Craftsman 944.365440 User Manual

Page 1
Owner's Manual
JCRAFTSMIIN' owER
ROTARY LAWN
5.5 Horsepower 21" Multi-Cut
Model No.
944.365440
CAUTION: Read andfollow all
Safety Rulesand Instructions beforeoperatingthis equipment
Sears Canada, Inc., Toronto, Ontario M5B 2B8
Page 2
Warranty .................................................. 2
Safety Rules ......................................... 2-4
Product Specifications ........................... 4
Assembly/P re-Operation ......................... 5
Operation .............................................. 6-9
Maintenance Schedule .......................... 10
LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER For two years from date of purchase Sears Canada, Inc. will repair or replace at Sears
option free of charge parts which are defective as a result of material or workmanship. COMMERCIAL OR RENTAL USE:
Warranty on Power Mower (Gas) will be ninety (90) days from date of purchase if used for commercial or rental purposes.
This Warranty does NOT cover:
Pre-delivery set-up.
Expendable items which become worn during normal use, such as rotary mower
blades, blade adapters, belts, air cleaners and spark plug.
Repairs necessary because of operator abuse or negligence, including bent crank- shafts and the failure to maintain the equipment according to the instructions contained
in the owner's manual. Warranty service is available by returning the Craftsman Power Mower to the nearest
Sears Service Centre/Department in Canada. This warranty applies only while this prod- uct is used in Canada.
Maintenance ..................................... 10-13
Service and Adjustments .................. 13-14
Storage ............................................. 14-15
Troubleshooting ................................ 15-16
Repair Parts ...................................... 18-23
Sears Service .......................... Back Cover
This warranty is in addition to any statutory warranty and does not exclude or limit legal
rights you may have but shall run concurrently with applicable provincial legislation. Fur-
thermore, some provinces do NOT allow limitation on how long an implied warranty will
last so the above limitations may not apply to you.
Sears Canada, Inc., Toronto, Ontario M5B 2B8
IMPORTANT: This cutting machine iscapable of amputating hands and feet and throwing ob-
jects. Failure to observe the following safety instructions could result in serious injury or death.
_Look for this symbol to point out im- I. GENERAL OPERATION
portant safety precautions. It means Read, understand, and follow all CAUTION!!! BECOME ALERT!!!
YOUR SAFETY IS INVOLVED. AWARNING: In order to prevent ac-
cidental starting when setting up, trans- porting, adjusting or making repairs,
always disconnect spark plug wire and place wire where it cannot come in contact with plug.
A CAUTION: Muffler and other engine
parts become extremely hot during operation and remain hot after engine has stopped. To avoid severe burns on contact, stay away from these areas.
instructions on the machine and in the manual(s) before starting. Be thoroughly
familiar with the controls and the proper use of the machine before starting.
Do not put hands or feet near or under
rotating parts. Keep clear of the dis- charge opening at all times.
Only allow responsible individuals, who are familiar with the instructions, to
operate the machine.
Clear the area of objects such as rocks, toys, wire, bones, sticks, etc., which
could be picked up and thrown by blade.
Be sure the area is clear of other people before mowing. Stop machine ifanyone
enters the area.
Do not operate the mower when bare-
foot or wearing open sandals. Always
2 wear substantial foot wear.
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Do not pull mower backwards unless
absolutely necessary. Always look down and behind before and while moving
backwards.
Never direct discharged material toward
anyone. Avoid discharging material against a wall or obstruction. Material may richochet back toward the operator.
Stop the blade when crossing gravel surfaces.
Do not operate the mower without
proper guards, plates, grass catcher or other safety protective devices in place.
See manufacturer's instructions for proper operation and installation of
accessories. Only use accessories ap- proved by the manufacturer.
Stop the blade(s) when crossing gravel drives, walks, or roads.
Stop the engine (motor) whenever you leave the equipment, before cleaning
the mower or unclogging the chute.
Shut the engine (motor) off and wait until the blade comes to complete stop
before removing grass catcher.
Mow only in daylight or good artificial light.
Do not operate the machine while under
the influence of alcohol or drugs.
Never operate machine in wet grass.
Always be sure of your footing: keep a firm hold on the handle; walk, never run.
Disengage the self-propelled mech-
anism or drive clutch on mowers so equipped before starting the engine.
If the equipment should start to vibrate
abnormally, stop the engine (motor) and check immediately for the cause. Vibra-
tion is generally a warning of trouble.
Always wear safety goggles or safety
glasses with side shields when oper- ating mower.
II. SLOPE OPERATION Slopes are a major factor related to slip &
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. Exercise extreme caution
when changing direction on slopes.
Remove obstacles such as rocks, tree
limbs, etc.
Watch for holes, ruts, or bumps.Tall grass can hide obstacles.
DO NOT:
Do not trim near drop-offs, ditches or embankments. The operator could lose
footing or balance.
Do not trim excessively steep slopes.
Do not mow on wet grass. Reduced footing could cause slipping.
III. CHILDREN
Tragic accidents can occur if the operator
is not alert to the presence of children.
Children are often attracted to the ma- chine and the mowing activity. Neveras-
sume that children will remain where you last saw them.
Keep children out of the trimming area
and under the watchful care of another
responsible adult.
Be alert and turn machine off if children
enter the area.
Before and while walking backwards,
look behind and down for small children.
Never allow children to operate the
machine.
Use extra care when approaching blind
corners, shrubs, trees, or other objects that may obscure vision.
IV, SAFE HANDLING OF GASOLINE Use extreme care in handling gasoline.
Gasoline is extremely flammable and the vapors are explosive.
Extinguish all cigarettes, cigars, pipes
and other sources of ignition.
Use only an approved container.
Never remove gas cap or add fuel with
the engine running. Allow engine to cool before refueling.
Never refuel the machine indoors.
Never store the machine or fuel contain- er where there is an open flame, spark
or pilot light such as a water heater or
on other appliances.
Never fill containers inside a vehicle, on a truck or trailer bed with a plastic liner.
Always place containers on the ground
away from your vehicle before filling.
