CLIPPER
46
CODE 401R
AUTO-DRIVE
OWNER’S HANDBOOK
(English Version)
FROM SERIAL NO: 401R001001
Issue: 25/02/99
HANDBOOK: 401001 (Rev.2.)
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CONTENTS
1.2
1.2
CONTENTS
Page No.
1.4
INTRODUCTION
WARRANTY
1.5
Limited Warranty
1.5
SAFETY PRECAUTIONS
Safety Precautions
Decals
1.6 - 1.10
1.6 - 1.9
1.10
SPECIFICATIONS
1.11
ASSEMBLY INSTRUCTIONS
General Assembly
1.12 - 1.14
1.12
Assembling the Mower for the First Time
1.13- 1.14
STARTING THE ENGINE
Before Starting the Engine
To Start the Engine
1.15 - 1.17
1.15 - 1.16
1.17
STOPPING THE ENGINE
1.18
OPERATING THE MOWER
Height of Cut
1.18 - 1.23
1.19
Travel
1.20
Turning the Mower
1.20
Moving the Mower across Non-Grassed Areas
Cutterbar Operation
1.21
1.22
Mowing and Grass Care Tips
1.22 - 1.23
MAINTENANCE
Engine
1.24 - 1.32
1.24
Carburettor Adjustments
Oil Service
1.25
1.25
Air Cleaner Service
Spark Plug Service
Keeping the Engine Clean
Deck Housing
1.26
1.26
1.27
1.28
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CONTENTS
1.3
1.3
CONTENTS
Page No.
MAINTENANCE Continued.
Securing Nuts and Bolts
Lubrication
1.28
1.28
Clutch Cable Adjustment
Cutterbar
Maintenance Schedule
- After First 5 Hours
1.29
1.30 - 1.31
1.32 - 1.33
1.32
- Every 5 Hours or Daily
- Every 25 Hours or Every Season
- Every 50 Hours or Every Season
- Every 100 Hours or Every Season
1.32
1.32
1.33
1.33
PREPARING THE MOWER FOR STORAGE
FAULT FINDING
1.34
1.35 - 1.37
2.1 - 2.2
2.3
401R CHASSIS PARTS LIST
401R PARTS DIAGRAM
401R TRANSMISSION PARTS LIST
401R TRANSMISSION PARTS DIAGRAM
ENGINE ANCILLARY PARTS
ENGINE WARRANTY
2.4
2.5
2.6
2.7
NOTES
2.8
CUSTOMER INFORMATION
2.9
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INTRODUCTION
1.4
1.4
INTRODUCTION
Thank you for purchasing a Hayter mower. The following pages are designed to help you
gain safe and efficient service from your machine.
IMPORTANT: This ‘Owners Handbook’ should be regarded as part of the machine as it
gives essential information regarding machine safety, operation, maintenance and
specifications. Read and understand this handbook prior to operating your machine for the
first time. Make sure you are familiar with all the controls and points of regular maintenance.
If you have any doubts, consult your Hayter authorised dealer who will be pleased to give
you assistance.
IMPORTANT: This machine is designed solely for use in a domestic grass cutting
environment. Use in any other way is considered as contrary to the intended use. Compliance
with and strict adherence to the conditions of operation, service and repair as specified in this
handbook also constitute essential elements of the intended use.
This machine should be operated, serviced and repaired only be persons who are familiar with
its particular characteristics and who are acquainted with the relevant safety procedures.
The safety precautions listed here in and all other generally recognised regulations on safety
must be observed at all times.
Any arbitrary modifications carried out to this machine may relieve Hayter Limited of
liability for any resulting damage or injury.
All Hayter mowers are robustly constructed and designed for efficient economical
performance under normal mowing conditions. Correct operation and maintenance will
ensure a long and satisfactory service life. Prior to despatch from our factory every effort is
made to ensure your machine arrives in perfect condition. Your dealer will carry out a
pre-delivery inspection to ensure that there has been no transit damage prior to installation.
Please allow your dealer to familiarise you with the controls and safety features of the
machine during installation.
Throughout this handbook all references to left hand and right hand are as viewed from
behind the handlebar, facing in the direction of forward travel.
This owners handbook is based on information available at the time of publication.
HAYTER LIMITED reserve the right to make changes at any time without notice.
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1.5
1.5
WARRANTY
LIMITED WARRANTY
Hayter Limited warrants to the original user/purchaser that this unit shall be free from defects
in material and workmanship under normal use and service for a period of three years from the
date of purchase. The manufacturers of the engine and battery pack system (where applicable)
furnish their own warranty and services are provided through their authorised network (Refer to
"Engine/Battery Pack Warranty Statement"). To qualify for the full benefit of the warranty, the
warranty registration card must be returned within 60 days of purchase. Subject to the conditions
and exclusions noted in this limited warranty, we shall at our option, repair or replace any
warranted part during the applicable period. If you are in doubt or experience any difficulty,
please consult a Hayter Authorised Service Dealer for clarification.
To qualify for the extended warranty (second and third year) of the three year limited warranty
the machine must have annual services carried out by an Authorised Hayter Service Dealer.
These chargeable services should be carried out within 12 and 24 months of the date of purchase.
Excluded from the extended warranty period are those items which are subject to normal wear
and tear e.g. tyres, wheels, cutterbars, cables, batteries and other consumable wearing parts.
All consumer machines which are fitted with a genuine Hayter friction disc as original
equipment before use, are covered by a Lifetime Warranty against the engine crankshaft
bending. Note: friction washers, blade brake units and other such devices are not applicable.
Only machines fitted with a genuine Hayter friction disc, which are used in accordance with the
recommended operating and maintenance procedures, are covered.
