Sears 502.254152, Owner'S Manual

Page 1: ...llow All Safety Rules And Instructions Before Operating This Equipment 11 P LECTRIC START 8 SPEED 30 MOWER EA ENG I Assembly Operation Maintenance o Repair and Adjustment Repair Parts F 88516 Sears Roebuck and Co Chicago IL 60684 U S A PrTnted fn U S A ...

Page 2: ...ollows 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 a grass 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...

Page 3: ...nit can use attachments 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 A Sears Maintenance Agreement Is available on this unit See the nearest Sears Store for information LIMITED TWO YEAR WARRANTY ON EL...

Page 4: ...uel 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...

Page 5: ... in a small box Remove and check each item Remove the small box 3 Cut each corner of the carton from the top to the bottom with a knife 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 ...

Page 6: ...r Steering Wheel STD551237 55804 1 Cover ForBattery Clamp Not shown fuil size 55253Z 1 Clamp Battery For Battery 4 Washer 2 Locknut Notsi_Own futI size 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 full size Not shown ful size 24582 20107 560...

Page 7: ...a and mix together using a piece of wood Add more baking soda until 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...

Page 8: ...olesin 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 into the control panel Move the steering panelback Putthe two tabsof the s...

Page 9: ...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...

Page 10: ...e Operation section Know the location and purpose of all the controls HOW TO INSTALL THE BA r rERY Use the fasteners shown below to installthe battery The fasteners are shown full size A C 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 termina...

Page 11: ...AKE PEDAL This unit has only one pedal that is located on the left side of the unit The pedal has two functions The first function is a clutch The second function is a brake Push the pedal completely forward to stop the unit HOW TO USE THE LIFT LEVER The lift lever is on the right side of the unit To change the height of cut raise or lower the lift lever When you ride on a sidewalk or a road move ...

Page 12: ... that includes a sensor switch mounted in the seat These components tell the electrical system ifthe operator is sitting on the seat For your protection always make sure this system operates correctly This system will stop the engine when the operator leaves the seat if the blade engagement control is engaged 1 Check the oil 2 Fill the fuel tank with regular unleaded gasoline Make sure the gasolin...

Page 13: ... Slope Guide inthe back of this book for information on how to check slopes 1 Before you ride up or down a hill move the shift lever to the slowest speed 2 Do not stop or change speed settings on a hill If you must stop quickly pushthe clutch brake pedalforward and set the parking brake 3 To start again make sure the shift feveristhe slowest speed Move the throttle control to the SLOW position Slo...

Page 14: ...se SAE 5W30 oil when the temperature is below 32 F 4 Clean the area around the dipstick Remove the dipstick Slowly pour approximately 3 pints 1 4 liters of oil into the oil extension tube 5 insert the dipstick into the oil extension tube Turn the dipstick in a clockwise direction until it is tight Remove the dipstick Check the oil level on the dipstick The oil level must reach the FULL mark on the...

Page 15: ...ment control i i i i1_ i i i Position _ L Oom o o y To Disengaged Position D4s_o _1 8 3ram 3 8 9 re m Pivot Rod And Bracket Assembly Clevis Clockwise O O D 4755 8 Check the operation of the blade brake Rotate the pulley with your hand Make sure that the blade brake pad presses tightly against the pulley 9 Move the blade engagement control to the ENGAGE posi tion Check the blade brake pad If the bl...

Page 16: ...Before you remove the blade dis connect the wire to the spark plug The blade has sharp edges When you hold the blade use gloves or cloth material to protect your hands 1 Remove the mower housing See the instructions on How To Remove The Mower Housing 2 Use a piece of wood to keep the blade from rotating 3 Remove the nut that holds the blade 4 Check the blade according to the Blade Service instruc ...

