Honda Power Equipment HRC7113 Lawn Mower User Manual
Contents
1. 9 operation 10 customer service 49 cutting height 37 D direction controls 19 driving the mower 19 E emission controls 24 Engine starting 19 F filter 29 fuel filter eese mm 29 oxygenated 50 recommendations 28 refueling 1 2 1 28 G grease lubrication points 35 H height cutting 37 Indicators location 9 operation 11 inspection before mowing 17 M maintenence lubrication points 35 safety 23 schedule DEREN 26 Mowing before MOWING 17 on slopes 22 MOWING e nnm 21 adjusting speeds 21 moving forward 20 reversing the mower 20 UPS re 22 MOWING procedures 21 oil Capacity 2 29 checking level 29 recommended 30 P parking 22 parts catalog2. 49 emission controls 25 preventing excessive belt wear 21 problems troubleshooting 45 publications 1 4 49 S oafety a few words 2 INDEX information 5 label locations 7 message to employers 6 safety maintenence 23 schedule maintenence 26 shifting gears 21 shop manual 49 Slopes MOWING on 22 Spanish manuals 49 Spark arrester 51 specifications 47 speed adjusting 21 starting the engine 19 steering the mower 19 stopping normal stop 20 parking 2 22 stopping the mower 19 Storage precautions 16 preparation 13 removal 16 tire pressure 36 transmission operation 21 Transporting 1 1 13 troubleshooting 45 52
3. OWNER S MANUAL I Mower HRC7113 TruGear Mid size Commerc _ H 29 2 i Click here to save this manual to your computer 1998 American Honda Motor Co Inc All Rights Reserved WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Keep this owner s manual handy so you can refer to it at any time and make sure the manual stays with the commercial mower if you sell it This owner s manual ts considered a permanent part of the commercial mower and should remain with the mower if resold The information and specifications included in this publication were in effect at the time of approval for printing American Honda Motor Co Inc Reserves the right to discontinue or change specifications at any time without notice and without incurring any obligation whatever Your mower is not equipped with a spark arrester and it may be illegal to operate the mower in some areas Check local laws and regulations An optional spark arrester is available from authorized Honda servicing dealers INTRODUCTION Congratulations on your selection of a Honda commercial mower We are certain you will be pleased with your purchase of one of the finest lawn mowers on the market We want to help you get the best results from your new mower and to operate it safely This manual contai
4. HONDA POM52733CVR Kinko s 50 2002 04 PRINTED IN U S A Printed on Recycled Paper 00X31 VG5 6000 31VG5600
5. SAFETY LABEL LOCATIONS These labels warn you of potenti al hazards that can cause serious injury Read them carefully If a label comes off or becomes hard to read contact your Honda Commercial Mower dealer for a replacement ud _ 4 WARNING by tha mower blade Thrown ab gris can dango Injury E ihe discharge guard 4 Ihe entira grass Catcher in place Weal aye prolaction Kemp paapia and pala awgy A WARNING hidden in the lawn can be thrown Clean lawn of gll debris before mowitg De ngl apsrala mirar wilde edhe A WARNING Gasolis and ba drad ar recae lalred wher eal B inp yad beet ond Urmi irti B Handie el B Wia ny jmmedigtulr WARNING Movlog bel and polis San sarinus injwry mel anging mhi rhipld ls A DANGER SHARP BLADE You will ba cut by Ihe Iotating blada Kaap hands and foot away when engin turning A WARNING To prevent serious Injury or death E Co not operate thle mewer wilkaut adequate training E Reed the owner s Manual carefully M Learn the location and function of all controls B Do nol allow children oparate his Slop angine belore perlorming rhainien nce Objects hidden In the lawn can be t
6. MINIMUM TIRES FRONT TIRE PRESSURE 193 KPA 28 PSI REAR TIRE PRESSURE 103 KPA 15 PSI Incorrect tire inflation can cause the mower not to track in a straight path Replace the tires when the tread is worn Worn out tires will not provide good traction especially on slopes and uneven ground 36 MAINTENANCE amp ADJUSTMENTS CUTTING HEIGHT The cutting height of your mower can be easily adjusted from 38 mm to 115 mm 1 to 4 inches Always shut off the engine and remove the key before adjusting cutting height Be sure to adjust botn the front and rear wheels to the same cutting height to get the best performance and cut quality Front Wheel Adjustment The front caster wheels are adjustable in increments of 13 mm 72 by changing the position of the six spacers on each caster post The following table shows the position of the spacers for the various cutting heights NUMBER OF LOWER SPACERS 0 1 2 3 4 o 6 To change the spacers 1 Raise and support the front of the mower deck 2 Remove the pin and lower the caster post about 6 mm 14 until the spacer can be removed over the flats in the caster post 3 Position the spacers in the desired locations 4 Raise the caster post and insert and lock the pin 5 Repeat the procedure on the other caster wheel Do not change the location of the washers on the caster post Rear Deck Adjustment The rear wheels are adjustable in 13 mm Ve increments
7. fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage if you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add gasoline stabilizer following manufacturer s instructions 2 After adding a gasoline stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and turn the fuel valve to the OFF position 14 TRANSPORTING AND STORING Draining the Fuel Tank and Carburetor 1 Loosen the carburetor drain screw and turn the fuel valve ON DRAIN SCREW WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 2 Drain the fuel into an approved gasoline container Reinstall the drain screw Engine Oil 1 Change the engine oil page 30 2 Remove the spark plug page 32 3 Pour a tablespoon 5 10 cc of clean engine oil into the cylinder 4 Pull the starter rope a few times to distribute the oil in the cylinder 5 Reinstall the spark plug Grease Lubricate all grease points page 35 Tires Check tire air pressure page 36 15 TRANSPORTING AND STORING STORAGE PRECAUTIONS If your mower will be stored with gasoline in the fuel tank and carburetor
8. installation of the filter The wrench P N 07912 6110001 is available from your authorized Honda servicing dealer 31 MAINTENANCE amp ADJUSTMENTS SPARK PLUG Recommended Types NGKBPRSES NDW16EPR U opark plugs of the wrong size or incorrect heat range can cause engine damage Checking the Spark Plug For good performance the spark plug should have the correct gap and be free of deposits 1 Disconnect the spark plug cap and remove any dirt from around the spark plug area 2 Remove the spark plug with a 1346 inch spark plug wrench 3 Inspect the spark plug for excessively worn electrodes chips or cracks in the insulator or excessive deposits Replace the spark plug if you have any doubts about its condition 4 Measure the electrode gap with a wire gap gauge Adjust the gap to 0 7 0 8 mm 0 028 0 031 in by bending the side electrode 5 Install the plug carefully by hand to avoid cross threading 6 Use a spark plug wrench to tighten the plug enough to compress the washer For a used plug tighten to of a turn after the spark plug seats For a new plug tighten turn after the spark plug seats A loose spark plug can become hot enough to damage the engine Over tightening spark plug can damage the threads in the engine 7 Install the spark plug cap on the plug 0 7 0 8 mm 0 028 0 031 in 32 MAINTENANCE amp ADJUSTMENTS VALVE CLEARANCE Adjust the valves at
