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Owner / Operator Manual TM Wide - Cut 33 " Combination Mower • Safety • Assembly • Controls • Operation • Maintenance Model 34356 GARDEN WAY INCORPORATED
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Dear Owner , This is a safety alert symbol . It is used in You now own one of the finest walk - this Owner / Operator behind mulching / side discharge mowers Manual to alert you available . to potential hazards . Whenever you see this symbol , read Your new Wide - Cut Mower allows you and obey the safety message that to mow much faster than the usual walk - follows it . Failure to obey the safety behind mower because of its wide 33 " message could result in personal in - jury or property damage . cut . Differential steering makes turning easy , while four forward speeds and one reverse speed allow precise mowing con - trol . The wide turf tires give excellent traction without leaving wheel marks , Be Sure To Return Your Owner and the cutting height can be adjusted Registration Card with the turn of a single lever . We know that there is no better walk - behind mower that is available for large lawns . Be sure to fill out and return Please carefully read this Manual the enclosed which tells you how to safely and easily Owner Regis - assemble , operate and maintain your ma - tration Card , which is located chine . Be sure that you and any other in your literature IMAILL MA operators carefully follow the recom - package . The in - mended safety practices at all times . formation contained on this card will register your machine with us . Failure to do so could result in personal injury or property damage . Of course , if you should ever have any problems or questions , please contact your local authorized service dealer or call us Toll - Free . Our telephone num - bers are listed on Page 2 and on the back cover of this Manual . We want to be sure that you are com - pletely satisfied at all times . WARNING : The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth de - fects , or other reproduc - tive harm . This product is certified to comply with INDEPENDENT BY CERTIFIED ANSI Standard B71.1 – 1996 . All products SPONSORED LABORATORY PROGRAM MODEL BY in this Manual meet the latest CPSC blade OUTDOOR POWER EQUIPMENT INSTITUTE ANS B71.1 - 1996 SAFETY STANDARD safety requirements .
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Table of Contents SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Owner's Record SECTION 1 : SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Please write the Model and Serial Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Numbers of your mower in Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 the spaces provided . You Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 can find the location of Maintenance and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 these numbers in the Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 illustration below . SECTION 2 : ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION 3 : FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . 14 Operating Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operator Presence Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Blade Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gear Select Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wheel Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Model Number : Cutting Height Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mulcher Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Ignition / Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine Recoil Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Serial Number : SECTION 4 : OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Adjust Mower Cutting Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Select Mulching or Side Discharge Mowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Moving the Mower Without Engine Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Starting and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engaging the Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 To Engage the Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Making Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Mowing Tips and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Blade Brake Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SECTION 5 : MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Model / Serial Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Number Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Location Tipping Mower for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Belt Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Blade Spindle Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Blade Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Blade Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Blade Drive Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Blade Drive Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wheel Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wheel Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wheel Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Transmission Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cleaning Underside of Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Off - Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1
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at Service ! We're Your If you have any Questions or HOW CTOHUS REA Problems . . . y ? ? ? ? . . . . Please contact your local authorized dealer or call or write the Factor When calling or writing , please be sure to pro - vide the Model and Serial Numbers of your machine ( refer to Address Page 1 ) . GARDEN WAY INCORPORATED look in the Yellow Pages of the 1 Garden Way , IF YOU NEED ENGINE telephone book under “ Engines - Troy , NY 12180 Gasoline . � SERVICE : Please remember that your en - If your engine gine is covered by the engine man - should ever re - ufacturer's Limited Warranty . Any quire service , unauthorized work performed on repair , or the engine during the warranty pe - Telephone Numbers parts , contact riod may void the warranty . For full details on the engine manufac - your nearest turer's Limited Warranty , refer to Outside dthea : USA anda : authorized engine ser - the separate Engine Owner's USA and Canad vice dealer . Manual . Cana To find the name of your nearest Customer authorized engine service dealer , Customer Service : 1 - 800 - 437 - 8686 Service : ( 518 ) 391 - 7007 Technical of the part you need . Then , call or Service : Technical IF YOU NEED PARTS : write our Parts Department , being 1 - 800 - 520 - 5520 Service : sure to provide the Model and Factory specified replace - ( 518 ) 391 - 7008 Serial Numbers of your ma - ment parts for your machine Parts Service : chine . ( other then engine parts ) are Parts Service : 1 - 800 - 648 - 6776 available from either your ( 518 ) 391 - 7006 FAX # : Our trained parts authorized dealer or di - FAX # : ( 518 ) 391 - 7332 specialists will gladly assist rectly from the Factory . ( 518 ) 391 - 7332 you if you have any difficulty To order a part from WEBSITE : www.troybilt.com in identifying the exact part the Factory , refer to that you need . your separate Parts Catalog to find the part number , description , and quantity 2
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Section 1 Safety WARNING TO ALL CALIFORNIA AND OTHER POWER EQUIPMENT OPERATORS Read Me Under California law , and under the laws of several other states , First ! you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest covered , brush cov - Please read and follow all of the ered , or grass covered land , or on land covered with grain , safety rules in this Safety Section . hay , or other flammable agricultural crop , without an en - Failure to comply could result in gine spark arrester in continuous effective working order . serious personal injury or prop - The engine on your power equipment , like most outdoor power equipment , is an erty damage . internal combustion engine that burns gasoline , a hydrocarbon fuel . Therefore , your power equipment must be equipped with a spark arrester muffler in continu - If you should lend this equipment ous effective working order . The spark arrester must be attached to the engine to another person , make sure that exhaust system in such a manner that flames or heat from the system will not ig - he or she reads , understands , and nite flammable material . Failure of the owner / operator of the equipment to com - always follows these safety ply with this regulation is a misdemeanor under California law , and may also be a instructions . violation of other state and / or federal regulations , laws , ordinances , or codes . Contact your local fire marshal or forest service for specific information about If you are not completely sure what regulations apply in your area . Contact your authorized engine dealer for in - about any of the information formation about obtaining a spark arrester . found here or elsewhere in the Manual , please contact either your local authorized dealer or the IMPORTANT Factory for assistance . Safe Operation Practices for Walk - Behind Mowers This cutting machine is capable of amputating hands and feet and throwing objects . Failure to observe the following safety instructions This is a safety alert could result in serious injury or death . symbol . It is used in this Owner / Operator Manual and on your 3 . Only allow responsible indi - I . GENERAL OPERATION machine to alert you viduals , who are familiar with to potential hazards . 1 . Read , understand , and follow the instructions , to operate the all instructions on the machine Whenever you see mower . this symbol , read and in the manuals . Be thor - 4 . Clear the area of objects such and obey the safety oughly familiar with the con - as rocks , toys , wire , bones , message that fol - trols and the proper use of the sticks , etc . , which could be lows it . Failure to mower before starting . obey the safety picked up and thrown by the 2 . Do not put hands or feet near message could re - blade . or under rotating parts . Keep sult in personal in - jury or property clear of the mower blade and 25 Ft . Ft . 25 damage . discharge opening at all times . OPERATING AREA 25 Ft . Ft . 25 5 . Be sure the area is clear of other people before mowing . Stop mower if anyone enters the area . Keep bystanders at least 25 feet away from the area of operation . 3
