PowerSmart DB8602C - Lawn Mower Manual

TECHNICAL DATA

INTRODUCTION

This manual provides information regarding the safe operation and maintenance of this product. Every effort has been made to ensure the accuracy of the information in this manual. PowerSmart^® reserves the right to change this product and specifications at any time without prior notice.
Please keep this manual available to all users during the entire life of the lawn mower.
This manual contains special messages to bring attention to potential safety concerns, lawn mower damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.

QUESTIONS? PROBLEMS?
Please contact our Customer Service Dept. with any questions and/or comments, either by Email:
support@amerisuninc.com, or Toll Free at (872) 314-0005. We are available Mon-Fri 9am-5pm EST to help solve any issues that you might encounter.

NOTICE REGARDING EMISSIONS
Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems:
(EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).

SAFETY INFORMATION

Before operating this lawn mower, read and observe all warnings, cautions, and instructions on the lawn mower and in this Owner's Manual.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. Read the entire Owner's Manual for safety and operating instructions. Failure to follow instructions and safety information could result in serious injury or death.
This safety alert symbol is used to identify safety information about hazards that can result in personal injury.
A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

indicates a hazard, which, if not avoided, will result in death or serious injury.

indicates a hazard, which, if not avoided, could result in death or serious injury.

indicates a hazard, which, if not avoided, might result in minor or moderate injury.

when used without the alert symbol, indicates a situation that could result in damage to the engine.

GENERAL SAFETY PROCEDURES

For any questions regarding the hazard and safety notices listed in this manual or on the product, please call (872) 314-0005 Mon-Fri 9-5 EST before using the engine.

CARBON MONOXIDE
Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the engine exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
NEVER use an engine inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan, or opening windows and/or doors will NOT properly vent CO nor supply adequate fresh air. ONLY use an engine outside and far away from windows, doors, and vents. These openings can pull in engine exhaust.
Even if you use an engine correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the engine has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

This engine may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if it isn't directly in contact with gasoline.

• Do not operate near an open flame.
• Do not smoke near the engine.
• Always operate on a firm, level surface.
• Always turn engine off before refueling. Allow engine to cool for at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.
• Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank. Allow for expansion.
• Always check for spilled fuel before operating.
• Empty fuel tank and carburetor bowl before storing or transporting the engine.

This engine produces heat when running. Temperatures near exhaust can exceed 150⁰F (65⁰ C).
Do not touch hot surfaces. Pay attention to warning labels on the engine identifying hot parts of the machine.
Allow engine to cool down after use before touching engine or areas of the engine that become hot during use.

Misuse of this engine can damage it or shorten its life. Only use engine for its intended purposes.

