Operator's Manual, Generic Poulan Pro (Push Mower), 2000 01, Walk Mower !! Push [1]
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OPERATOR'S MANUAL DELUXE PUSH ROTARY Lawn Mower • Assembly • Operation • Maintenance • Service and Adjustments • Storage • Troubleshooting 172782 Rev.1 01.10.00 VB PRINTED IN U.S.A. TABLE OF CONTENTS Safety Rules ........................................ 2 Assembly ............................................. 5 Operation ............................................. 8 Maintenance ........................................ 14 Service and Adjustments ..................... 16 Storage ................................................ 17 Troubleshooting .................................. 19 SAFETY RULES IMPORTANT: This cutting machine ie capable of amputating hands and feet and throwing objects.Failure toobserve the following safety instructions could result in serious injury or death. • Dress properly. Do not operate mower Safety standards require operator when barefoot or wearing open sandals. presence controls to minimize the risk of Wear only solid shoes with good traction injury. Your unit is equipped with such when mowing. controls. Do not attempt to defeat the • Check fuel tank before starting engine. function of the operator presence controls Do not fill gas tank indoors, when the under any circumstances. engine is running or when the engine is TRAINING: hot. Allow the engine to cool for several • Read this operator’s manual carefully. minutes before filling the gas tank. Become familiar with the controls and Clean off any spilled gasoline before know how to operate your mower starting the engine. properly. Learn how to quickly stop • Always make wheel height adjustments mower. before starting your mower. Never • Do not allow children to use your attempt to do this while the engine is mower. Never allow adults to use mower running. without proper instructions. • Mow only in daylight or good artificial • Keep the area of operation clear of all light. persons, especially small children and pets. OPERATION: • Use mower only as the manufacturer • Keep your eyes and mind on your intended and as described in this mower and the area being cut. Do not let manual. other interests distract you. • Do not operate mower if it has been • Do not mow wet or slippery grass. Never dropped or damaged in any manner. run while operating your mower. Always Always have damage repaired before be sure of your footing — keep a firm using your mower. hold on the handles and walk. • Do not use accessory attachments that • Do not put hands or feet near or under are not recommended by the manufacrotating parts. Keep clear of the disturer. Use of such attachments may be charge opening at all times. hazardous. • Always stop the engine whenever you • The blade turns when the engine is leave or are not using your mower, or running. before crossing driveways, walks, roads, and any gravel—covered areas. PREPARATION: • Never direct discharge of material • Always thoroughly check the area to be toward bystanders nor allow anyone mowed and clear it of all stones, sticks, near the mower while you are operating wires, bones, and other foreign objects. it. These objects will be thrown by the • Before cleaning, inspecting, or repairing blade and can cause severe injury. your mower, stop the engine and make • Always wear safety glasses or eye absolutely sure the blade and all moving shields when starting and while using parts have stopped. Then disconnect the your mower. spark plug wire and keep it away from the spark plug to prevent accidental 2 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 you 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. • 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 a building where fumes may reach an open flame or an ignition source such as a hot water heater, space heater, clothes dryer, etc. Look for this symbol to point out important safety precautions. It means CAUTION!!! BECOME ALERT!!! 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. 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. 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 CONGRATULATIONS on your purchase of a new Lawn Mower. It has been designed, engineered and manufactured to give you the best possible dependability and performance. Should you experience any problems you cannot easily remedy, please contact your nearest authorized service center. They have competent, well trained technicians and the proper tools to service or repair this unit. • Read the SAFETY RULES and this Operator's Manual in its entirety before you 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 LAWN 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 mulcher ready. To convert to a discharging mower, see the Operation section of this manual. What is the right and left side of the lawn mower? When right hand (RH) or left hand (LH) is mentioned in this manual, it means when you are in the operating position (standing behind the handle). What kind of engine is on my lawn mower? When learning how to operate your new lawn mower, you will need to know what kind of engine powers the mower. A decal on the engine will indicate the manufacturer and type or brand name of the engine. BRIGGS & STRATTON ENGINES CLASSIC FRONT ¤ RIGHT HAND SIDE LEFT HAND SIDE TECUMSEH ENGINES BACK or REAR (Operating Position) ® 4 HONDA ENGINES ASSEMBLY 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. CAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. HOW TO SET UP YOUR LAWN MOWER Axle 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. 