Craftsman 536885601 Owner’s Manual

Operator's Manual

Rotary Lawn Mower

26-inch Wide Cut Variable Speed

Rear Drive

• Safety

• Assembly

• Operation

• Maintenance

Model 536.885601

CAUTION: Before using this

product, read this manual

and follow all of its Safety

Rules and Operating Instructions.

Manual del usario

• Service And Adjustment

• Repair Parts

Cortacdsped

Ancho de corte de 26 pulg. Velocidad variable

Traccibn trasera

Modelo 536.885601

PRECAUCION: Antes de usar este

producto, lea este manual y siga

todas las reglas de seguridad e instrucciones de operaci6n.

Sears, Roebuck and Co., Hoffman Estates, IL. 60179 U.S.A.

F-020433M www.sears.com/craftsman

• Seguridad

• Ensamblaje

• Operacibn

• Mantenimiento

• Servicio y ajustes

• Piezas de repuesto

TABLE OF CONTENTS

WARRANTY .................................... 2

OWNER'S INFORMATION ....................... 4

CUSTOMER RESPONSIBILITIES ................. 4

PREPARATION ................................. 6

UNPACKING INSTRUCTIONS ................... 6

IMPORTANT! BEFORE YOU START MOWING ... 7

OPERATION ................................... 8

HOW TO USE THE THROTTLE CONTROL ....... 9

HOW TO ENGAGE THE BLADE ................. 9

HOW TO CHANGE THE HEIGHT OF CUT ........ 9

HOW TO OPERATE THE REAR WHEEL DRIVE ... 10

MULCHING TIPS .............................. 11

BEFORE STARTING THE ENGINE .............. 12

HOW TO START THE ENGINE .................. 12

MAINTENANCE ................................ 13

ENGINE TIPPING .............................. 13

HOW TO REMOVE AND INSTALL THE BLADE ... 14

HOW TO SHARPEN THE BLADE ................ 14

HOW TO CHANGE THE OIL .................... 15

HOW TO CLEAN THE COOLING SYSTEM ....... 15

HOW TO CHECK THE MUFFLER ................ 15

HOW TO CLEAN THE AIR FILTERS (FLAT TYPE) . 16

HOW TO CHECK THE SPARK PLUG ............ 16

SERVICE AND ADJUSTMENT .................... 17

HOW TO ADJUST THE BLADE DRIVE SYSTEM.. 17

HOW TO REPLACE THE BELTS ................ 18

HOW TO ADJUST THE DRIVE CABLE ........... 19

STORAGE ..................................... 20

FOLDING HANDLE STORAGE .................. 20

STORAGE (OVER 30 DAYS) .................... 20

TROUBLESHOOTING CHART ................... 21

SLOPE GUIDE .................................. 22

INDEX ......................................... 26

REPAIR PARTS ................................. 27

ESPANOL ...................................... 40

HOW TO CHECK THE OIL ...................... 15

REPAIR PARTS ORDERING INFORMATION ....... 64

LIMITED WARRANTY ON CRAFTSMAN EQUIPMENT PARTS

For two (2) years from the date of purchase, if this Craftsman Equipment is maintained, lubricated and tuned up according to the instructions in the owner's manual, Sears will repair or replace free of charge any parts found to be defective in material or workmanship. Warranty service is available free of charge by taking your Craftsman equipment to your nearest Sears Service Center. In-home warranty service is available but a trip charge will apply. This Warranty applies only while this product is in the

United States. This Warranty does not cover:

• Expendable items which become worn during normal use, such as blades, spark plugs, air cleaners, belts, and oil filters.

• Tire replacement or repair caused by punctures from outside objects, such as nails, thorns, stumps or glass.

• Repairs necessary because of operator abuse, including but not limited to, damage caused by towing objects beyond the capability of the equipment, impacting objects that bend the frame or crankshaft, or over-speeding the engine.

• Repairs necessary because of operator negligence, including but not limited to, electrical and mechanical damage caused by improper storage, failure to use the proper grade and amount of engine oil, failure to keep the deck clear of flammable debris, or failure to maintain the equipment according to the instructions contained in the owner's manual.

• Engine (fuel system) cleaning or repairs caused by fuel determined to be contaminated or oxidized (stale). In general, fuel should be used within 30 days of its purchase date.

• Equipment used for commercial or rental purposes.

TO LOCATE THE NEAREST SEARS SERVICE CENTER OR TO SCHEDULE SERVICE, SIMPLY CONTACT SEARS AT

1-800-488-1222. This warranty gives you specific legal rights, and you may also have other rights, which vary, from state to state.

Sears Roebuck and Co. D/817WA Hoffman IL 60179.

F-020433M 2

Congratulations on your purchase of a Craftsman Rotary Lawn

Mower. It has been designed, engineered and manufactured to

give you the best possible dependability and performance.

If you experience any problems you cannot easily remedy, please

see your nearest Sears Service Department. We have competent, well trained technicians and the proper tools to service or repair this unit.

Please read and keep this manual. The instructions will enable

you to assemble and maintain your unit properly. Always observe the "Safety Rules".

