Craftsman 3One 917.383640 User manual

®
0 EL U
oAssembly
- Operation
oCustomer
Responsibilities
° Service
oAdjustments
_oRepair Parts
Caution:
Read and Follow
all Safety Rules
and Instructions
Before Operating
This Equipment
917.383640 OWNER'S MANUAL
TM
:_'11 IIIIII ..................... 1! ...........................................

SAFETY RULES
PLUG TO PREVENTACCIDENTAL STARTING WHEN SETTING UP, TRANSPORTING, ADJUSTING OR MAKING
REPAIRS. IMPORTANT
SAFETY STANDARDS REQUIRE OPERATOR PRESENCE CONTROLS TO MINIMIZETHE RISK OF INJURY. YOUR UNIT IS EQUIPPED WITH
SUCH CONTROLS. DO NOT ATTEMPT TO DEFEAT THE FUNCTION OF THE OPERATOR PRESENCE CONTROLS UNDER ANY CIRCUM-
STANCES.
TRAINING:
• Read this operator's manual carefulIy. Become familiar with
the controls and know how to operate your mower properly.
Learn how to quickfy stop mower_
•Do not allow children to use your mower. Never allow aduffs
to use mower without proper instructions.
,Keep the area of operation clear of all persons, especially
small children and pets.
• Use mower only as the manufacturer intended and as de-
scribed inthis manual.
•Do not operate mower if ithas been dropped or damaged in
any manner. Always have damage repaired before using
your mower.
, Do not use accessory attachments that are not recommended
by the manufacturer. Use of such attachments may be
hazardous.
•The blade turns when the engine is running.
PREPARATION:
,, Always thoroughly check the area to be mowed and ctear it of
all stones, sticks, wires, bones, and other foreign objects.
These objects will be thrown by the blade and can cause
severe injury,
,, Always wear safety glasses or eye shields when starting and
while using your mower.
,, Dress properly. Do not operate mower when barefoot or
wearing open sandals. Wear only solid shoes with good
traction when mowing.
° Check fuel tank before starting engine. Do not fill gas tank
indoors, when the engine isrunning or when the engine ishot.
Allow the engine to cool for several minutes before filling the
gas tank. Clean off any spilled gasoline before starting the
engine.
,, Always make wheel height adjustments before starting your
mower. Never attempt to do this while the engine is running_
° Mow only in daylight or good artificial light.
OPERATION:
• Keep your eyes and mind on your mower and the area being
cut. Do not let other interests distract you.
• Do not mow wet or slippery grass. Never run while operating
your mower. Always be sure ofyour footing -keep a firm hold
on the handles and walk.
Do not put hands or feet near or under rotating parts. Keep
clear of the discharge opening at all times.
• Always stop the blade whenever you leave or are not using
you rmower, or before crossing driveways, walks, roads, and
any gravel-covered areas.
• Never direct discharge of material toward bystanders nor
allow anyone near the mower while you are operating it.
•Before cleaning, inspecting, or repairing your mower, stop
the engine and make absolutely sure the blade and all
moving parts have stopped. Then disconnect the spark plug
wire and keep it away from the spark plug to prevent
accidental starting.
• Do not continue to run your mower ifyou hit a foreign object.
Follow the procedure outlined above, then repair any dam-
age before restarting and operating you mower.
° Do not change the governor settings or overspeed the
engine. Engine damage or personal injury may result.
- Do not operate your mower if it vibrates abnormally. Exces-
sive vibration is an indication of damage; stop the engine,
safely check forthe cause of vibration and repair as required.
• Do not run the engine indoors. Exhaust fumes are danger-
ous.
,, Never cut grass by pulling the mower towards you. Mow
across the face of slopes, never up and clown or you might
lose your footing. Do not mow excessively steep slopes.
Use caution when operating the mower on uneven terrain or
when changing directions - maintain good footing.
• Never operate your mower without proper guards, plates,
grass catcher or other safety devices in place.
MAINTENANCE AND STORAGE:
', Check the blade and the engine mounting bolts often to be
sure they are tightened properly.
• Check all bolts, nuts and screws at frequent intervals for
proper tightness to be sure mower is in safe working condi-
tion.
,, Keep al! safety devices in place and working.
• To reduce fire hazard, keep the engine free of grass, leaves
or excessive grease and oil.
Q Check grass catcher often for deterioration and wear and
replace worn bags. Use only replacement bags that are
recommended by and comply with specifications of the
manufacturer of your mower.
- Always keep a sharp blade on your mower.
° Allow engine to coo! before storing in any enclosure.
• Never store mower with fuel in the tank inside a building
where fumes may reach an open flame or an ignition source
such as a hot water heater, space heater, clothes dryer, etc.
IS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS.
IT MEANS -ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED.

