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TURFMASTER 309002x24C, Safety, Assembly, Operating And Maintenance Instructions

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TURFMASTER 309002x24C Safety, Assembly, Operating And Maintenance Instructions Download Page 46

REPAIR PARTS

MODEL 309002x24C

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F

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0506014L

MOWER HOUSING

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Summary of Contents for 309002x24C

Page 1: ...ormation Is Necessary When Ordering Parts Or In Case Of Loss Or Theft WHERE PURCHASED DATE PURCHASED Month Day Year MODEL NO DATE OF MANUFACTURE PRODUCT INFORMATION The owner must be certain that all the product information is included with this unit This information includes the INSTRUCTION BOOKS the REPLACEMENT PARTS and the WARRANTIES This information must be included to make sure state laws an...

Page 2: ...e terms and conditions noted in this Limited Warranty we shall at our option repair or replace at no cost to the original purchaser any part covered by this Limited Warranty during the applicable warranty period In the event the battery proves defective within ninety 90 days from the date of purchase we will replace it without charge If the battery proves defective after 90 days but within one hun...

Page 3: ...ly adjust the unit 7 Service the unit only with authorized or approved replacement parts 8 Complete all maintenance on the unit Environmental Awareness D Do not fill the engine s fuel tank completely full D Drain fuel for off season storage D Use only unleaded gasoline D Service the air cleaner regularly D Change oil regularly Use 10W 30 oil in summer D Tune up the engine regularly D Keep equipmen...

Page 4: ...hine 6 Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction 7 Avoid starting or stopping on a slope If tires lose traction turn off the blades and proceed slowly straight down the slope DO NOT 1 Do not turn on slopes unless absolutely necessary then only turn slowly and gradually downhill if possible 2 Do not mow drop offs ditches or embankments A wheel...

Page 5: ...the machine indoors d Never store the machine with fuel in the tank or fuel container inside where there is an open flame such as a water heater 2 Never start or run the engine inside a closed area 3 Keep all nuts and bolts especially the blade attachment nuts tight Frequently check the blade s for wear or damage such as cracks and nicks A blade that is bent or damaged must be immediately replaced...

Page 6: ...rson Never let another person ride with you on the unit or on any accessories A passenger will make the unit harder to control block the visibility or distract the operator and is dangerous to the operator the passenger and the equipment Without a passenger seat the passenger can fall from the mower or contact dangerous parts A mower is not a toy for showing off or for giving rides Never cut a wet...

Page 7: ...the mower is not correctly assembled not operated correctly or not regularly serviced the mower can be dangerous The most important rule to follow is always use good judgement and common sense Mow safely and carefully Your mower will easily cut thick grass Fingers feet and other parts can also be cut by the blade Injuries occur when the operator does not think and reaches into the chute opening Al...

Page 8: ...ty the grass bagger always stop the engine Before each use of the grass bagger check for cracks wear or deterioration Before you use the grass bagger replace a damaged part with a replacement part approved by the factory For you to have a good green lawn follow the mowing procedures below Do not cut the grass too short If you cut the grass too short you can cause the grass to become yellow or make...

Page 9: ...essively F Do not make adjustments or repairs without stopping the engine Disconnect the spark plug wire F On or near roads watch out for traffic Direct discharge away from roads F When mowing avoid areas where traction is unsure Look back before changing direction of travel Look down and behind before and while backing F In heavy grass raise the cutting height Cut slower Stop the engine to remove...

Page 10: ...eep Bystanders Away Read User Instructions Before Operating This Machine 8 WARNING Do Not Use This Machine On Slopes Greater Than 15 Degrees 9 DANGER Keep People Especially Children Away From Unit 10 DANGER No Step 11 DANGER Keep Feet And Hands Away From Rotating Blade 12 DANGER Keep Hands Away From Rotating Blade 13 DANGER Disconnect Spark Plug Wire Before Servicing Unit 14 WARNING Hot Surface 15...

Page 11: ...the operator on the seat WARNING Before doing any assembly or mainte nance to the mower remove the wire from the spark plug PARTS BAG CONTENTS The fasteners and other loose parts are shown below The fasteners are shown full size The quantity is shown in brackets 2x82 2 Carriage Bolt 14x79 2 Wing Nut 17x47 2 Washer 1001054 2 Knob 2 Ignition Key 690604 1 Cover Terminal LOOSE PARTS CONTENTS Seat Stee...

