Form No. 3326–479 Mid–Size Mower ProLine Gear 12.5 HP with 36 in.
This spark ignition system complies with Canadian ICES-002. Cleaning the Cooling System . . . . . . . . . . . . . . . Checking Tire Pressure . . . . . . . . . . . . . . . . . . . . Fuse Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Electric Clutch . . . . . . . . . . . . . . . Fuel Tank Service . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter Service . . . . . . . . . . . . . . . . . . . . . .
or danger — “personal safety instruction.” Read and understand the instruction because it has to do with safety. Failure to comply with the instruction may result in personal injury. General Lawn Mower Safety 1 The following instructions have been adapted from the ISO standard 5395. m–5191 Figure 1 This cutting 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.
• Before using, always visually inspect to see that guards, and safety devices, such as deflectors and/or grass catchers, are in place and working correctly. Stop the blades if the lawn mower has to be tilted for transportation when crossing surfaces other than grass and when transporting the lawn mower to and from the area to be mowed. • Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged.
• To reduce the fire hazard, keep the engine, silencer, battery compartment and gasoline storage are free of grass, leaves, or excessive grease. • Check the grass catcher frequently and replace if worn or deteriorated. • Replace worn or damaged parts for safety. • Replace faulty silencers. • If the fuel tank has to be drained, do this out–doors. • Do not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed can increase the hazard of personal injury.
Slope Chart 7
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 98–4387 93-8069 1. Caution—wear hearing protection. 1. Warning hot surface—stay away. 98–3264 1. Read the operator’s manual for proper transmission shifting 93–7442 1. Parking brake 93–9353 1. Disengage and shut fuel valve off before transporting 93–7298 1. Forward to engage machine traction 2.
93–7010 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard—keep the deflector in place. 93–7316 3. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard—keep the deflector in place. 3. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 93-7818 93–7828 1. Thrown object hazard—keep the deflector in place. 1.
104–8184 1. Read the operator’s manual for proper procedure. Stop electric clutch before changing machines height–of–cut. 2. Insert pin at desired height–of–cut. 105–0885 1. Cutting/dismemberment hazard of hands or feet—stay away from rotating blades and moving parts. 2. Warning—stop engine before leaving the machine. 3. Warning—read the operator’s manual. 4. Thrown object hazard—keep bystanders away. 5. Thrown object hazard—keep the deflector in place. 104–8181 1. Choke 2. Fast 3. Variable speed 4.
Gasoline and Oil Recommended Gasoline Warning Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. Important Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Set Up Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY. USE Fuel tank 1 Control panel 1 Bolt, 5/16 x 7/8 in. (22 mm) 2 Lock washer, 5/16 in. 2 Washer, 5/16 in. 4 Spring 2 Stud 2 Hose clamp 1 Shift lever 1 Rubber seal 1 Square hole washer 1 Spring washer 1 Locknut, 3/8 in. 1 Upper handle 1 Flanged bolt 3/8 x 1 in.
Install Shift Lever 3 1. Remove the locknut (3/8 in.) and spring washer from the stud on top of the transmission. 2 Note: Do not remove rubber seal washer and square hole washer from transmission shaft. 1 2. Slide shift lever through control panel and align mounting hole in lever with square on transmission shaft. Secure lever to transmission with previously removed spring washer and locknut (Fig. 4). m–5221 Figure 2 1. Rear frame 2. Control panel 3. Fuel tank 3.
4 1 5 6 2 2 1 3 4 4 Rear View 7 8 2 3 m–5330 Figure 6 1. Upper handle 2. Rear frame 3. Flange bolt, 3/8 x 1 in. (26mm) 4. Flange nut, 3/8 in. m–5458 5. 6. 7. 8. Upper mounting hole Lower mounting holes Low position High position Figure 5 1. Shift lever, 2nd gear 2. Control panel 3. Shift lever, neutral 4. Equal distance Install Control Rods 1. Thread rod fittings equal distance onto each control rod. For a starting point, thread fittings on approximately 1–3/4 in.
2 1 4 1 2 3 4 m–5329 m–5233 Figure 7 1. Control rod and fitting 2. 1–3/4in. (44 mm) 3. Idler bracket Figure 9 4. Clevis pin, washer and hairpin cotter 1. Upper control bar 6. If brake adjustment is required, remove hairpin cotter and washer securing brake rod fitting to idler bracket (Fig. 10). 3. Check the gap between upper control bar and fixed bar with wheel drive fully engaged. Gap should be approximately 1 to 1-1/4 in. (25–32 mm) (Fig. 8). 7.
1. On opposite side of muffler, install extra hairpin cotter pins into front and rear height–of–cut pins (Fig. 11). 1 2 3 Figure 12 2 1. Caution 2. Wear hearing protection 1 Controls Become familiar with all the controls (Fig. 13) before you start the engine and operate the machine. m–5314 Figure 11 1. Hairpin cotter 2. Extra spacers Throttle Control – The throttle control has three positions: CHOKE, FAST and SLOW. 3.