....... i
CONGRATULATIONS on your purchase of a Sears
Craftsman Lawn Mower. It has been designed, engineered
and manufactured to give you the best possible de-
pendability and performance.
Should you experience any problems you cannot easily
remedy, please contact your nearest Sears Service Cen-
teriDepartmento Sears has competent, welt trained tech-
nicians and the proper tools to service or repair this unit.
Please read and retain this manual. The instructions will
enable you to assemble and maintain your lawn mower
properly. Always observe the "SAFETY RULES".
MODEL
NUMBER 917.383640
SERIAL
NUMBER
DATE OF
PURCHASE
THE MODEl_ AND SERIAL NUMBERS WILL BE
FOUND ON A DECAL ATTACHED TO THE REAR
OF THE LAWN MOWER HOUSING.
YOU SHOULD RECORD BOTH SERIAL NUMBER
AND DATE OF PURCHASE AND KEEP IN A SAFE
PLACE FOR FUTURE REFERENCE.
PRODUCT SPECIFICATIONS
HORSEPOWER: 3.8
DISPLACEMENT: 9.0 cu. in.
GASOLfNE CAPACITY: ! .5 quarts
(Unleaded)
OIL (20 oz. Capacity): SAE 30 (Above 32°F)
5W30 (Below 32°F)
SPARK PLUG (GAP .030 in.):
(0.76 ram) Champion
RJ19LM or
Sears _ 33312
or STD 361458
or STD 360950
VALVE CLEARANCE: Intake: .008 in.
Exhaust: .008 in.
SOLID STATE IGNITION
AIR GAP: .0125 in.
BLADE BOLT TORQUE: 35*40 ff.-lbs.
MAINTENANCE AGREEMENT
A Sears Maintenance Agreement is available on this product. Contact your nearest Sears store for details.
CUSTOMER RESPONSIB_UTJES
® Read and observe the safety rules.
= Follow a regular schedule in maintaining, caring for and using your lawn mower.
Follow the instructions under "Customer Responsibilities" and "Storage" sections of this Owne¢s Manual.
LiMiTED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER
For two years from date of purchase, when this Craftsman Lawn Mower is maintained, lubricated, and tuned up
according to the operating and maintenance instructions in the owner's manual, Sears will repair free of charge any
defect in material or workmanship.
If this Craftsman Lawn Mower isused for commercial or rental purposes, this warranty applies for only 90 days from
the date of purchase.
This Warranty does not cover:
Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts,
air cleaners and spark plug.
= Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to
maintain the equipment according to the instructions contained in the owner's manual.
WARRANTY SERVICE IS AVAILABLE BY RETURNING THE CRAFTSMAN POWER MOWER TO THE NEAREST
SEARS SERVICE CENTER/DEPARTMENT IN THE UNITED STATES. THIS WARRANTY APPLIES ONLY WHILE
THIS PRODUCT tS tN USE IN THE UNITED STATES.
This Warranty gives you specific tegal rights, and you may also have other rights which vary from state to state.
SEARS, ROEBUCK AND CO., D/817 WA, HOFFMAN ESTATES, ILLINOIS 60179
3

