Husqvarna 233RJ Lawn Mower User Manual
Contents
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3. ments section of this manual OPERATOR PRESENCE CONTROL BAR UPPER HANDLE LIFT UP TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher To convert to bagging or discharging See TO CONVERT MOWER in the operation section of this manual TO ASSEMBLE amp ATTACH GRASS CATCHER See Figs 2A amp 2B 1 Putgrass 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 over frame NOTE Ifvinyl bindings aretoo stiff holdthem in warm water for a few minutes If bag gets wet let it dry before using 3 Lifttherear door ofthelawn mower and place the grass catcher frame side hooks onto the door pivot pins 4 Thegrasscatcheris secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame CAUTION Do notrun your lawn mower without clipping deflector or approved grass catcher in place Neverattemptto operate the lawn mower with the rear door removed or propped open CATCHER FRAME HANDLE PIVOT z GRASS CATCHER FRAME HANDLE GRASS CATCHER N FRAME HOOK FIG 2B 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 The
4. 6522CH Owner s Manual 532177950 01 10 01 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 DONOT GENERAL OPERATION Read understand and follow all instructions onthe machine and in the manual s before starting Be thoroughly familiar with the controls and 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 e Clear the area of objects such as rocks toys wire bones sticks etc whichcouldbepickedupandthrownby theblade Besuretheareaisclearofother people before mowing Stop machine if anyone enters the area Do not operate the mower when barefoot or wearing open sandals Always wear substantial foot wear Donotpull mower backwards unless absolutely necessary Always look down and behind before and while moving backwards Donotoperatethe mowerwithoutproper 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
5. Stop the blade s when crossing gravel drives walks or roads Stopthe engine motor whenever you leave the equipment before cleaning the mower or unclogging the chute Shutthe engine motor off and wait until the blade comes to complete stop before removing grass catcher Mow only in daylight or good artificial light Do not operate the machine while under the influence of alcohol or drugs Neveroperate machine in wetgrass Always be sure of your footing keep a firm hold on the handle and walk never run Disengage the self propelled mechanism or drive clutch on mowers so equipped before starting the engine motor fthe equipment should start to vibrate abnormally stop the engine motor and check immediately for the cause Vibra tion is generally a warning of trouble Always wear safety goggles or safety glasses with side shields when operating mower ll 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 Mowacrosstheface of slopes never up and down Exercise extreme caution when changing direction on slopes Remove obstacles such as rocks tree limbs etc Watchforholes ruts or bumps Tallgrasscanhide obstacles Do not trim near drop offs ditches or embankments The operator could lose footing or balance Do not trim
6. 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 oF 20 0 30 32 40 60 80 100 9 30 20 10 0 10 20 30 40 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE NOTE Although multi viscosity oils BW30 10W30 etc improve starting in cold weather these multi viscosity oils will result in increased oil consumption when used above 32 F Check your engine oil level more frequently to avoid possible engine damage from running low on oil Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year Check the crankcase oil level before starting the engine and after each five 5 hours of continuous use Tighten oil plug securely each time you check the oil level TO CHANGE ENGINE OIL See Fig 11 NOTE Before tipping lawn mower to drain oil drain 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 spark plug 2 Remove engine oil cap lay aside on a clean surface 3 Tip lawnmower 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 4 Wipe off any spilled oil on lawn mower and on side of engine 5 Fill engi