This warranty does not apply to any unit that has been tampered with, altered, misused, abused or
used for hire, and will become invalid if non genuine Hayter parts are fitted. This warranty does
not cover minor mechanical adjustments unless they are due to defective material or
workmanship. Consult the Owner's Handbook or a Hayter Authorised Service Dealer for
assistance when making these adjustments.
A warranty period of 90 days applies to machines used for commercial purposes.
To make a warranty claim, return the unit to a Hayter authorised dealer along with proof of
purchase stating the machine serial number and date of purchase. The service receipt(s) or this
Owners Handbook with the 1st/2nd year service boxes fully completed, must be produced as
proof of entitlement to the extended warranty period. Subject to the conditions and exclusions in
this limited warranty, the authorised dealer will, at our option, repair or replace any warranted
part within the duration of the warranty period.
This limited warranty gives you specific legal rights and is in addition to any statutory rights to
which you may be entitled and your statutory rights are not affected by this warranty. If you need
additional information concerning this written warranty, or assistance in obtaining services,
please write to : HAYTER LIMITED, Service Department, Spellbrook, Bishop's Stortford,
Hertfordshire CM23 4BU
UK ONLY: Details of your local Hayter authorised dealer are contained in Yellow Pages or
contact:- Freephone 0800 616298.
1st Year
Service
Record
2nd Year
Service
Record
Date....................................................................
Signed................................................................
Date.............................................................
Signed..........................................................
400001MT270196A
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SAFETY PRECAUTIONS
1.6
1.6
SAFETY PRECAUTIONS
THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED.
WHEN YOU SEE THIS SYMBOL BE ALERT TO THE POSSIBILITY OF
INJURY. CAREFULLY READ THE MESSAGE THAT FOLLOWS AND
INFORM OTHERS. EXERCISE GREAT CARE AND FOLLOW THE
ADVICE GIVEN TO AVOID POTENTIALLY HAZARDOUS SITUATIONS.
Your mower is perfectly safe if used correctly. Failure to observe the
following simple precautions may result in serious injury.
Training:
Read the instructions carefully. Ensure that you are familiar with the controls and the
proper use of the equipment. Learn how to stop the mower quickly in an emergency.
Never allow children or people unfamiliar with these instructions to use the mower.
Never mow while people, especially children, or pets are nearby.
Keep in mind that the user is responsible for accidents or hazards occurring to other people
or their property.
Preparation:
While mowing, always wear substantial footwear and long trousers. Do not operate the
equipment when barefoot or wearing sandals.
Thoroughly inspect the area where the mower is to be used and remove all objects which may
be thrown by the machine.
WARNING: Petrol is highly flammable.
- Store fuel in containers specifically designed for this purpose.
- Refuel outdoors only and do not smoke while refuelling.
- Add fuel before starting the engine. Never remove the cap from the fuel tank or add petrol
while the engine is running or when the engine is hot. Allow the engine to cool for at least 2
minutes before refuelling.
- Do not attempt to start the engine if petrol is spilled or a smell of petrol is present. Move
the mower away from the area of spillage and avoid creating any source of ignition until
petrol vapours have dissipated.
- Always use fresh fuel. Stale fuel can block the carburettor and cause leakage.
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SAFETY PRECAUTIONS
1.7
1.7
SAFETY PRECAUTIONS
Continued.
- Replace fuel tank and container caps securely.
- Replace faulty silencers.
Always ensure that the mower is in a safe operating condition. Frequently check all nuts,
bolts and screws for tightness. Use only genuine Hayter replacement parts.
A damaged cutterbar or loose fixing bolt are major hazards. Before use, visually inspect the
cutting mechanism to ensure that it is in good condition. A damaged cutterbar must be
replaced immediately with a genuine Hayter replacement part. A cutterbar which is slightly
worn can be re-sharpened. Ensure that both cutting edges are re-sharpened equally to main-
tain balance. An unbalanced cutterbar may cause serious damage to your machine.
Refer to “Maintenance”.
Operation:
Do not operate the engine in a confined space where dangerous carbon monoxide fumes can
collect.
Always pull the starter cord slowly until resistance is felt, then pull the cord rapidly to avoid
kickback and prevent hand or arm injury.
Mow only in daylight or good artificial light.
Avoid using the mower on wet grass, where feasible.
Always be sure of your footing on slopes.
Walk, never run.
Mow across the face of slopes, never up and down.
Exercise extreme caution when changing direction on slopes.
Do not mow excessively steep slopes.
Use extreme caution when reversing or pulling the mower towards you.
Stop the engine if the mower has to be tilted for transportation when crossing surfaces other
than grass and when transporting the mower to and from the area to be mowed.
Never operate the mower unless the guards are securely in position and in good condition.
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SAFETY PRECAUTIONS
1.8
1.8
Continued.
SAFETY PRECAUTIONS
Operation continued:
Do not change the engine governor settings or overspeed the engine.
Disengage the ground drive clutch before starting the engine.
Start the engine carefully, with feet well away from the cutterbar.
Do not tilt the mower when starting the engine.
Do not put hands or feet near or under rotating parts.
Never pick up or carry a mower while the engine is running.
Stop the engine and disconnect the spark plug lead:
- Before clearing blockages.
- Before cleaning / checking or working on the mower.
- After striking a foreign object. Inspect the mower for damage and make repairs
before restarting and operating the mower.
- If the mower starts to vibrate abnormally (check immediately).
Stop the engine:
- Whenever you leave the mower.
- Before refuelling.
Never touch the engine muffler / muffler guard or cooling fins when the engine is hot.
WARNING: THE CUTTERBAR CAN CONTINUE TO ROTATE AFTER
THE ENGINE IS SWITCHED OFF
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SAFETY PRECAUTIONS
1.9
1.9
Continued.