IMPORTANT SAFETY INSTRUCTIONS

This machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

1. General Operation
   1. Read, understand, and follow instructions and warnings in this manual and on the machine, engine and attachments.
   2. Only allow operators, who are responsible, trained, familiar with the instructions, and physically capable to operate the machine.
   3. Do not carry passengers and keep bystanders away.
   4. Do not operate the machine while under the influence of alcohol or drugs.
   5. Follow the manufacturer's recommendation for wheel weights or counterweights.
2. PREPARATION BEFORE OPERATING
   1. Clear the operating area of any objects which could be thrown by or interfere with operation of the machine
   2. Keep the area of operation clear of all bystanders, particularly small children. Stop the machine and attachment(s) if anyone enters the area.
   3. Do not operate the machine without the entire grass catcher, discharge chute, or other safety devices in place and functioning properly. Check frequently for signs of wear or deterioration and replace as needed.
   4. Wear appropriate personal protective equipment such as safety glasses, hearing protection, and footwear.
3. OPERATING
   1. Only operate the engine in well ventilated areas. Exhaust gases contain carbon monoxide, a deadly poison.
   2. Only operate the machine in daylight or good artificial light.
   3. Avoid holes, ruts, bumps, rocks, or other hidden hazards. Uneven terrain could overturn the machine, or cause operator to lose their balance or footing.
   4. Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.
   5. Do not direct discharge material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blade(s) when crossing gravel surfaces.
   6. Do not leave a running machine unattended. Always park on level ground, disengage the attachment, set parking brake, and stop engine.
   7. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.
4. CHILDREN SPECIFIC
   1. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.
   2. Keep children out of the operating area and under the watchful care of a responsible adult other than the operator.
5. SLOPE SPECIFIC
   Slopes are a major factor related to accidents. Operation on slopes requires extra caution.
   1. Travel in the manufacturer recommended direction on slopes. Use caution while operating near drop offs.
   2. Avoid mowing wet grass. (Poor footing could cause a slip and fall accident.)
   3. Do not operate machine under any condition where traction, steering, or stability is in question. Tires could slide even if the wheels are stopped.
   4. Always keep the machine in gear when going down slopes. Do not coast downhill.
   5. Avoid starting and stopping on slopes. Avoid making sudden changes in speed or direction. Make turns slowly and gradually.
   6. Use extra care while operating machine with a grass catcher or other attachment(s). They can affect the stability of the machine.
6. FIRE AND FUEL SPECIFIC
   1. Extinguish all cigarettes, cigars, pipes and other sources of ignition.
   2. Use only an approved fuel container.
   3. Do not remove fuel cap or add fuel with the engine running or while hot.
   4. Do not refuel indoors or in enclosed spaces
   5. Do not store the machine or fuel container, or refuel, where there is an open flame, spark, or pilot light such as on a water heater or other appliance.
   6. If fuel is spilled, do not attempt to start the engine and avoid creating any source of ignition until fuel vapors have dissipated.
   7. To help prevent fires: keep machine free of grass, leaves, or other debris build up; clean up oil or fuel spillage and remove any fuel soaked debris; allow machine to cool before storing.
   8. Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.
7. HAULING
   1. 1. Use full width ramps for loading and unloading a machine for transport.
      1. Keep machine in good working order. Replace worn or damaged parts.
      2. Use caution when servicing blades. Wrap the blade(s) or wear gloves. Replace damaged blades. Do not repair or alter blade(s)
      3. Machines with hydraulic pumps, hoses, or motors; and/or diesel injection systems:
         
         Fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If fluid is injected into the skin, seek immediate medical attention. Keep body and hands away from pin holes or nozzles that eject fluid under high pressure. If a leak occurs, have the machine immediately serviced by a trained technician.
      4. If equipped, disconnect spark plug wire(s) before making any repairs.
8. SERVICE

WARNING LABLE INSTRUCTIONS

	Read carefully the manual before use.
	flying objects; keep safe distance from the machine as long as the engine is running.
	Do not open or remove safety shields while engine is running. .
	Pay more attention to the operator's hands and feet to avoid injury.
	Do not open or remove safety shields while engine is running.
	Fuel is flammable, keep fire away.
	Never fill up the fuel tank while the engine is running.
	Emission of toxic gas, do not use the mower in a close area or not well ventilated.
	Look behind while backing
	Steep slope hazard
	When repairing, please pull off the spark plug boot, then repair it according to the operational manual
	Hot surfaces
	When mowing, please wear the glasses ad ear plugs to defend the operator himself
	Keep bystanders away.
	Safety label found on the lawn mower: KEEP HANDS AND FEET AWAY.

Keep the safety signs clear and visible on the equipment. Replace the safety signs if they are missing or illegible.

KNOWING YOUR LAWN MOWER

Please use the illustration below to familiarize yourself with the location and function of the components that control of your lawn mower.

1. Recoil starter handle
2. Cutting height adjustment lever
3. Rear wheel
4. Side discharge chute
5. Oil dipstick
6. Cutting height adjustment lever
7. Front wheel

8. Primer bulb
9. Fuel tank cap
10. Lower tube
11. Foldable handle
12. Upper tube
13. Engine start/stop control

LAWN MOWER PREPARATION

The following section describes steps necessary to prepare the lawn mower for use. If after reading this section, you are unsure about how to perform any of the steps please call (872) 314-0005 Mon-Fri 9-5 EST for customer service. Failure to perform these steps properly can damage the lawn mower or shorten its lifespan.

UNPACKING
Unpack the lawn mower and all its parts, and compare against the list below. Do not discard the carton or any packaging until the engine is completely assembled.

