OPERATOR'S

DELUXE PUSH ROTARY LAWN MOWER

MANUAL

Assembly Operation Maintenance Service and Adjustments Storage Troubleshooting

172782 Rev. 2 08.06.01 VB/BY

Printed in U.S.A.

Safety Rules ......................................... 2-3 Assembly ............................................. 5-8 Operation ........................................... 9-15 Maintenance .................................... 16-18

Service and Adjustments ................. 18-20 Storage ............................................ 20-21 Troubleshooting ............................... 22-23

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. I. GENERAL OPERATION Mow only in daylight or good artificial light. Do not operate the machine while under the influence of alcohol or drugs. Never operate machine in wet grass. Always be sure of your footing: keep a firm hold on the handle and walk; never run. Disengage the self-propelled mechanism or drive clutch on mowers so equipped before starting the engine (motor). If the equipment should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble. Always wear safety goggles or safety glasses with side shields when operating mower. II. SLOPE OPERATION Slopes are a major factor related to slip and fall accidents which can result in severe injury. All slopes require extra caution. If you feel uneasy on a slope, do not mow it. Mow across the face of slopes: never up and down. Exercise extreme caution when changing direction on slopes. Remove obstacles such as rocks, tree limbs, etc. Watch for holes, ruts, or bumps. Tall grass can hide obstacles. DO NOT: Do not trim near drop-offs, ditches or embankments. The operator could lose footing or balance. Do not trim excessively steep slopes. Do not mow on wet grass. Reduced footing could cause slipping. 2

Read, understand, and follow all instructions on the machine and in the manual(s) before starting. Be thoroughly familiar with the controls and the proper use of the machine before starting. Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. Only allow responsible individuals, who are familiar with the instructions, to operate the machine. Clear the area of objects such as rocks, toys, wire, bones, sticks, etc., which could be picked up and thrown by the blade. Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. Do not operate the mower when barefoot or wearing open sandals. Always wear substantial foot wear. Do not pull mower backwards unless absolutely necessary. Always look down and behind before and while moving backwards. Do not operate the mower without proper guards, plates, grass catcher or other safety protective devices in place. See manufacturer's instructions for proper operation and installation of accessories. Only use accessories approved by the manufacturer. Stop the blade(s) when crossing gravel ddves, walks, or roads. Stop the engine (motor) whenever you leave the equipment, before cleaning the mower or unclogging the chute. Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catcher.

III. CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. Keep children out of the trimming area and under the watchful care of another responsible adult. Be alert and turn machine off if children enter the area. Before and while walking backwards, look behind and down for small children. Never allow children to operate the machine. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. IV. SERVICE Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. - Use only an approved container. - Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not smoke. - Never refuel the machine indoors. - Never store the machine or fuel container inside where there is an open flame, such as a water heater. Never run a machine inside a closed area. Never make adjustments or repairs with the engine (motor) running. Disconnect the spark plug wire, and keep the wire away from the plug to prevent accidental starting. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. Never tamper with safety devices. Check their proper operation regularly. Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage. Allow machine to cool before storing. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. Never attempt to make wheel height adjustments while the engine (motor) is running.

Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer's recommended parts, when necessary. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. Do not change the engine governor setting or overspeed the engine. _Look for this symbol to point out important safety precautions. It means CAUTION!!! BECOMEALERTH! YOUR SAFETY IS INVOLVED. A CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up, transporting, adjusting or making repairs. AWARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. _WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. CAUTION: Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped. To avoid severe burns on contact, stay away from these areas.

CONGRATULATIONS onyourpurchase ofanewLawn Mower. Ithasbeen designed, engineered andmanufactured youthebest ossible togive p dependability andperformance. Shouldouexperience y anyproblems youcannot easily remedy, pleaseontact c your nearest authorized serviceenter. have c They competent, trained well technicians and theproper toservicerrepair tools o thisunit. Read theSAFETYULESndthisOperator's R a Manual its entirety before you in
attempt to assemble or operate your new lawn mower to insure proper operation and to prevent injury to yourself and others. Save this manual for future reference. Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for shipping purposes. To ensure safe and proper operation of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to ensure proper tightness. All parts such as nuts, washers, bolts, etc., necessary to complete the assembly have been placed in the parts bag. TO REMOVE MOWER FROM CARTON

Remove all loose parts from carton. Remove lawn mower housing with care. Avoid touching blade under housing. Always wear gloves or other protection when working under or lifting mower. THINGS TO KNOW BEFORE YOU ASSEMBLE OR OPERATE YOUR MOWER

