Craftsman 486.24515 Chipper User Manual

Owner's
Manual
CRAFTSMAN°
5.0 HORSEPOWER
22" ECONOMY
SIDE DISCHARGE
ROTARY LAWN MOWER
Model No.
917.388230
•
•
•
•
•
•
Safety
Assembly
Operation
Maintenance
Espafiol
Repair Parts
CAUTION:
Read and follow all
Safety Rules and Insuuc_u_
before operating this equ_hF
Sears, Roebuck and Co., Hoffman Estates, IL 60179
Warranty
Safety Rules
Assembly
Operation
Maintenance Schedule
Maintenance
2
2
4
5
8
8
Product Specifications
Service and Adjustments
Storage
Troubleshooting
Repair Parts
Parts Ordering
9
12
13
14
32
Back Cover
LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER
For two years from date of purchase, when this Craftsman Lawn Mower is maintained,
lubricated, and tuned up according to the operating and maintenance instructions in the
owner's manual, Sears will repair free of charge any defect in matedal or workmanship.
If this Craftsman Lawn Mower is used for commercial or rental purposes, this warranty
applies for only 90 days from the date of purchase.
This Warranty does not cover:
• Expendable items which become worn during normal use, such as rotary mower
blades, blade adapters, belts, air cleaners and spark plug.
• Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual.
Warranty service is available by returning the Craftsman power mower to the nearest
Sears Service Center/Department in the United States. This warranty applies only while
this product is in use in the United States.
This Warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
SEARS, ROEBUCKAND
CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179
Safety standards require operator presence controls to minimize the risk of injury.
Your unit is equipped with such controls.
Do not attempt to defeat the function of the
operator presence controls under any
circumstances.
• Do not operate mower if it has been
dropped or damaged in any manner.
Always have damage repaired before
using your mower.
• Do not use accessory attachments that
are not recommended by the manufacturer. Use of such attachments may be
hazardous.
• The blade turns when the engine is
running.
TRAINING:
• Read this operator's manual carefully.
Become familiar with the controls and
know how to operate your mower
properly. Learn how to quickly stop
mower.
• Do not allow children to useyour mower.
Never allow adults to use mower without
proper instructions.
• Keep the area of operation clear of all
persons, especially small children and
pets.
• Use mower only as the manufacturer
intended and as described in this manual.
PREPARATION:
• Always thoroughly check the area to be
mowed and clear it of all stones, sticks,
wires, bones, and other foreign objects.
These objects will be thrown by the blade
and can cause severe injury.
• Always wear safety glasses or eye
shields when starting and while using
your mower.
2
•
• Do not run the engine indoors. Exhaust
fumes are dangerous.
• Never cut grass by pulling the mower
"towards you. Mow across the face of
slopes, never up and down or you might
lose your footing. Do not mow excessively steep slopes. Use caution when
operating the mower on uneven terrain
or when changing directions -- maintain
good footing.
• Never operate your mower without
proper guards, plates, grass catcher or
other safety devices in place.
Dress properly. Do not operate mower
when barefoot or wearing open sandals.
Wear only solid shoes with good traction
when mowing.
• Check fuel tank before starting engine.
Do not fill gas tank indoors, when the
engine is running or when the engine is
hot. Allow the engine to cool for several
minutes before filling the gas tank. Clean
off any spilled gasoline before starting the
engine.
• Always make wheel height adjustments
beforestarting your mower. Never
attempt to do this while the engine is
runnin_].
• Mow only in daylight or good artificial
light.
MAINTENANCE
AND STORAGE:
• Check the blade and the engine mounting bolts often to be sure they are
tightened properly.
• Check all bolts, nuts and screws at
frequent intervals for proper tightness to
be sure mower is in safe working
condition.
• Keep all safety devices in place and
working.
• To reduce fire hazard, keep the engine
free of grass, leaves or excessive grease
and oil.
• Check grass catcher often for deterioration and wear and replace worn bags.
Use only replacement bags that are
recommended by and comply with
specifications of the manufacturer of your
mower.
• Always keep a sharp blade on your
mower.
• Allow engine to cool before storing in any
enclosure.
• Never store mower with fuel in the tank
inside a building where fumes may reach
an open flame or an ignition source such
as a hot water heater, space heater,
Aclothes dryer, etc.
CAUTION: Always disconnect spark
plug wire and place wire where it cannot
contact spark plug in order to prevent
accidental starting when setting up,
transporting, adjusting or making repairs.
WARNING
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
OPERATION:
• Keep your eyes and mind on your mower
and the area being cut. Do not let other
interests distract you.
• Do not mow wet or slippery grass. Never
run while operating your mower. Always
be sure of your footing -- keep a firm
hold on the handles and walk.
, Do not put hands or feet near or under
rotating parts. Keep clear of the discharge
opening at all times.
Always stop the engine whenever you
leave or are not using your mower, or
before crossing driveways, walks, roads,
and any gravel--covered
areas.
Never direct discharge of material toward
bystanders nor allow anyone near the
mower while you are operating it.
Before cleaning, inspecting, or repairing
your mower, stop the engine and make
absolutely sure the blade and all moving
parts have stopped. Then disconnect the
spark plug wire and keep it away from the
spark plug to prevent accidental starting.
Do not continue to run your mower if you
hit a foreign object. Follow the procedure
outlined above, then repair any damage
before restarting and operating you
mower.
Do not change the governor settings or
overspeed the engine. Engine damage or
personal injury may result.