9. mowing conditions and should be in the same position front and rear See page 37 adjust cutting height 17 BEFORE MOWING Tire Pressure Check the tires for proper inflation page 36 CHECK THE LAWN For your safety and the safety of others always inspect the area before mowing Objects Anything which can be picked up by the blades and thrown is a potential hazard to you and others Look for things like stones sticks bones and wire and remove them from the mowing area People People and animals near the mowing area can move into your mowing path or into a position where they could be struck by thrown objects Clear the area of people especially children and pets Their safety is your responsibility Lawn Check the length and condition of the grass Adjust your mowing speed and cutting height accordingly Avoid mowing wet grass Not only does mowing wet grass result in poor cut quality it also provides poor traction increasing your risk of losing your footing PREPARE YOURSELF Your safety is your responsibility A little time spent in preparation will significantly reduce your risk Knowledge Head and understand this manual Know what the controts do and how to operate them i Familiarize yourself with the mower and its operation before you begin mowing Know what to do in case of emergencies Clothing Wearing protective clothing will reduce your risk of injury Long pants and eye protection reduce the r
10. on slopes Avoid stopping on a slope If you must stop on a slope apply the parking brake if you leave the machine unattended To start on a slope keep the throttle at SLOW to heip you avoid abrupt changes of direction Mowing on a slope when the grass is damp or wet could cause you to slip fall or lose control of the mower PARKING THE MOWER To stop the mower 1 Pull both forward direction control levers to the rear to apply the brakes 2 Press the parking brake pedal to lock the brakes on 3 Pull the blade control to OFF 4 Move the throttle to SLOW and let the engine idle 5 Turn the key off and remove it 6 Turn the carburetor fuel valve OFF Try to park the mower on level ground If you must park it on a slope apply the parking brake securly to prevent the mower from roiling Always remove the key when leaving the mower unattended to prevent children or unauthorized persons from operating it 22 Maintenance amp Adjustments THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and troubie free operation It will also help reduce air pollution A WARNING Incorrect maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual help you properly care for your mower the following pages include a mai
11. systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control Systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards 24 MAINTENANCE amp ADJUSTMENTS Tampering and Altering Tampering with or altering the emission control system may Increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters Problems that may Affect Emissions you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle e Misfiring or backfiring under load Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your new Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These origi
12. the fuel shut off valve at the fuel tank 7 Check for leaks ENGINE OIL Engine Oil Capacity 1 1 liters 1 2 US quarts Checking the Leve 1 Clean the area around the oil filler cap remove it and wipe the dipstick with a clean cloth 2 Insert the dipstick without screwing it into the filer neck Remove the dipstick and check the oil level on it 3 If the oil level is low near the bottom of the dipstick add enough oil to bring the level to the upper mark on the dipstick Do not overfill Running the engine with a low oil level will cause engine damage MAINTENANCE amp ADJUSTMENTS UPPER LIMIT D LOWER LIMIT 29 MAINTENANCE amp ADJUSTMENTS Recommended Oil Use a high detergent premium quality 4 stroke engine oil certified to meet API service Classification SJ or equivalent 20 0 20 AD 50 80 1OCFF 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE SAE 10W 30 is recommended for general all temperature use Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range Changing the Engine Oil Change the oil at the recommended interval or more frequently under extreme operating conditions Drain the oil while the engine is warm to assure rapid and complete draining 1 install one end of a section of hose over the drain outlet and place the other end in a suitable container to catch the used oil 2 Clean the area
13. will increase A very rich mixture will also foul the spark plug and cause hard starting High altitude performance can be improved by specific modifications to the carburetor If you always operate your mower at altitudes above 1 500 meters 5 000 feet have an authorized Honda commercial mower dealer perform this carburetor modification Even with the modification engine horsepower will decrease about 3 5 for each 300 meter 1000 foot increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made 49 ADDITIONAL INFORMATION When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low aititude use Operation at altitudes below 1 500 meters 5 000 feet with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have an authorized servicing dealer return the carburetor to original factory specifications SPARK ARRESTER SERVICE OPTIONAL EQUIPMENT Your lawn mower engine is not factory equipped with a spark arrester In some areas it is illegal to operate an engine without a spark arrester Check local laws and regulations An optional USDA approved spark arrester is available from an authorized Honda servicing dealer The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be hot
14. EVERSE Do not attempt to disconnect or modify the safety interlock system 4 Open the fuel valve Check the fuel valve at the tank to be sure it is open 5 Turn the key ON To start a cold engine move the throttle lever to the CHOKE position To restart a warm engine move the throttle lever to the FAST position 6 When the engine warms up move the throttle lever back to the FAST position for mowing or the SLOW position to idle For best engine performance move the throttle lever out of CHOKE position as soon as the engine will run smoothly USING THE DIRECTION CONTROLS The direction control levers allow you to control the speed and direction of the mower The mower will quickly respond to the position of the levers To avoid abrupt changes of direction squeeze the levers toward the support bar rather than treating them like a switch Operate the mower with the transmission in first gear until vou are familiar with the sensitivity of the direction control levers 19 OPERATING THE MOWER Moving Forward Rest your finger tips on the support bar while you squeeze the direction control levers forward As the levers move forward they apply tension to the drive belts and power to the wheels When the levers are fully forward the belts are fully engaged The maximum speed of the mower is controlled by the gear you select with the transmission shift lever steering the Mower To steer the mower to the right graduall