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. Washers (If provided) 3/8-16 Locknut FOR REAR DISCHARGE MOWERS ONLY - ASSEMBLE GRASS CATCHER IMPORTANT: If your model lawn mower is mulcher ready, the mulcher plate must be removed before using mower as a bagger. To convert mower to bagine 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 Operator presence control bar Upper handle Lift up TO ASSEMBLE & 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. • The grass catcher is secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame. Lift up Mowing position Lower handle 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 locknut and tighten securely. • Repeat procedure for other rear wheel. 5 HINGE BRACKET MOUNTED FABRIC TOP CATCHER Upper tubular frame Catcher frame Hem Start here Vinyl bindings Upper tubular frame Rigid bottom Rear door Catcher frame Vinyl bindings Lower frame 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 to rear holes first and tighten securely. • Pull 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. • Install two (2) blunt pointed screws in front holes and tighten securely. Hinge bracket tabs HANDLE BRACKET MOUNTED FABRIC TOP CATCHER Catcher frame Vinyl bindings Rigid bottom Rear door Sharp pointed screws (Rear and side holes) Handle bracket PULL CA BAG FORWTCHER REMOVE ARD TO SLACK Catcher bag and frame Catcher frame hook HARD TOP GRASS CATCHER 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. 6 Catcher top Blunt pointed screws (Front holes) TO ATTACH HARDTOP 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. Handle bracket slot 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. 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 protect the battery during winter storage. Rear door Catcher frame hook 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 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. Batter connector (male) Battery charger 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. Battery connector (female) Spark plug Battery connector (male) 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. Boot 7 OPERATION 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 for over the spectacles or standard safety glasses. BRIGGS & STRATTON CLASSIC AND SPRINT ENGINE MOUNTED SPEED CONTROL Rapid HOW TO USE YOUR LAWN MOWER ENGINE SPEED CONTROL 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. Fast Choke (start) Primer (if equipped) Spark plug Engine speed control lever BRIGGS & STRATTON QUANTUM ENGINE MOUNTED SPEED CONTROL Engine speed control lever Slow Remote throttle control Primer (if equipped) TECUMSEH ENGINE MOUNTED SPEED CONTROL 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. MODELS WITH FIXED SPEED ENGINES Engine speed was set at the factory for optimum performance. Engine speed is not adjustable. Engine speed control lever Primer (if equipped) 8 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 MANUAL ADJUST BOLT-ON WHEELS • Remove wheel, bolt, and hardware and reassemble in desired adjustment hole. Most lawn mowers are shipped ready to be used as a mulcher. REAR DISCHARGE MOWERS To convert to bagging or discharging, mulcher 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. 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. • 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 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 inserts 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 Raise Wheels for Low Cut Plate Tab Lever Slots Mulcher plate tabs MULCHER PLUG TYPE Mulcher plug SIDE DISCHARGE 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 9 hardware securely. Screw and lock nut 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. • 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 guard Housing opening Hooks Mulch plug Hinge Rod Tab COMBI-CUT MOWERS Hinge Bracket Mulcher plug 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. Lock lever down position Raise lever to lock TO CONVERT MOWER 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. Mulcher plate Lower lever to lock Tabs SIDE DISCHARGING • Mulcher plate must be installed into rear discharge opening of mower (see above instructions). 10 • Open discharge guard 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 discharge guard must be closed. Discharge guard Open discharge guard GRASS CATCHER (REAR DISCHARGE 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 manufacturer's specifications. CAUTION: Do not run lawn mower without the discharge guard (rear door), approved grass catcher or clipping deflector in place. Never attempt to operate mower with the discharge guard (rear door) removed or propped open. OPERATOR PRESENCE ENGINE CONTROL BAR Discharge deflector SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER Your lawn mower is equipped with an operator presence engine 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. BEFORE STARTING ENGINE Read the engine manual packed with your mower. FILL ENGINE WITH OIL FOR MULCHING Your lawn mower is shipped without oil in • Rear mulcher plate installed. the engine. • Side discharge guard closed. • Be sure mower is level and area FOR REAR BAGGING around oil fill is clean. • Rear mulcher plate removed. • Remove engine