Transcript
A S S E M B L Y IN S T R U C T IO N S FO R C H A RG ER A ND TH E BO SS Q U IC K A T T A C H G R A S S B A G G E R
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P Copyright, Shivvers Mfg., 2005
P-12102
(7/2005)
TABLE OF CONTENTS SECTION
PAGE
WARNING
1
BLOWER PULLEY INSTALLATION
2
ENGINE GUARD REMOVAL BOSS
3
ACCESSORY MOUNT INSTALLATION BOSS
4
ENGINE GUARD REMOVAL CHARGER
5
ACCESSORY MOUNT INSTALLATION CHARGER
6
BAGGER PULLEY ASSEMBLY
7
BAGGER MOUNT ASSEMBLY
8
MOUNTING GRASS BAGGER TO LAWN MOWER
9
BAGGER DOOR DUMP HANDLE ASSEMBLY
10
BLOWER TO HOPPER & EXTENSION PIECES
11
BLOWER TO BAGGER MOUNT
12
BLOWER TO BAGGER MOUNT FRONT
13
BELT INSTALLATION & ADJUSTMENT
14
WIRING HARNESS INSTALLATION
15
CHARGER WIRING HARNESS TO HOUR METER
16
BOSS WIRING HARNESS TO HOUR METER
17
FRONT WEIGHT KIT INSTALLATION
18
TRANSITION MOUNTING
19
QUICK CHANGE OVER PROCEEDURE
20
BAGGER REMOVAL & MOUNTING
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Copyright, Shivvers Mfg., 2005
Do not operate grass collector or mower without all guards and safety decals in place. Refer to the owners manual for safe and proper use of the mower. Make sure all guards, shields, and deflectors are in place and in good working condition.
1)
2) Make sure all decals are present and readable. Part no.’s are listed in the parts book section located at the back of this manual.
3) Examine flexible tubing for rips or worn places before each use. Make sure hose clamps at each end of the flexible tubing are tight. 4) Make sure transition is properly mounted and locked into position. Proper attaching of transition to deck is explained in the operation section In this manual
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P-12102
BLOWER PULLEY INSTALLATION 1) First unplug the clutch wire from the wire harness and remove deck drive belt. 2) Then remove the bolt in the end of the crank shaft. When you remove the bolt, flat washer, and lock washer the clutch will slide off of the crank shaft. (NOTE where the stop pin lines up with the notch in the clutch.) 3) Drive the “headed spacer” out of the clutch. Carefully hang clutch by wires. 4) Check the diameter on the “headed spacer” and use the appropriate pulley and shaft extension supplied with bagger. 5) Next slide the clutch back on the crank shaft rotating it so the clutch stop pin lines up with the notch in the clutch. Block the clutch up with a wooden block. Put set screw in blower pulley. 6) Slide the Shaft Extension up into the bore of the clutch, making sure the keyway in the shaft lines up with the key in the clutch.
Clutch
7) While holding the Extension Shaft up in the Clutch, slide the Blower Pulley over the Key Shaft, with the set screw down. Insert the Key into the key way and tighten the Set Screw.
Blower Pulley
Set Screw 8)
Flat washer Shaft Extension Lock Washer Bolt Note: Use metric bolt on Liquid cooled Kawasaki.
Secure with (2) 7/16 Flat Washers first, then the Lock Washer, then the Bolt supplied with the kit. Or use existing flat washers. Note: On liquid cooled Kawasaki Engines use the metric bolt. 9)
10) If your mower exhausts to the side this ELBOW and CLAMP is needed to deflect the hot exhaust from the bagger frame. Keep from pointing elbow down as this will burn the grass when stopped and engine idling.
2 Copyright, Shivvers Mfg., 2005
Torque Bolt to 50 foot lbs.
NOTE: THERE ARE TWO DRIVE PULLEYS AND TWO EXTENSION SHAFTS TO CHOOSE FROM. USE PROPER PAIR TO MATCH YOUR CLUTCH.
P12102
ENGINE GUARD REMOVAL BOSS LAWN MOWER ONLY
• • • • • • •
Raise deck to highest position and lock with handle. Loosen spring tension jam nut and remove from end of spring tension bolt. NOTE factory position of tension bolt so it can be returned after assembly of accessory mount. Loosen spring tension bolt until bolt is flush with nut welded to bracket. Their will still be some tension on spring, pull against tension and remove spring tension bolt. Remove 4 bolts holding engine guard on and remove guard. Bolts will be reused when accessory mount is assembled.