Page 17: ... the blade is balanced Use a screwdriver and hold the blade parallel to the ground as shown A blade that is balanced will stay parallel to the ground If the blade is not balanced the heavy end will rotate toward the ground Sharpen the heaw end until the blade is balanced 6 A new blade will cut batter than a badly worn blade Every three years have an authorized service person inspect the blade or r...

Page 18: ...om the positive terminal 3 Remove the battery clamp from the battery 4 Remove the battery from the unit 5 Wash the battery with a solution of one gallon of water and four tablespoons of baking soda sodiumbicarbonate Make sure the solution does not get into the battery cells 6 Clean the terminals and the ends of the cables with a wire brush 7 Install the battery See How To InstalI The Battery 8 Che...

Page 19: ...ssemble let the paper filter completely dry inthe air Do not put oil on the paper filter 12 Assemble the air filters 13 install the cover Fasten the cover with the cover screws HOW TO CHANGE THE OIL NOTE Drain the oil when the engine iswarm Be careful do not get oil on the belts 1 Put the plastic drain tube into the oil drain valve Put the other end of the drain tube into a container as shown Turn...

Page 20: ... 2 Slide the mower drive belt between the stack pulley and the belt guide Put the mower drive belt around thestack puliey Make surethe V side of the mower drive belt isagainst the stack pulley Make sure the drive belt is not twisted 3 Attach the mower housing to the front suspension bracket with the long pin Fasten with the washer and hair pin See illustration D below 4 Attach the rear hangers to ...

Page 21: ...the mower drive belt Before you operate the mower make sure the mower drive belt is inside all the belt guides 9 Before you mow check the blade engagement control lever See the instructions on How To Adjust The Blade Engage ment Control Lever HOW TO REPLACE THE MOTION DRIVE BELT t Remove the mower housing See the instructions on How To Remove The Mower Housing 2 Slide the motion drive belt off the...

Page 22: ... than _ adjust as follows 1 Disconnect one or both of the hangers from the adjuster plates 2 The higher numbers on the side of the adjuster plates will raise the height of the mower housing The lower numbers will lower the mower housing 3 Connect the hangers into the hole of the adjuster plates that will level the mower housing Fasten the hangers to the adjuster plates with the hair pins 4 Check t...

Page 23: ... idler See the drawing Insert A below 8 Pull on the motion drive pulley until the drive disc separates from the shaft 9 Remove the old drive disc Lift the motion drive pulley into position Align the shim washer and the special double DID washer on the shaft 10 Replace the drive disc Fasten the hex nut to the shaft To keep the drive disc from turning put a screwdriver under the drive disc between t...

Page 24: ...d speed position 13 Attach the spring to the carriage arm How To Adjust The Index Bracket 1 Engage the parking brake 2_ Move the shift lever to the slowest speed position 3 Tiltthe seat forward Check the distance between the neutral arm and the neutral bracket The distance must be approx imately 16 inch as shown If the distance is not correct adjust as follows 4 Loosen the two nuts on the index br...

Page 25: ...correct adjust as follows 4 Move the mower housing to the lowest height of cut for more work clearance 5 Disconnect the adjustable nut from the brake rod 6 To reduce the distance between the brake pad and the brake drum turn the adjustable nut clockwise To increase the dis tance turn the adjustable nut counterclockwise D_4609 2 Brake Pad C 4609 2 3 16 to 1 4 Brake Rod Washer Parking Brake Brake Li...

Page 26: ...pring from the chain idlers 4 Engage the parking brake 5 Loosen the three nuts on the chain bridge 6 To adjust the chain slide the chain bridge back Hold the bridge in place Tighten the three nuts to hold the bridge in place 7 Check the front drive chain Make sure the chain has no more than 3 16 inch of movement as shown 8 Connect the spring to the chain idlers 9 After the front drive chain is adj...

Page 27: ...et inprace Tighten one of the nuts to hold the axle bracket in place 5 Look at the side of the frame above the axle Find the index notches These index notches are a measurement of the location of the axle brackets Make sure the position of the axle bracket on the left side of the unit is like the right side If the position is the same tighten one of the nuts on the left side 6 Check the tension of...