Page 12: ...he wing bolts A Figure 1 Seat Seat Adjusting Hole Seat Support A B Seat Support Rod HOW TO ASSEMBLE THE STEERING WHEEL Attach the steering wheel as follows 1 Make sure the front wheels point forward 2 Slide the tube into the console Figure 2 Make sure the end of the tube fits over the steering bushing NOTE Before attachment of the steering wheel make sure that the front wheels point forward and ar...

Page 13: ...y retainer from the battery tray push in on the lower end of the battery retainer 2 Remove the battery from the right side of the unit 3 Remove the protective cap from the battery terminal 4 Use a 12 volt battery charger to charge the battery Charge at a rate of 6 amperes for one hour If you do not have a battery charger have an authorized service center charge the battery 5 Install the battery an...

Page 14: ...eral minutes IMPORTANT This unit is equipped with an internal combustion engine and must not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it must be maintained in effective working order by the operator In the State o...

Page 15: ...y stop the forward or reverse motion of the unit IGNITION KEYSWITCH Use the ignition key switch to start and stop the engine When you start the engine and release the ignition key the ignition key switch will automatically default to the recommended RUN MOW position for normal mowing SHIFT LEVER Use the shift lever to change the speed of the unit LIFT LEVER Use the lift lever to change the height ...

Page 16: ...urn the ignition switch to the START position The engine should not start If the engine starts the switch is defective and must be replaced 3 Check the Operator Presence System switch DO NOT sit in the seat Depress the clutch brake pedal Move the blade rotation control to the DISENGAGE position Turn the ignition switch to the START position The engine should not start If the engine starts the swit...

Page 17: ... blade rotation control to engage the blade Figure 7 1 Before you start the engine make sure the blade rotation con trol is in the DISENGAGE position 2 To rotate the blade move the blade rotation control forward to lock the blade in the ENGAGE position Note If the engine stops when you engage the blade s the transmission is in reverse 3 To stop the blade move the blade rotation control to the DIS ...

Page 18: ...he SLOW position see Figure 9 Throttle Control Lever Figure 9 3 To go forward move the shift lever to a forward speed setting 4 To go backward move the shift lever to reverse Always disen gage blades and look down and behind before and while back ing Shift Lever Figure 10 5 Slowly release the clutch brake pedal Do not keep your foot on the pedal 6 Move the throttle control to the FAST position FUN...

Page 19: ...ift lever forward to lower the mower housing and back to raise the mower housing Figure 12 2 When you ride on a sidewalk or road move the lift lever to the highest position and move the blade rotation control to the DISENGAGE position Lift Lever Figure 12 HOW TO STOP THE UNIT 1 Completely push the clutch brake pedal forward to stop the unit Keep your foot on the pedal 2 Move the blade rotation con...

Page 20: ... grass out the side install the side discharge attachment as follows 1 Remove the fasteners that secure the mulcher cover see Figure 13 2 Lift the mulcher cover Mount the side discharge attachment onto the same bolts that secured the mulcher cover 3 Secure the side discharge attachment with the fasteners 4 To mulch remove the side discharge attachment and mount the mulcher cover to the mower housi...

Page 21: ...ee the engine manufacturer s instructions 1 The engine has a loss of power or does not run smooth 2 A change from summer to winter operation 3 A 40 degree change in the operation temperature The carbure tor was adjusted at 80 degrees at the factory 4 The engine is operated above 4 000 feet HOW TO START THE ENGINE WARNING The electrical system has two primary components an operator presence system ...

Page 22: ...ease the clutch brake pedal 8 Move the throttle control to the FAST position If you need to go faster or slower stop the unit and move the shift lever to another speed setting 9 Make sure the level of cut is still correct After you mow a short distance look at the area that was cut If the mower housing does not cut level see the instructions on How To Level The Mower Housing in the Maintenance sec...

Page 23: ...e blade is bent or damaged immediately replace the blade Also make sure the nut for the blade is tight 4 Keep the blade s sharpened Worn blades will cause the ends of the grass to turn brown 5 Do not cut or bag grass that is wet Wet grass will not discharge correctly Let the grass dry before cutting 6 Use the left side of the mower housing to trim near an object 7 Discharge the cut grass onto the ...

