Rover 5377 - 12HP User manual

Ranger Auto - Drive
Owners Manual
Model No. 5377 – 12HP.
WARNING
•Amowerisahighspeedcuttingtool.Safetyprecautionsmustbeobservedtoreducetheriskof accident.
•Careless orimproper usemaycause seriousinjury.
•Besurethat you read and fullyunderstandthecontentsofthisOwner’s Manual.Should any point be unclear, contact
Rover-ScottBonnarLimited,inyourStateoranauthorised Rover-ScottBonnarServiceAgentforassistance.
•Keepthe Owner’s Manualinasafeplaceforfuture reference.Read the Owner’sManualperiodically to ensurethe
continuedsafeandproperuseof themower.

SAFETYINSTRUCTIONS
•Amower user mustbeingoodphysicalconditionand
mentalhealthandnotunder theinfluenceofanydrugor
alcohol whichmightimpairvision co-ordination or
judgement.
•Donotuse amowerwhen tiredorfatigued.Lackof
alertness maycauseseriousinjury.
•Know yourcontrols.
Read andunderstandOwner’s Manualbefore operating
mower. Learnhow tostopthe mower inanemergency.Refer
Operator’sInstructions.
•Donotlend orsell themower without the Owner’sManual.
•Besurethat anyone using the mower readsandfully
understandsthe informationcontainedinthisManualand
knowshowtosafely operatethe mower.
•Donotallowchildrenor peopleunfamiliarwiththese
instructions tousethe mower.
•Nevermowwhilstbystanders orpetsarepresentinthe
mowingarea.
•Never carrypassengers.
•Never mowwhilebarefootorwearing open sandalsor
thongs. Wearlongtrousersand heavynon-slip shoes.
•Itisadvisabletowearsuitableeyeprotectionwhen
operatingamower.
•Beforeusing,alwaysvisuallyinspect toseethatthe
blades,bladebolts,andcutterassemblyare notwornor
damaged.Replaceworn ordamagedblades andboltsin
setstopreservebalance.
•Damaged bladesand wornboltsaremajorhazards.
•Replacewornorfaulty silencers.
•Alwaysmountanddismountmower fromleft-handside
(oppositesidetodischargechute).
•Makesure the areatobemowediscleared of sticks,
stones, bones, wireand debris. Theycouldbethrownby the
blades.
•Store fuelinacool placeinacontainer specifically
designedforthatpurpose. Ingeneral,plasticcontainersare
unsuitable. Handlefuelcarefully.Itishighlyflammable.
•Refueloutdoors only.Donotsmokewhen refueling
engine. Add fuelbefore starting engine. Neverremovethe
capfromthe fueltankoradd petrol whilethe engineis
running. Allowenginetocool forseveralminutes before
refueling if engine ishot.Ifpetrol isspilled,donotattempt to
start the engine, but movethe mower away from the areaof
the spillandavoidcreating anysourceof ignitionuntilthe
petrolvaporshavedissipated.
•Removethefuelcapslowlytorelievefueltank pressure.
•Checkforfuelleakswhilerefuelingorusing themower.If
afuelleakisfound,donotstartorruntheengineuntil the
leakisfixedand spilledfueliswipedaway.
•Takecare nottogetfuelonyourclothing.Ifthisoccurs,
changeyourclothingimmediately.
•Donotoperatemower inconfinedspacewhere exhaust
fumes(carbonmonoxide)cancollect.
•Mow only ingooddaylight.
•Starttheenginecarefullywithfeetwell away fromthe
blades.
•When starting donotwrap the startedropearoundyour
hand.Donot allowthe started cord tosnap back.Return the
starter grip slowlytoallow thecordtorewindproperly.
•Strictlyfollowtheoperatorinstructionsbeforeattempting
tostartthemachine.
•Never mowwheremachinecouldtip orslip.
•Ifmachine stallsgoing uphill,stopblades andbackslowly
down.
•Mowup anddownslopes.Never mowacross aslope.
Exercise extremecautionwhenchanging directiononslopes.
Donotmowexcessivelysteepslopes.
•Donotaccelerateorstopthemower suddenlywhen ona
slope.
•Beextremelycarefulwhen using amoweronslopes. Stay
alertforholes inthe terrainandotherhiddenhazards.
•Disengage cutter drivebefore mowing across graveldrives,
walksorroads.
•Donot mow inreverse. Whenreversing keep a carefuland
continuousobservationofthe entireareabehindthemower.
•Never usethe mower unless allguardsprovidedby Rover-
ScottBonnarLimitedareinposition.
•Never disconnectthe safetyswitchesandneveroperate
themowerif any safetyswitchisinoperative.
•Never over-speed the engine oralter the governorsettings.
Excessivespeedisdangerousand shortensmower life.
•Takeallprecautionswhen leaving the mowerunattended.
Disengage the cutter drive, setthe parkbrake, shiftinto
neutral,stoptheengine,andremovethe key.
•Stopthe engine andremovethe keywhenever youleave
themower, evenforamoment.
•Stopthe engineanddisconnectthe sparkpluglead and
inspectmowerif:
a) The mower begins tovibrateabnormally:or
b) After strikingaforeignobject.
Repairthe damage beforecontinuing furtheroperationof
themower.
•Stop the engine anddisconnectthe spark pluglead before
clearingblockages,checkingorworkingonthe mower.
•Never pickup orcarryamowerwhileit isoperating.
•Wherefitted,turnfueltapoff attheconclusionof mowing.
•When transporting inavehicle, secure the mowerto
preventmovement,roll-over, fuelspillage, andmower
damage.
•Keepallnuts, boltsandscrewstighttobesure the
equipmentisinsafeworkingcondition.
•Never modify the mower inany way.Use onlyreplacement
partsmadeandguaranteedbyRover-Scott BonnarLimited.
•Keepall safety devices (guardsandswitches)inplaceand
working.
•Keepthe enginefree ofgrass, leaves orexcessivegrease –
thesecanbeafirehazard.
•Store the mower inawellventilatedroomawayfrom
nakedflames suchas may befoundinhot waterheaters.

