Husqvarna 5521CHV Lawn Mower User Manual
Contents
1. 2 Mulcher door closed FOR SIDE DISCHARGING 1 Rear door closed 2 Discharge deflector installed CAUTION Donotrun 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 CATCHER FRAME HANDLE DISCHARGE DEFLECTOR BAG HANDLE FIG 7 FIG 6 7 OPERATION BEFORE STARTING ENGINE ADD OIL See Figs 7 and 8 Your lawnmower is shipped without oil in the engine Fortype and grade of oil to use see ENGINE in the Maintenance section of this manual CAUTION DO NOT overfill engine with oil or it will smoke heavily from the muf fler on startup 1 Be sure lawnmower is level 2 Remove oil dipstick from oil fill spout 3 You receive a container of oil with the unit Slowly pour the entire container down the oil fill spout into the engine 4 Insert and tighten dipstick 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 dusty2. OVERSPEEDING THE ENGINE ABOVE THE 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 13 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 Lubricate as shown in the Maintenance section of this 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 16 and 17 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 When setting up your handle from the storage position
3. Screw V Belt Bar Control Drive Nut Hex Hubcap Locknut Pinion Assembly LH Wheel amp Tire Assembly E Ring Pinion Assembly RH Dust Cover Retainer Drive RH Washer 1 2 x 1 1 2 x 134 Pawl Selector Knob Spring Torsion Disc Drive Seal Pinion Retainer Drive LH Pan Head Tapping Screw 10 24 x 2 3 4 Drive Cover Hex Flange Nut Drive Pulley KEY PART NO NO 35 532 18 09 15 36 532 18 72 12 38 873 80 04 00 40 532 18 22 26 41 532 18 09 14 54 532 18 97 65 55 53217 57 39 57 532 18 88 15 60 532 18 35 13 61 532 18 75 25 62 532 18 75 27 63 532 18 35 05 64 532 18 34 99 65 532 18 35 09 66 532 18 75 29 67 532 18 35 11 68 532 18 75 26 69 532 18 35 14 70 53218 35 06 71 532 18 75 28 72 53218 35 08 DESCRIPTION Kit Wheel Adjuster LH Includes Knob and Bearing Gear Case Assembly Complete Locknut 1 4 20 Spring Kit Wheel Adjuster RH Includes Knob and Bearing Grassbag Assembly Driveshaft Cover Frame Screw Case Lower Shaft Input Wire Formed Gear 27 Teeth Washer Shaft Output Bushing Case Upper Seal Input Shaft Bearing Ball Spacer Seal Output Shaft Use Dow Corning 709 to reseal Gear Case Halves NOTE All component dimensions given in U S inches 1 inch 2 25 4 mm 2002 Ecd l8 8 LES 6928Z ON eHONLUD peoy aIjAsajeIs 6p Z VNYVADSNH ease INOA UI Je eep 10 ZIAMSNH 008 Buijjeo Aq 10 10 9911p aUOYda 9 e20 y jo sobed MOIIS
4. dirty conditions See TO CHANGE EN GINE OIL in the Maintenance section of this manual OIL FILLER CAP DIPSTICK XX X UPPER LIMIT CODO EIN AAA LOWER LIMIT GASOLINE FILLER CAP ADD GASOLINE See Fig 8 Fillfuel 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 leads to separation and formation of acids during storage Acidic gas can damage the fuel sys tem of an engine while in storage To avoid engine 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 Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon TO START ENGINE See Fig 9 NOTE Due to pr
5. Do not trim near drop offs ditches or embankments The operator could lose footing or balance Do not trim excessively steep slopes Do not mow on wet grass Reduced footing could cause slipping CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them Keep children out of the trimming area and under the watchful care of another responsible adult Be alert and turn machine off if children enter the area Before and while walking backwards look behind and down for small children Never allow children to operate the machine Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision IV SERVICE Use extra care in handling gasoline and other fuels They are flammable and vapors are explosive Use only an approved container Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling Do not smoke Never refuel the machine indoors Never store the machine or fuel container inside where there is an open flame such as a water heater Never run a machine inside a closed area Never make adjustments or repairs with the engine motor running Disconnect the spark plug wire and keep the wire away from the plug to prevent accidental starting Keep nuts and bolts
6. H Husqvarna 5521CHV Owner s Manual For Parts and Service call 1 800 448 7543 532 18 90 60 Rev 3 07 28 04 BY rad BY 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 DO NOT I GENERAL OPERATION e Read understand and follow all instructions on the machine and in the manual s before starting Be thor oughly familiar with the controls and the proper use of the machine before starting e Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times e Only allow responsible individuals who are familiar with the instructions to operate the machine e Clear the area of objects such as rocks toys wire bones sticks etc which could be picked up and thrown by the blade e 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 e Do not pull mower backwards unless absolutely nec essary Always look down and behind before and while moving backwards e Do not operate the mower without proper guards plates grass catcher or other safety protective devices in place See manufacturers instructions f