Rotary Lawn Mower

Record inthe space below the serial number and the date

of purchase of this unit.

The model number and serial number are found on a decal attached to the unit.

Model Number: 536.885601

Serial Number:

FEATURES

Variable Speed Transmission: Quickly and easily set the for-

ward speed.

Large Cutting Width: 26-inch cutting width.

Mow or Mulch: Side discharge attachment can be easily installed.

Quick Type Height Adjustment: Single lever adjust all wheels.

Engine Exhaust, some of its constituents, and certain vehicle components contain or emit

chemicals known to the State of California to cause cancer and birth defects or other repro-

ductive harm.

Battery posts, terminals and related accesso- ries contain lead and lead compounds, chemi-

cals known to the State of California to cause cancer and birth defects or other reproductive

harm. WASH HANDS AFTER HANDLING.

Date of Purchase:

Keep these numbers for future reference.

MAINTENANCE AGREEMENT

A Sears Maintenance Agreement is available on this unit. See the nearest Sears Store for information.

NOTE: This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine's

exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it

must 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 laws apply on federal lands. See a Sears Service Center for a spark arrester for the muffler.

NOTE: Actual sustained horsepower will likely be lower due to operating limitations and environmental factors.

F-020433M 3

OWNER'S INFORMATION

CUSTOMER RESPONSIBILITIES

It is the owner's responsibility to follow the instructions be- low.

1. Carefully read and follow the rules for safe operation.

2. Follow all the assembly instructions.

3. Inspect the unit.

4. Make sure that the operator of the unit knows how to correctly use all standard and accessory equipment.

5. Operate the unit only with guards, shields, and other safety items in place and working correctly.

6. Correctly adjust the unit.

7. Service the unit only with authorized or approved replacement parts.

8. Complete all maintenance on the unit.

SAFE OPERATION PRACTICES FOR WALK-BEHIND MOWERS

WARNING: This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the

following safety instructions could result in serious injury or death.

This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety in-

structions could result in serious injury or death.

General Operation

Read, understand, and follow all instructions on the machine

and in the manual(s). Be thoroughly familiar with the controls and the proper use of the mower before starting.

2. Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.

3. Only allow responsible individuals, who are familiar with the instructions, to operate the mower.

4. Thoroughly inspect the mower and area where the equipment is to be used. Clear the area of objects such as rocks, toys, wire, bones, sticks etc., which could be picked up and thrown

by the blade.

5. Be sure the area is clear of other people before mowing. Stop mower if anyone enters the area.

6. Do not operate the mower when barefoot or wearing open sandals. Always wear substantial foot wear.

7. Do not pull mower backwards unless absolutely necessary. Look down and behind before and while moving backwards.

8. Do not operate the mower without proper guards, plates, grass catcher or other safety protective devices in place.

9. See manufacturer's instructions for proper operation and installation of accessories. Only use accessories approved by

the manufacturer.

10. Stop the blade(s) when crossing gravel drives, walks, or roads.

11. Stop the engine (motor) whenever you leave the equipment, before cleaning the mower or unclogging the chute.

12. Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catcher.

F-020433M

Environmental Awareness

• Do not fill the engine's fuel tank completely full.

• Drain fuel for off-season storage.

• Use only unleaded gasoline.

• Service the air cleaner regularly.

• Change oil regularly. Use 10W-30 oil in summer.

• Tune-up the engine regularly.

• Keep equipment in efficient operating condition.

• Dispose of used engine oil properly.

13. Mow only in daylight or good artificial light.

14. Do not operate the mower while under the influence of alco- hol, drugs or other medication which can cause drowsiness or

affect your ability to operate this machine safely.

15. Never operate mower in wet grass. Always be sure of your footing; keep a firm hold on the handle and walk; never run.

16. Disengage the self-propelled mechanism or drive clutch on mowers so equipped before starting the engine (motor).

17. If the equipment should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration

is generally a warning of trouble such as a blade that is dam- aged, a loose blade, or the engine mounting bolts are loose.

18. Always wear safety goggles or safety glasses with side shields when operating mower to protect your eyes from for-

eign objects which can be thrown from the unit.

19. Plan your mowing pattern to avoid discharge of material to- ward roads, sidewalks, bystanders and the like.

20. After striking a foreign object, stop the engine. Remove the wire from the spark plug. Inspect the blade and mower for

damage. If damaged, repair before starting and operating the mower.

21. Keep any washout ports and other mower housing service openings closed when mowing.

II. Slope Operation

Slopes are a major factor related to slip and fall accidents which can result in severe injury. All slopes require extra caution. If you

feel uneasy on a slope, do not mow it. DO:

Mow across the face of slopes; never up and down. Do not

mow excessively steep slopes (maximum 15 degrees) or areas where the ground is very rough. See the "Guide" in the back of this manual to check a slope. Exercise extreme cau-

tion when changing direction on slopes.

Remove objects such as rocks, tree limbs, etc.

OWNER'S INFORMATION

Watch for holes, ruts, or bumps. Tall grass can hide obstacles.