SAFETY PRECAUTIONS
Maintenance and Storage:
Keep all nuts, bolts and screws tight to ensure that the equipment is in safe operating
condition.
Frequently check fuel lines and fittings for cracks or leaks and replace if necessary.
Never check for a spark with the spark plug removed. (Use an approved tester).
Never crank the engine with the spark plug removed.
Never strike the flywheel with a hammer or hard object as this may cause the flywheel to
shatter in operation. Always use the correct tools to service the engine.
Never operate the engine without a muffler guard. Inspect the muffler periodically and
replace if worn or leaking.
Never start the engine with the air-cleaner or air-cleaner cover removed.
Never store the mower with petrol in the tank within an enclosed area where fumes may reach
an open flame or spark.
Allow the engine to cool before storing in any enclosure.
To reduce the fire hazard, keep the engine, muffler, cooling fins and petrol storage area free
of grass, leaves, or excessive grease.
Replace worn or damaged parts for safety.
If the fuel tank has to be drained, it is essential that this be done outdoors.
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SAFETY PRECAUTIONS
1.10
1.10
DECALS
WARNING DECAL: Part No. 219189
WARNING -RISK OF DANGER - SAFETY ALERT.
DANGER OF SEVERING TOES OR FINGERS
IN CUTTING MECHANISM.
DANGER OF BEING HIT BY THROWN OBJECTS.
KEEP BYSTANDERS AT A SAFE DISTANCE
FROM THE MACHINE.
STOP ENGINE AND REMOVE SPARK PLUG LEAD
BEFORE PERFORMING MAINTENANCE OR REPAIR
WORK.
CAREFULLY READ THE OWNERS HANDBOOK
BEFORE USING THE MACHINE.
ENGINE STOP
STOP
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SPECIFICATIONS
1.11
1.11
SPECIFICATIONS
MODEL
CODE 401R
Auto-drive
Engine
Briggs & Stratton
Quattro 40
Engine Type
10C902
Engine / Cutterbar Speed 3000 rpm
Fuel Type
Unleaded Petrol
Fuel Capacity
Oil Type
1.5 litres
SAE 30 engine oil
0.6 litres
Oil Sump Capacity
Cutting Width
Cutting Height
Overall Dimensions
Dry Weight
460mm
35 - 65mm
1320 x 515 x 1010mm
27 Kg
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ASSEMBLY INSTRUCTIONS
1.12
1.12
ASSEMBLY INSTRUCTIONS
SAFETY NOTICE
Before using the mower, read the owner’s handbook carefully.
Pay particular attention to the safety precautions.
MS001
GENERAL ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
Front Height of Cut Adjuster
Muffler Guard
Spark Plug Lead
Engine Cowl
7
Oil Filler Cap & Dipstick
Engine Stop Lever
Top Handlebar
Ground Drive Clutch Lever
Engine Start Grip
6
8
10. Upper Handlebar Securing Knob
11. Lower Handlebar Securing Knob
12. Rear Height of Cut Adjuster
13. Air Cleaner
14. Fuel Filler Cap
15. Cable Tie
9
16. Serial No. Label
10
5
4
13
3
11
12
2
1
14
16
15
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ASSEMBLY INSTRUCTIONS
1.13
1.13
ASSEMBLING THE MOWER FOR THE FIRST TIME
DELIVERY CHECKLIST
Unpack the mower: Remove the mower from the packag-
ing and take great care to ensure that the control cables
between the engine and the upper handlebar are not dam-
aged in the process. Check that the loose items have been
supplied correctly. Refer to the delivery checklist opposite.
If any items are missing, contact your local authorised
Hayter Dealer.
Description
Quantity
Owner’s Handbook
Warranty Reg. Card
1
1
Assemble the lower handlebar: Carefully unfold the lower
handlebar into position behind the rear of the mower. Align
with the base of the handlebar and lock in position using the
lower securing knobs.
ST017
3
4
5
Assemble the upper handlebar: Carefully unfold the
upper handlebar into position whilst taking great care to
ensure that the control cables remain undamaged, untwisted
and free of kinks.
Align with the lower handlebar and ensure that the rope
guide is correctly orientated. Tighten the upper securing
knobs .
Operate the engine stop lever towards the handlebar and
very slowly pull the engine start-grip away from the engine
until there is sufficient slack in the rope to enable it to be
threaded into the rope guide. Gently release the start-grip
until it rests against the rope-guide.
1
2
6
8
ST001
7
1. Coach bolt M8
2. Rope guide
3. Engine start grip
4. Upper handlebar
5. Lower handlebar
6. Washer M8
7. Knob
Align the control cables neatly along each leg of the han-
dlebar and ensure that they are located in the plastic cable
holders. Use a screwdriver to clamp the cable holders in
position.
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ASSEMBLY INSTRUCTIONS
1.14
1.14
ASSEMBLING THE MOWER FOR THE FIRST TIME
Continued.
Check engine stop lever operation: Operate the engine
stop lever several times. Ensure that the cable moves
freely and that the lever returns automatically to the
engine stop position when released.
ST002
Check the ground drive clutch lever operation:
Operate the engine stop lever and push forward on the
clutch lever until it locks into position. Release the
engine stop lever to a half way position and check that
the clutch lever releases automatically to the disengaged
position. Operate several times and ensure that the cable
and mechanism operates freely.
ST007
STOP
ST004
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STARTING THE ENGINE
1.15
1.15
BEFORE STARTING THE ENGINE
IMPORTANT- PREVENT ENGINE DAMAGE: The
engine is shipped without oil or petrol. The engine must
be filled with the correct grade of oil and petrol before
starting the engine.
Oil recommendations: Always use high quality detergent
oil classified “For service SE, SF, SG” SAE 30 oil. Never
use additives with recommended oils.
