Husqvarna 7021CH1 Lawn Mower User Manual
Contents
1. To keep your drive system working properly the gear case and area around the drive should be kept clean and free of trash build up Clean under the drive cover twice a season e The gear case is filled with lubricant to the proper level at the factory The only time the lubricant needs attention is if service has been performed on the gear case e If lubricant is required use only ELF Multis EP00 Do not substitute GRASS CATCHER e The grass catcher may be hosed with water but must be dry when used e Check your grass catcher often for damage or dete rioration Through normal use it will wear If catcher needs replacing replace only with approved replace ment catcher shown in the Repair Parts section of this manual Give the mower model number when ordering MAINTENANCE ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SG SL Select the oil s SAE viscosity grade according to your expected operating temperature SAE VISCOSITY GRADES F 20 0 30 32 40 60 80 100 C_ 30 20 10 0 10 20 30 40 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE NOTE Multi viscosity oils 5W30 10W30 etc improve starting in cold weather and you should check your engine oil level frequently to avoid possible engine damage from running low on oil Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year C2. in the Maintenance section of this manual CYLINDER 1 Remove spark plug 2 Pour one ounce 29 ml of oil through spark plug hole into cylinder 3 Pull starter handle slowly a few times to distribute oil 4 Replace with new spark plug OTHER e Do not store gasoline from one season to another e Replace your gasoline can if your can starts to rust Rust and or dirt in your gasoline will cause problems e If possible store your unit indoors and cover it to give protection from dust and dirt e 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 CAUTION Never store the lawn mower with gasoline in the tank inside a build ing where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Does not start 1 Dirty air filter 1 Clean replace air filter 2 Out of fuel 2 Fill fuel tank 3 Stale fuel 3 Empty fuel tank and refill tank with fresh clean gasoline 4 Water in fuel 4 Empty fuel tank and refill tank with fresh clean gasoline 5 Spark plug wire is disconnected 5 Connect wire to plug 6 Bad spark plug 6 Replace spark plug 7 Loose blade or broken blade adapter 7
3. CHART 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 1 Change more often if operating under a heavy load or in high outdoor temperatures 2 Service more often if operating in dirty or dusty conditions 3 Replace blades more often when mowing in sandy soil 4 Charge 48 hours at end of season 5 And after each 5 hours of use LUBRICATION CHART WHEEL ADJUSTER ON EACH WHEEL ENGINE OIL D MULCHER DOOR HINGE PIN O HANDLE BRACKET MOUNTING PINS D SPRAY LUBRICANT 9 SEE ENGINE IN MAINTENANCE SECTION MAINTENANCE LAWN MOWER Always observe safety rules when performing maintenance TIRES e Keep tires free of gasoline oil or insect control chem icals which can harm rubber e Avoid stumps stones deep ruts sharp objects and other hazards that may cause tire damage DRIVE WHEELS Check front drive wheels each time before you mow to be sure they move freely The wheels not turning freely means trash grass cuttings etc are in the drive wheel area and must be cleaned to free drive wheels If necessary to clean the drive wheels be sure to clean both front wheels 1 Remove hubcaps locknuts and washers 2 Remove wheels from wheel adjusters 3 Remove any
4. Tighten blade bolt or replace blade adapter 8 Control bar in released position 8 Depress control bar to handle 9 Control bar defective 9 Replace control bar 10 Fuel valve lever if equipped in OFF position 10 Turn fuel valve lever to the ON position 11 Weak battery if equipped 11 Charge battery 12 Disconnected battery connector if equipped 12 Connect battery to engine Loss of power 1 Rear of lawn mower housing or cutting 1 Raise cutting height blade dragging in heavy grass 2 Cutting too much grass 2 Raise cutting height 3 Dirty air filter 3 Clean replace air filter 4 Buildup of grass leaves and trash under 4 Clean underside of mower housing mower 5 Too much oil in engine 5 Check oil level 6 Walking speed too fast 6 Cut at slower walking speed Poor cut 1 Worn bent or loose blade 1 Replace blade Tighten blade bolt uneven 2 Wheel heights uneven 2 Set all wheels at same height 3 Buildup of grass leaves and trash under 3 Clean underside of mower housing mower Excessive 1 Worn bent or loose blade 1 Replace blade Tighten blade bolt vibration 2 Bent engine crankshaft 2 Contact a qualified service center Starter rope 1 Engine flywheel brake is on when control 1 Depress control bar to upper handle before hard to pull bar is released pulling starter rope 2 Bent engine crankshaft 2 Contact a qualified service center 3 Blade adapter broken 3 Replace blade adapter 4 Blade
