Assembly

OMMT6006

Issue B8

Walk-Behind Greensmower

180A

(Serial No. 010001 - )

220A

(Serial No. 030001 - )

Assembly

Identify Parts

Attach Handlebar

Install Brake And Travel Clutch Cables

Install Throttle Cable

Install Run\Off Switch Cable

Install Front Roller

Installing Grass Catcher

Fuel

Engine Break-In

Install Transport Wheels

Installing Rotary Brush Or GTC (Greens Tender Conditioner)

Assembly

Identify Parts

M86648

A - Handlebar Assembly

B - Mower Assembly

C - Front Roller

D - Grass Catcher

E - Bag of Parts

Attach Handlebar

M60558

1. Remove bracket (A) by removing bolt and washer (one on each side).

2. Insert handlebar (B) in brackets.

M60521a

3. Slide end of handlebar over pegs (C).

4. Install brackets to mower using bolts and washers removed above.

5. Adjust handlebar. (See Adjusting Handlebar in Operating The Cutting Unit section.)

NOTE: Make sure brackets are straight UP and DOWN, and not at an angle.

Install Brake And Travel
Clutch Cables

M60584

1. Route cables (A) through slotted hole in lower handlebar bracket (B).

NOTE: Slide caps (C) up and remove top nut (D) in order to get cables into slots. Make sure one nut is on either side of bracket before tightening.

M60624

2. Put brake cable (E) into upper slot in handlebar bracket (F) and clutch cable (G) into lower slot.

M72974

3. Remove carriage bolt (H) and rotate brake lever (I) to put end of cable (J) in hole in brake arm lever.

NOTE: Cable end MUST swivel FREELY. (See Adjusting Brake in the Service-Cutting Unit section.)

4. Install carriage bolt and nut and tighten

5. Apply some grease to the cable end.

M72974

6. Fasten end of travel clutch cable
to hole in travel clutch bracket with drilled pin (K) and cotter pin (L).

7. If necessary, adjust cables. (See Service-Cutting Unit, Adjusting Brake and Adjusting Drive Belts in that section.)

Install Throttle Cable

1. On handlebar console, move throttle lever to the r SLOW position.

2. Remove air cleaner assembly.

M88114

3. On carburetor linkage, loosen screws (A and B).

4. Put throttle cable (C) under bracket and screw (A) and through swivel and screw (B).

5. Tighten screws (A and B).

6. On handlebar console, move throttle lever from the t SLOW position to the r FAST position.

7. Observe carburetor linkage, linkage must travel from slow idle
stop to full throttle.

8. If necessary, loosen both screws, reposition throttle cable and tighten screws.

9. Repeat steps 6 - 8 until carburetor linkage has full travel between the slow idle stop to full throttle.

10. Install air cleaner assembly.

Install Run\Off Switch Cable

1. Route run\off switch wiring harness:

· Route wiring harness (A) over recoil starter.

· Bend tabs (B) to hold harness.

M86645

· Attach run\off switch ground wire (C) with bolt (D).

· Put male end of connector (D) into female end of connector (E).

Install Front Roller

NOTE: Installation of Grooved Roller and Smooth Roller is the same. The Grooved Roller is shown.

M86650

1. Loosen jam nut and remove set bolt (A). (Repeat on the other side.)

2. Remove T-handle (B), lock washers, washer and bolt.

3. Remove bracket (C).

M86651

4. Position brackets (C) onto roller.

NOTE: Do not put set bolts into holes in roller shafts.

M86653

5. Tighten set bolt (A) to hold bracket onto roller shaft.

6. Tighten jam nut (E).

M86652

7. Install roller assembly (F). If necessary, remove adjusting bolt (G) to fit the roller assembly.

M86644

8. Install T-handle (B), lock washers, washer and bolt.

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9. Lubricate roller at points (G).

NOTE: DO NOT over-lubricate. Excess grease could fall from the mower during operation.

10. Adjust cutting height. (See Adjusting Cutting Height in Operating The Cutting Unit section.)

Installing Grass Catcher

NOTE: Install width indicator on Model 180A to help line up mower with cutting area. Bag of parts is included in operator manual packaging.

· Model 180A only

1. Place width indicator bracket (A) in recessed groove (D) on top of grass catcher.

M86643

2. Using the bracket hole as a guide, drill 7mm hole in catcher.

3. For each side, install M6 x 16 cap screw (B), washer and locknut (C).

· All models

· Install grass catcher (D) onto brackets (E).

Fuel

c CAUTION: Avoid injury! Handle fuel with care, it is highly flammable:

· DO NOT refuel machine while you smoke, when machine is near an open flame or sparks, or when engine is running. STOP engine.

· Fill fuel tank outdoors.

· Prevent fires: Clean oil, grease and dirt from machine. Clean up spilled fuel immediately.

· Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark.

· To prevent fire and explosion caused by static electric discharge, while you fill tank, use a non-metal fuel container. If you use a funnel, MAKE SURE it is PLASTIC. Avoid using a funnel which has a metal screen or filter.

· Use only clean oil and fuel and clean approved containers and funnels.

· Store oil and fuel in an area protected from dust, moisture and other contamination.


IMPORTANT: Avoid damage! DO NOT mix oil with gasoline.

M86620

1. Use fresh unleaded fuel.

2. Remove fuel tank cap (A) and fill fuel tank.

· Fuel tank capacity: 2.5 L
(2.6 U.S. qt).

