Hayter Mowers Lawn Mower 401R User Manual

CLIPPER  
46  
CODE 401R  
AUTO-DRIVE  
OWNERS HANDBOOK  
(English Version)  
FROM SERIAL NO: 401R001001  
Issue: 25/02/99  
HANDBOOK: 401001 (Rev.2.)  
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CONTENTS  
1.2  
1.2  
CONTENTS  
Page No.  
1.4  
INTRODUCTION  
WARRANTY  
1.5  
Limited Warranty  
1.5  
SAFETY PRECAUTIONS  
Safety Precautions  
Decals  
1.6 - 1.10  
1.6 - 1.9  
1.10  
SPECIFICATIONS  
1.11  
ASSEMBLY INSTRUCTIONS  
General Assembly  
1.12 - 1.14  
1.12  
Assembling the Mower for the First Time  
1.13- 1.14  
STARTING THE ENGINE  
Before Starting the Engine  
To Start the Engine  
1.15 - 1.17  
1.15 - 1.16  
1.17  
STOPPING THE ENGINE  
1.18  
OPERATING THE MOWER  
Height of Cut  
1.18 - 1.23  
1.19  
Travel  
1.20  
Turning the Mower  
1.20  
Moving the Mower across Non-Grassed Areas  
Cutterbar Operation  
1.21  
1.22  
Mowing and Grass Care Tips  
1.22 - 1.23  
MAINTENANCE  
Engine  
1.24 - 1.32  
1.24  
Carburettor Adjustments  
Oil Service  
1.25  
1.25  
Air Cleaner Service  
Spark Plug Service  
Keeping the Engine Clean  
Deck Housing  
1.26  
1.26  
1.27  
1.28  
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CONTENTS  
1.3  
1.3  
CONTENTS  
Page No.  
MAINTENANCE Continued.  
Securing Nuts and Bolts  
Lubrication  
1.28  
1.28  
Clutch Cable Adjustment  
Cutterbar  
Maintenance Schedule  
- After First 5 Hours  
1.29  
1.30 - 1.31  
1.32 - 1.33  
1.32  
- Every 5 Hours or Daily  
- Every 25 Hours or Every Season  
- Every 50 Hours or Every Season  
- Every 100 Hours or Every Season  
1.32  
1.32  
1.33  
1.33  
PREPARING THE MOWER FOR STORAGE  
FAULT FINDING  
1.34  
1.35 - 1.37  
2.1 - 2.2  
2.3  
401R CHASSIS PARTS LIST  
401R PARTS DIAGRAM  
401R TRANSMISSION PARTS LIST  
401R TRANSMISSION PARTS DIAGRAM  
ENGINE ANCILLARY PARTS  
ENGINE WARRANTY  
2.4  
2.5  
2.6  
2.7  
NOTES  
2.8  
CUSTOMER INFORMATION  
2.9  
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INTRODUCTION  
1.4  
1.4  
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 machine as it  
gives essential information regarding machine safety, operation, maintenance and  
specifications. Read and understand this handbook prior to operating your machine for the  
first time. Make sure you are familiar with all the controls and points of regular maintenance.  
If you have any doubts, consult your Hayter authorised dealer who will be pleased to give  
you assistance.  
IMPORTANT: This machine 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 machine should be operated, serviced and repaired only be persons who are familiar with  
its particular characteristics and who are acquainted with the relevant safety procedures.  
The safety precautions listed here in 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.  
All 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 your machine arrives in perfect condition. Your dealer will carry out a  
pre-delivery inspection to ensure that there has been no transit damage prior to installation.  
Please allow your dealer to familiarise you with the controls and safety features of the  
machine during installation.  
Throughout this handbook all references to left hand and right hand are as viewed from  
behind the handlebar, facing in the direction of forward travel.  
This owners handbook is based on information available at the time of publication.  
HAYTER LIMITED reserve the right to make changes at any time without notice.  
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1.5  
1.5  
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 manufacturers of the engine and battery pack system (where applicable)  
furnish their own warranty and services are provided through their authorised network (Refer to  
"Engine/Battery Pack Warranty Statement"). To qualify for the full benefit of the warranty, the  
warranty registration card must be returned within 60 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, cutterbars, cables, 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 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 or  
contact:- Freephone 0800 616298.  
1st Year  
Service  
Record  
2nd Year  
Service  
Record  
Date....................................................................  
Signed................................................................  
Date.............................................................  
Signed..........................................................  
400001MT270196A  
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SAFETY PRECAUTIONS  
1.6  
1.6  
SAFETY PRECAUTIONS  
THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED.  
WHEN YOU SEE THIS SYMBOL BE ALERT TO THE POSSIBILITY OF  
INJURY. CAREFULLY READ THE MESSAGE THAT FOLLOWS AND  
INFORM OTHERS. EXERCISE GREAT CARE AND FOLLOW THE  
ADVICE GIVEN TO AVOID POTENTIALLY HAZARDOUS SITUATIONS.  
Your mower is perfectly safe if used correctly. Failure to observe the  
following simple precautions may result in serious injury.  
Training:  
Read the instructions carefully. 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.  
- Refuel outdoors only and do not smoke while refuelling.  
- 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 2  
minutes before refuelling.  
- 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.  
- Always use fresh fuel. Stale fuel can block the carburettor and cause leakage.  
