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Honda HRC7013 User's Manual

1. T T o e Lubrication Points Lubricate j Check e amp Emissions related item Perform initial service at this time Service more frequently when used in dusty conditions Replace paper element only Tuneup Specifications ITEM SPECIFICATION Spark pluq 0 7 0 8 mm 0 028 0 032 1750 rpm Valve clearance cold IN 0 08 0 12 mm EX 0 13 0 17 mm Omer specifications _ tions _ 41 MAINTENANCE 4 ADJUSTMENTS Air Cleaner Check that the air cleaner elements are clean and in good condition A dirty air cleaner will restrict air flow to the engine reducing performance damaged air cleaner will allow dirt to enter the engine causing rapid engine wear 1 Remove the wing nut to remove the air cleaner cover f the foam element appears surface it does not need cleaning Reinstall the cover If the foam element appears dirty go to Step 2 s y 2 Remove the other wing nut T and remove the elements SM x H Ss clean over more than half its 3 Separate the foam element from the paper element and carefully check each one for holes or tears Replace any damaged element 4 Clean the foam element by squeezing it in warm soapy water rinsing it and allowing it to dry You may also use nonflammable solvent and 7 uL then allow it to dry WARNING
2. Power Equipment Owner s Manual Mid Size Commercial Mower HRC 7013 Ben manual to your computer In mau I I I e Rc NBERRBEBBREET a HH f LE BL lt bs h m da ix p EE E Messi Ameancan Honda Motor inc Rights sasa wama ER Keep this owner s manual handy so you can refer to it anytime and make sure the manual stays with the lawn mower if you sell it This owners manual is considered a permanent part of the lawn mower It must be available to all operators of the mower and should remain with the mower if resold The information and specifications in this publication were in effect at the time of approval for printing American Honda Motor Co Inc reserves the right to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever Your mower 15 not equipped with a spark arrestor and it may be illegal to operate the mower in some areas Check local laws and regulations An optional spark arrestor is available from authorized Honda servicing dealers Honda lawn mowers meet Consumer Product Safety Commission CPSC blade safety requirements for walk behind rotary mowers WARNING engine exhaust from this product contains
3. Deck and blade belts should be in good condition and at correct tension page 70 Cuts poorly Throttle should be in FAST Cutting height must be at the same setting at front and rear page 63 Blades should be in good condition page 67 Mower deck should be free of grass accumulation Deck and blade belts should be in good condition and at correct tension page 70 Tall grass should be cut at lower speeds and or higher cutting heights 81 SPECIFICATIONS This section provides you with important dimensions and capacities Mower 84 Engine 85 83 SPECIFICATIONS Mower Length 203 m BO Width Chute up 10 91 m 36 in Chute down 11 19 m 47 in 1 20 m 47 1 4 in Operating weight 241 kg 533 Maximum speed Forward 8km h 5 mph Reverse 3km h 2 mph Zero turn hydrostatic drive Hydrostatic oil 10W 40 SG Hydrostatic oil 9 8 10 4 qt capacity Tire size 1 93 m 76 in 1 24 m 49 in 1 50 m 59 in 267 kg 590 Ib Drive wheel 4 ply 16 x 6 50 x 8 Caster wheel 2 4 10 x 3 50 x 5 Tire pressure Drive wheel 103 15 Caster wheel 193 28 psi Cutting height Low range 38 89 mm 114 3 in High range 89 140 mm 314 5 in 84 SPECIFICATIONS Engine GXV390DA23 Horsepower rpm 113 hp 3600 rpm Maximum no load governed speed 3550 50 rpm Idle speed 1750 rom lgnitio
4. Gasoline is highly flammable and explosive You can be burned or seriously injured Never use gasoline to clean engine parts Use nonflammable solvent 5 Oil the foam element by dipping it in clean engine oil and squeezing out all excess oil If too much oil is left in the foam the engine will smoke when you first start it 42 MAINTENANCE 8 ADJUSTMENTS 6 Clean the paper element by tapping it on a hard surface to knock off dirt by blowing compressed air at less than 207 kPa 30 through the filter from the inside Never try to brush off the dirt that will just force it into the filter fibers 7 Use a damp rag to wipe any dirt from the inside of the air cleaner housing and cover Be careful not to allow dirt into the duct leading to the carburetor Be sure the rubber seal the base is in place and in good condition 8 Place the foam element over the paper element and install them with the wing nut 9 Install the cover with its wing nut Operating the engine with no air cleaner or with damaged elements can cause rapid engine wear Fuel Fuel tank capacity 16 7 liters 4 4 gallons Refueling Remove the cap on the tank and check the fuel level Refuel carefully to avoid overfilling or spilling fuel There should be no fuel in the filler neck WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured When refueling s Stop engine and keep heat spa
5. It s not likely that this adjustment will change by itself Perform this procedure only when the engine doesn t reach 5 maximum no load speed and you are sure that the engine Is correctly tuned good spark plug clean air cleaner etc Loosen but do not remove the nut on the governor arm pinch bolt Move the governor arm rearward to fully open the throttle and hold it in this position Rotate the governor arm shaft fully clockwise and hold it there with a pair of pliers GOVERNOR ARM GOVERNOR SHAFT Tighten the nut on the governor arm pinch bolt to 11 Nem 8 0 ft lb to secure the arm to the shaft Start the engine and allow it to warm to normal operating temperature With the throttle in FAST the engine should be at its maximum governed speed MAXIMUM NO LOAD SPEED 3550 50 rpm If the no load speed is not within the limits adjust the throttle cable MAINTENANCE 4 ADJUSTMENTS Throttle Cable normal use cables will lose their adjustment Perform this procedure if the no load speed is not within limits or the engine does not seem to respond correctly to throttle lever movements em GOVERNOR q SPRING imm Pat x 09m m eE 2 7 SCREW 1 Set the throttle lever to ast 2 On the engine check the clearance between the control lever and the choke lever It should be 1 mm 0 04 in or less in other words just touchi
6. mowing M Read Dinars Manus caratuly E nel ho mower without oithar the discharge guard Lam the locaton and function of controls or tha grass catchor in place Do nol allow children to oparalo this machina B Wear oye protection sip engine performing mandenme B pooplo away while mowing PARKING SAFETY E Park the mower a Arm level surface when possible E if the mower must be parked on a slope block the wheals 30 the mower can not rol Do open tha bypass valves when parked on slope When possibile park machine on lave surface WARNING magona m highiy feos and sipkrsiva and you can ba burned er Injured When rsfueling Y Keep and open famed away E Fil fuel tank only outdoors Wipe up before engine MOWER SAFETY WARNING Objects hidden the lawn be thrown by the mower blade Thrown objects can cause serious injury Clear lawn of all debris before mowing Do not operate the mower without either the discharge guard or entlre grass catcher in place Wear eye protection Keep people and pets away 1 WARNING Moving belts and pulleya can cause serious injury nat operate engine while shield in removed under cover 48 inch deck DANGER SHARP BLADE You will be seriously cut by the rotating blade Keep hands
7. you have special responsibilities to the people who work for you Before you ask anyone to operate this mower you need to determine whether the person is old enough large enough and strong enough to safely handle and control the mower If you decide they are make sure the employee reads and understands all instructions and warnings in this manual and on the labels betore operating the mower Allow adequate time for hands on training by a qualified instructor and personally supervise practice sessions until you feel sure the employee is ready to operate the machine Also be sure employees Wear proper clothing and have eye protection and any other gear that may be required by local ordinances or your insurance company Remember too that you are responsible for keeping the mower property maintained and safe operating condition Your commitment to safety on the job can help prevent accidents and result in longer and more productive years of service MOWER SAFETY Safety Label Locations These labels warn you of potential hazards that can cause serious injury Read them carelully label comes off or becomes hard to read contact your Honda Commercial Mower dealer for a replacement WARNING Objects hidden In the cam throw by the mowa black SPECIAL THAINING 15 NECESSARY Thrown objecia can cause saree Injury aperate mewar withal training ckan lem of dptris
8. and feet away when engine 15 running MOWER SAFETY 44 WARNING Objects hidden in the lawn can be thrown by the mower blade Thrown objects can cause serious injury B Clear tawn of debris before mowing Do not operate the mower without either the discharge guard entire grass catcher in plate Wear eye protection Keep people and pets away WARNING Moving balls and pulleys cause S rinus injury Do not operate ongina while shlFld m under cover DANGER SHARP BLADE You will ba seriously cut by the rotating blade Keep hands and feet away when engine is running CONTROLS 8 INDICATORS This section shows you where controls are located and tells you what they do and how they work Locations 8 Controls 11 Indicators 13 r s sr p CONTROLS amp INDICATORS Locations This shows where to find the most frequently used controls HYDROSTATIC OIL FILLER FUEL FILLER FRONT WHEEL ADJUSTMENT SPACERS CONTROLS amp INDICATORS DIRECTION CONTROL LEVERS OPERATOR PRESENCE LEVERS NEUTRAL LOCKS on hand grips HA ENGINE OIL FILLER MOWER DECK SERIAL NUMBER CONTROLS INDICATORS BLADE CONTROL FORWARD SPEED CONTROL LEVERS THROTTLE IGNITION SWITCH ENGINE SERIAL NUMBER POWER UNIT SERIAL NUMBER REAR WHEEL ADJUSTMENT PUMP BYPASS VALVES 10 CONTROLS amp INDICA
