Spirit Lawn Mower 617E User Manual

111-1102 (B) 11/11/08 9:56 am Page 1.1  
Spirit 41  
CODE  
617E 619E  
(Push)  
(Auto Drive)  
OWNER'S HANDBOOK  
(English Version)  
CODE  
617E  
619E  
FROM SERIAL NO:  
290000001  
290000001  
01.01.09  
HANDBOOK: 111-1102 (B)  
ISSUE  
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111-1102 (B) 11/11/08 9:56 am Page 1.3  
1st Year (12 months)  
1st Year (12 months)  
Owner’s Name:  
We certify that this service has been  
carried out by an Authorised Hayter  
Service Dealer  
Serial Number:  
Date:  
Date:  
Note for dealer: Please retain this voucher for your records.  
2nd Year (24 months)  
2nd Year (24 months)  
Owner’s Name:  
Serial Number:  
We certify that this service has been  
carried out by an Authorised Hayter  
Service Dealer  
Date:  
Date:  
Note for dealer: Please retain this voucher for your records.  
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CONTENTS  
1.2 Main Features/Specifications  
1.5 Contents  
1.20  
Maintenance Schedule  
1.6 Introduction  
1.21 - 1.28 Mower Maintenance  
1.21  
1.22  
1.22  
1.23  
1.23  
1.23  
1.24  
1.24  
1.24  
1.25  
1.25  
1.26  
1.26  
1.27  
- Engine  
- Oil Service  
- Air Cleaner Service  
- Spark Plug Service  
- Keeping Engine Clean  
- Grassbag  
1.7 Warranty  
1.8 - 1.11 Safety Precautions  
1.11 Safety Symbols  
1.11 Control Symbols  
- Deck Housing  
- Securing Nuts and Bolts  
- Clutch Cable Adjustment  
- Lubrication  
- Cutterblade Removal  
- Cutterblade Assembly  
- Cutterblade Sharpening  
- Storage  
1.12 Assembling the Mower  
1.12  
1.12  
1.12  
1.12  
- Delivery Checklist  
- Handlebar  
- Grassbag Assembly  
- Grassbag Attachment  
1.13 Before Starting the Engine  
1.13  
1.13  
1.13  
1.13  
- Prevent Engine Damage  
- Oil Type  
- Check Oil Level  
- Fuel Type  
1.28 - 1.29 Trouble Shooting  
1.31 Declaration of Conformity  
1.32 - 1.34 Parts List  
1.14 - 1.17 Operating The Mower  
1.14  
1.14  
1.14  
1.15  
1.15  
1.15  
1.15  
1.16  
1.16  
1.16  
1.16  
1.17  
1.17  
1.17  
1.17  
- Controls  
- Starting Step 1  
-
Step 2  
1.32  
1.33  
1.34  
1.35  
1.36  
1.37  
- Parts List - Upper  
- Exploded View - Upper  
- Parts List - Lower  
- Exploded View - Lower  
- Parts List - Lower  
- Exploded View - Lower  
- Forward Travel  
- Reverse Travel  
- Turning  
- Stopping  
- Slopes  
- Height of Cut  
- Before Mowing  
- Grassbag  
- Without Grass Collection  
- Heavy Growth  
- Friction Disc  
- Non-Grassed Areas  
1.38 - 1.39 Notes  
1.40 Customer Info  
1.18 - 1.19  
1.19  
- Lawn Care Calendar - Guide Only  
- Lawn Stripes  
1.5  
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INTRODUCTION  
Thank you for purchasing a Hayter mower. The following pages are designed to help you gain  
safe and efficient service from your machine.  
IMPORTANT: This ‘Owners Handbook’ should be regarded as part of the mower as it gives  
essential information regarding mower safety, operation, maintenance and specifications. Read  
and understand this handbook prior to operating your mower for the first time. Make sure you  
are familiar with all the controls and points of regular maintenance. If you have any doubts, con-  
sult your local Hayter authorised dealer who will be pleased to give you assistance.  
IMPORTANT: This mower is designed solely for use in a domestic grass cutting  
environment. Use in any other way is considered as contrary to the intended use. Compliance  
with and strict adherence to the conditions of operation, service and repair as specified in this  
handbook also constitute essential elements of the intended use.  
This mower should be operated, serviced and repaired only by persons who are familiar with  
its particular characteristics and who are acquainted with the relevant safety procedures.  
The safety precautions listed in this handbook and all other generally recognised regulations on  
safety must be observed at all times.  
Any arbitrary modifications carried out to this machine may relieve Hayter Limited of  
liability for any resulting damage or injury.  
Hayter mowers are robustly constructed and designed for efficient economical  
performance under normal mowing conditions. Correct operation and maintenance will ensure  
a long and satisfactory service life. Prior to despatch from our factory every effort is made to  
ensure that your mower is delivered in perfect condition.  
Throughout this handbook all references to left and right are as viewed from behind the han-  
dlebar, in the direction of forward travel.  
This handbook is based on information available at the time of publication.  
HAYTER LIMITED reserve the right to amend product specifications without prior notification.  
1.6  
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WARRANTY  
LIMITED WARRANTY  
Hayter Limited warrants to the original user/purchaser that this unit shall be free from defects  
in material and workmanship under normal use and service for a period of three years from the  
date of purchase. The manufacturer of major proprietry components ie. engines, gearbox /  
transaxle (where applicable) furnish their own warranty and services are provided through their  
authorised network. To qualify for the full benefit of the warranty, the warranty registration card  
must be returned within 14 days of purchase. Subject to the conditions and exclusions noted in  
this limited warranty, we shall at our option, repair or replace any warranted part during the  
applicable period. If you are in doubt or experience any difficulty, please consult a Hayter  
Authorised Service Dealer for clarification.  
To qualify for the extended warranty (second and third year) of the three year limited warranty  
the machine must have annual services carried out by an Authorised Hayter Service Dealer.  
