Owner`s Manual - Troy-Bilt

Owner’s Manual
♦SET-UP
♦OPERATION
♦MAINTENANCE
IMPORTANT: Read Safety Rules and Instructions Carefully
PRINTED IN CANADA
OG-4904
CALLING CUSTOMER SUPPORT
• LOCATE
YOUR MODEL NUMBER AND SERIAL NUMBER which appears on your unit
and record the information in the space provided below.
IMPORTANT: You must have these numbers, along with the date and proof of
purchase to receive warranty or service.
• If you are having difficulty assembling this product or if you have any questions regarding the controls, operation or maintenance of this unit, please call an authorized dealer.
• Please have your model number and serial number ready when you call.
NOTE: Although both numbers are important, you will be asked to enter only
your serial number before your call can be processed.
This is where your model number will be,
record model number here:
This is where your serial number will be,
record serial number here:
TABLE OF CONTENTS
CALLING CUSTOMER SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IMPORTANT SAFE OPERATION PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SLOPE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SET-UP INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OFF SEASON STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REPLACEMENT PARTS/PIÈCES DÉTACHÉES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WARRANTY: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2
This unit has been inspected against the manufacturers quality check list. In case of a discrepancy, please call us. We will make every effort to ship the part(s) by courier within one working
day of your call.
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.
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
• 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.
• Read, understand, and follow all instructions
on the machine and in the manual(s) before
attempting to assemble and operate. Keep
this manual in a safe place for future and
regular reference and for ordering replacement parts.
• 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.
• Be familiar with all controls and their proper
operation. Know how to stop the machine
and disengage them quickly.
• Never allow children under 14 years old to
• Never pull the mower back toward you while
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.
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.
• Never allow adults to operate this machine
without proper instruction.
• To help avoid blade contact or a thrown ob-
ject injury, keep bystanders, helpers,
children and pets at least 75 feet from the
machine while it is in operation. Stop machine if anyone enters the area.
• Thoroughly inspect the area where the
• Do not operate the mower while under 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.
influence of alcohol or drugs.
• Do not put hands or feet near rotating parts
or under the cutting deck. Contact with the
blade can amputate hands and feet.
• A missing or damaged discharge cover can
• Plan your mowing pattern to avoid dis-
charge of material toward roads, sidewalks,
bystanders and the like. Also, avoid disc h a r gin g mat er ial ag ai ns t a w a l l o r
obstruction which may cause discharged
material to ricochet back toward the operator.
cause blade contact or thrown object injuries.
• Do not engage the self-propelled mechanism on units so equipped while starting
engine.
• Always wear safety glasses or safety gog-
height adjustment while the engine is running.
• Never attempt to make a wheel or cutting
gles during operation and while performing
an adjustment or repair to protect your
eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
• The blade control handle is a safety device.
Never attempt to bypass its operation.
Doing so makes the safety device inopera-
3
DO:
tive 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.
• Mow across the face of slopes; never up
• Mow only in daylight or in good artificial
and down. Exercise extreme caution when
changing direction on slopes. Watch for
holes, ruts, bumps, rocks, or other hidden
objects 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.
• Stop the blade when crossing gravel drives,
• Do not mow near drop-offs, ditches or em-
• Never operate the mower in wet grass. Al-
ways 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.
light. Walk, never run.
DO NOT:
walks or roads.
bankments, you could lose your footing or
balance.
• If the equipment should start to vibrate ab-
normally, stop the engine and check
immediately for the cause. Vibration is generally a warning of trouble.
• Do not mow slopes greater than 15 degrees
as shown on the slope gauge.
• Do not mow on wet grass. Unstable footing
• Shut the engine off and wait until the blade
could cause slipping.
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.
CHILDREN
• Tragic accidents can occur if the operator is
not alert to the presence of children. Children
are often attracted to the mower and the
mowing activity. They do not understand the
dangers. Never assume that children will remain where you last saw them.
a) Keep children out of the mowing area
and under the watchful care of a responsible adult other than the operator.
b) Be alert and turn mower off if a child enters the area.
c) Before and while moving backwards, look
behind and down for small children.
d) 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.
e) Keep children away from hot or running
engines. They can suffer burns from a
hot muffler.
• 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.
• Muffler and engine become hot and can
cause a burn. Do not touch.
• Only use parts and accessories made for
this machine by the manufacturer. Failure to
do so, can result in personal injury.
