Porter-Cable D27243-028-0 Portable Generator User Manual
Contents
1. BACK or REAR Operating Position What is the right and left side of the lawn mower When right hand RH or left hand LH is mentioned in this manual it means when you are in the operating position standing behind the handle What kind of engine is on my lawn mower When learning how to operate your new lawn mower you will need to Know what kind of engine powers the mower A decal on the engine will indicate the manu facturer and type or brand name of the engine BRIGGS amp STRATTON ENGINES BRIGGS amp STRATTON BRIGGS amp STRATTON TECUMSEH ENGINES HONDA ENGINES TECUNISEH NOTE Depending upon the features on the lawn mower model you purchased all the parts shown may not be included with your mower For ease of assembly aside of your work area lay out all hardware in the groups shown Each step of the assembly instructions will identify the group needed for that step PARTS PACKED SEPARATELY IN CARTON NOTE Some model lawn mowers already have the wheels 1 Control Bar preassembled to the mower 1 Remote Throttle Control If Equipped wy QP FH con 4 4 Wheel Height Adjusters Wheels If Equipped 1 Upper Handle 1 Engine Zone Control Cable 1 Lower Handle S gt Grass Catcher Frame ma Discharge mowers only 1 Discharge Guard Grass Catcher Bag Side Discharge models only ea aa mowers only PARTS BAG CONTENTS NOT SHOWN ACTUAL SIZE2. OPERATOR S MANUAL ECONOMY PUSH ROTARY Lawn Mower e Assembly e Operation e Maintenance e Service and Adjustments e Storage e Troubleshooting 172777 Rev 2 05 08 03 BY Printed in U S A TABLE OF CONTENTS Safety Rules ccccceceeccssseeeseeeeeeeeeees 2 Service and Adjustments 0006 21 ASSemDIY acerina 9 AO e ee ene ese eee ener eee 22 OPONON ere rer ee ener serene eee 16 Troubleshooting x scacceseatoonssneteaarcecteeiaenee 23 Maintenance toetscctore sage taheesaesecsentycumeteas 19 SAFETY RULES IMPORTANT This cutting machine is capable of amputating hands and feet and throw ing objects Failure to observe the following safety instructions could result in serious injury or death ALook for this symbol to point out I GENERAL OPERATION important safety precautions It means e Read understand and follow all CAUTION BECOME ALERT instructions on the machine and in the YOUR SAFETY IS INVOLVED manual s before starting Be thoroughly familiar with the controls and the proper 4 WARNING In order to prevent acci use of the machine before starting dental starting when setting up e Do not put hands or feet near or under transporting adjusting or making repairs rotating parts Keep clear of the dis always disconnect spark plug wire and charge opening at all times place wire where it cannot contact plug e Only allow responsible individuals who are familiar with the instructions to
3. tain 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 Adjust ments section of this manual should be checked at least once each season e Once a year replace the spark plug clean or replace air filter element and check blade for wear A new spark plug and clean new air filter element assures proper air fuel mixture and helps your engine run better and last longer e Follow the Maintenance Schedule in this manual BEFORE EACH USE e Check engine oil level e Check for loose fasteners LUBRICATION Keep unit well lubricated IMPORTANT Do not oil or grease plastic wheel bearings Viscous lubricants will attract dust and dirt that will shorten the Me 4 Charge 48 hours at end of season 5 And after each 5 hours of use LUBRICATION CHART Wheel adjuster on each wheel D Engine oil Side dis charge mower J aa hinge rod Rear dis charge mower rear door hinge rod Handle bracket mounting pins D Spray lubricant 2 See ENGINE in Maintenance section of the self lubricating bearings If you feel they must be lubricated use only a dry gr aren graphite type lubricant sparingly LAWN MOWER Always observe safety rules when perform ing any maintenance TIRES e Keep tires free of gasoline oil or insect control chemicals which can harm rubber e Avoid stumps sto
4. STARTER ROPE GUIDE TO HANDLE PARTS BAG CONTENTS CON T Diecast Clamp with aim x 5 8 Hex Head Screw For Briggs Engines only NOTE Tecumseh engines have clamp and screw preassembled to engine Cable Clip with Fom a O x 5 8 Hex Head Screw For Briggs Classic amp Sprint Engines 2 Scans 1 4 20 x 3 8 nies with spark plug to front of mower For models without remote throttle control O Ma7 1 Hex Bolt 1 Locknut 1 4 20 x 1 1 2 1 Hex Head Screw 1 4 20 x 2 1 8 1 Keps Locknut 1 4 20 ASSEMBLY AACAUTION Do not operate this mower without the discharge guard or an entire ap proved grass catcher in place These guards are for your protection and are required by the American National Standards Institute and Consumer Products Safety Com mission AACAUTION Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug ASSEMBLE LOWER HANDLE REAR DISCHARGE MOWER SHOWN USE HARDWARE GROUP A rear of deck and block securely e Position lower handle on deck as shown N 20 mowers cut off flat forward D gt 22 mowers arrow down DI e Align holes in handle with holes in deck as shown and assemble 3 8 16 x 3 4 Handle Lower handle MODELS WITH BOLT ON LOWER SQUEEZE HANDLE TO INSTALL e For ease of lower handle assembly raise i KA hex bolts 7 8 washers and flanged Hairpin cotter bracket locknuts Tighten securely moun