9. careful to prevent water from entering the air cleaner NOTICE Using a garden hose or pressure washing equipment can force water into the air cleaner Water in the air cleaner will soak the filters and can enter the carburetor or engine cylinder causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Mower Deck If using a garden hose or pressure washing equipment to clean the mower deck be careful to avord getting water into controls and cables or anywhere near the engine air cleaner or muffler opening 17 m TRANSPORTING STORING Spraying water on hot mower deck bearings can cause them to be damaged from cooling too quickly Before washing the underside of the mower deck be sure the parking brake is set and the height adjustment lever is all the way up Grass Bag optional kit Remove the grass bag from the frame and wash it with a garden hose or pressure washing equipment Allow the bag to completely dry before storage After washing the mower wipe dry all accessible surfaces Start the engine outdoors and let it run until it reaches normal operating temperature to evaporate any water remaining on the engine While the engine is running hold the operator presence levers and operate the PTO clutch lever to expel water from the blade pulleys spindles and other mower deck items Aliow
10. chemicals known to the State of California to cause cancer birth defects and other reproductive harm Congratulations on your selection of the Honda Commercial Mower We are certain you will be pleased with your purchase You can enhance the performance of your new mower by taking time to study this manual In it you ll learn how to use it safely and efficiently The service interval and maintenance recommendations in this manual were developed to give you the optimum performance and service life of your mower We suggest you follow them Please take time to read the warranty policy so that you fully understand the coverages and the responsibilities of ownership The warranty policy a separate document that should have been given to you by your dealer Your authorized Honda servicing dealer and his staff are specially trained in the service and maintenance of your mower and are supported by the parts and service divisions of American Honda Your Honda dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns When you contact your Honda dealer about your mower he ll need to know the serial numbers of the engine power unit and mower deck Write those numbers the space below for future reference Best wishes Power Equipment Division American Honda Motor Co inc Engine number Power Unit number Mower Deck number kk LL Safety Messages Your safety and the safety of
11. control ON 6 Adjust the tensioner pulley guide s B to the positions shown about 3 5 mm 1 346 in from the belt 7 Tighten the guide pin s C at the driven spindle 8 Adjust the engine pulley guides A to 3 5 mm 15 34s in from the belt 9 Cycle the blade control on and off a few times and recheck the positions of the belt guides Check the tightness of all bolts 10 Adjust the belt tension page 70 7 MAINTENANCE amp ADJUSTMENTS Blade Brake Adjustment Check the blade brake adjustments whenever the deck belt is adjusted or replaced Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover removed Before removing belt cover for maintenance remove key from ignition switch and disconnect the spark plug lead 48 inch deck shown 72 5 Move the blade contro OFF and remove the belt cover The swivel on the brake rod should be in the center of its hole on the pulley arm while the pulley is lightly pushed in the direction shown If it isn t remove the spring and washer and adjust it Check the brake spring length MINIMUM SPRING LENGTH Hook to Hook 114 117 mm 414 4 in If the spring length is less than specification adjust it 36 deck Loosen the two bolts holding the spring bracket and slide the bracket to a new position Retighten the bolts 48 deck Loosen nut A on the spring post and turn nu
12. on a slope block the wheels securely if you leave the machine unattended To start on a slope keep the throttle at SLOW to help you avoiq abrupt changes of direction Mowing on a slope when the grass is damp or wet could cause you to slip or lose control of the mower Parking the Mower To stop mower 1 Squeeze both direction control levers to their neutral positions 2 Engage the neutral locks by pulling rearward with your thumbs 3 Pull both forward speed control levers to NEUTRAL 4 Pull the blade control to OFF 5 Move the throttle to SLOW and let the engine idle 6 Turn the key off and remove it 7 Turn the fuel valve OFF Try to park the mower on level ground If you must park it on a slope block the wheels to prevent it from rolling Always remove the key when leaving the mower unattended to prevent children or unauthorized persons from operating it 34 MAINTENANCE ADJUSTMENTS This section tells you how and when to perform normal maintenance and adjustments The Importance Of Maintenance 36 Emission Control System 38 Modification for High Altitude Operation 40 Maintenance Schedule 4 Tuneup Specs 41 Air Cleaner 42 Fuel 43 Engine Oil 46 Spark Plug 49 Valve Clearance 50 Carburetor 51 Governor Linkage 52 Throttte Cable 23 Hydrostatic 54 Lubrication Points 55 Control Linkage Adjustment 57 Tires 62 Cutting Height 63 Cutting Range 65 Blades 67 Deck Belt Adjustment and Replace
13. the blades to spin for several minutes to ensure that no water remains Stop the engine and allow it to cool After the mower is clean and dry touch up any damaged paint and coat other areas with a light film or oil Lubricate the throttle cable core with a silicone spray lubricant Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your mower deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced 18 TRANSPORTING STORING The length of time that gasoline be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under warranty You can extend fuel storage by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Add
14. the mower s path ts drifting off to the right move the right lever slightly ahead of the left lever If the mower s path is drifting off to the left move the left lever slightly ahead of the right lever You may also use this method to control your path when mowing on the side of a slope If the forward speed control knobs are separated by more than one inch the safety interlock system will shut off the engine If the mower will not track in a straight path on level ground within this range the tracking must be adjusted following the procedures on page 57 Mowing Tips Your mower is designed to trim closely on the left hand side and discharge clippings evenly on the right hand side For best cut quality run the engine with the throttle lever in FAST Always mow in daylight or under good artificial light Mowing on Slopes There are two ways you can keep a straight path when mowing across slopes Squeeze the direction control lever on the uphill side Adjust the ground speed control levers as described in Adjusting your Speed above Mow across slopes not up and down Avoid steep slopes more than 209 and be careful when changing direction When changing direction always turn the mower up stope This will give you better control and help you maintain your balance Avoid abrupt changes of direction or speed when operating on slopes 33 OPERATING THE MOWER Avoid stopping on a slope If you must stop
15. x 3 Remove the hair pin from the brake rod 4 Remove the rod from the brake EE band the spring will fall loose dd 5 Remove the blade belt from the right discharge side spindle pulley then from the rest of the pulleys 6 Remove the spring hook and install it in the primary position 7 Install the belt over the pulleys right pulley last 8 Install the deck belt over the right spindle pulley and tighten 10 11 the belt guide pin Install the rod in brake band while attaching the spring and install the hair pin Check the brake adjustment page 72 Install tha belt cover 17 MAINTENANCE amp ADJUSTMENTS Spark Arrester optional If the engine has been running the muffler will be hot enough to burn you Allow the muffler to cool before proceeding The spark arrester must be serviced every 100 hours to maintain its efficiency MUFFLER PROTECTOR GASKET 5 mm SCREW B mm NUT IDENTIFICATION SPARK ARRESTER PLATE OPTIONAL PART 1 Remove the three 5 mm screws and the muffler protector 2 Remove the 8 mm nuts then remove the identification plate muffler and gasket Remove the spark arrester 3 Check for carbon deposits on the spark arrester and clean if necessary Be careful to avoid damaging the spark arrester screen The screen must be free of breaks and holes Replace it if necessary 4 Install the spark arrester and muffler in the reverse order of removal 78 TROUBL
16. C D E Front Wheel Adjustment The front caster wheels are adjustable within their range in increments of 13 mm 4 in by changing the position of the four spacers on each caster post The following table shows the position of the spacers for the various cut ng heights Low Range Cutting Height COE 38 mm 1 ram in 8 Smenn 102 mm 4 in PER 127 mm i To change the spacers 1 Raise and support the front of the mower deck 63 MAINTENANCE 4 ADJUSTMENTS 2 Remove the pin and lower the caster post about 6 mm 1 4 inch until the spacer can be removed over the flats in the caster post 3 Position the spacers in the desired locations 4 Raise the caster post and insert and lock the pin J 5 Repeat the procedure on m WASHER LOCATIONS the other caster wheel Do not change the location of the washers on the caster post Rear Wheel Adjustment The rear wheels are adjustable within their range in 13 mm 1 in increments by placing the adjusting bar in the drive axle in one of the 5 holes on the power unit The adjusting lever helps you raise and lower the power unit 1 Remove the linchpin to remove the adjusting lever from its storage position 2 Remove the linchpin from one or the other ends of the adjusting bar 3 Place the adjusting lever in one of the holes on the power unit to raise the power unit until the adjusting bar can be removed 64 4 MAI