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SAFETY PRECAUTIONS  
1.7  
1.7  
SAFETY PRECAUTIONS  
Continued.  
- Replace fuel tank and container caps securely.  
- Replace faulty silencers.  
Always ensure that the mower is in a safe operating condition. Frequently check all nuts,  
bolts and screws for tightness. Use only genuine Hayter replacement parts.  
A damaged cutterbar or loose fixing bolt are major hazards. Before use, visually inspect the  
cutting mechanism to ensure that it is in good condition. A damaged cutterbar must be  
replaced immediately with a genuine Hayter replacement part. A cutterbar which is slightly  
worn can be re-sharpened. Ensure that both cutting edges are re-sharpened equally to main-  
tain balance. An unbalanced cutterbar may cause serious damage to your machine.  
Refer to Maintenance.  
Operation:  
Do not operate the engine in a confined space where dangerous carbon monoxide fumes can  
collect.  
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.  
Use extreme caution when reversing or pulling the mower towards you.  
Stop the engine if the mower has to be tilted for transportation when crossing surfaces other  
than grass and when transporting the mower to and from the area to be mowed.  
Never operate the mower unless the guards are securely in position and in good condition.  
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SAFETY PRECAUTIONS  
1.8  
1.8  
Continued.  
SAFETY PRECAUTIONS  
Operation continued:  
Do not change the engine governor settings or overspeed the engine.  
Disengage the ground drive clutch before starting the engine.  
Start the engine carefully, with feet well away from the cutterbar.  
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 a mower while the engine is running.  
Stop the engine and disconnect the spark plug lead:  
- Before clearing blockages.  
- Before cleaning / checking or working on the mower.  
- After striking a foreign object. Inspect the mower for damage and make repairs  
before restarting and operating the mower.  
- If the mower starts to vibrate abnormally (check immediately).  
Stop the engine:  
- Whenever you leave the mower.  
- Before refuelling.  
Never touch the engine muffler / muffler guard or cooling fins when the engine is hot.  
WARNING: THE CUTTERBAR CAN CONTINUE TO ROTATE AFTER  
THE ENGINE IS SWITCHED OFF  
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SAFETY PRECAUTIONS  
1.9  
1.9  
Continued.  
SAFETY PRECAUTIONS  
Maintenance and 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 with the spark plug removed. (Use an approved tester).  
Never crank the engine with the spark plug removed.  
Never strike the flywheel with a hammer or hard object as this may cause the flywheel to  
shatter in operation. Always use the correct tools to service the engine.  
Never operate the engine without a muffler guard. Inspect the muffler periodically and  
replace if worn or leaking.  
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.  
Allow the engine to cool before storing in any enclosure.  
To reduce the fire hazard, keep the engine, muffler, cooling fins and petrol storage area free  
of grass, leaves, or excessive grease.  
Replace worn or damaged parts for safety.  
If the fuel tank has to be drained, it is essential that this be done outdoors.  
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SAFETY PRECAUTIONS  
1.10  
1.10  
DECALS  
WARNING DECAL: Part No. 219189  
WARNING -RISK OF DANGER - SAFETY ALERT.  
DANGER OF SEVERING TOES OR FINGERS  
IN CUTTING MECHANISM.  
DANGER OF BEING HIT BY THROWN OBJECTS.  
KEEP BYSTANDERS AT A SAFE DISTANCE  
FROM THE MACHINE.  
STOP ENGINE AND REMOVE SPARK PLUG LEAD  
BEFORE PERFORMING MAINTENANCE OR REPAIR  
WORK.  
CAREFULLY READ THE OWNERS HANDBOOK  
BEFORE USING THE MACHINE.  
ENGINE STOP  
STOP  
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SPECIFICATIONS  
1.11  
1.11  
SPECIFICATIONS  
MODEL  
CODE 401R  
Auto-drive  
Engine  
Briggs & Stratton  
Quattro 40  
Engine Type  
10C902  
Engine / Cutterbar Speed 3000 rpm  
Fuel Type  
Unleaded Petrol  
Fuel Capacity  
Oil Type  
1.5 litres  
SAE 30 engine oil  
0.6 litres  
Oil Sump Capacity  
Cutting Width  
Cutting Height  
Overall Dimensions  
Dry Weight  
460mm  
35 - 65mm  
1320 x 515 x 1010mm  
27 Kg  
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ASSEMBLY INSTRUCTIONS  
1.12  
1.12  
ASSEMBLY INSTRUCTIONS  
SAFETY NOTICE  
Before using the mower, read the owners handbook carefully.  
Pay particular attention to the safety precautions.  
MS001  
GENERAL ASSEMBLY  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
Front Height of Cut Adjuster  
Muffler Guard  
Spark Plug Lead  
Engine Cowl  
7
Oil Filler Cap & Dipstick  
Engine Stop Lever  
Top Handlebar  
Ground Drive Clutch Lever  
Engine Start Grip  
6
8
10. Upper Handlebar Securing Knob  
11. Lower Handlebar Securing Knob  
12. Rear Height of Cut Adjuster  
13. Air Cleaner  
14. Fuel Filler Cap  
15. Cable Tie  
9
16. Serial No. Label  
10  
5
4
13  
3
11  
12  
2
1
14  
16  
15  
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ASSEMBLY INSTRUCTIONS  
1.13  
1.13  
ASSEMBLING THE MOWER FOR THE FIRST TIME  
DELIVERY CHECKLIST  
Unpack the mower: Remove the mower from the packag-  
ing and take great care to ensure that the control cables  
between the engine and the upper handlebar are not dam-  
aged in the process. Check that the loose items have been  
supplied correctly. Refer to the delivery checklist opposite.  
