Textron BOB-CAT 930022 User manual

WARNING: If incorrectly used this machine can cause severe injury. Those who use

and maintain this machine should be trained in its proper use, warned of its dangers

and should read the entire manual before attempting to set up, operate, adjust or

service the machine.

SETUP, PARTS & MAINTENANCE

MANUAL GEAR DRIVE MIDSIZE

2721693 REV D

Power Unit Models:

930022 Power Unit 15HP Kawasaki Gear Drive

930023 Power Unit 17HP Kawasaki Gear Drive

(Operation & Safety Manual: 2721692)

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of

its constituents are known to the State

of California to cause cancer, birth

defects and other reproductive harm.

Californie Proposition 65

Avertissement

Les échappements des moteurs diesel

et certains de leurs composés sont

reconnus par l’Etat de Californie pour

être cancérigènes, provoquer des

défauts congénitaux et d’autres dangers

en matière de reproduction.

ADVERTENCIA

AVERTISSEMENT

WARNING

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

California Advertencia

de la Proposicion 65

El estado de California hace saber que

los gases de escape de los motores

diesel y algunos de sus componentes

producen cáncer, defectos de

nacimiento y otros daños en el

proceso de reproducción humana.

L’

mission du moteur de ce mat

riel

contient des produits chimiques que

l’Etat de Californie consid

tre

canc

rig

nes, provoquer des d

fauts

cong

nitaux et d’autres dangers en

mati

re de reproduction.

El estado de California hace saber

que los gases de escape de este

producto contienen productos

quÍmicos que producen cáncer,

defectos de nacimiento y otros daños

en el proceso de reproducción

humana.

Gear

Drive

Midsize

10-2002-TGTSP

IMPORTANT MESSAGE

Thank you for purchasing this Bob-Cat product. You have purchased a world class mowing product, one of the

best designed and built anywhere.

This machine comes with an Operation and Safety Manual and a separate Setup, Parts and Maintenance Manual.

The useful life and good service you receive from this machine depends to a large extent on how well you read

and understand these manuals. Treat your machine properly, lubricate and adjust it as instructed, and it will give

you many years of reliable service.

Your safe use of this Bob-Cat product is one of our prime design objectives. Many safety features are built in, but

we also rely on your good sense and care to achieve accident-free operation. For best protection, study the

manuals thoroughly. Learn the proper operation of all controls. Observe all safety precautions. Follow all

instructions and warnings completely. Do not remove or defeat any safety features. Make sure those who operate

this machine are as well informed and careful in its use as you are.

See a Bob-Cat dealer for any service or parts needed. Bob-Cat service ensures that you continue to receive the

best results possible from Bob-Cat’s products. You can trust Bob-Cat replacement parts because they are

manufactured with the same high precision and quality as the original parts.

Bob-Cat designs and builds its equipment to serve many years in a safe and productive manner. For longest life,

use this machine only as directed in the manuals, keep it in good repair and follow safety warnings and instructions.

You'll always be glad you did.

Textron Golf, Turf & Specialty Products

One Bob Cat Lane

Johnson Creek, WI 53038-0469

TABLE OF CONTENTS FIGURES

PAGE

SAFETY ......................................................................................................................................................... 2

ASSEMBLY/SET-UP INSTRUCTIONS ....................................................................................................... 3-9

LUBRICATION ........................................................................................................................................ 10, 11

MAINTENANCE ..................................................................................................................................... 12, 13

SERVICE CHART ........................................................................................................................................ 14

SERVICE RECORD ..................................................................................................................................... 15

ADJUSTMENTS...................................................................................................................................... 16-18

BELT REPLACEMENT ......................................................................................................................... 19, 20

PARTS SECTION ........................................................................................................................................ 21

UPPER ENGINE DECK ASSY ........................... FIGURE 1 ................................................................. 22, 23

LOWER ENGINE DECK ASSY/CLUTCH .......... FIGURE 2 ................................................................. 24, 25

DRIVE WHEELS & BRAKES ............................. FIGURE 3 ................................................................. 26, 27

TRANSMISSION DRIVE .................................... FIGURE 4 ................................................................. 28, 29

UPPER HANDLE/ROLLER LATCH ................... FIGURE 5 ................................................................. 30, 31

OPERATOR PRESENT ..................................... FIGURE 6 ................................................................. 32, 33

DECALS ............................................................. FIGURE 7 ................................................................. 34, 35

PEERLESS TRANSMISSION ............................ FIGURE 8 ................................................................. 36, 37

ELECTRICAL DIAGRAM ................................... FIGURE 9 ................................................................. 38, 39

CUTTERDECK MOUNTING .............................. FIGURE 10 ............................................................... 40, 41

KAWASAKI ELECTRICAL SCHEMATIC ............ FIGURE 11 ...................................................................... 42

Gear

Drive

Midsize

MODEL NUMBER: This number appears on

sales literature, technical manuals and price lists.

