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Rally RA1638 Owner's Manual

16.0 hp 38 inch lawn tractor
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MODEL NO. RA1638 (96011020500)
16.0 HP 38 Inch
Lawn Tractor
401932 Rev. 1 11.16.05 TR
Printed in U.S.A.

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Summary of Contents for Rally RA1638

  • Page 1 MODEL NO. RA1638 (96011020500) 16.0 HP 38 Inch Lawn Tractor 401932 Rev. 1 11.16.05 TR Printed in U.S.A.

  • Page 2: Safety Rules

    SAFETY RULES Safe Operation Practices for Ride-On Mowers DANGER: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH. • Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before WARNING: In order to prevent ac- cleaning the machine, removing the grass catcher, or...
  • Page 3 SAFETY RULES Safe Operation Practices for Ride-On Mowers III. CHILDREN GENERAL SERVICE • Never operate machine in a closed are. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to •...

  • Page 4: Table Of Contents

    PRODUCT SPECIFICATIONS CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manu fac tured to give you the best possible dependability and performance. Gasoline Capacity 1.25 Gallons and Type: Unleaded Regular Should you experience any problem you cannot easily rem- Oil Type (API-SG-SL): SAE 30 (above 32°F) edy, please contact your nearest authorized service center/...
  • Page 5 CONTENTS OF HARDWARE PACK Steering Wheel Seat Steering Extension Shaft Steering Wheel Insert (1) Washer 17/32 x 1-3/16 x 12 Gauge Steering Steering Wheel Boot Adapter (1) Knob (1) 5/16 Lock Washer (1) Oil Drain Tube Slope Sheet (1) Large Flat Washer (1) Hex Bolt 5/16-18 x 4 (2) Keys...

  • Page 6: Assembly

    ASSEMBLY Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes. To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to insure proper tightness.
  • Page 7 ASSEMBLY DISCARD TER MI NAL SEAT SHOULDER PROTECTIVE CAPS BOLT KEPS TERMINAL HEX BOLT COVER SEAT PAN 02604 NEGATIVE (BLACK) POSITIVE (RED) CABLE CABLE FIG. 3 FLAT WASHER SEAT PAN 02464 ADJUSTMENT KNOB LABEL FIG. 2 CONNECT BATTERY (See Figs. 3 and 4) CAUTION: Do not short battery termi- nals by allowing a wrench or any other 02602...
  • Page 8 ASSEMBLY • Place gear shift lever in neutral (N) position. ✓CHECKLIST • Press lift lever plunger and raise attachment lift lever to its highest position. BEFORE YOU OPERATE YOUR NEW TRAC TOR, WE • Remove key from bag and start the engine (see "TO WISH TO ASSURE THAT YOU RECEIVE THE BEST PER- START"...

  • Page 9: Operation

    OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their mean- ing. FAST REVERSE HIGH SLOW NEUTRAL CHOKE IGNITION SWITCH ENGINE START MOWER HEIGHT REVERSE ENGINE ON PARKING BRAKE MOWER LIFT ENGINE OFF OPERATION SYSTEM (ROS)
  • Page 10 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 ad just ments. Save this manual for future reference. ATTACHMENT ROS "ON"...
  • Page 11 OPERATION The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye dam age. Always wear safety glass es or eye shields while operating your tractor or per form ing any adjustments or repairs. We rec om mend a wide vision safety mask over spectacles or stan dard safety glasses.
  • Page 12 OPERATION • Move gear shift lever to reverse (R) po si tion and slowly TO OPERATE MOWER (See Fig. 7) release clutch/brake pedal to start movement. Your tractor is equipped with an operator presence sensing • When use of the ROS is no longer needed, turn the switch.
  • Page 13 OPERATION TO START ENGINE (See Fig. 5) BEFORE STARTING THE ENGINE When starting the engine for the fi rst time or if the engine has run out of fuel, it will take extra cranking time to move CHECK ENGINE OIL LEVEL fuel from the tank to the engine.
  • Page 14 OPERATION MOWING TIPS • Mower should be properly leveled for best mowing per- for mance. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. • The left hand side of mower should be used for trim- ming.