If any items are missing, contact your local authorised  
Hayter Dealer.  
Description  
Quantity  
Owners Handbook  
Warranty Reg. Card  
1
1
Assemble the lower handlebar: Carefully unfold the lower  
handlebar into position behind the rear of the mower. Align  
with the base of the handlebar and lock in position using the  
lower securing knobs.  
ST017  
3
4
5
Assemble the upper handlebar: Carefully unfold the  
upper handlebar into position whilst taking great care to  
ensure that the control cables remain undamaged, untwisted  
and free of kinks.  
Align with the lower handlebar and ensure that the rope  
guide is correctly orientated. Tighten the upper securing  
knobs .  
Operate the engine stop lever towards the handlebar and  
very slowly pull the engine start-grip away from the engine  
until there is sufficient slack in the rope to enable it to be  
threaded into the rope guide. Gently release the start-grip  
until it rests against the rope-guide.  
1
2
6
8
ST001  
7
1. Coach bolt M8  
2. Rope guide  
3. Engine start grip  
4. Upper handlebar  
5. Lower handlebar  
6. Washer M8  
7. Knob  
Align the control cables neatly along each leg of the han-  
dlebar and ensure that they are located in the plastic cable  
holders. Use a screwdriver to clamp the cable holders in  
position.  
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ASSEMBLY INSTRUCTIONS  
1.14  
1.14  
ASSEMBLING THE MOWER FOR THE FIRST TIME  
Continued.  
Check engine stop lever operation: Operate the engine  
stop lever several times. Ensure that the cable moves  
freely and that the lever returns automatically to the  
engine stop position when released.  
ST002  
Check the ground drive clutch lever operation:  
Operate the engine stop lever and push forward on the  
clutch lever until it locks into position. Release the  
engine stop lever to a half way position and check that  
the clutch lever releases automatically to the disengaged  
position. Operate several times and ensure that the cable  
and mechanism operates freely.  
ST007  
STOP  
ST004  
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STARTING THE ENGINE  
1.15  
1.15  
BEFORE STARTING THE ENGINE  
IMPORTANT- 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 recommendations: Always use high quality detergent  
oil classified For service SE, SF, SGSAE 30 oil. Never  
use additives with recommended oils.  
SAE 10W-30 multigrade oil may be used, but this will result  
in higher engine operating temperatures with consequential  
high oil consumption. It is imperative that the oil level is  
checked more frequently if this grade of oil is used in order  
to guard against serious engine damage.  
CS042  
Check oil level: Clean around the oil filler cap before  
removing. With the mower on a 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 dip-  
stick. DO NOT OVERFILL.  
0.15  
Litres  
Slowly fill with engine oil as necessary and replace the oil  
filler - dipstick.  
CS043  
IMPORTANT: The oil filler - dipstick must be firmly  
secured to prevent oil leakage during operation.  
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STARTING THE ENGINE  
1.16  
1.16  
BEFORE STARTING THE ENGINE  
Continued.  
Fuel Recommendations: Always use clean, fresh unleaded  
petrol. Purchase fuel in quantities which can be used with-  
in 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 service dealer.  
Check fuel level: Clean around the fuel filler cap before  
removing and fill the fuel tank with clean unleaded petrol.  
6mm  
minimum  
Do not overfill the fuel tank. Allow 6mm minimum of tank  
space for fuel expansion.  
CS036  
IMPORTANT: The fuel filler cap must be firmly secured  
to prevent fuel leakage during operation.  
WARNING - PREVENT ACCIDENTS: The cutterbar  
rotates when the engine is operating.  
ALWAYS operate the engine stop lever several times and  
ensure the engine stop cable moves freely before starting the  
engine.  
ALWAYS position the mower on a level stone free grass  
surface before starting the engine. Ensure that the cutterbar  
is set above grass height to prevent the engine being started  
under load.  
CS037  
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STARTING THE ENGINE  
1.17  
1.17  
TO START THE ENGINE  
CS117  
Operate the primer bulb: When starting the engine for the  
first time firmly push the primer bulb 5 times at 2 second  
intervals to provide the extra fuel required to start a cold  
engine. When starting a cold engine thereafter it should  
only be necessary to push the primer bulb 3 times.  
Operation of the primer bulb is usually unnecessary when  
starting a warm engine.  
1
2
1. Engine  
2. Primer Bulb  
Operate the engine stop lever: Use one hand to hold the  
engine stop lever in the operating position firmly against the  
handlebar.  
To start and operate the engine, the engine stop lever must  
be held in the operating position. If the engine stop lever is  
released the engine will stop.  
STOP  
ST004  
Operate the engine start-grip: Stand behind the mower  
and maintain a firm hold on the handlebar and the engine  
stop lever to prevent the mower moving towards you. Use  
your right hand to hold the engine start - grip and pull slow-  
ly until resistance is felt, then pull rapidly to crank the  
engine. When the engine starts carefully return the engine  
start - grip to the storage position. If the engine does not  
start after 5 attempts - refer to Fault Finding.  
ST003  
IMPORTANT - PREVENT ENGINE DAMAGE: Never  
pull the engine start - grip when the engine is running.  