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8. 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 Thereardeflector 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 DISCHARGE GUARD The discharge guard attached to the discharge opening of your lawn mower is provided to prevent the possibility of injury resulting from objects being thrown out of the dis charge opening into the operator mowing position If the discharge guard becomes damaged it should be replaced TO REMOVE REPLACE DRIVE BELT See Fig 12 1 Remove drive cover Remove belt from gearcase pulley by pushing down on pulley and rolling belt off it 2 Turn lawn mower onits side with air filter and carburetor up Remove blade Remove debris shield Remove belt from engine pulley on crankshaft Install new belt by reversing above steps Always use factory approved belt to assure fit and long life Oo 13 TO ADJUST HANDLE See Fig 13 The handle can be mounted in a high or low position The mounting holes in the b
9. ROTARY LAWN MOWER MODEL NUMBER 6522CH 6522CHA KEY PART KEY PART NO NO DESCRIPTION NO NO DESCRIPTION 2 532176580 Control Bar 47 532150078 Self tapping Screw 5 16 18 x 3 4 3 532167163 Upper Handle 50 532177130 Handle Bracket Right 4 532063601 Locknut 51 532177131 Handle Bracket Left 5 532130861 Engine Zone Control Cable 52 532751592 Locknut 3 8 16 7 532700417 Throttle Control 54 532125078 Washer 8 532144929 Hex Washer Head Screw 1 4 20 x 2 1 8 55 532150406 Hex Head Thread Rolling Screw 3 8 16 x 1 1 8 9 532136376 Handle Knob 57 532170557 Front Baffle 12 532170947 Rear Door Kit 59 532851084 Hex Head Machine Screw 3 8 24 x 1 3 8 Gr 8 15 532164265 Handle Grip 60 532850263 Helical Lock Washer 17 532107339 Danger Decal 61 532851074 Hardened Washer 18 532150050 Screw 62 532141114 Blade 22 19 532155047 Wheel Adjusting Bracket 63 532851514 Blade Adapter 20 532084596 Engine Pulley 64 532176583 Lawn Mower Housing Kit Includes Key No 17 21 532087677 Hi Pro Key 505 65 Engine Briggs amp Stratton 120602 23 532125348 Rear Baffle 68 532088652 Hinge Screw 24 532140540 Rear Skirt 69 532166649 Mulcher Plug 25 532138860 Side Baffle 70 532134612 Debris Shield 26 532166800 Back Plate 75 874760612 Bolt 2 532083923 Flanged Locknut 77 532088348 Flat Washer 28 532054583 Screw Hex Head 1 4 20 x 1 2 78 532150756 Combi Cut Door Assm 29 532177133 Discharge Baffle 79 532057143 Wave Washer 30 532132001 Rope Guide 82 532083816 Screw 31 532066426 Wire Tie 83
10. cleaner products in the fuel tank or permanent damage may occur CAUTION Fill to bottom of gas tank filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame ENGINE OIL CAP GASOLINE FILLER CAP PRIMER FIG 8 TO START ENGINE See Fig 8 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 Tostartacoldengine 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 Move throttle control lever to fast position 3 Hold operator presence control bar down to the handle and pull starter handle quickly Do not allow starter rope to snap back TO STOP ENGINE 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 MOWING TIPS Undercertain conditions such as very tall grass it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings It may also be necessary to reduce ground speed and or run
11. 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 Keepchildren out ofthe trimming area and underthe watchful care of another responsible adult Be alert and turn machine off if children enter the area Before andwhilewalking backwards lookbehind and downfor small children Never allow children to operate the machine Useextracarewhenapproaching blindcorners shrubs trees or other objects that may obscure vision IV SERVICE Useextracarein handling gasoline and otherfuels They are flammable and vapors are explosive Useonlyanapproved container Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling Do not smoke Neverrefuelthe machine indoors Neverstore 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 Keepnuts andbolts especially blade attachementbolts tight and keep equipment in good condition Never tamper with safety devices Check their proper opera
12. grass catcher may be hosed with water but mustbe dry when used Check your grass catcher often for damage or deterio ration Through normal use it will wear If catcher needs replacing replace only with a manufacturer approved replacement catcher Give the lawn mower model number when ordering 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 areinthe drive wheel area and mustbe cleanedto free drive wheels If necessary to clean the drive wheels check both front wheels 1 Remove hubcaps hairpin cotters 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 aftercleaning the drive wheels do notturn freely contact your nearest authorized service center GEAR CASE Tokeep your drive system working properly the gear case and area around the drive should be kept clean andfree oftrash build up Clean underthe drive cover twice a season 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 Texaco Starplex Premium 1 Grease Part No 750369 Do not substi tute CUSTOMER RESPONSIBILITIES ENGINE LUBRICATION
