How to use this file...(Operators Manuals) ————————————————————————————————————————————––– Instructions for Print Vendors (Paper Manuals) Paper Size: * 11 x 17 * Body—50 lbs brilliant white offset or equivalent. * Cover—on pre-printed two-tone “Swash” stock. Press: * Body—1-color, 2-sided * Cover imprint —1-color, 1-sided Bindery: * Saddle Stitch, Face Trim, 3-Hole Drill * Face Trim COVERS: * This file contains several manuals, which differ only in their covers.
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Replacement OPERATOR’S MANUAL SunStar / 1900 / 2900 Series 18HP Hydro Tractors 48” Mower Decks Mfg. No. 1692521 1692523 1692525 Mfg. No. 1690986 1691183 Description SunStar, 18HP Hydro 1918H, 18HP Hydro 2918H, 18HP Hydro 20HP Hydro Tractors Mfg. No. 1692454 1692456 1692458 1692460 1692505 1692507 Description SunStar, 20HP Hydro SunStar, 20HP Hydro 1920H, 20HP Hydro 1920H, 20HP Hydro 2920H, 20HP Hydro 2920H, 20HP Hydro Description 48” Mower Deck 48” Mower Deck 60” Mower Decks Mfg. No.
MANUFACTURING, INC. 500 N Spring Street / PO Box 997 Port Washington, WI 53074-0997 www.simplicitymfg.com © Copyright 1998, Simplicity Manufacturing, Inc. All Rights Reserved. Printed in USA.
Table Of Contents Troubleshooting The Tractor ..............................................20 Troubleshooting The Mower ...............................................21 Checking the Battery ..........................................................21 Charging A Completely Discharged Battery ..........................................................22 Jump Starting with Auxiliary (Booster) Battery ...............................................22 Bulb Replacement ...........................................
Tractor & Mower Identification Record your model number, manufacturer number and engine serial number in the space provided for easy reference. The models and manufacturer numbers covered in this manual are listed on the front cover. MODEL REFERENCE Model Number: The tractor I.D. tag is located on the left-side, front of the frame, as shown below. The mower deck I.D. tag is also on the left side, on top of the mower deck, towards the rear. Manufacturer Number: Engine I.D.
Safety Rules Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of rider, severe personal injury or death to you, or bystanders, or damage to property or equipment. This mowing deck is capable of amputating hands and feet and throwing objects. The triangle in text signifies important cautions or warnings which must be followed. GENERAL OPERATION WARNING - SLOPE OPERATION Never operate on slopes greater than 30 percent (16.
Safety Rules running. Allow engine to cool before refueling. Do not smoke. CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them. c) Never refuel the unit indoors. • Never run a unit inside an enclosed area. • Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition.
Safety Decals This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing. your tractor and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important! The safety decals shown below are on your tractor and mower.
Features & Controls TRACTOR CONTROLS *1322 Y *1323 Right Side Left Side X Figure 2. Tractor Controls REF A NAME Mower Height Control Lever FUNCTION Controls mower cutting height. B Lift Lever, Hydraulic Lifts and lowers attachments. C Lift Lever, Dual (Optional) Allows use of second hydraulic function. D Engine Speed Controls engine speed. E Choke Engages/disengages engine choke for starting. F Oil Light (Red) Lights up to indicate low oil pressure.
Features & Controls SAFETY INTERLOCK SYSTEM *2374 Your tractor is equipped with a seat switch safety system that will automatically shut the engine off when the operator leaves the seat with the ground speed control lever in gear or with the PTO engaged. Once the engine has stopped, the electric PTO switch must be turned off after operator returns to the seat in order to start the engine. Check operation of dash safety lights. With operator in seat and ignition switch turned to ON (engine not running): A.
Operation GENERAL Before operating this tractor for the first time, the owner should operate in an open area without mowing, to become accustomed to the unit. The left side of the mower can be used to trim close to objects. Be sure to read all information in the Safety and Operation sections before attempting to operate this tractor and mower. CAUTION ON 18 HP MODELS, towing the tractor will cause transmission damage. Do not use another vehicle to push or pull tractor.
Operation 3. The mower drive shaft connects to the tractor drive shaft by a series of retracting balls located under the locking ring (A, figure 5). When the locking ring is released, the balls lock into a groove on the tractor drive shaft. To connect the drive shaft, proceed as follows: *1681 A. Place the mower drive shaft barely onto the tractor drive shaft. Turn the coupler (B, figure 5) to align the splines. B.
Operation *1323 Figure 9. Two-Speed Axle Shift (20 HP Models) A. Axle Shift Lever STARTING THE ENGINE Figure 8. Tractor Controls A. Seat Light G. B. Ground Speed H. Control Lever I. C. Parking Brake Knob J. D. Brake Pedals K. E. Front PTO Switch L. F. Rear PTO Switch (Optional) Refer to figure 8. Front PTO Light Choke Knob Throttle Lever Ignition Switch Key Brake Pedal Lock Lift Lever, Hydraulic 1. Operator must be seated. Seat light (A) will light up when key is turned on. 2.
