Husqvarna 5521BBC Lawn Mower User Manual
Contents
1. PROBLEM CAUSE CORRECTION Does not start 1 Dirty air filter 1 Clean replace air filter 2 Out of fuel 2 Fill fuel tank 3 Stale fuel 3 Drain fuel tank and refill tank with fresh clean gasoline 4 Water in fuel 4 Drain fuel tank and refill tank with fresh clean gasoline 5 Spark plug wire is disconnected 5 Connect wire to plug 6 Bad spark plug 6 Replace spark plug 7 Loose blade or broken blade adapter 7 Tighten blade bolt or replace adapter 8 Control bar in released position 8 Depress control bar to handle 9 Control bar defective 9 Replace control bar 10 Fuel valve lever if so equipped 10 Turn fuel valve lever to the ON position is in the OFF position 11 Weak battery if equipped 11 Charge battery 12 Disconnected battery connector if equipped 12 Connect battery to engine 13 Engine control lever is 13 Place engine control lever in STOP position in FAST position Loss of power 1 Rear of lawn mower housing or 1 Raise cutting height cutting blade dragging in heavy grass 2 Cutting too much grass 2 Raise cutting height 3 Dirty air filter 3 Clean replace air filter 4 Buildup of grass leaves trash under mower 4 Clean underside of mower housing 5 Too much oil in engine 5 Check oil level 6 Walking speed too fast 6 Cut at slower walking speed Poor cut 1 Worn bent or loose blade 1 Replace blade Tighten blade bolt uneven 2 Wheel heights uneven 22. 4 Remove blade bolts by turning counter clockwise TO REPLACE BLADE See Fig 16 1 Position the blade Be sure trailing edge of blade op posite sharp edge is up toward the engine and install the blade bolts 2 Use block of wood between blade and lawn mower hous ing and tighten the blade bolts turning clockwise The recommended tightening torque is 35 40 ft Ibs IMPORTANT BLADE BOLTS ARE HEAT TREATED IF BOLTS NEED REPLACING REPLACE ONLY WITHAPPROVED BOLTS SHOWN IN THE REPAIR PARTS SECTION OF THIS MANUAL TRAILING EDGE TO SHARPEN BLADE NOTE We do not recommend sharpening blade but if you do be sure the blade is balanced Care should be taken to keep the blade balanced An unbalanced blade will cause eventual damage to lawn mower or engine The blade can be sharpened with a file or on a grind ing wheel Do not attempt to sharpen while on the mower e To check blade balance drive a nail into a beam or wall Leave about one inch of the straight nail exposed Place center hole of blade over the head of the nail If blade is balanced it should remain in a horizontal position If either end of the blade moves downward sharpen the heavy end until the blade is balanced GRASS CATCHER The grass catcher may be hosed with water but must be dry when used e Check your grass catcher often for damage or dete rioration Through normal use it will wear If catcher needs replacing replace only with a
3. reduce the width of cut by overlapping previously cut path and mow slowly For better grass bagging and most cutting conditions the engine speed should be set in the fast position Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass To prevent this regularly hose catcher off with water and let dry before using e Keep top of engine around starter clear and clean of grass clippings and chaff This will help engine air flow and extend engine life MULCHING MOWING TIPS IMPORTANT FOR BEST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH SEE CLEANING IN MAINTENANCE SECTION OF THIS MANUAL The special mulching blade will recut the grass clip pings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed Also the mulched grass will biode grade quickly to provide nutrients for the lawn Always mulch with your highest engine blade speed as this will provide the best recutting action of the blades e Avoid cutting your lawn when itis wet Wet grass tends to form clumps and interferes with the mulching action The best time to mow your lawn is the early afternoon At this time the grass has dried yet the newly cut area will not be exposed to direct sunlight For best results adjust the lawn mower cutting height so that the lawn mower cuts off only the top one third of the
4. 4 Husqvarna 5521BBC Owner s Manual 532 40 05 15 11 28 05 BY Printed in U S A SAFETY RULES A Safe Operation Practices for Walk Behind Mowers IMPORTANT THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH Look for this symbol to point out im portant safety precautions It means CAUTION BECOME ALERT YOUR SAFETY IS INVOLVED CAUTION Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up transporting adjusting or making repairs WARNING Engine exhaust some of its constituents and certain vehicle compo nents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CAUTION Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped To avoid severe burns on contact stay away from these areas I GENERAL OPERATION Read understand and follow all instructions on the machine and in the manual s before starting Be thor oughly familiar with the controls and
