Bolens 112-400R000 User manual

OWNEirSOtIM
• ASSEMBLY • OPERATION • MAINTENANCE • PARTS •
21 "
ROTARY
MOWERS
(Model 413R Shown)
Important:
Read Safety Rules
and Instructions Carefully
Model Numbers
112-400R000
thru
112-428R000
IMPORTANT!
Record the Model No. and Mfg. Code which
appear on your unit in the space below. You
must have these numbers, along with the date
of purchase, in order to receive warranty or ser¬
vice.
MEETS ANSI SAFETY STANDARDS
MODEL NO.
MFG. CODE
WARNING: This unit is equipped with an internal combustion engine and should not be used
on or near any unimproved forest-covered, brush-covered or grass-covered land unless the
engine’s exhaust system is equipped with a spark arrester meeting applicable local or state
laws (if any). If a spark arrester is used, it should be maintained in effective working order by
the operator.
In the State of California the above is required by law (Section 4442 of the California Public
Resources Code). Other states may have similar laws. Federal laws apply on federal lands.
A spark arrester for the muffler is available through your nearest engine authorized service
dealer or contact the service department, P.O. Box 360900, Cleveland, Ohio 44136.
FORM NO. 770-7812G

J
IMPORTANT
SAFE OPERATION PRACTICES
▲
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED, COULD ENDANGER THE PERSONAL
SAFETY AND/OR PROPERTY OF YOURSELF AND OTI- ERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE
ATTEMPTING TO OPERATE YOUR LAWN MOWER. FAIl URE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY. WHEN YOU SEE THIS SYMBOL— ^ HEED IFS WARNING.
A
A
DANGER:
Your lawn mower was built to be operated according to tbe rules for safe operation in this manual. As
with any type of power equi| iment, carelessness or error on the part ot the operator can result in serious
injury. If you violate any of these rules, you may cause serious injury to yourself or others.
TRAINING
1 .
2 .
Read this owner’s guide carefully in its entirety befc re attempt¬
ing to assemble or operate this machine. Be comp etely famil¬
iar with the controls and the proper use of this mac hine before
operating it. Keep this manual in a safe place for future and
regular reference and for ordering replacement part i. [
Your rotary mower is a precision piece of power equipment,
not a plaything. Therefore, exercise extreme caution at all
times.
3. Never allow children to operate a power mower. 0 ily persons
well acquainted with these rules of safe operatioi should be
allowed to use your mower.
Keep the area of operation clear of all persons, particularly
small children and pets. Stop engine when the^ are in the
vicinity of your mower to help prevent blade conta(t or thrown
object injury. Although the area of operation shot Id be com¬
pletely cleared of foreign objects, an object maj have been
overlooked and could be accidently thrown by tha mower in
any direction and cause serious personal injury to he operator
or any others allowed in the area.
PREPARATION
9. 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° as shown
on the slope gauge, do not operate this unit on that area or
serious injury could result.
OPERATION
1 .
2 .
4.
1 .
2 .
4.
10 .
11 .
12 .
Thoroughly inspect the area where the equipmunt is to be
used. Remove all stones, sticks, wire, bones and c ther foreign
objects which could be picked up and thrown by the mower in
any direction and cause serious personal injury to he operator
or any others allowed in the area.
Always wear safety glasses or eye shields during )peration or
while performing an adjustment or repair, to prote :t eyes from
foreign objects that may be thrown from the ma ;hine in any
direction.
3. Wear sturdy, rough-soled work shoes and close-1 itting slacks
and shirts to avoid entanglement in the moving jarts. Never
operate a unit in bare feet, sandals, or sneakers.
Check the fuel before starting the engine. Ga ;oline is an
extremely flammable fuel. Do not fill the gasoline 1 ank indoors,
while the engine is running, or until engine has bet n allowed to
cool for two minutes after running. Replace gasoline cap
securely and wipe off any spilled gasoline before starting the
engine as it may cause a fire or explosion. ^
Disengage the self-propelled mechanism or dri 'e clutch on
units so equipped before starting the engine. 1 ■
The blade control handle is a safety device. New r attempt to
bypass its operation. Doing so makes the safety d jvice inoper¬
ative and may result in personal injury through coi tact with the
rotating blade. The blade control handle must ope rate easily in
both directions.
Never attempt to make a wheel or cutting height adjustment
while the engine is running.
8. Never operate the equipment in wet grass. Alwa\ s be sure of
your footing. A slip and fall can cause serious pe sonal injury.
Keep a firm hold on the handle and walk, never n n. Mow only
in daylight or in good artificial light.
6 .
7.
Do not change the engine governor settings or overspeed the
engine. Excessive engine speeds are dangerous.
Do not put hands or feet near or under rotating parts. Keep
clear of the discharge opening at all times as the rotating blade
can cause injury.
3. Stop the blade when crossing gravel drives, walks or roads.
4. After striking a foreign object, stop the engine, remove the wire
from the spark plug, and thoroughly inspect the mower for any
damage. Repair the damage before restarting and operating the
mower.
5. If the equipment should start to vibrate abnormally, stop the
engine and check immediately for the cause. Vibration is gen¬
erally a warning of trouble.
6. Shut the engine off and wait until the blade comes to a com¬
plete stop before removing the grass catcher or unclogging the
chute. The cutting blade continues to rotate for a few second;
after the engine is shut off. Never place any part of the body ii.
the blade area until you are sure the blade has stopped rotating.
7. Before cleaning, repairing or inspecting, make certain the blade
and all moving parts have stopped. Disconnect the spark plug
wire, and keep the wire away from the spark plug to prevent
accidental starting.
8. Do not run the engine indoors.
9. Mow across the face of slopes, never up-and-down. Exercise
extreme caution when changing direction on slopes. Do not
mow excessively steep slopes. Always be sure of your footing.
A slip and fall can cause serious personal injury.
Never operate mower without proper guards, plates or other
safety protective devices in place.
Do not operate this mower with the chute door open, unless
the complete grass catcher or chute deflector is properly
mounted on the mower.
Do not operate this mower with the chute door open, unless
the complete grass catcher or chute deflector is properly
mounted on the mower.
MAINTENANCE AND STORAGE
Check the blade and engine mounting bolts at frequent Inter¬
vals for proper tightness.
2. Keep all nuts, bolts, and screws tight to be sure the equipment
is in safe working condition.
3. Never store the equipment with gasoline in the tank inside of a
building where fumes may reach an open flame or spark. Allow
the engine to cool before storing in any enclosure.
4. To reduce fire hazard, keep the engine free of grass, leaves, or
excessive grease.
5. Check the grass catcher bag frequently for wear or deteriors^
tion. For safety protection, replace only with new bag meeting
original equipment specifications.
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SLOPE GAUGE
(Keep this sheet in a safe piece for future reference.)
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Do
not
mow
on
inclines
with
a
slope
in
excess
of
15
degrees
(a
rise
of
approximately
2-1/2
feet
every
10
feet).
A
riding
mower
could
overturn
and
cause
serious
injury.
If
operating
a
walk-behind
mower
on
such
a
slope,
it
is
extremely
difficult
to
maintain
your
footing
and
you
could
slip,
resulting
in
serious
injury.
Operate
RIDING
mowers
up
and
down
slopes,
never
across
the
face
of
slopes.
Operate
WALK-BEHiND
mowers
across
the
face
of
slopes,
never
up
and
down
slopes.

