Troy Bilt Lawn Mower OG 4904 User Manual

Owner’s Manual

♦SET-UP ♦OPERATION ♦MAINTENANCE

IMPORTANT: Read Safety Rules and Instructions Carefully

PRINTED IN CANADA

OG-4904

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This unit has been inspected against the manufacturers quality check list. In case of a discrep-

ancy, please call us. We will make every effort to ship the part(s) by courier within one working

day of your call.

IMPORTANT SAFE OPERATION PRACTICES

WARNING: This symbol points out important safety instructions which, if not fol-

lowed, could endanger the personal safety and/or property of yourself and others.

Read and follow all instructions in this manual before attempting to operate this

machine. Failure to comply with these instructions may result in personal injury.

When you see this symbol—

heed its warning.

DANGER: This machine was built to be operated according to the rules for safe op-

eration in this manual. As with any type of power equipment, carelessness or error

on the part of the operator can result in serious injury. This machine is capable of

amputating hands and feet and throwing objects. Failure to observe the following

safety instructions could result in serious injury or death.

GENERAL OPERATION

• Wear sturdy, rough-soled work shoes and

close-fitting slacks and shirts. Shirts and

pants that cover the arms and legs and

steel-toed shoes are recommended. Never

operate this machine in bare feet, sandals,

slippery or light weight (e.g. canvas) shoes.

• Read, understand, and follow all instructions

on the machine and in the manual(s) before

attempting to assemble and operate. Keep

this manual in a safe place for future and

regular reference and for ordering replace-

ment parts.

• Many injuries occur as a result of the mower

being pulled over the foot during a fall

caused by slipping or tripping. Do not hold

on to the mower if you are falling; release

the handle immediately.

• Be familiar with all controls and their proper

operation. Know how to stop the machine

and disengage them quickly.

• Never allow children under 14 years old to

operate this machine. Children 14 years old

and over should read and understand the

operation instructions and safety rules in

this manual and should be trained and su-

pervised by a parent.

• Never pull the mower back toward you while

you are walking. If you must back the

mower away from a wall or obstruction first

look down and behind to avoid tripping and

then follow these steps:

a) Step back from the mower to fully extend

your arms.

• Never allow adults to operate this machine

without proper instruction.

b) Be sure you are well balanced with sure

footing.

• To help avoid blade contact or a thrown ob-

ject injury, keep bystanders, helpers,

children and pets at least 75 feet from the

machine while it is in operation. Stop ma-

chine if anyone enters the area.

c) Pull the mower back slowly, no more than

half way toward you.

d) Repeat these steps as needed.

• Thoroughly inspect the area where the

equipment is to be used. Remove all stones,

sticks, wire, bones, toys and other foreign

objects which could be tripped over or

picked up and thrown by the blade. Thrown

objects can cause serious personal injury.

• Do not operate the mower while under the

influence of alcohol or drugs.

• Do not put hands or feet near rotating parts

or under the cutting deck. Contact with the

blade can amputate hands and feet.

• A missing or damaged discharge cover can

cause blade contact or thrown object inju-

ries.

• Plan your mowing pattern to avoid dis-

charge of material toward roads, sidewalks,

bystanders and the like. Also, avoid dis-

charging material against

wall or

• Do not engage the self-propelled mecha-

nism on units so equipped while starting

engine.

obstruction which may cause discharged

material to ricochet back toward the opera-

tor.

• Never attempt to make a wheel or cutting

height adjustment while the engine is run-

ning.

• Always wear safety glasses or safety gog-

gles during operation and while performing

an adjustment or repair to protect your

eyes. Thrown objects which ricochet can

cause serious injury to the eyes.

• The blade control handle is a safety device.

Never attempt to bypass its operation.

Doing so makes the safety device inopera-

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tive and may result in personal injury

through contact with the rotating blade. The

blade control handle must operate easily in

both directions and automatically return to

the disengaged position when released.

DO:

• Mow across the face of slopes; never up

and down. Exercise extreme caution when

changing direction on slopes. Watch for

holes, ruts, bumps, rocks, or other hidden

objects which can cause you to slip or trip.

Tall grass can hide obstacles. Always be

sure of your footing. A slip and fall can

cause serious personal injury. If you feel you

are losing your balance, release the blade

control handle immediately, and the blade

will stop rotating within 3 seconds.

• Never operate the mower in wet grass. Al-

ways be sure of your footing. A slip and fall

can cause serious personal injury. If you feel

you are losing your footing, release the

blade control handle immediately and the

blade will stop rotating within three seconds.

• Mow only in daylight or in good artificial

light. Walk, never run.

DO NOT:

• Stop the blade when crossing gravel drives,

walks or roads.

• Do not mow near drop-offs, ditches or em-

bankments, you could lose your footing or

balance.

• If the equipment should start to vibrate ab-

normally, stop the engine and check

immediately for the cause. Vibration is gen-

erally a warning of trouble.

• Do not mow slopes greater than 15 degrees

as shown on the slope gauge.

• Do not mow on wet grass. Unstable footing

could cause slipping.

• Shut the engine off and wait until the blade

comes to a complete stop before removing

the grass catcher or unclogging the chute.

The cutting blade continues to rotate for a

few seconds after the engine is shut off.

Never place any part of the body in the

blade area until you are sure the blade has

stopped rotating.

