Troy-Bilt 1900678 User Manual
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OWNER/OPERATOR MANUA
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Assembly, Safety, Operating and Maintenance Instructtons.
PLEASE READ CAREFULLY!
TABLE OF CONTENTS
Page
INTRODUCTION 1
FOR SERVICE OR PARTS 1
MOWER IDENTIFICATION NUMBERS 1
SECTION 1: RULES FOR
SAFE OPERATION
Training................................................................................. 2
Preparation
Operation.............................................................................. 3
Maintenance and Storage
Safety Decals....................................................................... 4
SECTION 2: ASSEMBLY INSTRUCTIONS
Check For Shipping Damage
Toois Needed For Assembiy
Mower Assembly Steps .................................................... 5
Electric Start Assembly Steps
SECTION 3: MOWER AND
ENGINE CONTROLS
Blade Drive Controls......................................................... 15
Wheel Drive Controls
Handlebar Height Adjustment ........................................ 16
Height of Cut Adjustment................................................. 16
Engine Throttie Control
Fuel Shut-Off Valve............................................................ 17
Engine Recoii Starter
Key Switch Starter ............................................................ 17
SECTION 4: OPERATING INSTRUCTIONS
Preparation Before Starting............................................. 18
To Start the Engine............................................................ 19
To Engage the Blade
To Engage the Wheels
To Stop the Engine............................................................ 20
Operating the Mower......................................................... 20
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2
4
5
5
10
16
16
17
19
20
SECTION 5: MAINTENANCE AND
ADJUSTMENTS
Maintenance Chart
Adjusting Wheei Drive Traction
Height of Cut Adjustment
Handlebar Height Adjustment ....................................
Sharpening or Repiacing the Mower Biade ..
Clean the Mower Housing and Discharge
Chute............................................................................
Check Tire Pressure......................................................
Check Bolts, Screws and Nuts....................................
Lubrication......................................................................
Wheel Drive Belt Tension.............................................
Repiacing the Wheel Drive Belt
Blade Drive Belt Tension
Replacing the Blade Drive Belt ..................................
Wheel Drive Chain Tension
Replacing the Blade Brake Band
Battery Care In Service ................................................
Battery Storage
Battery Removal and Replacement
Starting the Electric Start
Engine With the Recoil Starter
Engine Crankcase Oil
Engine Air Cleaner
Carburetor Adjustments...............................................
Air Cooling Service........................................................
Spark Plug.......................................................................
Throttle Cable Adjustments ........................................
Off-Season Storage
Engine Identification Numbers
Blade Brake Control Test Procedure
SECTION 6: TROUBLESHOOTING
Swivel Wheel Kit
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MAINTENANCE RECORD . Inside Back
Page
21
22
23
23
24
25
25
25
25
25
26
27
28
29
29
30
31
31
32
32
33
33
33
33
33
33
33
34
35
36
Cover
MODEL IDENTIFICATION
22" Push Model. 5HP
Recoil Start Engine.
NOTE: Optional swivel wheels are available for your TUFF-CUT® Mower. Please refer to Page 36 for additional details.
22"Self-Propelled Model.
5HP Recoil Start or
optional Electric Start Engine.
24" Self-Propelled Model.
8HP Recoil Start or
optional Electric Start Engine.
P
INTRODUCTION
Dear Owner:
Vi/e at Garden Wa/ want to thank you for purchasing our TROY-BILT TUFF-CUT® High
Wheei Mower.
Your new mower is a professionai-quaiity, rugged machine that wiii handie most ter
rain and perform dependabiy for many iong hours of heavy use. The big rear wheeis
roii smoothly through tall grass, and over uneven ground and rough areas with ease. Its
perfect balance makes it much more responsive and maneuverable than conventional
mowers. And its wide mowing path, extra horsepower, and easy trimming abilities
mean you’ll get your mowing chores done in as little time as possible.
We have prepared this Manual to assist you in the safe operation and care of your
new TUFF-CUT High Wheel Mower. BEFORE YOU OPERATE THE MOWER PLEASE
READ THIS WHOLE MANUAL CAREFULLY! Most importantly, please follow all of the
safety instructions given in Section 1, “Rules for Safe Operation.’’ Failure to do so could
result in serious injury or damage to equipment or property.