13. 532213146 Engine Clamp 32 532153605 Lower Handle 84 532063601 Nut 33 532131959 Handle Bolt 85 532150653 Clip on Guard 34 532051793 Hairpin Cotter 86 817600406 Screw 38 532752063 Wheel amp Tire Assembly 89 532165912 Bolt 39 532142748 Shoulder Bolt 91 532170939 Spring RH 40 532061651 Spring Washer 92 532170938 Spring LH 41 532162233 Axle Arm 532162300 Warning Decal 42 532177132 Selector Spring 532177950 Owner s Manual 43 532175477 Selector Knob 44 532128415 Rivet NOTE All component dimensions given in U S inches 45 532146630 Spacer 1 inch 25 4 mm 46 532155047 Wheel Adjusting Bracket REPAIR PARTS ROTARY LAWN MOWER MODEL NUMBER 6522CH 6522CHA REPAIR PARTS 61 NO PART NO 532146323 532751 152 532158755 532150495 532077400 532145212 532088558 812000058 532137054 532088080 532087877 532151521 532151520 532063601 532137090 ROTARY LAWN MOWER MODEL NUMBER 6522CH 6522CHA DESCRIPTION Drive Control Locknut 10 24 Pan Head Machine Screw 1 4 20 x 2 1 8 Spring Retainer Hubcap Nut Wheel amp Tire Assembly E ring Pinion Dust Cover Selector Knob Wheel Adjuster Assembly Left Wheel Adjuster Assembly Right Locknut Spring KEY NO 20 21 22 23 24 27 28 PART NO 532075192 532067725 53270251 1 532137052 532132010 532700479 532146072 532149746 532169931 532176575 532146527 532086012 DESCRIPTION Spring Washer 1 2 x 1 1 2 x 134 Gear Case Assembl
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15. LIEAA 189A L eseuound euin ye jonpoud ejejedes e peAie2a1 seu Jeseuound y uoiuM 10 euiBue ed puy Aq peunjoejnueuu sujejs s ped ase YOIUM sjueuoduaoo 2809 104 1deoxe ydg pue 6 Ajdwood auesseoeu Sjueuodujoo 5 uoissiurj paes se jdeoxe esn Bunpod JO jeuonninsur uou JO 5 eoujoeje pue 5 siewo g xoedyoeg pjeupueu MOUS smes siegnousnug SMES ureuo 5 5 sJoj9eJ pue juge M 489A c puey uo pue syeys saun Jejl YO 195 se 1onpoJd y jo ULEM y 10 eseuound jo eui pue Sj99Jep eq 0 y sjueueM Aueduio 9 159104 NOLLO3S INAWALVLS ALNVYYVM 8 ASSEMBLY Read these instructions and this manual in its entirety before you a
16. ONS 3 CUSTOMER RESPONSIBILITIES 3 10 12 WARRANTY TT 4 5 OPERATION eene nne 6 9 MAINTENANCE 10 SERVICE AND ADJUSTMENTS 13 STORAGE 14 TROUBLESHOOTING eene 15 REPAIR PARTS LAWN MOWER 16 20 66 11 22 18 8 LES 91282 ON ALLOTYVHO JAYA SGOOM YALAWIYAd 9006 VNHVAOSRH Jno ul Je eep 2 ZOAMSNH 008 1 Bui eo Aq e20 au Jo sabed MOJA eui yno pereoo Ajeuuou eq ued uy siy jou eje pue esuedxe s y je JSNW jonpoud eu anje 40 y Jo sKep 02 uey eye ou e Ul Jepeep ue eq SNW eq 0 pe erjeq1onpouJd y AjUBEM SIU JO jjeueg eui ureiqo o Jejeep ay Jo pue pue eues erep 1snuJ JooJd siu
17. RTEN THE LIFE OF THE SELF LUBRICATING BEARINGS IF YOU FEEL THEY MUST BE LUBRICATED USE ONLY A DRY POWDERED GRAPHITE TYPE LUBRICANT SPARINGLY CUSTOMER RESPONSIBILITIES LAWN MOWER Always observe safety rules when performing any mainte nance TIRES Keep tires free of gasoline oil or insect control chemi cals which can harm rubber Avoid stumps stones deep ruts sharp objects and other hazards that may cause tire damage BLADE CARE For best results mower blade mustbe kept sharp Replace bent or damaged blades TO REMOVE BLADE See Fig 10 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug 2 Turn lawn mower on its side Make sure air filter and carburetor are up 3 Use awood 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 Removeblade andattaching 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 Positionthe blade adapter on the engine crankshaft Be sure key in adapter andcrankshaft keyway are aligned 2 Position blade on the blade adapter aligning the two 2 holes in the bla
18. Store in aclean 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 securely 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 Fig 14 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 Whensettingup your handle from the storage position the lower handle will automatically lock into the mowing position OPERATOR PRESENCE CONTROL BAR UPPER HANDLE FOLD FORWARD FOR STORAGE J SN P E vy MOWING POSITION 14 ENGINE FUEL SYSTEM IMPORTANT IT IS IMPORTANT TO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALSO EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS CALLED GASOHOL OR USING ETHANOL OR METHANOL CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION AND FORMA