Do I have a side or rear discharge lawn mower? Look for the grass discharge opening on your mower. If the opening is on the right side of the mower housing, it is a side discharge mower. If the opening is at the back of the mower housing, it is a rear discharge mower. Only rear discharge lawn mowers have a grass catcher included with the mower. Approved grass catchers for side discharge mowers may be purchased from your nearest authorized dealer. Do I have a mulching lawn mower? Look for the grass discharge opening on your mower. Raise the discharge guard (rear door on rear discharge mowers). If the opening is closed off by a plate, then your lawn mower is muicher ready. To convert to a discharging mower, see the Operation section of this manual. What is the right and left side of the What kind of engine is on my lawn lawn mower? mower? When right hand (RH) or left hand (LH) is When learning how to operate your new mentioned in this manual, it means when lawn mower, you will need to know what you are in the operating position (standing kind of engine powers the mower. A decal behind the handle). on the engine will indicate the manufacturer and type or brand name of the FRONT engine. BRIGGS & STRATTON ENGINES

LEFT HAND SIDE

RIGHT HAND SIDE

CLASSIC
E=

TECUMSEH ENGINES

HONDA ENGINES

RACK or REAR (Operating Position)

_'ECUMSt_H

_I, CAUTION: Do not operate this mower without the discharge guard or an entire approved grass catcher in place. These guards are for your protection and are required by the American National Standards Institute and Consumer Products Safety Commission. _i'LCAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

HOWTO SET UP YOUR LAWN MOWER

UNFOLD HANDLE IMPORTANT: Unfold handle carefully so as not to pinch or damage control cables. Raise handles until lower handle section locks into place in operating position. Raise upper handle section into place on lower handle, remove protective padding and tighten both handle knobs. Remove handle padding holding operator presence control bar to upper handle. Your lawn mower handle can be adjusted for your mowing comfort. Refer to "ADJUST HANDLE" in the Service and Adjustments section of this manual. FOR HIGH WHEEL MOWERS ONLY INSTALL REAR WHEELS Some high wheel models require washers which will be provided in a parts bag. If provided, install washers on the axle first as shown. Install one (1) rear wheel on the axle of rear wheel adjuster. Install 3/8-16 Iocknut and tighten securely. Repeat procedure for other rear wheel.
Wheel assembly Axle

control bar

Lift L Iocknut

Wave Washers

Mowing position

Lower handle

NOTE: For shipp=ng purposes, the rear wheels on your lawn mower may not be adjusted to the same position as the front wheels. Before operating mower adjust all wheels to the same cutting height.

FOR REAR DISCHARGE MOWERS ONLY - ASSEMBLE GRASS CATCHER IMPORTANT: If your model lawn mower is mulcher ready, the mulcher plate or plug must be removed before using mower as a bagger. To convert mower to bagging or discharging, see the Operation section in this manual. Look at the different grass catcher illustrations that follow. Determine which type of grass catcher you have and follow the appropriate instructions. "FABRIC TOP" GRASS CATCHERS TO ASSEMBLE AND ATTACH GRASS CATCHER Put grass catcher frame into grass bag with rigid part of bag on the bottom. Slip vinyl bindings over frame. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. Lift the rear door on the mower housing. For HINGE BRACKET mounted catcher, place the grass catcher frame onto the formed tabs on the rear door hinge bracket. For HANDLE BRACKET mounted catcher, place frame side hooks into slots in handle brackets. For DOOR PIVOT PIN mounted catcher, place the grass catcher frame hooks onto the door pivot pins. For DOOR SLOT mounted catcher, place the grass catcher frame hooks into the slots of the rear door. NOTE: The grass catcher is secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame.
\

HINGE BRACKET MOUNTED

_oor

Hinge bracket
Grass catcher frame

Formed tabs

HANDLE

BRACKET

MOUNTED Rear Grass catcher handle

Handle bracket hooks _.

Catcher fram{

DOOR PIVOT PIN MOUNTED

Pivot " Rear Grass catcher handle

Catcher frame

Catcher frame hook DOOR SLOT MOUNTED Rear door slots Grass catcher handle Rigid

"HARDTOP"GRASSCATCHER ASSEMBLE FRAME AND BAG Thread upper tubular frame into hem of bag as shown. Be sure angled ends of frame point downwards. Slip lower frame into tubular upper frame as shown. Slip vinyl bindings over frame.