CHILDREN

• Tragic accidents can occur if the operator is

not alert to the presence of children. Children

are often attracted to the mower and the

mowing activity. They do not understand the

dangers. Never assume that children will re-

main where you last saw them.

• Never operate mower without proper trail

shield, discharge cover, grass catcher, blade

control handle or other safety protective de-

vices in place and working. Never operate

mower with damaged safety devices. Failure

to do so, can result in personal injury.

a) Keep children out of the mowing area

and under the watchful care of a respon-

sible adult other than the operator.

b) Be alert and turn mower off if a child en-

ters the area.

• Muffler and engine become hot and can

cause a burn. Do not touch.

c) Before and while moving backwards, look

behind and down for small children.

• Only use parts and accessories made for

this machine by the manufacturer. Failure to

do so, can result in personal injury.

d) Use extreme care when approaching

blind corners, doorways, shrubs, trees, or

other objects that may obscure your vi-

sion of a child who may run into the

mower.

• If situations occur which are not covered in

this manual, use care and good judgment.

Contact your customer support department.

e) Keep children away from hot or running

engines. They can suffer burns from a

hot muffler.

SLOPE OPERATION

Slopes are a major factor related to slip and

fall accidents which can result in severe in-

jury. Operation on slopes requires extra

caution. If you feel uneasy on a slope, do

not mow it. For your safety, use the slope

gauge included as part of this manual to

measure slopes before operating this unit on

a sloped or hilly area. If the slope is greater

than 15 degrees, do not mow it.

• Never allow children under 14 years old to

operate a power mower. Children 14 years

old and over should read and understand

the operation instructions and safety rules in

this manual and should be trained and su-

pervised by a parent.

SERVICE SAFE HANDLING OF GASOLINE:

• To avoid personal injury or property damage

use extreme care in handling gasoline. Gas-

oline is extremely flammable and the vapors

are explosive. Serious personal injury can

occur when gasoline is spilled on yourself

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or your clothes which can ignite. Wash your

skin and change clothes immediately.

GENERAL SERVICE:

• Never run an engine indoors or in a poorly

ventilated area. Engine exhaust contains car-

bon monoxide, an odorless and deadly gas.

a) Use only an approved gasoline container.

b) Never fill containers inside a vehicle or on

a truck or trailer bed with a plastic liner.

Always place containers on the ground

away from your vehicle before filling.

• Before cleaning, repairing, or inspecting,

make certain the blade and all moving parts

have stopped. Disconnect the spark plug

wire and ground against the engine to pre-

vent unintended starting.

c) When practical, remove gas-powered

equipment from the truck or trailer and

refuel it on the ground. If this is not possi-

ble, then refuel such equipment on a

trailer with a portable container, rather

than from a gasoline dispenser nozzle.

• Check the blade and engine mounting bolts

at frequent intervals for proper tightness.

Also, visually inspect blade for damage

(e.g., bent, cracked, worn) Replace blade

with the original equipment manufacturer’s

(O.E.M.) blade only, listed in this manual.

“Use of parts which do not meet the original

equipment specifications may lead to im-

proper performance and compromise

safety!”

d) Keep the nozzle in contact with the rim of

the fuel tank or container opening at all

times until fueling is complete. Do not

use a nozzle lock-open device.

e) Extinguish all cigarettes, cigars, pipes

and other sources of ignition.

• Mower blades are sharp and can cut. Wrap

the blade(s) or wear gloves, and use extra

caution when servicing them.

f) Never fuel machine indoors.

g) Never remove gas cap or add fuel while

the engine is hot or running. Allow en-

gine to cool at least two minutes before

refueling.

• Keep all nuts, bolts, and screws tight to be

sure the equipment is in safe working condi-

tion.

h) Never over fill fuel tank. Fill tank to no

more than ½ inch below bottom of filler

neck to provide space for fuel expansion.

• Never tamper with safety devices. Check

their proper operation regularly.

• After striking a foreign object, stop the en-

gine, disconnect the spark plug wire and

ground against the engine. Thoroughly in-

spect the mower for any damage. Repair

the damage before starting and operating

the mower.

i) Replace gasoline cap and tighten se-

curely.

j) If gasoline is spilled, wipe it off the en-

gine and equipment. Move unit to

another area. Wait 5 minutes before start-

ing the engine.

• Grass catcher components, discharge cover,

and trail shield are subject to wear and

damage which could expose moving parts

or allow objects to be thrown. For safety

protection, frequently check components

and replace immediately with original equip-

ment manufacturer’s (O.E.M.) parts only,

listed in this manual. “Use of parts which do

not meet the original equipment specifica-

tions may lead to improper performance

and compromise safety!”

k) Never store the machine or fuel container

inside where there is an open flame,

spark or pilot light as on a water heater,

space heater, furnace, clothes dryer or

other gas appliances.

l) To reduce fire hazard, keep machine free

of grass, leaves, or other debris build-up.

Clean up oil or fuel spillage and remove

any fuel soaked debris.

m) Allow machine to cool at least 5 minutes

before storing.

• Do not change the engine governor setting

or overspeed the engine. The governor con-

trols the maximum safe operating speed of

the engine.

• Maintain or replace safety and instruction la-

bels, as necessary.

• Observe proper disposal laws and regula-

tions. Improper disposal of fluids and

materials can harm the environment.