SAE 10W-30 multigrade oil may be used, but this will result
in higher engine operating temperatures with consequential
high oil consumption. It is imperative that the oil level is
checked more frequently if this grade of oil is used in order
to guard against serious engine damage.
CS042
Check oil level: Clean around the oil filler cap before
removing. With the mower on a level surface, unscrew and
remove the oil filler - dipstick. Wipe oil from it with a clean
cloth. Screw the oil filler - dipstick back in place, then
unscrew and remove it to check the oil level.
The oil level is correct when it is at the full mark on the dip-
stick. DO NOT OVERFILL.
0.15
Litres
Slowly fill with engine oil as necessary and replace the oil
filler - dipstick.
CS043
IMPORTANT: The oil filler - dipstick must be firmly
secured to prevent oil leakage during operation.
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STARTING THE ENGINE
1.16
1.16
BEFORE STARTING THE ENGINE
Continued.
Fuel Recommendations: Always use clean, fresh unleaded
petrol. Purchase fuel in quantities which can be used with-
in 30 days. Never mix oil with petrol. For added engine
protection Briggs & Stratton recommend the use of their
fuel additive which is available from an authorised Briggs &
Stratton service dealer.
Check fuel level: Clean around the fuel filler cap before
removing and fill the fuel tank with clean unleaded petrol.
6mm
minimum
Do not overfill the fuel tank. Allow 6mm minimum of tank
space for fuel expansion.
CS036
IMPORTANT: The fuel filler cap must be firmly secured
to prevent fuel leakage during operation.
WARNING - PREVENT ACCIDENTS: The cutterbar
rotates when the engine is operating.
ALWAYS operate the engine stop lever several times and
ensure the engine stop cable moves freely before starting the
engine.
ALWAYS position the mower on a level stone free grass
surface before starting the engine. Ensure that the cutterbar
is set above grass height to prevent the engine being started
under load.
CS037
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STARTING THE ENGINE
1.17
1.17
TO START THE ENGINE
CS117
Operate the primer bulb: When starting the engine for the
first time firmly push the primer bulb 5 times at 2 second
intervals to provide the extra fuel required to start a cold
engine. When starting a cold engine thereafter it should
only be necessary to push the primer bulb 3 times.
Operation of the primer bulb is usually unnecessary when
starting a warm engine.
1
2
1. Engine
2. Primer Bulb
Operate the engine stop lever: Use one hand to hold the
engine stop lever in the operating position firmly against the
handlebar.
To start and operate the engine, the engine stop lever must
be held in the operating position. If the engine stop lever is
released the engine will stop.
STOP
ST004
Operate the engine start-grip: Stand behind the mower
and maintain a firm hold on the handlebar and the engine
stop lever to prevent the mower moving towards you. Use
your right hand to hold the engine start - grip and pull slow-
ly until resistance is felt, then pull rapidly to crank the
engine. When the engine starts carefully return the engine
start - grip to the storage position. If the engine does not
start after 5 attempts - refer to “Fault Finding”.
ST003
IMPORTANT - PREVENT ENGINE DAMAGE: Never
pull the engine start - grip when the engine is running.
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STOPPING THE ENGINE
1.18
1.18
STOPPING THE ENGINE
Stopping the engine: Disengage the engine stop lever by
releasing the lever.
STOP
ST004
Emergency stop: If the engine stop lever fails, disconnect the
spark plug lead to stop the engine.
STOP
CS044
OPERATING THE MOWER
SAFETY NOTICE
WARNING - PREVENT ACCIDENTAL STARTING :
Always stop the engine and disconnect the spark plug lead
before cleaning, inspecting or working on the machine.
STOP
CS044
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OPERATING THE MOWER
1.19
1.19
SAFETY NOTICE
WARNING - PREVENTACCIDENTS : Before mowing,
thoroughly inspect the area where the mower is to be
used and remove all objects which when contacted by
the mower cutterbar could become dangerous projec-
tiles.
Inspect the area for hidden obstructions which when
contacted by the cutterbar could risk health and safety.
Remember the location of these obstructions and ensure
that you mow around them.
CS031
IMPORTANT- PREVENT ENGINE DAMAGE : DO
NOT use the mower on a slope greater than 20 degrees.
ST008
o
20 max.
HEIGHT OF CUT
To adjust the height of cut: Adjust each wheel in turn.
Adjust each front wheel by first moving the lever outward
to “unlock” and then towards the rear of the mower to
increase (+) or towards the front of the mower to decrease
(-) the height of cut. Release the lever and ensure that it
locks firmly in position.
+
Front
_
ST005
Repeat this procedure for the two rear wheels. To increase
(+) move the lever towards the front of the mower and to
decrease (-) move the lever towards the rear of the mower.
Rear
_
Finally check that the height of cut settings are the same for
all four wheels to ensure that the mower is level. There are
four height of cut positions
+
Always select a height of cut to suit operating conditions.
Aim to prevent engine overloading and blockages by avoid-
ing low cuts in long grass conditions. Be prepared to make
two cuts when the grass is long.
ST006
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OPERATING THE MOWER
1.20
1.20
TRAVEL
Forward travel: Use the left hand to hold the engine stop
lever against the handlebar and start the engine. Push down-
ward on the handlebar to raise the front wheels until they are
just out of contact with the ground. Use the right hand to
push the ground drive clutch lever forwards until it locks
into the engaged position. Remove the right hand and the
clutch lever will remain in the engaged position. Lower the
front wheels to the ground and the mower will drive in a for-
ward direction.
ST007
Note: To disengage the drive without stopping the engine,
release the engine stop lever to the half way position.
Reverse travel: Disengage the ground drive clutch lever by
releasing the engine stop lever to the half way position.
Hold and pull against the handlebar with both hands to
reverse the mower towards you.