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Safety catcher attachment must be in - 15 . Never operate mower in wet 6 . Do not operate the mower stalled properly and function grass . Always be sure of your when barefoot or wearing correctly . Do not use your footing ; keep a firm hold on open sandals . Always wear equipment otherwise . the handle and walk ; never run . substantial foot wear . 23 . Never run the engine in an en - 16 . Disengage the Wheel Drive 7 . Do not pull mower backwards closed area . Engine exhaust Lever on self - propelled mod - unless absolutely necessary . contains carbon monoxide , a els before starting the engine . Look down and behind before deadly gas that is odorless , col - and while moving backwards . 17 . If the unit should start to vi - orless , and tasteless . Always brate abnormally , stop the en - 8 . Do not operate the mower run the engine outdoors and gine and disconnect the spark without proper guards , plates , make sure there is adequate plug wire . Then check imme - grass catcher or other safety ventilation . diately for the cause . Vibration protective devices in place . is generally a warning of 9 . Refer to provided instructions trouble . for proper operation and in - II . SLOPE OPERATION 18 , Always wear safety goggles or stallation of accessories . Only Slopes are a major factor related safety glasses with side shields use accessories approved by to slip and fall accidents which when operating mower . Garden Way Incorporated . can result in severe injury . All 10 . Stop the blade when crossingds . 19 . Watch for traffic when operat - slopes require extra caution . If gravel drives , walks , or roa ing near , or when crossing you feel uneasy on a slope , do roadways . not mow it . 20 . Never attempt to carry chil - dren or other passengers on the mower . They could fall off and be seriously injured , or they could interfere with the safe operation of the mower . 11 . Stop the engine and disconnect 21 . Check the operation of the the spark plug wire from the Operator Presence Control Bar spark plug whenever you leave before each use . See the the unit , before cleaning the DO : Maintenance Section of this mower or unclogging the chute . manual for instructions . If the Mow across the face of slopes ; 12 . Shut the engine off , wait until engine runs longer than three never up and down . Exercise the blade comes to a complete seconds after the Operator extreme caution when changing stop , and disconnect the spark Presence Control Bar is re - direction on slopes . Avoid o plug wire before installing or leased , the system is not work - slopes greater than 15 . removing the mulcher cover or ing properly . Immediately con - Remove objects such as rocks , the optional grass catcher . tact your local service dealer tree limbs , etc . Make certain that the grass or the factory Technical catcher is securely attached Service Department for in - Watch for holes , ruts , or bumps . before operating the mower . structions . Do not use the Tall grass can hide obstacles . Empty the grass catcher after mower until the mechanism is each use – decomposing debris DO NOT : repaired . could generate enough heat to Do not mow near drop - offs , 22 . The mower is equipped with a catch fire . ditches , or embankments . The safety discharge chute , a mul - 13 . Mow in daylight or good arti - operator could loose footing or cher cover , and offers an op - ficial light . balance . tional grass catcher . The safety discharge chute must be 14 . Do not operate the mower Do not mow excessively steep working properly at all times . while under the influence of slopes . Never attempt to disconnect or alcohol or drugs . Do not mow on wet grass . otherwise cause this discharge Reduced footing could cause chute to cease working . If slipping . used , mulcher cover or grass 4
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Safety 3 . Never make adjustments or re - 13 . To access the underside of the III . CHILDREN pairs with the engine running . mower , tip the mower rear - Tragic accidents can occur if the Disconnect the spark plug wire ward . Do not tip the mower operator is not alert to the pres - and keep the wire away from forward or on either of its ence of children . Children are the plug to prevent accidental sides , unless specifically ad - often attracted to the mower starting . vised to do so in this manual . and to the mowing activity . 4 . Keep all nuts and bolts , espe - 14 . Maintain or replace safety and Never assume that children will cially the blade attachment instructional decals . Refer to remain where you last saw them . bolts , tight and keep equip - the separate Parts Catalog for ment in good condition . replacement decal information . 1 . Keep children out of the mow - 5 . Never tamper with safety de - 15 . For units equipped with elec - ing area and under the watch - vices . Check their operation tric start : ful care of a responsible adult . regularly . a ) Batteries produce explo - 2 . Be alert and turn mower off if 6 . Keep mower free of grass , sive gases . Keep sparks , children enter the area . leaves or other debris build - up . flame , cigarettes , etc . , 3 . Before and while moving Clean up oil or fuel spillage . away . Ventilate the area backwards , look behind and Allow mower to cool before when charging the battery . down for small children . storing . Do not charge the battery 4 . Never allow children to oper - in an airtight space . 7 . After striking an object , stop ate the mower . the engine and disconnect the b ) Do not use a battery 5 . Use extra care when approach - spark plug wire . Inspect the charger other than the one ing blind corners , shrubs , mower and repair , if necessary , provided with the mower . trees , or other objects that may before restarting . c ) The battery contains toxic obscure vision . 8 . Never attempt to make mower materials . Do not damage cutting height adjustments the battery case . If the case while the engine is running . is broken or damaged , IV . SERVICE avoid contact with the bat - 9 . Grass catcher components are tery contents . 1 . Use extra care in handling subject to wear , damage and gasoline and other fuels . They deterioration , which could ex - d ) Properly dispose of a dam - are flammable and their vapors pose moving parts or allow ob - aged or worn out battery . are explosive . jects to be thrown . Frequently Check with local authori - check components and replace ties for proper disposal a ) Use only an approved con - with factory recommended methods . tainer . parts , when necessary . e ) Do not short circuit the b ) Never remove gas cap or 10 . Mower blades are sharp and battery . Severe burns and add fuel when the engine is can cut . Wrap the blade or fire can result . running . Allow engine to wear gloves , and use extra cau - cool before refueling . Do tion when servicing them . not smoke . c ) Never refuel the machine indoors . d ) Never store the machine or fuel container inside where there is an open flame , 11 . Do not change the engine gov - such as a water heater , etc . ernor setting or overspeed the e ) Move mower away from engine . any gasoline fumes before 12 . Do not touch engine parts starting the engine . which may be hot from opera - 2 . Never run an engine inside a tion . Allow parts to cool com - closed area . pletely before inspecting , cleaning or repairing the mower . 5
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Safety SAFETY DECALS Make certain all safety decals on this equipment are kept clean and in good condition . The decals are shown ( at reduced sizes ) below . If you need a replacement decal , please refer to the Parts Catalog that accompanied this Manual . WARNING WARNING On top , rear of engine platform DANGER CAUTION KEEP HANDS and FEET AWAY PINCH POINTS . Do not operate with - out all belt guards in place . CK On left side of mower deck Beneath belt / pulley cover WARNING TO AVOID SERIOUS INJURY READ ALL SAFETY PRECAUTIONS CAREFULLY . Read Owner / Operator Manual . Do not allow children or untrained adults to operate machine . LIFT FOR REVERSE Go across slopes , not up and down . Look down and behind before and while moving backwards . Keep all safety devices in place and in working RELEASE OPERATOR order . PRESENCE CONTROL Do not mow when children and others are near . TO DISENGAGE Remove objects that could be thrown by blades . MOWER . 1768633 . C ( 2 / 98 ) On Control Panel ( for recoil start model ) 6
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Section 2 Assembly Subjects covered in this Section : • Inspection After Delivery Read Me • Unpacking Mower First ! • Attaching Handlebars and Control Rods • Preparing Electric Start Model Please carefully follow the instruc - • Filling Engine Crankcase with Oil tions in this Section to properly pre - pare your new machine for use . Remember that motor oil must be added to the engine before starting . WARNING To prevent personal injury or property damage , do not attempt to start the engine until all assembly steps are WARNING complete and you have read To prevent personal injury or prop - and understand the safety , erty damage , do not attempt to start controls , and operating the engine until all assembly steps instructions . are complete and you have read and understand the safety and operating instructions in this INSPECTION AFTER DELIVERY Manual . Inspect the shipping crate and of the specific damage and that machine immediately after you wish to file a claim . To pro - Supplies Needed : delivery . Make sure neither the tect your rights , be sure to put this • Wire Cutter carton nor the contents have been in writing to the carrier within 15 • 7 / 16 � Wrench damaged . days . The carrier will let you • 3 / 8 � Wrench know how to proceed with your If you find or suspect any damage , • Two 1 / 2 � Wrenches claim . Please let us know if you contact the carrier ( trucking com - • Scissors or Pen Knife need any assistance . pany ) immediately . Inform them • Needle - nose Pliers • Motor Oil ( see Step 5 ) • Tire Gauge ASSEMBLY STEPS unit on base of pallet during as - IMPORTANT : Motor oil must sembly steps ( to safely remove be added to the engine before it unit from base , wait until you have is started . The procedure for NOTE : All references to left , right , completed assembly steps 1 - 4 ) . adding oil is explained in Step 5 . front and rear of the machine are de - termined by standing behind the 2 . Remove and open hardware handlebars and facing the STEP 1 : Unpacking Mower bag . Check contents of bag against direction of forward travel . illustrated parts list on next page . 1 . Cut plastic banding with scis - Unless otherwise noted , all items sors . Open box flaps and remove are shown at actual size . liners . Remove any staples secur - 3 . Cut plastic tie straps holding ing bottom of carton to wood pal - four control rods to handlebars . let . Lift off carton . Cut metal Remove any cartoning from straps securing unit to base . Leave between handlebars and unit . 7
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Assembly Figure 2 - 1 – Contents of Hardware Bag Hex Flange Lock Screw , Flat Washer , Cotter Pin , 5 / 16 � - 18 x 3 / 4 � 5 / 16 � 3 / 32 � x 5 / 8 � Qty : 2 Qty : 4 Qty : 6 Hex Flange Lock Screw , Hex Flange Lock Nut , Oil Drain Tube ( shown reduced size ) 1 / 4 � - 20 x 1 / 2 � 1 / 4 - 20 � Qty . 1 Qty : 2 Qty : 2 ( used for changing oil - see Maintenance Section of this Manual for instructions ) Shift Link - Gear Select Lever ( shown reduced size ) Shift Rod Mounting Plate Qty : 1 ( shown reduced size ) Qty : 1 Plastic Cable Tie ( shown reduced size ) Qty : 1 ( Recoil Start Model ) Qty : 3 ( Electric Start Model ) ( Parts shown below are for electric start model only ) Ignition Keys ( not illustrated ) Qty : 2 ( store in safe place ) Battery Charger ( shown reduced size ) Qty : 1 8