....... i
TABLE OF
SAFETY RULES .................................................... 2
PRODUCT SPECiFICATiONS .............................. 3
CUSTOMER RESPONSIBILITIES ............. 3, 11-13
WARRANTY .......................................................... 3
LAWN MOWER ACCESSORIES .......................... 5
ASSEMBLY ........................................................... 6
OPERATION .......................................................... 7
CONTENTS
MAINTENANCE SCHEDULE .............................. 11
SERVICE AND ADJUSTMENTS ......................... 14
STORAGE ........................................................... 15
TROUBLESHOOTING ......................................... 21
REPAIR PARTS - LAWN MOWER ................ 16-17
REPAIR PARTS -ENGINE ............................ !8-20
PARTS ORDERING/SERVICE ........ BACK COVER
INDEX
A
Accessories ............................................. 5
Adjustments:
Carburetor .................................. 14
Handle Height ............................ i4
Height of Cut ................................ 9
Air Filter:
Service ........................................ 13
Assembly:
Handle .......................................... 8
Grass Catcher .............................. 6
B
Blade:
Sharpening ................................. 12
Replacement .............................. 12
C
Controls:
Operator Presence Control Bar..7
Speed Control .............................. 7
Customer Responsibifities ..... 3, 1i-i3
Air Filter ...................................... 13
Blade Care/Replacement .......... 1:2
Engine ........................................ 13
Lubrication ................................. 11
Spark Plug ................................. 13
E
Engine:
OJ!Change ................................. 13
Oi! Leve! ....................................... 9
Oil Type ........................................ 9
Starting ....................................... 10
Storage ....................................... 15
F
Fuel:
Type .............................................. 9
Storage ....................................... t5
H
Handle:
Adjustment ................................. 14
Assembly ..................................... 6
L
Lubrication:
Engine ........................................ 11
Brake Spring Bracket ................ 1t
Handle Bracket Mounting Pin .. 1t
Wheel Adjuster .......................... 11
M
Maintenance Agreement .................... 3
Mowing Tips ...................................... 10
Mowing Mulching Tips ..................... 10
O
Oih Engine ........................................ 18
Storage ....... ,............................... 15
Operation:
Operating Lawn Mower ............... 8
Control Bar ................................... 7
Engine Speed Control ................. 8
Operator Presence Contro! Bar ......... 7
Options:
Attachments ................................. 5
P
Repair Parts
Lawn Mower .......................... 16-17
Engine ................................... 18-20
R
Responsibilities, Customer .... 3, 11-13
S
Safety Rules ........................................ 2
Service and Adjustments:
Carburetor .................................. 14
Engine Speed ............................. !4
Handle ........................................ ! 4
Spark Plug ......................................... 13
Specifications ..................................... 3
Starting the Engine ........................... 10
Stopping the Engine ........................ 10
Storage .............................................. 15
T
Trouble Shooting Chart ................... 21
W
Warranty .................................... .......... 3
Wheels:
Wheel Adjusters .......................... 7
4

LAWN IVIOWER ACCESSO ES
These accessories were available when this lawn mower was produced. They are also available at most Sears retail outlets,
catalog and service centers. Most Sears stores can also order repair parts for you, when you provide the model number of
your lawn mower, Some of these accessories may not apply to your lawn mower.
ENGINE
SPARK PLUG MUFFLER AmRFILTER
If lawn mower is an electric start
LAWN MOWER PERFORMANCE
REAR BAG
OPTIONAL
GAS CAN
REPLACEMENT
BAG FOR REAR
DISCHARGE
LAWN MOWERS
ENGINE OIL
DUST SHIELD
FABRIC BAG
LAWN MOWER MAINTENANCE
BELT BLADE
OPTIONAL
CATCHER FOR
SiDE DISCHARGE
LAWN MOWER
CLiPPiNG DEFLECTOR
SIDE DISCHARGECATCHER
BLADE
ADAPTER WHEELS LAWN MOWER COVER
5

ASS
Read these instructions and the Operator's Manual in its
entirety before you attempt to assemble or operate your
new lawn mower. Your new lawn mower has been as-
sembled at the factory with the exception of those parts left
unassembled for shipping purposes. All parts such as nuts,
washers, bolts, etc., necessary to complete the assembly
have been placed in the parts bag. To ensure safe and
proper operation of your lawn mower, a!! parts and hard-
ware you assemble must be tightened securely. Use the
correct tools as necessary to ensure proper tightness.
TO REMOVE LAWN MOWER FROM
CARTON
• Remove loose parts included with mower.
o Cut down two end corners of carton and lay end panel
down fiat.
o Remove all packing materials except padding between
upper and lower handle and padding holding operator
presence control bar to upper handle.
Roii lawn mower out of carton and check carton thor-
oughly for additional loose parts.
HOW TO SET UP YOUR LAWN
MOWER
TO UNFOLD HANDLE (See Fig, I)
IMPORTANT: UNFOLD HANDLE CAREFULLY SO AS
NOT TO PINCH OR DAMAGE CONTROL CABLES.
* Raise handles untit lower handle section locks into
place in mowing position.
Raise upper handle section into place on _owerhandle,
remove protective padding and tighten both handle
knobs.
o Remove handle padding holding operator presence
control bar to upper handle.
o Your lawn mower handle can be adjusted for your
mowing comfort. Refer to "Adjust Handle" in the
Service and Adjustment section of this manual.
TO INSTALL ATTACHMENTS
(See Fig, 2)
Your lawn mower was shipped ready .to be used as a
mutcher. To convert to bagging or discharging:
o Open rear door and remove muncher plate. Store
mulcher plate in a safe place.
- You can now install catcher or optional clipping deflect
tor.
o To return to mulching operation, install mulcher plate
into discharge opening of mower. Be sure all tabs are
seated properly.
TO ASSEMBLE & ATTACH GRASS
CATCHER (See Figs, 3 & 4)
o Put grass catcher frame into grass bag with rigid part of
bag on the bottom. Make sure the frame handle is
o_Jtsideof the bag top.
Slip vinyl bindings over frame.
NOTE: tf vinyl bindings are too stiff, hoid them in warm
water for a few minutes. If bag gets wet, let it dry before
using.
Lift the rear door of the tawn mower and place the grass
catcher frame side hooks onto the handle bracket
hooks.
The grass catcher is secured to the lawn mower
housing when the rear door is lowered onto the grass
catcher frame.
LY
OPERATOR PRESENCE
CONTROLBAR
UPPER HANDLE
LIFT UP
MOWING POSiTiON
LOWER HANDLE
FIG, 1
SLOTS
MULCHER PLATE TABS
FIG.2
CATCHER FRAME
6
FRAME OPENING
REAR DOOR
GRASS CATCHER
FRAME
CAUTION: Do not run your lawn mower
without mutcher pmate in peace or ap-
proved ctipping deflector or grass
catcher in ptace. Never attempt to op-
erate the {awn mower with the rear door
removed or propped open.