WARNING - PREVENT ACCIDENTS: Never raise the
front of the mower excessively. Always reverse the
mower carefully towards you. Always stop the engine
before walking backwards with the mower.
TURNING THE MOWER
To make a wide turn: Steer the mower with the handlebar
in the direction required.
To make a tight turn: Stop and apply downward pressure
on the handlebar to raise the front wheels of the mower just
above ground level and steer the mower using the handlebar
in the required direction.
General manoeuvring: The mower may be manoeuvred in
tight spaces with the ground drive engaged, by pushing
downward on the handlebar to lift the front driving wheels
slightly clear of the ground.
WARNING - PREVENT ACCIDENTS: DO NOT raise
the front of the mower excessively when making turns.
NEVER raise the rear of the mower when the engine is
running.
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OPERATING THE MOWER
1.21
1.21
MOVING THE MOWER ACROSS NON-GRASSED AREAS
Set the mower to its maximum height of cut to protect the cutting mechanism when moving
the mower over surfaces other than grass.
WARNING - PREVENT ACCIDENTS: Push the mower carefully at slow walking
speed with the engine stopped.
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OPERATING THE MOWER
1.22
1.22
CUTTERBAR OPERATION
The cutterbar rotates at the same speed as the engine. The cutterbar will stop within three
seconds of the engine being stopped.
WARNING - PREVENT ACCIDENTS : DO NOT operate the mower if the cutterbar
fails to stop within three seconds. Return the mower to your Hayter dealer for exami-
nation and repair.
WARNING - PREVENT ACCIDENTS: ALWAYS stop the engine when a hidden
obstruction or excessive vibration is encountered. Disconnect the spark plug lead and
examine the cutting mechanism. ALWAYS replace a damaged cutterbar - refer to
“Maintenance”.
MOWING AND GRASS CARE TIPS
The Clipper 46 employs a mulching system. The grass is cut and then finely chopped before
being forced down by blown air into the root area. The fine clippings should be left to break
down naturally in order to fertilise the lawn. For best results, it is important that the grass is
not cut too short.
In dry weather conditions leave the grass long to help retain ground moisture.
Aerate the lawn to stimulate soil organisms and root growth. In spring and late summer
remove dead grass and aerate the lawn by raking or similar means.
Keep the cutterbar sharp. A blunt cutterbar will tear the grass and cause the tips to turn
brown.
Always keep the underside of the deck clean.
Avoid mowing when the grass is wet. Grass clippings will stick to the underside of the deck
and the mulching performance will be affected.
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OPERATING THE MOWER
1.23
1.23
MOWING AND GRASS CARE TIPS
Continued.
Prevent scalping. Plan your direction of travel to mow across hollows and humps.
Prevent grass damage. Take care when turning the mower.
Brush the lawn surface to disperse worm casts before mowing.
Spike compacted lawn areas with a fork. Fill the holes with sand to improve aeration and
drainage.
Mow lawns in a different direction to the previous cut.
Mow lawns twice a week when the grass is growing vigorously in the summer.
Mow lawns once a week in spring, autumn and during prolonged dry weather in the summer.
Prevent grass damage - DO NOT remove more than one third of the grass height in one
cut.
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MAINTENANCE
1.24
1.24
MAINTENANCE
WARNING: PREVENT ACCIDENTS - Stop the engine
and disconnect the spark plug lead before attempting to
carry out maintenance procedures on the mower.
STOP
CS044
ENGINE
4
3
1. Governor control lever
2. Air cleaner
2
3. Start-grip
4. Finger Guard
5. Muffler
1
6. Spark plug
7. Primer bulb
8. Carburettor
9. Fuel Cap
5
10.Fuel tank
6
11.Flywheel
12.Oil fill/Dipstick
12
7
8
9
10
11
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MAINTENANCE
1.25
1.25
CARBURETTOR ADJUSTMENTS
Carburettor adjustments should only be made by an authorised Briggs & Stratton dealer.
Under no circumstances should the engine be adjusted to run at a speed in excess of 3,000
r.p.m.
OIL SERVICE
Refer to the Maintenance Schedule at the end of this section and ensure that the recommen-
dations are followed. More frequent service is required when operating in adverse conditions.
- Check the oil level every 5 hours or daily before starting the engine and ensure that
the correct oil level is maintained. Refer to-‘Before Starting the Engine: Oil
Recommendations’ for oil checking procedure and filling instructions.
- Change the engine oil after the first 5 hours of operation and thereafter at the end of
every grass cutting season. In circumstances where the engine is being operated for
long periods under heavy load or high ambient temperatures, the oil should be changed
at 25 hour intervals.
- Change the oil while the engine is warm. Refill with fresh clean oil of the recom-
mended SAE viscosity grade. Refer to -‘Before Starting the Engine:Oil
Recommendations’.
WARNING - PREVENT ACCIDENTS: Drain fuel from the tank by running the engine
until the fuel tank is empty before attempting to tip the mower for oil draining
purposes.
- Remove the spark plug lead and allow the engine to
cool. Slacken the lower handlebar securing knobs and
move the handlebar assembly forwards. Tip the mower
backwards until the handlebar assembly is supported on
the ground, as shown. Remove the oil filler dipstick and
drain the oil into a suitable container.
ST014
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MAINTENANCE
1.26
1.26
AIR CLEANER SERVICE
Refer to the Maintenance Schedule at the end of this section
and ensure that the recommendations are followed. More
frequent service is required when operating in adverse con-
ditions.
1
2
- Replace the element if very dirty or damaged.
- Remove screw (1)
3
- Carefully remove the air cleaner to prevent debris
from falling into the carburettor.
4
- Take the air cleaner apart and clean all parts. Wash
the element (2) in liquid detergent and water. Wrap
the element in a clean cloth and squeeze dry.