Do not operate your mower if it vibrates
abnormally. Excessive vibration is an
indication of damage; stop the engine,
safely check for the cause of vibration
and repair as required.
3
Theseaccessories
were available when this lawn mower was produced. They are also
available at most Sears retail outlets and service centers. Most Sears stores can also
order repair parts for you, when you provide the model number of your lawn mower.
Some of these accessories may not apply to your lawn mower.
LAWN MOWER
PERFORMANCE
CUPPING DEFLECTOR
FOR REAR DISCHARGE LAWN MOWERS
MULCHER KITS
GRASS CATCHERS
FOR
REAR DISCHARGE
LAWN MOWERS
STABIMZER
FOR
SIDE DISCHARGE
GRASS
LAWN CATCHERS
MOWERS
GAS CANS
LAWN MOWER
MAINTENANCE
MUFFLERS
AIR RLTERS
SPARK PLUGS
%
BELTS
BLADES
BLADE ADAPTERS
WHEELS
ENGINE OIL
Read these instructions and this manual in
its entirety before you attempt to assemble
or operate your new lawn mower. Your
new lawn mower has been assembled at
the factory with the exception of those
parts left unassembled for shipping
purposes. All parts such as nuts, washers,
bolts, etc., necessary to complete the
assembly have been placed in the parts
bag. To ensure safe and proper operation
of your lawn mower, all parts and hardware
you assemble must be tightened securely.
Use the correct tools as necessary to
ensure proper tightness.
• Remove all packing materials except
padding between upper and lower
handle and padding holding operator
presence control bar to upper handle.
• Roll lawn mower out of carton and check
carton thoroughly for additional loose
parts.
TO REMOVE
CARTON
locks into place in mowing position.
• Remove protective padding, raise upper
handle section into place on lower
handle and tighten both handle knobs.
• Remove handle padding holding
operator presence control bar to upper
handle.
LAWN
MOWER
HOW TO SET UP YOUR LAWN
MOWER
TO UNFOLD HANDLE
IMPORTANT:
Unfold handle carefully so
as not to pinch or damage control cables.
• Raise handles until lower handle section
FROM
• Remove loose parts included with
mower.
.
• Cut down two end corners of carton and
lay end panel down flat.
4
• Your lawn mower handle can be
adjusted for your mowing comfort.
Refer to "Adjust Handle" in the Service
and Adjustment section of this manual.
Operator presence controlbar
Upper handle _
_,_t
Lift up __
.,_
Mowing
///
position
-:__,_2-"
KNOW YOUR LAWN
/_
MOWER
READ THIS OWNER'S MANUALAND SAFETY RULES BEFORE OPERATING YOUR LAWN
MOWER. Compare the illustrationswith your lawn mower to familiarize yourselfwith the
locationof various controls and adjustments. Save this manual for future reference.
These symbols may appear on your lawn mower or in literature supplied with the
product. Learn and understand their meaning.
CAUTION
OR WARN_G
ENGINE
ON
ENGINE
OFF
FAST
SLOW
CHOKE
FUEL
OIL
DANGER, KEEP HANDS
ANt) FEET AWAY
Operator presence controlbar
Engine zone controlcable
Handle knob
Starter handle
Engine oil cap with dipstick
Gasoline fillercap
Mulcher door
Primer
Wheel adjuster
(on each wheel)
MEETS CPSC SAFETY REQUIREMENTS
Sears rotary walk-behind power lawn mowers conform to the safety standards of the
American National Standards Institute and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running.
operator
presence
control bar- must be
held down to the handle to start the engine.
Release to stop the engine.
Primer - pumps additionalfuel from the
carburetor to the cylinderfor use when starting
a cold engine.
Starter handle - used for startingthe engine.
Mulcher- allows conversion to discharge or
bagging operation.
5
The operation of any lawn mower can result in
foreign objects thrown into the eyes, which can
result in severe eye damage. Always wear
safety glasses or eye shields while operating
your lawn mower or performing any adjustments or repairs. We recommend a wide
vision safety mask over spectacles or standard
safety glasses.
HOW TO USE YOUR LAWN MOWER
ENGINE SPEED CONTROL
The engine speed was set at the factory
for optimum performance.
Speed is not
adjustable.
ENGINE ZONE CONTROL
ACAUTION:
Federal regulations requ re an
engine control to be installed on this lawn
mower in order to minimize the risk of blade
contact injury. Do not under any circumstances
attempt to defeat the function of the operator
control. The blade turns when the engine is
running.
• Your lawn mower is equipped with an
operator presence control bar which
requires the operator to be positioned
behind the lawn mower handle to start and
operate the lawn mower.
TO ADJUST CUTFING HEIGHT
• Raise wheels for low cut and lower
wheels for high cut.
• Adjust cutting height to suit your
requirements.
Medium position is best
for most lawns.
• To change cutting height, squeeze
adjuster lever toward wheel. Move
wheel up or down to suit your requirements. Be sure all wheels are in the
same setting.
NOTE: Adjuster is properly positioned
when plate tab inserts into hole in lever.
Also, 9-position adjusters (if so equipped)
allow lever to be positioned between the
plate tabs.
Lower wheels for
high cut _
Lever
Plate tab
_
Raise wheels for low cut
BEFORE STARTING ENGINE OIL
• Use 20 ozs. of oil. For type and grade of oil
to use, see "ENGINE" in Maintenance
section of this manual.
• Pouroil slowly. Do not overfill.