SERIAL NUMBER: This number appears only

on your mower. It contains the model number

followed consecutively by the serial number. Use

this number when ordering parts or seeking

warranty information.

SAFETY

NOTICE !!!

Unauthorized modifications may present extreme

safety hazards to operators and bystanders and

could also result in product damage.

Textron Golf, Turf & Specialty Products strongly

warns against, rejects and disclaims any

modifications, add-on accessories or product

alterations that are not designed, developed, tested

and approved by Textron Golf, Turf & Specialty

Products Engineering Department. Any Textron

Golf, Turf & Specialty Products product that is

altered, modified or changed in any manner not

specifically authorized after original manufacture–

including the addition of “after-market” accessories

or component parts not specifically approved by

Textron Golf, Turf & Specialty Products–will result

in the Textron Golf, Turf & Specialty Products

Warranty being voided.

Any and all liability for personal injury and/or property

damage caused by any unauthorized modifications,

add-on accessories or products not approved by

Textron Golf, Turf & Specialty Products will be

considered the responsibility of the individual(s) or

company designing and/or making such changes.

Textron Golf, Turf & Specialty Products will

vigorously pursue full indemnification and costs

from any party responsible for such unauthorized

post-manufacture modifications and/or accessories

should personal injury and/or property damage

result.

This symbol means:

ATTENTION!

BECOME ALERT!

Your safety and the safety of others is involved.

Signal word definitions:

The signal words below are used to identify levels

of hazard seriousness. These words appear in this

manual and on the safety labels attached to Textron

Golf, Turf & Specialty Products machines. For your

safety and the safety of others, read and follow the

information given with these signal words and/or the

symbol shown above.

DANGER indicates an imminently hazardous

situation which, if not avoided, WILL result in death

or serious injury.

WARNINGindicates a potentially hazardous situation

which, if not avoided, COULD result in death or

serious injury.

CAUTION indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate

injury. It may also be used to alert against unsafe

practices or property damage.

CAUTION used without the safety alert symbol

indicates a potentially hazardous situation which, if

not avoided, MAY result in property damage.

Gear

Drive

Midsize

GENERAL NOTE: FRONT, REAR, RIGHT HAND AND LEFT HAND REFERENCES BELOW

ARE WITH RESPECT TO AN OPERATOR AT THE CONTROLS.

ASSEMBLY/SET-UP INSTRUCTIONS

2. Remove gear selector handle Afrom the power

unit and set aside for later use.

3. Unbolt the upper handle Bfrom shipping

brackets C.

4. Unbolt the shipping brackets Cfrom the lower

handle.

5. Attach the upper handle to the lower handle using

the 3/8"-16 X 1" bolts and 3/8"-16 nuts removed

in Step 3 as shown.

6. Remove tie wrap Dfrom the traction control lever.

1. UNCRATE - Place both power unit and cutterdeck crates on a level surface. Remove sides and top from

both the power unit and cutterdeck crates.

Gear

Drive

Midsize

ASSEMBLY/SET-UP INSTRUCTIONS

8. Remove the power unit from the crate and

support the rear of the power unit using a

jackstand.

9. Remove shipping bracket E.

10. Attach traction control rods Fby inserting the

swivel through the upper hole in the bellcranks G

and the other end of the traction control rods

through the traction control lever on the

handlebar. Secure with washers and hairpins.

11. To adjust traction control rods, remove the

traction control rod swivel and the brake rod from

the bellcrank Gand adjust swivel up or down the

control rod so that once reinstalled there is a 1/4"

(6.35mm) gap between the bottom of the rod and

the bottom of the traction lock.

12. To adjust the brakes, remove the brake rod from

the bottom of bellcrank Gand set the traction

lever in the neutral position. Adjust the brake rod

by turning it in or out of the swivel in the brake

arm until it just goes into the hole on the

bellcrank. Secure with hairpin.

NOTE: The machine should not move with the

traction levers in the parking brake position. If

machine moves in the parking brake position,

readjust brake rod length. Verify that machine

can be moved easily when the traction levers are

placed in the neutral position.

7. Unbolt shipping bracket Efrom the crate.

NOTE: It will be necessary to support the rear of

the power unit and level it for attachment to the

cutterdeck.

Gear

Drive

Midsize

ASSEMBLY/SET-UP INSTRUCTIONS

13. Attach gear shift lever Aremoved in Step 2 to the

lower shift arm with (1) M8-1.25 X 25 Bolt and (1)

M8-1.25 whizlock nut. Shift the lever to the

neutral position and verify that the lever is

centered side to side in the slot. If not, loosen the

M8 bolt and reposition lever. Retighten bolt.