Remove gas-powered equipment from
the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such equipment with a portable
container, rather than from a gasoline
dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change
clothing immediately.
Never overfill fuel tank. Replace gas
cap and tighten securely.
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V. GENERAL SERVICE
Never run machine inside a closed area.
Never make adjustments or repairs with
the engine (motor) running. Disconnectthe spark plug wire, and keep the wire away
fromthe plugto preventaccidental starting.
Keep nuts and bolts, especially blade attachment bolts, tight and keep equip-
ment in good condition.
Never tamper with safety devices. Check
their proper operation regularly.
Keep machine free of grass, leaves, or other debris build-up. Clean oil orfuel spill-
age. Allow machine to cool before storing.
Stop and inspect the equipment if you strike an object. Repair, if necessary,
before restarting.
AWARNING: This lawn mower is equipped with an internal combustion engine and should 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
should be maintained in effective working order by the operator. A spark arrester for the muffler is available through your nearest Sears Service Centre
(See the REPAIR PARTS section of this manual).
Never attempt to make wheel height adjustments while the engine is running.
Grass catcher components are subject to wear, damage, and deterioration,
which could expose moving parts or allow objects to be thrown. Frequently
check components and replace with manufacturer's recommended parts, when necessary.
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and
use extra caution when servicing them.
Do not change the engine governor set- ting or overspeed the engine.
Maintain or replace safety and instruc- tion labels, as necessary.
Serial Number:
Date of Purchase:
Gasoline Capacity /Type: 0,94 Litres (Unleaded Regular) Oil Capacity: 0,5 Litres
Oil Type (API SG-SL): SAE 30 (above 0°C/32°F) or SAE 10W-30
Spark Plug (Gap: 0,76 ram) NGK BPR6ES
Valve Clearance 0.04 ram): Intake: 0.015 mm; Exhaust: 0.020 mm
Blade Bolt Torque: 35-40 ft. Ibs. (47-54 N-m)
The model and serial numbers will be found on a decal on the rear of the lawn mower housing. Record both serial number and date of purchase in space provided above.
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Read these instructions and this manual in its entirety before you attempt to assemble
or operate your new lawn mower.
IMPORTANT: This lawn mower is shipped
WITHOUT OIL OR GASOLINE in the engine.
Your new lawn mower has been assem- bled at the factory with the exception of
those parts left unassembled for shipping purposes. All parts such as nuts, wash-
ers, bolts, etc., necessary to complete the assembly have been placed in the parts
bag. To ensure safe and proper opera- tion of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as neces-
sary to ensure proper tightness.
Operator MOWING
POSITION
control bar
uP
Lower handle
Upper
handle
Handle
knob
TO REMOVE MOWER FROM CARTON
1. Remove loose parts included with
mower.
2. Cut down two end corners of carton
and lay end panel down flat.
3. Remove all packing materials except padding between upper and lower
handle and padding holding operator presence control bar to upper handle.
4. Roll mower out of carton and check carton thoroughly for additional loose
parts.
HOWTO SET UPYOUR MOWER
TO UNFOLD HANDLE
IMPORTANT: Unfold handle carefully so as not to pinch or damage control cables.
1. Raise handles until lower handle sec- tion locks into place in mowing position.
2. Remove protective padding, raise up- per handle section into place on lower
handle and tighten both handle knobs.
3. Remove handle padding holding operator presence control bar to upper
handle.
Your lawn mower handle can be adjusted for your mowing comfort. Refer to "AD-
JUST HANDLE" inthe Service and Adjust-
ments section of this manual.
TO ASSEMBLE GRASS CATCHER
1. Put grass catcher frame into grass bag with rigid part of bag on the bottom.
Make sure the frame handle is outside of the bag top.
2. Slip vinyl bindings over frame. NOTE: If vinyl bindings are too stiff, hold
them in warm water for a few minutes. If
bag gets wet, let it dry before using.
_ame
Vinyl Frame
bindings opening
TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be
used as a mulcher. To convert to bag-
ging, see "TO CONVERT MOWER" in the Operation section of this manual
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KNOW YOUR LAWN MOWER READTHIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATINGYOUR LAWN MOWER, Compare the illustrations with your lawn mower to familiarize yourself with
the location of various controls and adjustments. Save this manual for future reference.
These symbols may appear on your lawn mower or in literature supplied with the product.
Learn and understand their meaning.
CAUTION ENGINE ENGINE FAST SLOW CHOKE FUEL OIL DANGER, KEEP HANDS
OR WARNING ON OFF AND FEET AWAY
:Dperatorpresence control bar
Starter
handle'
Gasoline filler cap
Grass
Fuel valve lever
Air filter
=o
+
,,=,
.=
==
+
,,=,
z
Engine oil plug
Muffler
Mulcher door
Wheel adjuster
IMPORTANT: This lawn mower is shipped
WITHOUT OIL OR GASOLINE in the engine.
MEETS CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the
American National Standards Institute and the U.S. Consumer Product Safety Com- mission. The blade turns when the engine is running.
Operator presence control bar - must be held down tothe handle to start the
engine. Release to stop the engine,
Mulcher door - allows conversion to discharging or bagging operation.
Starter handle - used for starting engine.
6
(on each wheel)
Housing
Spark plug
Page 7
The operation of any lawn mower can result in foreign
objects thrown into the eyes, which can result in
severe eye damage. Always
wear safety glasses or eye shields while operating your lawn mower or performing
any adjustments or repairs. We recom-
mend standard safety glasses or a wide
vision safety mask worn over spectacles.
HOWTO USI= YOUR LAWN MOWER
ENGINE SPEED
The engine speed was set at the factory for optimum performance. Speed is not adjustable.
ENGINE ZONE CONTROL
_I=CAUTION: Federal regulations require an engine control to be installed on this
lawn mower in order to minimize the
risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade
turns when the engine is running.
Your lawn mower is equipped with an
operator presence control bar which requires the operator to be positioned
behind the lawn mower handle to start and operate the lawn mower.