Operation 3. Make sure lever is firmly seated all the way in the low range or high range slot before operating tractor. 4. To set parking brake depress brake pedals, pull parking brake knob (C) out, then release pedals. OPERATION 5. Push hydraulic lift lever forward to lower attachment. 6. Turn ignition off and remove key to prevent unauthorized use. Refer to figure 8. 1. Press pedals (D) to release parking brake. WARNING 2.
Mowing Patterns & Tips • Aerate lawn in spring, consider renting an aerator which removes cores of soil from the lawn. This increases the speed of clipping decomposition and deep root growth by opening up the soil and permitting greater movement of water, fertilizer and air. • Don’t over-water. Too much water can encourage disease development. • Mow when the grass is dry, preferably in the late afternoon when the temperatures are cooler.
Normal Care SCHEDULE The following schedule should be followed for normal care of your tractor and mower. You will need to keep a record of your operating time. See Page 7 Every 100 Hours *Or Yearly ● Check tractor brakes. 24 ● Normal Care Items Check tractor & mower for loose hardware. – ● Clean heat exchanger. - ● Clean hydrostatic cooling fins with compressed air. - ● Check tires. 13 ● Lubricate tractor and mower. 14 Oil Pivot points. 15 Check transmission fluid.
Normal Care LUBRICATION Tractor & Mower Lubrication Lubricate the tractor and mower as shown in figures 10 18. When a grease gun is shown, wipe the fitting clean, apply two or three shots of lithium base automotive grease, and wipe off excess grease. When an oil can is shown, wipe the area clean, apply a few drops of oil (SAE 30), then wipe up drips or spills. *1873 *1875 Figure 12. Center Front Axle and Wheels *2528 Figure 10. Engine Drive Shaft *1681 Figure 13.
Normal Care *1872 *1384 Figure 15. PTO Idler Assembly Figure 17. Mower Drive Shaft *1684 *1606 Figure 16. Mower Belt Idler (Grease fitting located under rubber plug on arbor cover) Checking Mower Gear Box Fluid 1. See figure 11. Remove check plug on left-hand side of gear box. 2. Fluid should be at bottom of hole when mower is level. Add SAE 85W-90 gear oil as necessary. Figure 18. Mower Arbor 3. Install check plug.
Normal Care CHANGING TRANSMISSION FLUID & FILTER *2519 Transmission fluid and filter should be changed only when performing repair work or if fluid has become discolored from overheating or contamination. Perform fluid change every 400 hours of operation if no other transmission service has been done. Replace the transmission filter whenever changing transmission fluid. Make sure filter base and surrounding area is absolutely clean before removing old filter. 1.
Normal Care *1687 *169 Workbench Loosen Thin Finishing Nail Figure 22 Balancing The Blade Blade Mounting Capscrew *1688 Wooden Block Tighten Figure 21. Removing The Blade SERVICING THE MOWER BLADES 1. Remove mower from the tractor. 2. Blades should be sharp and free of nicks and dents. If not, sharpen blades as described in following steps. 3. To remove blade for sharpening, use wooden block to hold blade while removing the blade mounting capscrew (figure 21). 4.
Storage WARNING Never store the tractor, with gasoline in engine or fuel tank, in a heated shelter or in enclosed, poorly ventilated enclosures. Gasoline fumes may reach an open flame, spark or pilot light (such as a furnace, water heater, clothes dryer, etc.) and cause an explosion. Handle gasoline carefully. It is highly flammable and careless use could result in serious fire damage to your person or property. Drain fuel into an approved container outdoors away from open flame or sparks. b.
Storage 11. Transport the tractor to a suitable, dry, indoor location. If the tractor is to be stored 6 months or longer, block the tractor up off the wheels to relieve weight and also to keep the tires off a damp floor. Protect tires from prolonged exposure to direct sunlight. 2. Install the battery if it was removed. 3. Unplug the exhaust outlet and air cleaner. 4. Fill the fuel tank with fresh gasoline. See engine manual for recommendations. 5. Check crankcase oil level and add proper oil if necessary.
Troubleshooting & Repair GENERAL 5. Faulty engine electrical or fuel system. See engine manual or your dealer. WARNING To avoid serious injury, perform maintenance on the tractor or mower only when the engine is stopped and the parking brake engaged. Always remove the ignition key, disconnect spark plug wire and fasten away from the plug before beginning the maintenance, to prevent accidental starting of the engine. Engine starts hard or runs poorly. 1. Fuel mixture too rich. Clean air filter.