• If situations occur which are not covered in
this manual, use care and good judgment.
Contact your customer support department.
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.
• Never allow children under 14 years old to
operate a power mower. Children 14 years
old and over should read and understand
the operation instructions and safety rules in
this manual and should be trained and supervised by a parent.
SERVICE SAFE HANDLING OF GASOLINE:
• 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
4
GENERAL SERVICE:
or your clothes which can ignite. Wash your
skin and change clothes immediately.
a) Use only an approved gasoline container.
• Never run an engine indoors or in a poorly
ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.
b) 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.
c) 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.
• 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 manufacturer’s
(O.E.M.) blade only, listed in this manual.
“Use of parts which do not meet the original
equipment specifications may lead to improper performance and compromise
safety!”
d) 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.
e) Extinguish all cigarettes, cigars, pipes
and other sources of ignition.
f) Never fuel machine indoors.
• Mower blades are sharp and can cut. Wrap
the blade(s) or wear gloves, and use extra
caution when servicing them.
g) Never remove gas cap or add fuel while
the engine is hot or running. Allow engine to cool at least two minutes before
refueling.
h) Never over fill fuel tank. Fill tank to no
more than ½ inch below bottom of filler
neck to provide space for fuel expansion.
i) Replace gasoline cap and tighten securely.
j) If gasoline is spilled, wipe it off the engine and equipment. Move unit to
another area. Wait 5 minutes before starting the engine.
k) 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.
l) To reduce fire hazard, keep machine free
of grass, leaves, or other debris build-up.
Clean up oil or fuel spillage and remove
any fuel soaked debris.
m) Allow machine to cool at least 5 minutes
before storing.
• 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 en-
gine, disconnect the spark plug wire and
ground against the engine. Thoroughly inspect the mower for any damage. Repair
the damage before starting and operating
the mower.
• 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 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 la-
bels, as necessary.
• Observe proper disposal laws and regula-
tions. Improper disposal of fluids and
materials can harm the environment.
SI-102
7.23.03
5
6
DANGER
15º
ING
ENT
RES
, RE
P
LINE
A 15 o
PE
SLO
OR A FENCE POST
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
Operate RIDING mowers up and down slopes, never across the face of slopes.
SAFETY LABEL
Do not mow on inclines with a slope in excess excess of 15 degrees ( a rise of approximately 2½ 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.
FOL
D ON
DOT
TED
A CORNER OF A BUILDING
A POWER POLE
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
USE THIS SHEET AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.
OWNER'S
MANUAL
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.
WARNING - Your Responsibility:
SLOPE GAUGE
(Keep this sheet in a safe place for future reference.)
SET-UP INSTRUCTIONS
This unit is shipped WITHOUT GASOLINE
or OIL. After assembly, service engine with
gasoline and oil as instructed in the separate
engine manual packed with your unit.
brackets. Place the hairpin clips in the inner
hole. See Figure 2.
• Place one carriage bolt (found in the hard-
ware pack included with your unit) in the
upper hole of the right handle mounting
bracket from the inside outward. Secure
with one plastic wing nuts. Repeat process
on other side. See Figure 2.
NOTE: Reference to right or left
hand side of the mower is observed
from the operating position.
HOW TO SET-UP YOUR LAWN MOWER
NOTE: Make certain the drive cable is
routed around the outside and above
the lower handle so it does not interfere
with attaching the grass bag.
Refer to Illustration Below
• Disconnect the spark plug wire and move it
away from spark plug as instructed in the
separate engine manual packed with your
unit.
• The rope guide (pigs tail) is part of the grass
catcher support rod attached to the lower
handle. See Figure 3. With the spark plug
wire disconnected and grounded as instructed in the separate engine manual,
hold the blade control handle against the upper handle, and pull the starter rope out of
the engine slowly until it extends past the
rope guide (pigs tail).
• Remove the carton inserts (if any). Remove
the loose parts which are in the carton, lift
the mower from the carton, or cut the corners of the carton and roll the mower out.
• Pull up and back on the upper handle to
raise the handle into the operating position.
See Figure 1. Make certain the lower handle
is seated securely into the handle mounting
brackets. Tighten the wing nuts on each side
of the handle. See Figure 2.