TO ADJUST CUTTING HEIGHT
Raise wheels for low cut and lower wheels for high cut, adjust cutting height to suit your requirements. Medium position is
best for most lawns.
To change cutting height, squeeze ad-
juster lever toward wheel. Move wheel
up or down to suit your requirements. Be sure all wheels are in the same set-
ting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever.
Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs.
REAR BAGGING
Lift rear door of the lawn mower and place the grass catcher frame hooks
onto the door pivot pins.
To convert to mulching or discharging operation, remove grass catcher and
close rear door.
Pivot pins Rear
catcher
Catcher frame hook
SIDE DISCHARGING
Rear door must be closed.
Open mulcher door and install dis-
charge deflector under door as shown.
Mower is now ready for discharging operation.
To convert to mulching or bagging operation, discharge deflector must be
removed and mulcher door must be
closed.
Open mulcherdoor
Grass
handle
LEVER BACKWARD
TO LOWER MOWER
LEVER FORWARDTO RAISE MOWER Lever
TO CONVERT MOWER Your lawn mower was shipped ready to be
used as a mulcher. To convert to bagging or discharging:
Discharge
deflector
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deflector
SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING -
1. Rear door closed.
2. Mulcher door closed. FOR REAR BAGGING -
1. Grass catcher installed.
2. Mulcher door closed. FOR SIDE DISCHARGING -
1. Rear door closed.
2. Discharge deflector installed.
_CAUTION: Do not run your lawn mower
without rear door closed or approved grass catcher in place. Never attempt to
operate the lawn mower with the rear door removed or propped open.
TO EMPTY GRASS CATCHER
1. Lift up on grass catcher using the frame handle.
2. Remove grass catcher with clippings from under lawn mower handle.
3. Empty clippings from bag.
NOTE: Do not drag the bag when empty- ing; it will cause unnecessary wear.
"_l'k Grass
I_,_L_ catcher
"_,,,_ "'"--._,_. t_.,_:._) frame
_1_CAUTION: DO NOT overfill engine with
oil, or it will smoke on startup.
1. Be sure lawnmower is level.
2. Remove oil dipstick from oil fill spout.
3. You recieve a container of oil with the unit. Slowly pour the entire container
down the oil fill spout into the engine.
4. Insert and tighten dipstick.
IMPORTANT:
Check oil level before each use. Add oil
if needed. Fill to full line on dipstick.
Change the oil after every 25 hours of
operation or each season. You may
need to change the oil more often under dusty, dirty conditions. See "TO
CHANGE ENGINE Oil" in the Mainte-
nance section of this manual.
ADD GASOLINE
Fill fuel tank to bottom of tank filler neck.
Do not overfill. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline.
Purchase fuel in quantities that can be used within 30 days to assure fuel fresh-
BESS.
k CAUTION: Wipe off any spilled oil or
fuel. Do not store, spill or use gasoline ,_ar an open flame.
CAUTION: Alcohol blended fuels
(called gasohol or using ethanol or metha-
nol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To
avoid engine problems, the fuel system should be emptied before storage of 30
days or longer. Empty the gas tank, start the engine and let it run until the fuel lines
and carburetor are empty. Use fresh fuel
next season. See Storage Instructions for
additional information. Never use engine
or carburetor cleaner products in the fuel
tank or permanent damage may occur.
/ ---_ handle
BEFORE STARTING ENGINE ADD OIL Your lawnmower is shipped without oil in
the engine. For type and grade of oil to use, see "ENGINE" in the Maintenance
section of this manual.
Oil fill cap / Gasoline
filler cap
Upper
mark mark
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TO STOP ENGINE
To stop engine, release operator pres-
ence control bar. Wait until blade and
all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon.
TO START ENGINE
NOTE: Due to protective coatings on the
engine, a small amount of smoke may be present during the initial use of the product
and should be considered normal.
1. Be sure fuel valve is in the ON position.
2. Move choke lever to ON ( N ) position.
3. Hold operator presence control bar down to the handle and pull starter
handle quickly. Do not allow starter rope to snap back.
NOTE: The choke lever automatically begins moving to the OFF position when operator presence control bar is held
down to handle.
OFF
Fuel valve lever
Pores in cloth grass catchers can be- come filled with dirt and dust with use
and catchers will collect less grass. To prevent this, regularly hose catcher off
with water and let dry before using.
Keep top ofengine around starterclear and
clean ofgrass clippings and chaff.This will help engine airflow and extend engine life.
MULCHING MOWING TIPS IMPORTANT: For best performance,
keep mower housing free of built-up
grass and trash. See "CLEANING" in the
Maintenance section of this manual.
The special mulching blade will recut the
grass clippings many times and reduce
them in size so that as they fall onto the
lawn they will disperse into the grass and notbe noticed. Also, the mulched grass will biodegrade quicklyto provide nutrients for
the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades.
Avoid cutting your lawn when it iswet. Wet
grass tends to form clumps and interferes with the mulching action. The best time to
mow your lawn isthe early afternoon. Atthis time the grass has dried, yet the newly cut
area will not be exposed to direct sunlight.
Forbest results, adjustthe lawn mowercut- ting height so that the lawn mower cuts off
only the top one-third of the grass blades.
Ifthe lawn isovergrown itwillbenecessary
to raise the height ofcut to reduce pushing
effort and to keep from overloading the engine and leaving clumps of mulched
grass. For extremely heavy grass, reduce your width of cutby overlapping previously cut path and mow slowly.
MOWING TIPS
CAUTION: Do not use de-thatcher
blade attachments on your mower. Such attachments are hazardous, will damage your mower and could void your warranty.
Under certain conditions, such as very
tall grass, it may be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of grass clippings.
It may also be necessary to reduce ground speed and/or run the lawn
mower over the area a second time.
For extremely heavy cutting, reduce the
width of cut by overlapping previously cut path and mow slowly.
For better grass bagging and most cut- ting conditions, the engine speed should
be set in the FAST position.
Certain typesof grass and grass conditions may require that anarea be mulched a sec- ond time to completely hide the clippings.