It is our sincere hope that you enjoy using your mower. It is designed and con
structed to give you superior results and dependable service. Of course, if you have
any questions or problems in operating or servicing your mower, please remember that
we are here to serve you. We want to do everything we can to make sure that you are
completely satisfied 100 percent of the time.
Thank you.
Dean Leith, Jr.
Sales Manager
FOR SERVICE OR PARTS
For service or operating questions, or replacement
parts, you can either contact the factory or see your
local servicing dealer. Our addresses and telephone
numbers are listed below for your convenience.
Our telephone numbers are:
In the U.S.A.:
For Technical Service call Toll-Free: 1-800-833-6990
For Parts Service call Toll-Free: 1-800-648-6776
In Canada:
Call Toll-Free: 1-800-225-3585
Send correspondence to:
In the U.S.A.:
Troy-Bilt Mfg. Company
102nd St. & 9th Ave.,
Troy, New York 12180
In Canada:
Garden Way Canada, Inc.,
1515 Matheson Blvd., EUnitBII
Mississauga, Ontario L4W 2P5
For engine service, contact an Authorized Briggs &
Stratton Service Dealer. Look in the Yellow Pages of
your telephone directory, under "Engines-Gasoline."
Your Service Dealer can handle all parts, repairs, and
warranty service for problems concerning the engine
alone. For full details on the engine manufacturer's
limited warranty, please see the separate engine
owner's pamphlet that was included with this Manual.
(If you have any difficulty in locating an authorized
dealer or in obtaining warranty service, please contact
our Technical Service Department for assistance.)
RECORD YOUR MODEL
AND SERIAL NUMBERS
The arrow in the photo below shows the location of
the Model and Serial Number decal on your mower.
We will need these numbers if you call or write us for
parts or service assistance. For ready reference,
please record these numbers in the spaces provided
below.
MODEL NUMBER:.
SERIAL NUMBER:
DATE OF DELIVERY:
SECTION 1
A Rules for Safe Operation
Safe Operation is So Important...
Read the following rules carefully, and pay particular
attention to safety instructions printed elsewhere in this
manual. Failure to comply with safety instructions could
endanger your personal safety and the equipment and
property of yourself and others.
SAFETY ALERT SYMBOL
This symbol is used to alert you to important safety
messages in this manuai. When you see this
A
symbol, carefully read the message that follows.
The TUFF-CUT® Mower conforms to the CPSC
(Consumer Product Safety Commission) safety
standard 16 CFR Part 1205 for walk-behind pow
er lawn mowers. The CPSC is an agency of the
Federal Government, established and empowered
by Congress in 1972, to make and enforce safety
standards for consumer products sold in the Unit
ed States. All rotary walk-behind power lawn mow
ers manufactured after June 30, 1982 are
required to meet CPSC federally-mandated stan
dards. Accordingly, the TUFF-CUT® Mower meets
the standards in effect at the time of manufacture.
The TUFF-CUT® Mower also meets voluntary
safety standard B-71.1-1986, which is sponsored
by the Outdoor Power Equipment Institute and is
published by the American National Standards
Institute.
TRAINING:
1. Read both this Owner/Operator Manuai and the sep
arate engine owner’s pamphlet completely before using
the mower. Be thoroughly familiar with the controls and
proper use of the mower. Know how to stop the mower
and disengage the controls quickly in an emergency.
2. Never allow children to operate the mower. Do not
allow adults to operate the mower without proper
instruction.
3. Keep the area of operation clear of all persons, par
ticularly small children, and pets.
4. Under California law, and under the laws of several
other states, you are not permitted to operate an inter
nal combustion engine using hydrocarbon fuels on any
forest-covered, brush-covered, or grass-covered land, or
on land covered with grain, hay, or other flammable
agricultural crop, without an engine spark arrester in
continuous effective working order.
The engine on your power equipment, like most out
door power equipment, is an internal combustion engine
that burns gasoline, a hydrocarbon fuel. Therefore, your
power equipment must be equipped with a spark arrester
muffler in continuous effective working order. The spark
arrester must be attached to the engine exhaust system
in such a manner that flames or heat from the system will
not ignite flammable material. Failure of the owner/operator of the equipment to comply with this regulation is a
misdemeanor under California law, and may also be a
violation of other state and/or federal regulations, laws,
ordinances, or codes. Contact your local fire marshall or
forest service for specific information about what regula
tions apply in your area.
PREPARATION:
1. Thoroughly inspect the area where the mower is
to be used and remove all stones, sticks, wires,
bones, nails and other foreign objects.