• Check oil level before each use. Add oil if
needed. Fill to full line on dipstick.
• To read proper level, tighten engine oil cap
each time.
• Reinstall engine oil cap and tighten.
• Change the oil after every 25 hours of
operation or each season. You may need
to change the oil more often under dusty,
dirty conditions.
GAS
• Fill fuel tank. Use fresh, clean, regular
unleaded gasoline with a minimum of 87
octane. Do not mix oil with gasoline.
Purchase fuel in quantities that can be
used within 30 days to assure fuel
freshness.
WARNING: Experience indicates that alcohol
blended fuels (called gasohol or using ethanol
or methanol) can attract moisture which leads
to separation and formation of acids during
storage. Acidic gas can damage the fuel
system of an engine while in storage. To avoid
engine problems, the fuel system should be
emptied before storage of 30 days or longer.
Drain the fuel tank, start the engine and let it
run until fuel lines and carburetor are empty.
Use fresh fuel next season. See Storage
Instructions for additional information. Never
use engine or carburetor cleaner products in
fuel tank or permanent damage may occur.
Gasoline filler
Engine oil cap
cap
TO START
ENGINE
• To start a cold engine, push primer three
(3) times before trying to start. Use a
firm push. This step is not usually
necessary when starting an engine
which has already run for a few minutes.
• Hold operator presence control bar
down to the handle and pull starter
handle quickly. Do not allow starter
rope to snap back.
• To stop engine, release operator
presence control bar.
NOTE: In cooler weather it may be
necessary to repeat priming steps. In
warmer weather over priming may cause
Your lawn mower is shipped without oil in the
engine.
• Be sure mower is level and area around oil
fill is clean.
• Remove engine oil cap and fill to the full line
on the dipstick.
6 flooding and engine will not start. If you do
floodengine,
wait a few minutes before
attempting to start and do not repeat
priming steps.
TO CONVERT
MOWER
TO DISCHARGING
Your mower is shipped ready to be used
as a mulcher. To convert to bagging or
discharging:
• Lift discharge guard and remove
mulcher plate.
• Mower can now be used for side
discharge or optional grass catcher can
be attached.
• To return to mulching operation, simply
reinstall mulcher plate as shown.
CAUTION:
Do not run your lawn mower
without discharge guard, approved grass
catcher or mulcher plate in place.
J_
Hooks
.=rod
Mulch
MOWING TIPS
• Under certain conditions, such as very
tall grass, it may be necessary to raise
the height of cut to reduce pushing effort
and to keep from overloading the engine
and leaving clumps of grass clippings. It
may also be necessary to reduce
ground speed and/or run the lawn
mower over the area a second time.
• For extremely heavy cutting, reduce the
width of cut by overlapping previously
cut path and mow slowly.
• For better grass bagging and most
cutting conditions, the engine speed
should be set in the fast position.
• For side discharge lawn mowers, cutting
in a counter-clockwise direction, starting
at the outside of the area to be cut,
spreads grass clippings more evenly
and puts less load on the engine. To
keep clippings off of walkways, flower
beds, etc., make the first cuts in a
clockwise direction.
• Pores in cloth grass catchers can
become filled with dirt and dust with use
and catchers will collect less grass. To
prevent this, regularly hose catcher off
with water and let dry before using.
• Keep top of engine around starter clear
and clean of grass clippings and chaff.
This will help engine air flow and extend
engine life.
MULCHING MOWING TIPS
IMPORTANT: For best performance, keep
mower housing free of built-up grass and
trash. See "Cleaning" in MAINTENANCE
section of this manual.
• The special mulching blade will recut the
grass clippingsmany times and reduce
them in size so that as they fall onto the
lawn they will disperse intothe grass and
not be noticed. Also, the mulched grass will
biodegrade quickly to provide nutriantsfor
the lawn. Always mulch with your highest
engine (blade) speed as this will provide the
best recuttingaction of the blades.
• Avoid cutting your lawn when it is weL Wet
grass tends to form dumps and interferes
with the mulching action. The best time to
mow your lawn is the early aftemcon. At
this time the grass has dried and the newly
cut area will not be exposed to the direct
sun.
• For best results, adjust the lawn mower
cuttingheight so that the lawn mower cuts
off only the top one-third of the grass blades.
If the lawn is overgrown itwill be necessary
to raise the height of cut to reduce pushing
effort and to keep from overloading the
engine and leaving clumps of mulched
grass. For extremely heavy mulching,
reduce your width of cut by overlapping
previously out path and mow slowly.
• Certain types of grass and grass conditions
may require that an area be mulched a
second time to completely hide the
clippings. When doing a second cut, mow
across or perpendicular to the firstcut path.
• Change your cutting pattern from weekto
week. Mow north to south one week then
change to east to west the next week. This
willhelp prevent matting and grainingof the
lawn.
7
.A'NTENANCESC.EOULE
.s YOU
COMPL
o,,,,...
REGULAR SERVICE
f__-_t_(_:_._-_
Check for Loose Fasteners
a
O
SERVICE
_
(if Equipped)
Clean/Inspect Grass Catcher
Clean Lawn Mower
DATE:_
t##
_
(power-Propelled
Ctean
Under DriveMowers)
Cover
Check drive belt/pulleys
RE (Power-Propelled Mowers)
C hecWSharpen/Repla"ceBlade
_
Lubrication Chart
Clean BatteP//Recharge
IElactrla Start Mowers)
E Check Engine Oil Level
N Char_le Engine Oil
G
I
CLeanAir Filter
Inspect Muffler
N
Clean or Replace Spark Plug
IV#
(I,/4
t/_,z
I_
2
i,/°z
t - Change more ofl_ v_en operating under a heavy load or in high a'_0i*nl
2 -Ser, dce rnore onen '/A'_n operating in dirty or dwl'/condllk_s.
