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Snapper
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GC9520KWV
User Manual
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Snapper GC9520KWV User Manual

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1
DEALER SETUP AND CHECKLIST FOR
LUG NUTS
SNAPPER GROUNDS CRUISER UTILITY VEHICLE
4. Install left and right rear tires and secure each with
WARNING
DO NOT attempt any adjustments, maintenance or service with the engine running. STOP engine. Set park brake. Shift transmission to neutral and remove key. Remove spark plug wire from spark plug and secure wi re away from sp ark plug. Eng ine and components are HOT. Avoid serious burns, allow all parts to cool before working on machine.
STEP 1 INSTALL REAR TIRES
The machine is secur ely attached to the c rate bottom at each wheel location. See Figure 1.1. The four steel plates must be rem oved before lifting t he machine. The device used to lift the machine must have a capacity greater than 1230 lb. The c argo bed is attached to the frame of the machine with plastic straps. Carefully remove the straps and set the cargo bed aside for installation later.
5 lug nuts. NOTE: The tir es are directional. Instal l with valve stem out and the points of the chevron treads pointing forward. See Figure 1.2.
3
1
5
4
2
(LOOSEN ONLY)
REMOVE
FIGURE 1.1
1. Loosen only, two lug nuts at left and right rear
wheel hubs.
2. Remove the four bolts securing the left and right support plates to the crate bottom.
3. Lift machine, at t he rear hitch, onl y high enough to allow tire installation. Block machine securely to prevent it from falling. Remove support plates.
POINTS OF TREADS POINTING TOWARD FRONT OF VEHICLE.
FIGURE 1.2
5. Remove blocks and lower rear of machine.
6. Torque lug nuts to 75 f t-lb using sequence shown.
See Figure 1.2.
STEP 2 INSTALL FRONT BUMPER
The bolts used to attach the front bumper to the machine are already installed in the front frame. The bumper can be used t o lift the weight of the f ront of the machine. The mounting hardware must be tightened securely (30 ft-lb).
1. Place bumper over f our bolts at front of fram e. Note orientation, flat side of side plates towards bottom
2. Attach using (4) 3/8-16 flange lock nuts.
3. Torque nuts to 30 ft-lb.
INSTRUCTION No. 7-3574 (REV. 1, 8/25/00)
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STEP 3
REPRESENTING
SEAT
MOUNT
7/16-20X2”
1/2”X1
-
1/4”
1/2”X1
-
1/4”
7/16-20
2-1/2”
INSTALL FRONT TIRES
The front bumper can be used to lift the front of the machine. Block the machine to prevent it from falling. NOTE: The front tires are directional. Install with valve stems out and with the points of the chevron treads pointing forward.
1. Loosen only, two lug nuts at left and right front wheel hubs.
2. Remove the four bolts securing the left and right support plates to the crate bottom.
3. Lift front of machine on ly hi gh en oug h to ins t al l f r ont tires. Block machine securely to prevent it from falling. Remove support plates.
4. REMOVE OPERATOR PROTECTIVE STRUCTURE FROM CRATE B OTTOM A T TH IS TI ME.
5. Install left and right f ront tires and s ecure each with
5 lug nuts.
6. Remove blocks and lower machine.
7. Torque lug nuts to 75 f t-lb using sequence shown.
See Figure 1.2.
STEP 4 ADJUST TIRE PRESSURE
IMPORTANT! C orr ect tir e i nflatio n pres sur e is cr itic al to
the proper handling and braking of the machine.
1. Using a low-pressure tire gauge, check tire pressure.
2. Adjust tire pressure to 15 psi.
WARNING
Operator Protectiv e Structure and Seat Belts must be installed and all mounting hardware tightened securely before starting or operating machine.
STEP 5 INSTALL SEAT BELTS
Mounting of seat belts is very important. Assemble carefully using the sequ ence shown. The seat belt wi th the latch plate is typically attached at the outside mounting hole. The seat belt with th e buc k le is attac h e d at the inside or m iddle mounting hole. T ighte n hard w ar e to a snug rotating fit as described below.
IMPORTANT! The la rge 2 1/2” diameter f lat w ashers must be installed on the in side surface of the seat support structure. See Figure 1.3.