PACKING LIST
Side discharge chute*1
Cable clip*2
Spark plug wrench*1
User manual*1
Funnel*1
10W-30 oil*1

ASSEMBLE LOWER & UPPER TUBE

1. Take out the folded mower from the outer box.
2. Lock the foldable handle between the upper tube and lower tube. Turn the lower handle to an angle that matches the base and tighten the screws.
   
   

3. Lock the cable to the lower tube using cable clip.
   

SIDE DISCHARGE CHUTE
To convert mower for side discharge, the grass catcher has been removed and that the rear discharge door is closed.

1. Lift the spring-loaded discharge cover located on the side of the mower.
   
2. Slide two hooks of the side discharge chute under the hinge pin and lower the spring on the side discharge cover.
   

Do not attempt to remove the permanently mounted spring loaded side discharge cover at any time.

ADJUSTING THE CUTTING HEIGHT

Cutting height adjustments should only be performed after the engine and blades have come to a complete stop!
It is always best to begin cutting your lawn with a higher deck height to prevent scalping your lawn.
The cutting height is adjusted with front and rear levers.
Actuate the adjustment lever and pull it to the required position. Please make sure that the lever locks into same position.

OPERATION

GAS AND OIL FILL-UP
The engine comes shipped without oil or gasoline. Be sure to add oil and gasoline before starting the engine. The oil capacity of the engine crankcase is 16.9 fl. oz. For general use, we recommend 10W-30, 4-stroke engine oil.

1. Add oil before starting mower for the first time.
2. Service the engine with gasoline as instructed.

Use extreme care when handling gasoline. Gasoline is extremely flammable and its vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. Extinguish all cigarettes, cigars, pipes and other potential sources of ignition.

Engine Oil
Engine oil is a key factor in deciding the engines performance. Do not apply engine oil with additives or 2-stroke gasoline engine oil, because they haven't enough lubrication, and may shorten the engines service life.

Check the engine with it stopped on a level ground.
Engine oil recommended: 10W-30
As viscosity varies with regions and temperatures, SF class oil is recommended.

Check method

1. Remove the dipstick and Clean it.
2. Reinsert the dipstick into the oil filling hole, and insert it to the end.
3. Check the oil level: If the oil level is too low, add the recommended engine oil and make sure the oil level between upper level(1) and lower level(2).
4. Re-install the dipstick.

Adding Gasoline
Remove the fuel tank cap and check fuel level.
If the level is too low, refuel the tank, remember adding fuel not over the fuel upper level.

1. Gasoline is extremely flammable and is explosive under certain conditions.
2. Refueling in a well-ventilation area with the engine stopped. Do not smoke and allow flames or sparks in the area where gasoline is stored or where the fuel tank is refueled.
3. Do not overfill the fuel tank (there should be no fuel in the filling neck). After refueling, make sure the fuel tank cap is set back securely.
4. Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.
5. Avoid repeated or prolonged contact with skin or breathing of fuel vapor. Keep out of reach of children.

Use fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. Do not mix oil with gasoline.
To add gasoline, follow these steps:

1. Make sure the lawn mower is on a level surface.
2. Unscrew fuel tank cap and set aside. NOTE: The fuel cap may be tight and hard to unscrew.
3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. The capacity of the fuel tank is 0.21gallons.
   NOTE: Do not fill the fuel tank to the very top. Gasoline will expand and spill over during use even with the fuel cap in place.
4. Reinstall fuel cap and wipe clean any spilled gasoline with a dry cloth.

• Never use an oil/gasoline mixture.
• Never use old gasoline.
• Avoid getting dirt or water into the fuel tank.
• Gasoline can age in the tank and make starting difficult. Never store lawn mower for extended periods of time with fuel in the tank or the carburetor.

ENGINE START/STOP CONTROL
This lawn mower comes equipped with an engine start/stop control to prevent unintentional starting and to ensure safe operation. Releasing this lever will quickly stop the blade in case of danger. The lever must be actuated before the lawn mower is started. When the engine start/stop lever is released, it must return to its initial position.
Before you start mowing, you should run through this process several times in order to ensure that the lever and actuator cables are working properly. Repeat the test several times after the engine has started up. When the engine start/stop
Control is released, the engine must stop within a few seconds. If not, contact Customer Service.