Page 28: ... be removed WARNING For your protection use safety eye glasses 3 Puta punchagainstthe top side of the bearing Usea hammer and hit the punch until the bearing releases from the carriage arm CAUTION Do not use a hammer to put the new bearing into place You will damage the bearing Set the new bearing in the ca rriagearm Put the carriage arm and bearing with a piece of wood against the bearing into a ...

Page 29: ... the throttle control to the SLOW position Turn the idle speedscrew until afast idle is obtained 1750__ 200 RPM Turn the idle valve clockwise lean and counterclockwise rich until the engine idles smoothly Then turn the idle speed screw so that the engine idles at 1750 200 RPM 7 Move the throttle controt to the FAST position If the engine does not accelerate correctly adjust the carburetor to a ric...

Page 30: ...y last Allow the engine to run 6 To disconnect the Jumper Cables reverse the above steps STORAGE If the unit is not used for over 30 days prepare the unit for storage as follows THE ENGINE 1 Run the engine until the engine is warm 2 Stop the engine 3 Change the oil 4 Clean the air filter THE FUEL SYSTEM WARNING Always use a safety gasoline container Do not smoke when adding gasoline to the engine ...

Page 31: ...r Fill with clean gasoline On slopes the engine stops 1 Replace the spark plug 2 Adjust the throttle control 6 7 3 1 Mow up and down slopes Never mow 2 across a slope 1 Replace the spark plug 2 Clean the air filter 3 Adjust the carburetor The engine will not idle Add oil Adjust the carburetor Move the throttle control to FAST Try to start the engine to clear out excess fuel Replace the spark plug ...

Page 32: ...ton Clrcui Off M G On fl L Stert B S I i e 12V BIdck Black Yellow Yellow So l enoid Starter I I o f t I I I I _d Black Seat Swi fch seal unoccupied AI Ioc_en Tronmlssion Interlock _Itch Inferlock Svifch Ldlsengaged Lnoutral 1 I I I Yel low Block __ _ Yel low N C Conne_ior closedif unplugged frm Seat_Ifchj Spark Plug o_Solid Sfafe_ Ignition Headt ighf 2 2 Amp Red o_ Light Switch Charging Coil Recf ...

Page 33: ...ry 24x3 9 Ammeter 90729 10 Limit Switch 24273 11 Fuse 15 AMP 54212 12 Tray Batter 55792 13 Limit Switch 91032 Part is not shown F 88516 MFG NO 15x66 lx38 KEY NO DESCRIPTION 14 Wiring Harness 15 Switch Ignition 16 Key Only 17 Light Switch 18 Light Socket 19 Light Bulb 20 Solenoid Cap 21 Washer Shakeproof 22 Nut Hex 23 Switch Seat Sensor 24 Cap Switch 26 Tie Wire 27 Clamp Wire 28 Cover Seat Switch 2...

Page 34: ...MODEL NO 502 254152 1_4648 4 8 1 1 82 16 71 REPLACEMENT PARTS BODY AND CHASSIS 8O 39 33 43 3O 28 15 58 8 63 1 6 59 F 88516 6 51 64 65 34 13 52 55 ...

Page 35: ...roof STD551231 19x6 18 Cover Upper Console 55414 59 Bolt Engine Mount 25x6 19 Screw 26x161 60 v_asher Shakeproof t9x8 20 Console Upper 55413 61 Bolt Hex 5 16 18x3 r lx118 2t Screw STD610803 26x159 62 Muffler 56029 22 Bushing 55717 63 Engine Briggs Stratton 23 Bearing Steering Post 56022 Model 5oo 2537o7 o213 ot 55811PA 24 Console 70231SE 64 Fitting Oil Drain 55704 25 Screw 26x201 65 Hose Oil Drain...