17. ENTS Deck Belt Adjustment and Replacement Replace the deck beit if it is worn frayed or glazed You will need to remove the deck beit to replace the pump belt and disconnect it to replace the blade belt Whenever you remove and replace the deck belt check the adjustment of the belt guides blade control linkage and the blade brake WARNING Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover removed Before removing belt cover for maintenance remove key from ignition switch and disconnect the spark plug lead Adjust Belt Tension 1 Remove the belt cover 2 Move the blade control ON 3 Measure the length of the tensioner spring SPRING LENGTH 32 34 mm 114 1546 in 4 Turn the wing nut to set the spring length 5 Check the blade brake adjustment see page 72 6 Install the belt cover FO MAINTENANCE ADJUSTMENTS Replace Belt ha INCH INCH AS No 1 Move the blade control OFF and remove the belt cover 2 Loosen the bolts of the engine pulley belt guides A These are accessible from the top of the unit 3 Loosen the pivot bolt s on the tensioner pulley s and move the belt guide s B away from the pulley 4 Loosen the guide pin s C at the driven spindle and remove the belt Remove the belt from the other pulleys 5 Place the belt in position over the pulleys and move the blade
18. ESHOOTING This section tells you what to look for if you encounter problems Engine 80 Mower 80 79 TROUBLESHOOTING Engine Doesn t start The key must be Forward speed contrals must be in NEUTRAL Fuel tank should be full of fresh fuel 43 Fuel filter should be clean and free of obstructions Fuel valve should be on page 11 Throttle should be in CHOKE for cold engine FAST for warm engine Spark plug connector should be firmly attached to the spark plug Spark plug should be correctly gapped and be free of deposits Blade control must be OFF Low power Air cleaner elements should be clean 42 Spark plug should be correctly gapped and be free of deposits page 49 Mower deck should be free of grass accumulation Tall grass should be cut at lower speeds and or higher cutting heights Incorrect carburetor or governor linkage adjustment page Mower Doesn t move 80 Forward speed controls must be out of NEUTRAL Neutral locks must be released Both pump bypass valves must be closed 28 The pump drive belt must be in good condition page 73 The hydrostatic oil should be at the correct level page 54 TROUBLESHOOTING Pulls to one side Tires should be correctly inflated The control linkages must be correctly adjusted Both pump bypass valves must be closed Vibrates Blades should be in good condition The deck must be free of any accumulation of clippings
19. NTENANCE 8 ADJUSTMENTS Use the adjusting lever to align the gt 38mm 1 2in holes in the desired 89mm 3 in position and install C 51mm 2in the adjusting bar 402mm 4in x If you are adjusting 64mm 22 from one end of the 114mm 4 in range to the other 76mm you to install the adjusting 127mm ing C 89mm 3n bar in an 140mm 5551 intermediate x position to relocate the adjusting lever for better leverage Install the finchpin s in the adjusting bar Place the adjusting lever in its storage position and secure it with its spring pin Cutting Range To change the cutting range of your mower reposition the front caster wheels on the mower deck and change the drive axle pivot position on the power unit Always shut off the engine and remove the key before changing the cutting range Front Cutting Range Adjustment 1 2 Reinstall the caster wheel Repeat the procedure for the Raise and support the front of the mower deck Remove the 4 bolts holding the caster wheel assembly to the mower deck assembly in the alternate set of holes Upper 4 holes Low Range Lower 4 holes High Range other caster wheel and lower the deck to the ground Tighten the 4 bolts on each caster wheel assembly to LOW RANGE SHOWN 42 31 8 5 65 MAINTENANCE 4 ADJUSTMENTS 6 T Follow the procedures for Front Whe
20. OWING 2 This section shows you how fo prepare your mower the lawn and yourself OPERATING THE MOWER 27 This section tells you how to operate the mower for safe effective mowing MAINTENANCE amp ADJUSTMENTS 3 15 section tells you how and when fo perform norma maintenance and adjustments f 6 TROUBLESHOOTING 79 is section felis you what to look if you encounter problems SPECIFICATIONS 83 is section provides you with Important dimensions and capacities INDEX 37 ADDITIONAL INFORMATION 89 This section gives you sources for more information about your mower MOWER SAFETY This section explains what you need to know to operate your mower safely Safety Information 2 Important Message to Employers Safety Label Locations 4 MOWER SAFE TY Safety Information Most accidents with walk behind mowers can be prevented you follow all instructions in this manual and on the mower The most common hazards according to accident statistics are discussed below along with the best way to protect yourself and others Avoid Rotating Blades rotating blade can cause serious cuts and even amputate fingers hands toes or feet Keep away from the mower _ deck whenever the engine is running If you need to work around the deck to clear a grass accumulation adjust the cutting height or for any other reason always shut off the engine and remove the key Wear heavy gloves when you need to clean the mower d
21. TORS Controls You will use these controls every time you operate the mower Fuel Valve This valve is located on the carburetor and allows fuel to flow to the engine Push it toward the engine to ON to allow fuel to flow or pull it outward for OFF Ignition Switch The ignition switch controls the engine ignition system Turn the key clockwise to the ON position or turn the key counter clockwise to the OFF position Throttle The throttle lever controls engine speed Pull it rearward to the SLOW position for idle Push it forward to the FAST position for mowing Pushing it forward past a detent for the CHOKE position applies the choke for starting a cold engine Forward Speed Control The forward speed control levers set the maximum forward speed of the mower The rear position is NEUTRAL As the levers are pushed forward the maximum speed of the mower progressively increases See page 32 for details Blade Control blade control lever engages engine power to the mower deck The forward position is ON The rear position is OFF Operator Presence Levers The operator presence levers above the hand grips are part of the safety interlock system When the blade control is ON or the forward speed controls are forward of NEUTRAL you must hold at least one lever down on the hand grips If you don t the engine will shut off CONTROLS amp INDICATORS Direction Controls The direction control levers independently c
22. a high detergent premium quality 4 stroke engine oil certified to meet Service Classification SF SG or equivalent SAE 10W 30 is recommended for general all temperature use Other viscosities snown in the chart may be used when the average temperature in your area is within the indicated range 20 0 20 40 60 80 100 F _ toto 3 20 10 0 0 20 40 C AMBIENT TEMPERATURE 46 MAINTENANCE ADJUSTMENTS Changing the Engine Oil Change the oil at the recommended interval or more frequently under extreme operating conditions Drain the oil while the engine is warm to assure rapid and complete draining 1 Install one end of a section of 14 hose over the drain outlet and place the other end in a suitable container to catch the used oil 2 Clean the area around the oll filler cap and remove it 3 the drain valve counterclockwise about 4 turns to open it Do not open the valve more than 6 turns to avoid damaging the seals 4 When the oil has drained turn the valve clockwise to close it and remove the section of hose To avoid damaging the valve do not over tighten it 5 Refill the engine with the correct amount of the recommended oil 6 After running the engine recheck the oil level and adjust if necessary Used engine oil contains substances that have been identified as carcinogenic If repeatedly left in contact with the skin for prolonged periods it may cause s
23. age on each side so that the wheels do not rotate Lengthening the rod causes forward wheel rotation shortening the rod causes rearward wheel rotation 57 MAINTENANCE ADJUSTMENTS FORWARD SPEED CONTROL ADJUSTING NUTS REVERSE 55 DIRECTION CONTROL LINKAGE ADJUSTING NUTS PUMP LEVER PUMP LEVER a ROLLER Turn the adjusting nut to lengthen the rod until forward rotation just starts e Turn the adjusting nut counting the number of turns to shorten the rod until rear rotation just starts e Turn the adjusting nut to lengthen the rod one half the number of turns you counted 8 Tighten the locknut Adjust the linkage on the other side in the same manner 98 MAINTENANCE ADJUSTMENTS 9 Release the neutral locks and cycle the direction control levers forward and backward several times Engage the neutral locks and be sure the wheels come to a complete stop Readjust the linkage if necessary 10 With the neutral locks engaged adjust both reverse springs to a length of 58 62 mm 2 3 2 4 in Speed Control Linkage Adjustment Perform this adjustment if the mower creeps when the speed control levers are in neutral and the neutral locks released 1 Raise and support the rear of the mower so that the rear wheels are clear of the ground 2 Pull the forward speed control levers into neutral and engage the neutral flocks on the direction control levers 3 Loosen the lockn