2. Do not operate the mower when barefoot or
wearing open sandals. Always wear substantial
footwear. The operation of any powered machine can
result in foreign objects being thrown by high speed
rotating parts. Always wear approved safety glasses
or other eye protection when using the mower.
3. Do not wear loose-fitting clothing that could get
caught in moving parts.
4. Mow only in daylight, or in good artificial light.
5. Disengage the blade drive mechanism, and the
self-propelled mechanism on units so equipped,
before starting the engine.
6. Never operate the mower in wet grass. Always be
sure of your footing; keep a firm hold on the
handlebar and walk; never run.
Disengage Blade
and Wheel Drive
Controls Before
Starting
7. Never attempt to make a wheel height adjustment
while the engine is running.
8. Never operate the mower without the grass dis
charge deflector and all guards in place.
9. Never attempt to disconnect any safety devices or
to defeat the purpose of these safety devices.
10. Gasoline is highly flammable and its vapors are
explosive. Handle with extreme care. Use an approved
fuel container.
11. Check the fuel before starting the engine. Do not
fill the gasoline tank indoors, when the engine is run
ning or until the engine has been allowed to cool for
several minutes after running. Replace the fuel cap
securely and clean off any spilled gasoline before start
ing the engine.
12. Keep smoking materials, sparks and flame away
from the fuel tank or fuel container.
13. Move machine away from gasoline fumes before
starting engine.
14. Poison/Danger — Causes Severe Burns. The bat
tery on electric start models contains sulfuric acid. Avoid
contact with skin, eyes or clothing. Antidote: EXTER
NAL - Flush immediately with lots of water. INTERNAL
- Drink large quantities of water or milk. Follow with
milk of magnesia, beaten egg or vegetable oil. Call
physician immediately. Eyes - Flush with water for 15
minutes and get prompt medical attention. Keep out of
reach of children.
15. Batteries produce explosive gases. Keep sparks,
flame, or cigarettes away. Ventilate when charging or
using in an enclosed space. Always shield eyes when
working near batteries.
16. At the start of each season and every 10 operating
hours, perform the Blade Brake Control Test Procedure
described on Page 34.
OPERATION:
1. Do not put hands or feet near or under any rotating
parts. Keep clear of the mower blade and discharge
opening at all times.
2. Do not change the engine governor settings or over
speed the engine.
Stop The Blade
Before Crossing
Gravel Areas
5. Stop the engine, disconnect the spark plug wire,
and wait for all moving parts to stop before inspecting,
cleaning, adjusting or repairing the mower.
6. Never leave the mower unattended with the engine
running. Disconnect the spark plug wire and keep the
wire away from the spark plug to prevent accidental
starting. Remove the key on electric start models to
prevent unauthorized use.
7. Shut off the engine, disconnect the spark plug wire
and keep the wire away from the spark plug to prevent
accidental starting. Make sure that rotating parts have
completely stopped before cleaning out the discharge
opening.
Disconnect Spark Plug
Wire To Avoid
Accidental Starts
8. If the mower should start to vibrate abnormally, stop
the engine, disconnect the spark plug wire, and wait
for all moving parts to stop. Then, check immediately
for the cause. Vibration is generally a warning of
trouble.
9. After striking a foreign object, stop the engine and
disconnect the spark plug wire. Keep the spark plug
wire away from the plug to prevent accidental starting.
Wait for all moving parts to completely stop and then
inspect the mower for damage. Repair the damage
before restarting and operating the mower.
10. Do not run the engine indoors. Exhaust gases
contain carbon monoxide, a deadly gas that is odor
less and colorless. Always run the engine outdoors
and make sure there is adequate ventilation.
11. The Outdoor Power Equipment Institute recom
mends that you mow across the face of slopes; never
up and down. Exercise extreme caution when chang
ing direction on slopes. Do not mow excessively steep
slopes.
12. Do not touch engine parts which may be hot from
operation. Allow parts to cool before inspecting, clean
ing or repairing.
3. Stop the blade when crossing gravel drives, walks,
or roads where thrown objects would be a hazard.
4. Stop the blade when you are approached by any
child, pet, or inattentive person. (Curious toddlers can
too quickly endanger themselves.)
MAINTENANCE AND
STORAGE:
1. Check the blade and the engine mounting bolts at
frequent intervals for proper tightness.
2. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
3. Never store the mower with gasoline in the tank in
side a building where fumes may reach an open flame
or spark.
4. Allow the engine to cool before storing in any
enclosure.
^SAFETY DECALS
Safety decals are located near any area of potential
danger. Please contact us for replacement decals if
5. To reduce fire hazard, keep the engine free of
grass, leaves, or excessive grease.
6. Store gasoline in a cool, well-ventilated area, safely
away from any spark or flame-producing equipment.
Store in an approved container, safely out of the reach
of children.
7. Stop the engine, disconnect the spark plug wire,
and wait for ail moving parts to stop before inspecting,
cleaning, adjusting or repairing the mower. If the engine
has been running, allow the hot muffler to cool before
working near it.
they are missing, illegible, or damaged. See your Parts
Catalog for Part Number identification.
GRASP HANDLE GRIP WHEN
PULLING RECOIL STARTER.
1240263 (10/87)
ROTATING BLADE OR THROWN 0BJE(H^ CAN RESULT IN SERIOUS INJURY.
DO NOT OPERATE MOWER WITHOUT GRASS
DISCHARGE DEFLECTOR OR GUARD IN PLACE.
DO NOT PUT HANDS OR FEET NEAR OR UNDER
ROTATING PARTS. KEEP CLEAR OF THE DIS
CHARGE OPENING AT ALL TIMES.
Awarning
FAILURE TO FOLLOW SAFE OPERATING PROCEDURES MAY RESULT IN
INJURY. TO HELP REDUCE RISK:
1. READ OWNER/OPERATOR MANUAL.
2. KEEP ALL SAFETY GUARDS AND SHIELDS IN PLACE.
3. KEEP AREA OF OPERATION CLEAR OF ALL PERSONS AND PETS.
4. STOP ENGINE, DISCONNECT SPARK PLUG WIRE, AND WAIT FOR
ALL MOVEMENT TO STOP BEFORE CLEANING, INSPECTING OR
REPAIRING MACHINE.
For replacemenl Manual write lo: GARDEN WAY MFG. CO., TROY, N.Y. 1Z180 eooTBO/a?) J
ADANGER
80073 (9/87)
ACAUTION
DO NOT START ENGINE OR RUN MOWER UNLESS
BELT/PULLEY SAFETY COVER IS SECURELY FAS
TENED IN PLACE.
FAILURE TO INSTALL COVER CAN RESULT IN
INJURY FROM MOVING PARTS SUCH AS BELTS,
PULLEYS, CHAINS, ETC. T240226<9/87,
SECTION 2
Assembly Instructions
Your TUFF-CUT® Mower is shipped partially unassembled for safe shipment to you. You’ll find all the
loose parts and necessary hardware packed inside the shipping carton. Please follow the simple steps in
this Section for quick, easy and complete mower and engine preparation. After your mower is assembled,
carefully read and follow all of the safety and operating instructions in this manual and in the separate
engine owner’s pamphlet.
IMPORTANT
The engine on your mower was shipped without oil in
the crankcase. See Step 6 for oil filling instructions.
CHECK FOR SHIPPING DAMAGE
If you notice any freight damage or missing parts
either at the time of delivery or later during assembly,
make sure that you put it in writing, within 15 days, that
you intend to file a claim. Tell the driver, or phone the
truck terminal, that you intend to file a written claim.
They will advise you on how to proceed. However, if you
have any problems with this procedure, please call us
so that we can help you to get satisfaction.
Also, be sure to notify us if you find any parts are miss
ing or damaged. We will arrange to replace damaged
or missing parts as quickly as possible.
TOOLS NEEDED FOR ASSEMBLY
All Models:
• Two each of 7/16", 9/16", or Adjustable-Style
Wrenches
• Small Adjustable Pliers
• Phillips Head Screwdriver
• Oil Funnel
• Tire Pressure Gauge (pocket-type)
Electric Start Models:
• 1/2" or Adjustable-Style Wrench
E. Remove any protective wrapping from the upper and
lower ends of the handlebars. Also, there may be a plas
tic protective cap on the outer ends of the two rear wheel
mounting studs. If so, remove and discard the caps.
F. For shipping purposes only, a cardboard sleeve was
placed underneath the mower deck. Using care to avoid
cutting yourself on the sharpened blade (wear thick
gloves for extra protection), raise the front of the mower
and remove the cardboard sleeve.
HARDWARE PACKAGE
Photo 2-1: Remove mower, discharge deflector and
hardware package.