15. HEELS deck If you find grease there you have enough CASTER PIVOTS CONTROL LINKAGE ADJUSTMENT 1 Push the right hand forward direction control lever as far forward as you can with finger pressure 2 There should be a gap of 70 mm 234 between the direction control lever and the support bar 3 To adjust the gap loosen the two locknuts on the linkage the top nut has left hand threads and turn the collar to set the desired gap Hold the collar and tighten the lock nuts 4 Now pull the direction control lever LEFT HAND THREAD N rearward with finger pressure ADJUSTING VAN 5 There should be gap of 100 mm 4 between the direction control lever and the support bar 35 MAINTENANCE amp ADJUSTMENTS 6 To adjust the gap remove the cotter pin and washer from the brake rod swivel Screw the swivel in or out on the rod to set the desired gap The swivel always j LA goes into the forward hole Install the washer and a new cotterpin ORO e 7 Repeat the process with the left hand direction control lever so that the left lever travel matches that of the right lever BRAKE LINING THICKNESS Check the thickness of the brake lining on B both wheels as called out in the maintenance schedule i total thickness of the friction material EM and the band cannot be less than 3 2 mm at any point c 4 m 2 3 2 mm 1 6
16. S d dE Rd 35 Control Linkage eee 35 Brake Lining 36 5 os ooeGaacne hoe owe 2 eee 36 Cutting SIGH a aw os eee bee eee es Y m ar E ea eee ne 37 555 9545 4 GE 38 Deck Belt Adjustment And 40 Blade Brake Adjustment 41 Blade Belt Adjustment And Replacement 42 Drive Belt Replacement pe bere ene aes A3 TROUBLESHOOTING bee i C 4 eee eee ee 45 SPECIFICATIONS MOWED 222224 eens Kd 47 ADDITIONAL INFORMATION Manual en 4d Honda Publications anaana mr mme 48 Customer Service 48 Oxygenated Fuels 49 Modification for High Altitude Operation 49 Spark Arrester Service Optional Equipment 50 Mower Safety SAFETY INFORMATION Most accidents with walk behind mowers can be prevented if you follow all instructions in this manual and on the mowe
17. Slip the left side belt over the engine pulley then the tensioner pulley and finally the transmission pulley Do not change the positions of the belt guides on the tensioner pulleys 2 Install the right side belt in a similar manner 3 Move belt quides so that they are close to but not touching the belis when tension is applied 4 Install the deck belt page 40 5 Adjust the control linkages 35 44 Troubleshooting ENGINE Doesn t Start The key must be ON Blade control must be OFF Transmission must NOT be in REVERSE e Fuel tank should be full of fresh page 28 Fuel filter should be clean and free of obstructions page 29 Both fuel valves should be 10 Throttle should be in CHOKE for cold engine FAST for warm engine Spark plug connector should be firmly attached to the spark plug Spark plug should be correctly gapped and be free of deposits page 52 Low Power Air cleaner elements should be clean Spark plug should be correctly gapped and be free of deposits page 32 Mower deck should be free of grass accumulation grass should be cut at lower speeds and or higher cutting heights Incorrect carburetor or linkage adjustment page 34 MOWER Doesn t Move Forward speed controls must be out of NEUTRAL Parking brake must be released The drive belts must be in good condition 43 Pulls To On
18. al from the inner area of the cutting edge If you need to remove material to restore the cutting BLUNT EDGE edge taper the edge toward the tip Do not taper beyond an 1 5 of the blade width X Do not grind the back side of the blade Check the balance of the blade by placing a dowel through the mounting hole The blade should remain horizontal If one end drops remove additional material from it to make it lighter and recheck the balance 39 MAINTENANCE amp ADJUSTMENTS DECK BELT ADJUSTMENT AND REPLACEMENT Replace the deck belt if it is worn frayed or glazed You will need to remove the deck belt to replace the transmission belts and disconnect it to replace the blade belt Whenever you remove and repiace the deck belt check the adjustment of the belt guides belt tension and the blade brake A WARNING Moving belts and pulleys can cause serious injuries Do not operate engine with the beit cover s removed Before removing belt cover s for maintenance remove key from ignition switch and disconnect the spark plug lead Adjust Belt Tension 1 Remove the belt cover 2 Fully lower the rear of the deck and move the blade control ON 3 Measure the length of the tensioner spring TENSIONER SPRING LENGTH 1 in 4 Move the blade control OFF to turn the adjusting butterfly nut 5 Check the blade brake adjustment if you change the belt tension page 41 6 Install the belt cover Shown fro
19. around the oil filler cap and remove it 3 Turn the drain valve counterclockwise about 4 turns to open it Do not open the valve more than 6 turns to avoid damaging the seals 4 When the oil has drained turn the valve clockwise to close it and remove the section of hose To avoid damaging the valve do not overtighten it 5 Refill the engine with the correct amount of the recommended oil 6 After running the engine recheck the oil level and adjust if necessary Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of it properly Put it in a sealed container and take it to a recycling center Do not discard it in a trash bin or dump it on the ground 30 MAINTENANCE amp ADJUSTMENTS Changing the Engine Oil Filter 1 2 3 Clean the filter base with a clean cloth Coat the O ring of the new filter with clean 9 Drain the engine oil Remove the oil filter and let the remaining oil drain out Correctly dispose of the old oil filter engine oil Hand tighten the oii filter until the O ring seats against the filter base tighten the filter by hand an additional 34 1 turn Pour the specified amount of oil into the engine Run the engine for a few minutes and check for leaks in the area of the filter base Stop the engine and check the oil level Adjust if necessary A Honda oil filter wrench will simplify the removal and
20. ates the total operating time of the mower in hours and tenths of an hour It operates whenever the engine is running ALERT Buzzer The Honda OIL ALERT buzzer will sound whenever the engine oil level is below a safe operating level Whenever you hear the buzzer stop the engine and check the oil level page 29 11 CONTROLS amp INDICATORS ee 12 Transporting and Storing TRANSPORTING YOUR MOWER Use a loading ramp to get the mower on and off the vehicle Be sure both the ramps and vehicle are able to support the weight of the mower and operator When the mower is in position turn the fuel valve OFF to prevent the possibility of fuel leaking Tie the mower down front and rear with ropes or straps You may use the front caster brackets and holes in the rear of the engine bed to tie the mower down Be careful not to damage linkages when tightening the ropes or straps Remember that the engine and exhaust system become hot during operation Avoid touching them STORAGE PREPARATION Proper storage preparation is essential for keeping your mower trouble free and looking good The following steps will help to keep rust and corrosion from impairing your mower s function and appearance and will make the engine easter to start when you use the mower again Cleaning the Engine Wash the engine by hand and be careful to prevent water from entering the air cleaner NOTICE Using a garden hose or pressure washing eq
