HoverPro 450/500/550 Machine

• Read, understand, and follow all instructions on the machine and in the manual(s) before starting.

• Do not put hands or feet near or under the machine.

• Only allow responsible adults, who are familiar with the instructions, to operate this machine.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Clear the area of objects such as rocks, wire, toys, etc., which could be thrown by the blade or cutting line. Stay behind the handle when the engine is running.

• Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.

• Do not operate machine barefooted or while wearing sandals. Always wear substantial, slip-resistant footwear and long pants.

• Do not pull machine backward unless absolutely necessary. Always look down and behind before and while moving backward.

• Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator.

• Stop the engine of the machine when crossing surfaces other than grass, and when transporting the machine to and from the area to be cut.

• Stop the blade(s) if the machine has to be tilted for transportation when crossing surfaces other than grass, and when transporting the machine to and from the area to be mowed.

• Do not operate machine without the safety protective devices in place and working.

• Never leave a running machine unattended.

• Stop the engine, wait until the blade comes to a complete stop, and disconnect the spark plug wire before cleaning or unclogging the machine.

• Operate machine only in daylight or good artificial light.

• Do not operate machine while under the influence of alcohol or drugs.

• Never operate machine in wet grass. Always be sure of your footing; walk; never run.

• If the machine should start to vibrate abnormally, stop the engine and check for the cause immediately. Vibration is generally a warning of trouble.

• Always wear eye protection when operating machine.

• See manufacturer's instructions for proper operation and installation of accessories. Only use accessories approved by the manufacturer.

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

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

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

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

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

• When using the machine, always keep both hands on the handlebar.

• When cutting steep slopes from the top of the slope and a longer reach is needed, never tie the machine to a rope, use the extended handlebar kit option.

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.

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

• Be alert and turn machine off if a child enters the area.

• Never allow children to operate the machine.

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

This machine has a sound pressure level at the operator’s ear of 90 dBA (model 02602), 88.5 dBA (model 02604), or 88 dBA (model 02606) which includes an Uncertainty Value (K) of 2 dBA. The sound pressure level was determined according to the procedures outlined in EN 836.

This machine has a guaranteed sound power level of 100 dBA (model except 02602) or 98 dBA (models 02604 and 02606), which includes an Uncertainty Value (K) of 2 dBA. The sound power level was determined according to the procedures outlined in ISO 11094.

Measured vibration level for the left hand = 5.4 m/s2 (models 02602 and 02604) or 4.0 m/s2 (model 02606)

Measured vibration level for the right hand = 6.2 m/s2 (model 02602), 4.3 m/s2 (model 02604), 4.7 m/s2 (model 02606).

Uncertainty Value (K) = 3 m/s2 (model 02602), 2.5 m/s2 (model 02604), or 2 m/s2 (model 02606).

The measured values were determined according to the procedures outlined in EN 836.

1. Slide 2 bushes into the frame.

   

   Figure 3

   1. Lower handle
   2. Bushes
   3. Nut
   4. Frame
   5. Bolt
   6. Washers

2. Place the lower handle between the bushes and secure it with 1 handlebar bolt, 2 washers, and 1 nut.

   Note: Place the lower handle between the bushes with the kick stop assembly on the right hand side.

3. Repeat for the opposite side.

4. Align the holes on the upper handle with the lower handle.

   

   Figure 4

   1. Upper handle
   2. Hand wheel
   3. Washer
   4. U bolt
   5. Lower handle

5. Fit the U bolt through the upper and lower handle and secure it with a washer and a hand wheel.

6. Attach the throttle assembly to the outside of the handlebar and secure it with a nut and a pan screw.

   

   Figure 5

Important: Your machine does not come with oil in the engine. Before starting the engine, fill the engine with oil.

Max. fill: 0.59 l (20 oz.), type: Multigrade Mineral 10W-30 oil with an API service classification of SF, SG, SH, SJ, SL, or higher.

1. Move the machine to a level surface.

2. Remove the dipstick (Figure 6).

   

   Figure 6

   1. The oil level is at its maximum.
   2. The oil level is too high—remove oil from the crankcase.
   3. The oil level is too low—add oil to the crankcase.

