allen xr44 hovertrim User guide

XR44 Hovertrim
OWNER’S HANDBOOK
Original Version (EN)
Issue: 11.01.2011
From Serial No. 311000001 Part No: 111-1519 (E)
MODELS:
184 Hovertrim

3
CONTENTS
Contents 3
Main Features / Specications 5
Introduction 6
Warranty 7
Safety Precautions 8 - 13
- Safety Alert Symbol 8
- Training 8
- Preparation 8 - 9
- Operation 10 - 11
- Maintenance & Storage 11 - 12
- Safety Symbols 13
- Information Symbols 13
Assembling the Hovertrim 14
- Delivery Checklist 14
- Assembling the Handlebars 14
Before Starting the Hovertrim 15
- Prevent Engine Damage 15
- Oil Type 15
- Check Oil Level 15
- Fuel Type 15
Operating the Hovertrim 16 - 18
- Controls 16
- Starting 16
- Cutting Grass on Flat Ground 17
- Cutting Grass on Slopes &
Banks
17
- Stopping 18
- Adjusting the Cutting Height &
Replacement of Nylon Cutting
System 18
- Before Trimming 18
Hovertrim Maintenance 19 - 22
- Engine 19
- Carburettor Adjustments 19
- Air Cleaner Service 19
- Spark Plug Service 20
- Keeping the Engine Clean 20
- Deck Housing 20
- Securing Nuts & Bolts 21
- Oil Service 21
- Storage 22
Trouble Shooting 23
Parts List & Drawings 24 - 27
- Mainframe Parts List 24
- Mainframe Exploded Drawing 25
- Blade Options / Kits Parts List 26
- Blade Options / Kits Exploded
Drawing
27
Declaration of Conformity 28
Notes 29 - 31
Customer Info 32

5
Main Features
1. Footstop
2. Air Cleaner
3. Serial No. Label
4. Choke Lever
5. Man Eye/ Ear Protection
6. Petrol Safety Decal
7. Spark Plug / Lead
8. Exhaust Guard
9. Handlebar Securing Knob
10. Handlebar
11. Engine Stop Lever
12. OPC Switch
13. Oil Dipstick
14. Engine Cover
15. Engine Start Grip
16. Fuel Cap Vent Knob
17. Fuel Cap
18. Fuel Valve Lever
Specications
Code 184E
Model XR44 Hovertrim
Engine Honda
Engine Type GXV57
Engine Speed 4800 rpm
Fuel Type Unleaded petrol
Fuel Capacity 0.27 litres
Engine Oil Type SAE 10W-30
Oil Sump Capacity 0.25 litres
Cutting Width 40cm (16)
Dry Weight 12.5kg
7
8
14
3
15
9
11
10
17
13
2
4
16
1
HAY - G00108-B
12
18
5
6
MAIN FEATURES & SPECIFICATIONS

6
INTRODUCTION
Thank you for purchasing an Allen machine. The following pages are designed to help you
gain safe and efcient service from your machine.
IMPORTANT: This ‘Owners Handbook’ should be regarded as part of the product as it
gives essential information regarding product safety, operation, maintenance and speci-
cations. Read and understand this handbook prior to operating your machine for the rst
time. Make sure you are familiar with all the controls and points of regular maintenance.
If you have any doubts, consult your local authorised dealer who will be pleased to give
you assistance.
IMPORTANT: This machine is designed solely for cutting grass and other low lying
ground vegetation within the limitations stated in this handbook. 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 specied in this handbook also constitute
essential elements of the intended use.
This machine should be operated, serviced and repaired only by persons who are familiar
with its particular characteristics and who are acquainted with the relevant safety
procedures.
The safety precautions listed in this handbook and all other generally recognised
regulations on safety must be observed at all times.
Any arbitrary modications carried out to this machine may relieve the manufacturer of
liability for any resulting damage or injury.
Allen machines are robustly constructed and designed for efcient economical
performance under normal 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 that your machine is delivered in perfect condition.
Throughout this handbook all references to left and right are as viewed from behind the
handlebar, in the direction of forward travel.
This handbook is based on information available at the time of publication.
We reserve the right to amend product specications without prior notication.

