ASSEMBLY INSTRUCTIONS FOR CHARGER AND THE BOSS QUICK ATTACH GRASS BAGGER \ \ \ \ ~\ P 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 21 P-12102
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. 1) Make sure all guards, shields, and deflectors are in place and in good working condition. 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 1 P-12102 1
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. Clutch Blower Pulley Key 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. 7) While holding the Extension Shaft up in the Clutch, slide the Blower Pulley over the Shaft, with the set screw down. Insert the Key into the key way and tighten the Set Screw. Flat washer Lock Washer 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. Set Screw Shaft Extension Bolt Note: Use metric bolt on Liquid cooled Kawasaki. 8) 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) 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. 2 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. 3 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. 4 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 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. 6 P-12102
BAGGER PULLEY ASSEMBLY ACCESSORY MOUNT PULLEY REAR PULLYE BRACKET USE BOTTOM HOLES FOR BOSS MOWERS USE TOP HOLES FOR CHARGER MOWERS 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 P-12102
11 BAGGER MOUNT ASSEMBLY (1) Lay box on its side and slide bagger out on the ground. (2) Stand bagger on its top, making the underside reinforcements accessible. (3) Unpack parts box to get left and right hand mounts. (4) You will find hardware in a pack and will need (4) 3/8 flat washers and (4) lock nuts. (5) Assemble mounts as shown, and secure nuts with 9/16 socket or wrench. 8 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 P-12102
BAGGER DOOR DUMP HANDLE ASSEMBLY Install (2) dump handles, as shown, with 3/8 pins through the bottom holes in the door. Place the 2 nd 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. Hammer together FOAM TAPE STOP BOLT DOOR HINGE BOLT STOP PLATE PIVOT STUD DUMP HANDLE PLASTIC HANDLE RUE RING 10 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. 11 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 P-12102
Remove Top Belt Guard, ",1; Flat Washer I 0)" ' / ~ BLOWER TO BAGGER MOUNT FRONT * 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., // ;1, ~~yiock Nut Page 13 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 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 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 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 Hour Meter Red Double Wire on Hour Meter Blower Wire With Jumper 17 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 3/8-16 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 3/8-16 X 6 BOLT CARRIAGE BOLT, 3/8-16 X 3 BRACKET, WEIGHT MOUNT NUT PLATE, WEIGHT MOUNT NUT, 3/8-16 X NYLOC 18 P-12102
1) Rotate the discharge chute up as far as possible. TRANSITION MOUNTING 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. HOSE CLAMP LIP TRANSITION SADDLE DECK DISCHARGE STIFFENER HOSE TRANSITION LOOSEN THESE NUTS TO ADJUST ROD ASSEMBLY TRANSITION ANGLE ROD (2) HOLES 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 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 20 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. RUE RING T-HANDLE PIN FLAT WASHER CLEVIS PIN 21 P-12028