The blade begins to rotate as soon as the engine is started.

START THE ENGINE
To start the engine, perform the following steps:

1. Check the oil and fuel levels.
2. For cold starting, slightly press the primer bulb one to three times. For hot starting, directly pull the recoil starter handle.
3. Engage the engine Start/Stop Control and simultaneously pull on the recoil starter. Pull on the recoil starter handle slowly until a slight resistance is felt, then pull quickly to start the engine.
   Return cord gently into the recoil starter. Never allow the cord to snap back.
4. If engine fails to start, repeat step 3.

NOTE: After repeated failed attempts to start the engine, please consult the troubleshooting guide before attempting again. If problems persist, please call customer service.
NOTE: Don't allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

STOP THE ENGINE
Release the engine start/stop control to stop the engine.

MOWING
The engine throttle on your mower has been preset to provide optimum bagging and mulching performance for years to come.
Only use a sharp blade that is in good condition. This will prevent the grass blades from becoming frayed and the lawn from turning yellow.
Mow in straight lines for a nice, clean look. The swaths should overlap each other by a few inches in order to avoid stripes.
It's important to keep the underside of the mower deck clean and remove grass build-up. This buildup will decrease mulching quality.
Always mow along inclines (not up and down). You can prevent the lawn mower from slipping down by holding a position at an angle upwards. Select the cutting height according to the length of the grass. If necessary, mow a number of times so that you never cut more than 2 inches of grass in one go.
Turn off the engine before doing any checks on the blade. Keep in mind that the blade continues to rotate for a few seconds after the engine has been turned off. Never attempt to manually stop the blade. Regularly check to see if the blade is securely attached, is in good condition and is sharp. If the contrary is the case, sharpen the blade or replace it. In the event that the blade strikes an object, immediately turn off the lawn mower and wait for the blade to come to a complete stop. Then inspect the condition of the blade and the blade mount. Replace any parts that are damaged.

USING AS SIDE DISCHARGE
You should close the rear cover with mulching adapter in order to use the side discharge.

1. On the side of the mower, lift the side discharge cover.
   
2. Slide two hooks of side discharge chute under hinge pin on the side discharge cover. Lower the side discharge cover.
   

Do not remove side discharge cover at any time.

MAINTENANCE

Proper routine maintenance of this mower will help prolong the life of the machine.
Always observe safety rules when performing any maintenance.
The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence.
To receive full valve from warranty, operator must maintain the lawn mower as instructed here.
Changing of engine-governed speed will void engine warranty.
All adjustments should be checked at least once each season.
Periodically check all fasteners and make sure these are tight.

Always stop engine, allow engine to cool, disconnect spark plug wire before performing any type of maintenance on your machine.

DECK CARE
It is important to clean underside of the mower deck after use to prevent the build-up of grass clippings or other debris. Follow steps below for proper cleaning.

1. Allow the engine to run until it is out of fuel. Do not attempt to pour fuel from the engine.
2. Disconnect spark plug wire.
3. Slowly tip mower so that it rests on the housing.
4. To prevent oil spills, always tip the mower so that the Air Filter is facing up.
5. Hold mower firmly and scrape and clean the underside of the deck with a suitable tool.
6. Gently lower the mower back on its wheels on the ground.

Never tip the mower more than 90° in any direction and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.

MOWER BLADE
To ensure safe operation, have all blade sharpening, balancing and mounting work carried out by an authorized service center. To achieve optimal results, we recommend having the blade checked once a year.
If, in spite of all caution, the blade comes into contact with an obstacle, switch off the engine immediately and pull off the spark plug connector. Tilt the lawn mower to the rear and check the blade for damage. Always keep the side with the air cleaner facing up. Damaged or bent blades must be replaced. Never straighten a bent blade. Never work with bent or heavily worn blades as this will result in vibrations, causing further damage to the mower.

Risk of injury when working with a damaged blade.