SAFETYFEATURES
Tractiondrive, blade drive and seat
safety interlock
Lowcentreofgravity, stablewidetrack
Enclosed drives
Parking brake
Full footrests Convenient – easytooperate controls
1

SPECIFICATIONS
ROVERRANGER
MachineModelNo. 5377
Engine ModelNo. 281707
SingleCylinder Briggs &Stratton
4 Stroke 12Hp465cc
FuelCapacity 4.0 Litres
Oil Capacity 1.42 Litres
Lubrication GearImpellor
Spark Plugtype ChampionCJ8
SparkPlug gap 0.7to0.8mm
Ignition type Magnetron
Engine Oil 10w-30orSAE30
TRANSMISSION
Auto-Drivesystemconsistsof acontinuousbeltbeingdriven
by anidler pulleyover two drivepulleysandaroundareturn
pulley.Frictionplates are broughtintocontactwiththedrive
pulleystoimparteither forwardorreversemotiontorear
drivewheelsbymeansof adriveselectorpedalontheright
sideofthemachine.
Ground speedat3600rpm isvariableduetoAuto – Drive
systemdependingonpressure appliedtodrive selector
pedal.
Max.speed= 8.6 km/hr
CUTTING HEAD
Model160 Full floating pressedsteelhousingwithright
sidedischarge. Widthof cut760 mm (30”).
TYRES
FrontTyres: 4.1x6Tube
Pressure140KPA maximum
RearTyres: 16x6.5x8Tubeless
Pressure96KPAmaximum
CONTROLS
∗Throttlecontrol withFast,SlowandChokepositions;
∗KeyswitchwithOff,OnandStartpositions;
To emphasise specialinformationthewords WARNING and
CAUTION areused.
WARNING: The safetyof theuser and others
involved.
Personalinjurymay resultshouldthis
informationbedisregarded.
CAUTION: Followtheseinstructionscarefullyto
avoid mowerdamageand lossof
warranty.
STEERINGWHEEL
325MM Dia.SteeringWheel.1 ¼turnslock tolock.
CLUTCH/BRAKEPEDAL
Foot operatedpedal.Leftsideof machine.
PARKING BRAKE KNOB
Handoperatedcatch.Lefthand side.Usedinconjunction
withclutch/brakepedal.
DRIVE SELECTOR
Foot operated pedallocated onright sideof machine. Spring
loaded soastoreturntoneutralposition.
CUTTING HEIGHT
Lever righthandside. 8heightof cut positionsfrom15mm
to65mm.
CUTTER DRIVE
Leverlocatedleftsideof seat cowl.
GENERAL
WheelBase: 135cm Length: 164cm
Track63cm.R69cm F Width: 80cm
TurningCircle: 5.8m Height: 95cm
TurningRadius:2.0m Weight: 195kg
2

LOOSE PARTS KIT
DESCRIPTION
Steeringwheel
Roll Pin
StoneGuardAssy.
SpringStoneGuard
‘E’Clip
IgnitionKeys
Plug Spanner
QTY
1
1
1
1
1
1
1
USE
Onsteeringshaft
Secure steeringwheeltoshaft
Fittedtocutter head
Onstoneguardpivotrod
Ingrooveinpivotrod
To start machine
SETTINGUP INSTRUCTIONS
Fig. 2
INSTALL STEERINGWHEEL
1. Slipsteeringwheelover steering shaftand alignthewheel
holewiththeshafthole;
2. Insertdriftpunch – partiallythroughtheholes tomaintain
alignmentand insertroll pinintheoppositeside; See
Fig.2.
3. Driveroll pininuntil flushwiththeoutsideof wheel.
Fig. 3
FIT STONEGUARD
1. Slipspringintostoneguardpivotrodsothattheshortleg
restsontop ofthestoneguard;
2. Now twistthespringasshownandfeedtheendofthe
pivotrod intotheforwardpivotbracket:SeeFig.3.
3. Inserttheshortendof thepivotrodfullyintotherearward
pivot bracket;
4.Release thespring.Itshouldspring downontothetopof
thecutterheadandbetensioningthestoneguarddown;
Fig. 4
5.Secure byclipping an‘E’Clipintothegrooveonthepivot
rod.See Fig.4.
INSTALLING THEBATTERY
BATTERY
1. RemoveBatteryasfollows;
(a). removeterminalcablefrombattery;
(b). undowingnutsandremoveclamp bar.
2. Thebatteryisnotfilledwith Electrolyte. This shouldbe
donebyadding 33%strengthbatteryacidtoeach cell
until plates are covered.Electrolytemust bepurchased
fromalocalbattery supplyoutlet.
IMPORTANT:DONOTOVERFILLBATTERY.ACIDWILL
OVERFLOW INTOOTHERPARTSOFTHEMACHINEAND
SEVERE CORROSIONAND DETERIORATIONWILLRESULT.
3. Leavefiller capsoff and connectbatterycharger to
batteryterminal.Chargeattherateindicated inthe
instructionssupplied withthebattery.
4. After charging,checkthat Electrolyteisstill covering
plates, ifnot,addtocorrect level.Install filler caps.
5. Replacebatteryand secure.
6. Installthepositive(red)cabletothepositive(+)
terminaland thenegative(black) cabletothenegative
(-)terminal.
Secure forgoodelectricalcontact.
3

