Mtd 120-848e000 User manual

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1

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$

1

.

OWNER’S

GUIDE

ASSEMBLY

•

OPERATION

•

MAINTENANCE

•

PARTS

21

"

6

SPEED

ELECTRIC

START

CONVERTIBLE

ROTARY

MOWER

Model

Number

120-848E000

■

^IMPORTANT

The

battery

pack

is

shipped

in

a

partially

charged

state

and

must

be

charged

16

hours

prior

to

initial

use.

Follow

charging

instructions

on

page

13.

Important:

Read

Safety

Rules

and

Instructions

Carefully

PRINTED

IN

U.S.A.

FORM

NO.

770-7246E

Slope

Gauge.

Contents

of

Hardware

Pack

Safe

Operation.

Assembly

Instructions.

Controls.

Operation.

Adjustments.

INDEX

.

3

Lubrication.15

.

4

Maintenance

..16

.

5

Off-Season

Storage.18

.6

Trouble

Shooting

Guide.19

12

Replacement

Parts

.20-23

12

Parts

Information.Back

Cover

14

A

i

nstrl

ctions

given

with

this

sym¬

bol

AFIE

FOR

PERSONAL

SAFETY.

BE

SURE

TO

FOLLOW

THEM.

NOTE:

The

use

of

any

accsssory

on

this

Rotary

Mower

other

than

those

manufactured

by

the

mowei

manufacturer

is

not

recommended.

A

WARNING:

To

reduce

the

risk

of

injury,

do

not

operate

mower

unless

rear

trailin

3

shield

and

guard

or

entire

grass

catcher

is

in

its

proper

plaoi.

NOTE:

Under

normal

usage

bag

material

is

subject

to

wear

and

should

be

checked

periodically.

Be

sur

3

any

replacement

bag

complies

with

the

mower

manufacturer’s

recommendations.

For

replacement

bags,

use

only

factory

authorized

replacement

bag

No.

764-0257.

WARNING:

This

unit

is

equipped

with

an

internal

combustion

engine

and

should

not

be

used

on

or

near

any

unim¬

proved

forest-covered,

brush-covered

or

grass-covered

land

unless

the

engine’s

exhaust

system

is

equipped

with

a

spark

arrester

meeting

applicable

local

or

stc

te

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

law

s

apply

on

federal

lands.

A

spark

arrester

for

the

muffler

is

available

through

your

nearest

engine

authorized

servi

:e

dealer.

2

SLOPE

GAUGE

(Keep

this

sheet

in

a

safe

place

for

future

reference.)

Z)

3

Do

not

mow

on

inclines

with

a

slope

in

excess

of

15

degrees

(a

rise

of

approximately

2Vz

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

HARDWARE

PACK

Remove

this

sheet

from

your

owner’s

manual

£

nd

lay

the

hardware

on

the

illustration

for

identification

purposes.

After

assembly,

keep

the

Slope

Gauge

which

is

on

the

reverse

side

of

this

sheet

for

future

use.

(Hardware

pack

may

contair

extra

items

which

are

not

used

on

your

unit.)

ATTACHING

THE

LOWER

HANDLE

Truss

Machine

Screw

5/16-18

x

3/4"-

Long

Split

Washer—

5/16"

I.D.

Hex

Nut

5/16-18

Thread

ATTACHING

THE

UPPER

HANDLE

Curved

Head-

Bolts

Split

Washers-

5/16"

I.D.

I

C

I

FINAL

Li—I

ASSEH

ASSEMBLY

Hex

Nuts-

5/16-18

Thread

P

GRASS

CATCHER

ASSEMBLY

Plastic

—

Plug

(If

Required)

Self-Tapping

Screws

—

1!A"

Long

SECURING

THE

CABLES

Cable

Ties

l

i

l

i

i

i

0

INCHES

I

I

I

I

I

I

I

I

I

I

1

2

Cut

AiL..^

This

Line

IMPORTANT

RULES

FOR

SAFE

OPERATION

THIS

SYMBOL

POINTS

OUT

IMPORTANT

SAFETY

INSTRUCTIONS

WHICH,

IF

NOT

FOLLOWED,

COULD

ENDANGER

THE

PERSONAL

SAFETY

£H£-

R

r^

R0PERTY

0F

OURSELF

AND

OTHERS.