These chargeable services should be carried out within 12 and 24 months of the date of purchase.  
Excluded from the extended warranty period are those items which are subject to normal wear  
and tear e.g. tyres, wheels, cutterblades, belts, cables, grassbags, brush/bristles, batteries and  
other consumable wearing parts.  
All consumer machines which are fitted with a genuine Hayter friction disc as original  
equipment before use, are covered by a Lifetime Warranty against the engine crankshaft  
bending. Note: friction washers, blade brake clutch (B.B.C) units and other such devices are not  
applicable. Only machines fitted with a genuine Hayter friction disc, which are used in  
accordance with the recommended operating and maintenance procedures, are covered.  
This warranty does not apply to any unit that has been tampered with, altered, misused, abused or  
used for hire, and will become invalid if non genuine Hayter parts are fitted. This warranty does  
not cover minor mechanical adjustments unless they are due to defective material or  
workmanship. Consult the Owner’s Handbook or a Hayter Authorised Service Dealer for  
assistance when making these adjustments.  
A warranty period of 90 days applies to machines used for commercial purposes.  
To make a warranty claim, return the unit to a Hayter authorised dealer along with proof of  
purchase stating the machine serial number and date of purchase. The service receipt(s) or this  
Owners Handbook with the 1st/2nd year service boxes fully completed, must be produced as  
proof of entitlement to the extended warranty period. Subject to the conditions and exclusions in  
this limited warranty, the authorised dealer will, at our option, repair or replace any warranted  
part within the duration of the warranty period.  
This limited warranty gives you specific legal rights and is in addition to any statutory rights to  
which you may be entitled and your statutory rights are not affected by this warranty. If you need  
additional information concerning this written warranty, or assistance in obtaining services,  
please write to : HAYTER LIMITED, Service Department, Spellbrook, Bishop’s Stortford,  
Hertfordshire CM23 4BU  
UK ONLY: Details of your local Hayter authorised dealer are contained in Yellow Pages and  
1.7  
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SAFETY PRECAUTIONS  
Safety Alert Symbol  
This safety alert symbol indicates important safety messages. When  
you see this symbol be alert to the possibility of injury. Carefully read  
the following and inform others.  
Your mower is perfectly safe if used correctly. Failure to observe the  
following precautions may result in serious injury.  
Training  
Before using the mower read the owners handbook carefully. Pay par-  
ticular attention to the safety precautions. Ensure that you are familiar  
with the controls and the proper use of the equipment. Learn how to  
stop the mower quickly in an emergency.  
Never allow children or people unfamiliar with these instructions to  
use the mower.  
Never mow while people, especially children, or pets are nearby.  
Keep in mind that the user is responsible for accidents or hazards  
occurring to other people or their property.  
Preparation  
While mowing, always wear substantial footwear and long trousers.  
Do not operate the equipment when barefoot or wearing sandals.  
Thoroughly inspect the area where the mower is to be used and remove  
all objects which may be thrown by the machine.  
WARNING: Petrol is highly flammable.  
- Store fuel in containers specifically designed for this purpose.  
- Add fuel before starting the engine. Never remove the cap from the  
fuel tank or add petrol while the engine is running or when the engine  
is hot. Allow the engine to cool for at least two minutes before refu-  
elling.  
- Do not attempt to start the engine if petrol is spilled or a smell of  
petrol is present. Move the mower away from the area of spillage  
and avoid creating any source of ignition until petrol vapours have  
dissipated.  
1.8  
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SAFETY PRECAUTIONS  
Preparation  
- Always use fresh fuel. Stale fuel can block the carburettor and cause  
leakage.  
- Replace fuel tank and oil tank caps securely.  
- Replace faulty exhaust.  
A damaged cutterblade or loose fixing bolt are major hazards. Before  
use, always visually inspect the cutting mechanism to ensure that it is  
in good condition. A damaged cutterblade must be replaced immedi-  
ately with a genuine Hayter replacement part  
Operation  
Do not operate the engine in a confined space where exhaust fumes  
(carbon monoxide) can collect. Refuel outdoors only and do not smoke  
while refuelling.  
Always pull the starter cord slowly until resistance is felt. Then pull  
the cord rapidly to avoid kickback and prevent hand or arm injury.  
Mow only in daylight or good artificial light.  
Avoid using the mower on wet grass, where feasible.  
Always be sure of your footing on slopes.  
Walk, never run.  
Mow across the face of slopes, never up and down.  
Exercise extreme caution when changing direction on slopes.  
Do not mow excessively steep slopes of more than 20 degrees.  
Use extreme caution when reversing or pulling the mower towards you.  
Stop the engine before moving the mower across areas other than grass.  
Never operate the mower unless the guards are securely in position and  
in good condition.  
Do not change the engine governor settings or overspeed the engine.  
Disengage the rear roller drive clutch before starting the engine.  
Start the engine carefully, with feet well away from the cutterblade.  
Variable speed control must only be operated whilst the engine is run-  
ning.  
1.9  
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SAFETY PRECAUTIONS  
Operation  
Do not tilt the mower when starting the engine.  
Do not put hands or feet near or under rotating parts.  
Never pick up or carry the mower while the engine is running.  
Never lift the rear deflector while the engine is running.  
Never touch the exhaust/exhaust guard or cooling fins when the engine  
is hot.  
Stop the engine and disconnect the spark plug lead:  
- Before clearing blockages or unclogging the discharge chute.  
- Before cleaning/checking or working on the mower.  
- After striking a foreign object. Inspect the mower for damage and  
ensure necessary repairs are made before re-starting.  
- If the mower starts to vibrate abnormally (check immediately).  
Stop the engine:  
- Whenever you leave the mower.  
- Before refuelling.  
- Reduce throttle control setting during engine shutdown.  