BEFORE OPERATING
FILL CRANKCASEWITH OIL
Therider mower maybedeliveredwithoutoil inthe
crankcase. Oil mustbeaddedbefore attemptingto
starttheengine.
1. Placemachineonlevelsurface. Ensurethatthe
oil plug issecurelytightened.Cleanaround
dipstick.
2. Unscrewand removedipstickfrom oilfiller tube.
3. Insertfunnelintofiller tubeand slowlyadd oil in
accordancewiththeenginemanufacturer’s
direction.
NOTE:Avoidpremature enginefailure by ensuring
the funneliscleansocontaminantsare not
introducedintothe crankcase. Wipeanyoil
spillssoit willnotcausedirttocollect onthe
engine.
4. Ensure oil levelisatthefull markonthedipstick,
whenscrewedcompletelyin.Whenfinished
replacedipstickandretighten.
NOTE: See MaintenanceInstructions.
FILL FUELTANK – SeeSafety Instructions.
Use onlyregulargradeorunleadedpetrol.
Donot mixoil withpetrol – engine damagemayresult.
1. Clean aroundfueltankcapsoforeign mattercannot
entertankwhencapisremoved.
2. Using afunnel, fill tankwithregulargradeorunleaded
petrol.Replacecap.
3. Wipeupany petrol that mayhavespilled.
CHECKTYREPRESSURE
Checkand maintaintyre pressure at140KPA(20PSI) front
and 96KPA(14 PSI)rearmaximum.
ADJUSTING THE SEAT
Tiptheseatforward,
loosentheseatsecuring
screws. Relocatetheseat
for operatorcomfort.
Tightentheseatsecuring
screwsand lowerstheseat
See Fig.5
Fig.5
CONTROLS
Fig.6
1. Throttle Control –Mountedonthecontrolpanelandconnected
totheenginecarburetorcontrols.Has thesymbols forSlow,
Fast andChoke.
2. IgnitionSwitch – This switchis partof thebatteryignition
system andhas threepositionsmarkedforOff,On andStart.
Theswitchis key operatedandautomaticallyreturnstotheOn
position from Startposition whenreleased.
3. Brake/Clutch – Footoperatedpedalonleftsideof machine.
Depressingthepedaldisengagesthedrive belt andengages
BrakeDisc.
4. ParkingBrake – Handoperated knoblefthandside.
Depressingthebrakeclutch footpedalenablesthis knobtobe
engagedanddisengaged.Brakeis lockedonwithknobinup
position.
5. Drive Selection– Footoperatedrighthandside. Depress with
toe pressuregives forwardmotion;depress withheelgives
reversemotion.Automaticallyreturnsto neutralposition.
6. Cutting Height Adjuster – Located onrightof seatwithlowcut
atbottomand high cutatthetopsetting.
7. CutterDrive – Leverlocatedonlefthandsideofseatmounting
box.Down positiondisengagesbladedriveandappliesblade
brake,Uppositionengagesblades.
4