When doing a second cut, mow across
(perpendicular) to the first cut path.
Change your cutting pattern from week
to week. Mow north to south one week then change to east to west the next week. This will help prevent matting and
graining of the lawn.
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MAINTENANCE SCHEDULE
Check for Loose Fasteners
Check Tires
i Clean / Inspect Grass Catcher *
Check Drive Wheels ***
Clean Lawn Mower ....
_ Clean under Drive Cover *'*
Check Drive Belt / Pulleys "*"
_ Check / Sharpen / Replace Blade R Lubrication
Clean and Recharge Battery *" Check Engine Oil level
E Change Engine Oil
mClean Air Filter
Inspect Muffler
_t Replace Spark Plug
E Replace Air Filter Paper Cartridge
Empty fuel system or add Stabilizer
* (if so equipped)
** Electric-Start mowers
.1,* Power-Propelledmowers
**** Use a scraper
to clean underdeck
1 - Change more often ifoperatingunder a heavy loador inhigh outdoortemperatures. 2 - Service more often it operating in dirty or dusty conditions.
3 - Replace blades more often when mowing in sandy soil. 4 - Charge 48 hours at end of season.
5 - And after each 5hours of use.
BEFORE AFTER EVERY EVERY EVERY BEFORE
EACH EACH 10 25 HOURS 100 STORAGE
USE USE HOURS OR SEASON HOURS
v'
v'
GENERAL RECOMMENDATIONS
The warranty on this lawn mower does not cover items that have been subjected to
operator abuse or negligence. To receive
full value from the warranty, operator must
maintain unit as instructed inthis manual,
Some adjustments will need to be made periodically to properly maintain your unit.
At least once a season, check to see if
you should make any of the adjustments described in the Service and Adjustments
section of this manual.
At least once a year, replace the spark plug, clean or replace air filter element
and check blade for wear. A new spark plug and clean/new air filter element
assure proper air-fuel mixture and help your engine run better and last longer.
Follow the maintenance schedule in this
manual.
BEFORE EACH USE
Check engine oil level.
Check for loose fasteners.
LUBRICATION Keep unit well lubricated
(See "LUBRICATION CHART").
LUBRICATION CHART
(!) Wheel
juster (on
ch wheel)
Engine oil
C) Mulcher
,door hinge pin
Rear door
hinge
(_) Handle bracket mounting pins
_ Spray lubricant
See "ENGINE" in Maintenance section.
IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will
attract dust and dirtthatwillshorten the lifeof the self-lubricating bearings. If you feel they
must be lubricated, use only a dry,powdered
10 graphite type lubricant sparingly.
Page 11
LAWN MOWER
Alwaysobservesafetyruleswhenper- forming any maintenance.
TIRES
Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber.
Avoid stumps, stones, deep ruts, sharp objects and other hazards that may
cause tire damage.
BLADE CARE For best results, blade must be kept sharp.
_eplace a bent or damaged blade.
CAUTION: Use only a replacement
blade approved by the manufacturer of
your mower. Using a blade not approved
by the manufacturer of your mower is hazardous, could damage your mower and
void your warranty.
TO REMOVE BLADE
1. Disconnect spark plug wire from spark plug and place wire where it cannot
come in contact with plug.
2. Turn lawn mower on its side. Make sure air filter and carburetor are up.
3. Use a wood block between blade and mower housing to prevent blade from
turning when removing blade bolt.
NOTE: Protect your hands with gloves
and/or wrap blade with heavy cloth.
4. Remove blade bolt by turning counter- clockwise.
5. Remove blade and attaching hardware (bolt, lock washer, hardened washer).
NOTE: Remove the blade adapter and
check the key inside hub of blade adapter. The key must be in good condition to work
properly. Replace adapter if damaged. TO REPLACE BLADE
1. Position the blade adapter on the en- gine crankshaft. Be sure key in adapter
and crankshaft keyway are aligned.
2. Position blade on the blade adapter aligning the two (2) holes in the blade
with the raised lugs on the adapter.
3. Be sure the trailing edge of blade (oppo- site sharp edge) is up toward engine.
4. Install the blade bolt with the lock washer and hardened washer into
blade adapter and crankshaft.
5. Use block of wood between blade and lawn mower housing and tighten the
blade bolt, turning clockwise.
The recommended tightening torque is
35-40 ft. Ibs. / 47-54 N-m.
IMPORTANT: Blade bolt is heat treated. If bolt needs replacing, replace only with
approved bolt shown in the Repair Parts section of this manual.
Blade adapte
Lockwasher
Blade
Blade bolt H
washer Crankshaft
Crankshaft
keyway
TO SHARPEN BLADE
NOTE: We do not recommend sharpening blade - but ifyou do, be sure the blade is bal-
anced. Care should be taken to keep the blade
balanced. An unbalanced blade will cause
eventual damage to lawn mower or engine.
The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower.
To check blade balance, drive a nail into a beam or wall. Leave about one inch of
the straight nail exposed. Place center hole of blade over the head of the nail.
If blade is balanced, it should remain in a horizontal position. If either end of the
blade moves downward, sharpen the heavy end until the blade is balanced.
GRASS CATCHER
The grass catcher may be hosed with water, but must be dry when used.
Check your grass catcher often for dam- age or deterioration. Through normal
use it will wear. If catcher needs replac- ing, replace only with approved replace- ment catcher shown in the Repair Parts
section of this manual. Give the lawn mower model number when ordering.
ENGINE Maintenance, repair, or replacement of the
emission control devices and systems, which
are being done at the customers expense, may be performed by any non-road engine
repair establishment or individual. Warranty repairs must be performed by an authorized engine manufacturer's service out]et.
LUBRICATION Use only highquality detergent oil rated with
API service classification SG--SL. Select the
oil's SAE viscosity grade according to your expected operating temperature.