Install two (2) blunt pointed screws in front holes and tighten securely.
Sharp pointed screws (Rear and side holes) Catcher top

Catcher bag and {rame

Blunt pointed screws (Front holes)

Hem / Start here j

Uppe

TO ATTACH HARD TOP CATCHER Open the rear door on mower housing. Place frame side hooks into slots in handle brackets. Release rear door, allowing it to nest into top of catcher.
Upper tubular frame Rear door slots

Vinyl bindings Lower frame

Grass catcher _" frame hook

ASSEMBLE TOP TO FRAME AND BAG NOTE: For ease of assembly, place catcher top upside down on work surface. Nest bag and frame assembly into catcher top. Install two (2) sharp pointed screws into rear holes first and tighten securely. Pull catcher bag forward on frame to remove slack. Install two (2) remaining sharp pointed screws in side holes and tighten securely. Align lower frame and catcher top front holes.

_,CAUTION: Under normal usage, the catcher matedal is subject to deterioration and wear and should, therefore, be checked frequently for replacement. Any replacement catcher should be checked to ensure compliance with original manufacturer's specifications. _CAUTION: Do not run lawn mower without the discharge guard (rear door), approved grass catcher, clipping deflector or mulcher plate in place. Never attempt to operate mower with the discharge guard (rear door) removed or propped open.

SPARK

PLUG BOOT

On some models a spark plug boot is packed loose in the parts bag. If your model has the boot, install on spark plug wire and reconnect spark plug wire to spark plug.
Spark plug

FOR ELECTRIC START MODELS ONLY-TO PREPARE BATTERY NOTE: Your battery must be charged before you can start your lawn mower. Disconnect engine connector (male) from battery connector (female). Connect battery charger connector (male) to battery connector (female). Plug battery charger into 110 volt A.C. outlet. Leave battery charger connected for 24 hours before starting your engine for the first time. After charging, connect engine connector (male) to battery connector (female). Your engine has an integral alternator for partial charging. Connect your battery charger to charge battery as required. IMPORTANT: The engine alternator will not charge a discharged battery. At the end of the mowing season the battery should be charged for 48 hours to Iqrotect the battery during winter storage. _,CAUTION: Always disconnect the engine connector (male) from the battery connector (female) to prevent accidental starting when transporting or storing your lawn mower after the season. DECK-MOUNTED BATTERY =:_ Engine //

_Boot

__connector

_:'------_:_'_ __

C', ,l_attery _

charger

jjt

f_

_i--t

\
charger connector (Male)
BATTERY

jjJ _ -J.f_ /_ _/f_'_ Battery connector (Female)

TRIMPLATE-MOUNTED Charger connector

Battery connector (female)

Engine connector (male)

Battery charge

lawn mower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. HOWTO USE YOUR LAWN MOWER ENGINE SPEED CONTROL MODELS WITH FIXED SPEED ENGINES Engine speed was set at the factory for optimum performance. Engine speed is not adjustable. MODELS WITH REMOTE THROTTLE Engine speed is controlled by the throttle control located on the upper handle. Move lever forward for fast engine speed, starting, and for better grass bagging. Move lever backward for slow engine speed. Some models have engines equipped with a choke feature. Move the lever all the way forward to the choke position when starting a cold engine.

The operationany of

MODELS WITH ENGINE MOUNTED SPEED CONTROL The engine speed is controlled by a lever located at the carburetor on the engine. High or fast position is for starting engine, normal cutting and better grass bagging. Low or slow position is for light cutting, trimming and fuel economy.
BRIGGS & STRATTON CLASSIC AND SPRINT Rapid

Spark plug /

Primer (if equipped)

_Engine speed control lever

BRIGGS & STRATTON QUANTUM Engine speed

control lever

\
Choke (start) TECUMSEH

Engine speed controllever

Remote throttle control

TO ADJUST

CUTTING

HEIGHT

FOR MULCHING

MOWERS

ONLY

Adjust cutting height to suit your requirements. Medium position is best for most lawns. Raise wheels for low cut and lower wheels for high cut. MODELS WITH MANUALADJUST BOLTON WHEELS Remove wheel, bolt, and hardware and reassemble in desired adjustment hole. Reinstall wheel components in the same order as they were before removal. Tighten securely. Make sure all wheels are at the same height.
Shoulder bolt

