Powermate PM2015 Operator's Manual

Operator’s Manual

WALK-BEHIND LAWN MOWER

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Page

Safety Definitions 2 Important Safety Information 3-6 Product Specifications 7 Parts & Features 7 Safety Decals 8 Assembly 9-12 Operation 13-15 Routine Maintenance 16-19 Common Repair Parts 19 Storage 19 Troubleshooting 20 Technical Service 21 Warranty 21-24

MODEL NO. PM2015

IMPORTANT:

This manual provides complete instructions for safely operating and maintaining your mower. Read and save these instructions. Refer to this manual each time before using your mower.

Record the following for future reference: Model No: ___________________ Mfg. Date Code: ______________________ Date of Purchase: Attach a copy of your sales receipt. Consumer Toll Free Number: 1-800-737-2112

Refer to the website for electronic manual and parts book.

www.powermateoutdoor.com

WARNING

Engine exhaust, some of its constituents, and certain product components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

If you have a question or problem...

CALIFORNIA PROPOSITION 65 WARNING

CALL TOLL FREE: 1-800-737-2112

KEEP THIS MANUAL FOR FUTURE REFERENCE

07/14/2016 Printed in China A203240

PUSH TO PRIME

Safety Definitions

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Become familiar with and understand the meaning of the warning symbols found on your mower.

Important Safety Information

SAFETY WARNING SYMBOLS

DANGER

KEEP HANDS and FEET AWAY

Indicates WARNING, DANGER, or CAUTION. It means: Attention! Become Alert! Your Safety Is Involved.

Read operator’s manual before operating this machine. Failure to follow directions could result in serious injury.

Keep hands and feet away from rotating parts.

Do not mow slopes greater than 15°. Mow across slopes, never up and down.

The mower is capable of amputating hands and feet. To avoid risk or serious injury, do not put hands or feet near or under the mower. Keep clear of the discharge opening at all times.

Engine exhaust contains large amounts of poisonous carbon monoxide (CO) gas.

Do not mow when children or others are around.

This mower can throw small objects at high speed causing personal injury or property damage. Remove objects that could be thrown by the blade.

Wear eye protection that meets or exceeds the requirements of ANSI Z87.1.

Hot surface. The muffler and engine become hot and can burn you. Do not touch.

Gasoline is flammable. Handle with care.

Engine exhaust contains carbon monoxide, an odorless and deadly gas. NEVER run unit indoors or in a poorly ventilated area.

CONTROL AND OPERATING SYMBOLS

Push primer 3 times before starting a cold engine . Important: Do not prime to restart a warm engine.

SAFETY ALERT SYMBOLS

The symbols below identify important safety information in this manual. Become familiar with these symbols and the warnings associated with these symbols.

DANGER

WARNING

CAUTION

NOTICE

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor/moderate injury.

Indicates a situation which may result in equipment / property damage or may relate to general safety messages.

Oil Fill Location

Do Not Overfill

ENG - 2

Important Safety Information

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BEFORE OPERATING THE MOWER

1. READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE OPERATING THE MOWER.

DANGER

The mower is capable of amputating hands and feet and throwing objects. Read and follow all warnings and safety instructions on the mower and in this manual. Failure to do so can result in serious injury or death to you or bystanders.

2. Avoid Dangerous Environments a. Do not operate the mower while under the influence of alcohol, medications, or drugs. b. Do not operate the mower when you are tired. c. Do not use this mower if you are mentally or physically unable to operate safely.

3. Make sure all fasteners are tight and safety devices (guards, shields, blade control, etc.) are in place and working correctly. Inspect mower for damaged parts. Replace any damaged parts.

4. Dress properly when operating the mower. a. Always wear substantial footwear that provides protection and reliable footing. Never operate the mower in bare feet or sandals. b. Heavy long pants, steel-toed boots, gloves, and a long-sleeve shirt are recommended. c. Do not wear loose clothing or jewelry that can get caught in the moving parts of the mower.

5. Always wear eye protection that meets or exceeds the requirements of ANSI Z87.1.

6. Operate the mower only in daylight or good lighting conditions.

7. Thoroughly inspect the area where the mower is to be used and remove all foreign objects such as rocks, wire, toys, etc., which could be thrown by the blade.