Maintenance & Storage  
Keep all nuts, bolts and screws tight to ensure that the equipment is in  
safe operating condition.  
Frequently check fuel lines and fittings for cracks or leaks and replace  
if necessary.  
Never check for a spark when the spark plug is removed. (Use approved  
tester)  
Inspect the exhaust periodically and replace if worn or leaking.  
Never crank the engine with the spark plug removed.  
Never start the engine with the air-cleaner or air-cleaner cover removed.  
Never store the mower with petrol in the tank within an enclosed area  
where fumes may reach an open flame or spark.  
This machine contains spring loaded assemblies which could cause a  
hazard when dis-assembled and re-assembled, this maintenance should  
only be carried out by a Hayter authorised dealer.  
1.10  
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SAFETY PRECAUTIONS  
Maintenance & Storage  
Allow the engine to cool before storing in any enclosure. To reduce the  
fire hazard, keep the engine and the surrounding deck area free of  
grass, leaves, or excessive grease.  
Check the rear deflector and grassbag frequently for wear or deterioration.  
Replace worn or damaged parts for safety.  
If the fuel tank has to be drained, this should be done outdoors and  
when the engine is cool.  
Wear strong work gloves when removing and reassembling the cut-  
terblade.  
Always replace worn or faulty parts with genuine Hayter parts.  
Safety Symbols  
Danger of being hit by thrown  
objects.  
Safety Alert - Be aware to the  
possibility of injury.  
Danger of severing toes or fin-  
gers in cutting mechanism.  
Carefully read the Owners  
Handbook before using the  
machine.  
Stop engine and remove spark  
plug lead before working on  
the mower.  
Keep bystanders at a safe dis-  
tance from the mower.  
Control Symbols  
Engine Stop  
(Symbol)  
Height of Cut Adjustment  
(Symbol)  
STOP  
305113  
1.11  
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ASSEMBLING THE MOWER  
Delivery Checklist  
Remove the mower from the packaging and check that the following  
items have been supplied correctly. If any items are missing contact,  
your local Hayter dealer.  
1. Grassbag.  
2. Grassbag Frame.  
To prevent accidents cut off the long ribbon attached to the grass-  
bag and discard.  
Handlebar  
Unscrew the handlebar securing knobs sufficiently to allow the handle-  
bar to pivot. Move the engine stop lever away from the engine to avoid  
damage and unfold the handlebar to the operating position. Make sure  
the knobs are assembled to the outside of the handlebar and tighten to  
secure in position.  
Take care to ensure that the control cables do not become snagged at  
the pivot point.  
Grassbag Assembly  
(1) Insert metal frame into grassbag fabric and (2) Clip into position.  
2
1
Grassbag Attachment  
Raise the rear deflector, lower the grassbag through the handlebar and  
hook in position. Lower the deflector to rest on the grassbag.  
1.12  
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STARTING THE MOWER  
BEFORE  
Prevent Engine Damage  
To prevent engine damage the engine is shipped without oil or  
petrol. The engine must be filled with the correct grade of oil and  
petrol before starting the engine.  
Oil Type  
Always use high quality detergent oil classified SAE 30 oil. Never use  
additives with recommended oil.  
To prolong the life of your engine it is important that the oil is changed  
after the first 5 hours of use - refer to ‘Maintenance Schedule’.  
Check Oil Level  
0.15  
Clean around the oil filler cap before removing. With the mower on a  
Litres  
level surface, unscrew and remove the oil filler - dipstick. Wipe oil  
from it with a clean cloth. Screw the oil filler - dipstick back in place,  
then unscrew and remove it to check the oil level.  
The oil level is correct when it is at the full mark on the dipstick.  
DO NOT OVERFILL.  
V15C  
Fuel Type  
Always use clean, fresh unleaded petrol. Purchase fuel in quantities  
that can be used within 30 days. Never mix oil with petrol. For added  
engine protection Briggs & Stratton recommend the use of their fuel  
additive which is available from an authorised Briggs & Stratton ser-  
vice dealer.  
Fill to base of neck to allow for fuel expansion. Do not overfill the  
fuel tank.  
1.13  
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OPERATING THE MOWER  
Controls  
Operate all control levers several times and ensure that the cables  
move freely. Check that the engine stop and ground drive clutch levers  
return freely to their rest position when released.  
Starting - Step 1  
Operate the primer bulb: Note: Push on the primer bulb 5 times at  
two second intervals to provide the extra fuel to start the engine after  
assembling the mower for the first time.  
In normal use push on the primer bulb 3 times at 2 second intervals to  
provide the extra fuel required to start a cold engine. Operation of the  
primer bulb is usually unnecessary when starting a warm engine.  
Step 2  
Stand behind the mower and hold the handlebar together with the  
engine stop lever with your left hand. With your right hand hold the  
engine start - grip and pull slowly until resistance is felt, then pull  
rapidly to crank the engine. Carefully return the start grip to the stor-  
age position when the engine starts.  
If the engine does not start after 5 attempts - refer to “Trouble  
Shooting”.  
The engine stop lever must be held firmly against the handlebar to  
start and keep the engine running. If the engine stop lever is  
released the engine will stop.  
To prevent damage never pull the engine start grip when the  
engine is running.  
1.14  
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OPERATING THE MOWER  
Forward Travel  
(617E Only) - Hold and push against the handlebar with both hands to  
move the mower forwards.  
(619E Only) - Hold the handlebar and operate the ground drive clutch  
lever to power the mower in a forward direction.  
When the ground drive clutch lever is disengaged the mower may be  
pushed. This feature is useful when mowing in confined areas.  
IMPORTANT To avoid damage this control should only be opert-  
ed whilst the engine is running. If the engine stop lever is released  
the engine will stop.  
Reverse Travel  
Hold and pull against the handlebar with both hands to reverse the  
mower.  