5. 53 13 53218 86 45 14 532 19 41 28 16 532 16 15 84 17 53216 16 02 532 19 61 62 19 532 19 06 22 20 812 00 00 22 21 532 16 33 65 22 532 16 99 11 23 532 16 45 55 24 53205 78 08 25 532 40 07 83 26 53275 06 34 27 53205 21 60 28 81200 00 58 29 532 18 94 03 30 532 17 51 04 31 532 18 41 72 32 532 18 07 74 cO Oo O OQ1 Q N 6L DESCRIPTION Drive Control Assembly Auto Walk Cover Top Auto Walk Drive Control Pulley Lever Auto Walk Drive Control Cover Bottom Auto Walk Drive Control Screw Phillips Head 10 x 5 8 Bracket Drive Control Cap Drive Control Bottom Cable Drive Control Decal Drive Control Screw Gear Case Assembly Complete Pulley Drive Rod Connecting Spring Extension Spring Selector Knob Selector Spring E Ring Bearing Support Bearing Ball Retainer Drive Assembly Stamped Screw Tapping Hex Head 1 4 20 x 75 Cover Drive Screw Threaded Rolled 10 25 x 50 Washer Shim as required E Ring 7 16 Cover Dust Wheel Disc Drive Seal Friction Wheel Driven Rear 9 x 2 KEY PART NO NO 33 532 08 39 23 34 532 18 06 26 35 532 19 60 16 36 532 19 34 38 37 53216 14 63 38 532 16 34 09 39 53270 02 79 40 532 15 03 39 41 532 18 83 30 42 532 1452 12 43 532 18 83 31 44 532 18 22 12 45 53217 50 98 46 532 18 82 91 47 532 06 77 25 48 53217 51 05 49 53217 51 03 50 532 17 51 02 51 532 18 75 30 52 5382 18 75 31 53 532 18 75 32 54 5382 18 75 33 55 532 19 12 49 5
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7. PRESENCE CONTROL BAR MOWING POSITION Z 7 N ef y UPPER amen HANDLE s lt lt aie i HANDLE SQUEEZE FIG 2 TO ASSEMBLE GRASS CATCHER See Fig 3 1 Put grass catcher frame into grass bag with rigid part of bag on the bottom Make sure the frame handle is outside of the bag top 2 Slip vinyl bindings over frame NOTE If vinyl bindings are too stiff hold them in warm water for a few minutes If bag gets wet let it dry before using aod fa te TOO w Ne OPENING TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher To convert mower to bagging or discharging see TO CONVERT MOWER in the Operation section of this manual OPERATION KNOW YOUR LAWN MOWER READ THIS OWNER S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for future reference These symbols may appear on your lawn mower or in literature supplied with the product Learn and understand their meaning O GO a N g ENGINE FAST SLOW CAUTION ENGINE ORWARNING ON OFF OPERATOR PRESENCE CONTROL BAR THROTTLE ENGINE V CONTROL STARTER HANDLE GRASS CATCHER MULCHER PLUG SINGLE POINT HEIGHT ADJUSTER HANDLE ENGINE OIL CAP WITH DIPSTICK IMPORTANT This law
8. UNC Cotter Hairpin Spring Rear Door LH Rear Door Assembly Bolt Rear Door Plug Mulcher Kit Housing Handle Bracket Assembly LH Handle Bracket Assembly RH Screw Hex Washer Head Bolt Hex Head 5 16 18 x 5 8 Nut Hex with Lock Washer Insert 5 16 18 Baffle Side Screw 12 x 5 8 Skirt Rear Screw Hinge 1 4 20 x 1 25 Blade 21 Bolt Engine Engine Honda Model No GCV160 For engine service and replacement parts call Honda at 1 800 426 7701 Grassbag Frame Grassbag Danger Decal Screw Mulcher Door Assembly Deflector Discharge Nut Hex Spring Return Screw Pulley Assembly V Groove Flange Nut Locknut KEY PART NO NO 54 532 19 68 12 55 532 16 60 43 56 532 16 08 29 57 532 19 33 15 58 532 18 20 03 59 532 18 27 48 60 53219 12 57 61 532 18 33 65 62 532 18 21 31 64 87390 06 00 65 532 19 09 03 66 532 18 99 37 67 532 19 65 41 68 532 18 04 60 69 ie 70 532 19 09 30 71 532 18 01 91 72 532 75 00 97 73 532 18 03 93 74 873 90 04 00 75 532 19 09 29 76 874 78 04 10 77 53205 39 98 78 87351 06 00 79 53218 86 30 80 532 18 03 94 81 532 18 01 88 82 532 19 50 49 83 532 19 50 72 84 532 19 50 53 85 532 19 50 73 86 532 19 50 74 87 582 19 50 57 88 532 19 50 60 89 532 19 50 63 90 532 19 50 64 91 532 19 50 65 92 532 19 50 67 93 532 19 50 68 94 532 19 50 69 95 532 19 50 70 i 532 16 23 00 s 532 40 05 15 DESCRIPTION Idler Arm Idler Pulley Shoulder Bolt Bracket Assembly Clip G
9. of the trimming area and under the watchful care of another responsible adult Be alert and turn machine off if children enter the area Before and while walking backwards look behind and down for small children Never allow children to operate the machine Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision IV SAFE HANDLING OF GASOLINE Use extreme care in handling gasoline Gasoline is ex tremely flammable and the vapors are explosive Extinguish all cigarettes cigars pipes and other sources of ignition Use only an approved container Never remove gas cap or add fuel with the engine run ning Allow engine to cool before refueling e Never refuel the machine indoors e Never store the machine or fuel container where there is an open flame spark or pilot light such as a water heater or on other appliances e Neverfillcontainers inside a vehicle on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling Remove gas powered equipmentfrom the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank orcontainer opening at all times until fueling is complete Do not use a nozzle lock open device e If fuel is spilled on clothing cha
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11. the entire container down the oil fill spout into the engine Insert and tighten oil fill cap dipstick ORTANT Check oil level before each use Add oil if needed Fill to full line on dipstick Change the oil after every 25 hours of operation or each season You may need to change the oil more often under dusty dirty conditions See TO CHANGE EN GINE OIL in the Maintenance section of this manual L FILL GASOLINE FILLER PER LOWER MARK FIG 13 OPERATION MOWING TIPS CAUTION Do not use de thatcher A blade attachments Such attachments ADD GASOLINE See Fig 13 Fill fuel tank to bottom of tank filler neck Do not over fill Use fresh clean regular unleaded gasoline with a minimum of 87 octane Do not mix oil with gasoline Purchase fuel in quantities that can be used within 30 days to assure fuel freshness CAUTION Wipe off any spilled oilor fuel Do not store spill or use gasoline near an open flame Alcohol blended fuels called gasohol or using ethanol or methanol can at tract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel sys tem of an engine while in storage To avoid engine problems the fuel system A should be emptied before storage of 30 days or longer Empty the gas tank start the engine and let it run until the fuellines and carburetor are empty Use fresh fuel next season See Storage Instructions for additional info
