Benchmark 163CC User manual

WEAR CSA APPROVED
EYE PROTECTION
WEAR EAR
PROTECTION
WEAR A
FACE MASK
5 Year Limited Warranty
163CC 3 IN 1 LAWN MOWER

1
PRODUCT SPECIFICATIONS
PRODUCT NAME
Gasoline capacity and type: Unleaded regular (maximum 10% ethanol)
Oil type (API: SG-SL): SAE 30 (above 32°F/0°C) SAE 10W-30 (below 32°F/0°C)
Oil capacity: See engine manual for more information
Spark plug: See engine manual
Blade bolt torque: Std hex = 33-40 ft-lb. (45-55 Nm)
IMPORTANT NOTE: Gasoline containing up to 10% ethanol (E10) is acceptable for use
in this machine. The use of ANY gasoline exceeding 10% ethanol (E10) violates federal
law and will void the product warranty.
START-UP CHECKLIST
Before you start up your new mower, we wish to ensure that you receive the best perfor-
mance and satisfaction from this quality product.
PLEASE REVIEW THE FOLLOWING CHECKLIST:
• All assembly instructions have been completed.
• No remaining loose parts in the carton.
• Before starting to mow, make sure the area is clear of debris or objects that may be
thrown by the blades.
• Check the engine oil level before starting the machine.
• Ensure a responsible adult, other than the operator, is supervising children in a safe
location AWAY FROM THE MOWING AREA before starting the mower.
• Be sure the Operator Presence Control (OPC) is working properly.

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TABLE OF CONTENTS
Product specifications
Table of contents
General safety warnings
Safety
Setup
Know your Lawn Mower
Symbols
Safety symbols
Operation
Maintenance
Troubleshooting
Exploded view
Parts list
Warranty
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.…………………………………………………..................…………27-29
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CAUTION: The operation of any lawn mower can re-
sult in foreign objects thrown into the eyes, which
can result in severe eye damage. ALWAYS wear safe-
ty glasses or eye shields while operating your lawn
mower or performing any adjustments or repairs. We
recommend standard safety glasses or a wide vision
safety mask worn over spectacles.
PLEASE READ AND RETAIN THIS INSTRUCTION MANUAL. These instructions will en-
able you to assemble and maintain your lawn mower properly. ALWAYS observe the
“SAFETY RULES”.
The instruction manual was designed to conveniently help you get your purchase
ready to use so there’s less risk of damaging it and to provide you with enough in-
formation for you to get familiar with your product’s controls and features to operate
it safely. This manual however, is NOT a replacement for you reading your complete
owner’s manual and all the details it covers, such as mower maintenance, adjust-
ments and storage.
KIDS AND MOWERS DON’T MIX! Tragic accidents can happen. You can SE-
VERELY INJURE or KILL a child with a lawn mower. Please leave children in-
doors and supervised!
Please read this manual carefully and make sure you understand the instruc-
tions before using the machine.

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CAUTION: Muer and other engine parts become extremely hot during oper-
ation and remain hot after engine has stopped. To avoid severe burns on con-
tact, stay away from these areas.
DANGER: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS
AND FEET AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOL-
LOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR
DEATH.
SAFETY
SAFE OPERATION PRACTICES FOR PEDESTRIAN CONTROLLED
LAWN MOWERS
WARNING: This mower is equipped with an internal combustion engine and
should NOT be used on or near any unimproved forest-covered, brush-cov-
ered, or grass covered land unless the engine’s exhaust system is equipped
with a spark arrester meeting applicable local or provincial laws (if any). If a
spark arrester is used, it should be maintained in eective working order by
the operator. A spark arrester for the muer is available through your nearest
authorized service centre/department.
I. CHILDREN
WARNING: CHILDREN CAN BE SERIOUSLY INJURED OR KILLED BY THIS
EQUIPMENT. Carefully read and follow all of the safety instructions below.
Tragic accidents can occur if the operator is not alert to the presence of children.
Children are often attracted to the machine and the mowing activity. NEVER assume
that children will remain where you last saw them.
• Keep children out of the mowing area and in the watchful care of a responsible adult
other than the operator.
• Be alert and turn machine o if a child enters the area.
• Before and while backing up, look behind and down for small children.
• Use extra care when approaching blind corners, shrubs, trees or other objects that
may block your view of a child.
• NEVER OPERATE THE MOWER WHEN CHILDREN ARE PRESENT.
II. SLOPE OPERATION
Slopes are a major factor related to slip and fall accidents which can result in severe
injury. All slopes require extra caution. If you feel uneasy on a slope, do not mow it.