Page 24: ...warnings in the Owner s Manual Add fuel stabilizer Refer to the Engine Owner s Manual Prepare battery for storage a Remove from unit b Fully charge c Move to cool dry place GENERAL RECOMMENDATIONS 1 The owner s responsibility is to maintain this product This will extend the life of the product and is also necessary to maintain warranty coverage 2 Check the spark plug drive brake lubricate the unit...

Page 25: ...ot cut correctly and can cause an accident 8 Fasten the blade with the original washers and nut Make sure the outside rim of the Belleville washer is against the blade Figure 16 WARNING Always keep the nut tight that holds the blade A loose nut or blade can cause an accident 9 Tighten the nut that holds the blade to a torque of 35 foot pounds 47 5 N m 10 Install the mower housing See How To Instal...

Page 26: ...ion control to the DISENGAGE posi tion Stop the engine Disconnect the wire from the spark plug 7 Check the operation of the blade brake Rotate the pulley with your hand Make sure the brake pad is pressed tightly against the pulley Figure 19 WARNING If the brake pad does not press tightly against the pulley take the unit to a Sears or other qu alified service center 8 Move the blade rotation contro...

Page 27: ...ut HOW TO CHECK AND ADJUST THE CLUTCH If the motion drive belt is loose the clutch will slip when 1 going up a hill 2 pulling a heavy load or 3 the unit will not move forward Adjust the clutch as follows WARNING Before you make an inspection adjust ment or repair to the unit disconnect the wire to the spark plug Remove the wire from the spark plug to prevent the engine from starting by accident 1 ...

Page 28: ...3 2 Disconnect the red cable from the positive terminal 3 To disconnect the battery retainer from the battery tray push in on the lower end of the battery retainer 4 Remove the battery from the right side of the unit HOW TO CLEAN THE BATTERY 1 Remove the battery 2 Wash the battery with a solution of one gallon of water and four tablespoons of baking soda sodium bicarbonate Make sure the solution d...

Page 29: ...uel line the fuel tank must be empty If the fuel filter is dirty the engine will run rough and have less performance Remove the old filter Figure 25 Replace the old filter with a new filter Use an original equipment part See an authorized service dealer in your area Fuel Line Clips Fuel Filter Figure 25 CHECK THE TIRES Check the air pressure in the tires Tires with too much air pressure will cause...

Page 30: ...Figure 27 Make sure both sides of the mower housing are set ting on a flat surface 7 Make sure that the adjuster plate is loose and can easily move up or down see Figure 27 8 Tighten the front and rear adjuster knobs Make sure the ad juster knobs are tight If necessary use a wrench to tighten the adjuster knobs Tighten to a torque of 10 foot pounds 13 5 N m 9 Raise the lift lever from the LEVEL AD...

Page 31: ...mower drive belt is against the stack pulley Also make sure the mower drive belt is not twisted 3 Attach the front hanger to the frame support with the hanger rod Fasten with the fasteners as shown See illustration F 4 Make sure the mower drive belt is between the stack pulley and the two belt guides See illustration G 5 Attach the suspension links to the lifter assembly Fasten with the washers an...

Page 32: ... side of the belt is against the pulley 2 Install the end of the motion drive belt around the drive pulley 3 Make sure the motion drive belt is inside of the belt guides next to the drive pulley Tighten the belt guides 4 Put the belt around the idler pulley Assemble the idler pulley Fasten the idler pulley with the hex nut Make sure the V side of the belt is against the idler pulley Also make sure...

Page 33: ...r 4 Install the new mower drive belt Pull the brake pad away from the jackshaft pulley Put the mower drive belt around the jackshaft pulley 5 Pull thebelt retainer away from the idler pulley Put the mow er drive belt around the idler pulley 6 Make sure the V side of the mower drive belt is against the jackshaft pulley and the idler pulley 7 Install the mower housing See the instructions on How To ...

Page 34: ...Make sure the washer hold the hub caps in place Rear Wheel 1 Install the washers and spacer onto the axle as shown in Figure 34 2 Mount the square key in the key slot See Figure 34 3 Make sure the valve stem is to the outside of the tractor Align the slot in the rear wheel with the square key Slide the rear wheel on the axle 4 Fasten the rear wheel with washer and e ring 5 If your model has hub ca...