5. lll 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 e Keep children out of the trimming area and under the watchful care of another responsible adult e Be alert and turn machine off if children enter the area e Before and while walking backwards look behind and down for small children e Never allow children to operate the ma chine e Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision IV SERVICE e Use extra care in handling gasoline and other fuels They are flammable and vapors are explosive Use only an approved container Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling Do not smoke Never refuel the machine indoors Never store the machine or fuel container inside where there is an open flame such as a water heater e Never run machine inside a closed area e 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 e Keep nuts and bolts especially blade attachment bolts tight and keep equip ment in good condition e Never tamper with safety devices Check their proper operation regularly Keep machine free
6. of grass leaves or other debris build up Clean oil or fuel spillage Allow machine to cool before storing e Stop and inspect the equipment if you strike an object Repair if necessary before restarting e Never attempt to make wheel height adjustments while the engine motor is running e Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recommended parts when necessary e Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them e Do not change the engine governor set ting or overspeed the engine CONGRATULATIONS on your purchase of a new Lawn Mower It has been designed engineered and manufactured to give you the best possible dependability and perfor mance Should you experience any problems you cannot easily remedy please contact your nearest authorized service center They have competent well trained technicians and the proper tools to service or repair this unit e Read the SAFETY RULES and this Operator s Manual in its entirety before you at tempt to assemble or operate your new lawn mower to insure proper operation and to prevent injury to yourself and others Save this manual for future reference e Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for
7. oper AWARNING Engine exhaust some of its ate the machine constituents and certain vehicle compo e Clear the area of objects such as rocks nents contain or emit chemicals Known to toys wire bones sticks etc which the State of California to cause cancer and could be picked up and thrown by the birth defects or other reproductive harm blade e Be sure the area is clear of other people AWARNING Battery posts terminals and before mowing Stop machine if anyone related accessories contain lead and lead enters the area compounds chemicals known to the State e Do not operate the mower when bare of California to cause cancer and birth foot or wearing open sandals Always defects or other reproductive harm Wash wear substantial foot wear hands after handling Do not pull mower backwards unless absolutely necessary Always look down amp CAUTION Muffler and other engine and behind before and while moving parts become extremely hot during backwards operation and remain hot after engine has Do not operate the mower without stopped To avoid severe burns on contact proper guards plates grass catcher or Stay away from these areas other safety protective devices in place See manufacturer s instructions for proper operation and installation of accessories Only use accessories ap proved by the manufacturer Stop the blade s when crossing gravel drives walks or roads e Stop the engine motor whenever you leave th
8. shipping purposes 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 e All parts such as nuts washers bolts etc necessary to complete the assembly have been placed in the parts bag TO REMOVE MOWER FROM CARTON e Remove all loose parts from carton e Remove lawn mower housing with care Avoid touching blade under housing Always wear gloves or other protection when working under or lifting mower THINGS TO KNOW BEFORE YOU ASSEMBLE OR OPERATE YOUR LAWN MOWER Do I have a side or rear discharge lawn mower Look for the grass discharge opening on your mower If the opening is on the right side of the mower housing it is a side discharge mower If the opening is at the back of the mower housing it is a rear dis charge mower Only rear discharge lawn mowers have a grass catcher included with the mower Approved grass catchers for side discharge mowers may be purchased from your nearest authorized dealer Do I have a mulching lawn mower Look for the grass discharge opening on your mower Raise the discharge guard rear door on rear discharge mowers If the opening is closed off by a plate then your lawn mower is mulcher ready To convert to a discharging mower see the Operation section of this manual FRONT LEFT RIGHT HAND HAND SIDE SIDE
