CRAFTSMAN Walk Behind Lawnmower, Gas Manual L0030043
User Manual: CRAFTSMAN CRAFTSMAN Walk Behind Lawnmower, Gas Manual CRAFTSMAN Walk Behind Lawnmower, Gas Owner's Manual, CRAFTSMAN Walk Behind Lawnmower, Gas installation guides
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Owner's Manual (RRFTSMRN° 5.5 HORSEPOWER 21" MULTI-CUT ROTARY LAWN MOWER Model No. 917,388330 • • • • Safety Assembly Operation Maintenance • • EspaSol Repair Parts CAUTION: Read and follow all Safety Rules and Instructions before operating this equipment Sears, Roebuck and Co., Hoffman Estates, IL 60179 Visit our Craftsman website: www.sears.com/craftsman Warranty ............................................... Safety Rules ......................................... Assembly .............................................. Operation .............................................. Maintenance Schedule ........................ Maintenance ......................................... LIMITED TWO YEAR WARRANTY 2 2 4 6 10 10 Product Specifications .......................... 11 Service and Adjustments ...................... 13 Storage ................................................. 14 Troubleshooting ................................... 15 Repair Parts .......................................... 34 Parts Ordering ...................... Back Cover ON CRAFTSMAN POWER MOWER For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any defect in material or workmanship. If this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty applies for only 90 days from the date of purchase. This Warranty does not cover: • Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts, air cleaners and spark plug. • Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual. Warranty service is available by returning the Craftsman power mower to the nearest Sears Service Center/Department in the United States. This warranty applies only while this product is in use in the United States. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. SEARS, ROEBUCKAND CO., D/817 WA, HOFFMAN Safety standards require operator presence control to minimize the risk of injury. Your unit is equipped with cuch controls, do not attempt to defeat the function of the operator presence controls under any circumstances. TRAINING: ESTATES, ILLINOIS 60179 • Do not operate mower if it has been dropped or damaged in any manner. Always have damage repaired before using your mower. • Do not use accessory attachments that are not recommended by the manufacturer. Use of such attachments may be hazardous. • Read this operator's manual carefully. Become familiar with the controls and • The blade turns when the engine is running. know how to operate your mower properly. Learn how to quickly stop mower. PREPARATION: • Always thoroughly check the area to be mowed and clear it of all stones, sticks, wires, bones, and other foreign objects. These objects will be thrown by the blade and can cause severe injury. • Always wear safety glasses or eye shields when starting and while using your mower. • Dress properly. Do not operate mower when barefoot or wearing open • Do not allow children to use your mower. Never allow adults to use mower without proper instructions. • Keep the area of operation clear of all persons, especially small children and pets. • Use mower only as the manufacturer intended and as described in this manual. 2 sandals. Wear only solid shoes with good traction when mowing. • Check fuel tank before starting engine. Do not fill gas tank indoors, when the engine is running or when the engine is hot. Allow the engine to cool for several minutes before filling the gas tank. Clean off any spilled gasoline before starting the engine. • Always make wheel height adjustments before starting your mower. Never attempt to do this while the engine is running. • Mow only in daylight or good artificial light. OPERATION: • Keep your eyes and mind on your mower and the area being cut. Do not let other interests distract you. • Do not mow wet or slippery grass. Never run while operating your mower. Always be sure of your footing - keep a firm hold on the handles and walk. • Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. • Always stop the engine whenever you leave or are not using your mower, or before crossing