19. TION OF ACIDS DURING STORAGE ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE e Drain the fuel tank Start the engine and let it run until the fuel lines and carburetor are empty Neveruse 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 minimizing the formation of fuel gum deposits during stor age Add stabilizer to gasoline in fuel tank or storage container Always follow the mix ratio found on stabilizer container Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor Do not drain the gas tank and carburetor if using fuel stabilizer ENGINE OIL Drainoil with engine warm and replace with clean engine oil See ENGINE inthe Customer Responsibilities section of this manual CYLINDER 1 Remove spark plug 2 Pouroneounce 29 ml ofoil through spark plug hole into cylinder 3 Pull starter handle slowly a few times to distribute oil 4 Replace with new spark plug OTHER Do not store gasoline from one season to another Replace your gasoline can if your can starts to rust Rust and or dirt in your gasoline will cause problems If possible store your unit indoors and cover it to give protection from dust and dirt Coveryourunitwith a suitable protective coverthat does not retain moisture Do not use plastic Plast
20. bar down against handle to continue mowing without self propelling 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 CON TROL DISENGAGED TO ENGAGE DRIVE CONTROL TO ADJUST CUTTING HEIGHT See Fig 5 Raise wheels forlow cut and lower wheels for high cut adjust cutting heightto suit your requirements Medium position is best for most lawns Tochangecutting height squeeze adjuster lever toward wheel Move wheel up or down to suit your requirements Be sure all wheels are in the same setting NOTE Adjuster is properly positioned when plate tab inserts into hole in lever Also 9 position adjusters if so equipped allow lever to be positioned between the plate tabs LOWER WHEELS FOR HIGH CUT PLATE TAB FIG 5 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 6A Openreardoorandremove mulcher plug Store mulcher plug in a safe place You can now install grass catcher e Toconvertto mulching or discharging operation install mulcher plug into rear discharge opening of mower SIDE DISCHARGING See Fig 6B e Mulcher plug must be installed into rear discharge opening of mower see above instructions e Open discharge guard and install discharge deflector under guard as show
21. d 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 MODELAND SERIAL NUMBERS WILL BE FOUND ON ADECALATTACHED TO THE 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 A WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other repro ductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer andbirth defects or other reproductive harm Wash hands after handling PRODUCT SPECIFICATIONS GASOLINE CAPACITY 1 6 quarts AND TYPE UNLEADED REGULAR ONLY OIL TYPE API SF SJ SAE 30 above 32 F SAE 5W 30 BELOW 32 F 20 ozs Champion RC12YC OIL CAPACITY SPARK PLUG GAP 030 BLADE BOLT TORQUE 35 40 FT LBS CUSTOMER RESPONSIBILITIES Read and observe the safety rules e Follow a regular schedule in maintaining caring for and using your lawn mower Follow the instructions under Customer Responsibili ties and Storage sections of this owner s manual TABLE OF CONTENTS SAFETY RULES erii vied 2 PRODUCT SPECIFICATI
22. damage Always wear safety glasses or eye shields while operating your FORESIGHT IS BETTER THAN NO SIGHT lawn mower or performing any adjustments or repairs We recommend wide vision safety mask over spectacles or standard safety glasses available ENGINE SPEED See Fig 3 The engine speed is controlled by a throttle located on the side of the upper handle Fast position is for starting normal cutting trimming and better grass bagging Slow position is for light cutting trimming and fuel economy 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 con trol The blade turns when the engine is running e Yourlawn mower is 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 4 Self propelling is controlled by holding the operator presence control bar down to the handle and pushing the drive control lever forward until it clicks then releasing the lever Forward motion will stop when the operator presence control bar is released To stop forward motion without stopping engine release the operator presence control bar slightly until the drive control disengages Hold operator presence control
23. de with the raised lugs on the adapter 3 Besure the trailing edge of blade opposite sharp edge is up toward the engine 4 Install 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 Ibs IMPORTANT Blade bolt is grade 8 heat treated TO SHARPEN BLADE NOTE Wedo 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 orengine The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen while on the mower e Tocheckblade balance drive nail into abeam or wall Leave about one inch ofthe 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 11 CRANKSHAFT BLADE KEYWAY ADAPTER KEY BLADE BOLT HARDENED CRANKSHAFT WASHER gt TRAILING EDGE LOCK WASHER BLADE ADAPTER FIG 10 GRASS CATCHER The
