Maintenance & Repair Instructions - Cub Cadet BC509 Operator's Manual

MAINTENANCE AND REPAIR INSTRUCTIONS
MAINTENANCE SCHEDULE
WARNING:
To prevent serious injury, never perform maintenance or repairs with unit
running. Always service and repair a cool unit. Disconnect the spark plug wire to ensure
that the unit cannot start
.
Perform these required maintenance procedures at the frequency stated in the table. These procedures
should also be a part of any seasonal tune-up.
NOTE: Some maintenance procedures may require special tools or skills. If you are unsure about these
procedures take your unit to any non-road engine repair establishment, individual or authorized service
dealer.
NOTE: Maintenance, replacement, or repair of the emission control devices and system may be
performed by any non-road engine repair establishment, individual or authorized service dealer.
NOTE: Please read the California/EPA statement that came with the unit for a complete listing of terms
and coverage for the emissions control devices, such as the spark arrestor, muffler, carburetor, etc.
FREQUENCY MAINTENANCE REQUIRED
Every 10 hours Clean and oil air filter
Change 1st 10 hours Change oil
Change oil
Every 25 hours Check rocker arm to valve clearance and adjust
Check spark plug condition and gap
LINE INSTALLATION
WARNING:
Never use metal-reinforced line, wire, chain or rope. These can break off and
become dangerous projectiles
This section covers both SplitLine® and standard single line installation.
Always use original equipment manufacturer 0.105 in. (2.67 mm) replacement line. Other types of line may
make the engine overheat or fail.
There are two methods to replace the trimming line:
• Wind the inner reel with new line
• Install a prewound inner reel
Winding the Existing Inner Reel
1. Hold the outer spool with one hand and unscrew the bump knob clockwise (Fig. 27). Inspect the bolt
inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.
2. Remove the inner reel from the outer spool (Fig. 27).
3. Remove spring from the inner reel (Fig. 27).
4. Use a clean cloth to clean the inner reel, spring, shaft and inner surface of the outer spool (Fig. 28).
5. Check the indexing teeth on the inner reel and outer spool for wear (Fig. 29). If necessary, remove
burrs or replace the reel and spool.
NOTE: Always use the correct line length
when installing trimming line on the unit.
The line may not release properly if the
line is too long.
Single Line Installation
Go To Step 8 for SplitLine® Installation
6. Take approximately 18 feet (6 m) of new
trimming line, loop it into two equal
lengths. Insert each end of the line through one of the two holes in the
inner reel (Fig. 30). Pull the line through the inner reel so that the loop is
as small as possible.
7. Wind the lines in tight even layers, onto the reel
(Fig. 31). Wind the line in the direction indicated on the inner reel. Place
your index finger between the two lines to stop the lines from
overlapping. Do not overlap the ends of the line. Proceed to step 11.
SplitLine® Installation
8. Take approximately 10 feet (3 m) of new trimming line. Insert one end of
the line through one of the two holes in the inner reel (Fig. 32). Pull the line through the inner reel until
only about 4 inches is left out.
9. Insert the end of the line into the open
hole in the inner reel and pull the line tight
to make the loop as small as possible
(Fig. 32).
10.Before winding, split the line back about
6 inches.
11.Wind the line in tight even layers in the
direction indicated on the inner reel.
NOTE: Failure to wind the line in the
direction indicated will cause the cutting
attachment to operate incorrectly.
12.Insert the ends of the line into the two
holding slots (Fig. 33).
13.Insert the ends of the line through the
eyelets in the outer spool and place inner
reel with spring inside the outer spool
(Fig. 34). Push the inner reel and outer
spool together. While holding the inner
reel and outer spool, grasp the ends and
pull firmly to release the line from the holding slots in the reel.
NOTE: The spring must be assembled on the inner reel before
reassembling the cutting attachment.
14.Hold the inner reel in place and install the bump knob by turning
counterclockwise. Tighten securely.
INSTALLING A PREWOUND REEL
1. Hold the outer spool with one hand and unscrew the bump knob
clockwise (Fig. 27). Inspect the bolt inside the bump knob to make sure
it moves freely. Replace the bump knob if damaged.
2. Remove the old inner reel from the outer spool (Fig. 27).
3. Remove the spring from the old inner reel (Fig. 27).
4. Place the spring in the new inner reel.
NOTE: The spring must be assembled on the inner reel before reassembling the cutting attachment.
5. Insert the ends of the line through the eyelets in the outer spool (Fig. 34).
6. Place the new inner reel inside the outer spool. Push the inner reel and outer spool together. While
holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the
holding slots in the spool.
7. Hold the inner reel in place and install the bump knob by turning counterclockwise. Tighten securely.
.
Outer Spool
Spring
Inner Reel
Bolt
Bump Knob
Fig. 27
Loop
Fig. 30
Loop
Fig. 32
CHECKING THE OIL LEVEL
WARNING:
proper oil level in the crankcase. Never operate the unit with a low oil level.
The importance of checking and
maintaining the proper oil level in the
crankcase cannot be overemphasized.
Check oil before each use:
1. Stop the engine and allow oil to drain
into the crankcase.
2. Place the engine on a flat, level surface
with the cutting head shield hanging off
a work bench or table to get a proper oil
level reading (Fig. 35).