5. 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 1 Remove upper handle and all wire tie s securing cable s to lower hanale 2 Remove hairpin cotters from lower handle bracket mounting pin 3 Squeeze lower handle into remove from mounting pins Turn lower handle over to raise or lower handle 5 Squeeze lower handle in and position holes onto mounting pins on handle bracket 6 Reassemble upper handle and all parts removed from lower handle gt SQUEEZE TO ADJUST LOWER HANDLE SIS RK MOUNTING PIN SIZSS ZZ gt 1 HANDLE HAIRPIN I BRACKET COTTER lt lt lt gt ASA MOWING POSITION MOWING POSITION HAIRPIN COTTER HANDLE MOUNTING BRACKET PIN ROTATE ENGINE FIG 16 ENGINE SPEED Your engine speed has been factory set Do not attempt to increase engine speed or it may result in personal injury If you believe that the engine is running too fast or too slow take your lawn mower to an authorized service center for repair and adjustment CARBURETOR Your carburetor is not adjustable If your engine does not operate properly due to suspected carburetor problems take your lawn mower to an authorized service center for repair and or adjustment IMPORTANT NEVERTAMPERWITHTHE ENGINE GOVERNOR WHICH IS FACTORY SET FOR PROPER ENGINE SPEED OVERSPEEDING THE ENGINE ABOVE THE
6. cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings It may also be necessary to reduce ground speed and or run the lawn mower over the area a second time e For extremely heavy cutting reduce the width of cut by overlapping previously cut path and mow slowly e For better grass bagging and most cutting conditions the engine speed should be set in the fast position e Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass To prevent this regularly hose catcher off with water and let dry before using e Keep top of engine around starter clear and clean of grass clippings and chaff This will help engine air flow and extend engine life MULCHING MOWING TIPS 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 clip pings 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 biode grade 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 e 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
7. dragging in grass 4 Move lawn mower to cut grass or other hard surface before starting Grass catcher 1 Cutting height too low 1 Raise cutting height not filling 2 Lift on blade worn off 2 Replace blade if so equipped 3 Catcher not venting air 3 Clean grass catcher Hard to push 1 Grass is too high or wheel height is too low 1 Raise cutting height 2 Rear of lawn mower housing or cutting 2 Raise rear of lawn mower housing one 1 blade dragging in heavy grass setting higher 3 Grass catcher too full 3 Empty grass catcher 4 Handle height position not right for you 4 Adjust handle height to suit Loss of drive 1 Belt wear 1 Check replace drive belt or slowing of 2 Belt off of pulley 2 Check reinstall drive belt drive speed 3 Drive cable worn or broken 3 Replace drive cable 14 SERVICE NOTES ROTARY LAWN MOWER MODEL NUMBER 7021CH1 96143000600 PRODUCT NUMBER 961 43 00 06 ROTARY LAWN MOWER MODEL NUMBER 7021CH1 96143000600 PRODUCT NUMBER 961 43 00 06 KEY PART NO NO 1 5321925 18 2 532 15 34 18 3 582 18 55 78 4 53218 27 55 5 53219 15 74 6 53219 18 56 7 582 05 17 93 8 532 06 64 26 9 53218 04 79 10 532 12 84 15 11 532 18 25 38 12 532 18 25 39 2 18 817 06 04 10 S 14 532 18 25 43 15 53218 25 45 16 532 18 00 71 17 532 18 00 72 18 532 13 20 04 19 532 17 95 85 20 532 18 90 05 21 532 08 86 52 24 Ge 25 532 15 04 06 26 532 08 39 23 27 532 18
8. in daylight or good artificial light Donot operate the machine while under the influence of alcohol or drugs e Never operate machine in wet grass Always be sure of your footing keep a firm hold on the handle and walk never run e Disengage the self propelled mechanism or drive clutch onmowerssoequippedbeforestartingtheengine motor e If the equipment should start to vibrate abnormally stop the engine motor and check immediately for the cause Vibration is generally a warning of trouble e Always wear safety goggles or safety glasses with side shields when operating mower Il SLOPE OPERATION Slopes are a major factor related to slip and fall accidents which can result in severe injury All slopes require extra caution If you feel uneasy on a slope do not mow it DO e Mowacross the face of slopes never up and down Exer cise extreme caution when changing direction on slopes Remove obstacles such as rocks tree limbs etc e Watch for holes ruts or bumps Tall grass can hide obstacles DO NOT e Do not trim near drop offs ditches or embankments The operator could lose footing or balance e Do not trim excessively steep slopes Donotmow on wet grass Reduced footing could cause slipping lil CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain whe
