Assembly Instructions & Operator's Manual for
MODEL NUMBERS: W32080 W32120 W32120K
W36120 W36120K
W48120 W48120K W48140S
(12/87) Manual # 05119
WARNING: Failure to comply with the following instructions may result in serious injury to the operator or other persons. The owner of the mower must understand these instructions and, furthermore, must allow only persons who understand these instructions to operate the mower. Each person operating the mower must be of sound mind and body and must not be under the influence of any substance which might impair vision, dexterity, or judgment. If you have any questions pertaining to your mower which your dealer cannot answer to your satisfaction, call or write the Customer Service Department at SNAPPER POWER EQUIPMENT, McDonough Georgia, 30253 (Phone 404-957-9141).
Symbols like the one shown at left are used to call your attention to specific safety information in the text. This information deserves your careful attention and understanding. Failure to understand or comply with safety related information may result in injury to you or others.
.
ower Assembly | 8 |
---|---|
eration | 0 |
justments | 9 |
Belts | 5 |
A. Belt Kouting1
B. Belt Tension 1 |
5
0 |
C. Guides and Snubbers |
0
9 |
Brake/Propel Mechanism 1 | 4 |
Brake Tension | 5 |
Î |
Cutting Height |
|
11 |
---|---|---|
Drivewheel Scrapers |
|
19 |
Interlock Switches |
|
15 |
ervice |
|
20 |
Cutting Blades |
|
20 |
Worm Gear Reduction Box |
|
20 |
Maintenance Chart |
|
23 |
Hardware Torque Specifications |
|
23 |
Troubleshooting |
|
22 |
Warning or operating decals that become damaged or illegible should be replaced immediately.
Decal Kits: | ||||
---|---|---|---|---|
32" m | iowers . |
|
|
Part No. 771 |
36" m | lowers . |
|
|
Part No. 772 |
48" | mowers | . Part No. 77367 |
---|---|---|
48" | mower (14 H.P.) | Part No. 77375 |
This section describes recommended assembly procedures for mowers as shipped from the factory. Once initial assembly is complete, refer to pages 11-19 for final adjustments.
Note: If your mower has already been assembled and adjusted by your authorized Snapper Dealer, move directly to "Pre-operation Service" (Pg. 7).
Inspect mower mainframe and all loose parts for signs of damage before proceeding with assembly. Contact your Snapper dealer if damage is noted.
Mowers already removed from the shipping pallet must be propped up from the floor to allow clearance for front wheel attachment. Use the 2" x 4" x 7" blocks attached to the pallet for this purpose.
Refer to the Torque Specifications on Page 23 for correct hardware installation figures.
Note: Use of a pneumatic wrench is not recommended for Nyloc nuts. High speed installation can damage locking capability.
Figure 1 Front Wheel Assembly (caster) Attachment
%" | x 1¼" Bolt | 3. | 3%)" | x 1¾" | Bolt |
---|---|---|---|---|---|
%" | x 1" Bolt | 4. | 7⁄8" | Clamp | Colla |
2
Note: For Model W48140S. omit Step C.
Figure 2 Fuel Tank Attachment
1. Short Tank Band 2. Long Tank Band 3. Gas Tank Pads
A. Route fuel line from gas tank through nylon tie on lower handle and connect it to fuel filter, using gas line hose clamp provided. Tighten nylon tie to prevent gas line from contacting worm gear reduction box.
Note: A fuel shut-off is provided at the tank outlet and at the carburetor inlet. Check to be sure both are open for operation.
1. | Nylon Tie | 3. | Tank Shut-off |
---|---|---|---|
2. | Fuel Filter | 4. | Worm Gear Reduction Box |
Note: For Model W48140S, omit all of Step #4.
2. Clamp
3. ¼" x %" Bolt and ¼' Lockwasher
Figure 5 Muffler Installed
1. ¼" x 1" Grade 5 Bolt and ¼" Lockwasher
Proper Hardware Assembly Sequence
Figure 6 Control Lover Installation
(12/87) Manual #05119
Figure 7 Controls and Linkages
4
Ground Speed Linkage:
Upper Blade-drive Linkage:
Note: Do not over tighten, tank damage could occur.
Pull throttle control to slowest position. Insert cable in hole on throttle linkage arm (behind intake manifold). With throttle in slowest position, push linkage arm toward center of engine and secure conduit with clip provided on engine intake manifold.
Note: The throttle control will not shut off engine. The engine can only be shut off with the key switch.