3. Slowly pour oil into the oil fill hole, wait 3 minutes, and check the oil level on the dipstick by wiping the dipstick clean and then inserting, but not screwing in, the oil fill cap into the hole (Figure 7).

   

   Figure 7

   Note: Fill the engine crankcase with oil until the dipstick indicates that the engine oil level is correct as shown in Figure 6. If you overfill the engine with oil, remove the excess oil as directed in Changing the Engine Oil.

4. Install the dipstick and hand tighten it securely.

   Important: Change the engine oil after the first 5 operating hours; change it yearly thereafter. Refer to Changing the Engine Oil.

Recommended Fuel:

• For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

• Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

• Do not add oil to gasoline.

Figure 10

1. Move the machine to a level surface.

2. Remove the dipstick and wipe it with a clean cloth.

3. Insert, but do not screw in, the dipstick into the oil fill hole.

4. Remove the dipstick and check it.

5. To determine the proper oil level on the dipstick, refer to Figure 11).

   

   Figure 11

   1. The oil level is at its maximum.
   2. The oil level is too high—remove oil from the crankcase.
   3. The oil level is too low—add oil to the crankcase.

6. If the oil level is low, slowly pour oil into the oil fill hole, wait 3 minutes, and check the oil level on the dipstick by wiping the dipstick clean and then inserting, but not screwing in, the oil fill cap into the hole.

   Note: Max. fill: 0.59 l (20 oz.) Multigrade Mineral 10W-30 oil with an API service classification of SF, SG, SH, SJ, SL, or higher.

   Note: Fill the engine crankcase with oil until the dipstick indicates that the engine oil level is correct as shown in Figure 11. If you overfill the engine with oil, remove the excess oil as directed in Changing the Engine Oil.

7. Install the dipstick and hand tighten it securely.

   Important: Change the engine oil after the first 5 operating hours; change it yearly thereafter. Refer to Changing the Engine Oil.

Adjust the cutting height as desired.

1. Turn the fuel switch to the off position.

2. Disconnect the wire from the spark plug.

3. Tilt the machine on its left side.

4. Wearing protective gloves, remove the flexiblade/cutterbar.

5. Remove the retaining bolt.

6. Reposition the spacers to the desired height, then reinstall the flexiblade/cutterbar (Figure 13, Figure 12).

   

   Figure 12

   1. Spacers
   2. Blade retainer
   3. Bolt
   4. Flexiblade
   5. Blade retainer
   

   Figure 13

   1. Cutterbar
   2. Spacers
   3. Blade retainer
   4. Bolt
   5. Large spacer

   Note: The large spacer must be positioned directly below the impeller at all times.

1. Place the throttle control to the choke position, ensure that the fuel switch is in the On’ position.

   

   Figure 14

2. Hold the engine stop handle against the handle.

   

   Figure 15

   1. Handle
   2. Engine stop handle

3. Place your foot on the deck and tilt the machine towards you (Figure 16).

   

   Figure 16

4. Pull the recoil start handle.

Note: If the machine does not start after several attempts, contact an Authorized Service Dealer.

Use the throttle assembly to adjust the choke (Figure 17).

Figure 17

1. Choke on
2. Choke off

To stop the engine, release the blade control bar (Figure 18).

Important: When you release the engine stop handle, both the engine and blade should stop within 3 seconds. If they do not stop properly, stop using your machine immediately and contact an Authorized Service Dealer.

Figure 18

• Use care when loading or unloading the machine into a trailer or a truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both the front and the rear straps should be directed down and outward from the machine.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the spark plug wire from the spark plug (Figure 19) before performing any maintenance procedure.

   

   Figure 19

   1. Spark plug wire

3. After performing the maintenance procedure(s), connect the spark plug wire to the spark plug.

   Warning

   Tipping the machine may cause the fuel to leak. Gasoline is flammable, explosive and can cause personal injury.

   Run the engine dry or remove the gasoline with a hand pump; never siphon.