• Guide the starter rope around the rope guide
• Remove the hairpin clips from the outer hole
• Make certain all nuts and bolts are tightened
(pig tail) until the rope is securely in the center.
in the weld pins on the handle mounting
securely.
Upper
Handle
Wing Nut
Cutting Height
Adjustment Lever
Rope Guide
Lower Handle
Handle Mounting
Bracket
Blade Control Handle
Drive Clutch
Control
Shift Lever
Figure 1
7
Upper Hole
Lower Handle
Carriage
Bolt
Lower
Handle
Recoil
Starter
Wing Nut
Support
Rod
Rope
Guide
Weld Pin
Place the hairpin clips in the inner hole.
Figure 3
Figure 2
Ignition Key (Switch)
CONTROLS
BLADE CONTROL HANDLE
WARNING: This control mechanism
is a safety device. Never attempt to
bypass its operations.
The blade control handle is located on the
upper handle of the mower. See Figure 1.
The blade control handle must be depressed
in order to operate the unit. Release the
blade control handle to stop the engine and
blade.
Figure 4-(Electric Start Units Only)
NOTE: Only move the shift lever when
the engine is running. Changing the
shift lever setting with the engine off
can cause damage to the mower.
WARNING: The blade will be rotating whenever the engine is running.
CUTTING HEIGHT ADJUSTMENT LEVER
(Models: 959 & 979)
RECOIL STARTER
The recoil starter handle is attached to the
handle. See Figure 3. Stand behind the unit
in the operating position to start the unit.
The height adjuster determines the cutting
height of the mower. The adjuster is located
above the left rear wheel. To adjust the cutting height, pull the lever out and away from
the mower and then move it forward or back
to select a new cutting height. See Figure 5.
IGNITION SWITCH (Electric Start Units
Only)
The ignition switch is located on the left side
of the handle panel. It is used for starting
only. See Figure 4.
CUTTING HEIGHT ADJUSTMENT LEVER
(Model: 999)
DRIVE CLUTCH CONTROL
Squeezing the drive clutch control engages
the drive system. Releasing the clutch
control disengages the drive system.
Release the clutch control to slow down
when negotiating an obstacle, making a turn
or stopping.
SHIFT LEVER
The shift lever is located on the drive clutch
control housing on the upper handle. See
Figure 1. This lever is used to select the
forward speed of the mower. When
changing your speed selection, release the
drive clutch control.
The rear wheel height adjuster determines
the cutting height of the mower. The adjuster
is located above the left rear wheel. To adjust the cutting height, pull the lever out and
away from the mower and then move it forward or back to select a new cutting height.
See Figure 5.
The front wheel cutting height is determined
by the selection of one of six positions in
each caster assembly. See Figure 6.
8
To adjust, remove the wing nut from the axle
bolt. Slide the axle bolt and spring washer
from the assembly and select a cutting
LOWER
Locking Pin
Axle Bolt
and
Spring
Washer
HIGHER
Figure 6
Cutting Height Adjustment Lever
Figure 5
BEFORE STARTING
MODELS WITH ELECTRIC START ONLY:
height. With the spring washer on the axle
bolt reinsert in the square hole desired,
through the wheel assembly and secure with
the wing nut previously removed.
WARNING: The battery contains
corrosive fluid and toxic material.
HANDLE WITH CARE. Keep away
from children. Do not puncture, disassemble, mutilate or incinerate. Explosive gases could be vented during charging or discharging. Use in
a well-ventilated area, away from
sources of ignition.
• Charge battery for 16 hours before initial
use. DO NOT CHARGE LONGER THAN 20
HOURS.
IMPORTANT: All wheels must be placed in
the same relative position.
NOTE: For rough or uneven lawns,
move the height adjustment lever to a
higher position. This will help stop
scalping.
CASTER LOCK
WARNING: When operating mower
on hills, front wheels should be
locked in the straight ahead position.
IMPORTANT: Use only the battery
charger supplied with this mower.
To charge the battery, first remove the protective cap from the end of the battery pack
lead. Always plug charger lead into battery
pack lead before inserting battery charger
plug into 120 volt standard household outlet.
See Figure 7.
The casters can be locked in a straight
ahead position or can be left to swivel freely.
Lift and place the lock pins in the larger
holes for locked, straight ahead operation,
place pins in smaller holes to allow casters
to rotate freely.