Route choke conduit down from control panel, through first gusset of battery stand, and up around to front of engine. With choke control pushed in, assemble inner cable into the lowest hole in linkage arm (located on side of carburetor). Push arm back toward center of engine and secure conduit with the clip provided on the engine.
Point 1 through 6
Connect wires with corresponding numbers 1 through 6 to interlock switches and insert into flex guard loom. Attach to upper handle by pulling loom tight against switch body and fasten with plastic tie above cross bar (see Snapper Parts Manual #06119, page 11).
Point A :
Remove nut and lock washer from starter motor terminal. Place starter cable on terminal and secure with lock washer and nut.
Route the long flex guard loom down from control panel, through first gusset of battery stand, around the front of the engine, and under air breather between carburetor and engine.
Point 8 and 9
Connect to spade terminal as shown.
Point 10 :
Snap D.C. wire connectors together.
Note: Tuck as much wire of 8, 9 & 10 as possible back into loom.
Point AL & A
Connect battery ground cable to negative post on battery with (1) 5/16"-18x3/4" bolt and 5/16"-18 Nyloc Hex nut lise similar hardware for positive cable connection
Continue through Operator's Manual starting with Step #9. excluding Step #11.
Choke Control:
Positions: "OFF"
Note: Always turn to off position when not in use.
Hour Meter: Shows amount of time engine has been running
Note: If key is left in the run position when engine is not running, hour meter will continue to run.
Ammeter: Shows amount of current being supplied by the engine to the battery. At full throttle, maximum reading should be approximately 3 amps.
Fuse: Protects engine charging system and instrumentation from possible electrical malfunction.
Engine won't start
(12/87) Manual #05119
Note: Continue with Step #9, Page 7.
Note: For Model 48140S skip to Page 7.
1 Clamp Screw 2 #10 x 116" Bolt 3 #10 Nyloc Nut
Figure 9 Throttle Control Mechanism (B&S Engines) 1. Cable Clip
A. Install and secure belt shield with three 5/16" washers and Nyloc nuts.
Shaft guards are designed to swing away, allowing convenient access to shafts. Nyloc nuts should be left loose enough to allow easy cover movement when hairpin cotter is removed from its retaining pin.
Safety Warning: Never operate the mower unless discharge chute or grass catcher is securely in place.
Note: For Model W48140S, skip to Step #12.
Safety Warning: Handle gasoline with extreme care. Never allow sparks or flame nearby.
Figure 10 Interlock Switch Wiring
Safety Warning: Be certain you know and understand all control locations and functions Review Safety Instructions in the front of this manual before beginning mower operation.
Move lever as directed to vary engine speed, shut off engine, or prepare engine for starting.
Note: On Kawasaki engines "Start" position auto-matically engages choke. Briggs & Stratton engines must be choked manually
Drive Levers (Fig. 11)
Figure 11 Drive Leve
1. Drive Lever (shown in 2. Handle Grip "Neutral Lock" position) 3 Thumb Latch
wheels and brakes both disengaged).
To lock drive levers in neutral position, pull back on the thumb latches, then release the levers so they catch as shown in Fig. 11.
4. Steering the mower See "To steer mower," under Operating Procedures (Pg. 10).
Cutter Blade Control (Fig. 12)
Move to start or stop blade rotation
1. Disengage (stop blade rotation) 2. Engage (start blade rotation)
Move as desired to change ground speed.
Caution: Change speed only while engine is running to avoid damage to components
1 Slowest 2. Fastest
If drive levers are correctly adjusted, mower will travel in a straight line when both levers are released.
To turn, simply squeeze the drive lever on the same side as the direction you wish to turn. This locks the wheel brake on that side and causes the machine to turn.
Continue holding the drive lever until the mower is headed in the desired direction. Release the drive lever and the mower will resume straight-ahead travel.
To Stop Operation:
Use the thumb latches to lock the drive levers in "Neutral Lock" position (see Fig. 11), then move throttle control lever to "Stop" position. Units with Kawasaki engine turn "shut-off" switch to "off" position.
Safety Warning: Shut off engine and disconnect spark plug wire before making any adjustments.
Your Snapper mower may be set to any of 10 different cutting heights, ranging from 1½" to 5".
It will be necessary to alter the deck height (distance from the bottom edge of the mower deck to the ground)
in order to achieve the desired final cut. This will involve relocation of the rear axle and the front wheels or front wheel assemblies.
Note: Whenever the rear axle has been relocated, you must adjust the brake/propel mechanism and the drivewheel scrapers.
