Bolens 506 Lawn Mower User Manual

Operator’s 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 forestcovered, 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.fm
(10/2002)
TABLE OF CONTENTS
Content
Page
Important Safe Operation Practices................................................................... 3
Slope Gauge...................................................................................................... 6
Assembling Your Lawn Mower........................................................................... 7
Know Your Lawn Mower .................................................................................... 9
Operating Your Lawn Mower ............................................................................. 10
Making Adjustments .......................................................................................... 12
Maintaining Your Lawn Mower........................................................................... 13
Off Season Storage ........................................................................................... 14
Troubleshooting ................................................................................................. 15
Parts List ............................................................................................................ 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.
Before you start assembling your new equipment, please locate the model plate on the
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
equipment in the space below.
(Model Number)
(Serial Number)
Copy the model number here:
Copy the serial number here:
www.yardman.com
MTD LLC
P. O. BOX 361131
CLEVELAND,OH 44136
330-220-4683
800-800-7310
ENGINE INFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, powerrating, 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 CUSTOMER 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
call. See previous section to locate this information. You will be asked to enter the serial
number in order to process your call.
For more details about your unit, visit our website at www.yardman.com
2
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
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 instructions could result in serious injury or death.
General Operation
9.
1.
10.
2.
3.
4.
5.
6.
7.
8.
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,
not a 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 instructions 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. Contact with the blade can amputate hands
and feet.
11.
12.
13.
14.
15.
16.
17.
18.
19.
3
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:
a. Step back from the mower to fully extend your
arms.
b. Be sure 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 place any part of the body in the blade area until
you are sure the blade has stopped rotating.
6.
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.
Service
Safe Handling Of Gasoline:
1.
2.
3.
4.
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.
5.
Do:
1.
2.
3.
6.
Mow across the face of slopes; never up and down.
Exercise extreme caution when changing direction on
slopes.
Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide
obstacles.
Always be sure of your footing. A slip and fall can cause
serious personal injury. If you feel you are losing your
balance, release the blade control handle immediately,
and the blade will stop rotating within 3 seconds.
7.
8.
9.
10.
Do Not:
1.
2.
3.
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.
Do not mow near drop-offs, ditches or embankments, you
could lose your footing or balance.
Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
Do not mow on wet grass. Unstable footing could cause
slipping.
11.
12.
13.
Children
14.
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.
15.
To 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.
Wash your skin and change clothes immediately.
Use only an approved gasoline container.
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.
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.
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.
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Never fuel machine indoors because flammable vapors
will accumulate in the area.
Never remove gas cap or add fuel while the engine is hot
or running. Allow engine to cool at least two minutes
before refueling.
Never over fill fuel tank. Fill tank to no more than ½ inch
below bottom of filler neck to provide space for fuel
expansion.
Replace gasoline cap and tighten securely.
If gasoline is spilled, wipe it off the engine and equipment.
Move unit to another area. Wait 5 minutes before starting
the engine.
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.
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.
Allow a mower to cool at least 5 minutes before storing.
General Service:
1.
2.
3.
4
Never run an engine indoors or in a poorly ventilated
area. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
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.
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
4.
5.
6.
7.
8.
9.
meet the original equipment 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 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
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.
Your Responsibility
•
Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in
this manual and on the machine.
5
SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower
on such slopes.
FOL
D
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
° SL
OP E
OR A FENCE POST
A CORNER OF A BUILDING
ON D
O
T
T
ED L
IN E
,
R
EPR
ESE
N
T
I
N
GA
15
15°
WARNING
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower 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.
6
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
and oil as instructed in the separate engine manual
before operating your mower.
2. Lift lower handle
1. Move bag
away
Removing Unit From Carton
•
•
•
3. Lift upper
handle
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.)
Cut along corners, lay carton down flat, and remove
packing material.
Roll or slide unit out of carton and check carton
thoroughly for loose parts.
Figure 2
•
Hardware Pack
Please identify each piece
of the hardware pack as
shown here.
Wing
Nut
1/4-20 (2)
Carriage
Bolt
1/4-20 (2)
•
Disconnecting Spark Plug Wire
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.
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
hairpin clip into the inner hole on the weld pin.
