Chrysler 2005 Pacifica Automobile User Manual
Contents
1. CAUTION DO NOT overfill engine with 1 Be sure lawnmower is level 2 Remove oil dipstick from oil fill spout 3 Engine holds 18 5 ounces of oil For type and grade of oil to use see ENGINE in the Maintenance section of this manual 4 Pour oil slowly Do not overfill Wait one minute to al low 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 IMPORTANT e Check oil level before each use Add oil if needed Fill to full line on dipstick e Changethe 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 z OIL FILLER CAP DIPSTICK D et Le gt _7 UPPER LIMIT DISCHARGE PERRESI N N o 10 Y KORK LOWER LIMIT GASOLINE FILLER CAP OPERATION ADD GASOLINE See Fig 8 e 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 oil or fuel Do not store spill or use gasoline near an open flame Alcohol blended fuels called gasohol or using ethanol or methanol ca2. The operator could lose footing or balance Do not trim excessively steep slopes Do not mow on wet grass Reduced footing could cause slipping CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them Keep children out of the trimming area and under the watchful care of another responsible adult Be alert and turn machine off if children enter the area Before and while walking backwards look behind and down for small children Never allow children to operate the machine Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision IV SERVICE Use extra care in handling gasoline and other fuels They are flammable and vapors are explosive Use only an approved container Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling Do not smoke Never refuel the machine indoors Never store the machine or fuel container inside where there is an open flame such as a water heater Never run a machine inside a closed area Never make adjustments or repairs with the engine motor running Disconnect the spark plug wire and keep the wire away from the plug to prevent accidental starting Keep nuts and bolts especially blade attachement bolts tight and keep
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4. tank by running engine until fuel tank is empty 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug 2 Remove engine oil cap lay aside on a clean surface 3 Tip 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 OIL FILLER CAP DIPSTICK EY Bie A AN a k ai ei T TERN OOK FIG 16 4 Wipe off any spilled oil from lawn mower or side of engine 5 Slowly pour oil down the oil fill spout stopping every few ounces to check the oil level with the dipstick 6 Stop adding oil when you reach the FULL mark on the dipstick Wait a minute to allow oil to settle 7 Continue adding small amounts of oil rechecking the dipstick until oil level settles at FULL DO NOT over fill or engine will smoke heavily from the muffler on Startup 8 Always be sure to retighten oil dipstick before starting engine 9 Reconnect spark plug wire to spark plug AIR FILTER Your engine will not run properly and may be damaged by using a dirty air filter Replace the air filter every 100 hours of operation or every season whichever occurs first Service air cleaner more often under dusty conditions See the maintenance section of your engine manual MUFFLER Inspect and replace corroded muffler as it could create a fire hazard and or damage SPARK PLUG
5. 42 05 3 532 18 27 48 4 532 17 95 85 5 532 13 20 04 6 532 06 64 26 7 532 13 19 59 8 532 18 55 88 9 532 18 55 99 10 532 16 15 51 11 873 99 05 00 12 53205 17 93 13 532 18 27 55 14 532 12 51 62 15 532 75 06 34 16 532 16 20 85 17 532 17 98 85 18 532 18 27 78 19 532 18 56 01 20 532 18 60 04 21 532 18 60 05 22 532 15 00 78 23 532 16 31 83 24 53206 31 24 25 532 16 13 33 26 532 16 34 09 27 5932 16 15 50 28 5382 08 86 52 30 53285 15 14 31 532 17 50 64 32 532 85 10 74 33 5382 85 02 63 DESCRIPTION Handle Upper Includes Foam Grip Handle Lower Grip Handle Foam Smooth Guide Rope Side Nut Hex Lockwasher Insert 1 4 20 Wire Tie Bolt Handle 5 16 18 x 1 75 Knob Handle Bail Flat Auto Walk Orange Bolt Carriage Nut Hex Lockwasher Insert 5 16 18 UNC Cotter Hairpin Engine Zone Control Cable Bracket Upstop Screw Kit Door Rear Seal 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 Screw Hinge 1 4 20 x 1 25 Adapter Blade with Key Blade 21 Washer Hardened Lockwasher Helical Spring 3 8 KEY PART NO NO 34 532 85 10 84 37 532 15 04 06 38 a 39 532 18 55 96 40 582 18 00 26 41 532 10 73 39 57 532 18 58 99 58 53205 78 08 59 532 16 60 42 60 582 16 60 50 61 532 14 52 12 62 532 15 55 52 63 5382 18 58 98 64