21. brication points lubricate Brake linings check Service more frequently when used in dusty areas Replace paper filter element only iFirst change only 26 AIR CLEANER Check that the air cleaner elements are clean and in good condition A dirty air cleaner will restrict air flow to the engine reducing performance A damaged air cleaner will allow dirt to enter the engine causing rapid engine wear 1 Remove the elements Do not allow dirt to fall into the Separate the foam element from the paper element Clean the foam element by squeezing it in warm MAINTENANCE amp ADJUSTMENTS Remove the wing nut to remove the air cleaner cover If the foam element appears clean over more than half its surface it does not need cleaning Reinstall the cover If the foam element appears dirty go to step 2 carburetor and carefully check each one for holes or tears Replace any damaged element soapy water rinsing it and allowing it to dry You may also use nonflammable solvent and then allow it to dry AWARNING Gasoline is highly flammable and explosive You can be burned or seriously injured Never use gasoline to clean engine parts Use a nonflammabie solvent Oil the foam element by dipping it in clean engine oil and squeezing out ail excess oil If too much oil is left in the foam the engine will smoke when you first start it Clean the paper element by tapping
22. by moving the deck height lever Be sure that the setting for the deck matches the setting for the caster wheels 37 MAINTENANCE amp ADJUSTMENTS BLADES It is important for your safety and the safety of others that you inspect the blades for condition and correct installation before operating the mower AWARNING A worn cracked or damaged blade can break and pieces of the broken blade can become dangerous projectiles Thrown objects can cause serious injury Inspect the blades regularly and do not operate the mower with a worn or damaged blade The blades are subject to wear during normal operation and should be inspected regularly If a blade strikes an object it may be damaged Immediately stop the mower and inspect the blades Before working on or around the blades disconnect the spark plugs connectors from the spark plugs This will prevent the engine from starting inadvertently Always wear heavy gloves to protect your hands when working with or near the mower blades Inspecting the Blades NEW WORN BENT CRACKED 1 Tum the ignition switch key OFF and remove the key from the switch 2 Move the blade control lever OFF 3 Raise and support the front of the mower deck 4 Inspect each of the blades for cracking bending deep nicking and wear If any of the blades show signs of damage or excessive wear remove the blades for a more thorough inspection Hemoving the Blades 1 Turn the ignition swit
23. ch key and remove the key from the switch 2 Move the blade control lever OFF 3 Remove the cover s by removing the knobs 4 Raise and support the front of the mower deck 38 MAINTENANCE amp ADJUSTMENTS 5 Use a block of wood to prevent the Do not hold the nut on the top of the spindle Loosening the nut will affect the spindle bearing preload 6 Repeat the process for the other Installing the Blades 1 Servicing the Blades A dull blade may be sharpened but a blade that is worn out bent cracked or otherwise damaged must be replaced Always use genuine Honda replacement blades Substitute blades may not meet Honda specifications and may be dangerous To sharpen a blade blade from turning and remove the bolt washer blade and spacer blade s Reinstall the blades by placing the washer blade and spacer over the bolt Insert the bolt into the spindle and tighten it by hand Hold the nut on top of the spindle with a wrench and tighten the blade bolt to 88 102 N m 65 75 ft lb torque Repeat the procedure for the other blade s 5 6 Lower the mower deck to the ground Install the belt cover s with the knobs Maintain the original angle of the blade about 30 Leave a blunt edge of 1 mm 1 5 1 5 in Do not sharpen to a knife edge Remove an equal amount of material from each end of the TAPER THE blade to maintain balance CUTTING EDGE Do not remove materi
24. discharge side pulley D and then from the remaining pulley s The tensioner spring anchor bolt E should be in the shortest position Install the new belt over the pulleys Install the deck belt on its pulley 9 Install the blade brake pivot and brake rod stay Install the deck belt guide 10 Check the adjustment of the blade brake DR Qo C DRIVE BELT REPLACEMENT Replace the transmission belts if they are worn frayed or glazed You will need to remove the deck belt from the engine pulley first WARNING Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover s removed Before removing belt cover s for maintenance remove key from ignition switch and disconnect the spark plug lead Hemove 1 Loosen but do not remove the four belt i quide nuts on the top of the deck 2 Remove the right side transmission belt first by sliding the belt off the transmission pulley then off the tensioner and the engine pulley 3 Remove the left side belt in a similar manner Do not change the positions of the belt guides on the tensioner pulleys The belts TUA may be removed without loosening the tensioner pulley bolt 43 MAINTENANCE amp ADJUSTMENTS Install Viewed from above the mower ENGINE PULLEY BELT GUIDE LEFT TRANSMISSION PULLEY BELT GUIDE BELT GUIDE TRANSMISSION PULLEY The left side is longer than the right side 1
25. e Side Tires should be correctly inflated page 36 lt The control linkages must be correctly adjusted page 35 The drive belts must be in good condition page 43 Vibrates Blades should be in good condition page 38 The deck must be free of any accumulation of clippings Deck and blade belts should be in good condition and at correct tension page 40 8 page 42 45 TROUBLESHOOTING Cuts Poorly Throttle should be in FAST Cutting height must be at the same setting at front and rear page 37 Blades should be in good condition page 38 Mower deck should be free of grass accumulation Deck and blade belts should be in good condition and at correct tension Tall grass should be cut at lower speeds and or higher cutting heights 46 Specifications MOWER 76 Wath chute 821 360 _ Dy weight 22 37 0522 Maximum speed 151 2 1 m s 1 3 mph 2nd 4 4 m s 2 7 mph 3rd 6 4 m s 4 0 mph Ath 8 2 m s 5 1 mph Tire Size Drive wheel Caster wheel 2 ply 9x3 5 4 Tire Pressure Drive wheel 38 mm 114 mm 1 4 in ENGINE Mod 99 Horsepower rpm 13 3600 Maximum no load governed speed 3550 50 rpm Idle speed 1750 299 Valve clearance Intake 0 08 0 12 mm Exhaust 0 13 0 17 mm NGK W16EPR U ihe a 47 Additional Information MANUAL EN ESPANOL Una v
26. e exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to ciean parts Keep cigarettes sparks and flames away from all fuel reiated parts For certain operations the mower must be raised off the ground Be sure the mower is solidly supported before you put any part of your body under it Wear heavy gloves when near the mower deck belts or blades Hemember that your authorized Honda servicing dealer knows your mower best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda utilizes lean carburetor settings and other
27. e potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining a commercial mower You must use your own good judgement You will find important safety information in a variety of forms including Safety Labels on the mower Safety Messages preceded by a safety alert symbol 4 and one of three words DANGER WARNING or CAUTION These signal words mean DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION You CAN be HURT if you don t follow instructions Safety Headings such as Important Safety Information Safety Section such as MOWER SAFETY instructions how to use this mower correctly and safely This entire book is filled with important safety information please read it carefully INTRODUCTION Contents Safety ua rs hee eed EE EGG as Important Message to 6 Safety Label 5 ed 7 2 2 10 5 11 Transporting your St
