Toro 4502 User manual

SCAMP AND UTILITY MODELS

SERVICING

4502,4503, 8602, 8603

WITH

“F”

SERIES ENGINES

SELF-PROPELLED BELT DRIVE

Adjustments

and

servicing of the Scamp and

Utility self-propelled mowersare very different

from

all

previousmodels of self-propelled

mowers.

SAFETY WARNING

BEFORE

ANY

ADJUSTMENTS OR

REPAIRS ARE ATTEMPTED, DIS-

CONNECT

AND

REMOVESPARK

PLUG TO PREVENTSTARTING.

INSTALLING CONTROL

ROD

Placeretainerclip on clutch arm

with

long side

clip on the inside

clutch arm.

Align

holein

clip

with

holein arm and

assemblelower end

thecontrol

rod

hole.

Turn (swivel) long end

clip up and snap

intoposition on lower control rod as shown.

SAFETY WARNING

THE LOWER SELFPROPEL CON-

TROL RODMUST

ASSEMBLED

TO CLUTCHARM

SHOWN. IF

NOT THESELFPROPEL MECH-

ANISM WILL NOTRETURNTO

NEUTRAL WHEN THE CONTROL

LEVER IS RELEASEDFROM THE

ENGAGEDPOSITION.

10-44

REVISED

1983

SERVICE BULLETIN REFERENCES

With

the control handle in "neutral" (free)

position as shown.

SCAMP AND UTILITY MODELS

SERVICING

Secureupper and lowercontrolrods

together with theclampscrewas shown.

Thisscrewshouldbetightenedsecurely

SELF=PROPELLEDBELT DRIVE

by hand.

With

the clutch arm resting on the handle

and wheel bracket asshown.

SAFETY WARNING

IMPROPER TIGHT.ENING OF CLAMP

SCREW ONCONTROLRODMAY

RESULT

OPERATOR LOSS OF

DRIVE CONTROLMECHANISM.

NOTE

put mower in motion, pull upward

oncontrolhandleand hold indrive

position.Tostopforwardmotion

mower, releasecontrolhandle.

Mower drivemechanismfunctions

only when thecontrolhandle

held

in "DRIVE" position.

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

DRIVE ROLLER ADJUSTMENT

With thecontrol handlein"Neutral",

place both rear wheelheight adjustersin

(lowest)cuttingposition as shown.

gap of 3/16" shouldappear between the

drive rollers and tires.

Loosenbolt and nut locatedindrive

roller gap adjustingslot on each side of

drive roller bracket.

3. Move the drive roller bracket up or down

toobtainthenecessary 3/16'' driveroller

gap. Hold bracket

position and tighten

both bolts and nuts securely.

ENGINE REMOVAL

REPLACEMENT

SAFETY WARNING

TO PREVENT STARTING OF EN-

GINE,DISCONNECT

AND

REMOVE

SPARK PLUG PRIOR TOREMOVING

THE ENGINE.

Remove bladebolt,washer,blade

stiffener,collar and threeboltssecuring

muffler and remove muffler.

Remove

three

boltssecuringengineto

muffler plate and remove engine.

Do not removemufflerplatefrom

housing when removing engine.

10-46

SERVICE BULLETIN REFERENCES

REVISED

1983

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

BELT REMOVAL

REPLACEMENT

SAFETY WARNING

TOPREVENT STARTINGENGINE,

DISCONNECT SPARK PLUGLEAD

ANDREMOVE SPARK PLUG.

The

"V"

beltused on theutilityself-

propelledmodelmowers

a SPECIAL

BELT.

NOTUSE

SUBSTITUTE. It

won't work as WELL or asLONG.

remove the belt:

Remove

four

belt guardcoverscrewsand

remove cover.

Remove engine

and

remove drive belt from drive

pulley.

SAFETY WARNING

NOT OPERATE MOWERWITH

BELT GUARDREMOVED.

Removeroll pin fromleft hand drive

roller and remove roller.

Remove belt from driven pulley and slide

shaftassemblytotheright. Remove belt

from mower as shown.

SERVICE BULLETIN REFERENCES

10-47

REVISED

1983

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

NOTE

Afterthebelthasbeenremoved,

examine for broken, crackedor mis-

alignedpulleys.