9. is the early afternoon At this time the grass has dried yet the newly cut area will not be exposed to direct sunlight e 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 See Fig 9 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 overlap ping previously cut path and mow slowly FIG 9 e 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 perpendicular to the first cut path Change your cutting pattern from week to week Mow north south one week then change to east west the next week This helps prevent matting graining of lawn MAINTENANCE BEFORE MAINTENANCE o SCHEDULE USE Check for Loose Fasteners Clean Inspect Grass Catcher Check Tires Check Drive Wheels Clean Lawn Mower Clean under Drive Cover Check Drive Belt Pulleys Check Sharpen Replace Blade Lubrication Clean and Recharge Battery kkk Check Engine Oil level Change Engine Oil Clean Air Filter Inspect Muffler Replace Spark Plug Replace Air Filter Paper Cartridge Empty fuel system or add Stabilizer Check for Loose Fasteners Y Clean
10. raised lugs on the adapter 10 3 Besurethe trailing edge of blade opposite sharp edge is up toward the engine 4 Install the blade bolt with the lock washer and hardened washer into blade adapter and crankshaft 5 Use block of wood between blade and lawn mower housing and tighten the blade bolt turning clockwise The recommended tightening torque is 35 40 ft lbs IMPORTANT BLADE BOLT IS HEAT TREATED IF BOLT NEEDS REPLACING REPLACE ONLY WITH APPROVED BOLT SHOWN IN THE REPAIR PARTS SECTION OF THIS MANUAL BLADE ADAPTER KEY CRANKSHAFT KEYWAY BLADE LOCK WASHER Fi mm Y X ad Er CRANKSHAFT BOLT HARDENED WASHER BLADE TRAILING EDGE FIG 10 TO SHARPEN BLADE NOTE We do not recommend sharpening blade but if you do be sure the blade is balanced Care should be taken to keep the blade balanced An unbalanced blade will cause eventual damage to lawn mower or engine e The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen while on the mower e 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 GEAR CASE
11. trash or grass cuttings from inside the dust cover pinion and or drive wheel gear teeth 4 Put wheels back in place NOTE If after cleaning the drive wheels do not turn freely contact a qualified service center BLADE CARE For best results mower blade must be kept sharp Replace a bent or damaged blade CAUTION Use only areplacementblade approved by the manufacturer of your mower Using a blade not approved by the manufacturer of your mower is hazardous could damage your mower and void your warranty TO REMOVE BLADE See Fig 10 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug 2 Turn lawn mower on its side Make sure air filter and carburetor are up 3 Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt NOTE Protect your hands with gloves and or wrap blade with heavy cloth 4 Remove blade bolt by turning counter clockwise 5 Remove blade and attaching hardware bolt lock washer and hardened washer NOTE Remove the blade adapter and check the key inside hub of blade adapter The key must be in good condition to work properly Replace adapter if damaged TO REPLACE BLADE See Fig 10 1 Position the blade adapter on the engine crankshaft Be sure key in adapter and crankshaft keyway are aligned 2 Position the blade on the blade adapter aligning the two 2 holes in the blade with the
12. 1 12 and 45 Danger Decal Blade Adapter Pulley Blade 21 Hardened Washer Helical Washer 3 8 Hex Head Machine Screw 3 8 24 x 1 3 8 Grade 8 Discharge Deflector Hinge Bracket Assembly Spring Rod Hinge Locknut Hex Mulcher Door O Ring Washer Flat 3 8 Warning Decal not shown Owner s Manual English French NOTE All component dimensions given in U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your lawn mower and void your warranty 66 72 74 aan ROTARY LAWN MOWER MODEL NUMBER 7021CH1 96143000600 PRODUCT NUMBER 961 43 00 06 ROTARY LAWN MOWER MODEL NUMBER 7021CH1 96143000600 PRODUCT NUMBER 961 43 00 06 KEY PART NO NO 1 532 18 45 88 2 532 08 80 58 3 532 17 52 62 4 532 15 87 55 5 532 17 54 36 6 532 15 04 95 7 532 19 17 30 8 532 18 06 26 9 532 14 52 12 11 532 18 07 67 12 81200 00 58 13 532 13 70 54 532 18 94 03 16 53206 77 25 18 532 18 55 74 28 532 18 55 79 31 532 13 20 10 32 532 18 94 07 35 532 15 15 21 6L P 36 532 18 01 84 38 87380 04 00 40 532 13 70 90 41 532 15 15 20 DESCRIPTION Drive Control Assembly Bearing Wheel Adjuster Pan Head Tapping Screw 10 24 x 2 3 4 Screw V Belt Retainer Spring Nut Hex Flanged 1 4 20 Hubcap Locknut Wheel 8 Tire Assembly E Ring Pinion Dust Cover Washer 1 2 Selector Knob Drive Cover Hex Flange Nut
