MTD 120-848E000 User manual

$ 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

Grass Catcher
4. Place the grass catcher handle in position on top
—of the grass bag and frame as shown in figure 15.
Secure with four self-tapping screws.
TO ATTACH BAG TO MOWER
1. Hold the chute door on the catcher panel open as
-shown in figure 16.
2 . Slide the frame of the grass catcher down into the
channels on each side of the mower. The hooks
on the frame go over the panel on the discharge
chute. See figure 16.
To remove the grass catcher, lift the grass catcher
straight up.
TO CONVERT MOWER TO SIDE DISCHARGE
To convert your mower to a side discharge unit, pro¬
ceed as follows.
1 . Remove the rear discharge chute assembly by
removing two wing nuts. Lift up on the two bottom
corners of the discharge chute assembly, and slide
it off the deck.
2. Attach the side chute deflector by first placing it
over the rear bolt in the side of the deck. Then slide
the notch in the top of the deflector around the
shoulder bolt on top of the deck. Slide the notch
in the side of the deflector around the front bolt in
-the side of the deck. See figure 17.
3. S ecure the front of the chute deflector to the bolt
on the side of the deck with one wing nut. See
figure 17. Secure the back of the chute deflector
—in the same manner. See figure 18.
11

I
CONTROLS
Blade Control
BLADE CONTROL HANDLE
WARNING
THIS CONTROL MECHANISM IS A
SAFETY DEVICE NEVER ATTEMPT
TO BYPASS ITS OPERATIONS
The blade control handle is located on the uppe han¬
dle of the mower. See figure 19. The blade control han¬
dle must be depressed in order to operate the unit.
Release the blade control handle to stop the engine and
blade.
WARNING: The blade will be rotating
whenever the engine is running.
THROTTLE CONTROL
The throttle control is located on the left side of the up¬
per handle. It is used to regulate the engine speed.
A WARNING: The throttle control cannot be
used to stop the engine.
IGNITION SWITCH
The ignition switch is located on the left side of handle
panel. It is used for starting only. See figure 19.
DRIVE CLUTCH CONTROL
Squeezing the drive clutch control engages the drive
mechanism to the rear wheels. Releasing the clutch
control stops the rear wheels from driving. Release the
drive clutch control to slow down when negotiating an
obstacle, making a turn or stopping. See figure 19.
SHIFT LEVER
The six speed shift lever is located on the drive clutch
control housing on the upper handle. See figure 19.
This lever is used to select the operating speed of the
mower. Release the drive clutch control when chang¬
ing speeds.
IMPORTANT: Move the shift lever ONLY when the
engine is running. Shifting the speeds with the
engine off can cause damage to 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.
DANGER
KEEP HANDS and FEET AWAY
FIGURE 20.
Keep hands and feet away from the chute area on cut¬
ting deck. See figure 20.
The operation of any lawn mower can result in
foreign 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.
NOTE: For best results raise the cutting position until
it is determined which height is best for your lawn. See
cutting height adjustment section.
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.
12

*v
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.
BEFORE STARTING
A DANGER: The battery contains corrosive
fluid and toxic material. HANDLE WITH
CARE. Keep away from children. Do not
puncture, disassemble, mutilate or in¬
cinerate. Explosive gases could be vented
during charging or discharging. Use in a
well-ventilated area, away from sources of
ignition.
1. C harge battery for 16 hours before initial use.
DO NOT CHARGE LONGER THAN 20 HOURS.
IMPORTANT: Use only the battery charger supplied
with this mower.
To charge the battery, first remove the protective cap
from the end of the battery pack lead. See figure 13.
Always plug charger lead into the battery pack lead
^ before inserting battery charger plug into 120 volt stan-
dard household outlet.
After charging, disconnect battery charger plug from
household outlet first, then disconnect charger lead
from battery pack lead.
A WARNING: Do not remove the battery pack
from the handle panel for any reason other
than replacement. When replacing the bat¬
tery pack, refer to instructions in
Maintenance section.
2. B efore each use, check for proper drive clutch
operation by performing the following before start¬
ing the engine:
With the drive clutch control released, push mower
forward. It should move freely. Pull mower
backward. It should move freely.
If it does not and the rear wheels tend to lock up,
the clutch may not be releasing completely. Do not
start the engine until corrections have been made.
Check the control cable for severe bend, kinks and
binding, or grass build-up in the pulley groove. Cor¬
rect and adjust as required. Refer to adjustment
section for additional information.
3. A ttach spark plug wire to spark plug. 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 21.
Metal Loop
on Spark
Plug Wire
Rubber Boot
FIGURE 21.
4. T he fuel shut-off valve is located beneath the fuel
tank. The fuel shut-off valve should be in the open
position. See figure 22. Open fuel shut-off valve
if it is closed.
TO START ENGINE AND ENGAGE BLADE
IMPORTANT: Move the shift lever only when the
engine is running. Shifting the speeds with the engine
off can cause damage to the unit. Disengage the drive
clutch control when shifting speeds.
A WARNING: When starting the unit for the
first time, place mower in first speed (slow)
position. Face the mower against a solid
object such as a wall, fence, etc. Start the
unit, and if it shows any signs of motion
with the drive clutch control disengaged,
shut the engine off immediately. Make cer¬
tain the drive clutch control is adjusted so
the drive belt is as loose as possible. Refer
to the Adjustment Section.
1. M ove the throttle control lever to CHOKE position.
(A warm engine may not require choking.)
2 . S tanding behind the unit, depress the blade con¬
trol handle and hold it against the upper handle.
Make certain drive clutch control handle is
released.
3. T urn the ignition key to the right to start the engine.
Release the key after engine starts.
4. A fter engine starts, move throttle control to FAST
or desired engine speed.
13