9. MOTE THROTTLE Engine speed is controlled by the throttle control located on the upper handle e Move lever forward to FAST engine speed for starting and better bagging e Move lever backward for SLOW engine speed e Some models have engines equipped with a choke feature Move the lever all the way forward to the CHOKE position when starting a cold engine X N ye CHOKE h START 1I Remote throttle control MODELS WITH ENGINE MOUNTED SPEED CONTROL The engine speed is controlled by a lever located at the carburetor on the engine HIGH or FAST position is for starting engine normal cutting and better grass bagging LOW or SLOW position is for light cutting trimming and fuel economy MODELS WITH FIXED SPEED ENGINES Engine speed was set at the factory for optimum performance Engine speed is not adjustable BRIGGS amp STRATTON CLASSIC or SPRINT ENGINE MOUNTED SPEED CONTROL Engine speed Primer if equipped control lever BRIGGS amp STRATTON QUANTUM ENGINE MOUNTED SPEED CONTROL Primer if RX equipped TECUMSEH ENGINE MOUNTED SPEED CONTROL Engine speed Sse control lever _ Primer if equipped TO ADJUST CUTTING HEIGHT Adjust cutting height to suit your require ments Medium position is best for most lawns Raise wheels for low cut and lower wheels for high cut MODELS WITH MANUAL ADJUST BOLT ON WHEELS e Remove wheel bolt and hardware and reas
10. One 1 only of the Starter Rope Guides shown below X Center Mount 1 Upstop 4 Hubcaps e a Equipped Side Mount ASSEMBLY LOCATION PARTS BAG CONTENTS GROUP A For models with Bolt on lower handle only DNN 4 Hex Bolts a 16 x 3 4 4 Flange Locknuts 3 8 16 4 Washers 7 8 Dia For models with deck handle brackets only SA 2 Hairpin Cotters GROUP B For models with fixed upper handle For all models Ba Upstop Bracket Screw 10 24 x 1 2 Q 2 Wing Nuts 4 Hex Bolts 3 8 16 x 3 4 NSZ 2 Locknuts 8 7 2 Handle Bolts ASSEMBLY LOCATION PARTS BAG CONTENTS continued GROUP C For models with bolt on wheels only WHEELS 4 Shoulder Bolts 4 Locknuts 3 8 16 2 or 4 Washers 1 1 4 Dia For models with Quick Adjust wheel 4 Locknuts height adjusters only 3 8 16 4 Retainer res N 4 Flanged a dl 3 8 16 4 Washers 1 Dia 4 Whee Adjuster Knobs GROUP D For models with bolt on discharge guard only Q08 2 Spacers 2 Wash Locknuts aa ars 20 2 Hex Bolts 1 4 20 HOUSING gi Dia Side Discharge i If equipped For models with spring loaded models only Screw Mounted discharge guard only Nut Mounted ZED x Hex Washer Head fom Sel tapping Screws 2 Locknuts O 20 x 3 8 14 20 cy ASSEMBLY LOCATION REMOTE THROTTLE CONTROL If equipped TO ENGINE CONTROL CABLE S TO UPPER HANDLE
11. above lower handle crossbar Secure with 1 4 20 keps locknut e Hold control bar against upper handle and slowly pull starter rope out until rope will slip into loop of rope guide 15 Control bar Upper Rope guide 1 4 20 Keps locknut Lower handle crossbar Engine starter we rope R SPARK PLUG BOOT IF EQUIPPED NO HARDWARE REQUIRED On some model lawn mowers a spark plug boot is packed loose in the parts bag If your model has one install it on spark plug wire and then reconnect plug to spark plug py Wa Spark Spark NS plug wire k Yi LL a Boot ASSEMBLE GRASS CATCHER REAR DISCHARGE MODELS ONLY NO HARDWARE REQUIRED e Put grass catcher frame into grass bag with rigid part on bottom e Slip vinyl bindings over frame If bind ings are too stiff hold them in warm water for a few minutes Allow bag to dry before using Catcher frame Frame opening OPERATION WEAR YOUR The operation of any lawn mower can result in foreign objects thrown into the awe eyes which can result in severe eye damage Always wear Safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs We recom mend standard safety glasses or a wide vision safety mask worn over spectacles HOW TO USE YOUR LAWN MOWER ENGINE SPEED CONTROL MODELS WITH RE
12. cable and assemble to side of engine with supplied hex head screw Tighten securely MODELS WITH TECUMSEH ENGINE e Straighten cable and find the end with the small tapered plastic fitting e Hook the Z bend fitting on inner wire of cable into hole as shown e Align the tapered end of the plastic fitting with the hole in the mounting bracket and push in until fitting snaps into place e Route cable under crossbar portion of lower handle and up to upper handle control bar e Hook Z bend fitting on inner wire into hole in control bar See ASSEMBLE CABLES TO UPPER HANDLE in this manual TECUMSEH ENGINES WITH SPARK PLUG FORWARD Mounting bracket gt k lt J Small plastic fitting Z Fitting TECUMSEH ENGINES WITH SPARK PLUG REARWARD NS biai _ ia N hg dling f bee Pe Tae plastic Mounting yk y N fitting bracket S MODELS WITH BRIGGS amp STRATTON QUANTUM ENGINES e Hook the Z bend fitting on inner wire of cable end with tapered plastic fitting into hole in brake lever of engine Cor rect brake lever to use is determined by position of spark plug on your mower forward or rearward e Position the tapered plastic fitting into the mounting bracket on engine Snap fitting into place e Route cable under crossbar portion of lower handle and up to upper handle control bar e Hook Z bend fitting on inner wire into hole in control bar S