12. the proper use of the machine before starting Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times Only allow responsible individuals who are familiar with the instructions to operate the machine Clear the area of objects such as rocks toys wire bones sticks etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mow ing Stop machine if anyone enters the area Do not operate the mower when barefoot or wearing open sandals Always wear substantial foot wear Do not pull mower backwards unless absolutely nec essary Always look down and behind before and while moving backwards Never direct discharged material toward anyone Avoid discharging material against a wall or obstruc tion Material may richochet back toward the operator Stop the blade when crossing gravel surfaces Do not operate the mower without proper guards plates grass catcher or other safety protective devices in place See manufacturer s instructions for proper operation and installation of accessories Only use accessories approved by the manufacturer Stop the blade s when crossing gravel drives walks or roads Stop the engine motor whenever you leave the equip ment before cleaning the mower or unclogging the chute Shutthe engine motor off and wait until the blade comes to complete stop before removing grass catcher Mow only in daylight
13. the same your drive belt is worn and should be replaced OPERATION TO ADJUST CUTTING HEIGHT See Fig 8 All four wheels are adjusted by a single lever Pulladjusterlevertoward wheel To raisemower move lever forward to desired position To lower mower move the lever toward the rear LEVER BACKWARD TO LOWER MOWER LEVER FORWARD TO RAISE MOWER FIG 8 TO ATTACH GRASS CATCHER See Fig 9 1 Liftthe rear door of the lawn mower and place the grass catcher frame side hooks onto the door pivot pins 2 Thegrasscatcheris secured to the lawn mower housing when the rear door is lowered onto the grass catcher frame CAUTION Donotrun your lawn mower without mulcher plug or approved grass catcher in place Never attempt to op erate the lawn mower with the rear door removed or propped open PIVOT PINS REAR DOOR GRASS CATCHER HANDLE CATCHER FRAME HOOK FIG 9 TO EMPTY GRASS CATCHER See Fig 10 1 Lift up on grass catcher using the frame handle 2 Remove grass catcher with clippings from under lawn mower handle 3 Empty clippings from bag NOTE Do not drag the bag when emptying it will cause unnecessary wear FIG 10 TO CONVERT MOWER Your lawn mower was shipped ready to be used as a mulcher To convert to bagging or discharging REAR BAGGING See Fig 11 Open rear door and remove mulcher plug Store mulcher plug in a safe place You can now install the grass catch
14. 6 532 18 35 06 57 532 18 35 08 58 532 18 35 09 59 532 18 35 11 60 532 19 09 48 61 532 18 35 13 62 532 18 35 14 DESCRIPTION Nut Hex Flangelock 3 8 16 Hubcap Shaft Assembly Rear Shaft Assembly Front Retainer Front Shaft Screw 12 x 5 8 Clip Retainer Wheel Front 8 x 2 Pinion Assembly RH Nut Hex Pinion Assembly LH V Belt Pawl Spring Torsion Washer 1 2 x 1 1 2 x 134 Retainer Drive LH Gear Pinion Retainer Drive RH Case Lower Case Upper Gear 24 Teeth Shaft Input Wire Formed Bearing Ball Seal Output Shaft Washer Bushing Shaft Output Screw Seal Input Shaft NOTE All component dimensions given in U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your unit and void your warranty g00Z 2 18 8 LES 69782 ON eHopeyD peot ll AS9181S 6r Z VNHVAOS nH ease Ino ul J e p 10 ZOAMSNH 008 Hues Aq 10 AsoyoasIp uoud l jed0 BU jo sebed NOJI A 84 yno peyeoo Ajjewsou eq ued Jajeap eEWeADSNH p zluoulne uy Auenem siy Aq p 1 A0o2 Jou are seBseyo M nj p pue dn yolq su dx SJOUMO dU ye p i Al p q Snu onpoid y nre 10 Wajqoid Iguonei do y jo ayep Wo sAep Og Ayu uey 19e OU souuew Ajo e u 19 e p eUJeADSNH pazuoy ne ue 0 PasAljap eq snw sAOaJap eq 0 p A l j q JONpoid y uenem SIU JO 1llJ u q y Ule qO OL 1 e p fu
15. Figs 20 and 21 You can fold your lawn mower handle for storage 1 Loosen the two 2 handle knobs on sides of the upper handle and allow handle to fold down to the rear 2 Squeeze the bottom ends of lower handle toward each other until pins in handle clear the brackets and pivot entire handle assembly forward and allow it to rest on mower When setting up your handle from the storage position the lower handle will require manually locking into the mowing position IMPORTANT WHEN FOLDING THE HANDLE FOR STORAGE OR TRANSPORTATION BE SURE TO FOLD THE HANDLE AS SHOWN OR YOU MAY DAMAGE THE CONTROL CABLES STORAGE OPERATOR UPPER x 4 HANDLE HANDLE KNOB LOWER HANDLE HANDLE PIN HANDLE BRACKET FIG 21 14 ENGINE FUEL SYSTEM IMPORTANT ITISIMPORTANT TOPREVENT GUMDEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALCOHOL BLENDED FUELS CALLED GASOHOL OR USING ETHANOL OR METHANOL CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION AND FORMATION OF ACIDS DURING STORAGE ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE Empty the fuel tank by starting the engine and letting it run until the fuel lines and carburetor are empty e Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur e Use fresh fuel next season NOTE Fuel stabilizer is an acceptable alternative in