CHECKING THE OIL
The oil capacity of the engine crankcase is 16.9 fl. oz.
Check the oil level of the engine according to the Recommended Maintenance Schedule.
The lawn mower should be checked before each use for proper oil level. This is a critical step for proper engine starting.
To check the oil level:

1. Remove the dipstick and clean it.
2. Reinsert the dipstick into the Oil filling hole without screwing it and check Oil lever.
3. If the Oil lever is too low, add the recommended engine oil up to the oil upper lever.
4. Reinstall oil dipstick.

CHANGING/ADDING OIL
Change the oil according to the Recommended Maintenance Schedule. Change the oil when the engine is warm. This will allow for complete drainage. Change oil more often if operating under heavy load or high ambient temperatures. It is also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. The oil capacity of the engine is 16.9 fl.oz. Add oil when the oil level is low. For proper type and weight of oil refer to "GAS AND OIL FILL-UP" portion of the "OPERATION" section.

To refill the crankcase with oil, follow these steps:

1. Make sure the lawn mower is on a level surface. Tilting the lawn mower to assist in filling will cause oil to flow into engine areas and will cause damage. Keep lawn mower level!
2. Remove the dipstick from the engine.
3. Using a funnel or appropriate dispenser, add the correct amount of oil (16.9 fl.oz) into the crankcase.
4. Reinstall dipstick.
   NOTE: Never dispose of used motor oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange oil disposal.

AIR CLEANER MAINTENANCE
Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor. Occasionally check that the air cleaner is free of excessive dirt. Refer to Recommended Maintenance Schedule. For air cleaner detail:

1. Open the air cleaner cover.
2. Remove the sponge-like element from the casing.
3. Wipe the dirt from inside the empty air cleaner casing.
4. Wash the sponge-like element in household detergent and warm water. Small amount of oil in the element is normal and necessary for the engine to work properly.
5. If necessary, replace the paper element.
6. Reinstall the sponge-like element in the air cleaner casing and reinstall the cover.

running the engine with dirty, damaged or missing air cleaner element will cause the engine to wear out prematurely.

SPARK PLUG MAINTENANCE
The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gaped. Refer to Recommended Maintenance Schedule. To inspect the spark plug:

1. Remove spark plug boot. Be careful not to tear insulation or wire.
2. Unscrew the spark plug from the engine using the spark plug wrench provided. There is limited space for the wrench to turn. Use both rows of holes in the spark plug wrench to gain leverage to loosen the plug.
3. Visually inspect the spark plug for cracks or excessive electrode wear. Replace as necessary.
4. Measure the plug gap with a wire gauge. The gap should be 0.028-0.031 inch.
5. If re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base then re-gap the spark plug.
6. Screw the spark plug back into the spark plug hole using the spark plug wrench. Do not over-tighten spark plug. Recommended tightening of spark plug is ½ to ¾ of a turn after spark plug gasket contacts spark plug hole. Reinstall the spark plug boot.

MAINTENANCE SCHEDULE

1. Service more frequently when used in dusty areas.
2. Change engine oil every 25 hours when used under heavy load or in high outside air temperatures.

STORAGE

Never place any type of storage cover or tarp on the MOWER while it is still hot.
If the MOWER is being stored for extended periods of time (30 days or more), drain fuel tank and carburetor bowl.
When storing the mower for extended periods of time:

1. Start the engine and run it until the tank, carburetor bowl and fuel line are completely empty and the engine stalls.
2. Change the oil after each season.
3. Remove the spark plug. Use an oil-can to fill the cylinder with approx. 2 ml of oil. Slowly pull back the starter handle, which will bathe the cylinder wall with oil. Screw the spark plug back in.
4. Clean the cooling fins of the cylinder and the housing.
5. Be sure to clean the entire equipment to protect the paint.
6. Store the equipment in a well-ventilated place.

NOTE: LIMITED WARRANTY does not cover fuel system damage or engine performance problems resulting from neglected storage preparation.

TROUBLESHOOTING

EXPLODED VIEW AND PART LIST

ENGINE EXPLODE VIEW AND PART LIST

Have product questions or need technical support? Please feel free to contact us!
Website: www.powersmartusa.com
Toll free: 1-872-314-0005 (Mon-Fri 9-5 EST)
Email: support@amerisuninc.com
support@powersmartusa.com
Website