2 2 5 1 7 9 3 m–5233 6 Figure 14 8 1. Upper control bar 1 2. Parking brake lever (set position) 4 Starting and Stopping the Engine m–5190 Starting Figure 13 1. Throttle control 2. Blade control bail 3. Blade control switch (PTO) 4. Gear shift lever 5. 6. 7. 8. 9. 1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open. Upper control bar Lower control bar Parking brake lever Ignition switch Handle 2.
2 2 1 3 1 m–5190 m–5190 Figure 15 1. Throttle lever Figure 16 2. Ignition key 1. Upper control bar 2. Blade control bail 3. Blade control switch (PTO) 4. Set the parking brake. 5. Pull wire off spark plug(s) to prevent possibility of accidental starting before storing machine. Disengaging the Mower Blades (PTO) 6. Close fuel shut off valve before storing machine. 1. Releasing blade control bail to disengage blades (Fig. 16).
Backward 1. Set the parking brake and start the engine; refer to Starting and Stopping the Engine, page 18 1. To go backward, move the shift lever to reverse gear. 2. Squeeze the blade control bail against upper control bar. The blades should not rotate. 2. Release the parking brake; refer to Releasing the Parking Brake, page 18. 3. Then continue holding the blade control bail and pull up on the blade control switch and release. The clutch should engage and the mower blades begin rotating. 3.
Transporting Machines 1 Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. 2 To transport the machine: • Lock brake and block wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes.
2. Select hole in height-of-cut post corresponding to the height-of-cut desired (Fig. 20). 3. Reinstall the bolt, washers and nut (Fig. 21). 3. Lift on side of deck and remove hairpin cotter (Fig. 20). 3 4. Add or remove spacers if needed and then align holes and insert hairpin cotter (Fig. 20). 4 Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Air Cleaner Service Important worn. Replace the foam element if it is torn or Service Interval/Specification 2 Foam Element: Clean and re-oil after every 25 operating hours. 1 Paper Element: Clean after every 100 operating hours. Replace after every 300 operating hours. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. ÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓ m–1213 Figure 23 1. Foam element Removing the Foam and Paper Elements 1.
3. Install the air cleaner cover and secure with cover nuts (Fig. 22). 1 2 Engine Oil Service 3 Service Interval/Specification Change oil: • After the first 5 operating hours. • After every 50 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Figure 25 1. Oil dipstick 2. Metal end Oil Type: Detergent oil (API service SF, SE/CC, CD or SE) Crankcase Capacity: with filter, 54 oz. (1.6 l) with out filter, 47 oz. (1.4 l) 3.
Spark Plug Service 5. Slowly pour approximately 80% of the specified oil, page 25, into the filler tube (Fig. 25). Now check the oil level; refer to Checking Oil Level, page 25. Slowly add additional oil to bring to “FULL” mark on dipstick. Service Interval/Specification Service Interval/Specification Check the spark plug(s) after every 100 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
Lubricate the castor and wheel bearings 2. Check the gap between the center and side electrodes (Fig. 29). Bend the side electrode (Fig. 29) if the gap is not correct. 2 1. Lubricate the front wheel bearings and front spindles until grease begins to ooze out of the bearings (Fig. 30). 3 2. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Fig. 30). 1 Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. 0.025 in. (0.65 mm) Figure 29 1.
2. Grease the fitting on the PTO belt idler arm pivot (Fig. 32). 1 2 m–2147 Figure 33 1. Rear Tire 2. Castor tire Fuse Service m–5247 Service Interval/Specification Figure 32 Cleaning the Cooling System The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows check component or circuit for malfunction or short. To replace fuse pull out on the fuse (Fig. 34) to remove or replace it. Service Interval/Specification Fuse: F1–7.
Checking the Brake 1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 3 4 2. Rear wheels must lock when you try to push the machine forward. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 29. 6 2 5 1 3. Release the brake and press upper control bar very lightly, approximately 1/2 in. (13 mm), wheels should rotate freely.
Fuel Tank Service Danger In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 1 2 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. m–5185 Figure 37 1. Fuel shut-off valve Draining The Fuel Tank 2.
3 1 2 1 1 3 3 2 m–5234 Figure 38 1. Hose clamp 2. Fuel line m–151 Figure 39 3. Filter 1. Cutting Edge 2. Curved Area Cutting Blade Service 3. Wear/slot Forming Checking for Bent Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. 1. Rotate the blades until the ends face forward and backward (Fig. 40). Measure from a level surface to the cutting edge, position “A”, of the blades (Fig. 41).
1/8 in. (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 32. 1 Warning m–1854 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. Figure 43 1. Sharpen at original angle • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. 2. Check the balance of the blade by putting it on a blade balancer (Fig. 44).
5. Perform steps in the following sections Frame Set Up, Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling. Checking Engine Deck Height Frame Set Up 2. Adjust the tire pressure in all tires to specifications on page 28. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 3. Measure engine deck height at location “A” (Fig. 46). Checking Carrier Frame and Deck Alignment 4. Measure engine deck height at location “B” (Fig. 46). 5.