13. ced blade will cause excessive vibration and eventual damage to lawn mower and engine e The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen while on the mower To check blade balance drive a nail into a beam or wall Leave about one inch of the straight nail exposed Place center hole of blade over the head of the nail If blade is balanced it should remain in a horizontal position If either end of the blade moves downward sharpen the heavy end until the blade is balanced GRASS CATCHER IF SO EQUIPPED Grass catcher may be hosed with water but must be dry when used AACAUTION Under normal usage the catcher material is subject to deterioration and wear and should therefore be checked to ensure compliance with original manufacturer specifications ENGINE Read the maintenance section of your engine manual LUBRICATION Change the oil after the first two hours of operation and every 25 hours thereafter or at least once a year if the lawn mower is not used for 25 hours in one year Refer to engine manual TO CHANGE ENGINE OIL SEE ENGINE MANUAL e Be sure mower is on a level surface e Oil will drain more freely when warm e Catch oil in a suitable container e For engines without dipstick remove bottom oil drain plug e For engines with oil fill cap dipstick remove bottom drain plug or remove en gine oil cap and turn mower on its side After oil has drained completely
14. curely ASSEMBLE WHEELS USE HARDWARE GROUP C NOTE Some model mowers do not have baffles on underside of mower housing On models without baffle in front and or rear of housing use the 1 1 4 washers supplied when you assemble the wheels MODELS WITH BOLT ON WHEELS Cutting height is determined by assem bling wheels in one of four possible posi tions on the mower housing All wheels must be in the same height position for even cutting e For each wheel assemble shoulder bolt wheel and spacer as shown e Assemble 1 1 4 diam washer if sup plied and 3 8 16 locknut on inside of mower housing and tighten securely SIDE DISCHARGE MOWER SHOWN 1 1 4 diameter Washer Rear wheels only Mower housing Shoulder bolt Wheel Locknut MODELS WITH QUICK ADJUST WHEEL HEIGHT ADJUSTERS Look carefully at the four 4 adjuster assemblies Notice that there are two 2 each of two 2 different types Type I is for the Right Rear and Left Front installation Type Il is for the Right Front and Left Rear installation TYPE TYPE Il ASSEMBLE ADJUSTERS TO MOWER DECK e Position appropriate adjuster at each corner of mower e Install each adjuster with adjuster bolt and tab in deck holes as shown and secure with 1 1 4 diam washer if sup plied and 3 8 16 locknut Tighten all adjusters securely SIDE DISCHARGE MOWERS 1 1 4 Washer If supplied Tab hole TYPE Righ
15. e Pour one ounce 29 ml of oil through spark plug hole into cylinder e Pull starter handle slowly to distribute oil e Replace with new spark plug OTHER e Do not store gasoline from one season to another e Replace your gasoline can if your can starts to rust Rust and or dirt in your gasoline will cause problems e If possible store your unit indoors and cover it to protect it from dust and dirt e Cover your unit with a suitable protective cover that does not retain moisture Do not use plastic Plastic cannot breathe 22 which allows condensation to form and will cause your unit to rust IMPORTANT Never cover mower while engine and exhaust areas are still warm 4 amp CAUTION Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before stor ing in any enclosure TROUBLESHOOTING See appropriate section in this manual unless directed to an authorized service center PROBLEM CAUSE CORRECTION Does not start Dirty air filter Out of fuel Stale fuel Water in fuel disconnected Bad spark plug Loose blade or broken blade adapter Control bar in released position Control bar defective 10 Fuel valve lever if so i 2 3 4 5 Spark plug wire is 6 7 8 9 equipped in OFF position 11 Weak battery if equipped 12 Disconnected battery connector if equipped Rear of lawn
16. e equipment before cleaning the mower or unclogging the chute e Shut the engine motor off and wait until the blade comes to complete stop before removing grass catcher e Mow only in daylight or good artificial light e Do not operate the machine while under the influence of alcohol or drugs e Never operate machine in wet grass Always be sure of your footing keep a firm hold on the handle and walk never run e Disengage the self propelled mech anism or drive clutch on mowers so equipped before starting the engine motor e If the equipment should start to vibrate abnormally stop the engine motor and check immediately for the cause Vibra tion is generally a warning of trouble e 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 cau tion If you feel uneasy on a slope do not mow it DO e Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes e Remove obstacles such as rocks tree limbs etc e Watch for holes ruts or bumps Tall grass can hide obstacles DO NOT e Do not trim near drop offs ditches or embankments The operator could lose footing or balance e Do not trim excessively steep slopes e Do not mow on wet grass Reduced foot ing could cause slipping
17. e or adjustments e Release operator presence control bar e Make sure the blade and all moving parts have completely stopped e Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug LAWN MOWER REAR DEFLECTOR IF EQUIPPED The rear deflector attached between the rear wheels of your mower is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator mowing position If the deflector becomes damaged it should be replaced ENGINE CARBURETOR The carburetor has been preset at the fac tory and adjustment should not be neces sary However minor adjustment may be required to compensate for differences in fuel temperature altitude or load e The air filter must be assembled to the carburetor when running engine e Best carburetor adjustment is obtained when fuel tank is 1 4 full e In order for the engine to run the opera tor presence control bar must be held in the operating position Therefore and assistant will be required to hold the control bar in the operating position when making final adjustment to the carburetor See the adjustment section of your engine manual for further instructions ENGINE SPEED The engine speed has been factory set Do not attempt to increase engine speed as it may result in personal injury If you believe the engine is running too fast or too slow take your lawn mower to an au