Repeat on other side. See Figure 3.
After you have moved the hairpin clip, install the
carriage bolt, (carriage bolt must go to the inside of
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.
Carriage Bolt
Spark Plug
Wire
Upper
Hole
Handle
Mounting
Brkt.
Spark Plug
Wing Nut
Figure 1
Move Hairpin Clip
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
Figure 3
•
Assembling Handle
•
•
•
Lift up and pull back on the upper handle to raise
the handle into the operating position.
Make certain the lower handle is seated securely
into the handle bracket assemblies.
Tighten the wing nuts between the upper handle
and the lower handle (carriage bolts must be
seated properly into the handle). See Figure 2.
Fasten the cable to the lower handle with the two
cable ties found on the lower handle. Pull the cable
ties tight and trim off the excess. See Figure 4.
Cable Tie
Lower
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
7
Attaching Starter Rope
•
•
The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 5.
Starter
Rope
All the plastic channels attach from the outside of
bag. See Figure 7.
Plastic
Channel
Grass Catcher
Upper Handle
Wing Nut
Rope
Guide
Lower
Handle
Figure 7
Attaching Grass Catcher To Mower
Figure 5
•
•
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.
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.
Assembling Grass Catcher
NOTE: If your mower’s grass catcher has been already
assembled before shipping, proceed to the next
section. If it is unassembled, follow the steps below.
•
Insert frame into grass bag with the black plastic
side on the bottom of bag. See Figure 6.
Insert frame
into bag
Figure 8
Grass Catcher
Frame
Converting To Mulcher
Grass
Bag
•
Figure 6
•
Slip the side openings of the plastic channel on the
bag over the hooks on the grass catcher frame.
Secure bag to the frame by working the six plastic
channels on bag over frame.
Lift the rear discharge door on the mower and lift
the grass catcher up. Release the rear discharge
door to allow it to cover the rear opening of the
machine.
WARNING: Never operate the lawn mower
without the grass catcher assembly or the
mulching baffle firmly secured on the machine.
8
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.
WARNING: The operation of any lawn mower can result in foreign objects being thrown into the
operator’s eyes and causing severe eye damage. Always wear safety glasses while operating the mower,
or while performing any adjustments or repairs on it.
Blade Control
Handle
Start Control
Button
Recoil
Starter
Grass
Catcher
Spark
Plug
Rear Cutting Height
Adjustment Lever
Front Cutting Height
Adjustment Lever
Safety
Key
Figure 9
Recoil Starter
Cutting Height Adjustment Levers
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.
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.
Blade Control Handle
Safety Key
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.
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.
WARNING: The blade control handle is a
NOTE: The safety key must be in the run position to
safety device. Never attempt to bypass its
operations. Doing so, may result in personal
injury through contact with the rotating blade.
The blade rotates whenever the engine is
running and when the self starter is deenergized.
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.
9
Stopping Engine
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.
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
•
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.
SECTION 5: OPERATING YOUR LAWN MOWER
WARNING: Read, understand, and follow
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.
all instructions and warnings on the machine
and in this manual before operating.
Gas & Oil Fill-Up
•
•
Check oil level and add oil if necessary. Follow
relevant instructions in the engine manual for this.
Service the engine with gasoline as instructed in
the engine manual.
WARNING:
Use extreme care when
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.
Second Time Starting Engine
NOTE: Follow these instructions if the self starter is
already in the energized mode.
Before Starting Mower
•
WARNING: NEVER assume starter is in
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.
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.
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 deenergized mode, follow instructions as follows.
1.
2.
3.
4.
5.
6.
7.
Starter Control
Button
Blade Control
Handle
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.
Figure 10
10
•
1.
2.
3.
4.
Check oil level and add fuel, if necessary.
Open shut off valve (if equipped) 1/4 turn.
Turn safety key 1/4 turn clockwise 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.)
•
•
•
NOTE: If 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.
Throttle Speed
Your lawn mower engine is equipped with a constant
speed throttle, which is set at full throttle for best
performance.
2. Turn safety key 1/4 turn counterclockwise to LOCK
position. Remove key and store in a safe place.
