Dura-Max 338491 Assembly instructions

24 V CORDLESS
LAWN MOWER
TM
Owner's Manual
Read all safety rules and operating instructions carefully before using this product.
WARNING
TOLL FREE HELPLINE: 1-866-456-8934
WARNING

READ ALL INSTRUCTIONS!
WARNING: This symbol indicates important safety instructions. if these instuctions are not
followed, it could endanger the personal safety and/or property of the operator and others.
Read and understand all instructions in this manual before attempting to operate the mower.
Failure to comply with these instructions may result in personal injury.
DANGER: This mower was built to be operated according to the rules for safe operation that
are contained in this manual. As with any type of power equipment, carelessness or error on
the part of the operator can result in serious injury. This mower is capable of amputating
body parts and throwing objects. Failure to observe the following safety rules could result in
serious injury or death.
Basic safety precautions should always be followed when using electric lawn mowers, in
order to reduce the risk of fire, electric shock, and personal injury.
TABLE OF CONTENTS
General Safety Rules
Know Your Lawn Mower
4-5
6-7
8-9
3
Specific Safety Rules
Symbols
10-16
30-34
Assembly
Operation 17-21
Tro
ubleshooting 28
Warranty 29
Exploded View/Parts List
SPECIFICATIONS
Model 338491number:
Motor: 24 V
Battery: 24 V, 20 Ah lead-acid
No-load Speed: 3500 RPM
Hei
Weight:
ght adjustments: 1 1/2—3 3/4” (3.8 cm-9.5 cm)
2
Specifications 2
Maintenance 22-27
Cutting Path: 20” (50.8 cm)
54 lb (24.3 kg) without battery
86 lb (39 kg) with battery
Functions: 3-in-1: Mulch, side discharge or rear bag.

GENERAL SAFETY RULES
WARNING:
READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow
all instructions listed below and on the machine may result in electric shock, fire, and/or
serious personal injury.
READ ALL INSTRUCTIONS
■ This cutting machine is capable of amputating hands and feet and throwing objects.
Failure to observe all safety instructions could result in serious injury or death.
■ Do not use the lawn mower in damp or wet conditions or operate in the rain.
■ Keep the area clear of all bystanders, children, and pets while mowing. Stop machine if
anyone enters the area.
■ 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 under the watch-ful care of a responsible
adult other than the operator.
• Be alert and turn mower off if a child enters the area.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners, shrubs, trees, or other objects that may
block your view of a child.
■ Do not wear loose clothing or jewelry. They can be caught in moving parts. Use of rubber
gloves and footwear is recommended when working outdoors.
■ Keep firm footing and balance. Do not overreach. Overreaching can result in loss of
balance.
■ Do not operate the equipment while barefoot or when wearing sandals or similar
lightweight footwear. Wear protective footwear that will protect your feet and improve your
footing on slippery surfaces.
■ Do not leave the mower unattended while running.
■ Keep hands and feet away from cutting area. Keep clear of the discharge opening at all
times.
■ Operate the lawn mower only in daylight or good artificial light.
■ Always wear safety glasses with side shields. Everyday glasses have only impact
resistant lenses. They are NOT safety glasses. Following this rule will reduce the risk of
eye injury. Use face mask if operation is dusty.
■ Wear safety glasses or goggles that are marked to comply with ANSI Z87.1 standard
when operating this product.
■ Use the right appliance. Do not use the lawn mower for any job except that for which it is
intended.
■ Do not force the lawn mower. It will do the job better and safer at the rate for which it was
designed.
■ Stay alert, watch what you are doing and use common sense when operating the lawn
mower. Do not operate the mower while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating the lawn mower may result in serious
personal injury.
■ Keep machine in good working condition. Keep blades sharp and guards in place and in
working order.
■ Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the
equipment is in safe working condition.
■ Stop the motor and wait until the blade comes to a complete stop before cleaning the
lawn mower, removing the grass catcher, or unclogging the discharge guard.
■ When not in use, mower should be stored indoors in a dry, locked up place—out of the
reach of children.
3