1. Remove the top t wo bolts from the fuel tank straps
and slide tank out. This will allow clearance to install the bolt used to mount the right seat belt. See Figure 1.4.
NOTE: tank straps r em ain loos e unti l ST EP 6, O perato r Protective Structure installation has been completed.
2. Locate seat belts and hardware bag.
3. Place (1) 1/2” x 1 1/4“ d iameter flat washer on (1)
7/16-20 x 2” bolt. Inser t bolt with washer into seat belt mounting plate. See Figure 1.3.
4. Insert bolt into hole in seat support. Place large 2 1/2” diameter flat washer over bolt against inside surface of seat support.
5. Place (1) 1/2” x 1 1/4” flat washer on bolt. Install (1) 7/16-20 top lock nut.
BELT
PLATE
HEX BOLT
FLAT WASHER
SEAT SUPPORT STRUCTURE
DIAMETER FLAT WASHER
NYLOC NUT
FLAT WASHER
FIGURE 1.3
6. Tighten nut to a snug rotating fit. When properly
tightened the mounting bracket should be able to rotate with some resistance to align properly with seat position and size of operator, but not rattle.
7. Repeat for remaining three belts.
WARNING
Safe operation of machin e limits total occupants to (2), one operator and one passenger. Seat belts must be securely latched and adjusted to a snug fit before starting or operating the machine.
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STEP 6
FUEL TANK
REMOVE TOP
HEAT
INSTALL OPERATOR PROTECTIVE STRUCTURE (OPS)
The installation of the Operator Protective Structure requires two people. The mounting hardware for the OPS and seat belts must be properly torqued. Do Not modify the OPS in an y way. Install the OPS with the “WARNING” sign on the ri ght (passenger’s) side of the machine.
SHIELD
STRAPS
1. Locate the mounting hardware – (12) 3/8-16 x 1”
round head carriage bolts and (12) 3/8-16 Nyloc nuts. Place 6 of each in the left and right seat support tray for easy access when attaching OPS to frame.
2. Raise OPS to vertical pos ition and ori entate so that the “WARNING” decal located on the side of the OPS is on the passenger’s side of the mac hine.
3. Align holes in OPS with holes in frame. Get (1) carriage bolt started on each side. NOTE: insert bolts with head to wards outs ide of fram e as sho wn. Secure with 3/8-16 Nyloc n ut. Do not tight en at this time.
4. Install remainder of the bolts and secure eac h with a Nyloc nut.
5. Torque ALL OPS mounting hardware to 30-35 ft-lb.
6. Reattach fuel tank straps. Tighten hardware
securely.
7. Attach heat shield to OPS using (2) 5/16-18 self­tapping bolts. Do Not tighten at this time.
8. Attach heat shield to left and right f rame rails usin g (2) 5/16-18 x 7/8” bolts and (2) 5/16-18 NyLoc nuts.
9. Tighten all heat shield hardware securely.
10. Reattach fuel tank straps. Tighten hardware
securely.
TWO BOLTS
FIGURE 1.4
STEP 7 ENGINE OIL AND TRANSMISSION FLUID
The engine oil an d transmission fluid m ust be checked before operation.
1. Fill engine crankcase to proper level. Refer to Engine Owner’s Manual for capacity and oil specifications. Check with dipstick unthreaded.
2. Check transmis sion fluid leve l. Bring to f ull level as necessary using MOBILFLUID 424 or equivalent. Check with dipstick fully threaded.
STEP 8 ACTIVATE BATTERY
Battery is located under the operator’s seat. Remove battery from com partm ent before acti vatin g or char gin g. Activate and charge t he battery in well ventilated area away from sparks and flame. Do Not smoke.
1. Remove battery from the battery compartment before charging.
2. Place battery in a well ventilated area on a level non-concrete surface.
WARNING
The electrolyte (acid) produces a highly explosive gas. Keep all sparks, flame and fire away from area when charging battery or when handling electrolyte or battery. Electrolyte (acid) is a highly corrosiv e liquid. Wear eye protection. Wash affected areas immediately after hav ing e ye o r skin c ont act with e lect rol yte ( aci d). Battery acid is corrosive. Rinse empty acid containers with water and mutilate before discarding. If acid is spilled on battery, bench, or clothing, etc., Fl ush with clear water and neutralize with baking soda.