CONTENTS OF HARDWi\RE PACK/PARTS IDENTIFICATION
Remove this sheet from your owner’s manual and lay the hardware on the illustration for identification purposes.
After assembly, keep the Slope Gauge which i > on the reverse side of this sheet for future use.
(Hardware pack may contain extra items vrhich are not used on your unit.—Part numbers are shown in
parentheses.)
I I I I
0
INCHES
I I ) i I i I I I I I I I I ) II
1 2 3
•Cut
Aioi,
is
Line

ASSEMBLY INSTRUCTIONS
This owner’s guide covers various models of
mowers. Follow only those instructions which
pertain to your unit.
IMPORTANT: This unit is shipped WITHOUT
GASOLINE or OIL. After assembly, service engine
with gasoline and oil as instructed in the separate
engine manual packed with your unit.
NOTE: Reference to right or left hand side of the
mower is observed from the operating position.
Tools Required for Assembly
(1) Pair of Pliers
(1) Phillips Screwdriver
(1) 1/2“ Wrench*
(1) 7/16" Wrench*
*Or two 6" Adjustable Wrenches
FIGURE 1.
UNPACKING
1. Remove the lawn mower from the carton by
opening the top flaps and lifting the unit out. Be
careful of the staples. Make certain all parts and
literature have been removed from the carton
before the carton is discarded.
2. Disconnect the spark plug wire and move away
from the spark plug.
3. Stretch out all control cables with control box
attached to the left side of the mower and place
on the floor. Be careful not to bend or kink the
cables at any time during assembly.
4. Remove page four from this manual and lay the
contents of the hardware pack on the illustration
for identification.
AHACHING THE LOWER HANDLE (Hardware A)
1. Slide the control box over the lower handle so
that the cable with the “Z” end is routed above the
lower handle, and the other cable is routed below.
See figure 2.
2. Attach the lower handle by placing the bottom
holes in the lower handle over the weld pins on
the handle mounting brackets on the rear of the
deck.
3. Using a pair of pliers, squeeze one leg of the
lower handle against the handle mounting brack¬
et. Insert the hairpin clip into the hole on the weld
pin. See figure 1. Repeat on other side.
AHACHING THE UPPER HANDLE (Hardware B)
1. Place the upper handle in position over the lower
handle. The hole in the side of the blade control
handle (attached to the upper handle) must be on
the left side.
2. Secure the upper handle to the lower handle
using the curved head bolts, split washers and
-hex nuts as shown in figure 2.
ATTACHING THE CDNTRDL BDX
Attach the control box to the upper handle as follows.
1. Remove the truss machine screw and hex lock
nut from the middle of the control box using a
Phillips screwdriver. (Hold your finger over the
hex lock nut so it stays inside the control box so
you can unscrew the truss machine screw.)
2. Make certain the blade control handle is on top of
the upper handle.
3. Holding the control box near the left side of the
upper handle (control box must be inside the han¬
dle), hook the “Z” end of the brake cable into the
control handle from the outside to the inside. See
figure 3.
5

