Sunlawn EM-2 User manual

Owner’s Manual
for
™
Electric Rechargeable Power
Reel Mower
(Model EM-2)

Table of Contents
Welcome ............................................................................1
Warranty ............................................................................1
Use of This Product ..............................................................1
Assembly ............................................................................2
Parts List ....................................................................2
Assemble Handle Section ..............................................3
Adjust Cutting Height ...................................................4
Change Battery ...........................................................5
Operations ..........................................................................6
Inspect Mowing Area ....................................................6
Starting and Operating .................................................7
Normal Mowing ...........................................................7
Using Grass Catcher .....................................................7
Overloading/overheating ..............................................8
Mowing: General Information ................................................9
1/3 Rule .....................................................................9
Maintenance .......................................................................9
Cleaning .....................................................................10
General Maintenance ....................................................10
Storage ......................................................................10
Re-adjust Blade Clearance ............................................10
Replace Battery ...........................................................12
Technical Data .....................................................................13
™
Sunlawn, Inc.
325 Garfield Street
Fort Collins, CO 80524
Tel: [phone]
FAX: [phone]
For service inquiries, parts replacement,
and maintenance tips, see
www.sunlawn.com
© 2006 by Sunlawn, Inc

Owner’s Manual — Sunlawn EM-2
1
Congratulations on your purchase of a Sunlawn mower. This and our
other Sunlawn products originate from our commitment to
conscientious gardening solutions. Please use this manual as a
reference.
Sunlawn, Inc. (the Manufacturer) guarantees this product for private
use for a period of 2 years from the date of purchase. This guarantee
applies to all serious defects of the product which can be proven to
have been caused by faulty materials or workmanship. The
Manufacturer has the option of supplying a replacement of the product
in perfect working order or repairing the product free of charge at an
authorized facility, provided that the following conditions are fulfilled:
•The appliance has been handled correctly and in accordance with
the instructions in the Owner’s Manual.
•Neither the buyer nor a third party has attempted to repair the
product.
This guarantee is void if replacement parts or accessories are used
other than those approved by the Manufacturer.
The product, accompanied by a copy of the original receipt, must be
delivered, prepaid, to a service center authorized by the Manufacturer.
This Manufacturer’s guarantee shall not affect any guarantee claims
against the dealer or seller of the product.
WARRANTY
USE OF THIS PRODUCT
WARNING
For safety reasons persons of less than 16 years of age
or persons not familiar with these operating instructions
must not use the electric rechargeable mower.
!
WELCOME

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PARTS LIST
1. Handle top section
2. Handle grip
3. Handle mid
section
4. Handle lower
section
5. Handle bolt (4)
6. Handle wing
nut (4)
7. Handle spacer
8. Handle cotter
pin
9. Adjustment knob
10. Side panels (L/R)
11. Adjusting arms
(L /R)
12. Compression
nut (2)
13. Reel blade
14. Catcher apron
15. Roller assembly
16. Roller screw (2)
17. Cutting bar
18. Cutting bar secure
bolt (2)
19. Cutting bar
adjusting bolt (2)
20. Cutting bar
spring (2)
21. Wheel (2)
22. Wheel spacer (2)
23. Wheel Clip (2)
24. Hub cap (2)
25 Two hand safety
switch
26. Switch cable
27. Motor assembly
28. Lower drive gear
29. Lower drive gear
secure pin
30. Drive belt
31. Motor drive gear
32. Battery cover
33. Power housing
34. Housing
screws (4)
35. OFF/RESET switch
36. Battery (2)
37. Battery charger
38. Adjustment gauge
ASSEMBLY

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ASSEMBLE THE HANDLE SECTIONS
1. Set the cutting height to the highest setting as shown below. This
will make it easier to attach the lower handle section.
a. Loosen the two large black knobs [Part # 9], one on each side
of the mower body, to allow movement of the height
adjustment arms [Part # 11]. NOTE: the handle is mounted to
the adjusting arms and thus moves with the arms.
b. Set the height to the highest setting and re-tighten the black
knobs.
2. Fit the lower section of the handle [Part # 4] so that the holes are
over the handle posts on the mower. [See Insert B] Then rock the
handle to align the locking tabs and allow the handle section to fit into
place. Place the spacer [Part # 7] over the post and put the cotter pin
(Part # 8] through the hole to secure the handle.
CAUTION
Always keep the battery cover locked. Failure
to do so may allow batteries to fall out,
causing damage to batteries, cables, and
electric circuits.
!