WARNING

Important Safety Information

This mower can throw small objects at high speed causing personal injury or property damage.

WHILE OPERATING THE MOWER

1. Stay alert. Watch what you are doing.

2. Do not operate the mower if it is damaged or not securely and fully assembled.

DANGER

Never start or run the mower inside a closed room or building; breathing exhaust fumes can kill.

WARNING

Tragic accidents can occur if you are not alert to the presence of children. Children are often attracted to the mower and mowing activity. Never assume that children will remain where you last saw them.

3. Only well instructed and responsible adults should operate the mower. Never allow children to operate the mower.

4. Keep children and bystanders out of the mowing area. Keep children under the watchful care of a responsible adult other than the operator.

5. Be alert and turn the mower engine off if anyone enters the mowing area.

6. Use extreme care when approaching blind corners, shrubs, trees or other objects that may block your view of a child.

7. Never leave a running mower unattended.

8. Do not pull the mower backwards unless absolutely necessary. When moving the mower backwards, look down and behind for small children and foreign objects. Take extreme care when moving the mower backwards to keep your feet clear of the mower and to maintain your footing and balance.

DANGER

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

9. Do not operate mower without the entire discharge guard, trailing rear shield, blade control or other safety protective devices in place and working.

ENG - 3

Important Safety Information (Continued)

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Important Safety Information

WARNING

Disconnect spark plug wire before servicing blade or cleaning underneath mower deck. Failure to disconnect spark plug wire could lead to incidental engine starting resulting in serious injury or death.

10. Stop the engine (motor) and wait for the blade to completely stop before cleaning the mower or unclogging the discharge guard.

11. Maintain your balance and proper footing at all times. Always be sure of your footing; walk; never run.

12. The blade control lever is a safety device. Do not attempt to bypass or override the blade control lever. Doing so may cause severe personal injury from contact with a rotating blade. Stay behind the handle when the engine is running.

13. Never direct the mower’s discharge toward anyone. Avoid discharging the mower against a wall or other obstruction. Objects may ricochet back toward the operator or bystanders. Stop the engine when crossing gravel drives and walkways.

14. Do not force mower. It will do the job better, last longer and with less likelihood of a risk of injury at the rate for which it was designed.

15. If the mowers starts to vibrate abnormally, stop the engine and check for the cause immediately. Vibration is generally a warning of trouble.

16. The muffler and engine become hot and can burn you. Do not touch.

WHILE OPERATING THE MOWER ON SLOPES

WARNING

Slopes are a major factor related to slip and fall accidents, which can result in severe injury. Operation on all slopes requires extra caution. If you feel uneasy on a slope, do not mow it.

1. If a slope is greater than 15 degrees, do not mow. Use the slope gauge inside this manual (see pg. 6) to measure slopes before operating this mower on a slope or hilly area.

2. Mow across the face of slopes; never up and down. Exercise extreme caution when changing direction on slopes.

3. Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could cause a slip and fall accident. Tall grass can hide obstacles.

4. Do not mow on wet grass or excessively steep slopes. Poor footing could cause a slip and fall accident.

5. Do not mow near drop-offs, ditches, or embankments. You could lose your footing or balance.

6. If you do lose your balance, release the handle and blade control lever immediately.

FUEL SAFETY

WARNING

To avoid personal injury or property damage, use extreme care when handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

1. Do not smoke or allow smoking near fuel or the mower. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

2. Never refuel the mower indoors. Refuel outdoors WHERE THERE ARE NO SPARKS OR FLAMES.

3. Use a container approved for gasoline.

4. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

5. Do not lock the fuel dispensing nozzle in the open position.

6. Remove gas-powered equipment from the truck or trailer and refuel it on the ground. Always refuel the mower using a portable container. Never refuel mower from a fuel dispensing nozzle.

7. Never remove the fuel cap or add fuel with the engine running. Always stop engine and allow to cool before removing fuel cap. Remove fuel cap slowly.

8. Never overfill fuel tank. Avoid spilling fuel or oil. Wipe up all fuel spills.

9. After refueling, replace fuel cap and tighten securely.

10. If fuel is spilled on clothing, change clothing immediately.

11. Move at least 10 feet (3 meters) away from fueling site before starting engine.

ENG - 4

Important Safety Information (Continued)

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MAINTENANCE AND STORAGE OF THE MOWER

1. Disconnect the spark plug before performing maintenance.

2. Maintain the mower with care. Inspect the mower periodically. If the mower is not working properly or damaged, have it repaired by a qualified service center.