READ

AND

FOLLOW

ALL

INSTRUCTIONS

IN

THIS

MANUAL

BEFORE

ATTEMPTING

TO

OPERATE

YOUR

LAWN

MOWER.

FAILURE

TO

COMPLY

WITH

THESE

INSTRUCTIONS

MAY

RESULT

IN

PERSONAL

INJURY

WHEN

YOU

SEE

THIS

SYMBOL-

^

HEED

ITS

WARNING.

▲

DANGER

i

Your

lawn

mower

was

built

to

be

operated

according

to

the

rules

for

safe

operation

in

this

manual.

As

with

any

type

of

power

equipment,

carelessness

or

error

on

the

part

of

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.

Read

this

owner’s

guide

carefully

in

its

entirety

before

attempting

to

assemble

or

operate

this

machine.

Be

completely

familiar

with

the

controls

and

the

proper

use

of

this

machine

before

operating

it.

Keep

this

manual

in

a

safe

place

for

future

and

regular

reference

and

for

ordering

replacement

parts.

2.

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.

Only

persons

well

acquainted

with

these

rules

of

safe

operation

should

be

allowed

to

use

your

mower.

4.

Keep

the

area

of

operation

clear

of

all

persons,

particularly

small

children

and

pets.

Stop

engine

when

they

are

in

the

vicinity

of

your

mower

to

help

prevent

blade

contact

or

thrown

object

in¬

jury.

Although

the

area

of

operation

should

be

completely

cleared

of

foreign

objects,

an

object

may

have

been

overlooked

and

could

be

accidently

thrown

by

the

mower

in

any

direction

and

cause

serious

personal

injury

to

the

operator

or

any

others

allowed

in

the

area.

A

PREPARATION

AA

1.

Thoroughly

inspect

the

area

where

the

equipment

is

to

be

used.

Remove

all

stones,

sticks,

wire,

bones

and

other

foreign

objects

which

could

be

picked

up

and

thrown

by

the

mower

in

any

direc¬

tion

and

cause

serious

personal

injury

to

the

operator

or

any

others

allowed

in

the

area.

2.

Always

wear

safety

glasses

or

eye

shields

during

operation

or

while

performing

an

adjustment

or

repair,

to

protect

eyes

from

foreign

objects

that

may

be

thrown

from

the

machine

in

any

direction.

3.

Wear

sturdy,

rough-soled

work

shoes

and

close-fitting

slacks

and

shirts

to

avoid

entanglement

in

the

moving

parts.

Never

operate

a

unit

in

bare

feet,

sandals,

or

sneakers.

4.

Check

the

fuel

before

starting

the

engine.

Gasoline

is

an

extreme¬

ly

flammable

fuel.

Do

not

fill

the

gasoline

tank

indoors,

while

the

engine

is

running,

or

until

engine

has

been

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.

5.

Disengage

the

self-propelled

mechanism

or

drive

clutch

on

units

so

equipped

before

starting

the

engine.

6.

The

blade

control

handle

is

a

safety

device.

Never

attempt

to

bypass

its

operation.

Doing

so

makes

the

safety

device

inoperative

and

may

result

in

personal

injury

through

contact

with

the

rotating

blade.

The

blade

control

handle

must

operate

easily

in

both

directions.

7.

Never

attempt

to

make

a

wheel

or

cutting

height

adjustment

while

the

engine

is

running.

8.

Never

operate

the

equipment

in

wet

grass.

Always

be

sure

of

your

footing.

A

slip

and

fall

can

cause

serious

personal

injury.

Keep

a

firm

hold

on

the

handle

and

walk,

never

run.

Mow

only

in

daylight

or

in

good

artificial

light.