MOWER ASSEMBLY STEPS:
NOTE: All references to “Left” and “Right” are given
from the operator's position behind the handlebars.
STEP 1: Unpacking and Loose Parts
A. Remove the mower, discharge deflector, and hard
ware package from the shipping carton (lift carton off
base to remove mower). See Photo 2-1.
B. If you ordered an electric start model, also remove
the battery carton (containing battery, vent tube, and bat
tery bolts and nuts), the battery mounting bracket
assembly, and the battery hold-down clamp. See Photo
2-2.
C. The contents of the hardware bag can be identified
by referring to the separate “Hardware Bag Contents”
sheet that is included in your literature package.
D. Assembly should be done on a clean, level surface.
If you need to move the mower, be careful not to severely
bend or stretch any wires or cables.
Photo 2-2: Loose parts for electric start models include:
1. Battery
2. Vent Tube
3. Two Bolts and Nuts
4. Battery Mounting Bracket Assembly
5. Battery Hold-Down Clamp
STEP 2: Attach Handlebars
A. Parts Needed: (3) 3/8"-16x3/4" long Hex Hd.
Screws, (3) 3/8" Lockwashers, (3) 3/8"-16 Hex Nuts,
(1) Plastic Tie (for 22" Mower Only).
B. Gently fold back the handlebars from their shipping
position atop the mower and align the holes in the
ends of the left and right handlebars with the holes in
the mower frame handlebar mounting brackets. See
Photo 2-3. Note that the ends of the handlebars can be
positioned to either the inside or the outside of the
mounting brackets (make certain that both ends are
positioned the same way: either both inside or both
outside).
E. Select a hole combination according to the chart
below, then temporarily insert a 3/4" long screw through
the brace and bracket from right to left. Check that the
handlebars are set at a comfortable operating height
and readjust the setting if necessary. When you are
satisfied with the height setting, add a 3/8" lockwasher
and 3/8" hex nut and tighten securely using two 9/16"
wrenches.
USE HOLES
1-4
1-3 & 2-4
2-3
LOWEST HANDLEBAR HEIGHT
MEDIUM HANDLEBAR HEIGHT
HIGHEST HANDLEBAR HEIGHT
TO OBTAIN:
F. Securely tighten the two upper handlebar mounting
screws that you finger-tightened in Step C.
G. On the 22" mower (5HP engine) only, use a plastic
tie to secure the blade drive control cable (the thick
black cable attached to the blade drive control on the
left handlebar) to the center handlebar brace. Locate
the tie 3" to 4" above the bend at the lower end of the
center brace.
NOTE: For future handlebar height adjustments, refer
to the instructions found in Section 5.
Photo 2-3: Attach left and right handlebars.
C. Install two 3/4" long screws through the mounting
holes with the screw heads facing outside. Add 3/8"
lockwashers and hex nuts and tighten both screws
finger-tight.
D. There are two height adjustment holes at the bottom
of the center handlebar brace and two adjustment
holes in the height adjustment bracket which is welded
to the mower frame. See Photo 2-4. The four holes
allow you to choose three different handlebar height
positions: LOW, MEDIUM and HIGH.
STEP 3: Attach Wheel Drive Control Rod (Self-Propelled Models Only)
A. Parts Needed: (1) Clevis Pin, (1) Spring Clip.
B. One end of the upper wheel drive control rod is
already attached to the wheel drive lever located on
the right side of the handlebars. See Photo 2-5. The
clevis at the bottom of the control rod must be attached
to the bellcrank located at the rear of the mower. See
Photo 2-6.
C. There are three positioning holes in the bellcrank
that are identified in Photo 2-6 with the letters “H”, “M”
and “L”. As shown in the chart below, the clevis must
be installed in the correct bellcrank hole, relative to the
height setting of the handlebars.
USE HOLE
“H”
“M”
iilJl
IF HANDLEBARS ARE IN:
HIGHEST HEIGHT SETTING
MEDIUM HANDLEBAR SETTING
LOWEST HANDLEBAR SETTING
ff -«-WHEEL DRIVE LEVER
'i.'
Photo 2-4: Handlebar height adjustment holes. (Bell-
crank plate on self-propelled model has been rotated
upward for photo clarity.)
WHEEL DRIVE
CONTROL ROD
1
Photo 2-5: Wheel drive lever and upper control rod.
