Toro 4502 User manual

SCAMP AND UTILITY MODELS
SERVICING
4502,4503, 8602, 8603
WITH
“F” SERIES ENGINES
SELF-PROPELLED BELT DRIVE
Adjustments and servicing of the Scamp and
Utility self-propelled mowersare very different
from
all previousmodels of self-propelled
mowers.
SAFETY WARNING
BEFORE
ANY ADJUSTMENTS OR
REPAIRS ARE ATTEMPTED, DIS-
CONNECT
AND REMOVESPARK
PLUG TO PREVENTSTARTING.
INSTALLING CONTROL ROD
1. Placeretainerclip on clutch arm with
long side of clip on the inside of clutch arm.
2. Align holein clip with holein arm and
assemblelower end
of thecontrol rod in
hole.
3. Turn (swivel) long end of clip up and snap
intoposition on lower control rod as shown.
SAFETY WARNING
THE LOWER SELFPROPEL CON-
TROL RODMUST
BE ASSEMBLED
TO CLUTCHARM
AS SHOWN. IF
NOT THESELFPROPEL MECH-
ANISM WILL NOTRETURNTO
NEUTRAL WHEN THE CONTROL
LEVER IS RELEASEDFROM THE
ENGAGEDPOSITION.
10-44
REVISED 1983
SERVICE BULLETIN REFERENCES

4. With the control handle in "neutral" (free)
position as shown.
SCAMP AND UTILITY MODELS
SERVICING
6. Secureupper and lowercontrolrods
together with theclampscrewas shown.
Thisscrewshouldbetightenedsecurely
SELF=PROPELLEDBELT DRIVE
by hand.
5. With the clutch arm resting on the handle
and wheel bracket asshown.
SAFETY WARNING
IMPROPER TIGHT.ENING OF CLAMP
SCREW ONCONTROLRODMAY
RESULT
IN OPERATOR LOSS OF
DRIVE CONTROLMECHANISM.
NOTE
To put mower in motion, pull upward
oncontrolhandleand hold indrive
position.Tostopforwardmotion
of mower, releasecontrolhandle.
Mower drivemechanismfunctions
only when thecontrolhandle
is held
in "DRIVE" position.

!
SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
DRIVE ROLLER ADJUSTMENT
1. With thecontrol handlein"Neutral",
place both rear wheelheight adjustersin
#1 (lowest)cuttingposition as shown. A
gap of 3/16" shouldappear between the
drive rollers and tires.
2. Loosenbolt and nut locatedindrive
roller gap adjustingslot on each side of
drive roller bracket.
3. Move the drive roller bracket up or down
toobtainthenecessary 3/16'' driveroller
gap. Hold bracket
in position and tighten
both bolts and nuts securely.
ENGINE REMOVAL OR REPLACEMENT
SAFETY WARNING
TO PREVENT STARTING OF EN-
GINE,DISCONNECT
AND REMOVE
SPARK PLUG PRIOR TOREMOVING
THE ENGINE.
1. Remove bladebolt,washer,blade
stiffener,collar and threeboltssecuring
muffler and remove muffler.
n
2. Remove three boltssecuringengineto
muffler plate and remove engine.
Do not removemufflerplatefrom
housing when removing engine.
10-46 SERVICE BULLETIN REFERENCES
REVISED 1983

SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
V BELT REMOVAL OR REPLACEMENT
SAFETY WARNING
TOPREVENT STARTINGENGINE,
DISCONNECT SPARK PLUGLEAD
ANDREMOVE SPARK PLUG.
The
"V" beltused on theutilityself-
propelledmodelmowers
is a SPECIAL
BELT.
DO NOTUSE A SUBSTITUTE. It
won't work as WELL or asLONG.
To remove the belt:
1. Remove four belt guardcoverscrewsand
remove cover.
2. Remove engine and remove drive belt from drive
pulley.
SAFETY WARNING
DO NOT OPERATE MOWERWITH
BELT GUARDREMOVED.
3. Removeroll pin fromleft hand drive
roller and remove roller.
4. Remove belt from driven pulley and slide
shaftassemblytotheright. Remove belt
from mower as shown.
SERVICE BULLETIN REFERENCES 10-47
REVISED 1983

SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
NOTE
Afterthebelthasbeenremoved,
examine for broken, crackedor mis-
alignedpulleys.
The condition and
thewearpattern of
the belt will
provide clues for the above possibili-
ties.Replacedamaged or worn
pulleys.
5. Thecrankshaftpulley(drive pulley) is
securedto the crankshaft with a SPECIAL
slottedsetscrew.The end of this screw
locates ina holeinthe crankshaft.The
correct position and tightness
is very
IMPORTANT. If nottightened securely,
damagetothe pulley, crankshaft and pre-
maturewear of thedrivebelt
will result.
NOTE
Apply OMC Ultra-Lock(partno. 388517)
to threads of setscrew priortoinstallation.
6. When reinstalling pulley tocrankshaft,
theside of the pulley
with set screw is the
lowerside. If assembledupside down (set
screw on top) misalignment and interference
of pulley operation
will result. Always
check pulley fordamage.Replace if
necessary.
10.48
REVISED 1983
SERVICE BULLETIN REFERENCES

IDLER
PULLEYS TOP STRAND
SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
SAFETY WARNING
INCORRECTDRIVEBELTINSTAL-
LATIONMAYALLOW
MOWER TO
OPERATE IN REVERSE DIRECTION
TOROR BYSTANDERS. ASSEMBLE
DRIVEBELT
AS SHOWN.
CAUSING INJURY
TO THE OPERA-
DRIVE-BOTTOMSTRANDENGINE
SHAFT DRIVE
PULLEY PULLEY
INSTALL BELTAS SHOWN
FOR PROPER PULLEY ROTATION
8. Check the conditionofthedriveshaft,bronze
bearings,andsleeve.If
signs ofdamageor wear
appear, replace them.
7. Placebeltoverleft end of driveshaft
as shown.
Do not assemble on driveshaft
pulley.
9. BUSHING AND BEARINGINSTALLA-
TIONS.
NOTE
Thesleeve
has a flat surface that matches
the flat surface
of the bracket.Whenre-
assembling,the flat surfaces must match.

SCAMP AND UTILITY MODELS
SERVICING
SELF=PROPELLEDBELT DRIVE
10. Reassemble the drive shaft into the bearing
and slide
it to the left as far as possible. Assemble
thewasher and driveroller onthedriveshaft.
11. The drive rollers must be properly installed to
utilize theself-cleaningfeature. Proper installation
is with thevee pointingtowardthewheel.
12. Using a new roll pin, assemblethe drive roller
to the drive shaft. Use a 5/32” or larger drift
punch, drive the roll pin into place, flush with the
outer surface. Neither end shouldprotrudebeyond
theroller surface.
INSTALL BELTAS SHOWN
FOR PROPER PULLEY ROTATION
13. As you face the frontof the mower, twist the
forward end of the belt 1/4 turn counter clockwise
and assemble onthe enginedrive pulley. Assemble
engineonmufflerplate andsecurewith threebolts.
14. Release springtension on idler pulleys and as-
semblebelt on drive shaft pulley. Reassemble idler
pulley spring and rotate the belt severalrevolu-
tions. Check
to make sure the belt is centered on
the pulleys and TURNING IN RIGHT DIREC-
TION. Note direction of arrow on large pulley in
illustration above.Check andadjust belt tension
if necessary.Refer to BELT TENSION
ADJUSTMENT.
Whenreplacing either of the belt idler
assemblies,use idler
kit part no. 682374
for the topand kit part no. 682564 on the
bottom.
10.50
SERVICE BULLETIN REFERENCES
REVISED 1983

BELT TENSION ADJUSTMENT
1. Check drivebeltinstallation.Drivebelt
mustbeinstalledbetweenidlerpulleysas
shown.
2. Drivebeltshouldbecheckedtoinsure
thatpropertensionexistsinordertopre-
ventprematurebeltfailure. Lift floating
idlerfromtheupperstrand of
"V" belt.
Belt
will thenbecomeloose.Setfloating
idler onto
"V" belt and checkclearancebe-
tween the two strands of the
"V" belt.The
distancebetweenthe two strands should not
be less than
1/2" as shown.
SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
3. To adjust belt tension; loosen four handle
bracket mounting screws (two on each
bracket) and two screws (one on each side)
located on thesides of rear heightadjuster
bracketas shown. Slideentireself-propell-
ingmechanismindirectionnecessaryto
obtain the proper
"V" belt tension.
4. Care should be taken toinsurethat both
sides of theself-propellingmechanism are
positionedequally on themowerhousing.
Thiscanbeaccomplished by measuring the
distancefrom
the front edge on theheight
adjuster brackets to the' 1/4" diameter gage
holeslocateddirectlyinfront of these
bracketsas shown. Thisdistancemustbe
thesamefor both sides.Beforetightening
screwsmakesurethedistancebetweenthe
strands of
the "V" belt is not less than
1/2". Tightenthefourhandlebracket
screws and the two sidescrewssecurely.
Reassemblebeltguardtoself-propel
mechanismusingscrewspreviously
removed.
SAFETY WARNING
DO NOT OPERATE MOWERWITH
BELT GUARDREMOVED.
SERVICE BULLETIN REFERENCES 10.51
REVISED 1983