Wheel assembly

Most mulching mowers are shipped ready to be used as a mulcher. "REAR DISCHARGE ONLY" MOWERS Some models have a seperate mulcher plug, other models have the mulcher plug built into the rear door. To convert to bagging or discharging, the plate or plug (if so equipped) must be removed from the discharge opening of the lawn mower. Open rear door and remove mulcher plate or plug (if so equipped). Store mulcher plate or plug in a safe place. You can now install grass catcher or optional clipping deflector accessory. To return to mulching operation, install mulcher plate or plug into discharge opening of mower. _I, CAUTION: Do not run your lawn mower without mulcher plate/plug in place or approved clipping deflector or grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open.
MULCHER PLATE TYPE

MODELS WITH "QUICK ADJUST" WHEEL HEIGHT ADJUSTERS NOTE: For shipping purposes, the rear wheels on your lawn mower may not be adjusted to the same position as the front wheels. Before operating mower adjust all wheels to the same cutting height. Raise wheels for low cut and lower wheels for high cut. Adjust cutting height to suit your requirements. Medium position is best for most lawns. To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your requirements. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inser[s into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs.
Lower Wheels for High Cut Plate Tab

Slots

Mulcher plate tabs MULCHER PLUG TYPE

Raise Wheels for Low Cut

Lever 10

Mulcher plug /

MULCHER BUILT REAROOR PLUG INTO D

Position lock lever over hinge bracket as shown and raise lever to lock mulcher plug in place. Allow discharge guard to rest against lock lever. To return to discharging or bagging operation, simply lower lock lever and remove mulcher plug from mower. _CAUTION: Do not run your lawn mower without discharge guard, approved grass catcher or mulcher plate or plug in place.

Raise discharge

"SIDE DISCHARGE

ONLY" MOWERS MULCHER PLATE TYPE TO convert to bagging or discharging, mulcher plate must be removed from underside of lawn mower. Remove the four (4) screws and lock nuts securing the mulcher plate to the mower. Store mulcher plate and hardware in a safe place. Mower can now be used for side discharging or optional grass catcher accessory can be attached. To return to mulching operation, simply reinstall mulcher plate and tighten hardware securely.
Screw and

e bracket

Mulcher

lever "down" position

Raise lever to lock

Mulcher plate

MULCHER PLUG TYPE "A" TO convert to mulching operation, mulcher plug must be installed into discharge opening of mower. Raise discharge guard and work mulcher plug into discharge opening of mower.

/f 11

Lower lever to unlock

MULCHER PLUG TYPE "B" To convert to mulching operation, mulcher plug must be installed into discharge opening of mower. Open discharge guard. Insert tab of mulch plug into housing opening. Align hooks of mulch plug over hinge rod of discharge guard. Push mulch plug down until mulch plug is seated in housing opening. _CAUTION: Do not run your lawn mower without discharge guard, approved grass catcher or mulcher plug in place.

"COMBI-CUT" MOWERS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging: REAR BAGGING Open rear door and remove mulcher plate. Store mulcher plate in a safe place. You can now install grass catcher. To convert to mulching or discharging operation, install mulcher plug into rear discharge opening of mower, making sure all tabs are seated properly.

Housing opening Mulch Mulcher plate tabs

Hinge rod

SIDE DISCHARGING Mulcher plate must be installed into rear discharge opening of mower (see above instructions). Open mulcher door and install discharge deflector under door as shown. Mower is now ready for discharging operation. To convert to mulching or bagging operation, discharge deflector must be removed and muicher door must be closed.

Mulcher door

12

Open mulcher door

GRASS

CATCHER

Discharge deflector

(REAR BAGGING MODELS ONLY) TO EMPTY GRASS CATCHER Simply open rear door and lift grass catcher up and away from mower. NOTE: Do not drag the bag when emptying. It will cause unnecessary wear. _CAUTION: Under normal usage, the catcher material is subject to deterioration and wear and should, therefore, be checked frequently for replacement. Any replacement catcher should be checked to ensure compliance with original manufactureCs specifications. _CAUTION: Do not run lawn mower without the rear door, approved grass catcher or clipping deflector in place. Never attempt to operate mower with the rear door removed or propped open. OPERATOR BAR PRESENCE CONTROL

SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR "COMBI-CUT" LAWN MOWER FOR MULCHING Rear mulcher plate installed and rear door closed. Mulcher door closed. FOR REAR BAGGING Rear mulcher plate removed. Grass catcher installed. Mulcher door closed. FOR SIDE DISCHARGING Rear mulcher plate installed and rear door closed. Side discharge deflector installed. _,CAUTION: Do not run your lawn mower without rear mulcher plate or plug in place or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open.

