DR 46 Lawn Mower Deck User Manual
s
DR® ALL-TERRAIN™ MOWER
46" LAWN MOWER DECK
Safety & Operating Instruction
Please read these safety and operating instructions before using this
product. Failure to do so can result in serious injury.
And congratulations on your purchase of a new DR 46" LAWN MOWER DECK!
We have done our utmost to ensure that your DR 46" LAWN MOWER DECK will be
one of the most trouble-free and satisfying pieces of equipment you have ever owned.
Please let us know of any questions or problems you may have. We want to answer or
correct them as quickly as possible. (When you do call, please have your serial number
and/or order number handy—it will speed things up!) We also hope to hear from you
on how much you like your new helper.
And, please tell your friends about your new DR 46" LAWN MOWER DECK! Having
DR owners spread the word about our products and our way of doing business is the
best advertising we can have, and the best way to help us provide even better service in
the years to come.
Thanks once again!
for all of us at
Country Home Products, Inc.
COPYRIGHT
2005 Country Home Products, Inc. All rights reserved.
DOCUMENTATION
Written by: Ed Melen of EVM Technical Writing
Country Home Products, Inc.
Meigs Road
P.O. Box 25
Vergennes, VT 05491
Toll-free phone: 1-800-DR-OWNER (376-9637)
Fax: 1-802-877-1213
Web site: www.dr-owner.com
ii DR 46" LAWN MOWER DECK Safety & Operating Instructions
Table of Contents
Chapter 1: Introducing the DR 46" LAWN MOWER DECK...................................1
Conventions used in this Manual.................................................................................................... 1
Chapter 2: Safety Considerations.......................................................................... 3
Preparing to Use the DR 46" LAWN MOWER DECK..................................................................... 3
Safety and Information Labels........................................................................................................ 3
Protecting Yourself ......................................................................................................................... 4
Operating the Machine Safely ........................................................................................................ 4
Slope Operation ............................................................................................................................. 5
Safety for Children.......................................................................................................................... 6
Safety with Gasoline-Powered Machines ....................................................................................... 6
Additional Information and Potential Changes................................................................................ 7
Chapter 3: Setting Up Your DR 46" LAWN MOWER DECK..................................9
Assembling the Lawn Mower Deck ................................................................................................ 9
Removing the Brush Deck.............................................................................................................11
Installing the 46" Lawn Mower Deck..............................................................................................13
Check the Tire Pressure................................................................................................................15
Installing the Mulching Plate..........................................................................................................16
Chapter 4: Operating Your DR 46" LAWN MOWER DECK ................................17
The Pre-Start Safety Check...........................................................................................................17
Before Starting the Engine ............................................................................................................18
Starting the Engine........................................................................................................................18
Engaging the Wheel Drive.............................................................................................................19
Engaging the Lawn Deck Blades...................................................................................................19
Stopping the Lawn Deck Blades....................................................................................................19
Stopping the Engine ......................................................................................................................20
Adjusting the Cutting Height ..........................................................................................................20
Obstacle Tips ................................................................................................................................21
Slopes ...........................................................................................................................................21
If the machine gets hung up ..........................................................................................................21
Turns .............................................................................................................................................22
Reverse.........................................................................................................................................22
Cutting in Wet & Heavy Grass.......................................................................................................22
Mowing Tips ..................................................................................................................................22
Chapter 5: Maintaining the DR 46" LAWN MOWER DECK ................................23
Regular Maintenance Check List...................................................................................................23
Lubrication.....................................................................................................................................24
Removing and Replacing the 56" Deck Drive Belt.........................................................................26
Removing and Replacing the 80" Lawn Deck Belt ........................................................................27
Removing and Replacing the Blades ............................................................................................28
Removing the Caster Wheels........................................................................................................29
End of Season & Storage ..............................................................................................................29
Chapter 6: Troubleshooting .................................................................................31
Troubleshooting Table...................................................................................................................31
Chapter 7: Parts Lists, Schematic Diagrams and Warranty .............................. 32
Parts List — 46" Deck Drive Assembly..........................................................................................32
Schematic – 46" Deck Drive Assembly .........................................................................................33
Parts List — 46" Main Deck Assembly ..........................................................................................34
Schematic — 46" Main Deck Assembly ........................................................................................35
Warranty........................................................................................................................................37
DR 46" LAWN MOWER DECK Safety & Operating Instructions iii
iv DR 46" LAWN MOWER DECK Safety & Operating Instructions
w
r
Chapter 1: Introducing the DR 46" LAWN MOWER DECK
This manual will help you set up and safely operate your new DR 46" LAWN MOWER
DECK. Careful adherence to the safety and operating instructions in this manual will ensure
many years of productive use.