GENERAL
(I/
_/'
E Replace Air Filter Paper Cartridge
3 - Repk:q blade= morro on_ wi_m mow_g
4 - ChaiSe 48 hours at end of =euon.
3
If
Ii_tp*rals'es.
in =andy K*IIL
(_)
RECOMMENDATIONS
LUBRICATION
Wheel
adjuster
The warranty on this lawn mower does not
cover items that have been subjected to
operator abuse or negligence. To receive full
value from the warranty, operator must
maintain mower as Instructed in this manual.
Some adjustments will need to be made
periodicallyto pmpedy maintain your unit.
All adjustments in the Service and Adjustmerits section of this manual should be
checked at least once each season.
• Once a year, replace the spark plug, clean
or replace air filterelement and check blade
for wear. A new spark plug and clean/new
air filterelement assures proper air-fuel
mixture and helps your engine run better
and last longer.
• Follow the maintenance schedule in this
manual.
BEFORE EACH USE
CHART
(_) Mulcher door
_J
oil
__
(_) Handle bracket
mounting pin
(_
(_)
Spray lubricante
Referto MAINTINANCE"ENGiNE"
SECTION.
IMPORTANT: Do not oil or grease plastic
wheel bearings. Viscous lubricantswill attract
dust and dirtthat will shorten the life of the self
lubricatingbearings, if you feel they must be
lubricated,use only a dry, powdered graphite
type lubricant sparingly.
• Check engine oil level.
• Check for loose fasteners.
LUBRICATION
Keep unit well lubricated (See "LUBRICATION
CHART").
8
PRODUCT
SPECIFICATIONS
MODEL NUMBER
SERIAL
917.388230
NUMBER
DATE OF PURCHASE
HORSEPOWER:
5.0
DISPLACEMENT:
11.5 CU. IN.
GASOLINE
1.5 QUARTS
CAPACITY/TYPE:
UNLEADED
dL TYPE (API-SF/SG/SH):
REGULAR
SAE 30 (ABOVE 32°F)
SAE 5W-30 (BELOW
)IL CAPACITY:
SPARK PLUG(GAP:
32°F)
20 OZS.
.030")
VALVE CLEARANCE:
CHAMPION
RJ19LM OR J19LM
INTAKE:
.004 - .008
EXHAUST:
.004 - .008
SOLID STATE iGNITION
AIR GAP:
.0125 IN.
BLADE BOLT TORQUE:
35-40 FT. LBS.
• The model and serial numbers will be found on a decal attached to the rear of the
lawn mower housing.Record
both serial number and date of purchase in space
provided above.
LAWN
MOWER
Always obsewe safety rules when performing
any maintenance.
TIRES
• Keep tires free of gasoline, oil, or insect
control chemicals which can harm rubber.
• Avoid stumps,stones,deep ruts,
sharp
objects
and otherhazardsthatmay cause
tire
damage.
BLADE CARE
For best results, mower blade must be
kept sharp. Replace bent or damaged
blades.
TO REMOVE BLADE
• Disconnect spark plug wire from spark
plug and place wire where it cannot
come in contact with spark plug.
• Turn lawn mower on its side. Make sure
air filter and carburetor are up.
• Use a wood block between blade and
mower housing to prevent blade from
turning when removing blade bolt.
• Protect your hands with gloves and/or
wrap blade with heavy cloth.
• Remove blade bolt by turning counterclockwise.
• Remove blade and attaching hardware
(bolt, lock washer and hardened
washer).
NOTE: Remove the blade adapter and
check the key inside hub of blade adapter.
The key must be in good condition to work
properly. Replace adapter if damaged.
TO REPLACE
BLADE
• Position the blade adapter on the engine
crankshaft. Be sure key in adapter and
crankshaft keyway are aligned.
• Position blade on the blade adapter
aligning the two (2) holes in the blade
with the raised lugs on the adapter.
• Be sure the trailing edge of blade
(opposite sharp edge) is up toward the
engine.
• Install the blade bolt with the lock
washer and hardened washer into blade
adapter and crankshaft.
• Use block of wood between blade and
lawn mower housing and tighten the
blade bolt, turning clockwise.
• The recommended tightening torque is
35-40 ft. Ibs.
IMPORTANT:
treated.
Blade bolt is grade 8 heat
TO SHARPEN
BLADE
NOTE: We do not recommend sharpening
blade - but if you do, be sure the blade is
balanced.
Care should be taken to keep the blade
balanced. An unbalanced blade will cause
eventual damage to lawn mower or
engine.
• The blade can be sharpened with a file
or on a grinding wheel. Do not attempt
to sharpen while on the mower. • To check blade balance, drive a nail into
a beam or wall. Leave about one inch of
the straight nail exposed. Place center
hole of blade over the head of the nail.
If blade is balanced, it should remain in
a horizontal position. If either end of the
blade moves downward, sharpen the
heavy end until the blade is balanced.
Blade
Crankshaft
Key
keyway
Blade
Lockwasher
\
Blade
bolt
shaft
Hardened
washer
Trailing
edge
Blade adapter
GRASS CATCHER
(If purchased as an accessory)
• The grass catcher may be hosed with
water, but must be dry when used.
