Bolens 506 Lawn Mower User Manual
Contents
1. 17 MANUFACTURER S LIMITED WARRANTY FOR YARD MaN The limited warranty set forth below is given by MTD LLC with respect to new merchandise purchased and used in the United States its possessions and territories MTD LLC warrants this product against defects for a period of two 2 years commencing on the date of original purchase and will at its option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any accessory or attachment not approved by MTD LLC for use with the product s covered by this manual will void your warranty as to any resulting damage Normal wear parts or components thereof are subject to separate terms as follows All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts Normal wear parts and components include but are not limited to2. This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state MTD LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 800 800 7310
3. a Step back from the mower to fully extend your arms b Besure you are well balanced with sure footing c Pull the mower back slowly no more than half way toward you d Repeat these steps as needed Do not operate the mower while under the influence of alcohol or drugs Do not engage the self propelled mechanism on units so equipped while starting engine The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your footing release the blade control handle immediately and the blade will stop rotating within three seconds Mow only in daylight or in good artificial light Walk never run Stop the blade when crossing gravel drives walks or roads If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never pl
4. YARD MAN Operators Manual 21 Self Starter High Wheel Rotary Mower Model 589 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning This unit is equipped with an internal 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 If a spark arrester is used it should be maintained in effective working order by the operator 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 through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 MTD LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 PRINTED IN U S A FORM NO 769 00004A 10 2002 TABLE 0F CONTENTS Content Page Important Safe Operation Practices oooooronronnnn o nn oonnnnnn nen 3 Slope GAUGES rio a u 6 Assembling Your Lawn Mower oorononrnnnn no non rosnonn nn 7 Know Your Lawn MOWeEP oooooonrnnn nn no on on o nn nn 9 Operating Your LAWN Mower ooorrnnnonon nn non nen trne 10 Making Adj stments zs 1251 0700001510x01101017x211011 1 1a0rolsb rh ns inane o hh geet O A 12
5. batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates auger spiral rubber and tires HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area check your Yellow Pages or contact MTD LLC at P O Box 361131 Cleveland Ohio 44136 0019 or call 1 800 800 7310 or log on to our Web site at www mtdproducts com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manufacturer s warranty Refer to applicable manufacturer s warranty for terms and conditions b Log splitter pumps valves and cylinders have a sepa rate one year warranty c Routine maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure PF 777 d MTD LLC does not extend any warranty for products sold or exported outside of the United States its possessions and territories except those sold through MTD LLC s authorized channels of export distribution e Parts that are not genuine MTD parts are not covered by this warranty f Service completed by someone other than an authorized service dealer is not covered by this warranty g Transportation charges an
6. Contact with the blade can amputate hands and feet 10 11 12 13 14 15 16 17 18 19 WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before attempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol HEED ITS WARNING WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm DANGER This machine was built to be operated according to the rules for safe operation in this manual As with any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety instruc A missing or damaged discharge cover can cause blade contact or thrown object injuries Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping Do not hold on to the mower if you are falling release the handle immediately Never pull the mower back toward you while you are walking If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps
7. blade NOTE For repairs beyond the minor adjustments listed above contact your nearest authorized service dealer 15 SECTION 10 PARTS LIST FOR MODEL 589 A F DIDE S d S H a A i fe S 53 I NA A f ja Z D 54 gt LIP N AY N 44 Model 589 Series A Part No Part Description A Part No Part Description 1 749 04001 Upper Handle 40 738 0507B Shoulder Screw 2 647 0070 Control Handle 41 734 2043 Rear Wheel Assembly 14 x 2 1 5 712 0324 Hex Lock Nut 1 4 20 42 736 0272 Flat Washer 510 ID x 1 00 OD 6 712 0397 Wing Nut 43 736 0182 Wave Washer 500 ID x 1 0 OD 7 710 1205 Rope Guide 44 738 0481A Shoulder Screw 8 710 1174 Carriage Bolt 5 16 18 x 2 45 14578 Front Height Adjuster RH 9 736 0451 Shoulder Washer 320 ID x 930 OD 14579 Front Height Adjuster LH 10 720 0284 Wing Nut 46 734 2004A Front Wheel Assembly 8 x 2 1 12 746 1141 Self Start Control Cable 58 25 47 738 0102 Shoulder Bolt 13 749 0907B Lower Handle 49 712 0431 Flange Lock Nut 3 8 16 14 664 0085 Grass Bag 50 782 5002 Front Baffle 15 747 04080 Grass Catcher Frame 51 782 5003 Rear Baffle LH 17 782 5004A Rear Baffle RH 52 710 1017 Tap Screw 1 4 14 x 625 18 714 0104 Hairpin Clip 53 15261A Height Adjustment Plate 19 731 04134 Grass Bag Door 54 720 0426 Height Adjustment Knob 20 732 0700 Wire Rod 55 15262B Pivot Bar 21 731 1236 Trail Shield 56 7
8. by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly It is recommended that the blade always be removed from the adapter when testing for balance Before reinstalling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil To Reinstall Blade e Be sure to install the blade with the side marked Bottom or with part number facing the ground when the mower is in the operating position e Slide the blade adapter onto the engine crankshaft e Place the blade on the adapter The blade has to be aligned and seated on the blade adapter flanges e Place blade bell support on blade Make sure the notches on the blade bell support are aligned with small holes in the blade e Replace hex bolt and tighten hex bolt to torque 450 in Ibs min 600 in Ibs max NOTE To ensure safe operation the blade bolt must be checked periodically for correct torque Lubrication 1 WARNING Always stop engine and lubricating or doing any kind of service work on the lawn mower Lubricate the pivot points on the blade control handle at least once a season with light oil The blade control Wheels Lubricate the wheels at least once a season with light reason lubricate the surface of the axle bolt and inner surface of the wheel with light oil See Figure 14 Lubricate the torsion springs and pivot points on rear d
9. on water heater furnace clothes dryer or other gas appliance A NOTE We do not recommend the use of pressure washers or garden hose to clean your unit They may cause damage to electric components spindles pulleys bearings or the engine The use of water will result in shortened life and reduce serviceability e Refer to engine manual for storage instructions e Coat mower s cutting blade with chassis grease to prevent rusting e Store mower in a dry clean area Do not store next to corrosive materials such as fertilizer NOTE When storing any type of power eguipment in a poorly ventilated or metal storage shed care should be taken to rust proof the equipment Using a light oil or silicone coat the equipment especially cables and all moving parts SECTION 9 TROUBLESHOOTING Problem Cause Remedy Engine fails to start 1 Blade control handle disengaged 1 Engage blade control handle 2 Start control button not depressed 2 Depress starter control button 3 Spark plug wire disconnected 3 Connect wire to spark plug 4 Safety key notin run position 4 Place safety key in run position 5 Fuel tank empty or stale fuel 5 Fill tank with clean fresh gasoline 6 Blocked fuel line 6 Clean fuel line 7 Faulty spark plug 7 Clean adjust gap or replace 8 Engine flooded 8 Wait a few minutes to restart but do not prime 9 Self starter already de energized 9 Use recoil start
10. regularly After striking a foreign object stop the engine disconnect the spark plug wire and de energize the starter See section To De energize Self Starter Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower Never attempt to make a wheel or cutting height adjustment while the engine is running Grass catcher components discharge cover and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown For Your Responsibility 10 11 12 13 safety protection frequently check components and replace immediately with original equipment manufacturer s O E M parts only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Do not change the engine governor setting or overspeed the engine The governor controls the maximum safe operating speed of the engine Maintain or replace safety and instruction labels as necessary Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment ALWAYS de energize self starter prior to performing any maintenance or service to the engine and or mower Follow instructions both in manual and on the engine and or machine to de energize starter Restrict the use of this power machine to persons who read understand and follow