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Assembly handlebar . Place the two rods engine deck . Use two wrenches to STEP 2 : Attach Handlebars safely aside . tighten securely . NOTE : It may be necessary to 3 . Rotate handlebars to align holes 6 . Secure throttle cable to left loosen screws ( Y , Figure 2 - 2 ) to at front of handlebars with holes in handlebar with cable tie from allow handlebars to clear engine frame . Be careful that the handle - hardware bag . Clip off excess tie . air cleaner . The screws are backed bars clear the unit while unfolding . with lock nuts inside the engine Also , put end of control rod ( E , A deck . Two wrenches may be re - Figures 2 - 6 and 2 - 7 ) into cut - out quired when loosening . ( W , Figures 2 - 2 & 2 - 6 ) in back of 1 . Handlebars ( A , Figure 2 - 2 ) are frame while rotating handlebars shipped partially assembled with into position . two screws ( Y ) loosely installed . 4 . Install two 5 / 16 - 18 x 3 / 4 " long 2 . If applicable , cut and remove screws ( B , Figure 2 - 2 ) . plastic tie ( s ) holding wheel drive W 5 . Secure all four screws ( B and B lever control rod ( F , Figure 2 - 7 ) to Y Y ) . Note that screws ( Y ) are left handlebar and blade drive con - backed with lock nuts inside Figure 2 - 2 : Attach handlebars . trol rod ( C , Figure 2 - 7 ) to right STEP 3 : Electric Start Model WARNING Black ( Ground Lead ) Black ( Ground Lead ) ( - ) V Charge battery only with A . Secure Wire Harness charger supplied with ma - 1 . Plug wire harness into bottom chine . Do not short circuit of ignition switch on console ( not battery wires . Remove any pictured ) . ositive Lead ) Red jewelry before working on or ( Positive near the battery or electric 2 . Use cable ties provided in hard - Lead ) start system . Failure to fol - ware bag to secure electrical wire low these instructions could harness ( leading from keyswitch ) ( + ) U result in personal injury or to right handlebar , away from any property damage . moving parts . Place cable ties an Figure 2 - 3 : Connect wire terminals equal distance apart on handlebar . to battery terminals . C . Battery Charging B . Attach Wire Leads to Battery A new battery should be charged W 1 . Battery is located at rear , right - for 24 - 48 hours to ensure a full side of engine deck . charge . If the mower must be used 2 . Locate wiring harness that immediately , the battery may have leads from ignition switch on un - enough charge to start the engine . derside of handlebar console . At If not , the engine can be started the lower end of the wiring har - with the rope pull starter . ness locate a red wire lead and a Charge the battery after initial use black wire lead . of the mower to help ensure it is • Plug terminal on red ( positive ) fully charged . wire into red terminal ( U , Figure Figure 2 - 4 : Wire harness secured 2 - 3 ) on battery . by J - clips . • Plug terminal on black ( negative ) wire into black terminal ( V , Figure CAUTION 2 - 3 ) on battery . If battery is removed , do not operate engine without insu - 3 . If applicable , secure wire har - lating positive ( + ) battery ness in place against deck with cable terminal with electrical pre - installed J - clips ( W , Figure 2 - tape or sparking from battery 4 ) . Insert wire harness into J - clips cells can result . as shown in Figure 2 - 4 , and bend J - clips over to retain wire harness . 9
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Assembly 1 . To charge the battery , locate the connector ( T , Figure 2 - 5 ) that hangs from the wire harness below the handlebar console . 2 . Plug the connector on the bat - tery charger ( Z , Figure 2 - 5 ) into the connector on the wire harness ( T ) . 3 . Plug battery charger into 120V grounded wall outlet . NOTE : Battery charger is designed for use T indoors and should not be exposed to rain or snow . Z 4 . Charge battery for 24 - 48 hours . 5 . After charging , unplug battery To grounded charger from wall outlet , then un - wall outlet plug charger from connector on Figure 2 - 5 : Connect battery charger terminal to wire harness wire harness . terminal . STEP 4 : Attach Control Rods E WARNING Control rods are adjusted at F the factory and should not re - W quire additional adjustment U during assembly . After as - sembling unit , control rod ad - justment should be checked ( and re - adjusted , if neces - sary ) according to informa - tion in Maintenance Section . Severe personal injury or property damage could result G from not following this instruction . H T B A Figure 2 - 6 : Left - hand control rods detail . A . Attach Wheel Drive Control Rod 3 . Add one 5 / 16 � washer ( A , 1 . Locate the wheel drive control Figure 2 - 6 ) . Secure with cotter rod ( F , Figures 2 - 6 & 2 - 7 ) that you pin ( B , Figure 2 - 6 ) . Bend ends of removed from the left handlebar in cotter pin to secure . Step 2 . This rod has a swivel block BB ( H , Figure 2 - 6 ) on one end . 4 . At upper end of control rod , secure angled end to Wheel Drive 2 . At left side of engine frame , Control lever ( V , Figure 2 - 6A ) , insert swivel block ( H , Figures 2 - 6 V using a cotter pin ( BB ) . Bend & 2 - 7 ) on wheel drive control rod ends of cotter pin to secure . into wheel drive control arm ( U , Figure 2 - 6A : Attach wheel drive Figure 2 - 6 ) . control rod to lever . 10
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Assembly B . Attach Operator Presence Control Rod : L W J 1 . Locate control rod ( E , Figures . 2 - 6 & 2 - 7 ) attached at upper end to Operator Presence Control ( W , V Figure 2 - 7 ) . AA 2 . At bottom of control rod , insert swivel block ( G , Figures 2 - 6 & 2 - 7 ) into control arm ( T , Figure 2 - 6 ) . I 3 . Add one 5 / 16 � washer and se - cure with cotter pin . Bend ends of cotter pin to secure . E C C . Attach Blade Drive Control Rod : F 1 . Locate the blade drive control rod ( C , Figure 2 - 7 ) that you re - moved in Step 2 . Insert one end of control rod into blade drive bracket ( D , Figure 2 - 7 ) . Add one CC 5 / 16 � washer and secure with cot - ter pin ( CC ) . Bend ends of cotter pin to secure . H D 2 . Insert upper end of rod into bot - tom end of Blade Drive Control lever ( J ) . Add one 5 / 16 � washer N G M P and secure with cotter pin ( AA ) . O Bend ends of cotter pin to secure . Figure 2 - 7 : Rear view of control rods . D . Attach and Adjust Gear Select Lever : B NOTE : To remove unit from ship - I ping crate , hold down Operator Presence Control lever ( W , Figure L 2 - 7 ) which releases the wheel brake . Z 1 . Using the edge of a piece of flat wood ( such as a ruler ) , remove the vinyl grip ( B , Figure 2 - 8 ) from J the gear select lever ( I ) . Place the wood edge against the edge of the P grip and slowly pull off the grip . K 2 . Insert nylon bushing ( Z , Figure Pin ( K ) must be in this detent 2 - 8 ) up into console ( L ) . when transmission neutral is 3 . Slide spring and washers ( J ) adjusted . down onto gear select lever . 4 . Insert gear select lever ( I ) up through nylon bushing ( Z ) in han - dlebar console ( L , Figure 2 - 8 ) . Figure 2 - 8 : Detail – Gear Select Lever in Neutral ( N ) position . Guide pin ( K ) on gear select lever into groove in shift quadrant ( P ) . 11
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Assembly 5 . Hold lower part of gear select lever ( I ) against bracket ( M , I Figure 2 - 9 ) . Position retaining O plate ( N ) from parts bag in place as shown in Figure 2 - 9 ( plate below bracket ) . Secure plate with two 1 / 4 � - 20 x 1 / 2 � long screws ( O ) and 1 / 4 � - 20 locknuts . 6 . Slide grip ( B , Figure 2 - 8 ) back N M onto upper end of gear select lever ( I ) . Y Q 7 . Rotate gear select lever ( I , Figures 2 - 8 & 2 - 9 ) clockwise until spur ( K - short rod ) on gear select rod stops in the neutral position detent on the shift pattern quadrant X ( Figure 2 - 8 ) . P 8 . At bottom of control rod , Figure 2 - 9 : Detail – Transmission Neutral Adjustment . thread shift link ( P , Figure 2 - 9 ) partially into ball - joint ( Y ) . 11 . Insert hooked end of shift link 9 . Move shift arm ( X , Figure 2 - 9 ) WARNING ( P , Figure 2 - 9 ) into hole in bottom from side to side as necessary into Do not use the mower if the end of gear select lever ( I ) and se - each transmission gear detent until wheels continue to turn after cure with cotter pin ( Q ) . Bend transmission is in neutral . releasing the Operator ends of cotter pin . NOTE : It may NOTE : Moving shift arm ( X ) all Presence Control and the be necessary to lift gear select the way to the left , and then one Wheel Drive Control . Severe lever ( I ) to install shift link ( P ) . notch back to the right , should put personal injury or property transmission into neutral . When 12 . Remove unit from shipping damage could result if this transmission is in neutral , unit will crate . To remove , hold down instruction is not followed . move freely when pushed while Operator Presence Control lever holding the Operator Presence ( W , Figure 2 - 7 ) which releases the Control lever ( W , Figure 2 - 7 ) wheel brake . down . If transmission is NOT in neutral , there will be a slight drag 13 . Hold down Operator Presence on the wheels when pushing unit . Control lever ( W , Figure 2 - 7 ) and WARNING push unit forward and backward . 10 . When shift arm ( X ) is in neu - The wheels should move freely . If Control rods are adjusted at tral position , rotate shift link ( P ) not , adjust length of shift link ( P , the factory and should not re - toward end of gear select lever rod Figure 2 - 9 ) as necessary . quire additional adjustment ( I ) . Adjust length of shift link ( P ) during assembly . After as - as necessary to fit into hole in bot - 14 . Put the Gear Select Lever in sembling unit , control rod ad - tom of gear select lever ( I ) . in neutral ( N ) , release all of the justment should be checked control levers , and try to push the NOTE : Pin ( K ) on Gear Select ( and re - adjusted , if neces - unit forward and backward . The Lever ( I ) must be held in the neu - sary ) according to informa - wheels should not turn . If they do tral position detent on the shift tion in Maintenance Section . turn , an adjustment is necessary . quadrant ( see Figure 2 - 8 ) while Severe personal injury or DO NOT OPERATE THE UNIT shift link ( P , Figure 2 - 9 ) is property damage could result UNTIL THE WHEEL BRAKE adjusted . from not following this MECHANISM HAS BEEN instruction . ADJUSTED AND IS WORKING PROPERLY . See “ Wheel Brake Adjustment � in Section 5 “ Maintenance . � 12
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Assembly STEP 7 : After Assembling and STEP 5 : Fill Engine Crankcase STEP 6 : Check Tire Pressure Before Using Unit with Oil 1 . Use a tire gauge to check the air pressure in the rear tires . The 1 . Read this entire air pressure should be between 15 - Owner / Operator Manual for CAUTION 20 PSI ( 20 PSI maximum ) . proper safety , operation and main - Unit is shipped without oil in tenance information . 2 . Keep both tires equally inflated engine crankcase . DO NOT to help prevent machine from 2 . Make sure spark plug wire is start engine until oil has pulling to one side . connected to spark plug before been added . Severe engine starting unit . damage will result if this in - struction is not followed . NOTE : Refer to the separate Engine Owner’s Manual for engine oil specifications and capacities . To add oil : 1 . Move mower to a level area . Press and hold down Operator Presence Control lever ( W , Figure 2 - 7 ) to move mower . 2 . Refer to separate Engine Owner’s Manual for type and amount of oil required ( always use dipstick to determine whether the crankcase is properly filled ) . 3 . Remove dipstick ( Z , Figure 2 - 10 ) from engine . 4 . Using a funnel , pour oil slowly through dipstick opening . Stop frequently , re - insert dipstick until it is seated completely , remove and check oil level . ( Wipe dip - stick clean each time before re - inserting . ) 5 . Fill crankcase until oil level is at “ FULL � mark on dipstick . DO NOT FILL ABOVE “ FULL � MARK ! 6 . Replace dipstick securely . Z Figure 2 - 10 : Engine oil fill . 13