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3. Continue assembly of the middle [Part # 3] and top sections [Part
# 1] of the handle using the handle bolts and wing nuts [Part # 5 and
6]. The top section must be attached with the two holes near
the grip area on the right side (standing behind the mower).
4. Attach the two-handed safety switch [Part # 25] to the top section.
Run the cable [Part # 26] along the top side of the handle (so it does
not hang down behind the mower) and close the “clamshell” portion of
the safety switch around the screw holes. Fasten by inserting and
tightening the two screws provided.
5. Secure the cable to the handle using the two Velcro cable keeper
straps.
ADJUSTING THE CUTTING HEIGHT
The cutting height of the EM-2 may be adjusted from approximately .4
inch up to approximately 2.2 inches. Actual height may vary according
to the height of the turf. Adjust the mower to the desired height as
follows:

Owner’s Manual — Sunlawn EM-2
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1. Loosen the two large black knobs [Part # 9], one on each side of
the mower body, to allow movement of the height adjustment arms
[Part # 11]. (This is the same movement used to attach the
handle.) NOTE: the handle is mounted to the height adjustment
arms and thus moves with the arms.
2. Set the height, using the scale on the back of the adjusting arms to
the same setting on both sides and re-tighten the black knobs. The
mower is now ready to mow at the desired height setting.
CHARGING THE MOWER BATTERIES
The batteries come from the factory properly connected. All that is
necessary is to charge them.
The batteries must be charged before using the mower for the first
time and after each use. NOTE: Do not leave batteries uncharged
through the winter.
1. Move the OFF/RESET switch [Part # 35] up to the OFF position.
2. Plug the charger [Part # 37] into the mower charging receptacle
and then into a 110V power outlet.
3. A light on the circuit board and on the charger itself will indicate
that the unit is charging. (Set to RESET position when operating.)

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Recharging time for the mower is approximately 5-8 hours. The
charger light, which glows red when the battery is not fully charged,
will glow green when charging is complete. To prolong the overall life
of the batteries you will need to charge the batteries for a full 24 hours
before the first use.
NOTE: The sealed lead acid batteries of the EM-2 do not need to be
fully discharged. The batteries will not develop a “memory.”
INSPECT THE MOWING AREA
1. Before beginning to mow, remove any foreign objects, such as
stones, branches, or toys, from the area.
2. Continue to check for such obstacles during mowing.
The Lawn Should Be Relatively Dry
1. Mowing wet grass causes an uneven cut and can cause damage to
the electrical components of the mower.
2. Do not mow when it is raining.
OPERATIONS

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7
STARTING AND OPERATING
1. To start and operate the mower, press and hold down the red
safety button with your finger, and with the other hand pull the
starting lever back toward the handle grip. There are similar
instructions on the handle itself stating: “To operate pull handle
while depressing safety button.”
2. As soon as the mower has started, release the red safety button.
3. When the starting lever is released, the motor switches off.
4. The mower may be restarted at any time with the same procedure.
Please note: there is two to three second delay before the
mower will restart.
NORMAL MOWING
To obtain a clean cut, push the mower in straight lines (passes) at a
deliberate walking pace. Overlap the passes to even the cut and to
avoid any uncut strips.
MOWING USING THE GRASS CATCHER (OPTIONAL ACCESSORY)
The grass catcher collects the clippings as it mows.
1. Install the catcher apron [Part # 14] on the non-spring pin side
2. Push the spring pin on the other side
3. Install the apron on the spring pin side
WARNING
•Before starting the mower, check within the blade area for any
foreign objects and remove them.
•Do not operate the mower on areas other than turf surfaces.
The mower should be sitting upright on a level part of the lawn
before starting operation.
!

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The grass catcher attaches at the grass catcher hooks on the mower
and by the strap to the mower handle, as seen below.
Mow using the same procedure as for normal mowing (described
above).
OVERLOADING/OVERHEATING
If the mower blade is blocked, the blade drive will overload and cause
slippage of the belt, resulting in a loud “brrrrrrr” sound.
1. Release the starting lever. If there is any foreign object in the blade
area, it must be removed before proceeding.
2. The motor is equipped with a circuit limiter that prevents the motor
from overworking.
Do not attach or remove the grass
catcher while the motor is running.
!CAUTION