It may also be necessary to relocate the drivewheel scrapers and/or the brake plate swivel.
All of these operations are described following the chart below.
Т ́ | ||||||
---|---|---|---|---|---|---|
STE | EP #1 | STEP #2 | ||||
Select desired ground clearance and
cutting height |
Position front and rear axles as noted below to correspond to cutting height selection. | |||||
Front Axle
(Fig. 18) and |
Check listings below to see which
mounting positions correspond to cutting height selection. Reposition if Necessary. |
|||||
Cutting
Height |
Ground
Clearance |
Hear Axle
(Fig. 16) Setting |
Drivewheel Scraper
(Fig. 16) |
Brake Plate Swivel
(Fig. 17) |
||
11⁄2" | 1" | #1 | А | A | ||
2" | 1½" | #2 | А | Α | ||
* 2½" | 2" | #3 | А | Α | ||
3" | 21/2" | #4 | А | В | ||
31⁄2" | 3" | #5 | В | с | ||
4" | 31⁄2" | #6 | В | С |
*Shipped from factory in this position
Note: 4¼"-5" cutting height, see Fig. 19, Pg. 13.
Figure 14 Cutting Height Adjustments
Safety Warning: Secure the mower in place to prevent it from falling. Disconnect the spark plug wire.
Flaure 15 Rear Axle Adjustments
1. Axle Retaining Bolt 2. Axle Adjusting Bolt
H. Adjust the drivewheel scrapers and belt guides as shown in Fig. 32, Pg. 19.
A. Refer to the chart in Fig. 14 to see if repositioning is necessary. If repositioning is not needed, disregard steps B and C.
1. Brake Adjustment Plate 2. Swivel
Figure 18 Front Wheel Positions
To achieve cutting heights of 41/4" to 5", move the spacers from under the cutter housing to above the cutter pulley. Move one additional spacer for each additional 1/4" of cutting height.
Flaure 19 Seacer Placement
This mechanism allows a single lever (drive lever) to control braking, forward motion, and the selection of a "neutral" position (for each drivewheel)
Mechanism actions are interdependent: that is movement of any one portion affects all other parts of the system For example: when you pull the drive lover to activate the wheel brake, the mechanism first lifts the tension idler from the wheel-drive belt. Then as you continue to null the lever, it causes activation of the hrako
Note: This procedure also serves as adjustment for correct brake tension
7. #2 Hairoin Cotter
Adjustment of the brake/propel mechanism includes correct brake tension adjustment. To adjust brake tension, follow the complete sequence (A thru J) under "Brake/Propel Mechanism." Po. 14.
Note: Do not change location of the short swivel in the brake adjustment plate to adjust brake tension. Short swivel position is dictated by rear axle location only.
Three interlock switches prevent the engine from starting if the drive levers are not in the neutral position or if the cutting-blade drive system is engaged.
The drive-lever interlock switches should be mounted so that the stem begins to retract as the drive linkage in the drive lever falls below its "Neutral" position. The stem should be at its full extension when the drive lever is actually in neutral.
The blade-drive interlock switch must be mounted so that the stem retracts before the drive belt becomes fully engaged. The stem must be fully extended when the lever is in the "Stop" position, to enable the engine to start.
If these interlock switches require adjustment, reposition them as needed (see Fig. 21 for adjustment nut location):
Figures 23 through 26 show correct belt routing for all models.
32" and 36" Models
Figure 23 32" & 36" Belt Routing (Beneath frame)
Figure 24 32" & 36" Beit Routing
1. Lower Blade-drive Linkage 3. Belt Snubber
2. Tightening Arm
1. Lower Blade-drive Linkage 4. Blade-drive Belt
Blade-drive Belt Auxiliary Blade-drive Belt Adjusting Nut
Figure 26 48" Belt Reuting (Beneath frame)
*The Tangent Line is a line from the center of the shaft through the point at which the outside of the belt enters or exits the pulley.
Figure 27 Belt Guide Adjustment
The 48" mower comes with five adjustable belt guides. Correct location of these guides is essential for proper blade disengagement. The blades should come to a stop from maximum speed within 7 seconds after disengaging. If they do not, please adjust each belt guide as shown.