Please let us know of any questions you may have. We want to answer them as quickly as
possible. When you do call, please have your order number handy. For technical assistance,
please call Toll-Free 1-800-DR-OWNER (376-9637) and one of our Technical Support
Representatives will be happy to help you.
Conventions used in this Manual
WARNING! This indicates a hazardous situation,
could result
CAUTION! This indicates a hazardous situation, which, if not avoided,
could result
in
death or serious injury
in
minor or moderate injury.
hich, if not avoided,
.
NOTICE! This information is important in the proper use of your machine.
Failure to follow this instruction could result in damage to you
machine or property.
Tip: This is a helpful hint to guide you in getting the most out of your lawn deck.
Tools Needed: This indicates you will need a special tool to perform a maintenance
function on your lawn deck.
Note: This information may be helpful to you.
If you are ever unsure about an action you are about to take, contact Country Home
Product’s toll-free support at 1-800-DR-OWNER (376-9637).
DR 46" LAWN MOWER DECK Safety & Operating Instructions 1
2 DR 46" LAWN MOWER DECK Safety & Operating Instructions
T
(
)
T
f
T
y
Chapter 2: Safety Considerations
WARNING!
his mowing machine is capable of amputating hands and feet
and throwing objects. Failure to observe the following safet
instructions could result in serious injury or death.
Preparing to Use the DR 46" LAWN MOWER DECK
Read these Safety & Operating Instructions before you use the DR 46" LAWN MOWER
DECK. Also, review the Safety & Operating Instructions for your DR ALL-TERRAIN FIELD
and BRUSH MOWER before the set-up and operation of the lawn deck. Become familiar
with the controls, engine and service recommendations to ensure the best performance from
your equipment.
WARNING! Inspect the area in which you will be working. Look for rocks,
logs, sticks, rope, wire, garden tools, etc., and remove these
objects before mowing. Mowing over these objects could
damage the machine and cause injury.
Safety and Information Labels
Always replace damaged or missing safety and information labels immediately.
o avoid injury, keep your hands and
feet away from the spinning blade.
#136491
his label shows the proper routing o
the drive belt.
(#AT14600)
DR 46" LAWN MOWER DECK Safety & Operating Instructions 3
Protecting Yourself
p
p
w
WARNING! This is a high-
high energy at high speeds. Proper clothing and safety gear must be used when
operating this machine to prevent or minimize the risk of severe injury. Always take
the following precautions when operating this machine:
■ Always wear the protective goggles or safety glasses with side shields while mowing to
owered machine, with moving parts operating with
protect your eyes from possible thrown objects.
■ Wear shoes with non-slip treads when using your DR 46" LAWN MOWER DECK. If
you have safety shoes, we recommend wearing them. Do not use the machine while
barefoot or wearing open sandals.
■ Wear long pants while mowing.
■ Avoid wearing loose clothing or jewelry, which might get caught on brush or in the
mower’s moving parts.
■ Use earmuffs or earplugs to protect your hearing.
■ We recommend wearing gloves while mowing.
Operating the Machine Safely
WARNING! This is a high-
ith high energy at high speeds. The machine must be operated safely. Unsafe
operation can create a number of hazards for you, as well as anyone else in the
nearby area. Always take the following precautions when using this machine:
■ Keep bystanders at least 100 feet away from your work area at all times. Objects can be
owered machine, with moving parts operating
thrown far from the mower and at great speeds. To be safe, do not operate the
machine near small children or pets, and never allow children to operate the mower.