   Important: Always tip the machine onto its side with the dipstick down.

1. Press down on the latch tabs on top of the air cleaner cover (Figure 20).

   

   Figure 20

   1. Cover
   2. Latch tabs
   3. Filter

2. Open the cover.

3. Remove the filter (Figure 20).

4. Inspect the filter, and replace it if it is damaged or excessively dirty.

5. Inspect the paper air filter.

   1. If the filter is damaged or is wet with oil or fuel, replace it.

   2. If the filter is dirty, tap it on a hard surface several times or blow compressed air less than 207 kPa (30 psi) through the side of the filter that faces the engine.

      Note: Do not brush the dirt off the filter; brushing forces dirt into the fibers.

6. Remove dirt from the air cleaner body and cover using a moist rag. Do not wipe dirt into the air duct.

7. Insert the filter into the air cleaner.

8. Install the cover.

1. Ensure that the fuel tank contains little or no fuel so that fuel does not leak out when you tip the machine onto its side.

2. Run the engine a few minutes before changing the oil to warm it.

   Note: Warm oil flows better and carries more contaminants.

3. Disconnect the wire from the spark plug. Refer to Preparing for Maintenance.

4. Remove the dipstick.

5. Tip the machine onto its side, with the dipstick down, to drain the used oil out through the oil fill tube.

6. Return the machine to the operating position.

7. Slowly pour oil into the oil fill hole, wait 3 minutes, and check the oil level on the dipstick by wiping the dipstick clean and then inserting, but not screwing in, the oil fill cap into the hole.

   Note: Max. fill: 0.59 l (20 oz.), type: Multigrade Mineral 10W-30 oil with an API service classification of SF, SG, SH, SJ, SL, or higher.

   Note: Fill the engine crankcase with oil until the dipstick indicates that the engine oil level is correct as shown in (Figure 21). If you overfill the engine with oil, remove the excess oil as directed in 5.

   

   Figure 21

   1. The oil level is at its maximum.
   2. The oil level is too high—remove oil from the crankcase.
   3. The oil level is too low—add oil to the crankcase.

8. Install the dipstick and hand tighten it securely.

9. Dispose of the used oil properly at a local recycling center.

Check the spark plug after every 100 operating hours. Use an Champion RN9YC spark plug or equivalent.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug.

3. Clean around the spark plug.

4. Remove the spark plug from the cylinder head.

   Important: Replace a cracked, fouled, or dirty spark plug. Do not clean the electrodes because grit entering the cylinder can damage the engine.

5. Set the gap on the plug to 0.76 mm (0.030 inch) (Figure 22).

   

   Figure 22

   1. Center electrode insulator
   2. Side electrode
   3. Air gap (not to scale)

6. Install the spark plug and the gasket seal.

7. Torque the plug to 20 N-m (15 ft-lb).

8. Connect the wire to the spark plug.

Important: You will need a torque wrench to install the blade properly. If you do not have a torque wrench or are uncomfortable performing this procedure, contact an Authorized Service Dealer.

Examine the blade whenever you run out of gasoline. If the blade is damaged or cracked, replace it immediately. If the blade edge is dull or nicked, have it sharpened or replace it.

1. Disconnect the spark plug wire from the spark plug. Refer to Preparing for Maintenance.

2. Tip the machine onto its side, with the air filter up.

3. Use a block of wood to hold the blade steady.

4. Remove the blade (turn the blade bolt counterclockwise), saving all the mounting hardware.

5. Install the new blade (turn the blade bolt clockwise) and all mounting hardware.

   Important: Position the curved ends of the blade to point toward the machine housing.

6. Use a torque wrench to tighten the blade bolt to 25 N-m (18 ft-lb).

   Important: A bolt torqued to 25 N-m (18 ft-lb) is very tight. While holding the blade with a block of wood, put your weight behind the ratchet or wrench and tighten the bolt securely. This bolt is very difficult to overtighten.

1. Tip the machine on its side.

2. Use a brush or compressed air to remove grass and debris from the exhaust guard, the top cowl, and the surrounding deck areas.