DO NOT:

Do not mow near drop-offs, ditches, or embankments. The operator could lose footing or balance.

Do not mow excessively steep slopes. Do not mow on wet grass. Reduced footing could cause slip-

ping.

II1. Children

Tragic accidents can occur if the operator is not alert to the pres- ence of children. Children are often attracted to the mower and

the mowing activity. Never assume that children will remain where you last saw them.

1. Keep children out of the mowing area and under the watchful care of a responsible adult.

2. Be alert and turn mower off if children enter the area.

3. Before and while moving backwards, look behind and down for small children.

4. Never allow children to operate the mower.

5. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

IV. Service

"1. Use extra care in handling gasoline and other fuels. They are

flammable and vapors are explosive. a. Use only an approved container. b. Never remove gas cap or add fuel with the engine running. Al-

low engine to cool before refueling. Do not smoke.

c. Never refuel the machine indoors. d. Never store the machine or fuel container inside where there

is an open flame, such as a water heater.

*2. Never run an engine indoors or inside a closed area.

3. Never make adjustments or repairs to items such as the height adjusters or grass catcher with the engine (motor) run-

ning. Disconnect the spark plug wire, and keep the wire away from the plug to prevent accidental starting. Always wear eye protection when you make adjustments or repairs.

Keep all nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition.

Never tamper with safety devices. Check their proper opera-

tion regularly.

To reduce fire hazard, keep mower free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage. Allow mow- er to cool before storing.

Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

Never attempt to make wheel height adjustments while the

engine (motor) is running.

Always disconnect electric mowers (live operated) before cleaning, repairing, or adjusting.

10. Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow ob-

jects to be thrown. Frequently check components and replace

with manufacturer's recommended parts, when necessary. For storage, always make sure grass catcher is empty.

11. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.

12. Do not change the engine governor setting or over-speed the engine.

13. Frequently check the blade for wear or damages such as cracks and nicks. A blade that is bent or damaged must be

immediately replaced with a factory replacement blade. For safety and good cutting performance, replace the blade every two years. Frequently check the blade bolt and the engine

mounting bolts. Replace damaged bolts and tighten loose bolts.

14. Use only original equipment or authorized replacement parts.

* Asterisked items do not apply to electric mowers.

precautions. This symbol indicates: "Attention!

Look for this symbol to indicate important safety Become Alert! Your Safety Is At Risk."

F-020433M 5

PREPARATION

UNPACKING INSTRUCTIONS

The mower was fully assembled at the factory. When the mower was put in the carton, the handle was put in a folded position (see

Figure 1). To put the handle in the operating position, follow the

steps below.

Handle

1. Remove the packing material from the carton.

Folded Position

2. Remove the side discharge attachment, the oil, and the fuel stabilizer from the carton. Put the fuel stabilizer in a safe

place until needed for storage.

3. Cut down all four corners of the carton.

CAUTION: Be careful when you fold or raise the handle. Do not damage the cables. A cable that is bent will not work

correctly. Before you use the unit, replace a bent or dam- aged cable.

4. Raise the upper handle and the lower handle to the operat- ing position (see Figure 2). Tighten the knobs that secure the upper handle to the lower handle.

Each adjuster arm has three mounting holes. These mounting holes will raise the height of the handle approxi- mately four inches. Determine the desired height and mount

the adjuster arms to the lower handle (see Figure 3).

RecoiI-Sta

Rope Guide

Adjuster Arm Figure 2

Side Discharge Attachment Figure 1

Blade Rotation

Control

Upper Handle

Knob

Lower Handle

Adjuster Arm

Knob

6. Tighten the knobs that secure the lower handle to the han- dle brackets.

7. To attach the recoil-start grip to the rope guide, twist the rope through the rope guide mounted on the right side of the

handle (Figure 2).

F-020433M 6

Adjuster Arm

Lower Handle

Handle Brack_

Knob

Figure 3

PREPARATION

HOW TO PREPARE THE ENGINE

ENGINE DOES NOT CONTAIN OIL OR GASOLINE

See "Before Starting The Engine" in the Operation section for the type of oil and gasoline to use. Before you use the unit, read the information on safety, operation, maintenance, and storage.

IMPORTANT: This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is

equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it must 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 laws apply on

federal lands. See a Sears Service Center for a spark arrester for the muffler.

In some areas, local law requires the use of a resistor spark plug to control the ignition signals. See a Sears Service

Center for a resistor spark plug for the engine.

FINAL PREPARATION

Before you mow, check the handle and the controls. Make sure all fasteners are tight.

_ WARNING: Before doing any assembly or mainte-

nance to the mower, remove the wire from the spark plug.

IMPORTANT! BEFORE YOU START MOWING

[] The engine was shipped without engine oil. Make sure to

fill the engine with the correct amount of engine oil.

[] Fill the fuel tank with gasoline.