• Check your grass catcher often for
damage or deterioration. Through
normal use it will wear. If catcher needs
replacing, replace only with a manufacturer approved replacement catcher.
Give the lawn mower model number
when ordering.
ENGINE
LUBRICATION
Use only high quality detergent oil rated with
API service classification SF, SG or SH.
Select the oil'sSAE viscositygrade according
to your expected operating temperature.
SAE VISCOSITY
•30-
-_.
.,o-
o-
GRADES
_.
_-
_
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OILCHANGE
,G.
NOTE: Although multi-viscosityoils (5W30,
10W30 etc.) improve starting in cold weather,
these multi-viscosity oils will result in increased
oil consumption when used above 32°F.
Check your engine oil level more frequently to
avoid possible engine damage from running
low on oil.
Change the oil after every 25 hours of
operation orat least once a year if the lawn
mower is not used for 25 hours in one year.
Check the crankcase oil level before starting
the engine end after each five (5) hours of
continuous use. _ghten oil plug securely each
time you check the oillevel.
TO CHANGE ENGINE OIL
NOTE: Before tipping lawn mower to drain
oil, drain fuel tank by running engine until
fuel tank is empty.
• Disconnect spark plug wire from spark
plug and place wire where it cannot
come in contact with spark plug.
• Remove engine oil cap; lay aside on a
clean surface.
• Tip lawn mower on its side as shown
and drain oil into a suitable container.
Rock lawn mower back and forth to
remove any oil trapped inside of engine.
• Wipe off any spilled oil on lawn mower
and on side of engine.
• Fill engine with oil. Fill only to the
"FULL" line on the dipstick. DO NOT
OVER FILL.
• Replace engine oil cap.
• Reconnect spark plug wire to spark
plug.
Container
AIR FILTER
Your engine will not run properly and may be
damaged by using a dirty air filter.
Replace the air filterevery year, more often if
you mow in very dusty, dirtyconditions. Do not
wash air filter.
TO CHANGE AIR FILTER
• Loosen screw and tilt cover to remove.
• Carefully remove cartridge.
• Clean by gently tapping on a flat
surface. If very dirty, replace cartridge.
,ACAUTION:
Petroleum solvents, such
as kerosene, are not to be used to clean
10
;artridge. They may cause deterioration of
the cartridge. Do not oil cartridge. Do not
use pressurized air to clean or dry
cartridge.
• Install cartridge, then replace cover
making sure the tabs are aligned with
the slots in the back plate. Fasten
screw securely.
Back
plate
Lip
Cover
tabs
Slots
Cover
Ca_ddge
CLEANING
IMPORTANT: For best performance, kiip
mower housing free of built-grass and trash.
Clean the underside of your mower after each
use.
ACAUTION:
Disconnect spark plug wire
from spark plug and place wire where it cannot
come in contact with the spark plug.
• Turn lawn mower on its side. Make sure air
filter and carburetor are up. Clean the
underside of your lawn mower by scraping
to remove build-up of grass and trash.
• Clean engine often to keep trash from
accumulating. A clogged engine runs hotter
and shortens engine life.
• Keep finished surfaces and wheals free of
all gasoline, oil,etc.
• We do not recommend using a garden
hose to clean lawn mower unless the
electrical system, muffler, air filter and
carburetor are covered to keep water out.
Water in engine can result in shortened
engine life.
MUFFLER
Inspect and replace corroded muffler as it
could create a fire hazard and/or damage.
SPARK PLUG
Change your spark plug each year to make
your engine start easier and run better. Set
spark plug gap at .030 inch.
11
• Reassemble the starter rope guide. "
• Reassemble the controls and the
operator presence control bar to the
upper handle.
ShippingPosition
Medium low
Medium high
A.CAUTION:
Before performing any
service and adjustments:
•
Release control bar and stop engine.
•
Make sure the blade and all moving
parts have completely stopped.
•
Disconnect spark plug wire from spark
plug and place where it cannot come
in contact with plug.
LAWN MOWER
TO ADJUST cu'n'ING
HEIGHT
See "TO ADJUST CUTTING HEIGHT" in
the Operation section of this manual.
L
REAR DEFLECTOR
The rear deflector, attached between the
rear wheels of your mower, is provided to
minimize the possibility that objects will be
thrown out of the rear of the mower into
the operator's mowing position. If the
deflector becomes damaged, it should be
replaced.
DISCHARGE
_
High
Low
GUARD
The discharge guard, attached to the
discharge opening of your lawn mower, is
provided to prevent the possibility of injury
resulting from objects being thrown out of
the discharge opening into the operator
mowing position. If the discharge guard
becomes damaged, it should be replaced.
TO ADJUST
HANDLE
Your lawn mower handle can be raised or
lowered for your mowing comfort. Four
(4) positions are available: high, medium
high, medium low and low. Handles are
shipped mounted in the medium low
position.
• To change from medium low to medium
high position, the upper and lower
handle sections will have to be turned
over.
• Remove the cable clips.
• Remove the controls and operator
presence control bar from the upper
handle.
• Remove the starter rope guide from the
upper handle.
• Remove hairpin cotters.
• Disconnect the lower handle from the
handle brackets.
• Turn the handle over and reassemble
the hairpin cStters that have been
removed.