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STOPPING THE ENGINE  
1.18  
1.18  
STOPPING THE ENGINE  
Stopping the engine: Disengage the engine stop lever by  
releasing the lever.  
STOP  
ST004  
Emergency stop: If the engine stop lever fails, disconnect the  
spark plug lead to stop the engine.  
STOP  
CS044  
OPERATING THE MOWER  
SAFETY NOTICE  
WARNING - PREVENT ACCIDENTAL STARTING :  
Always stop the engine and disconnect the spark plug lead  
before cleaning, inspecting or working on the machine.  
STOP  
CS044  
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OPERATING THE MOWER  
1.19  
1.19  
SAFETY NOTICE  
WARNING - PREVENTACCIDENTS : Before mowing,  
thoroughly inspect the area where the mower is to be  
used and remove all objects which when contacted by  
the mower cutterbar could become dangerous projec-  
tiles.  
Inspect the area for hidden obstructions which when  
contacted by the cutterbar could risk health and safety.  
Remember the location of these obstructions and ensure  
that you mow around them.  
CS031  
IMPORTANT- PREVENT ENGINE DAMAGE : DO  
NOT use the mower on a slope greater than 20 degrees.  
ST008  
o
20 max.  
HEIGHT OF CUT  
To adjust the height of cut: Adjust each wheel in turn.  
Adjust each front wheel by first moving the lever outward  
to unlockand then towards the rear of the mower to  
increase (+) or towards the front of the mower to decrease  
(-) the height of cut. Release the lever and ensure that it  
locks firmly in position.  
+
Front  
_
ST005  
Repeat this procedure for the two rear wheels. To increase  
(+) move the lever towards the front of the mower and to  
decrease (-) move the lever towards the rear of the mower.  
Rear  
_
Finally check that the height of cut settings are the same for  
all four wheels to ensure that the mower is level. There are  
four height of cut positions  
+
Always select a height of cut to suit operating conditions.  
Aim to prevent engine overloading and blockages by avoid-  
ing low cuts in long grass conditions. Be prepared to make  
two cuts when the grass is long.  
ST006  
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OPERATING THE MOWER  
1.20  
1.20  
TRAVEL  
Forward travel: Use the left hand to hold the engine stop  
lever against the handlebar and start the engine. Push down-  
ward on the handlebar to raise the front wheels until they are  
just out of contact with the ground. Use the right hand to  
push the ground drive clutch lever forwards until it locks  
into the engaged position. Remove the right hand and the  
clutch lever will remain in the engaged position. Lower the  
front wheels to the ground and the mower will drive in a for-  
ward direction.  
ST007  
Note: To disengage the drive without stopping the engine,  
release the engine stop lever to the half way position.  
Reverse travel: Disengage the ground drive clutch lever by  
releasing the engine stop lever to the half way position.  
Hold and pull against the handlebar with both hands to  
reverse the mower towards you.  
WARNING - PREVENT ACCIDENTS: Never raise the  
front of the mower excessively. Always reverse the  
mower carefully towards you. Always stop the engine  
before walking backwards with the mower.  
TURNING THE MOWER  
To make a wide turn: Steer the mower with the handlebar  
in the direction required.  
To make a tight turn: Stop and apply downward pressure  
on the handlebar to raise the front wheels of the mower just  
above ground level and steer the mower using the handlebar  
in the required direction.  
General manoeuvring: The mower may be manoeuvred in  
tight spaces with the ground drive engaged, by pushing  
downward on the handlebar to lift the front driving wheels  
slightly clear of the ground.  
WARNING - PREVENT ACCIDENTS: DO NOT raise  
the front of the mower excessively when making turns.  
NEVER raise the rear of the mower when the engine is  
running.  
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OPERATING THE MOWER  
1.21  
1.21  
MOVING THE MOWER ACROSS NON-GRASSED AREAS  
Set the mower to its maximum height of cut to protect the cutting mechanism when moving  
the mower over surfaces other than grass.  
WARNING - PREVENT ACCIDENTS: Push the mower carefully at slow walking  
speed with the engine stopped.  
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OPERATING THE MOWER  
1.22  
1.22  
CUTTERBAR OPERATION  
The cutterbar rotates at the same speed as the engine. The cutterbar will stop within three  
seconds of the engine being stopped.  
WARNING - PREVENT ACCIDENTS : DO NOT operate the mower if the cutterbar  
fails to stop within three seconds. Return the mower to your Hayter dealer for exami-  
nation and repair.  
WARNING - PREVENT ACCIDENTS: ALWAYS stop the engine when a hidden  
obstruction or excessive vibration is encountered. Disconnect the spark plug lead and  
examine the cutting mechanism. ALWAYS replace a damaged cutterbar - refer to  
Maintenance.  
MOWING AND GRASS CARE TIPS  
The Clipper 46 employs a mulching system. The grass is cut and then finely chopped before  
being forced down by blown air into the root area. The fine clippings should be left to break  
down naturally in order to fertilise the lawn. For best results, it is important that the grass is  
not cut too short.  
In dry weather conditions leave the grass long to help retain ground moisture.  
Aerate the lawn to stimulate soil organisms and root growth. In spring and late summer  
remove dead grass and aerate the lawn by raking or similar means.  
Keep the cutterbar sharp. A blunt cutterbar will tear the grass and cause the tips to turn  
brown.  