Using Your Lawn Mower
WARNING: The blade will continue to
rotate for three seconds after the blade
control lever is released.
WARNING: Never operate the mower
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.
To De-Energize Self Starter
•
•
•
•
•
•
ALWAYS disconnect spark plug, de-energize
starter, lock and remove safety key BEFORE
performing ANY service to the engine or mower.
DO NOT attempt any maintenance or repairs to the
self starter.
NEVER assume starter is de-energize, even if key
is in LOCK AND REMOVE position and/or removed
from engine.
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 mowerALWAYS DE-ENERGIZE SELF STARTER.
ALWAYS lock and remove safety key and store in a
safe place until next use. The safety key is
designed and intended to be removed from engine
when not in 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 be
removed.
Remove spark plug wire from spark plug.
Turn safety key to RUN position (1/4 turn
clockwise).
While standing in the operating position, depress
the starter control button fully with the thumb of your
right hand.
Using your left hand, pull the control handle all the
way toward the upper handle. (Release button and
wait until engine and starter stop rotating.)
Release safety blade control handle (the start
control button will automatically return to the off/up
position.)
Remove safety key.
•
•
•
•
NOTE: Engine will crank over upon actuating
equipment 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.
11
You can use your mower as a mulching mower or a
rear bagger.
Do not operate the mower without the rear
mulching baffle or the grass catcher bag properly
installed.
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.
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.
For a 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,
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
determined which height is best for your lawn.
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 operation is an indication of damage.
The unit should be promptly inspected and
repaired.
SECTION 6: MAKING ADJUSTMENTS
Handle Height
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.
Your mower is shipped with the handle in the higher
height position.
•
•
WARNING: NEVER assume starter is deenergized, 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
Remove the starter rope from the rope guide.
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.
Remove the hairpin clips from the weld pins on the
handle brackets. Refer to Figure 3.
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.
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.
Height Adjustment
Lever
Notch
Lower
Handle
Figure 12
•
•
Figure 11
An adjusting plate and spring lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has several height positions.
•
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.
Reassemble the upper handle to the lower handle.
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.
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.
12
SECTION 7: MAINTAINING YOUR LAWN MOWER
WARNING: Be sure to disconnect the
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.
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.
Cutting Blade
•
NEVER assume starter is de-energized, even
if the key is in the locked position and/or
removed from the engine. ALWAYS deenergize 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.
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
•
•
Engine
Remove the bolt and the blade bell support which
hold the blade and the blade adapter to the engine
crankshaft. See Figure 13.
Remove the blade and the adapter from the
crankshaft.
Blade
Adapter
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.
Blade Bell
Support
Refer to the engine manual for all engine maintenance
instructions.
Hex Bolt
•
Maintain engine oil as instructed in the engine
manual. Check oil level before starting mower.
• 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.
• 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.
Figure 13
WARNING: Periodically inspect the blade
adapter for cracks, especially if you strike a
foreign object. Replace when necessary.
•
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
cause excessive vibration when rotating at
high speeds. It may damage the mower, and/
or cause personal injury.
•
Deck
The underside of the mower deck should be cleaned
after each 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).
The blade can be tested 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
•
13
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.
•
•
•
•
Engine
Slide the blade adapter onto the engine crankshaft.
Place the blade on the adapter.The blade has to be
aligned and seated on the blade adapter flanges.
Place blade bell support on blade. Make sure the
notches on the blade bell support are aligned with
small holes in the blade.
Replace hex bolt and tighten hex bolt to torque: 450
in. lbs. min., 600 in. lbs. max.
Follow the engine manual for lubrication instructions.
Lubricate
NOTE: To ensure safe operation, the blade bolt must
be checked periodically for correct torque.
Lubrication
WARNING: Always stop engine and
Figure 14
disconnect spark plug wire before cleaning,
lubricating or doing any kind of service work
on the lawn mower.
Replacing Rear Flap
•
Blade Control
Lubricate the pivot points on the blade control handle at
least once a season with light oil. The blade control
must operate freely in both directions.See Figure 14.
•
To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck. See Figure 15.
Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck.