28. enough to burn you Allow the muffler to cool before proceeding MUFFLER PROTECTOR GASKET 5 mm SCREW B mm NUT IDENTIFICATION SPARK ARRESTER PLATE 1 Remove the three 5 mm screws and the muffler protector 2 Remove the 8 mm nuts then remove the identification plate muffier and gasket Remove the spark arrester 3 Check for carbon deposits on the spark arrester and clean if necessary Be careful to avoid damaging the spark arrester screen The screen must be free of breaks and holes Replace it if necessary 4 Install the spark arrester and muffler in the reverse order of removal 50 Index A adjustment control linkage 35 air cleaner 2 27 air filter 27 altitude modifications for 50 belt blade adjustment 42 blade replacement 42 deck 4 4 0 0001 40 deck replacement 41 deck tension adjustment 40 drive replacement 43 blade brake 1411 41 blades inspection 38 removal 38 Sharpening 1 39 brake lining 36 brake blade 41 C control linkage adjustment 35 controlling mowing speed 21 controlling the mower 19 Controls location
29. ersion de este manual en Espanol esta disponible Favor de ponerse en contacto con el departamento de relaci nes al cliente a la direcci n o tel fono listado abajo HONDA PUBLICATIONS These publications will give you additional information about maintaining your mower You may order them from an authorized Honda servicing dealer Shop Manual This manual covers complete maintenance and overhaul procedures it is intended to be used by a skilled technician Parts Catalog This provides a complete pictorial parts listing CUSTOMER SERVICE INFORMATION Honda Power Equipment dealerships are staffed by trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management Almost all problems are solved in this way If you are not satisfied with the decision made by the dealership s management contact Honda Power Equipment Customer Service Office You can write to Honda Power Equipment Division Customer Service Office 4475 Hiver Green Parkway Duluth G 30096 Or telephone 770 497 6400 When you write or call please give us this information Identification number power unit and mower deck Name of the dealer who sold the mower to you Name and address of the dealer who services your mower Date of purchase Your name address and telephone number A detailed desc
30. for idle Push it forward to the FAST position for mowing Pushing it forward past detent for the CHOKE position applies the choke for starting a cold engine Transmission Shift Lever Use the shift lever to select among four forward speeds neutral or reverse To select reverse the reverse operator presence lever must be pushed down or the engine wiil stop Blade Control The blade control lever engages engine power to the mower deck and causes the blades to turn The forward position is The rear position is OFF Any one of the operator presence levers must be held down when you engage the blade control or the engine will stop Direction Controls There are two sets of direction control levers one set for forward travel and the other for reverse The direction control levers independently control each drive wheel for steering slowing and stopping Pushing a forward direction control lever gradually supplies power to the respective wheel Pulling a lever applies the brake to that wheel Pulling up on the reverse direction control levers gradually supplies power to the respective wheels The use of the direction control levers is explained on page 19 10 CONTROLS amp INDICATORS Operator Presence Levers The three operator presence levers are part of the safety interlock system There is a lever at each forward direction control lever and one above the reverse support bar When the blade control is ON you m
31. hrown by the mower blade Thrown objacis can cause serious injury E Cisan fown of aii debris before mowing er the entire grass catcher In place Wear aye Keep people away while mowing SHARP BLADE You wih be gui by ihe ralang blada Keep hands and iant away whan running De nat operate the mower without either Ihe discharge guard MOWER SAFETY Controls amp Indicators LOCATIONS THROTTLE M ae FUEL FILLER NM FRONT WHEEL ADJUSTMENT SPACERS MOWER DECK SERIAL NUMBER SUPPORT BAR DIRECTION CONTROL LEVERS TRANSMISSION SHIFT LEVER MM BLADE CONTROL FORWARD PRESENCE LEVERS CARBURETOR FUEL VALVE REVERSE PRESENCE LEVER HOURHMETEHR IGNITION SWITCH DECK HEIGHT LEVER POWER UNIT SERIAL NUMBER PARKING BRAKE CONTROLS amp INDICATORS CONTROLS Fuel Valve This valve is located on the carburetor and allows fuel to flow to the engine Push it toward the engine to ON to allow fuel to flow or pull it outward for OFF The fuel valve located at the fuel tank should used to shut off the fuel only when a changing the fuel filter Ignition Switch The ignition switch controls the engine ignition system Turn the key clockwise to the ON position or turn the key counter clockwise to the OFF position Throttle The throttle lever controls engine speed Pull it rearward to the SLOW position
32. ing 1 Select your desired ground speed with the transmission shift lever 2 Depress the operator presence lever on one of the forward direction control levers 3 Slowly move the blade control lever to ON to start the blades rotating 4 Rest your finger tips on the support bar and squeeze the direction control levers forward ADJUSTING YOUR SPEED Your mowing speed should be controlled by the transmission gear you have selected the direction control levers should be in their full forward position for normal mowing If you find that mowing conditions cause you to operate with the forward direction control levers pulled slightly back shift to a lower gear You may shift gears while the mower is in motion NOTICE Operating the mower for a long period of time with the direction control levers partially engaged will cause damage to the belts 21 OPERATING THE MOWER MOWING TIPS Your mower is designed to trim closely on the left hand side and discharge clippings evenly on the right hand side For best cut quality run the engine with the throttle lever in FAST Always mow in daylight or under good artificial light Mowing on Slopes Mow across slopes not up and down Avoid steep slopes more than 20 and be careful when changing direction When changing direction always turn the mower up slope This will give you better control and help you maintain your balance Avoid abrupt changes of direction or speed when operating