I
4. Place the control box on the upper handle just
below the end of the control handle as shown in
-figure 4. Secure with hardware removed in step
one by placing hex lock nut into the indent on the
inside of the control box. Screw the truss machine
screw into the hex lock nut.
SECURING THE CABLES (Hardware E)
Secure cables to the left side of the handle as follows.
WARNING: When attaching the control
cables, the cables must be routed to
avoid contact with all sharp edges and
hot surfaces to prevent damage to the
cables, which will render the controls
inoperative.
1. Insert posts on cable ties into holes provided on
the handles, one on the upper handle and two on
the lower handle. The holes may be either on the
inside or outside of the handles. See figure 5A.
2. Secure the cables with the cable ties. See figure
5B. Trim excess ends of cable ties.
Axle Bolt
FIGURE 7.
B
Cupped
Washer
Hole in
Pivot Bar„^
Dupped
Axle Bolt i/Vasher
AHACHING THE STARTER ROPE (Hardware C)
1. The starter rope is inside the top of the engine.
Additional rope may be wound around the starter
handle. If so, unwind the rope from the handle.
2. With the spark plug wire disconnected and
grounded, depress the blade control handle and
pull the rope out of the engine.
3. Place the rope guide around the starter rope, so
the rope guide is positioned as shown (bends
downward slightly). Insert the rope guide through
the side of the upper handle, and secure with hex
lock nut.
INSTALLATION OF WHEELS (Hardware F)
1. Insert axle bolts through wheels, then place
cupped washers on bolts (crowned side of wash¬
ers go against the wheels).
2. Attach the wheels to the pivot bar on the height
adjusters. Use the top hole in the pivot bar when
assembling the front wheels; use the rear hole in
the pivot bar when assembling the rear wheels.
See figure 7.
6

FIGURE 8.—Optional Hub Caps
Front
Frame
Assembly
Rear
Frame
B
Bag-
Hook
Plastic
Channels
FIGURE 9.
INSTALLATION OF HUB CAPS (Optional)
Attach hub caps (optional) to wheels by placing in
position against the inner hub of the wheel. For units
with 2" wide tires, press firmly around the center por¬
tion of hub cap in a circular motion, similar to installing
-^a lid on a round, plastic container. See figure 8. The
hub caps are flexible and will snap over the wheel
hubs.
NOTE: It may be helpful to place the hub caps in hot
tap water for several minutes to make them pliable
before installing, especially if the temperature is less
than 6CPF.
FINAL ASSEMBLY OF MOWER
Make certain all nuts and bolts are tightened securely.
ASSEMBLY OF OPTIONAL GRASS CATCHER
NOTE: Make certain the grass bag is turned right side
out before assembiing (warning label will be on the
outside).
Models 41 OR thru 418R (Soft Grass Bag):
1. Join the rear frame and front frame assembly as
-shown in figure 9A.
2. Place bag over frame (black plastic side is the
bottom of bag). Slip the openings in the side of
the plastic channel on bag over the hooks on the
grass catcher frame.
3. Secure bag to frame by working the plastic chan¬
nels on bag aver frame as shown in figure 9B. All
of the plastic channels except center top of bag
attach from the outside of bag. Center top of bag
attaches from the inside of bag.
Models 420R thru 428R (Hardtop Grass Bags):
1. Insert one end of the rear frame into the cloth
channel on the edge of the grass bag. See figure
10. Feed all the material on one side of the frame
before working it around frame.
7