Rear Discharge
Door
Wheels
Lubricate the wheels at least once a season with light
oil (or motor oil). If the wheels are removed for any
reason, lubricate the surface of the axle bolt and inner
surface of the wheel with light oil. See Figure 14.
Handle
Bracket
re
Wi
d
Ro
Handle
Bracket
Rear Discharge Door
Lubricate the torsion springs and pivot points on rear
discharge door using light oil. This will insure the door,
which is a safety device, can always work properly.
Rear
Flap
Figure 15
SECTION 8: OFF-SEASON STORAGE
WARNING: Never store the machine or
fuel container indoors where there is an open
flame, spark or pilot light such as on water
heater, furnace, clothes dryer or other gas
appliance.
The following steps should be taken to prepare your
lawn mower for storage.
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.
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.
WARNING: NEVER assume starter is deenergized, 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.
•
•
•
Refer to engine manual for storage instructions.
Coat mower’s cutting blade with chassis grease to
prevent rusting.
Store mower in a dry, clean area. Do not store next
to corrosive materials, such as fertilizer.
NOTE: When storing any type of power equipment 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.
14
SECTION 9: TROUBLESHOOTING
Problem
Cause
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
Blade control handle disengaged.
Start control button not depressed.
Spark plug wire disconnected.
Safety key not in run position
Fuel tank empty or stale fuel.
Blocked fuel line.
Faulty spark plug.
Engine flooded
1.
2.
3.
4.
5.
6.
7.
8.
9.
Self starter already de-energized
9.
1.
2.
Spark plug wire loose.
Blocked fuel line or stale fuel.
1.
2.
3.
4.
5.
6.
Vent in gas plugged.
Water or dirt in fuel system.
Dirty air cleaner.
Carburetor out of adjustment.
3.
4.
5.
6.
Connect and tighten spark plug wire.
Clean fuel line; fill tank with clean, fresh
gasoline
Clear vent.
Drain fuel tank. Refill with fresh fuel.
Clean air cleaner.
Adjust carburetor.
1.
2.
3.
Engine oil level low.
Air flow restricted.
Carburetor not adjusted properly.
1.
2.
3.
Fill crankcase with proper oil.
Remove blower housing and clean.
Adjust carburetor.
Occasionally skips (hesitates) 1.
at high speed
Spark plug gap too close.
1.
Adjust gap to.030”.
Idles poorly
1.
Reset gap to.030” or replace spark plug.
2.
3.
Spark plug fouled, faulty or gap too
wide.
Carburetor improperly adjusted.
Dirty air cleaner.
2.
3.
Adjust carburetor.
Clean air cleaner.
Excessive vibration
1.
2.
Cutting blade loose or unbalanced.
Bent cutting blade.
1.
2.
Tighten blade and adapter. Balance blade.
Replace blade.
Mower will not mulch grass
1.
Wet grass.
1.
2.
Excessively high grass.
2.
3.
Dull blade.
3.
Do not mow when grass is wet; wait until
later to cut.
Mow once at a high cutting height, then mow
again at desired height or make a narrower
cutting path.
Sharpen or replace blade.
1.
Wheels not positioned correctly.
1.
2.
Dull blade.
2.
Engine fails to start
Engine runs erratic
Engine overheats
Uneven cut
1.
Engage blade control handle.
Depress starter control button.
Connect wire to spark plug.
Place safety key in run position.
Fill tank with clean, fresh gasoline.
Clean fuel line.
Clean, adjust gap, or replace.
Wait a few minutes to restart, but do not
prime.
Use recoil starter to start engine.
Place all four wheels in same height
position.
Sharpen or replace blade.
NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized service dealer.
15
SECTION 10: PARTS LIST FOR MODEL 589
73
70
69
65
72
2
1
14
68
67
71
63
64
66
12
15
9
5
76
8
7
75
10
9
8
13
28
18
6
19
23
24
77
18
46
25
20
28
78
33
37
47
17
29
38
32
27
21
41
26
45
22
34
74
31
42
32
38
25
49
53
40
39
35
36
54
40
44
51
52
43
50
46
55
57
56
61
38
62
59
74
60
47
16
58
Model 589 Series
Ref.
No.
1.
2.
5.
6.
7.
8.
9.
10.
12.