3. Check for misalignment of moving parts, binding of moving parts, broken parts, mounting, and any other condition that may affect its operation.

4. Check guards frequently and keep guards in place and in working order.

5. A guard or other part that is damaged should be properly repaired or replaced by a qualified service center.

6. Use only genuine Powermate accessories could lead to injury, damage to the unit, and void your warranty.

7. Maintain or replace safety and instruction labels as necessary. Do not remove safety or any labels from the mower for any reason.

8. Do not change engine governor setting or overspeed the engine.

9. Do not remove or modify any parts. Removing or modifying parts could lead to injury, damage the mower and will void the warranty.

10. Keep machine free of grass, leaves or other debris build-up. Clean up oil or fuel spills and remove any fuel-soaked debris.

11. Allow engine to cool and empty the fuel tank before storing or transporting in vehicle. Use up remaining fuel in the carburetor by starting the engine and letting it run until it stops.

12. Use extra caution when servicing mower blades. Disconnect spark plug wire before servicing blade or cleaning underneath mower deck. Blades are sharp. To protect your hands, wrap the blade or wear gloves when handling.

13. Store unit and fuel in area where fuel vapors cannot reach sparks or open flames from water heaters, electric motors or switches, furnaces, or where power tools are operated.

14. When not in use, store the mower in a clean, dry and well ventilated area.

replacement parts and accessories. Use of any non-Powermate® parts or

Important Safety Information

ENG - 5

WARNING!

Slopes are a major factor related to slip and fall accidents, which can

result in severe injury. Operation on all slopes requires extra caution.

If you feel uneasy on a slope, do not mow it. Mow across the face of

slopes; never up and down. Exercise extreme caution when chang-

ing direction on slopes.

FOLD ALONG DOTTED LINE

15 Degrees

10 Degrees

SLOPE GUIDE

SIGHT AND HOLD THIS GUIDE LEVEL WITH A VERTICAL TREE, A

CORNER OF A STRUCTURE, A POWER LINE POLE, OR A FENCE.

Use this guide and do not mow on a slope greater than 15 degrees.

A 15-degree slope is a hill that increases in height at approximately 2.5 feet in 10 feet.

ENG - 6

Product Specifications

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If you need assistance or have any questions, CALL TOLL FREE: 1-800-737-2112.

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 20 in (510 mm)

Cutting Heights . . . . . . . . . . . . . . . .2.25-3.5 in (57-89 mm)

Engine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . .3000 RPM

Unit Weight. . . . . . . . . . . . . . . . . . . . . . . . . 48.5 lb (22.0 kg)

Gasoline Type....... Regular

Gasoline Capacity . . . . . . . . . . . . . . . . . . . . . . . 1.06 qt (1L)

Oil Type (API SG, SH, SJ or higher) 10W-30 is

recommended for all service temperatures. See page 11 for

Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . .15 oz (450 ml)

Unleaded – 87 Octane (min.)

additional information.

Parts & Features

To be able to operate your mower safely and get the best performance, become familiar with the key product features (shown below) and all warning and instructions in this manual.

1. Blade Control Lever

2. Primer Bulb

3. Starter Rope Handle

4. Starter Rope Guide

5. Discharge Guard

6. Gasoline Fill

7. Oil Fill

8. Lower Handle

9. Upper Handle

10. Air Filter

11. Mufﬂer

12. Spark Plug

Spark Plug Model...TORCH K7RTC / Champion RC9YC4

Spark Plug Gap . . . . . . . . . .0.028-0.031 in (0.70-0.80 mm)

Engine Type ............. 4 stroke, single cylinder, OHV

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150cc

Torque Rating . . . . . . . . . . . . . . . . . . . . . 5.75 ft-lb (7.8 N.m)

. . . . . . . . . . . . . . . . . . . . . . . . gross torque per SAE J1940

Intake Valve Clearance. . . . 0.004 - 0.008 in (0.1 - 0.2 mm)

Exhaust Valve Clearance 0.006 - 0.010 in (0.15 - 0.25 mm)

Wheel Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 in

ENG - 7

Safety Decals

A202448

A202325

• Gasoline is flammable. Allow engine to cool at least 2 minutes before refueling.

• Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

Read Userʼs Manual Before Operation

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This mower has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing.

Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operated this equipment safely and effectively, we have placed several safety labels on the mower to remind you of this important information while you are operating the unit.

These important safety labels are illustrated below, and are shown here to help familiarize you with the location and content to the safety messages you will see as you perform normal mowing operations. Please review these labels now. If you have any questions regarding their meaning or how to comply with these instructions, reread the complete safety instruction text on the preceding pages, or

contact your local dealer. Should any of the safety labels become unreadable because of being worn, faded, or otherwise damaged during the use of your mower, please contact your local authorized dealer to order replacement label.

The safety labels are easily applied, and will act as a constant visual reminder to you and others who may use the equipment. Following the safety instructions is necessary for safe, effective operation of your mower.

See “Safety Deﬁnitions” section of this manual for explanations of the safety symbols.

ENG - 8

Assembly

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NOTE: ALL REFERENCES TO RIGHT OR LEFT SIDE OF THE MOWER ARE FROM THE OPERATOR’S POSITION

BEHIND THE UNIT.

IMPORTANT: THE ASSEMBLY INSTRUCTIONS WERE WRITTEN FOR PERSONS WITH SOME MECHANICAL ABILITY AND EXPERIENCE. ALL STEPS ARE NOT INCLUDED IN THESE INSTRUCTIONS. PERSONS WITH SOME MECHANICAL ABILITY ARE FAMILIAR WITH TIGHTENING FASTENERS SO THESE STEPS ARE NOT INCLUDED. DO NOT ATTEMPT TO ASSEMBLE BEYOND YOUR ABILITY.

If you need assistance or have any questions, CALL TOLL FREE: 1-800-737-2112.

WARNING

Do not operate the mower if it is damaged or not securely and fully assembled.

PARTS INCLUDED WITH THE PACKED MOWER

Item in Figure 1 QTY

1 Bolt, Axle - 3/8 in 4 2 Bolt, Hex Head - 3/8-16 X 1 1/2 inch 2

Figure 1

Bolt, Round Head Square Neck - 3/8

in 4 Bolt, Hex Head -1/4 in 2 5 Locknut - 1/4 in 2 6 Spacer 2 7 Washer - 1/4 in 2 8 Clip, Cable 1 9 Washer - 3/8 in 6

10 Wingnut, Plastic 2

Nut, Flange (Serrated Bottom) - 3/8 in

11 12 Nut, Flange (Smooth Bottom) - 3/8 in 2

Item in Figure 2 QTY

13 Upper Handle 1 14 Lower Handle 1 15 Discharge Guard 1 16 Wheels 4

Parts Bag 1

not

shown

Operator’s Manual 1

Quick Start Guide 1

4-Stroke Engine Oil 15 oz (450 ml) 1

Figure 2

ENG - 9

Assembly (Continued)

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If you need assistance or have any questions, CALL TOLL FREE: 1-800-737-2112.

NOTICE

COMPLETING THE ASSEMBLY STEPS BELOW. DURING ASSEMBLY THE ENGINE MAY BE TIPPED FOR EXTENDED TIMES. OIL CAN DRAIN INTO THE UPPER PART OF THE ENGINE CAUSING DIFFICULTY IN STARTING ENGINE.

TO ASSEMBLE THE DISCHARGE GUARD

DO NOT ADD ENGINE OIL BEFORE

TO ASSEMBLE THE LOWER HANDLE

Figure 4

Item numbers in assembly instructions and figure correspond to parts list on page 9.

Figure 3

Item numbers in assembly instructions and figure correspond to parts list on page 9.

NOTE: Use 7/16 in. wrenches, sockets or adjustable

wrenches to complete the following steps.

1. Holding the holes on the discharge guard (item 15) aligned with corresponding holes in the mower deck, insert hex bolts (item 4) through the washer (item 7), discharge guard (item 15) and through the deck.

2. Secure each bolt with a lock nut (item 5) as shown in Figure 3.

NOTE: Use 9/16 in. wrenches, sockets or adjustable wrenches to complete the following steps.