2. Slide the ends of the front frame assembly into
the ends of the rear frame as shown in figure 11.
3. Slip the openings in the side of the plastic chan¬
nel on bag over hooks on the grass catcher
— frame. See figure 11.
4. Secure front of bag to front frame by working the
plastic channeis on sides and bottom of bag over
frame.
5. S l i d e the handle on the grass catcher frame into
the slot in the hardtop cover from beneath the
-cover. See figure 12.
Rear
Discharge
Door
Slot in
Handle
Bracket
Assembly
6. P l a ce the mounting bracket under the front of the
handie, with the tabs on the bracket facing up.
Insert phillips head screw down through the hard¬
top cover and mounting bracket. Secure with hex
— iock nut. See figure 13.
ATTACHING GRASS CATCHER TO MOWER
Lift the rear discharge door on the mower. Place the
hooks on the grass catcher into the slots in the handle
-^bracket assemblies. See figure 14. Release the rear
discharge door.
To remove the grass catcher, lift the rear discharge
door on the mower. Lift the grass catcher up, out of
the siots in the handle bracket assemblies. Release
the rear discharge door.
A WARNING: Never operate the mower
unless the hooks on the grass catcher
are seated in the slots on the handle
bracket assemblies, and the rear dis¬
charge door rests firmly against the top
of the grass catcher.
FIGURE 14.

CONTROLS
BLADE CONTROL HANDLE
A WARNING; This control mechanism is a
safety device. Never attempt to bypass
its operations.
The blade control handle is located on the upper han¬
dle of the mower. See figure 15. The blade control
handle must be depressed in order to operate the
unit. Release the blade control handle to stop the
engine and blade.
A WARNING: The blade will be rotating
whenever the engine is running.
THROTTLE CONTROL
The throttle control is located on the side of the upper
handle or on the engine. It is used to regulate the
engine speed.
A WARNING: The throttle control cannot be
used to stop the engine.
RECOIL STARTER
The recoil starter handle is attached to the handle.
See figure 15. Stand behind the unit in the operating
position to start the unit.
OPERATION
TO REDUCE THE RISK OF INJURY. DO NOT
OPERATE MOWER UNLESS REAR TRAILING
SHIELD AND THIS GUARD OR ENTIRE
GRASS CATCHER IS IN ITS PROPER PLACE.
Keep hands and feet away from the chute area on
cutting deck. See figure 16.
GAS AND OIL FILL-UP
Service the engine with gasoline and oil as instructed
in the separate engine manual packed with your
mower. Read instructions carefully.
WARNING: Never fill fuel tank Indoors,
with engine running or until the engine
has been allowed to cool for at least two
minutes after running.
TO START ENGINE AND ENGAGE BLADE
1. 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 16.
The operation of any lawn mower can result in for¬
eign objects being thrown into the eyes, which
can result in severe eye damage.
Always wear safety glasses or eye
shields. We recommend wide vision
safety mask for over spectacles or
standard safety glasses.
Metal Loop
on Spark _
Plug Wire
FIGURE 16.
Rubber Boot
9

I
2. Move throttle control lever all the way forv ard.
3. If unit is equipped with a primer, prime ei igine as
instructed in the separate engine manual.
4. Standing behind the unit, depress the bUide con¬
trol handle and hold it against the uppe • handle
as shown. See figure 17.
5. Grasp the recoil starter handle and pu I slowly
until resistance is felt. Then pull handle r ipidly to
overcome compression, prevent kickb nek and
start engine. Repeat if necessary.
6. After engine starts, move throttle control to
desired engine speed.
NOTE: If any problems are encountered, reUr to the
Trouble Shooting Guide on page 16.
Recoil
Starter
Handle
FIGURE 17.
TO STOP ENGINE AND BLADE
1. Release the blade control handle to ;>top the
engine and blade.
WARNING: The blade continues to rotate
for a few seconds after the engint s is shut
off.
2. Disconnect the spark plug wire and c round it
against the engine to prevent accidents starting
while equipment is unattended.
USING YOUR ROTARY MOWER
A WARNING: Never operate your unit with¬
out either the rear deflector or entire
grass catcher assembiy in place.
Be sure that lawn is clear of stones, sticks wire, or
other objects which could damage lawn mower or
engine. Such objects could be accidently thrown by
the mower in any direction and cause seriou: > person¬
al injury to the operator and others.
For the best results, do not cut wet grass because it
tends to stick to the underside of the mower prevent¬
ing proper discharge of grass clippings, and could
cause you to slip and fall. New grass, thick grass or
wet grass may require a narrower cut. Blade speed
should be adjusted to the condition of the lawn.
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.
This mower is designed to be operated at full throttle
to give you the best cut and do the most effective job
of bagging the cut grass.
A WARNING: If you strike a foreign object,
stop the engine. Remove wire from spark
plug, thoroughly inspect the mower for
any damage, and repair the damage
before restarting and operating the
mower. Extensive vibration of the mower
during operation is an indication of dam¬
age. The unit should be promptly
inspected and repaired.
USING YOUR MULCHER
(Mulching Kit is Optional Equipment)
For effective mulching, do not cut wet grass because
it tends to stick to the underside of the deck, prevent¬
ing proper mulching of grass clippings. New or thick
grass may require a narrower cut. The ground speed
should be adjusted to the condition of the lawn. If
mowing has been delayed and the grass has been
allowed to grow in excess of 4", mulching is not rec¬
ommended. Mow using the grass bag (if so equipped)
to reduce the grass height to 3-1/4" maximum before
mulching.
To remove the mulching kit, simply lift the rear dis¬
charge door and remove the mulching baffle plug
(Ref. No. 66 on page 14). Then attach the grass
catcher (optional equipment).
ADJUSTMENTS
A WARNING: Do not at any time make any
adjustment to lawn mower without first
stopping engine and disconnecting spark
plug wire.
CUniNG HEIGHT ADJUSTMENT
An adjusting plate and thumb lever at each wheel
position provides cutting height adjustment. Each
adjusting plate has nine height positions. Height of cut
will be changed when the thumb lever is moved from
one hole to another. Simply depress the lever towards
wheel and move wheel and lever assembly to desired
position. All wheels must be placed in the same rela¬
tive position. See figure 18.
10