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Section 3 Features and Controls IMPORTANT : The mower is WARNING equipped with a blade - brake - clutch The blade - brake - clutch con - control system which is designed Read Me trol system should stop the to stop the mower blades within First ! mower blades within three three ( 3 ) seconds after release of ( 3 ) seconds after release of the Operator Presence Control . Learn the location of the features the Operator Presence This system will stop the blades and controls on your machine before Control . If the blades do not but not the engine . Therefore , you starting the engine . For detailed stop within three ( 3 ) seconds , can disengage the blade drive at step - by - step operating instructions , put the Engine Throttle please refer to “ Section 4 : anytime without having to stop and Control in the STOP position . Operation . � Disconnect the spark plug restart the engine . This feature is wire and do not operate the particularly useful when you need mower until the blade - brake - to cross gravel drives or rough ter - clutch control system has rain and you do not want the spin - been repaired . ning blades to strike stones or hid - WARNING den obstacles . Before operating mower , be sure to read all safety , con - LOCATION AND USE OF trols , and operating instruc - Control , which will apply a brake CONTROLS tions in this Manual and on de - that stops the blades within three cals located on machine . ( 3 ) seconds . Always disengage the Operator Presence Control before starting Operating Symbols the engine . Always engage this Various symbols are used on control before engaging the sepa - the mower to indicate control rate blade drive or wheel drive Operator Presence Control settings ( your model may not controls . have all of the symbols ) . These This lever ( A , Figure 3 - 1 ) regu - symbols are shown below with lates the operation of the rear a description of their meaning . wheel brake and the separate A – OPERATOR Blade Drive Control . PRESENCE CONTROL To engage the Operator Presence Control , press and hold the lever FAST SLOW CHOKE against the handlebar grip . Engaging the lever releases the Disengaged brake on the rear wheels ( allows wheels to turn ) . The engaged posi - tion also permits the separate Engaged Blade Drive Control to lock in its ENGINE ENGINE ENGINE RUN START STOP engaged position ( allows the mower blades to turn ) . Releasing the lever ( disengaged position ) applies the rear wheel brake and quickly stops the wheels . Releasing the lever will ENGAGE DISENGAGE also disengage the Blade Drive Figure 3 - 1 14
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Features and Controls NOTE : Pushing the Blade Drive maintain constant pressure on the Blade Drive Control Control forward will engage the lever ( releasing lever disengages Use this lever ( B , Figure 3 - 2 ) to blades even though the Operator blades ) . Always engage the engage drive to the mower blades . Presence Control is not engaged . Operator Presence Control before To engage the blades , first engage However , this procedure is NOT engaging the Blade Drive Control . the Operator Presence Control ( A , RECOMMENDED as you must Figure 3 - 2 ) . Then , push the spring - loaded Blade Drive Control lever ( B ) forward until it stays in the en - A – OPERATOR B – BLADE gaged position . PRESENCE CONTROL DRIVE CONTROL To stop the blades , release the Operator Presence Control ( A ) . Doing so will disengage the Blade Disengage Drive Control ( B ) and automati - cally apply the brake that stops the blades . Disengage When starting the engine , the Engage Blade Drive Control should be dis - Engage engaged ( released ) . This helps to ensure that the blades will not start turning when the engine starts . Figure 3 - 2 Gear Select Lever This lever ( C , Figure 3 - 3 ) is used to select any of three forward C – ground speeds ( 1 - Slow , 2 - Medium , Gear Select 3 - Fast ) , N ( Neutral ) and R Lever ( Reverse ) . The gear shift pattern is LIFT FOR shown in Figure 3 - 4 . To avoid damaging the trans - REVERSE mission , do not shift gears when the mower is moving . Select for - ward ground speeds according to mowing conditions and terrain ( use slower speeds in high grass or on rough terrain ) . For forward travel , move the Figure 3 - 4 : Shift pattern on console . Figure 3 - 3 lever into one of the three num - bered settings . To select reverse , shift to neutral and then pull up on the lever . Turn the lever to the R ( reverse ) position and release the lever . Put the lever in N ( neutral ) to manually push the mower and when the mower is not in use . 15
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Features and Controls Wheel Drive Control wheels will gradually slow to a A – OPERATOR stop . NOTE : To stop the wheels PRESENCE CONTROL Use this lever ( D , Figure 3 - 5 ) to quickly , release the Operator engage and disengage drive to the Presence Control along with the wheels . Wheel Drive Control . To engage the wheels , first select Disengage When starting the engine , the a forward or reverse gear with the Wheel Drive Control should be dis - Gear Select Lever and press the engaged ( released ) . This helps to Operator Presence Control ( A , ensure that the wheels will not start Figure 3 - 5 ) against the handlebar turning when the engine starts . Engage grip . Then , squeeze the Wheel Drive Control lever ( D ) up against the handlebar grip . The ground CAUTION Engage speed can be varied in any gear by Do not engage the Wheel increasing ( to go faster ) or decreas - Drive Control without first en - Disengage ing ( to go slower ) pressure on the gaging the Operator Presence lever . To avoid sudden accelera - Control . Doing so could re - D – WHEEL tion , slowly squeeze the lever sult in wear or damage to the DRIVE CONTROL when first engaging the wheels . wheel brake mechanism . Release the Wheel Drive Control Figure 3 - 5 to disengage the wheels . The on the right side of the mower deck Cutting Height Control Lever show the cutting height settings This lever ( E , Figure 3 - 6 ) is used ranging from A ( highest ) to G to adjust the mower cutting height . ( lowest ) . Note that the actual cut - The cutting height can be adjusted ting heights will vary according to from 1 to 4 inches . soil conditions . Turn the lever clockwise to raise the cutting height or counterclock - wise to lower the cutting height . A decal and pointer ( not illustrated ) E – CUTTING HEIGHT CONTROL LEVER Figure 3 - 6 Mulcher Cover To use the mulching feature , in - NOTE : The mulcher cover is sert the mulcher cover ( Figure 3 - 7 ) designed to keep the discharge securely in the right side of the chute raised up while you mow . deck beneath the discharge chute . When the cover is removed , the AA Insert the front tab of the cover discharge chute lowers . into the mower front support bracket ( AA , Figure 3 - 7 ) and then DANGER close the cover , making sure that Before installing or re - the slot ( BB ) in the cover is com - moving mulching cover , pletely engaged in the rear edge of stop engine , wait for parts BB the deck opening . to stop moving , and dis - Remove the mulcher cover if you connect spark plug wire . want to do side - discharge mowing . Remove ignition key on Figure 3 - 7 The mulcher cover is pre - installed electric start models . at the factory . 16
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Features and Controls Engine Throttle Control This lever ( F , Figure 3 - 8 ) is used CHOKE - Use when F – THROTTLE CONTROL to adjust engine speeds and to stop starting a cold engine . the engine . Always run engine at fast speed setting for best mower FAST - Use during mower performance . The throttle settings operation . are shown to the right . SLOW - Use when idling engine . STOP - Stops engine . Figure 3 - 8 Ignition / Starter Switch - ( Electric Start Model ) This three - position switch ( G , G – IGNITION STARTER Figure 3 - 9 ) is used to start and stop STOP - Stops engine . SWITCH the engine on electric start models . The ignition key settings are RUN - After starting , key shown to the right . returns to run position . Do not turn the key until you have read the Operation Section in this Manual . START - Starts engine . Always remove ignition key Release key when engine when leaving mower unattended or starts . when inspecting , cleaning or ser - vicing mower . Figure 3 - 9 Engine Recoil Starter The engine recoil starter ( H , Figure 3 - 10 ) is used to “ pull - start � the engine . Detailed instructions for using the engine recoil starter are found in the Operation Section of this Manual and in the Engine Owner's Manual . Do not pull the recoil starter until you have read the H – RECOIL Operation Section . STARTER Figure 3 - 10 17
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Section Operation 4 BEFORE OPERATING Read Me First ! Pre - Operation Checklist As with any other piece of outdoor powered equipment , getting the “ feel � for how your machine oper - Perform the following checks before each use of your ates and getting to know the best machine : techniques for particular jobs are very important to overall good � Review Section 1 : “ Safety � and Section 3 : “ Features and performance . Controls . � Read this Section thoroughly be - � Check for loose or missing hardware . Tighten or replace fore you start the engine . The in - before starting engine . structions given here will help you become familiar with your ma - � Check the engine oil level . Refer to Section 5 : chine and have you operating it ef - “ Maintenance � for instructions . ficiently in a short time . � Check the fuel level in the fuel tank ( refer to next page for instructions ) . � Check all levers for freedom of movement . Do not start engine if any lever does not function correctly . WARNING � Adjust the blade cutting height ( refer to this Section for instructions ) . Before operating your machine , be sure you read and understand � Inspect the area to be mowed and remove any debris . all safety , controls , and operating instructions in this � Check that all guards and shields are in place and prop - Owner / Operator Manual and on erly secured . the decals on your machine . � Check the installation of the mulcher cover in the right Failure to follow these instruc - side deck opening . Remove the mulcher cover if you tions can result in serious injury want to side discharge the grass . or property damage . � On electric start models , check that all wiring connec - NOTE : All references to left , right , tions are clean and tight . front and rear of the machine are de - termined by standing behind the � Check air pressure in rear tires at first use and every 25 handlebars and facing the operating hours . Maintain 15 - 20 PSI ( maximum 20 PSI ) direction of forward travel . in each tire . Keep tires inflated equally or mower may pull to one side . � Attach the spark plug wire to the spark plug . 18