1. Support the rear of the mower deck on a block of wood or similar support.

2. Insert the lower handle (item 14) into and through the slots on each side of the rear of the deck, and align the holes in the deck with the holes in the lower handle. See Figure 4.

3. On each side of the lower handle and deck, insert the hex head shoulder bolt through the deck, the washer (item 9), the spacer (item 6) and through handle (item 14).

4. Secure the hex head shoulder bolt using the flange nuts (item 12).

ENG - 10

Assembly (Continued)

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TO ASSEMBLE THE UPPER HANDLE

Recoil Handle

Rope Guide

If you need assistance or have any questions, CALL TOLL FREE: 1-800-737-2112.

Item numbers in assembly instructions and figure correspond to parts list on page 9.

1. Place the upper handle (item 13) in position over the lower handle (item 14). See Figure 5.

2. Insert the round head, square neck bolts (item 3) through the holes in each side of the upper and lower handles, and secure with the large wing nuts (item 10).

3. Pull the recoil starter and thread the rope through the rope guide, as shown in Figure 5.

Figure 5

TO ASSEMBLE THE BLADE CONTROL ASSEMBLY

1. Insert the T-Bar pin into the Bracket as shown in Figure 6. NOTE: It may be necessary to temporarily remove the pre-assembled cable clip from the upper handle, to get enough slack in the cable. Reassemble the clip after the pin is inserted.

2. Secure the cable to the upper handle with the cable clip (item 8). See Figure 7.

3. Insert the opposite side (left) end of the blade control lever into the hole in the upper handle. See Figure 5. IMPORTANT: After completing these steps, pull the Blade Control Lever down against the upper handle. This should actuate the spring loaded brake lever on the engine. The Blade Control Lever should spring back to the upper position when released.

WARNING

The Blade Control Assembly is required to be able to stop the engine and brake the blade. Never run the lawn mower without the Blade Control Assembly correctly assembled.

Blade Control Lever

Bracket

T-Bar Pin

Pre-assembled Cable Clip

Figure 6

Figure 7

ENG - 11

Assembly (Continued)

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TO ASSEMBLE THE WHEELS (See Figure 8)

IMPORTANT: Before assembling the wheels, consider your

lawn and decide which available cutting height is best for your lawn. For best results, never cut off more than onethird of the total length of the grass.

NOTE: Use 3/4 and 9/16 in. wrenches, sockets or adjustable wrenches to complete the following steps.

If you need assistance or have any questions, CALL TOLL FREE: 1-800-737-2112.

Hole for 2.25” cutting height

Hole for 2.88” cutting height

Each corner of the mower deck has a group of 3 vertical holes representing the 3 possible cutting height settings. The cutting height is fixed and adjusted with the choice of hole the wheels are assembled. Make sure to assemble the wheels in the same choice of hole for each corner of the deck.

Hole for 3.5” cutting height

Figure 8

Item numbers in assembly instructions and figure correspond to parts list on page 9.

1. Secure each wheel to the deck by inserting the axle bolt (item 1) into and through the wheel (item 16), washer (item 9), and hole in the deck. Secure with flange nut (item 11).

a. To adjust the cutting height, disassemble each wheel and re-assemble to your new choice of hole location / cutting height.

NOTE: Make sure all four (4) wheels are assembled in the same wheel height position.

ENG - 12

Operation

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BEFORE STARTING ENGINE

NOTICE

Your mower’s engine is shipped from the factory without engine oil. A bottle of engine oil (15 fluid oz.) is included with your mower’s packaging. Check oil level before starting engine. If you start the engine without oil, the engine will be damaged beyond repair and will void your warranty.

Checking and Adding Engine Oil

Types of Oil to Use

Use high detergent motor oil having an API service classification of SG, SH, SJ or higher. Choose motor oil viscosity according to Fig. 15. For most range of service temperatures, 10-30 viscosity oil is recommended.

NOTICE

Use of non-detergent oil or 2-stroke engine oil may damage the engine and void your warranty.

1. Check oil level each time before starting engine. Check oil level daily or every eight (8) hours of operation. Keep oil level at UPPER LEVEL on dipstick (See Figure 9).