Troubleshooting & Repair 4. Transmission fluid low. Add as required. Check for leaks. Engine stalls easily with mower engaged. 1. Engine speed too slow. Set for 3/4 to full throttle. 5. Transmission oil too hot. Check transmission cooling fins for grass or clippings and clean with brush or compressed air. Do not use water. 2. Ground speed too fast. 3. Engine cold. Allow warm-up period. 4. Cutting height set too low when mowing tall grass. Cut tall grass at maximum cutting height during first pass. 6.
Troubleshooting & Repair battery properly. If there is any doubt about the cause of the problem, see your dealer. If you need to replace the battery, follow the steps under Cleaning the Battery & Cables in the Normal Care Section. WARNING For your personal safety, use extreme care when jump starting. Never expose battery to open flame or electric spark – battery action generates hydrogen gas which is flammable and explosive. Do not allow battery acid to contact skin, eyes, fabrics, or painted surfaces.
Troubleshooting & Repair Figure 24. Jump Starting Diagram BULB REPLACMENT WARNING Any procedure other than the preceding could result in: (1) personal injury caused by electrolyte squirting out the battery vents, (2) personal injury or property damage due to battery explosion, (3) damage to the charging system of the booster vehicle or of the immobilized vehicle. Dash Indicator Bulbs Do not attempt to jump start a vehicle having a frozen battery because the battery may rupture or explode.
Adjustments *2374 *1646 Latch Figure 25. Seat Adjustment WARNING To avoid serious injury, perform adjustments only with engine stopped, key removed and tractor on level ground. Brake Tool SEAT ADJUSTMENT Figure 26. Brake Shoe Adjustment See figure 25. Use the lever to adjust the seat forward or rearward for best rider comfort. L.H. Side - 1-9/16” R.H. Side - 1-5/8” BRAKE ADJUSTMENTS Brake Shoes NOTE: On 18 HP models, engage the release valve (W, figure 2).
Adjustments FRONT CLUTCH ADJUSTMENT Burnishing The Clutch Before the front clutch is used for the first time, it should be burnished as follows. Also, if mower cut is rough looking, the clutch may require burnishing. To burnish the clutch, the mower must be installed. 1. Start the engine and set at full throttle. 2. Pull the front PTO switch out to the on position, leave for 15 seconds, then push in to the off position. 3. Repeat ten times to burnish the clutch. Clutch Adjustment 1.
Adjustments adjust, proceed to step 7. *1684 7. See figure 28. Loosen both jam nuts (B) on both rods (only one shown). Turn the bolt (C) in to raise front of mower, or out to lower front of mower. Be sure to adjust both sides equally. 8. When measurement is correct, tighten both nuts (B) securely while holding bolt (C). ADJUSTMENTS FOR THE 60” MOWER Idler Bracket 1. When the belt is installed, the bracket (B, figure 30) should touch the stop (C, figure 30).
Belt Replacement *2530 Idler Pulley Figure 33. Mower Belt - 48” Mower A. Cotter Pin (2) E. Nut, Idler Pulley B. Trunnion Pin (2) F. Stop, Idler Pulley C. Arm Assy. (2) G. Idler Pulley D. Lift Clevis (2) *2529 Figure 32. Tractor PTO Belts CAUTION To avoid damaging belts, do not pry belts over pulleys. TRACTOR PTO BELTS 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, turn off the engine and lock the parking brake. Remove the key. 2. See figure 32.
Specifications NOTE: Specifications are correct at time of printing and are subject to change without notice. ENGINE TRANSMISSION 18 HP Kohler Type Pump Motor Hydraulic Fluid Model Horsepower Cylinders Bore Stroke Displacement Construction Electrical System Ignition Governor Air Cleaner Lubrication Oil Capacity Fuel Tank Muffler Command OHV 18 HP @ 3600 rpm 2 3.03 In. (77 mm) 2.64 In. (67 mm) 38 Cu. In.
Specifications CHASSIS Frame Rear Wheels Front Wheels Accessibility Seat Turning Radius DIMENSIONS Side Rail Construction; Electrically Welded Heavy Guage Steel Power Take-Off Points: Front & Rear (Opt.) Engine Mounting Above Front Axle Pivot Point Location: double Pivoting Heavy Duty Cast Front Axle Tire Size 23 x 10.5-12 or 24 x 13 x 12 Pneumatic Inflation Pressure 6-8 psi (41-55 kPa) Tire Size 16 x 6.
Parts & Accessories COMMON REPLACEMENT PARTS MAINTENANCE ITEMS Listed below are the more common replacement parts. Only genuine factory replacement parts will assure optimum performance and safety. Do not attempt repairs or maintenance unless proper procedures and safety precautions are followed. For assistance in any area, see your dealer. • Simplicity Engine Oils Case of 12 qts. (Your dealer has 1 qt.
Parts & Accessories OPTIONAL ACCESSORIES See your dealer to purchase these items.
International Symbols Fast Lights Oil Pressure Slow Operator Present Switch (Seat) Forward PTO Engaged Reverse 32 Parking Brake Choke Engine Running