13.
14.
15.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Part No.
749-04001
647-0070
712-0324
712-0397
710-1205
710-1174
736-0451
720-0284
746-1141
749-0907B
664-0085
747-04080
782-5004A
714-0104
731-04134
732-0700
731-1236
732-04090
747-0996
750-04162
687-02032
687-02034
26.
27.
28.
29.
31.
32.
33.
34.
35.
36.
37.
38.
39.
787-01103
710-0654A
710-0703
712-3005
712-0431
687-02033
687-02031
710-0286
710-0896
710-0216
720-0312
17488A
17489A
736-0105
732-0866
Part Description
Upper Handle
Control Handle
Hex Lock Nut 1/4-20
Wing Nut
Rope Guide
Carriage Bolt 5/16-18 x 2”
Shoulder Washer.320 ID x.930 OD
Wing Nut
Self Start Control Cable 58.25”
Lower Handle
Grass Bag
Grass Catcher Frame
Rear Baffle - RH
Hairpin Clip
Grass Bag Door
Wire Rod
Trail Shield
Door Spring R.H.
Chute Door Pivot Rod
Spacer.375 O.D. X.50 I.D. X. 1.02”
Handle Bracket Assy. Complete - LH
(Includes 29, 32, 37, 39, 40)
Handle Bracket Assy. Complete - RH
(Includes 29, 32, 37, 39, 40)
Deck 21”
Hex Washer Screw 3/8-16 x 1.0
Hex Carriage Screw 1/4-20
Flange Lock Nut 3/8-16
Flange Lock Nut 3/8-16
Handle Bracket Assembly - RH
Handle Bracket Assembly - LH
Machine Screw 1/4-20 x.500
Hex Washer Screw 1/4-14 x.625
Hex Cap Screw 3/8-16 x.75
Foam Grip
Pivot Bar - RH
Pivot Bar - LH
Spring Washer.375 ID x.870 OD
Spring Lever
Ref.
No.
40.
41.
42.
43.
44.
45.
46.
47.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
17
Part No.
738-0507B
734-2043
736-0272
736-0182
738-0481A
14578
14579
734-2004A
738-0102
712-0431
782-5002
782-5003
710-1017
15261A
720-0426
15262B
732-0404
748-0376C
742-0741
736-0524A
710-1044
731-1506
731-1426
710-0501
710-1256
731-2532
731-2533
715-0168
732-1171
720-0428
716-0209
732-1172
782-0156
731-2623
736-0504
726-0240
720-0279
732-04089
782-5003
Part Description
Shoulder Screw
Rear Wheel Assembly 14 x 2.1
Flat Washer.510 ID x 1.00 OD
Wave Washer.500 ID x 1.0 OD
Shoulder Screw
Front Height Adjuster - RH
Front Height Adjuster - LH
Front Wheel Assembly 8 x 2.1
Shoulder Bolt
Flange Lock Nut 3/8-16
Front Baffle
Rear Baffle - LH
Tap Screw 1/4-14 x.625.
Height Adjustment Plate
Height Adjustment Knob
Pivot Bar
Spring Lever
Blade Adapter
21” Mulching Blade
Blade Bell Support
Hex Cap Screw 3/8-24 x 1.5
Front End Cover
Hub Cap
Hex Hd. Cap Scr. 1/4-20 Gr.5
Hi-Low Screw
Control Cover LH
Control Cover RH
Pin
Compression Spring
Button
Retention Spring
Torsion Spring
Lever
Bail Cover (Not shown)
Wave Washer.510 x.750
Cable Tie
Wing Nut
Door Spring L.H.
Left Rear Baffle
MANUFACTURER’S LIMITED WARRANTY FOR:
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 to: 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.
b.
c.
The engine or component parts thereof. These items
carry a separate manufacturer’s warranty. Refer to
applicable manufacturer’s warranty for terms and
conditions.
Log splitter pumps, valves, and cylinders have a sepa
rate one year warranty.
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.
d.
e.
f.
g.
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.
Parts that are not genuine MTD parts are not covered
by this warranty.
Service completed by someone other than an
authorized service dealer is not covered by this
warranty.
Transportation charges and 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.
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