18. e sure to fold handles as shown or you may damage the control cables When setting you handles up from the storage position the lower handle will au tomatically lock into mowing position 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 formation of acids during storage Acidic gas can damage the fuel systme of an engine while in storage e Drain the fuel tank e Start the engine and let it run until the fuel lines and carburetor are empty e Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur e Use fresh fuel next season NOTE Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage Add stabilizer to gasoline in fuel tank or storage container Always follow the mix ratio found on stabilizer container Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor Do not drain the gas tank and carburetor if using fuel stabilizer ENGINE OIL Drain oil with engine warm and replace with clean oil See ENGINE in the Maintenance section of this manual CYLINDER e Remove spark plug
19. ee ASSEMBLE CABLES TO UPPER HANDLE Brake lever rearward spark plug Brake lever forward spark plug Mounting bracket rearward spark plug Mounting bracket forward spark plug ASSEMBLE CABLE S TO UPPER HANDLE USE HARDWARE GROUP F e Assemble cable s to opposite side of upstop bracket e Be sure to route cable s underneath crossbar of lower handle Position throttle control if equipped on outside of handle and zone control square fitting on the inside Secure to handle with the 1 4 20 ma chine screw or hex bolt supplied and locknut as shown Tighten securely Secure cable s to crossbar and lower handle with cable ties as needed 14 Throttle control p Control bar If Se 1 4 20 Machine screw or hex bolt supplied ASSEMBLE STARTER ROPE GUIDE USE HARDWARE GROUP G CENTER MOUNT TYPE e Install threaded end of rope guide through hole in top of lower handle crossbar e Loosely assemble 1 4 20 keps locknut on threaded portion of rope guide Do not tighten e Hold control bar against upper handle and slowly pull starter rope out and up over lower handle crossbar and slip into loop of rope guide e Push rope guide down against crossbar and tighten nut securely Engine starter rope Rope guide aK Lower handle Saan N ay N RQ 2 SN RN 1 4 20 Keps locknut SIDE MOUNT TYPE e Put threaded end of rope guide through hole in side of upper handle
20. ess control bar to when control bar is released Bent engine crankshaft Blade adapter broken Blade dragging in grass Cutting height too low 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 cutting blade dragging in grass Grass catcher too full Handle height position not right for you 24 upper handle before pulling starter rope Contact a qualified service center Replace blade adapter Move lawn mower to cut grass or to hard surface 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
21. gs lever Diecast clamp 13 QUANTUM ENGINES SPARK PLUG TO REAR OF MOWER Por Throttle lever N Diecast clamp Se V7 Throttle cable pe lt lt Hex Head Screw 10 x 5 8 ASSEMBLE ENGINE ZONE CONTROL CABLE TO ENGINE NO HARDWARE REQUIRED Follow the appropriate instructions below for the brand or type of engine on your lawn mower MODELS WITH BRIGGS amp STRATTON CLASSIC OR SPRINT ENGINE Cable attaches under the brake arm cover which is opposite the spark plug end of engine e Straighten cable and find the end with the small plastic fitting e Hook the Z bend fitting on inner wire of cable into hole in brake arm of engine Align the tapered end of the plastic fitting with the hole in mounting bracket and push in until fitting Snaps into place Route cable below crossbar portion of lower handle and up to upper handle control bar e Hook Z bend fitting on inner wire into hole in control bar See ASSEMBLE CABLES TO UPPER HANDLE in this manual Engine cable clip rearward spark plug models only Brake Mounting arm bracket cover Brake Z Fitting Small plastic fitting Hex head screw 10 x 5 8 rearward spark plug models only MODELS WITH SPARK PLUG TO REAR OF MOWER To prevent cable damage the cable must be attached to the side of engine away from the muffler e Above the muffler locate the hole in en gine shroud Install supplied cable clip on
