Husqvarna 5521CHV Lawn Mower User Manual

Husqvarna 5521CHV Lawn Mower User Manual

5521CHV

Owner’s Manual

For Parts and Service, call 1-800-448-7543

532 18 90-60 Rev. 3 07.28.04 BY/rad/BY/BY

Printed in U.S.A.

SAFETY RULES

Safe Operation Practices for Walk-Behind Mowers

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE

TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

I. GENERAL OPERATION

• Read, understand, and follow all instructions on the machine and in the manual(s) before starting. Be thor-

ough ly familiar with the controls and the proper use of the machine before starting.

• Do not put hands or feet near or under rotating parts.

Keep clear of the discharge opening at all times.

• Only allow responsible individuals, who are familiar with the instructions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, bones, sticks, etc., which could be picked up and thrown by the blade.

• Be sure the area is clear of other people before mow-

ing. Stop machine if anyone enters the area.

• Do not operate the mower when barefoot or wearing open sandals. Always wear substantial foot wear.

• Do not pull mower backwards unless absolutely nec-

es sary. Always look down and behind before and while moving backwards.

• Do not operate the mower without proper guards, plates, grass catcher or other safety protective devices in place.

• See manufacturer’s instructions for proper operation and installation of accessories. Only use accessories approved by the manufacturer.

• Stop the blade(s) when crossing gravel drives, walks, or roads.

• Stop the engine (motor) whenever you leave the equip-

ment, before cleaning the mower or unclogging the chute.

• Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catch er.

• Mow only in daylight or good artifi cial light.

• Do not operate the machine while under the infl uence of alcohol or drugs.

• Never operate machine in wet grass. Always be sure of your footing: keep a fi rm hold on the handle and walk; never run.

• Disengage the self-propelled mechanism or drive clutch on mowers so equipped before starting the engine (motor).

• If the equipment should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble.

• Always wear safety goggles or safety glasses with side shields when operating mower.

II. SLOPE OPERATION

Slopes are a major factor related to slip and fall accidents which can result in severe injury. All slopes require extra caution. If you feel uneasy on a slope, do not mow it.

DO:

• Mow across the face of slopes: never up and down. Exercise extreme caution when changing direction on slopes.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Tall grass can hide obstacles.

2

DO NOT:

• Do not trim near drop-offs, ditches or embankments.

The operator could lose footing or balance.

• Do not trim excessively steep slopes.

• Do not mow on wet grass. Reduced footing could cause slipping.

III. CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

• Keep children out of the trimming area and under the watchful care of another re spon si ble adult.

• Be alert and turn machine off if children enter the area.

• Before and while walking backwards, look behind and down for small children.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

IV. SERVICE

• Use extra care in handling gasoline and other fuels.

They are fl ammable and vapors are explosive.

- Use only an approved container.

- Never remove gas cap or add fuel with the

engine running. Allow engine to cool before

refueling. Do not smoke.

- Never refuel the machine indoors.

- Never store the machine or fuel container inside

where there is an open fl ame, such as a water heater.

• Never run a machine inside a closed area.

• Never make adjustments or repairs with the engine

(motor) running. Disconnect the spark plug wire, and keep the wire away from the plug to prevent accidental starting.

• Keep nuts and bolts, especially blade attachement bolts, tight and keep equipment in good condition.

• Never tamper with safety devices. Check their proper operation regularly.

• Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage. Allow machine to cool before storing.

• Stop and inspect the equipment if you strike an object.

Repair, if necessary, before restarting.

• Never attempt to make wheel height adjustments while the engine (motor) is running.

• Grass catcher components are subject to wear, dam-

age, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check com po nents and replace with manufacturer’s rec om mend ed parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.

• Do not change the engine governor setting or overspeed the engine.

Look for this symbol to point out im-

por tant safety precautions. It means

SAFE TY IS IN VOLVED.

CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent ac ci den tal adjusting or making re pairs.

WARNING: Engine exhaust, some of cals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm.

WARNING: Battery posts, terminals and related ac ces so ries contain lead and lead compounds, chemicals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm. Wash hands after handling.

CAUTION: Muffl er and other engine parts become extremely hot during operation and remain hot after engine has stopped. To avoid severe burns on contact, stay away from these areas.

CONGRATULATIONS on your purchase of a new lawn mower. It has been designed, engineered and man u fac tured to give you the best possible dependability and performance.

Should you experience any problem you cannot easily remedy, please contact your nearest authorized service center/department. We have competent, well-trained tech ni cians and the proper tools to service or repair this lawn mower.

Please read and retain this manual. The instructions will enable you to assemble and maintain your lawn mower properly. Always observe the “SAFETY RULES”.

SERIAL

NUMBER: _________________________________

DATE OF PURCHASE: _______________________

THE MODEL AND SERIAL NUMBERS WILL BE FOUND

ON A DECAL ATTACHED TO THE REAR OF THE LAWN

MOWER HOUSING.

YOU SHOULD RECORD BOTH SERIAL NUMBER AND

DATE OF PURCHASE AND KEEP IN A SAFE PLACE

FOR FUTURE REFERENCE.