FIGURE 18,
THROTTLE CONTROL ADJUSTMENT
If the throttle control needs adjustment or if it has
been replaced, adjust as follows.
1. Remove the screw shown in figure 19. Remove
the cable clamp from the cable.
NOTE: If you have a Tecumseh engine, simply loosen
the screw shown in figure 19B so the cable will move
freely beneath the clamp. It is not necessary to
remove the screw and clamp completely.
2. Push the throttle control lever on the handle all
the way fonward as far as it will go, then back it off
one “click,” Make certain the throttle control
lever remains in this position.
3. Push the control lever on the engine as far toward
the rear of the engine as it will go. Secure the
cable in this position with the cable clamp and
screw.
FIGURE 19B,—Tecumseh Engines
CARBURETOR ADJUSTMENTS
WARNING: If any adjustments are made
to the engine whiie the engine is running
(e.g. carburetor), keep clear of all moving
parts. Be careful of heated surfaces and
muffler.
Minor carburetor adjustments may be required to
compensate for differences in fuel, temperature,
altitude and load. To adjust carburetor, refer to the
separate engine manual packed with your mower.
NOTE: A dirty air cleaner will cause an engine to run
rough. Be certain air cleaner is clean and attached to
the carburetor before adjusting carburetor. Refer to
the separate engine manual.
LUBRICATION
A WARNING: Always stop engine and dis¬
connect spark plug wire before cleaning,
lubricating or doing any kind of work on
lawn mower.
Blade Control— L ubricate the pivot points on the
blade control handle and the brake cable at least
once a season with light oil. See figure 20. The blade
control must operate freely in both directions.
FIGURE 19A.—Briggs & Stratton Engines
11

