51 251 228 229 21 214 61 15 89 120 27 51 48 150 151 202 49 47 50 120 66 56 38 39 95 41 96 253 64 65 212 63 116 70 drive hydro stlt_70 272 273 69 ...

Page 35: ... 2 unc 70 134683 Guide Belt Mower Drive RH 74 137057 Spacer Axle 75 121749X Washer 25 32 x 1 1 4 x 16 Ga 76 12000001 E Ring 77 123583X Key Square 78 121748X Washer 25 32 x 1 5 8 x 16 Ga 89 188308X428 Console Shift 95 180825 Rod Bypass 96 4497H Retainer Spring 1 Zinc Cad 116 72140608 Bolt RDHD SQNK 3 8 16 unc x 1 120 73900600 Nut Lock Flg 3 8 16 unc 150 175456 Spacer Retainer 151 19133210 Washer 13...

Page 36: ...ACTOR MODEL NUMBER 944 604931 STEERING ASSEMBLY 5 5 4 3 43 95 43 8 10 40 32 11 8 6 87 46 46 8 6 87 29 88 71 17 43 91 2 1 41 42 37 36 37 38 12 39 44 51 54 33 35 34 68 67 67 67 13 65 68 15 15 15 29 29 82 steering_pl lt_29 ...

Page 37: ...4 X 16 34 10040500 Washer Lock 5 16 35 73540500 Crownlock Nut 5 16 24 36 155099 Bushing Strg 37 152927 Screw 38 159946X428 Insert Cap Strg Wh Au 39 19182411 Washer 40 73540600 Nut Crownlock 3 8 24 41 159945 Adaptor Wheel Strg 42 145054X428 Boot Steering Shaft 43 121749X Washer 25 32 X 1 1 4 X 16 Ga 44 180640 Extension Steering Shaft LR LT 46 184946X505 Cap Spindle Fr Top Red 51 73540400 Nut Crownl...

Page 38: ...at 1 2 13 Unc Blk 12 121246X Bracket Mounting Switch KEY PART NO NO DESCRIPTION 13 121248X Bushing Snap Blk Nyl 50 Id 14 72050412 Bolt Rdhd Sqnk 1 4 20x1 1 2 15 134300 Spacer Split 28x 96 Yel Zinc 16 121250X Spring Cprsn 1 27 Blk Pnt 17 123976X Nut Lock 1 4 Lge Flg Gr 5 Zinc 18 124238X Cap Spring seat Blk 1 75 x 1 0 21 171852 Bolt Shoulder 5 16 18 Unc 22 STD541431 Nut Hex Lock W Ins 5 16 18 24 191...

Page 39: ...al Mower Warn Keep Hand Away 3 186366 Decal Hood RH LH 5 164065 Decal Strng Whl Domed Prem 6 186741 Decal HP Engine 7 186478 Decal Dash Pnl 8 172331 Decal Deck 9 186572 Decal Craftsman 10 157140 Decal Fender Danger Eng Fr 11 186367 Decal Hood Side Panel 13 166960 Decal By Pass KEY PART NO NO DESCRIPTION 6 2 1 5 8 4 10 3 9 11 7 WHEELS TIRES 14 160396 Decal V Belt Schematic 15 190141 Decal Replaceme...

Page 40: ...3 4 10 146629 Heat Shield 13 Gasket Order from engine Manufacturer 14 148456 Tube Drain Oil Easy 17 17120616 Screw Thdrol 3 8 16x1 1 2 Tytt 23 169837 Shield BRN DBR Guard KEY PART NO NO DESCRIPTION NOTE All component dimensions given in U S inches 1 inch 25 4 mm KEY PART NO NO DESCRIPTION 25 187766X428 Control Choke 29 137180 Arrestor Spark 31 179022 Tank Fuel 4 0 32 179124X428 Cap Fuel Gauge 33 1...

Page 41: ...22365X Button Plunger 11 139865 Link Lift Lh Fixed Length 12 139866 Link Lift Rh Fixed Length 13 STD624008 Retainer Spring 15 173288 Link Front 16 73350800 Nut Jam Hex 1 2 13 Unc NOTE All component dimensions given in U S inches 1 inch 25 4 mm 17 175689 Trunnion Blk Zinc 18 73800800 Nut Lock w Wsh 1 2 13 Unc 19 139868 Arm Suspension Rear 20 163552 Spring Retainer 31 169865 Bearing Pvt Lift 32 7354...

Page 42: ...55 56 34 1 46 44 21 24 25 26 27 2 28 29 23 21 21 21 18 18 20 2 48 59 19 4 5 6 21 40 143 36 40 40 159 140 184 42_D_man t path_stlt_4 3 129 92 131 130 92 118 136 21 139 2 119 117 116 5 21 134 21 5 134 135 136 116 113 117 119 118 2 138 113 102 102 104 103 105 106 104 105 106 103 101 185 67 158 4 2 _ c l u t c h _ m o d _ 7 152 132 95 94 182 91 183 132 ...