6. The tire pressure may also be adjusted slightly to make a 1/4 in. (6 mm) pitch. 5 5 3 2 5 2 3 24 in. (61cm) A B 5 A 4 2 4 B 4 1 1 4 m–5231 Figure 48 m–5242 1. Caster Wheel 2. Carrier Frame 3. Front height–of–cut pins Figure 47 1. Caster Wheel 2. Carrier Frame 3. 1/4–3/8 in. (6 mm–10 mm) pitch over 24 in. (61 cm) length 1 4. Height at locations A and B 5. Caster spacers 4. Same height at locations A and B 5.
Checking the Deck Side-to-Side Leveling 1. Check the tire pressure on both deck and traction unit. MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2. Position the blades side-to-side (Fig. 52). Measure at “A” and “B” locations (Fig. 52) from a level surface to the cutting edge of blade tips (Fig. 53). m–1087 Figure 50 3. The difference between measurements “A” and “B” should be no more than 1/4 in. (6 mm).
2. Set the height-of-cut to the 4 in. (101.6 mm) position following the height-of-cut decal. 2. Remove top capscrew securing idler support and idler bracket to rear frame (Fig. 56). 3. With the machine on level surface, position one blade front-to-rear (Fig. 54). Measure at “A” and from level surface to the cutting edge of the blade tips (Fig. 55). 3. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Fig. 56). 4. The measurement should be 4 in. (101.
11. Install PTO drive belt. Install lower shield. 3 1 1 4 4 9 3 5 7 2 6 8 m–5335 Figure 57 1. 2. 3. 4. 5. Traction belt Idler pulley Clutch retainer Tension spring Clutch wire connector 6. 7. 8. 9. 2 Pivot bolt Drive pulley Engine deck Lower shield 5 m–5247 Figure 58 1. Deck belt 2. Idler arm spring 3. Outward pulley Replacing the Deck Belt 4. PTO Drive Belt 5.
11. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs. 1 12. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the hand knobs. 2 3 2 1 3 4 m-5198 2 Figure 60 4 1. Locking Pin 2. Spacers (locate as required) m–5247 3. Carrier frame mounting tube 4. Caster wheel fork Figure 59 1. PTO engagement pulley 2. Drive belt idler 3. Drive Belt 4. Double Spindle Pulley 4.
2 2 1 1 3 2 m–5197 5 4 Figure 61 1. Carrier Frame Mounting Tube 3 m-5210 Figure 62 2. Bushing 1. Locknut 2. Wheel Bolt 3. Bushing Caster Wheel and Bearings Service 4. Spanner Bushing 5. Roller Bearing 5. To assemble, place one bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Fig. 62). The caster wheels rotate on a roller bearing supported by a spanner bushing.
2. Place spacer and spring onto grass deflector. Place the “L” end of spring behind deck edge. Note: Make sure the “L” end of spring is installed behind deck edge before installing the bolt as shown in figure 63. 3. Install bolt and nut. Place “J” hook end of spring around grass deflector (Fig. 63). Important The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 8 6 4 2 3 5 1 7 m-5037 Figure 63 1. 2. 3. 4. 5.
BK J9–1 BK GND BK P5–4 BK PTO CLUTCH GN P5–3 HOURMETER (OPTIONAL) D2 K1 DELAY MODULE P5–2 PK 7.5A F1 T1 D3 R2 D1 P5–1 S2 CLUTCH SW. OR (MOMENTARY) 2 5 BK W C1 D4 S3 BAIL SW. BN (NORMALLY OPEN) J8–1 PK R1 M R3 G 1 3 4 41 R4 S1 IGNITION C2 D5 D6 BK PK – HOURMETER (OPTIONAL) PK BU W + BU BRIDGE RECTIFIER PK KEY SW.
Cleaning and Storage A. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. B. Stop engine, allow to cool and drain the fuel tank; refer to Fuel Tank, page 30, or operate engine until it stops. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
PROBLEM Engine g loses power. Engine g overheats. Machine does not drive. Abnormal vibration. POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine load is excessive. 1. Reduce ground speed. 2. Air cleaner is dirty. 2. Clean air cleaner element. 3. Oil level in crankcase is low. 3. Add oil to crankcase. 4. Cooling fins and air passages under engine blower housing are plugged. 4. Remove obstruction from cooling fins and air passages. 5. Spark plug is pitted, fouled, or gap is incorrect. 5.
PROBLEM Uneven cutting g height. g Blades do not rotate. POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade(s) not sharp. 1. Sharpen blade(s). 2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s). 3. Mower is not level. 3. Level mower from side-to-side and front-to-rear. 4. Underside of mower is dirty. 4. Clean the underside of the mower. 5. Tire pressure is incorrect. 5. Adjust tire pressure. 6. Blade spindle bent. 6. Contact Authorized Service Dealer. 1.