SCAMP AND UTILITY MODELS
SERVICING
SELF-PROPELLED BELT DRIVE
LUBRICATION
10 HOURS
1. DRIVE ROLLERBEARINGS-Disassemble
rotating shaftcover from self-propel mechanism by
removing four screws.Unscrewplugfromend of
each drive roller (Point
“A”). Fillexposed cavity
610721 OR EQUIVALENT.Replaceplugand
tightenuntil snug. Repeat procedure until lubri-
cant appears on cross-shaft at Point
“B”. Reas-
semblerotating shaftcover toself-propel assembly.
with LAWN-BOY
“A” GREASE, PART NO.
FLOATING IDLER PULLEY-Do not immerse
the idler pulley in solvent.
Use a rag containing
solvent, clean the hole in the idler pulley and the
shoulder
bolt thoroughly.Useing a smallamount of
LAWN-BOY
A GREASEorEQUIVALENT,re-
lubricate the shoulder bolt and remount idler
pulley assemblyin thesameorderit
was originally.
ASREQUIRED
1. CLUTCHLINKAGE-Apply severaldrops
of lightmachineoil on clutchmechanism
at
all pivoting points.
10-52
NEW STYLE
LOWER IDLER ASSEMBLY
PART
#682564
BOLT-PULLEY-ARM-NUT
LOWER IDLER PULLEY Permanently lubri-
cated. No lubricationrequired.
SERVICE BULLETIN REFERENCES
REVISED 1983

UTILITY MODELS 4502 AND 8602
SCAMPMODELS 4503 AND 8603
SELF-PROPELLEDSERVICING
On 4502,4503,8602,8603 models of Utilityand
Scampmowers,ablade nut has replaced the
blade bolt previously used onearlier models.
SAFETYWARNING
THE BLADE
NUT MUSTBE RE-
PLACED AFTER BEINGREMOVED
AND REINSTALLED FOUR
(4)
TIMES. THELOCKING FEATURE OF
THE BLADE NUT WILLHAVE
DECREASED ANDBLADECOULD
LOOSEN IF REPLACEMENT
IS NOT
MADE.
1. Collar 4. Blade
2. Stiffener 5. Nut
3. Washer (20 and 21 inch
models only)
Before assemblingcollar on crankshaft,checkto
be sure it did not get bent or distortedwhen be
ing removed. If so, replaceit. Do notuse,
because, it will cause vibration.
If theblade nut is to be reused,cleanthe threads
thoroughly. Also clean threads on crank shaft.
Apply OMC Ultra-Lock
Part No. 388517 on the
threads.
NOTE
When installing blade after sharpening
and balance, torque blade nut
to 45-50 ft.
1bS.
SAFETYWARNING
ALWAYSUSE ORIGINAL EQUIP-
MENT REPLACEMENT BLADE AND
ATTACHMENTHARDWARE TO
IN-
SURE COMPLIANCE WITH SAFETY
STALLING BLADE, BE SURE PARTS
QUENCE IN WHICH THEY WERE
REMOVED. ALWAYS REPLACE
BLADE WITH CURVED EDGE UP
(TOWARD HOUSING).
SPECIFICATIONS. WHEN REIN-
ARE REPLACED INTHE SAME SE-
A blade collar that was damaged and bent when
beingremovedfrom crankshaft shouldalwaysbe
replaced.
If not replaced, a vibration in the mower
and a rough, uneven
or ragged cuttingmay result.
KEEP BLADE SHARP AND BALANCED REVISED 198310-53