SPECIFIC SAFETY RULES
■ Do not operate the mower without the entire grass catcher, discharge guard, rear guard,
or other safety protective devices in place and working.
■ Follow manufacturer’s instructions for proper operation and installation of accessories.
Only use accessories approved by the manufacturer.
■ Clear the work area before each use. Remove all objects such as rocks, sticks, wire,
bones, toys, or other objects which can be thrown by the blade.Stay behind the handle
when the motor is running.
■ Avoid holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could cause a
slip and fall accident.
■ Do not mow near drop-offs, ditches, or embankments.
■ Mow across the face of slopes, never up and down. Exercise extreme caution when
changing direction on slopes.
■ Plan your mowing pattern to avoid discharge of material toward roads, sidewalks,
bystanders and the like. Also, avoid discharging material against a wall or obstruction,
which may cause the material to ricochet back toward the operator.
■ Do not mow on wet grass or excessively steep slopes. Poor footing could cause a slip
and fall accident. Walk, never run.
■ Use extra care when approaching blind corners, shrubs, trees, or other objects that may
block your view.
■ Do not pull the mower backward unless absolutely necessary. If you must back the
mower away from a wall or obstruction, first look down and behind to avoid tripping.
■ Never direct discharged material toward anyone. Avoid discharging material against a
wall or obstruction. Ma-terial may ricochet back toward the operator. Stop the blade when
crossing gravel surfaces.
■ Objects struck by the lawn mower blade can cause severe injuries to persons. The lawn
should always be carefully examined and cleared of all objects prior to each mowing.
■ If the lawn mower strikes a foreign object, follow these steps:
• Stop the lawn mower and release the switch control lever. • Disconnect the power cord.
• Thoroughly inspect the mower for any damage.
• Repair any damage before restarting and continuing to operate the mower.
■ Stop the motor, remove the switch key, and wait until the blade comes to a complete stop
before removing the grass catcher or unclogging the chute. The cutting blade continues
to rotate for a few seconds after the motor is shut off. Never place any part of the body in
the blade area until you are sure the blade has stopped rotating.
■ If the mower should start to vibrate abnormally, stop the motor and check immediately for
the cause. Vibration is generally a warning of trouble.
■ Service on the product must be performed by qualified repair personnel only. Service or
maintenance performed by unqualified personnel could result in injury to the user or
damage to the product.
■ Use only identical replacement parts when servicing the product. Use of unauthorized
parts may create a risk of serious injury to the user, or damage to the product.
■ Do not place battery tools or their batteries near fire or heat. This will reduce the risk of
explosion and possibly injury.
■ Do not open or mutilate battery (ies). Released electrolyte is corrosive and may cause
damage to the eyes or skin. It may be toxic if swallowed.
■ If electrolyte contacts the skin, wash it off immediately with water.
■ If electrolyte contacts the eyes, flush thoroughly and immediately with water. Seek
medical attention.
4

SPECIFIC SAFETY RULES
SAFETY RULES FOR CHARGER
■ Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power
tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled
cords increase the risk of electric shock.
■ Use of an attachment not recommended or sold by the battery charger manufacturer may
result in a risk of fire, electric shock, or injury to persons. Following this rule will reduce
the risk of electric shock, fire, or serious personal injury.
■ Do not service mower with switch key or charger in-stalled.
■ Do not use the charger when the ambient temperature is above 40°C or below 0°C.
■ Do not operate charger with a damaged cord or plug, which could cause shorting and
electric shock. If damaged, have the charger replaced by an authorized serviceman.
■ Do not operate charger if it has received a sharp blow, been dropped, or otherwise
damaged in any way. Take it to an authorized serviceman for electrical check to
determine if the charger is in good working order.
■ Unplug charger from outlet before attempting any maintenance or cleaning to reduce the
risk of electric shock.
■ Disconnect charger from the power supply when not in use to prevent damage to the
charger during a power surge.
■ Risk of electric shock. Do not touch uninsulated portion of output connector or
uninsulated battery terminal.
■ Do not expose charger to wet or damp conditions. Water entering charger will increase
the risk of electric shock.
■ Make sure cord is located so that it will not be stepped on, tripped over, come in contact
with sharp edges or moving parts or otherwise subjected to damage or stress. This will
reduce the risk of accidental falls, which could cause injury, and damage to the cord,
which could result in electric shock.
■ Keep cord and charger away from heat to prevent damage to housing or internal parts.
■ Do not let gasoline, oils, petroleum-based products, etc. come in contact with plastic
parts. They contain chemicals that can damage, weaken, or destroy plastic.
■ An extension cord should not be used unless absolutely necessary. Use of improper
extension cord could result in a risk of fire and electric shock. If extension cord must be
used, make sure:
a. That pins on plug of extension cord are the same number, size and shape as those of
plug on charger.
b. That extension cord is properly wired and in good electrical condition; and
c. That wire size is large enough for AC ampere rating of charger as specified below:
Cord Length (Feet) 25' 50' 100'
Cord Size (AWG) 16 16 16
NOTE: AWG = American Wire Gauge
■ Save these instructions. Refer to them frequently and use them to instruct others who
may use this product. If you loan someone this tool, loan them these instructions also.
5