I
NOTE: The engine on your unit is provided with m aux¬
iliary recoil starter system. To start the engine ui ing the
auxiliary starter system, proceed as follows.
A. Depress the blade control handle, and hold it igainst
the upper handle.
B. Grasp the recoil starter handle, slowly pull the rope
out from the engine about two feet and hold rop* > in this
position.
C. Step behind the handle into the operating position.
With the blade control handle still depressed, pi II recoil
starter handle using a quick, firm motion. Repe at until
engine starts. After engine starts, return rope slowly to
the engine.
NOTE: If any problems are encountered, refer to the
Trouble Shooting Guide on page 19.
A WARNING: Never operate your unit
without either the side chute deflector or
entire rear discharge chute and grass
catcher assembly in place.
TO STOP ENGINE AND BLADE
1 . Release the blade control handle to s op the
engine and blade.
WARNING: The blade continues tc rotate
for a few seconds after the engine is shut
off.
2. Disconnect the spark plug wire and ground it
against the engine to prevent accidental starting
while equipment is unattended.
USING YOUR ROTARY MOWER
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 serious personal iijury 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, anj could
cause you to slip and fall. New grass, thick grass or
wet grass may require a narrower cut. Spee d of the
mower should be adjusted to the condition of the lawn.
When using the side discharge mower, the best mow¬
ing pattern is one that allows the clippings to di scharge
towards the uncut part of the lawn. This permits re¬
cutting of the clippings to further pulverize them. When
cutting high weeds, discharge towards cut porti sn, then
recut at right angles to first direction.
For best results, cut off one-third or less of i he total
length of the grass. Lawn should be cut in ths 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. Exten¬
sive vibration of the mower during opera¬
tion is an indication of damage. The unit
should be promptly inspected and
repaired.
ADJUSTMENTS
WARNING: Do not at any time make any
adjustment to lawn mower without first
stopping engine and disconnecting spark
plug wire.
DRIVE CLUTCH CONTROL ADJUSTMENT
Use the adjustment wheel located on the underside of
the clutch control housing to tighten the drive belt if
mower does not self-propel with the drive clutch con¬
trol engaged, or if drive belt is slipping (unit hesitates
while engine maintains the same speed). See figure 23.
In addition, the adjustment wheel may also be used to
determine the position in which the drive clutch con¬
trol is engaged. If it is more comfortable to have the
drive engaged with the lever further away from the han¬
dle, tighten the drive belt.
Make certain to retest the unit for neutral as instructed
in the Operation Section. Move the adjustment wheel
in the opposite direction to loosen the drive belt if
necessary.
FIGURE 23.
14