OPERATINGINSTRUCTIONS
AUTO – DRIVEOPERATION
Forwardand backwardmovementof themower iscontrolledbythedriveselectorpedal.Aswithamotorvehicle,
speed iscontrolled by theamount of pressure onthedriveselectorpedal.Ensurethat themower user isfamiliarwith
thismeansof operationbeforeoperatingthemower,particularlyintight orconfinedareas.
TO STARTENGINE
NOTE: Theengine willnotstartunlessthe cutterdriveis
disengaged,andclutch/brake pedalisdepressed.
1. Depressclutch/brakepedal – Applytheparkingbrake
2. Movethedriveselectortoneutral
3. Disengagethecutterdrive
4. Movethethrottlelevertothechokeposition
5. Turntheignitionkeytothestartpositionandrelease
whentheenginestarts
6. Movethethrottlelevertoabout ¼position
TO MOWOR DRIVE
1. Depressclutch/brakepedal
2. Disengagetheparkingbrake
3. Selectheight ofcut
4. Movethrottletoabout ¾position
5. Engagecutter drive
6. Select desireddrive
7. Slowly releaseclutch/brakepedalto moveoff
TO STOPENGINE
1. Depressclutch/brakepedal
2. Shiftthedriveselectortoneutral
3. Disengagethecutterdrive
4. Apply theparkingbrake
5. Movethrottleleverto the slow position
6. TurntheignitionkeytoOFF.Removethekeys
TO STOPINANEMERGENCY
1. Depress brake/clutchpedalanddriveselectorpedal
together. (Thisdisengages powerfromtheengineand
engagesthediscbrake)
2. Apply parkbrakeand lock
3. Movethrottletoslow positionand switchoff ignitionkey
4. Dismount from mower ifitissafetodoso
IMPORTANT
1. Theparkingbrakeshouldalwaysbeappliedbefore
leavingthemachine
2. Theparking brakemust bereleasedbefore attemptingto
drive
3. Depress theclutch/brakepedal-whenstarting orcoming
torest
4. Donotuse suddendirectionalreversal which can cause
wheelspinning
ENGAGINGCLUTCHES
When engaging thecutter drivelever orreleasing the
clutch/brakepedal,alwaysoperateslowly.Donotuse a
jerking motion.Moving thesecontrolstoo fastcould
possiblyoverloadand stalltheengine.
WARNING: Toavoidloss ofcontrol alwayscometoa
completestopbefore changing drivedirection
andslow downbeforeturning.
REMEMBER
1. Alwayslookbehindthemachinebeforereversing
2. Donotrefuelwhentheengineisrunning orwhilethe
engineishot
3. Keepbystandersaway – Keephandsandfeetclearof
movingparts
4. Keep machinecleanofgrass anddebris
5. Keepall safety devices (guardsand switches)inplace
andworking
Periodicallycheckthemachineand thecuttingmechanism.
If partsare wornorneedreplacingdosoby usingonly
GenuineRoverReplacement Parts.
There isacomprehensiveRanger Spare PartsListcontained
inthisbook tohelpyouselecttherightpartquickly.
Before working onthemower, disconnect thespark pluglead
fromthesparkplug and placeitwhere itcannotcontactthe
sparkplug.
CheckyourRover Ranger frequentlyforloose nuts, bolts,
beltsetc,andkeepthese itemscorrectlytightenedand
adjusted.
Note:Acheckafter thefirsttwo hours of operationis
recommended.Engine failure orrapidengine wear
mainly result fromthefollowing causes –
1. Dirtorabrasives enteringtheengineviatheair
cleaner dueto –
a. Theaircleanerelementnotbeingserviced
regularly,or
b. Theaircleaner damaged ordislodged
2. Dirtorabrasives enteringtheengineviatheoil
filler tubedueto –
a. Usingafunnelnot cleanedof dirtandgrit,
b. Toppingup withcontaminated oil.Oil stored
inanuncleancontainer
3. Lackof oil.Itisimportantto –
a. Check theoil levelregularly (every5 hours of
operation)
b. Maintainafull sump
5

MAINTENANCE INTERVAL CHART
See
Page 5 Hours 25 Hours PERIODIC SERVICEEVERY25HRS 5075100125150175200
ChangeOil (Initial) 6 X
ChangeOil (Periodic) 6 X
CheckInterlock 11 X X
CheckCuttingBlades - X X
CheckCuttingUnit Brake 9 X
Check RearWheelsBrake 9 X
LubricatePivot Points 7 X
LubricateDriveChain 7 X
LubricateThrottleCable 7 X
GreaseFront AxleSpindles 7 X
ServiceAirCleaner 6 X
Check SparkPlug 6 X
Check DriveBelts 10 X
Check DriveChain 10 X
CheckTyrePressure 4 X
Clean Outsideof Engine - X
Clean CutterHousing - X
PaintChippedSurfaces - X
AIRCLEANER:DualElementType –
1. Removetwo cover knobsand removeaircleaner
cover.
2. Removefoam pre-cleaner, if soequipped
a. Washpre-cleaner inliquiddetergentandwarm
watertoremovedirt
b. Wrap pre-cleaner inclothand squeezedry
c. Saturatefoaminengineoil.Squeezetoremove
excess oil.
3. Removetwo nutsfrom topof cartridge.
4. Removecartridgeand cleanaircleanerbody carefully
topreventdirtfromentering carburetor. Brushdirt
from loweraircleaner bodyintoduct.
5. Clean cartridgeby gentlytappingonflatsurface
a. Ifverydirty,replacecartridgeorwashinalow or
nonsudsingdetergentand warm water solution
b. Rinse thoroughlyfromINSIDE OUTuntil water is
clear
c. Cartridgemustbeallowedtostandand airdry
thoroughlybeforeusing.
6. Reassembleaircleaner.
NOTE:Nutsholding aircleaner cartridge must beinstalled
withfiber washers downoncartridgeplateto
preventdirtfromenteringcarburetor.Tighten nuts
byhand.Overtighteningcouldcollapse cartridge.
NOTE:Petroleum solvents, suchaskerosene, are notto
beusedtocleancartridge. Theymay cause
deteriorationofthecartridge.DONOTOIL
CARTIRIDGE.DONOTUSEPRESSURISEDAIRTO
CLEAN ORDRYCARTRIDGE.
OILCHANGE
See enginemanufacturer’s instructions.
1.Placemachineonalevelsurface.Start and runengine
foraperiodtowarmtheoil.
2. Fit draintubetodrainfitting;see Fig.8.
3. Placeanoil panundertheend ofdraintube;
4. Openthedrainfittingabout1 turnandallowtheoilto
draincompletely;
5. Retightendrainfittingand refill sump withnewoil.For
correctviscosityandserviceclassification,see theengine
manufacturer’s instructions.
SPARKPLUG
Thesparkpluggapgradually increases duringenginerunning
andshould becheckedperiodicallyand whenevertheengine
malfunctions.
1. Clean around sparkplug areasothatdirtwill not enter
enginewhenplugisremoved
2. Disconnectsparkplugleadand removespark plug
3. Check conditionofelectrodes andensurethereisno
damagetoinsulator
4. Carefullycleanthespark plug.Donotgritblast
5. Setthegapto.8mm(.30”)
6. Installpluginengineandtightento20Nm.If atorque
wrenchisnotavailablehand tightenplug.Thenwithtube
spannertightenplugabout1/12of 1turn
7. Refithightensionlead.Pushontoplugfirmly.
6