Photo 2-6: Clevis attaches to bellcrank. Do not remove
alignment screw and nut during attachment steps.
IMPOFnANT
Whenever the handlebar height is changed, the posi
tion of the control rod clevis must be changed accord
ingly. Moving the handlebars changes the tension on the
upper control rod and this tension must be adjusted by
relocating the clevis in the appropriate bellcrank hole.
Refer to the “Handlebar Height Adjustment" instructions
in Section 5 for the correct procedure to follow.
D. Before the mower left the factory, the bellcrank was
rotated upward and secured in place with a #10-24 x
5/8" long Phillips head screw and #10 lockwasher/nut.
See Photo 2-6. This aligns the bellcrank. The bellcrank
must be aligned in this manner every time the control
rod clevis is relocated to a different bellcrank position
ing hole. Do not remove the screw and lockwasher/nut
at this time.
NOTE: If the screw and lockwasher/nut has been
removed, rotate the bellcrank upward and reinstall the
screw and lockwasher/nut.
E. Slide the arms of the clevis over the bellcrank, push
ing the clevis forward as far as it will go.
F. Pull the handle on the wheel drive lever all the way
back into its most reanward position and, while holding
the lever in this position, try to align the clevis hole with
the appropriate bellcrank hole. Do not let the wheel
drive lever move from its most rearward position while
you are moving the clevis.
G. If the holes line up, insert the clevis pin through the
right side of the clevis and secure it with the spring
clip. See Photo 2-7. If the holes do not line up, remove
the clevis from the bellcrank and adjust the clevis by
rotating it up or down the control rod.
H. Repeat Steps E, F and G until the holes are
aligned.
I. Remove the screw and lockwasher/nut (shown in
Photos 2-6 & 2-7) from the bellcrank alignment holes.
You may have to jiggle the bellcrank slightly to free
them. Be sure to save the screw and lockwasher/nut
for any future readjustments of the upper wheel drive
control rod.
J. At this time, check to see that the wheel drive rollers
are not touching the rear tires. See Photo 2-8. With the
wheel drive lever in the upward, NEUTRAL position,
there should be a minimum clearance of 1/16" be
tween the rollers and the tires. This clearance ensures
that the rollers will not drive the wheels when the wheel
drive lever is in NEUTRAL. If there is not at least 1 /16"
of clearance, an adjustment must be made before the
engine is started. Please refer to Section 5, “Adjusting
Wheel Drive Traction” for the necessary adjustment
procedure.
Photo 2-8: Check for minimum clearance of 1/16"
between rollers and tires. (Belt/pulley safety cover re
moved for photo clarity.)
STEP 4: Check Tire Pressure
A. Use a pocket-type tire pressure gage to check the
inflation pressures in the rear tires. See Photo 2-9. The
tires should be equally inflated to between 25-30 psi.
B. Incorrect or unequal air pressure can result in ab
normal tire wear and difficult steering. On self-propelled
models, it can result in poor traction between the wheel
drive rollers and the tires. For best results, check the
inflation pressures after every 10 hours of operation or
once a week, whichever occurs sooner.
Photo 2-7: Secure clevis with clevis pin and spring clip. Photo 2-9: Check tire pressures in rear tires.
STEP 5: Attach Mower Discharge Deflector
CAUTION
• The discharge deflector must be installed before
operating the mower.
• Before installing the deflector, disconnect the
spark plug wire and keep the wire away from
the spark plug to prevent accidental starting.
• It will be necessary to reach below the blade
housing to install the discharge deflector.
Before doing so. put on heavy gloves to protect
your hands from the sharpened mower blade.
A. Parts Needed: (1) Discharge Deflector, (4) 1/4"-20
X 5/8" long Carriage Bolts, (4) 1/4" Lockwashers,
(4) 1 /4"-20 Hex Nuts.
B. It will be easier to install the deflector if you raise
the front of the mower a few inches off the ground and
then block the rear wheels.
C. Place the discharge deflector on the right side of
the mower deck so that the two square holes on the top
of the deflector are aligned with the square holes in the
top of the mower deck. Make sure that the right side of
the deflector overlaps the front wrap of the mower deck
and the left side of the deflector overlaps the rear mount
ing bracket. See Photo 2-10.
