Textron BOB-CAT 930022 User manual

WARNING: If incorrectly used this machine can cause severe injury. Those who use
and maintain this machine should be trained in its proper use, warned of its dangers
and should read the entire manual before attempting to set up, operate, adjust or
service the machine.
SETUP, PARTS & MAINTENANCE
MANUAL GEAR DRIVE MIDSIZE
2721693 REV D
Power Unit Models:
930022 Power Unit 15HP Kawasaki Gear Drive
930023 Power Unit 17HP Kawasaki Gear Drive
(Operation & Safety Manual: 2721692)

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the State
of California to cause cancer, birth
defects and other reproductive harm.
Californie Proposition 65
Avertissement
Les échappements des moteurs diesel
et certains de leurs composés sont
reconnus par l’Etat de Californie pour
être cancérigènes, provoquer des
défauts congénitaux et d’autres dangers
en matière de reproduction.
ADVERTENCIA
AVERTISSEMENT
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
California Advertencia
de la Proposicion 65
El estado de California hace saber que
los gases de escape de los motores
diesel y algunos de sus componentes
producen cáncer, defectos de
nacimiento y otros daños en el
proceso de reproducción humana.
L’ é mission du moteur de ce mat é riel
contient des produits chimiques que
l’Etat de Californie consid è re ê tre
canc é rig è nes, provoquer des d é fauts
cong é nitaux et d’autres dangers en
mati è re de reproduction.
El estado de California hace saber
que los gases de escape de este
producto contienen productos
quÍmicos que producen cáncer,
defectos de nacimiento y otros daños
en el proceso de reproducción
humana.
© 2002, TEXTRON INC

1
Gear
Drive
Midsize
10-2002-TGTSP
IMPORTANT MESSAGE
Thank you for purchasing this Bob-Cat product. You have purchased a world class mowing product, one of the
best designed and built anywhere.
This machine comes with an Operation and Safety Manual and a separate Setup, Parts and Maintenance Manual.
The useful life and good service you receive from this machine depends to a large extent on how well you read
and understand these manuals. Treat your machine properly, lubricate and adjust it as instructed, and it will give
you many years of reliable service.
Your safe use of this Bob-Cat product is one of our prime design objectives. Many safety features are built in, but
we also rely on your good sense and care to achieve accident-free operation. For best protection, study the
manuals thoroughly. Learn the proper operation of all controls. Observe all safety precautions. Follow all
instructions and warnings completely. Do not remove or defeat any safety features. Make sure those who operate
this machine are as well informed and careful in its use as you are.
See a Bob-Cat dealer for any service or parts needed. Bob-Cat service ensures that you continue to receive the
best results possible from Bob-Cat’s products. You can trust Bob-Cat replacement parts because they are
manufactured with the same high precision and quality as the original parts.
Bob-Cat designs and builds its equipment to serve many years in a safe and productive manner. For longest life,
use this machine only as directed in the manuals, keep it in good repair and follow safety warnings and instructions.
You'll always be glad you did.
Textron Golf, Turf & Specialty Products
One Bob Cat Lane
Johnson Creek, WI 53038-0469
TABLE OF CONTENTS FIGURES
PAGE
SAFETY ......................................................................................................................................................... 2
ASSEMBLY/SET-UP INSTRUCTIONS ....................................................................................................... 3-9
LUBRICATION ........................................................................................................................................ 10, 11
MAINTENANCE ..................................................................................................................................... 12, 13
SERVICE CHART ........................................................................................................................................ 14
SERVICE RECORD ..................................................................................................................................... 15
ADJUSTMENTS...................................................................................................................................... 16-18
BELT REPLACEMENT ......................................................................................................................... 19, 20
PARTS SECTION ........................................................................................................................................ 21
UPPER ENGINE DECK ASSY ........................... FIGURE 1 ................................................................. 22, 23
LOWER ENGINE DECK ASSY/CLUTCH .......... FIGURE 2 ................................................................. 24, 25
DRIVE WHEELS & BRAKES ............................. FIGURE 3 ................................................................. 26, 27
TRANSMISSION DRIVE .................................... FIGURE 4 ................................................................. 28, 29
UPPER HANDLE/ROLLER LATCH ................... FIGURE 5 ................................................................. 30, 31
OPERATOR PRESENT ..................................... FIGURE 6 ................................................................. 32, 33
DECALS ............................................................. FIGURE 7 ................................................................. 34, 35
PEERLESS TRANSMISSION ............................ FIGURE 8 ................................................................. 36, 37
ELECTRICAL DIAGRAM ................................... FIGURE 9 ................................................................. 38, 39
CUTTERDECK MOUNTING .............................. FIGURE 10 ............................................................... 40, 41
KAWASAKI ELECTRICAL SCHEMATIC ............ FIGURE 11 ...................................................................... 42