OPERATION
Protective
Cap
IMPORTANT: Move the shift lever ONLY
when the engine is running. Shifting the
speeds with the engine off can cause damage to the unit. Disengage the drive clutch
control before changing the speed selection.
Battery
pack
Service the engine with gasoline and oil as
instructed in the separate engine manual
packed in your mower. Read instructions
carefully.
Figure 7
WARNING: Never fill fuel tank indoors, with engine running or until
the engine has been allowed to cool
for at least two minutes after running.
After charging, disconnect battery charger
plug from household outlet first, then disconnect charger lead from battery pack lead.
9
WARNING: Do not remove the battery pack from the handle panel for
any reason other than replacement.
When replacing the battery pack,
refer to instructions in Maintenance
section.
Blade Control Handle
Drive
Clutch
NEUTRAL TEST FOR ALL MODELS:
Six Speed
Shift Lever
• Before each use, check for proper drive
clutch operation by performing the following
before starting the engine:
With the drive clutch control released, push
mower forward. It should move freely.
If it does not and the rear wheels tend to
lock up, the clutch may not be releasing
completely. Do not start the engine until corrections have been made. Check the control
cable for severe bend, kinks and binding, or
grass build-up in the pulley groove. Refer to
the "Adjustment" section for any additional
information.
TO START ENGINE AND ENGAGE BLADE
WARNING: When starting the unit
for the first time, place mower in
first speed (slow) position. Face the
mower against a solid object such
as a wall, fence, etc. Start the unit,
and if it shows any signs of motion
with the drive clutch control disengaged, shut the engine off immediately. Make certain the drive clutch
control is adjusted so the drive belt
is as loose as possible. Refer to the
Adjustment Section.
• Attach spark plug wire to spark plug. If unit
is equipped with a rubber boot over the end
of the spark plug wire, make certain the
metal loop on the end of the spark plug wire
(inside the rubber boot) is fastened securely
over the metal tip on the spark plug. See
Figure 8.
Recoil Start
Handle
Figure 9-RECOIL START MODEL SHOWN
• Standing behind the unit, depress the blade
control handle and hold it against the upper
handle as shown in Figure 9.
ELECTRIC START MODELS ONLY:
• Turn the ignition key to the right to start the
engine. Release the key after engine starts.
See Figure 4.
NOTE: The engine on your unit is
provided with an auxiliary recoil
starter system. To start the engine
using the auxiliary start system, proceed as follows for recoil start
models:
RECOIL START MODELS ONLY:
• Grasp the recoil starter handle as shown and
pull slowly until resistance is felt, then pull
rapidly to start engine and avoid kickback.
Return it slowly to the rope guide bolt. See
Figure 9.
• To engage the drive, squeeze the drive clutch
control handle (see Figure 9) towards the upper handle. Release the drive clutch control
to slow down when negotiating an obstacle,
making a turn, or stopping.
• The six speed shift lever is located on the
Metal
Loop
on Spark
Plug Wire
drive clutch control housing on the upper
handle. See Figure 9. This lever is used to select the operating speed of the mower.
Release the drive clutch control when changing speeds.
Rubber Boot
WARNING: THIS CONTROL MECHANISM IS A SAFETY DEVICE. NEVER
ATTEMPT TO BYPASS ITS OPERATIONS.
Figure 8
• If your unit is equipped with a primer, prime
engine as instructed in the separate engine
manual packed with your unit.
The blade control handle must be depressed
in order to operate the unit. Release the
blade control handle to stop the engine and
blade.
• If your unit is equipped with a two speed
control on the engine refer to the separate
engine manual packed with your unit.
10
TO STOP ENGINE
Wing Nuts
• Release the blade control handle to stop the
engine and blade.
WARNING: The blade continues to
rotate for a few seconds after the
engine is shut off.
• Disconnect the spark plug wire and ground it
against the engine as instructed in the separate engine manual to prevent accidental
starting while equipment is unattended.
Mulching
Baffle
USING YOUR ROTARY MOWER
Be sure that lawn is clear of stones, sticks,
wire, or other objects which could damage
lawn mower or engine. Such objects could
be accidentally thrown by the mower in any
direction and cause serious personal injury to
the operator and others.
Figure 10
Bagging Adapter
For the best results, do not cut wet grass because it tends to stick to the underside of the
mower, preventing proper mulching of grass
clippings. In addition, wet grass could cause
you to slip and fall. New grass, thick grass or
wet grass may require a narrower cut.