11. the outside of e The rope guide is attached to the right side of upper handle Loosen the wing nut which secures the rope guide See Figure 5 Upper Handle bag See Figure 7 Plastic Channel Grass Catcher Wing Nut Handle Figure 7 Figure 5 Attaching Grass Catcher To Mower e Lift the rear discharge door and place the grass catcher on the pivot rod Let go of discharge door so that it rests on the grass catcher See Figure 8 e With the spark plug wire disconnected and grounded hold the blade control handle against the upper handle and pull the starter rope out of the engine Release the blade control handle Slip the starter rope into the rope guide Tighten wing nut H w OS A Assembling Grass Catcher ESS NOTE If your mowers grass catcher has been already Bey assembled before shipping proceed to the next section If it is unassembled follow the steps below e Insert frame into grass bag with the black plastic side on the bottom of bag See Figure 6 Insert frame Figure 8 Grass Catcher p Frame Converting To Mulcher e Liftthe rear discharge door on the mower and lift the grass catcher up Release the rear discharge Figure 6 door to allow it to cover the rear opening of the machine e Slip the side openings of the plastic channel on the bag over the hooks on the grass catcher frame WARNING Never operate the lawn mower Secure bag to the frame by working th
12. 32 0404 Spring Lever 22 732 04090 Door Spring R H 57 748 0376C Blade Adapter 23 747 0996 Chute Door Pivot Rod 58 742 0741 21 Mulching Blade 24 750 04162 Spacer 375 O D X 50 I D X 1 02 59 736 0524A Blade Bell Support 25 687 02032 Handle Bracket Assy Complete LH 60 710 1044 Hex Cap Screw 3 8 24 x 1 5 Includes 29 32 37 39 40 61 731 1506 Front End Cover 687 02034 Handle Bracket Assy Complete RH 62 731 1426 Hub Cap Includes 29 32 37 39 40 63 710 0501 Hex Hd Cap Scr 1 4 20 Gr 5 26 1787 01105 Decker 64 710 1256 Hi Low Screw 27 710 0654A Hex Washer Screw 3 8 16 x 1 0 65 731 2532 Control Cover LH 28 710 0703 Hex Carriage Screw 1 4 20 66 731 2533 Control Cover RH 29 712 3005 Flange Lock Nut 3 8 16 67 715 0168 Pin 31 712 0431 Flange Lock Nut 3 8 16 68 732 1171 Compression Spring 32 687 02033 Handle Bracket Assembly RH 69 720 0428 Button 687 02031 Handle Bracket Assembly LH 70 716 0209 Retention Spring 33 710 0286 Machine Screw 1 4 20 x 500 71 732 1172 Torsion Spring 34 710 0896 Hex Washer Screw 1 4 14 x 625 72 782 0156 Lever 35 710 0216 Hex Cap Screw 3 8 16 x 75 73 731 2623 Bail Cover Not shown 36 720 0312 Foam Grip 74 736 0504 Wave Washer 510 x 750 37 17488A Pivot Bar RH 75 726 0240 Cable Tie 17489A Pivot Bar LH 76 720 0279 Wing Nut 38 736 0105 Spring Washer 375 ID x 870 OD 77 732 04089 Door Spring L H 39 732 0866 Spring Lever 78 782 5003 Left Rear Baffle
13. Maintaining Your Lawn Mower oooroooononnonnnnnn nn nn nnnnnnnnnnn nn 13 Off Season Storage rnana dada a a 14 THOUBIGSHOOUNG nirekin aeaaea r aa 15 Parts LIST ss eeen a anaa e Aaa aa aa aa eaaa ala dbs 16 FINDING MODEL NUMBER This Operator s Manual is an important part of your new lawn mower It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says equipment and copy the information from it in the space provided below The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by looking down at the rear of the deck A sample model plate is explained below For future reference please copy the model number and the serial number of the eguipment in the space below amp Before you start assembling your new equipment please locate the model plate on the Model Number Copy the model number here Serial Number Copy the serial number here YARD MAN Po sox Se1131 CLEVELAND OH 44136 www yardman com 330 220 4683 800 800 7310 ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your unit for more information CALLING CUS
14. TOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit please call the Customer Support Department Call 1 330 220 4MTD 4683 or 1 800 800 7310 to reach a Customer Support representative Please have your unit s model number and serial number ready when you A call See previous section to locate this information You will be asked to enter the serial number in order to process vour call For more details about your unit visit our website at www yardman com SECTION 1 IMPORTANT SAFE OPERATION PRACTICES A A A tions could result in serious injury or death General Operation 1 Read this operator s manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this manual in a safe place for future and regular reference and for ordering replacement parts This machine is a precision piece of power equipment nota plaything Therefore exercise extreme caution at all times Your unit has been designed to perform one job to mow grass Do not use it for any other purpose Never allow children under 14 years old to operate this machine Children 14 years old and over should read and understand the operation instruc
15. ace any part of the body in the blade area until you are sure the blade has stopped rotating 20 Never operate mower without proper trail shield discharge cover grass catcher blade control handle or other safety protective devices in place and working Never operate mower with damaged safety devices Failure to do so can result in personal injury 21 Muffler and engine become hot and can cause a burn Do not touch 22 Only use parts and accessories made for this machine by the manufacturer Failure to do so can result in personal injury 23 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Telephone 1 800 800 7310 for the name of your nearest dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy on a slope do not mow it For your safety use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes 2 Watch for holes ruts rocks hidden objects or bumps which can cause you to slip or trip Tall grass can hide obstacles 3 Always be sure of your footing A slip and fall can cause serious per
16. avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite 2 Wash your skin and change clothes immediately Use only an approved gasoline container 4 Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 5 When practical remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition 8 Never fuel machine indoors because flammable vapors will accumulate in the area 9 Never remove gas cap or add fuel while the engine is hot or running Allow engine to cool at least two minutes before refueling 10 Never over fill fuel tank Fill tank to no more than inch below bottom of filler neck to provide space for fuel expansion 11 Replace gasoline cap and tighten securely 12 If gasoline is spilled wipe it off the engine and equipment Move unit to anoth
17. blade rotates whenever the engine is running and when the self starter is de energized Cutting Height Adjustment Levers These levers are located on each wheel and are used to adjust the cutting height These levers have to be at the same relative position to ensure uniform cut See Figure 9 Safety Key The safety key is located on the engine See Figure 9 The safety key is a safety device used to activate and deactivate the self starter system The self starter system will not work without the key in it s proper position See engine manual for further information pertaining to the safety key NOTE The safety key must be in the run position to start the mower for both systems either the self starter or recoil starter Start Control Button The start control button is located on the upper left side of the handle See Figure 9 The start control button must be depressed fully while pulling the blade control handle toward upper handle for the engine to start The starter control button will automatically return to the off up position once the blade control handle is released NOTE The starter button must be depressed to start the engine with either the self starter or recoil starting system Engine Controls See the separate engine manual for the location and function of the controls on the engine Stopping Engine e Release safety blade control handle the start control button will automatically return to the off up posi
18. d service calls are not covered No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind MTD LLC During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale MTD LLC shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product
19. e removed Throttle Speed Your lawn mower engine is equipped with a constant speed throttle which is set at full throttle for best performance Using Your Lawn Mower WARNING Never operate the mower A unless the hooks on the grass catcher are seated in the slots on the handle bracket assemblies and the rear discharge door rests firmly against the top of the grass catcher e You can use your mower as a mulching mower ora rear bagger e Do not operate the mower without the rear mulching baffle or the grass catcher bag properly installed e Be sure that the lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others e For best results do not cut wet grass because it tends to stick to the underside of the mower preventing proper discharge of grass clippings and possibly causing you to slip and fall New grass thick grass or wet grass may require a narrower cut e Fora healthy lawn always cut off one third or less of the total length of the grass Lawn should be trimmed in fall as long as there is growth WARNING If you strike a foreign object stop the engine Remove wire from spark plug and de energize thoroughly inspect the mower for any damage and repair the damage before restarting and operating the mower Excessive vibration of the mower during o
20. e six plastic A without the grass catcher assembly or the channels on bag over frame mulching baffle firmly secured on the machine SECTION 4 KNOW YOUR LAWN MOWER Read this owner s manual and safety rules before operating your lawn mower Compare the illustrations in Figure 9 with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for future reference operator s eyes and causing severe eye damage Always wear safety glasses while operating the mower 1 WARNING The operation of any lawn mower can result in foreign objects being thrown into the or while performing any adjustments or repairs on it Rear Cutting Height Adjustment Lever Start Control Button Front Cutting Height Adjustment Lever Figure 9 Recoil Starter The recoil starter handle is attached to the upper handle See Figure 9 The recoil starter is used to start the engine when the self starter is in the de energized mode Blade Control Handle The blade control handle is located on the upper handle of the mower The blade control handle and starter control button must be depressed in order to operate the unit Release blade control handle to stop engine and blade and to energize the self starter See Figure 9 WARNING The blade control handle is a A safety device Never attempt to bypass its operations Doing so may result in personal injury through contact with the rotating blade The