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Midsize
MODEL NUMBER: This number appears on
sales literature, technical manuals and price lists.
SERIAL NUMBER: This number appears only
on your mower. It contains the model number
followed consecutively by the serial number. Use
this number when ordering parts or seeking
warranty information.
SAFETY
NOTICE !!!
Unauthorized modifications may present extreme
safety hazards to operators and bystanders and
could also result in product damage.
Textron Golf, Turf & Specialty Products strongly
warns against, rejects and disclaims any
modifications, add-on accessories or product
alterations that are not designed, developed, tested
and approved by Textron Golf, Turf & Specialty
Products Engineering Department. Any Textron
Golf, Turf & Specialty Products product that is
altered, modified or changed in any manner not
specifically authorized after original manufacture–
including the addition of “after-market” accessories
or component parts not specifically approved by
Textron Golf, Turf & Specialty Products–will result
in the Textron Golf, Turf & Specialty Products
Warranty being voided.
Any and all liability for personal injury and/or property
damage caused by any unauthorized modifications,
add-on accessories or products not approved by
Textron Golf, Turf & Specialty Products will be
considered the responsibility of the individual(s) or
company designing and/or making such changes.
Textron Golf, Turf & Specialty Products will
vigorously pursue full indemnification and costs
from any party responsible for such unauthorized
post-manufacture modifications and/or accessories
should personal injury and/or property damage
result.
This symbol means:
ATTENTION!
BECOME ALERT!
Your safety and the safety of others is involved.
Signal word definitions:
The signal words below are used to identify levels
of hazard seriousness. These words appear in this
manual and on the safety labels attached to Textron
Golf, Turf & Specialty Products machines. For your
safety and the safety of others, read and follow the
information given with these signal words and/or the
symbol shown above.
DANGER indicates an imminently hazardous
situation which, if not avoided, WILL result in death
or serious injury.
WARNINGindicates a potentially hazardous situation
which, if not avoided, COULD result in death or
serious injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate
injury. It may also be used to alert against unsafe
practices or property damage.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, MAY result in property damage.

3
Gear
Drive
Midsize
GENERAL NOTE: FRONT, REAR, RIGHT HAND AND LEFT HAND REFERENCES BELOW
ARE WITH RESPECT TO AN OPERATOR AT THE CONTROLS.
ASSEMBLY/SET-UP INSTRUCTIONS
2. Remove gear selector handle Afrom the power
unit and set aside for later use.
3. Unbolt the upper handle Bfrom shipping
brackets C.
4. Unbolt the shipping brackets Cfrom the lower
handle.
5. Attach the upper handle to the lower handle using
the 3/8"-16 X 1" bolts and 3/8"-16 nuts removed
in Step 3 as shown.
6. Remove tie wrap Dfrom the traction control lever.
1. UNCRATE - Place both power unit and cutterdeck crates on a level surface. Remove sides and top from
both the power unit and cutterdeck crates.

4
Gear
Drive
Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
8. Remove the power unit from the crate and
support the rear of the power unit using a
jackstand.
9. Remove shipping bracket E.
10. Attach traction control rods Fby inserting the
swivel through the upper hole in the bellcranks G
and the other end of the traction control rods
through the traction control lever on the
handlebar. Secure with washers and hairpins.
11. To adjust traction control rods, remove the
traction control rod swivel and the brake rod from
the bellcrank Gand adjust swivel up or down the
control rod so that once reinstalled there is a 1/4"
(6.35mm) gap between the bottom of the rod and
the bottom of the traction lock.
12. To adjust the brakes, remove the brake rod from
the bottom of bellcrank Gand set the traction
lever in the neutral position. Adjust the brake rod
by turning it in or out of the swivel in the brake
arm until it just goes into the hole on the
bellcrank. Secure with hairpin.
NOTE: The machine should not move with the
traction levers in the parking brake position. If
machine moves in the parking brake position,
readjust brake rod length. Verify that machine
can be moved easily when the traction levers are
placed in the neutral position.
7. Unbolt shipping bracket Efrom the crate.
NOTE: It will be necessary to support the rear of
the power unit and level it for attachment to the
cutterdeck.