For best results, cut off one-third or less of
the total length of the grass. Lawn should be
cut in the fall as long as there is growth.
Figure 11
The mower is designed to be operated at full
throttle to give you the best cut and do the
most effective job of mulching.
Flap
Bagging
Adapter
WARNING: If you strike a foreign
object, stop the engine. Remove
wire from spark plug, thoroughly inspect the mower for any damage,
and repair the damage before restarting and operating the mower.
Extensive vibration of the mower
during operation is an indication of
damage. The unit should be
promptly inspected and repaired.
BAGGING GRASS CLIPPINGS
Figure 12
This mower can bag grass clippings. Follow
steps 1 through 3 to ready the mower for
bagging.
1. Remove wing nuts holding mulching baffle
(see Figure 10) or side discharge chute
(see Figure 14) in place. Then remove
baffle or discharge chute.
2, Replace with bagging adapter (see Figure
11). Attach using wing nuts. Be sure that
inner lip of attachment goes under the
edge of the deck.
EMPTYING YOUR GRASS BAG
Lift grassbag from the bagging adapter using the lower handle. While holding the lower
handle lift up the rear section of the
grassbag. The bag will open and the grass
clippings will fall out. See Figure 13. When
replacing your grassbag be sure the top of
the bag rests on the wire support between
the handles.
3. Lift flap and slide bag onto adapter. See
Figure 12.
11
Side
Discharge
Chute
Wing Nut
Figure 13
Figure 14
SIDE DISCHARGE GRASS CLIPPINGS
This mower can also side discharge grass
clippings. Follow steps 1 and 2 to ready this
mower for side discharge operation.
Lower Handle
1. Remove mulching baffle or grass bag
adapter. See Figure 10.
2. Attach discharge chute with wing nuts. See
Figure 14.
Notch
Figure 15
ADJUSTMENT
Reassemble, placing the bottom holes in
the handle over the weld pins in the handle mounting bracket.
5. Reassemble the upper handle to the lower
handle.
6. Place the hairpin clips in the inner holes of
the weld pins and secure with carriage
bolts and wing nuts as instructed in
the“Set-Up” section of this manual.
7. Attach the starter rope and rope guide as
instructed in the “Set-Up” section of this
manual.
CAUTION: DO NOT AT ANY TIME MAKE
ADJUSTMENTS TO LAWNMOWER WITHOUT FIRST STOPPING THE ENGINE AND
DISCONNECTING THE SPARK PLUG
WIRE
CAUTION: Before changing mowing
height, stop mower and disconnect
spark plug cable.
MODELS WITH SINGLE LEVER HEIGHT
ADJUSTERS:
Refer to “Controls Section” and Figure 5.
DRIVE CLUTCH CONTROL ADJUSTMENT
HANDLE HEIGHT ADJUSTMENT
Use the adjustment wheel located on the underside of the clutch control housing to
tighten the drive belt if mower does not
self-propel with the drive clutch control engaged, or if drive belt is slipping (unit
hesitates while engine maintains the same
speed). See Figure 16.
Your mower is shipped with the handle in
the higher height position. To lower the handle height, proceed as follows.
1. Remove the starter rope and the rope
guide.
2. Remove the upper handle by removing the
wing nuts and carriage bolts. Lay the upper handle out of the way, being careful
not to bend or kink the cables.
In addition, the adjustment wheel may also
be used to determine the position in which
the drive clutch control is engaged. If it is
more comfortable to have the drive engaged
with the lever further away from the handle,
tighten the drive belt.
3. Remove the hairpin clips from the weld
pins on the handle brackets. Press out on
the legs of the lower handle. Remove
lower handle from the mower.
4. Turn the lower handle around so the notch
on the bottom of the lower handle is facing forward as shown in Figure 15.
Make certain to retest the unit for neutral as
instructed in the operation Section. Move the
adjustment wheel in the opposite direction to
loosen the drive belt if necessary.
12
n
Loose
BOTTOM
VIEW
Hex Nut
Adjustable
Cable Bracket
n
Tighte
Figure 17
Figure 16
SIX SPEED SHIFT CABLE ADJUSTMENT
MAINTENANCE
Periodic adjustment of the six speed shift cable may be required due to normal stretch
and wear on the cable. Adjustment is
needed if all six speeds cannot be obtained.