Turning  
To make a wide turn steer the mower with the handlebar in the direc-  
tion required.  
To make a tight turn release the ground drive clutch lever, apply down-  
ward pressure on the handlebar to raise the front wheels just above  
ground level and steer in the required direction.  
To prevent accidents do not raise the front of the mower exces-  
sively when making a turn. Never raise the rear of the mower  
when the engine is running.  
Stopping  
(617E Only) - Release the engine stop lever.  
(619E Only) - Release the ground drive clutch lever followed by the  
engine stop lever.  
Emergency stop: Release both ground drive clutch lever and engine  
stop lever together.  
STOP  
If the engine fails to stop, disconnect the spark plug lead.  
1.15  
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OPERATING THE MOWER  
Slopes  
To prevent engine damage do not use the mower on slopes greater  
than 20 degrees.  
Height of Cut  
Move the height of cut lever sideways to disengage it from the locking  
notch, then push forwards to lower or pull backwards to raise the height  
of cut. Release the lever in the required position and ensure that it locks  
firmly into one of the seven notch settings.  
Always select a height of cut to suit operating conditions. Prevent  
engine overloading and blockages by avoiding low cuts in long grass  
conditions. Be prepared to make two cuts when the grass is long.  
305113  
Before Mowing  
To prevent accidents thoroughly inspect the area and remove all  
objects which when contacted by the mower cutterblade could  
become dangerous projectiles. Inspect the area for hidden obstruc-  
tions which when contacted by the cutterblade could risk health  
and safety or result in damage to the mower damage. Remember  
the location of these obstructions and ensure that you mow around  
them.  
Grassbag  
Raise the rear deflector and lift the grassbag through the handlebar and  
lower the rear deflector to rest against the rear of the mower.  
To empty the grassbag, pour out the grass clippings and shake the  
grassbag vigorously to clean the airways. Good grass collection  
depends on good air flow through the grassbag. When collecting grass  
clippings it is important that the grassbag is emptied regularly to pre-  
vent blockages and engine overloading.  
1.16  
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OPERATING THE MOWER  
Without Grass Collection  
Remove the grassbag and operate the mower with the rear deflector in  
the closed position.  
Heavy Growth  
Areas of heavy growth should be mown without collecting the clip-  
pings. If collection is required, first mow the area without the grassbag  
at the maximum height of cut setting. Allow the grass clippings to dry  
out and then mow the area at the maximum height of cut setting with  
the grassbag fitted. Reduce the height of cut and mow the area again  
as necessary until the required finish is obtained.  
30513  
To prevent grass damage do not remove more than one third of grass  
height in one cut.  
Friction Disc  
The cutterblade is driven by the engine via a friction disc to help pre-  
vent damage occurring to the engine crankshaft and cutting mecha-  
nism when a hidden obstruction or overload is encountered.  
Always stop the engine when a hidden obstruction or excessive vibra-  
tion is encountered. Disconnect the spark plug lead and examine the  
cutting mechanism. ALWAYS replace a damaged cutterblade - refer to  
“Maintenance”.  
Non-Grassed Areas  
When moving the mower across non-grassed areas, stop the engine  
and set the mower to the maximum height of cut to protect the cutting  
mechanism.  
STOP  
1.17  
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LAWN CARE CALENDAR  
To be used as a guide only.  
January  
There is very little work to do this month apart from brushing away  
leaves. Keep off the grass if frozen or waterlogged.  
February  
Rake the grass thoroughly. Spike the lawn to aerate and stimulate soil  
organisms and root growth and apply lawn sand if necessary.  
March  
The yearly lawn work programme really starts this month. As soon as  
the ground conditions are suitable, the first cut can be made. The first  
cut should merely “top” the grass as close cutting at this stage could  
result in severe yellowing or browning. Two cuts are generally suffi-  
cient this month.  
April  
Mow often enough to stop grass growing away. Dig out patches of  
coarse grass or resistant weed. Re-seed bare patches.  
May  
Keep mowing increasing the frequency as required. Treat with selec-  
tive weed killers or combined weed/feed preparations if you did not  
feed the lawn in April.  
June  
Summer mowing should now be under way. It should be necessary to  
mow the lawn twice a week. Raking before mowing is important this  
month as the combined action keeps runners of clover under control.  
Water the grass if necessary, and remember to soak thoroughly.  
July  
Treat the grass with the second application of fertiliser or weed  
killer/fertiliser. Water when necessary and rake occasionally. As a gen-  
eral rule the grass clippings should be removed each time you mow. If  
weather conditions are dry and hot and the grass is weed free, leave the  
clippings on the lawn to help maintain ground moisture.  
1.18  
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LAWN CARE CALENDAR  
August  
Keep mowing regularly and watering as necessary. Fill any cracks  
caused by drought with a mixture of sharp sand and soil. In dry weath-  
er conditions leave the grass longer to help retain ground moisture.  
September  
Raise the height of cut to allow the grass to thicken and protect the  
roots from the winter frost and snow.  
October  
Rake out the thatch from the turf and spike the lawn to assist in  
drainage. Brush in peat and sharp sand.  
November  
Use a stiff broom to disperse worm casts before mowing. Keep turf  
free from leaves.  
December  
Apart from brushing away leaves, December is a slack end of a busy  
year. Keep off the lawn if it is very wet or frozen.  
Lawn Stripes  
1
The way to achieve a neat striped effect is for the lawn being cut in  
parallel stripes, alternate stripes being mown in opposite directions. A  
much more important routine is to cut at right angles to the line of the  
previous mowing. If the work has been carried in a north-south line,  
then the next cutting should be in an east-west direction. The cross-cut-  
ting keeps down the coarse weed grasses.  
2
1CG480V05A  
To prevent grass damage do not remove more than one third of the  
grass height in one cut.  