F-O20433M 7

Blade Rotation Control

Drive Lever

Throttle Control

Recoil-Start

Grip

OPERATION

Transmission"

Speed Control

Blade Rotation

Oil Fill

Mulch Cover

Attachment

Side Discharge

Attachment

KNOW YOUR

BLADE ROTATION CONTROL: For the blade to ro-

tate, the blade rotation control must be in the ENGAGED position (against the handle). To quickly stop the blade, release the con-

trol.

BLADE CONTROL LEVER: Usethe blade control

lever to engage the blade.

Gas Fill

Single Lever

Height Adjuster

Primer Button

Figure 4

PRODUCT

MULCH COVER ATTACHMENT: Useto mulch the

grass.

SIDE DISCHARGE ATTACHMENT: Useto dis-

charge the grass out the side.

SINGLE LEVER HEIGHT ADJUSTER: Useto

quickly change the cutting height.

DRIVE LEVER: To quickly disengage the drive, release the

drive lever.

RECOIL-START GRIP: To start the engine, quickly pull

the recoil-start grip.

TRANSMISSION SPEED CONTROL: Toincrease

the forward speed, move the transmission speed control forward.

F-O20433M 8

THROTTLE CONTROL: Use the throttle control lever to

increase or decrease the speed of the engine.

PRIMER BUTTON: When starting a cold engine, use the

primer button the choke the engine.

OIL FILL / DIPSTICK: Usetocheck and add oil.

GAS FILL: Use to add gasoline.

OPERATION

HOW TO USE THE THROTTLE CONTROL

Use the throttle control to increase or decrease the speed of the

engine.

1. To increase the engine speed, move the throttle control forward to the FAST position. For normal operation and when using a grass bagger, move the throttle control to the FAST

position. Also, for a cooler running engine, operate the en- gine in the FAST position.

2. The engine governor is set at the factory for maximum per- formance. Do not adjust the governor to increase the speed

of the engine.

HOW TO ENGAGE THE BLADE

1. When you start the engine, do not engage the blade rota- tion control.

2. To rotate the blade, hold the blade rotation control in the ENGAGE position (against the handle).

3. With the blade rotation control against the handle, push the blade control lever forward.

4. To stop the blade, release the blade rotation control. Be- fore you leave the operator's position, make sure the blade

has stopped rotating.

HOW TO CHANGE THE HEIGHT OF CUT

To change the height of cut, move the position of the adjuster arm (see Figure 6).

1. Disengage the adjuster arm.

2. Move the adjuster arm to another position.

r Arm

Blade Control Lever

Throttle Control Figure 5

5. Before you go across a sidewalk or a road, release the blade rotation control to stop the blade.

_ ARNING: Always keep your hands and feet away

from the blade, deflector opening, and the mower

housing when the engine runs.

Rear Wheel Figure 6

F-020433M 9

OPERATION

HOW TO OPERATE THE REAR WHEEL DRIVE

IMPORTANT: When you operate, always operate with the throttle control in the FAST position.

Height Of Cut

Set the height of cut. See "How To Change The Height Of Cut". In high or thick grass, cut the grass in the highest position first and

then change to a lower position.

Rear Wheel Drive System

The mower has a multi-speed transmission with a rear wheel drive system. To change the speed, follow the steps below.

1. Start the engine. See "How To Start The Engine".

2. DO NOT engage the drive lever.

3. Move the transmission speed control forward to the de-

sired speed (see Figure 7).

_ ARNING: For better control of the unit, always

4. To go forward, hold the drive lever against the handle in the

select a safe speed.

ENGAGED position.

NOTE: To stop the engine, move the throttle control lever to the

OFF position.

WARNING: For safe operation, the drive system

is released. If the drive system does not disengage

must immediately disengage when the drive lever correctly, do not operate the mower until the drive

system is adjusted or repaired by a Sears service center.

Engage

Hold An;

Drive Lever

TransmissionSpeed

Control

Figure 7

5. When operating, always keep both hands on the handle (see Figure 8).

6. To stop forward motion, release the drive lever.

7. To shift to a different speed, release the drive lever. Move the transmission speed control to another speed.

Check the operation of the drive system as follows.

1. With the engine not running and the drive lever in the DIS- ENGAGED position, pull the mower backwards. The rear

wheels must freely turn.

2. With the engine not running and the drive lever in the EN- GAGED Position, pull the mower backwards. The rear wheels must now be engaged and will not turn.

3. If the drive system does not operate correctly, adjust the drive cable. See "How To Adjust The Drive Cable" in the

maintenance section.

Figure 8

F-020433M 10

OPERATION

HOW TO INSTALL

THE SIDE DISCHARGE ATTACHMENT

_ ARNING: To prevent the engine from starting, dis-

1. Remove the three wingnuts that secure the mulch cover to

connect the wire from the spark plug.

the mower housing (see Figure 9).

Wingnut

Figure 9

2. Remove the mulch cover.

Mount the side discharge attachment on the mower hous- ing (see Figure 10).

Make sure the side discharge attachment is mounted on all three bolts and fasten with the wingnuts that were removed

in step 1.

Wingnut

Side Discharge

Attachment

Wingnut

Figure 10

MULCHING TIPS

When you use a mulcher attachment, the grass is cut into very small pieces. These small pieces will quickly break down.