OPERATION
KNOW YOUR LAWN MOWER
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR LAWN MOWER. Compare the
illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this
manual for future reference.
OPERATOR PRESENCE CONTROL BAR
ENGINE ZONE CONTROL CABLE STARTER HANDLE
HANDLE KNOB
GRASS CATCHER
MULCHER PLATE
ENGINE OIL CAP WITH
DIPSTICK
ENGINE SPEED CONTROL LEVER
PRIMER
AiR FILTER
WHEEL ADJUSTER
GASOLINE FILLER CAP (ON EACH WHEEL)
LAWN MOWER HOUSING
MEETS CPSC SAFETY REQUIREMENTS
Sears rotary walk-behind power iawn mowers conform to the safety standards of the American National Standards institute
and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running.
OPERATOR PRESENCE CONTROL BAR - must be held
down to the handle to start the engine. Release to stop the
engine.
PRIMER - pumps additional fuel from the carburetor to the
cylinder for use when starting a cold engine,
STARTER HANDLE =used for starting the engine.
ENGINE SPEED CONTROL - located on the side of the
engine which allows you to select either fast (#,_) or slow
(,!_) engine speed.
MULCHER PLATE - located at the discharge opening,
must be removed when converting to bagging or discharg-
ing operation,
7

....... i
OPE 0
HOW TO USE YOUR LAWN MOWER
ENGINE SPEED CONTROL (See Fig. 5)
The engine speed is controlled by a lever (red knob)
located on the side of the engine. Fast (_) position is for
starting the engine, normal cutting, and better grass
bagging. Slow (,_!) position is for light cutting, trimming
and fuel economy.
ENGINE ZONE CONTROL
CAUTION: Federal regulations require
an engine control to be installed on this
lawn mower in order to minimize the
risk of blade contact injury. Do not un-
der any circumstances attempt to de-
feat the function of the operator control.
The blade turns when the engine is
running.
. Your lawn mower is equipped with an operator pres-
ence control bar which requires the operator to be
positioned behind the lawn mower handle to start and
operate the fawn mower.
TO ADJUST CUTTING HEIGHT (See Fig. 6)
•Raise wheels for low cut and lower wheels for high cut.
. Wheels are set in low cut for shipping. Adjust cutting
height to suit your requirements. Medium position is
best for most lawns.
•To change cutting height, squeeze adjuster lever to-
ward wheel. Move wheel up or down to suit your
requirements, Be sure al] wheels are in the same
setting,
ENGINE SPEED
CONTROL LEVER
FIG. 5
LOWER WHEELS
FOR HIGH CUT RAISE WHEELS
FOR LOW CUT
FIG. 6
8