2. Always check oil level with engine cool and mower on flat, level surface.

3. Clean around oil fill spout, remove dipstick and wipe clean with a cloth.

4. Replace dipstick – without tightening. Make sure dipstick is fully inserted into oil fill spout. Remove and check oil level.

5. Oil level should be at UPPER LEVEL on dipstick. See Figure 9.

6. If oil is needed, add oil slowly through the oil fill spout and recheck. Do not overfill.

Figure 15

Recommended oil viscosity for ambient service temperatures.

SAE

SAE 10W-30

SAE 30

TEMP

Lower Limit

-20

Upper Limit

-20-30 -1000 Ambient Service Temperature

60 80

2010

100° F

Figure 9

40° C

NOTICE

Overfilling with oil may cause hard starting, spark plug fouling, and engine smoking.

ENG - 13

Primer Bulb

Push 3

Times

Operation (Continued)

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BEFORE STARTING ENGINE

Filling the Fuel Tank

DANGER

To avoid personal injury or property damage, use extreme care when handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Do not smoke or allow smoking near fuel or the mower. Extinguish all cigarettes, cigars, pipes and other sources of ignition. Never refuel the mower indoors. Refuel outdoors WHERE THERE ARE NO SPARKS OR FLAMES. Never remove the fuel cap or add fuel with the engine running. Always stop engine and allow to cool before removing fuel cap. Remove fuel cap slowly. Never overfill fuel tank. Avoid spilling fuel or oil. Wipe up all fuel spills.

Use fresh, clean regular unleaded gasoline with a minimum 87 octane. Fresh fuel prevents buildup of varnish and gum in the carburetor and fuel system. Commonly available fuel additives which reduce varnish and gum in your engine’s fuel system can be added according to the manufacturer’s instructions. Do not use gasoline which contains methanol. Do not mix oil with gasoline.

1. Remove cap slowly. Fill tank to approximately 1-1/2 inches below the top of the filler neck to allow for fuel expansion. Never overfill fuel tank.

2. After refueling, replace fuel cap and tighten securely.

3. If fuel is spilled on clothing, change clothing immediately.

4. Move at least 10 feet (3 meters) away from fueling site before starting engine.

STARTING THE ENGINE

DANGER

Never start or run the mower inside a closed room or building; breathing exhaust fumes can kill. Do not put hands or feet near or under the mower. Keep clear of the discharge opening at all times. Keep children and bystanders away when starting the engine and out of the mowing area.

1. Push the primer slowly three times – waiting about 2 seconds between each push (see fig. 10a) When tem peratures are below 55ºF, press primer five times. When restarting a warm engine, do not use the primer.

2. Stand behind the mower handle, grasp the blade control lever – holding it firmly against the upper handle. See fig. 10b.

3. Grasp the starter rope handle and pull slowly until resistance is felt, then pull rapidly to start engine.

WARNING

Rapid retraction of the starter rope (kickback) may pull your hand and arm back toward the engine faster than you can let go. Kickback is typically caused by improper ignition timing. If kickback is evident, have the engine examined and repaired by an authorized Service Dealer.

4. Slowly return starter rope handle to the starter rope guide and release. IMPORTANT: To avoid damage to the engine’s starter, do not allow the starter rope to snap back against the rope guide.

Figure 10a

Blade Control Lever

Upper Handle

Recoil Handle Starter

Figure 10b

ENG - 14

Operation (Continued)

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STOPPING THE ENGINE AND BLADE

WARNING

Wait for the blade to come to a complete stop before attempting to perform any work on the mower.

1. Release blade control lever to stop the engine and the blade.

ADJUSTING CUTTING HEIGHT

Reassemble the wheels in the desired wheel height position. Refer to the “To assemble the wheels” section in the assembly portion of the manual

MOWING TIPS

Thoroughly inspect the area where the mower is to be used and remove all foreign objects such as rocks, wire, toys, etc.

WARNING

This mower can throw small objects at high speed causing personal injury or property damage.

CAUTION

If you strike a foreign object or if the mower starts to vibrate abnormally, stop the engine. Remove spark plug boot from the spark plug, thoroughly inspect the mower for any damage, and repair the damage before restarting and operating the mower. Vibration is generally a warning of trouble.