33. inspect your mower before using it Before beginning your pre operation check be sure The mower is parked on a level surface The blade control lever is disengaged and the transmission shift lever is in NEUTRAL The ignition switch is off and the key is removed Walk around the mower and check its general condition Look around and underneath it for signs of fluid leaks Remove any excessive dirt and debris especially around moving componenis Look for signs of damage Check nuts bolts screws and pins for tightness Never operate the mower with the safety interlock system inoperative Do not attempt to bypass or defeat the system Keep all shields and covers in place while operating the mower you find any problems or defects have them repaired before mowing Blades Before each use check each mower blade for damage or abnormal wear See page 38 for details Belts Check the blade deck and transmission belts for wear and correct tension See page 40 for details Engine Oil Check the level on the dipstick Running the engine with a low oil level will cause engine damage See page 29 details Fuel Remove the cap on the tank and check the fuel level See page 28 for refueling details Air Filter Check that the air cleaner elements are clean and in good condition See page 27 for information on servicing the air cleaner Cutting Height The cutting height of your mower should be set for the
34. isk of injuries from thrown objects Sturdy shoes with aggressive soies wiil help protect your feet and give you better traction on slopes or uneven ground While the sound level of the mower is weil within safe limits hearing protection will further protect your hearing 18 Operating the Mower The Honda Mid Size Commercial Mower is a powerful highly maneuverable mower designed to enhance the productivity of a lawn care professional You will need a complete understanding of its operation and a certain amount of practice with its controls to safely realize the fuil potential of this mower Read this section completely before operating the mower Take time to familiarize yourself with the controls and how they operate Get used to the feel of the transmission shift lever and direction control levers by running the engine at about half throttle The small amount of time spent in familiarization will reward you with greater efficiency and reduced risk STARTING THE ENGINE Because of the risk of carbon monoxide poisoning it makes good sense to start the mower outside or at least in an open area with good ventilation 1 Pull the blade control lever to The mower should not be started without the entire grass catcher or the discharge guard in place 2 Place the transmission shift lever in NEUTRAL 3 The safety interlock system will prevent the engine from starting if the blade control is ON or if the transmission is in R
35. it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless ali fue has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of fuel leakage Park the mower on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the mower to keep out dust hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover nonporous cover will trap moisture around the mower promoting rust and corrosion REMOVAL FROM STORAGE Check your mower as described in the Before Mowing chapter of this manual page 17 If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting lf the cylinder was coated with oil during storage preparation the engine may srnoke briefly at startup This is normal 16 Before Mowing CHECK THE MOWER For your safety and the service life of your equipment always
36. it on a hard surface to knock off dirt or by blowing compressed air at less than 207 kPa 30 psi through the filter from the inside Never try to brush off the dirt that will just force it into the filter fibers Remove any dirt from the inside of the air cleaner housing and cover Be careful not to allow dirt into the duct leading to the carburetor Place the foam element over the paper element and install them Install the cover with its wing nut NOTICE Operating the engine with no air cleaner or with damaged elements can cause rapid engine wear 27 MAINTENANCE amp ADJUSTMENTS FUEL Fuel tank capacity 24 6 liters 6 5 gallons Refueling Remove the cap on the tank and check the fuel level Refuel carefully to avoid overfilling or spilling fuel There should be no fuel in the filler neck VS le Gasoline is highly flammable and explosive You can be burned or seriously injured When refueling Stop engine and keep heat sparks and flame away Refuel only outdoors Wipe up spills immediately Never refuel the mower inside a building where fumes may reach an open flame or spark Keep gasoline away from appliance pilot lights electric motors etc in a well ventilated area before starting the engine If the engine has been running allow it to cool Avoid overfilling the tank or spilling fuel opilled fuel not only creates a fire hazard it can cause environmental damage Wipe up
37. m beneath mower TENSIONER PULLEY TENSIONER SPRING LENGTH 40 MAINTENANCE ADJUSTMENTS Replace Belt 48 inch deck shown 1 Move the blade control OFF and remove the belt ENGINE cover PULLEY 2 Loosen the two nuts on the belt guide at the deck pulley TENSIONER 3 Starting at the engine pulley lift the belt out of the PULLEY pulley grooves 4 Install the new belt by first setting it in the deck pulley then the tensioner pulley and finally the engine pulley a 5 Tighten the two nuts on the belt guide at the deck pulley 6 Adjust the belt tension and blade brake DECK PULLEY BLADE BRAKE ADJUSTMENT Check the blade brake adjustments after the deck belt is adjusted or replaced AWARNING Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover s removed Before removing belt cover s for maintenance remove key from ignition switch and disconnect the spark plug lead 1 Fully lower the rear of the deck move the blade control OFF and remove the belt cover s 2 Remove the hairpin clip and lower washer from the brake rod at the pivot plate The rod should slip freely in and out of the hole in the arm If not screw the rod in or out of the pivot at the tensioner arm until it s a slip fit 3 Install the rod in the pivot plate with two washers and two hairpin clips as shown 4 Start the engine and engage and release the blade contro se
38. nal design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may tmpair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on the following page Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 25 MAINTENANCE amp ADJUSTMENTS MAINTENANCE SCHEDULE Service Interval hours months Action whichever comes first Page daily 25 50 100 300 3 6 12 36 70 me 9 E mw 191 1 mec LE NN pee Idle speed check amp 34 adjust Throttle cable check amp 34 eee _ fa S ISI MK M O EE NEN Wo NEN Engine oil check Spark plug Blade brake check adjust Blade balts tightness check Lu
39. nd dry touch up any damaged paint and coat other areas with a light film or oil Do not apply oil to the pulleys brake drums or to the blade brake drum Lubricate the throttle cable core with a silicone spray lubricant Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your mower deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under warranty You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer fill the fuel tank with
40. ns the information on how to do that please read it carefully As you read this manual you will find information preceded by a NOTICE symbol That information is intended to help you avoid damage to your mower other property or the environment We suggest you read the Distributors Limited Warranty and Emission Control System Warranty to fully understand coverage and your responsibilities of ownership When your mower needs scheduled maintenance keep in mind that an authorized Honda servicing dealer is specially trained in servicing Honda mowers and is supported by the parts and service divisions of American Honda Your Honda dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns When you contact your Honda dealer about your mower he ll need to know the serial numbers of the engine power unit and mower deck Write those numbers in the space below for future reference Best wishes Power Equipment Division American Honda Motor Co Inc Engine number Power Unit number Mower Deck number 1998 AMERICAN HONDA MOTOR CO INC ALL RIGHTS RESERVED INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others is very important And using this lawn mower Safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on tabels and in this manual This information alerts you to th
41. ntenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your mower under severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to standards MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task AWARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual 23 MAINTENANCE amp ADJUSTMENTS Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engin
42. orage Preparation sus ucc ace eee as 13 Storage precautions sssr sansapa enhn ar rh n 16 Removal From Storage 16 Check the Rock d eR OS Re o Check the Lawn 18 Prepare 18 Starting the Engine de Using the Direction 5 19 Starting to Mow DURS NOS RENS R NINE RENE EN ea 21 Adjusting your 21 MOWING EINE EEERITTTIL IL LTIAXILLLLITILITLIDSTIT 22 Parking the Mower 22 MAINTENANCE amp ADJUSTMENTS The Importance Of Maintenance Maintenance Safety ciis nes 23 Emission Control System 24 Maintenance 26 PiPCledneh 25 445 cod oP T eee 27 e 2925355 4 2 u RE 28 eI Oll s csc cecwtewd Gadd eee ets eee 29 INTRODUCTION Ieri lUe CRT ETE TERTIO se eGe oe Ve 32 Valve 33 er ell i o eo Beh ee 34 Throttle Gable 2222 2521 tt Tl I TT 34 Lubrication P p 9 SOEUR R
43. r The most common hazards according to accident statistics are discussed below along with the best way to protect yourself and others Avoid Rotating Blades A rotating blade can cause serious cuts and even amputate fingers hands toes or feet Keep away from the mower deck whenever the engine is running If you need to work around the deck to clear a grass accumulation adjust the cutting height or for any other reason always shut off the engine and remove the key Wear heavy gloves when you need to clean the mower deck or handle a blade Clear the Mowing Area Mower blades can throw rocks and other objects with enough force to cause serious injury Before mowing carefully inspect the area and remove all sticks stones pieces of wire and other loose objects Never operate the blades over gravel Keep Shields in Place Guards and shields are designed to protect you from being hit by thrown objects and from touching hot engine parts and moving components For your safety and the safety of others keep all shields in place when the engine is running Refuel with Care Gasoline is extremely flammable and gasoline vapor can explode Refuel only outdoors in a well ventilated area with the engine OFF Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container Wear Protective Clothing Wearing protective clothing will reduce your risk of injury Long pants and eye protection red
44. ription of the problem 48 Current customer service contact information United States Puerto Rico and U S Virgin Islands Honda Power Equipment dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager or General Manager can help Almost all problems are solved in this way If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 am 5 00 pm EST When you write or call please provide the following information e Model and serial numbers e Name of the dealer who sold the Honda power equipment to you e Name and address of the dealer who services your equipment e Date of purchase e Your name address and telephone number Adetailed description of the problem ADDITIONAL INFORMATION OXYGENATED FUELS Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the USA and Canada use oxygenated fuels to help reduce emissions If you u
45. se an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohofl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty MODIFICATION FOR HIGH ALTITUDE OPERATION At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption
46. spills immediately Dispose of gasoline properly Fuel Recommendation Use unleaded gasoline with a pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixtures Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging a metallic rapping noise when operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load the engine can be damaged Try using fresh gasoline in the tank or change brands of gasoline If spark knock or pinging persists contact your authorized Honda Commercial Mower dealer Running the engine with persistent spark knock or pinging can cause engine damage This type of damage is not covered by the Distributor s Limited Warranty 28 Changing the Fuel Filter Change the fuel fitter at the recommended interval 1 Close the fuel shut off valve at the fuel tank 2 Place a container under the filter to catch any spilled fuel 3 Squeeze the hose clamps and remove the lines from the filter 4 Install the new filter with the arrow pointing toward the engine 5 Be sure the clamps securely hold the fuel lines to the new filter 6 Dispose of the old filter and any spilled fuel properly and open
47. the recommended interval Valve clearance inspection and adjustment must be done with the engine cold 1 Remove the valve cover 2 Set the piston at top dead center of the compression stroke both valves will be fully closed The cutout mark in the starter pulley will align with the index mark on the fan cover when the piston is at top dead center of either the compression or exhaust stroke 3 Measure the clearance between the rocker Roe eee arm and the valve with a feeler gauge EXHAUST 0 13 0 17 mm INTAKE 0 08 0 12 mm EXHAUST 0 13 0 17 mm 4 To adjust valve clearance hold the rocker arm E pivot and loosen the pivot lock nut 5 Turn the rocker arm pivot to obtain the specified clearance Hold the rocker arm pivot and tighten the pivot lock nut 7 Recheck the clearance and readjust if necessary 8 Install the valve cover 33 MAINTENANCE amp ADJUSTMENTS CARBURETOR Perform this adjustment if the idle is slow or rough and you re sure the air cleaner and spark plug are in good condition 1 Start the engine in an area with adequate ventilation to IDLE STOP SCREW avoid carbon monoxide poisoning Allow the engine to warm to normal operating temperature 2 With the throttle lever at sLow tum the throttle stop screw to set the idle speed IDLE SPEED 1750 1950 rpm The pilot screw is fitted with a limiter cap to prevent excessive enrichment of the fuel air mixture Do not attempt
48. to remove the limiter cap It cannot be removed without breaking the pilot screw THROTTLE CABLE In normal use cables will lose their adjustment Perform this procedure if the no load speed is not within limits or the engine does not seem to respond correctly to throttle lever movements or if the choke doesn t fuily close GOVERNOR SPRING Nu CABLE HOLDER 0 1mm 0 0 0 04 STOP SCREW 1 Set the throttle lever to FAST 2 On the engine check the clearance between the control lever and the choke lever It should be 1 mm 0 04 in or less In other words just touching The choke should be fully open If you need to adjust the clearance loosen the cable holder and adjust the position of the cable housing 4 Next set the throttle lever to CHOKE 5 Adjust the stopper screw so that it just contacts the choke lever when the choke is fully closed 6 Check maximum engine speed with a tachometer Adjust the cable slightly to obtain the rated speed MAXIMUM NO LOAD SPEED 3550 50 rpm 34 MAINTENANCE amp ADJUSTMENTS LUBRICATION POINTS PULLEY PIVOT Grease NGLI 2 Lithium Base EP under deck SPINDLES Follow the diagram to lubricate these 2 or 3 fittings 43 Caster wheels 2 Caster pivots 2 Pulley pivots 1 Spindles 2 or 3 Do not over grease the spindle Use a long narrow screwdriver to check for grease between the pulley and the CASTER W