PRODUCT SPECIFICATIONS

Gasoline Capacity 1.0 Quarts and Type: (Unleaded Regular Only)

Oil Type (API-SF-SJ): SAE 10W-30

Oil Capacity: 18.5 Ounces

Spark Plug: NGK BPR6ES (Gap: .030")

Valve Clearance:

(± 0.04 mm)

Intake: 0.015 mm

Exhaust: 0.020 mm

Blade Bolt Torque: 35-40 ft. lbs.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for and using your lawn mower.

• Follow the instructions under “Maintenance” and “Stor-

age” sec tions of this own er’s manual.

TABLE OF CONTENTS

SAFETY RULES ......................................................... 2-3

PRODUCT SPECIFICATIONS ....................................... 3

CUSTOMER RESPONSIBILITIES................................. 3

ASSEMBLY .................................................................... 4

OPERATION ............................................................... 5-9

MAINTENANCE SCHEDULE ...................................... 10

MAINTENANCE ...................................................... 10-12

SERVICE AND AD JUST MENTS ................................. 13

STORAGE .................................................................... 14

TROU BLE SHOOT ING ................................................. 15

REPAIR PARTS....................................................... 16-19

WARRANTY................................................................. 20

3

ASSEMBLY

Read these instructions and this man u al in its entirety before you attempt to assemble or operate your new lawn mow er.

IMPORTANT: THIS LAWN MOWER IS SHIPPED WITH-

OUT OIL OR GASOLINE IN THE ENGINE.

Your new lawn mower has been as sem bled at the factory with the ex cep tion of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc., necessary to com plete the as sem bly have been placed in the parts bag. To ensure safe and proper operation of your lawn mow er, all parts and hard ware you assemble must be tightened se cure ly. Use the correct tools as nec es sary to ensure proper tightness.

OPERATOR PRESENCE

CONTROL BAR

UPPER HANDLE

LOWER HANDLE

LIFT

UP

TO RE MOVE LAWN MOW ER FROM CAR TON

1. Remove loose parts included with mower.

2. Cut down two end corners of car ton and lay end panel down fl at.

3. Remove all packing materials ex cept padding be tween upper and lower handle and padding holding operator presence control bar to up per handle.

4. Roll lawn mower out of carton and check carton thorougly for ad di tion al loose parts.

HOW TO SET UP YOUR LAWN MOW ER

TO UNFOLD HANDLE (See Figs. 1 and 2)

IMPORTANT: UNFOLD HANDLE CAREFULLY SO AS

NOT TO PINCH OR DAMAGE CON TROL CABLES.

1. Raise handles until lower handle section locks into place in mowing position.

2. Remove protective padding, raise upper handle sec-

tion into place on lower handle and tighten both handle knobs.

3. Remove handle padding holding operator pres ence control bar to upper handle.

Your handles may be adjusted for your mowing comfort.

Refer to “ADJUST HANDLE” in the Service and Ad just ments sec tion of this man u al.

CATCHER

FRAME

HANDLE

LIFT UP

VINYL

BINDINGS

MOWING

PO SI TION

FIG. 1

TO ASSEMBLE GRASS CATCHER

(See Fig. 2)

1. Put grass catcher frame into grass bag with rigid part of bag on the bottom. Make sure the frame handle is outside of the bag top.

2. Slip vinyl bindings over frame.

NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using.

FRAME

OPENING

FIG. 2

TO INSTALL ATTACHMENTS

Your lawn mower was shipped ready to be used as a mulcher. To convert mower to bagging or discharging, see “TO CON VERT MOWER” in the Operation section of this man u al.

4

OPERATION

KNOW YOUR LAWN MOWER

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER.

Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments.

Save this manual for future reference.

These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand their meaning.

DRIVE

CONTROL

BAR

STARTER

HANDLE

OPERATOR PRESENCE CON TROL BAR

HANDLE KNOB

GRASS

CATCHER

EN GINE OIL CAP

WITH DIPSTICK

GAS O LINE FILL ER CAP

FUEL VALVE LEVER

AIR FILTER

HOUSING

DRIVE

COVER

MULCHER DOOR

MUFFLER

IMPORTANT: This lawn mower is shipped

WITHOUT OIL OR GASOLINE in the engine.

WHEEL ADJUSTER (ON EACH WHEEL)

MEETS CPSC SAFETY REQUIREMENTS

Our rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running.

OPERATOR PRESENCE CONTROL BAR - must be held down to the handle to start the engine. Release to stop the engine.

STARTER HANDLE - used for starting the engine.

5

DRIVE CONTROL BAR - used to engage power-propelled forward motion lawn mower.

MULCHER DOOR - allows conversion to discharge or bagging operation.

OPERATION

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 standard safety glasses or a wide vision safety mask over spectacles.

HOW TO USE YOUR LAWN MOWER

ENGINE SPEED

The engine speed was set at the factory for optimum performance. Speed is not adjustable.

ENGINE ZONE CONTROL

OPERATOR PRESENCE CONTROL BAR

CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not un der any cir cum stanc es 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.

DRIVE CONTROL (See Fig. 3)

• Self-propelling is controlled by hold ing the operator presence control bar down to the handle and pulling the drive control bar up to the handle. The closer to the handle the bar is pulled, the faster the unit will travel.