Saturate the element in engine oil. Wrap in a clean
cloth and squeeze to remove excess oil.
5
- Install the element and cup (3) into the body (4).
Install the element so that lip (5) extends over the
edge of the body to form a protective seal when
cover is assembled.
-Install the air cleaner securely on the carburettor
with the screw.
SPARK PLUG SERVICE
Use only Briggs & Stratton spark tester (1) to check for a
spark as shown in the diagram.
1
Replace the spark plug every 100 hours or every season,
which ever occurs first. A spark plug wrench is available
from any authorised Briggs & Stratton service dealer.
The spark plug gap (2) should be checked with a feeler
gauge and set at 0.76mm.
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MAINTENANCE
1.27
1.27
KEEPING THE ENGINE CLEAN
WARNING - PREVENT ACCIDENTS : Accumulation of debris around the muffler
could cause a fire. Inspect and clean the engine after every use.
Remove all grass and debris from the engine including the muffler / muffler guard, the air
ways in the finger guard (1) and the surrounding deck areas on a daily basis after use.
3
2
1
2
5
ST009
4
CS045
IMPORTANT - PREVENT ENGINE DAMAGE: Never spray the engine with water
during cleaning. Water can contaminate the fuel. Always clean with a brush or com-
pressed air.
NOTE: Grass and debris may clog the engine’s air cooling system especially after prolonged
operation while cutting tall, dry grass. The internal cooling fins and surfaces may require
cleaning to prevent overheating and engine damage.
- Remove the three screws (2) and lift the cowl and blower
housing assembly to clean areas within the heavy line (3) as
shown in the diagram.
- Do not loosen 2 band brake bracket screws (4).
- Do not bend or remove flywheel guard (5).
After cleaning replace the cowl and the blower housing assembly and secure with the 3
screws.
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MAINTENANCE
1.28
1.28
DECK HOUSING
Remove grass debris from the top and underside of the deck
housing immediately after use. It is particularly important to
keep the underside clean to preserve the mulching action and
prevent corrosion.
If grass debris has dried onto the deck housing, it should be
removed using a suitable brush. If necessary touch in any areas
of damaged paintwork with a suitable paint to prevent rusting.
IMPORTANT - PREVENT DAMAGE: DO NOT use high
pressure washing units to clean the mower.
SECURING NUTS AND BOLTS
Regularly check that all securing nuts and bolts are tight.
Replace missing or damaged items immediately.
CS015
LUBRICATION
Apply a good quality medium grease to the inner control cables
every 25 operating hours at the point of entry and exit from
their outer casings.
CS022
Clean the insides of the front drive wheels once a season.
Remove the hub caps, screws, washers and wheels. Remove
any debris from the gears and gear rings using a brush.
Reassemble the wheels.
ST011
Lubricate the driveshaft slide bearings at least once a season.
Set the mower at the minimum height of cut and remove the
transmission casing to gain access to the lubrication points.
Replace the transmission casing.
ST012
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MAINTENANCE
1.29
1.29
CLUTCH CABLE ADJUSTMENT
Check the clutch cable operation every 25 operating hours and
adjust if necessary.
Adjustment is carried out as follows:
- Set the mower at the minimum height of cut position
and remove the transmission casing.
- Use the left hand to hold the engine stop lever
against the handlebar but do not start the engine. Use
the right hand to push the ground drive clutch lever for-
wards until it locks into the engaged position. Push
the mower in a forward direction until the front wheels
lock.
In this position the tension spring (K) should have
extended by approximately 9mm from the original
position with the controls released.
- If the adjustment is incorrect, slacken the lock nuts
(M) and rotate the cable adjuster (L) as necessary.
Retighten the lock nuts.
ST013
- After adjustment check to ensure that there is a small
amount of free play in the clutch control mechanism
with the controls released.
- Replace the transmission casing.
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MAINTENANCE
1.30
1.30
CUTTERBAR
WARNING - PREVENT ACCIDENTS : Never work on
the cutterbar unless the spark plug lead has been
removed. The cutterbar has sharp edges. ALWAYS wear
strong gloves to protect your hands when working on the
cutterbar. DO NOT rotate tools towards the cutting
edges to avoid the risk of injury should the tool slip.
ALWAYS use genuine Hayter replacement parts.
The condition of the cutterbar and its mounting
arrangement should be checked regularly for signs of
wear or damage. Ensure that the cutterbar is not bent
or cracked.
A damaged cutterbar that is out of balance will vibrate
excessively and may break. DO NOT use an unbalanced
cutterbar.
Regularly check that the bolt securing the cutterbar is
tightened to the specified torque of 40Nm.
Replace the cutterbar every 2 years of sooner if exces-
sively worn or damaged.
How to remove the cutterbar: Drain the fuel by operating
the engine until the fuel tank is empty and the engine stops.
Remove the spark plug lead and allow the engine to cool.
Slacken the lower handlebar securing knobs and move the
handlebar assembly forwards. Tip the mower backwards
until the handlebar assembly is supported on the ground, as
shown.
ST014
Firmly grip the end of the cutterbar with the gloved hand
and remove the bolt and washer securing the cutterbar with
a 9/16” A/F spanner.
ST015
How to assemble the cutterbar: Assemble the cutterbar
with the blade cutting edges facing away from the engine.
Secure the cutterbar using the blade holder, bolt and
washer and tighten to a torque of 40Nm.
1. Blade Holder
2. Bolt
3. Washer
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MAINTENANCE
1.31
1.31
CUTTERBAR
Continued.