5
• 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. Uneven terrain could
cause a slip and fall accident. Tall grass can hide obstacles.
• DO NOT mow near drop-os, ditches, or embankments. You could lose your footing
or balance.
• DO NOT mow on wet grass or excessively steep slopes. Poor footing could cause a
slip and fall accident.
III. GENERAL OPERATION
• Read, understand, and follow all instructions on the machine and in the instruction
manual before starting.
• DO NOT put hands or feet near rotating parts or under the machine. Keep clear of
the discharge opening at all times.
• Allow only responsible adults familiar with the instructions to operate the machine.
• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up
and thrown by the blades. Stay behind the handles while the engine is running.
• Be sure the area is clear of bystanders before operating. Stop machine if anyone
enters the area.
• DO NOT operate the mower when barefoot or while wearing sandals. ALWAYS wear
substantial footwear.
• DO NOT pull mower backwards unless absolutely necessary. ALWAYS look down
and behind before and while moving backwards.
• NEVER direct discharged material toward anyone. Avoid discharging material
against a wall or obstruction. Material may ricochet back toward the operator. Stop
the blades when crossing gravel surfaces.
• DO NOT operate machine without the entire grass catcher, discharge chute or other
safety devices in place and working.
• See manufacturer’s instructions for proper operation and installation of accesso-
ries. Only use accessories approved by the manufacturer.
• NEVER leave a running machine unattended.
• Stop the engine (motor) and wait until the blade comes to a complete stop before
cleaning the mower, removing the grass catcher, or unclogging the discharge guard.
• Operate machine only in daylight or good artificial light.
• DO NOT operate the machine while under the influence of alcohol or drugs.
• Disengage the drive system on mowers so it is equipped before starting the engine
(motor).

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• If the equipment should start to vibrate abnormally, stop the engine (motor) and
check for the cause immediately. Vibration is generally a warning of trouble.
• ALWAYS wear eye protection when operating the machine.
IV. SERVICE
SAFE HANDLING OF GASOLINE
• To avoid personal injury or property damage, use extreme care in handling gasoline.
Gasoline is extremely flammable and the vapors are explosive.
• Extinguish all cigarettes, cigars, pipes and other sources of ignition.
• Use only an approved gasoline container.
• NEVER remove gas cap or add fuel with the engine running. Allow engine to cool
before refueling.
• NEVER fuel the machine indoors.
• NEVER store the machine or fuel container where there is an open flame, spark or
pilot light such as on a water heater or other appliances.
• 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 when filling.
• Remove gas-powered equipment from the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such equipment with a portable container,
rather than from a gasoline dispenser nozzle.
• 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.
• If fuel is spilled on clothing, change clothing immediately.
• NEVER overfill fuel tank. Replace gas cap and tighten securely.
GENERAL SERVICE
• NEVER operate machine in a closed area.
• Keep all nuts and bolts tight to ensure the equipment is in safe working condition.
• NEVER remove or tamper with any safety devices. Check their proper operation
regularly. NEVER do anything to interfere with the function of a safety device or to
reduce the protection oered by the safety device.
• Keep machine free of grass, leaves, or other debris buildup. Clean oil or fuel spillage
and remove any fuel-soaked debris. Allow machine to cool before storing.
• If you strike a foreign object, stop and inspect the machine. Repair, if necessary,
before restarting.