z
OPERATION
TO EMPTY GRASS CATCHER
(See Fig, 7}
• Lift up on grass catcher using the frame handle.
® Remove grass catcher with clippings from under lawn
mower handle.
Empty clippings from bag using both frame handle and
bag handle.
NOTE: Do not drag the bag when emptying; it will cause
unnecessary wear.
BEFORE STARTING ENGINE
OIL
Your lawn mower is shipped without oil in the engine.
,Be sure mower is level and area around oil fill is clean.
Remove engine oil cap w/dipstick and fill to the full line
on the dipstick.
• Use 20 ozs. of oil. For type and grade of oil to use, see
"ENGINE" in Customer Responsibilities section of this
manual,
Pour oil slowly. Do not over fil!.
• Check oil level before each use. Add oil if needed. Fill
to full fine on dipstick.
•To read proper level, tighten engine oil cap each time.
• Reinstall engine oil cap and tighten.
After the first two (2) hours of mowing, change the oil,
and every 25 hours thereafter. You may need to
change the oil more often under dusty, dirty conditions.
GAS
, Fill gasoline tank with fresh, clean, unleaded gasoline.
DO NOT USE PREMIUM GASOLINE, BE CAREFUL
NOT TO OVER FILL TANK.
WARNING: Experience indicates that alcohol blended
fuels (called gasoho! 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 stor-
age of 30 days or longer. Drain the fuel tank, start the
engine and let it run until fuel lines and carburetor are
empty, Use fresh fuel next season. See Storage lnstruc-
tions for additional information. Never use engine or
carburetor cleaner products in fuel tank or permanent
damage may occur.
A
FIG. 7
9

OPERATIO
TO START ENGINE
To start a cold engine, push primer five (5) times
before trying to start. Use a firm push. This step is not
usually necessary when starting an engine which has
already run for a few minutes.
,Push engine speed control lever to fast (_) position.
•Hold operator presence control bar down to the
handle and pull starter handle quickly, Do not
allow starter rope to snap back.
•To stop engine, release operator presence control
bar.
NOTE: In cooler weather it may be necessary to repeat
priming steps. 1n warmer weather over priming may cause
flooding and engine will not start, if you do flood engine,
wait a few minutes before attempting to start and do not
repeat priming steps.
MOWING TIIPS
o Under certain conditions, such as very tall grass, it
may be necessary to raise the height of cut to reduce
pushing effort and to keep from overloading the en-
gine and leaving clumps of grass clippings.
For extremely heavy cutting, reduce the width of cut
and raise the rear of the lawn mower housing one (1)
wheel adjuster setting higher than the front for better
discharge of grass.
* For better grass bagging and most cutting conditions,
the engine speed should be set in the fast ('_)
position.
When using a rear discharge lawn mower in moist,
heavy grass, clumps of cut grass may not enter the
grass catcher. Reduce ground speed (pushing speed)
and/or run the lawn mower over the area a second
time.
* tf a trail of grass clippings is left on the right side of a
rear discharge lawn mower, mow in a clockwise
direction with a small overlap to collect the clippings
on the next pass.
Keep top of engine around starter clear and clean of
grass clippings and chaff. This will help engine air
flow and extend engine life.
, Pores in cloth grass catchers can become filled with
dirt and dust with use and catchers will collect tess
grass. To prevent this, regularly hose catchers off
with water and let dry before using.
MAX 113
FIG, 8
MULCHING MOWING TIPS
IMPORTANT: FOR BEST PERFORMANCE, KEEP
MOWER HOUSING FREE OF BUILT-UP GRASS AND
TRASH. CLEAN UNDERSIDE OF MOWER HOUSING
AFTER EACH USE. SEE "CLEANING" IN CUSTOMER
RESPONSIBILITIES SECTION OF THIS MANUAL.
The speciat mulching blade will recut the grass clip-
pings 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 wilt
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 interferes with the mulching
action. The best time to mow your tawn is the early
afternoon. At this time the grass has dried and the
newly cut area will not be exposed to the direct sun.
•For best results, adjust the tawn mower cutting height
so that the lawn mower cuts off only the top one-third
of the grass blades (See Fig. 8). If the lawn is
overgrown itwill be necessary to raise the height of cut
to reduce pushing effort and to keep from overloading
the engine and leaving clumps of mulched grass. For
extremely heavy mulching, reduce your width of cut,
mow slowly and raise the rear of the lawn mower one
wheel adjuster setting higher than the front.
Certain types of grass and grass conditions may
require that an area be mulched a second time to
completely hide the clippings. When doing a second
cut, mow across or perpendicular to the first cut path.
• Change your cutting pattern from week to week. Mow
north to south one week then change to east to west
the next week. This wilt help prevent matting and
graining of the lawn.
10