MAINTENANCE
COOLINGSYSTEM
TheRangerhasanaircooled4strokeengine. Itmustbe
cleanedfrequently.Removeanybuild-up ofgrass, dirtorother
debrisfromthe -
1. Cylinder;
2. Cylinderheadcoolingfins;
3. Cooling airintakescreenand;
4. Carburetor governorleversand linkages.
Thiswill ensureadequatecoolingandcorrect enginespeed.
THROTTLECONTROL
Proper chokeandstopswitchoperationisdependanton
adjustmentof remotecontrols –
1. Loosenoutercableclampscrew(D)onengine;See
Fig.9.
2. Setthrottlecontrol tochokeposition;
3. Adjustouter cableunder clampplatesothatchokeis
operated;
4. Tightenclamp platescrewandcheck –
a. Chokedoes notoperateinfastposition,
and
b. Stopswitchoperatescorrectly.
CARBURETORADJUSTMENT
The carburetorhasbeenfactorysetandshouldonlyrequire
occasionalfinetuning.See Figs.9&10.
1. Close high speedneedlevalve(A) inbottomof
carburetorbowl.Close finger tightinclockwise
direction;
2. Open(anti-clockwise)theneedlevalve2turns(thatis
anapprox. setting);
3. Startengineand letitwarmup.Approx. 2minutes.
Cutter drivemustbedisengaged.SpeedSelect-ormust
beinNeutral positionandParkBrakeapplied,air
cleaner mustbefittedandsecuredandfueltankmust
behalf full.
4. Withtheenginerunningathighspeed,adjustthe
needlevalve1/8turnatatime. Clockwise oranti-
clockwise until enginerunssmoothly.
NOTE: Allow severalsecondsbetween eachadjustmentfor
enginetoadapt tothenewsetting
5. Movethrottletotheslow positionand adjusttheslow
runningstopscrew(B)togiveanenginespeedof1700
to1800RPM.
6. Adjusttheidleneedle valve(C) slowlyin(lean)andout
(rich) until engineidlessmoothly.
7. Resetengineidlespeed.
8. Checkoperation.Engineshouldincrease speed
withouthesitationwhenthrottlecontrol ismoved
quickly fromslow tofast.If theenginetendstodieout,
adjustthehighspeedneedlevalve1/8turnanti-
clockwise until engineacceleratessmoothly.
Never tamperwiththeenginegovernorsetting.
Changingtheenginegovernorspeedwill voidengine
warranty.
LUBRICATIONGENERAL
UsingGeneralPurposeGrease – (Every25hours)
-Greasenipplesonfront wheelpivots.See Fig.11
-FrontAxlebeamguides
-GreasenipplesonsteeringpivotblocksFig.21
-Steeringgears Fig.21
-Greasenippleonengagement leverpivotFig.23
UsingCleanEngineOil –
-Jockeypivotarms
-Throttlecontrol cableFig.9
-ChainFig.23
7

MAINTENANCE
-Cutter DriveLeverPivot;
-Clutch/brakepedalpivot;SeeFig.15
-Tierodball ends;Fig.11
-All connectingrodpivotpoints.
NOTE:All ball bearingsaresealedandrequireno
maintenance.
CUTTING UNIT:
Removesparkpluglead and disengagecutter drivebefore
working oncutterunit,topreventaccidentalstartingof the
engine.
Before usingmachine alwaysinspectcuttingunittoseethat
thecutting disc,blades andbladefixingsare notwornor
damaged.
Alwayscheckafter striking asolidobject.Donotoperate
machinewhenunusualvibrationoccurs.
Replacewornordamagedbladesinsetstopreservebalance.
Removeany build-up of grass orclogging withinthecutting
unitordischargechuteorsafetyflap.
CUTTING UNIT REMOVAL
1.Disconnect PushRods&BrakeRod Fig.12
2. Removetensioning spring.Aloop hasbeenprovided on
thespringtoassistinthisoperation;SeeFig.12
3.Slidecutterdecktowardsbackof machineandremove
beltfromaroundcutterdeck pulley.
4.Undolargeretaining washer bolts(A) Fig.12.Thiswill
allow front ofdeck tobeloweredtoground.
5.Slidecutterdeckforward.Thiswill allow therearof the
deck tobeloweredtotheground and beslid from under
themachine.
6.Replaceinreverseorder.
NOTE: Toremovecutterdeckbeltfrommachine,thebelt
guardItem52,Page 20,hastobemoved away from
the drivepulleytoallowthebelttoberemovedfrom
the V-groove andthecutterhead lifting rodItem15,
Page 16,istobedisengagedfromthe cutterhead
selectionarmassemblyItem5, Page 16 toallow belt
tobedrawnout.
WHEELREMOVAL
CAUTION: Alwaysdeflatetyre beforeremoving rimnutson
front wheelonly.
Front –
1. Chockwheelsand removeaxlenut;SeeFig.13
2. Raise frontof machine;
3. Slidewheelfromshaft;
4. Replaceinreverse order;
5. Retightenaxlenut firmly.
Rear –
1. Chockfrontwheelsand raise rearof machine;
2. Removefourwheelnuts;
3. Slidewheelfromhub;Fig.14
4. Refit wheeltohub
5. Replacewheelnutsand tighten.
BRAKE CALIPERADJUSTMENT C
BA
1.Loosenlocknut‘A’Fig.15
2.LoosenBolt ‘B’till brakecaliper‘C’touches brake
Disc.
3.RetightenLocknut ’A’
BRAKEARMADJUSTMENT
1. Check thatbrakecaliperiscorrectlyadjusted;
2. Adjustlocknut‘E’Fig.15.Till brakearm‘D’pad
comes intocontact withdisc;
3. Checkoperationofbraketoensureparkbrakecan
beapplied,andbrakeoperates correctly.
8