• Forward motion will stop when either the operator presence control bar or drive control bar are released. To stop forward motion without stop ping engine, re lease the drive control bar only. Hold op er a tor presence control bar down against handle to con tin ue mowing without self-propelling.

NOTE: If after releasing the drive control the mower will not roll backwards, push the mower forward slightly to disengage drive wheels.

• To keep drive control engaged when turning corners, push down on the handle to lift the front wheels off the ground while turning lawn mower.

THUMB-

SCREW

DRIVE

CONTROL

ENGAGED

FIG. 3

DRIVE

CONTROL

BAR

DRIVE

CONTROL

DISENGAGED

TO ADJUST CUTTING HEIGHT (See Fig. 4)

Raise wheels for low cut and lower wheels for high cut, adjust cutting height to suit your requirements. Me di um position is best for most lawns.

• To change cutting height, squeeze adjuster lever to ward wheel. Move wheel up or down to suit your re quire ments.

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.

LEVER BACKWARD TO LOWER MOWER

PLATE

TAB

LEVER FORWARD TO RAISE MOWER LEVER

DRIVE CONTROL ADJUSTMENT (See Fig. 3)

Over time, the drive control system may become “loose”, resulting in decreased speed. There is a thumbscrew on the un der side of the drive control housing to increase tension on the drive cable. Pro ceed as follows:

1. Turn unit off and disconnect spark plug wire from spark plug.

2. Rotate thumbscrew counter-clockwise to tighten the drive cable.

3. Operate mower to test drive speed.

4. If condition fails to improve after the above steps (forward speed remains the same), your drive belt is worn and should be re placed.

NOTE: If mower begins to “creep” forward, the drive cable is too tight. Rotate thumbscrew clockwise to loosen drive cable.

6

FIG. 4

TO CONVERT MOWER

Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging:

REAR BAGGING (See Fig. 5)

• Lift rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins.

• To convert to mulching or dis charg ing operation, remove grass catch er and close rear door.

SIDE DISCHARGING (See Fig. 6)

• Rear door must be closed.

under door as shown.

• Mower is now ready for discharging operation.

• To convert to mulching or bagging operation, dis charge defl ector must be removed and mulcher door must be closed.

PIVOT PINS

CATCH ER FRAME HOOK

FIG. 5

REAR

DOOR

OPERATION

GRASS

CATCHER

HANDLE

SIMPLE STEPS TO REMEMBER

WHEN CONVERTING YOUR LAWN MOWER

FOR MULCHING -

1. Rear door closed.

2. Mulcher door closed.

FOR REAR BAGGING -

1. Grass catcher installed.

2. Mulcher door closed.

FOR SIDE DISCHARGING -

1. Rear door closed.

2. Discharge defl ector installed.

CAUTION: Do not run your lawn mower with out rear door closed or ap proved grass catcher in place. Never at tempt to op er ate the lawn mow er with the rear door re moved or propped open.

OPEN

MULCHER

DOOR

TO EMPTY GRASS CATCHER (See Fig. 7)

1. Lift up on grass catcher using the frame han dle.

2. Remove grass catcher with clippings from under lawn mower han dle.

3. Empty clippings from bag using both frame handle and bag handle.

NOTE: Do not drag the bag when emptying; it will cause unnecessary wear.

DISCHARGE

DEFLECTOR

GRASS

CATCHER

FRAME

HANDLE

BAG

HANDLE

FIG. 7

FIG. 6

7

OPERATION

BEFORE STARTING ENGINE

ADD OIL (See Figs. 7 and 8)

Your lawnmower is shipped without oil in the engine. For type and grade of oil to use, see “EN GINE” in the Maintenance section of this manual.

ADD GASOLINE (See Fig. 8)

• Fill fuel tank to bottom of tank fi ller neck. Do not overfi ll. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline.

Purchase fuel in quan ti ties that can be used within 30 days to assure fuel freshness.

CAUTION: DO NOT overfi ll engine with oil, or it will smoke heavily from the muffl er on startup.

1. Be sure lawnmower is level.

2. Remove oil dipstick from oil fi ll spout.

3. You receive a container of oil with the unit. Slowly pour the entire container down the oil fi ll spout into the engine.

4. Insert and tighten dipstick.

IMPORTANT:

• Check oil level before each use. Add oil if needed. Fill to full line on dipstick.

• Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. See “TO CHANGE EN-

GINE OIL” in the Maintenance section of this manual.

CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open fl ame.

Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and for ma tion 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 stor age of

30 days or longer. Empty the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage

In struc tions for additional information.

Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

OIL FILLER CAP/DIPSTICK

UPPER LIMIT

FIG. 7

LOWER LIMIT

GASOLINE

FILLER CAP

TO STOP ENGINE

• To stop engine, release operator presence control bar.

Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to re start the engine soon.

TO START ENGINE (See Fig. 9)

NOTE: Due to protective coatings on the engine, a small amount of smoke may be present during the initial use of the product and should be considered normal.