7. adapter broken 3 Replace blade adapter 4 Blade 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 Put belt on pulleys replace belts if broken 4 Loose drive control system 4 Adjust drive control 15 ROTARY LAWN MOWER MODEL NUMBER 5521CHV 5521CHVA PRODUCT NUMBER 954 22 38 83 12 3 13 di 83 E 88 86 o5 45 84 ZI ROTARY LAWN MOWER MODEL NUMBER 5521CHV 5521CHVA PRODUCT NUMBER 954 22 38 83 KEY PART NO NO 532 18 60 24 532 15 34 18 532 18 60 11 532 18 27 55 532 13 19 59 532 18 55 77 532 05 17 93 532 06 64 26 532 18 04 79 532 12 84 15 532 18 25 38 532 18 25 39 817 06 04 10 532 18 25 43 532 18 25 45 532 18 00 71 532 18 00 72 18 532 1
8. especially blade attachement bolts tight and keep equipment in good condition Never tamper with safety devices Check their proper operation regularly Keep machine free of grass leaves or other debris build up Clean oil or fuel spillage Allow machine to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting Never attempt to make wheel height adjustments while the engine motor is running Grass catcher components are subject to wear 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 blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Donotchange the engine governor setting or overspeed the engine 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 components contain or emit chemi cals known to the State of California to cause cancer and birth defects or other reproductive harm CONGRATULATIONS on your purchase of a ne
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10. out Water in engine can result in shortened engine life CLEAN UNDER DRIVE COVER Clean under drive cover at leasttwice a season Scrape un derside of cover with putty knife or similartoolto remove any 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 1 Release control bar and stop engine 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 and belt keeper 2 Remove belt from gearcase pulley by pushing down on pulley and rolling belt off it 3 Turnlawnmoweronitsside withairfilterandcarburetorup 4 Remove blade and debris shield 5 Remove belt from engine pulley on crankshaft TO REPLACE DRIVE BELT See Fig 13 1 Install new belt on engine pulley 2 Reinstall debris shield and blade 3 Return mower to upright position 4 Install new belt on gearc
11. 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 CATCHER FRAME E HANDLE 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 OO 9 IN ge e CAUTION ENGINE ENGINE FAST SLOW CHOKE FUEL OIL DANGER KEEP HANDS ORWARNING ON OFF AND FEET AWAY m DRIVE OPERATOR PRESENCE CONTROL BAR CONTROL BAR STARTER HANDLE GRASS CATCHER ENGINE OIL CAP WITH DIPSTICK HANDLE KNOB GASOLINE FILLER CAP FUEL VALVE LEVER AIR FILTER HOUSING DRIVE COVER MULCHER DOOR MUFFLER 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
12. 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 Figs 1 and 2 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 UPPER HANDLE LOWER HANDLE MOWING POSITION 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 vinyl bindings
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15. 73 92 532 13 20 04 93 532 18 63 62 S 532 16 23 00 532 18 90 60 DESCRIPTION Axle Arm Assembly LR Washer Bolt Thread Cutting Screw w Sems 5 16 18 x 3 4 Washer Washer Keeper Belt Screw Screw Belt Cover Belt Cover Bottom Lawn Mower Housing Includes Key Numbers 10 11 12 and 45 Danger Decal Blade Adapter Blade 21 Hardened Washer Helical Washer 3 8 24 x 1 3 8 Grade 8 Hex Head Machine Screw 3 8 24 x 1 3 8 Grade 8 Bracket Upstop Screw Mulch Door Hinge Bracket Assembly Spring Rod Hinge Locknut Clipping Deflector Hubcap Nut Hex Grip Foam Warning Decal Not Shown Owner s Manual English French NOTE All component dimensions given in U S inches 1 inch 2 25 4 mm ROTARY LAWN MOWER MODEL NUMBER 5521CHV 5521CHVA PRODUCT NUMBER 954 22 38 83 4 TU dio o Ll 6L ROTARY LAWN MOWER MODEL NUMBER 5521CHV 5521CHVA PRODUCT NUMBER 954 22 38 83 KEY PART NO NO 532 18 91 82 532 16 99 11 532 17 51 03 532 18 56 81 532 16 97 78 532 18 89 76 532 75 11 52 532 18 06 26 532 14 52 12 532 18 82 92 532 18 07 67 812 00 00 58 532 18 82 93 532 18 05 04 532 17 51 02 532 06 77 25 532 17 50 98 532 18 55 74 532 18 82 91 20 532 17 51 04 21 532 17 51 01 23 532 17 51 05 26 532 17 52 62 28 532 18 55 79 31 532 13 20 10 32 532 18 94 06 OONDOARWN Lll lll OONDARWN O DESCRIPTION Vari Speed Drive Control Assembly Bearing Wheel Adjuster Gear Pinion