24. and put the forward speed control levers in neutral 3 Start the engine 4 Hold an operator presence lever down on the hand grip for the length of this procedure 5 Watch the rear wheels while you slowly move both speed control levers forward keeping them even Both wheels should begin turning at about the same time When the levers are both positioned about one inch fonward of neutral both wheels should rotate at about the same speed 6 Adjust the speed control rod lengths slightly if necessary Lengthening the rod slightly will increase wheel speed and cause the wheel to begin to rotate sooner e Shortening the rod slightly will decrease the wheel speed and cause the wheel to begin to rotate later 7 Tighten the locknuts and be sure that the wheels don t rotate when the levers are in neutral 8 Operate the mower on level ground to be sure that it tracks straight when the levers are even Readjust the rods slightly if necessary Be sure that the mower doesn t creep when the speed control levers are in neutral 61 MAINTENANCE 8 ADJUSTMENTS Speed Control Switch Adjustment 1 Adjust the switch bolt on the left forward speed control lever so that there is 0 5 1 0 mm 0 02 0 04 in clearance between the end of the switch bolt and the housing of the ball switch on the right forward speed control lever When the knobs of the f forward speed control levers are even the ba
25. arize yourself with the controls and how they operate Get used to the feel of the forward speed controls and direction control levers by running the engine at about half throttle small amount of time spent in familiarization will reward you with greater efficiency and reduced risk Starting the Engine Because of the risk of carbon monoxide poisoning it makes good sense to start the mower outside or at least in an open area with good ventilation Pump Bypass Valves In order to move the mower from its storage area to a safe place to start it you must open the pump bypass valves on each pump Open each valve by turning it one turn counter clockwise When you ve moved the mower to its desired position close each valve by turning it clockwise To avoid damaging the valves and their seals do not open the valves more than two turns and do not over tighten the valves when closing them When the bypass valves are open the normal braking action of the hydraulic system is bypassed Never move the mower on slopes when the bypass vaives are open Always close both bypass valves when you are finished moving the mower The mower will not move under its own power unless both bypass valves are closed 28 OPERATING THE MOWER 1 Pull the blade control lever to OFF The mower should not be started without the entire grass catcher the mulching plug or the guard in place 2 Pull both forward speed control levers t
26. as coated with oil during storage preparation the engine may smoke briefly at startup This is normal 21 TRANSPORTING and STORING 22 BEFORE MOWING This section shows you how to prepare your mower the lawn and yourself Check the Mower 24 Check the Lawn 25 Prepare Yourself 26 BEFORE MOWING Check the Mower For your safety and the service life of your equipment always inspect your mower before using it Before beginning your pre operation check be sure mower is parked on a level surface e The blade control lever is disengaged and the ground speed contro levers are in NEUTRAL e The ignition switch is off and the key is removed Walk around the mower and check its general condition Look around and underneath it for signs of fluid teaks Remove any excessive dirt and debris especially around moving components Look for signs of damage Check nuts bolts screws and pins for tightness Never operate the mower with the safety interlock system inoperative Do not attempt to bypass or defeat the system Keep all shields and covers in place while operating the mower If you find any problems or defects have them repaired before mowing Blades Before each use check each mower blade for damage or abnormal wear See 67 for details Belts Check the blade deck and pump belts for wear and correct tension 70 for details Engine Oil Check the level on the dipstick Run
27. aximum speed of the mower is controlled by the forward speed control levers Moving Forward 1 Hold down one operator presence lever The safety interlock system will shut off the engine if you move the forward speed controls out of neutral unless one of the operator presence levers is held against the hand grip 2 Move both forward speed control levers to the desired speed 3 Slightly squeeze both UNLOCK direction control levers just ud enough to release the neutral locks by pushing them forward with your thumbs If you squeeze the direction control levers too far you will engage reverse Squeeze them just far enough to release the neutral locks 4 Slowly release pressure evenly on both direction control levers and the mower will move forward Steering the Mower To steer the mower to the right gradually squeeze the right hand direction contro lever To steer the mower to the left gradually squeeze the left hand direction control lever The more you squeeze a direction control lever the slower that wheel will turn and the sharper the turn will be 30 Zero radius turns turns which the mower has forward or reverse motion just turns in place are accomplished by squeezing one direction control lever into reverse while the other is in forward Practice this maneuver at slow speeds until you become accustomed to the mowers responsiveness Stopping the Mow
28. by the Distributor s Limited Warranty Oxygenated Fuels 44 Some conventional gasolines are being blended with alcohol or ether compound These gasolines are collectively _ referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states and provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates Ethanol ethyl or grain alcohol 10 by volume MAINTENANCE 4 ADJUSTMENTS You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume Methanol methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanoi by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems lt may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of ga
29. eck or handle a blade Clear Mowing Area Mower blades can throw rocks and other objects with enough force to cause serious injury Before mowing inspect the area and remove all sticks stones pieces of wire and other loose objects Never operate the blades over gravel Keep Shields in Place Guards and shields are designed to protect you from being hit by thrown objects and from touching hot engine paris and moving components For your safety and the safety of others keep all shields in place when the engine is running Refuel with Care Gasoline is extremely flammable and gasoline vapor explode Refuel only outdoors in a well ventilated area with the engine OFF Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container SAFETY Wear Protective Clothing Wearing protective clothing will reduce your risk of injury Long pants and eye protection reduce the risk of injuries from thrown objects Sturdy shoes with aggressive soles will help protect your feet and give you better traction on slopes or uneven ground Ear protection and a helmet may be required by local ordinances or insurance policies Turn Engine Off When Not Mowing If you need to leave the mower for any reason even just to inspect the lawn ahead always turn the engine off And take the key if you go farther away Important Message to Employers an
30. el Adjustment 63 to set the desired cutting height Lower the mower deck to the ground Rear Cutting Range Adjustment 1 66 Roll the wheels to align Install the pivot bolts Open the pump bypass valves on both pumps 2 Raise and support the rear of the power unit so that the rear wheels clear the ground by about 3 inches Follow the procedures for Rear Wheel Adjustment to remove the adjusting bar and lower the wheels to the ground Remove the nut from the pivot bolt on each side of the axle assembly and remove the pivot bolts the pivot hole on the axle assembly with the alternate pivot holes in the power head and tighten the nuts on the pivot bolts to 103 Nem 76 ft lb LOW RANGE POSITION SHOWN Follow the procedures for Rear Wheel Adjustment page 64 to set the desired cutting height Tighten the wheel nuts to 47 35 ft Ib Lower the power unit to the ground 10 Close both pump bypass valves Be sure to adjust both the front and rear wheels to the same cutting height to get the best performance and cut quality MAINTENANCE amp ADJUSTMENTS Blades It is important for your safety and the safety of others that you inspect the blades for condition and correct installation before operating the mower WARNING worn cracked damaged blade can break and pieces of the broken biade can become dangerous projectiles Thrown objects can cause
31. engine to operate outside its design parameters Problems that may Affect Emissions 38 If you are aware of any of the following symptoms have your engine inspected and repaired by your authorized Honda servicing dealer Hard starting or stalling after starting e Hough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption MAINTENANCE 8 ADJUSTMENTS Proper Maintenance 15 the Owner s Responsibility Replacement Parts The emission control systems on your new Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system Maintenance Follow the Maintenance Schedule on Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 39 MAINTENANCE 8 ADJUSTMENTS Modification for High Altitude Operation 40 At high altitude the standard carburetor air fuel mixture