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Operation Fill Fuel Tank IMPORTANT : Do not mix oil with gasoline . Do not use Methanol . Refer to the separate Engine Owner's Manual for instructions and precau - Use clean , fresh , unleaded regu - lar gasoline . Leaded gasoline may tions regarding the use of gasoline containing alcohol ( such as Gasohol ) . be used if lead - free is not avail - able . ( Use of lead - free gasoline re - DANGER sults in fewer combustion deposits Gasoline is highly flammable and its vapors are explosive . Read and and longer valve life . ) Purchase follow these precautions to help avoid severe personal injury or prop - fuel in a quantity that will be used erty damage . within 30 days . This will assure fuel freshness and volatility tai - • Do not remove gas cap or add gasoline if engine is running or still hot lored to the season . from operation . Allow engine to cool at least three minutes before refu - eling . 1 . Stop engine and allow it to cool • Keep open flame , matches , sparks , or smoking materials away from for three minutes before removing fuel tank and fuel container . fuel fill cap . Do not check fuel • Do not fill fuel tank indoors . After filling , wipe up any spills and move level or add fuel while indoors . machine away from gasoline fumes before starting engine . Securely re - 2 . Clean area around fuel fill cap place the caps on the fuel tank and fuel container . and remove fill cap . • Do not fill fuel tank completely . Fill tank to 1 / 2 � below bottom of filler 3 . Using a funnel or spout , fill neck to provide space for fuel expansion . tank to 1 / 2 inches below bottom of • Store gasoline in an approved fuel container and in a well - ventilated fuel tank filler neck to prevent area . Store it safely out of the reach of children . spills and to allow for fuel expan - • Do not store gasoline where vapors may reach an open spark or flame , sion . or where ignition sources ( such as hot water heaters , space heaters , 4 . Install fill cap securely and furnaces , clothes dryers , stoves , electric motors , etc . ) are present . wipe up any spilled gasoline . 1 . Release all mower controls be - Adjust Mower Cutting Height CAUTION fore adjusting cutting height . The cutting height can be ad - To avoid personal injury , do 2 . Turn Cutting Height Control justed from 1 to 4 inches by rotat - not adjust cutting height lever clockwise to raise cutting ing the Cutting Height Control while wheels or blades are height or counterclockwise to lever ( A , Figure 4 - 1 ) . turning . Release all handle - lower cutting height . A decal and bar controls and wait for all Choose cutting heights accord - motion to stop before adjust - pointer ( not illustrated ) on the right ing to grass conditions and terrain . ing cutting height . side of the mower deck show cut - In heavy or tall grass , it is usually ting height settings ranging from A better to make the first cut at a ( highest ) to G ( lowest ) . Note that higher setting and then make a sec - actual cutting heights will vary ond cut at the desired setting . according to the grass and soil When mowing in rough terrain , a conditions . higher setting is recommended as it will minimize the chances of the blade striking the ground or hidden obstructions . A Figure 4 - 1 : Cutting Height Control lever . 19
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Operation Test Blade - Brake - Clutch MOVING THE MOWER WITHOUT ENGINE POWER Control System The mower can be manually Control ( A , Figure 4 - 3 ) down The mower is equipped with a pushed or pulled by putting the against the handlebar grip . blade - brake - clutch which is de - Gear Select Lever ( C , Figure 4 - 3 ) To stop the wheels at anytime , re - signed to stop the mower blades in N ( neutral ) and pressing and lease the Operator Presence within three ( 3 ) seconds after re - holding the Operator Presence Control . lease of the Operator Presence Control or the Blade Drive Control . Never tamper with , or at - tempt to defeat the purpose of this safety device . The control system is a mechani - cal device which is subject to wear . STARTING AND STOPPING THE ENGINE Therefore , test the operation of the blade - brake - clutch control system DANGER before each use of the mower . Do not operate engine in an enclosed area . Engine exhaust contains Refer to " Blade Brake Control carbon monoxide , a deadly gas that is odorless , colorless and taste - Test " at the end of this Section . less . Always run engine outdoors and make sure there is adequate ventilation . Select Mulching or Side - Discharge Mowing To Start the Engine WARNING 1 . Move mower to a level area . To avoid injury : • Keep hands and feet clear 2 . Release all controls on mower of mower blades or other ro - to prevent wheels or mower blades tating parts . from rotating when engine starts . • Look behind you to be sure 3 . Move Engine Throttle Control there are no obstacles before ( E , Figure 4 - 3 ) fully upward to pulling recoil starter rope . choke setting to start a cold engine or to fast ( rabbit ) setting to start a warm engine . F – Ignition / Starter C – Gear Select Lever Figure 4 - 2 : Mulcher cover ( Electric Start E – Engine Throttle Your combination mower allows Model ) Control you to select either mulching or side - discharge of the grass clip - A – Operator pings . To use the mulching fea - Presence Control ture , insert the mulcher cover to mulch the grass ; or remove the cover if side discharge mowing is desired . Refer to “ Mulching Cover � on page 16 for installation instructions . B – Blade Drive Control DANGER Before installing or removing mulching cover , stop engine , wait for parts to stop moving , and disconnect spark plug D – wire . Remove ignition key on Wheel Drive Control electric start models . Figure 4 - 3 : Mower Controls 20
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Operation 4 . To start engine using recoil D . Operate engine at fast throttle starter : setting ( move throttle from choke setting to fast setting ) . A . Stand on left side ( as viewed from behind handlebars ) of ma - NOTE : If the electric start system chine . Be sure your feet are is not functioning , the engine can safely away from the underside be started with the recoil starter . of the mower deck and all To do so , first put the ignition key G mower controls are released . in the run ( middle ) position . Then Place one foot on top of tire . follow Steps 1 - 4 above . Leave the B . Grasp rope handle ( G , Figure 4 - key in the run position during en - 4 ) and pull slowly until rope gine operation . pulls slightly harder . Let rope Figure 4 - 4 : Engine recoil starter . rewind slowly . Then pull rope To Stop the Engine with a rapid , full arm stroke . Let B . Turn ignition key ( F , Figure 4 - rope return slowly . If engine 1 . Release all mower controls to 3 ) fully clockwise to crank en - fails to start after three pulls , re - stop wheels or mower blade . gine . To avoid damage to peat instructions starting with starter motor , do not crank en - 2 . Move throttle control down to Step 2 ( try setting throttle at fast gine for longer than five sec - slow ( turtle ) position . ( Whenever setting ) . onds at a time . Also , allow 15 possible , gradually reduce engine C . When engine starts , operate in seconds between each start at - speed before stopping engine . ) fast throttle setting ( move throt - tempt . If engine fails to start tle from choke setting to fast 3 . Move Throttle Control all the after three attempts , repeat in - setting ) . structions starting with Step 2 way down to stop position or turn ( try setting throttle at fast ignition key ( electric start models ) 5 . To start engine using electric setting ) . starter ( if so equipped ) : fully counterclockwise to stop position . C . When engine starts , release key A . Stand behind the handlebars and it will return to the run and release all mower controls . 4 . On electric start models , re - ( middle ) position . move ignition key before leaving mower unattended . ENGAGING THE BLADES 3 . Slowly push Blade Drive To Engage the Blades DANGER Control ( B , Figure 4 - 3 ) fully for - 1 . Start engine as described in “ To To avoid injury from rotating ward until it stays in the engaged Start the Engine � instructions . Put blades , keep face , hands and position . The blades are now engine throttle in fast speed feet clear of mower blades at rotating . setting . all times . 2 . Press and hold Operator To Stop the Blades Presence Control ( A , Figure 4 - 3 ) against handlebar grip . To stop the blades , release the Operator Presence Control . 21
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Operation TO ENGAGE THE WHEELS C . To start the wheels , slowly E . TO STOP THE WHEELS : CAUTION squeeze the Wheel Drive • To stop drive power to the • To avoid damaging the Control ( D , Figure 4 - 3 ) . The wheels , release the Wheel transmission , do not shift harder you squeeze , the faster Drive Control . The wheels gears while in motion . the wheels will turn . To avoid will gradually slow to a stop . sudden acceleration , slowly • To avoid damaging the • To quickly stop the wheels , re - squeeze the lever . wheel brake mechanism , do lease both the Wheel Drive not engage the Wheel Drive D . TO STOP THE WHEELS : Control and the Operator Control without first engaging • To stop drive power to the Presence Control . the Operator Presence wheels , release the Wheel • Return the Gear Select Lever Control . Drive Control . The wheels to the N ( neutral ) position will gradually slow to a stop . when you have completed re - 1 . Start engine as described in • To quickly stop the wheels , re - verse operation . Allow the “ To Start the Engine � instructions . lease both the Wheel Drive wheels to stop completely be - Control and the Operator fore shifting from R ( reverse ) 2 . FOR FORWARD TRAVEL : Presence Control . into a forward speed . A . Press and hold Operator Presence Control ( A , Figure 4 - 3 ) against handlebar grip . WARNING B . Put the Gear Select Lever ( C , To avoid injury or property Figure 4 - 3 ) into one of the damage : numbered settings ( 1 – Slow , • Look behind mower before 2 – Medium , 3 – Fast ) . When first and during reverse operation . practicing with the mower , put • Stop the mower blades be - lever in No . 1 setting . Select fore operating in reverse . forward speeds according to mowing conditions and terrain . Use slower speeds on rough ter - MAKING TURNS rain or when grass is heavy or 3 . FOR REVERSE TRAVEL : thick . The forward speed can A . Stop the mower blades and be increased on smooth terrain wheels by releasing the or if the grass cover is light . Operator Presence Control ( A , Allow the wheels to stop com - Figure 4 - 3 ) . The mower turns easily by push - pletely before shifting from one ing the handlebars in the opposite B . Press and hold Operator forward speed into another . direction that you want to turn . The Presence Control against han - differential mechanism inside the dlebar grip . transaxle will allow the inside turn - C . Put the Gear Select Lever ( C , WARNING ing wheel to stop or slow down Figure 4 - 3 ) in R ( reverse ) set - while the outside turning wheel is Before engaging the Wheel ting by first moving lever to N powered by the drive system . Drive Lever for the very first ( neutral ) . Then pull lever up , Reduce the wheel speed before time , check that the neutral turn it to R position , and release turning the mower . For tight turns , ( N ) position on the Gear lever . disengage the Wheel Drive Control Select Lever is properly ad - D . To start the wheels , slowly and manually push the mower justed . See “ Neutral squeeze Wheel Drive Control through the turn ( if needed , put the Adjustment � in Section 5 : ( D , Figure 4 - 3 ) . To avoid sud - Gear Select Lever in neutral so the Maintenance for the proce - den acceleration , slowly wheels turn freely ) . dure to follow . squeeze the lever . Failure to follow this instruc - tion could result in personal injury or property damage . 22