1.19  
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MAINTENANCE SCHEDULE  
To prevent accidents stop the engine and disconnect the spark plug  
lead before attempting to carry out maintenance procedures on the  
mower.  
After the very first hour check clutch adjustment. See page 1.24.  
After the very first five hours change the engine oil.  
Follow the hourly or calendar intervals, whichever occurs first. More  
frequent service will be required if working for prolonged periods  
under dusty, dry conditions, or when airborne debris is present or after  
extensive operation cutting tall, dry grass.  
Daily  
Check the oil level  
Remove grass debris from around the engine, exhaust/exhaust guard and  
air ways in the top cowl and underside of the deck housing.  
Remove grass debris from the grassbag and check for signs of damage.  
Check the condition of guards and safety devices and cutterblades.  
25Hrs or Every Season  
Change the engine oil if continuously operating under heavy load or  
high ambient temperature.  
Service the air cleaner.  
Lubricate wheels, pivot points and linkages and grease the inner con-  
trol cables at point of entry and exit from their outer casing.  
Check the clutch cable adjustment.  
Sharpen the cutterblade.  
50Hrs or Every Season  
Change the engine oil.  
1.20  
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111-1102 (B) 11/11/08 9:56 am Page 1.21  
MOWER MAINTENANCE  
100Hrs or Every Season  
Clean the engine cooling system. Clean more often under dusty  
conditions or when airborne debris is present or after prolonged  
operation whilst cutting tall, dry grass.  
Replace the spark plug.  
Engine  
1. Air Filter  
2. Primer Bulb  
3. Fuel Cap  
4. Start Grip  
5. Oil Cap/ Dipstick  
6. Exhaust Guard  
7. Spark Plug / Lead  
1.21  
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111-1102 (B) 11/11/08 9:56 am Page 1.22  
MAINTENANCE  
MOWER  
Oil Service  
Check the oil level daily before starting the engine and ensure that the  
correct oil level is maintained. Refer to-‘Before Starting the Mower’  
for oil checking and filling instructions.  
Change the engine oil after the first 5 hours of operation and thereafter  
according to the ‘Maintenance Schedule’:-  
1. Drain fuel by running the engine until the fuel tank is empty.  
2. Remove the spark plug lead.  
3. Allow the engine to cool.  
4. Drain the oil while the engine is warm.(Not hot)  
5. Tip the mower over on to its left hand side thus ensuring that  
the air cleaner is kept uppermost to prevent engine damage.  
6. Remove the oil filler dipstick and drain the oil into a suitable  
container.  
7. Refill with new oil of the recommended SAE viscosity grade.  
(Refer to-‘Before Starting the Mower’)  
Air Cleaner Service  
To service the air cleaner, remove screw (1) and remove cover (2).  
Carefully remove foam element (3) and wash in a solution of liquid  
detergent and water. Allow to air dry thoroughly before fitting or wrap  
in a cloth and squeeze dry. If very dirty, replace.  
Saturate with clean engine oil and squeeze out excess.  
After servicing, re-assemble the air cleaner and fasten securely.  
1.22  
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111-1102 (B) 11/11/08 9:56 am Page 1.23  
MOWER MAINTENANCE  
Spark Plug Service  
Use only Briggs & Stratton spark tester (1) to check for a spark as  
shown in the diagram.  
Replace the spark plug every 100 hours or every season, whichever  
occurs first. A spark plug wrench is available from any authorised  
Briggs & Stratton service dealer.  
1
Check the spark plug gap with a feeler gauge and set at 0.76mm.  
Keeping Engine Clean  
Remove all grass and debris from the engine including the  
exhaust/exhaust guard, the air ways in the top cowl and the surround-  
ing deck areas on a daily basis after use. Never spray the engine with  
water during cleaning. Water can contaminate the fuel. Always clean  
with a brush or compressed air.  
Grass and debris may clog the engine’s air cooling system especially  
after prolonged operation while cutting tall, dry grass. The internal cool-  
ing fins and surfaces may require cleaning to prevent overheating and  
engine damage. We recommended that this service be carried out by an  
authorised Briggs and Stratton dealer.  
Grassbag  
Remove grass debris from the grassbag immediately after use and  
check its condition for signs of damage.  
To prevent accidents replace a damaged grassbag immediately.  
1.23  
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111-1102 (B) 11/11/08 9:56 am Page 1.24  
MAINTENANCE  
MOWER  
Deck Housing  
Remove grass debris from the top and underside of the deck housing  
immediately after use.  
Fertilisers and top dressings are particularly corrosive.  
Thoroughly clean the mower deck immediately after use on treat-  
ed grass and store well away from corrosive materials.  
Securing Nuts & Bolts  
Regularly check that all securing nuts and bolts are tight. Replace  
missing or damaged items immediately.  
1CG480V36B  
Clutch Cable Adjustment  
(619E Only)  
55-70mm  
Check the clutch cable operation after the first hour and then every 25  
operating hours and adjust if necessary. The clutch cable is adjusted  
correctly when the drive engages with the clutch lever positioned 55-  
70mm from the handlebar.  
Set the adjuster (1) as necessary.  
1.24  
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111-1102 (B) 11/11/08 9:56 am Page 1.25  
MOWER MAINTENANCE  
Lubrication  
Lubricate the wheels, pivot points and linkages with engine oil every 25  
operating hours.  
Apply a good quality medium grease to the inner control cables at the  
point of entry and exit from their outer casing.  
Cutterblade Removal  
Drain the fuel by running the engine until the fuel tank is empty and the  
engine stops. Remove the spark plug lead and allow the engine to  
cool. Turn the mower on its left hand side and ensure that the air clean-  
er side of the engine is uppermost.  
Firmly grip the end of the cutterblade with the gloved hand and remove  
the bolt, spring washer and distance piece securing the cutterblade with  
a 9/16” A/F spanner.  