16. 8 81 52 19 53217 95 85 20 532 18 90 05 21 532 08 86 52 22 532 18 50 05 23 53218 77 23 24 SONDA RONa ca clc NOOR WONM O 25 532 15 04 06 26 53208 39 23 27 53218 55 72 28 53216 08 28 29 53208 83 48 30 5321825 41 31 532 18 55 75 32 532 18 25 37 33 873 80 05 00 DESCRIPTION Upper Handle Includes Foam Grip Lower Handle Control Bar Engine Zone Control Cable Handle Bolt Handle Knob Hairpin Cotter Wire Tie Rear Door Kit Includes Key 16 and 17 Pop Rivet Support Bracket LH Support Bracket RH Screw 1 4 20 x 5 8 Handle Bracket Assembly Left Handle Bracket Assembly Right Spring LH Spring RH O Ring Rope Guide Rear Skirt Hinge Screw 1 4 20 x 1 1 4 Engine Pulley Hi Pro Key Engine Honda Model Number GCV160 Order parts from engine manufacturer Hex Head Thread Rolling Screw 3 8 16 x 1 1 8 Hex Flange Nut Wheel Shoulder Bolt 5 16 18 x 33 Washer Flat 3 8 Axle Arm Assembly RR Selector Knob Selector Spring Locknut KEY PART NO NO 34 532 18 25 42 35 532 12 50 78 36 53218 41 93 37 53215 00 78 38 53218 39 01 39 53285 10 74 40 532 18 81 02 41 532 17 37 15 42 532 18 80 40 43 532 18 70 38 44 53218 55 83 45 532 10 73 39 46 532 18 45 90 47 53217 61 35 48 532 18 60 39 49 532 85 02 63 50 532 85 10 84 51 532 12 51 62 52 53275 06 34 83 532 18 55 76 84 532 17 57 35 85 532 17 52 85 86 532 17 56 50 87 87380 04 00 88 532 18 55 82 91 532 18 55
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18. EST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH SEE CLEANING INTHEMAINTENANCESECTIONOFTHISMANUAL 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 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 10 If the lawn is over grown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass For extremely heavy mulching reduce your width of cut by overlapping previously cut path and mow slowly i ny VOD UN 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 e Change your cutting pattern f
19. GAGED 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 BAGGING See Fig 5 e Lift rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins e Toconvertto mulching or discharging operation remove grass catcher and close rear door SIDE DISCHARGING See Fig 6 e Rear door must be closed e Open mulcher door and install discharge deflector under door as shown e Mower is now ready for discharging operation Toconvertto mulching or bagging operation discharge deflector must be removed and mulcher door must be closed OPERATION SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER GRASS FOR MULCHING CATCHER HANDLE 1 Rear door closed 2 Mulcher door closed FOR REAR BAGGING 1 Grass catcher installed
20. ase pulley 5 Reinstall belt keeper and drive cover NOTE Always use factory approved belt to assure fit and long life COVER PUSH DOWN FIG 13 TO ADJUST HANDLE See Figs 14 and 15 The handle can be mounted in a high or low position The mounting holes in the bottom of lower handle are off center for raising or lowering the handle 1 Remove upper handle and all wire tie s securing cable s to lower handle 2 Remove hairpin cotters from lower handle bracket mounting pin 3 Squeeze lower handle into remove it from mounting pins 4 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 LOWER HANDLE MOWING POSITION MOWING POSITION LOW POSITION FIG 15 HIGH POSITION ENGINE 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
21. d 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 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 CD WHEEL ADJUSTER ON EACH WHEEL ENGINE OIL CD MULCHER DOOR HINGE PIN CD REAR DOOR HINGE CD HANDLE BRACKET MOUNTING PINS CD SPRAY LUBRICANT 2 SEE ENGINE IN MAINTENANCE SECTION MAINTENANCE LAWN MOWER Always observe safety rules when performing any main tenance 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 i
22. d replace with clean en gine oil See ENGINE in the Maintenance section of this manual CYLINDER 1 Remove spark plug 2 Pourone 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 f 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 Allowthe engineto cool before storing in any enclosure TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Does notstart 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 s
23. e Bolt Torque 35 40 ft Ibs CUSTOMER RESPONSIBILITIES Read and observe the safety rules 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 eren nennen nnn 2 3 PRODUCT SPECIFICATIONS eene 3 CUSTOMER RESPONSIBILITIES 3 ASSEMBLY 1 tioeirecic ces etea decet str v aeree brane r niina 4 OPERATION cscssactscotcsateecsectderecccesasetvccsuecetees 5 9 MAINTENANCE SCHEDULE 10 MAINTENANCE eere 10 12 SERVICE AND ADJUSTMENTS 13 STORAGE isso 14 TROUBLESHOOTING eere 15 REPAIR PARTS eere 16 19 WARRANTY eeesseeeeeeeeeses eene nnn tnna asina aaa ennenen 20 ASSEMBLY Read these instructions and this manual in 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 necessary to complete the assembly have been