Always keep the underside of the deck clean.  
Avoid mowing when the grass is wet. Grass clippings will stick to the underside of the deck  
and the mulching performance will be affected.  
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OPERATING THE MOWER  
1.23  
1.23  
MOWING AND GRASS CARE TIPS  
Continued.  
Prevent scalping. Plan your direction of travel to mow across hollows and humps.  
Prevent grass damage. Take care when turning the mower.  
Brush the lawn surface to disperse worm casts before mowing.  
Spike compacted lawn areas with a fork. Fill the holes with sand to improve aeration and  
drainage.  
Mow lawns in a different direction to the previous cut.  
Mow lawns twice a week when the grass is growing vigorously in the summer.  
Mow lawns once a week in spring, autumn and during prolonged dry weather in the summer.  
Prevent grass damage - DO NOT remove more than one third of the grass height in one  
cut.  
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MAINTENANCE  
1.24  
1.24  
MAINTENANCE  
WARNING: PREVENT ACCIDENTS - Stop the engine  
and disconnect the spark plug lead before attempting to  
carry out maintenance procedures on the mower.  
STOP  
CS044  
ENGINE  
4
3
1. Governor control lever  
2. Air cleaner  
2
3. Start-grip  
4. Finger Guard  
5. Muffler  
1
6. Spark plug  
7. Primer bulb  
8. Carburettor  
9. Fuel Cap  
5
10.Fuel tank  
6
11.Flywheel  
12.Oil fill/Dipstick  
12  
7
8
9
10  
11  
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MAINTENANCE  
1.25  
1.25  
CARBURETTOR ADJUSTMENTS  
Carburettor adjustments should only be made by an authorised Briggs & Stratton dealer.  
Under no circumstances should the engine be adjusted to run at a speed in excess of 3,000  
r.p.m.  
OIL SERVICE  
Refer to the Maintenance Schedule at the end of this section and ensure that the recommen-  
dations are followed. More frequent service is required when operating in adverse conditions.  
- Check the oil level every 5 hours or daily before starting the engine and ensure that  
the correct oil level is maintained. Refer to-Before Starting the Engine: Oil  
Recommendationsfor oil checking procedure and filling instructions.  
- Change the engine oil after the first 5 hours of operation and thereafter at the end of  
every grass cutting season. In circumstances where the engine is being operated for  
long periods under heavy load or high ambient temperatures, the oil should be changed  
at 25 hour intervals.  
- Change the oil while the engine is warm. Refill with fresh clean oil of the recom-  
mended SAE viscosity grade. Refer to -Before Starting the Engine:Oil  
Recommendations.  
WARNING - PREVENT ACCIDENTS: Drain fuel from the tank by running the engine  
until the fuel tank is empty before attempting to tip the mower for oil draining  
purposes.  
- Remove the spark plug lead and allow the engine to  
cool. Slacken the lower handlebar securing knobs and  
move the handlebar assembly forwards. Tip the mower  
backwards until the handlebar assembly is supported on  
the ground, as shown. Remove the oil filler dipstick and  
drain the oil into a suitable container.  
ST014  
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MAINTENANCE  
1.26  
1.26  
AIR CLEANER SERVICE  
Refer to the Maintenance Schedule at the end of this section  
and ensure that the recommendations are followed. More  
frequent service is required when operating in adverse con-  
ditions.  
1
2
- Replace the element if very dirty or damaged.  
- Remove screw (1)  
3
- Carefully remove the air cleaner to prevent debris  
from falling into the carburettor.  
4
- Take the air cleaner apart and clean all parts. Wash  
the element (2) in liquid detergent and water. Wrap  
the element in a clean cloth and squeeze dry.  
Saturate the element in engine oil. Wrap in a clean  
cloth and squeeze to remove excess oil.  
5
- Install the element and cup (3) into the body (4).  
Install the element so that lip (5) extends over the  
edge of the body to form a protective seal when  
cover is assembled.  
-Install the air cleaner securely on the carburettor  
with the screw.  
SPARK PLUG SERVICE  
Use only Briggs & Stratton spark tester (1) to check for a  
spark as shown in the diagram.  
1
Replace the spark plug every 100 hours or every season,  
which ever occurs first. A spark plug wrench is available  
from any authorised Briggs & Stratton service dealer.  
The spark plug gap (2) should be checked with a feeler  
gauge and set at 0.76mm.  
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MAINTENANCE  
1.27  
1.27  
KEEPING THE ENGINE CLEAN  
WARNING - PREVENT ACCIDENTS : Accumulation of debris around the muffler  
could cause a fire. Inspect and clean the engine after every use.  
Remove all grass and debris from the engine including the muffler / muffler guard, the air  
ways in the finger guard (1) and the surrounding deck areas on a daily basis after use.  
3
2
1
2
5
ST009  
4
CS045  
IMPORTANT - PREVENT ENGINE DAMAGE: Never spray the engine with water  
during cleaning. Water can contaminate the fuel. Always clean with a brush or com-  
pressed air.  
NOTE: Grass and debris may clog the engines air cooling system especially after prolonged  
operation while cutting tall, dry grass. The internal cooling fins and surfaces may require  
cleaning to prevent overheating and engine damage.  
- Remove the three screws (2) and lift the cowl and blower  
housing assembly to clean areas within the heavy line (3) as  
shown in the diagram.  