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P-12102
ACCESSORY MOUNT INSTALLATION BOSS LAWN MOWER ONLY • • • •
Assemble accessory mount to frame in lower holes with (4) existing bolts from engine guard, returning spring take up brackets to front bolt left hand side. Hook spring to bracket, pull bracket stretching spring and start tension bolt into bracket loose. Retighten bolt for spring tension to position as noted when removed or adjust until deck lifts up and down comfortably to your strength. Assemble jam nut to tension bolt, tighten while holding tension bolt with wrench.
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P-12102
ENGINE GUARD REMOVAL CHARGER
• • • • • • • •
Raise deck to highest position and lock with handle. Use one of the dump rods as a pry tool to remove spring. Remove the clevis pin from the clevis and position clevis over spring under bolt, then reinsert pin and clamp over rod. Pry against bolt and outward until spring comes off end of bolt. Maintain a good grip on rod and keep fingers away from spring. Remove (4) bolts from engine guard and remove guard. Keep bolts to assemble accessory mount. Remove spring bolt for accessory mount application.
5 Copyright, Shivvers Mfg., 2005
P-12102
ACCESSORY MOUNT INSALLATION CHARGER • • • • • • •
Assemble accessory mount to mower frame with the bolts from engine guard. Use upper holes in accessory mount for charger. Assemble spring bolt from engine guard to lowest hole in accessory mount. With deck in highest position assemble spring. Using the dump rod open tube end as a tool, position rod through spring end first. Position hollow end over bolt head, keeping pressure on rod pry spring rearward. Push spring down rod as you pry until spring snaps over bolt head.
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P-12102
BAGGER PULLEY ASSEMBLY
ACCESSORY MOUNT
USE BOTTOM HOLES FOR BOSS MOWERS USE TOP HOLES FOR CHARGER MOWERS
PULLEY REAR PULLYE BRACKET FRONT PULLEY BRACKET PULLEY
(1) Attach FRONT and REAR PULLEY BRACKETS to the ACCESSORY MOUNT with 5/16 x ¾” long bolts and lock nuts. Secure the PULLEY BRACKETS together with a 5/16 x ¾” long bolt. Use top set of holes for Charger mowers and bottom set of holes for Boss mowers. (2) Install (2) PULLEYS, as shown, with long end of bearing toward brackets. Then a thin series ½” flat washer followed by ½ x 1-1/2” long bolt. The nuts go on the inside of the brackets.
7 Copyright, Shivvers Mfg., 2005
P-12102
BAGGER MOUNT ASSEMBLY
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(1) (2) (3) (4) (5)
Lay box on its side and slide bagger out on the ground. Stand bagger on its top, making the underside reinforcements accessible. Unpack parts box to get left and right hand mounts. You will find hardware in a pack and will need (4) 3/8” flat washers and (4) lock nuts. Assemble mounts as shown, and secure nuts with 9/16” socket or wrench.
8 Copyright, Shivvers Mfg., 2005
P12102
MOUNTING GRASS BAGGER TO LAWN MOWER • Back mower into bagger.
• Refer to air cleaner instructions before lifting bagger into place. • Position lower mounting arms with U shaped mounts over bar of accessory mount attached to mower. • Assemble clevis pins through holes in U shaped mounting arms and assemble, flat washer and rue pin. • For safety purposes tie a rope or chain around bagger and tie or hook to arm rest brackets, while lifting bagger up into position. •
Tie or hook bagger before the upper arm bushing holes are to the holes on the accessory mount, giving you adjustment movement to be able to lift bagger and line up holes.
• Assemble T-Handle pins through bushings on upper mounting arms, into bushings on accessory mount, on lawn mower. Untie bagger.
9 Copyright, Shivvers Mfg., 2005
P-12102
BAGGER DOOR DUMP HANDLE ASSEMBLY •
Install (2) “dump handles”, as shown, with 3/8” pins through the bottom holes in the “door”. nd Place the 2 hole in the “dump handles” over the 3/8” pins protruding from the “dump rod”, as shown. Adjust the “dump handles”, on the threaded end, until the “door” is tightly closed when the arms on the “dump rod” are parallel with the “ dump handles”.
•
Install a “rue ring” on each pin to hold the “dump handle” on.
•
Adjust “stop bolt” until the dump rod locks over center to hold the “door” closed.
•
Install “plastic handle” over left “dump handle” by putting some Rubbing Alcohol inside the handle.
STOP BOLT Hammer together
FOAM TAPE
HINGE BOLT
DOOR
STOP PLATE PIVOT STUD
DUMP HANDLE PLASTIC HANDLE
RUE RING
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P-12102
BLOWER TO HOPPER & EXTENSION PIECES • • • • • •
Get blower & (2) bolts ¼-20x3/4 (2) nuts & position to hopper tipping edge into extension plate. Assemble bolt & nuts loose to hold blower up in position. Get blower extension top & (8) ¼-20x3/4 bolts & ¼-20 nuts. Assemble extension top to extension right & left & blower loose. With 7/16 socket & wrench secure blower to extensions right, left & top. Do not tighten the carriage bolts at the hopper until belt has been insalled.