oil filler plug (oil fill • Grass catcher installed. cap/dipstick on models so equipped). • Side discharge guard closed. • Slowly add oil. For type and grade of oil to use, see "ENGINE" in Maintence FOR SIDE DISCHARGING section of this manual. • Rear mulcher plate installed. • Fill to the top of slot in filler hole (to • Side discharge deflector installed. “FULL” line on dipstick on models so CAUTION: Do not run your lawn mower equipped). Do not overfill. without rear mulcher plate in place or • Replace plug (oil fill cap/dipstick on approved grass catcher in place. models so equipped) and tighten. Never attempt to operate the lawn mower • Check oil level before each use. Add with the rear door removed or propped oil as needed. open. 11 • To change oil, see Maintence section of this manual. FILL GASOLINE TANK Operator presence control bar Recoil starter handle (center Mount type) • Fill gasoline tank with fresh, clean, unleaded gasoline. DO NOT USE PREMIUM GASOLINE. BE CAREFUL Recoil starter NOT TO OVERFILL TANK. handle (side WARNING: Experience indicates that mount type) alcohol blended fuels (called gasohol or MODELS WITH ELECTRIC STARTER using ethanol or methanol) can attract moisture which leads to separation and • Move engine speed control to fast formation of acids during storage. Acidic position or to choke/start position on gas can damage the fuel system of an models so equipped with choke engine while in storage. To avoid engine feature. problems, the fuel system should be • If your mower has a primer, to start a emptied before storage of 30 days or cold engine, push primer the number of longer. Drain the fuel tank, start the times as instructed in the engine engine and let it run until fuel lines and manual packed with your mower. Use carburetor are empty. Use fresh fuel next a firm push. This step is not usually season. See Storage Instructions for necessary when starting an engine additional information. Never use engine which has already run for a few or carburetor cleaner products in fuel tank minutes. or permanent damage may occur. • Hold operator presence control bar down against handle. TO START ENGINE • Push the engine start button. CAUTION: The mower blade rotates IMPORTANT: Do not crank engine more whenever the engine is running. than five continous seconds between MODELS WITH RECOIL STARTER each time you try to start. Wait 5 to 10 • Move engine speed control to fast seconds between each attempt. position or to choke/start position on • For engines equipped with choke, models so equipped with choke slowly move engine speed control lever feature. to fast after engine starts. • If your mower has a primer, to start a • To STOP engine, release operator cold engine, push primer the number of presence engine control bar. times as instructed in the engine NOTE: For engines with a primer, it may manual packed with your mower. Use be necessary to repeat priming steps in a firm push. This step is not usually cooler weather. In warmer weather, necessary when starting an engine overpriming may cause flooding and which has already run for a few engine will not start. If you do flood minutes. engine, wait a few minutes before • Hold operator presence control bar attempting to start and DO NOT repeat down against handle. priming steps. • Pull starter handle quickly. Do not allow starter rope to snap back. • For engines equipped with choke, slowly move engine speed control lever to fast after engine starts. • To STOP engine, release operator presence engine control bar. NOTE: For engines with a primer, it may be necessary to repeat priming steps in cooler weather. In warmer weather, overpriming 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 12 priming steps. 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. MULCHING MOWING TIPS (IF SO EQUIPPED) IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See “Cleaning” in 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 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 by overlapping previously cut path and mow slowly. 1/3 MAX • 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. 13 MAINTENANCE MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE M O W E R E N G I N E E E N US USE URS URS SO RAG A H H O O E O C ST EA AC 0 H 5 H S E R E Y 1 Y 2 ERY RE R FO FTE VER VERR EV EFO SERVICE DATES E O E B BE A Check for Loose Fasteners Clean/Inspect Grass Catcher (If Equipped) Clean Lawn Mower Clean Under Drive Cover (Power-Propelled Mowers) Check drive belt/pulleys (Power-Propelled Mowers) Check/Sharpen/Replace Blade Lubrication Chart Clean Battery/Recharge (Electric Start Mowers) 3 4 Check Engine Oil Level Change Engine Oil Clean Air Filter Inspect Muffler Clean or Replace Spark Plug 1,2 2 Replace Air Filter Paper Cartridge 2 2 1 - Change more often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty or dusty conditions. 3 - Replace blades more often when mowing in sandy soil. 4 - Charge 48 hours at end of season. LUBRICATION CHART GENERAL 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. • 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. 1 Engine 2 Wheel adjusters 2 Side discharge nower guard hinge rod 2 Handle bracket mounting pin 1 2 2 Rear discharge nower rear door hinge rod Refer to Maintenance section Spray Lubricant 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. 