32. ength MINIMUM SPRING LENGTH Hook to Hook 172 mm 6 If the spring length is less than specification the belt needs to be adjusted 4 Replace the belt cover Alternate Position E Guide Pins Positioning Bolt 74 MAINTENANCE ADJUSTMENTS Adjust 1 2 3 4 5 Move the control OFF and remove the belt cover Remove the blade belt from the right discharge side spindle pulley Remove the positioning bolt and install it in the alternate position If the spring is less than minimum length with the tensioner in alternate position the belt must be replaced Install the belt over the right spindle pulley Install the belt cover Replace 1 2 10 11 Brake Remove the hair pin from the Rod brake rod Remove the rod from the brake Remove the belt cover Loosen the two belt guide pins at the center spindle pulley and remove the deck belt from the pulley band the spring will fall loose at this time Hair Pin Remove the blade belt from the right discharge side pulley then from the rest of the pulleys Remove the positioning bolt and install it in the primary position Install the over the pulleys right pulley last Install the deck belt over the center spindle pulley and tighten the belt guide pins Install the rod in brake band while attaching the spring and install the hair pin Check the brake adj
33. er To slow the mower slowly squeeze both levers the same amount the more you squeeze the slower the mower will travel When you squeeze to the neutral position the mower will stop You may hold the mower stopped by engaging the neutral locks pulling them rearward with your thumbs Remember that if you release the operator presence levers and the forward speed control levers are not in neutral the safety system will shut off the engine Reversing the Mower To reverse the direction of the mower squeeze the direction control levers toward the handgrips from the neutral position The more you squeeze the faster the mower will travel in reverse If the neutral locks are applied when you release the direction control levers they will return to neutral If the neutral locks are not applied releasing the levers will result in the machine moving forward when the forward speed controls are nat in neutral You may reverse the mower even when the forward speed controls are in neutral their operation is independent of one another Be careful when operating the mower in reverse Be aware of what is behind you Be sure of your footing steer to the right in reverse squeeze the left direction control lever more To steer to the left in reverse squeeze the right direction control lever more 31 OPERATING THE MOWER Making an Emergency Stop Starting to Mow To make an emergency stop release the ha
34. es 68 1 Reinstall the blades by placing a washer blade and spacer on the spindle bolt 2 Insert the spindle bolt up through the spindle 3 Install the nut on the spindle bolt Tighten to 88 102 N m 65 75 ft Ib torque 4 Repeat the procedure for the other blade s 5 Lower the mower deck to the ground 6 Install the belt cover with the wing nuts MAINTENANCE 4 ADJUSTMENTS Servicing the Blades dull blade may be sharpened but a blade that is worn out bent cracked or otherwise damaged must be replaced Always use genuine Honda replacement blades Substitute blades may not meet Honda specifications and may be dangerous To sharpen a blade Maintain the original angle of the blade about 309 Leave a blunt edge of 1 mm 146 Do not sharpen to a knife edge Remove an equal amount of material from each end of the blade to maintain balance Do not remove material from the inner area of the cutting edge If you need to remove material to restore the cutting edge taper the edge toward the tip Do not taper beyond 14 of the blade width Do not grind the back side of the blade Check balance of the blade by placing a dowel through the mounting hole The blade should remain horizontal one end drops remove additional material from it to make it lighter and recheck the balance TAPER THE CUTTING EDGE BLUNT EDGE E 69 MAINTENANCE amp ADJUSTM
35. id damaging the valve do not over tighten it Refill the reservoir with the correct amount of the recommended oil Start the engine and allow it to idle for 3 to 5 minutes to circulate the oil and allow any trapped air to escape Stop the engine and recheck the oil level Ch 1 6 9 Hand tighten the oil filter until the Refill the reservoir with the MAINTENANCE ADJUSTMENTS anging the Hydrostatic Oil Filter Drain the reservoir 2 Remove the oil filter with a filter wrench and let the remaining oil drain out Correctly dispose of the old oil filter Clean the filter base with a clean cloth Coat the O ring of the new filter with clean oil ring seats against the filter base Tighten the filter by hand an additional 3 4 1 turn correct amount of the recommended oil Start the engine and allow it to idle for 3 to 5 minutes to circulate the oil and allow any trapped air to escape Stop the engine and recheck the oil level Lubrication Points Grease 2 Lithium Base EP Follow the diagrams on the next page to lubricate these fittings Caster wheels 2 Caster pivots 2 e Pulley pivots 1 Forward speed control shaft 2 55 MAINTENANCE ADJUSTMENTS B FORWARD SPEED CONTROL SHAFT CASTER PIVOTS CASTER WHEELS 56 MAINTENANCE amp ADJUSTMENTS Control Linkage Adjustment any of the following conditi
36. ing a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer fill the fuel tank with fresh gasoline H only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Add gasoline stabilizer following manufacturer s instructions After adding a gasoline stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor Stop the engine and turn the fuel valve to the OFF position 19 TRANSPORTING STORING Draining the Fuel Tank and Carburetor Loosen the carburetor drain screw and turn the fuel valve x ON kl gy ON i m DRAIN SCREW Gasoline is highly flammable and explosive and you can burned or seriously injured when handling fuel Stop engine and keep heat sparks and flame away Refuel only outdoors Wipe up spills immediately Drain the fuel into an approved gasoline container Reinstall the drain bolt Engine Oil Change the engine oil page 46 Remove the spark plug page 49 Pour a tablespoon 5 10 cc of clean engine oil into the cylinder Pull the starter rope a few times to distribute the oil in the cylinder Reinstall the spark plug Grease Lubricate all grease points page 55 Transmission Check the hydrostatic oil and top off if nece
37. kin cancer Wash your hands thoroughly with soap and water as soon as possible after contact with used oil Please dispose of used engine oil and the oil containers ina manner that is compatible with the environment We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash or pour it on the ground or down a drain 47 MAINTENANCE amp ADJUSTMENTS Changing the Engine Oil Filter 1 Drain the engine oil 2 Remove the oil filter and let the remaining oil drain out Correctly dispose of the old oil filter 3 Clean the filter base with a clean cloth 4 Coat the O ring of the new filter with clean engine oil OIL FILTER 5 Hand tighten the oil filter until _ the O ring seats against the gt filter base 6 Tighten the filter by hand an additional 3 4 1 turn 7 Pour the specified amount of oil into the engine Run the for a few minutes and check for leaks in the area of the filter base 8 Stop the engine and check the oil level Adjust if necessary A Honda oil filter wrench will simplify the removal and installation of the filter The wrench P N 07912 6110001 15 available from your authorized Honda servicing dealer 48 MAINTENANCE amp ADJUSTMENTS Spark Plug 0 7 0 8 mm Recommended Types ue 0 028 0 032 in NGK BPR5ES ND W16EPR U Spark plugs of the wrong
38. ll in the switch should be depressed and the bolt SWITCH should be centered onthe BOLT ball Operator Presence Lever Operation 1 Start the engine and move the forward speed control levers forward out of neutral BALL SWITCH Slowly release each 1 operator presence lever d one at a time H should O L stop the engine and the 2 NZ N lever should touch the Front Tire Pressure 103 kPa 28 psi Rear Tire Pressure 193 kPa 15 psi Incorrect tire inflation can cause the mower not to track in a straight path Replace the tires when the tread is worn Worn out tires will not provide good traction especially on slopes and uneven ground 62 MAINTENANCE amp ADJUSTMENTS Cutting Height The cutting height of your mower can be easily adjusted within two ranges a low range of 38 mm to 89 mm 115 3 in and a high range of 89 mm to 140 mm 3 5 in Your Honda dealer assembled your mower with the wneels in the most common range for your area If you need to change the range follow the procedures in Cutting Range on Always shut off the engine and remove the key before adjusting cutting height Be sure to adjust both the front and rear wheels to the same cutting height to get the best performance and cut quality 5 Es E E gt Es E Es 8 en ee LE T Dem D gt ie tj td be E 2 Es E
39. ment 70 Blade Brake Adjustment 72 Pump Belt Replacement and Adjustment ____ 73 Blade Belt Adjustment and Replacement 48 inch deck 74 36 inch deck 76 Spark Arrester optional 78 MAINTENANCE ADJUSTMENTS The Importance Of Maintenance Good maintenance is essential for safe economical and trouble free operation It will also help reduce air pollution To help you properly care for your mower the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate the mower under unusual conditions consult a servicing dealer for recommendations applicable to your individual needs and use Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to EPA standards WARNING Incorrect maintenance or failure to correct a problem before operation can cause a malfunction which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owners manual Maintenance Safety Some of the most important safety preca