_.CAUTION:
The operator
presence
control bar must pivot freely to permit
blade/brake engagement when control bar
is released. Do not overtighten the
fasteners holding the controls to the upper
handle.
• To change from medium low to high
position only the upper handle section
will have to be turned over.
• To change from medium low to low
position, only the lower handle section
will have to be turned over.
Squeeze to
remove
Handle bracket
Mountin pin
Hairpin cotter
ENGINE
ENGINE SPEED
Your_engine speed has been factory set.
Do not attempt to increase engine speed
or it may result in personal injury. If you
believe that engine is running too fast or
too slow, take your mower to an authorized
service center for repair and adjustment.
12
CARBURETOR
Your carburetor has a non-adjustable fixed
main jet for mixture control. If your engine
does not operate properly due to suspected carburetor problems, take your
lawn mower to an authorized service
center for repair and/or adjustment.
IMPORTANT:
Never tamper with the
engine governor, which is factory set for
the proper engine speed. Overspeeding
the engine above the factory high speed
scan be dangerous.
If you think the
engine-governed high speed needs
adjusting, contact your nearest authorized
service center, which has proper equipment and experience to make any
necessary adjustments.
Immediately prepare your lawn mower for
storage at the end of the season or if the unit
will not be used for 30 days or more.
LAWN
Operator presence control
bar
\_
Upper handle -......._///
MOWER
.,
When lawn mower is to be stored for a period
of time, clean it thoroughly, remove all dirt,
grease, leaves, etc. Store in a clean, dry area.
• Clean entire lawn mower (See "CLEANING"
in the Maintenance section of this manual).
• Lubricate as shown in the Maintenance
section of this manual.
• Be sure that all nuts, bolts, screws, and pins
are securely fastened. Inspect moving
parts for damage, breakage and wear.
Replace if necessary.
• Touch up all rusted or chipped paint
surfaces; sand lightly before painting.
HANDLE
You can fold your lawn mower handle for
storage.
• Squeeze the bottom ends of the lower
handle toward each other untilthe lower
handle clears the handle bracket, then
move handle forward.
• Loosen upper handle mounting bolts
enough to allow upper handle to he folded
back.
IMPORTANT: When folding the handle for
storage or transportation,be sure to fold the
handle as shown oryou may damage the
controlcables.
• When setting up your handle from the
storage position,the lower handle will
automaticallylock into the mowing position.
Lower handle
Squeeze to
<_ _'._
remove_
/.
Hairpin
r
Fold forward for
_
storage
"_
f'J
.=.....
F",,,
,,Yl
Fold
,y / boekward
Mowing
position
Lower handle
ENGINE
FUEL SYSTEM
IMPORTANT: It is importantto prevent gum
deposits from forming in essential fuel system
parts such as carburetor,fuel filter, fuel hose,
or tank during storage. Also, experience
indicates that alcohol blended fuels (called
gasohol or using ethanol or methanol) can
attract moisture which leads to separation and
formation of acids during storage. Acidic gas
can damage the fuel system of an engine
while in storage.
• Drain the fuel tank.
• Start the engine and let it run untilthe fuel
lines and carburetor are empty.
• Never use engine or carburetor cleaner
products in the fuel tank or permanent
damage may occur.
• Use fresh fuel next season.
NOTE: Fuel stabilizer is an acceptable
alternative in minimizing the formation of fuel
gum deposits during storage. Add stabilizerto
gasoline in fuel tank or storage container.
Always follow the mix ratiofound on stabilizer
container. Run engine at least 10 minutes
after adding stabilizer to allow the stabilizer to
reach the carburetor. Do not drain the gas
tank and carburetor ifusing fuel stabilizer.
pin
13
ENGINE
OIL
OTHER
• Do not store gasoline from one season to
another.
• Replace your gasoline can if your can starts
to rust. Rust and/or dirt in your gasoline will
cause problems.
• If possible, store your unit indoors and cover
itto give protectionfrom dust and dirt.
• Cover your unitwith a suitable protective
cover that does not retain moisture. Do not
use plastic. Plastic cannot breathe which
allows condensation to form and will cause
your unitto rust.
IMPORTANT:
Never cover mower while
engine and exhaust areas are still warm.
ACAUTION:
Never store the lawn
Drain oil (with engine warm) and replace with
clean engine oil. (See "ENGINE" in the
Maintenance section of this manual).
CYMNDER
• Remove spark plug.
• Pour one ounce (29 ml) of oil through spark
plug hole into cylinder.
• Pull starter handle slowly a few times to
distribute oil.
• Replace with new spark plug.
mower with gasoline in the tank inside a
building where fumes may reach an open
flame or spark. Allow the engine to cool
before storing in any enclosure.
TROUBLESHOOTING
PROBLEM
Does not start
CHART
CAUSE
CORRECTION
• Dirty air filter.
• Out of fuel.
• Stale fuel.
• Clean/replace air filter.
• Fill fuel tank.
• Drain tank and refill with
fresh dean fuel.
.o Drain fuel tank and
carburetor and refilltank
• Waterinfuel.
with fresh gasoline.
• Connect wire to plug.
• Spark plug wire is
disconnected.
• Bad spark plug.
• Loose blade or broken blade
adapter.
• Control bar in released
position.
• Control bar defective.
14
• Replace spark plug.
• Tighten blade bolt or
replace blade adapter.
• Depress control barto
handle.
• Replace control bar.
TROUBLESHOOTING
CHART
PROBLEM
CAUSE
CORRECTION
Lossofpower
• Rear of lawn mower housing
or cutting blade dragging
in heavy grass.