_JUEVISCOSITY GRADES
'F -2O 0 30 ,32 4_ eo 0O 100
-._ -_ -,o o 1_ =o ;o 4o
11 TEMPERATURIERANGEANTICIPATEDBEFORENEXTOtLCHANGE
Page 12
NOTE: Multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, and
you should check your engine oil level fre- quently to avoid possible engine damage
from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the
lawn mower is not used for 25 hours in
one year. Check the crankcase oil level before
starting the engine and after each five (5) hours of continuous use. Tighten oil plug
securely each time you check the oil level. TO CHANGE ENGINE OIL
NOTE: Before tipping lawn mower to drain oil. empty fuel tank by running engine until fuel tank is empty.
1. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.
2. Remove engine oil cap; lay aside on a
clean surface.
3. Tip lawn mower on its side as shown
and drain oil into a suitable container. Rock lawn mower back and forth to re-
move any oil trapped inside of engine.
9. Reconnect spark plug wire to plug.
Oil fill cap / /_, \ _,,',,,LL_"
dipstick _--_ \_
mark-_'-'_ \ _l,f-_,%-_,,,,,_ _//_
LowerJ _ J _,0_,_,(_-- II
mark N_'_' .'_ III
AIR FILTER Your engine will not run properly and may
be damaged by using a dirty air filter.
Replace the air filter every 100 hours of
operation or every season, whichever oc- curs first. Service air cleaner more often
under dusty conditions. TO CLEAN AIR FILTER
1. Remove cover.
2. Carefully remove cartridge.
3. Clean by gently tapping on a flat sur- A face. If very dirty, replace cartridge.
CAUTION: Petroleum solvents, such as
kerosene, are not to be used to clean car- tridge. They may cause deterioration of the
cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge.
4. Install cartridge, then replace cover.
4. Wipe off any spilled oil from lawn
mower or side of engine.
5. Fill engine with oil. The engine oil capacity is 18.5 oz. If oil is not com-
pletely drained from engine, you may not need the entire container of a 20
oz, bottle of oil. Slowly pour 314 of the oil from the container down the oil fill
spout into the engine.
6. Wait one minute to allow oil to settle. Use guage on oil fill cap/dipstick for
checking level. Insert dipstick into the tube and rest the oil fill cap on the tube.
DO NOT thread the cap into the tube
when taking reading.
7. Continue adding small amounts of
oil and rechecking the dipstick until it
reads full. DO NOT overfill, or engine
will smoke on startup.
8. Always be sure to retighten oil dipstick before starting engine.
Filter Filter
Cover
Tabs
MUFFLER Inspect and replace corroded muffler as it
could create a fire hazard and/or damage.
SPARK PLUG
Replace spark plug at the beginning of
each mowing season or after every 100
hours of operation, whichever occurs
first. Spark plug type and gap setting are shown in the "PRODUCT SPECIFIC-
ATIONS" section of this manual.
12
Page 13
CLEANING
IMPORTANT: For best performance, keep mower housing free of built-up grass and
trash. Clean the underside of your mower
after each use.
ACAUTION: Disconnect spark plug wire
from spark plug and place wire where it
cannot come in contact with plug.
Clean the underside of your lawn mower
by scraping to remove build-up of grass and trash.
Clean engine often to keep trash from accumulating. A clogged engine runs
hotter and shortens engine life. Keep finished surfaces and wheels free
of all gasoline, oil, etc. We do not recommend using a garden
hose to clean lawn mower unless the electrical system, muffler, air filter and
carburetor are covered to keep water out. Water in engine can result in short-
ened engine life.
_WARNING: To avoid serious injury,
before performing any service or adjust- ments:
1. Release control bar and stop engine.
2. Make sure the blade and all moving parts have completely stopped.
3. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.
LAWN MOWER
TO ADJUST CUTTING HEIGHT See =TOADJUST CUTTING HEIGHT" in
the Operationsectionof this manual.
REAR DEFLECTOR
The rear deflector, attached between the
rear wheels of your mower, is provided to minimize the possibility that objects will
be thrown out of the rear of the mower into the operator mowing position. If the
deflector becomes damaged, it should be replaced.
SQUEEZE
TO ADJUST
Mowing .,_. Mowing ._
,-_ poe tion I , _o_ pos'don i i
', / /
I I I I
I I / I I I I l
'] ,/
. I !
Mountingl _ LJlJ bracket -- LU pin LOW POSITION HIGH POSITION
TO ADJUST HANDLE The handle can be mounted in a high or
low position, The mounting holes in the bottom of lower handle are off center for
raising or lowering the handle.
1. Remove upper handle and all wire
tie(s) securing cable(s) to lower handle.
2. Remove hairpin cotters from lower handle bracket mounting pin.
3. Squeeze lower handle in to remove it
from mounting pins.
4. Turn lower handle over to raise or lower handle.
5. Squeeze lower handle in and position holes onto mounting pins on handle
bracket.
6. Reassemble upper handle and all parts removed from lower handle.
\
Lowe r
ROTATE
13
Page 14
ENGINE Maintenance, repair, or replacement of the
emission control devices and systems, which are being done at the customers expense, may be performed by any non-road engine
repair establishment or individual. Warranty repairs must be performed by an authorized
engine manufacturer's service outlet. ENGINE SPEED
Your engine speed has been factory set.
Do not attempt to increase engine speed
or it may result in personal injury. If you believe that the engine is running too fast
or too slow, take your lawn mower to a
Sears or other qualified service center for repair and adjustment.
CARBURETOR
Your carburetor is not adjustable. If your
engine does not operate properly due to suspected carburetor problems, take your
lawn mower to a Sears or other qualified service center for repair or adjustment.
IMPORTANT: Never tamper with the
engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed
setting can be dangerous. If you think the engine-governed high speed needs
adjusting, contact a Sears or other
qualified service center, which has proper
equipment and experience to make any
necessary adjustments.
Immediately prepare your lawn mower for
storage at the end of the season or if the unit will not be used for 30 days or more.
LAWN MOWER
When lawn mower is to be stored for a period of time, clean it thoroughly, remove
all dirt, grease, leaves, etc. Store in a clean, dry area.