14 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. lbs. NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced. • 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. Blade adapter Key Blade bolt Crankshaft Lock washer Flat steel washer Blade trailing edge 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. 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 TO SHARPEN BLADE side. • After oil has drained completely, Care should be taken to keep the blade replace oil drain plug and tighten balanced. An unbalanced blade will securely. cause excessive vibration and eventual • Refill engine with oil. Pour slowly. Do damage to lawn mower and engine. not overfill. • The blade can be sharpened with a file • Fill to top of slot inside of filler hole or to or on a grinding wheel. Do not attempt “FULL” line on dipstick on models so to sharpen while on the mower. 15 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, more often if lawn mower is used in very dusty, dirty conditions. See the maintenance section of your engine manual. SPARK PLUG Change the spark plug once a year to make the engine run better and easier to start. Set spark plug gap according to engine manual specifications. MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and/or damage. 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. SERVICE AND ADJUSTMENTS CAUTION: Before performing any service or adjustments• Release operator presence control bar. • Make sure the blade and all moving parts have completely stopped. • Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug. Off center hole Low position LAWN MOWER TO ADJUST CUTTING HEIGHT See “TO ADJUST CUTTING HEIGHT” in the Operation section of this manual. TO ADJUST HANDLE 2 POSITION Turn lower handle over to adjust height 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 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. High position 3 POSITION 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. 16 • Align opposite side of handle with same positioning hole and secure with bolt and knob. Handle adjustment bracket Bolt Knob REAR DEFLECTOR (IF EQUIPPED) The rear deflector, attached between the rear wheels of your mower, is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator mowing position. If the deflector becomes damaged, it should be replaced. 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. STORAGE 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. 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 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. When setting you handles up from the storage position, the lower handle will automatically lock into mowing position. 17 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 ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel systme 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. • Pour one ounce (29 ml) of oil through spark plug hole into cylinder. • 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. 18 TROUBLESHOOTING CHART PROBLEM Does not start CAUSE CORRECTION 1. Dirty air filter. 2. Out of fuel. 3. Stale fuel. 4. Water in fuel. 5. Spark plug wire is disconnected. 6. Bad spark plug. 7. Loose blade or broken blade adapter. 8. Control bar in released position. 9. Control bar defective. 1. Clean/replace air filter. 2. Fill fuel tank. 3. Drain tank and refill with fresh clean fuel. 4. Drain fuel tank and carburetor and refill tank with fresh gasoline. 5. Connect wire to plug. 6. Replace spark plug. 7. Tighten blade bolt or replace blade adapter. 8. Depress control bar to handle. 9. Replace control bar. Loss of power 1. Rear of lawn mower housing 1. Set to “Higher Cut” or cutting blade dragging position. in heavy grass. 2. Cutting too much grass. 2. Set to “Higher Cut” position. 3. Dirty air filter. 3. Clean/replace air filter. 4. Buildup of grass, leaves, 4. Clean underside of mower and trash under mower. housing. 5. Too much oil in engine. 5. Check oil level. 6. Walking speed too fast. 6. Cut at slower walking speed. Poor cut – uneven 1. Worn, bent or loose blade. 2. Wheel heights uneven. 3. Low engine speed 4. Buildup of grass, leaves and trash under mower. 19 1. Replace blade. Tighten blade bolt. 2. Set all wheels at same height 3. Contact an authorized center/ department 4. Clean underside of mower housing. TROUBLESHOOTING CHART PROBLEM Excessive vibration CAUSE 1. Worn, bent or loose blade. 2. Bent engine crankshaft. CORRECTION 1. Replace blade. Tighten blade bolt. 2. Contact an authorized service center. Starter rope hard to pull 1. Engine flywheel brake is on 1. Depress control bar to when control bar is released. upper handle before pulling starter rope. 2. Bent engine crankshaft. 2. Contact an authorized service center. 3. Blade adapter broken. 3. Replace blade adapter. 4. Blade dragging in grass. 4. Move lawn mower to cut grass or to hard surface Grass catcher not filling (if so equipped) 1. 2. 3. 4. Hard to push 1. Grass is too high or wheel height is too low. 2. Rear of lawn mower housing or blade dragging in grass. 3. Grass catcher too full. 4. Handle height position not right for you. Cutting height too low. Lift on blade worn off. Catcher not venting air. Low engine speed 1. 2. 3. 4. Raise cutting height. Replace blade. Clean grass catcher. Contact an authorized center/ department 1. Raise cutting height. 2. Raise rear of lawn mower housing one (1) setting higher. 3. Empty grass catcher. 4. Adjust handle height to suit.
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