• Cutting too much grass
• Set to "Higher Cut"
position.
• Dirty air filter.
• Buildupof grass, leaves,
and trash under mower.
• Too much oil in engine.
• Walking speed too fast.
• Set to "Higher Cut"
position.
• Clean/replace air filter.
• Clean underside of mower
housing.
• Check oil level.
• Cut at slower walking
speed.
Poor cut- uneven
•Wom,
bent or loose blade.
• Wheel heights uneven.
• Buildupof grass, leaves
and trash under mower.
Excessive
vibration
• Worn, bent or loose blade.
• Bent engine crankshaft.
Starter rope hard
to pull
• Engine flywheel brake is on
when control bar is released.
• Bent engine crankshaft.
• Blade adapter broken.
• Blade dragging in grass.
• Replace blade.'Tightan
blade bolt.
• Set all wheels at same
height
• Clean underside of
mower housing.
• Replace blade. "lighten
blade bolt.
• Contact an authorized
service center.
• Depress controlbar to
upper handle before
pullingstarter rope.
• Contact an authorized
service center.
• Replace blade adapter.
• Move lawn mower to cut
grass or to hard surface
Grass catcher
not filling (if so
equipped)
Hard to push
• Cutting height too low.
• Lift on blade wom off.
• Catcher not venting air.
• Raise cutting height.
• Replace blade.
• Clean grass catcher.
• Grass istoo high or wheal
height is too low.
• Rear of lawn mower
• Raise cutting height.
housing or blade dragging
in grass.
• Grass catcher too full.
housing one (1) setting
higher.
• Empty grass catcher.
• Adjust handle height to
suit.
• Handle height position not
right for you.
15
• Raise rear of lawn mower
SERVICE
31
NOTES
32
XX
o
XXXX
_o_o8_=__
_
33
X_
_
BRIGGS & STRATI'ON
ENGINE
969_
MODEL NUMBER 12HS02-1978-E1
968
6O6
971A
843
967
o
_163
_134
%
124
_634
130
95
110_
7
9_
o;i
34
BRIGGS
& STRATTON
ENGINE
MODEL NUMBER 12H802-1978-E1
15
22
_54
625
9/
51
383
306
lk REQUIRES SPECIAL TOOLS
TO INSTALL SEE REPAIR
INSTRUCTION MANUAL.
35
BRIGGS & STRA'I-FON
_) 670A
ENGINE
_
358 GASKET SET
MODEL NUMBER 12H802-1978-E1
3
1
104
_)
634
977 CARBURETOR
134
617
127
617
GASKET SET
I
121 CARBURETOR
_88A
36
110
°
634
KIT
BRIGGS & _TRAI-rON
MODEL NUMBER 12H802-1978-E1
ENGINE
1095 VALVE OVERHAUL
GASKET SET
930
605
55
_332
455
i
461
37
1036 LABEL KIT - EMISSION
[
BRIGGS & STRA'rTON
KEY
NO.
1
2
3
4
5
7
8
9
9A
10
11
12
13
15
16
20
22
23
24
25
PART
NO.
493260
293708
299819
493279
214368
272916
495786
272481
272238
94650
231933
272198
94547
94880
498566
94388
399781
94220
94612
492177
222698
499429
499430
499431
499432
26
499425
27
28
499426
499427
499428
263190
499423
29
499424
32
33
34
35
40
45
94699
262651
262652
262224
93312
262204
DESCRIPTION
•
....
....
*
•
*
MODEL NUMBER
ENGINE
KEY
NO,
Cylinder Assembly
Bushing, Cylinder
Seal, Oil
Sump, Engine
Head, Cylinder
Gasket, Cylinder Head
Breather Assembly
Gasket, Valve Cover
Gasket, Baffle Plate
Screw, Hex Head
Tube, Breather
Gasket, Crankcase
Screw, Cylinder Head
Plug, Oil Drain
Crankshaft
Timing Gear Key
Seal, Oil
Screw, Hex Head
Screw, Hex Head
(Used in Hole Nearest
Breather)
Flywheel
Key, Flywheel
Piston Assembly,
Standard Size
Piston Assy. (.010" O.S.)
Piston Assy. (.020" O.S.)
Piston Assy. (.030" O.S.)
Ring Set, Piston,
Standard Size
Ring Set (.010" O.S.)
Ring Set (.020• O.S.)
Ring Set (.030• O.S.)
Lock, PistonPin
Pin, Piston,Standard
Size
Rod, Connecting,
Standard Size
Screw, ConnectingRod
Valve, Exhaust
Valve, Intake
Spring,Valve
Retainer,Valve Spring
Tappet, Valve
PART
NO.