Your lawn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle in order to start and operate the lawn mower. _CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade turns when the engine is running.

13

BEFORE

STARTING

ENGINE

Read the engine manual packed with your mower. FILL ENGINE WITH OIL Your lawn mower is shipped without oil in the engine. Be sure mower is level and area around oil fill is clean. Remove engine oil filler plug (oil fill cap/ dipstick on models so equipped). Slowly add oil. For type and grade of oil to use, see "ENGINE" in the Maintenance section of this manual. Fill to the top of slot in filler hole (to "FULL" line on dipstick on models so equipped). Do not overfill. Replace plug (oil fill cap/dipstick on models so equipped) and tighten. Check oil level before each use. Add oil as needed. To change oil, see Maintenance section of this manual. FILL GASOLINE TANK Fill gasoline tank with fresh, clean, unleaded gasoline. DO NOT USE PREMIUM GASOLINE. BE CAREFUL NOT TO OVERFILL TANK. WARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the fuel tank, start the engine and let it run until fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in fuel tank or permanent damage may occur.

TO START ENGINE _I, CAUTION: The mower blade rotates whenever the engine is running. Move engine speed control to fast position (or to choke/start position on models equipped with choke feature). If your mower has a primer, to start a cold engine, push primer as many times as instructed in the engine manual packed with your mower. Use a firm push. This step is not usually necessary when starting an engine which has already run for a few minutes. Hold operator presence control bar down against handle. MODELS WITH RECOIL STARTER Pull starter handle quickly. Do not allow starter rope to snap back. MODELS WITH ELECTRIC STARTER Push the engine start button (or turn the key on models so equipped). IMPORTANT: Do not crank engine more than five continous seconds between each time you try to start. Wait 5 to 10 seconds between each attempt. ALL MODELS For engines equipped with choke, slowly move engine speed control lever to fast after engine starts. TO STOP ENGINE To STOP engine, release operator presence control bar. NOTE: For engines with a primer, it may be necessary to repeat priming steps in cooler weather. In warmer weather, overpdming may cause flooding and engine will not start. If you do flood engine, wait a few minutes before attempting to start and DO NOT repeat priming steps.
Operator presence control barRecoil starter handle (center mount type)

Recoil / starter handle (side mount type)

14

MOWING

TIPS

For most cutting conditions and better bagging performance, the engine speed should be set in the fast position. Under certain conditions, such as when mowing very tall grass, raise the mower height on the first cut to reduce pushing effort, to avoid overheating the engine, and to avoid leaving clumps of grass clippings. Make the second cut to the desired height. For extremely heavy cutting, reduce the width of cut. For side discharge lawn mowers, cut in a counterclockwise direction, starting at the outside of the area to be cut, in order to spread grass clippings more evenly and to put less load on the engine. To keep clippings off of walkways, flower beds, etc., make the first cuts in a clockwise direction. When using a rear discharge lawn mower in moist, heavy grass, clumps of cut grass may not enter the grass catcher. Reduce ground speed (pushing speed) and/or run the lawn mower over the area a second time. If a trail of grass clipping is left on the right side of a rear discharge lawn mower, mow in a clockwise direction with a small overlap to collect the clippings on the next pass. Pores in cloth grass catchers can become filled with dirt and dust with use and the catcher will collect less grass. To prevent this, regularly hose catcher off with water and let dry before use.

FOR MULCHING MOWERS MULCHING MOWING TIPS

ONLY-

IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See "CLEANING" in the Maintenance section of this manual The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recurring action of the blades. Avoid cutting your lawn when it is wet. Wet grass tends to form clumps and interferes with the mulching action. The best time to mow your lawn is the early afternoon. At this time the grass has dried and the newly cut area will not be exposed to the direct sun. For best results, adjust the lawn mower cutting height so that the lawn mower cuts off only the top one-third of the grass blades. If the lawn is overgrown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy mulching, reduce your width of cut by overlapping previously cut path and mow slowly. Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mow across or perpendicular to the first cut path. Change your cutting pattern from week to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and graining of the lawn.
1/3 MAX