3. Remove battery ce ll c aps . Fill c e lls as r e quired with
electrolyte (purchased separately) to proper level. Fill to 3/16” above cell plates. Filling battery with electrolyte will bring the battery to 80% of full charged state.
IMPORTANT: 3/16” above cell plates is the recommend ed leve l. Never p lace an ything in ba tter y other than specified electrolyte.
WARNING
DO NOT OVERFILL!
4. With cell caps removed, c onnect battery charger to
battery terminals; RED to positive (+) and BLACK to negative (-) terminal.
5. Slow charge the batter y at 4 to 6 amps f or 2 hours to bring the battery to full charge.
6. After charging, check level of electrolyte and add as needed to bring level to 3/16” above cell plates.
7. Reinstall cell caps. Tighten securely to prevent leakage.
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STEP 8 (Continued)
RETAINING
POSITIVE (+) CABLES
NEGATIVE (
-
)
ACTIVATE BATTERY
8. Thoroughly clean any spilled acid from battery.
Neutralize with Baking Soda and flush with large quantity of water. Dry off battery.
9. Install battery into power unit. Place battery into battery tray and secure i n place with retaining rod. See Figure 1.5.
ROD
FIGURE 1.5
10. Attach battery cables to t erminals on the batt ery as
shown. See Figure 1.6. Co nnect positive ( +) cables (red) first, from wiring harness to the positive terminal (+) on battery and secure wit h nu t pro vi ded in hardware bag. Connect negative (-) cables (black) last, to negative ter minal (-) on battery and secure. Apply a small amount of grease over terminals to prevent corrosion. See Figure 1.6.
(RED) WITH TERMINAL COVER
CABLES (BLACK)
FIGURE 1.6
WARNING
Shield the positive terminal with Terminal Cover located on Positive Battery Cable. This prevents metal from touching the positive terminal, which could cause sparks.
STEP 9 INSTALL STEERING WHEEL
Make sure that the front tires are aligned perfectly straight before installing the steer in g whee l.
1. Make sure that front tires are pointing straight forward.
2. Slide foam cover over steering shaft.
3. Remove plastic cover from center of steering
wheel.
4. Orientate the steering wheel so that spokes are horizontal and align splines.
5. Place washer and nu t on steer ing shaft. T orque nut to 50-70 ft-lb.
6. Install plastic cover in center of steering wheel.
STEP 10 INSTALL O PERATOR ’S A ND PASS ENGER’ S SEAT
Carefully complete the following steps to install the seats.
1. Check seat bolts to insure hinge p late is tightened securely to the bottom of the seat. See Figure 1.7.
2. Align hinge plate with seat/pedestal assem bly and insert hinge rod.
IMPORTANT: Hinge rod must protrude past both sides of the hinge plate and be positively retained by the hair pin.
3. Insert hair pin full y into hinge rod. Hairpin mus t be
between hinge plate and s eat/pedest al to reta in rod properly. See Figure 1.7.
4. Check for 5/16” flat washer under head of seat knobs. Install washer, if missing, and tighten knobs securely.
5
STEP 10 (Continued)
1/2-13 X 3”
1/2-13 X 3 3/4”
NYLOC NUT
STRIKER
INSTALL O PERATOR ’S A ND PASS ENGER’ S SEAT
(3) SEAT BOLTS
BOLT & 1/2-13 NYLOC NUT
HINGE ROD
HAIRPIN
FIGURE 1.7
STEP 11 ATTACH CARGO BED
Attach bed to pivots at rear of frame. A prop rod is provided to support an empty cargo bed onl y in a rais e d position.
1. Align brackets on bottom rear of car go bed with left and right pivots loc ate d at rear of f r am e. See Fig ur e
1.8.
2. Insert (1) 1/2-13 x 3 3/4” b olt in to eac h left an d right pivot and secure with 1/2-13 NyLoc nuts. Tighten securely.