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Operation Mulching Leaves MOWING TIPS AND HINTS • The mower can also be used to mow leaves in the fall . The leaf WARNING particles filter down into the lawn To avoid injury or property damage : and provide added fertilizer . • Before mowing , thoroughly inspect area where mower is to be used • The leaves must be dry in order and remove all stones , sticks , wires , bones , nails and other foreign ob - to be mulched . jects . • Disengage mower blades before crossing gravel drives , roads , or • Use a slower ground speed if the sidewalks to prevent blades from throwing stones or other hazardous leaves are not mulched into fine objects . particles . • If you mulch oak leaves ( which add acid to the soil ) , add lime to the lawn in the spring to reduce the acidity of the soil . Mow When Mowing on Slopes Lawn Is Dry Keep Mower Blades Sharp For best mower performance , For best results , avoid cutting keep the blades sharp . A dull grass when it is wet . Wet grass blade will tear , bruise and split the tends to form clumps which inter - ends of grass . See blade sharpen - fere with the cutting action . The ing instructions in Section 5 : best time to mow is in the late af - Maintenance . Do not mow excessively steep ternoon or early evening when the slopes ( see WARNING statement grass is usually dry . Clean Mower Frequently below ) . Slow down and exercise 13 extreme caution when changing di - Cut Top 1 / 3 of Clean the underside of the mower rection on slopes . Before mowing deck frequently to remove grass Grass Blades on slopes , check the engine oil build - up . See mower cleaning in - level and make sure that the level structions in Section 5 : is at the FULL mark . Maintaining Maintenance . a FULL oil level is particularly im - Cutting more than 1 / 3 of grass portant when operating on slopes Precision Trimming length may cause the grass to be - as oil can be drained away from come excessively dry . In tall grass , vital engine parts . For precision trimming , use the it may be necessary to mow at a slowest gear and inch the mower higher setting and then mow again along by “ feathering � the Wheel WARNING at the desired height . NOTE : The Drive Control lever . Or , disengage To avoid injury or property cutting height is critical to achiev - the wheel drive by releasing the damage : ing a well - groomed lawn . You Wheel Drive Control so that you should experiment with various • Maximum safe operating can manually maneuver the mower settings to find that “ just right � o angle is 15 . ( if needed , put the Gear Select cutting height . • Exceeding maximum safe Lever in neutral so that the wheels operating angle may cause turn freely ) . tipping or loss of footing . Vary Cutting Pattern • Do not mow wet slopes . Mowing Ditches • Mow across slopes , not up If you have to mow ditches , stop and down . the engine and adjust the cutting • Exercise extreme caution height to its highest setting . Mow when changing direction on in the direction of the ditch . Mow slopes . Vary the cutting pattern from both sides of the ditch first , and week to week to help prevent mat - then mow the bottom . When ting of the grass . One week , mow mowing ditches , watch out for from north to south , the next week cans , bottles , or other debris . mow from east to west . Overlap several inches when mowing to ob - tain an even appearance . 23
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Operation BLADE BRAKE CONTROL TEST 1 . Park mower on a portion of 7 . If the mower cuts the grass in When the Operator Presence lawn which has not been recently Step 6 - B , the Operator Presence Control is released during opera - mowed . Control is NOT disengaging the tion of the mower , the engine does blade drive . Immediately stop the not stop , but the blades should stop 2 . Set the cutting height so the engine , disconnect the spark plug within three ( 3 ) seconds . The fol - mower cuts 1 / 3 of the grass height . wire , and move the wire away lowing test provides a visual test of 3 . Start the engine . from the spark plug . whether the Blade Brake Control System is functioning . Perform 4 . Press the Operator Presence 8 . Do not use the mower until the this test before each use of the Control down against the handle - Blade Brake Control System has mower . bar grip and push the Blade Drive been inspected , adjusted or re - Control fully forward until it stays paired by an authorized dealer . in the engaged position . WARNING 5 . Put the Gear Select Lever in the To avoid personal injury or No . 1 setting . property damage , make sure 6 . Engage the wheels with the that the mower is on grass , Wheel Drive Control and drive the and that the test area is clear mower for several feet . Then re - of foreign objects and by - lease the Operator Presence standers before you begin the Control . Blade Brake Control Test . A . Look at the lawn just mowed . If the Operator Presence The lawn should be cut up to Control or the Blade Drive the point where the Operator Control are not adjusted cor - Presence Control was released . rectly , the blades may con - tinue to rotate after release B . Press the Operator Presence of the Operator Presence Control against the handlebar Control . If the blades do not grip but DO NOT re - engage the stop within three ( 3 ) seconds Blade Drive Control . Drive the of release of the Operator mower forward for several more Presence Control , move the feet . Release the Operator Engine Throttle Control to the Presence Control and look at STOP position , disconnect the lawn . The grass should NOT the spark plug wire , and have been cut . This indicates move the wire away from the that the Operator Presence spark plug . Do not operate Control has disengaged the the mower until the Blade blade drive and stopped the Brake Control System has blades . been repaired . Failure to do this could result in personal injury or property damage . 24
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Section 5 Maintenance IMPORTANT : Read Me Refer to Maintenance Chart in this Section for a listing of regularly First ! scheduled maintenance procedures . Carefully read this Section on Checking Oil Level ENGINE SERVICE mower and engine maintenance and service . 1 . Park machine on level ground . Routine engine service is de - Performing the required mainte - 2 . Stop engine , wait for parts to scribed below . For more com - nance according to schedule will stop moving , and disconnect plete engine service information , ensure the proper performance spark plug wire . refer to the engine manual pro - and long life of your machine . vided with your machine . For 3 . Clean area around dipstick ( Z , complete engine service , contact Figure 5 - 1 ) to prevent dirt from an authorized engine dealer . entering oil fill hole . WARNING 4 . Remove dipstick . Oil level must be between “ ADD � and “ FULL � ENGINE OIL marks . Do not exceed “ FULL � Before inspecting , cleaning or mark on dipstick . servicing the machine , shut off OIL LEVEL : Engine oil level 5 . To add oil , pour slowly into dip - engine , disconnect spark plug must be between " ADD " and stick opening . While adding , wire , and make sure that all " FULL " marks on dipstick at all check oil level frequently by se - moving parts have come to a times . Check before each use and curely replacing dipstick and re - complete stop . every 5 operating hours . moving to read oil level . Wipe dip - Failure to follow these instruc - stick clean each time oil level is OIL CHANGE : On a new engine , tions can result in personal in - checked . change oil after first 2 hours of jury or property damage . use , then change oil regularly as 6 . After filling to “ FULL � mark , specified on the Maintenance securely replace dipstick . Chart . Refer to Engine Owner's Manual for oil capacity . NOTE : All references to left , right , OIL TYPE : Refer to the separate front and rear of the machine are Engine Owner’s Manual to deter - determined by standing behind the mine the type and viscosity motor handlebars and facing the direction oil to use in your engine . of forward travel . 25
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Maintenance cleaning and inspection . Replace Changing Oil Z if damaged . Change oil while engine is still • Grass or chaff may clog engine's warm from recent operation . air cooling system , especially after Warm oil flows more freely and prolonged operation cutting tall , carries away more impurities . dry grass . See engine owner's 1 . Stop engine , wait for parts to manual for instructions on clean - stop moving , and disconnect ing underneath the engine blower spark plug wire . housing . 2 . Remove dipstick ( Z , Figure 5 - 1 ) . Figure 5 - 1 3 . Remove protective cap ( A , AIR CLEANER SERVICE Figure 5 - 2 ) to expose oil drain Improper air cleaner maintenance port ( B ) . can cause engine damage . Refer to 4 . Push oil drain hose ( D ) ( in - the engine owner's manual for C cluded in hardware bag with unit ) A more complete air cleaner service onto oil drain port . Route other information . end of hose to an appropriate oil B IMPORTANT : Do not run engine collection receptacle . D without complete air cleaner in - 5 . Twist oil drain fixture ( C ) to the stalled . open position . Pull out . Drain oil SERVICE SCHEDULE : completely . Outer foam pre - cleaner ( A , Figure 6 . Push in and twist oil drain fix - 5 - 3 ) - wash and re - oil every 25 op - ture to the closed position . Remove Figure 5 - 2 : Oil drain . erating hours or every three drain hose . Replace protective cap months , whichever occurs first . ( A ) . Service more often is used in ex - 7 . Refill engine with fresh oil and tremely dusty conditions . securely replace dipstick . Inner paper cartridge ( B , Figure 5 - NOTE : Please dispose of all waste 3 ) - Replace every 100 operating materials in an ecologically re - hours or every season , whichever sponsible manner . Use proper occurs first . Replace more often if waste material storage containers used in extremely dusty conditions . ENGINE CLEANING • Stop engine , wait for parts to stop moving , disconnect spark plug wire , and allow engine to cool before inspecting or clean - B A ing engine . • Daily or more often , before run - ning engine , remove grass and chaff from recoil finger guard or rotating screen to prevent engine damage caused by overheating . Also keep cooling vanes , governor Figure 5 - 3 : Air cleaner assembly . linkage , springs and controls free of debris . • Daily or more often , before run - ning engine , clean muffler area ( be sure muffler is cool ) to remove all grass and combustible debris . If engine is equipped with a spark arrestor screen , remove assembly every 50 hours for 26