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P-12102
BLOWER TO BAGGER MOUNT • •
Get a 5/16” bolt & flat washer. Secure bottom left side of blower to rear mount leg.
'--13011 5/16-1 8x3/4" Flat Washer 5/16" DfT.... ' , ,, " SGJIlE
12 Copyright, Shivvers Mfg., 2005
P-12102
Remove Top Belt Guard
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Flat Washer
, BLOWER TO BAGGER MOUNT FRONT
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* Assemble 5I16-18x314 boll &flat washer through RH front mount leg &through front bell guard. * Assemble 5116 nykx:k. nut loose. This will be tightened after belt is aSlembled and tension is adjusted.
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;1,
~~yiock Nut
P-12102
BELT INSTALLATION & ADJUSTMENT 1) Install the “Adjustment screw” (5/16-18 x 4”) and flat washer into the hole in the “Adjustment tab” and down through the rear belt guard. Install a flat washer and a lock nut on the bottom of the “Adjustment screw” 2) MAKE SURE THE DECK BELT IS ON NOW. 3) Install “V-Belt” over pulley on the “Clutch” and down around the (2) “Idler” pulleys. Route the belt around The “Engine pulley” as shown. Check for proper “twist’ in belt from one v-pulley to the next. Note: 75” belt on Boss mowers and 72” belt on Charger mowers 4) Tighten the “Adjustment screw” until you can flex the belt 3/8” to 3/4” at the mid point. 5}
When the belt tension is correct, tighten the (6) bolts and nuts that connect the blower to the frame and hopper.
ADJUSTMENT TAB
ADJUSTMENT SCREW
CLUTCH
V-BELT
IDLERS
14 Copyright, Shivvers Mfg., 2005
P-12102
WIRING HARNESS INSTALLATION 1) Remove nut from toggle switch. 2) Insert the “Toggle switch” through the hole in the right frame, as shown, with the groove in the threaded stud to the top and secure with nut. 3) Route the “Clutch wire” through the frame, as shown. Secure the clutch wire away from the belt By passing it through the “Kurly loc”. 4) The “Bagger Connector” is used only when installing and removing the bagger. 5)
Unplug the red wire on the hour meter of the tractor. Plug the single red wire from the “switch” into the hour meter, where you removed the old wire. Plug the old wire into the tab on the new red wire. Use wire ties to fasten the red wire to the throttle cable.
6) Unplug the connector to the deck clutch, in front of the engine. Plug in the connectors from the “switch” wire harness into the (2) ends you just unplugged. Use wire ties to tie the wire harness away from the engine where possible. 7) Secure all loose wires with wire ties. 8) With wiring complete, secure the “Belt cover” over the Front and rear belt guards with (2) 1/4x3/4” bolts, locks Washers, and flat washers.
TOGGLE SWITCH With groove in threaded stud to the top.
NUT BAGGER CONNECTER
TO DECK CLUTCH
TO ENGINE
TO HOUR METER See page 16
BELT COVER
CLUTCH WIRE
KURLY-LOC
15 Copyright, Shivvers Mfg., 2005
P-12102
CHARGER WIRING HARNESS TO HOUR METER • • • • •
Remove cover under right hand armrest, (3) bolts. Pull red double wire from hour meter spade. Connect red single blower wire with jumper to hour meter. Reconnect double red to jumper connection on blower wire. Reassemble cover with (3) bolts and secure. Cover
Hour Meter
Red Double Wire on Hour Meter
Blower Wire with Jumper 16 Copyright, Shivvers Mfg., 2005
P-12102
BOSS WIRING HARNESS TO HOUR METER • • • • •
Remove cover under right hand arm rest, (4) bolts. Pull red double wire from hour meter spade. Connect red single blower wire with jumper to hour meter spade. Reconnect double red to jumper connection on blower wire. Reassemble cover with (4) bolts and secure.
Cover
Red Double Wire on Hour Meter
Hour Meter
Blower Wire With Jumper
17 Copyright, Shivvers Mfg., 2005
P-12102
FRONT WEIGHT KIT INSTALLATION NOTE: MOWERS REQUIRE 3 WEIGHTS AND APPROPRIATE BRACKETS.
1) Mount (two) weight mount brackets to the axle behind the caster pivot tubes using (four) carriage bolts 3/816 x 3”, (two) plate mounts and (four) 3/8-16 nyloc nuts. Locate these back away from the pivot tube far enough to allow it to caster properly. 2)
Weights can be set into the brackets from the top and secured with (two) (3/8 bolts 6” long with nuts.)