For best results: a) Do not cut wet grass b) Never cut off more than one-third of the total length of the grass. c) Plan ahead and use a mowing path in a counterclock wise direction that discharges the new grass clippings away from the remaining area to mow. d) Adjust your mowing speed to the condition of the lawn. Do not force mower. It will do the job better, last longer and with less likelihood of a risk of injury at the rate for which it was designed. e) New grass, thick grass or wet grass may require you to use less than the mower’s full advertised cutting width. f) When mowing very tall grass, adjust the mower height to its highest setting and make a first cut. Adjust mower

to the desired height for a second cut.

ENG - 15

Routine Maintenance

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WARNING

Disconnect the spark plug before performing maintenance.

Maintain the mower with care. Inspect the mower periodically. If the mower is not working properly or damaged, have it repaired by a qualified service center. Do not change engine governor setting or overspeed the engine. Do not remove or modify any parts. Removing or modifying parts could lead to injury, damage the mower and will void the warranty. Use only genuine Powermate® replacement parts and accessories. Use of any non-Powermate® parts or accessories could lead to injury, damage to the unit, and void your warranty.

GENERAL MOWER CARE

1. After each use, remove any grass clippings or debris from the top of the mower deck and engine area with a brush or lawn and garden blower.

2. Periodically clean underside of the mower deck to pre vent buildup of grass clippings, etc. a) Before cleaning the underside of the deck, always drain the fuel tank by running the engine till the tank is empty. Disconnect the spark plug wire before performing this or any other maintenance. b) Tip the mower to expose the underside of the mowing deck.

NOTICE

Always tip the mower so it is resting on the side of the deck and the air filter side of the engine is facing up. Make sure the lawn mower is resting in a stable position before beginning to clean the deck. Never tip the mower more than 90 degrees in any direction and do not leave the mower tipped for extended periods of time. Oil can drain into the top part of the engine and cause starting problems.

c) Scrape excess grass clippings with an appropriate tool. Do not spray deck with water.

3. Using a light lubricating oil: a) lubricate pivot points on the blade control lever at least once each season. b) lubricate the wheels at least once each season.

Replace when necessary. a. Before tipping the mower to inspect the blade area, always drain the fuel tank by running the engine until the tank is empty. Disconnect the spark plug wire before performing this or any other maintenance. b. Tip the mower to expose the underside of the mowing deck.

To remove / replace the blade:

1. Remove the bolt and the washers holding the blade and the blade adapter to the engine crankshaft. See Figure 11

Blade Adapter

Blade

Disk Spring Washer

Flat Washer

Crankshaft

Blade Adapter

Blade

Disk Spring Washer

Flat Washer Bolt

2. Remove blade and adapter from the crankshaft.

3. The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen the blade while it is still on the mower. When sharpening the blade, follow the original angle of grind. Grind each cutting edge equally to keep the blade balanced. To check for blade balance, place blade on a round shaft screwdriver. Remove blade material from the heavy side until it balances evenly.

Bolt

Figure 11

CAUTION

BLADE CARE

CAUTION

Use extra care when servicing mower blades. Blades are sharp. To protect your hands, wrap the blade or wear gloves when handling.

1. Periodically inspect the blade and blade adapter for wear or damage, especially if you strike a foreign object.

An unbalanced blade will cause excessive vibration when rotating at high speeds. It may cause damage to mower and could break causing personal injury.

4. Lubricate the engine crankshaft and the inner surface of the blade adapter with light oil. Slide the blade adapter onto the engine crankshaft.

ENG - 16

Routine Maintenance (Continued)

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5. Position the blade onto the blade adapter in the correct orientation. On each end of the blade, a blade “lift” portion lies on the opposite side of the blade from the sharpened edge. When positioning the blade onto the blade adapter, make sure the blade “lift” portion is facing towards the mower deck. See Figure 11.

6. Assemble the retaining bolt through the flat washer, (2) disc spring washers, blade, and blade adapter. Make sure the flat washer and (2) disc spring washers are in the proper order and orientation shown in fig. 11.

7. Tighten the retaining bolt to 30 – 37 ft –lbs (40-50 N-m).

8. To ensure safe operation of your mower, periodically check the blade bolt for correct torque

ENGINE CARE

A list of key engine maintenance items required for good performance by the mower is given below.