driveways, walks, roads, and any gravel-covered areas. • Never direct discharge of material toward bystanders nor allow anyone near the mower while you are operating it. • Before cleaning, inspecting, or repairing your mower, stop the engine and make absolutely sure the blade and all moving parts have stopped. Then disconnect the spark plug wire and keep it away from the spark plug to prevent accidental starting. • Do not continue to run your mower if you hit a foreign object. Follow the procedure outlined above, then repair any damage before restarting and operating your mower. • Do not change the governor settings or overspeed the engine. Engine damage or personal injury may result. • Do not operate your mower if it vibrates abnormally. Excessive vibration is an indication of damage; stop .the engine, safely check for the cause of vibration and repair as required. • Do not run the engine indoors. Exhaust fumes are dangerous. • Never cut grass by pulling the mower towards you. Mow across the face of slopes, never up and down or you might lose your footing. Do not mow excessively steep slopes. Use caution when operating the mower on uneven terrain or when changing directions maintain good footing. • Never operate your mower without proper guards, plates, grass catcher or other safety devices in place. MAINTENANCE AND STORAGE: • Check the blade and the engine mounting bolts often to be sure they are tightened properly. • Check all bolts, nuts and screws at frequent intervals for proper tightness to be sure mower is in safe working condition. • Keep all safety devices in place and working. • To reduce fire hazard, keep the engine free of grass, leaves or excessive grease and oil. • Check grass catcher often for deterioration and wear and replace worn bags. Use only replacement bags that are recommended by and comply with specifications of the manufacturer of your mower. • Always keep a sharp blade on your mower. • Allow engine to cool before storing in any enclosure. • Never store mower with fuel in the tank inside reach source space a building where fumes may an open flame or an ignition such as a hot water heater, heater, clothes dryer, etc. _,Look for this symbol to point out important safety precautions. It means CAUTION!H BECOMEALERT!!! YOUR SAFETY IS INVOLVED. &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. _,WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 3 These accessorieswere available when this lawn mower was produced. They are not shipped with your mower. They are also available at most Sears retail outlets and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of your lawn mower. Some of these accessories may not a_l_ _v_d_lit_R MA N C E CLIPPING DEFLECTOR FOR REAR DISCHARGE LAWN MOWERS MULCHER GRASS CATCHERS FOR REAR DISCHARGE LAWN MOWERS KITS STABILIZER FOR SIDE DISCHARGE GRASS LAWN CATCHERS MOWERS GAS CANS LAWN MOWER MAINTENANCE o MUFFLERS BELTS Read these instructions AIR FILTERS BLADES BLADE ADAPTERS and this manual TO REMOVE CARTON in its entirety before you attempt to assemble or operate your new lawn mower. WHEELS ENGINE OIL LAWN MOWER FROM • Remove loose parts included with mower. • Cut down two end comers of carton IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine. Your new lawn mower SPARK PLUGS and lay end panel down flat. • Remove all packing materials padding between upper and handle and padding holding presence control bar to upper • Roll lawn mower out of carton has been as- sembled 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. check carton thoroughly loose parts. 4 except lower operator handle. and for additional HOW TO SET UP YOUR LAWN MOWER TO 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 mowing position. • Remove protective padding, raise upper handle section into place on lower handle 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. Operator presence control bar handle Lift up Mowing position Lower handle TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a muicher. To convert to bagging or discharging, see "To convert mower" in the OPERATION section of thi manual. KNOW YOUR LAWN MOWER READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference. These symbols may appear on your lawn mower or in literature product. Learn and understand their meaning. CAUTION