CUTTING HEIGHT ADJUSTMENT
The height adjustment handle is located on the left side
of the deck. The handle may be placed in one of nine
cutting height positions. Push the handle to the left and
then either forward to lower the cutting height or
backward to raise the cutting height. See figure 24.
For rough or uneven lawns, move the height adjustment
handle to a position which will give a higher cutting
height.
k THROTTLE
The throttle control wire assembly can be adjusted if
necessary. Remove the screw and cable clamp shown
in figure 5. Remove the cable from the clamp. Adjust
as instructed in step 4 of “Attaching the Throttle Con¬
trol Cable” in Assembly Instructions.
SIX SPEED SHIFT CABLE ADJUSTMENT
Periodic adjustment of the six speed shift cable may
be required due to normal stretch and wear on the
cable. Adjustment is needed if all six speeds cannot
be obtained.
The adjustable cable bracket is located on the left side
of the mower, beside the engine. To adjust, loosen the
hex nut which secures the adjustable cable bracket.
See figure 25. Pull backward on the bracket (toward
the rear of the mower). Retighten the hex nut. Test the
speeds on the mower (engine must be running).
CARBURETOR ADJUSTMENTS
A WARNING: If any adjustments are made to
the engine while the engine is running
(e.g. carburetor), keep clear of all moving
parts. Be careful of heated surfaces and
muffler.
Minor carburetor adjustment may be required to
compensate for differences in fuel, temperature,
altitude and load. Refer to the separate engine manual
packed with your mower for carburetor adjustment
information.
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.
LUBRICATION
A WARNING: Always stop engine and
disconnect spark plug wire before clean¬
ing, lubricating or doing any kind of work
on lawn mower.
Blade Control— Lubricate the pivot points on the blade
control handle and the brake cable at least once a
season with light oil. See figure 26. The blade control
must operate freely in both directions.
Wheels— Lubricate the wheel bearings at least once
a season with light oil. Also, if the wheels are removed
for any reason, lubricate 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.
15

Engine —Follow engine manual for lubrication in¬
structions.
Throttle— Periodically lubricate throttle control lever
and throttle wire assembly with a few drops of light oil
for ease of operation.
Transmission— The transmission is pre-lubrica ted and
sealed at the factory. It does not require checking. If
disassembled for any reason, fill with 2 ouices of
Alvania grease, part number 737-0168.
MAINTENANCE
A WARNING: Be sure to disconnect and
ground the spark plug wire before per¬
forming any repairs or maintenar ce.
NOTE: When tipping the unit, empty the fuel lank and
keep engine spark plug side up.
TROUBLE SHOOTING
Refer to page 19 of this manual for trouble ehooting
information.
BATTERY PACK REPLACEMENT
Remove the battery pack from the handle panel for
replacement only. Do not separate the batterie 3 for any
reason. Dispose of batteries properly.
A WARNING: Batteries contain sulfi ric acid
which may cause burns. Do not s lort cir¬
cuit or mutilate in any way. Do not put bat¬
teries in fire. They may burst or release
toxic materials.
The positive lead on the wire harness has the smaller
connector. Connect the positive lead to the positive side
of the battery pack, then connect the negative side.
IN-LINE FUSE
The unit is equipped with an in-line fuse. If unit fails
to start, check the fuse in the wiring harness by turn¬
ing the end of the fuse holder and pulling apart. See
figure 28. Replace with standard automotive 7V2 amp
fuse.
Harness
FIGURE 28.
CUTTING BLADE
When removing the cutting blade for sharpening or
replacement, protect hands by using heavy gloves or
a rag to grasp the cutting blade. Remove the bolt and
bell washer which hold the blade and adapter 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.
When replacing battery pack in handle panel, battery
pack must be positioned with the positive tei minal to
the right hand side and the negative terminal tD the left
hand side of panel. See figure 27. Replacing the bat¬
tery pack incorrectly will cause serious damage.
WARNING: Periodically inspect the blade
adapter for cracks, especially if you strike
a foreign object. Replace when necessary.
When sharpening the blade, follow the original angle
of grind as a guide. It is extremely important that each
cutting edge receives an equal amount of grinding to
prevent an unbalanced blade. An unbalanced blade will
cause excessive vibration when rotating at high speeds,
may cause damage to the mower and could break,
causing personal injury.
It is recommended that the blade always be removed
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 heavy 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
16

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 and Blade Adapter Bolts: 375 in. lb.-min.,
450 in. lb. max.
To insure safe operation of your unit, all nuts and bolts
must be checked periodically for correct tightness.
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
specifications.
Clean the engine regularly with a cloth or brush. Keep
the cooling system (blower housing area) clean to per¬
mit proper air circulation which is essential to engine
performance and life. Be certain to remove all grass,
dirt and combustible debris from muffler area.
STORAGE OF THE BATTERY
The battery must be stored with a full charge. A
discharged battery will freeze.
IMPORTANT: All batteries discharge during storage.
Recharge battery every two months and before return¬
ing to service. Refer to charging instructions on page
13.
BELT REMOVAL AND REPLACEMENT
1. Disconnect the spark plug wire and ground it
against the engine.
2. Drain the fuel tank or place a piece of plastic
beneath the cap to prevent gasoline leakage.
3. Remove the grass bag, rear discharge chute
assembly and catcher panel.
4. Remove the transmission belt cover by removing
three bolts. See figure 29.
5. Tip the mower on its side, and block securely.
6 . R emove the center bolt which secures the blade
to the crankshaft. See figure 30. Remove the
blade, blade adapter and pulley half. Remove the
belt.
7. R emove the inside belt guard by removing two self¬
tapping screws. A 3/8" wrench is required. See
figure 30.
17