24. er is level and area around oil fill is clean 2 Remove engine oil cap and fill to the full line on the dipstick Pour oil slowly Do not over fill NOTE ALLOW OIL TO SETTLE DOWN INTO ENGINE FOR ACCURATE READING TO READ PROPER LEVEL TIGHTEN ENGINE OIL CAP THEN REMOVE IT TO READ THE DIPSTICK 3 Reinstall engine oil cap and tighten 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 ADD GASOLINE See Fig 8 NOTE BEFORE FILLING FUEL TANK REMOVE AND DISCARD THE DEBRIS PLUG THAT IS INSIDE THE TANK e Fill fuel tank Use fresh clean regular unleaded gasoline with a minimum of 87 octane Do not mix oil with gasoline Purchase fuel in quantities that can be used within 30 days to assure fuel freshness WARNING Experience indicates that alcohol blended fuels called gasohol or using ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer Drain the gas tank startthe 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
25. g yourlawn when itis wet Wet grass tends to form clumps and interferes with the mulching action The best time to mow your lawn is the early afternoon Atthis time the grass has dried and the newly cut area will not be exposed to the direct sun Forbestresults adjustthe lawn mower cutting height so thatthe 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 overlapping previously cut path and mow slowly 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 or perpendicular to the first cut path Change your cutting pattern from week to week Mow north to south one week then change to east to west the next week This will help prevent matting and graining of the lawn CUSTOMER RESPONSIBILITIES MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE Check for Loose Fasteners Clean Inspect Grass Catcher If Equipped Clean Lawn Mower Clean Under Drive Cover Power Propelled Mowers Check drive belt pulleys Clean Battery Recharge Electric Start Mowers Clean Air Filter Inspect Muffler Change more often
26. ic 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 Does not start Loss of power Poor cut uneven Excessive vibration Starter rope hard to pull Loss of drive Grass catcher not filling if so equipped Hard to push CAUSE Dirty air filter Out of fuel Stale fuel Water in fuel Spark plug wire is disconnected Bad spark plug Loose blade or broken blade adapter Control bar in released position Control bar defective Rear of lawn mower housingor cutting blade dragging in heavy grass Cutting too much grass position Dirty air filter Buildup of grass leaves and trash under mower Too much oil in engine Walking speed too fast Worn bent or loose blade Wheel heights uneven height Buildup of grass leaves and trash under mower Worn bent or loose blade Bent engine crankshaft Engine flywheel brake is on when control bar is released pulling starter rope Bent engine crankshaft Blade adapter broken Blade dragging in grass Drive wheels not turning with drive control engaged Belt not driving Cutting height too l
27. n e Moweris now ready for discharging operation e Toconvertto mulching or bagging operation discharge deflector must be removed and discharge guard must be closed OPERATION SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING 1 Rear mulcher plug installed 2 Sidedischarge guard closed FOR REAR BAGGING 1 Rearmulcher plug removed 2 Grass catcher installed 3 Sidedischarge guard closed FOR SIDE DISCHARGING 1 Rearmulcher plug installed 2 Sidedischarge deflector installed CAUTION Do notrun your lawn mower without rear mulcher plug in place or approved grass catcher in place Neverattemptto operate the lawn mower with the rear door removed or propped MULCHER PLUG FIG 6A NC ES amp DISCHARGE GUARD OPEN B DISCHARGE GUARD DISCHARGE DEFLECTOR FIG 6B 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 baghandle NOTE Do not drag the bag when emptying it will cause unnecessary wear BAG __ GRASS CATCHER HANDLE FRAME HANDLE FIG 7 BEFORE STARTING ENGINE ADD OIL See Fig 8 Yourlawnmoweris shipped without oilin the engine Engine holds 20 oz of oil For type and grade of oil to use see ENGINE in Customer Responsibilities section of this manual 1 Be sure lawnmow