For best results your blade should be sharp.
The blade may be resharpened by removing
it and either grinding or filing the cutting
edge keeping as close to the original bevel
as possible.
The adjustable cable bracket is located on
the left side of the mower, beside the engine. To adjust, loosen the hex nut which
secures the adjustable cable bracket. See
Figure 17. Pull backward on the bracket (toward the rear of the mower). Retighten the
hex nut. Test the speeds on the mower (engine must be running).
Improper blade balance will result in excessive vibration causing eventual damage to
the engine and mower. Be sure to carefully
balance blade after sharpening.
After prolonged use, especially in sandy soil
conditions, the blade will become worn and
lose some of the original shape. Cutting efficiency will be reduced and the blade should
be replaced. Replace with an approved factory
replacement blade only. Possible damage resulting from blade unbalance condition is not
the responsibility of the manufacturer.
CARBURETOR ADJUSTMENT
Refer to the separate engine manual packed
with your mower for carburetor adjustment
information.
LUBRICATION
ENGINE
CAUTION: DISCONNECT SPARK
PLUG WIRE BEFORE SERVICING.
Refer to the separate engine manual for engine maintenance instructions.
WHEELS - If your mower is equipped with
ball bearing wheels, lubricate at least once a
season with a light oil, all other types require
no lubrication. However, if the wheels are removed for any reason, lubricate the surface
of the axle bolt and the inner surface of the
wheel with light automotive oil.
Maintain engine oil as instructed in the separate engine manual packed with your unit.
Read and follow instructions carefully.
Under normal conditions service air cleaner
as instructed in the separate engine manual
packed with your unit.
Clean every few
hours under extremely dusty conditions.
Poor engine performance and flooding usually indicates that the air cleaner should be
serviced.
ENGINE - Follow engine manual for lubrication
instructions.
BLADE CONTROL - Lubricate the pivot points
on the blade control handle and the brake cable
at least once a season with light oil. The blade
control must operate freely in both directions.
TRANSMISSION - The transmission is
pre-lubricated and sealed at the factory. It
does not require checking. If disassembled
for any reason, fill with 2 ounces of Alvania
grease, part number 737-0168.
Six Speed
Cable
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; check engine manual for correct plug type and gap specifications.
13
NOTE: This spark ignition system meets
all requirements of the Canadian Interference-Causing Equipment Regulations.
Blade Adapter
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.
Blade
Blade Bell
Support
Hex Bolt
DECK
Figure 18
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.
Before reassembling the blade and the blade
adapter to the unit, lubricate the engine crankshaft and the inner surface of the blade
adapter with light oil. Install the blade adapter
on the crankshaft with the “star” away from the
engine. Refer to Figure 18. Place the blade
with the side marked bottom (or with part
number) facing away from the adapter. Align
the blade bell support over the blade with the
tabs in the holes of the blade and insert the
hex bolt. Tighten the hex bolt to the torque
listed below:
The deck may be cleaned by tilting the mower
and scraping clean with a suitable tool (make
certain the spark plug wire is disconnected).
CUTTING BLADE
WARNING: Be sure to disconnect
and ground the spark plug wire and
remove ignition key before working
on the cutting blade to prevent accidental engine starting. Protect hands
by using heavy gloves or a rag to
grasp the cutting blades.
Blade Mounting Torque
Center Bolt 450 in. lb. min., 600 in.lb. max.
To insure safe operation of your unit, ALL
nuts and bolts must be checked periodically
for correct tightness.
Tip mower as specified in separate engine
manual. If it is not specified tip with carburetor
up.
CAUTION: Cutting grass in sandy
soil conditions causes abrasive
wear to the blade.
Remove the bolt and blade support which
holds the blade and adapter to the engine
crankshaft. Remove the blade and adapter
from the crankshaft.
After prolonged use, especially in sandy soil
conditions, the blade will become worn and
lose some of the original shape. Cutting efficiently will be reduced and the blade should be
replaced. Replace with an approved factory replacement blade only. Possible damage
resulting from blade unbalance condition is not
the responsibility of the manufacturer.
WARNING: Periodically inspect the
blade adapter for cracks, especially if
you strike a foreign object. Replace
when necessary.
For best results your blade should be sharp.