13. 55 72 28 532 16 08 28 30 532 18 25 41 31 532 18 55 75 DESCRIPTION Upper Handle Lower Handle Control Bar Engine Zone Control Cable Handle Bolt Handle Knob Hairpin Cotter Wire Tie Kit Rear Door Includes Key 16 and 17 Pop Rivet Support Bracket LH Support Bracket RH Screw 1 4 20 x 5 8 Handle Bracket Assembly LH Handle Bracket Assembly RH Spring Rear Door LH Spring Rear Door RH Nut Hex Rope Guide Rear Skirt Hinge Screw 1 4 20 x 1 1 4 Engine Briggs amp Stratton Model Number 12H602 For engine service and replacement parts call Briggs amp Stratton at 1 800 233 3723 Screw Hex Head Threaded Rolled 3 8 16 x 1 1 8 Nut Hex Flanged Wheel Assembly Rear Shoulder Bolt 5 16 18 x 33 Axle Arm Assembly Rear RH Selector Knob KEY PART NO NO 32 532 18 25 37 33 87380 05 00 34 532 18 25 42 35 532 19 18 53 36 532 18 41 93 37 532 15 00 78 38 81911 22 06 41 532 19 23 25 43 532 18 87 84 44 532 18 55 83 45 532 10 73 39 46 532 18 91 79 47 532 18 90 28 48 53285 10 74 49 532 85 02 63 50 53285 10 84 59 532 18 55 82 60 532 17 57 35 61 532 17 52 85 62 532 17 56 50 63 87380 04 00 64 532 18 55 76 65 532 18 81 52 66 532 08 83 48 a 532 16 23 00 532 19 36 97 DESCRIPTION Selector Spring Locknut Axle Arm Assembly Rear LH Hubcap Bolt Thread Cutting Screw w Sems 5 16 18 x 3 4 Washer Screw Debris Shield Debris Shield Kit Lawn Mower Housing Includes Key Numbers 10 1
14. D Husqvarna 7021CH1 Owner s Manual 532 19 39 67 10 22 04 BY Printed in U S A SAFETY RULES A Safe Operation Practices for Walk Behind Mowers IMPORTANT THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH Look for this symbol to point out im portant 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 WARNING Engine exhaust some of its constituents and certain vehicle compo nents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CAUTION Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped To avoid severe burns on contact stay away from these areas I GENERAL OPERATION Read understand and follow all instructions on the machine and in the manual s before starting Be thor oughly familiar with the controls an
15. FACTORY HIGH SPEED SETTING CAN BE DANGEROUS IF YOU THINK THE ENGINE GOVERNED HIGH SPEED NEEDS ADJUSTING CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER WHICH HAS PROPER EQUIPMENT AND EXPERIENCE TO 12 MAKE ANY NECESSARY ADJUSTMENTS 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 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 1 Clean entire lawn mower See CLEANING in the Maintenance section of this manual 2 LubricateasshowninMaintenancesectionofthis manual 3 Be sure that all nuts bolts screws and pins are se curely fastened Inspect moving parts for damage breakage and wear Replace if necessary 4 Touch up all rusted or chipped paint surfaces sand lightly before painting HANDLE See Figs 17 and 18 You can fold your lawn mower handle for storage 1 Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket then move handle forward 2 Loosen upper handle mounting bolts enough to allow upper handle to be folded back IMPORTANT WHEN FOLDING THE HANDLE FOR STORAGE OR TRANSPORTATION BE SURE TO FOLD THE HANDLE AS SHOWN OR YOU MAY DAMAGE THE CONTROL CABLES e Whensettingupyourhandlefromthestorageposition the lower handle will automatically lock into mowing pos
16. ING See Fig 5 e Lift rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins Toconvertto mulching or discharging operation remove grass catcher and close rear door HANDLE FIG 5 SIDE DISCHARGING See Fig 6 Rear door must be closed Open mulcher door and install discharge deflector under door as shown Mower is now ready for discharging operation e Toconvertto mulching or bagging operation discharge deflector must be removed and mulcher door must be closed OPERATION DISCHARGE DEFLECTOR 7 FIG 6 SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING 1 Rear door closed FOR REAR BAGGING 1 Grass catcher installed FOR SIDE DISCHARGING 1 Rear door closed 2 Discharge deflector installed 7 2 Mulcher door closed 2 Mulcher door closed CAUTION Do not run your lawn mower without rear door closed or approved grass catcher in place Never attempt to operate the lawn mower with the rear door removed or propped open TO EMPTY GRASS CATCHER See Fig 7 1 Lift up on grass catcher using the frame handle 2 Remove grass catcher with clippings from under lawn mower handle 3 Empty clippings from bag using both frame handle and bag handle NOTE Do not drag the bag when emptying it will cause unnecessary wear BAG HANDLE BEFORE STARTING ENGINE ADD OIL See Fig 8 Your lawnmower is shipped w
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18. Inspect Grass Catcher Y CheckTires wv Check Drive Wheels vY Clean Lawn Mower f Clean under Drive Cover Check Drive Belt Pulleys Check Sharpen Replace Blade Lubrication Clean and Recharge Battery Check Engine Oillevel v Change Engine Oi Clean Air Filter LI Inspect Muffler _ o Replace Spark Plug f Replace Air Filter Paper Cartridge Empty fuel system or add Stabilizer if so equipped Electric Start mowers xxx Power Propelled mowers xxxx Use a scraper to clean under deck 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 At least once a season check to see if you should make any of the adjustments described in the Service and Ad justments section of this manual e Atleast 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 e Follow the maintenance schedule in this manual BEFORE EACH USE 1 Check engine oil level 2 Check for loose fasteners LUBRICATION Keep unit well lubricated See LUBRICATION