6. 532 16 60 43 65 582 16 08 29 66 532 18 55 97 67 5932 18 55 98 68 532 08 83 49 71 532 05 45 83 73 53208 76 77 77 532 08 45 96 78 532 18 20 01 79 532 18 22 27 80 532 18 22 28 81 532 18 20 02 82 532 18 20 03 a 532 16 23 00 932 18 55 94 DESCRIPTION Screw Hex Head 3 8 24 x 1 38 Bolt Engine Engine Honda Model Number GCV160 Order parts from engine manufacturer Grass Catcher Bag Grass Catcher Frame Danger Decal Bracket Assembly Screw Pulley V Groove Spacer Idler Arm Flange Nut Locknut Idler Arm Idler Pulley Shoulder Bolt Door Assembly Deflector Door Nut Screw Hi Pro Key Pulley Belt Keeper Screw Nut Hex Debris Shield Clip Warning Decal Not Shown Owner s Manual English French NOTE All component dimensions given in U S inches 1 inch 25 4 mm ROTARY LAWN MOWER MODEL NUMBER 5521RS 5521RSA PRODUCT NUMBER 954 22 34 70 LE ROTARY LAWN MOWER MODEL NUMBER 5521RS 5521RSA PRODUCT NUMBER 954 22 34 70 KEY PART NO NO 1 532 18 59 05 2 532 18 06 12 3 532 05 45 83 4 532 18 59 63 5 532 18 55 92 6 532 75 06 34 7 532 18 22 12 8 532 13 20 10 9 532 18 06 07 10 53217 76 54 11 817 54 10 11 12 53218 06 04 13 532 18 08 68 14 53214 53 54 15 53205 70 79 16 532 16 15 84 17 53216 16 02 18 532 16 45 54 19 532 18 55 90 20 81200 00 22 21 532 16 33 65 22 5382 16 99 11 23 532 16 45 55 24 532 05 78 08 25 532 18 06 03 26 53205 70 79 27 532 05 21 60 28 81200 00 5
7. Replace spark plug at the 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 CAUTION Disconnect spark plug wire from spark plug and place wire where it cannotcome in contact with spark plug e Clean the underside of your lawn mower by scraping to remove build up of grass and trash e Cleanengine often to keep trash from accumulating A clogged engine runs hotter and shortens engine life e Keepfinishedsurfacesandwheelsfreeofgasoline 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 1 Release control bar and stop engine 2 Make sure the blade and all moving parts have completely stopped 3 Disconnect spark plug wire from spark plug and place where i
8. dj Husqvarna 5521RS Owner s Manual 532 18 55 94 Rev 2 09 02 03 BY Printed in U S A A SAFETY RULES Safe Operation Practices for Walk Behind Mowers A IMPORTANT THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH DO NOT I GENERAL OPERATION e Read understand and follow all instructions on the machine and in the manual s before starting Be thor oughly familiar with the controls and the proper use of the machine before starting e Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times e Only allow responsible individuals who are familiar with the instructions to operate the machine e Clear the area of objects such as rocks toys wire bones sticks etc which could be picked up andthrown by the blade e Be sure the area is clear of other people before mow ing Stop machine if anyone enters the area e Do not operate the mower when barefoot or wearing open sandals Always wear substantial foot wear e Do not pull mower backwards unless absolutely nec essary Always look down and behind before and while moving backwards e Do not operate the mower without proper guards plates grass catcher or other safety protective devices in place e See manufacturer s instructions for proper operation and installation of accesso
9. equipment in good condition Never tamper with safety devices Check their proper operation regularly Keep machine free of grass leaves or other debris build up Clean oil or fuel spillage Allow machine to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting Never attempt to make wheel height adjustments while the engine motor is running Grass catcher components are subject to wear dam age and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recom mended parts when necessary Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Do notchange the engine governor setting or overspeed the engine Look for this symbol to point out im portant safety precautions It means CAUTION BECOME ALERT YOUR SAFETY IS INVOLVED CAUTION Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent accidental starting when setting up transporting adjusting or making repairs WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemi cals known to the State of California to cause cancer and birth defects or other reproductive harm CONGRATULATIONS on your purchase of a new lawn mower Ithas been designed engineered a