A

ror

your

saieiy,

use

ine

slope

gauge

inciuaea

as

part

or

tms

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.

Do

not

change

the

engine

governor

settings

or

overspeed

the

engine.

Excessive

engine

speeds

are

dangerous.

2.

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

generally

a

warn¬

ing

of

trouble.

6.

Shut

the

engine

off

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

engine

is

shut

off.

Never

place

any

part

of

the

body

in

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

ex¬

treme

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.

10.

Never

operate

mower

without

proper

guards,

plates

or

other

safety

protective

devices

in

place.

11.

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

1.

Check

the

blade

and

engine

mounting

bolts

at

frequent

intervals

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

deterioration.

For

safety

protection,

replace

only

with

new

bag

meeting

original

equipment

specifications.

5

I

ASSEMBLY

INSTRUCTIONS

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

)f

the

mower

is

observed

from

the

operating

position.

Tools

Required

for

Assembly

(1)

Phillips

Head

Screwdriver

(1)

1/2"

Wrench*

(1)

7/16"

Wrench*

(1)

Flat

Blade

Screwdriver

*Or

one

6"

Adjustable

Wrench.

UNPACKING

1.

Remove

the

lawn

mower

from

the

carton

by

open¬

ing

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

car¬

ton

is

discarded.

2.

Disconnect

and

ground

the

spark

plug

wire

by

hooking

it

into

the

“V”

slot

on

the

engine.

Check

beneath

the

deck

for

any

cardboard

packaging.

Remove

if

present.

3.

Stretch

out

all

control

cables

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.

ATTACHING

THE

LOWER

HANDLE

(Hardware

A)

1.

For

shipping

purposes

your

mower

is

set

with

the

wheels

in

the

lowest

cutting

height

position.

Raise

the

mower

to

the

highest

setting

for

assembly

of

lower

handle.

2.

On

the

left

side

of

the

mower,

remove

the

truss

machine

screw,

hex

nut

and

split

washer

from

the

handle

wheel

bracket

assembly

as

shown

in

figure

3.

Attach

the

lower

handle

by

placing

the

bottom

holes

in

the

lower

handle

over

the

weld

pins

on

the

handle

wheel

bracket

assemblies.

4.

Pivot

catcher

panel

support

arm

in

position

as

shown

in

figure

1.

Insert

truss

machine

screw

through

catcher

panel

support

arm,

wheel

bracket

assembly

and

handle.

Secure

using

the

split

washer

and

hex

nut

removed

in

step

2.

Tighten

securely.

5.

Secure

the

right

side

of

the

handle

to

handle

wheel

bracket

assembly

using

truss

machine

screw,

5/16"

split

washer

and

hex

nut.

Tighten

securely.

ATTACHING

THE

UPPER

HANDLE

(Hardware

B)

1.

Place

the

upper

handle

in

position

over

the

lower

handle.

The

label

on

the

throttle

control

housing

and

the

control

lever

must

be

facing

up.

2.

Secure

the

upper

handle

using

the

curved

head

bolts,

split

washers

and

hex

nuts

as

shown

in

figure

-

2

.

FIGURE

2.

6

S

g

M

.

FIGURE

3.

ATTACHING

THE

BRAKE

CABLE

1.

The

brake

cable

is

attached

to

the

engine,

and

has

a

“Z”

fitting

on

the

loose

end.

Route

the

brake

cable

in

back

of

the

engine,

to

the

outside

of

the

height

adjustment

handle

and

handle

mounting

bracket,

and

below

the

lower

handle.

Place

end

of

cable

into

the

upper

hole

on

the

bottom

of

the

control

housing,

and

through

the

slot

as

shown.

The

angle

of

the

plastic

flange

must

be

positioned

-downward

as

shown

in

figure

3.

Be

careful

not

to

bend

or

kink

the

cable

at

any

time.

2.

Push

the

plastic

fitting

until

it

locks

into

the

con¬

trol

housing.