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20. Pulley Drive Kit Wheel Adjuster LH Includes Knob and Bearing Gear Case Assembly Complete Locknut 1 4 20 Spring Tension Kit Wheel Adjuster RH Includes Knob and Bearing KEY PART NO NO 54 532 19 47 24 55 532 17 57 39 57 532 18 88 15 60 532 18 34 97 61 532 18 34 98 62 532 18 34 99 63 532 18 35 00 64 532 18 35 01 65 532 18 35 02 66 532 18 35 03 67 532 18 35 04 68 532 18 35 05 69 532 18 35 06 70 532 18 35 07 71 532 18 35 08 72 532 18 35 09 73 532 18 35 10 74 532 18 35 11 75 532 18 35 12 76 532 18 35 13 77 532 18 35 14 DESCRIPTION Grassbag Assembly Driveshaft Cover Frame Grassbag Case Lower Case Upper Gear 27 Teeth Lever Clutch Spring Return Shaft Input Dog Movable Dog Fixed Wire Formed Bearing Ball Fork Shift Seal Output Shaft Washer Seal Case Bushing Shaft Output Screw Seal Input Shaft Use Dow Corning 709 to reseal Gear Case Halves NOTE All component dimensions given in U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your lawn mower and void your warranty 2003 c 18 8 LES 69282 ON SHO 1BYg peoy aJ111soje1S 6vgZ VNYVAOSNH gase INOA ul Jejesp e 10 ZYAMSNH 008 1 Hules Aq 10 10 9911p suoydaja eso y jo sabed MOJI A SU YBnoAy pajeso ewou eq ued Jajesp eulenbsnH pezuoyine uy Ajuenem siy Aq paano zou eje sebieyo lani
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22. and should not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any effective working order by the operator A spark arrester for the muffler is available through your nearest authorized If a spark arrester is used it should be maintained in CONGRATULATIONS on your purchase of a new lawn mower lthas been designed engineered and manufactured to give you the best possible dependability and performance Should you experience any problem you cannot easily remedy please contact your nearest authorized service center department We have competent well trained technicians and the proper tools to service or repair this lawn mower Please read and retain this manual The instructions will enable you to assemble and maintain your lawn mower properly Always observe the SAFETY RULES SERIAL NUMBER DATE OF PURCHASE THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON ADECAL ATTACHED TOTHE REAR OF THE LAWN MOWER HOUSING YOU SHOULD RECORD BOTH SERIAL NUMBERAND DATE OF PURCHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE PRODUCT SPECIFICATIONS 1 6 Quarts Unleaded Regular Only SAE 30 above 32 F SAE 5W 30 below 32 F 20 Ounces Champion RC12YC 35 40 ft lbs 47 54 N m Gasoline Capacity and Type Oil Type API SG SL Oil Capac
23. ary to complete the assembly have been placed in the parts bag 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 TO REMOVE LAWN MOWER FROM CARTON 1 Remove loose parts included with mower 2 Cut down two end corners of carton and lay end panel down flat 3 Remove all packing materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle 4 Roll lawn mower out of carton and check carton thor ougly for additional loose parts HOW TO SET UP YOUR LAWN MOWER TO UNFOLD HANDLE See Fig 1 IMPORTANT UNFOLD HANDLE CAREFULLY SO AS NOT TO PINCH OR DAMAGE CONTROL CABLES 1 Raise handles until lower handle section locks into place in mowing position 2 Remove protective padding raise upper handle sec tion into place on lower handle and tighten both handle knobs 3 Remove handle padding holding operator presence control bar to upper handle Your handles may be adjusted for your mowing comfort Refer to ADJUST HANDLE in the Service and Adjustments section of this manual OPERATOR PRESENCE CONTROL BAR MOWING _POSITION LOWER FIG 1 TO ASSEMBLE GRASS CATCHER See Fig 2 1 Put grass catcher frame into grass bag with rigid part of bag on the bottom Make sure the frame handle is outside of the bag top 2 Slip v
24. d the proper use of the machine before starting Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times Only allow responsible individuals who are familiar with the instructions to operate the machine Clear the area of objects such as rocks toys wire bones sticks etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mow ing Stop machine if anyone enters the area Do not operate the mower when barefoot or wearing open sandals Always wear substantial foot wear Do not pull mower backwards unless absolutely nec essary Always look down and behind before and while moving backwards Never direct discharged material toward anyone Avoid discharging material against a wall or obstruc tion Material may richochet back toward the operator Stop the blade when crossing gravel surfaces Do not operate the mower without proper guards plates grass catcher or other safety protective devices in place See manufacturer s instructions for proper operation and installation of accessories Only use accessories approved by the manufacturer e Stop the blade s when crossing gravel drives walks or roads e Stop the engine motor whenever you leave the equip ment before cleaning the mower or unclogging the chute e Shutthe engine motor off and wait until the blade comes to complete stop before removing grass catcher Mow only