MAINTENANCE
PARKING BRAKE
Should alwaysbechecked foroperationafter clutch/brake
rodshavebeenadjusted.
CUTTER DRIVEADJUSTMENT
1. MoveCutter HeightSelectorLevertoNo.4Positionin
Rack
2. MoveCutter DriveLevertotheEngagedPosition
3. AdjustPushRodsFig.16togive aspringcompression
of 30mm,Fig.17.
4. AdjustLocknut‘A’togive7mmclearancetoback of
swivelblockFig.17
5. Disengagethe Cutter DriveSelectorLever
6. Adjustlocknut ‘A’inFig.20togiveCutter Engagement
Leverafreetravelof 30mm from bottomof slot in
Fig.18.
NOTE IMPORTANT
Check toensureLeverhas30mm offreetravelby working
lever.
CUTTER HEADBRAKE
Shouldregularlybecheckedforoperation.
PADREPLACEMENT
1. Remove‘R’ clipand
pushrod pin (See
Fig.19)
2. Removebrakepivot
bolt (B)andtwo
spacers(SeeFig.19)
3. Removebrakeplate
assembly
4. Drill out pad retaining
rivets
5. Rivetreplacement
pad inposition
6. Refit inreverseorder.
B
CUTTERHEADBRAKEADJUSTMENT
1. Withcutter headdisengagedand inlow cut
position
2. Adjustnylocnutonrodasperstep6forCutter
DriverAdjustment
3. Adjusttensiononspring using locknutstogive
lengthof58mm,Fig.20
STEERING GEARS
GREASE
To adjustoutexcessiveplaycausedby wearinthe
gears.
1. Loosenboltssecuringsteeringshaftpivotblock(A).
2. Lightlytap pivotblocktowardslayshaftpivotblock
andretightenbolts(A).
3. Checksteering gearengagement.Checkthat
there are notightspotswhenturning steering
wheelfrom lock tolock.
9

MAINTENANCE
AUTO DRIVE
TheAuto-Drivefrictionplates anddrivepulleysare factoryset
fortravelrequiredalongkeyshaftandthisshouldnotneed
adjusting.
If duringoperationitisfoundthatthe relationshipbetween
forwardand reverse hasbecomeunbalancedadjustas
follows:-
1. Loosenlocknut(A) Fig.22
2. Centralise engagementlever(D)withfrictionplates
betweendrivepulleys, Fig.23
3. Re-tighenlocknuts(A),Fig.22
CONTINUOUS BELT
Thiscanbe adjustedasfollows:-
1. Loosenlocknut(A) Fig.23
2. Loosenpivotbolt(B)Fig.23
3. Adjust belttensionusingbolt (C) Fig.23
4. Re-tightenlocknut (A) andpivotbolt (B)
NOTE:Belttohave5mmdeflectionwithfinger pressure
betweenreturnpulleyanddrivepulley.
DRIVECHAINADJUSTMENTS
Primary
1. Loosenoffbolt ‘A’Fig.24
2. Slideidlerback till chaintightens
3. Re-tightenbolt‘A’andcheck chainfortightspots
Secondary
1. Loosenoffbolt ‘B’Fig.24
2. Slidesprocketbacktill chaintightens
3. Re-tightenbolt‘B’ andcheck chainfortightspots
CAUTION:Donotover-tensionbeltsordrivechains.
DRIVE SELECTORPEDAL
Thepedalanglecan betiltedeither forwardonbacktosuit
individualrequirementsif necessary.
1. Loosenlocknuts(A) oncontrol rod Fig.25
2. Tilt controlpedaltorequiredangletogivemaximum
operatorcomfort.
3. Retightenlocknuts
Fig. 22
Fig. 23D
Fig. 24
Fig. 25A
10