5
Gear
Drive
Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
13. Attach gear shift lever Aremoved in Step 2 to the
lower shift arm with (1) M8-1.25 X 25 Bolt and (1)
M8-1.25 whizlock nut. Shift the lever to the
neutral position and verify that the lever is
centered side to side in the slot. If not, loosen the
M8 bolt and reposition lever. Retighten bolt.
GEARBOX ADJUSTMENT NOTE: The detents
between gears and at neutral may be made more
positive by turning set screw Hclockwise. Do not
turn set screw more than two turns below flush
with the housing.
14. Attach cutterdeck per the instructions on the following pages then return to Step 15 of this section.
15. Fill engine with oil. (See engine manual for specifications.)
16. Fill fuel tank with with clean, fresh unleaded fuel.
GASOLINE IS HIGHLY FLAMMABLE!
•Fill fuel tank with good quality, clean, regular unleaded gasoline.
•Do not use hi-test fuel.
•Do not smoke.
•Do not spill fuel.
•Fill outdoors.
•Do not overfill. Fill to 1" below bottom of filler neck to allow room for expansion.
•USE A FUNNEL TO FILL GAS TANK
17. Adjust tire pressure in drive wheels and casters to 14 psi (1 kg/cm2).
18. Before attempting to start the mower, read and understand all sections of the Operation & Safety manual.
NOTICE: Special setup instructions.
•Before engaging the cutterdeck, run the engine for five minutes at full RPM. This is recommended for new
engine installation to permit complete engine lubrication prior to load.
•Do not engage the cutterdeck at full throttle. Set the throttle half way between the highest and lowest
engine speed, engage the PTO switch and increase the engine speed to full before cutting.
•
Do not use this machine without an approved grasscatcher, grass discharge chute or mulching plate(s)
correctly fitted.

6
Gear
Drive
Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
CUTTERDECK ATTACHMENT: Two types of cutterdeck mounting systems are available, fixed and floating.
Fixed mounting rigidly attaches the cutterdeck to the power unit. Floating mounting allows the cutterdeck to
move independant of the power unit providing a more uniform cut. Follow the appropriate instructions below
for the type of cutterdeck being attached to the power unit.
FIXED CUTTERDECK ATTACHMENT
1. Remove the cutterdeck from the crate.
2. Unbolt the caster wheels and the shipping
brackets from the crate.
3. Remove the shipping bracket from the caster
wheel by loosening the caster bolt and sliding the
shipping bracket off and retighten caster bolt.
4. Remove quick pin and remove the appropriate
number of spacers for the desired height of cut.
See height of cut chart below.
NOTE: Height of cut chart is also located on
bottom of belt cover or in the Operation & Safety
Manual.
5. Repeat for other caster wheel assembly.

7
Gear
Drive
Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
6. Remove belt cover and set aside.
7. Block the rear of the cutterdeck with the
appropriate height block for the desired height of
cut B. See Support Block Chart below.
GNITTUC
THGIEH
ELOH
NONOITISOP
ENIGNE
*KCED
KCOLB
TATHGIEH
FORAER
)B(KCED
"526.1-"573.15"52.1
"573.2-"578.14"00.2
"521.3-"526.23"57.2
"578.3-"573.32"05.3
"526.4-"521.41"52.4
elohtsehgihehtsi1noitisoP*
.kcedenigneehtno
8. Position the power unit behind the cutterdeck.
9. Move the power unit towards the cutterdeck until
the guide pins Aengage the appropriate hole C
on the power unit for the desired height of cut.
Fasten with (4) M12-1.75 X 30 bolts at D.
10. Loop the PTO belt Earound the electric clutch
pulley. Using a 3/8" ratchet wrench or 3/8"
breaker bar rotate the PTO belt idler while looping
the PTO belt around the cutterdeck pulley.
11. Reinstall belt cover and fasten in place with
knobs F.
12. Remove support block from the rear of
cutterdeck.
13. Remove support from the rear of the power unit.

8
Gear
Drive
Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
6. Remove belt cover from cutterdeck cradle.
7. Remove the cutterdeck cradle Afrom the crate
and insert guide pins Binto top hole Cin power
unit.
8. Attach cutterdeck cradle to power unit using (4)
M12-1.75 X 35 bolts at D and tighten securely.
9. Remove support from rear of power unit.
FLOATING CUTTERDECK ATTACHMENT
1. Unbolt the caster wheels and the shipping
brackets from the crate.
2. Remove the shipping bracket from the caster
wheel by loosening the caster bolt and sliding the
shipping bracket off and retighten caster bolt.
3. Remove snap ring, (2) washers and (1) 1/4"
spacer from one caster wheel assembly.
4. Insert caster yoke through cradle bushing from
the bottom up and place (2) washers and (1) 1/4"
spacer removed in Step 3 back onto the shaft
above the cradle bushing and secure using the
snap ring removed in Step 3 as shown.
5. Repeat for other caster wheel assembly.