25. en the engine is running STARTER HANDLE used for starting the engine OPERATOR PRESENCE CONTROL BAR must be held PRIMER pumps additional fuel from the carburetor to the fone handle to start the engine Release to stop cylinder for use when starting a cold engine MULCHER DOOR allows conversion to discharge or bagging operation DRIVE CONTROL LEVER used to engage power pro pelled forward motion of lawn mower OPERATION WEAR TOUR 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 per Pere forming any adjustments or repairs We recommend standard safety glasses or a wide vision safety mask THAN NO SIGHT over spectacles HOW TO USE YOUR LAWN MOWER ENGINE SPEED The engine speed was set at the factory for optimum per formance Speed is not adjustable ENGINE ZONE CONTROL 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 e Yourlawn moweris equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower DRIVE CONTROL See Fig 3 e Self propell
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27. heck the crankcase oil level before starting the engine and after each five 5 hours of continuous use Tighten oil plug securely each time you check the oil level TO CHANGE ENGINE OIL See Fig 11 NOTE Before tipping lawn mower to drain oil empty fuel tank by running engine until fuel tank is empty 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug 2 Remove engine oil cap lay aside on a clean surface 3 Tip lawn mower on its side as shown and drain oil into a suitable container Rock lawn mower back and forth to remove any oil trapped inside of engine A container FIG 11 4 Wipe off any spilled oil from mower or side of engine 5 Slowly pour oil down the oil fill spout stopping every few ounces to check the oil level with the dipstick 6 Stop adding oil when you reach the FULL mark on the dipstick Wait a minute to allow oil to settle 7 Continue adding small amounts of oil rechecking the dipstick until oil level settles at FULL DO NOT over fill or engine will smoke heavily from the muffler on startup 8 Always be sure to retighten oil dipstick before starting engine 9 Reconnect spark plug wire to spark plug AIR FILTER See Fig 12 Your engine will not run properly using a dirty air filter Replace paper cartridge every 100 hours of operation or every season whichever occurs first Service air cleaner more often under dusty condit
28. ing is controlled by holding the operator presence control bar down to the handle and push ing the drive control lever forward until it clicks then releasing the lever e Forward motion will stop when the operator presence control bar is released To stop forward motion without stopping engine release the operator presence con trol bar slightly until the drive control disengages Hold operator presence control bar down against handle to continue mowing without self propelling e To keep drive control engaged when turning corners push down on handle and lift front wheels off ground while turning lawn mower OPERATOR PRESENCE CONTROL BAR DRIVE CONTROL DRIVE CONTROL DISENGAGED TO ENGAGE DRIVE CONTROL FIG 3 TO ADJUST CUTTING HEIGHT See Fig 4 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 e Tochange 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 LEVER BACKWARD TO LOWER MOWER LEVER FORWARD TO RAISE MOWER FIG 4 TO CONVERT MOWER Your lawn mower was shipped ready to be used as a mulcher To convert to bagging or discharging REAR BAGG
29. inyl 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 EG x nn OPENING FIG 2 TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher To convert mower to bagging or discharging see TO CONVERT MOWER in the Operation section of this manual OPERATION KNOW YOUR LAWN MOWER READ THIS OWNER S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for future reference These symbols may appear on your lawn mower or in literature supplied with the product Learn and understand their meaning AAN se Y CAUTION ENGINE ENGINE FAST SLOW CHOKE FUEL OIL DANGER KEEP HANDS OR WARNING ON OFF AND FEET AWAY OPERATOR PRESENCE Er E CONTROL a BAR N DRIVE CONTROL LEVER N py HANDLE KNOB STARTER i cae 5 DN ENGINE OIL CAP WITH DIPSTICK GRASS MUFFLER CATHER E DRIVE COVER GASOLINE WHEEL FILLER CAP ADJUSTER ON EACH WHEEL AIR FILTER MULCHER DOOR IMPORTANT This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine MEETS CPSC SAFETY REQUIREMENTS Our rotary walk behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U S Consumer Product Safety Commission The blade turns wh