A

WARNING:

Brake

cable

must

be

assem¬

bled

as

shown

for

proper

blade

brake

operation.

3.

H

ook

the

“Z”

end

of

the

brake

cable

into

the

hole

in

the

blade

control

handle

from

the

inside

to

the

—outside

as

shown

in

figure

4.

FIGURE

5.

ATTACHING

THE

THROTTLE

CABLE

1.

Push

the

throttle

control

lever

on

the

handle

all

the

way

forward

to

CHOKE

position.

See

figure

5.

2.

The

throttle

control

cable

is

attached

to

the

upper

handle.

Route

the

throttle

control

cable

under

the

lower

handle.

Route

the

cable

to

the

outside

of

the

handle

wheel

bracket

assembly

and

height

adjust¬

ment

lever

then

in

back

of

the

engine.

Hook

the

“Z”

end

of

the

throttle

control

cable

into

the

hole

-in

the

control

lever

on

the

engine

shown

in

figure

5.

3.

Using

a

screwdriver,

remove

the

screw

and

cable

clamp

shown

in

figure

5.

4.

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.

7

I

FIGURE

6.—Bottom

View

ATTACHING

THE

SIX

SPEED

SHIFT

CABLE

AND

DRIVE

CLUTCH

CONTROL

CABLE

(Hardware

E)

Both

the

drive

clutch

cable

and

the

six

speed

shift

cable

are

attached

to

the

deck.

Attach

both

cables

to

the

underside

of

the

drive

clutch

control

housing,

located

in

the

middle

of

the

upper

handle.

NOTE:

The

drive

clutch

cable

is

the

cable

with

the

ad¬

justment

wheel

attached.

1.

Place

the

shift

lever

(located

on

the

bottom

of

the

drive

clutch

housing)

in

1st

speed

(slow)

position.

2.

Route

the

six

speed

shift

cable

to

the

outside

of

the

height

adjustment

handle

and

handle

mount¬

ing

bracket.

Attach

as

follows.

a.

Slide

the

barrel

end

of

the

six

speed

shift

cable

into

the

hole

provided

in

the

six

speed

shift

lever

-(lever

with

the

ratchets).

See

figure

6A.

b.

Slip

the

braided

wire

into

the

vertical

slot

as

shown.

c.

Slide

the

braided

wire

around

in

the

horizontal

slot.

d.

Place

the

metal

fitting

on

the

end

of

the

shift

cable

into

the

slot

in

the

housing

shown

in

figure

6A.

Hold

the

fitting

in

this

position

as

you

assemble

the

drive

clutch

control

cable.

3.

Assemble

the

drive

clutch

control

cable

as

follows.

a.

Slide

the

barrel

end

of

the

cable

into

the

hole

provided

in

the

end

of

the

drive

clutch

control

lever.

Slip

the

braided

wire

into

the

vertical

slot

as

shown

in

figure

6B.

b.

Slide

the

braided

wire

around

in

the

horizontal

slot.

c.

Make

certain

the

adjustment

wheel

is

thread¬

ed

onto

the

cable

as

far

as

possible

as

shown

in

figure

6B.

Place

the

adjustment

wheel

into

the

clutch

control

housing.

4.

Secure

the

plastic

cap

to

the

clutch

control

hous¬

ing

using

the

two

Phillips

head

screws.

See

figure

6C.

A

WARNING:

Drive

clutch

adjustment

must

be

checked

before

the

unit

is

operated,

as

described

in

the

operation

section.

ATTACHING

THE

WIRE

HARNESS

1.

Remove

the

wing

nuts

that

secure

the

rear

discharge

chute

assembly

from

the

deck.

Then

remove

the

chute

from

the

deck

by

lifting

up

on

the

two

bottom

corners

of

the

discharge

chute

assembly,

and

sliding

it

off

the

deck.

2.

Plug

the

end

of

the

wire

lead

coming

from

the

starter

on

the

engine

into

the

plug

on

the

end

of

-the

wire

harness.

See

figure

7.