22. injury Do not under any circumstances attempt to defeat the function of the operator control The blade turns when the engine Is running GRASS CATCHER REAR DISCHARGE MODELS ONLY TO ATTACH GRASS CATCHER e Open rear door Place frame onto formed tabs on hinge bracket e Release rear door and allow to rest on catcher TO REMOVE GRASS CATCHER e Simply open rear door and lift grass catcher up and away from mower Rear door Hinge bracket formed tabs Catcher frame AACAUTION Under normal usage the catcher material is subject to deterioration and wear and should therefore be checked frequently for replacement Any replacement catcher should be checked to ensure compliance with original manufacturer s specifications AACAUTION Do not run lawn mower without the discharge guard rear door approved grass catcher or clipping deflector in place Never attempt to operate mower with the discharge guard rear door removed or propped open BEFORE STARTING ENGINE Read engine manual packed with your unit FILL ENGINE WITH OIL Your lawn mower is shipped without oil in the engine e Be sure mower is level and area around oil fill is clean e Remove engine oil filler plug oil fill cap dipstick on models so equipped e Slowly add oil For type and grade of oil to use see ENGINE in the Mainte nance section of this manual e Fill to the top of slot in filler hole to FULL line on dipstick on models so equ
23. ipped Do not overfill e Replace plug oil fill cap dipstick on models so equipped and tighten e Check oil level before each use Add oil as needed e To change oil see TO CHANGE EN GINE OIL in the Maintenance section of this manual FILL GASOLINE TANK e Fill gasoline tank with fresh clean un leaded gasoline DO NOT USE PRE MIUM GASOLINE BE CAREFUL NOT TO OVERFILL TANK 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 fuel tank start the engine and let it run until fuel lines and carburetor are empty Use fresh fuel next season See Storage Instructions for additional information Never use engine or carburetor cleaner products in fuel tank or permanent damage may occur TO START ENGINE AACAUTION The mower blade rotates whenever the engine is running e Move engine speed control to FAST position or to CHOKE START position on models equipped with choke feature e f your mower has a primer to start a cold engine push primer the number of times as instructed in the engine manual packed with your mower Use a firm push This step is not usually necessary when starting an engine which has already
24. mower housing or cutting blade dragging in heavy grass Cutting too much grass 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 Buildup of grass leaves and trash under mower Worn bent or loose blade Bent engine crankshaft 23 Clean replace air filter Fill fuel tank Drain fuel tank and refill tank with fresh clean gasoline Drain fuel tank and refill tank with fresh clean gasoline Connect wire to plug Replace spark plug Tighten blade bolt or replace blade adapter Depress control bar to handle Replace control bar 10 Turn fuel valve lever to the ON position 11 Charge battery 12 Connect battery to engine O 0 No eS PY Raise cutting height Raise cutting height 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 height Clean underside of mower housing Replace blade Tighten blade bolt Contact a qualified service center TROUBLESHOOTING continued See appropriate section in this manual unless directed to an authorized service center PROBLEM CAUSE CORRECTION Starter rope hard to pull Grass catcher not filling If so equipped Hard to push Engine flywheel brake is on 1 Depr
25. n a clockwise direction e When using a rear discharge lawn mower in moist heavy grass clumps of cut grass may not enter the grass catcher Reduce ground speed pushing speed and or run the lawn mower over the area a second time e Ifa trail of grass clipping is left on the right side of a rear discharge lawn mower mow in a clockwise direction with a small overlap to collect the clippings on the next pass e Pores in cloth grass catchers can be come filled with dirt and dust with use and the catcher will collect less grass To prevent this regularly hose catcher off with water and let dry before use MAINTENANCE MAINTENANCE SCHEDULE FILL INDATES AS YOU COMPLETE REGULAR SERVICE vee TA os a Sr P ff Ce A tt Power Propelled Mowers Yi M Clean Inspect Grass Catcher O If Equipped W Clean Lawn Mower Clean Battery Recharge Electric Start Mowers Check Engine Oil Level Change Engine Oil Clean Air Filter Inspect Muffler Replace Spark Plug Replace Air Filter Paper Cartridge 1 Change more often when operating under a heavy load or in high ambient temperatures 2 Service more often when operating in dirty or dusty conditions 3 Replace blades more often when mowing in sandy soil GENERAL RECOMMENDATIONS The warranty on this lawn mower does not cover items that have been subjected to op erator abuse or negligence To receive full value from the warranty operator must main
26. nes deep ruts sharp objects and other hazards that may cause tire damage BLADE CARE For best results mower blade must be kept sharp Replace bent or damaged blades TO REPLACE BLADE e Turn lawn mower on it s side See engine manual for proper direction of turning over the engine e Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt e Protect your hands with gloves and or wrap blade with heavy cloth e Remove blade bolt lock washer and flat washer e Remove blade and blade adapter e Inspect the key inside blade adapter Replace adapter if damaged IMPORTANT Blade bolt is grade 8 heat treated e Install new or sharpened blade with trailing edge up toward the engine e Position blade on blade adapter Align the two 2 holes in blade with raised lugs of adapter e Reassemble blade bolt lock washer and flat washer into blade adapter and crankshaft in exact order as shown e Position block of wood between blade and mower housing e Tighten blade bolt securely Recom mended tightening torque is 35 40 ft Ibs NOTE We do not recommend sharpening the blade but if you do be sure the blade is balanced Blade adapter Key Crankshaft keyway L y Lockwasher Blade DD Blade bolt Hardened washer Trailing edge Blade adapter TO SHARPEN BLADE Care should be taken to keep the blade balanced An unbalan