21. e to RUN position Firmly push primer bulb 3 times For a cold engine only 5 While standing at upper handle depress the starter control button with the thumb of your right hand 6 Using your left hand pull the blade control handle all the way toward the upper handle See Figure 10 Starter will de energize and engine will start NOTE If engine does not start release the blade control handle and follow steps 8 9 10 11 and 12 in the First Time Starting Engine instructions PONS NOTE f any problems are encountered refer to the Trouble Shooting Guide for helpful information To Stop Engine And Blade 1 Release safety blade control handle the start control button will automatically return to the off up position engine and blade will stop within a few seconds NOTE Engine may stop with a ratcheting sound This sound is the self starter being reactivated energized for the next start 2 Turn safety key 1 4 turn counterclockwise to LOCK position Remove key and store in a safe place WARNING The blade will continue to rotate for three seconds after the blade control lever is released n De Energize Self Starter Remove spark plug wire from spark plug e Turn safety key to RUN position 1 4 turn clockwise e While standing in the operating position depress the starter control button fully with the thumb of your right hand e Using your left hand pull the control handle all the way toward th
22. e upper handle Release button and wait until engine and starter stop rotating e Release safety blade control handle the start control button will automatically return to the off up position e Remove safety key NOTE Engine will crank over upon actuating eguipment starting controls but will not spark if spark plug wire was removed from spark plug as described above Once engine has stopped cranking self starter is de energized WARNING Self Starting System If these instructions are not followed amputation or severe laceration can result e ALWAYS disconnect spark plug de energize starter lock and remove safety key BEFORE performing ANY service to the engine or mower e DONOT attempt any maintenance or repairs to the self starter e NEVER assume starter is de energize even if key is in LOCK AND REMOVE position and or removed from engine e BEFORE removing grass or other debris from under mower deck BEFORE changing oil air filter or spark plug BEFORE removing blade for servicing BEFORE performing any other service to engine or mower BEFORE transporting mower ALWAYS DE ENERGIZE SELF STARTER e ALWAYS lock and remove safety key and store ina safe place until next use The safety key is designed and intended to be removed from engine when notin use Removing key will prevent unsupervised or unexpected starting of mower by children or unsuspecting adults The safety key must be in the locked position before it can b
23. er area Wait 5 minutes before starting the engine 13 Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances 14 To reduce fire hazard keep mower free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris 15 Allow a mower to cool at least 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas 2 Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine to prevent unintended starting 3 Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manufacture s O E M blade only listed in this manual Use of parts which do not w meet the original eguipment specifications may lead to improper performance and compromise safety Mower blades are sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing them Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation
24. er could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes Operate WALK BEHIND mowers across the face of slopes never up and down slopes SECTION 3 ASSEMBLING YOUR LAWN MOWER IMPORTANT This unit is shipped without gasoline or oil in the engine Be certain to service engine with gasoline 2 Lift lower handle and oil as instructed in the separate engine manual before operating your mower Removing Unit From Carton e Remove staples break glue on top flaps or cut tape at carton end and peel along top flap to open carton Remove loose parts if included with unit i e operator s manual etc e Cutalong corners lay carton down flat and remove packing material e Roll or slide unit out of carton and check carton thoroughly for loose parts Figure 2 e Remove the hairpin clips from the outer hole in the weld pins on the handle bracket assemblies Using a pair of pliers squeeze one leg of the lower handle against the handle bracket assemblies Insert the Hardware Pack Please identify each piece of the hardware pack as i Carriage hairpin clip into the inner hole on the weld pin shown here Bolt Repeat on other side See Figure 3 1 4 20 2 1 4 20 2 e After you have moved the hairpin clip install the carriage b