OR WARNING ENGINE ON ENGINE OFF FAST SLOW CHOKE FUEL OIL supplied with the DANGER, KEEP HANDS AND FEET AWAY Operator presence control bar zone control cable Grass filler cap valve Engine oil cap with dipstick Mulcher door Lawn mower housing IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine, MEETS Wheel adjuster (on each wheel) CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running. Operator Presence Control Bar- must be held down to the handle to start the engine. Release to stop the engine. Primer - pumps additional fuel from the carburetor to the cylinder for use when starting a cold engine. Starter Handle - used for starting the engine. 6 The operation of any 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. HOW TO USE YOUR LAWN MOWER Lower Wheels for High Cut Plate Tab ENGINE bagging SPEED Lever Raise Wheels for Low Cut TO CONVERT MOWER Your lawn mower was shipped ready to be used as a mulcher. To convert to or discharging: The engine speed is controlled by a throttle control located on the side of the REAR BAGGING upper handle. Choke position is for starting a cold engine and fast position is for normal cutting, trimming, and better grass bagging. Slow position is for light cutting, trimming and fuel economy. Fast ,_ .==Slow place the grass catcher frame hooks onto the door pivot pins. • To convert to mulching or discharging operation, remove grass catcher and close rear door. • Lift rear door of the lawn mower and ChokeI\1 Pivot pros SIDE DISCHARGING ENGINE • Rear door must be closed. ZONE CONTROL • Open mulcher door and install discharge deflector under guard as shown. • Mower is now ready for discharging operation. • To convert to mulching or bagging operation, discharge deflector must be removed and mulcher door must be closed. SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR 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. • Your lawn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start FOR MULCHING and operate the lawn mower. TO ADJUST CU'I-I'ING 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 inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. - • Rear door closed. • Mulcher door closed. FOR REAR BAGGING - • Grass catcher installed. • Mulcher door closed. FOR SIDE DISCHARGING - • Rear door closed. • Side discharge deflector installed. _I, CAUTION: Do not run your lawn mower without rear door closed or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. 7 ADD GASOLINE • Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness. Mulcher door _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. Open Mulcher Door Discharge deflector BEFORE STARTING ACAUTION: Fill to bottom of gas tank filler neck. Do not overfill. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame. ENGINE OIL Gasoline filler cap 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 cap and fill to the upper limit mark on dipstick. NOTE: Allow oil to settle down into engine for accurate dipstick Oil filler reading. cap • Engine holds 18 1/2 ozs. of oil. For type and grade of oil to use, see "ENGINE" in Maintenance section of this manual. • Pour oil slowly. Do not over fill. • Check oil level before each use. Oil filler cap/dipstick Add oil if needed. Fill to the upper limit mark on dipstick. • To read proper level, insert the dipstick into the tube and rest engine oil cap on the tube. Do not thread the cap onto the tube. Remove and read the oil level. • Reinstall engine oil cap and tighten. • Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. 8 TO START ENGINE MULCHING MOWING TIPS • Turn fuel valve to ON position. • To start a cold engine, move handle mounted throttle/choke control lever to IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. Clean UNDERSIDE OF MOWER choke position. • Hold operator presence control bar down to the handle and pull starter handle quickly. Do not allow starter rope to snap back. • Slowly move throttle control lever to fast position after engine starts. • To start a warm engine, move throttle control lever to fast or slow position then follow steps above. • To stop engine, release operator presence control bar. Wait until blade and a!l moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon. HOUSING after each use. See "Cleaning" in MAINTENANCE section of this