SI-102

7.23.03

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OWNER'S

MANUAL

SAFETY LABEL

WARNING - Your Responsibility:

Restrict the use of this power machine to persons who

read, understand and follow the warnings and instruc-

tions in this manual and on the machine.

SLOPE GAUGE

(Keep this sheet in a safe place for future reference.)

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SET-UP INSTRUCTIONS

This unit is shipped WITHOUT GASOLINE

brackets. Place the hairpin clips in the inner

hole. See Figure 2.

or OIL. After assembly, service engine with

gasoline and oil as instructed in the separate

engine manual packed with your unit.

• Place one carriage bolt (found in the hard-

ware pack included with your unit) in the

upper hole of the right handle mounting

bracket from the inside outward. Secure

with one plastic wing nuts. Repeat process

on other side. See Figure 2.

NOTE: Reference to right or left

hand side of the mower is observed

from the operating position.

HOW TO SET-UP YOUR LAWN MOWER

NOTE: Make certain the drive cable is

routed around the outside and above

the lower handle so it does not interfere

with attaching the grass bag.

Refer to Illustration Below

• Disconnect the spark plug wire and move it

away from spark plug as instructed in the

separate engine manual packed with your

unit.

• The rope guide (pigs tail) is part of the grass

catcher support rod attached to the lower

handle. See Figure 3. With the spark plug

wire disconnected and grounded as in-

structed in the separate engine manual,

hold the blade control handle against the up-

per handle, and pull the starter rope out of

the engine slowly until it extends past the

rope guide (pigs tail).

• Remove the carton inserts (if any). Remove

the loose parts which are in the carton, lift

the mower from the carton, or cut the cor-

ners of the carton and roll the mower out.

• Pull up and back on the upper handle to

raise the handle into the operating position.

See Figure 1. Make certain the lower handle

is seated securely into the handle mounting

brackets. Tighten the wing nuts on each side

of the handle. See Figure 2.

• Guide the starter rope around the rope guide

(pig tail) until the rope is securely in the cen-

ter.

• Remove the hairpin clips from the outer hole

in the weld pins on the handle mounting

• Make certain all nuts and bolts are tightened

securely.

Upper

Handle

Wing Nut

Cutting Height

Adjustment Lever

Rope Guide

Lower Handle

Handle Mounting

Bracket

Blade Control Handle

Drive Clutch

Control

Shift Lever

Figure 1

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Upper Hole

Carriage

Bolt

Lower Handle

Lower

Handle

Recoil

Starter

Support

Rod

Rope

Guide

Weld Pin

Wing Nut

Place the hairpin clips in the inner hole.

Figure 3

Figure 2

Ignition Key (Switch)

CONTROLS

BLADE CONTROL HANDLE

WARNING: This control mechanism

is a safety device. Never attempt to

bypass its operations.

The blade control handle is located on the

upper handle of the mower. See Figure 1.

The blade control handle must be depressed

in order to operate the unit. Release the

blade control handle to stop the engine and

blade.

Figure 4-(Electric Start Units Only)

NOTE: Only move the shift lever when

the engine is running. Changing the

shift lever setting with the engine off

can cause damage to the mower.

WARNING: The blade will be rotat-

ing whenever the engine is running.

RECOIL STARTER

CUTTING HEIGHT ADJUSTMENT LEVER

(Models: 959 & 979)

The recoil starter handle is attached to the

handle. See Figure 3. Stand behind the unit

in the operating position to start the unit.

The height adjuster determines the cutting

height of the mower. The adjuster is located

above the left rear wheel. To adjust the cut-

ting height, pull the lever out and away from

the mower and then move it forward or back

to select a new cutting height. See Figure 5.

IGNITION SWITCH (Electric Start Units

Only)

The ignition switch is located on the left side

of the handle panel. It is used for starting

only. See Figure 4.

CUTTING HEIGHT ADJUSTMENT LEVER

(Model: 999)

DRIVE CLUTCH CONTROL

The rear wheel height adjuster determines

the cutting height of the mower. The adjuster

is located above the left rear wheel. To ad-

just the cutting height, pull the lever out and

away from the mower and then move it for-

ward or back to select a new cutting height.

See Figure 5.

Squeezing the drive clutch control engages

the drive system. Releasing the clutch

control disengages the drive system.

Release the clutch control to slow down

when negotiating an obstacle, making a turn

or stopping.

SHIFT LEVER

The front wheel cutting height is determined

by the selection of one of six positions in

each caster assembly. See Figure 6.

The shift lever is located on the drive clutch

control housing on the upper handle. See

Figure 1. This lever is used to select the

forward speed of the mower. When

changing your speed selection, release the

drive clutch control.

To adjust, remove the wing nut from the axle

bolt. Slide the axle bolt and spring washer

from the assembly and select

cutting

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LOWER

Locking Pin

Axle Bolt

and

Spring

Washer

HIGHER

Figure 6

Cutting Height Adjustment Lever

Figure 5

BEFORE STARTING

MODELS WITH ELECTRIC START ONLY:

height. With the spring washer on the axle

bolt reinsert in the square hole desired,

through the wheel assembly and secure with

the wing nut previously removed.

WARNING: The battery contains

corrosive fluid and toxic material.

HANDLE WITH CARE. Keep away

from children. Do not puncture, dis-

assemble, mutilate or incinerate. Ex-

plosive gases could be vented dur-

ing charging or discharging. Use in

IMPORTANT: All wheels must be placed in

the same relative position.