46
47
51
54
55
56
58
498275
493737
272199
94526
497442
498144
280399
60
65
81
98
104
110
281434
94696
223664
94098
231371
- --
117
121
124
494870
498260
94840
125
127
498170
---
130
131
133
134
224908
493267
398187
398188
137
---
163
187
188
188A
202
209
272653
298049
398540
94644
262579
263044
12H802-1978-E1
DESCRIPTION
Gear, Cam
Slinger, Oil
• Gasket, Intake Elbow
Screw, Hex Head
Housing, Rewind Starter
Pulley, Rewind Starter
Rope, Rewind Starter
(Cut To 88-5/8•)
Grip, Starter Rope
Screw, Phillips
Lock, Muffler Screw
Screw, Round Head
"• Pin, Float Hinge
•** Gasket, Sealing (Sold in
Kit Only)
Jet, Main
Carburetor Kit
Screw, Carburetor
Mounting
Carburetor
•" Plug, Welch (Sold in Kit
Only)
Valve, Throttle
Shaft, Throttle
Float, Carburetor
Valve, Inlet (Includes
Seat)
*•" Gasket, Bowl (Sold in Kit
Only)
• Gasket, Air Cleaner
Hose, Fuel
Screw, Hex Head
Screw, Hex Head
Link, Governor
Spring, Governor
Included in Gasket Set (497316)
*"
•••
Included in Carburetor Kit (498260)
Included in both Carburetor Kit (498260),
and Carburetor Gasket Set (498261)
.... Included in both Gasket Set (497316),
Set (497316) and Valve overhaul
Gasket Set (498528).
NOTE: All componentdimensionsgiven in U.S. inches
1 inch= 28.4 mm
38
BRIGG S & STRATTON
KEY
NO.
PART
NO.
227
492349
230
67072
258
94512
284
94511
300
497838
304
493293
305
94744
306
224324
307
94515
332
94877
333
802574
334
94731
337
802592
356
497833
358
497316
363
19069
383
89838
387
496115
447
95013
455
225121
456
281503
459
281505
481
94943
515
263073
523
495264
524
280393
525
495265
529
281299
562
94852
572
224328
592
231082
601
93053
605
225103
606
224815
608
497680
Includes:
94904
94908
613
94231
615
94474
616
263175
617
270344
620
499836
621
396847
625
497466
634
--°
ENGINE
DESCRIPTION
Lever, Governor
Washer, Thrust
Screw, Hex Head
Screw. Hex Head
Muffler, Exhaust
Housing. Blower
Screw, Seres
Shield, Cylinder
Screw, Hex Head
Nut, Flywheel
Armature, Magneto
Screw, Seres
Plug, Spark
Wire;. Ground
Gasket Set
Puller, Flywheel
Wrench, Spark Plug
Primer, Carburetor
Screw, Hex
Cup, Starter
Retainer, Starter
Pawl, Rachet
Screw, Shoulder
Spring, Retainer
Cap, Oil Fifler
* Seal, Filler Tube
Tube. Oil Fill
Grommet
Bolt, Govemor Lever
Baffle, Cylinder
Nut, Hex
Clamp, Hose
Cover, Control
Strap, Bracket
Starter, Rewind
MODEL NUMBER 12H802-1978-E1
KEY
NO.
635
670
670A
741
842
843
847
851
869
870
871
922
923
925
930
957
966
967
968
969
3971
971A
972
975
977
1036
1095
2500
----
PART
NO.
66538
280512
493823
262598
280966
272616
495263
493880
213512
213513
262001
63709
262640
493442
261145
281136
397974
496116
491588
281340
94872
94873
94749
495224
493640
498261
499341
498258
12J802-2915
498826
RPM Settings:
DESCRIP_ON
Elbow,Spark Plug
Spacer, Fuel Tank
• Spacer, Bracket
Gear, Timing
• Seal, O-Ring
Sleeve, Lever
Tube Assembly,Oil
Terminal,ignitionCable
Seat, Intake Valve
Seat, ExhaustValve
Guide, ExhaustValve
Guide, Intake Valve
Spring,Brake
BrakeAssembly
Cover, Linkage
Guard, Finger
Cap, Fuel"tank
Base, Air Cleaner
Filter,Air
Cover,Air Cleaner
Screw, Hex Head
Screw, Hsx Head
Screw, Hex Head
Tank, Fuel
Bowl,Float
Gasket Set, Carburetor
Label Kit, Emission
Gasket Set, Valve
Overhaul
ReplacementEngine
ReplacementShortblock
Low: 1900-2100;
3000-3200
High:
Includedin Gasket Set (497316)
Screw, Hex
Nut, Hex
Screw, Hex Head
Fastener
Crank, Governor
"*" Seal, Intake Elbow
Bracket, Carburetor
Switch, Stop
Tube, Fuel Intake
*** Washer, Shaft (Sold in
Kit Only)
Includedin CarburetorKit (498260)
Included in both CarburetorKit(498260),
and CarburetorGasket Set (498261)
***t
Included in both Gasket Set (497316),
Sot (497316) and Valve overhaul
Gasket Set (498528).
NOTE:
All componentdimensionsgiven in U,S. inches
1 inch= 25.4 mm
39
For the repair or replacement parts you need
delivered directly to your home
Call 7 am - 7 pm, 7 days a week
1-800-366-PART
(1-800-366-7278)
Para ordenar piezas con entrega a
domicUio - 1-800-659-7084
For in-house major brand repair service
Call 24 hours a day, 7 days a week
1-800-4-REPAIR
(1-800-473-7274)
Para pedir servicio de reparaci6n
domicilio - 1-800-676-5811
a
For the location of a Sears Parts and
Repair Center in your area
Call 24 hours a day, 7 days a week
1-800-488-1222
For information on purchasing a Sears
Maintenance Agreement or to inquire
about an existing Agreement
Call 9 am - 5 pm, Monday-Saturday
1-800-827-6655
When requesting service or ordering
parts, always provide the following
information:
• Product Type
• Part Number
• Model Number
• Part Description
SE /ARS
Amenca's
166865
12.28.98
VB
Repair
Specianst$
Printed
in U.S.A.