Because the nutrients are returned to the soil, the lawn will need less fertilizer. To correctly mulch the grass, follow the steps

below.

1. Set the throttle in the FAST position. Operate the mower at a slower ground speed. If ground speed is too fast, the grass will not have an even cut.

2. Keep a sharp edge on the blade. A blade that is not sharp will cause the ends of the grass to become brown.

F-020433M 11

Make sure the grass is dry. Wet grass is difficult to cut.

Set the height of the mower housing so that only the top third of the grass is cut. If the grass is too high, set the height of

the mower housing to the maximum height. Then, lower the mower housing for the second cut. Also, instead of using the

full width of the mower housing, mulch at half the width.

Clean the bottom of the mower housing. Grass and other debris can keep the mower from working correctly.

If the grass grows fast, mulch more often.

If an area needs improvement, mulch a second time.

OPERATION

BEFORE STARTING THE ENGINE ADD GASOLINE

WARNING: Always use a safety gasoline container.

Do not smoke when adding gasoline to the fuel

ADD OIL

NOTE: This unit is shipped without oil in the engine. Before

adding oil, be sure that the engine is level.

TO FILL WITH OIL CAUTION: DO NOT overfill the engine with oil or it will

smoke on startup.

Remove the oil dipstick from the oil fill spout. Make sure that the rim of the oil fill spout is clean.

You received a 20 oz. container of oil with the unit. Slowly pour 3/4 (15 oz.) of the oil from the container down the oil fill

spout into the engine.

Wait one minute to allow oil to settle. Insert and tighten the dipstick, then remove it to check the oil level.

Continue adding small amounts of oil and rechecking the dipstick until it reads full. DO NOT overfill, or the engine will smoke on startup.

Always make sure to retighten the oil dipstick before starting the engine.

Fill the fuel tank with regular FuelTank unleaded gasoline. Do not use __ premium unleaded gasoline.

Make sure the gasoline is fresh and clean. Leaded gasoline will increase deposits and shorten

the life of the valves.

CAUTION: A mixture of alcohol (ethanol or methanol) and gasoline (called gasohol), will attract moisture and cause acid deposits during storage. While the unit is in storage, the

acids in the fuel can damage the fuel system.

To prevent engine problems with the fuel system, empty the fuel system before storage of 30 days or longer as follows.

1. Drain the fuel tank.

2. Start the engine. Let the engine run until the fuel lines and

3. After storage, make sure you use fresh fuel. See the storage

4. Never use engine cleaner or carburetor cleaner in the fuel

tank. Do not add gasoline when you are inside an

enclosure. Before you add gasoline, stop the en- gine and let the engine cool for several minutes.

the carburetor are empty.

instructions for additional information.

tank or permanent damage can occur.

HOW TO START THE ENGINE

NOTE: The mower is equipped with a no-adjust carburetor. For increased performance, the carburetor has been preset to run in the FAST position. The FAST position will also improve lubrication and prolong engine life.

1. Move the throttle control lever to the FAST position.

NOTE: For the engine to start, the throttle control lever must be in the FAST position.

Push the primer button (see Figure 11). Every time you push the primer button, wait two seconds. For the number

of times required to push the primer button, see the decal located on the engine.

NOTE: Do not use the primer button when starting a warm engine.

3. Make sure the drive lever is in the DISENGAGED Position

(see Figure 12).

4. Stand behind the mower. Rapidly pull the recoil-start grip.

Slowly return the recoil-start grip.

NOTE: If the engine does not start after four or five tries, see the TROUBLESHOOTING CHART.

5. Let a cold engine run for several minutes. Begin work when

the engine is warm.

6. To stop the engine, move the throttle control lever to the

OFF position.

F-020433M 12

Primer Button Figure 11

Drive Lever

Recoil-Start Grip Figure 12

MAINTENANCE

MAINTENANCE CHART

FIRST EVERY EVERY EVERY

EACH 2 25 50 100 BEFORE

PROCEDURE USE HOURS HOURS HOURS HOURS STORAGE

Oil, Check V_

Cooling System, Clean V_

Air Filter, Clean / Change V_ V_

Spark Plug, Replace V_

Dusty conditions every 25 hours.

GENERAL RECOMMENDATIONS

1. The owner's responsibility is to maintain this product. This will extend the life of the product and is also necessary to

maintain warranty coverage.

2. Check the spark plug, blade brake, lubricate the unit, and clean or replace the air filter once a year.

3. Check the fasteners. Make sure all fasteners are tight.

4. Follow the Maintenance section and the Service And Adjust- ment section to keep the unit in good operating condition.

ENGINE TIPPING

When you service the engine, inspect the blade, or clean the un- derside of the mower housing; make sure to always tip the en-

gine with the spark plug up. Transporting or tipping the engine with the spark plug down will cause:

• Hard starting.

• Engine smoking.

• Spark plug fouling.

• Oil or gas saturation of the air filter.