- Do not loosen 2 band brake bracket screws (4).  
- Do not bend or remove flywheel guard (5).  
After cleaning replace the cowl and the blower housing assembly and secure with the 3  
screws.  
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MAINTENANCE  
1.28  
1.28  
DECK HOUSING  
Remove grass debris from the top and underside of the deck  
housing immediately after use. It is particularly important to  
keep the underside clean to preserve the mulching action and  
prevent corrosion.  
If grass debris has dried onto the deck housing, it should be  
removed using a suitable brush. If necessary touch in any areas  
of damaged paintwork with a suitable paint to prevent rusting.  
IMPORTANT - PREVENT DAMAGE: DO NOT use high  
pressure washing units to clean the mower.  
SECURING NUTS AND BOLTS  
Regularly check that all securing nuts and bolts are tight.  
Replace missing or damaged items immediately.  
CS015  
LUBRICATION  
Apply a good quality medium grease to the inner control cables  
every 25 operating hours at the point of entry and exit from  
their outer casings.  
CS022  
Clean the insides of the front drive wheels once a season.  
Remove the hub caps, screws, washers and wheels. Remove  
any debris from the gears and gear rings using a brush.  
Reassemble the wheels.  
ST011  
Lubricate the driveshaft slide bearings at least once a season.  
Set the mower at the minimum height of cut and remove the  
transmission casing to gain access to the lubrication points.  
Replace the transmission casing.  
ST012  
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MAINTENANCE  
1.29  
1.29  
CLUTCH CABLE ADJUSTMENT  
Check the clutch cable operation every 25 operating hours and  
adjust if necessary.  
Adjustment is carried out as follows:  
- Set the mower at the minimum height of cut position  
and remove the transmission casing.  
- Use the left hand to hold the engine stop lever  
against the handlebar but do not start the engine. Use  
the right hand to push the ground drive clutch lever for-  
wards until it locks into the engaged position. Push  
the mower in a forward direction until the front wheels  
lock.  
In this position the tension spring (K) should have  
extended by approximately 9mm from the original  
position with the controls released.  
- If the adjustment is incorrect, slacken the lock nuts  
(M) and rotate the cable adjuster (L) as necessary.  
Retighten the lock nuts.  
ST013  
- After adjustment check to ensure that there is a small  
amount of free play in the clutch control mechanism  
with the controls released.  
- Replace the transmission casing.  
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MAINTENANCE  
1.30  
1.30  
CUTTERBAR  
WARNING - PREVENT ACCIDENTS : Never work on  
the cutterbar unless the spark plug lead has been  
removed. The cutterbar has sharp edges. ALWAYS wear  
strong gloves to protect your hands when working on the  
cutterbar. DO NOT rotate tools towards the cutting  
edges to avoid the risk of injury should the tool slip.  
ALWAYS use genuine Hayter replacement parts.  
The condition of the cutterbar and its mounting  
arrangement should be checked regularly for signs of  
wear or damage. Ensure that the cutterbar is not bent  
or cracked.  
A damaged cutterbar that is out of balance will vibrate  
excessively and may break. DO NOT use an unbalanced  
cutterbar.  
Regularly check that the bolt securing the cutterbar is  
tightened to the specified torque of 40Nm.  
Replace the cutterbar every 2 years of sooner if exces-  
sively worn or damaged.  
How to remove the cutterbar: Drain the fuel by operating  
the engine until the fuel tank is empty and the engine stops.  
Remove the spark plug lead and allow the engine to cool.  
Slacken the lower handlebar securing knobs and move the  
handlebar assembly forwards. Tip the mower backwards  
until the handlebar assembly is supported on the ground, as  
shown.  
ST014  
Firmly grip the end of the cutterbar with the gloved hand  
and remove the bolt and washer securing the cutterbar with  
a 9/16A/F spanner.  
ST015  
How to assemble the cutterbar: Assemble the cutterbar  
with the blade cutting edges facing away from the engine.  
Secure the cutterbar using the blade holder, bolt and  
washer and tighten to a torque of 40Nm.  
1. Blade Holder  
2. Bolt  
3. Washer  
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MAINTENANCE  
1.31  
1.31  
CUTTERBAR  
Continued.  
How to sharpen and balance the cutterbar: A slightly  
worn cutterbar may be re-sharpened. All cutting edges must  
be sharpened equally to ensure balance. Sharpen the cutter-  
bar every 25 mowing hours or more frequently if conditions  
require. Remove the cutterbar from the mower and clean  
using a brush and water. Inspect the cutterbar for signs of  
damage.  
30 -45  
CS040  
WARNING - PREVENT ACCIDENTS: DO NOT use a  
damaged or excessively worn cutterbar.  
Sharpen all the cutting edges with a flat file to restore the  
original cutting edges.  
CS025  
Ensure that the cutterbar is balanced. Use a screw driver  
with a round shaft to support the cutterbar through its centre  
hole. Hold the cutterbar horizontal and then release. A bal-  
anced cutterbar will remain horizontal. If the cutterbar is  
not balanced the heavy end will rotate downward. Sharpen  
the heavy end until the cutterbar is correctly balanced.  
CS026  
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MAINTENANCE  
1.32  
1.32  
MAINTENANCE SCHEDULE  
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.  
AFTER FIRST 5 HOURS  
Change engine oil  
G
EVERY 5 HOURS OR DAILY  
Check oil level  
G
G
Remove grass debris from around engine, muffler/muffler guard and air ways in the top  
cowl.  