1. Be sure fuel valve is in the ON po si tion.

2. Move choke lever to ON ( ) position.

3. Hold operator presence control bar down to the han dle and pull starter handle quickly. Do not allow starter rope to snap back.

NOTE: The choke lever automatically begins moving to the OFF position when operator presence control bar is held down to handle.

OIL

FILLER

CAP

FIG. 8

8

OFF

ON

( )

FUEL VALVE LEVER

ON

FIG. 9

OFF

OPERATION

CHOKE LEVER

MULCHING MOWING TIPS

IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER

HOUSING FREE OF BUILT-UP GRASS AND TRASH. SEE

“CLEANING” IN THE MAINTENANCE SECTION OF THIS MANUAL.

• The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades.

• Avoid cutting your lawn when it is wet. Wet grass tends to form clumps and interferes with the mulching action.

The best time to mow your lawn is the early afternoon.

At this time the grass has dried, yet the newly cut area will not be exposed to direct sunlight.

• For best results, adjust the lawn mower cutting height so that the lawn mower cuts off only the top one-third of the grass blades (See Fig. 10). If the lawn is overgrown it will be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy mulching, reduce your width of cut by overlapping previously cut path and mow slowly.

MAX 1/3

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.

• Pores in cloth grass catchers can become fi lled 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 fl ow and extend engine life.

FIG. 10

• Certain types of grass and grass conditions may require that an area be mulched a second time to completely hide the clippings. When doing a second cut, mow across (perpendicular) to the fi rst cut path.

• Change your cutting pattern from week to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and graining of the lawn.

9

MAINTENANCE

BEFORE

EACH

USE

AFTER

EACH

USE

EVERY

10

HOURS

EVERY

25 HOURS

OR SEASON

EVERY

100

HOURS

BEFORE

STORAGE

**

*

***

****

Check for Loose Fasteners

Clean / Inspect Grass Catcher *

Check Tires

Check Drive Wheels ***

Clean Lawn Mower ****

Clean under Drive Cover ***

Check Drive Belt / Pulleys ***

Check / Sharpen / Replace Blade

Lubrication

Clean and Recharge Battery **

Check Engine Oil level

Change Engine Oil

Clean Air Filter

Inspect Muffler

Replace Spark Plug

Replace Air Filter Paper Cartridge

Empty fuel system or add Stabilizer

(if so equipped)

Electric-Start mowers

Power-Propelled mowers

Use a scraper to clean under deck

1 - Change more often if operating under a heavy load or in high outdoor temperatures.

2 - Service more often if operating in dirty or dusty conditions.

3 - Replace blades more often when mowing in sandy soil.

4 - Charge 48 hours at end of season.

5 - And after each 5 hours of use.

GENERAL RECOMMENDATIONS

The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain mower as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain your unit.

At least once a season, check to see if you should make any of the adjustments described in the Service and Ad-

just ments section of this manual.

• At least once a year, replace the spark plug, clean or replace air fi lter element and check blade for wear. A new spark plug and clean/new air fi lter element assure proper air-fuel mixture and help your engine run better and last longer.

• Follow the maintenance schedule in this manual.

LUBRICATION CHART

WHEEL

ADJUSTER

(ON EACH

WHEEL)

ENGINE OIL

MULCHER

DOOR

HINGE PIN

BEFORE EACH USE

1. Check engine oil level.

2. Check for loose fasteners.

REAR DOOR HINGE

LUBRICATION

Keep unit well lubricated (See “LUBRICATION CHART”).

IMPORTANT: DO NOT OIL OR GREASE PLASTIC WHEEL

BEARINGS. VISCOUS LU BRI CANTS WILL ATTRACT DUST

AND DIRT THAT WILL SHORT EN THE LIFE OF THE SELF-

LU BRI CAT ING BEARINGS. IF YOU FEEL THEY MUST BE

TYPE LUBRICANT SPAR INGLY.

10

SPRAY LUBRICANT

HANDLE BRACK ET MOUNT ING PINS

SEE “ENGINE” IN MAINTENANCE SECTION

MAINTENANCE

LAWN MOWER

Always observe safety rules when performing any main-

te nance.

TIRES

• Keep tires free of gasoline, oil, or insect control chem-

i cals which can harm rubber.

• Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage.

DRIVE WHEELS

Check front drive wheels each time be fore you mow to be sure they move freely.

The wheels not turning freely means trash, grass cuttings, etc. are in the drive wheel area and must be cleaned to free drive wheels.

If necessary to clean the drive wheels, be sure to clean both front wheels.

1. Remove hubcaps, locknuts and washers.

2. Remove wheels from wheel ad just ers.

3. Remove any trash or grass cuttings from inside the dust cover, pinion and/or drive wheel gear teeth.

4. Put wheels back in place.

NOTE: If after cleaning, the drive wheels do not turn freely, contact a qualifi ed service center.

BLADE CARE

For best results, mower blade must be kept sharp. Re place bent or dam aged blades.

TO REMOVE BLADE (See Fig. 11)

1. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

2. Turn lawn mower on its side. Make sure air fi lter and carburetor are up.

3. Use a wood block between blade and mower hous ing to prevent blade from turning when re mov ing blade bolt.

NOTE: Protect your hands with gloves and/or wrap blade with heavy cloth.