Disengage the blade and stop the engine when another person or pet approaches.
■ Clear the area of objects such as rocks, toys, wire, bones, sticks etc., which could be
picked up and thrown by the blade.
■ Be sure all blade and wheel controls are DISENGAGED before attempting to start the
engine. Engage and disengage the blade a few times to get used to it before mowing.
■ Keep your hands and feet away from the blade, belts, chains, blade pulleys, and
concealed areas while the engine is running. NEVER reach under the deck or grab
hold of any part of the deck when the engine is running.
■ ALWAYS shut off the engine whenever you leave the machine. Remove the spark plug
wire(s) before adjusting the machine. If you have to stop to remove grass or debris
from the underside of the deck, ALWAYS disconnect the spark plug wire(s) first.
■ The exhaust area on the engine becomes very hot with use. Allow the engine to cool
before doing maintenance or making adjustments.
■ Keep combustible substances away from the engine when it is hot.
■ When operating over uneven terrain and slopes, use EXTREME CAUTION to ensure
solid and firm footing. Keep a firm hold on the handlebars and walk, never run.
4 DR 46" LAWN MOWER DECK Safety & Operating Instructions
w
y
■ Stop the blade when crossing gravel drives, walks, or roads.
■ Use the machine only in daylight or good artificial light.
■ Use extra caution when mowing in wet or slippery conditions.
■ ALWAYS OPERATE THE MOWER FROM BEHIND. Never pass or stand on the
discharge (right) side or in front of machine when the engine is running.
■ Do not pull the mower backwards unless absolutely necessary. Look down and behind
before and while moving backwards.
■ Do not, under any conditions, remove, bend, cut, fit, weld, or otherwise alter standard
parts on the DR 46" LAWN MOWER DECK. This includes all shields and guards.
Modifications to your machine could cause personal injuries and property damage and
will void your warranty.
■ Immediately stop the mower and turn off the power unit if you accidentally hit
anything. Check everything thoroughly before you continue.
■ If the machine starts to make an unusual noise or vibration, immediately shut off the
engine, disconnect the spark plug wire(s), and allow all moving parts to come to a
complete stop. Vibration is generally a warning of trouble. Inspect for clogging or
damage. Clean and repair and/or replace damaged parts.
■ While using the DR 46" LAWN MOWER DECK, don't hurry or take things for
granted. When in doubt about the equipment or your surroundings, stop the machine
and take the time to look things over. Make sure that you have 100% control of the
mower at all times.
■ Never allow people who are unfamiliar with these instructions to use the DR
MOWER.
■ Do not operate the machine when under the influence of alcohol or medication.
■ Watch for traffic when mowing near roadways.
Slope Operation
WARNING! Slopes are a major factor related to slip and fall accidents,
hich can result in severe injury. All slopes require caution. If you feel uneas
on a slope, do not mow it. Always follow these precautions:
DO:
Mow across the face of slopes, never up and down. Exercise extreme caution when
changing direction on slopes.
Remove objects such as rocks, tree limbs etc.
Watch for holes, ruts, or bumps. Tall grass can hide obstacles.
DO NOT:
Do not mow near drop-offs, ditches, or embankments. You could lose your footing
or balance.
Do not mow on slopes greater than 20 degrees or any excessively steep slopes.
Do not mow on wet slopes. Reduced traction could result in slipping.
DR 46" LAWN MOWER DECK Safety & Operating Instructions 5
Safety for Children
f
p
w
WARNING! Tragic accidents can occur if the operator is not alert to the
resence of children. Children are often attracted to the mower and the
mowing activity.
them. Always follow these precautions:
Never
assume that children will remain where you last sa
Keep children out of the mowing area and under the watchful care of a responsible
adult.
Be alert and turn the mower OFF if children enter the work area.
Before and while moving backwards, look behind and down for small children.
Never allow children to operate the mower.
Use extra care when approaching blind corners, shrubs, trees, or other objects that may
obscure your vision.