7
WARRANTY
LIMITED WARRANTY
Allen products are manufactured by Hayter Limited.
The manufacturer 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 one
year from the date of purchase. The manufacturers of the engine furnish their own war-
ranty and services are provided through their authorised network (Refer to “Engine War-
ranty Statement”). To qualify for the full benet of the warranty, the Warranty Registration
Card must be returned within 14 days of purchase. If the selling dealer has not returned
the Warranty Registration Card, please complete and return. Subject to the conditions and
exclusions noted in this limited warranty, we shall at our option, repair or replace any war-
ranted part during the applicable period. If you are in doubt or experience any difculty,
please consult an Authorised Service Dealer for clarication.
A 90 day warranty period applies to those items which are subject to normal wear and tear
e.g. wheels, cutterbars, cables and other consumable wearing parts.
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 parts are tted. This war-
ranty does not cover for minor mechanical adjustments unless they are due to defective
material or workmanship. Consult the Owner’s Handbook or an Authorised Service Dealer
for assistance when making these adjustments.
To make a warranty claim, return the unit to an Authorised Service Dealer along with
proof of purchase, stating the machine serial number and date of purchase. 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 specic 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 war-
ranty. 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 authorised dealer are contained in Yellow Pages and the
Hayter web site www.hayter.co.uk or contact:- Freephone 0800 616298.

8
SAFETY PRECAUTIONS
Safety Alert Symbol
This safety alert symbol indicates important safety
messages. When you see this symbol be alert to the
possibility of injury. Carefully read the following and
inform others.
Your machine is perfectly safe if used correctly. Failure
to observe the following precautions may result in seri-
ous injury.
Training
Read the Owner’s Handbook and other training material.
If the operator (s) or mechanic (s) cannot read English it is
the owner’s responsibility to explain this material to them.
Become familiar with the safe operation of the equipment,
operator controls, and safety signs.
All operators and mechanics should be trained. The owner is
responsible for accidents or injuries occurring to themselves,
other people or property.
Never let children or untrained people operate or service the
equipment. Local regulations may restrict the age of the
operator.
Preparation
While using the machine, always wear substantial footwear
and long trousers. Do not operate the equipment when bare-
foot or wearing sandals.
Wear appropriate clothing including hard hat, safety glasses
and hearing protection. Long hair, loose clothing or jewel-
lery may get tangled in moving parts.
Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which can be
thrown by the machine.

9
Preparation continued
Use extra care when handling petrol and other fuels. They
are ammable and vapors are explosive.
a. Use only an approved container
b. Never remove petrol cap or add fuel when engine is
running. Do not smoke.
c. Never refuel or drain the machine indoors.
d. Always use fresh fuel. Stale fuel can block the
carburettor and cause leakage.
Check that the operator’s presence controls, safety switches
and shields are attached and functioning properly.
Do not operate unless they are functioning properly.
Keep all parts in good working condition and all hardware
tightened. Replace all worn or damaged decals.
Never trim while people, especially children, or pets are
nearby.
A damaged cutting device or impeller or both must be
replaced. Before use, always visually inspect the cutting
mechanism to ensure that it is in good condition. Do not
operate the machine with an out of balance cutting device or
impeller.
SAFETY PRECAUTIONS

10
Operation
Do not operate the engine in a enclosed space where exhaust
fumes (carbon monoxide) can collect. Refuel outdoors only
and do not smoke while refuelling.
Do not operate the machine under the inuence of alcohol
or drugs.
Always pull the starter cord slowly until resistance is felt.
Then pull the cord rapidly to avoid kickback and prevent
hand or arm injury. Ensure that feet are away from the cut-
ting mechanism.
Operate only in daylight or good articial light, keeping
away from holes and hidden hazards.
Avoid operating the trimmer in wet grass, or take additional
precautions to avoid slipping.
Walk, never run.
Operate across the face of slopes, never up and down.
Exercise extreme caution when changing direction on slopes
and when pulling the machine towards you. Do not use on
excessively steep slopes.
Stop the engine before moving the machine across areas
other than grass.
Do not change the engine governor settings or overspeed the
engine.
Never pick up or carry the machine whilst the engine is run-
ning.
Never touch the exhaust / exhaust guard or cooling ns
when the engine is hot.
SAFETY PRECAUTIONS

11
Operation continued
Stop the engine and disconnect the spark plug lead:
- Before clearing blockages.
- Before cleaning / checking or working on the machine.
- After striking a foreign object. Inspect the machine for
damage and ensure necessary repairs are made before
re-starting.
- If the machine starts to vibrate abnormally (check
immediately). An out of balance cutting device causes
severe vibration.
Stop the engine:
- Whenever you leave the machine.
- Before refuelling.
Maintenance & Storage
Disengage the drive, stop the engine and disconnect the
spark plug. Wait for all movement to stop before adjusting,
cleaning or repairing. Keep hands and feet away from
moving parts.
Park the machine on level ground. Never allow untrained
personnel to service the machine.
Keep all nuts, bolts and screws tight to ensure that the equip-
ment is in safe operating condition.
Frequently check fuel lines and ttings for cracks or leaks
and replace if necessary.
Never check for a spark when the spark plug is removed.
Use an approved tester.
Never start the engine with the air-cleaner or air-cleaner
cover removed.
SAFETY PRECAUTIONS