15

,+.s COMPLB'rE .,ou

REGULAR SERVICE Check for Loose Fasteners Clean]Inspect Grass Catcher M O (If Equipped) Clean Lawn Mower ( Power+Propelled Clean Under DriveMowers) Cover

MA.NTE.A.OESO.EDULE FiLL IN DATES

j_t_v_v _ _4 _)_._ _ _ fl_

+
,:,. +,-,,,',+o o
bP_HVIt_ L)P,.L_+

( Power+Propelled Mowers) R_ Check drive belt/pulleys Check/Sharpen/Replace Blade Lubrication Chart Clean Battery/Rechar IElectric Start aowerrl E Check Engine Oil Level N Change Engine Oil G Clean Air Filter Inspect Muffler Clean or Replace Spark Plug Replace Air Filter Paper Cart ridge
ServK;e more olten when operating in dirbJ or dusty mowing in 8_ndy conditions soil

I_ 3 I_ I1_ 11_4

e I_ 11/1,2 ll_ 2

N
E
2.

1_#2

I - Change more often when oFeratil_g under a heavy load or in high ambient temperatures
3 + Replace 4 + Charge blades more often when 48 hours _t end of season

GENERAL

RECOMMENDATIONS

LUBRICATION

CHART Wheel adjuster (on each wheel)

The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain mower as instructed in this manual. Some adjustments will need to be made pedodically to properly maintain your unit. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. Once a year, replace the spark plug, clean or replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assure proper air-fuel mixture and help your engine run better and last longer. Follow the maintenance schedule in this manual. BEFORE EACH USE Check engine oil level. Check for loose fasteners. LUBRICATION Keep unit well lubricated (See "LUBRICATION CHART").

Hinge pin (if equipped) Reardoor hinge (if equipped)

1_ Handle bracket mounting pins 1_ Spray lubricant 2_ See "ENGINE" in Maintenance section+

16

IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will attract dust and dirt that will shorten the life of the self-lubdcating bearings. If you feel they must be lubricated, use only a dry, powdered graphite type lubricant sparingly.

LAWN

MOWER

Always observe safety rules when performing any maintenance. TIRES Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. BLADE CARE For best results, mower blade must be kept sharp. Replace bent or damaged blades. TO REPLACE BLADE Turn lawn mower. See engine manual for proper direction of turning over the engine. Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt. Protect your hands with gloves and/or wrap blade with heavy cloth. Remove blade bolt, lock washer and flat washer. Remove blade and blade adapter. Inspect the key inside blade adapter. Replace adapter if damaged. IMPORTANT: Blade bolt is grade 8 heat treated. Install new or sharpened blade with trailing edge up toward the engine. Position blade on blade adapter. Align the two (2) holes in blade with raised lugs of adapter. Reassemble blade bolt, lock washer and flat washer into blade adapter and crankshaft in exact order as shown. Position block of wood between blade and mower housing. Tighten blade bolt securely. Recommended tightening torque is 35-40 ft. Ibs. NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced.

TO SHARPEN BLADE Care should be taken to keep the blade balanced. An unbalanced blade will cause excessive vibration and eventual damage to lawn mower and engine. The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. To check blade balance, drive a nail into a beam or wall. Leave about one inch of the straight nail exposed. Place center hole of blade over the head of the nail. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. ENGINE Read the maintenance section of your engine manual. LUBRICATION Change the oil after the first two hours of operation and every 25 hours thereafter or at least once a year if the lawn mower is not used for 25 hours in one year. Refer to engine manual. TO CHANGE ENGINE OIL (SEE ENGINE MANUAL) Be sure lawn mower is on level surface. Oil will drain more freely when warm. Catch oil in a suitable container. For engines without dipstick, remove bottom oil drain plug. For engines with oil fill cap/dipstick, remove bottom drain plug or remove engine oil cap and turn mower on its side. After oil has drained completely, replace oil drain plug and tighten securely. Refill engine with oil. Pour slowly. Do not overfill. Fill to top of slot inside of filler hole or to "FULL" line on dipstick on models so equipped. Keep oil at proper level. AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter. Clean the element after every 25 hours of operation or every season. Replace the air filter every 100 hours of operation or every season, whichever occurs first. Service air cleaner more often under dusty conditions. See the maintenance section of your engine manual. MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and/or damage.

washer

Trailin_ edge

Blade adapter 17

SPARK PLUG Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Set spark plug gap according to engine manual specifications. CLEANING IMPORTANT: For best performance, keep mower housing free of grass build-up and trash. Clean the underside of your mower after each use. Clean the underside of your lawn mower by scraping to remove buildup of grass and trash. Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life.