16. HE LAWN MOWER HOUSING YOU SHOULD RECORD BOTH SERIAL NUMBERAND DATE OF PURCHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE Intake 0 015 mm Exhaust 0 020 mm Valve Clearance 0 04 mm 35 40 ft Ibs Blade Bolt Torque ONS TOMEN RESPONSIBILITIES Read and observe the safety rules Follow a regular schedule in maintaining caring for and using your lawn mower e Follow the instructions under Maintenance and Stor age sections of this owner s manual TABLE OF CONTENTS SAFETY RULES 2 3 PRODUCT SPECIFICATIONS 3 CUSTOMER RESPONSIBILITIES 3 ASSEMBLY uu malu ua as sassa nanata inaani 4 OPERATION sos cccc sets deceessecccecccssaceectzconeesutecedecencenvstevece 5 9 MAINTENANCE SCHEDUIE 10 MAINTENANCE 10 12 SERVICE AND ADJUSTMENTS 13 STORAQE u u u usss sk aa asas awa upaku 13 14 TROUBLESHOOTING 15 REPAIR PARTS 16 19 ASSEMBLY Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower IMPORTANT THIS LAWN MOWER IS SHIPPED WITHOUT OIL OR GASOLINE IN THE ENGINE Your new lawn mower has b
17. NCE TO CHANGE ENGINE OIL See Figs 17 amp 18 NOTE Before tipping lawn mower to drain oil empty fuel tank by running engine until fuel tank is empty 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug 2 Remove oil fill cap dipstick lay aside on a clean sur face 3 Tip lawn mower on its side as shown and drain oil into a suitable container Rock lawn mower back and forth to remove any oil trapped inside of engine 4 Wipe off any spilled oil from lawn mower or side of pi CONTAINER FIG 17 engine 5 Fill engine with oil Slowly pour oil down the oil fill spout into the engine 6 Wait one minute to allow oil to settle Use guage on oil fill cap dipstick for checking level Insert dipstick into the tube and rest the oil fill cap on the tube DO NOT thread the cap into the tube when taking reading 7 Continue adding small amounts of oil and rechecking the dipstick until it reads full DO NOT overfill or engine will smoke on startup 8 Always be sure to retighten oil fill cap dipstick before starting engine 9 Reconnect spark plug wire to spark plug OIL FILL CAP DIPSTICK LOWER MARK 12 AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter Replace the air filter every 100 hours of operation or every season whichever occurs first Service air cleaner more often under dusty conditions See the maintena
18. ONTROL BAR BLADE BRAKE CONTROL LEVER TO ENGAGE BLADE FIG 6 DRIVE CONTROL See Fig 7 Self propelling is controlled by holding the operator presence control bar down to the handle and pulling the drive control lever rearward to the handle The farther toward the handle the lever is pulled the faster the unit will travel Forward motion will stop when either the operator pres ence control bar or drive control lever are released To stop forward motion without stopping engine release the drive control lever only Hold operator presence control bar down against handle to continue mowing without self propelling NOTE If after releasing the drive control the mower will not roll backwards push the mower forward slightly to disengage drive wheels BLADE DISENGAGED OPERATOR PRESENCE CONTROL BAR CONTROL LEVER ENGAGE DRIVE DRIVE CONTROL DISENGAGED ADJUSTMENT TURNBUCKLE ON UNDERSIDE CONTROL FIG 7 DRIVE CONTROL ADJUSTMENT See Fig 7 Over time the drive control system may become loose resulting in decreased speed There is a turnbuckle on the drive control housing to increase tension on the drive cable Proceed as follows 1 Turn unit off and disconnect spark plug wire from spark plug 2 Rotate turnbuckle on drive control to increase drive speed 3 Operate mower to test drive speed Readjust as re quired 4 If condition fails to improve after the above steps for ward speed remains
19. Setall wheels at same height 3 Buildup of grass leaves trash under mower 3 Clean underside of mower housing Excessive 1 Worn bent or loose blade 1 Replace blade Tighten blade bolt vibration 2 Bent engine crankshaft 2 Contact a qualified service center Starter rope 1 Engine flywheel brake is on 1 Depress control bar to upper handle hard to pull when control bar is released before pulling starter rope 2 Bent engine crankshaft 2 Contact a qualified service center 3 Blade adapter broken 3 Replace blade adapter 4 Blade dragging in grass 4 Move mower to cut grass hard surface 5 Defective blade brake clutch 5 Replace blade brake clutch Grass catcher 1 Cutting height too low 1 Raise cutting height is not filling 2 Lift on blade worn off 2 Replace blade If so equipped 3 Catcher not venting air 3 Clean grass catcher Hard to push 1 Grass is too high or wheel height is too low 1 Raise cutting height 2 Rear of lawn mower housing or 2 Raise cutting height cutting blade dragging in heavy grass 3 Grass catcher too full 3 Empty grass catcher 4 Handle height position is not right for you 4 Adjust handle height to suit Blade brake 1 Defective blade brake control 1 Replace blade brake control does not engage Engine dies when 1 Cold engine 1 Allow engine to warm up for one minute starting blade 2 Mower is in uncut grass 2 Move mower to cleared area Loss of drive 1 Belt wear 1 Check
20. YPE LUBRICANT SPARINGLY SPRAY LUBRICANT SEE ENGINE IN MAINTENANCE SECTION 10 ENGINE OIL MULCHER DOOR HINGE PIN REAR DOOR HINGE MAINTENANCE LAWN MOWER Always observe safety rules when performing maintenance TIRES Keep tires free of gasoline oil or insect control chem icals which can harm rubber e Avoid stumps stones deep ruts sharp objects and other hazards that may cause tire damage DRIVE WHEELS Check rear drive wheels each time you mow to be sure they move freely The wheels not turning freely means trash grass cuttings etc may be inside the drive wheel and dust cover area and must be cleaned out to free drive wheels If necessary to clean drive wheels check both rear wheels BLADE CARE For best results mower blade must be kept sharp Replace a bent or damaged blade CAUTION Use only areplacementblade approved by the manufacturer of your mower Using a blade not approved by the manufacturer of your mower is hazardous could damage your mower and void your warranty TO REMOVE BLADE See Fig 16 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug 2 Turn lawn mower on its side Make sure air filter and carburetor are up 3 Useawood block between blade and mower housing to prevent blade from turning when removing blade bolts NOTE Protect your hands with gloves and or wrap blade with heavy cloth