27. replace oil drain plug and tighten securely Refill engine with oil Pour slowly Do not overfill Fill to top of slot inside of filler hole or to FULL line on dipstick on models so equipped Keep oil at proper level 20 AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter Clean the element after every 25 hours of operation more often if lawn mower is used in very dusty dirty conditions See the maintenance section of your engine manual SPARK PLUG Change the spark plug once a year to make the engine run better and easier to start Set spark plug gap according to engine manual specifications MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage CLEANING IMPORTANT For best performance keep mower housing free of grass build up and trash Clean the underside of your mower after each use e Clean the underside of your lawn mower by scraping to remove buildup 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 We do not recommend using a garden hose to clean your lawn mower unless the electrical system muffler air filter and carburetor are covered to keep water out Water in engine can shorten engine life SERVICE AND ADJUSTMENTS AACAUTION Before performing any servic
28. run for a few minutes e Hold operator presence control bar down against handle Pull starter handle quickly Do not allow starter rope to snap back e For engines equipped with choke slowly move engine speed control lever to FAST position after engine starts e To STOP engine release operator pres ence engine control bar NOTE For engines with a primer it may be necessary to repeat priming steps in cooler weather In warmer weather overpriming 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 Operator presence Recoil control bar starter handle Recoil starter center handle side mount mount type type MOWING TIPS e For most cutting conditions and better bagging performance the engine speed should be set in the FAST position e Under certain conditions such as when mowing very tall grass raise the mower height on the first cut to reduce pushing effort to avoid overheating the engine and to avoid leaving clumps of grass clippings Make the second cut to the desired height e For extremely heavy cutting reduce the width of cut e For side discharge lawn mowers cut in a counterclockwise direction starting at the outside of the area to be cut in order to spread grass clippings more evenly and to put less load on the engine To keep clippings off of walkways flower beds etc make the first cuts i
29. semble in desired adjustment hole e Reinstall wheel components in the same order as they were before removal Tighten securely e Make sure all wheels are at the same height Flat washer 3 8 16 Spacer Locknut MODELS WITH QUICK ADJUST WHEEL HEIGHT ADJUSTERS NOTE For shipping purposes the rear wheels on your lawn mower may not be adjusted to the same position as the front wheels Before operating mower adjust all wheels to the same cutting height e Raise wheels for low cut and lower wheels for high cut Adjust cutting height to suit your require ments Medium position is best for most lawns e To change cutting height squeeze ad juster lever toward wheel Move wheel up or down to suit your requirements Be sure all wheels are in the same set ting 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 ie See Plate tab RAISE WHEELS FOR LOW CUT Lever 17 OPERATOR PRESENCE ENGINE CONTROL BAR Your lawn mower is equipped with an op erator presence engine control bar which requires the operator to be positioned behind the lawn mower handle in order to start and operate the lawn mower AACAUTION Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact
30. t rear left front height adjuster TYPE Il Right front left rear height adjuster Tab hole REAR DISCHARGE MOWERS Tab hole 1 1 4 Washer If supplied Locknuts TYPE Right rear left front height adjuster TYPE Il Right front left rear height adjuster Tab hole ASSEMBLE WHEELS TO ADJUSTER AXLE ARMS e Secure each wheel with flat washer and retainer spring or flange locknut if equipped with threaded axle e Assemble adjustment knobs to adjuster levers by pressing or tapping lightly e f your mower is equipped with hubcaps install by pressing or tapping lightly until hubcap snaps securely over flat washer Axle arm Wheel Flat washer Retainer spring Adjustment knob Flange locknut If equipped with Hubcap If epuipped threaded axle arm INSTALL DISCHARGE GUARD SIDE DISCHARGE MODELS ONLY USE HARDWARE GROUP D If your mower is a rear discharge mower go on to INSTALL CONTROL BAR MODELS WITH BOLT ON GUARD NOTE If your discharge guard has ribbing as shown in the illustration below there are two 2 spacers which must be placed between guard and mower housing e Place discharge guard on top of lawn mower discharge opening Install two 2 1 4 20 short hex bolts through housing and discharge guard Install two 2 3 4 washers and two 2 1 4 20 locknuts Tighten securely BOLT ON GUARD WITH RIBBING eir Locknuts Washers p Discharge g