3. Attach prop rod t o bracket on bottom of cargo bed using (1) 1/2-13 x 3” bolt a nd (1) 1/2-13 N yLoc nut. Tighten to a snug rotating fit.
BOLT & 1/2-13
PROP ROD
FIGURE 1.8
STEP 12 ALIGN LATCH IF NECCESARY
Lower the Cargo bed slowl y until the latch contacts the striker pin. The head of the striker pin s hould be inside of the latch as shown in figure 1.9. If it is not aligned correctly, loosen the bolts that attach the left and right bed pivot brackets. Then, position the latch over the striker pin as show n in figur e 1.9 and re- tighten th e bed pivot bracket bolts.
PIN
FIGURE 1.9
LATCH ASSEMBLY
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DEALER CHECKLIST FOR
SNAPPER GROUNDS CRUISER
The following must be completed prior to sale. Refer to the previous pages in this setup instruction and in the Operator’s manual for de tailed instructions. Revie w this checklist with purchaser. Ch eck () all items actually performed. Purchaser and dealer must sign this form and the dealer retain the form for future reference.
SET-UP
_____ GEN E R A L I N SPECTI ON for loose, missing or damaged components. Rep aired as necessary. _____ WHEEL LUG NUTS checked and torqued to 75 ft-lb. _____ TIRE PRESSURE, FRONT AND REAR, adjusted to 15 PSI. _____ SEAT BELTS installed, hardware tightened, and function of buckles verified. _____ OPER ATOR P R OTECTI V E STR U C T U R E ins t a l led an d har d w are torqued to 5 0-70 f t - l b. _____ BATTERY activated, charged and installed properly. _____ STEERING WHEEL installed, alignment checked and nut torqued to 50-70 ft-lb. _____ CA R GO B E D A N D P R O P R O D i n s t a l l e d and hardware tightened according to instructions. _____ CARGO BED LATCH function verified. _____ OPERATOR CONTROLS checked for binding and damage.
LUBRICATION AND FUEL
_____ ENGINE OIL added to bring level up to full mark (Refer to Engine Manual). _____ TRANSMISSION FLUID checked and adjusted to full mark. (MOBILFLUID 424) _____ AX L E C O U P L I N GS A N D S T E E R I N G KI N G P I N S g r e a se d . ( R e f e r t o O p e r a t o r ’ s manual). _____ FUEL added to tank. (Refer to Engine Manual).
OPERATIONAL TEST
_____ ENGINE started, engine idles without dieing and runs smoothly. _____ SAFETY INTERLOCKS checked and all function correctly. (Refer to Operator’s manual). _____ TRANSMISSION shifts into forward and reverse without excessive grinding of gears. _____ CLUTCH engages and accelerates smoothly and does not drag at idle. _____ STEERING checked and functions properly. _____ SE R V I C E B R AKE AND PARK BRAKE checked and both function properly. (Refer to Operator’s manual).
DEALER’S RECORDS & FINAL CHECK
_____ PERSONALLY HANDED Safety Instructions and Operator’s Manual to purchaser. _____ INSTRUCTED purchaser to read and follow all instructions and warnings in Operator’s Manual. _____ DEMONSTRATED proper starting procedure and operation of machine to purchaser. _____ INSTRUCTED purchaser how to service air cleaner, maintain oil level (4-cycle). _____ ASSISTED purchaser in completing Product Registration Card.
CONSUMER/OPERATOR PRODUCT REGISTRATION CARD
Purchase Date ________________ Model_____________________ Serial No. ____________________ Retailer’s Name _______________________________ Signature ________________________________ Address _________________________________ City _________________ State ______ Zip _____ MACHINE WILL BE USED COMMERCIALLY? _ YES ____ NO Purchaser’s Name _____________________________ Signature ________________________________ Address _________________________________ City __________________ State______ Zip ______
IMPORTANT: This form is to be retained by the Dealer for future reference regarding Warranty, proof of purchase, traceability for product recall or service, etc. Complete the Product Registration Card and Mail to Customer Service Department at SNAPPER, P.O. BOX 1379, McDonough, Georgia, 30253.
INSTRUCTION No. 7-3574 (REV. 1, 8/25/00)
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