Page 36: ...MODEL NO 502 254152 PARTS DRIVE SYSTEM D_4702 3 1 42 3 4 55 47 49 51 46 33 17 18 26 25 54 37 36 6O 35 58 6 I F 88516 36 ...

Page 37: ...ller 40 Link Master 41 Sprocket and Guard Assembly 42 Nut Hex 5 16 18 43 Washer 44 Valve Stem and Cap 45 Tire Only 46 Wheel Only 47 Key Square 49 Retainer Ring 50 Washer 51 Hub Cap 54 Rod Parking Brake 55 Grip Parking Brake 56 Pin Cotter 57 Link Parking Brake 58 Washer 59 Stop Parking Brake 60 Pin Clevis PART MFG NO NO STD533107 2x53Z 55650 701 55839 55556PA 56018 STD560907 30x20 STD541431 15x88 9...

Page 38: ...MODEL NO 502 254152 0 4608 3 REPLACEMENT PARTS STEERING SYSTEM 44 43 1 8_ 1t 32 33 10 25 30 d 5 24_ 7 j18 16 9 2O i 1 34 46 28 27 30 F 88516 38 ...

Page 39: ... Bolt 24x2 Left Spindle Assembly Tie Rod Right Spindle Assembly Bearing Flanged Wheel Only Tire Only Valve Stem and Cap Washer Hub Cap Bearing Washer Bushing Nylon Bolt Hex 16x_ 4 Washer Shakeproof Washer Adapter Steering Wheel Locknut 5 16 18 Bolt Contour 5 16 18xl 4 Bellows Steering Post Washer Formed The part is also included with Key No 31 REPLACEMENT PARTS STEERING SYSTEM PART MFG NO NO 55919...

Page 40: ...MODEL NO 502 254152 MOWER HOUSING SUSPENSION D 4529 5 5 8 2 43 38 Q 41 37 34 3 1 3 3O t 31 12 _ _3435 34 29 35 A 23 24 40 2 12 _ 27 Fo88516 40 ...

Page 41: ...is 27 Bolt Shoulder 3 8 16 28 Nut Hex Jam 3 8 _16 29 Rod Assembly 30 Link 31 Bolt Shoulder 32 Clevis Adjuster 33 Nut Hex 5 16 18 34 Hairpin 35 Plate Adjuster 36 Plate Mounting 37 Rod Assembly Suspension 38 Bolt Carriage 39 Rod Lifter 40 Washer 41 Strut Frame 42 Bolt Hex 5 16 18x 43 Locknut Hex 20 PART MFG NO NO 55449 55928Z STD54t425 15x89 STD522510 lx76 55440 STD551050 17x67Z 55853 55439 56031 3x...

Page 42: ...MODEL NO 502 254152 MOWER HOUSING BOTTOM HALF 8 11 12 24 28 37 26 17 q 28 33 18 43 17 41 _42 39 D 4745 F 88516 42 ...

Page 43: ...sion 33 Housing Blade 34 Bracket Front 35 Screw 36 Bolt Hex 5 16 18x7 8 37 Deflector Chute 38 Mandrel 39 Blade 40 Washer Belteville 41 Washer Hardened 42 Nut Hex 9 16 18 43 Pin Pull 44 Washer 45 Pin Hair Mower Housing Complete These parts are included with key no 33 MOWER HOUSING BOTTOM HALF PART MFG NO NO 37x57 55452 18x33 15x101 STD541450 15x41 91178 55921E601 55895 55979 8TD541431 15x88 29x99 2...

Page 44: ...MODEL NO 502 254152 IN O REPLACEMENT PARTS TRANSMISSION D4600 2 O cox co o IN O3 co c q D CO I _ w _D LO IN F 88616 44 ...