WARNING: Before you make an inspection, adjust-

_ ent, or repair to the unit, disconnect the wire to

NOTE: Torque is measured in foot pounds (metric Nm). This

measurement describes how tight a nut or bolt must be. The torque is measured with a torque wrench.

the spark plug. Remove the wire from the spark

plug to prevent the engine from starting by acci- dent.

F-020433M 13

DO NOT TIP OR STORE UNIT WITH

SPARK PLUG POINTING DOWN.

Figure 13

MAINTENANCE

INSPECT BLADE

WARNING: Before you inspect or remove the blade,

disconnect the wire to the spark plug. If the blade hits an object, stop the engine. Check the unit for

damage. The blade has sharp edges. When you hold the blade, use gloves or cloth material to pro-

tect your hands.

If you keep the blade sharp and inspect the blade for damage, the blade will cut better and be more safe to operate. Frequently check the blade for excessive wear, cracks, or other damage.

Frequently check the nut that holds the blade. Keep the nut tight.

Ifthe blade hits an object, stop the engine. Disconnect the wire to the spark plug. See if the blade is bent or damaged. Check the blade adapter for damage. Before you operate the unit, replace damaged parts with original equipment parts. See a Sears service center in your area. Every three years, have an authorized service person inspect the blade or replace the old blade with an original equipment part.

HOW TO REMOVE AND INSTALL THE BLADE

1. Drain the fuel tank.

2. Lift the side of the mower that has the muffler or spark plug.

3. As you loosen the nut, use a piece of wood to keep the blade

from rotating.

4. Remove the nut, washers, and blade (Figure 14).

Hi-Lift

EdgeUp _,.._

Blade _e_@

BellevilleWasher i_i_ _

5. Check the blade and the blade adapter according to the

instructions for "Inspect Blade". Replace a badly worn or damaged blade with an original equipment blade. See a

Sears service center in your area.

6. Clean the bottom of the mower housing. Remove all the

grass and debris.

7. Mount the blade and blade adapter on the mandrel

(Figure 14).

8. Mount the blade so that the hi-lift edges are up. If the

blade is upside down, the blade will not cut correctly and can cause an accident.

9. Fasten the blade with the original washers and nut. Make

sure the outside rim of the Belleville washer is against the blade (Figure 15).

_ ARNING: Always keep the nut tight that holds the

F-020433M 14

blade. A loose nut or blade can cause an accident.

_ Mandrel r

Washer

Nu Figure 14

10. Tighten the nut that holds the blade to a torque of 35 foot pounds (47,5 N-m).

BladeAdapter

BellevilleWasher /_ Nut

(Outside rim must be

against the blade.) I

j___,_J_ Washer

EZ3

HOW TO SHARPEN THE BLADE

WARNING: Vibration can be caused if the blade is

not correctly balanced or if the blade is damaged.

A blade that is damaged with cracks can break and

cause an accident.

Keep a sharp edge on the blade. A blade that is not sharp will cause the tips of the grass to become brown.

1. Sharpen the blade two times a year or every 25 hours.

2. Remove the blade according to the instructions in "How To Remove And Install The Blade".

3. Clean the blade with a brush, soap and water. Check the blade. Look for cracks, nicks, or other damage. Replace a

badly worn or damaged blade with an original equipment blade. See a Sears service center in your area.

4. Sharpen the blade with a file (Figure 16). Make sure you keep the original bevel angle.

5. Make sure the blade is balanced. Use a screwdriver and hold the blade parallel to the ground (Figure 16). A blade

that is balanced will stay parallel to the ground. If the blade is not balanced, the heavy end will rotate toward the ground.

Sharpen the heavy end until the blade is balanced.

6. A new blade will cut better than a badly worn blade. Every three years, have an authorized service person inspect the

blade or replace the old blade with an original equipment blade.

7. Assemble the blade according to the instructions "How To Remove And Install The Blade".

Screwdrv__

I Blade is balanced I when para e to the ground.

Ground

Blade

Figure 15

Blade

File

Figure 16

MAINTENANCE

ENGINE

HOW TO CHECK THE OIL

NOTE: Do not check the level of the oil while the engine

runs,

1. Make sure the unit is level.

2. Clean the area around the dipstick (Figure 17). Remove the dipstick. Wipe the oil from the dipstick.

3. Insert the dipstick into the oil fill tube. Turn the dipstick clockwise until it is tight. Remove the dipstick. Check the oil

level on the dipstick. The oil level must reach the FULL mark on the dipstick.

4. If necessary, add oil until the oil reaches the FULL mark on the dipstick. The quantity of oil needed from ADD to FULL is shown on the dipstick. Do not add too much oil.

Fuel Cap

Dipstick

Engine Shroud

Figure 17

HOW TO CHANGE THE OIL

NOTE: Do not drain the oil from a cold engine. Before you drain the oil, let the engine run for several minutes. Make sure you do not get oil on the belts.

Loosen the oil fill cap to serve as an air vent.

Turn oil drain valve counter- clockwise and pull to release

the oil drain valve. See Figure 18.

Open the oil drain cap. NOTE: To make the job

cleaner, use an optional hose to drain the oil.

4. After draining the oil, close

the oil drain cap.