Belt tension should be set so that belt vibration is minimized or eliminated when belts are moving during normal operation (6-9 lbs, tension at center of belt span between pullevs)
Minor adjustments (see Fig. 28)
Maior Adjustments (see Fig. 29)
4. Approximately 1/8" space with
Turn the adjusting nut shown in Fig. 25 to provide nroner helt tension
Although these adjustments affect belt tension. their primary effect will be to increase or decrease overall ground speed
Caution: Do not reposition ground speed control lever without engine running or worm gear reduction box damage could occur
Upper Adjustments (see Fig. 30)
Clockwise rotation of the voke will result in less overall ground speed. Counter-clockwise rotation of the voke will result in greater overall ground speed.
C. Reconnect the voke to the control lever
Figure 30 Honer Adjustment
Lower Adjustments (see Fig. 31)
Figure 31 Lower Adjustment
1. Variable Adjustment Rod 3. Bellcrank
2. Adjusting Swivel
The wheel-drive belts are held under spring tension during forward drive. If belt slippage occurs, simply reconnect the extension spring in the next forward hole (see Fig. 20, Pg. 14).
Belt guide pins or snubbers are located at various places on the mower. They should be adjusted so that they do not contact belts while under tension.
Contact is necessary, however, when belts are slack, to aid in belt disengagement.
A setting of 1/6" clearance usually provides the desired effect. Exceptions are the belt guide pins noted in Fig. 23 and 26. They should be adjusted to 1/4".
Note: All guide pins and snubbers should be adjusted while belts are ur der tension.
1, 1/16" clearance to pulley center
2. 1/8" clearance to belt (under tension)
Note: This adjustment can affect belt guide position. Be sure to position guide correctly before securing the scraper.
Safety Warning: Shut off engine, allow it to cool, and disconnect spark plug wire before performing any service. If mower is raised, be sure to secure it in place to prevent falling
A. Raise the front of the mower to allow access to cutter shaft bolts.
Safety Warning: Secure mower in place to prevent falling.
B. Use two 15/16" box-end wrenches to remove the blade bolts and blades.
A. With mower secured in position, replace blade and blade bolt. Refer to Fig. 19 for correct replacement sequence.
Safety Warning: Be certain cutter shaft bolts are installed from beneath and that none of the 1/4" spacers is installed below the blade.
File or grind blades only along the area previously sharpened by the factory.
Safety Warning: Wear eye protection when filing or grinding.
Safety Warning: Wear eye protection when filing or grinding.
Symptom | Possible Problem | - Remedy | ||
---|---|---|---|---|
Engine
Won't Start |
Fuel tank empty |
Fill with fresh regular grade
gasoline |
||
Fuel tank shut-off
valve closed |
Open shut-off valve | |||
Carburetor inlet
shut-off closed (B&S engines only) |
Open shut-off valve | |||
Spark plug wire
disconnected |
Reconnect wire | |||
Throttle control
not in START position |
Move control to correct
position (close manual choke on Briggs & Stratton engines) |
|||
Keyswitch "OFF"
(Kawasaki) |
Turn Keyswitch
to "ON" |
|||
Air cleaner
clogged |
Remove and service per
engine manufacturer's instructions |
|||
Throttle cable broken
or needs adjustment |
Visually inspect. Repair
or adjust (see Pgs. 6-7). |
|||
Drive levers not in
NEUTRAL position |
Move drive levers to NEUTRA
position |
|||
Cutting-blade drive
system engaged |
Disengage system | |||
Interlock switches need
adjustment or replacement |
Check switches. Adjust or replace. | |||
Interlock switches corroded. |
Spray penetrating oil on
plunger of switch, work in and out several times. |
|||
Interlock switch wiring
connections loose or disconnected. |
Check and secure connections. | |||
Uneven cutting
or poor discharge of clippings |
Blades dull |
Visually inspect. Sharpen
per instructions on Pg. 20. |
||
Blades installed
improperly (upside-down) |
Visually inspect. Install
per instructions on Pg. 20. |
|||
Blade spacers not
positioned uniformly on all blade shafts |
Visually inspect. Reposition
spacers as necessary. See Fig. 19, Pg. 13. |
|||
Blade-drive belts
slipping |
Visually inspect. Replace
or adjust as necessary. See Pg. 15. |
|||
Front wheel casters
not in correct relationship with rear axle location |
Adjust as necessary. See chart on Pg. 11. | |||
Tire pressure uneven |
Adjust to correct pressure
(14 P.S.I.) Rear (30 P.S.I.) Front |
Symptom | Possible Problem | Remedy |
---|---|---|
Mower will not
self-propel correctly |
Drive levers need
adjustment |
Visually inspect. Adjust per instructions on Pg. 14. |
Drive belts worn
or improperly adjusted |
Visually inspect. Replace
or adjust as necessary. See Pg. 19. |
|
Debris in
drivewheel pulleys |
Visually inspect. Clean
and adjust scrapers. See Pg. 19. |
|
Worm gear reduction box worn or damaged |
Remove, disassemble and
inspect. Repair or replace if necessary. |
|
Belt idler loose |
See "Wheel-drive Belt,"
Pg. 19. |
|
Drive tire pressure uneven | Adjust to correct pressure (14 P.S.I.) | |
Blades spin more
than 7 seconds after power is disengaged |
Blade belt snubber
and/or guide(s) need adjustment |
Adjust correctly
See Pg. 17 or Pg. 19. |
Upper and/or lower
Blade-drive linkage(s) need(s) adjustment |
Adjust correctly.