49. uce the risk of injuries from thrown objects Sturdy shoes with aggressive soles will help protect your feet and give you better traction on slopes or uneven ground Ear protection and a helmet may be required by local ordinances or insurance policies Turn Engine Off When Not Mowing If you need to leave the mower for any reason even just to inspect the lawn ahead always turn the engine off And take the key if you go farther away MOWER SAFETY IMPORTANT MESSAGE TO EMPLOYERS As an employer you have special responsibilities to the people who work for you Before you ask anyone to operate this mower you need to determine whether the person is old enough large enough and strong enough to safely handle and control the mower Then be sure the employee reads and understands all instructions and warnings in this manual and on the labels before operating the mower Allow adequate time for hands on training by a qualified instructor and personally supervise practice sessions until you feel sure the employee is ready to operate the machine Also be sure employees wear proper clothing and have eye protection and any other gear that may be required by local ordinances or your insurance company Remember too that you are responsible for keeping the mower properly maintained and in safe operating condition Your commitment to safety on the job can help prevent accidents and result in longer and more productive years of service MOWER SAFETY
50. uipment can force water into the air cleaner Water in the air cleaner will soak the filters and can enter the carburetor or engine cylinder causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Cleaning the Mower Deck If using a garden hose or pressure washing equipment to clean the mower deck be careful to avoid getting water into controls and cables or anywhere near the engine air cleaner or muffler opening Spraying water on hot mower deck bearings can cause them to be damaged from cooling too quickly Before washing the underside of the mower deck be sure the parking brake is set and the height adjustment lever is all the way up Remove the grass bag optional kit from its frame and wash it with a garden hose or pressure washing equipment Allow the bag to completely dry before storage 13 TRANSPORTING AND STORING After washing the mower wipe dry all accessible surfaces Start the engine outdoors and let it run until it reaches normal operating temperature to evaporate any water remaining on the engine While the engine is running hold an operator presence lever and operate the blade control lever to expel water from the blade pulleys spindies and other mower deck areas Allow the blades to spin for several minutes to ensure that no water remains Stop the engine and allow it to cool After the mower is clean a
51. ust hold at least one lever down Before shifting into reverse you must hold the reverse presence lever down In either case if you don t hold the appropriate lever the engine will stop Parking Brake The parking brake locks the brakes ON Pull the forward direction control levers to apply the brakes and then press on the parking brake pedal Release the brake by pulling harder on both forward direction control levers Front Wheel Adjustment Spacers The front wheel adjustment spacers allow adjustment of the cutting height in 9 5 inch increments from 1 5 to 4 5 inches 38 114 mm Their use is explained page 37 Deck Height Lever The deck height lever allows adjustment of the cutting height in 0 5 inch increments from 1 5 to 4 5 inches 38 114 mm Its use is explained on page 37 CGT Center of Gravity Transfer System The center of gravity may be shifted toward the rear of the mower for specific mowing situations Remove the plastic plug at the front of the control panel and add a quantity of sand to produce the desired weight distribution Use only play sand to reduce the chance of corrosion The sand may be removed by removing plugs on the sides of the tank Be aware that the center of gravity is moved not only rearward but also upward This higher center of gravity may decrease stability when operating on slopes INDICATORS These indicators help you monitor the condition of the mower Hour meter The hour meter indic
52. veral times Confirm that the brake operates correctly 5 Install the belt cover 41 MAINTENANCE amp ADJUSTMENTS BLADE BELT ADJUSTMENT AND REPLACEMENT Replace the blade belt if it is worn frayed or glazed WARNING Moving belts and pulleys can cause serious injuries Do not operate engine with the belt cover s removed Before removing belt cover s for maintenance remove key from ignition switch and disconnect the spark plug lead Inspect and Adjust ANCHOR BOLT 1 Move the blade control orr Remove the belt cover s 2 Check the tensioner spring length MINIMUM SPRING LENGTH hook to hook 120 140 mm 4 5 in If the spring is too short adjust the tensioner 3 Remove the blade belt from the right discharge side pulley 4 Hemove the spring from the anchor bolt and install the bolt in an alternate hole Install the spring over the bolt 5 Install the belt over the pulleys If the spring is still too short with the anchor bolt in the last position replace the belt 6 Install the belt cover 4B inch deck shown Replace 45 inch deck 1 Move the blade control OFF and remove the belt cover 2 From under the deck remove the two nuts from the deck belt guide 42 MAINTENANCE amp ADJUSTMENTS 3 From under the deck remove the nuts from the blade brake pivot B and the brake rod stay Remove the deck belt from the pulley Remove the blade belt from the right
53. y release pressure on the right hand direction control lever To steer the mower to the left gradually release pressure on the left hand direction control lever As you release pressure on a direction contro lever that respective wheel will tum slower and the mower will turn in that direction Tighter turns can be made by pulling rearward on a direction control lever to apply the brake on that wheel Stopping the Mower Pull the direction control levers rearward to apply brakes Reversing the Mower With the mower stopped press on the reverse presence lever then shift the transmission lever into reverse If you do not hold the presence lever the engine will shut off Squeeze the reverse direction contro levers To steer to your right gradually release pressure on the right reverse direction control lever Steer to the left by releasing pressure on the left lever 20 OPERATING THE MOWER Making an Emergency Stop Grab the forward direction control levers and pull STARTING TO MOW AWARNING Objects hidden in the lawn can be thrown by the mower blades Thrown objects can cause serious injury Clear lawn of all debris before mowing Do not operate the mower without either the dis charge chute mulching plug or the entire grass catcher in place Wear eye protection Keep people and pets away For best cutting performance always mow with the throttle lever in FAST position To begin mow
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