NOTE: For rough or uneven lawns,

move the height adjustment lever to a

higher position. This will help stop

scalping.

a well-ventilated area, away from

sources of ignition.

• Charge battery for 16 hours before initial

use. DO NOT CHARGE LONGER THAN 20

HOURS.

CASTER LOCK

WARNING: When operating mower

on hills, front wheels should be

locked in the straight ahead posi-

tion.

IMPORTANT: Use only the battery

charger supplied with this mower.

To charge the battery, first remove the pro-

tective cap from the end of the battery pack

lead. Always plug charger lead into battery

pack lead before inserting battery charger

plug into 120 volt standard household outlet.

See Figure 7.

The casters can be locked in

straight

ahead position or can be left to swivel freely.

Lift and place the lock pins in the larger

holes for locked, straight ahead operation,

place pins in smaller holes to allow casters

to rotate freely.

OPERATION

Protective

Cap

IMPORTANT: Move the shift lever ONLY

when the engine is running. Shifting the

speeds with the engine off can cause dam-

age to the unit. Disengage the drive clutch

control before changing the speed selection.

Battery

pack

Service the engine with gasoline and oil as

instructed in the separate engine manual

packed in your mower. Read instructions

carefully.

Figure 7

WARNING: Never fill fuel tank in-

doors, with engine running or until

the engine has been allowed to cool

for at least two minutes after run-

ning.

After charging, disconnect battery charger

plug from household outlet first, then discon-

nect charger lead from battery pack lead.

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WARNING: Do not remove the bat-

tery pack from the handle panel for

any reason other than replacement.

When replacing the battery pack,

refer to instructions in Maintenance

section.

Blade Control Handle

Drive

Clutch

NEUTRAL TEST FOR ALL MODELS:

Six Speed

Shift Lever

• Before each use, check for proper drive

clutch operation by performing the following

before starting the engine:

With the drive clutch control released, push

mower forward. It should move freely.

Recoil Start

Handle

If it does not and the rear wheels tend to

lock up, the clutch may not be releasing

completely. Do not start the engine until cor-

rections have been made. Check the control

cable for severe bend, kinks and binding, or

grass build-up in the pulley groove. Refer to

the "Adjustment" section for any additional

information.

Figure 9-RECOIL START MODEL SHOWN

• Standing behind the unit, depress the blade

control handle and hold it against the upper

handle as shown in Figure 9.

ELECTRIC START MODELS ONLY:

• Turn the ignition key to the right to start the

engine. Release the key after engine starts.

See Figure 4.

TO START ENGINE AND ENGAGE BLADE

WARNING: When starting the unit

for the first time, place mower in

first speed (slow) position. Face the

mower against a solid object such

as a wall, fence, etc. Start the unit,

and if it shows any signs of motion

with the drive clutch control disen-

gaged, shut the engine off immedi-

ately. Make certain the drive clutch

control is adjusted so the drive belt

is as loose as possible. Refer to the

Adjustment Section.

NOTE: The engine on your unit is

provided with an auxiliary recoil

starter system. To start the engine

using the auxiliary start system, pro-

ceed as follows for recoil start

models:

RECOIL START MODELS ONLY:

• Grasp the recoil starter handle as shown and

pull slowly until resistance is felt, then pull

rapidly to start engine and avoid kickback.

Return it slowly to the rope guide bolt. See

Figure 9.

• Attach spark plug wire to spark plug. If unit

is equipped with a rubber boot over the end

of the spark plug wire, make certain the

metal loop on the end of the spark plug wire

(inside the rubber boot) is fastened securely

over the metal tip on the spark plug. See

Figure 8.

• To engage the drive, squeeze the drive clutch

control handle (see Figure 9) towards the up-

per handle. Release the drive clutch control

to slow down when negotiating an obstacle,

making a turn, or stopping.

• The six speed shift lever is located on the

drive clutch control housing on the upper

handle. See Figure 9. This lever is used to se-

lect the operating speed of the mower.

Release the drive clutch control when chang-

ing speeds.

Metal

Loop

on Spark

Plug Wire

Rubber Boot

WARNING: THIS CONTROL MECHA-

NISM IS A SAFETY DEVICE. NEVER

ATTEMPT TO BYPASS ITS OPERA-

TIONS.

Figure 8

• If your unit is equipped with a primer, prime

engine as instructed in the separate engine

manual packed with your unit.

The blade control handle must be depressed

in order to operate the unit. Release the

blade control handle to stop the engine and

blade.

• If your unit is equipped with a two speed

control on the engine refer to the separate

engine manual packed with your unit.

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TO STOP ENGINE

Wing Nuts

• Release the blade control handle to stop the

engine and blade.

WARNING: The blade continues to

rotate for a few seconds after the

engine is shut off.

• Disconnect the spark plug wire and ground it

against the engine as instructed in the sepa-

rate engine manual to prevent accidental

starting while equipment is unattended.

Mulching

Baffle

USING YOUR ROTARY MOWER

Be sure that lawn is clear of stones, sticks,

wire, or other objects which could damage

lawn mower or engine. Such objects could

be accidentally thrown by the mower in any

direction and cause serious personal injury to

the operator and others.