33C  
To prevent accidents never work on the cutterblade unless the  
spark plug lead has been removed. The cutterblade has sharp  
edges. ALWAYS wear strong gloves to protect your hands when  
working on the cutterblade. DO NOT rotate tools towards the cut-  
ting edges to avoid the risk of injury should the tool slip. ALWAYS  
use genuine Hayter replacement parts.  
The condition of the cutterblade and its mounting arrangement should  
be checked regularly for signs of wear or damage. Ensure that the cut-  
terblade is not bent or cracked.  
A damaged cutterblade that is out of balance will vibrate excessively  
and may break. DO NOT use an unbalanced cutterblade.  
Regularly check that the bolt securing the cutterblade is tightened to the  
specified torque of 54Nm.  
Replace the cutterblade every 2 years of sooner if excessively worn or  
damaged.  
To prevent injury it is wise to seek assistance when turning the mower  
on its side.  
1.25  
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111-1102 (B) 11/11/08 9:56 am Page 1.26  
MAINTENANCE  
MOWER  
Cutterblade Assembly  
Assemble the cutterblade with the turned up edges facing towards the  
engine. Secure the cutterblade using the bolt (1), spring washer (2), and  
distance piece (3) and tighten to a torque of 54Nm.  
1
3
2
Cutterblade Sharpening  
A slightly worn cutterblade may be re-sharpened. Both blade edges  
must be sharpened equally to ensure balance. Sharpen the cutterblade  
every 25 mowing hours or more frequently if conditions require.  
Remove the cutterblade from the mower and clean using a brush and  
water. Inspect the cutterblade for signs of damage.  
Sharpen both cutting edges with a flat file to restore performance.  
Ensure that the cutterblade is balanced. Use a screw driver with a  
round shaft to support the cutterblade through its centre hole. Hold the  
cutterblade horizontal and then release. A balanced cutterblade will  
remain horizontal.  
If the cutterblade is not balanced the heavy end will rotate downwards.  
Sharpen the heavy end until the cutterblade is correctly balanced.  
1.26  
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111-1102 (B) 11/11/08 9:56 am Page 1.27  
MOWER MAINTENANCE  
Storage  
To store the handlebar unscrew the 2 securing knobs sufficiently to  
allow it to be pivoted forwards to rest against the mower. Take care to  
ensure that the control cables do not become snagged at the pivot point  
and depress the engine stop lever to prevent it being damaged through  
contact with the engine spark plug.  
Engines stored in excess of 30 days need to be protected with Briggs &  
Stratton fuel additive or drained of fuel to prevent gum from forming in  
the fuel system or on essential carburettor parts. To ensure your mower  
is maintained in good working order it is important that the following  
procedure is adopted. Refer to the Maintenance section as necessary.  
Drain fuel from the engine by operating the engine until it stops.  
Disconnect the spark plug lead.  
Change the engine oil.  
Remove the engine spark plug and pour 15ml of engine oil into the  
engine cylinder and replace the spark plug. Do not exceed the stated  
volume of oil as engine damage may occur on re-starting. Do not  
replace the spark plug lead. Slowly pull the engine start - grip once  
to crank the engine. This will distribute the oil and help prevent engine  
corrosion.  
Clean grass and debris from the engine cylinder, cylinder head cooling  
fins, under top cowl, and around and behind exhaust/exhaust guard.  
Clean all other areas of the mower and ensure that the grassbag is clean.  
Lubricate the mower.  
Treat metal parts with a water repellent anti-corrosion product.  
Cover the mower with a protective sheet and store it in a dry, ventilat-  
ed area.  
1.27  
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111-1102 (B) 11/11/08 9:56 am Page 1.28  
TROUBLE SHOOTING  
PROBLEM  
POSSIBLE FAULT  
Engine stop lever released.  
Incorrect oil level.  
REMEDY  
Engine will not turn over  
Operate engine stop lever.  
Check oil level.  
Obstruction under deck.  
Remove obstruction.  
Engine smokes  
Excess oil level.  
Check oil level.  
Air cleaner cartridge oil  
soaked or blocked.  
Service air cleaner.  
Engine runs then stops  
Engine will not start  
Fuel starvation.  
Fill fuel tank.  
Fuel cap vent blocked.  
Clean fuel cap vent.  
Engine under load.  
Fuel starvation.  
Raise height of cut.  
Fill fuel tank.  
Engine cold.  
Set throttle to ‘choke’ position.  
Incorrect/contaminated fuel.  
Drain fuel tank and fill with  
correct fuel.  
Spark plug lead disconnected.  
Engine brake not released.  
Faulty spark plug.  
Connect spark plug lead.  
Operate engine brake lever.  
Clean and adjust gap or replace.  
Engine runs rough  
Spark plug lead becoming  
disconnected in use.  
Connect spark plug lead.  
Faulty spark plug.  
Clean and adjust gap or replace.  
Service air cleaner.  
Air cleaner blocked.  
Incorrect/contaminated fuel.  
Drain tank and fill with correct fuel.  
1.28  
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111-1102 (B) 11/11/08 9:56 am Page 1.29  
TROUBLE SHOOTING  
PROBLEM  
POSSIBLE FAULT  
Mounting bolts loose.  
Cutterblade bolt loose.  
Cutterblade out of balance.  
Bent crankshaft.  