24. n 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 trash or grass cuttings from inside the dust cover pinion and or drive wheel gear teeth 4 Putwheels back in place NOTE If after cleaning the drive wheels do notturn freely contact a qualified service center BLADE CARE For best results mower blade must be kept sharp Replace bent or damaged blades TO REMOVE BLADE See Fig 11 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 preventblade fromturning 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 11 1 Position the blade adapter on the engine crankshaft Be sure key in adapter and crankshaft keyway are aligned 2 Position blade on the blade adapter aligning the two 2 holes in
25. ne will smoke on startup 8 Always be sure to retighten oil dipstick before starting engine 9 Reconnect spark plug wire to spark plug AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter Replace the air filter every 100 hours of operation or every season whichever occurs first Service air cleaner more often under dusty conditions See the maintenance section of your engine manual MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage SPARK PLUG Replace spark plug atthe 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 and wheels free of all gasoline oil etc e 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
26. or 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 Shuttheengine motor off and wait until the blade comes to complete stop before removing grass catcher e Mow only in daylight or good artificial light Do not 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 on mowers so equipped before starting the engine mo tor 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 e Remove obstacles such as rocks tree limbs etc e Watch for holes ruts or bumps Tall grass can hide obstacles
27. otective 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 Be sure fuel valve is in the ON position 2 Move choke lever to ON position 3 Hold operator presence control bar down to the handle and pull starter handle quickly Do not allow starter rope to snap back NOTE The choke lever automatically begins moving to the OFF position when operator presence control bar is held down to handle M OPERATION CHOKE LEVER FUEL VALVE LEVER FIG 9 OWING TIPS Under certain conditions such as very tall grass it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings It may also be necessary to reduce ground speed and or runthe lawn mower over the area a second time For extremely heavy cutting reduce the width of cut by overlapping previously cut path and mow slowly For better grass bagging and most cutting conditions the engine speed should be set in the fast position Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass To prevent this regularly hose catcher off with water and let dry before using Keep top of engine around starter clear and clean of grass clippings and chaff This will help engine air flow and extend engine life MULCHING MOWING TIPS IMPORTANT FOR B
28. park plug 7 Loose blade or broken blade adapter 7 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 Cutat slower walking speed Poor cut 1 Worn bent or loose blade 1 Replace blade Tighten blade bolt uneven 2 Wheel heights uneven 2 Setall 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
29. rom week to week Mow north to south one week then change to east to west the next week This will help prevent matting and graining of the lawn MAX 1 3 T gt f V WN MAINTENANCE BEFORE EACH MAINTENANCE SCHEDULE 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 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 if so equipped xx Electric Start mowers Power Propelled mowers xxx 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 an
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31. sharpen the heavy end until the blade is balanced GRASS CATCHER 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 lawn mower model number when ordering GEAR CASE e 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 EPOO Do not substitute MAINTENANCE ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SF SJ 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 BW30 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 leas