Service Item Each Use First 5 to 8

hours

Check Engine Oil √ Change Engine Oil √ √ Check Air Filter √ Service Air Filter √ Check Spark Plug √ Service Spark Plug √ Clean Around Mufﬂer √

Every Season or

25 hours

Every Season or

50 hours

Every Season or

100 hours

Service Date

Record

1. Check engine oil level before each use and maintain oil level to the full mark on the dipstick. See section titled “Checking and Adding Engine Oil” on page 13.

2. Service air filter every 25 hours under normal conditions. Clean every few hours under extremely dusty conditions. Poor engine performance and flooding usually indicates that the air cleaner should be serviced. Never run the engine without an air filter installed. Running the engine without the filter can cause excessive engine wear and damage.

3. Clean engine regularly with a cloth or brush. Keep the top of the engine free of debris to permit proper air circulation. Remove all grass, dirt and combustible material from muffler area.

ENG - 17

Routine Maintenance (Continued)

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TO SERVICE THE AIR FILTER

A dirty air filter will restrict air intake. Periodic maintenance of the air filter will help improve engine performance and reduce emissions.

WARNING

Never clean air filter with gasoline or an easy ignited solvent because it may create a fire hazard.

1. Remove the air filter cover, and carefully remove the filter element. (See Figure 12)

2. Clean all parts. Clean filter element by gently tapping it on a flat surface. Replace if very dirty

3. Reinstall the filter element and air filter cover.

TO SERVICE THE SPARK PLUG

1. Clean the spark plug and reset the gap once a season. Spark plug replacement is recommended at the start of each mowing season. See “PRODUCT SPECIFICATIONS” on page 6 for correct plug type and gap specifications.

Filter Element Air Filter Cover

Figure 12

0.028 - 0.031 in.

0.7 - 0.8 mm

WARNING

Do not check for spark with spark plug removed. Do not crank engine with spark plug removed.

For good engine operation, the spark plug must be free of deposits or excessive electrode wear.

2. Remove the spark plug wire and remove spark plug with a spark plug wrench.

CAUTION

If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

3. Visually inspect the spark plug. Discard the spark plug if there is apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

4. Measure the spark plug gap with a feeler gauge. Adjust plug gap as required by bending electrode. See Figure 13

5. Reinstall the spark plug – starting by hand to prevent cross-threading.

6. After the spark plug is seated, tighten with a spark plug wrench an additional ¼ turn (18 ft-lbs)

Figure 13

NOTICE

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine.

ENG - 18

Routine Maintenance (Continued)

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TO CHANGE THE OIL

1. Change engine oil after every season or 50 hours of operation.

2. Drain the fuel tank by running the engine till tank is empty.

Figure 14

STORAGE

Mowers stored over 30 days need to be drained of fuel to prevent deterioration and gum from forming in the engines fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor, and other fuel system components, serviced or replaced. Commonly available fuel additives which reduce varnish and gum in your engine’s fuel system can be added according to the manufacturer’s instructions.

1. Remove all fuel from tank by running engine until it stops from lack of fuel.

2. Change oil. See the section “ To Change the Oil”.

3. Remove spark plug and pour about 1/2 an ounce of engine oil into cylinder. Replace spark plug and slowly pull the starter rope several times to distribute oil.

4. Clean grass and debris from around engine, and under, around and behind muffler.

5. Store in a clean, dry and well ventilated area away from water heaters, electric motors or switches, furnaces, or where power tools are operated.

6. Keep the engine level in storage. Tilting can cause fuel or oil leakage.

3. Clean around oil fill spout, remove dipstick.

4. Place a suitable container next to mower to catch the used oil, and then tilt the mower on its right side. The used oil will drain through the filler neck. Allow oil to drain completely. See Figure 14.

NOTE: Oil will drain more freely when warm. IMPORTANT: Used oil is hazardous waste. Place oil in a

sealed container and take to your local recycling center. Do NOT discard with household waste.

5. Refill engine with oil. Pour slowly. Do not overfill. See “Checking and Adding Engine Oil” on page 13.

COMMON REPAIR PARTS

1. Air Filter A203228

2. Spark Plug A203244

3. Blade A202068

4. Wheel A202052

ENG - 19

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