1. Clean entire lawn mower (See
"CLEANING" in the Maintenance sec- tion of this manual).
2. Lubricate as shown in the Maintenance section of this manual.
3. Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage
and wear. Replace if necessary.
4. Touch up all rusted or chipped paint surfaces; sand lightly before painting.
HANDLE You can fold your lawn mower handle for
storage.
1. Squeeze the bottom ends of the lower handle toward each other until the
lower handle clears the handle bracket,
then move handle forward.
2. Loosen upper handle mounting bolts enough to allow upper handle to be
folded back.
IMPORTANT: When folding the handle for storage or transportation, be sure to fold
the handle as shown or you may damage the control cables.
When setting up your handle from the
storage position, the lower handle will automatically lock into the mowing posi-
tion.
SQUEEZE
TO FOLD
MOWING
POSITION
control bar
FOLD FORWARD Upper
FOR handle STORAGE
Handle
knob
Lower handle
ENGINE
Maintenance, repair, or replacement of the emission controldevices and systems, which
are being done at the customers expense, may be performed by any non-road engine
repair establishment or individual. Warranty repairs must be performed by an authorized
engine manufacturer's service outlet.
14
Page 15
FUELSYSTEM IMPORTANT: It is important to prevent
gum deposits from forming in essential
fuel system parts such as carburetor, fuel filter, fuel hose or tank during storage.
Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage.
Empty the fuel tank by starting the en- gine and letting it run until the fuel lines
and carburetor are empty.
Never use engine or carburetor cleaner products in the fuel tank or permanent
damage may occur.
Use fresh fuel next season.
NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage.
Add stabilizer to gasoline in fuel tank or
storage container. Always follow the mix ratio found on stabilizer container. Run
engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach
the carburetor. Do not empty the gas tank
and carburetor if using fuel stabilizer.
ENGINE OIL Drain oil (with engine warm) and replace
with clean engine oil. (See "ENGINE" in the Maintenance section of this manual).
CYLINDER
1. Remove spark plug.
2. Pour 29 ml of oil through spark plug hole into cylinder.
3. Pull starter handle slowly a few times to distribute oi1.
4. Replace with new spark plug.
OTHER
Do not store gasoline from one season
to another.
Replace your gasoline can if your can
starts to rust. Rust and/or dirt in your gasoline will cause problems.
If possible, store your unit indoors and
cover it to protect it from dust and dirt.
Cover your unit with a suitable protective
cover that does not retain moisture. Do not use plastic. Plastic cannot breathe,
which allows condensation to form and will cause your unit to rust.
IMPORTANT: Never cover mower while engine and exhaust areas are still warm.
_CAUTION: Never store the lawn mower with gasoline in the tank inside a building
where fumes may reach an open flame
or spark. Allow the engine to cool before storing in any enclosure.
TROUBLESHOOTING - See appropriate section in manual unless directed to a Sears Parts & Repair Centre.
PROBLEM CAUSE CORRECTION
Does not start 1. Dirty air filter. 1. Clean/replace air filter.
.
Out of fuel.
3.
Stale fuel.
4.
Water in fuel.
5.
Spark plug wire is disconnected.
6.
Bad spark plug.
7.
Loose blade or broken blade adapter.
8. Control bar in released position.
9. Control bar defective.
10. Fuel valve lever (if so
equipped) in OFF position.
11.Weak battery (if equipped).
12. Disconnected battery connector (if equipped).
.
Fill fuel tank.
3.
Empty fuel tank and refill tank with fresh, clean gasoline.
4.
Empty fuel tank and refill tank with fresh, clean gasoline.
5.
Connect wire to plug.
6.
Replace spark plug.
7.
Tighten blade bolt or replace blade adapter.
8. Depress control bar to handle.
9. Replace control bar.
10. Turn fuel valve lever
to the ON position.
11. Charge battery.
12. Connect battery to engine.
15
Page 16
TROUBLESHOOTING - See appropriate section in manual unless directed
to a Sears Parts & Repair Centre,
CAUSEPROBLEM
CORRECTION
LOSS of power
Poor cut - uneven
Excessive vibration
Starter rope hard to pull
1. Rear of mower housing or blade dragging in grass.
2. Cutting too much grass.
3. Dirty air filter.
4. Buildup of grass, leaves, and trash under mower.
5. Too much oil in engine.
6. Walking speed too fast.
1. Worn, bent or loose blade.
2. Wheel heights uneven.
3. Buildup of grass, leaves and trash under mower.
1. Worn, bent or loose blade.
2. Bent engine crankshaft.
.
Engine flywheel brake is on
when control bar is released.
2.
Bent engine crankshaft.
3.
Blade adapter broken.
4.
Blade dragging in grass.
1. Raise cutting height.
2. Raise cutting height.
3. Clean/replace air filter.
4. Clean underside of mower housing.
5. Check oil level.
6. Cut at slower walking speed.
1. Replace blade. Tighten blade bolt.
2. Set all wheels at same height.
3. Clean underside of mower housing.
1. Replace blade. Tighten blade bolt.
2. Contact a Sears or other
qualified service center.
1. Depress control bar to
upper handle before
pulling the starter rope.
2. Contact a Sears or other
qualified service center.
3. Replace blade adapter.
4. Move lawn mower to cut grass or to hard surface.
Grass catcher 1. Cutting height too low. 1. Raise cutting height. not filling 2. Lift on blade worn off. 2. Replace blade.
(If so equipped) 3. Catcher not venting air. 3. Clean grass catcher.
Hard to push 1. Raise cutting height.1. Grass is too high or wheel
height is too low.
2. Rear of mower housing or blade dragging in grass.
3. Grass catcher too full.
4. Handle height position not
right for you.