21. een assembled at the factory with the exception of those parts left unassembled for shipping purposes All parts such as nuts washers bolts etc necessary to complete the assembly have been placed in the parts bag To ensure safe and proper operation of your lawn mower all parts and hardware you assemble must be tightened securely Use the correct tools as necessary to ensure proper tightness TO REMOVE LAWN MOWER FROM CARTON 1 Remove loose parts included with mower 2 Cutdown two end corners of carton andlay end panel down llat 3 Removeall packing materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle 4 Roll lawn mower out of carton and check carton thor ougly for additional loose parts HOW TO SET UP YOUR LAWN MOWER TO UNFOLD HANDLE See Figs 1 amp 2 IMPORTANT UNFOLD HANDLE CAREFULLY SO AS NOT TO PINCH OR DAMAGE CONTROL CABLES 1 Raise lower handle section to operating position and squeeze the bottom ends of lower handle towards each other until the pin in handle can be inserted into one of the three height adjustment holes 2 Remove protective padding raise upper handle sec tion into place on lower handle and tighten both handle knobs 3 Remove any packing material from around control bar Your handles may be adjusted for your mowing comfort Refer to ADJUST HANDLE in the Service and Adjustments section of this manual OPERATOR
22. er Toconvertto mulching or discharging operation install mulcher plug into rear discharge opening of mower MULCHER PLUG FIG 11 OPERATION SIDE DISCHARGING See Fig 12 Mulcher plug must be installed into rear discharge opening of mower Open mulcher door and install discharge deflector under door as shown Mower is now ready for discharging operation Toconvertto mulching or bagging operation discharge deflector must be removed and mulcher door closed DISCHARGE DEFLECTOR FIG 12 SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING 1 2 Rear mulcher plug installed Mulcher door closed FOR REAR BAGGING 1 Rear mulcher plug removed 2 Grass catcher installed 3 Mulcher door closed FOR SIDE DISCHARGING 1 2 Rear mulcher plug installed Discharge deflector installed CAUTION Donotrun your lawn mower without mulcher plug or approved grass catcher in place Never attempt to op erate the lawn mower with the rear door removed or propped open BEFORE STARTING ENGINE AD D OIL See Fig 13 Your lawnmower is shipped without oil in the engine Fortype and sect grade of oil to use see ENGINE in the Maintenance ion of this manual 4 IMP Ol CAP DIPSTICK UP MARK Be sure lawnmower is level Remove oil fill cap dipstick from oil fill spout You recieve a container of oil with the unit Slowly pour
23. grass blades See Fig 15 If the lawn is over grown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass For extremely heavy mulching reduce your width of cut by overlapping previously cut path and mow slowly FIG 15 e Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings When doing a second cut mow across perpendicular to the first cut path e Change your cutting pattern from week to week Mow north to south one week then east to west the next week This will help prevent matting and graining of the lawn MAINTENANCE MAINTENANCE s ron EVERY BEFORE USE EACH SCHEDULE USE HOURS OR SEASON Hours STORAGE Check for Loose Fasteners Clean Inspect Grass Catcher V r Q Y Check Tires Ww j Check Drive Wheels Y V kkkk Clean Lawn Mower ooo Clean under Drive Cover Check Drive Belt Pulleys Check Sharpen Replace Blade Lubrication Clean and Recharge Battery j Check Engine Oil level Change Engine Oil S Clean Air Filter as o Inspect Muffler Replace Spark Plug Replace Air Filter Paper Cartridge Empty fuel system or add Stabilizer i if so equipped 1 Change more often if operating under a heavy load or in high outdoor temperatures xx Elect
24. l combustion engine and should not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any In the state of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available If a spark arrester is used it should be maintained in CONGRATULATIONS on your purchase of a new lawn mower Ithas been designed engineered and manufactured to give you the best possible dependability and performance Should you experience any problem you cannot easily remedy please contact your nearest authorized service center department We have competent well trained technicians and the proper tools to service or repair this lawn mower Please read and retain this manual The instructions will enable you to assemble and maintain your lawn mower properly Always observe the SAFETY RULES PRODUCT SPECIFICATIONS 1 0 Quarts Unleaded Regular Only Gasoline Capacity and Type Oil Type API SG SL SAE 30 above 0 C 32 F SAE 10W 30 below 0 C 32 F Oil Capacity 18 5 Ounces Spark Plug NGK BPR6ES Gap 030 SERIAL NUMBER DATE OF PURCHASE THE MODELAND SERIAL NUMBERS WILL BE FOUND ON ADECALATTACHED TO THE REAR OF T