· Install fuel tank cap and tighten.

Engine Break-In

c CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death:

· If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove the fumes.

· Always try to work in a well ventilated area.


IMPORTANT: Avoid damage! Break in engine before using machine.

Advise customer to follow this engine break-In procedure.

M86619

1. Reel Clutch handle (A) should be in the STOP position.

2. Allow engine to run and warm up for 15 minutes at 1/2-3/4 throttle before applying load.

3. After first 20 hours, change engine oil while engine is warm.

Install Transport Wheels

The following should be in the bag of parts:


Qty. Used	Qty. Used	Qty. Used
2	Hex Flange Bolts	M8 x 25
2	Socket Head Screws	M8 x 25
2	Wheel and Tire Assemblies
1	Stand
2	Keys
2	Hubs

M60592a

1. Attach stand (A) to frame of mower using two bolts (B).

M60596

2. Place key (C) in shaft.

3. Slide drive collar (D) (flat side of collar facing machine).

M60597

4. Set distance from inside groove (F) on end of shaft to end (G) of drive collar at 62 mm (2.4-in.).

5. Tighten allen screw (E).

6. Repeat Steps 2, 3, 4, and 5 for the other side.

NOTE: Before removing or installing wheels, DISENGAGE travel clutch and STOP engine.

M60595

7. Raise mower on stand (H).

M60598a

8. Slide transport wheel on shaft and rotate wheel to engage collar.

9. Engage plate (I) in groove of shaft. Repeat for the other side.

10. Lower mower.

11. Check for 125-140 kPa (18-20 psi) tire pressure.

Installing Rotary Brush Or GTC (Greens Tender Conditioner)

The following parts should be in the bag of parts:


Qty. Used	Qty. Used	Qty. Used
1	Key (Reel Shaft)	5 x 5 x 22
2	Lock Nuts (Shaft)	M10
2	Bolts (GTC Height of Cut)	M8 x 70
4	Bolts (Bullhorns)	M8 x 30
2	Bolts (Height of Cut Adjuster)	M8 x 40
4	Lock Washer (GTC Height of Cut)
4	Socket Head Screws (GTC Side Plates)	M6 x 16
4	Nuts (GTC Side Plates)	M6
2	Cap Screws (Gear Case)	M8 x 45
4	Washers (Gearcase Cover & Spring)	M9 x 17
1	Key	4 x 4 x 14
1	Spacer (GTC Shaft)
1	Housing
2	Springs
2	Adjusters
2	Step Blocks
2	Knobs
2	Jam Knobs
1	Knob (Gearcase)
1	Set Screw (Gearcase Knob)
1	Gasket
1	Spur Gear (Reel Shaft)
1	Special Cap Screw
1	Spur Gear (Gear Case Shaft)
1	Bushing
1	Snap Ring
2	Brackets (RH/LH)
2	Pads (RH/LH)
2	T-handles
1	Cover Assembly
1	Gear Drive Assembly

NOTE: The following hardware, when removed, needs to be saved for future use:

· 2 bolts in steps 1 & 4.

· O-ring and reel cap in Step 5.

· Spacer in Step 6.

· Bracket in Step 8.

· 4 bolts in step 9.

M86644

1. Remove T-handle (A), lock washers, washer, and bolt. Discard bolt.

2. Remove nut (B) (bottom nut) and adjusting knob (C).

M60575b

3. Loosen jam nut and set screw (D) (on both sides) and remove roller (E) and bracket (F).

4. Repeat the above steps for the other side.

M60571

5. Remove reel cap (G) and O-ring (H).

M60580

6. Remove reel bolt (I), spring (J), and spacer (K).

M60572a

7. Remove one M6 x 16 socket head cap screw (L) and one M8 x 25 socket head cap screw (M) and lock washer. Discard lock washer.

8. Repeat on the other side.

M60572c

9. Remove catcher brackets (A) from each side. Discard bolts. Remove front brace (N) and bracket (O) from each side.

M60607a

10. Install bracket (P), pad (Q), and front brace (R), and fasten with four socket head screws (S) and (T):

· Two that were removed earlier
(S) and two out of the bag of parts (T).

· Two nuts out of bag of parts for socket head screws (T).

11. Repeat for the other side.

M60609

12. Install collar (U) with flange away from mower frame.

NOTE: If necessary, tap collar fully onto the casting housing using a hammer and punch.

13. Install key (V).

NOTE: Gear case comes assembled in the bag of parts.

M60610

14. Loosen two bolts on gear case cover and remove gear case and gasket.

c CAUTION: Avoid injury! Always wear gloves when working around the reel.

M60611

15. Slide gear case onto hub and fasten with snap ring (W).

M60613

16. Install gear (X).

17. Grease spring (Y) and fasten with bolt (Z).

c CAUTION: Avoid injury! GTC blades are very sharp. To prevent injury always wrap a protective cloth around blades and wear gloves when handling the GTC.

NOTE: 180A models (GTC) only-Remove hex nut (F). Remove all spacers (G) and blades (H).

10 blades total are being removed, leaving 65.
Re-install 5 spacers (G) without blades (H) and slide down shaft to collar (E). Install blade then spacer until only six spacers remain. Install remaining 6 spacers (without blades) and hex nut. Tighten nut (F) enough to remove all play between spacers and blades. DO NOT over-tighten.