12
Maintenance & Storage continued
Inspect the exhaust periodically and replace if worn or
leaking.
Never crank the engine with the spark plug removed.
Allow the engine to cool before storing in any enclosure. To
reduce the risk of re hazard, keep the engine and the sur-
rounding deck area free of grass, leaves, or excessive grease.
If the fuel tank has to be drained, this should be done out-
doors and when the engine is cool.
Wear strong work gloves when removing and reassembling
the cutting device.
Always replace worn or faulty parts with genuine Allen
parts.
Never replace the cutting mechanisms with metal parts and
only use cutting mechanisms which are suitable for use at
the operating speed of the machine.
Never store the machine with petrol in the tank within an en-
closed area where fumes may reach an open ame or spark.
SAFETY PRECAUTIONS

13
Safety Alert - Be aware to
the possibility of injury.
SAFETY PRECAUTIONS
Danger of severing toes or
ngers in mechanism.
Danger of being hit by
thrown objects.
Carefully read the Owners
Handbook before using the
machine.
Stop engine and remove
spark plug lead before
working on the machine.
Safety Symbols
Information Symbols
Engine Stop
STOP
Hearing and eye protection
should be worn.
Never t metal cutting
parts.
Keep bystanders at least
15m from the machine.
15m
Serial Number Decal
2010
Code Serial No:
184E 311000001
XR44 Hovertrim 40cm 16’’
Petrol
kg:
RPM :
kW :
Manufactured by Hayter Limited, Spellbrook,
Bishop’s Stortford Herts. England CM23 4BU
98
dB

14
Delivery Checklist
Remove the machine from the packaging and check that the
following items have been supplied correctly. If any items
are missing, contact your local dealer. Main deck, lower and
upper handlebars.
1. R-Clip x 3 2. Retaining Pin x 3
3. Nylon line (cut to length) x 4 4. M6 Washer x 2
5. U Bolt x 2 6. Hand wheel x 2
7. Engine Handbook* 8. Warranty Reg Card*
* Items 7 - 8 not illustrated
Assembly - Step 1 Lower Handlebar
Fit the lower handle rst.
Slide the retaining pin through the deck and lower the
handlebar starting from the outside. Secure with R-Clip.
Repeat for the opposite side.
Use the remaining R-Clip and retaining pin to secure the
footstop.
Assembly - Step 2 Upper Handlebar
Assemble the upper handle align holes and t U-bolts,
washer and hand/wheel.
Ensure the M6 Washer is assembled before the hand/wheel.
ASSEMBLING THE HOVERTRIM
1
2
3
4
5
6
1
2
1
5
6

15
Prevent Engine Damage
To prevent engine damage the engine is shipped without
oil or petrol. The engine must be lled with the correct
grade of oil and petrol before starting.
Oil Type
Always use high quality detergent oil classied
SAE 10W-30. Never use additives with recommended
oil. To prolong the life of your engine it is important
that the oil is changed after the rst 5 hours of use -
refer to ‘Maintenance Schedule’.
Check Oil Level
Clean around the oil lter cap before removing.
With the mower on a level surface. Remove the oil ller cap
and wipe the dipstick with a clean cloth. Insert the dipstick
into the oil ller neck, but do not screw it in, then remove it
to check the oil level.
The oil level is correct when it is at the FULL mark on the
dipstick. DO NOT OVERFILL.
Fuel Type
Always use clean, fresh unleaded petrol. Purchase fuel in
quantities that can be used within 30 days. Never mix oil
with petrol.
Fill to base of neck to allow for fuel expansion. Do not
overll the fuel tank.
BEFORE STARTING THE HOVERTRIM
O
I
L
MAX
MIN
FILLER CAP/DIPSTICK
ADD FULL
0.15
Litres

16
Controls
Check that the engine stop lever moves freely and returns to
it’s rest position when released.
Starting
1. Open the fuel tank vent by turning the vent knob
at least 2 or 3 turns counterclockwise.
2. Turn the fuel valve lever to the ON position.
3. To start a cold engine, move the choke lever to the
CLOSED position.
To restart a warm engine, leave the choke lever in the
OPEN position.
OPERATING THE HOVERTRIM
NEPO
FUEL CAP VENT
OPEN
FUEL VA LVE LEVER
ON
CLOSED
CHOKE LEVER
OPEN