4. Remove blade bolt by turning counter-clockwise.

5. Remove blade and attaching hardware (bolt, lock wash er and hardened wash er).

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 dam aged.

TO REPLACE BLADE (See Fig. 11)

1. Position the blade adapter on the engine crank shaft.

Be sure key in adapter and crankshaft key way are aligned.

2. Position blade on the blade adapter aligning the two

(2) holes in the blade with the raised lugs on the adapter.

3. Be sure the trailing edge of blade (opposite sharp edge) is up toward the engine.

4. Install the blade bolt with the lock washer and hard ened washer into blade adapter and crank shaft.

5. Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clock wise.

• The recommended tightening torque is 35-40 ft. lbs.

IMPORTANT: BLADE BOLT IS HEAT TREATED. IF BOLT NEEDS

REPLACING, REPLACE ONLY WITH APPROVED BOLT SHOWN

IN THE REPAIR PARTS SECTION OF THIS MANUAL.

BLADE ADAPTER

KEY

BLADE

LOCK

WASHER

CRANKSHAFT

KEY WAY

BLADE

BOLT

HARDENED

WASHER

TRAILING EDGE

CRANK-

SHAFT

BLADE ADAPT ER

FIG. 11

TO SHARPEN BLADE

NOTE: We do not recommend sharp en ing blade - but if you do, be sure the blade is balanced.

Care should be taken to keep the blade balanced. An un bal anced blade will cause eventual damage to lawn mower or engine.

• The blade can be sharp ened with a fi le 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 ex posed.

Place center hole of blade over the head of the nail.

If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced.

GRASS CATCHER

• The grass catcher may be hosed with water, but must be dry when used.

• Check your grass catcher often for damage or de te ri o ra tion. Through normal use it will wear. If catcher needs replacing, replace only with ap proved replacement catcher shown in the Repair Parts section of this manual. Give the lawn mower model number when ordering.

GEAR CASE

• To keep your drive system working properly, the gear case and area around the drive should be kept clean and free of trash build-up. Clean under the drive cover twice a season.

• The gear case is fi lled with lubricant to the proper level at the factory. The only time the lubricant needs attention is if service has been performed on the gear case.

• If lubricant is required, use only ELF Multis EP00.

Do not substitute.

11

MAINTENANCE

ENGINE

LUBRICATION

Use only high quality detergent oil rated with API service classifi cation SF-SJ. Select the oil's SAE viscosity grade according to your expected operating temperature.

NOTE: Multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, and you should check your engine oil level frequently to avoid possible engine damage from running low on oil.

Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year.

Check the crankcase oil level before starting the engine and after each fi ve (5) hours of continuous use. Tighten oil plug securely each time you check the oil level.

TO CHANGE ENGINE OIL (See Fig. 12)

NOTE: Before tipping lawn mower to drain oil, empty fuel tank by running engine until fuel tank is empty.

1. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

2. Remove engine oil cap; lay aside on a clean surface.

3. Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine.

5. Fill engine with oil. The engine oil capacity is 18.5 oz.

If oil is not com plete ly drained from engine, you may not need the entire container of a 20 oz. bottle of oil.

Slowly pour 3/4 of the oil from the container down the oil fi ll spout into the engine.

6. Wait one minute to allow oil to settle. Use guage on oil fi ll cap/dipstick for checking level. Insert dipstick into the tube and rest the oil fi ll cap on the tube. DO NOT thread the cap into the tube when taking reading.

7. Continue adding small amounts of oil and rechecking the dipstick until it reads full. DO NOT overfi ll, or engine will smoke on startup.

8. Always be sure to retighten oil dipstick before starting engine.

9. Reconnect spark plug wire to spark plug.

AIR FILTER

Your engine will not run properly and may be damaged by using a dirty air fi lter. Replace the air fi lter every 100 hours of operation or every season, whichever occurs fi rst.

Ser vice air cleaner more often under dusty conditions. See the main te nance section of your engine manual.

MUFFLER

Inspect and replace corroded muffl er as it could create a fi re hazard and/or damage.

SPARK PLUG

Replace spark plug at the beginning of each mowing season or after every 100 hours of operation, whichever occurs fi rst. Spark plug type and gap setting are shown in the

“PROD UCT SPEC I FI CA TIONS” section of this manual.

OIL FILLER CAP/DIPSTICK

UPPER

LIMIT

LOWER

LIMIT

FIG. 12

4. Wipe off any spilled oil from lawn mower or side of engine.

CLEANING

IMPORTANT: FOR BEST PERFORMANCE, KEEP MOWER

HOUSING FREE OF BUILT-UP GRASS AND TRASH. CLEAN

THE UNDERSIDE OF YOUR MOWER AFTER EACH USE.

CAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

• 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 fi nished surfaces and wheels free of all gasoline, oil, etc.

• We do not recommend using a garden hose to clean lawn mower unless the electrical system, muffl er, air fi lter and carburetor are covered to keep water out.

Water in engine can result in shortened engine life.

CLEAN UNDER DRIVE COVER

Clean under drive cover at least twice a season. Scrape underside of cover with putty knife or similar tool to remove any build-up of trash or grass on underside of drive cover.