Remove grass debris from top and underside of deck housing.  
Check condition of guards and safety devices.  
Check condition of cutterbar.  
G
G
G
EVERY 25 HOURS OR EVERY SEASON  
GGG  
Change engine oil if continuously operating under heavy load or high ambient temperature.  
GGG  
Service air cleaner element.  
GGG  
Grease inner control cables at point of entry and exit from their outer casings.  
GGG  
Check clutch cable adjustment  
G
Sharpen cutterbar.  
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MAINTENANCE  
1.33  
1.33  
MAINTENANCE SCHEDULE Continued.  
EVERY 50 HOURS OR EVERY SEASON  
Change engine oil.  
GGG  
GGG  
Clean the insides of the front drive wheels.  
Lubricate the transmission drive shaft slide bearings.  
GGG  
EVERY 100 HOURS OR EVERY SEASON  
Clean engine cooling system. Clean more often under dusty conditions or when airborne  
GGG  
debris is present or after prolonged operation whilst cutting tall, dry grass.  
Replace spark plug.  
GGG  
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PREPARING THE MOWER FOR STORAGE  
1.34  
1.34  
PREPARING THE MOWER FOR STORAGE  
Handlebar storage: Slacken the upper and lower handlebar securing knobs and fold into  
the storage position. Take great care to ensure that the control cables do not become  
snagged or damaged during folding.  
Storage for periods in excess of 30 days: Engines stored in excess of 30 days need to be  
protected with Briggs & Stratton fuel additive or drained of fuel to prevent gum from form-  
ing 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. Operate the engine stop lever and  
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 blower  
housing and around and behind the muffler/muffler guard.  
Clean all other areas of the mower.  
Lubricate the mower.  
Treat metal parts with a water repellent anti-corrosion product.  
Fold the handlebar to the storage position if desired. Rest the mower deck on wooden  
blocks with the wheels clear of the ground.  
Cover the mower with a protective sheet and store it in a dry, ventilated area.  
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FAULT FINDING  
1.35  
1.35  
FAULT FINDING  
PROBLEM  
POSSIBLE FAULT  
REMEDY  
Engine will not turn over  
Engine stop lever released  
Incorrect oil level  
Operate engine stop lever  
Check oil level  
Obstruction under deck  
Remove obstruction  
Engine smokes  
Excess oil level  
Check oil level  
Air cleaner plugged  
or dry.  
Service air cleaner  
Engine runs then stops  
Fuel starvation  
Fill fuel tank  
Fuel cap vent blocked  
Clean fuel cap vent  
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FAULT FINDING  
1.36  
1.36  
FAULT FINDING  
Continued.  
PROBLEM  
POSSIBLE FAULT  
REMEDY  
Engine will not start  
Engine under load  
Fuel starvation  
Raise height of cut  
Fill fuel tank  
Engine cold  
Operate primer bulb.  
Incorrect/contaminated fuel  
Drain fuel tank and fill with  
correct fuel  
Spark plug lead disconnected Connect spark plug lead  
Engine brake not released  
Faulty spark plug  
Operate engine stop 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  
Air cleaner element blocked Service air cleaner.  
Incorrect/contaminated fuel  
Drain fuel tank and fill with  
correct fuel  
Engine vibrates excessively  
Mounting bolts loose  
Cutterbar bolt loose  
Tighten bolts  
Tighten bolt  
Cutterbar out of balance  
Engine crankshaft bent  
Balance cutterbar  
Consult your dealer  
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FAULT FINDING  
1.37  
1.37  
FAULT FINDING  
Continued.  
POSSIBLE FAULT  
Grass is wet  
PROBLEM  
REMEDY  
Uneven cut  
Mow dry grass  
Undulating ground conditions Change direction of travel  
Cutterbar worn  
Sharpen the cutterbar  
Cutterbar out of balance  
Wheels damaged  
Balance the cutterbar  
Inspect and replace as necessary  
Mower is hard to push  
Cut height too low  
Wheels damaged  
Increase cut height  
Inspect and replace  
as necessary  
Mower will not self propel  
Clutch out of adjustment  
Drive belt damage  
Adjust clutch  
Replace drive belt  
Poor mulching performance Underside of deck is dirty  
Clean underdeck  
Height of cut set too low  
Cutterbar worn  
Increase height of cut  
Sharpen the cutterbar  
Mow dry grass  
Grass is wet  
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401R CHASSIS PARTS LIST  
2.1  
2.1  
PARTS LIST  
TEM NO.  
DESCRIPTION  
PART NO.  