Figure 10

Bagging Adapter

For the best results, do not cut wet grass be-

cause it tends to stick to the underside of the

mower, preventing proper mulching of grass

clippings. In addition, wet grass could cause

you to slip and fall. New grass, thick grass or

wet grass may require a narrower cut.

For best results, cut off one-third or less of

the total length of the grass. Lawn should be

cut in the fall as long as there is growth.

Figure 11

The mower is designed to be operated at full

throttle to give you the best cut and do the

most effective job of mulching.

Flap

Bagging

Adapter

WARNING: If you strike a foreign

object, stop the engine. Remove

wire from spark plug, thoroughly in-

spect the mower for any damage,

and repair the damage before re-

starting and operating the mower.

Extensive vibration of the mower

during operation is an indication of

damage. The unit should be

promptly inspected and repaired.

BAGGING GRASS CLIPPINGS

Figure 12

This mower can bag grass clippings. Follow

steps 1 through 3 to ready the mower for

bagging.

EMPTYING YOUR GRASS BAG

Lift grassbag from the bagging adapter us-

ing the lower handle. While holding the lower

handle lift up the rear section of the

grassbag. The bag will open and the grass

clippings will fall out. See Figure 13. When

replacing your grassbag be sure the top of

the bag rests on the wire support between

the handles.

1. Remove wing nuts holding mulching baffle

(see Figure 10) or side discharge chute

(see Figure 14) in place. Then remove

baffle or discharge chute.

2, Replace with bagging adapter (see Figure

11). Attach using wing nuts. Be sure that

inner lip of attachment goes under the

edge of the deck.

3. Lift flap and slide bag onto adapter. See

Figure 12.

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Side

Discharge

Chute

Wing Nut

Figure 13

Figure 14

SIDE DISCHARGE GRASS CLIPPINGS

This mower can also side discharge grass

clippings. Follow steps 1 and 2 to ready this

mower for side discharge operation.

Notch

Lower Handle

Figure 15

1. Remove mulching baffle or grass bag

adapter. See Figure 10.

2. Attach discharge chute with wing nuts. See

Figure 14.

ADJUSTMENT

Reassemble, placing the bottom holes in

the handle over the weld pins in the han-

dle mounting bracket.

CAUTION: DO NOT AT ANY TIME MAKE

ADJUSTMENTS TO LAWNMOWER WITH-

OUT FIRST STOPPING THE ENGINE AND

DISCONNECTING THE SPARK PLUG

WIRE

5. Reassemble the upper handle to the lower

handle.

6. Place the hairpin clips in the inner holes of

the weld pins and secure with carriage

bolts and wing nuts as instructed in

the“Set-Up” section of this manual.

CAUTION: Before changing mowing

height, stop mower and disconnect

spark plug cable.

7. Attach the starter rope and rope guide as

instructed in the “Set-Up” section of this

manual.

MODELS WITH SINGLE LEVER HEIGHT

ADJUSTERS:

Refer to “Controls Section” and Figure 5.

DRIVE CLUTCH CONTROL ADJUSTMENT

HANDLE HEIGHT ADJUSTMENT

Use the adjustment wheel located on the un-

derside of the clutch control housing to

tighten the drive belt if mower does not

self-propel with the drive clutch control en-

gaged, or if drive belt is slipping (unit

hesitates while engine maintains the same

speed). See Figure 16.

Your mower is shipped with the handle in

the higher height position. To lower the han-

dle height, proceed as follows.

1. Remove the starter rope and the rope

guide.

2. Remove the upper handle by removing the

wing nuts and carriage bolts. Lay the up-

per handle out of the way, being careful

not to bend or kink the cables.

In addition, the adjustment wheel may also

be used to determine the position in which

the drive clutch control is engaged. If it is

more comfortable to have the drive engaged

with the lever further away from the handle,

tighten the drive belt.

3. Remove the hairpin clips from the weld

pins on the handle brackets. Press out on

the legs of the lower handle. Remove

lower handle from the mower.

Make certain to retest the unit for neutral as

instructed in the operation Section. Move the

adjustment wheel in the opposite direction to

loosen the drive belt if necessary.

4. Turn the lower handle around so the notch

on the bottom of the lower handle is fac-

ing forward as shown in Figure 15.

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BOTTOM

VIEW

Hex Nut

Six Speed

Cable

Adjustable

Cable Bracket

Figure 17

Figure 16

SIX SPEED SHIFT CABLE ADJUSTMENT

MAINTENANCE

Periodic adjustment of the six speed shift ca-

ble may be required due to normal stretch

and wear on the cable. Adjustment is

needed if all six speeds cannot be obtained.

For best results your blade should be sharp.

The blade may be resharpened by removing

it and either grinding or filing the cutting

edge keeping as close to the original bevel

as possible.

The adjustable cable bracket is located on

the left side of the mower, beside the en-

gine. To adjust, loosen the hex nut which

secures the adjustable cable bracket. See

Figure 17. Pull backward on the bracket (to-

ward the rear of the mower). Retighten the

hex nut. Test the speeds on the mower (en-

gine must be running).

Improper blade balance will result in exces-

sive vibration causing eventual damage to

the engine and mower. Be sure to carefully

balance blade after sharpening.

After prolonged use, especially in sandy soil

conditions, the blade will become worn and

lose some of the original shape. Cutting effi-

ciency will be reduced and the blade should

be replaced. Replace with an approved factory

replacement blade only. Possible damage re-

sulting from blade unbalance condition is not

the responsibility of the manufacturer.