31. thorized engine service center for repair and adjustment THROTTLE CONTROL If it becomes necessary to adjust or replace the throttle control see the adjust ment section of your engine manual 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 CAUTION Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure LAWN MOWER When lawn mower is to be stored for a pe riod of time clean it thoroughly remove all dirt grease leaves etc Store in a clean dry area e Clean entire lawn mower See CLEANING inthe Maintenance section of this manual e Lubricate as shown in the Maintenance section of this manual e Be sure that all nuts bolts screws and pins are securely fastened Inspect moving parts for damage breakage and wear Replace if necessary e Touch up all rusted or chipped paint surfaces sand lightly before painting HANDLE STORAGE HANDLE BRACKET MODELS ONLY Your handle may be folded for storage as shown e Squeeze the bottom ends of lower handle towards each other until handle clears the handle brackets and swing handles forward over mower e Loosen upper handle mounting hard ware enough to allow upper handle to be folded back IMPORTANT When folding handles for storage or transportation b
32. ting pin e Repeat for opposite side of mower Flanged ASSEMBLE UPPER HANDLE n locknuts A ieee ji USE HARDWARE GROUP B Arrow down 22 Mowers Lower handle N MODELS WITH FIXED NON FOLDING HANDLES e Position upper handle over lower handle 20 mowers small hole for mounting upstop bracket to left hand side ima 22 mowers side of handle with four 4 holes as shown to left hand side vo e Assemble 1 4 20 x 1 1 2 hex bolts and Cut off flat forward 1 4 20 locknuts Tighten securely Hex 20 Mowers bolts Four 4 holes MODELS WITH DECK HANDLE 22 Mowers BRACKETS e Install lower handle onto handle brackets by squeezing the bottom ends of handle towards each other until the handle will slip onto the mounting pins on the Hex handle brackets bolts e Pull handle back to lock in operating Upstop bracket position Locknuts screw 10 24 x 1 2 Install the two 2 hairpin cotters sup plied onto the mounting pins MODELS WITH FOLDING UPPER HANDLE e Position upper handle over lower handle with small hole for mounting upstop bracket to left hand side e Assemble handle bolts and wing nuts Tighten securely Upstop bracket Upstop bracket screw 10 24 x 1 2 I SS Handle bolts ASSEMBLE UPSTOP BRACKET SEE ILLUSTRATION ABOVE e Position upstop bracket over hole inside the left side of upper handle and install upstop bracket screw 10 24 x 1 2 Tighten se
33. uard ribbing a Hex bolts BOLT ON GUARD WITHOUT RIBBING Si Locknuts Washers Discharge guard MODELS WITH SPRING LOADED DISCHARGE GUARD e Place discharge guard on top of lawn mower discharge opening e Install two 2 hex self tapping screws through housing and into guard mount ing bracket or install two 2 1 4 20 locknuts If equipped Tighten securely SCREW MOUNTED TYPE Discharge guard Hex head self tapping Locknuts INSTALL CONTROL BAR NO HARDWARE REQUIRED e Position control bar so flattened section with hole is on opposite side of upstop bracket e Insert one end of control bar into hole be hind upstop bracket Carefully push in on opposite end of control bar and insert into formed hole on inside of upper handle qs Fr E A E Control bar Upstop bracket ASSEMBLE REMOTE THROTTLE CONTROL TO ENGINE ON MODELS SO EQUIPPED USE HARDWARE GROUP E If your mower does not have a remote throttle control go on to ASSEMBLE ENGINE ZONE CONTROL CABLE TO ENGINE e First move lever on remote throttle control to the CHOKE if equipped or FAST START position i CHOKE DN NI Determine the manufacturer and brand or type engine on your lawn mower and follow the appropriate instructions that follow MODELS WITH BRIGGS amp STRATTON CLASSIC OR SPRINT AND TECUMSEH ENGINES NOTE Tecumseh engines have cable mounting clamp and scre
34. w preassembled on engine e At engine carburetor insert wire Z bend of throttle control into hole of speed lever use inner hole on Briggs amp Stratton engine Briggs amp Stratton only Assemble di ecast clamp and 10 x 5 8 screw loosely to engine Position throttle cable under clamp and push cable towards speed lever until speed lever touches boss Hold cable at this po 42 Sition and tighten clamp screw securely BRIGGS amp STRATTON ENGINE SHOWN Clamp and Screw are preassembled on Tecumseh engines Speed lever w x BY CS 4 oe G Diecast clamp Py 10 x 5 8 bA Hex head screw BRIGGS amp STRATTON CLASSIC AND SPRINT ENGINES WITH THE SPARK PLUG TO FRONT OF MOWER e Attach throttle cable to side of engine housing with cable clip and 10 x 5 8 hex washer head screw Tighten securely Throttle cable i 10 x 5 8 iL IDN ER Hex head W Mie By te Us 5 i Cable clip MODELS WITH BRIGGS amp STRATTON QUANTUM ENGINES e Slide throttle lever on engine to CHOKE position away from spark plug Push gently beyond first stop to lock in detent CHOKE position e Insert wire Z bend of throttle cable into throttle lever hole from top side e Secure throttle cable to engine with diecast clamp and 10 x 5 8 hex head screw and tighten securely QUANTUM ENGINES SPARK PLUG TO FRONT OF MOWER Throttle cable Hex Head P L Screw y 10 x 5 8 p Throttle
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