25. er to start engine Engine runs erratic 1 Spark plug wire loose 1 Connect and tighten spark plug wire 2 Blocked fuel line or stale fuel 2 Clean fuel line fill tank with clean fresh gasoline 3 Ventin gas plugged 3 Clear vent 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Clean air cleaner 6 Carburetor out of adjustment 6 Adjust carburetor Engine overheats 1 Engine oil level low 1 Fill crankcase with proper oil 2 Air flow restricted 2 Remove blower housing and clean 3 Carburetor not adjusted properly 3 Adjust carburetor Occasionally skips hesitates 1 Spark plug gap too close 1 Adjust gap to 030 at high speed Idles poorly 1 Spark plug fouled faulty or gap too 1 Resetgap to 030 or replace spark plug wide 2 Carburetor improperly adjusted 2 Adjust carburetor 3 Dirty air cleaner 3 Clean air cleaner Excessive vibration 1 Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance blade 2 Bentcutting blade 2 Replace blade Mower will not mulch grass 1 Wetgrass 1 Donotmow when grass is wet wait until later to cut 2 Excessively high grass 2 Mowonce ata high cutting height then mow again at desired height or make a narrower cutting path 3 Dull blade 3 Sharpen or replace blade Uneven cut 1 Wheels not positioned correctly 1 Place all four wheels in same height position 2 Dull blade 2 Sharpen or replace
26. etermined which height is best for your lawn Handle Height Your mower is shipped with the handle in the higher height position e Remove the starter rope from the rope guide e Remove the upper handle by removing the hand knobs and carriage bolts Lay the upper handle out of the way being careful not to bend or kink cables e Remove the hairpin clips from the weld pins on the handle brackets Refer to Figure 3 e Remove the carriage bolts and wing nuts from the handle brackets Press out on the legs of the lower handle Remove lower handle from the mower e Turn the lower handle around so the notch on the bottom of the lower handle is facing forward as shown in Figure 12 Reassemble placing the bottom holes in the handle over the weld pins in the handle mounting bracket Lower Handle Figure 12 e Reassemble the upper handle to the lower handle e Place the hairpin clips in the inner holes of the weld pins and replace the carriage bolts and wing nuts on the handle brackets Attach the starter rope as instructed in the Assembly section Engine Adjustments Refer to the engine manual for details and instructions regarding engine adjustments SECTION 7 MAINTAINING YOUR LAWN MOWER WARNING Be sure to disconnect the spark plug wire and DE ENERGIZE starter before performing any repairs or maintenance DO NOT attempt any maintenance or service to the engine and or mower equipped with the safety key in the unlocked and
27. follows Place lawn mower on a level surface outdoors Remove clear plastic packaging under fuel cap Check oil level Add fuel Open shut off valve if equipped 1 4 turn Push spark plug wire firmly on spark plug Turn safety key 1 4 turn clockwise to RUN position NOGOBON gt 8 Firmly push primer bulb 3 times 9 While standing in the operating position depress the starter control button fully with the thumb of your right hand 10 Using your left hand pull the control handle all the way toward the upper handle See Figure 10 11 Release the button 12 Grasp the recoil rope starter handle with your right hand and slowly pull towards you until you feel a slight resistance then pull firmly until your arm is fully extended 13 If engine does not start by the second pull repeat steps 8 9 10 11 and 12 Second Time Starting Engine NOTE Follow these instructions if the self starter is already in the energized mode 1 WARNING NEVER assume starter is in the de energized mode even if the key is in the locked position and or removed from the engine ALWAYS de energize starter prior to performing any maintenance or service to the engine and or mower Follow instructions on the engine and or machine to de energize starter Starter Control Button Blade Control Handle Figure 10 Check oil level and add fuel if necessary Open shut off valve if equipped 1 4 turn Turn safety key 1 4 turn clockwis
28. ischarge door using light oil This will insure the door disconnect spark plug wire before cleaning Blade Control must operate freely in both directions See Figure 14 oil or motor oil If the wheels are removed for any Rear Discharge Door which is a safety device can always work properly SECTION 8 OFF SEASON STORAGE The following steps should be taken to prepare your lawn mower for storage 1 WARNING Be sure to disconnect the spark plug wire and DE ENERGIZE starter before performing any repairs or maintenance DO NOT attempt any maintenance or service to the engine and or mower equipped with the safety key in the unlocked and or energized mode WARNING NEVER assume starter is de energized even if the key is in the locked position and or removed from the engine ALWAYS de energize self starter prior to performing any maintenance or service to the engine and or mower Follow instructions on the engine and or machine to de energize starter A Engine Follow the engine manual for lubrication instructions Figure 14 Replacing Rear Flap e To remove rear flap cut off the flat end of the wire rod which secures it to the deck See Figure 15 e Attach the new flap and new rod to deck bending the ends of the new rod over to secure to deck Handle Bracket Handle Bracket Figure 15 WARNING Never store the machine or fuel container indoors where there is an open flame spark or pilot light such as