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Maintenance SPARK PLUG BATTERY ( if applicable ) CARBURETOR Inspect the spark plug ( Figure 5 - 4 ) Charge battery if unit is to be The carburetor is adjusted at the after every 100 hours of operation . stored for longer than three weeks . factory . It should not need to be Be sure the gap is set at . 030 " . Do During the mowing season , battery reset . If black exhaust is noted , not reuse plug if it is severely worn is kept charged by charging sys - check the air cleaner first . An or damaged . tem on engine . over - rich mixture is usually caused by a poorly serviced or clogged air To Charge Battery Best results are obtained with a cleaner element , not an improperly new plug . See engine owner's 1 . Plug charger connector into adjusted carburetor . If readjust - manual to determine proper re - wire harness connector located ment is necessary , refer to engine placement plug . Use of incorrect below ignition switch in handlebar owner's manual or contact your plug can cause engine damage . console . engine dealer . NOTE : Do not clean spark plug in 2 . Plug charger into 120V wall out - machines which use abrasive grit . let . ( Note that battery charger is de - Clean spark plug by scraping or ENGINE STORAGE signed for use indoors and should wire brushing , or washing with a not be exposed to rain or snow . ) If engine will be unused for 30 commercial solvent . days or more , prepare it for stor - 3 . Charge battery for 24 - 48 hours age by following the recom - if unit is to be stored for longer mended procedures found in the than three weeks . engine owner’s manual . WARNING Charge battery only with charger supplied with ma - chine . Do not short circuit battery wires . Remove any jewelry before working on or near the battery or electric . 030 " Feeler Gauge start system . Failure to fol - Figure 5 - 4 : Spark plug . low these instructions could result in personal injury or property damage . 4 . After charging , unplug charger from outlet , then unplug charger from connector on wire harness lo - cated below handlebar console . TIP : Before tipping mower , install from falling ) . Tipping the mower MOWER SERVICE a small plastic sandwich style bag forward or to either side could re - under the gas cap and tighten se - The following maintenance / repair sult in damage to engine . curely . This will virtually elimi - procedures can be performed by nate any fuel weepage from the either the owner or an authorized WARNING cap . Be sure to remove the plastic service dealer . See an authorized Before servicing underside of bag before re - using mower . service dealer for complete mower mower , stop engine , wait for service . all parts to stop moving , and disconnect spark plug wire . Remove ignition key from TIPPING MOWER FOR SERVICE keyswitch on electric start models . Failure to follow When servicing the underside of this instruction could result in the mower for any reason , the personal injury or property mower should only be tipped damage . backward on its rear wheels ( and securely propped up to prevent it 27
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Maintenance To Reinstall Belt Cover BELT COVER REMOVAL 1 . Position belt cover in place . The belt cover must be removed to perform several maintenance pro - 2 . Secure with four screws re - cedures . moved earlier . To Remove Belt Cover 1 . Stop engine , wait for all parts WARNING to stop moving , and disconnect R Do not operate unit without spark plug wire . belt cover installed . Failure 2 . Remove four screws ( R , Figure to follow this instruction 5 - 5 ) and remove cover . could result in personal in - jury or property damage . Figure 5 - 5 : Belt cover removal . 5 . Loosen four mounting bolts ( L ) 7 . Replace belt ( N ) with new belt . BLADE SPINDLE BELT RE - securing spindle housing ( beneath IMPORTANT : Set blades per - PLACEMENT mower deck ) to mower deck . pendicular ( 90 ° ) to each other . Follow this procedure to remove 6 . Slide spindle housing ( with pul - and replace the blade spindle drive 8 . Rotate arm ( K ) to move spindle ley attached ) toward center . belt ( remove blade drive belt first ; housing and apply tension to belt . see “ Blade Drive Belt Belt cogs and pulley grooves must Replacement � below ) . mesh together . When applying FRONT moderate finger tension ( 8 - 12 lbs . ) , 1 . Stop engine , wait for all parts P N belt should deflect approximately O to stop moving and disconnect J 1 / 2 � ( 12.7 mm ) at ( P ) , midpoint of spark plug wire . deck . M 2 . Remove belt cover ( see “ Belt 9 . Tighten bolts ( L ) to 15 ft . - lbs . Cover Removal � ) . ( 20.3 Nm ) . Tighten screw ( J ) . K L 3 . Align sight holes ( O , Figure 5 - BLADES 10 . Blades must not contact deck . 6 ) in pulley with spindle housing - MUST BE PERPENDICULAR Check and readjust as needed . to - mower deck mounting bolts ( L ) . TO EACH OTHER 11 . Reinstall blade drive belt and 4 . Loosen screw ( J ) and rotate arm Figure 5 - 6 : Blade Spindle Belt . belt cover ( removed earlier ) . ( K ) to the rear . 4 . Disengage Blade Drive Control . 6 . Remove belt ( A , Figure 5 - 8 ) BLADE DRIVE BELT from around sheaves . 5 . Re - tighten two screws ( M , REPLACEMENT Figure 5 - 8 ) that secure flap To Install Belt Follow this procedure to remove bracket ( N ) . 1 . Route belt ( A , Figure 5 - 8 ) and replace the blade drive belt . 6 . Reinstall belt cover securely . around sheaves as shown . An assistant will be needed . 2 . Have an assistant hold down To Remove Belt Operator Presence Control and Blade Drive Disengaged 1 . Stop engine , wait for all parts then push the Blade Drive Control to stop moving , and disconnect forward until it latches in place A spark plug wire . ( Figure 5 - 7 ) . 2 . Disengage blade drive control 3 . With the Blade Drive Control ( Figure 5 - 7 ) by releasing all con - lever engaged , adjust and tighten trols on the mower . belt guide ( B ) to 1 / 32 - 1 / 16 " 3 . Remove belt cover ( see “ Belt away from tensioned belt . ( Be Cover Removal � ) . sure that belt does not contact belt Blade Drive Engaged guide when belt is under tension . ) 4 . Loosen belt guides ( B and C , Secure belt guide ( C ) rotated into Figure 5 - 8 ) . RIGHT VIEW position as shown in Figure 5 - 8 . 5 . Move flap bracket ( N , Figure Figure 5 - 7 : Blade Drive Control . 5 - 8 ) out of the way by loosening two screws ( M ) . 28
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Maintenance BLADE BRAKE REPLACEMENT B Follow this procedure to install a new blade brake . J G To Remove Blade Brake H 1 . Stop engine , wait for all parts to stop moving , and disconnect spark plug wire . K 2 . Remove belt cover as described I in “ Belt Cover Removal � instruc - C tions . 3 . Remove hardware ( G , Figure L 5 - 8 ) securing blade brake ( H ) . 4 . Remove old brake ( H ) from X idler arm ( I ) . To Install Brake 1 . Position new brake ( H ) in place on idler arm ( I ) . 2 . Center brake in sheave groove A and secure brake ( H ) with hard - ware ( G ) removed earlier . 3 . Reinstall belt cover securely . N 4 . Test operation of blade brake M M ( see “ Blade Brake Control Test � in Operation section ) . BLADE DRIVE BELT ADJUSTMENT Figure 5 - 8 : Blade drive . If the blade drive belt is slipping due to lack of belt tension , follow the steps below . Adjust idler in direction 1 . Stop engine , wait for all parts of arrow to tighten blade to stop moving , and disconnect drive belt spark plug wire . D 2 . Remove belt cover as described J 1 / 8 " E in “ Belt Cover Removal � instruc - tions . 3 . With mower on level ground , F adjust blade cutting height at about 3 " ( measure from ground to flat portion of blade ) . 4 . With the Blade Drive Control ( Figure 5 - 7 ) in the disengaged po - sition , set a gap of 1 / 8 " between Figure 5 - 9 : Blade drive adjustment . the spring ( F , Figure 5 - 9 ) and flat washer ( E ) by adjusting the nut ( D ) . 29
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Maintenance 5 . Reinstall the belt cover WHEEL DRIVE BELT REPLACEMENT securely . 5 . Install new belt shown in Follow this procedure to replace 6 . Test the operation of the blade Figure 5 - 11 . Belt must be in - the wheel drive belt . brake ( see “ Blade Brake Control stalled “ inside out � “ V � side of 1 . Stop engine , wait for all parts Test � in the Operation section ) . belt lies against engine sheave to stop moving , and disconnect 7 . If the drive belt slips during op - only . Flat side of belt lies against spark plug wire . eration , it may be necessary to re - transmission sheave ( R ) and back - 2 . Release all mower controls . locate idler ( J , Figure 5 - 9 ) in the sided idlers ( P and Q ) . 3 . Remove belt cover as described slot provided in the mounting 6 . Make sure belt is inside belt in “ Belt Cover Removal � instruc - bracket . With the engine stopped guide ( S , Figure 5 - 11 ) . tions . and the spark plug wire discon - 7 . Reinstall belt cover securely . 4 . Locate wheel drive belt ( O , nected , loosen the hardware on the 8 . An adjustment to the drive belt Figure 5 - 11 ) and remove it from idler ( J ) and slide it forward to may be necessary . See “ Wheel top sheave of engine sheave , back - take up slack in the belt . Drive Belt Adjustment � on the sided idlers ( P and Q ) and trans - 8 . Engage the blade drive and next page . mission sheave ( R ) . measure the distance ( X , Figure 5 - 8 ) between the centers of pul - leys ( K ) and ( L ) . The distance should be 5 - 1 / 2 to 5 - 5 / 8 " . After C obtaining the correct dimension , A E reinstall the belt cover securely and test the operation of the blade brake . B BLADE DRIVE CONTROL LEVER ADJUSTMENT Make the following adjustment if the Blade Drive Control Lever re - leases during operation . D 1 . Stop engine , wait for all parts to stop moving , and disconnect spark plug wire . Figure 5 - 10 : Blade Drive Control Lever adjustment . 2 . Engage the Operator Presence Control and the Blade Drive Control . Without releasing the controls , look inside the cutout at the rear of the frame and make sure the Operator Presence Q Control latches ( A and B , Fig . 5 - O 10 ) are fully engaged at point ( C ) . S If they are not fully engaged , im - proper operation or premature wear could result . To adjust , loosen hex nut ( D ) and shorten P length of control rod ( E ) . To avoid over - adjusting , turn rod only 1 to 2 turns per adjustment . 3 . Tighten hex nut securely after R adjusting control rod . 4 . Test by releasing the Operator Presence Control . If properly ad - justed , the Blade Drive Control will disengage when the Operator Figure 5 - 11 : Wheel drive belt replacement . Presence Control is released . Re - adjust as necessary by repeating 30 Steps 2 and 3 .