SYMBOLS
6
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts Voltage
A Amperes
Hertz
Current
Hz Frequency (cycles per second)
W Watt Power
hrs Hours Time
Precautions that involve your safety.
Wet Conditions Alert Do not expose to rain or use in damp locations.
Always wear safety goggles or safety glasses
with side shields and, as necessary, a full face
shield when operating this product.
Failure to use in dry conditions and to observe
safe practices can result in electric shock.
To reduce the risk of injury, user must read and
understand operator’s manual before using this
product.
Read The Operator’s
Manual
Eye Protection
Safety Alert
Electric Shock
Some of the following symbols may be used on this product. Please study them and
learn their meaning. Proper interpretation of these symbols will allow you to operate the
product better and safer.

SYMBOLS
7
SYMBOL SIGNAL MEANING
DANGER:
WARNING:
CAUTION:
CAUTION:
The following signal words and meanings are intended to explain the levels of risk
associated with this product.
Indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation, which, if not
avoided, may result in minor or moderate injury.
(Without Safety Alert Symbol) Indicates a situation that may
result in property damage.
SERVICE
Servicing requires extreme care and knowledge and should be performed only by a
qualified service technician. For service we suggest you return the product to your nearest
AUTHORIZED SERVICE CENTER for repair. When servic-ing, use only identical
replacement parts.
WARNING:
To avoid serious personal injury, do not attempt to use this product
until you read thoroughly and understand com-pletely the operator’s manual. If you do
not understand the warnings and instructions in the operator’s manual, do not use this
product. Call DURAMAXX customer service for assistance.
The operation of any power tool can result in foreign objects being thrown into
your eyes, which can re-sult in severe eye damage. Before beginning power
tool operation, always wear safety goggles or safety glasses with side shields
and, when needed, a full face shield. We recommend Wide Vision Safety Mask
for use over eyeglasses or standard safety glasses with side shields. Always
use eye protection which is marked to comply with ANSI Z87.1.
SAVE THESE INSTRUCTIONS

KNOW YOUR LAWN MOWER
8
Fig. 1
GRASS CATCHER
MOTOR HOUSING
MULCHING PLUG
HEIGHT ADJUSTMENT
LEVER
SIDE DISCHARGE
DEFLECTOR
SIDE
DISCHARGE
COVER
POWER SWITCH
ASSEMBLY
LOWER
HANDLE
UPPER
HANDLE
CHARGER
SWITCH
KEY

KNOW YOUR LAWN MOWER
9
The safe use of this product requires an understanding of the information on the product
and in this operator’s manual as well as a knowledge of the project you are attempting.
Before use of this product, familiarize yourself with all operating features and safety rules.
(Fig. 1)
BATTERY METER
The battery meter measures the amount of charge remaining in the battery.
GRASS CATCHER
The grass catcher prevents grass clippings from being strewn across your lawn as you
mow.
HEIGHT ADJUSTMENT LEVER
The height adjustment lever provides cutting height adjustments.
MOTOR/BLADE CONTROL ASSEMBLY
The motor/blade control, located on the upper handle of the mower, engages and
disengages the motor and blade.
MULCHING PLUG
Your mower is equipped with a mulching plug that cuts and recuts the grass for finer
clippings.
SWITCH KEY
The switch key must be inserted before the mower can be started.
SIDE DISCHARGE DEFLECTOR
Use the side discharge deflector on your mower when the grass is too high to mulch or
when side discharging is preferred. The grass clippings produced when using the side
discharge deflector are noticeably larger than those produced when using the mulching
plug.