  • Page 15: Maintenance Schedule

    MAINTENANCE MAINTENANCE BEFORE EVERY EVERY EVERY EVERY EVERY BEFORE EACH SEASON STORAGE SCHEDULE HOURS HOURS HOURS HOURS Check Brake Operation Check Tire Pressure Check Operator Presence & ROS Systems Check for Loose Fasteners Check/Replace Mower Blades Lubrication Chart Check Battery Level Clean Battery and Terminals Check Transaxle Cooling Check Mower Levelness...

  • Page 16: Maintenance

    MAINTENANCE TRACTOR BLADE CARE For best results mower blades must be kept sharp. Re place Always observe safety rules when per form ing any main- bent or damaged blades. te nance. BRAKE OPERATION CAUTION: Use only a replacement blade approved by the manufacturer of your If tractor requires more than fi...
  • Page 17 MAINTENANCE SAE VISCOSITY GRADES • Slide blade on to an unthreaded portion of the steel bolt or pin and hold the bolt or pin parallel with the ground. SAE 30 If blade is balanced, it should remain in a horizontal 5W-30 position.
  • Page 18 MAINTENANCE CLEAN AIR SCREEN IN-LINE FUEL FILTER (See Fig. 13) Air screen must be kept free of dirt and chaff to prevent The fuel fi lter should be replaced once each season. If fuel engine dam age from overheating. Clean with a wire brush fi...

  • Page 19: Service And Adjustments

    SERVICE AND ADJUSTMENTS WARNING: TO AVOID SE RI OUS IN JU RY, BEFORE PERFORMING ANY SERVICE OR ADJUST- MENTS: • Depress clutch/brake pedal fully and set parking brake. • Place gearshift lever in neutral (N) position. • Place attachment clutch in “DISENGAGED” position. •...
  • Page 20 SERVICE AND ADJUSTMENTS • Install belt onto engine pulley. • If links are not equal in length, adjust one link to same length as other link. IMPORTANT: CHECK BELT FOR PROPER ROUTING IN ALL MOWER PULLEY GROOVES. • To lower front of mower loosen nut “E” on both front links an equal number of turns.
  • Page 21 SERVICE AND ADJUSTMENTS • Measure distance between brake operating arm and • Install new belt into engine pulley grove. nut “A” on brake rod. • Make sure belt is inside the belt keeper at the idler and • If distance is other than 1-1/2", loos en jam nut and turn on both sides of the wire belt keeper as shown.
  • Page 22 SERVICE AND ADJUSTMENTS TRANSAXLE GEAR SHIFT LEVER NEU TRAL- ADJUSTMENT (See Fig. 22) WASH ERS RE TAIN ING The transaxle should be in neutral when the gear shift RING lever is in neutral (N) (lock gate) position. The adjustment is preset at the factory; however, if adjustment is needed, AXLE proceed as follows: COVER...
  • Page 23 SERVICE AND ADJUSTMENTS TO REMOVE HOOD AND GRILL ASSEMBLY TO REPLACE HEADLIGHT BULB (See Fig. 25) • Raise hood. • Raise hood. • Pull bulb holder out of the hole in the backside of the grill. • Unsnap headlight wire connector. •...

  • Page 24: Storage

    STORAGE Immediately prepare your tractor for storage at the end ENGINE of the season or if the tractor will not be used for 30 days or more. FUEL SYSTEM IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS WARNING: Never store the trac tor with FROM FORMING IN ES SEN TIAL FUEL SYSTEM PARTS SUCH gas o line in the tank inside a building AS CARBURETOR, FUEL FIL TER, FUEL HOSE, OR TANK...