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Maintenance WHEEL DRIVE BELT ADJUSTMENT The wheel drive belt requires an adjustment if loss of drive belt tension ( slippage ) occurs . This is most noticeable when more trac - tion is required ( such as going up slopes ) . To Test Wheel Traction 1 . Park machine on a paved ( con - crete , etc . ) surface with front edge up against a sturdy wall , fence , etc . 2 . Put Gear Select Lever in No . 1 E setting . IMPORTANT : Do not park D against a painted or sided wall . B Testing the wheel drive system re - quires machine to be forcibly pushed against wall . Damage to paint or siding could result . 3 . With engine running , and ma - Figure 5 - 12 : Wheel drive belt adjustment . chine placed firmly up against wall , hold down Operator Presence Control and fully engage wheel drive by squeezing Wheel 3 . Loosen jam nut ( D , Figure Drive Control until it contacts 5 - 12 ) . handlebar . 4 . Thread rod ( E , Figure 5 - 12 ) one 4 . Wheels should slip on paved or two turns clockwise for more surface . If they do not , an adjust - tension or counterclockwise for ment is required . less tension . To Adjust Wheel Drive Belt 5 . Insert rod back into hole in 1 . Stop engine , wait for all parts Wheel Drive Control lever and in - to stop moving , and disconnect stall cotter pin . Bend ends of cot - spark plug wire . ter pin to secure . A 2 . Remove cotter pin ( A , Figure 5 - 6 . Retest wheel traction . Repeat 12A ) from upper end of Wheel adjustment procedure , if necessary . Drive Control rod . Slide rod out of Best operation is obtained when lever assembly . the adjustment allows the lever to - Figure 5 - 12A just make contact with the hand - grips as sufficient wheel traction is obtained . When adjustment is complete , tighten jam nut ( D ) firmly against block ( B ) . 31
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Maintenance WHEEL BRAKE ADJUSTMENT This adjustment may be required if the machine does not hold on a M hill with the Operator Presence Control disengaged , or if the brake drags with the Operator Presence Control engaged and the transmis - sion in neutral . 1 . Stop engine , wait for all parts to stop moving , and disconnect spark plug wire . 2 . Disengage ( release ) the Operator Presence Control ( M , N Figure 5 - 13 ) . P 3 . Slowly adjust at nut ( O ) , if nec - essary , until the distance between the back of brake arm ( N ) and N O bracket ( P ) is 3 / 8 � - 5 / 16 " . Use small adjustments ( 1 / 4 turn maxi - 3 / 8 � - mum ) . NOTE : It may be neces - O 5 / 16 � sary to relieve spring tension when decreasing distance . To do so , have an assistant engage the Operator Presence Control while Figure 5 - 13 : Wheel brake adjustment . you adjust the nut . TRANSMISSION NEUTRAL I ADJUSTMENT Follow this procedure to adjust neutral on the transmission . 1 . Stop engine , wait for all parts to stop moving , and disconnect spark plug wire . 2 . Rotate shift rod ( I , Figures 5 - 14 and 5 - 15 ) clockwise until it stops Detent for in the neutral ( N ) position ( from Neutral Position forward gear positions ) . 3 . Hold down Operator Presence Control ( M , Figure 5 - 13 ) and push Figure 5 - 14 : Gear Select Lever in neutral ( N ) position . unit forward and backward . Unit should move freely . If not , con - NOTE : Shift rod ( I ) must be held into neutral . When transmission is tinue with Step 4 . in the neutral position ( see Figure in neutral , unit will move freely 4 . Remove cotter pin securing 5 - 14 ) while shift link ( P ) is when pushed while holding the shift link ( P , Figure 5 - 15 ) to shift adjusted . Operator Presence Control lever rod ( I ) . down . If transmission is NOT in 7 . Secure shift link ( P ) into shift 5 . Move shift arm ( X ) back and neutral , there will be a slight drag rod ( I ) with cotter pin removed forth as necessary into each detent on the wheels when pushing unit . earlier . until transmission is in neutral . 6 . When shift arm ( X ) is in neutral 8 . Re - check neutral by pushing NOTE : Moving shift arm ( X ) position , rotate shift link ( P ) until unit back and forth and shifting clockwise all the way to the left , hooked end fits back into hole in lever ( I ) from reverse to neutral . A and then one notch back counter - bottom end of shift rod ( I ) . small fine - tune adjustment may be clockwise , should put transmission required . 32
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Maintenance MOWER BLADES I Examine mower blades before op - eration . For efficient mowing , cut - ting edges of blades should always be kept sharp . Check for blade wear or damage . See Figure 5 - 16 . Y Replace a severely worn or dam - aged blade with a new one . WARNING X Mower blades are sharp . • When working near blades , P wear heavy leather gloves or wrap blades in thick rags to Figure 5 - 15 : Transmission neutral ( N ) adjustment . protect yourself from the sharp edges . • Wear eye protection when sharpening blades . To Inspect Blades 1 . Stop engine , wait for all parts to stop moving , and disconnect spark plug wire . 2 . Tip mower on rear wheels by following instructions “ Tipping Mower For Service � in this Section of Manual . To Remove Blade Remove bolt ( Figure 5 - 18 ) and Replace if separation washer ( s ) . Remove mower blade . begins to form . Blade Sharpening Grind or file the same amount from each blade end to maintain blade balance . An unbalanced mower blade produces excessive vibration and may damage spindle bearings . Sharpen cutting edge straight across , parallel to rear edge of mower blade . See Figure 5 - 16 . After sharpening , blade bal - ance must be checked . Sharpen blade cutting edge straight IMPORTANT : Professional across , parallel to blade trailing edge . sharpening services or your autho - rized dealer are equipped to Figure 5 - 16 : Blade Inspection sharpen mower blades safely . 33
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Maintenance Blade Installation CLEANING UNDERSIDE OF MOWER DECK Blades must be installed perpen - dicular to each other ( see Figure Frequently check , and clean if 5 - 17 ) . necessary , the underside of the mower deck . Grass build - up in Install mower blade as shown in this area can affect the cutting per - Figure 5 - 18 with flat side down . formance . Before inspecting or Install washer on bolt . Tighten cleaning , make sure that the en - bolts to a torque value of 35 ft . gine is shut off and the spark plug lbs . ( 47 Nm ) . wire is disconnected from the NOTE : If top bolt is removed , re - spark plug . install using LOCTITE # 242 thread sealant . WARNING Mower blades are sharp . When working near blades , wear heavy leather gloves or FRONT wrap blades in thick rags to protect yourself from the sharp edges . Inspection / Cleaning of Mower Deck 1 . Stop engine , wait for all parts to stop moving , and disconnect BLADES MUST BE PERPENDICULAR spark plug wire . TO EACH OTHER 2 . Tip mower on rear wheels by following instructions " Tipping Figure 5 - 17 Mower For Service " in this Section of Manual . 3 . Use a plastic or metal scraper to remove grass build - up from deck Torque to or blades . If needed , spray with a 35 Ft . Lbs . garden hose . Mower Blade Washer Bolt Torque to 35 Ft . Lbs . Figure 5 - 18 : Blade spindle . 34
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Maintenance LUBRICATION OFF - SEASON STORAGE WARNING Oil and grease the mower accord - • Stop engine , wait for all parts to Never store machine with ing to the recommendations listed stop moving , and disconnect fuel in the fuel tank inside a in the Lubrication Chart below . spark plug wire before perform - building where fumes may ing any storage procedures . reach an open flame or • Stop engine , wait for all parts to Review the " Maintenance and spark , or where ignition stop moving , and disconnect Storage " safety rules in the sources are present such as spark plug wire before perform - Safety section of this Manual . hot water and space heaters , ing any lubrication procedures . furnaces , clothes dryers , • If engine will be unused for 30 • The transmission has been fac - stoves , electric motors , etc . days or more , prepare it for stor - tory sealed and requires no lubri - age by following the recom - cation . If a leak should develop , mended procedures found in the contact the Factory or your local Engine Owner's Manual . authorized dealer for service infor - mation . • Inspect all parts for damage , breakage , and wear . Tighten or re - place fasteners . Contact the Factory or your local authorized dealer for factory - approved re - placement parts . • Clean the exterior of the mower thoroughly and touch up all chipped or scratched surfaces to prevent rust from forming . Lubrication Chart ITEM LUBRICATION TYPE AMOUNT REQUIRED INTERVAL Engine Crankcase Change Oil See Engine Manual First 2 hours Change oil more often Change Oil 25 - 50 hours in extremely dirty or ( Lubrication Intervals Vary dusty conditions . with Operating Conditions and Type of Oil Used ) Front Wheel Bearings Grease 1 - 3 Strokes * 50 hours Control Linkages / Pivots Light Oil A Few Drops 25 hours * A hand - type grease gun is recommended . 35
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Maintenance ATTENTION ! This chart describes service guidelines only . It does not provide complete service information . Complete service is available from your authorized mower or engine dealer . Before performing any of the main - tenance procedures , refer to the appropriate information contained in this Manual or the Engine Owner’s Manual for the correct safety precautions and maintenance procedures . WARNING Before inspecting , cleaning or servicing the machine , shut off engine , make sure that all moving parts have come to a com - plete stop , and disconnect spark plug wire . Failure to follow this instruction could result in personal injury or property damage . Maintenance Chart INTERVAL * ITEM SERVICE Each use Mower Blade As Required Loose or Missing Hardware Tighten or Replace Belts Check Engine Oil Level Check Controls Check for Proper Operation Mulching Cover Check for Proper Cover Installation 1st 2 hours Engine Oil Change 25 hours Engine Oil * * * Change Foam Air Filter * * * * Clean Mower Blade ( s ) Sharpen and Balance Control Linkages and Pivots Lube with Light Oil Engine Oil * * * Change 50 hours Blade Drive Belt Adjust Adjust Tension Engine Cooling Fins Clean Grease Fittings * * Grease Air Filter Element * * * * Replace Annually or 100 hours Spark Plug Clean / Replace , Re - gap Linkages Monthly Adjust Belts Check / Replace , Adjust Annually or 50 hours Front Wheel Bearings Grease * Interval describes running time . * * A hand - type grease gun is recommended when greasing your unit . High - pressure type grease guns could cause damage to fit - tings / seals . * * * Consult engine manual for more detailed engine service infor - mation . * * * * Clean more often under dusty conditions or when airborne debris is present . Replace air cleaner parts , if very dirty . 36
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Maintenance ATTENTION ! This table describes service guidelines only . It does not provide complete service information . Complete service is available from your authorized mower or engine dealer . Before performing any of the cor - rections in this table , refer to the appropriate information contained in this Manual or the Engine Owner’s Manual for the correct safety precautions and operating or maintenance procedures . WARNING Before inspecting , cleaning or servicing the machine , Symptom shut off engine , make sure that all moving parts have tries . move . come to a complete stop , start . applicable ) . Operator and disconnect spark plug repeated seconds . not not wire . released . engaged . engaged . performance . over . will does when Failure to follow this instruc - off . inoperative . hot . ( if after tion could result in personal but shut roughly . unit turn few vibration . charging stop injury or property damage . is always when always overheats . over only Control a not not but not in mowing starts stalls turns stalls does does runs runs drive not drive drive does Excessive Troubleshooting Chart Presence Battery Engine Engine Engine Engine Engine Engine Engine Engine Engine Wheel Blade Blade Blade Poor Possible cause Engine malfunction ( refer to engine manual ) . • • • • • • • • • Improperly adjusted drive linkage . • • • • • • • Dirty engine cooling fins or flywheel screen . • Faulty ignition . • • • • • • • Faulty spark plug . • • • • • Empty fuel tank . • • • • Battery or charging malfunction ( if applicable ) . • • • • Improperly adjusted or dirty carburetor . • • • • • Improper oil level . • • Dirty air cleaner element . • • • • Improperly adjusted choke ( if applicable ) . • • • • • Transmission malfunction . • • Improperly adjusted drive linkage . • • • • • Broken , loose or worn belt ( s ) . • • • • • • Dull blade ( s ) . • • Throttle control out of adjustment . • • • Blade / brake system out of adjustment . • • • Blade ( s ) out of balance . • • Loose hardware . • • • 37
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For customer assistance , contact your nearest authorized dealer or call or write : GARDEN WAY INCORPORATED • 1 Garden Way • Troy , New York 12180 Customer Service : 1 - 800 - 437 - 8686 • Technical Service : 1 - 800 - 520 - 5520 • Parts Service : 1 - 800 - 648 - 6776 • FAX : ( 518 ) 391 - 7332 WEBSITE : www.troybilt.com Outside the United States and Canada : Customer Service : ( 518 ) 391 - 7007 • Technical Service : ( 518 ) 391 - 7008 • Parts Service : ( 518 ) 391 - 7006 • FAX : ( 518 ) 391 - 7332 1905252 ( 1 / 99 ) Printed in U.S.A . © 1999 Garden Way Incorporated