5. To lock the oil drain valve,

push and turn the oil drain valve clockwise. Container

6. Only use a high quality detergent oil rated with API service

classification SG. Select the oil's SAE viscosity grade ac- cording to the expected operating temperature using the

temperature chart below:

Oil Drain Valve

Oil Drain Cap

Optional Hose

Figure 18

Required SAE viscosity grades

F 20 ? 20 3240 e0 80 1p0

, i

C 30 20 10 0 10 20 30 4_0

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

NOTE: Although multi-viscosity oils (5W30, 10W30, etc.)

improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 320 F.Check the engine oil level more frequently to avoid possible engine damage from running low on oil.

7. Remove oil dipstick from oil fill spout. Make sure that rim of oil fill spout is clean.

8. Slowly pour 15 oz. of the oil down the oil fill spout into the engine.

9. Wait one minute to allow the oil to settle. Insert and tighten the dipstick, then remove it to check the oil level.

10. Continue adding small amounts of oil and rechecking the dipstick until it reads FULL. DO NOT overfill, or the engine will smoke on startup.

11. Always be sure to retighten oil dipstick before starting en- gine.

HOW TO CLEAN THE COOLING SYSTEM

The engine is air cooled. The air that cools the engine enters through the air screen on top of the engine. Clean the engine every 100 hours or every year as follows.

1. Remove any grass, dirt or debris from the air screen with a cloth or brush.

2. Inspect the edge of the engine shroud for grass or debris. Remove any grass or debris visible at the bottom edge of the

engine shroud.

F-020433M

HOW TO CHECK THE MUFFLER

Check the muffler every 50 hours. Make sure the muffler is cor- rectly mounted and is not loose. If the muffler is worn or burnt, replace with a new muffler. A worn muffler is a fire hazard and can damage the engine.

If you mount a spark arrester to the muffler, also check the spark arrester when you check the muffler. If the spark arrester is worn or damaged, replace it with a new spark arrester. See your near- est Sears service center for a spark arrester.

MAINTENANCE

HOW TO CLEAN THE AIR FILTERS (FLAT TYPE)

NOTE: Never run the engine with the air filters removed. The air

filters will help protect the engine against wear. For the correct replacement filter, see the parts list for the engine.

Loosen screw and tilt cover down (Figure 19).

Remove the air filters.

Clean the inside of the base and the cover with a cloth.

If equipped with a pre-cleaner, separate the pre-cleaner from the cartridge. Wash the pre-cleaner in a detergent and water

solution. Let the pre-cleaner thoroughly air dry. CAUTION: Do not wash the filters in gasoline or other

solvents that will burn.

To clean the cartridge, lightly tap the cartridge against a hard flat surface.

If the cartridge is very dirty, replace the cartridge.

Assemble the air filters.

If equipped with a pre-cleaner, the lip of the per-cleaner must touch the base of the cartridge.

Mount the tabs on the cover to the slots in the bottom of the base.

10. Close the cover and secure with screw.

Pre-cleaner /

Pre-cleaner Lip

Base

Cover

Screw

Cartridge

Figure 19

HOW TO CHECK THE SPARK PLUG

1. Check the gap of the spark plug with a feeler gauge (Figure 20). The correct gap is 0.030".

2. For easy starting and good performance, replace the spark plug every two years or after every 100 hours of use.

F-020433M 16

Feeler Gauge

0.030"

Spark Plug

Figure20

SERVICE AND ADJUSTMENT

HOW TO ADJUST THE BLADE DRIVE SYSTEM

_ ARNING: To prevent an injury, the blade rotation

control must operate correctly.

In normal usage, the blade drive system will not require an

adjustment. However, if the cutting performance decreases or the quality of cut is poor, make the following changes.

1. Start the engine. Make sure the throttle control is in the FAST position.

2. Release the blade rotation control.

Turn the cable adjuster one turn in the direction shown in Figure 21.

Engage the blade. See "How To Engage The Blade". Mow for a short distance and again check the quality of cut. If nec-

essary, turn the cable adjuster one more turn to shorten the cable.

Repeat the adjustment and check the quality of cut.

If the quality of cut does not improve, replace the mower drive belt. See "How To Replace The Mower Drive Belt". If replacing the belt does not correct the problem, take the unit

to a Sears service center.

Release the blade rotation control. Stop the engine. Dis- connect the wire from the spark plug.

Check the operation of the blade brake. Rotate the pulley with your hand. Make sure the brake pad is pressed tightly

against the pulley (Figure 22).

Drive Control

Cable Adjuster

Figure 21

_ WARNING: If the brake pad does not press tightly

against the pulley, take the unit to a Sears service center.

Move the blade rotation control to the ENGAGE position. Check the pad for the blade brake. If the pad is excessively worn or damaged, replace the brake pad assembly. Correct replacement parts and assistance are available from a Sears

service center.

10.

Attach the wire to the spark plug and start the engine. Mow for a short distance and again check the operation of the

blade drive system.

11.