  • Page 25: Trou Ble Shoot Ing

    TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Will not start Out of fuel. Fill fuel tank. Engine not “CHOKED” properly. See “TO START ENGINE” in Operation section. Engine fl ooded. 3. Wait several minutes before attempting to start. Bad spark plug. Replace spark plug. Dirty air fi...
  • Page 26 TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine dies when 1. Reverse operation system 1. Turn ignition key to tractor is shifted (ROS) is not "ON" while ROS "ON" position. into reverse mower or other attachment See Operation section. is engaged. Engine continues to run Faulty operator-safety presence control system.
  • Page 27 TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 SCHEMATIC 02836_193374 / 390 BATTERY STARTER FUSE AMMETER (OPTIONAL) WHITE CLUTCH / BRAKE ATTACHMENT CLUTCH (PEDAL UP) (CLUTCH OFF) BLACK BLACK SEAT SWITCH (NOT OCCUPIED) BLACK BLACK GRAY...

  • Page 28: Repair Parts

    REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 ELECTRICAL 197428...
  • Page 29 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 ELECTRICAL PART DESCRIPTION 532 16 34-65 Battery 12 Volt 25 Amp 874 76 04-12 Bolt Hex Hd 1/4-20 Unc x 3/4 532 17 66-89 Battery Box...
  • Page 30 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 CHASSIS AND ENCLOSURES Chassis-Elite_Basic_LT_5...
  • Page 31 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 CHASSIS AND ENCLOSURES PART DESCRIPTION 532 17 46-20 Chassis 532 17 65-54 Drawbar 532 15 52-72 Bumper, Hood/Dash 532 18 44-19 Saddle 532 15 51-38 Clip Retainer Slide-On...
  • Page 32 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 DRIVE drive-fender_49...
  • Page 33 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 DRIVE PART PART DESCRIPTION DESCRIPTION - - - - - - - - - Transaxle Dana D4360-139 532 12 48-72 Cover Pedal Round Order parts from transaxle manu-...
  • Page 34 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 STEERING steering_pl.lt_58...
  • Page 35 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 STEERING PART DESCRIPTION 532 18 67-80 Wheel Steering 532 17 51-31 Axle Asm 532 16 98-40 Spindle Asm LH 532 16 98-39 Spindle Asm RH 532 12 49-31...
  • Page 36 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 ENGINE OPTIONAL EQUIPMENT Spark Arrester engine-bs.1cyl_49...
  • Page 37 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 ENGINE PART DESCRIPTION 532 17 05-51 Control Throttle /Choke 817 72 04-08 Screw Hex Thd Cut 1/4-20 x 5/8 T - - - - - - - -...
  • Page 38 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 SEAT seat_lt.knob_13 PART PART DESCRIPTION DESCRIPTION 532 40 10-42 Seat 532 12 12-48 Bushing Snap Blk Nyl 532 14 05-51 Bracket Seat Pivot 872 05 04-12...
  • Page 39 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 DECALS PART PART DESCRIPTION DESCRIPTION 532 40 20-77 Decal Chassis 532 40 22-26 Decal, Whl Strg. 532 19 68-41 Decal Warning Eng. Sym. 532 18 76-20...
  • Page 40 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 MOWER DECK 38_deck-manual_4...
  • Page 41 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 MOWER DECK PART PART DESCRIPTION DESCRIPTION 532 19 25-56 Mower Housing Assembly 532 19 32-14 V-Belt 872 14 05-06 Bolt Carriage 5/16-18 x 3/4 532 19 32-16...
  • Page 42 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 MOWER LIFT 16 17 lift-rh.1piece_27...
  • Page 43 REPAIR PARTS TRACTOR - - MODEL NUMBER RA1638 (96011020500), PRODUCT NO. 960 11 02-05 MOWER LIFT PART DESCRIPTION 532 19 84-17 Wire Asm Inner/Sprg w/plunger 532 19 80-70 Shaft Asm Lift RH 532 18 88-22 Pin Groove 812 00 00-02...

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