The blade may be resharpened by removing it
and either grinding or filing the cutting edge
keeping as close to the original bevel as possible. It is extremely important that each
cutting edge receives an equal amount of
grinding to prevent an unbalanced blade. Improper blade balance will result in excessive
vibration causing eventual damage to the engine and mower. Be sure to carefully balance
blade after sharpening. The blade can be
tested for balance by balancing it on a round
shaft screwdriver. Remove metal from the
heavy side until it balances evenly.
BELT REMOVAL AND REPLACEMENT
1. Disconnect the spark plug wire and
ground it against the engine.
2. Drain the fuel tank or place a piece of
plastic beneath the cap to prevent gasoline leakage.
3. Tip the mower on its side. Block securely.
4. Remove the blade and blade adapter as
described previously.
5. Move rear height adjuster to the highest
position. See Figure 21.
14
6. Using a 3/8" socket remove three hex
screws holding the baffle to the deck. See
Figure 19.
7. Pivot baffle towards the rear of the mower.
See Figure 20.
Transmission
Pulley
Belt
Belt Keeper
Bracket
Transmission
Idler Pulley
Bracket
Hex
Screw
Idler Pulley
Hex
Screw
Bolt and
Locknut
Hex
Screw
Figure 19
Figure 22
Mower is shown tipped on engine for clarity.
Remember, only tip mower back on its handle with the spark plug facing up.
Baffle
Figure 20
Six-Speed
Cable Slot
Belt
Control
Arm
Rear Wheels Adjustment Lever
Hex
Bolt
Baffle
Figure 21
8. Remove the hex bolt holding the transmission to the mower housing. See Figure
21.
9. Tilt the transmission forward and loosen
the idler pulley bolt and locknut ½ turn
using two 7/16" wrenches.
Figure 23
10. Using a pair of pliers, pull back and rotate
belt keeper bracket from the slot on idler
pulley.
11. Slide the belt out from between the belt
keeper bracket and the idler pulley. See
Figure 22.
12. Squeeze the belt together and push belt
forward. Press the control arm inward towards the deck and remove the six speed
cable from the slot. See Figure 23.
13. Pivot the control arm down away from the
pulley and belt. See Figure 24.
14. Lift off the lower pulley assembly and remove the old belt from around the
crankshaft. See Figure 25.
15
Upper Pulley
Half
Six-Speed
Cable Slot
Belt
Control
Arm
Belt Guard
Pin
Figure 26
Figure 24
Lower Pulley
Half
Lower
Pulley
Half
Crankshaft
Lower Pulley
Half
Belt
Belt Guard
Pin
Belt
Figure 27
Figure 25
15. Place the new belt over the transmission
pulley. Start the belt in pulley groove and
rotate pulley until belt is seated in transmission pulley. See Figure 25.
16. Place belt between idler pulley and the
belt keeper bracket.
17. Using pliers, rotate the belt keeper bracket
so that it snaps into slot on the idler
bracket.
18. Tighten the idler pulley bolt and locknut ½
turn using two 7/16" wrenches. See Figure
22.
19. Place belt between the two pulley halves on
the crankshaft. Make sure to route the belt
inside the belt guard pin. See Figure 26.
IMPORTANT: For proper assembly, it
is essential to keep the assembly
positioned as shown in Figure 26.
20. Pinch belt together so that it is not in the pulley groove, and the lower pulley can be
pushed towards the engine. See Figure 27.
21. Pivot the control arm back to its original position and reinstall the six-speed cable into the
slot.
Figure 28
22. Check and make sure the belt is routed inside the pulley halves and the belt guard
pin. See Figure 28.
23. Reinstall the bolt securing transmission to
rear mower housing.
24. Pivot the baffle back to its original position
and secure with three hex screws earlier removed. You will need a 3/8" socket for these
screws.
25. Lightly lubricate the crankshaft and reinstall
blade and blade adapter as described in the
“Cutting Blade” section.
26. Tip the mower back on its wheels.
27. Make certain to retest the unit for neutral as
instructed in the Operation Section.
16
OFF SEASON STORAGE
INSTRUCTIONS
Fuse Holder
Positive
terminal
The following steps should be taken to prepare lawn mower for storage.
1. Clean and lubricate mower thoroughly as
described in the lubrication instructions.
Negative
terminal
2. Refer to engine manual for correct engine
storage instructions.
3. Coat mower’s cutting blade with chassis
grease to prevent rusting.