28. ne with oil See Add Oil in the Operacion section of this manual 6 Reconnect spark plug wire to spark plug CONTAINER AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter Replace the air filter every year more often if you mow in very dusty dirty conditions Do not wash air filter To change air filter see engine manual MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage SPARK PLUG Change your spark plug each year to make your engine start easier and run better Set spark plug gap at 030 inch CLEANING IMPORTANT FOR BEST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH CLEAN THE UNDERSIDE OF YOUR MOWER AFTER EACH USE CAUTION Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with the spark 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 Wedonot 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 can result in shortened engine life SERVICE AND ADJUSTMENTS CAUTION BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS
29. ottom of lower handle are off center for raising or lowering the handle 1 Remove upper handle and all parts attached to lower handle 2 Remove hairpin cotters from lower handle bracket mount ing pin 3 Squeeze lower handle in to remove it from mounting pins 4 Turnlower handle over to raise or lower handle 5 Squeeze lower handle in and position holes onto mount ing pins on handle bracket 6 Reassemble upper handle and all parts removed from lower handle 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 THROTTLE CONTROL If it becomes necessary to adjust or replace the throttle control see the adjustment section of your engine manual CARBURETOR The carburetor has been preset at the factory and adjust ment should not be necessary However minor adjustment may be required to compensate for differences in fuel temperature altitude or load See the Adjustment section of your engine manual for further instruction 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
30. ow Lift on blade worn off Catcher not venting air Grass is too high or wheel height is too low Rear of lawn mower housing or blade dragging in grass Grass catcher too full Handle height position not right for you 15 CORRECTION Clean replace air filter Fill fuel tank Drain tank and refill with fresh clean fuel Drain fuel tank and carburetor and refill tank with fresh gasoline Connect wire to plug Replace spark plug Tighten blade bolt or replace blade adapter Depress control bar to handle Replace control bar Set to Higher Cut position Set to Higher Cut Clean replace air filter Clean underside of mower housing Check oil level Cut at slower walking speed Replace blade Tighten blade bolt Set all wheels at same Clean underside of mower housing Replace blade Tighten blade bolt Contact a qualified service center Depress control bar to upper handle before Contact a qualified service center Replace blade adapter Move lawn mower to cut grass or to hard surface Adjust or replace drive control cable Put belt on pulleys or replace belts if broken Raise cutting height Replace blade Clean grass catcher Raise cutting height Raise rear of lawn mower housing one 1 setting higher Empty grass catcher Adjust handle height to suit 91 REPAIR PARTS ROTARY LAWN MOWER MODEL NUMBER 6522CH 6522CHA ZI REPAIR PARTS
31. sesymbols may appear on your lawnmowerorin literature supplied with the product Learn and understandtheir meaning 0 53 9 gl CAUTION ENGINE ENGINE FAST SLOW CHOKE FUEL OIL DANGER KEEP HANDS OR WARNING ON OFF AND FEET AWAY OPERATOR PRESENCE CONTROL BAR DRIVE CONTROL LEVER u THROTTLE CONTROL STARTER HANDLE P ds GRASS CATCHER HANDLE KNOB OIL x LAWN MOWER HOUSING f s ag MULCHER PLUG 9 DRIVE COVER wy MULCHER DOOR IMPORTANT THIS LAWN MOWER IS PRIMER WHEEL ADJUSTER 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 when the engine is running OPERATOR PRESENCE CONTROL BAR must be held PRIMER pumps additional fuel from the carburetor to the down to the handle to start the engine Release to stop the cylinder for use when starting a cold engine engine MULCHER PLUG located at the discharge opening must DRIVE CONTROL LEVER used to engage power propelled be removed when converting to bagging operation foward motion lawn mower STARTER HANDLE used for starting the engine OPERATION WEAR YOUR The operation of any lawn mower can result in foreign objects thrown into the eyes which can result in severe eye