Safety with Gasoline-Powered Machines
WARNING! Gasoline is a highly flammable liquid. Gasoline also gives of
flammable vapor that can be easily ignited and cause a fire or explosion. Do
not overlook the hazards of gasoline. Always follow these precautions:
■ Do not run the engine in an enclosed area or without proper ventilation.
■ Store all fuel in containers specifically designed and approved for this purpose.
■ Fill the gasoline tank outdoors with the engine off and allow the engine to cool
completely. Don't handle gasoline if you or anyone nearby is smoking, or if you're near
anything that could cause it to ignite or explode.
■ If you spill gasoline, do not attempt to start the engine. Move the machine away from
the area of the spill and avoid creating any source of ignition until the gas vapors have
dissipated. Wipe up any spilled fuel to prevent a fire hazard and properly dispose of the
waste.
■ Allow the engine to cool completely before storing in any enclosure. Never store the
machine with gas in the tank or a fuel container, near an open flame or spark such as a
water heater.
■ Never make adjustments or repairs with the engine running. Disconnect the spark plug
wire(s) and keep the wire(s) away from the spark plug(s) to prevent accidental starting.
■ Do not change the engine governor settings or modify the engine speed.
■ Keep all nuts and bolts, especially the blade attachment bolts, tight and keep the
equipment in good operating condition.
■ Never tamper with safety devices. Check their proper operation regularly.
■ Keep the mower free of grass, leaves or other debris build-up.
■ Stop and inspect the equipment if you strike an object. Repair, if necessary, before
restarting.
■ The mower blade is sharp and can cut. Wrap the blade or wear gloves, and use extra
caution when serving them.
Note: If situations occur that are not covered by this manual, use care and good judgment.
Call Toll-Free 1-800-DR-OWNER (376-9637) for assistance.
6 DR 46" LAWN MOWER DECK Safety & Operating Instructions
Additional Information and Potential Changes
Country Home Products, Inc. reserves the right to discontinue, change, and improve its
products at any time without notice or obligation to the purchaser. The descriptions and
specifications contained in this manual were in effect at printing. Equipment described
within this manual may be optional. Some illustrations may not be applicable to your
machine.
DR 46" LAWN MOWER DECK Safety & Operating Instructions 7
8 DR 46" LAWN MOWER DECK Safety & Operating Instructions
T
r
t
w
l
Chapter 3: Setting Up Your DR 46" LAWN MOWER DECK
This chapter outlines a few simple steps you will need to follow to set up your new DR 46"
LAWN MOWER DECK before you use it.
Assembling the Lawn Mower Deck
Assembly Components: (Figure 1)
46" Lawn Deck (A)
(2) Caster Wheels (B)
(1) Caster Wheel Support Bracket (C)
(1) 3/8" x 1" Cap Screw (D)
(2) 3/8" x 1-3/4" Bolts (E)
(6) 5/16" Lock Nuts (F)
(4) 5/16" Washers (G)
(1) 5/16" x 2" Pivot Tube Bolt (not shown)
(2) 1/4"-20 x 2" Cap Screw (H)
(8) Cutting Height Spacers (I)
(1) Deck Support Bracket (J)
(4) 1/4" Lock Nuts (not shown)
(1) Mulching Plate (not shown)
Tools & Supplies Needed:
9/16" Socket or Wrench
(2) 7/16" Wrench
1/2" Wrench
1/2" Socket w/Extension
Vise Grips or Wire Pull
2" Block to prop up deck
Grease gun w/
Lithium Grease
Mounting the Front Caster Wheels
he caster wheel support is secured to the
lawn deck for shipping with two 5/16" nuts
and washers. Remove the caster wheel
support and keep the nuts and washers fo
assembly.
1. Position the caster wheel support bracke
over the four studs coming up through
the deck (Figure 2).
2. Install the 3/8" x 3/4" cap screw and
asher in the rear support hole and hand
tighten it (Figure 3).
Figure 1
Figure 2
Note: Do not fully tighten the nuts until al
of them are installed.
DR 46" LAWN MOWER DECK Safety & Operating Instructions 9
Figure 3
Loading...