See Pg. 18. |
|
Blade belt worn | Replace with new part. | |
Blade will
not rotate |
Upper and/or lower
blade-drive linkage(s) need(s) adjustment |
Adjust correctly.
See Pg. 18. |
Belt off of drive
(engine) pulley |
Replace on pulley | |
Excessive
Vibration |
Blade(s) out of
balance |
See Pg. 20. |
Blade assembly
incorrect |
Reassemble correctly.
See Fig. 19, Pg. 13. |
|
Belt tension incorrect
(too loose) |
See Pg. 18. | |
Engine crankshaft
damaged |
See your Authorized
Snapper Service Dealer. |
|
Mower will not
drive straight |
Tire pressure
uneven |
Adjust to correct pressure
(14 P.S.I.) Rear (30 P.S.I.) Front |
Brake/propel
mechanism needs adjustment |
Adjust correctly.
See Pg. 14. |
ltem | Frequency | Procedure |
---|---|---|
Pulleys: Blade
Blade Drive Variable Speed Worm Gear Reduction Box |
Whenever
removed |
Apply Loctite #RC609
to shaft before re-assembly |
Linkages & Adjustments:
Brake Drive Forward Motion Blade |
100 hrs. |
Inspect for worn
or broken linkages or hairpin cotters. Re-adjust per specifications in "Adjustments" section. |
Interlock Switches | 100 hrs. |
Apply light penetrating
oil to plunger. Work in and out several times |
Point between neutral
lock and drive slot on thumb latch |
Check every 250 hrs.
Replace before each mowing season |
Check if point is worn round. If so replace. |
Underside
of mowing deck and above rear safety shield |
After each
mowing period |
Remove matted grass
and debris |
Engine
Crankcase |
Before each
mowing period |
Fill per engine manufacturer's specifications |
End of mowing season | Drain and refill per engine manufacturer's specs. | |
Worm Gear
Reduction Box |
After initial 10-15 hour
break-in |
Drain and refill with EP90W oil |
40 hrs. |
Check oil level (see
"Worm Gear Reduction Box" Pg. 20) |
|
200 hrs. | Drain and refill with EP90W oil | |
Front & Rear
Wheels |
100 hrs. | Lubricate with "Moly" EP grease |
Wheel
Casters |
100 hrs. | Lubricate with "Moly" EP grease |
Rear Tires
Front Tires Units equipped with dual rear wheels: Inside Outside |
Before each
mowing period |
Inflate to 14 P.S.I.*
Inflate to 30 P.S.I.* Inflate to 14 P.S.I. Inflate to 13 P.S.I. |
Cutter
Shaft Spindles |
100 hrs. | Lubricate with "Moly" EP grease |
*It is important that tire pressures be equal to insure straight travel.
NOTE: Service more frequently under extreme conditions (heat, dust, etc.)
Bolt Size | #10 | 1/4 | 5/16 | 3/8 | 7/16 | 1/2 | 5/8 |
---|---|---|---|---|---|---|---|
Torque (FtLbs.) | 4-6 | 7-9 | 10-15 | 20-25 | 30-40 | 50-60 | 100-120 |
IT IS THE POLICY OF SNAPPER POWER EQUIPMENT TO IMPROVE ITS PRODUCTS WHENEVER IT IS POSSIBLE AND PRACTICAL TO DO SO. WE RESERVE THE RIGHT TO MAKE CHANGES OR ADD IMPROVEMENTS AT ANY TIME WITHOUT INCURRING ANY OBLIGATION TO MAKE SUCH CHANGES ON PRODUCTS MANUFACTURED PREVIOUSLY.