30. ions 1 Loosen screws and remove cover 2 Carefully remove cartridge 3 Clean by gently tapping on a flat surface If very dirty replace cartridge CAUTION Petroleum solvents suchas kerosene are not to be used to clean cartridge They may cause deterioration of the cartridge Do not oil cartridge Do not use pressurized air to clean or dry cartridge 4 Install cartridge then replace cover MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage SPARK PLUG Replace spark plug at the beginning of each mowing season or after every 100 hours of operation whichever occurs first Spark plug type and gap setting are shown in the PRODUCT SPECIFICATIONS section of this manual CLEANING IMPORTANT FOR BEST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH CLEAN THE UNDERSIDE OF YOUR MOWER AFTER EACH USE A CAUTION Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug e Clean the underside of your lawn mower by scraping to remove build up of grass and trash e Clean engine often to keep trash from accumulating A clogged engine runs hotter and shortens engine life e Keep finished surfaces wheels free of gasoline oil etc We do not recommend using a garden hose to clean lawn mower unless the electrical system muffler air filter and carburetor are covered to keep water out Water in engine ca
31. ithout oil in the engine For type and grade of oil to use see ENGINE in the Maintenance section of this manual 1 Be sure lawnmower is level 2 Remove oil dipstick from oil fill spout 3 Engine holds 20 ounces of oil For type and grade of oil to use see ENGINE in the Maintenance section of this manual 4 Pour oil slowly Do not overfill Wait one minute to allow oil to settle Insert and tighten dipstick then remove it to check oil level IMPORTANT e Check oil level before each use Add oil if needed Fill to full line on dipstick e Change the oil after every 25 hours of operation or each season You may need to change the oil more often under dusty dirty conditions See TO CHANGE EN GINE OIL in the Maintenance section of this manual OPERATION GASOLINE ENGINE FIG 8 ADD GASOLINE See Fig 8 e Fill fuel tank to bottom of tank filler neck Do not over fill Use fresh clean regular unleaded gasoline with a minimum of 87 octane Do not mix oil with gasoline Purchase fuel in quantities that can be used within 30 days to assure fuel freshness CAUTION Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame Alcohol blended fuels called gasohol or using ethanol or methanol can at tract moisture which leadsto separation and formation of acids during storage Acidic gas can damage the fuel sys tem of an engine while in storage To avoid e
32. ition SQUEEZE TO ADJUST LOWER HANDLE ISIN x SS SS S 2S 2S 2S 3338 ei gt Kee ISS S Se Se 25 SL 2S Se Se SSS Se Sse 232 SIS Sos Se SS gt gt gt SS IS OPERATOR PRESENCE CONTROL HANDLE KNOB LOWER HANDLE ENGINE FUEL SYSTEM IMPORTANT ITISIMPORTANT TO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALCOHOL BLENDED FUELS CALLED GASOHOL OR USING ETHANOL OR METHANOL CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION AND FORMATION OF ACIDS DURING STORAGE ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE Empty the fuel tank by starting the engine and letting it run until the fuel lines and carburetor are empty e Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur e Use fresh fuel next season NOTE Fuel stabilizer is an acceptable alternative in mini mizing 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 empty the gas tank and carburetor if using fuel stabilizer ENGINE OIL Drain oil with engine warm and replace with clean en gine oil See ENGINE
33. ity Spark Plug Gap 030 Blade Bolt Torque CUSTOMER RESPONSIBILITIES Read and observe the safety rules e Follow a regular schedule in maintaining caring for and using your lawn mower e Follow the instructions under Maintenance and Stor age sections of this owner s manual TABLE OF CONTENTS SAFETY RULES nuesnnnannsnnnsnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnn nn 2 3 PRODUCT SPECIFICATIONS nnnenneeennennnnnnnnnnennnnnnnn 3 CUSTOMER RESPONSIBILITIEG cssceseeeseeees 3 ASSEMBLY E 4 OPERATION 2 cosccioccctscssnctsceccsccescesceorcenceecadeseceesscevece 5 8 MAINTENANCE SCHEDULE ccseessesseesseesereees 9 MAINTENANCE nuussnseennennnnennnnnnnnnnnnnnnnennnnnnnnnnnnnnn en 9 11 SERVICE AND ADJUSTMENTS nnurssneennnnennnnnnnenennn 12 4 10 2 7 1 c AA RIESE A SEHE ROF RER ERBERSOETEREREEESREREEEOR 13 TROUBLESHOOTING uuenuesnnnennnnnnnnnunnnnnnnnnnnennnnn nn 14 REPAIR PARTS ae ae 16 19 WARRANT uunnsssssnnensnnnnunnnnnnunnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnn 20 ASSEMBLY Read these instructions and this manualin its entirety before you attempt to assemble or operate your new lawn mower IMPORTANT THIS LAWN MOWER IS SHIPPED WITH OUT OIL OR GASOLINE IN THE ENGINE Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for ship ping purposes All parts such as nuts washers bolts etc necess