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26. mini mizing the formation of fuel gum deposits during storage Add stabilizer to gasoline in fuel tank or storage container Always follow the mix ratio found on stabilizer container Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor Do not empty the gas tank and carburetor if using fuel stabilizer ENGINE OIL Drain oil with engine warm and replace with clean en gine oil See ENGINE in the Maintenance section of this manual CYLINDER 1 Remove spark plug 2 Pour one ounce 29 ml of oil through spark plug hole into cylinder 3 Pull starter handle slowly a few times to distribute oil 4 Replace with new spark plug OTHER 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 If possible store your unit indoors and cover it to give protection from dust and dirt e Cover your unit with a suitable protective cover that does not retain moisture Do not use plastic Plastic cannot breathe which allows condensation to form and will cause your unit to rust IMPORTANT NEVER COVER MOWER WHILE ENGINE AND EXHAUST AREAS ARE STILL WARM CAUTION Never store the lawn mower with gasoline in the tank inside a build ing where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure TROUBLESHOOTING
27. n mower is shipped WITHOUT OIL OR GASOLINE in the engine OIL DANGER KEEP HANDS AND FEET AWAY CHOKE FUEL DRIVE CONTROL LEVER a BLADE BRAKE CONTROL aN HANDLE KNOBS DRIVE COVER GASOLINE FILLER CAP FUEL VALVE LEVER AIR FILTER SPARK PLUG HOUSING MUFFLER MEETS CPSC SAFETY REQUIREMENTS Our rotary walk behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U S Consumer Product Safety Commission OPERATOR PRESENCE CONTROL BAR must be held down to the handle to start the blade Release to stop the blade DRIVE CONTROL LEVER used to engage power pro pelled forward motion lawn mower BLADE BRAKE CONTROL used to engage the blade after the engine is started SINGLE POINT HEIGHT ADJUSTER used to adjust cutting height of lawn mower THROTTLE ENGINE CONTROL used for starting and stopping the engine and allows you to select either FAST or SLOW engine speed STARTER HANDLE used for starting the engine MULCHER DOOR allows conversion to discharge or bagging operation MULCHER PLUG located at the discharge opening must be removed when converting to bagging operation OPERATION wean voue The operation of any lawn mower can result in foreign objects thrown into the eyes which can result in severe eye damage Always wear safety glasses or eye shields while operating your lawn mower or per forming any adjustments or re
28. nce section of your engine manual MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage SPARK PLUG Replace spark plug atthe beginning of each mowing season or after every 100 hours of operation whichever occurs first Spark plug type and gap setting are shown in the PRODUCT SPECIFICATIONS section of this manual CLEANING IMPORTANT FOR BEST PERFORMANCE KEEP MOWER HOUSING FREE OF BUILT UP GRASS AND TRASH CLEAN THE UNDERSIDE OF YOUR MOWER AFTER EACH USE A CAUTION Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug e Clean the underside of your lawn mower by scraping to remove build up of grass and trash e Clean engine often to keep trash from accumulating A clogged engine runs hotter and shortens engine life e Keep finished surfaces and wheels free of gasoline oil etc e We do not recommend using a garden hose to clean lawn mower unless the electrical system muffler air filter and carburetor are covered to keep water out Water in engine can result in shortened engine life CLEAN UNDER DRIVE COVER Clean under drive cover at least twice a season Scrape un derside of cover with putty knife or similar tool to remove any build up of trash or grass on underside of drive cover SERVICE AND ADJUSTMENTS CAUTION To avoid serious injury before performing any service or adjustments Release control bar and s
29. nge clothing immedi ately e Never overfill fuel tank Replace gas cap and tighten securely V GENERAL SERVICE e Never run a machine inside a closed area e Never make adjustments or repairs with the engine motor running Disconnect spark plug wire and keep wire away from plug to prevent accidental starting e Keep nuts and bolts especially blade attachement bolts tight and keep equipment in good condition e Never tamper with safety devices Check their proper operation regularly Keep machine free of grass leaves or other debris build up Clean oil or fuel spillage Allow machine to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting e Never attempt to make wheel height adjustments while the engine motor is running e Grass catcher components are subject to wear dam age and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recom mended parts when necessary Mower blade is sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing it Donotchange the engine governor setting or overspeed the engine e Maintain or replace safety and instruction labels as necessary effective working order by the operator through your nearest authorized service center AWARNING This lawn mower is equipped with an interna