I
Rear Discharge Door— The torsion springs a id pivot
points should be lubricated periodically with lie ht oil to
prevent any rust or binding. Door must work freely.
Wheels —Mower may be provided with ball bearing
wheels. Lubricate at least once a season with light oil.
Also, if the wheels are removed for any reason, lubri¬
cate the surface of the axle bolt and the inner surface
of the wheel with light oil. A 4 oz. plastic bottle of light
oil lubricant is available. Order part number 737-0170.
Engine oil may also be used.
Engine —Follow engine manual for lubrication instruc¬
tions.
MAINTENANCE
A WARNING: Be sure to disconne ct and
ground the spark plug wire befere per¬
forming any repairs or maintenanc e.
NOTE: When tipping the unit, empty the fuel i ink and
keep engine sparkplug side up.
TROUBLE SHOOTING
Refer to page 16 of this manual for trouble iihooting
information.
CUTTING BLADE
When removing the cutting blade for sharpening or
replacement, protect hands by using heavy g oves or
a rag to grasp the cutting blade. Remove the Dolt and
bell washer which hold the blade and adaptf r to the
engine crankshaft. Remove the blade and adapter
from the crankshaft.
If the blade or blade adapter needs replacing, remove
the two small bolts, lock washers and nuts which hold
the blade to the adapter.
A WARNING: Periodically inspect the blade
adapter for cracks, especially if you
strike a foreign object. Replac : when
necessary.
When sharpening the blade, follow the origin al angle
of grind as a guide. It is extremely important that each
cutting edge receives an equal amount of gri nding to
prevent an unbalanced blade. An unbalanct d blade
will cause excessive vibration when rotating at high
speeds, may cause damage to the mower ai id could
break, causing personal injury.
It is recommended that the blade always be i emoved
from the adapter for the best test of balance.
The blade can be tested by balancing it on a round
shaft screwdriver. Remove metal from the he avy side
until it balances evenly.
Before reassembling the blade and the blade adapter
to the unit, lubricate the engine crankshaft and the
inner surface of the blade adapter with light oil.
Lubricating the bolt holes, bolts and inner surface of
the nuts with light oil is also recommended. A 4 oz.
plastic bottle of light oil lubricant is available. Order
part number 737-0170. Engine oil may also be used.
When replacing the blade, be sure to install the blade
with the side of the blade marked “Bottom” (or with
part number) facing the ground when the mower is in
the operating position.
Blade Mounting Torque
Center Bolt: 450 in. lbs. min., 600 in. lbs. max.
Blade Adapter Bolts: 200 in. lbs. min., 350 in. lbs. max.
To insure safe operation of your unit, all nuts and
bolts must be checked periodically for correct tight¬
ness.
DECK
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 invite rust and corrosion, and may
cause an uneven discharge of grass clippings at the
next cutting.
The deck may be cleaned by tilting the mower and
scraping clean with a suitable tool (make certain the
spark plug wire is disconnected).
ENGINE
Refer to the separate engine manual for engine
maintenance instructions.
Maintain engine oil as instructed in the separate
engine manual packed with your unit. Read and follow
instructions carefully.
Service air cleaner every 25 hours under normal con¬
ditions. Clean every few hours under extremely dusty
conditions. Poor engine performance and flooding
usually indicates that the air cleaner should be ser¬
viced. To service the air cleaner, refer to the separate
engine manual packed with your unit.
The spark plug should be cleaned and the gap reset
once a season. Spark plug replacement is recom¬
mended at the start of each mowing season; check
engine manual for correct plug type and gap specifi¬
cations.
Clean the engine regularly with a cloth or brush.
Keep the cooling system (blower housing 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.
12

REAR FLAP REPLACEMENT
The rear flap is attached to the back of the mower
deck, and is designed to minimize the possibility that
objects will be thrown from the rear of the mower
toward the operator. If the rear flap becomes dam¬
aged, replace as follows.
To remove the old rear flap, cut off the flat end of the
wire rod which secures it to the deck using a pair of
side-cutters. Attach the new rear flap using the new
rod provided with the rear flap, bending the ends of
the rod over to secure.
OFF-SEASON STORAGE
The following steps should be taken to prepare lawn
mower for storage.
1. Clean and lubricate mower thoroughly as
described in the lubrication instructions.
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. Do not store
next to corrosive materials, such as fertilizer.
NOTE: When storing any type of power equipment in
an unventiiated or metal storage shed, care should be
taken to rust-proof the equipment. Using a light oil or
silicone, coat the equipment, especially cables and all
moving parts.
OPTIONAL MULCHING KIT
_ AVAILABLE _
Mulching Kit model 190-082 is available as optional
equipment for the mowers shown in this manual. The
special high lift mulching blade and baffles will pulver¬
ize the grass clipping, making it unnecessary to bag
the grass.
NOTE: The use of any accessory on this Rotary Mower other than those manufactured by the mower manufac¬
turer is not recommended.
A WARNING: DO NOT operate the mower without the entire grass catcher or rear discharge door
in piece. DO NOT operate the mower without the protective shieid on the rear of the deck in
place.
NOTE: Under normal usage bag material is subject to wear and should be checked periodically. Be sure any
replacement bag complies with the mower manufacturer’s recommendations.
13

NOTE: The engine Is not under warranty by the
mower manufacturer. . .If repairs or service is
needed on the engine, please contact your
nearest authorized engine —"t
service outlet. Check the
“Yellow Pages” of your
telephone book under
“Engines-Gasoline.”
Description
Part No.
Gray (5-1/2" Dia.)
Beige (5-1/2“ Dia.)
Gray (3-1/2" Dia.)
Black (1-1/2" Dia.)
Red (1-3/8“ Dia.)
731-0981A
731-0982A
720-0249
720-0251
731-0342
~(57( (‘(t^
Wheel w/o Bearings
FRONT WHEEL CHART
Wheels With Bearings
*Tread Type: Waffle
Bearings
Axle Bolt
Ball Brg. 1/2" I.D.-741-0180 (2 per Wheel)
738-0102
Ball Brg. 1/2" I.D.-741-0180 (2 per Wheel)
738-0102
Ball Brgs. 3/8" I.D.-741-0267,1/2“ I.D.-741-0484, Spacer 750-0434
710-1020
Ball Brg. 1/2“ I.D.-741-0180 (2 per Wheel)
738-0102
Ball Brgs. 3/8" I.D.-741-0267, 1/2" I.D.-741-0484, Spacer-750-0434
710-1020
I ; “T” Tread
14
; “S” Wave BSS ; Diamond