17
Starting continued
4. Hold the handlebar together with the engine stop lever,
place your foot on the deck and tilt the machine towards
you.
This will take the load off the engine making it easier to
start.
Pull the starter grip lightly until you feel resistance, then
pull briskly.
Return the starter grip gently.
Do not allow the starter grip to snap back against
the engine. Return it gently to prevent damage to
the starter.
5. If the choke lever was moved to the CLOSED
position to start the engine, gradually move it to
the OPEN position as the engine warms up.
Cutting Grass on Flat Ground
Start at the outside boarder of the lawn and move up and
down as you would with a conventional walk behind ma-
chine.
Cutting Grass on Slopes and Banks
Start at the top and move the mower from side to side while
slowly and carefully moving down the slope.
Caution: Try to keep the mower moving to reduce excessive
loading on the engine.
OPERATING THE HOVERTRIM
CLOSED
CHOKE LEVER
OPEN

18
Stopping
Release the engine stop lever.
Emergency stop: Release the engine stop lever.
If the engine fails to stop, disconnect the spark plug lead.
Adjusting the Cutting Height & Replacement of
Nylon Cutting System
The cutting height of your machine has been set at the
highest position (1). If you prefer a lower cut follow these
instructions:
a. Turn the petrol tap to the off position and close the vent
knob.
b. Disconnect the spark plug lead.
c. Turn the machine on its left hand side, keeping the
carburettor uppermost.
d. Wearing protective gloves remove the nylon cutting
line.
e. There are 3 different cutting height settings.
Position one length of nylon cutting line into
the desired cutting height setting. Ensure that
a second length is positioned in the corresponding
cutting height on the opposite side of the cutting
disc.
If using spare reel of line, cut to the length of 200mm and
t as shown in illustration.
Before Trimming
To prevent accidents, thoroughly inspect the area and
remove all objects which when contacted by the mower
cutterbar could become dangerous projectiles. Inspect
the area for hidden obstructions which when contacted
by the cutterbar could risk health and safety or result in
damage to the mower. Remember the location of these
obstructions and ensure that you mow around them.
OPERATING THE HOVERTRIM
1
3
2
2
1 = HIGH
2 = MID
3 = LOW
Cutterbar 450 / 453
STOP

19
To prevent accidents stop the engine and disconnect the
spark plug lead before attempting to carry out mainte-
nance procedures on the mower.
Engine
1. Spark Plug / Lead
2. Exhaust Guard
3. Exhaust
4. Oil Filler Cap / Dipstick
5. Finger Guard
6. Starter Grip
7. Fuel Cap Vent Knob
8. Fuel Cap
9. Choke Lever
10. Air Cleaner
11. Carburettor
Carburettor Adjustments
Should only be made by an authorised Honda dealer. Under
no circumstances should the engine be adjusted to run at a
speed in excess of that shown in ‘Specications’.
Air Cleaner Service
Clean the lter element in warm soapy water,
rinse and allow to dry thoroughly. Or clean in
nonammable solvent and allow to dry.
Dip the lter element in clean oil, then squeeze
out all the excess oil. The engine will smoke
when started if too much oil is left in the foam.
Wipe dirt from the air cleaner body and cover,
using a moist rag. Be careful to prevent dirt from
entering the carburetor.
HOVERTRIM MAINTENANCE
1
2
3
4
5
6
7
8
9
10
11
AIR CLEANER COVER
UPPER TABS
LOWER TABS
AIR CLEANER BODY
FILTER ELEMENT

20
Spark Plug Service
Use only an approved spark tester (1) as shown in the dia-
gram.
Replace the spark plug every 100 hours or every season,
which ever occurs rst. A spark plug wrench is available
from any authorised Honda service dealer.
Check the spark plug gap with a feeler gauge and set at
0.7 - 0.8mm.
Keeping Engine Clean
Remove all grass and debris from the engine including the
exhaust / exhaust guard, the air ways in the top cowl and
the surrounding deck areas on a daily basis after use. Never
spray the engine with water during cleaning. Water can con-
taminate the fuel. Always clean with a brush or compressed
air.
Grass and debris may clog the engine’s air cooling system
especially after prolonged operation while cutting tall, dry
grass. The internal cooling ns and surfaces may require
cleaning to prevent overheating and engine damage. We
recommend that this service be carried out by an authorised
dealer.
Deck Housing
Remove grass debris from the top and underside of the deck
immediately after use.
1
HOVERTRIM MAINTENANCE