30. or good artificial light Do not operate the machine while under the influence of alcohol or drugs Never operate machine in wet grass Always be sure of your footing keep a firm hold on the handle and walk never run Disengage the self propelled mechanism or drive clutch onmowerssoequippedbeforestartingtheengine motor If the equipment should start to vibrate abnormally stop the engine motor and check immediately for the cause Vibration is generally a warning of trouble Always wear safety goggles or safety glasses with side shields when operating mower SLOPE OPERATION Slopes are a major factor related to slip and fall accidents which can result in severe injury All slopes require extra caution If you feel uneasy on a slope do not mow it DO Mow across the face of slopes never up and down Exer cise extreme caution when changing direction on slopes Remove obstacles such as rocks tree limbs etc Watch for holes ruts or bumps Tall grass can hide obstacles DO NOT Do not trim near drop offs ditches or embankments The operator could lose footing or balance Do not trim excessively steep slopes Do not mow on wet grass Reduced footing could cause slipping CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them Keep children out
31. pairs We recommend standard safety glasses or a wide vision safety mask THAN NO SIGHT over spectacles HOW TO USE YOUR LAWN MOWER THROTTLE ENGINE CONTROL See Fig 5 The engine is controlled by a throttle control located on the side of the upper handle CHOKE position is for starting a cold engine FAST position is for starting a warm engine normal cutting trimming and better grass bagging SLOW position is for light cutting trimming and fuel economy and STOP position is for stopping the engine 2 FAST SLOW FIG 5 BLADE CONTROL See Fig 6 CAUTION When the blade control is engaged the blade turns To start the blade hold the operator presence control bar down to the handle and push the blade brake con trol lever forward until it latches To stop the blade release the operator presence control bar Do not pull the blade brake lever rearward with the operator presence control bar down against the handle Allow a cold engine to warm up in high idle position for one minute before engaging the blade NOTE It is normal to hear the belt slip as the blade is engaged and comes up to speed Donotstart the blade in uncut grass Move the mower out of uncut grass before starting the blade CAUTION Federal regulations require this blade brake control to minimize the risk of blade contact injury Donot under any circumstances attempt to defeat the function of this control OPERATOR PRESENCE C
32. pproved replace ment catcher shown in the Repair Parts section of this manual Give the mower model number when order ing GEAR CASE To keep your drive system working properly the gear case and area around the drive should be kept clean and free of trash build up Clean under the drive cover twice a season The gear case is filled with lubricant to the proper level at the factory The only time the lubricant needs attention is if service has been performed on the gear case e If lubricant is required use only Texaco Starplex Pre mium 1 Grease Part No 750369 Do not substitute ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SG SL Select the oil s SAE viscosity grade according to your expected operating temperature SAE VISCOSITY GRADES F 20 0 30 32 40 60 80 100 C 30 20 10 0 10 20 30 40 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE NOTE Multi viscosity oils 5W30 10W30 etc improve starting in cold weather and you should check your engine oil level frequently to avoid possible engine damage from running low on oil Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year Check the crankcase oil level before starting the engine and after each five 5 hours of continuous use Tighten oil plug securely each time you check the oil level MAINTENA
33. replace drive belt or slowing of 2 Belt off of pulley 2 Check reinstall drive belt drive speed 3 Drive cable worn or broken 3 Replace drive cable if self propelled 4 Loose drive control system 4 Adjust drive control 15 RAS 7 SASL CRIZE HAAN ae A 4 KG eI ROTARY LAWN MOWER MODEL NUMBER 5521BBC 96143001300 PRODUCT NUMBER 961 43 00 13 L ROTARY LAWN MOWER MODEL NUMBER 5521BBC 96143001300 PRODUCT NUMBER 961 43 00 13 KEY PART NO NO 1 532 18 97 40 2 532 19 60 05 3 532 18 60 53 4 532 19 47 88 5 532 13 20 04 6 532 06 64 26 7 532 19 15 74 8 532 18 55 88 9 532 19 49 19 10 532 18 88 21 11 873 93 05 00 12 53205 17 93 13 532 18 60 52 16 532 1905 74 17 532 18 41 93 18 532 1981 70 19 532 19 45 39 20 532 19 40 29 21 532 19 40 31 22 532 15 00 78 23 532 16 31 83 24 873 80 05 00 25 532 16 13 33 26 532 16 34 09 27 53218 89 86 28 53208 86 52 31 532 18 04 59 37 532 15 04 06 38 sere 39 532 40 16 83 40 532 19 46 44 41 532 10 73 39 42 53205 45 83 45 532 1905 10 46 53219 05 12 47 532 08 83 49 48 532 18 22 26 50 532 05 78 08 51 532 19 37 91 52 532 14 52 12 53 532 15 55 52 DESCRIPTION Handle Upper Includes Foam Grip Handle Lower Spring Rear Door RH Guide Rope Side Nut Hex Lockwasher Insert 1 4 20 Wire Tie Bolt Handle 5 16 18 x 1 75 Knob Handle Bar Control Auto Walk Bolt Carriage Nut Hex Centerlock 5 16 18
34. ric Start mowers 2 Service more often if operating in dirty or dusty conditions xxx Power Propelled mowers 3 Replace blades more often when mowing in sandy soil xxx Use a scraper 4 Charge 48 hours at end of season to clean under deck 5 And after each 5 hours of use GENERAL RECOMMENDATIONS LUBRICATION CHART The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence To receive full value from the warranty operator must maintain mower as instructed in this manual Some adjustments will need to be made periodically to properly maintain your unit At least once a season check to see if you should make any of the adjustments described in the Service and Adjustments section of this manual Atleast once a year replace the spark plug clean or replace air filter element and check blade for wear A new spark plug and clean new air filter element assure proper air fuel mixture and help your engine run better and last longer Follow the maintenance schedule in this manual BEFORE EACH USE 1 Check engine oil level 2 Check for loose fasteners LUBRICATION Keep unit well lubricated See LUBRICATION CHART IMPORTANT DO NOT OIL OR GREASE PLASTIC WHEEL BEARINGS VISCOUS LUBRICANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELF LUBRICATING BEARINGS IF YOU FEEL THEY MUST BE HANDLE BRACKET MOUNTING PINS LUBRICATED USE ONLY A DRY POWDERED GRAPHITE T