10. 8 29 532 18 05 04 30 532 06 77 25 32 53218 07 53 33 5382 18 16 09 DESCRIPTION Drive Control Assembly Auto Walk Cable Drive Control Screw Cover Top Auto Walk Drive Control Cover Drive Screw Threaded Rolled 10 25 x 50 V Belt Nut Hex Flanglock Zinc Plated 3 8 16 Spring Pulley Adjuster Belt Keeper Bracket Screw Hex Washer Head 10 24 x 668 Pulley Split Upper Gear Case Assembly See Breakdown Pin Spring Thrust Washer Hardened Rod Connecting Spring Extension Spring Selector Knob Selector Spring E Ring 7 8 Bearing Support Bearing Ball Retainer Drive Assembly Stamped Screw Tapping Hex Head 1 4 20 x 75 Pulley Split Lower Pinion Drive Washer E Ring 7 16 Cover Dust Wheel Washer 1 2 x 1 1 2 x 134 Wheel 9 x 2 Connector Lever Pulley KEY PART NO NO 34 532 18 06 26 35 5382 16 45 52 36 53216 45 50 37 53216 14 63 38 53216 34 09 39 532 70 02 79 40 532 14 35 93 41 532 18 81 52 42 5382 08 39 23 43 81957 22 16 44 532 18 59 61 45 532 18 60 06 46 532 18 58 58 47 532 18 16 98 48 532 18 58 59 49 532 17 51 03 50 532 17 51 02 51 532 17 50 98 52 532 18 82 91 53 532 17 51 04 54 532 17 51 01 55 53218 82 93 56 532 18 82 92 57 532 18 06 06 58 532 17 51 05 59 532 18 10 45 60 5932 18 47 49 61 532 18 59 64 62 53218 24 94 63 532 08 83 48 DESCRIPTION Hubcap Shaft Assembly Rear Shaft Assembly Front Retainer Front Shaft Screw 12 x 5 8 Clip Retainer Wheel 8
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12. FIG 18 8 Remove blade attaching hardware bolt lock washer hardened washer blade adapter and debris shield Note that the debris shield has a tab which fits into the housing hole 9 Remove drive belt from engine pulley discard old belt 13 TO REPLACE DRIVE BELT 1 Place new drive belt on engine pulley 2 Route the other end of the new drive belt through hole in housing 3 Return mower to upright position 4 Install new drive belt into idler arm assembly then around the drive pulley Be sure belt is inside of belt keepers 5 Reattach idler arm assembly with hex nut previously removed 6 Turn lawn mower on its side Make sure air filter and carburetor are up 7 Reattach debris shield to housing with tab of debris shield in housing hole 8 Position blade on the blade adapter aligning the two 2 holes in the blade with the raised lugs on the adapter 9 Besurethetrailing edge of blade opposite sharp edge is up toward the engine as shown 10 Install the blade bolt with the lock washer and hardened washer into blade adapter and crankshaft 11 Use block of wood between blade and lawn mower housing and tighten the blade bolt turning clockwise e The recommended tightening torque is 35 40 ft lbs IMPORTANT BLADE BOLT IS HEAT TREATED IF BOLT NEEDS REPLACING REPLACE ONLY WITH APPROVED BOLT SHOWN IN THE REPAIR PARTS SECTION OF THIS MANUAL 12 Return mower to upright position 13 Reattach
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14. PARINGLY 10 D SEE ENGINE IN MAINTENANCE SECTION T REAR DOOR HINGE DDD a T A gt O O O yByxV f Io DODODO MAINTENANCE LAWN MOWER Always observe safety rules when performing any main tenance TIRES e Keep tires free of gasoline oil or insect control chem icals which can harm rubber e Avoid stumps stones deep ruts sharp objects and other hazards that may cause tire damage DRIVE WHEELS Check 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 bent or damaged blades TO REMOVE BLADE See Fig 15 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug 2 Turn lawn mower on its side Make sure air filter and carburetor are up 3 Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt NOTE Protect your hands with gloves and or wrap blade with heavy cloth 4 Remove blade bolt by turning counter clockwise 5 Remove blade andattaching hardware bolt lock washer and hardened washer NOTE Remove the blade adapter and check the key inside hub of blade adapter The key must be in good