MAINTENANCE
STEERINGRODS
Should notnormally require resetting.
1. Loosenrodlocknut;(A) SeeFig.11
2. Releasethefixingbolt;
3. Turntierodend toadjust forlengthclockwise to
shorten,anti-clockwise tolengthen
4. Replacethefixingboltandtighten;
5. Tightenrodlock nut;
6. Makesurerodisfreetopivot.
CUTTER HEADTILT
Thiswill notnormallyrequireresetting.
1. LoosenU-Bracketnuts;(B)SeeFig.12.
2. Adjustnutsupordowntosettilt;
3. Model160(760mm cut)doesrequirebackof blade
circletilted15mm abovefrontof bladecircleinlow cut
position;
4. Retightenall nuts.
STEERINGSTOPS
These will notnormallyrequire resetting.
1Checkifsteeringsegmentgearrotatesinboth
directions.
2Loosenlocknutonfrontbeamandadjustbolt till
numberofturnsinbothdirectionsisequal.
3Retightenlocknut.
HEIGHTOFCUT ADJUSTMENT
To adjustthe heightof
cutrotatethenylocnut
(A) situated under the
centre of machineon
the rear cutter support
assembly.
Adjustnylocnutto
obtainlow cut at front of
bladecircleof 15mm.
SAFETYINTERLOCKSYSTEM
Thesafety interlocksystemhasbeendesigned foryour
protectionandshouldnot betampered with.Itgivesthe
Ranger thefollowingcharacteristics.
Theenginewill notstart unlesstheclutch/brakepedalis
depressed andthecutterdriveisdisengaged.
NOTE: Theengineshouldstop iftheoperatorleaves the
seatwithoutengagingparkbrakeand/orthe
cutterdriveengaged.
WARNING:If theinterlocksystemfails, see anauthorised
dealer.Donooperateuntilthe faultiscorrected.
CAUTION:Safetyswitchcircuit may becomedefectiveif
wet. Donotspray switches andconnections.
STORAGE
Never storeenginewithfuelintankindoors orinpoor
ventilatedenclosures where fuelfumes may
accumulate.
If machineistobestoredover 30 daysproceedas
follows:-
1. Removeall fuelfromcarburetorand fueltank
topreventvarnish-likegum deposits.
2. Removesparkplug and pour30mlof engineoil
intocylinder.Crankengineseveraltimes to
distributeoil.Replacespark plug.
3. Clean engineandcoolingfins, etc., of any
clippings,dirtandchaff.
4. Clean undersideof mower and cuttingunit.
Paintany chipsorscratches.
5. Lubricatechassiscomponents.
6. Removeandchargebatteryandstoreinacool
dryspot.Rechargeevery30days.
7. Storemachineinacleandryplace.
REMOVALFROMSTORAGE
1. Changeoil.
2. Fill fuel tankwithfuel.
3. Check spark plug.
4. Check drivebelts.
5. Check drivechain.
6. Lubricatedrivechain.
7. Lubricatepivotpoints.
8. Greasefrontaxlespindles.
9. Check tyrepressure.
10. Check safetyinterlock.
11. Check cuttingblades.
11

SAFETY ANDINSTRUCTIONDECALS
SafetyandInstructiondecals are mountedon the RANGERRearEngine Rider.
Replace anythat become damagedorillegible.
12

CIRCUITDIAGRAM ANDSPARES
ITEM DESCRIPTION PARTNo.
1 KEYSWITCH A07678
2 KEY A07679
3 BLADESWITCH A06406
4 BRAKESWTICH A06406
5 SOLENOID A07107
6 BATTERY A05262
7 FUSE A07513
8 POWERLEAD A12277
9 EARTHLEAD A12278
10 EARTHSTRAP A12020
11 WIRINGLOOM A10274
12 SEAT SWITCH A10257
13 SEAT PANELSW. A06406
14 RESISTANCELEAD A12283
13

TROUBLE SHOOTING
PROBLEM POSSIBLECAUSES CORRECTIVEACTION
Engineloses power 1.Oil levelincrankcaseinlow 1.Addoil tocrankcase
2.Coolingfinsandairpassagesunderengine
blower housingareblocked 2.Removeobstructionfrom passages
3.Engineload isexcessive 3.Select alower speedtoreduceload
4.Aircleaner isdirty 4.Cleanaircleaner element
5.Dirt orwaterisinfuelsystem 5.HavemachineservicedbyAuthorised
ServiceDealer
6.Carburetorisadjustedincorrectly 6.Adjustthecarburetor
7.Spark plugispitted,fouledordefectivein
someother way 7.Install newcorrectlygappedsparkplug
Engineoverheats 1.Coolingfinsandair passagesunderengine
blower housingareblocked 1.Removeobstructionfrom coolingfinsair passages
2.Carburetorisadjustedincorrectly 2.Adjustthecarburetor
3.Oil levelincrankcaseislow 3.Addoil tocrankcase
4.Engineload isexcessive 4.Select alower speedtoreduceload
Mowervibrates abnormally 1.Enginemountingboltsare loose 1.Tightenmountingbolts
2.Loose cutterpulley,idlerpulleyordrive
pulley 2.Tightentheappropriate pulley
3.Cutterassemblyisunbalanced 3.Replacebrokenbladesinsets
4.Cutterassemblyisloose 4.Tightensecuringnut
Cutter doesnotrotate 1.Cutterdrivebelt isworn,looseorbroken 1.Install newcutter drivebelt
2.Cutterdrivebelt isoff pulley 2.Install drivebelt
Mowerdoesnotdrive 1.Drivebelt isworn,loose orbroken 1.Install newdrivebelt
2.Drivebelt isoff pulley 2.Install drivebelt
3.Unabletoselectspeedontransaxle 3.HavemachineservicedbyAuthorised
ServiceDealer
Enginedoesnot start,hard 1.Fueltankisempty 1.Fill fueltankwithpetrol
tostart,loses power,orfails 2.Speedselected 2. Select Neutral
tokeeprunning 3.CutterDriveisengaged 3.Disengage Cutter Drive
4.Spark plugisloose 4.Tightenspark plug
5.Spark plugleadislooseordisconnected
from spark plug 5.Install sparkpluglead onspark plug
6.Spark pluggap isincorrect 6.Setgap betweenelectrodes at 0.8mm
7.Spark plugispitted,fouled,ordefectivein
someother way 7.Install newcorrectlygappedsparkplug
8.Wrongspark plugisused 8.Install correctsparkplug
9.Electricalconnectionsareloose 9.Checkelectricalsystemtoensuregood
contact
10. Carburetorisadjustedincorrectly 10. Adjustthecarburetor
11. Aircleanerisdirty 11. Cleantheaircleanerelement
12. Ventholeinfuel tankisplugged 12. Inspectand openvent
13. Dirtorwater infuelsystem
14. Deadbattery
15. Defectivepoints,condenser, ignitioncoil,
or ignitionswitch 13. Havemachineservicedby Authorised ServiceDealer
16. Moduleorswitchisdefective
Engine doesnot idleoridles 1.Aircleaner isdirty 1.Cleanaircleaner element
Poorly 2.Oil levelincrankcaseislow 2.Addoil tocrankcase
3.Coolingfinsandairpassagesunderengine
blower housingareplugged 3.Removeobstructionfrom coolingfins and airpassages
4.Idlespeedistoo low orhighspeed mixture
isincorrect 4.Adjustthecarburetor
5.Dirt orwaterisinfuelsystem 5.HavemachineservicedbyAuthorised
ServiceDealer
6.Venthole infueltankisplugged 6.Cleanfueltankvent
7.Spark plugispitted,fouledordefectivein
someother way 7.Install newcorrectlygappedsparkplug
14