Page 43: ... ing Shaft and Shaft Hardware Only Pulley Not Included 186917 Replacement Mower Complete Std Deck Order separately nose roller mulcher cover and gauge wheel components key nos 91 94 95 132 182 183 101 106 116 119 5 134 136 1 182032 Mower Deck Assembly 42 2 STD533107 Bolt 3 138017 Bracket Assembly Sway Bar Front 4 165460 Bracket Sway Bar 38 42 Deck 5 STD624008 Retainer Spring 6 178024 Bar Sway Deck...

Page 44: ...44 REPAIR PARTS TRACTOR MODEL NUMBER 944 604931 HYDRO GEAR TRANSAXLE MODEL NUMBER 336 0510 ...

Page 45: ... W Patch SpecialFlange 64 142892 Bolt 1 4 20 X 1 W Patch 65 170411 Spacer 66 170412 Spring Brake Arm Bias 67 170413 Sq Hd Bolt 5 16 24 Ribbed KEY PART NO NO DESCRIPTION 68 178782 Arm Brake 69 170415 Slotted Hex Nut 5 16 24 70 170416 Cotter Pin 3 32 X 3 4 71 170417 Compression Spring Brake Anti Drag 72 170418 Washer Ht 5 I D X 1 O D X 032 73 142884 Flat Washer 11 32 I D X 7 8 O D 74 170419 Oil Seal...

Page 46: ...46 REPAIR PARTS TRACTOR MODEL NUMBER 944 604931 HONDA ENGINE MODEL NUMBER GXV530 TYPE NUMBER EXA2 ...

Page 47: ...47 REPAIR PARTS TRACTOR MODEL NUMBER 944 604931 HONDA ENGINE MODEL NUMBER GXV530 TYPE NUMBER EXA2 ...

Page 48: ...48 REPAIR PARTS TRACTOR MODEL NUMBER 944 604931 HONDA ENGINE MODEL NUMBER GXV530 TYPE NUMBER EXA2 ...

Page 49: ...x Valve Rocker 6 6604755 Shaft Rocker Arm 7 6604763 Valve In 8 6604771 Valve Ex 9 1426972 Spring Valve 10 1426980 Retainer In Valve Spring 11 0294819 Screw Tappet Adj 12 0004598 Nut Tappet Adj 13 6315873 O ring 6 8x1 9 CARBURETOR KEY PART NO NO DESCRIPTION 2 6604847 Gasket Set 3 6604854 Valve Float 4 6604862 Float Set 5 6604888 Chamber Set Float 6 6604896 Screw Set 7 6604904 Screw Set Drain 8 6662...

Page 50: ...4 Pipe Oil Supply 26 6853451 Holder Oil Pipe 27 6698823 O ring 5 8x2 28 2105799 Bolt Flange 6x12 CRANKSHAFT KEY PART NO NO DESCRIPTION 1 6853410 Crankshaft 2 6607188 Washer Thrust 3 2027159 Key Special Woodruff 25x18 PISTON CONNECTING ROD KEY PART NO NO DESCRIPTION 1 6695571 Ring Set Piston Std Nippon 6656425 Ring Set Piston 2 6604672 Piston Std 3 6223994 Pin Piston 4 6853402 Rod Assy Connecting 5...

Page 51: ...IPTION 1 6853311 Crankcase Assy 2 6604540 Cover Breather 1 3 6604557 Gasket Breather Cover 4 2515195 Plate Valve 5 6604565 Stopper Valve 6 6388482 Filter Oil 7 6604805 Extension Oil Filler 8 6853477 Dipstick Oil 9 6604821 Tube Breather 10 0928051 Bolt Flange 5x10 11 2488187 Bolt Flange 6x45 12 3509528 Holder Oil Filter 13 0748111 Bolt Flange 6x25 14 2108595 Oil Seal 35x52x8 15 2280006 O ring 22 5x...

Page 52: ...52 SERVICE NOTES ...

Page 53: ...53 SERVICE NOTES ...

Page 54: ...54 SERVICE NOTES ...

Page 55: ...the face Do not mow slopes greater than 15 degrees Make turns gradually to prevent tipping or loss of control Exercise extreme caution when changing direction on slopes 1 Fold this page along dotted line indicated above 2 Hold page before you so that its left edge is vertically parallel to a tree trunk or other upright structure 3 Sight across the fold in the direction of hill slope you want to me...

Page 56: ...PRINTED IN U S A 191883 03 09 04 RD 02488 ...

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