29. olt carriage bolt must go to the inside of Disconnecting Spark Plug Wire handle included in the hardware pack in the upper hole on the handle mounting bracket Secure with one plastic wing nut also included in the hardware pack See Figure 3 Repeat process on other side AN Carriage Bolt e A sy ff r o Handle Y z Mounting 4 Brkt Wing Nut Before setting up your lawn mower disconnect the spark plug wire from the spark plug and ground to a bolt on the engine Leave safety key in locked position See Figure 1 of Spark Plug Spark Plug Figure 1 NOTE Reference to right or left hand side of the mower Move Matkin Sip is observed from the operating position Figure 3 P e Fasten the cable to the lower handle with the two Assembling Handle cable ties found on the lower handle Pull the cable e Lift up and pull back on the upper handle to raise ties tight and trim off the excess See Figure 4 the handle into the operating position e Make certain the lower handle is seated securely into the handle bracket assemblies e Tighten the wing nuts between the upper handle and the lower handle carriage bolts must be seated properly into the handle See Figure 2 Handle NOTE Your mower is shipped with the handle in the higher position If you wish to lower the height of the handle refer to the Adjustment Section at this time Figure 4 Attaching Starter Rope e All the plastic channels attach from
30. or energized mode A NEVER assume starter is de energized even if the key is in the locked position and or removed from the engine ALWAYS de energize self starter prior to performing any maintenance or service to the engine and or mower Follow instructions on the engine and or machine to de energize starter A Engine NOTE When tipping the unit empty the fuel tank and keep the spark plug side of engine up Never tip the mower more than 90 degrees and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem Refer to the engine manual for all engine maintenance instructions e Maintain engine oil as instructed in the engine manual Check oil level before starting mower e Service air cleaner every 25 hours under normal conditions Poor engine performance and flooding usually indicate that the air cleaner should be serviced To service the air cleaner refer to the engine manual e The spark plug should be cleaned and the gap reset once a season Spark plug replacement is recommended at the start of each mowing season Clean the engine regularly with a cloth or brush Keep the cooling system blower housing area clean to permit proper air circulation which is essential to engine performance and life Be certain to remove all grass dirt and combustible debris from muffler area Deck The underside of the mower deck should be cleaned after each
31. peration is an indication of damage The unit should be promptly inspected and repaired A SECTION 6 MAKING ADJUSTMENTS WARNING Be sure to disconnect the spark plug wire and DE ENERGIZE starter before performing any adjustments or repairs DO NOT attempt any maintenance or service to the engine and or mower equipped with the safety key in the unlocked and or energized mode WARNING NEVER assume starter is de energized even if the key is in the locked position and or removed from the engine ALWAYS de energize self starter prior to performing any maintenance or service to the engine and or mower Follow instructions on the engine and or machine to de energize starter Cutting Height A A Height Adjustment Lever Figure 11 An adjusting plate and spring lever at each wheel position provides cutting height adjustment Each adjusting plate has several height positions e Move the spring lever to one of these height positions and the height of cut will be changed Simply depress the lever towards wheel and move lever assembly to desired position See Figure 11 IMPORTANT All wheels must be placed in the same relative position For rough or uneven lawns move the height adjustment lever to a higher position This will help stop scalping of the grass NOTE For shipping purposes your mower is set with the wheels in a low cutting height position For best results raise the cutting position until you have d