3. Keep dirt, grass clippings and other debris out of the engine. Clean the area around the dipstick
SEE
before removing it.
p. 5
4. Remove the oil fill plug.
p. 5 5. Look into the oil fill hole, use a flashlight if needed. The oil should be
just touching the inner most thread (Fig. 36).
p. 5
6. If the oil level is not touching the inner most thread on the oil fill hole,
p. 5
add a small amount of oil to the oil fill hole and recheck (Fig. 37).
p. 5
Repeat this procedure until the oil level reaches the inner most thread
on the oil fill hole.
NOTE: Do not overfill the unit.
NOTE: Make sure the O-ring is in place on the oil fill plug when checking and changing the oil (Fig. 37).
CHANGING THE OIL
CAUTION:
Change the oil while the engine is still warm. The oil will flow freely and
carry away more impurities.
1. Remove the oil fill plug.
2. Pour the oil out of the oil fill hole and into a container by tipping the unit
to a vertical position (Fig. 38). Allow ample time for complete drainage.
3. Wipe up any oil residue on the unit and
clean up any oil that may have spilled.
Dispose of the oil according to federal,
state and local regulations.
4. Refill the crankcase with 3.04 fluid ounce
(90 ml) of SAE 30 SF, SG, SH oil. (Fig. 39)
NOTE: Use the bottle and spout saved from
initial use to measure the correct amount
of oil. The top of the label on the bottle
measures approximately 3.04 ounces (90 ml) (Fig. 40). Check the level. See Checking the Oil Level. If
the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 39).
5. Replace the oil fill plug.
AIR FILTER MAINTENANCE
Fig. 28
Cleaning the Air Filter
Failure to maintain your air filter properly can result in poor performance or
can cause permanent damage to your engine.
1. Open the air filter cover. Push the tab on the under side of the cover
inward. Then pull the air filter cover out and up. (Fig. 41).
2. Remove the air filter (Fig. 41).
Index Teeth
3. Wash the filter in detergent and water. Rinse the filter thoroughly and
allow it to dry.
Fig. 29
4. Apply enough clean SAE 30 motor oil to lightly coat the filter.
5. Squeeze the filter to spread and remove excess oil.
6. Replace the filter (Fig. 42).
NOTE: If the unit is operated without the air filter, you will VOID the
warranty.
7. Reinstall the air filter cover. Position the slots on the top of the air filter
cover onto the tabs at the top of the back plate (Fig. 42).
8. Swing the cover down until the tab on the air filter backplate snaps into
place in the slot on the air filter cover (Fig. 41).
Fig. 31
IDLE SPEED ADJUSTMENT
WARNING:
protective clothing and observe all safety instructions to prevent serious personal injury.
The idle speed of the engine is adjustable. An idle adjustment screw is between the air filter cover and
the engine starter housing (Fig. 43).
NOTE: Careless adjustments can seriously damage your unit. An authorized service dealer should make
Holding Slots carburetor adjustments.
Fig. 33
If, after checking the fuel and cleaning the air filter, the engine still will not
idle, adjust the idle speed screw as follows:
1. Start the engine and let it run at a high idle for a minute to warm up.
Refer to Starting/Stopping Instructions.
2. Release the throttle trigger and let the engine idle. If the engine stops,
insert a small Phillips screwdriver in between the air filter cover and the
engine cover (Fig. 43). Turn the idle speed screw in, clockwise, 1/8 of a
turn at a time (as needed) until the engine idles smoothly.
Spring
NOTE: The cutting attachment should not rotate when the engine idles.
Fig. 34
3. If the cutting attachment rotates when the engine idles, turn the idle speed screw counterclockwise
1/8 of a turn at a time (as needed), to reduce idle speed.
Checking the fuel, cleaning the air filter, and adjusting the idle speed should solve most engine
problems. If not and all of the following are true:
• the engine will not idle
• the engine hesitates or stalls on acceleration
• there is a loss of engine power
Have the carburetor adjusted by an authorized service dealer.
ROCKER ARM CLEARANCE
This service requires disassembly of the engine. If feeling
unsure or unqualified to perform this service, take the unit
to an authorized service center.
• The engine must be cold when checking or adjusting
the valve clearance.
• This task should be performed inside, in a clean, dust
free area.
1. Remove the six (6) screws on the back of the engine
cover with a Flat-head or T-25 Torx screwdriver (Fig. 44).
2. Disconnect the spark plug wire.
3. Clean dirt from around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.
socket counterclockwise.
4. Remove the engine cover (Fig. 44).
5. Clean dirt from around the rocker arm cover. Remove
the screw holding the rocker arm cover with a large flat blade screwdriver or Torx
T-25 bit (Fig. 45). Remove the rocker arm cover and gasket.
6. Pull the starter rope slowly to bring the piston to the top of its travel, (known as
top dead center). Check that:
• The piston is at the top of its travel while looking in the spark plug hole (Fig. 45).
• Both rocker arms move freely, and both valves are closed.
If these statements are not true, repeat this step.
MAINTENANCE AND REPAIR INSTRUCTIONS
To prevent extensive engine wear and damage to the unit, always maintain the
Fig. 35
Wear gloves to prevent injury when handling the unit.
Fig. 39
The cutting attachment may spin during idle speed adjustments. Wear
View Of The Rear Engine Cover
Screws
Max Oil Fill Line
Fig. 36
Oil Fill
Plug
O-Ring
Oil Fill
Hole
Fig. 37
Fig. 38
Fill Line
Fig. 40
Air Filter
Cover
Air
Filter
Tab
Fig. 41
Back Plate Tabs
Air
Filter
Locking Tab
Fig. 42
Idle Adjustment Screw
Fig. 43
Screws
Fig. 44
Rocker Arm
Cover
Spark
Plug Hole
Fig. 45
5