2. Raise rear of mower housing one (1) setting higher.
3. Empty grass catcher.
4. Adjust handle height to suit.
16
Page 17
SERVICE NOTES
17
Page 18
CRAFTSMAN ROTARY LAWN MOWER - - MODEL NUMBER 944.365440
3
co
40
5O
\
6
11
12
13
5
21
41
14
7
15
34
143dm_ 42 Iii
\
23
37
37
36
j
52
18
t9
51
37
33
3O
28 37
48
36 32 26 10 36 20 45 j_
Page 19
CRAFTSMAN ROTARY LAWN MOWER - - MODEL NUMBER 944.364490
KEY PART KEY PART NO. NO. DESCRIPTION NO. NO, DESCRIPTION
¢JO
1 194177X428 Control Bar 34 186576X004 2 194179X479 Upper Handle 36 160828
3 169708X479 Lower Handle 37 193851X460 4 179585 Rope Guide 39 83923
5 132004 Nut, Hex 40 188813 6 191574 Handle Bolt 41 88652 7 66426 Wire Tie 42 165766
9 154132 Hinge Bracket 43 165767 10 165754 Mulcher Door 44 184193
11 176556 Engine Zone Control Cable 45 150406 12 750634 Hex Washer Head Screw 46 107339X
13 86899)(004 Up-Stop Bracket 48 186575X004 14 189713X428 Handle Knob 50 196076
15 51793 Hairpin Cotter 51 147286 17 165946X479 Support Bracket 52 190490
18 851856 Screw 1/4-20 x 3/8 19 186577X004 Axle Arm Assembly, LF 53 851084
20 186578X004 Axle Arm Assembly, RF 54 850263 21 188987 Rear Skirt 55 851074
22 168360X004 Selector Spring, Front 56 189028 23 186612 Kit, Rear Door (Includes Springs) 57 184590
24 73930500 Locknut, Hex 5/16-18 59 - - - 25 166111X479 Handle Bracket Assembly, LH 26 166112X479 Handle Bracket Assembly, RH 62 73800400
27 17600406 Screw 67 192770 28 152124 Hinge Spring - - 162300
29 160835X007 Wheel Adjusting Bracket, Front - - 196069
30 183901 Spacer - - 196071 31 165760 Discharge Deflector 32 169421X004 Selector Spring, Rear
33 701037 Selector Knob
NOTE: All component dimensions given in U.S. inches.
1 inch = 25.4 mm
Axle ArmAssembly,LR ShoulderBolt 5/16-18
Wheel& TireAssembly FlangedLecknut Frame,Grassbag HingeScrew
Spring,LH Spring,RH Bolt,Rear Door
Screw,Hex Head,Threaded, Rolled 3/8-16 x 1 DangerDecal AxleArmAssembly,RR
Gressbag
HingeRod Kit,Lawn Mower HousingAssembly
(IncludesKeyNumbers17, 18and46) Screw,Hex Head,Grade 8 3/8-24x 1-3/8 HelicalLockwasher
HardenedWasher 21"Blade BladeAdapter Engine,Honda,Model Number GCV160-AS3A(See Breakdown)
Locknut,Hex 1/4-20
Clip, Cable
Warning Decal(not shown)
Owner's Manual, English
Owner'sManual, French
IMPORTANT:Use onlyOriginal Equipment Manufacturer(O.E.M.) replacementparts. Failureto do socouldbe hazardous,damage yourlawn mower andvoidyourwarranty.
Page 20
HONDA 4-CYCLE ENGINE MODEL NUMBER GCV-160-AS3A
LABEL J
FAN COVER I
CHOKE !.__
:) I CAMSHAFT PULLEY
_---lo
$
7
AIR CLEANER I
2
12 |0
12 4
13---4D
2
14
_3
CARBURETOR I
RECOIL STARTER J
2O
Page 21
HONDA 4-CYCLE ENGINE MODEL NUMBER GCV-160-AS3A
LABELS
KEY PART NO. NO. DESCRIPTION
9 7400187 Mark, Choke Indication
CHOKE
KEY PART NO, NO, DESCRIPTION
1 7257157 Seal, ChokeLever 2 4209581 Spring,CableReturn
3 7257165 Lever,Choke 4 7257173 BaseComp.,Choke
5 7257181 Spring,ChokeLever 6 7257199 Hook,ChokeSpring
7 7257207 Plate,Choke
8 7229867 Rod,Stop 9 0747733 Bolt,Flange #6 x 16
10 3674413 Screw,Tapping #4 x 8 (PO) 11 2544690 Screw,Pan Head #5 x19
12 0369017 Screw,PanHead #4 x8 13 0636951 Nut,Flange 5 mm
FAN COVER
KEY PART NO. NO. DESCRIPTION
1 3683646 RubberSupporter(107 mm) 2 7357379 CockAssembly,Fuel
3 5189352 Bracket,FuelCock 4 6673289 Cap Assembly,FuelTank
5 5580469 Tube,Fuel 6 7399371 CoverComp., Fan(T89)
8 6978399 Collar,FuelCock 9 5581004 Bolt,Stud
10 0671636 Screw,WasherHead #5 x 10 11 6754279 Tube,FuelTank 12 0250647 Clip,Tube(B8) 13 0250985 Clip,Tube(1310)
14 0053447 Clip,Tube(C9)
CAMSHAFT PULLEY
KEY PART NO. NO, DESCRIPTION
1 7049679 2 5580063
3 7058985
4 5580089
5 5580097 6 5580105
7 5580113 8 5580121 9 5580139 10 1426980
11 0294819 12 0004598
13 6315873 14 6839831
CARBURETOR
PulleyComp.,Camshaft
Shaft,Cam Pulley
Belt,Timing(84HU7 G200) RockerArm,IntakeValve
RockerArm,ExhaustValve
Shaft,RockerArm Valve,Intake Valve,Exhaust
Spring,Valve
Retainer,IntakeValveSpring
Screw,TappetAdjusting
Nut,TappetAdjusting
ORing 6.8 x 1.9(ARAI)
Seal,ValveStem
KEY PART NO. NO,
1 3088416 2 5580162 3 3465879
5 1441518
7 7301138 8 5580212
9 5580220
10 5580238 11 5580246 12 4581120
13 5580253 14 5580535 15 0639419 16 0635474
0635482 0636126
17 1672187
AIR CLEANER
DESCRIPTION
PackingSet
FloatSet
ChamberSet,Roat
ScrewSet
CarburetorAsssembly(BB62GA) Valve,Float
Nozzle,Main
Insulator,Carburetor
Packing,Insulator
Packing,Carburetor
Packing,Carburetor
GuideComp., Air
Screw,Pan Head #5 x 6
Jet,Main #60
Jet,Main #62
Jet,Main #65
ScrewSet, Drain
RECOIL STARTER KEY PART
NO. NO. DESCRIPTION 1 6092886 StarterAssembly,Recoil
8 5580634 Grip,Starter 9 5580642 Rope, RecoilStarter
11 6478812 Nut, Flange 6 mm
KEY PART NO. NO.