Page 45: ...9 20xt 55643 9x30 55562E701 STD560907 30x20 STD551037 17x53Z 55570 55514Z 55513Z 11x18 55543 55651 165x27 56021 11x 3 55635 KEY NO DESCRIPTION 35 Locknut 5 16 18 36 Housing Bearing 37 Screw Set 38 Carriage Arm 39 Bail Bearing Assmbly 40 Ring Retainer 41 Hex Shaft Assembly 42 Brake Arm Assembly 43 Bearing Flanged 44 Bushing F anged 45 Pivot Rod Assembly 46 Washer Curved Spring 47 Washer 48 Screw 49...

Page 46: ...r lncl No 13 774345 1A Housing Differential carrier Incl No t3 774344 2 Axle 8 11 64 long 774532A 3 Axle 19 3 32 long 774531A 4 Gear Bevel 778067 5 Gear Pinion 778068 6 Pin Drive 786040 7 Washer Thrust 780096 8 Washer 780001 10 Ring Snap 792018 11 Screw Hex 5 16 18x3 792041 13 Bushing 780077 14 Washer 792061 F 88516 46 ...

Page 47: ...GS STRATTON ENGINE MODEL 500 253707 0213 01 305 it 334 337 _ 635 552 BUSH 1 46 _SPECIAL TO 11 o 356 201 232 6 15 SEEREPAIR MA_ Assemblies include all parts shown in frames 230 161 757 219 525 524 F 88516 47 ...

Page 48: ...SEARS RIDING MOWER MODEL 502 254152 BRIGGS STRATrON ENGINE MODEL 500 253707 0213 01 l 534 643 534A 887 877 28 t 88516 Assemblies include all parts shown in frames 48 ...

Page 49: ...BRIGGS STRATTON ENGINE MODEL 500 253707 0213 01 310 _ _HoU NG_LENGTH _ Assemblies include all parts shown in frames F 88516 49 ...

Page 50: ...n Assembty Piston 005 O S Rod Assembly Connecting For Connecting Rod with O20 undersize Crankpin Bore Order No 393712 Lock Conn Rod Screw 186 Screw Conn Rod 1 87 Valve Exhaust Valve Intake Spring Intake Valve 201 Spring Exhaust Valve 209 Retainer Intake Valve 216 Rotocoil Exhaust Valve KEY PART NO NO 42 93630 45 261183 46 212897 52 270872 75 220865 78 93805 94 t292681 95 93499 98 91920 99 26157 t0...

Page 51: ...lug Spark t t 2 high BRIGGS STRATTON ENGINE MODEL 500 253707 0213 01 PART NO 23_O82 1193053 93306 93307 261116 270382 66538 280118 93496 222311 93572 392134 395405 93535 261196 212359 391373_ 298909 93875 394856 395537 393825 270920 392067 221798 261463 210940 291961 Note DESCRIPTION Nut Hex 10 24 Clamp Fuel Pipe Cotter Hair Pin Retainer E Ring Spring Choke Return Washer Choke Shaft Elbow Spark Pl...

Page 52: ...NOTES F 885 16 52 ...

Page 53: ...NOTES i_ F 88516 53 ...

Page 54: ...NOTES F 88516 54 ...

Page 55: ..._0 0 _ 3 o 0 0 P o a o o P o 3 o o g 0 _ r o_ _ N _ m 3 E _p _ O _ _ m NN c g i N i _ 0 t_ o_ toO 0 m m oN m m g r 0 o 0 0 i O o O 0 0 0 O o 0 o g 0 o 0 g 0 0 F 88S16 55 ...

Page 56: ...ents and most Sears Stores WHEN ORDERING REPAIR PARTS ALWAYS HAVE THE FOLLOWING INFORMATION AS SHOWN IN THIS LIST 1 PART NUMBER 2 PART DESCRIPTION 3 MODEL NUMBER 4 NAME OF ITEM 5 ENGINE MODEL NUMBER Your Sears merchandise has added value when you consider Sears has service units nationwide staffed with Sears trained technicians Sears technicians have the necessaryParts tools and equipment to meet ...