RANGERAUTO – DRIVE SPARE PARTS LIST
ITEM PARTNo. DESCRIPTION
*COMMONHARDWARE ITEM
1 A07937 FuelTank
2 A12005 FuelTankCap
3 A07999 FuelTank Bracket
4 A12001 FuelTankStrap – Front
5 A12002 FuelTankStrap – Rear
6 A12009 FuelLine – ¼ID
7 A12010 Hose Clamp
8 A12011 FuelLineRetainer ½” CopperHalf Clip
9 * ¼” x ”UNC Hex Bolt
10 * ¼” UNC Std.Nyloc Nut
11 * 73AS5-5 BlindRivet
12 A03422 Filter – CentCap
13 A03421 Vent Cap
14
15 * 5/16”Shakeproof Washer
16 A12019 FuelTankCautionLabel
15

16

RANGERAUTO – DRIVE SPARE PARTS LIST
ITEM PART No. DESCRIPTION
*COMMONHARDWAREITEM
1 A10260 Chassis Assembly
2 A10041 HeightSelectorShaftAssembly
3 A10280 CutterheadEngage. SelectorAssembly
4 A10248 DriveSelector PedalAssembly
5 A00980 Cutterhead SelectorArmAssembly
6 A10250 PedalArmAssembly
7 A10243 PedalAssembly
8 A10276 FrontBumperBarAssembly
9 A10265 Engagement ShaftAssembly
10 A10273 PushRodAssembly
11 A10277 EngagementRod Assembly
12 A10057 CutterheadEngage. ArmAssembly
13 A06318 SelectorLever
14 A07652 LeverKnob
15 A06316 CutterheadLiftingRod
16 A07616 ParkBrakeRod
17 A07617 Knob
18 A07615 PedalRubber
19 A01275 NylonBush
20 A07657 EndCap
21 A07971 EndCap
22 A12047 Spacer
23 A12284 Decal – FloorPanel
24 A05417 Decal – Forward-Reverse
25 A07649 Rubber Washer
26 A12234 Swivel Block
27 A12263 Spring Guide
28 A12264 Spring
29 A04006 Pin
30 A01080 Spring Clip
31 A07755 Swivel Block
32 A10178 RearSupportAssembly
33 A07745 Spring
34 A07736 FrontArm
35 A07750 RetainingWasher
36 A07751 Spacer
37 A07897 Sleeve
38 * Poprivet – 73AS 5-5
39 * Rollpin – ⅛“x ⅞”
40 * Rollpin ¼” x1⅛”
41 * Split Pin – ⅛”x¼”
42 * Setscrew – 5/16”x2”UNC. Hex
43 * Bolt – 5/16”x ”UNC.WasherFace
44 * Setscrew – ⅜”x1¼”UNF. Hex
45 * Setscrew – ⅜”x1”UNC. Hex
46 * Bolt – ⅜”x½” UNC. Hex
47 * Setscrew – ⅜”x2”UNC. Hex
48 * Bolt – ⅜”x1¾” UNF. HT. Hex
49 * Nut – 5/16” UNC. Hex
50 * Nut – ⅜”UNC. Hex
51 * Nut – ⅜”UNF. Hex
52 * NylocNut – 5/16” UNC.
53 * NylocNut – ⅜”UNC. Thin
54 * NylocNut – ⅜”UNF. Thin
55 * NylocNut – M12 x1.75P
56 * Washer – 5/16” x ⅞”x16G Flat
57 * Washer – 5/16” Internal Shakeproof
58 * Washer – ⅜”x¾”x16G Flat
59 * Washer – ⅜”Internal Shakeproof
60 * Washer – 12
61 * Washer ”x1”x16GFlat
62 A12102 DriveSelector PedalRubber
63 * Setscrew – 5/16”x1½”UNF. H.T.
64 * NylocNut – 5/16” UNF.
65 A04034 CotterPin
66 * Roll Pin – 5/32” x1¼”17

18