manual. On Fuel Valve lever MOWING TIPS • Under certain conditions, such as very tall grass, it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings. It may also be necessary to reduce ground speed and/or run the lawn mower over the area a second time. • For extremely heavy cutting, reduce the width of cut by overlapping previously cut path and mow slowly. • For better grass bagging and most cutting conditions, the engine speed should be set in the fast position. • Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass. To prevent this, regularly hose catcher off with water and let dry before using. • Keep top of engine around starter clear and clean of grass clippings and chaff. This will help engine air flow and extend engine life. • 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 recutting 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, mow slowly and raise the rear of the lawn mower one wheel adjuster setting higher than the front. 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. Max 1/3 9 .A,.TE.A.CESC.EOU'E F,LLi. OATEB AS YOU COMPLETE '_'_ Check for Loose Fasteners Clean/Inspect Grass Catcher !/ I/ I_ Check/Sharpen/Replace Blade Lubrication Chart Clean Battery/Recharge (Electric Start Mowers) Check Engine Oil Level N Change G I Clean Air Filter Inspect Muffler Engine Clean or Replace Spark Plug 3 Replace 4 - Charge GENERAL more often when operating blades I_ 11/4 _ Replace Air Filter Paper Cartridge more often when I_ 11_1,2 E + Change _g t## Oil N 2 - Se_ice _"_"_/ ()_?_ I_ Mowers) E _ Ii/ Power-Propelled Clean Under Drive Mowers) Cover Check drive beWpulleys RE (Power-Propelled >1 _ Equipped) M ,! (If Clean Lawn Mower O _" operating under 2 1_2 a heavy 1cad or in high ambient temperatures in dirty or dusty conditions. more often when mowing in _andy soil¸ 48 hours at end of season. LUBRICATION Whee! adjusters RECOMMENDATIONS 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 periodically to properly maintain your unit. All adjustments in the Service and Adjustments section of this manual should be checked at least once each season. igine oil • Once a year, replace the spark plug, replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assures proper air-fuel mixture and helps 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 TION CHART"). (See "LUBRICA- CHART Rear door hinge Handle bracket mounting pin (_) SPRAY LUBRICANT (_) SAE 30 MOTOR OIL. REFER TO ENGINE - MAINTENANCE SECTION. IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will attract dust and dirt that will shorten the life of the self lubricating bearings. If you feel they must be lubricated, use only a dry, powdered graphite type lubricant sparingly. 10 PRODUCT MODEL NUMBER SERIAL NUMBER SPECIFICATIONS 917.388330 DATE OF PURCHASE GASOLINE CAPACITY/TYPE: 1.0 QUARTS UNLEADED REGULAR OIL TYPE (API-SF/SG/SH): SAE 30 (ABOVE 32°F) SAE 5W-30 (BELOW 32°F) OIL CAPACITY: 18.50ZS. SPARK PLUG(GAP: .030") (NGK) BPR6ES VALVE CLEARANCE: INTAKE: EXHAUST: BLADE 35-40 FT. LBS. BOLT TORQUE: • The model and serial numbers lawn mower housing. provided above. LAWN Record will be found on a decal attached both serial number 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 REMOVE .004 - .007 .006 - .009 BLADE • Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. • Turn lawn mower on its side. Make sure air filter and carburetor are up. • Use a wood block between blade and to the rear of the and date of purchase TO REPLACE in space BLADE • Position the blade adapter on the engine crankshaft. Be sure the spacer is in the adaptor and key in shaft and adaptor keyway are aligned. • Position blade on the blade adapter. Be sure the trailing edge of blade (opposite sharp edge) is up toward the engine. • Install the blade bolt with washers into blade adapter and crankshaft. • Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clockwise. • The recommended tightening torque is 35-40 ft, Ibs. IMPORTANT: treated. 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 by turning counterclockwise. Use a 9/16" box or openend wrench. • Remove blade and attaching hardware. 