1 5720289
2 6718159 3 5580410
5 5664560 6 6673255 7 5580964
8 2374742
21
DESCRIPTION
Tube,Breather
Element, AirCleaner
Case Assembly,AirCleaner
Packing,Air Cleaner
Cover,AirCleaner
Bolt,Flange #6 x 86(CT200)
Bolt, Flange #6x 14
Page 22
HONDA 4-CYCLE ENGINE MODEL NUMBER GCV-160-AS3A
CYLINDER BARREL J
CRANKSHAFT J OIL PAN]
PISTON CONNECTING ROD J
?
I MUFFLER
J FLYWHEEL
22
Page 23
HONDA 4-CYCLE ENGINE MODEL NUMBER GCV-160-AS3A
FLYWHEEL
KEY PART NO. NO. DESCRIPTION
1 0348433 3 6859722
4 6859714
5 6315816 6 5580683
8 5580790 10 0803619 11 1725050
12 0671552
13 0442038 15 0485946
16 1510361
19 1824630 20 1240845 21 7301591
CYLINDER BARREL
Key, Special,Woodruff#25 x 18 Coil Assembly,Ignition
FlywheelAssembly
Cord,StopSwitch SwitchAssembly, EngineStop
Spring,BrakeLever
Bolt,Flange #6 x 14(CT200) Bolt,Flange #6 x 23(CT200)
Bolt,Flange #6 x 20 (CT200) Nut,Special 14 mm
Screw,WasherHead #4x12
Washer,Plain 4 mm
ClipA, Cable GrommetA, RearCover BrakeSub-Assembly
KEY PART NO. NO. DESCRIPTION
1
6842413
2
2399780
3
5579990
4
5580006
5
0636845
6
0803619
7
5581038
8
1441112
9
1899848
Barrel Assembly, Cylinder
Clip, Valve Guide Cover, Head
Cover Comp., Breather
Bolt, Flange #6 x 12 (CT200) Bolt, Flange #6 x 14 (CT200)
Oil Seal 25A x 62 x 6
Plug, Spark (BPR6ES) (NGK)
Guide, Exhaust Valve (O.S.)
CRANKSHAFT
KEY PART NO. NO.
3 5664495 5 5581012
OIL PAN
KEY PART NO. NO.
1 6771489
2 5716915 4 1452754
5 5664503 6 5664511 8 6384341
9 6384333 10 5580287
11 5580295 12 1427244
13 1427251 14 5580303 15 0803619
16 0748111 17 2413862 18 2456697 19 5581046
20 1377704 21 0345900
22 0115527 23 1417369
DESCRIPTION
Crankshaft Comp.
Washer, Thrust
DESCRIPTION PanAssembly,Oil
GaugeAssembly,Oil Level Packing,Oil Fillercap
Extension,OilFiller
Washer,ExtensionRock
ShaftComp., GovernorHolder GovernorAssembly
Weight,Governor
Holder,GovernorWeight
Pin,GovernorWeight
Slider,Governor Shaft,GovernorArm
Bolt,Flange #6 x 14 (CT200) Bolt,Flange #6 x 25
Washer,Thrust 6 mm Clip,GovernorHolder
Oil Seal 28 x 41.25 x6 ORing 14.8 x 2.4 (NOK)
Washer,Plain 6 mm
Pin,Lock 8 mm DowelPin #8 x 20
PISTON/ CONNECTING ROD
KEY PART
NO. NO. DESCRIPTION
1
5580014
2
1426576
3
5580022
4
1431055
5
2605517
6
5655949
7154727
Piston
Pin, Piston RodAssembly,Connecting Bolt, Connecting Rod
Clip,PistonPin 13 mm RingSet, Piston(Riken) RingSet, Piston(Teikoku)
MUFFLER
KEY PART NO. NO.
1 5580485 2 5664610
3 5737457
4 5580972
5 0636845 6 5656012
7 5611397 8 1431121
23
DESCRIPTION Muffler,Complete
Protector, Muffler(CBU) Gasket,Muffler
Bolt,Flange #6 x 79 (CT200) Bolt,Flange #6 x 12(CT200) SparkArraster
Plate,ArrssterNumber Screw,Tapping#4 x 6
Page 24
Just Call:
1-800-4-MY-HOME ®
(1-800-469-4663)
24 hoursa day,7 days a week
Fortherepairofmajorbrandappliancesin yourown home...
nomatterwhomadeit,nomatterwhosoldit!
For yournearestSears Parts and Service IocaUon,
to bring inproducts likevacuums,lawnequipmentand electronics.
For Sears Parts & Service, to orderthe replacementparts,
accessoriesand owner'smanualsthatyouneedtodo-it-yourseff.
www.sear$.ca
To purchaseorinquireabouta Sears MaintenanceAgreement,call:
1-800-361-6665
9 a.m.-11 p.m. Mon.- Fri.,EST, 9 a.m.- 4 p.m. Sat.
}',a N i{{ s _
Pourserviceen fl'ang_s:
1-800-LE-FOYER _c
(1-800-533-6937)
www,eear_,ca
®/'ru Trademarks of Seam, Roebuck endCo. used underlicense by Sears Canada
M_Marqued6posde / MCMarquede commerce de Seam, Roebuck and Co. utllis6een ve_u d'une Iioence de Sears Canada
196069 12.06.04 BY Printed in U.S.A.
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