15. TO PREVENT GUM DEPOSITS FROM FORMING INESSENTIAL 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 SYSTEM OF AN ENGINE WHILE IN STORAGE e 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 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 15 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 Repla
16. above steps will return your unit to the proper adjustment and speed 6 If condition fails to improve after the above steps for ward speed remains the same your drive belt is worn and should be replaced TO ADJUST CUTTING HEIGHT See Fig 6 All four wheels are adjusted by a single lever e Pull adjuster lever toward wheel To raise mower 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 6 OPERATION TO ATTACH GRASS CATCHER See Fig 7 1 Lift the rear door of the lawn mower and place the grass catcher frame side hooks into the slots of the rear door 2 The grass catcher is 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 HANDLE CATCHER FRAME HOOK FIG 7 TO EMPTY GRASS CATCHER See Fig 8 1 Lift up on grass catcher using the frame handle 2 Remove grass catcher with clippings from under lawn mower handle 3 Empty clippings from bag using both frame handle and bag handle NOTE Do not drag the bag when emptying it will cause unnecessary wear BAG HANDLE FIG 8 TO CONVERT MOWER Your lawn mower was shipped ready to be used as a mulcher To convert to baggi
17. ce your gasoline can if your can starts to rust Rust and or dirt in your gasoline will cause problems e f possible store your unit indoors and cover it to give protection from dust and dirt e Cover your unit with a suitable protective cover that does not retain moisture Do not use plastic Plastic cannot breathe which allows condensation to form and will Cause your unit to rust IMPORTANT NEVER COVER MOWER WHILE ENGINE AND EXHAUST AREAS ARE STILL WARM CAUTION Never store the lawn mower with gasoline in the tank inside a build ing where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure Does not start Loss of power Poor cut uneven Excessive vibration Starter rope hard to pull Grass catcher not filling if so equipped Hard to push Loss of drive or slowing of drive speed TROUBLESHOOTING POINTS Dirty air filter Out of fuel Stale fuel Water in fuel Spark plug wire is disconnected Bad spark plug Loose blade or broken blade adapter Control bar in released position Control bar defective Fuel valve lever if equipped in OFF position Weak battery if equipped Disconnected battery connector if equipped Rear of lawn 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 fas
18. condition to work properly Replace adapter if damaged TO REPLACE BLADE See Fig 15 1 Position the blade adapter on the engine crankshaft Be sure key in adapter and crankshaft keyway are aligned 2 Position blade on the blade adapter aligning the two 2 holes in the blade with the raised lugs on the adapter 3 Besure the trailing edge of blade opposite sharp edge is up toward the engine 4 Installthe blade bolt with the lock washer and hardened washer into blade adapter and crankshaft 5 Use block of wood between blade and lawn mower housing and tighten the blade bolt turning clockwise e The recommended tightening torque is 35 40 ft lbs IMPORTANT BLADE BOLT IS HEAT TREATED IF BOLT NEEDS REPLACING REPLACE ONLY WITH APPROVED BOLT SHOWN IN THE REPAIR PARTS SECTION OF THIS MANUAL 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 11 e The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen while on the mower e To check blade balance drive a nail into a beam or wall Leave about one inch of the straight nail exposed Place center hole of blade over the head of the nail If blade is balanced it should remain in a horizontal position If either end of the blade moves downward sharpen the