12

SERVICE AND ADJUSTMENTS

CAUTION: TO AVOID SERIOUS INJURY, BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS:

1. Release control bar and stop engine.

2. Make sure the blade and all moving parts have completely stopped.

3. Disconnect spark plug wire from spark plug and place where it cannot come in contact with plug.

LAWN MOWER

TO ADJUST CUTTING HEIGHT

See “TO ADJUST CUTTING HEIGHT” in the Operation section of this manual.

2. Remove hairpin cotters from lower handle bracket mount ing pin.

3. Squeeze lower handle in to remove it from mounting pins.

4. Turn lower handle over to raise or lower handle.

REAR DEFLECTOR

The rear defl ector, 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 defl ector becomes damaged, it should be replaced.

TO REMOVE DRIVE BELT (See Fig. 13)

1. Remove drive cover and belt keeper.

2. Remove belt from gearcase pulley by push ing down on pulley and rolling belt off it.

3. Turn lawn mower on its side with air fi lter and car bu re tor up.

4. Remove blade and debris shield.

5. Remove belt from engine pulley on crankshaft.

TO REPLACE DRIVE BELT (See Fig. 13)

1. Install new belt on engine pulley.

2. Reinstall debris shield and blade.

3. Return mower to upright po si tion.

4. Install new belt on gearcase pulley.

5. Reinstall belt keeper and drive cover.

NOTE: Always use factory approved belt to assure fi t and long life.

mount ing pins on handle bracket.

6. Reassemble upper handle and all parts removed from lower handle.

MOWING

POSITION

ROTATE

FIG. 14

LOWER

HANDLE

MOWING

POSITION

HAIRPIN

COTTER

HANDLE

BRACKET

MOUNTING

PIN

LOW POSITION HIGH POSITION

DRIVE

COVER BELT

FIG. 15

ENGINE

ENGINE SPEED

Your engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that the engine is running too fast or too slow, take your lawn mower to an authorized service center for repair and adjustment.

BELT KEEPER

PUSH DOWN

FIG. 13

TO ADJUST HANDLE (See Figs. 14 and 15)

The handle can be mounted in a high or low position. The mounting holes in the bottom of lower handle are off center for raising or lowering the handle.

1. Remove upper handle and all wire tie(s) securing cable(s) to lower handle.

13

CARBURETOR

Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to an authorized service center for repair and/or adjustment.

IMPORTANT: NEVER TAMPER WITH THE ENGINE GOVERNOR,

WHICH IS FACTORY SET FOR PROPER ENGINE SPEED.

OVER SPEED ING THE ENGINE ABOVE THE FACTORY HIGH

SPEED SETTING CAN BE DANGEROUS. IF YOU THINK THE

ENGINE-GOVERNED HIGH SPEED NEEDS ADJUSTING,

CONTACT YOUR NEAREST AUTHORIZED SER VICE CEN TER,

WHICH HAS PROPER EQUIP MENT AND EXPERIENCE TO

MAKE ANY NEC ES SARY ADJUSTMENTS.

STORAGE

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 MOWER

When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area.

1. Clean entire lawn mower (See “CLEANING” in the

Maintenance section of this manual).

2. Lubricate as shown in the Maintenance section of this manual.

3. Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary.

4. Touch up all rusted or chipped paint surfaces; sand lightly before painting.

HANDLE (See Figs. 16 and 17)

You can fold your lawn mower handle for storage.

1. Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket, then move handle forward.

2. Loosen upper handle mounting bolts enough to allow upper handle to be folded back.

IMPORTANT: WHEN FOLDING THE HANDLE FOR STORAGE

OR TRANSPORTATION, BE SURE TO FOLD THE HANDLE AS

SHOWN OR YOU MAY DAMAGE THE CONTROL CABLES.

• When setting up your handle from the storage position, the lower han dle will automatically lock into mow ing position.

SQUEEZE

TO ADJUST

LOWER HANDLE

ENGINE

FUEL SYSTEM

IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS

FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH

AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK

DURING STORAGE. ALSO, ALCOHOL BLENDED FUELS

(CALLED GASOHOL OR USING ETHANOL OR METHANOL)

CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION

AND FORMATION OF ACIDS DURING STORAGE. ACIDIC GAS

CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN

STORAGE.

• Empty the fuel tank by starting the engine and letting it run until the fuel lines and carburetor are empty.

• 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 stor age.

Add stabilizer to gasoline in fuel tank or storage container.

Always follow the mix ratio found on stabilizer container.

Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not empty the gas tank and carburetor if using fuel stabilizer.

ENGINE OIL

Drain oil (with engine warm) and replace with clean engine oil. (See “ENGINE” in the Maintenance section of this manual).

CYLINDER

1. Remove spark plug.

2. Pour one ounce (29 ml) of oil through spark plug hole into cylinder.

3. Pull starter handle slowly a few times to distribute oil.

4. Replace with new spark plug.

OPERATOR PRES ENCE

CONTROL BAR

UPPER HANDLE

LOWER

HANDLE

FIG. 16

FOLD

FORWARD

FOR

STORAGE

FOLD

BACKWARD

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 it to give protection from dust and dirt.