REF.
NO.
PART
NO.
747-0824
647-0004
2
710-1205
3
712-0324
4
710-0671
5
736-0119
6
712-0267
7
710-0605
8
736-0501
9
712-0291
10
746-0876
11
749-0538C
12
720-0226
13
749-0372B
14
726-0240
15
764-0310
16
746-0550
746-0552
746-0553
17
746-0842
■ X
746-0845
746-0843
18
764-0311
19
764-0309
>0
714-0104
21
732-0678
>2
732-0677
>3
782-7000
>4
751-0568
>5
746-0875
>6
811-00185
>7
_
>8
710-1237
!9
735-0639
10
732-e7ee^-
PARTS LIST FOR MODELS 400R THRU 428R ROTARY MOWERS
CODE
DESCRIPTION
REF.
NO.
PART
NO.
31
731-1236
32
753-0484
753-0485
33
710-1044
710-0757
34
736-0452
736-0453
35
710-1055
36
742-0306A
742-0563
37
736-0169
38
712-0241
39
736-0356
40
712-0798
41
15261A
42
15262B
43
14832
44
738-0507B
45
736-0105
46
47
720-0190
48
732-0417A
49
14578
14579
50
14765
51
782-5002
52
710-0654
53
782-5003
54
710-1017
55
710-0892
56
682-0503
57
682-0502
58
782-0310
59
**
60
**
61
764-0433
62
731-1322
63
710-0286
64
712-0324
65
782-9011
66
782-5007
67
782-5004
CODE
DESCRIPTION
N
N
N
N
N
N
N
N
N
N
N
N
Control Handle Ass’y. (Std.)
Control Handle Ass’y- w/Plastic
Rope Guide Bolt
Hex L-Nut 1/4-20 Thd.
Curved Carr. Bolt 5/16-18 x
1.38" Lg.
L-Wash. 5/16" I.D.*
Hex Nut 5/16-18 Thd.*
Oval C-Sunk Mach. Scr.
Spr. Wash. .66" I.D.
Hex L-Nut 1/4-20 Thd.
Throttle Lever
Upper Handle
Foam Grip (Optional)
Lower Handle
Cable Tie
Rear Catcher Frame
Control Cable—39" (400R,
402R, 41 OR, 412R,420R,
422R)
Control Cable—49" (403R,
405R, 413R,415R,423R,
425R)
Control Cable—36" (404R,
406R, 408R, 414R, 416R,
418R, 424R, 426R, 428R)
Throttle Control Wire—51"
(400R, 402R, 41 OR, 412R,
420R, 422R)
Throttle Control Wire—45"
(403R,405R, 413R, 415R,
423R, 425R)
Throttle Control Wire—55"
(404R, 406R, 408R, 414R,
416R, 418R, 424R, 426R,
428R)
Front Catcher Frame
Grass Bag
Int. Cotter Pin 5/16" Dia.
Door Spring—R.H.
Door Spring—L.H.
Rear Discharge Door
Cable Clamp (B&S)
Throttle Body
Throttle Box Comp. (Inch Ref. 7,
8, 9, 10, 25)
Engine
Hex Wash. Hd. Scr. #10-32 x
.62" Lg. (B&S)
Spark Plug Boot (Optional)
Wire Rod
N
N
N
N
N
Rear Flap
Blade Adapter Kit (Keyed)
Blade Adapter Kit (Splined)
Hex Bolt 3/8-24 X 1.5" Lg.
(Used w/Keyed Adapter)
Hex Bolt 7/16-20 x 1.5" Lg.
(Used w/Splined Adapter)
Bell-Wash. .39“ I.D.
(Used w/Keyed Adapter)
Bell-Wash. .46" I.D.
(Used w/Splined Adapter)
Hex Bolt 3/8-24 x1"Lg.
21“ Blade
21" Mulching Blade (Optional)
L-Wash. 3/8" I.D.*
Hex Nut 3/8-24 Thd.
Bell-Wash. .39" I.D. x 1.38“
Hex Nut 3/8-16 Thd.*
Height Adj. Plate
Pivot Bar
Spring Lever Ass’y. w/Knob
Shid. Bolt .5" Dia. x .357"
Bell-Wash. .38" I.D. x .88" O.D.
Axle Bolt
Spring Lever Knob
Spring Lever
Height Adj. Ass’y. Comp.—R.H.
Height Adj. Ass’y. Comp.—L.H.
(Not Shown)
Pivot Bar
Front Baffle
Hex L-Wash. Hd. Scr. 3/8-16 x
T'Lg.
Rear Baffle
Torx Mach. AB-Tap Scr. 1/4 x
.62" Lg.
Hex L-Wash. Hd. AB-Tap Scr.
1/4 X .62" Lg.
Handle Brkt. Ass’y.—R.H.
Handle Brkt. Ass’y.—L.H.
21" R.D. Deck
Wheel Ass’y. Comp.
Hub Cap
Grass Bagtt
Hard Top Covertt
Pan Hd. Mach. Scr. 1/4-20 x .5"
Lg-tt
Hex Nylon L-Nut 1/4-20 Thd.tt
Mounting Bracketft
Mulching Baffle Plug (Optional)
Mulching Baffle—R.R. (Optional)
tModels 41 OR thru 418R only.
ttModels 420R thru 428R only.
*For faster service obtain standard nuts, boits and washers iocally.
If these items cannot be obtained iocally, order by part number
and size as shown on parts list.
K, CODE: N notates a new part (not previously existing). A three digit
number is the color code. Specify color code as shown at right
if color or finish is important when ordering parts, [i.e., 638 for
Red Finish].
NOTE: This instruction manual covers various models, and all
specifications shown do not necessarily apply to your model.
Specifications subject to change without notice or obligation.
Color Codes
456—Radiant Tangerine
637—Black
460—Green Flake
638—Red
483—Charcoal Gray
640—Green
498—Yellow
646—CM Blue
499—Beige
629—Silver Flake
657—Teal
15