How to sharpen and balance the cutterbar: A slightly
worn cutterbar may be re-sharpened. All cutting edges must
be sharpened equally to ensure balance. Sharpen the cutter-
bar every 25 mowing hours or more frequently if conditions
require. Remove the cutterbar from the mower and clean
using a brush and water. Inspect the cutterbar for signs of
damage.
30 -45
CS040
WARNING - PREVENT ACCIDENTS: DO NOT use a
damaged or excessively worn cutterbar.
Sharpen all the cutting edges with a flat file to restore the
original cutting edges.
CS025
Ensure that the cutterbar is balanced. Use a screw driver
with a round shaft to support the cutterbar through its centre
hole. Hold the cutterbar horizontal and then release. A bal-
anced cutterbar will remain horizontal. If the cutterbar is
not balanced the heavy end will rotate downward. Sharpen
the heavy end until the cutterbar is correctly balanced.
CS026
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MAINTENANCE
1.32
1.32
MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first. More frequent service
will be required if working for prolonged periods under dusty, dry conditions, or when
airborne debris is present or after extensive operation cutting tall, dry grass.
AFTER FIRST 5 HOURS
Change engine oil
G
EVERY 5 HOURS OR DAILY
Check oil level
G
G
Remove grass debris from around engine, muffler/muffler guard and air ways in the top
cowl.
Remove grass debris from top and underside of deck housing.
Check condition of guards and safety devices.
Check condition of cutterbar.
G
G
G
EVERY 25 HOURS OR EVERY SEASON
GGG
Change engine oil if continuously operating under heavy load or high ambient temperature.
GGG
Service air cleaner element.
GGG
Grease inner control cables at point of entry and exit from their outer casings.
GGG
Check clutch cable adjustment
G
Sharpen cutterbar.
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MAINTENANCE
1.33
1.33
MAINTENANCE SCHEDULE Continued.
EVERY 50 HOURS OR EVERY SEASON
Change engine oil.
GGG
GGG
Clean the insides of the front drive wheels.
Lubricate the transmission drive shaft slide bearings.
GGG
EVERY 100 HOURS OR EVERY SEASON
Clean engine cooling system. Clean more often under dusty conditions or when airborne
GGG
debris is present or after prolonged operation whilst cutting tall, dry grass.
Replace spark plug.
GGG
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PREPARING THE MOWER FOR STORAGE
1.34
1.34
PREPARING THE MOWER FOR STORAGE
Handlebar storage: Slacken the upper and lower handlebar securing knobs and fold into
the storage position. Take great care to ensure that the control cables do not become
snagged or damaged during folding.
Storage for periods in excess of 30 days: Engines stored in excess of 30 days need to be
protected with Briggs & Stratton fuel additive or drained of fuel to prevent gum from form-
ing in the fuel system or on essential carburettor parts. To ensure your mower is maintained
in good working order it is important that the following procedure is adopted. Refer to the
Maintenance section as necessary.
Drain fuel from the engine by operating the engine until it stops.
Disconnect the spark plug lead.
Change the engine oil.
Remove the engine spark plug and pour 15ml of engine oil into the engine cylinder and
replace the spark plug. Do not exceed the stated volume of oil as engine damage may occur
on re-starting. Do not replace the spark plug lead. Operate the engine stop lever and
slowly pull the engine start - grip once to crank the engine. This will distribute the oil and
help prevent engine corrosion.
Clean grass and debris from the engine cylinder, cylinder head cooling fins, under blower
housing and around and behind the muffler/muffler guard.
Clean all other areas of the mower.
Lubricate the mower.
Treat metal parts with a water repellent anti-corrosion product.
Fold the handlebar to the storage position if desired. Rest the mower deck on wooden
blocks with the wheels clear of the ground.
Cover the mower with a protective sheet and store it in a dry, ventilated area.
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FAULT FINDING
1.35
1.35
FAULT FINDING
PROBLEM
POSSIBLE FAULT
REMEDY
Engine will not turn over
Engine stop lever released
Incorrect oil level
Operate engine stop lever
Check oil level
Obstruction under deck
Remove obstruction
Engine smokes
Excess oil level
Check oil level
Air cleaner plugged
or dry.
Service air cleaner
Engine runs then stops
Fuel starvation
Fill fuel tank
Fuel cap vent blocked
Clean fuel cap vent
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FAULT FINDING
1.36
1.36
FAULT FINDING
Continued.
PROBLEM
POSSIBLE FAULT
REMEDY
Engine will not start
Engine under load
Fuel starvation
Raise height of cut
Fill fuel tank
Engine cold
Operate primer bulb.
Incorrect/contaminated fuel
Drain fuel tank and fill with
correct fuel
Spark plug lead disconnected Connect spark plug lead
Engine brake not released
Faulty spark plug
Operate engine stop lever
Clean and adjust gap or replace
Engine runs rough
Spark plug lead becoming
disconnected in use
Connect spark plug lead
Faulty spark plug
Clean and adjust gap or replace
Air cleaner element blocked Service air cleaner.
Incorrect/contaminated fuel
Drain fuel tank and fill with
correct fuel
Engine vibrates excessively
Mounting bolts loose
Cutterbar bolt loose
Tighten bolts
Tighten bolt
Cutterbar out of balance
Engine crankshaft bent
Balance cutterbar
Consult your dealer
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FAULT FINDING
1.37
1.37
FAULT FINDING
Continued.
POSSIBLE FAULT
Grass is wet
PROBLEM
REMEDY
Uneven cut
Mow dry grass
Undulating ground conditions Change direction of travel
Cutterbar worn
Sharpen the cutterbar
Cutterbar out of balance
Wheels damaged
Balance the cutterbar
Inspect and replace as necessary
Mower is hard to push
Cut height too low
Wheels damaged
Increase cut height
Inspect and replace
as necessary
Mower will not self propel
Clutch out of adjustment
Drive belt damage
Adjust clutch
Replace drive belt
Poor mulching performance Underside of deck is dirty
Clean underdeck
Height of cut set too low
Cutterbar worn
Increase height of cut
Sharpen the cutterbar
Mow dry grass
Grass is wet
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401R CHASSIS PARTS LIST
2.1
2.1
PARTS LIST
TEM NO.