The

condition and

thewearpattern of

the

belt

will

provide clues for the above possibili-

ties.Replacedamaged or worn

pulleys.

Thecrankshaftpulley(drive pulley)

securedto

the

crankshaft

with

SPECIAL

slottedsetscrew.The end of

this

screw

locates ina holeinthe crankshaft.The

correct position and tightness

very

IMPORTANT.

nottightened securely,

damagetothe pulley, crankshaft and pre-

maturewear of thedrivebelt

will

result.

NOTE

Apply

OMC

Ultra-Lock(partno.

388517)

threads

setscrew priortoinstallation.

When reinstalling pulley tocrankshaft,

theside of the pulley

with

set screw

the

lowerside.

assembledupside

down

(set

screw on top) misalignment and interference

of pulley operation

will

result. Always

check

pulley fordamage.Replace

necessary.

10.48

REVISED

1983

SERVICE BULLETIN REFERENCES

IDLER

PULLEYS TOP STRAND

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

SAFETY

WARNING

INCORRECTDRIVEBELTINSTAL-

LATIONMAYALLOW

MOWER

OPERATE IN REVERSE DIRECTION

TOROR BYSTANDERS. ASSEMBLE

DRIVEBELT

SHOWN.

CAUSING INJURY

THE OPERA-

DRIVE-BOTTOMSTRANDENGINE

SHAFT DRIVE

PULLEY PULLEY

INSTALL BELTAS SHOWN

FOR PROPER PULLEY ROTATION

Check

the conditionofthedriveshaft,bronze

bearings,andsleeve.If

signs

ofdamageor

wear

appear, replace them.

Placebeltoverleft end of driveshaft

as shown.

not assemble

driveshaft

pulley.

BUSHING AND BEARINGINSTALLA-

TIONS.

NOTE

Thesleeve

has

flat surface that matches

the flat surface

the bracket.Whenre-

assembling,the flat surfaces must match.

SCAMP AND UTILITY MODELS

SERVICING

SELF=PROPELLEDBELT DRIVE

10.

Reassemble the drive

shaft

into the bearing

and slide

the left

far

possible. Assemble

thewasher and driveroller onthedriveshaft.

11.

The drive rollers must be properly installed

utilize theself-cleaningfeature. Proper installation

with thevee pointingtowardthewheel.

12.

Using

new roll pin, assemblethe drive roller

the drive shaft. Use

5/32”

or larger

drift

punch, drive the roll pin

into

place, flush with the

outer surface. Neither end shouldprotrudebeyond

theroller surface.

INSTALL BELTAS SHOWN

FOR

PROPER PULLEY ROTATION

13.

you face the frontof the mower,

twist

the

forward

end of the belt

1/4

turn counter clockwise

and assemble onthe enginedrive pulley. Assemble

engineonmufflerplate andsecurewith threebolts.

14.

Release springtension on idler pulleys and

as-

semblebelt on drive shaft pulley. Reassemble idler

pulley spring and rotate the belt severalrevolu-

tions. Check

make sure the belt

centered on

the pulleys and TURNING IN RIGHT DIREC-

TION. Note direction of arrow on large pulley in

illustration above.Check andadjust belt tension

necessary.Refer

BELT TENSION

ADJUSTMENT.

Whenreplacing either of the belt idler

assemblies,use idler

kit

part no.

682374

for the topand

kit

part no.

682564

on the

bottom.

10.50

SERVICE BULLETIN REFERENCES

REVISED

1983

BELT TENSION ADJUSTMENT

Check drivebeltinstallation.Drivebelt

mustbeinstalledbetweenidlerpulleysas

shown.

Drivebeltshouldbecheckedtoinsure

thatpropertensionexistsinordertopre-

ventprematurebeltfailure. Lift floating

idlerfromtheupperstrand of

"V"

belt.

Belt

will

thenbecomeloose.Setfloating

idler onto

"V"

belt and checkclearancebe-

tween the two strands of the

"V"

belt.The

distancebetweenthe two strands should not

be less than

1/2"

as shown.

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

adjust belt tension; loosen four handle

bracket mounting screws (two on each

bracket) and two screws (one on each side)

located on thesides of rear heightadjuster

bracketas shown. Slideentireself-propell-

ingmechanismindirectionnecessaryto

obtain the proper

"V"

belt tension.