TROUBLE SHOOTING GUIDE
Trouble
Possible Cause( 0
Corrective Action
Engine fails to start
1. Blade control t andle disengaged.
1. Engage blade control handle.
2. Spark plug wiro disconnected.
2. Connect wire to spark plug.
3. Throttle contro lever not in CHOKE
3. Move throttle lever to CHOKE or
or START position.
START position.
4. Fuel tank empt y, or stale fuel.
4. Fill tank with clean, fresh gasoline.
5. Blocked fuel Hr e (if so equipped).
5. Clean fuel line.
6. Faulty spark pi jg.
6. Clean, adjust gap or replace.
7. Engine floodec.
7. Remove spark plug, dry the plug, and
crank engine with plug removed and
throttle in off position. Replace spark
plug, connect wire and resume starting
procedures.
Engine runs erratic
1. Unit running in CHOKE or START
1. Move throttle lever to FAST
position.
position.
2. Spark plug wir 3 loose.
2. Connect and tighten spark plug wire.
3. Blocked fuel lii le (if so equipped) or
3. Clean fuel line; fill tank with clean.
Stale fuel.
fresh gasoline.
4. Vent in gas caa plugged.
4. Clear vent.
5. Water or dirt ir fuel system.
5. Drain fuel tank. Refill with fresh fuel.
6. Dirty air cleanor.
6. Clean air cleaner.f
7. Carburetor ou' of adjustment.
7. Adjust carburetor.t
Engine overheats
1. Engine oil Iev61 low.
1. Fill crankcase with proper oil.
2. Air flow restric:ed.
2. Remove blower housing and clean.t
3. Carburetor no adjusted properly.
3. Adjust carburetor.t
Occasional skip
1. Spark plug ga} too close.
1. Adjust gap to .030"
(hesitates) at high speed
2. Carburetor idio mixture adjustment
improperly sel.
2. Adjust carburetor.t
Idles poorly
1. Spark plug foi led, faulty or gap too wide.
1. Reset gap to .030" or replace spark plug.
2. Carburetor im )roperly adjusted.
2. Adjust carburetor.t
3. Dirty air clean 3r.
3. Clean air cleaner.f
Excessive vibration
1. Cutting blade oose or unbalanced.
1. Tighten blade and adapter.
Balance blade.
2. Bent cutting b ade.
2. Replace blade.
Mower will not
1. Engine speed too low.
1. Set throttle between 3/4 and full throttle.
discharge grass
2. Wet grass.
2. Do not mow when grass is wet; wait until
later to cut.
3. Excessively h gh grass.
3. Mow once at a high cutting height, then
mow again at desired height or make a
narrower cutting swath (1/2 width).
Uneven cut
1. Wheels not p jsitioned correctly.
1. Place all four wheels in same height
position.
2. Dull blade.
2. Sharpen or replace blade.
fRefer to separate engine manual packed with yo ur unit.
Note: For repairs beyond the minor adjustments li sted above, contact your local authorized service dealer.
FOR REPLACEMENT PARTS, CONTACT:
SERVICE DEPARTMENT • P.O. BOX 360900 • CLEVELAND, OHIO 44136