19. d 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 Q a gr Y CAUTION a ENGINE FAST SLOW CHOKE FUEL OIL DANGER KEEP HANDS OR WARNING OFF AND FEET AWAY l k a PRESENCE CONTROL BAR DRIVE CONTROL LEVER HANDLE KNOB GASOLINE FILLER CAP STARTER HANDLE GRASS CATCHER SINGLE POINT HEIGHT ADJUSTER HANDLE DRIVE COVER FUEL VALVE LEVER AIR FILTER MULCHER PLUG ENGINE OIL CAP WITH DIPSTICK MULCHER DOOR MUFFLER IMPORTANT This lawn mower is shipped HOUSING WITHOUT OIL OR GASOLINE in the engine MEETS CPSC SAFETY REQUIREMENTS Our rotary walk behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U S Consumer Product Safety Commission The blade turns when the engine is running OPERATOR PRESENCE CONTROL BAR must be held SINGLE POINT HEIGHT ADJUSTER used to adjust down to the handle to start the engine Release to stop cutting height of la
20. drive cable spring to the idler arm assembly then reattach drive cable to anchor 14 Reattach drive cover with screws previously removed 15 Connect spark plug wire to spark plug 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 SQUEEZE HANDLE BRACKET SERVICE AND ADJUSTMENTS ENGINE ENGINE SPEED Your engine speed has been factory set Do not attempt to increase engine speed or it may result in personal injury If you believe that the engine is running too fast or too slow take your lawn mower to an authorized service center for repair and adjustment CARBURETOR Your carburetor is not adjustable If your engine does not operate properly due to suspected carburetor problems take your lawn mower to an authorized service center for repair and or adjustment IMPORTANT NEVERTAMPERWITHTHE ENGINE GOVERNOR WHICH IS FACTORY SET FOR PROPER ENGINE SPEED 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 lawn mower for storage at the end o
21. en upper and lower handle and padding holding operator presence control bar to upper handle 4 Roll lawn mower out of carton and check carton thor ougly for additional loose parts HOW TO SET UP YOUR LAWN MOWER TO UNFOLD HANDLE See Figs 1 and 2 IMPORTANT UNFOLD HANDLE CAREFULLY SO AS NOT TO PINCH OR DAMAGE CONTROL CABLES 1 Raise 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 PRESENCE I CONTROL BAR I Zu y Z Y fo UPPER HANDLE LOWER HANDLE MOWING POSITION HANDLE PIN SQUEEZE HANDLE BRACKET 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 CATCHER FRAME HANDLE FRAME OPENING TO INSTALL ATTACHMENTS Your lawn mower was shippe
22. ever rearward to the handle The farther toward the handle the lever is pulled the faster the unit will travel e 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 OPERATOR PRESENCE CONTROL BAR e DEA DRIVE CONTROL LEVER DRIVE CONTROL DISENGAGED ADJUSTMENT BUTTON ON TO ENGAGE UNDERSIDE DRIVE CONTROL FIG 5 DRIVE CONTROL ADJUSTMENT Over time the drive control system may become loose resulting in decreased speed There is a button on the underside of 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 Pull drive control lever ALL THE WAY BACK to the handle 3 Push button on underside of drive control While hold ing button in return drive control lever to disengaged position ALL THE WAY FORWARD NOTE Do not ratchet the adjustment 4 Release button 5 Operate mower to test drive speed If condition be comes worse after the above steps forward speed has become slower your system was not loose Repeating the
23. f 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 HANDLE See 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 e 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 14 OPERATOR PRESENCE CONTROL BAR UPPER HANDLE LOWER HANDLE MOWING POSITION HANDLE PIN SQUEEZE HANDLE BRACKET FIG 21 STORAGE ENGINE FUEL SYSTEM IMPORTANT IT IS IMPORTANT
24. heavy end until the blade is balanced BLADE ADAPTER CRANKSHAFT KEYWAY SHAFT BLADE ADAPTER HARDENED WASHER TRAILING EDGE FIG 15 GRASS CATCHER e The grass catcher may be hosed with water but must be dry when used e Check your grass catcher often for damage or dete rioration Through normal use it will wear If catcher needs replacing replace only with approved replace ment catcher shown in the Repair Parts section of this manual Give the lawn mower model number when ordering ENGINE LUBRICATION Use only high quality detergent oil rated with API service classification SF SJ Select the oil s SAE viscosity grade according to your expected operating temperature SAE VISCOSITY GRADES SAE 30 10W 30 EA F 0 30 32 40 60 80 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 100 MAINTENANCE TO CHANGE ENGINE OIL See Fig 16 NOTE Before tipping lawn mower to drain oil empty fuel