ASSEMBLY
10
UNPACKING
This product requires assembly.
■ Carefully remove the product and any accessories from the box. Make sure that all
items listed in the packing list are included.
■ Inspect the product carefully to make sure no breakage or damage occurred during
shipping.
■ Do not discard the packing material until you have carefully inspected and satisfactorily
operated the product.
■ If any parts are damaged or missing, please call 1-866-456-8934 for assistance.
PACKING LIST
Mower
Switch key
Side Discharge Deflector
Mulching Plug
Grass Catcher
Charger
Operator’s Manual
WARNING:
If any parts are damaged or missing do not operate this product until
the parts are replaced. Failure to heed this warning so could result in serious personal
injury.
WARNING:
Do not attempt to modify this product or create accessories not
recommended for use with this product. Any such alteration or modification is misuse
and could result in a hazardous condition leading to possible serious personal injury.
WARNING:
Do not insert switch key until assembly is complete. Failure to
comply could result in accidental starting and possible serious personal injury.
WARNING:
To prevent accidental starting, do not make any adjustments or
installations with the switch key inserted.

ASSEMBLY
11
ASSEMBLING THE HANDLE
WARNING:
Never operate the mower without the proper safety devices in place
and working. Never operate the mower with damaged safety devices. Failure to heed
this warning can result in serious personal injury.
■ Remove any packing material which may be between the upper and lower handles for
shipping purposes.
■ Pull up and back on the upper handle to raise the handle into operating position. Make
certain the handles snap into place securely. (Fig. 2).
■ Align the holes (3) between the upper handle (1) and lower (2) handles. Insert the bolts
(4) and tighten them with the wing nuts (5) provided.
■ Secure the lower handle to the bracket with the knob (6) in each side (Fig. 3).
Fig. 2
Fig. 3
3
4
5
2
1
6

ASSEMBLY
12
INSTALLING SIDE DISCHARGE DEFLECTOR (Fig. 4)
■ Lift the side discharge door (1).
■ Align the grooves on the deflector (2) with the pins on the underside of the door.
■ Lower the deflector until the hooks on the mower deck are secured in the openings in the
deflector.
■ Release the deflector and door.
Fig. 4
2
2
1
1

ASSEMBLY
13
INSTALLING THE MULCHING PLUG (Fig. 5)
NOTE: When using the mulching plug, do not install either the side discharge deflector or
the grass catcher.
■ Lift the rear discharge door (1).
■ Grasp the mulching plug (2) by its handle and tilt at an approximate 15 degree angle.
■ Insert the plug into the rear discharge opening.
■ Lower the rear discharge door.
Fig. 5
1
2

ASSEMBLY
14
INSTALLING THE GRASS CATCHER (Fig. 6)
NOTE: When using the grass catcher, do not install either the side discharge deflector or
the mulching plug.
■ Lift the rear discharge door (1).
■ Lift the grass catcher (2) by its handle and place under the rear discharge door so that
the hooks on the grass catcher are seated on the door rod (3).
■ Release the rear discharge door. When installed correctly, the hooks on the grass
catcher will extend through the openings on the rear discharge door.
Fig. 6
1
2
3

WARNING:
Never operate the mower without a proper trail shield, discharge
cover, grass catcher, switch, or other safety protective device in place and in working
order. Do not operate the mower with a damaged safety device. Doing so can result in
injury.
CHARGING PROCEDURE (Fig. 7)
15
NOTE: The battery can be charged in or out of the mower.
The charger that is supplied with this mower is a specially designed 2-stage charger.
Step 1: The red light will light up during the recharge cycle.
Step 2: The green light will light up when the battery is fully charged.
1. Remove the jack cover.
2. Plug the charger connector into the jack on the battery.
3. Insert the 120 V plug from the charger into the electrical outlet.
4. The red light on the charger should come on, which indicates that the charger is working
and the battery is being charged.
The red light will go out and the green light will come on when the battery is completely
charged (it takes approximately 15 hours to charge a fully discharged battery).
Fig. 7
ASSEMBLY

BATTERY CAPACITY INDICATORS
16
When you start the mower, the lights will indicate the battery’s capacity, according to the
following chart.
ASSEMBLY
Lights
3 Green Lights
2 Green Lights
1 Green Light
Yellow Light
Red Light
At Full capacity
At 60% capacity
At 45% capacity
At 25% capacity
At ＜20% capacity
Capacity
Green Green Green Yellow Red BCI switch