DESCRIPTION
PART NO.
QTY
1
6
7
Blade
Blade bolt
Washer
Blade holder
Key
Shoulder bolt
Washer
Flat washer
Axle mounting
Control lever
*Plastic knob
Hole plate
Bushing
Wheel lock kit
*Lock washer
Slotted pin
Front axle
Hub cap-black
Nut
Screw
Flat washer
Plug
Lock nut
Nut guard
Screw
Handlebar-lower part
Handle bolt kit
*Locking knob
*Washer
*Screw
*Reinforcement
Eyelink
ST1111-3099-01
ST9987-5257-12
ST9696-0011-01
ST1111-2142-01
ST9600-0014-00
ST1111-0545-00
ST9694-0003-00
ST9699-0069-02
ST1111-1268-01
ST1111-1337-01
ST1111-2549-01
ST1111-0497-00
ST1111-2057-02
ST1111-9042-01
ST9675-0017-02
ST9595-0182-00
ST1111-2526-01
ST1111-3085-06
ST9739-0831-22
ST9955-3732-12
ST9699-0029-02
ST9403-0043-70
ST9747-0831-02
ST9403-0113-00
ST9898-0835-12
ST1111-2962-01
ST1111-9030-02
ST1111-0035-01
ST9699-0025-02
ST9899-3551-12
ST1111-0178-00
ST1111-3062-01
ST1111-2961-01
ST1111-2018-01
ST9836-9216-12
ST1111-3079-05
1
1
1
1
1
2
2
2
2
2
1
2
2
1
4
2
1
2
2
3
3
2
4
4
4
1
2
2
2
2
2
1
1
1
1
1
10
11
12
13
14
15
16
17
18
19
20
20
21
22
23
25
26
27
30
31
32
33
34
35
35
36
37
38
39
40
41
42
45
Handlebar-interm.part
Cable holder
Screw
Chassis-black
46
Handlebar-upper part
ST1111-2960-01
1
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401R CHASSIS PARTS LIST
2.2
2.2
PARTS LIST
ITEM NO. DESCRIPTION
PART NO.
QTY
47
48
49
50
51
52
54
55
55
56
59
60
61
62
63
64
65
Decal - Engine
Engine - Cowl
Washer
Screw
Screw
401008
1
1
1
1
1
1
1
ST1111318601
ST9699009902
ST9987473219
ST9948064016
ST9747063102
ST1111295201
ST1111296803
ST1111296805
ST1111296901
ST1111118003
ST1111113801
ST1111266501
ST1111904701
ST1111118401
ST9500740405
219189
Lock nut
Control handle
Engine brake cable
Engine brake cable
Cable attachment
Wheel cover
Spring
Wheel assy
*Ball bearing kit
*Bearing cone
Engine
1
1
2
2
2
1
2
1
1
Decal- Caution
*These components form part of a sub-assembly.
The quantities indicated are per sub-assembly
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401R CHASSIS PARTS DIAGRAM
2.3
2.3
50
49
47
48
64
65
3D401102A
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401R TRANSMISSION PARTS LIST
2.4
2.4
PARTS LIST
TEM NO.
DESCRIPTION
PART NO.
QTY
1
2
3
4
5
6
7
8
Wheel mounting-R.H.
Wheel mounting-L.H.
*Bronze bearing
*Plastic knob
Spacer
Cover plate
Pin
Gear wheel
Washer
Screw
Washer
Spring
Wheel assy
*Ball bearing kit
*Bearing cone
Washer
ST1111290001
ST1111290101
ST9548001400
ST1111254901
ST1111306501
ST1111256101
ST1111238201
ST1111263502
ST9699010002
ST9943061216
ST9699003702
ST1111113801
ST1111266501
ST1111904701
ST1111118401
ST9699010002
ST9943061216
ST1111308506
ST1111263302
ST9943053016
ST9943054016
ST9739053122
ST1111906201
ST1111291501
ST9910061216
ST1111305501
ST1111304701
ST9594005500
ST1111306001
ST1111296503
ST9747063102
ST9948065516
ST9836951212
ST1111201801
ST9836921612
ST9579000800
ST1111198702
533005
1
1
2
1
2
2
2
2
2
2
2
2
2
1
2
2
2
2
1
1
2
2
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
9
10
16
17
18
19
20
21
22
23
30
31
32
33
40
41
42
45
46
47
49
65
66
67
68
75
76
77
78
79
Screw
Hub cap-black
Front cover-black
Screw
Screw
Nut
V-belt
Engine belt pulley
Set screw
Transmission assy
*Belt pulley dito
*Locating pin
Spring
Clutch control
Lock nut
Screw
Screw
Cable holder
Screw
Cable holder
Control knob-black
Decal - Hayter
*These components form part of a sub-assembly.
The quantities indicated are per sub-assembly
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401R TRANSMISSION PARTS DIAGRAM
2.5
2.5
79
3D401101A
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ENGINE ANCILLARY PARTS
2.6
2.6
These parts are available through an authorised Briggs & Stratton dealer.
FUEL ADDITIVE
AIR CLEANER CARTRIDGE
ST018
SPARK PLUG
SPARK PLUG WRENCH
SPARK PLUG TESTER
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ENGINE WARRANTY
2.7
2.7
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NOTES
2.8
2.8
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CUSTOMER INFORMATION
2.9
2.9
Machine Serial No : .................................................................................................................
Engine Serial No :.....................................................................................................................
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