32. the lawn mower over the area a second time OPERATION 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 For side discharge lawn mowers cutting in a counter clockwise direction starting at the outside of the areato be cut spreads grass clippings more evenly and puts less load on the engine To keep clippings off of walkways flower beds etc make the first cuts in a clockwise direction Poresincloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass Topreventthis 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 BEST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH SEE CLEANING IN MAINTENANCE SECTION OF THIS MANUAL e Thespecial mulching blade will recutthe grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and notbe noticed Also the mulched grass will biodegrade quickly to provide nutrients for the lawn Always mulch with your highest engine blade speed as this will provide the best recutting action of the blades Avoidcuttin
33. tion regularly Keep machine free of grass leaves or other debris build up Clean oil orfuel spillage Allowmachinetocoolbefore storing Stopandinspectthe equipmentif youstrike an object Repair if necessary before restarting Never attempt to make wheel height adjustments while the engine motor is running Grass catcher components are subjecttowear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replacewith manufacturer s recommendedparts when nec essary Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Do notchangethe 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 CONGRATULATIONS on your purchase of a new lawn mower 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 tech nicians and the proper tools to service or repair this lawn mower Please read an
34. ttempt 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 shipping purposes All parts such as nuts washers bolts etc necessary to complete the assembly have been placed inthe 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 Cutdown two end corners of carton and lay end panel down flat 3 Removeallpacking materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle 4 Rolllawn moweroutofcarton and checkcartonthorougly for additional loose parts HOW TO SET UP YOUR LAWN MOWER TO UNFOLD HANDLE See Fig 1 IMPORTANT Unfold handle carefully so as notto pinch or damage control cables 1 Raisehandlesuntillowerhandle section locks into place in mowing position 2 Remove protective padding raise upper handle section into place on lower handle and tighten both handle knobs 3 Remove handle padding holding operator presence control bar to upper handle Your lawn mower handle can be adjusted for your mowing comfort Referto Adjust Handle in the Service and Adjust
35. when operating under a heavy load or in high ambient temperatures Service more often when operating in dirty or dusty conditions 1 2 3 Replace blades more often when mowing in sandy soil 4 Charge 48 hours at end of season GENERAL RECOMMENDATIONS The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence To receive full value from the warranty operator must maintain mower as instructed in this manual Some adjustments will need to be made periodically to properly maintain your unit All adjustments in the Service and Adjustments section of this manual should be checked at least once each season Onceayear replace the spark plug clean or replace air filter element and check blade for wear A new spark plug andclean new air filter element assures proper air fuel mixture and helps your engine run better and last longer Follow the maintenance schedule in this manual BEFORE EACH USE 1 Checkengine oil level 2 Check for loose fasteners LUBRICATION Keep unit well lubricated See LUBRICATION CHART 10 LUBRICATION CHART ENGINE OIL DISCHARGE GUARD REAR DOOR FRINGE WHEEL ADJUSTER REFER TO CUSTOMER RESPONSIBILITIES ENGINE SECTION SPRAY LUBRICANT IMPORTANT DO NOT OIL OR GREASE PLASTIC WHEEL BEARINGS VISCOUS LUBRICANTS WILL ATTRACT DUST AND DIRT THAT WILL SHO
36. y Drive Pulley Locknut Drive Cover Screw Pan Head Tapping Screw 10 24 x 1 3 4 Catcher Frame Grass Bag V Belt Drive Shaft Cover NOTE All component dimensions given in U S inches 1 inch 25 4 mm REPAIR PARTS ROTARY LAWN MOWER MODEL NUMBER 6522CH 6522CHA GEAR CASE ASSEMBLY PART NUMBER 532702511 KEY PART KEY PART NO NO DESCRIPTION NO NO DESCRIPTION 1 817490416 Tapping Screw 1 4 20 x 1 1 4 11 532131484 Clutch Yoke 2 532140269 Engagement Bracket 12 532700343 Bushing 3 532137053 Shifter 13 532086447 Plug 4 532057072 Seal 14 532137050 Helical Gear 6 532048373 Gear Case Halves Kit 15 532750436 Clutch Jaw Includes Key Nos 4 and 7 16 532750369 Grease 7 532077881 Bearing 17 812000003 E Ring 8 532137051 Worm Shaft 18 532850848 Hi Pro Key 9 532137074 Drive Shaft 19 532125441 Spring Bracket 10 532057079 Hardened Washer NOTE All component dimensions given in U S inches 1 inch 2 25 4 mm 20
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