I
8 . Remove the belt from between the idler pt lley and
the belt guard on the idler pulley bracket, Tefer to
figure 32.
9. Remove the belt from the transmission pulley.
10. A ssemble the new belt as follows.
A. Push the idler pulley up out of the way as
shown in figure 31.
B. Slide the belt in from the rear of the deck, and
place it around the transmission pulley. See
figure 31.
C. Release the idler pulley so it falls down into
position. Slide the belt in between the idler
pulley and the belt guard on the idle' pulley
bracket as shown in figure 32.
D. Grease the crankshaft. Place belt between the
two pulley halves, and reassemble th e blade
adapter and blade. Reassemble the inside belt
guard.
E. Reassemble the transmission belt cover, follow¬
ing instructions in step 4 in reverse o-der.
NOTE: When reassembling the transmission belt cover,
be certain the belt guard on the transmission < over is
approximately 1/8" away from the belt. Make certain
to tighten all nuts and bolts securely. If plas ic was
placed under the gas cap, be certain to remo ve it.
FIGURE 32.
OFF-SEASON STORAGE
The following steps should be taken to prepare lawn
mower for storage.
1 . Clean and lubricate mower thoroughly as de¬
scribed 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.
NOTE: When storing any type of power equipment in
an unventilated or metal storage shed, care should be
taken to rustproof the equipment. Using a light oil or
silicone, coat the equipment, especially cables and all
moving parts.
18

Trouble Shooting Guide
Trouble
Possible Cause(s)
Corrective Action
Engine fails to start
1. Blade control handle disengaged.
2. Spark plug wire disconnected.
3. Throttle control lever not in CHOKE
position.
4. Fuel shut-off valve closed.
5. Discharge battery.
6 . Fuel tank empty, or stale fuel.
7. Blocked fuel line.
8 . Faulty spark plug.
9. Engine flooded.
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Move throttle lever to CHOKE
position.
4. Open fuel shut-off valve.
5. Charge battery or use auxiliary
recoil starter as instructed in
Operation section.
6 . Fill tank with clean, fresh gasoline.
7. Clean fuel line.
8 . Clean, adjust gap or replace.
9. Remove spark plug, dry the plug,
and crank engine with plug re¬
moved and throttle in off position.
Replace spark plug, connect wire
and resume starting procedures.
Engine runs erratic
1. Unit running in CHOKE position.
2. Spark plug wire loose.
3. Blocked fuel line or stale fuel.
4. Vent in gas cap plugged.
5. Water or dirt in fuel system.
6 . Dirty air cleaner.
7. Carburetor out of adjustment.
1. Move throttle lever to FAST position.
2. Connect and tighten spark plug wire.
3. Clean fuel line; fill tank with clean,
fresh gasoline.
4. Clear vent.
5. Drain fuel tank. Refill with fresh fuel.
6 . Clean air cleaner.t
7. Adjust carburetor.t
Engine overheats
1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
1. Fill crankcase with proper oil.
2. Remove blower housing and clean.f
3. Adjust carburetor.t
Occasional skip
(hesitates) at high speed
1. Spark plug gap too close.
2. Carburetor idle mixture adjustment
improperly set.
1. Adjust gap to .030".
2. Adjust carburetor.t
Idles poorly
1. Spark plug fouled, faulty or gap too
wide.
2. Carburetor improperly adjusted.
3. Dirty air cleaner.
1. Reset gap to .030" or replace
spark plug.
2. Adjust carburetor.t
3. Clean air cleaner.t
Excessive vibration
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Tighten blade and adapter.
Balance blade.
2. Replace blade.
Mower will not
discharge grass
1. Engine speed too low.
2. Wet grass.
3. Excessively high grass.
1. Set throttle between 3/4 and full
throttle.
2. Do not mow when grass is wet;
wait until later to cut.
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
Dull blade.
Sharpen or replace blade.
^ fRefer to separate engine manual packed with your unit.
Note: For repairs beyond the minor adjustments listed above, contact your local authorized service dealer.
19