8

WARNING:

Never

operate

your

unit

without

either

the

side

chute

deflector

or

entire

rear

discharge

chute

and

grass

catcher

assembly

in

place.

3.

Replace

the

rear

discharge

chute

assembly

as

follows.

Slide

the

ribs

on

the

discharge

chute

assembly

under

the

flange

on

rear

panel

as

you

insert

the

side

of

the

discharge

chute

under

the

two

tabs.

See

—figure

8.

The

edge

of

the

discharge

chute

assembly

goes

under

the

shoulder

bolt

on

deck.

Push

down

on

the

chute

assembly,

and

slide

the

bottom

corner

slots

over

the

bolts

on

side

of

deck.

Press

down

on

the

discharge

chute

assembly

and

secure

with

wing

nuts.

Make

certain

wing

nuts

are

seated

properly.

Hex

Nut

Split

Washer

Grass

Catcher

Panel

Height

Adjustment

Lever

Handle

Wheel

Bracket

Assembly

FIGURE

9.

SECURING

THE

CABLES

(Hardware

D)

Attach

cables

to

the

left

handle

wheel

bracket

assembly

as

follows,

using

the

cable

clamp

provided.

1.

Open

the

clamp

and

slip

the

cables

inside.

2.

Remove

the

hex

nut

and

split

washer

from

the

side

of

the

left

handle

wheel

bracket

assembly

as

-shown

in

figure

9.

Attach

the

cable

clamp

to

the

left

hand

wheel

bracket

assembly

as

shown.

Secure

with

hardware

just

removed.

3.

Place

the

height

adjustment

lever

in

the

lowest

position.

Secure

all

the

control

cables

to

the

left

side

of

the

han¬

dle

with

the

cable

ties

as

follows,

taking

the

slack

out

of

the

cables

so

they

do

not

contact

the

wheel.

1.

Insert

posts

on

cable

ties

into

holes

provided

on

the

lower

handle,

one

near

the

top

and

one

near

the

bottom

of

lower

handle.

The

holes

may

be

on

either

the

inside

or

outside

of

the

handle.

See

-figure

10A.

2.

Secure

the

cables

with

the

cable

ties.

See

figure

10B.

3.

Trim

excess

ends

of

cable

ties.

9

I

FIGURE

11.

FINAL

ASSEMBLY

OF

MOWER

(Hardware

F)

1.

If

plastic

plug

is

needed

and

is

not

already

assembled,

insert

plastic

plug

into

hole

in

the

top

rear

of

the

deck

by

slipping

one

end

of

plug

into

hole,

then

pressing

down

on

the

other

end

of

plug.

Use

a

soft

hammer

if

necessary.

2.

Place

hub

caps

in

position

against

the

inner

hub

of

the

wheel.

Press

firmly

around

the

center

por¬

tion

of

hub

cap

in

a

circular

motion,

similar

to

in¬

stalling

a

lid

on

a

round,

plastic

container.

See

-figure

11.

The

hub

caps

are

flexible

and

will

snap

over

the

3

V

2

"

diameter

wheel

hubs.

3.

Make

certain

all

nuts

and

bolts

are

tightened

securely.

4.

Be

certain

to

charge

the

battery

as

instructed

in

“Before

Starting”

section

under

Operation.

Read

instructions

carefully.

GRASS

CATCHER

ASSEMBLY

(Hardware

C)

1.

J

oin

the

rear

frame

and

front

frame

assembly

as

-shown

in

figure

12.

NOTE:

Make

certain

the

grass

bag

is

turned

right

side

out

before

assembling

(warning

label

will

be

on

the

outside).

2.

P

lace

the

frame

inside

the

grass

catcher

bag.

The

bottom

of

the

grass

bag

is

black

plastic.

The

hooks

on

the

front

frame

go

toward

the

top

of

the

bag.

-See

figure

13.

3.

S

ecure

front

of

bag

to

frame

by

working

the

plastic

—channels

on

bag

over

frame.

See

figure

14.

10