If you replace the mower drive belt, turn the cable adjuster in the OPPOSITE direction as shown in Figure 21. Turn the cable adjuster until all the adjustment that was set with the

old belt has been removed.

12.

When you move the blade rotation control to the DISENGAGE position, all movement will stop within three

seconds. If there is movement of the belt or the blade contin- ues to rotate, engage and disengage the blade rotation

control five times to remove any excess rubber from a new mower drive belt. If you need assistance, take the unit to a

Sears service center.

Brake Pad

F-020433M 17

SERVICE AND ADJUSTMENT

HOW TO REPLACE THE BELTS

_ ARNING: Before you remove a belt, disconnect

Blade Drive Belt

1. Remove the front belt cover (see Figure 23).

2. Remove the blade drive belt from the engine stack pulley

3. Remove the blade drive belt from the mandrel pulley.

the wire from the spark plug.

(see Figure 24).

NOTE: Replace the blade drive belt with an original equipment belt. See a Sears service center in your area.

Make sure the the cable adjuster is turned so that all adjust- ment is removed the the blade drive cable. See "How To Ad-

just The Blade Drive System".

To install a new blade drive belt, put the belt around the mandrel pulley. Make sure that the "V" side of the belt is against the mandrel pulley.

6. Put the blade drive belt onto the bottom pulley of the en- gine stack pulley. Make sure that the flat side of the blade drive belt is against the idler pulley.

7. Check the routing of the blade drive belt as shown in the illustration.

Motion Drive Belts

1. Remove the rear belt cover (see Figure 23).

2. Remove the blade drive belt from the engine stack pulley (see Figure 24).

3. Remove the secondary drive belt from the transmission.

4. Remove the primary drive belt from the engine stack pulley and from the variator.

5. Remove the secondary drive belt. NOTE: Replace the motion drive belts with original

equipment belts. See a Sears service center in your area.

6. To install new motion drive belts, reverse the above steps.

Rear Cover

Front Cover

Figure23

Secondary Drive

Belt

Variator

Primary

EngineStack

>ulley

Transmission

F-020433M 18

Figure 24

SERVICE AND ADJUSTMENT

HOW TO ADJUST THE DRIVE CABLE

If the drive system does not engage and disengage correctly, check the handle for correct assembly. Make sure that all parts are in good condition, not broken or bent, and that all fasteners are tight.

Worn parts and cable stretch will change the performance of the drive system. When you mow in high or thick grass or on hills, the

drive system can slip. If the drive system is slipping, adjust as follows or take the mower to a Sears service center.

1. If the drive system is slipping, loosen the jam nut (see Figure 25).

2. Turn the cable adjuster one turn in the direction shown in the illustration. Test the drive system and check for slippage.

3. If the drive system still slips, turn the cable adjuster one more turn to shorten the cable. Again, test the drive system.

4. Repeat the adjustment and test until the drive system does not slip.

5. Before you begin to mow, make sure the drive system will correctly disengage and that the mower will stop. If the drive system will not disengage, take the mower to a Sears ser- vice center before you operate the mower.

6. Tighten the jam nut.

Adjuster

Figure25

F-020433M 19

STORAGE

FOLDING HANDLE STORAGE

CAUTION: Be careful when you fold or raise the handle. Do not damage the cables. A cable that is bent will not work cor-

rectly. Before you use the unit, replace a bent or damaged cable.

How To Fold The Handle

1. Remove the adjuster arms from the lower handle (see

Figure 26).

Adjuster Arm

2. Loosen the knobs that secure the lower handle to the handle brackets.

3. Rotate the handle forward over the engine (see Figure 27). As you fold the handle, make sure the cables are not around the loose fasteners and do not become damaged.

How To Raise The Handle

1. Liftthe handle intothe operator's position.

Each adjuster arm has three mounting holes (see Figure 26). These mounting holes will raise the height of

the handle approximately four inches. Determine the desired height and mount the adjuster arms to the lower handle.

3. Tighten the knobs that secure the lower handle to the handle brackets.

Lower Handle

Handle Bracket

Knob

Figure 26

Folding Handle

Adjuster Arms

Figure27

STORAGE (over 30 days)

At the end of each year, prepare the unit for storage as follows.

WARNING: Do not remove gasoline while inside a

_ uilding, near a fire, or while you smoke. Gasoline

1. Drain the fuel tank.

2. Let the engine run until it is out of gasoline.

3. Drain the oil from the warm engine. Fill the engine crankcase

4. Remove the spark plug from the cylinder. Pour one ounce of

F-020433M 20

fumes can cause an explosion or a fire.

with new oil.

oil into the cylinder. Slowly pull the recoil-start grip so that the

oil will protect the cylinder. Install a new spark plug in the cylinder.

5. Clean the dirt and debris from the cylinder cooling fins and the engine housing.

6. Clean the bottom of the mower housing.

7. Completely clean the mower to protect the paint.

8. Put the unit in a building that has good ventilation.

NOTE: Fuel stabilizer is an acceptable alternative in minimiz- ing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Al-

ways follow the mix ratio found in stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not drain the gas tank and carburetor if using stabilizer.

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