Keep finished surfaces and wheels free of all gasoline, oil, etc. We do not recommend using a garden hose to clean your lawn mower unless the electrical system, muffler, air filter, and carburetor are covered to keep water out. Water in engine can shorten engine life. GRASS CATCHER (IF SO EQUIPPED) Grass catcher may be hosed with water but must be dry when used. _CAUTION: Under normal usage, the catcher material is subject to deterioration and wear and should therefore be checked to ensure compliance with original manufacturer specifications.

ACAUTION: Before performing any service or adjustments: Release operator presence control bar. Make sure the blade and all moving pads have completely stopped. Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug.

LAWN MOWER
TO ADJUST CUTTING HEIGHT See "TO ADJUST CUTTING HEIGHT" in the Operation section of this manual. TO ADJUST HANDLE 2 POSITION The handle can be mounted in a high or low position. The mounting holes in the bottom of lower handle are off center for raising or Iowedng the handle. Remove upper handle and all parts attached to lower handle. Remove hairpin cotters from lower handle bracket mounting pin. Squeeze lower handle in to remove it from mounting pins. Turn lower handle over to raise or lower handle. Squeeze lower handle in and position holes onto mounting pins on handle bracket. Reassemble hairpin cotters onto mounting pins. Reassemble upper handle and all parts removed from lower handle.

"'" I" i
J i

Off center

Low position

High position

adjust height

18

3 POSITION "EURO" OR "EZ" The handle on your lawn mower has three (3) height positions - adjust to height that suits you. Remove knob and carriage bolt on one side of the lower handle. While holding handle assembly, remove knob and carriage bolt from opposite side, align hole in handle with desired hole in handle bracket and reassemble bolt and knob and tighten securely. Align opposite side of handle with same positioning hole and secure with bolt and knob. "EURO" ADJUSTMENT
Handle adjustment bracket _ Knob

High Medium_

pin 3-positionhandle _adjustment bracket

Bolt

"ADJUSTABLE" HANDLES The upper handle may be adjusted to four (4) different height positions. Loosen both handle knobs only enough to allow the upper handle to pivot to the desired adjustment position. Tighten both handle knobs securely.

""

Handle knob

_Handle Jstment / Handle knob

Knob

REAR DEFLECTOR (IF EQUIPPED) 3 POSITION "QUICK" The rear deflector, attached between the The handle on your lawn mower has three rear wheels of your mower, is provided to (3) height positions - adjust to height that minimize the possibility that objects will be thrown out of the rear of the mower into suits you. Squeeze the bottom ends of lower the operator mowing position. If the handle towards each other until the pin deflector becomes damaged, it should be in handle can be inserted into one of the replaced. three height adjustment holes. 19

ENGINE
CARBURETOR The carburetor has been preset at the factory and adjustment should not be necessary. However, minor adjustment may be required to compensate for differences in fuel, temperature, altitude or load. The air filter must be assembled to the carburetor when running engine. Best carburetor adjustment is obtained when fuel tank is 1/4 full. In order for the engine to run, the operator presence control bar must be held in the operating position. Therefore, and assistant will be required to hold the control bar in the operating position when making final adjustment to the carburetor.

See the adjustment section of your engine manual for further instructions. ENGINE SPEED The engine speed has been factory set. Do not attempt to increase engine speed as it may result in personal injury. If you believe the engine is running too fast or too slow, take your lawn mower to an authorized engine service center for repair and adjustment. THROTTLE CONTROL If it becomes necessary to adjust or replace the throttle control, see the adjustment section of your engine manual.

Immediately prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more. _CAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. / _ Squeeze to fold LAWN MOWER i When lawn mower is to be stored for a """"-- Lower handle period of time, clean it thoroughly, remove all did, grease, leaves, etc. Store in a clean, dry area. Clean entire lawn mower (See "CLEANIbracket Hairpin cotter ING" in the Maintenance section of this Mounting pinT 1 manual). Handle Lubricate as shown in the Maintenance section of this manual. Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect Operator presence moving parts for damage, breakage and control bar Fold wear. Replace if necessary. Touch up all rusted or chipped paint surfaces; sand lightly before painting. Lower HANDLE Your handle may be folded for storage as shown. Squeeze the bottom ends of lower handle towards each other until handle clears the handle brackets and swing handles forward over mower. Loosen upper handle mounting hardware enough to allow upper handle to be folded back. IMPORTANT: When folding handles for storage or transportation, be sure to fold handles as shown or you may damage the control cables.