CARBURETOR ADJUSTMENT

Refer to the separate engine manual packed

with your mower for carburetor adjustment

information.

LUBRICATION

ENGINE

CAUTION: DISCONNECT SPARK

PLUG WIRE BEFORE SERVICING.

Refer to the separate engine manual for en-

gine maintenance instructions.

WHEELS - If your mower is equipped with

ball bearing wheels, lubricate at least once a

season with a light oil, all other types require

no lubrication. However, if the wheels are re-

moved for any reason, lubricate the surface

of the axle bolt and the inner surface of the

wheel with light automotive oil.

Maintain engine oil as instructed in the sepa-

rate engine manual packed with your unit.

Read and follow instructions carefully.

Under normal conditions service air cleaner

as instructed in the separate engine manual

packed with your unit.

Clean every few

ENGINE - Follow engine manual for lubrication

instructions.

hours under extremely dusty conditions.

Poor engine performance and flooding usu-

ally indicates that the air cleaner should be

serviced.

BLADE CONTROL - Lubricate the pivot points

on the blade control handle and the brake cable

at least once a season with light oil. The blade

control must operate freely in both directions.

The spark plug should be cleaned and the

gap reset once a season. Spark plug replace-

ment is recommended at the start of each

mowing season; check engine manual for cor-

rect plug type and gap specifications.

TRANSMISSION

The transmission is

pre-lubricated and sealed at the factory. It

does not require checking. If disassembled

for any reason, fill with 2 ounces of Alvania

grease, part number 737-0168.

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NOTE: This spark ignition system meets

all requirements of the Canadian Interfer-

ence-Causing Equipment Regulations.

Blade Adapter

Blade

Clean the engine regularly with a cloth or

brush. Keep the cooling system (blower hous-

ing area) clean to permit proper air circulation

which is essential to engine performance and

life. Be certain to remove all grass, dirt and

combustible debris from muffler area.

Blade Bell

Support

Hex Bolt

DECK

Figure 18

The underside of the mower deck should be

cleaned after each use to prevent a buildup of

grass clippings, leaves, dirt or other matter. If

this debris is allowed to accumulate, it will in-

vite rust and corrosion, and may prevent

proper mulching.

Before reassembling the blade and the blade

adapter to the unit, lubricate the engine crank-

shaft and the inner surface of the blade

adapter with light oil. Install the blade adapter

on the crankshaft with the “star” away from the

engine. Refer to Figure 18. Place the blade

with the side marked bottom (or with part

number) facing away from the adapter. Align

the blade bell support over the blade with the

tabs in the holes of the blade and insert the

hex bolt. Tighten the hex bolt to the torque

listed below:

The deck may be cleaned by tilting the mower

and scraping clean with a suitable tool (make

certain the spark plug wire is disconnected).

CUTTING BLADE

WARNING: Be sure to disconnect

and ground the spark plug wire and

remove ignition key before working

on the cutting blade to prevent acci-

dental engine starting. Protect hands

by using heavy gloves or a rag to

grasp the cutting blades.

Blade Mounting Torque

Center Bolt 450 in. lb. min., 600 in.lb. max.

To insure safe operation of your unit, ALL

nuts and bolts must be checked periodically

for correct tightness.

Tip mower as specified in separate engine

manual. If it is not specified tip with carburetor

up.

CAUTION: Cutting grass in sandy

soil conditions causes abrasive

wear to the blade.

Remove the bolt and blade support which

holds the blade and adapter to the engine

crankshaft. Remove the blade and adapter

from the crankshaft.

After prolonged use, especially in sandy soil

conditions, the blade will become worn and

lose some of the original shape. Cutting effi-

ciently will be reduced and the blade should be

replaced. Replace with an approved factory re-

placement blade only. Possible damage

resulting from blade unbalance condition is not

the responsibility of the manufacturer.

WARNING: Periodically inspect the

blade adapter for cracks, especially if

you strike a foreign object. Replace

when necessary.

For best results your blade should be sharp.

The blade may be resharpened by removing it

and either grinding or filing the cutting edge

keeping as close to the original bevel as pos-

sible. It is extremely important that each

cutting edge receives an equal amount of

grinding to prevent an unbalanced blade. Im-

proper blade balance will result in excessive

vibration causing eventual damage to the en-

gine and mower. Be sure to carefully balance

blade after sharpening. The blade can be

tested for balance by balancing it on a round

shaft screwdriver. Remove metal from the

heavy side until it balances evenly.

BELT REMOVAL AND REPLACEMENT

1. Disconnect the spark plug wire and

ground it against the engine.

2. Drain the fuel tank or place a piece of

plastic beneath the cap to prevent gaso-

line leakage.

3. Tip the mower on its side. Block securely.

4. Remove the blade and blade adapter as

described previously.

5. Move rear height adjuster to the highest

position. See Figure 21.

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6. Using a 3/8" socket remove three hex

screws holding the baffle to the deck. See

Figure 19.

Transmission

Pulley

7. Pivot baffle towards the rear of the mower.

See Figure 20.

Belt

Belt Keeper

Bracket

Transmission

Idler Pulley

Bracket

Hex

Screw

Idler Pulley

Bolt and

Locknut

Hex

Screw

Figure 19

Figure 22

Mower is shown tipped on engine for clarity.

Remember, only tip mower back on its han-

dle with the spark plug facing up.