REMEDY  
Engine vibrates excessively  
Tighten bolts  
Tighten bolt  
Balance cutterblade  
Consult your dealer  
Uneven cut  
Undulating ground conditions  
Cutterblade worn  
Change direction of travel  
Sharpen the cutterblade  
Cutterblade out of balance  
Wheels / roller damaged  
Balance the cutterblade  
Inspect and replace as necessary  
Discharge chute blocks  
Grass is wet  
Mow dry grass  
Cut height too low  
Grassbag full  
Increase cut height  
Empty grassbag  
Clean the grassbag  
Airflow through the  
grassbag is restricted  
Engine speed too slow  
Set throttle to fast position  
Mower is hard to push  
Cut height too low  
Increase cut height  
Wheels / roller damaged  
Inspect and replace as necessary  
Mower will not self propel  
(Autodrive Only)  
Clutch out of adjustment  
Drive belt damaged  
Adjust clutch cable  
Replace drive belt  
Poor grass collection  
Airflow through the  
grassbag is restricted  
Clean the grassbag  
Discharge chute blocked  
Wet grass  
Remove blockage  
Mow dry grass  
Grassbag full  
Empty grassbag  
Engine speed too slow  
Set throttle to fast position  
1.29  
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111-1102 (B) 11/11/08 9:56 am Page 1.30  
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111-1102 (B) 11/11/08 9:56 am Page 1.31  
DECLARATION OF CONFORMITY  
EC DECLARATION OF CONFORMITY  
Manufactured for: HAYTER LIMITED,  
Address:  
Spellbrook, Bishop’s Stortford, Herts. CM23 4BU. ENGLAND  
declare that the lawnmower:  
Model name:  
Spirit 41  
Spirit 41  
Push  
Autodrive  
Type:  
Model No:  
Cutting width:  
Pedestrian Rotary  
CODE 617E  
41 cm  
Pedestrian Rotary  
CODE 619E  
41 cm  
Speed of rotation of the cutting device:  
Engine manufacturer:  
Speed of rotation of engine:  
2850 rpm  
Briggs and Stratton  
2850 rpm  
2850 rpm  
Briggs and Stratton  
2850 rpm  
Complies with the provisions of Directive: 98/37/EC Essential Health & Safety Requirements Relating to the Design &  
Construction of Machinery and Safety Components, as amended and the regulations transposed into national law.  
Also Directive 89/336/EEC Electromagnetic Compatibility, as amended and the regulations transposed into national law.  
Also Directive 2000/14/EC Noise emission in the environment by equipment for use outdoors and the regulations transposed into  
national law.  
Procedure applied for the conformity assessment: ANNEX VI, procedure 1.  
Notified Body: TÜV Industrie Service GMBH – TÜV SÜD Group, Westendstraße 199, 80686 MÜNCHEN. Germany  
Notified body identification No: 0036  
Measured sound power level:  
Guaranteed sound power level:  
96 dB(A)  
96 dB(A)  
96 dB(A)  
96 dB(A)  
Complies with harmonized standards: EN 292, EN 836 and EN ISO 14982  
Signed  
Date: January 2006  
Declaration done and technical documentation kept at:  
HAYTER LIMITED  
Spellbrook, Bishop’s Stortford,  
Herts. CM23 4BU ENGLAND  
S.A Maryniak  
(Technical Director)  
VIBRATION INFORMATION  
The vibration level at the operator contact positions, measured in accordance with European Standard EN 836  
CODE 617E – 12.9ms-2 CODE 619E - 12.9ms-2  
1.31  
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111-1102 (B) 11/11/08 9:56 am Page 1.32  
UPPER MAINFRAME PARTS LIST  
617  
Qty  
619  
Qty  
Item No. Description  
Part No.  
Item Note  
1
2
3
4
5
6
7
8
KNOB M8 HANDLEBAR  
SCREW M4*16  
CABLE CLUTCH  
BOLT HANDLEBAR  
ENGINE LEVER  
GUIDE ROPE  
LEVER CLUTCH  
PIN PIVOT  
PLUG HANDLEBAR  
SPRING DEFLECTOR  
WASHER NYLON 19*11*1.6  
CABLE ENGINE BRAKE  
NUT M6 NYLOC ' T ' TYPE  
UPPER DECK MOULDING UPPER  
MOULDING REAR DEFLECTION  
PLATE HOC  
GRASS BAG  
GRASS BAG FRAME  
GUIDE CABLE  
HANDLEBARS LOWER  
BAR HINGE  
DECAL SAFETY  
480088  
2
3
0
2
1
1
0
2
2
1
2
1
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
2
3
2
1
3
2
2
3
1
2
1
1
1
2
2
1
2
1
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
2
3
2
1
3
2
111-0094  
111-0095  
HY226024  
111-0102  
305093  
306094W  
340182  
300160  
410030  
09688  
111-0096  
09438  
111-1054  
111-1043  
111-0040  
111-0042  
111-0045  
410037  
111-0051  
111-0056  
111-0083  
ZBH1F040U  
111-0079  
111-0098  
111-0089  
410087  
-----------  
111-0082  
111-2644  
09575  
09687  
320006  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
BOLT M6*40  
HANDLEBARS  
P CLIP  
MOULDING TRIM  
DECAL HAYTER ROYAL WARRANT  
DECAL SERIAL NUMBER  
DECAL ENGINE  
ENGINE  
TAPTITE M6*20 SCREW  
SCREW 6*20 PT PAN FLANGE  
DECAL HEIGHT OF CUT  
SCREW M6*35 SCO  
SCREW TAPITE 9.3*30.8  
NUT M6 NYLON INSERT T TYPE  
WASHER M6 PLAIN  
SCREW PT M4*25  
HANDBAR PLUGS  
111-0118  
111-0805  
09544  
09472  
111-0100  
111-0960  
1.32  
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111-1102 (B) 11/11/08 9:56 am Page 1.33  
UPPER MAINFRAME PARTS LIST  
8
5
11  
7
11  
32  
23  
8
24  
36  
6
3
12  
19  
37  
36  
1
19  
9
20  
4
29  
1
30  
18  
20  
15  
31  
21  
22  
39  
31  
10  
28  
2
25  
26  
14  
27  
17  
16  
34  
33  
13  
38  
35  
1.33  
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111-1102 (B) 11/11/08 9:56 am Page 1.34  
LOWER MAINFRAME PARTS LIST  
617  
Qty  
619  
Qty  
Item No. Description  
Part No.  