11 Blade bolt is grade 8 heat TO SHARPEN NOTE: BLADE We do not recommend sharpening blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause eventual damage to lawn mower or 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. Crank Spacer shaft Spacer washer Blade °°\i I Lockwasher Hardened washer GRASS Blade Trailing adapter edge CATCHER • The grass catcher may be hosed with water, but must be dry when used. • Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher needs replacing, replace only with a manufacturer approved replacement catcher. Give the lawn mower model number when ordering. NOTE: Although multi--viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi--viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year. Check the crankcase oil level before starting the engine and after each five (5) hours of continuous use. Tighten oil plug securely each time you check the oil level. TO CHANGE ENGINE OIL NOTE: Before tipping lawn mower to drain oil, drain fuel tank by running engine until fuel tank is empty. • Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug. • Remove engine oil cap; lay aside on a clean surface. • Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine. • Wipe off any spilled oil on lawn mower and on side of engine. • Fill engine with oil. Fill to the upper limit mark on the dipstick. DO NOT OVER FILL. • To read proper level, insert the dipstick into the tube and rest oil fill cap on the tube. Do not thread the cap onto the tube. Remove and read the oil level. • Replace engine oil cap. • Reconnect spark plug wire to spark plug. Oil filler cap/dipstick ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SF, SH or SG. Select the oil's SAE viscosity grade according to your expected operating temperature. --? Jpper limit --Lower 12 limit AIR FILTER MUFFLER Your engine will not run properly and may be damaged by using a dirty air filter. Replace the air filter every year, more often if you mow in very dusty, dirty conditions. Inspect and replace corroded muffler as could create afire hazard and/or damag_ SPARK PLUG TO CLEAN AIR FILTER • Remove cover. CLEANING • Carefully remove cartridge. • Clean by gently tapping on a flat surface. If very dirty, replace cartridge. _I, CAUTION: Petroleum solvents, such as kerosene, are not to be used to clean cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge. • Install cartridge, then replace cover. .... _] Change your spark plug each year to make your engine start easier and run better. Set spark plug gap at .030 inch. Filter IMPORTANT: For best performance, ke_ mower housing free of built--up grass and trash. Clean underside of mower housing _,CAUTION, Disconnect spark from spark plug and place wire cannot come in contact with the plug. • Turn lawn mower on its side. plug wir_ where it spark Make SUl air filter and carburetor are up. Clean the underside of your lawn mower by scraping to remove build_up of grass and trash. Filter Cover Tabs after each use. • Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life. • Keep finished surfaces and wheels fre of all gasoline, oil, etc. • We DO NOT recommend using a garden hose to clean lawn mower unless the electrical system, muffler, a filter and carburetor are covered to Tabs keep water out. Water in engine can result in shortened engine life. _,CAUTION: Before performing service or adjustments: any TO ADJUST HANDLE • Release control bar and stop engine. • Make sure the blade and all moving parts have completely stopped. • Disconnect spark plug wire from spark p_ug and place where it cannot come in contact with plug. LAWN MOWER TO ADJUST CUTTING See "TO ADJUST HEIGHT CUTTING the Operation section REAR DEFLECTOR HEIGHT" in of this manual. The rear deflector, attached between the rear wheels of your lawn mower, is provided to minimize the possibility that objects will be thrown out the rear of the lawn mower into the operator's mowing position. If the rear deflector becomes damaged, it should be replaced. 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 lowering 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 Iow_ handle. • Squeeze lower handle in and position holes onto mounting pins on handle bracket. • Reassemble upper handle and all pan removed from lower handle. 