7
• NEVER attempt to make any adjustments or repairs while the engine (motor) is
running. Disconnect the spark plug wire and ground against the engine to prevent
unintended starting.
• Check grass catcher components and the discharge chute frequently, and replace
with manufacturer’s recommended parts when necessary.
• Mower blade is sharp. Wrap the blade or wear gloves and use extra caution when
servicing it.
• DO NOT change the engine governor setting or over speed the engine.
• Maintain or replace safety and instruction labels as necessary.
SETUP
PREPARING THE ENGINE
• IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the en-
gine.
• NOTE: Gasoline containing up to 10% ethanol (E10) is acceptable for use in this
machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product
warranty.
V. CUSTOMER RESPONSIBILITIES
• Read and observe the safety rules.
• Follow a regular schedule in maintaining, caring for and using your lawn mower.
• Wear proper personal protective equipment (PPE) while operating this machine,
including (at a minimum) sturdy footwear, eye protection and hearing protection. DO
NOT mow in shorts and/or open-toed footwear.
• ALWAYS let someone know you are outside mowing.
• NEVER allow children in the vicinity of any operating mower, even if the blades are
o. Children should be under the supervision of a responsible adult other than the
operator for the duration of the mowing operation.
• Follow the instructions under “Maintenance” section of the operator’s manual.
CAUTION: An Operator Presence Control is installed on this lawn mower in
order to minimize the risk of blade contact injury. DO NOT under any circum-
stances attempt to defeat the function of the operator control. The blade
turns when the engine is running.

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ASSEMBLY/ PRE-OPERATION
CAUTION: Read complete INSTRUCTION MANUAL before operating this
machine.
IMPORTANT: THIS LAWN MOWER IS SHIPPED WITHOUT OIL OR GASOLINE IN THE
ENGINE.
Your new lawn mower has been assembled at the factory with the exception of those
parts left disassembled for shipping purposes. All parts such as nuts, washers, bolts,
etc., necessary to complete the assembly have been placed in the parts bag. To en-
sure safe and proper operation of your lawn mower, all parts and hardware you as-
semble must be tightened securely. Use the correct tools as necessary to ensure
proper tightness.
SETUP
TO REMOVE LAWN MOWER FROM CARTON
1. Remove loose parts included with mower.
2. Cut down two end corners of carton and lay end panel down flat.
3. Remove all packing materials except padding between upper and lower handle
and padding holding operator presence control bar to upper handle.
4. Roll lawn mower out of carton and check carton thoroughly for additional loose
parts.
HOW TO SET UP YOUR LAWN MOWER
IMPORTANT: Unfold handle carefully to avoid pinching or damaging the control cables.

9
1. Insert the lower handle to the two side brackets on the mower deck. Use corre-
sponding holes on the brackets when attaching lower handle pin for a suitable handle
height desired.
NOTE: The washer should be pressed against the inner face of the bracket.
2. Fasten the lower handle to the lawn mower by using handle bolts, install and tight-
en knobs to secure the handle.
Raise the upper handle into place and attach it to lower handle by using handle bolts.
4. Install and tighten knobs to secure the handle.
NOTE: Your lawn mower handle can be adjusted for your mowing comfort. Refer to
the “TO ADJUST HANDLE” section of the operator’s manual.
5. Slip starter rope into loop on upper handle.
6. Attach the connection cord to the handle
with the cord clip (supplied).
Bolt
Fixing knob
Bolt
Fixing knob

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TO ASSEMBLE THE GRASS CATCHER
1. Put the grass catcher frame into the grass bag with the rigid part of the bag on the
bottom. Make sure the frame handle is outside of the bag top.
2. Slip the vinyl bindings over the frame.
ADD GASOLINE
Fill fuel tank to bottom of tank filler neck. DO NOT overfill. Use fresh, clean, regular
unleaded gasoline with a minimum of 87 octane.
DO NOT mix oil with gasoline. Purchase fuel in quantities that can be used within 30
days to assure fuel freshness.
Alcohol-blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads
to separation and formation of acids during storage. Acidic gas can damage the fuel system of an
engine while in storage.
To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer.
Empty the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use
fresh fuel next season. NEVER use engine or carburetor cleaner products or permanent damage
may occur.
CAUTION: Wipe o any spilled oil or fuel. DO NOT store, spill or use gasoline
near an open flame.