Six-Speed

Cable Slot

Belt

Baffle

Figure 20

Control

Arm

Rear Wheels Adjustment Lever

Figure 23

Hex

Bolt

10. Using a pair of pliers, pull back and rotate

belt keeper bracket from the slot on idler

pulley.

11. Slide the belt out from between the belt

keeper bracket and the idler pulley. See

Figure 22.

Baffle

Figure 21

12. Squeeze the belt together and push belt

forward. Press the control arm inward to-

wards the deck and remove the six speed

cable from the slot. See Figure 23.

8. Remove the hex bolt holding the transmis-

sion to the mower housing. See Figure

21.

13. Pivot the control arm down away from the

pulley and belt. See Figure 24.

9. Tilt the transmission forward and loosen

the idler pulley bolt and locknut ½ turn

using two 7/16" wrenches.

14. Lift off the lower pulley assembly and re-

move the old belt from around the

crankshaft. See Figure 25.

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Upper Pulley

Half

Six-Speed

Cable Slot

Belt

Control

Arm

Lower

Pulley

Half

Belt Guard

Figure 26

Figure 24

Lower Pulley

Half

Crankshaft

Lower Pulley

Half

Belt

Belt Guard

Belt

Figure 27

Figure 25

15. Place the new belt over the transmission

pulley. Start the belt in pulley groove and

rotate pulley until belt is seated in trans-

mission pulley. See Figure 25.

16. Place belt between idler pulley and the

belt keeper bracket.

17. Using pliers, rotate the belt keeper bracket

so that it snaps into slot on the idler

bracket.

18. Tighten the idler pulley bolt and locknut ½

turn using two 7/16" wrenches. See Figure

22.

Figure 28

19. Place belt between the two pulley halves on

the crankshaft. Make sure to route the belt

inside the belt guard pin. See Figure 26.

22. Check and make sure the belt is routed in-

side the pulley halves and the belt guard

pin. See Figure 28.

23. Reinstall the bolt securing transmission to

rear mower housing.

IMPORTANT: For proper assembly, it

is essential to keep the assembly

positioned as shown in Figure 26.

24. Pivot the baffle back to its original position

and secure with three hex screws earlier re-

moved. You will need a 3/8" socket for these

screws.

20. Pinch belt together so that it is not in the pul-

ley groove, and the lower pulley can be

pushed towards the engine. See Figure 27.

25. Lightly lubricate the crankshaft and reinstall

blade and blade adapter as described in the

“Cutting Blade” section.

21. Pivot the control arm back to its original posi-

tion and reinstall the six-speed cable into the

slot.

26. Tip the mower back on its wheels.

27. Make certain to retest the unit for neutral as

instructed in the Operation Section.

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Fuse Holder

OFF SEASON STORAGE

INSTRUCTIONS

Positive

terminal

The following steps should be taken to pre-

pare lawn mower for storage.

1. Clean and lubricate mower thoroughly as

described in the lubrication instructions.

Negative

terminal

2. Refer to engine manual for correct engine

storage instructions.

3. Coat mower’s cutting blade with chassis

grease to prevent rusting.

4. Store mower in a dry, clean area.

Figure 29

STORAGE OF THE BATTERY

BATTERY PACK REPLACEMENT (Electric

start Models Only)

The battery must be stored with

charge. A discharge battery will freeze.

full

Remove the battery pack from the handle panel

for replacement only. Do not separate the bat-

teries for any reason. Dispose of batteries

properly.

IMPORTANT: All batteries discharge

during storage.

Recharge battery every two months and be-

fore returning to service. Refer to charging

instructions on page 9.

WARNING: Batteries contain sulfu-

ric acid which may cause burns. Do

not short circuit or mutilate in any

way. Do not put batteries in fire.

They may burst or release toxic ma-

terial.

NOTE: When storing any type of power

equipment in an unventilated or metal

storage shed, care should be taken to

rust-proof the equipment. Using a light

oil or silicone, coat the equipment, es-

pecially cables and all moving parts.

When replacing battery pack in handle

panel, battery pack must be positioned with

the positive terminal to the right hand side

and the negative terminal to the left hand

side of panel. See Figure 29. Replacing the

battery pack incorrectly will cause serious

damage.

CAUTION: Never fold or unfold

handle without disconnecting spark

plug.

NOTE: Be careful not to bend of kink

cables.

The positive lead on the wire harness has

the smaller connector. Connect the positive

lead to the positive side of the battery pack,

then connect the negative side.

NOTE: If the starter rope becomes dis-

connected from rope guide on handle,

disconnect and ground the spark plug

wire. Depress the bail and pull the

starter rope out from engine slowly. Slip

the starter rope into the rope guide bolt

on handle.

IN-LINE FUSE

The unit is equipped with an in-line fuse. If

unit fails to start, check the fuse inside the

battery cover by turning the end of the fuse

holder and removing from the battery cover.

See Figure 29. Replace with standard auto-

motive 7-1/2 amp fuse.

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THREE (3) YEAR LIMITED WARRANTY

For three (3) years from the date of original purchase of our products, we will either repair or

replace, at its option, free of charge, F.O.B. Factory or authorized service firm, any part found

to be DEFECTIVE IN MATERIAL and WORKMANSHIP for the original purchaser. all transporta-

tion charges on parts submitted for replacement under this warranty must be paid by the

purchaser unless return is requested by the manufacturer.