32. t once a year if the lawn mower is not used for 25 hours in one year Check the crankcase oil level before starting the engine and after each five 5 hours of continuous use Tighten oil plug securely each time you check the oil level TO CHANGE ENGINE OIL See Fig 12 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 Tiplawn 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 OIL FILLER CAP DIPSTICK t Do Dy t i7 A watt MAA FIG 12 4 Wipe off any spilled oil from lawn mower or side of engine 12 5 Fill engine with oil The engine oil capacity is 18 5 oz If oil is not completely drained from engine you may not need the entire container of a 20 oz bottle of oil Slowly pour 3 4 of the oil from the container down the oil fill spout into the engine 6 Waitone minute to allow oil to settle Use guage on oil fill cap dipstick for checking level Insert dipstick into the tube and rest the oil fill cap on the tube DO NOT thread the cap into the tube when taking reading 7 Continue adding small amounts of oil and rechecking the dipstick until it reads full DO NOT overfill or engi
33. the blade with the raised lugs on the adapter 3 Besurethetrailing edge of blade opposite sharp edge is up toward the engine 4 Installthe blade bolt with the lock washer and hardened washer into blade adapter and crankshaft 11 5 Use block of wood between blade and lawn mower housing and tighten the blade bolt turning clockwise e The recommended tightening torque is 35 40 ft Ibs 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 CRANKSHAFT KEYWAY KEY LOCK WASHER CRANK SHAFT BLADE ADAPTER HARDENED WASHER TRAILING EDGE FIG 11 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
34. the lower handle will automatically lock into mowing position SQUEEZE TO ADJUST gt LOWER HANDLE SS SSS Xx XI S eS SSI 99 97 7974474 X2 Se SSL Se Ee Se Sos 2S2 Ses ee Se ese Se MS Se Se FIG 16 OPERATOR PRESENCE CONTROL BAR UPPER HANDLE LOWER HANDLE MOWING POSITION ENGINE FUEL SYSTEM IMPORTANT ITISIMPORTANTTO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALSO 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 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 an
35. to the handle and pulling the drive control bar up to the handle The closerto the handle the bar is pulled the faster the unit will travel e Forward motion will stop when either the operator pres ence control bar or drive control bar are released To stop forward motion without stopping engine release the drive control baronly Hold operator presence control bar down against handle to continue mowing without self propelling NOTE If after releasing the drive control the mower will not roll backwards push the mower forward slightly to disengage drive wheels e To keep drive control engaged when turning corners push down on the handle to lift the front wheels off the ground while turning lawn mower DRIVE CONTROL ADJUSTMENT See Fig 3 Over time the drive control system may become loose resulting in decreased speed There is a thumbscrew on the underside of the drive control housing to increase ten sion on the drive cable Proceed as follows 1 Turnunitoff and disconnect spark plug wire from spark plug 2 Rotate thumbscrew counter clockwise to tighten the drive cable 3 Operate mower to test drive speed 4 If condition fails to improve after the above steps for ward speed remains the same your drive belt is worn and should be replaced NOTE If mower begins to creep forward the drive cable is too tight Rotate thumbscrew clockwise to loosen drive cable OPERATOR PRESENCE CONTROL BAR ENGAGED DISEN
36. w lawn mower Ithas 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 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 PRODUCT SPECIFICATIONS Gasoline Capacity 1 0 Quarts and Type Unleaded Regular Only Oil Type API SF SJ SAE 10W 30 Oil Capacity 18 5 Ounces Spark Plug NGK BPR6ES Gap 030 Intake 0 015 mm Exhaust 0 020 mm Valve Clearance 0 04 mm SERIAL NUMBER DATE OF PURCHASE THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON ADECAL ATTACHEDTOTHE REAR OF THE LAWN MOWER HOUSING YOU SHOULD RECORD BOTH SERIAL NUMBER AND DATE OF PURCHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE Blad
37. when the engine is running WHEEL ADJUSTER ON EACH WHEEL OPERATOR PRESENCE CONTROL BAR must be held DRIVE CONTROL BAR used to engage power propelled down to the handle to start the engine Release to stop forward motion lawn mower the engine MULCHER DOOR allows conversion to discharge or STARTER HANDLE used for starting the engine 5 bagging operation OPERATION WEAR YOUR 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 e performing any adjustments or repairs We recommend standard safety glasses or a wide vision safety THAN NO SIGHT mask 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 anengine controlto be installed onthis lawn mowerin orderto 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 operatorto be positioned behind the lawn mower handle to start and operate the lawn mower DRIVE CONTROL See Fig 3 e Self propelling is controlled by holding the operator presence control bar down
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