WEIGHTS
CARRIAGE BOLT, 3/8-16 X 3” 3/8-16 X 6” BOLT BRACKET, WEIGHT MOUNT NUT
PLATE, WEIGHT MOUNT
NUT, 3/8-16 X NYLOC
18 Copyright, Shivvers Mfg., 2005
P-12102
TRANSITION MOUNTING 1)
Rotate the discharge chute up as far as possible.
2) Remove, and discard, the bolts, washers, and nuts from the center “(2) holes” on the “discharge stiffener.” 3) Place the “transition angle” and the “transition saddle” over the “(2) holes” and lightly secure with (2) 5/16” x 1-1/4” carriage bolts, lock washers and plain nuts. The saddle goes on top of the angle.
TRANSITION
4) While holding the transition with round hole to the back of the mower, lift the outside of the transition up slightly, and insert the “lip” of the transition under the open chute and into the angle and the saddle. 5) The “adjustment plate” allows the transition to fit either the 52” or the 60” deck. Lightly tighten the (2) ¼” bolts, lock washers, and washers with the “adjustment plate” as far back as it will go to start. After the adjustments on the transition are made, then adjust the “adjustment plate forward until it comes in contact with the back of your deck. Tighten the bolts at this time. ADJUSTMENT PLATE
5) Once the “lip” on the transition is in the angle and saddle, rotate outside end down until the top of the transition is parallel with the top of the deck. The “rod” on the end of the transition should fall into the “hole in deck” at this point. If not, loosen the (2) nuts on the end of the transition, and move the “rod” around until it falls into the hole. Tighten the (2) nuts by the “rod”. If the nuts holding down the angle and saddle have been left loose, they should be located by now. Tighten the (2) nuts. The “lip” on the transition should fit tightly into the saddle and angle. If it is loose, adjust, and retighten. 6) Once the nuts are all tight, pull the rod out of the hole, and remove the transition. Reinstall the transition several times to make sure all adjustments are correct. Slight pressure up or down on the transition will help the “rod” fall into place easier. DECK
HOSE CLAMP TRANSITION SADDLE LIP
DISCHARGE STIFFENER HOSE
TRANSITION TRANSITION ANGLE LOOSEN THESE NUTS TO ADJUST ROD ASSEMBLY
(2) HOLES ROD
HOLE IN DECK
Place one of the “hose clamps” on each end of the hose. With the clamps loose, slide the hose on the transition, and the intake of the blower about 1-1/2”. Tighten the clamps. Read and understand owners manual completely before using grass bagger.
19 Copyright, Shivvers Mfg., 2005
P-12102
QUICK CHANGE OVER PROCEDURE To change from mowing with the grass bagger to mowing side discharge follow this procedure.
HOLDING BRACKER FOR TRANSITION
1)
Disengage the deck by pressing down the deck switch.
2)
Remove the transition from the discharge end of the deck.
3)
Swing the transition up and over the blower and slide the transition (opening facing up), onto the “holding bracket” mounted on the blower. (there are (2) slots in the transition that slide onto the (2) hooks on the bracket.)
4)
Flip the discharge chute down to resume side discharge.
5)
To go from side discharge to grass bagging reverse process.
DUMPING AND CLEANOUT 1) When hopper is full, push dump handle down. Slight forward and reverse movement of the mower helps free debris that does not readily come out. To close door and resume mowing, lift dump handle up and lock over center.
SLOTS IN TRANSITION
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Copyright, Shivvers Mfg., 2005
P-12102
BAGGER REMOVAL & MOUNTING A
On models with Kohler engines, first remove the standard engine air cleaner before removing or Mounting “BAGGER”
B PROCEDURE FOR REMOVING GRASS BAGGER 1) Disconnect the connector in the wire harness. 2) For safety purposes, before pulling T-Handle pins out, first tie a length of rope or chain around one side of the frame and over one of the seat arm rests to keep the bagger from falling over backwards. 3) Pull the (2) T-Handle pins out of the front of the bagger and mount. By forcing the bagger forward The belt can be rolled off of the engine pulley. 4) While holding the bagger in the up position, remove the rope, and simply lay the bagger down. 5) Remove the (2) “Rue rings”. “Flat washers” and “Clevis pins” and drive away. 6) Replace air cleaner. C
TO MOUNT GRASS BAGGER 1) Back mower into bagger and reverse procedure. 2)
On Boss mowers it may be necessary to place a 2 X 4 under bagger to help align legs with mounting bracket.
T-HANDLE PIN RUE RING FLAT WASHER
CLEVIS PIN
21 P-12028 Copyright, Shivvers Mfg., 2005