This warranty DOES NOT apply to any part which has become inoperative through misuse, ex-

cessive use, accident, neglect, improper maintenance or alterations by unauthorized persons.

The limited warranty does not extend to the replacement of parts which are not defective, but

where regular usage has exhausted the life of the part.

ENGINES, ELECTRIC START KITS, PEERLESS TRANSMISSIONS AND PEERLESS

TRANSAXLES ARE WARRANTED BY THEIR RESPECTIVE MANUFACTURER. ALL CLAIMS

AGAINST THESE COMPONENTS MUST BE HANDLED THROUGH THE RESPECTIVE MANU-

FACTURER’S SERVICE DEALERS.

Belts, light bulbs, clutch parts (friction wheels), grass bags, tires, seats, rider deck wheels and

cutting blades are covered by a 60 day limited warranty.

Batteries are covered by a 90 day limited warranty.

Fuses, shear bolts and blade adapters are considered consumable items and as such are not

warranted.

NOTE: Regular maintenance replacement parts and related inspections and adjustments are

excluded from coverage when made as part of normal maintenance service.

TRACTOR ATTACHMENT WARRANTY

Mower decks included with your product, or sold separately, as an attachment for your garden

tractors will be warranted according to the above terms of the manufacturer three (3) year lim-

ited consumer warranty.

ALL OTHER ATTACHMENTS will be sold under the same condition as above except the war-

ranty will be ONE YEAR FROM DATE OF ORIGINAL PURCHASE.

PERSONAL USE

THE FOREGOING PARAGRAPHS CONSTITUTE THE MANUFACTURER’S ENTIRE WARRANTY

WITH RESPECT TO ANY PRODUCT PURCHASED AND USED FOR PERSONAL FAMILY,

HOUSEHOLD/RESIDENTIAL PURPOSES, AS DISTINGUISHED FROM COMMERCIAL USAGE.

COMMERCIAL USE

ALL APPLICATIONS OTHER THAN PERSONAL USE AS OUTLINED ABOVE, ARE CON-

SIDERED COMMERCIAL USAGE.

New products purchased for commercial usage are warranted in the same manner and to the

same extend EXCEPT the term of warranty will be 60 DAYS from date of purchase.

WARRANTY SERVICE CAN ONLY BE PERFORMED BY AN AUTHORIZED SERVICE DEALER.

ANY NON-ORIGINAL EQUIPMENT REPLACEMENT PART USED ON OR IN A PRODUCT

UNDER WARRANTY WILL BE EXCLUDED FROM THAT WARRANTY COVERAGE, AS WILL BE

ANY RELATED DAMAGED COMPONENTS RESULTING FROM THE INSTALLATION OF A RE-

PLACEMENT PART FROM ANOTHER SOURCE OTHER THAN THE MANUFACTURER.

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TROUBLE SHOOTING

PROBLEM

POSSIBLE CAUSE(S)

CORRECTIVE ACTION

Engine fails to start

1. Blade control handle disen-

gaged.

1. Engage blade control handle.

2. Spark plug wire disconnected. 2. Connect spark plug wire.

3. Fuel tank empty, or stale fuel.

4. Blocked fuel line.

3. Fill tank with clean, fresh gasoline.

4. Clean the fuel line.

5. Faulty spark plug.

5. Clean, adjust gap or replace.

6. Engine flooded.

6. Wait a few minutes to restart, but

do not prime.

Engine runs erratic

1. Spark plug wire loose.

1. Connect and tighten spark plug wire.

2. Blocked fuel line or stale fuel.

2. Clean the fuel line; fill the tank

with clean, fresh gasoline.

3. Vent in gas plugged.

3. Clear vent.

4. Water or dirt in fuel system.

4. Drain the fuel tank and carburetor.

Refill with fresh fuel.

5. Dirty air cleaner.

5. Clean air cleaner.

6. Carburetor out of adjustment.

1. Engine oil level low.

2. Air flow restricted.

6. Adjust carburetor.

Engine overheats

Idles poorly

1. Fill crankcase with proper oil.

2. Remove blower housing and

clean.

3. Carburetor not adjusted prop-

erly.

3. Adjust carburetor.

1. Spark plug fouled, faulty or gap 1. Reset gap to .030" or replace

too wide. spark plug.

2. Carburetor improperly adjusted. 2. Adjust carburetor.

3. Dirty air cleaner.

3. Clean air cleaner.

Excessive vibration

1. Cutting blade loose or unbal-

anced.

1. Tighten blade and adapter. Bal-

ance blade.

2. Bent cutting blade.

1. Wet grass.

2. Replace blade.

Mower will not mulch grass

1. Do not mow when grass is wet;

wait until later to cut.

2. Excessively high grass.

2. Mow once at a high cutting

height, then mow again at desired

height or make a narrower cutting

path.

3. Dull blade.

3. Sharpen or replace blade.

Uneven cut

1. Wheels not positioned correctly. 1. Place all four wheels in same

hight position.

2. Dull blade.

2. Sharpen or replace blade.

Wheels will not propel

1. Belt not installed properly.

1. Check belt for proper pulley in-

stallation and movement.

2. Debris clogging drive operation. 2. Clean out debris.

NOTE: For repairs beyond the minor adjustments listed above, contract your nearest authorized

service dealer.

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notes . . .

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