40. n Its use is explained on page 64 Indicators These indicators help you monitor the condition of the mower Hour meter The hour meter indicates the total operating time of the mower in hours and tenths of an hour It operates whenever the engine is running OIL ALERT Buzzer The Honda ALERT buzzer will sound whenever the engine oil level is below a safe operating level Whenever ou hear the buzzer stop the engine and check the oil level page 46 13 TRANSPORTING STORING This section tells you how to safely transport and store your mower Transporting your Mower Storing your Mower Storage Preparation Removal From Storage 16 17 17 21 TRANSPORTING STORING There is very important thing to remember when transporting your mower when you open the pump bypass valves to move the mower without the running engine you disable all braking action For this reason CLOSED Always close both pump bypass valves after moving the mower by hand e Always drive the mower under its own power on any incline If you must move the mower on an incline without running the engine use a suitable device winch block amp tackle come along Remember that the mower weighs over 272 kg 600 Ib When moving the mower without running the engine do not move it at more than a walking speed or more than 91 meters 100 yd Be sure the bypass valves are open at least one turn but not m
41. n system Transistorized magneto Valve clearance 0 08 0 12 mm 0 003 0 005 in Intake NSK WIGEPR U uneaded gasotne 96 pump ocane min 85 INDEX A Air Cleaner 37 B Battery 74 Belts Blade Belt YO Deck Belt 66 PumpBelt 72 Blade Brake 69 Blade Control 11 Blades _ 62 Choke 10 Customer Service 89 Cutting Height 58 D Direction Controls Location a on 9 Operation 25 Engine Fuel 38 AMM 41 Stating 24 F Forward Speed Control 10 Operation 26 Front Wheel Adjustment 58 Fuel Valve _ _ 11 87 INDEX H Hourmeter Ignition Switch N Neutral Lock Operator Presence Levers ae we ewe 2 Preoperation Check Publications Pump Bypass Valves zu e ee Operation Precautions R Rear Wheel Adjustment 5 Safety Rules Serial Number Locations 9 Spark Arrester Service Storage res T Throttle Carbureto
42. nd grips When you let go of the operator presence levers the safety interlock system will stop the engine and the mower will come to a stop within 3 to 6 feet WARNING Objects hidden in the lawn can be thrown by the mower blades Thrown objects can cause serious injury e Clear lawn of all debris before mowing Do not operate the mower without either the discharge chute mulching plug or the entire grass catcher in place e Wear eye protection Keep people and pets away For best cutting performance always mow with the throttle lever in FAST position To begin mowing Be sure the direction controls are locked in neutral Hold down one operator presence lever Move both ground speed control levers to the desired mowing speed Always begin mowing with a slow ground speed Increase the ground speed to match mowing conditions and your experience Slowly move the blade control lever to ON to start the blades rotating Slightly squeeze both direction control levers and release the neutral locks by pushing them forward with your thumbs Slowly release pressure on both direction control levers and begin mowing Adjusting your Speed 32 Adjust the forward speed controls to set your best mowing speed If the mower does not travel in a straight path you may move one of the ground speed control levers ahead of the other to make the mower track straight THE MOWER If
43. ng Tne choke should be fully open 3 If you need to adjust the clearance loosen the cable holder and adjust the position of the cable housing 4 Next set the throttle lever to CHOKE 5 Check that the choke valve on the carburetor is fully closed isn t bend the U section of the choke rod 6 Adjust the stopper screw so that it just contacts the choke lever when the choke is fully closed 7 Check maximum engine speed 53 MAINTENANCE amp ADJUSTMENTS Hydrostatic Oil Hydrostatic Oil Capacity 9 8 liters 10 4 quarts Checking the Level Oil Recommendation 1 Remove the cap on the 2 The oil level should be even reservoir with the lower hole Add oil to bring it to the correct level SAE 10 40 engine oil meeting or exceeding Service Classification 5 Changing the 54 Change the at the recommended interval or more frequently under extreme operating conditions Drain the oil while it is warm to assure rapid and complete draining Install ane end of a section of 14 inch hose over the drain outlet and place the other end in a suitable container to catch the used oil Clean the area around the oil filler cap and remove it Turn the drain valve counterclockwise about 4 turns to open it Do not open the valve more than 6 turns to avoid damaging the seals When the oil has drained turn the valve clockwise to close it and remove the section of hose To avo
44. ning the engine with a low oil level will cause engine damage See page 46 details Hydrostatic Oil Check the oil level in the reservoir See page 54 for details Fuel Remove the cap on the tank and check the fuel level See page 43 refueling details 24 BEFORE MOWING Air Filter Check that the air cleaner elements are clean and in good condition See page 42 information on servicing the air cleaner Cutting Height The cutting height of your mower should be set for the mowing conditions and should be in the same position front and rear See page 6310 adjust cutting height Tire Pressure Check the tires for proper inflation page 62 Check the Lawn For your safety and the safety of others always inspect the area before mowing Objects Anything which can be picked up by the blades and thrown is a potential hazard to you and others Look for things like stones sticks bones and wire and remove them from the mowing area People People and animals near the mowing area can move into your mowing path or into a position where they could be struck by thrown objects Clear the area of people especially children and pets Their safety 15 your responsibility Lawn Check the length and condition of the grass Adjust your mowing speed and cutting height accordingly Avoid mowing wet grass Not only does mowing wet grass result in poor cut quality also affords poor traction increasing yo
45. o NEUTRAL The safety interlock system will prevent the engine from starting if the blade control is ON or if the forward speed controls are not in neutral Do not attempt to disconnect or modify the satety interlock system 3 Squeeze both direction control levers to their neutral position and apply the neutral locks by pulling them back with your thumbs Be sure both pump bypass valves are closed Open the fuel valve Turn the key ON To start a cold engine move the throttle lever to the CHOKE position Tn ao A To restart a warm engine move the throttle lever to the FAST position 8 When the engine warms up move the throttle lever back to the FAST position for mowing or the SLOW position to idle For best engine performance move the throttle lever out of CHOKE position as soon as the engine will run smoothly Using the Direction Controls The direction control levers allow you to control the speed and direction of the mower NEUTRAL FORWARD OPERATING THE MOWER EN The mower will quickly respond to the position of the levers avoid abrupt changes of direction squeeze the levers slowly rather than treating them like a switch Operate the mower with the forward speed control levers in their SLOW position until you are completely familiar with the sensitivity of the direction control levers The direction control levers are spring loaded to their forward or engaged position In this position the m
46. ons are noticed the control linkage must be adjusted Mower creeps when the direction control levers are positioned in neutral with the neutral locks Mower creeps when the forward speed control levers are in neutral Mower will not track straight when the forward speed control levers are even Before beginning the adjustment procedure check the tires for correct inflation and even wear Worn or incorrectly inflated tires can cause tracking problems Check the hydrostatic level Operate the mower to bring the hydrostatic oil up to operating temperature At times during this adjustment procedure you must run the engine Be sure there is adequate ventilation Direction Control Linkage Adjustment 4 5 Perform this adjustment if the mower creeps when the direction control levers are locked in neutral with the neutral locks Raise and support the rear of the mower so that the rear wheels are clear of the ground Lock the direction control levers in neutral with the neutral locks Move the forward speed control levers full forward so that the rollers do not contact the pump levers Adjust the direction control linkage on each side so that the control arms on the side of each pump are vertical Hold an operator presence lever down on the hand grip for the length of this procedure Start the engine and move the throttle lever to FAST Loosen the locknuts and adjust the direction control link