D. Insert two 5/8" carriage bolts down through the
holes in the top of the deflector and loosely attach 1 /4"
lockwashers and hex nuts. See Photo 2-10.
side of the mower deck out through the holes in the
front wrap and the deflector. Loosely attach a 114" lockwasher and hex nut. See Photo 2-11. If necessary, loosen
the bumper nut (shown in Photo 2-11) to gain clearance
for the carriage bolt and nut. After adding the bolt and
nut, securely tighten the bumper nut.
G. Using a 7/16" wrench, tighten all four carriage bolts
securely.
Photo 2-11: Location of fourth carriage bolt.
STEP 6: Add Oil to Engine Crankcase
CARRIAGE BOLT
(HEAD GOES INSIDE)
Photo 2-10: Location of three carriage bolts. (Belt/pulley
safety cover removed for photo clarity.)
E. Insert a 5/8" carriage bolt from the inside of the
mower deck out through the holes in the bottom, left
side of the mounting bracket and the deflector. Loosely
attach a 114" lockwasher and hex nut. See Photo 2-10.
F. On the bottom, right side of the deflector (behind
the front wheel), insert a 5/8" carriage bolt from the in
CAUTION: The engine was shipped to you
“dry", and oil must be added to the crank
O
case before the engine is started to avoid damag
ing the engine.
A. Make sure that the engine is level.
B. Use a high quality detergent oil classified "For
Service; SE, SF, or SG." Above 40°F, use SAE 30.
From 0° to 40°F, use 5W-30 or 10W-30. (See the
engine owner's pamphlet for synthetic oil
recommendations.) No special additives should be
added to the oil. DO NOT MIX OIL WITH
GASOLINE.
C. The 5HP engine (22" mower) requires
approximately 20 ounces; the 8HP engine (24"
mower) requires approximately 36 ounces.
D. Clean the area around the oil fill hole before
removing the oil fill plug or dipstick.
IMPORTANT: Always stop engine before adding oil.
E. 8 HP ENGINE: Remove the dipstick by rotating it
counterclockwise. See Photo 2-12. Using a clean funnel,
slowly pour oil into the filler neck. While adding oil, fre
quently check the level by replacing the dipstick and
rotating the cap until it is secure. Then remove the dip
stick and check the oil level by reading the dipstick
markings (wipe the dipstick with a clean rag each time
before replacing it). Stop adding oil when the level
reaches the FULL mark. Do not overfill. ALWAYS MAIN
TAIN THE OIL LEVEL AT THE FULL MARK ON THE
DIPSTICK.
8
F. 5 HP ENGINE: Remove the oil fill cap by rotating it
counterclockwise. See Photo 2-13. Using a clean fun
nel, slowly add oil until it reaches the point of overflow
ing at the oil fill hole. ALWAYS MAINTAIN THE OIL
LEVEL AT THE POINT OF OVERFLOWING.
G. After adding oil, securely replace the oil fill cap or
the dipstick.
Photo 2-12: Oil fill hole on 8 HP engine.
NOTE: On the 22" mower (5 HP engine) the throttle
cable should be routed above the tubular frame cross
piece located behind the engine; on the 24" mower {8
HP engine) the cable should be below the crosspiece.
See Photo 2-15.
C. Insert a 1 1/2" long screw through the handlebar
and into the metal clamp that is attached to the throttle
control. Add a 1/4" lockwasher and hex nut and
tighten securely using two 7/16" wrenches.
D. On the 24" mower only, use a plastic tie to secure
the throttle control cable and the blade control cable
(the thick, black cable that is attached to the blade drive
control on the left handlebar) to the center handlebar
brace. Locate the tie approximately in the middle of the
center brace.
Photo 2-13: Oil fill hole on 5 HP engine.
IMPORTANT
Check the oil level each time before starting the
engine and after each 5 hours of continuous opera
tion.
Change the oil after the first 5 operating hours and
every 25 hours thereafter. Change the oil more fre
quently in extremely dusty or dirty conditions.
Clean the air cleaner after every 25 operating hours,
or sooner under extremely dusty or dirty operating
conditions.
STEP 7: Attach Engine Throttle Control
A. Parts Needed: (1) 1/4"-20 x 1 1/2" long Hex Hd.
Screw, (1) 1 /4" Lockwasher, (1) 1 /4"-20 Hex Nut, (1)
Plastic Tie (for 24" Mower Only).
B. Uncoil the throttle cable and position the throttle
control on the inside edge of the left handlebar as
shown in Photo 2-14.
Photo 2-14: Install engine throttle control.