Owner’s Manual — Sunlawn EM-2
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If the motor stops during operation and the batteries have charge
remaining, then the motor may be overloaded or overheated. Wait 2-5
minutes to allow an automatic reset before resuming operation.
THE 1/3 RULE
This is the key to enjoyable mowing and a healthy lawn.
1. The lawn should be mowed regularly, at least once a week during
the growing season.
2. Be guided by observing the lawn and taking care not to remove
more than 1/3 of the total height of the turf at any mowing.
3. Following this rule will stimulate the turf’s root growth, maintain its
health, and encourage its natural ability to crowd out unwanted
weeds.
If the lawn has become too high (over 4 inches in height) then it is
best to set the mower to the highest setting to mow. After mowing,
reset down to the normal level and mow again within a day or two.
Removing too much of the turf’s height, especially in the heat of
summer, can cause root shock and weaken the lawn; bringing down
the height by successive mowings over two or more days can avoid
this damage and maintain the health of the turf.
If the lawn is overgrown (to higher than 4 inches) it may be advisable
to use a brush cutter to remove the excess turf mass before resuming
mowing at normal heights.
MOWING: GENERAL INFORMATION
MAINTENANCE
WARNING
To avoid injury or damage to the unit do not clean the EM-2
using running water, a hose, or a high pressure stream.
!

Owner’s Manual — Sunlawn EM--2
10
CLEANING
After using the mower, clean with a moist cloth. Spray the cylinder
and cutting bar with silicon spray lube.
GENERAL MAINTENANCE
Regularly check to insure that all bolts, nuts, and screws are tight and
that the mower is in good working order. Worn out and damaged parts
should be replaced.
The blades, if properly cared for, will mow for years before requiring
sharpening. Sharpening can only be done by a professional using
a cylinder grinder and proper techniques.
STORAGE
1. Store the EM-2, fully charged, in a cool, dry place.
2. The batteries need not be removed for winter storage unless they
will be subject to sub-zero temperatures.
3. The mower should be stored out of the reach of children.
READJUST THE BLADE CLEARANCE
The blades are optimally adjusted from the factory. However, after
using the mower for a long period, if the cut is not clean, the blades
need readjusting. The procedure is as follows:
1. Turn off the mower.
2. Set OFF/RESET switch to OFF. Make sure the battery cover is
locked. [Part # 32]. Note: If the battery cover is not latched
and the mower is not upright, the batteries can fall out,
causing damage to the batteries or electric circuits.
3. Turn the mower over to expose the cutting bar on the bottom of the
mower. [Part # 17].
4. Using a 10mm open end wrench, tighten the hex bolt approximately
1/4 turn [Part # 19] at one end of the cutting bar until the cutting
bar and cylinder come into contact. Spin the blade cylinder by hand
and back off the bolt approximately 1/8 turn or until the cutting bar
and cylinder are no longer in contact.

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5. Make the same adjustment at the other end of the cutting bar.
6. Now check the adjustment using the small 0.05mm/0.002 inch
gauge (silver strip) [Part # 38] supplied with the EM-2 (or any
0.05mm/0.002 inch feeler gauge). If the gauge is held by the
cylinder blades but the cylinder and cutting bar are not touching
then the adjustment is correct.
7. The blades may also be tested by inserting a piece of paper
vertically into the blades while turning them by hand.
WARNING
Blades are sharp! Be careful of injury —
handle the blades carefully to avoid
cutting yourself. Wear appropriate gloves
or hand
p
rotection.
!

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12
REPLACING THE BATTERIES
These instructions are for replacing the batteries if necessary.
Note: the two batteries are identical. Look carefully before removing
the batteries to ensure proper replacement.
Connect the batteries as follows:
1. Attach the WHITE jumper cable from the + (positive) terminal of
one of the batteries to the – (negative) terminal of the other
battery.
2. Attach the BLACK cable to the - (negative) terminal of the first
battery.
3. Attach the RED cable to the + (positive) terminal of the second
battery.
Do not have batteries resting on cables. Be sure cables are placed in
the groves provided.
WARNING
•Be careful to connect batteries correctly. Failure to do so
may result in electric shock or damage to the electrical
system of this mower.
•Close and latch the battery cover before using or servicing
the mower. Otherwise the batteries can fall out, damaging
the mower
!

Owner’s Manual — Sunlawn EM-2
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Battery 2 x 12V / 7.2Ah
Motor Drive 24V, 6A, 140W
Charger Input: AC 100 – 240V 50 / 60 Hz 1.5A
Output: 24V_ _ _ _ 1500 mA
UL listed
Mower Cutting width: 40 cm (16 inches)
Weight with battery: 35.2 lb
Cutting height rough (from floor): .4 to 2.2 inches
CE certified: Declaration of Conformity (November 30, 2005)
EMC Order No. MT-E0511395-1
Machinery Order No. MT-S0511320-1
TECHNICAL DATA

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