25. n at tract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel sys tem of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer Empty the gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel next season See Storage Instructions for additional information Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur TO STOP ENGINE e To stop engine release operator presence control bar Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon TO START ENGINE See Fig 13 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 Move choke lever to ON position 3 Hold operator presence control bar down to the handle and pull starter handle quickly Do not allow starter rope to snap back NOTE The choke lever automatically begins moving to the OFF position when operator presence control bar is held down to handle CHOKE LEVER FUEL VALVE LEVER FIG 13 MOWING TIPS Under certain conditions such as very tall grass it may be necessary to raise the height of cut to reduce pu
26. nd 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 SERIAL NUMBER THE MODEL AND SERIAL NUMBERSWILL BE FOUND ON ADECAL ATTACHED TOTHE REAR OF THE LAWN MOWER HOUSING YOU SHOULD RECORD BOTH SERIAL NUMBER AND DATE OF PURCHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CAUTION Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped To avoid severe burns on contact stay away from these areas PRODUCT SPECIFICATIONS 1 0 Quarts Unleaded Regular Only SAE 10W 30 18 5 Ounces NGK BPR6ES Gap 030 35 40 ft lbs Gasoline Capacity and Type Oil Type API SF SJ Oil Capacity Spark Plug Blade Bolt Torque CUSTOMER RESPONSIBILITIES e Read and observe the safety rules e Follow aregular schedule in maintaining ca
27. ng or discharging REAR BAGGING See Fig 9 e Open rear door and remove mulcher plug Store mulcher plug in a safe place e You can now install the grass catcher e Toconvertto mulching or discharging operation install mulcher plug into rear discharge opening of mower MULCHER PLUG FIG 9 SIDE DISCHARGING See Fig 10 e Mulcher plug must be installed into rear discharge opening of mower e Open mulcher door and install discharge deflector under door as shown e Mower is now ready for discharging operation e Toconvertto mulching or bagging operation discharge deflector must be removed and mulcher door closed SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING 1 Rear mulcher plug installed 2 Mulcher door closed FOR REAR BAGGING 1 Rear mulcher plug removed 2 Grass catcher installed 3 Mulcher door closed FOR SIDE DISCHARGING 1 Rear mulcher plug installed 2 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 OPERATION BEFORE STARTING ENGINE ADD OIL See Figs 11 and 12 Your lawnmower is shipped without oil in the engine For type and grade of oil to use see ENGINE in the Maintenance section of this manual oil or it will smoke heavily from the muf fler on startup
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29. on At this time the grass has dried yet the newly cut area will not be exposed to direct sunlight e For best results adjust the lawn mower cutting height so that the lawn mower cuts off only the top one third of the grass blades See Fig 14 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 14 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 change to east to west the next week This will help prevent matting and graining of the lawn MAINTENANCE MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE Lubrication pop fF IC IIS j Power Propelled Mowers wwf o m veje v yf EEE If Equipped V Clean Lawn Mower lv wf Clean Under Drive Cover Power Propelled Mowers Check drive belt pulleys Clean Battery Recharge Electric Start Mowers Check Engine Oil Level Change Engine Oil 1 Change more often when operating under a heavy load or in high ambient temperat