• Cover your unit with a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe, which allows condensation to form and will cause your unit to rust.

IMPORTANT: NEVER COVER MOWER WHILE ENGINE AND

EXHAUST AREAS ARE STILL WARM.

CAUTION: Never store the lawn mower with gasoline in the tank inside a build-

ing where fumes may reach an open fl ame or spark. Allow the engine to cool before storing in any enclosure.

MOWING

POSITION

FIG. 17

14

TROUBLESHOOTING POINTS

PROBLEM CAUSE CORRECTION

Does not start 1. Dirty air fi lter. 1. Clean/replace air fi lter.

2. Out of fuel. 2. Fill fuel tank.

3. Stale fuel. 3. Empty fuel tank and refi ll tank with fresh,

clean gasoline.

4. Water in fuel. 4. Empty fuel tank and refi ll tank with fresh,

clean gasoline.

5. Spark plug wire is disconnected. 5. Connect wire to plug.

6. Bad spark plug. 6. Replace spark plug.

7. Loose blade or broken blade adapter. 7. Tight en blade bolt or replace blade adapter.

8. Control bar in released position. 8. Depress control bar to handle.

9. Control bar defective. 9. Replace control bar.

10. Fuel valve lever (if equipped) in OFF position. 10. Turn fuel valve lever to the ON position.

11. Weak battery (if equipped). 11. Charge battery.

12. Disconnected battery connector (if equipped). 12. Connect battery to engine.

Loss of power 1. Rear of lawn mower housing or cutting 1. Raise cutting height.

blade dragging in heavy grass.

2. Cutting too much grass. 2. Raise cutting height.

3. Dirty air fi lter. 3. Clean/replace air fi lter.

4. Buildup of grass, leaves and trash under 4. Clean underside of mower housing.

mower.

5. Too much oil in engine. 5. Check oil level.

6. Walking speed too fast. 6. Cut at slower walking speed.

Poor cut – 1. Worn, bent or loose blade. 1. Replace blade. Tighten blade bolt.

uneven 2. Wheel heights uneven. 2. Set all wheels at same height.

3. Buildup of grass, leaves and trash under 3. Clean underside of mower housing.

mower.

Excessive 1. Worn, bent or loose blade. 1. Replace blade. Tighten blade bolt.

vibration 2. Bent engine crankshaft. 2. Contact a qualifi ed service center.

Starter rope 1. Engine fl ywheel brake is on when control 1. Depress control bar to upper handle before

hard to pull bar is released. pulling starter rope.

2. Bent engine crankshaft. 2. Contact a qualifi ed service center.

3. Blade adapter broken. 3. Replace blade adapter.

4. Blade dragging in grass. 4. Move lawn mower to cut grass or other

hard surface before starting.

Grass catcher 1. Cutting height too low. 1. Raise cutting height.

not fi lling 2. Lift on blade worn off. 2. Replace blade.

(if so equipped) 3. Catcher not venting air. 3. Clean grass catcher.

Hard to push 1. Grass is too high or wheel height is too low. 1. Raise cutting height.

2. Rear of lawn mower housing or cutting 2. Raise rear of lawn mower housing one (1)

blade dragging in heavy grass. setting higher.

3. Grass catcher too full. 3. Empty grass catcher.

4. Handle height position not right for you. 4. Adjust handle height to suit.

Loss of drive 1. Belt wear. 1. Check/replace drive belt.

(or slowing of 2. Belt off of pulley. 2. Check/reinstall drive belt.

drive speed) 3. Drive cable worn or broken. 3. Put belt on pulleys / replace belts if broken.

4. “Loose” drive control system. 4. Adjust drive control.

15

ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVA) - PRODUCT NUMBER 954 22 38-83

ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVA) - PRODUCT NUMBER 954 22 38-83

KEY PART

NO. NO. DESCRIPTION

1 532 18 60-24 Upper Handle (Includes Foam Grip)

2 532 15 34-18 Lower Handle

3 532 18 60-11 Control Bar

4 532 18 27-55 Engine Zone Control Cable

5 532 13 19-59 Handle Bolt

6 532 18 55-77 Handle Knob

7 532 05 17-93 Hairpin Cotter

8 532 06 64-26 Wire Tie

9 532 18 04-79 Rear Door Kit (Includes Key #16 and 17)

10 532 12 84-15 Pop Rivet

11 532 18 25-38 Support Bracket, LH

12 532 18 25-39 Support Bracket, RH

13 817 06 04-10 Screw 1/4-20 x 5/8

14 532 18 25-43 Handle Bracket Assembly (Left)

15 532 18 25-45 Handle Bracket Assembly (Right)

16 532 18 00-71 Spring, LH

17 532 18 00-72 Spring, RH

18 532 18 81-52 O-Ring

19 532 17 95-85 Rope Guide

20 532 18 90-05 Rear Skirt

21 532 08 86-52 Hinge Screw 1/4-20 x 1-1/4

22 532 18 50-05 Engine Pulley

23 532 18 77-23 Hi-Pro Key

24 - - - Engine, Honda, Model Number GCV160

(Order parts from engine manufacturer)