Photo 2-15: Throttle cable goes below crosspiece on 8
HP engine (as shown above), and above crosspiece
on 5 HP engine.
IMPORTANT
This completes the mower assembly steps if you have a
recoil (rope pull) starting engine. If you have an electric
(key switch) starting engine, please continue with the
following electric start assembly steps.
CAUTION: To avoid personal injury, carefully
read and follow all of the Safety, Controls,
B
and Operating instructions in this manual and in
the separate engine owner's pamphlet before
attempting to start the engine or operate the mower.
ELECTRIC START ASSEMBLY STEPS:
IMPORTANT
Your new battery must be activated with eiectroiyte and
fuiiy charged before placing it in service.
The optional electric start system includes a 12-volt
side-vented battery, a key switch ignition system, a
solenoid, a starter motor (attached to the engine), and
the cables and wires that connect the electrical
system. A built-in recharging circuit automatically
recharges the battery during mower operation.
The following steps explain how to activate and
charge the battery, and how to assemble the electric
start system. For your safety, please follow each step
carefully and observe all of the accompanying Safety
Warnings and Cautions.
DANGER — POISON -
A.
■ CAUSES SEVERE BURNS!
• Electrolyte is a sulfuric acid solution.
• Avoid contact with skin, eyes or clothing.
• To prevent accidents and avoid personal injury,
wear protective clothing, rubber gloves, and
shield eyes with safety goggles.
• Neutralize acid spills with baking soda and
water solution. Neutralize empty container with
baking soda and rinse with watei.
ANTIDOTE: External — Flush with water. Eyes
— Flush with water for 15 minutes ana get prompt
medical attention.
ANTIDOTE: Interna! — Drink large quantities of
water or milk. Follow with milk of magnesia, beat
en eggs, or vegetable oil. Call physician immedi-
KEEP OUT OF REACH OF CHILDREN.
DANGER — BATTERIES PRODUCE
B
• Keep sparks, fiame. cigarettes away.
• Ventilate area when charging or using battery
in enclosed space.
• Make sure venting path of battery is alv/ays
open once battery is filled with acid.
EXPLOSIVE GASES!
B. There may be a sealed plastic tube covering the
vent fitting on the positive (-i-) side of the battery. Be
sure to remove and discard this tube before activating
the battery. See Photo 2-16.
C. Piace battery on level surface and remove all filler
caps. Leave caps off during filling and charging
procedures.
POSITIVE
(+)POST
VENT.
Photo 2-16: Add electrolyte to UPPER LEVEL line.
NEGATIVE
(-)POST
UPPER
LEVEL
LINE
WARNING: Remove metal jev,ielry before
working near the battery or any pari of the
n
electrical system. Failure to do so can cause a
short circuit that could result in electrical burns,
an elect'ical shock, or an explosion of battery
D. Carefully fill the cells with battery grade electrolyte
(1.265 Specific Gravity sulfuric acid) until it reaches
the UPPER LEVEL LINE that is marked on the outside
of the battery case. See Photo 2-16. The temperature of
the battery and the electrolyte should be between 60°F
to 80°F for best results. No water or other liquid should
be added to the battery during this initial activation.
E. Allow the battery to stand for 30 minutes. Then
check each cell and, if necessary, add more electro
lyte until it reaches the UPPER LEVEL LINE. DO NOT
overfill with electrolyte as this may cause electrolyte to
flood over during battery charging.
STEP 1: Activate and Charge the Battery
A. The battery is shipped to you “dry”, and it cannot
be used until it has been activated with electrolyte (bat
tery grade sulfuric acid) and given a proper start-up
charge. Activating a battery with electrolyte is danger
ous work (the acid can eat through clothing and burn
skin) and we therefore strongly recommend that you
take the battery to a reliable service station, battery
store, or farm/outdoor power equipment center where
a trained battery technician can complete the job safe
ly. PLEASE DO NOT ATTEMPT TO ACTIVATE THE
BATTERY YOURSELF UNLESS YOU ARE FULLY EX
PERIENCED IN BATTERY SERVICE WORK!
10
DANGER
A
Batteries generate explosive gases Keep sparks
and flames away from battery at all times.
Ventilate area when charging or using battery
in enclosed space.
We recommend that the battery not be left on
charge while unattended (the charging time
need not be continuous).
Carefully follow charging instructions and
Safety Rules provided by the manufacturer of
the charging equipment being used.
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