35. rip Handle Foam Smooth one side Throttle Engine Control Screw Hex Head 1 4 20 x 2 1 8 Belt Guide Stud Nut Hex 3 8 16 Bracket Throttle Screw Hex Washer Head 1 4 20 x 1 2 Blade Brake Clutch Control Bolt Hex Head Blade Brake Clutch Includes Key Numbers 82 95 Belt Cover Upper Belt Cover Lower Screw Tapping Hex Washer Head 10 24 Spring Nut Hex Centerlock Zinc Plated 1 4 20 Bracket Bolt Hex Cap Head 1 4 20 x 5 8 Washer Flat Nut Hex 3 8 16 Belt Keeper Spring Link Torque Holder Assembly Blade Plate Assembly Ball Control Ball Steel Plate Spring Hook Plate Brake Spring Ball Plate Disk Drive Disk Driven Pulley Drive Spring Clutch Bolt Flange 10 x 24 Bearing Radial Ball 6006 Bearing Radial Ball 6204 Key Woodruff 16 x 15 Warning Decal not shown Owner s Manual English French NOTE All component dimensions given in U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your unit and void your warranty ROTARY LAWN MOWER MODEL NUMBER 5521BBC 96143001300 PRODUCT NUMBER 961 43 00 13 ROTARY LAWN MOWER MODEL NUMBER 5521BBC 96143001300 PRODUCT NUMBER 961 43 00 13 KEY PART NO NO 532 19 67 55 532 19 57 61 532 18 73 53 532 19 00 39 532 19 57 62 532 18 16 98 532 40 07 23 532 18 62 97 532 19 67 84 10 532 18 90 74 12 532 18 76
36. rmation Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur TO STOP ENGINE e To stop engine move throttle control lever to STOP position Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon TO START ENGINE See Fig 14 NOTE Due to protective coatings on the engine a small amount of smoke may be present during the initial use of the product and should be considered normal 1 Be sure fuel valve is in the ON position 2 To start a cold engine move handle mounted throttle choke control lever to CHOKE position 3 Pull starter handle quickly Do not allow starter rope to snap back 4 Slowly move throttle control lever to FAST position after engine starts To start a warm engine move throttle control lever to FAST position then follow steps above NOTE Allow a cold engine to warm up for one minute before starting the blade See BLADE CONTROL in this section of this manual are hazardous will damage your mower and could void your warranty e Under certain conditions such as very tall grass it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings It may also be necessary to reduce ground speed and or run the lawn mower over the area a second time For extremely heavy cutting
37. se engine speed or it may resultin personal injury If you believe that the engine is running too fast or too slow take your lawn mower to an authorized service center for repair and adjustment CARBURETOR Your carburetor is not adjustable If your engine does not operate properly due to suspected carburetor problems take your lawn mower to an authorized service center for repair and or adjustment IMPORTANT NEVERTAMPERWITHTHEENGINE GOVERNOR WHICH IS FACTORY SET FOR PROPER ENGINE SPEED OVERSPEEDING THE ENGINE ABOVE THE FACTORY HIGH SPEED SETTING CAN BE DANGEROUS IF YOU THINK THE ENGINE GOVERNED HIGH SPEED NEEDS ADJUSTING CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER WHICH HAS PROPER EQUIPMENT AND EXPERIENCE TO MAKE ANY NECESSARY ADJUSTMENTS STORAGE Immediately prepare your mower for storage at the end of the season or if the unit will not be used for 30 days or more LAWN MOWER When lawn mower is to be stored for a period of time clean it thoroughly remove all dirt grease leaves etc Store in a clean dry area 1 Clean entire lawn mower See CLEANING in the Maintenance section of this manual 2 Lubricate as shown in the Maintenance section of this manual 3 Besurethatall nuts bolts screws and pins are securely fastened Inspect moving parts for damage breakage and wear Replace if necessary 4 Touch up all rusted or chipped paint surfaces sand lightly before painting 13 HANDLE See
38. top engine Make sure the blade and all moving parts have completely stopped Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug LAWN MOWER TO ADJUST CUTTING HEIGHT See TO ADJUST CUTTING HEIGHT in the Operation section of this manual REAR DEFLECTOR The rear deflector attached between the rear wheels of your mower is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator s mowing position If the deflector becomes damaged it should be replaced TO REMOVE DRIVE BELT If your mower does not operate properly due to suspected drive belt problems take your mower to a qualified service center for repair and or adjustment TO ADJUST HANDLE See Fig 19 The handle on your lawn mower has three 3 height posi tions adjust to height that suits you e Squeeze the bottom ends of lower handle towards each other until the pin in handle can be inserted into one of the three height adjustment holes HANDLE PIN HANDLE BRACKET ENGINE Maintenance repair or replacement of the emission con trol devices and systems which are being done at the customers expense may be performed by any non road engine repair establishment or individual Warranty repairs must be performed by an authorized engine manufacturer s service outlet ENGINE SPEED Your engine speed has been factory set Do not attempt to increa
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