Care should be taken toinsurethat both

sides of theself-propellingmechanism are

positionedequally on themowerhousing.

Thiscanbeaccomplished by measuring the

distancefrom

the

front edge on theheight

adjuster brackets to the' 1/4" diameter gage

holeslocateddirectlyinfront of these

bracketsas shown. Thisdistancemustbe

thesamefor both sides.Beforetightening

screwsmakesurethedistancebetweenthe

strands of

the

"V"

belt

not

less

than

1/2".

Tightenthefourhandlebracket

screws and the two sidescrewssecurely.

Reassemblebeltguardtoself-propel

mechanismusingscrewspreviously

removed.

SAFETY WARNING

NOT

OPERATE MOWERWITH

BELT

GUARDREMOVED.

SERVICE BULLETIN REFERENCES

10.51

REVISED

1983

SCAMP AND UTILITY MODELS

SERVICING

SELF-PROPELLED BELT DRIVE

LUBRICATION

HOURS

DRIVE ROLLERBEARINGS-Disassemble

rotating shaftcover from self-propel mechanism by

removing four screws.Unscrewplugfromend of

each drive roller (Point

“A”).

Fillexposed cavity

610721

OR EQUIVALENT.Replaceplugand

tightenuntil snug. Repeat procedure until lubri-

cant appears on cross-shaft at Point

“B”.

Reas-

semblerotating shaftcover toself-propel assembly.

with LAWN-BOY

“A”

GREASE, PART NO.

FLOATING IDLER PULLEY-Do not immerse

the idler pulley in solvent.

Use

a rag containing

solvent, clean the hole in the idler pulley and the

shoulder

bolt

thoroughly.Useing a smallamount of

LAWN-BOY

GREASEorEQUIVALENT,re-

lubricate the shoulder bolt and remount idler

pulley assemblyin thesameorderit

was

originally.

ASREQUIRED

CLUTCHLINKAGE-Apply severaldrops

lightmachineoil on clutchmechanism

all

pivoting points.

10-52

NEW STYLE

LOWER IDLER ASSEMBLY

PART

#682564

BOLT-PULLEY-ARM-NUT

LOWER IDLER PULLEY Permanently lubri-

cated.

No lubricationrequired.

SERVICE BULLETIN REFERENCES

REVISED

1983

UTILITY

MODELS

4502 AND 8602

SCAMPMODELS 4503 AND 8603

SELF-PROPELLEDSERVICING

4502,4503,8602,8603

models of Utilityand

Scampmowers,ablade nut has replaced the

blade bolt previously used onearlier models.

SAFETYWARNING

THE BLADE

NUT

MUSTBE RE-

PLACED AFTER BEINGREMOVED

AND REINSTALLED FOUR

(4)

TIMES. THELOCKING FEATURE OF

THE BLADE NUT WILLHAVE

DECREASED ANDBLADECOULD

LOOSEN IF REPLACEMENT

NOT

MADE.

Collar

Blade

Stiffener

Nut

Washer

(20

and

inch

models only)

Before assemblingcollar on crankshaft,checkto

be sure it did not get bent or distortedwhen be

ing

removed.

so,

replaceit.

notuse,

because, it will cause vibration.

theblade nut

reused,cleanthe threads

thoroughly. Also clean threads on crank shaft.

Apply OMC Ultra-Lock

Part

No.

388517

on the

threads.

NOTE

When installing blade after sharpening

and balance, torque blade nut

45-50

ft.

1bS.

SAFETYWARNING

ALWAYSUSE ORIGINAL EQUIP-

MENT REPLACEMENT BLADE AND

ATTACHMENTHARDWARE TO

IN-

SURE COMPLIANCE WITH SAFETY

STALLING BLADE, BE SURE PARTS

QUENCE IN WHICH THEY WERE

REMOVED. ALWAYS REPLACE

BLADE WITH CURVED EDGE UP

(TOWARD HOUSING).

SPECIFICATIONS. WHEN REIN-

ARE REPLACED INTHE SAME SE-

blade collar that

was

damaged

and

bent when

beingremovedfrom crankshaft shouldalwaysbe

replaced.

not replaced, a vibration in the mower

and a rough, uneven

ragged cuttingmay

result.

KEEP

BLADE SHARP AND BALANCED

REVISED

198310-53

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