32. sonal injury If you feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you could lose your footing or balance 2 Donot mow slopes greater than 15 degrees as shown on the slope gauge 3 Do not mow on wet grass Unstable 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 mower and the mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator 2 Be alert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care when approaching blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run into the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Service Safe Handling Of Gasoline 1 To
33. the warnings and instructions in this manual and on the machine TO REDUCE THE RISK OF INJURY DO NOT OPERATE UNLESS DISCHARGE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE IF DAMAGED REPLACE IMMEDIATELY DANGER KEEP HANDS and FEET AWAY AWARNING BLADE ROTATES WHEN SELF STARTER IS ENERGIZED BUTTON DE ENERGIZE SELF STARTER BEFORE SERVICING MOWER ADANGER AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM ROTATING PARTS e REMOVE OBJECTS THAT CAN BE THROWN BY THE BLADE IN ANY DIRECTION WEAR SAFETY GLASSES e DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND e USE EXTRA CAUTION ON SLOPES DO NOT MOW SLOPES GREATER THAN 15 MOW ACROSS NEVER UP AND DOWN NEVER PULL MOWER CLOSE TO YOUR FEET LOOK DOWN AND BEHIND BEFORE AND WHILE MOVING BACKWARDS MAX 15 READ OPERATOR S MANUAL KEEP SAFETY DEVICES BLADE CONTROL TRAILING SHIELD DISCHARGE COVER ETC IN PLACE AND WORKING DAMAGED REPLACE IMMEDIATELY SLOPE GAUGE SECTION 2 Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes eso T o SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE i I0 A POWER POLE rc 14 gt gt gt gt 55 A CORNER OF A BUILDING S l amp ORA FENCE POST Do not mow on inclines with a slope in exce of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mow
34. tion engine and blade will stop within a few seconds NOTE Engine may stop with a ratcheting sound This sound is the self starter being reactivated energized for the next start e Turn safety key 1 4 turn counterclockwise to LOCK position Remove key and store in a safe place A WARNING The blade will continue to rotate for three seconds after the blade control lever is released SECTION 5 OPERATING YOUR LAWN MOWER WARNING Read understand and follow all instructions and warnings on the machine A and in this manual before operating Gas amp Oil Fill Up e Check oil level and add oil if necessary Follow relevant instructions in the engine manual for this e Service the engine with gasoline as instructed in the engine manual WARNING Use extreme care when A handling gasoline Gasoline is extremely flammable and the vapors are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Before Starting Mower e Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug First Time Starting Engine NOTE Use recoil starter rope to start engine for the very first time The mower is shipped with the safety key in the locked position and the self starter in the de energized mode follow instructions as
35. tions and safety rules in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine Thoroughly inspect the area where the equipment is to be used Remove all stones sticks wire bones toys and other foreign objects which could be tripped over or picked up and thrown by the blade Thrown objects can cause serious personal injury Plan your mowing pattern to avoid discharge of material toward roads sidewalks bystanders and the like Also avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep children bystanders helpers and pets at least 75 feet from the mower while it is in operation Stop machine if anyone enters the area Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes Thrown objects which ricochet can cause serious injury to the eyes Wear sturdy rough soled work shoes and close fitting slacks and shirts Shirts and pants that cover the arms and legs and steel toed shoes are recommended Never operate this machine in bare feet sandals slippery or light weight e g canvas shoes Do not put hands or feet near rotating parts or under the cutting deck
36. use to prevent a buildup of grass clippings leaves dirt or other matter If this debris is allowed to accumulate it will invite rust and corrosion and may prevent proper mulching discharge or bagging The deck may be cleaned by tilting the mower and scraping clean with a suitable tool make certain the spark plug wire is disconnected IMPORTANT We do not recommend the use of a pressure washer or garden hose to clean your unit The use of water will result in shorter life and less serviceability Cutting Blade e When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade To Remove Blade e Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft See Figure 13 e Remove the blade and the adapter from the crankshaft Blade Adapter Blade Bell Support Hex Bolt Figure 13 WARNING Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary A When sharpening the blade follow the original angle of grind as a guide It is extremely important that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade WARNING An unbalanced blade will A cause excessive vibration when rotating at high speeds It may damage the mower and or cause personal injury The blade can be tested
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