30. ries Only use accessories approved by the manufacturer e Stop the blade s when crossing gravel drives walks or roads e Stop the engine motor whenever you leave the equip ment before cleaning the mower or unclogging the chute e Shutthe 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 mechanism or drive clutch on mowers so equipped before starting the engine mo tor e If the equipment should start to vibrate abnormally stop the engine motor and check immediately for the cause Vibration is generally a warning of trouble e Always wear safety goggles or safety glasses with side shields when operating mower ll SLOPE OPERATION Slopes are a major factor related to slip and fall accidents which can result in severe injury All slopes require extra caution If you feel uneasy on a slope do not mow it DO e Mowacross the face of slopes never up and down Exer cise extreme caution when changing direction on slopes e Remove obstacles such as rocks tree limbs etc e Watch for holes ruts or bumps Tall grass can hide obstacles Do not trim near drop offs ditches or embankments
31. ring 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 cuado 2 3 PRODUCT SPECIFICATIONS 3 CUSTOMER RESPONSIBILITIES 3 ASSEMBLY nissan 4 OPERATION nun ae 5 9 MAINTENANCE SCHEDUIE 10 MAINTENANCE LI I III III asas 10 12 SERVICE AND ADJUSTMENTS 12 14 STORAGE uuu uu uuu odds 14 15 TROUBLESHOOTING nu nee 16 REPAIR PARTS 17 21 WARRANTY serien nn 24 ASSEMBLY Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower IMPORTANT THIS LAWN MOWER IS SHIPPED WITH OUT OIL OR GASOLINE IN THE ENGINE Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for ship ping purposes All parts such as nuts washers bolts etc necessary to complete the assembly have been placed in the parts bag To ensure safe and proper operation of your lawn mower all parts and hardware you assemble must be tightened securely Use the correct tools as necessary to ensure proper tightness TO REMOVE LAWN MOWER FROM CARTON 1 Remove loose parts included with mower 2 Cut down two end corners of carton and lay end panel down flat 3 Remove all packing materials except padding betwe
32. shing 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 e For extremely heavy cutting reduce the width of cut by overlapping previously cut path and mow slowly e For better grass bagging and most cutting conditions the engine speed should be set in the fast position e 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 INTHEMAINTENANCESECTIONOFTHISMANUAL e 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 afterno
33. t Worn bent or loose blade Wheel heights uneven Buildup of grass leaves and trash under mower Worn bent or loose blade Bent engine crankshaft Engine flywheel brake is on when control bar is released 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 heavy grass Grass catcher too full Handle height position not right for you Belt wear Belt off of pulley Drive cable worn or broken Loose drive control system 16 Clean replace air filter Fill fuel tank Empty fuel tank and refill tank with fresh clean gasoline Empty 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 Turn fuel valve lever to the ON position Charge battery Connect battery to engine 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 Depress control bar to upper handle before pulling star
34. t 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 SERVICE AND ADJUSTMENTS TO REMOVE DRIVE BELT See Figs 17 amp 18 1 Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with spark plug 2 Remove screws retaining drive cover not shown and remove drive cover from lawn mower housing 3 Remove drive cable from anchor then detach spring from idler arm assembly DRIVE CABLE ANCHOR DRIVE BELT 7 A IDLER ARM HOUSING KEEPERS ASSEMBLY HOLE FIG 17 4 Remove idler arm assembly from housing by removing hex nut then remove drive belt from drive pulley belt keepers and idler arm assembly 5 Turn lawn mower on its side Make sure air filter and carburetor are up 6 Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt NOTE Protect your hands with gloves and or wrap blade with heavy cloth 7 Remove blade bolt CRANKSHAFT HOUSING HOLE Y P wer HARDENED WASHER b y N pers um TRAILING EDGE LOCKWASHER