QTY  
1
6
7
Blade  
Blade bolt  
Washer  
Blade holder  
Key  
Shoulder bolt  
Washer  
Flat washer  
Axle mounting  
Control lever  
*Plastic knob  
Hole plate  
Bushing  
Wheel lock kit  
*Lock washer  
Slotted pin  
Front axle  
Hub cap-black  
Nut  
Screw  
Flat washer  
Plug  
Lock nut  
Nut guard  
Screw  
Handlebar-lower part  
Handle bolt kit  
*Locking knob  
*Washer  
*Screw  
*Reinforcement  
Eyelink  
ST1111-3099-01  
ST9987-5257-12  
ST9696-0011-01  
ST1111-2142-01  
ST9600-0014-00  
ST1111-0545-00  
ST9694-0003-00  
ST9699-0069-02  
ST1111-1268-01  
ST1111-1337-01  
ST1111-2549-01  
ST1111-0497-00  
ST1111-2057-02  
ST1111-9042-01  
ST9675-0017-02  
ST9595-0182-00  
ST1111-2526-01  
ST1111-3085-06  
ST9739-0831-22  
ST9955-3732-12  
ST9699-0029-02  
ST9403-0043-70  
ST9747-0831-02  
ST9403-0113-00  
ST9898-0835-12  
ST1111-2962-01  
ST1111-9030-02  
ST1111-0035-01  
ST9699-0025-02  
ST9899-3551-12  
ST1111-0178-00  
ST1111-3062-01  
ST1111-2961-01  
ST1111-2018-01  
ST9836-9216-12  
ST1111-3079-05  
1
1
1
1
1
2
2
2
2
2
1
2
2
1
4
2
1
2
2
3
3
2
4
4
4
1
2
2
2
2
2
1
1
1
1
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
20  
21  
22  
23  
25  
26  
27  
30  
31  
32  
33  
34  
35  
35  
36  
37  
38  
39  
40  
41  
42  
45  
Handlebar-interm.part  
Cable holder  
Screw  
Chassis-black  
46  
Handlebar-upper part  
ST1111-2960-01  
1
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401R CHASSIS PARTS LIST  
2.2  
2.2  
PARTS LIST  
ITEM NO. DESCRIPTION  
PART NO.  
QTY  
47  
48  
49  
50  
51  
52  
54  
55  
55  
56  
59  
60  
61  
62  
63  
64  
65  
Decal - Engine  
Engine - Cowl  
Washer  
Screw  
Screw  
401008  
1
1
1
1
1
1
1
ST1111318601  
ST9699009902  
ST9987473219  
ST9948064016  
ST9747063102  
ST1111295201  
ST1111296803  
ST1111296805  
ST1111296901  
ST1111118003  
ST1111113801  
ST1111266501  
ST1111904701  
ST1111118401  
ST9500740405  
219189  
Lock nut  
Control handle  
Engine brake cable  
Engine brake cable  
Cable attachment  
Wheel cover  
Spring  
Wheel assy  
*Ball bearing kit  
*Bearing cone  
Engine  
1
1
2
2
2
1
2
1
1
Decal- Caution  
*These components form part of a sub-assembly.  
The quantities indicated are per sub-assembly  
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401R CHASSIS PARTS DIAGRAM  
2.3  
2.3  
50  
49  
47  
48  
64  
65  
3D401102A  
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401R TRANSMISSION PARTS LIST  
2.4  
2.4  
PARTS LIST  
TEM NO.  
DESCRIPTION  
PART NO.  
QTY  
1
2
3
4
5
6
7
8
Wheel mounting-R.H.  
Wheel mounting-L.H.  
*Bronze bearing  
*Plastic knob  
Spacer  
Cover plate  
Pin  
Gear wheel  
Washer  
Screw  
Washer  
Spring  
Wheel assy  
*Ball bearing kit  
*Bearing cone  
Washer  
ST1111290001  
ST1111290101  
ST9548001400  
ST1111254901  
ST1111306501  
ST1111256101  
ST1111238201  
ST1111263502  
ST9699010002  
ST9943061216  
ST9699003702  
ST1111113801  
ST1111266501  
ST1111904701  
ST1111118401  
ST9699010002  
ST9943061216  
ST1111308506  
ST1111263302  
ST9943053016  
ST9943054016  
ST9739053122  
ST1111906201  
ST1111291501  
ST9910061216  
ST1111305501  
ST1111304701  
ST9594005500  
ST1111306001  
ST1111296503  
ST9747063102  
ST9948065516  
ST9836951212  
ST1111201801  
ST9836921612  
ST9579000800  
ST1111198702  
533005  
1
1
2
1
2
2
2
2
2
2
2
2
2
1
2
2
2
2
1
1
2
2
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
9
10  
16  
17  
18  
19  
20  
21  
22  
23  
30  
31  
32  
33  
40  
41  
42  
45  
46  
47  
49  
65  
66  
67  
68  
75  
76  
77  
78  
79  
Screw  
Hub cap-black  
Front cover-black  
Screw  
Screw  
Nut  
V-belt  
Engine belt pulley  
Set screw  
Transmission assy  
*Belt pulley dito  
*Locating pin  
Spring  
Clutch control  
Lock nut  
Screw  
Screw  
Cable holder  
Screw  
Cable holder  
Control knob-black  
Decal - Hayter  
*These components form part of a sub-assembly.  
The quantities indicated are per sub-assembly  
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401R TRANSMISSION PARTS DIAGRAM  
2.5  
2.5  
79  
3D401101A  
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ENGINE ANCILLARY PARTS  
2.6  
2.6  
These parts are available through an authorised Briggs & Stratton dealer.  
FUEL ADDITIVE  
AIR CLEANER CARTRIDGE  
ST018  
SPARK PLUG  
SPARK PLUG WRENCH  
SPARK PLUG TESTER  
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ENGINE WARRANTY  
2.7  
2.7  
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NOTES  
2.8  
2.8  
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CUSTOMER INFORMATION  
2.9  
2.9  
Machine Serial No : .................................................................................................................  
Engine Serial No :.....................................................................................................................  
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