OPERATION
Fig. 8
CAUTION:
Do not attempt to override the operation of the safety key or lever.
WARNING:
The operation of any mower can result in foreign objects being
thrown into the eyes, which can cause severe eye damage. Always wear safety glasses
while operating the mower and while performing any adjustments or repairs.
WARNING:
Ensure that other people and pets remain at least 100' (30 m) away
when the mower is in use.
STARTING AND STOPPING (Fig. 8)
17
Switch key (1)
Power button (2)
Bail switch (3)
To start the motor:
1. Remove the switch key (1).
2. Press and hold the Power button (2). This makes the Bail switch operational.
3. Pull the bail switch (3) upward to the handlebar to operate and release the Power button.
To stop the motor:
1. Release the bail switch.
2. Replace switch key for storage.
INSPECT THE CUTTING AREA
Remove all stones, sticks, wire, bones, and other debris that might be thrown by the rotating
blades.

18
SETTING BLADE HEIGHT (Fig. 9)
When shipped, the wheels on the mower are set to a low-cutting position. Before using the
mower for the first time, adjust the cutting position to the height best suited for your lawn.
The average lawn should be between 1-1/2 in. to 2 in. during cool months and between 2
in. and 3-1/4 in. during hot months.
To set the blade height:
■ To raise the blade height, grasp the height adjustment lever and move it toward the back
of the mower.
■ To lower the blade height, grasp the height adjustment lever and move it toward the front
of the mower.
Fig. 9
HIGH
LOW
1
OPERATION

OPERATION
19
■ The battery that is supplied with this mower is a maintenance-free, sealed, 24 V storage
battery. It can be tipped without danger of acid spillage.
■ For optimal performance, charge the battery every two weeks, even when it is not in use.
■ Charge the battery in a cool, dry place.
■ The battery does not have to be fully discharged before recharging. This battery will not
develop a memory. 2 to 3 initial charging/discharging cycles may be required in order to
reach the maximum run time/capacity. When it is fully charged, the battery can be stored in
temperatures as low as –40° F (–40° C) for a period of up to two weeks before it requires
recharging.
■ The battery charger should be operated in temperatures between 23° and 104° F (–5° and
40°C).
■ The battery supplied is sealed, maintenance-free, and spill-free.
BATTERY USE & CARE
■ Charge the mower battery in a dry area that is protected from the weather. Do not expose
the mower or the charger to rain.
■ Do not charge the battery in a wet location. Operate the battery charger in temperatures
between 23° and 104°F (–5° and 40°C). In order to reduce the risk of electric shock, use
only the charger that is provided by the manufacturer to charge the battery.
■ DO NOT ABUSE THE CHARGE CORD. Never carry the charger by the cord. Do not
disconnect the charger from the outlet or from the mower by pulling the charger cord.
■ Do not service the mower with the charger connected. Do not use a damaged charger.
■ Replace the charger cords or the charger immediately.
■ Keep the mower and the charger away from water, heat sources(radiators, heaters,
stoves, etc.), flames, and chemicals.
CHARGER SAFETY RULES

OPERATION
20
1. Mow a cross the face of slopes; never up and down. Exercise extreme caution when
changing direction on slopes.
2. Watch for holes, ruts, rocks, hidden objects or bumps that may cause you to slip or trip.
Tall grass can hide obstacles.
3. Always be sure of your footing. If you feel you are losing you rbalance, release the
blade/motor control handle immediately, and the blade will stop rotating within 3 seconds.
4.Do not mow near drop-offs, ditches or embankments; you could lose your footing or
balance.
5. Do not mow slopes greater than 15° as shown on the slope gauge.
6. Do not mow wet or damp grass.Unstable footing could cause slipping.
SLOPE GAUGE
Use this page as a guide in order to identify slopes that cannot be mowed safely.
SLOPE OPERATION (Fig. 10)
WARNING:
Slopes are a major factor related to slip and fall accidents that can
result in severe injury. Operation on slopes requires extra caution. If you feel uneasy on
a slope, do not mow it. For your safety, use the slope gauge included as part of this
manual to measure slopes before operating this unit on a sloped or hilly area.
WARNING:
Do not mow a slope that has an angle of greater than 15° (a rise
of approximately 2 1/2’ [.75 m] every 10’ [3 m]). Mow across the face of a slope, and
never up and down.
Fig. 10