Page 35: ...n 4 Again clean the top of the mower housing 5 After you cut the grass clean the bottom of the mower housing STORAGE over 30 days At the end of each year prepare the unit for storage as follows THE ENGINE For storage information see the the engine manufacturer s instructions THE BATTERY 1 Remove the battery 2 Clean the battery terminals of any deposits 3 Charge the battery See the instructions on ...

Page 36: ... PROBLEM Excessive vibration 1 Replace the blade 2 Check for loose engine bolts 3 Decrease the air pressure in the tires 4 Adjust the carburetor 5 Check for a damaged belt or damaged pulley Replace the damaged parts PROBLEM The grass does not discharge correctly 1 Stop the engine Clean the mower housing 2 Raise the height of cut 3 Replace or sharpen the blade s 4 Move the shift lever to a slower s...

Page 37: ...tte Ravalli Shoshone Valley Washington Montana counties Flathead Lake Lincoln Mineral Missoulo Ravalli Sanders Oregon Washington CPT CANADA POWER TECHNOLOGY LIMITED Mississauga 161 Watline Avenue Mississauga Ontario L4Z 1P2 905 890 6900 1 800 861 9559 Edmonton 101 10411 178th Street Edmonton Alberta T5S 1R5 780 453 5791 1 800 861 9559 Ville St Laurent 234 Migneron Street Ville St Laurent Quebec H4...

Page 38: ...REPAIR PARTS MODEL 309002x24C 38 F 0506014L CHASSIS HOOD 1 2 3 4 5 6 7 10 11 11 12 13 13 14 15 16 17 18 13 19 20 20 19 21 22 23 24 16 26 43 27 28 30 31 32 33 37 39 40 16 41 42 8 44 36 29 48 49 47 ...

Page 39: ...076E701 Tray Battery 18 015x79 Nut Flange 19 017x37 Washer 20 0031x6 Pin Cotter 21 092317 Cap Fuel Tank 22 1401361 Tank Fuel 23 06x111 Screw 24 26x253 Screw 26 1401110 Rod Hood Prop 27 1401282 Spring Seat Deck 28 1401352E701 Bracket Prop Rod 29 26x201 Screw 30 15x116 Nut NY Lock 31 1401248 Control Throttle 32 1401084 Cover Detent Black 33 009x47 Bolt Shoulder 36 1401145 Footmat Left 37 1401144 Foo...

Page 40: ...11 12 13 11 13 13 10 73 14 15 15 15 15 15 15 15 16 16 17 18 19 20 21 22 23 58 53 24 25 26 35 37 34 33 32 36 50 50 51 51 53 53 49 52 49 27 28 29 30 31 30 38 39 34 40 41 42 43 44 45 46 47 48 52 54 55 56 11 57 59 60 61 62 64 64 65 66 67 68 69 70 13 72 71 5 34 5 74 75 76 7 76 77 ...

Page 41: ...upport 36 094815 Nut Adjusting 37 1401078 Rod Clutch 38 1401128E701 Clutch Arm Assembly 39 0011x7 Ring Retainer 40 1401077 Pulley Drive 41 002x53 Bolt Carriage 42 009x39 Bolt Shoulder 43 1401252 Pulley Idler 44 37x110 Belt Motion Drive 45 1401066 Pulley Split Stack 46 019x35 Washer Star 47 17x170 Washer 48 01x140 Bolt Hex 49 17x120 Washer 50 1401031E701 Arm Rear 51 1401039E701 Bracket Rear Hanger ...

Page 42: ...REPAIR PARTS MODEL 309002x24C 42 F 0506014L STEERING 2 1 3 4 5 6 7 8 9 9 9 9 9 10 11 12 13 14 15 10 12 16 17 17 18 19 20 24 21 22 25 27 28 34 29 30 31 32 33 35 23 4 14 36 37 26 39 38 ...