47. ontro each drive wheel for steering slowing and reversing Squeezing the levers toward the hand grips slows the mower from the maximum forward speed Squeezing the levers further to their neutral position stops forward motion Squeezing the levers past neutral reverses direction REVERSE NEUTRAL FORWARD The use of the direction control levers is explained on Neutral Lock The neutral locks hold the direction control levers in their neutral position Pulling the locks rearward prevents the direction control levers from going into their forward position The levers can still be squeezed for reverse however When the neutral locks are engaged and you release the levers after reversing they will return to neutral 12 CONTROLS amp INDICATORS Pump Bypass Valves The bypass valves on each drive pump allow you to move the mower when the engine is not running Open the valves by turning them one tum counterclockwise See pages 16 28 CLOSED Front Wheel Adjustment Spacers The front wheel adjustment spacers allow adjustment of the cutting height in either of two ranges a low range of 38 mm to 89 mm 1 3 in and a high range of 89 mm to 140 mm 3 5 in Their use is explained page 63 Rear Wheel Adjustment Bar The rear wheel adjustment bar allows adjustment of the cutting height in either of two ranges a low range of 38 mm to 89 mm 1 3 in and a high range of 89 mm to 140 mm 3 5 i
48. ore than two turns See page 28 more information on operating the bypass valves Transporting your Mower Use a loading ramp to get the mower on and offthe vehicle Be sure both the ramps and vehicle are able to support the weight of the mower and operator When the mower is in position turn the fuel valve OFF to prevent the possibility of fuel leaking Tie the mower down front and rear with ropes or straps You may use the front caster brackets and the rear cross member to tie the mower down Be careful not to damage hoses or linkages when tightening the ropes or straps Remember that the engine and exhaust system become hot during operation Avoid touching them 16 TRANSPORTING STORING Storing your Mower When leaving your mower unattended always e Turn key off and remove it from the ignition switch e Turn the fuel valve off e If you opened the pump bypass valves close both of them If you re leaving the mower on a slope even a slight one block both drive wheels front and rear Storage Preparation Proper storage preparation is essential for keeping your mower trouble free and looking good The following steps will help to keep rust and corrosion from impairing your mower s function and appearance and will make the engine easier to start when you use the mower again Cleaning Wash the mower including the underside of the mower deck Engine Wash the engine by hand and be
49. others is very important We have provided Important safety messages in this manual and on the lawn mower Please read these messages carefully A safety message alerts you to potential hazards that can hurt you and others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These mean DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING You CAN be KILLED or SERIOUSLY HURT il you don t follow instructions A CAUTION You CAN be HURT if you don t follow instructions Each message tells you what the hazard is what can happen and what you can do to avoid or reduce injury Damage Prevention Messages You will also see other important messages that preceded by the word NOTICE This word means NOTICE Your lawn mower or other property be damaged if you don t follow instructions The purpose of these messages is to help prevent damage to your lawn mower other property or the environment sur 5 Turn to the beginning of each section for a complete list of subjects MOWER SAFETY This section explains what you need to know to operate your mower Safely CONTROLS amp INDICATORS This section shows you where controls are located and tells you what they do and how they work TRANSPORTING and STORING 45 This section tells you how fo safely transport and store your mower BEFORE M
50. r Adjustment Transporting 88 ADDITIONAL INFORMATION This section gives you sources for more information about your mower Honda Publications 90 Customer Service Information 91 69 ADDITIONAL INFORMATION Honda Publications These publications will give you additional information about maintaining your mower You may order them from an authorized Honda servicing dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Parts Catalog This provides a complete pictorial parts listing 90 ADDITIONAL INFORMATION Customer Service Information Honda Power Equipment dealerships are staffed by trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management Almost all problems are solved in this way If you are not satisfied with the decision made by the dealership s management contact Honda Power Equipment Customer Service Office You can write to Honda Power Equipment Division Customer Service Office 4475 River Green Parkway Duluth GA 30136 2565 Or telephone 404 497 6400 When you write or call please give us this information e Identification number power unit and mower deck of the dealer who sold the mower
51. rks and flame away e Refuel only outdoors e Wipe up spills immediately Never refuel the mower inside a building where fumes may reach an open flame or spark Keep gasoline away from appliance pilot lights electric motors etc Refuel in a well ventilated area before starting the engine If the engine has been running allow it to cool Avoid overfilling the tank or spilling fuel 43 MAINTENANCE 6 ADJUSTMENTS Spilled fuel not only creates a fire hazard it can cause environmental damage Wipe up spills immediately Dispose of gasoline properly Fuel Recommendation Use unleaded gasoline with a pump octane rating of 86 or higher This engine is certifled to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixtures Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging a metallic rapping noise when operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load the engine can be damaged Try using fresh gasoline in the tank or change brands of gasoline If spark knock or pinging persists contact your authorized Honda Commercial Mower dealer Running the engine with persistent spark knock or pinging can cause engine damage This type of damage is not covered
52. serious injury Inspect the blades regularly and do not operate the mower with a worn or damaged blade The blades are subject to wear during normal operation and should be inspected regularly If a blade strikes an object it may be damaged Immediately stop the mower and inspect the blades Before working on or around the blades disconnect the spark plugs connectors from the spark plugs This will prevent the engine from starting inadvertently Always wear heavy gloves to protect your hands when working with or near the mower blades J NEW WORN BENT CRACKED Inspecting the Blades 1 Tum the ignition switch Key OFF and remove the key from the switch 2 Move the blade control lever OFF 3 Raise and support the front of the mower deck 67 MAINTENANCE 8 ADJUSTMENTS 4 Inspect each of the blades for cracking bending deep nicking and wear If any of the blades show signs of damage or excessive wear remove the blades for a more thorough inspection Removing the Blades 1 Turn the ignition switch key OFF and remove the key from the switch Move the blade control lever OFF w A Remove the belt cover by fo removing the wing nuts 4 Raise and support the front of the mower deck uu 5 Remove the nut from the spindle bolt Remove the spindle bolt a washer blade and spacer 7 Repeat the procedure for the other blade s Installing the Blad
53. size or incorrect heat range can cause damage Checking the Spark Plug Remove the spark plug with a Inspect the spark plug for For good performance the spark plug should have the correct gap and be free of deposits Disconnect the spark plug and remove any dirt from around the spark plug area 1346 inch spark plug wrench excessively worn electrodes chips or cracks in the insulator or excessive deposits Replace the spark plug if you have any doubts about its condition Measure the electrode gap with a wire gap gauge Adjust the gap to 0 7 0 8 mm 0 028 0 031 in by bending the side electrode Install the plug carefully by hand to avoid cross threading Use a spark plug wrench to tighten the plug enough to compress the washer For a used plug tighten to 1 4 of a turn after the spark plug seats For a new plug tighten turn after the spark plug seats A loose spark plug become hot enough to damage the engine Over tightening a spark plug can damage the threads in the engine Install the spark plug cap on the plug 49 MAINTENANCE 6 ADJUSTMENTS Valve Clearance Adjust the valves at the recommended interval Valve clearance inspection and adjustment must be done with the engine cold Remove the valve cover Set the piston at top dead center of the compression stroke both valves will be fully closed The cutout mark in
54. soline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Changing the Fuel Filter Change the fuel filter at the recommended interval 1 Clamp off the fuel line between the fuel tank and the filter to prevent fuel flow Use a small gt locking pliers hemostat or other BA _ device LT 2 Place a container under the filler _ to catch any spilled fuel uE Er 8 jim 4 Install the new filter with the arrow pointing toward the engine 3 Squeeze the hose clamps and remove the lines from the filter 5 Be sure the clamps securely hold the fuel lines to the new filter 6 Dispose of the old filter and any spilled fuel properly and remove the clamping device from the fuel line 7 Check for leaks 45 MAINTENANCE 4 ADJUSTMENTS Engine Oil Engine Oil Capacity 1 1 liters 1 2 US quarts Checking the Level Upper limit 8 Lower limit 1 Clean the area around the oil filler cap remove it and the dipstick with a clean cloth 2 Insert the dipstick without screwing it into the filler neck Remove the dipstick and check the oil level an it 3 If the oil level is low near the bottom of the dipstick add enough oil to bring the level to the upper mark on the dipstick Running the engine with a low oil level will cause engine damage Recommended Oil Use