13 J "' ¥ "' Rotate _ " Lower handle F "_,- Vinyl b nd no,. " t "%'_,',_"1.... ] • ENGINE Frame opening CARBURETOR TO ASSEMBLE GRASS CATCHER • Put grass catcher frame into grass bag with rigid part of bag on the bottom• Make sure the frame handle is outside of the bag top. • 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• _,CAUTION: Do not run your lawn mower without clipping deflector or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. 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. LAWN MOWER When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. • Clean entire lawn mower (See "CLEANING" in the Maintenance section of this manual). • Lubricate as shown in the Maintenance section of this manual• • Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. • Touch up all rusted or chipped paint surfaces; sand lightly before painting. HANDLE You can fold your lawn mower handle for storage. • Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket, then move handle forward. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to an authorized service center for repair or adjustment. IMPORTANT: Never tamper with the engine govemor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous• if you think the engine-govemed high speed needs adjusting, contact your nearest authorized service center, which has proper equipment and experience to make any necessary adjustments. ENGINE SPEED Your engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that the engine is running too fast or too slow, take your lawn mower to an authorized service center for repair and adjustment. • Loosen upper handle mounting bolts enough to allow upper handle to be folded back. IMPORTANT: When folding the handle for storage or transportation, be sure to fold the handle as shown or you may damage the control cables. • When setting up your handle from the storage position, the lower handle will automatically lock into the mowing position. ., 7 Lower handle Squeeze _ to fold _'-"_ J 14 Handle /bracket Mounting Pin Hairpin cotter 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 tanl and carburetor if using fuel stabilizer, Operator Presence Control Bar Upper Handle Fold Forward For Storage ENGINE OIL Fold Backward Lower Handle Mowing Position Drain oil (with engine warm) and replac_ with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). CYLINDER 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 ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can dama_le 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. Remove spark plug. Pour one ounce (29 ml) of oil through spark plug hole into cylinder. • PuU starter handle slowly a few times 1 distribute oil. • Replace with new spark plug. OTHER • Do not store gasoline from one seasol 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 an_ dirt. • Cover your unit with a suitable protective cover that does not retain moistur{ 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 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 _,CAUTION: Never store the lawn mow_ with gasoline in the tank inside a buildin_ where fumes may reach an open flame ( spark. Allow the engine to cool before storing in any enclosure. ENGINE FUEL SYSTEM TROUBLESHOOTING CHART PROBLEM Does not start CAUSE CORRECTION 1. 2. 3. Dirty air filter. Out of fuel. Stale fuel. 1. 2. 3. Clean/replace air filter. Fill fuel tank. Drain tank and refill with fresh clean fuel. 4. Water in fuel. 4. Drain fuel tank and carburetor and refill tank 5. Spark plug wire is disconnected. 5. 6. 7. Bad spark plug. 6. Loose blade or broken blade _7. adapter. Control bar in released 8. position. Control bar defective. 9. 8. 9. 15 with fresh gasoline. Connect wire to plug. Replace spark plug. Tighten blade bolt or reptace blade adapter. Depress control bar to handle. Replace control bar. TROUBLESHOOTING CHART CAUSE PROBLEM Loss of power Poor cut- uneven 1. Rear of lawn mower housing 1. 2. or cutting blade dragging in heavy grass. Cutting too much grass, 3. Dirty air filter. 4. Buildup of grass, leaves, and trash under mower. 5. Starter rope hard to pull 2. Set to "Higher Cut" position. 3. 4. Set to "Higher Cut" position. Clean/replace air filter. Clean underside of mower Too much oil in engine. 5. housing. Check oil level. 6. Walking speed too fast. 6. Cut at slower walking speed. 1. Wom, bent or loose blade. 1. 2. Wheel heights uneven. 2. Replace blade. 13ghten blade bolt. Set all wheels at same 3. Low engine speed 3. height Contact an authorized center/ Buildup of grass, leaves and trash under mower. 