Item Note  
1
2
3
4
5
6
7
8
HOUSING GEARBOX BEARING RH  
410047  
410078  
219102  
410069  
0
1
2
2
0
0
1
0
1
1
1
0
0
1
1
1
1
1
1
0
1
1
1
1
1
1
2
2
1
1
1
0
0
0
1
15  
1
10  
2
0
2
4
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
2
15  
1
13  
2
1
2
4
1
1
1
CARRIER BLADE BOSS-DIE CAST  
HOUSING BEARING ROLLER  
BEARING FRONT AXLE  
VARIATOR  
CHAIN 40 PITCHES 3/8" INC LINK  
FRICTION DISC  
GEARBOX  
HOUSING PIVOT BEARING RR AXLE  
PLATE SECURING  
SPRING COUNTER BALANCE  
SPROCKET 10T*3/8"  
SPROCKET 18T*3/8"  
AXLE FRONT WA  
CAST CHASSIS  
MOULDING FIN  
411001  
111-0077  
410057W  
111-0804  
410048  
219037  
410050  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
111-0123  
111-0122  
111-0027  
111-0031  
111-0034  
111-0037  
111-0038  
111-0039  
411020  
111-0050  
111-0093  
111-0055  
111-0057  
111-0058  
111-0063  
111-2021  
111-0066  
111-0073  
1662  
09438  
411021  
411025  
411024  
09441  
111-0100  
09565  
09365  
09575  
MOULDING SNAIL DECK  
MOULDING SNAIL DECK ACCESS  
MOULDING THROW PLATE  
CLUTCH LEVER  
MOUNT BEARING  
CUTTER BAR  
HOC KNOB RIGHT  
COVER ROLLER L.H.  
COVER ROLLER R.H.  
ROD CONNECTING  
WHEEL  
WHEEL CENTRE CAP  
PLATE SPRING MOUNT  
KEY WOODRUFF  
NUT M6 NYLOC  
SPRING  
BELT VARIATOR  
BELT VARIATOR  
NUT M8 NYL INSERT T TYPE  
SCREW PT M4*25  
BOLT M8*55 HEX  
TAPTITE M6*16 SCREW  
TAPTITE M6*20 SCREW  
TAPTITE M8*25 SCREW  
SCREW M4  
SCREW TAPTITE M6*16 C/SK POSI  
WASHER PLAIN  
09787  
HY100078  
09545  
09262  
111-0028  
111-0078  
ROLLER FRAME WA  
SPRING TORSION HOC GALVANISED  
1.34  
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111-1102 (B) 11/11/08 9:56 am Page 1.35  
LOWER MAINFRAME PARTS LIST  
35  
57  
38  
15  
40  
33  
5
*
17  
*
34  
*
*
50  
49  
19  
33  
36  
*
39  
21  
*
36  
23  
46  
41  
63  
61  
31  
32  
36  
36  
1
20  
38  
38  
25  
42  
45  
38  
64  
3
60  
30  
8
37  
34  
2
10  
62  
44  
42  
64  
38  
35  
31  
52  
11  
43  
38  
51  
58  
9
38  
28  
29  
53  
3
27  
18  
12  
60  
13  
26  
6
24  
38  
4
59  
14  
36  
60  
48  
*
*
7
16  
62  
47  
22  
28  
53  
27  
36  
55  
56  
54  
36  
36  
1.35  
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111-1102 (B) 11/11/08 9:56 am Page 1.36  
LOWER MAINFRAME PARTS LIST  
617  
Qty  
619  
Qty  
Item No. Description  
Part No.  
Item Note  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
HOC LEVER  
REAR AXLE ROLLER  
ROLLER  
PULLEY  
PIN  
PIN SELLOC SPRING 5*25  
PIN ROLL DIA 5*20  
NUT M12 THIN  
BOLT UNF 3/8 X 3 1/4 HEX HD  
DISTANCE PIECE  
WASHER SPRING  
LEVER CLUTCH  
WASHER M8 SHAKEPROOF  
KEY  
111-0059  
111-0067  
410044  
411019  
411023  
111-0120  
111-0121  
111-0119  
09788  
HY4014  
09273  
111-0104  
09476  
411037  
09491  
111-0105  
0201086  
111-0116  
411027  
1
1
1
0
0
0
0
2
1
1
1
0
0
1
6
1
2
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
6
1
2
2
2
WASHER  
HOC KNOB LEFT  
WASHER STARLOCK  
SCREW M6*25 TAPTITE  
Bearing 6001-2RS  
1.36  
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111-1102 (B) 11/11/08 9:56 am Page 1.37  
LOWER MAINFRAME PARTS LIST  
35  
57  
38  
15  
40  
33  
5
*
17  
*
34  
*
*
50  
49  
19  
33  
36  
*
39  
21  
*
36  
23  
46  
41  
63  
61  
31  
32  
36  
36  
1
20  
38  
38  
25  
42  
45  
38  
64  
3
60  
30  
8
37  
34  
2
10  
62  
44  
42  
64  
38  
35  
31  
52  
11  
43  
38  
51  
58  
9
38  
28  
29  
53  
3
27  
18  
12  
60  
13  
26  
6
24  
38  
4
59  
14  
36  
60  
48  
*
*
7
16  
62  
47  
22  
28  
53  
27  
36  
55  
56  
54  
36  
36  
1.37  
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111-1102 (B) 11/11/08 9:56 am Page 1.38  
NOTES  
1.38  
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111-1102 (B) 11/11/08 9:56 am Page 1.39  
NOTES  
1.39  
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111-1102 (B) 11/11/08 9:56 am Page 1.40  
CUSTOMER INFORMATION  
Serial No:  
Engine:-Briggs & Stratton Sprint XQ40  
Date of Sale:-  
Your Local Dealer:-  
1.40  
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