Fold backward

position

2 POSITION /"ADJUSTABLE" HANDLES When setting you handles up from the storage position, the lower handle will automatically lock into mowing position.

2O

3 POSITION HANDLES When settingpyourhandle the u from storage position, thelower andle ill h w require anually m locking intothemowing position. 3 POSITION "EURO" 3-Position handle adjustment bracket
Knob

Bolt

3 POSITION Knob

"EZ"

ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. Drain the fuel tank. Start the engine and let it run until the fuel lines and carburetor are empty. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer. ENGINE OIL Drain oil (with engine warm) and replace with clean oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER Remove spark plug.

_f
handle adjustment bracket \

3 POSITION "QUICK"
._pin Sq 3-Position handle bracket J

i spark one ounce into cylinder. through Pour plug hole (29 ml) of oil Pull starter handle slowly to distribute oil. Replace with new spark plug. BATTERY (IF EQUIPPED) Disconnect the battery from the engine connector and charge battery 48 hours. OTHER Do not store gasoline from one season to another. Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. If possible, store your unit indoors and cover it to give protection from dust and dirt. Cover your unit with a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe, which allows condensation to form and will cause your unit to rust. IMPORTANT: Never cover mower while engine and exhaust areas are still warm. _'iI, CAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. 21

\ \

ENGINE
FUEL SYSTEM IMPORTANT: It is important to prevent gum deposits from forming in essential 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

TROUBLESHOOTING PROBLEM Does net start

CHART CAUSE 1. Dirty air filter. 2. Out of fuel. 3. Stale fuel. 4. Water in fuel. 1. 2. 3. 4.

CORRECTION Cleen/replace air filter. Fill fuel tank. Drain tank and refill with fresh, clean fuel. Drain fuel tank and carburetor and refill tank with fresh gasoline. Connect wire to plug.

5. 6. 7. 8.

Spark plug wire is disconnected. Bad spark plug. Loose blade or broken blade adapter. Control bar in released

5. 6. 7.

position. 9. Control bar defective. 10. Week battery. 11. Disconnected battery connector. Loss of power 1. Rear of lawn mower housing or cutting blade dragging in heavy grass. Cutting too much grass. Dirty air filter. Buildup of grass, leaves, and trash under mower. Too much oil in engine. Walking speed too fast.

Replace spark plug. ]]ghten blade bolt or replace blade adapter. 8. Depress control bar to handle. 9. Replace control bar. 10. Charge battery. 11. Connect battery to engine.

1.

Set to "Higher Cut" position.

2. 3. 4. 5. 6. Poor cut- uneven

2. 3. 4. 5. 6. 1. 2. 3.

Set to "Higher Cut" position. Cleenireplace air filter. Clean underside of mower housing. Check oil level. Cut at slower walking speed. Replace blade. ]]ghten blade bolt. Set all wheels at same height. Clean underside of mower housing.

1. Worn, bent or loose blade. 2. 3. Wheel heights uneven. Buildup of grass, leaves and trash under mower.

22

TROUBLESHOOTING PROBLEM Excessive vibration

CHART CAUSE 1. 2. Worn, bent or loose blade. Bent engine crankshaft.

CORRECTION 1. 2. Replace blade. 33ghten blade bolt. Contact an authorized service center. Depress control bar to upper handle before pulling starter rope. Contact an authorized service center. Replace blade adapter. Move lawn mower to cut grass or to hard surface. Raise cutting height. Replace blade. Clean grass catcher. Raise cutting height. Raise rear of lawn mower housing one (1) setting higher. Empty grass catcher. Adjust handle height to suit.

Starter rope hard to pull

1.

Engine flywheel brake is on when control bar is released Bent engine crankshaft. Blade adapter broken. Blade dragging in grass.

1.

2. 3. 4.

2. 3. 4.

Grass catcher not filling (if so equipped) Hard to push

1. 2. 3. 1. 2.

Cutting height too low. Lift on blade worn off. Catcher not venting air. Grass is too high or wheel height is too low. Rear of lawn mower housing or cutting blade dragging in grass. Grass catcher too full. Handle height position not right for you.

1. 2. 3. 1. 2.

3. 4.

3. 4.

23