4. department Clean underside of 4. Excessive vibration CORRECTION mower housing. 1. Worn, bent or loose blade. 2. Bent engine crankshaft. 2. . Engine flywheel brake is on when control bar is released. 1. . Bent engine crankshaft. 2. Replace blade. 13ghten blade bolt. Contact an authorized service center. Depress control bar to upper handle before pulling starter rope. Contact an authorized service center. 3. 4. Blade adapter broken. Blade dragging in grass. 3. 4. Replace blade adapter. Move lawn mower to cut grass or to hard surface Grass catcher not filling (if so equipped) 1. 2. Cutting height too low. Lift on blade worn off. 3. 4. Catcher not venting air. Low engine speed 1. Raise cutting height. 2. 3. 4. Replace blade. Clean grass catcher. Contact an authorized center/ department Hard to push 1. 2. Grass is too high or wheel height is too low. Rear of lawn mower 3. housing or blade dragging in grass. Grass catcher too full. 4. Handle height position net right for you. 16 1. Raise cutting height. 2. Raise rear of lawn mower 3. 4. housing one (1) setting higher. Empty grass catcher. Adjust handle height to suit. 33 CRAFTSMAN ROTARY LAWN MOWER -- MODEL NO. 917.388330 1 71 39 40 37 33 \ 33 4O 68 67 19 56 3, _" ' ';F 3 ,'t.-- - 28 _ _" 18 CRAFTSMAN KEY NO. 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PART NO. 86902 169709X479 169708X479 132001 636O1 131959 66426 154132 165754 851671 750097 850733X004 136376 51793 147286 165946X479 17600406 167132)(004 167133X004 165858 168-360X004 166875 751153 166111 X479 166112X479 851856 152124 160835X007 19112222 165760 169421X004 87877 ROTARY DESCRIPTION Control Bar Upper Handle Lower Handle RopeGuide Locknut 1/4-20 Handle Bolt Wim33e Hinge Bracket Mulcher Door Engine Zone Control Cable Hex Washer Head Screw #10-24 x 1/2 Up-Stop Bracket HandleKnob Hairpin Cotter HingeRod Support Bracket Screw Axle Arm Assembly - LF Axle Arm Assembly - RF Rear Skirt Selector Spring- Front Rear Door Assembly Kit (Incl. Spdngs) Locknut 5/16-18 Handle BracketAssembly (Left) Handle BracketAssembly (Right) Screw 1/4-20 x 3/8 HingeSpring Wheel AdjustingBracket - Front Spacer Clip on Discharge Guard Selector Sprfng- Rear Selector Knob LAWN MOWER -- MODEL NO. 917.388330 KEY NO. PART NO. 34 36 37 39 40 41 42 43 44 45 46 48 52 53 54 55 56 57 67 68 70 165762X004 160828 151157 83923 77400 88652 165766 165767 165912 150406 85463 165761X004 166878 851084 850263 851074 165833 851514 166113 165785 71 72 --- 147758 144929 161058 172490 Available accessories 7.133623 7"133500 7"133000 DESCRIPTION Axle Arm Assembly - LR Shoulder Bolt 5/16-18 Wheel Assembly Flanged Locknut Hubcap Hinge Screw Spring (LH) Spring (RH) Door Bolt Hex Head Thread Rolling Screw 3/8-16 x 1 Danger Decal Axle Arm Assembly - RR Housing Assembly (Incl. Ref. #17, 18 & 46) Hex Head Screw 3/8-24 x 1-3/8 Grd. 8 Helical Lookwasher Hardened Washer 21" Blade Blade Adapter Grass Bag Cat_cherFrame Engine - (See Breakdown) HondaGCV160 Throttle Control Screw Warning Decal (Not Shown) Owner'sManual not included with lawn mower: Gas Can (2.5 gal.) Fuel Stabilizer SAE 3OW Oil (20 oz.) 4-CYCLE ENGINE MODEL NUMBER - GCV160A1A CONTROL..._ 8 CAMSHAFT J 9 2--__ 1211 8 1_2_ Y 13--" 1 lO CARSURETORJ 11 _p--13 36 4-CYCLE ENGINE MODEL NUMBER - GCV160AIA CONTROL KEY NO. CARBURETOR PART NO, 1 2 3 4 5 6 7 5580311 5580329 558O345 5580352 4439428 0800466 5580378 7 6094122 8 9 10 11 12 5580386 2418671 5580998 0145557 0471623 CAMSHAFT DESCRIPTION Arm, Governor Rod, Governor Spring, Governor Spring, Throttle Return Spring, Lever Holder, Cable Base Comp., Control Use up to SN 1177559. Base Comp., Control Use from SN 1177560. Rod, Governor Boll, Governor arm Bolt, Flange (6X45) (CT200) Screw Pan (5X16) Nut Flange (GMM) PULLEY KEY NO. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 5580055 5580063 5580071 5580089 5580097 5580105 5580113 5580121 5580139 1426980 0294819 0004598 0018044 DESCRIPTION Pulley Comp., Camshaft Shaft, Cam Pulley Belt, Timing Arm In. Valve Rocker Arm Ex. Valve Rocker Shaft Rocker Arm Valve, In. Valve, Ex. Spring, Valve Retainer, In. Valve Spring Screw, Tappet Adj. Nut, Tappet Adj. O-ring 37 KEY NO. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 3088416 5580162 4930756 4481818 1441518 5580170 5664552 5580212 5580220 5580238 5580246 4581120 5580253 5580535 3344520 0635474 0635482 0636126 DESCRIPTION Gasket Set Float Set Chamber Set Float Screw Set Screw Set Screw Set Carburetor Assy. Valve, Float Nozzle, Main Insulator, Carburetor Gasket, Carburetor Gasket, Carburetor Gasket, Carburetor Guide Comp., Air Screw Pan (5X6) Jet, Main #60 (OPTIONAL) Jet, Main #62 (OPTIONAL) Jet, Main #65 (OPTIONAL) 4-CYCLE FAN ENGINE MODEL NUMBER - GCV160A1A COVERJ 6- RECOIL FLYWHEELJ STARTER J 6 12_ 4 1 3 5 2 L 6 I 38 AIR CLEANER 4-CYCLE ENGINE MODEL NUMBER - GCV160AIA FAN COVER KEY NO. PART NO. 1 2 3 4 5 6 3683646 5028923 5580394 5580451 5580469 5580519 7 8 9 10 11 12 13 14 5580527 2499440 5581004 0671636 2449593 0250647 0250985 0053447 FLYWHEEL KEY NO. DESCRIPTION Rubber, Supporter 107 mm Petcock Assy. Man Bracket, Petcock Cap Assy., Fuel Tank Tube, Fuel Cover Comp., Fan NH1 Black Coller, Fan Cover Collar, Fr. Turn Signal Bolt, Stud Screw-Washer 5X10 Bulk Hose, Fuel Clip, Tube (B8) Clip, Tube (B10) Clip, Tube (C9) AIR CLEANER KEY NO. 1 2 3 5 6 7 8 PART NO. 5580154 5580402 5581410 5664560 5580444 5580964 2374742 PART NO. 1 0348433 2 3 4 5 6 7 8 9 10 11 12 13 14 5580659 5723747 5580675 5580683 5580782 5580790 0803619 1725050 0671552 0442038 1824630 0485946 1510361 DESCRIPTION Key, Special Woodruff (25X18) Coil Assy., Ignition Flywheel Assy. Wire, Stop Switch Switch Assy., Engine Stop Brake Assy. Spring, Brake Lever Bolt Flange (6X14) Bolt, Flange (6X23) Bolt, Flange (6X20) Nut, Special 14mm Clip Cable Screw-Washer (4X12) Washer, Plain RECOIL STARTER KEY NO. DESCRIPTION PART NO. 5597869 Tube, Breather Element, Air Cleaner Case Assy., Air Cleaner Gasket, Air Cleaner Cover, Air Cleaner Bolt, Flange (6X86) Bolt, Flange (6X14) 2 3 4 39 5580634 5580642 2866341 DESCRIPTION Starter Assy., Recoil NH1 Long Rope Black Knob, Recoil Starter Rope, Recoil Starter Nut, Flange 6mm 4-CYCLE CYLINDER ENGINE BARREL MODEL NUMBER - GCV160AIA OIL PAN J I 0-18 5 12 T 5 4 5 | CRANKSHAFT I PISTON CONNECTING ROD J 3 5_ ,-0 MUFFLER 4 4O 4-CYCLE ENGINE CYLINDER KEY NO. 1 2 3 4 5 6 7 8 MODEL NUMBER - GCV160A1A BARREL PART NO. 5579982 2399780 5579990 558OOO6 0636845 0803619 5581O38 1441112 DESCRIPTION KEY NO. 1 2 3 4 5 6 6 Cylinder Assy. Clip, Valve Guide Cover, Head Cover Comp. Breather Bolt, Flange (6X12} Bolt, Flange (6X14) Oil Seal 25.4X62X6 Spark Plug (BPR6ES NGK) OIL PAN KEY NO. PISTON CONNECTING PART NO. 5579974 4497947 5580261 5 8 7 8 9 10 11 12 13 14 15 16 17 18 19 5580279 5580287 5580295 1427244 1427251 5580303 0803619 0748111 2413862 2456697 5581046 0345900 0115527 1417369 5722996 DESCRIPTION KEY NO. Pan Assy,, Oil Gasket, Oil Filler Cap Shaft Comp., Governor Holder Governor Assy. Weight, Governor Holder, Governor Weight Pin, Governor Weight Slider, Governor Shaft, Governor Arm Bolt Flange (6X14) Bolt, Flange (6X25) Washer, Thrust 6mm Clip, Governor Holder Oil Seal (28X41.25X6) Washer, Plain 6mm Pin, Lock 8ram Pin, Dowel (8X20) Gauge Assy., Oil Level 1 2 3 4 5 CRANKSHAFT 1 5 5580014 1426576 558OO22 1431055 2605517 5655949 5655956 DESCRIPTION Piston Pin, Piston Rod Assy., Connecting Bolt, Connecting Rod Clip, Piston Pin 13mm Ring Set, Piston (Riken) Ring Set, Piston (Teikoku) MUFFLER 1 2 4 KEY NO. PART NO. ROD PART NO, 5580030 5581012 DESCRIPTION Crankshaft Comp. (N1-Type) Washer Thrust 41 PART NO. 5580485 5580501 5580972 0636845 5737457 DESCRIPTION Muffler Comp. Protector, Muffler Boil, Flange (6X79) CT200 Bolt, Flange (6X12) Gasket, Muffler (Optional) 42 43 For in-home major brand repair service: Call 24 hours a day, 7 days a week 1-800-4-MY-Home sM (1-800-469-4663) Para pedir servicio de reparaci6n a domicilio 1-800-676-5811 In Canada for all your service and parts needs call Au Canada pour tout le service ou les pi_ces 1-800-665-4455 For the repair or replacement parts you need: Call 6 am-llpm CST, 7 days a week PartsDirect 1-800-366-PART s. (1-800-366-7278) Para ordenar piezas con entrega a domicilio 1-800-659-7084 For the location of a Sears Parts and Repair Center in your area: Call 24 Hours a day, 7 days a week 1-800-488-1222 For information on purchasing a Sears Maintenance Agreement or to inquire about an existing Agreement: Call 9 am-5 pm, Monday - Saturday 1-800-827-6655 SEAR8 172490 Rev.1 12.21.99 VB Printed in U.S.A.
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