55. ssary page 54 Tires Check tire air pressure page 62 20 TRANSPORTING STORING Placing in Storage if your mower will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a electric motor where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of fuel leakage Park the mower on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the mower to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover nonporous cover will trap moisture around the mower promoting rust and corrosion Removal From Storage Check your mower as described in the Before Mowing chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinder w
56. system Make sure all connections are tight and all hoses and lines are in good condition before operating the mower Remember that your authorized Honda servicing dealer knows your mower best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement 37 MAINTENANCE 6 ADJUSTMENTS Emission Control System Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic The U S and California Clean Air Act EPA and California regulations require ali manufacturers to furnish written instruction describing the operation and maintenance of emission control systems The following instructions and procedures must be followed order to keep the emissions from your Honda engine within the emisston standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the
57. t B to set the length Retighten nut A Recheck the position of the swivel and adjust if necessary 6 Install the belt cover MAINTENANCE 6 ADJUSTMENTS Pump Belt Replacement and Adjustment Replace the pump belt if it is worn frayed or glazed You will need to remove the deck belt from the engine pulley first page 70 _ Pivot bolt Remove 1 Adjust the rear mowing height to the highest setting 2 Remove the tensioner pivot bolt and remove the tensioner 3 Remove the belt Install and Adjust 1 Place the belt over the engine and pump pulleys 2 Connect the tensioner spring to the tensioner and the S hook on the deck There are three holes in the deck of the power unit for the S hook Use the nearest hole when the belt is new As the belt ages move the S hook to farther holes 3 Insert the pivot bolt through the tensioner and into the power unit Install and tighten the flange nut Readjust the mowing height 7 amp ADJUSTMENTS Blade Belt Adjustment and Replacement 48 inch deck Replace the blade belt if it is worn frayed or glazed WARNING Moving belts pulleys cause serious injuries not operate engine with the belt cover removed Before removing belt cover for maintenance remove key from ignition switch and disconnect the spark plug lead Inspect 1 Move the blade control OFF and remove the belt cover 2 Check the tensioner spring l
58. the starter pulley will align with the index mark on the fan cover when the piston is at top dead center of either the compression or exhaust stroke Measure the clearance between the rocker arm and the valve with a feeler gauge INTAKE 0 08 0 12 mm 0 003 0 005 in EXHAUST 0 13 0 17 mm 0 005 0 007 in To adjust valve clearance hold the rocker arm pivot and loosen the pivot lock nut Turn the rocker arm pivot to obtain the specified clearance Hold the rocker arm pivot and tighten the pivot lock nut Recheck the clearance and readjust if necessary Install the valve cover A ROCKER ARM PIVOT PIVOT LOCK 50 MAINTENANCE 3 ADJUSTMENTS Carburetor Perform this adjustment if the idle is slow or rough and you re sure the air cleaner and spark plug are in good condition Start the engine in an area with adequate ventilation to avoid carbon monoxide bern e poisoning Allow the STOP SCREW engine to warm to normal operating temperature EN Er With the throttle lever at SLOW turn the throttle stop screw to set the dle speed IDLE SPEED 1750 7 rpm The pilot screw is fitted with a limiter cap to prevent excessive enrichment of the fuel air mixture Do not attempt PILOT remove the limiter cap it SCREW gt cannot be removed without breaking the pilot screw 51 MAINTENANCE ADJUSTMENTS Governor Linkage ch 52
59. to you e Name and address of the dealer who services your mower Date of purchase Your name address and telephone number A detailed description of the problem 91 yt __ __ _ _ E 31V 4710 BEEN Printed an cea y50970h 00X31 VE4 7100 Paper PRINTED IN U S A
60. ur risk of losing your footing 25 BEFORE MOWING Prepare Yourself Your safety is your responsibility A little time spent in preparation will significantly reduce your risk Knowledge Read and understand this manual Know what the controls do and how to operate them Familiarize yourself with the mower and its operation before you begin mowing Know what to do in case of emergencies Clothing Wearing protective clothing will reduce your risk of injury Long pants and eye protection reduce the risk of injuries from thrown objects Sturdy shoes with aggressive soles will help protect your feet and give you better traction on slopes or uneven ground While the sound level of the mower 15 well within safe limits hearing protection will further protect your hearing 26 OPERATING THE MOWER This section tells you how to operate the mower for safe and effective mowing Starting the Engine Using the Direction Controls Starting to Mow Adjusting your Speed Mowing Tips Parking the Mower 28 29 32 32 33 34 27 OPERATING THE MOWER _ The Honda Mid Size Commercial Mower is a powerful highiy maneuverable mower designed to enhance the productivity of a lawn care professional You will need a complete understanding of its operation and a certain amount of practice with its controls to safely realize the full potential of this mower Read this section completely before operating the mower Take time to famili
61. ustment 72 Install the belt cover 75 MAINTENANCE ADJUSTMENTS Blade Belt Adjustment and Replacement 36 inch deck Replace the blade belt if it is worn frayed or glazed Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover removed Before removing belt cover for maintenance remove key from ignition switch and disconnect the spark plug lead Inspect 1 Move the blade control OFF and remove the belt cover 2 Check the tensioner spring length MINIMUM SPRING LENGTH Hook to Hook 120 140 mm 4 5 in 3 If the spring length is less than specification the belt needs to be adjusted CA YFF E Tensioner spring E oO dij DN pin Alternate Primary position m positions T HHR 76 MAINTENANCE amp ADJUSTMENTS Adjust 1 Move the blade control OFF and remove the belt cover 2 Remove the blade belt from the right discharge side spindle pulley 3 Remove the spring hook and install it in the next position There are two alternate positions If the spring is less than minimum length with the tensioner in alternate position the belt must be replaced 4 Install the belt over the right spindle pulley 5 Install the belt cover Replace 1 Remove the belt cover 2 Loosen the belt guide pin at the right spindle pulley and remove the deck belt from the pulley Rd
62. utions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual 36 ADJUSTMENTS Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts For certain operations the mower must be raised off the ground Be sure the mower is solidly supported before you put any part of your body under the mower Wear heavy gloves when near the mower deck belts or blades The mower uses pressurized oil to run the hydrostatic drive
63. uts on the forward speed linkage 4 Adjust the length of the rod until the roller just contacts the pump control arm with no slack in the linkage Adjust the other side the same way 5 Start the engine move the throttle lever to FAST and release the neutral locks 6 Adjust each forward speed linkage rod e Turn the adjusting nut to lengthen the rod until forward rotation just starts Turn the adjusting nut counting the number of turns to shorten the rod until rear rotation just starts Turn the adjusting nut to lengthen the rod one half the number of turns you counted 7 Tighten the locknut Adjust the linkage on the other side in the same manner 8 Adjust both pump arm springs to a length of 115 125 mm 4 5 4 9 in 9 Cycle the forward speed control levers from neutral to full forward a number of times Readjust the linkage to stop any wheel rotation in neutral 59 MAINTENANCE 8 ADJUSTMENTS FORWARD SPEED _ ONTROLS FORWARD SPEED 7 CONTROL LINKAGE LOCKNUTS 135 125 mm ws 4 9 in udi _ a ROLLER 60 B MAINTENANCE 4 ADJUSTMENTS Tracking Adjustment Perform this adjustment if the mower will not track stralght with the speed control levers evenly positioned Adjust the speed control linkage before performing this adjustment 1 Raise and support the rear of the mower so that the rear wheels are clear of the ground 2 Release the neutral locks
64. will be too rich Performance will decrease and fuel consumption will increase very rich mixture will also foul the spark plug and cause hard starting High altitude performance can be improved by specific modifications to the carburetor If you always operate your mower at altitudes above 1 800 meters 6 000 feet have an authorized Honda commercial mower dealer perform this carburetor modification Even with the modification engine horsepower will decrease about 3 5 for each 300 meter 1000 foot increase in altitude The effect of alt tude on horsepower will be greater than this if no carburetor modification is made When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 1 800 meters 6 000 feet with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have an authorized servicing dealer return the carburetor to original factory specifications MAINTENANCE ADJUSTMENTS Every Every Every Every 50 100 300 1000 Hours Hours Hours Hours Hours NY Check bolttorque Engine Oil Check e J Maintenance Schedule Blades Engine Oil Filter Spark Plug Replace Spark Arrester optional part Clean Valve Clearance Adjust Fuel Filter Replace Fuel Line Check Replace Hydrostatic Check Change 7

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