11
KNOW YOUR LAWN MOWER
Compare the illustrations with your lawn mower to familiarize yourself with the lo-
cations of various controls and adjustments. Save this instruction manual for future
reference. Not every model of lawn mower will have all these features.

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SYMBOLS
Oil
Fuel
Engine o
Engine on
GENERAL IGNITION SWITCH
Choke
Fast
Slow
THROTTLE

13
DANGER: KEEP HANDS AND FEET AWAY (See SAFETY section). *These symbols
may appear on your lawn mower or in the literature supplied with the product. Learn
and understand their meaning.
HAZARD ALERT - The hazard alert symbol informs the user of potential hazards.
SAFETY
READ THE OPERATOR’S MANUAL(S) - Read, understand, and follow all instructions
in the manual(s) before attempting to assemble and operate.
Wear hearing protection.
DANGER — ROTATING BLADES -To reduce the risk of injury, keep hands and feet
away. Do not operate unless discharge cover or grass catcher is in its proper place. If
damaged, replace immediately.
DANGER — BYSTANDERS - Do not mow when children or others are around.
SAFETY SYMBOLS
Look down and behind before and while backing up.
DANGER — ROTATING BLADES - Never operate the machine without proper
guards, plates, or other safety protective devices in place.
DANGER — HAND/ FOOT CUT - Keep hands and feet away from rotating parts.
DANGER — THROWN DEBRIS - Remove objects that can be thrown by the blade in
any direction. Wear safety glasses.
DANGER — SLOPES - Use extra caution on slopes. Do not mow slopes greater than
15°.
WARNING — GASOLINE IS FLAMMABLE - Allow the engine to cool at least two
minutes before refueling.
WARNING — CARBON MONOXIDE - Never run an engine indoors or in a poorly venti-
lated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.
WARNING — HOT SURFACE - Engine parts, especially the muer, become extreme-
ly hot during operation. Allow engine and muer to cool before touching.

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GLOSSARY OF SAFETY SYMBOLS
Failure to follow instructions could result in serious injury or death. The safety alert
symbol is used to identify safety information about hazards which can result in
death, serious injury and/or property damage.
DANGER indicates a hazard which, if not avoided, WILL result in death or serious
injury.
WARNING indicates a hazard which, if not avoided, COULD result in death or serious
injury.
CAUTION indicates a hazard which, if not avoided, COULD result in minor or moder-
ate injury.
CAUTION when used without the alert symbol, indicates a situation that could result
in damage to the lawn mower and/or engine.
HOT SURFACES indicates a hazard which, if not avoided, could result in death,
serious injury and/or property damage.
FIRE indicates a hazard which, if not avoided, could result in death, serious injury
and/or property damage.

15
OPERATION
TO START THE ENGINE
NOTE: Due to protective coatings on the engine, a small amount of smoke may be
present during the initial use of the lawn mower. This is normal.
NOTE: Your engine may be equipped with an automatic choke system. No priming or
choking is required before starting for these models. On other models, either a choke
lever or a priming bulb is provided. Use this to start a cold engine.
TO START THE ENGINE USING STARTER ROPE
•To start the engine using the starter rope,
hold the operator presence control bar
down to the upper handle.
•Pull the starter handle (at the end of the
starter rope) quickly. DO NOT allow the
starter rope to snap back.
IMPORTANT NOTE: DO NOT CRANK THE
ENGINE CONTINUOUSLY FOR MORE
THAN FIVE SECONDS EACH TIME YOU TRY
TO START. WAIT FIVE TO TEN SECONDS
BETWEEN EACH ATTEMPT TO START.
TO STOP THE ENGINE AND BLADE
1. To stop the engine, release the operator
presence control bar.
TO SET THE MOWER CUTTING HEIGHT
IMPORTANT NOTE: MAKE SURE ENGINE AND BLADE ARE STOPPED.
Adjust the cutting height to suit your requirements. The middle position is suitable for
most lawns. Raise the wheels for low cut and lower the wheels for a high cut. See page
17 of this manual for a grass height cutting guide.
NOTE: For shipping purposes the height adjustment position may not be adjusted to
the cutting position. Before operating the mower adjust cutting height to the normal
cutting position.