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35. le lock open device e If fuel is spilled on clothing change clothing immedi ately e Never overfill fuel tank Replace gas cap and tighten securely V GENERAL SERVICE e Never run a machine inside a closed area Never make adjustments or repairs with the engine motor running Disconnect spark plug wire and keep wire away from plug to prevent accidental starting e Keep nuts and bolts especially blade attachement bolts tight and keep equipment in good condition e Never tamper with safety devices Check their proper operation regularly e Keep machine free of grass leaves or other debris build up Clean oil or fuel spillage Allow machine to cool before storing e Stop and inspect the equipment if you strike an object Repair if necessary before restarting e Never attempt to make wheel height adjustments while the engine motor is running e Grass catcher components are subject to wear dam age and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recom mended parts when necessary Mower blade is sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing it Donotchangethe engine governor setting or overspeed the engine e Maintain or replace safety and instruction labels as necessary service centre AWARNING This lawn mower is equipped with an internal combustion engine
36. n result in shortened engine life CLEAN UNDER DRIVE COVER Clean under drive cover at least twice a season Scrape un derside of cover with putty knife or similar tool to remove any 11 build up of trash or grass on underside of drive cover SERVICE AND ADJUSTMENTS CAUTION TO AVOID SERIOUS INJURY BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS Release control bar and stop engine 1 A 2 Make sure the blade and all moving parts have completely stopped 3 Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug LAWN MOWER TO ADJUST CUTTING HEIGHT See TO ADJUST CUTTING HEIGHT in the Operation section of this manual REAR DEFLECTOR 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 s mowing position If the deflector becomes damaged it should be replaced TO REMOVE DRIVE BELT See Fig 13 1 Remove drive cover Remove belt from gearcase pulley by pushing down on pulley and rolling belt off it Turn mower on its side air filter and carburetor up Remove blade Remove debris shield Remove belt from engine pulley on crankshaft pico drive belt by reversing above steps NOTE Always use factory approved belt to assure fit and long life nap DRIVE COVER PUSH DOWN FIG 13 TO ADJUST HANDLE See Figs 14 thru 16 The handle
37. ngine problems the fuel system should be emptied before storage of 30 days or longer Empty the gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel next season See Storage Instructions for additional information Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur TO STOP ENGINE e To stop engine release operator presence control bar NOTE In cooler weather it may be necessary to repeat priming steps In warmer weather over priming may cause flooding and engine will not start If you do flood engine wait a few minutes before attempting to start and do not repeat priming steps TO START ENGINE NOTE Due to protective coatings on the engine a small amount of smoke may be present during the initial use of the product and should be considered normal 1 To start a cold engine push primer three 3 times before trying to start Use a firm push This step is not usually necessary when starting an engine which has already run for a few minutes 2 Hold operator presence control bar down to the handle and pull starter handle quickly Do not allow starter rope to snap back MOWING TIPS CAUTION Do not use de thatcher blade attachments on your mower Such at tachments are hazardous will damage yourmowerandcouldvoidyourwarranty e Under certain conditions such as very tall grass it may be necessary to raise the height of
38. re you last saw them e Keep children out of the trimming area and under the watchful care of another responsible adult e Be alert and turn machine off if children enter the area e Before and while walking backwards look behind and down for small children e Never allow children to operate the machine e Useextracare when approaching blind corners shrubs trees or other objects that may obscure vision IV SAFE HANDLING OF GASOLINE Use extreme care in handling gasoline Gasoline is ex tremely flammable and the vapors are explosive e Extinguish all cigarettes cigars pipes and other sources of ignition e Use only an approved container Never remove gas cap or add fuel with the engine run ning Allow engine to cool before refueling e Never refuel the machine indoors Never store the machine or fuel container where there is an open flame spark or pilot light such as a water heater or on other appliances e Never fill containers inside a vehicle on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment with a portable container rather than from a gasoline dispenser nozzle e Keep the nozzle in contact with the rim of the fuel tank or container opening tall times until fueling is complete Do not use a nozz
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