4. Store mower in a dry, clean area.
Figure 29
STORAGE OF THE BATTERY
BATTERY PACK REPLACEMENT (Electric
start Models Only)
The battery must be stored with a full
charge. A discharge battery will freeze.
Remove the battery pack from the handle panel
for replacement only. Do not separate the batteries for any reason. Dispose of batteries
properly.
IMPORTANT: All batteries discharge
during storage.
Recharge battery every two months and before returning to service. Refer to charging
instructions on page 9.
WARNING: Batteries contain sulfuric acid which may cause burns. Do
not short circuit or mutilate in any
way. Do not put batteries in fire.
They may burst or release toxic material.
NOTE: When storing any type of power
equipment in an unventilated 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.
When replacing battery pack in handle
panel, battery pack must be positioned with
the positive terminal to the right hand side
and the negative terminal to the left hand
side of panel. See Figure 29. Replacing the
battery pack incorrectly will cause serious
damage.
CAUTION: Never fold or unfold
handle without disconnecting spark
plug.
NOTE: Be careful not to bend of kink
cables.
The positive lead on the wire harness has
the smaller connector. Connect the positive
lead to the positive side of the battery pack,
then connect the negative side.
NOTE: If the starter rope becomes disconnected from rope guide on handle,
disconnect and ground the spark plug
wire. Depress the bail and pull the
starter rope out from engine slowly. Slip
the starter rope into the rope guide bolt
on handle.
IN-LINE FUSE
The unit is equipped with an in-line fuse. If
unit fails to start, check the fuse inside the
battery cover by turning the end of the fuse
holder and removing from the battery cover.
See Figure 29. Replace with standard automotive 7-1/2 amp fuse.
17
TROUBLE SHOOTING
PROBLEM
Engine fails to start
Engine runs erratic
Engine overheats
Idles poorly
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
1. Blade control handle disengaged.
1. Engage blade control handle.
2. Spark plug wire disconnected.
2. Connect spark plug wire.
3. Fuel tank empty, or stale fuel.
3. Fill tank with clean, fresh gasoline.
4. Blocked fuel line.
4. Clean the fuel line.
5. Faulty spark plug.
5. Clean, adjust gap or replace.
6. Engine flooded.
6. Wait a few minutes to restart, but
do not prime.
1. Spark plug wire loose.
1. Connect and tighten spark plug wire.
2. Blocked fuel line or stale fuel.
2. Clean the fuel line; fill the tank
with clean, fresh gasoline.
3. Vent in gas plugged.
3. Clear vent.
4. Water or dirt in fuel system.
4. Drain the fuel tank and carburetor.
Refill with fresh fuel.
5. Dirty air cleaner.
5. Clean air cleaner.
6. Carburetor out of adjustment.
6. Adjust carburetor.
1. Engine oil level low.
1. Fill crankcase with proper oil.
2. Air flow restricted.
2. Remove blower housing and
clean.
3. Carburetor not adjusted properly.
3. Adjust carburetor.
1. Spark plug fouled, faulty or gap 1. Reset gap to .030" or replace
too wide.
spark plug.
2. Carburetor improperly adjusted. 2. Adjust carburetor.
3. Dirty air cleaner.
3. Clean air cleaner.
Excessive vibration
1. Cutting blade loose or unbalanced.
1. Tighten blade and adapter. Balance blade.
2. Bent cutting blade.
2. Replace blade.
Mower will not mulch grass
1. Wet grass.
1. Do not mow when grass is wet;
wait until later to cut.
2. Excessively high grass.
2. Mow once at a high cutting
height, then mow again at desired
height or make a narrower cutting
path.
3. Dull blade.
3. Sharpen or replace blade.
Uneven cut
1. Wheels not positioned correctly. 1. Place all four wheels in same
hight position.
2. Dull blade.
2. Sharpen or replace blade.
Wheels will not propel
1. Belt not installed properly.
1. Check belt for proper pulley installation and movement.
2. Debris clogging drive operation. 2. Clean out debris.
NOTE: For repairs beyond the minor adjustments listed above, contract your nearest authorized
service dealer.
30
notes . . .
31
Download PDF
Similar pages
18A136163
769-07586
Great States Corporation 90 Day Limited Warranty Applies to reel
Rotary mower KDN
1981s
Toro Mower Safety Tips
769 03121B
No.39 Grass Cutting, Ride-on Mower
753-0836
753-0647A