35. ter rope Contact a qualified service center Replace blade adapter Move lawn mower to cut grass or other hard surface before starting 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 Check replace drive belt Check reinstall drive belt Put belt on pulleys replace belts if broken Adjust drive control ROTARY LAWN MOWER MODEL NUMBER 5521RS 5521RSA PRODUCT NUMBER 954 22 34 70 GEAR CASE ASSEMBLY PART NUMBER 532 18 08 68 KEY PART NO OONOOABRWN NO 817 54 10 11 532 16 06 72 532 05 70 72 532 17 97 54 532 16 08 18 532 07 78 81 532 16 08 17 532 85 08 48 532 16 06 78 532 16 06 79 532 16 06 73 532 05 70 79 812 00 00 39 532 08 64 47 532 75 03 69 532 18 75 40 DESCRIPTION Screw Tapping 10 24 x 668 Gear Case Upper Seal Drive Shaft Bearing Needle Thrust Bearing Washer Thrust Key Hi pro Shaft Worm Gear Helical Gear Case Lower Washer Hardened E Ring Plug Grease Kit Gearcase Replacement Includes Grease NOTE All component dimensions given in U S inches 1 inch 25 4 mm 17 ROTARY LAWN MOWER MODEL NUMBER 5521RS 5521RSA PRODUCT NUMBER 954 22 34 70 6 ROTARY LAWN MOWER MODEL NUMBER 5521RS 5521RSA PRODUCT NUMBER 954 22 34 70 KEY PART NO NO 1 532 18 56 12 2 532 17
36. ures 2 Service more often when operating in dirty or dusty conditions 4 Charge 48 hours at end of season 3 Replace blades more often when mowing in sandy soil 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 2 ENGINE OIL At least once a year replace the spark plug clean or 1 MULCHER replace air filter element and check blade for wear A P on new spark plug and clean new air filter element assure proper air fuel mixture and help your engine run better and last longer e Follow the maintenance schedule in this manual BEFORE EACH USE 1 Check engine oil level 2 Check for loose fasteners LUBRICATION Keep unit well lubricated See LUBRICATION CHART IMPORTANT DO NOT OIL OR GREASE PLASTIC WHEEL BEARINGS VISCOUS LUBRICANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELF LUBRICATING BEARINGS IF YOU FEEL THEY MUST BE D HANDLE BRACKET MOUNTING PINS LUBRICATED USE ONLY A DRY POWDERED GRAPHITE D SPRAY LUBRICANT TYPE LUBRICANT S
37. wn mower the engine MULCHER DOOR allows conversion to discharge or STARTER HANDLE used for starting the engine bagging operation DRIVE CONTROL LEVER used to engage power pro MULCHER PLUG located at the discharge opening must pelled forward motion lawn mower 5 be removed when converting to bagging operation OPERATION re 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 ee performing any adjustments or repairs We recommend standard safety glasses or a wide vision safety THAN NO SIGHT mask over spectacles HOW TO USE YOUR LAWN MOWER ENGINE SPEED The engine speed was set at the factory for optimum per formance Speed is not adjustable ENGINE ZONE CONTROL CAUTION Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury Do not under any circumstances attempt to defeat the function of the operator control The blade turns when the engine is running e Yourlawn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower DRIVE CONTROL See Fig 5 e Self propelling is controlled by holding the operator presence control bar down to the handle and pulling the drive control l
38. x2 O Ring Nut Hex Flangelock 3 8 16 Washer Cover Bottom Auto Walk Drive Control Plate Trigger Auto Walk Drive Control Decal Drive Control Screw Phillips Head 10 x 5 8 Decal Drive Control Operation Gear Pinion Retainer Drive RH Pawl Spring Torsion Disc Drive Seal Friction Pinion Pawl Assembly RH Pinion Pawl Assembly LH Screw 8 x 3 4 Retainer Drive LH Spring Return Lever Pulley Drive Lever Auto Walk Drive Control Decal Drive Control Adjustment bottom Washer Flat 3 8 NOTE All component dimensions given in U S inches 1 inch 25 4 mm SERVICE NOTES 22 SERVICE NOTES 23 2002 E2 18 8 LES 69282 ON yoeyg peoy 9 1AS9181S 6y Z VNYVAOSNH eae INOA ul Jajesp e 101 Z3AASNH 008 1 Buleo Aq Jo Alopa p suoydaja e90 ay jo sebed NOII A u yBnoJy pajeso jpeuwJou aq ued Jajesp eulenbsnH pazioyine uy Ajuenem siy Aq palanoo zou aie sobleyo lenep pue dn 4914 asuadxa SJ UMO au je pajaniep eq Isnw jonpold y anpe 10 w jqod euoyelado y jo sep wo SAep HE Alu uey Jeje ou UUeW Awy e u Jejesp eulenbsnH paziouyl ne ue ol palaniep sq jsnu annosjep eq o panaljaq j9npold ay Aueuem siy jo 1eusq y Ule GO o Jayesp Bul os y jo sseJppe pue awueu ajajduos pue equinu penes QuUINU jepou paseyoind ayjep apnjou Jsnw Jood silu 2 A Jas JUBJJIem uieqo O Japo ul Jayesep eulenbsnH pazioyine y o pajuasald aq snu aseyolnd jo JOOJy 8
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