25 532 15 04-06 Hex Head Thread Rolling Screw 3/8-16 x 1-1/8

26 532 08 39-23 Hex Flange Nut

27 532 18 55-72 Wheel

28 532 16 08-28 Shoulder Bolt 5/16-18 x .33

29 532 08 83-48 Washer, Flat 3/8

30 532 18 25-41 Axle Arm Assembly RR

31 532 18 55-75 Selector Knob

32 532 18 25-37 Selector Spring

33 873 80 05-00 Locknut

KEY PART

NO. NO. DESCRIPTION

34 532 18 25-42 Axle Arm Assembly, LR

35 532 12 50-78 Washer

36 532 18 41-93 Bolt

37 532 15 00-78 Thread Cutting Screw w/Sems 5/16-18 x 3/4

38 532 18 39-01 Washer

39 532 85 10-74 Washer

40 532 18 81-02 Keeper, Belt

41 532 17 37-15 Screw

42 532 18 80-40 Screw, Belt Cover

43 532 18 70-38 Belt Cover, Bottom

44 532 18 55-83 Lawn Mower Housing

(Includes Key Numbers 10, 11, 12 and 45)

45 532 10 73-39 Danger Decal

46 532 18 45-90 Blade Adapter

47 532 17 61-35 Blade, 21"

48 532 18 60-39 Hardened Washer

49 532 85 02-63 Helical Washer 3/8-24 x 1-3/8 Grade 8

50 532 85 10-84 Hex Head Machine Screw 3/8-24 x 1-3/8 Grade 8

51 532 12 51-62 Bracket, Upstop

52 532 75 06-34 Screw

83 532 18 55-76 Mulch Door

84 532 17 57-35 Hinge Bracket Assembly

85 532 17 52-85 Spring

86 532 17 56-50 Rod, Hinge

87 873 80 04-00 Locknut

88 532 18 55-82 Clipping Defl ector

91 532 18 55-73 Hubcap

92 532 13 20-04 Nut, Hex

93 532 18 63-62 Grip, Foam

- - 532 16 23-00 Warning Decal (Not Shown)

- - 532 18 90-60 Owner’s Manual, English / French

NOTE: All component dimensions given in U.S. inches.

1 inch = 25.4 mm

ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVA) - PRODUCT NUMBER 954 22 38-83

ROTARY LAWN MOWER - - MODEL NUMBER 5521CHV (5521CHVA) - PRODUCT NUMBER 954 22 38-83

KEY PART

NO. NO. DESCRIPTION

1 532 18 91-82 Vari-Speed Drive Control Assembly

2 532 16 99-11 Bearing, Wheel Adjuster

3 532 17 51-03 Gear, Pinion

4 532 18 56-81 Screw

5 532 16 97-78 V-Belt

6 532 18 89-76 Bar, Control, Drive

7 532 75 11-52 Nut, Hex

8 532 18 06-26 Hubcap

9 532 14 52-12 Locknut

10 532 18 82-92 Pinion Assembly, LH

11 532 18 07-67 Wheel & Tire Assembly

12 812 00 00-58 E-Ring

13 532 18 82-93 Pinion Assembly, RH

14 532 18 05-04 Dust Cover

15 532 17 51-02 Retainer, Drive. RH

16 532 06 77-25 Washer 1/2 x 1-1/2 x .134

17 532 17 50-98 Pawl

18 532 18 55-74 Selector Knob

19 532 18 82-91 Spring, Torsion

20 532 17 51-04 Disc, Drive

21 532 17 51-01 Seal, Pinion

23 532 17 51-05 Retainer, Drive, LH

26 532 17 52-62 Pan Head Tapping Screw #10-24 x 2-3/4

28 532 18 55-79 Drive Cover

31 532 13 20-10 Hex Flange Nut

32 532 18 94-06 Drive Pulley

KEY PART

NO. NO. DESCRIPTION

35 532 18 09-15 Kit, Wheel Adjuster, LH

(Includes Knob and Bearing)

36 532 18 72-12 Gear Case Assembly, Complete

38 873 80 04-00 Locknut 1/4-20

40 532 18 22-26 Spring

41 532 18 09-14 Kit, Wheel Adjuster, RH

(Includes Knob and Bearing)

54 532 18 97-65 Grassbag Assembly

55 532 17 57-39 Driveshaft Cover

57 532 18 88-15 Frame

60 532 18 35-13 Screw

61 532 18 75-25 * Case, Lower

62 532 18 75-27 Shaft, Input

63 532 18 35-05 Wire, Formed

64 532 18 34-99 Gear, 27 Teeth

65 532 18 35-09 Washer

66 532 18 75-29 Shaft, Output

67 532 18 35-11 Bushing

68 532 18 75-26 * Case, Upper

69 532 18 35-14 Seal, Input Shaft

70 532 18 35-06 Bearing, Ball

71 532 18 75-28 Spacer

72 532 18 35-08 Seal, Output Shaft

* Use Dow Corning #709 to reseal Gear Case Halves.

NOTE: All component dimensions given in U.S. inches.

1 inch = 25.4 mm

20

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