GEARBOX ADJUSTMENT NOTE: The detents

between gears and at neutral may be made more

positive by turning set screw Hclockwise. Do not

turn set screw more than two turns below flush

with the housing.

14. Attach cutterdeck per the instructions on the following pages then return to Step 15 of this section.

15. Fill engine with oil. (See engine manual for specifications.)

16. Fill fuel tank with with clean, fresh unleaded fuel.

GASOLINE IS HIGHLY FLAMMABLE!

•Fill fuel tank with good quality, clean, regular unleaded gasoline.

•Do not use hi-test fuel.

•Do not smoke.

•Do not spill fuel.

•Fill outdoors.

•Do not overfill. Fill to 1" below bottom of filler neck to allow room for expansion.

•USE A FUNNEL TO FILL GAS TANK

17. Adjust tire pressure in drive wheels and casters to 14 psi (1 kg/cm2).

18. Before attempting to start the mower, read and understand all sections of the Operation & Safety manual.

NOTICE: Special setup instructions.

•Before engaging the cutterdeck, run the engine for five minutes at full RPM. This is recommended for new

engine installation to permit complete engine lubrication prior to load.

•Do not engage the cutterdeck at full throttle. Set the throttle half way between the highest and lowest

engine speed, engage the PTO switch and increase the engine speed to full before cutting.

•

Do not use this machine without an approved grasscatcher, grass discharge chute or mulching plate(s)

correctly fitted.

Gear

Drive

Midsize

ASSEMBLY/SET-UP INSTRUCTIONS

CUTTERDECK ATTACHMENT: Two types of cutterdeck mounting systems are available, fixed and floating.

Fixed mounting rigidly attaches the cutterdeck to the power unit. Floating mounting allows the cutterdeck to

move independant of the power unit providing a more uniform cut. Follow the appropriate instructions below

for the type of cutterdeck being attached to the power unit.

FIXED CUTTERDECK ATTACHMENT

1. Remove the cutterdeck from the crate.

2. Unbolt the caster wheels and the shipping

brackets from the crate.

3. Remove the shipping bracket from the caster

wheel by loosening the caster bolt and sliding the

shipping bracket off and retighten caster bolt.

4. Remove quick pin and remove the appropriate

number of spacers for the desired height of cut.

See height of cut chart below.

NOTE: Height of cut chart is also located on

bottom of belt cover or in the Operation & Safety

Manual.

5. Repeat for other caster wheel assembly.

Gear

Drive

Midsize

ASSEMBLY/SET-UP INSTRUCTIONS

6. Remove belt cover and set aside.

7. Block the rear of the cutterdeck with the

appropriate height block for the desired height of

cut B. See Support Block Chart below.

GNITTUC

THGIEH

ELOH

NONOITISOP

ENIGNE

*KCED

KCOLB

TATHGIEH

FORAER

)B(KCED

"526.1-"573.15"52.1

"573.2-"578.14"00.2

"521.3-"526.23"57.2

"578.3-"573.32"05.3

"526.4-"521.41"52.4

elohtsehgihehtsi1noitisoP*

.kcedenigneehtno

8. Position the power unit behind the cutterdeck.

9. Move the power unit towards the cutterdeck until

the guide pins Aengage the appropriate hole C

on the power unit for the desired height of cut.

Fasten with (4) M12-1.75 X 30 bolts at D.

10. Loop the PTO belt Earound the electric clutch

pulley. Using a 3/8" ratchet wrench or 3/8"

breaker bar rotate the PTO belt idler while looping

the PTO belt around the cutterdeck pulley.

11. Reinstall belt cover and fasten in place with

knobs F.

12. Remove support block from the rear of

cutterdeck.

13. Remove support from the rear of the power unit.

Gear

Drive

Midsize

ASSEMBLY/SET-UP INSTRUCTIONS

6. Remove belt cover from cutterdeck cradle.

7. Remove the cutterdeck cradle Afrom the crate

and insert guide pins Binto top hole Cin power

unit.

8. Attach cutterdeck cradle to power unit using (4)

M12-1.75 X 35 bolts at D and tighten securely.

9. Remove support from rear of power unit.

FLOATING CUTTERDECK ATTACHMENT

1. Unbolt the caster wheels and the shipping

brackets from the crate.

2. Remove the shipping bracket from the caster

wheel by loosening the caster bolt and sliding the

shipping bracket off and retighten caster bolt.

3. Remove snap ring, (2) washers and (1) 1/4"

spacer from one caster wheel assembly.

4. Insert caster yoke through cradle bushing from

the bottom up and place (2) washers and (1) 1/4"

spacer removed in Step 3 back onto the shaft

above the cradle bushing and secure using the

snap ring removed in Step 3 as shown.

5. Repeat for other caster wheel assembly.

This manual suits for next models

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