Page 43: ...15 015x84 Nut Flange 16 17x104 Washer 17 015x88 Nut Flange 18 01x111 Bolt Hex 19 17x118 Washer 20 1401099 Gear Pinion 21 01x146 Bolt Hex 22 011x23 E Ring Retainer 23 030x35 Pin Cotter 24 094131 Retainer Spring 25 1401046E701 Rack Steering 26 17x201 Washer 27 1401376E701 Bracket Axle Front 28 17x157 Washer 29 1401250E701 Axle Spindle Assembly 30 1401059E701 Bracket Support 31 15x118 Nut Flange 32 1...

Page 44: ...REPAIR PARTS MODEL 309002x24C 44 F 0506014L MOWER HOUSING SUSPENSION 1 2 3 4 5 13 5 6 14 5 16 15 4 9 10 11 12 9 24 25 26 27 19 13 20 21 22 23 18 17 7 8 31 17 30 ...

Page 45: ...0031x4 Pin Hair 10 002x93 Bolt Carriage 11 1401030E701 Bracket Front Hanger Pivot 12 1401118 Pin Front Hanger 13 26x249 Screw 14 1401129E701 Arm Assembly Lifter 15 17x206 Washer 16 093349 Screw Guide 17 015x79 Nut Flange 18 015x84 Nut Flange 19 1401147 Spring Leaf 20 1401040E701 Hanger Front 21 1401116 Lever PTO 22 26x263 Screw 23 094198 Grip PTO 24 1401369E701 Bracket PTO 25 009x42 Bolt Shoulder ...

Page 46: ... 2 3 4 5 6 7 8 9 7 9 6 9 9 9 8 10 11 12 11 10 12 13 13 14 6 6 6 8 15 16 16 17 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 29 34 35 29 38 39 40 43 64 45 49 47 48 45 45 50 51 45 53 54 56 55 58 57 62 59 60 61 34 9 63 63 50 52 51 29 37 42 52 36 6 18 18 42 6 65 6 6 ...

Page 47: ...haft Splined 27 1401258E701 Arm Assembly Idler 28 009x39 Bolt Shoulder 29 017x47 Washer 30 165x157 Spring Extension 31 166x46 Spring Torsion 32 009x42 Bolt Shoulder 34 030x20 Pin Cotter 35 1401185E701 Arm Assembly Brake 36 1401119 Link Idler Arm 37 0025x7 Bolt 38 1401052E701 Bracket Brake Mounting 39 1401094 Spacer Jackshaft 40 1401259 Z Plate Idler Mounting 42 019x45 Washer 43 002x94 Bolt Carraig...

Page 48: ...S MODEL 309002x24C 48 F 0506014L ELECTRICAL SYSTEM 94613 1001995 94159 24x37 24x24 24x24 30 MID ENGINE RIDER 2004 WIRING HARNESS FOR MAIN HARNESS 250x145 92739 94136 24273 1001575 OPTIONAL 3 5 9 2 4 1 6 7 8 10 11 ...

Page 49: ...6 Switch Limit PTO 4 302031 Fuse 407078 Holder Fuse 5 1002004 Solenoid 26x229 Screw Mounting 15x116 Locknut 6 024x37 Cable Battery Ground 26x229 Screw Ground Cable 7 021075 Battery 690604 Cover Battery Terminal 002x82 Bolt Carriage 014x79 Wingnut 8 024273 Switch Select Reverset 26x270 Screw Mounting 9 094159 Switch Seat Sensor 10 024x24 Cable 11 1001575 Switch Clutch Brake ...

Page 50: ...50 F 0506014L ...

Page 51: ...utch 27 Drive Brake 27 Filter Fuel 29 Fuse 35 Install Wheels 34 Lubrication 29 Mower Housing Clean 35 Install 31 Level 30 Remove 31 Muffler 24 Storage 35 Maintenance Chart 24 Motion Drive Belt Adjust 27 Replace 32 Mower Drive Belt Adjust 26 Replace 33 Mower Housing Clean 35 Cutting Height 19 Install 31 Level Adjustment 30 Operation 22 Remove 31 Muffler 24 Spark Arrester 24 Mulcher Cover Remove 20 ...

Page 52: ...n this page can be used on your Mid Engine Rider See the Store or Dealer where you purchased your Mid Engine Rider If you are unable to obtain the necessary information contact the Central Parts Distribution Center for your area as listed in your Repair Parts Book LAWN SWEEPER Model No 24720 GRASS BAGGER Model No 247930x00A ...

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