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SINGLE POINT HEIGHT ADJUST-
MENT MODELS
All four wheels are adjusted by a single lever.
1. Pull height adjuster toward wheel.
2. To raise the mower, move the lever for-
ward to desired position. To lower the mow-
er, move the lever toward the rear.
TO CONVERT MOWER
Your lawn mower may have been shipped ready to be used as a mulcher. Convert to
bagging or discharge modes by changing the installed accessories.
NOTE: This lawn mower has three functions. Change functions by changing the in-
stalled accessories as shown in the following chart.
To convert mower mulching plug grass catcher side discharge deflector
For rear bagging x x
For mulching x x
For side discharging x
✓
✓
✓
✓
" ✓ " Installed "x" Removed

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REAR BAGGING
1. Lift rear door of the lawn mower.
2. Remove the mulching plug when you set your lawn mower for rear bagging.
3. Place the grass catcher frame hooks onto the grass bag brackets.
NOTE: For clarity, rear door is not shown.
4. Pull the operator presence control bar down to the upper handle.
5. Ensure that rear door covers any gap between mower deck and bagging unit.
6. To convert to mulching or discharging operation, remove grass catcher, assemble
the mulching plug and close the rear door.

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SIDE DISCHARGING
IMPORTANT: THE REAR DOOR MUST BE
CLOSED.
1. Open the mulch door.
2. Install the discharge deflector under the
door as shown. The mower is now ready for
discharging operation.
NOTE: To convert to mulching or bagging
operation, side mulch door must be closed.
MULCH/DISCHARGE GUARD
1. Open the mulch door.
2. Remove the discharge deflector.
3. Assemble the mulching plug as shown.
The mower is now ready for mulching oper-
ation.
SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOW-
ER FOR MULCHING
• The rear door is closed.
• The mulch door is closed, and the mulching plug must be assembled.
FOR REAR BAGGING
• Remove the mulching plug.
• The grass catcher is installed.
• The mulch door is closed.
FOR SIDE DISCHARGING
• The rear door is closed.
• Assemble the mulching plug.
• The discharge deflector is installed.

19
CAUTION: DO NOT run your lawn mower without the rear door closed or
an approved grass catcher properly installed. NEVER attempt to operate the
mower with the rear door removed or propped open. Serious injury may result
from operating the mower with the rear discharge open.
MOWING TIPS
CAUTION: DO NOT use dethatcher blade attachments on your mower.
Such attachments are hazardous, will damage your mower, and could void
your warranty.
• Under certain conditions, such as very tall grass, it may be necessary to raise the
height of cut to reduce pushing eort and to keep from overloading the engine and
leaving clumps of grass clippings. It may also be necessary to reduce ground speed
and/or run the lawn mower over the area a second time.
• For extremely heavy cutting, reduce the width of cut by overlapping previously cut
path and mow slowly.
• For better grass bagging and most cutting conditions, the engine speed should be
set in the fast position (if equipped).
• Pores in cloth grass catchers can become filled with dirt and dust with use and
catchers will collect less grass. To prevent this, regularly hose catcher o with water
and let dry before using.
• Keep top of engine around starter clear and clean o grass clippings and cha. This
will help engine airflow and extend engine life.
MULCHING MOWING TIPS
IMPORTANT: For best performance, keep mower housing free of built-up grass and
trash. See “Cleaning” in the Maintenance section of the operator’s manual.
• The special mulching blade will recut the grass clippings many times and reduce
them in size so that as they fall onto the lawn they will disperse into the grass and not
be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for
the lawn. ALWAYS mulch with your highest engine (blade) speed as this will provide
the best recutting action of the blades.
• Avoid cutting your lawn when it is wet. Wet grass tends to form clumps and inter-
feres with the mulching action. The best time to mow your lawn is the early afternoon.
At this time the grass has dried, yet the newly-cut area will not be exposed to direct
sunlight.