Service Manual

ManualsBrandsToro ManualsOutdoor Power EquipmentTimeCutter SS4225 42 in. 22.5 HP V-Twin Gas Dual Hydrostatic Zero Turn Riding Mower with Smart Speed

FormNo.3433-938RevA

TIMECUTTER®ServiceManual

Published:June2020

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

Summary of content (215 pages)

PAGE 1
Form No. 3433-938 Rev A TIMECUTTER® Service Manual Published: June 2020 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 CV Original Instructions (EN) Contact us at www.Toro.com.
PAGE 2
Revision History Revision History Page 2 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 3
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
PAGE 4
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
PAGE 5
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
PAGE 6
Preface Page 6 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 7
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
PAGE 8
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
PAGE 9
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
PAGE 10
Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
PAGE 11
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–4 Equivalents and Conversions............................................................................................................. 2–9 U.S.
PAGE 12
Specifications Model 74685 74687 Deck Size 74690 107 cm (42 inches) Deck Construction 127 cm (50 inches) Fabricated Stamped 3 Point HOC Type HOC Range Engine 74694 3.81–11.43 cm (1.5-4.
PAGE 13
Engine Displacement Engine RPM 452cc 603cc 708cc 726cc 3300 ± 100 rpm 3250 ± 100 rpm 3300 ± 100 rpm 3250 ± 100 rpm Fuel Tank Cap 11 L (3 gallons) Hydro Transaxle Hydro-Gear ZT-2100 Suspension N/A MYRIDE® Bagger Capacity 8 Bushel Battery Size 230 CCA Model 75745 Deck Size 75750 75751 107 cm (42 inches) 75753 127 cm (50 inches) Deck Construction Fabricated 3 Point HOC Type HOC Range 3.81–11.43 cm (1.5-4.
PAGE 14
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
PAGE 15
Metric Bolts and Screws g272209 Figure 2 1. TIMECUTTER® Service Manual 3433-938 Rev A Class 8.8 2. Page 2–5 Class 10.
PAGE 16
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) in-lb in-lb N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
PAGE 17
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb N • cm in-lb N • cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lb N • m ft-lb N • m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
PAGE 18
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N • m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N • m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N •m M12 X 1.5 Class 8.
PAGE 19
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
PAGE 20
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
PAGE 21
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
PAGE 22
GEARS The Systematic approach to defining, diagnosing and solving problems.
PAGE 23
General Troubleshooting Problem The starter does not crank The engine does not start, starts hard, or fails to keep running Engine loses power TIMECUTTER® Service Manual 3433-938 Rev A Possible Cause Corrective Action The blade control switch (PTO) is engaged. Move the blade-control switch (PTO) to the disengaged position. The parking brake is not engaged. Move the motion control levers to the neutral lock (park) position. The battery is dead. Charge the battery.
PAGE 24
General Troubleshooting (continued) Problem The engine overheats The mower pulls to the left or right (with levers fully forward) The machine does not drive The machine vibrates abnormally The machine produces an uneven cutting height The blades do not rotate Troubleshooting: General Troubleshooting Possible Cause Corrective Action The engine load is excessive. Reduce the ground speed or raise height-of-cut. The oil level in the crankcase is low. Add oil to the crankcase.
PAGE 25
General Troubleshooting (continued) Problem The clutch does not engage TIMECUTTER® Service Manual 3433-938 Rev A Possible Cause Corrective Action There is a low voltage supply at the clutch. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. The coil is damaged. Replace the clutch. There is inadequate current supply. Repair or replace the clutch lead wire or electrical system. Clean the connector contacts.
PAGE 26
Troubleshooting: General Troubleshooting Page 3–6 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 27
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Engine Replacement.......................................................................................................................... 4–7 Muffler Replacement ..........
PAGE 28
General Information The TIMECUTTER® series of mowers use 4 different engine combinations; 452cc Toro single cylinder OHV 4 cycle engine (LC1P92F-1), 708cc Toro twin cylinder OHV 4 cycle engine (LC2P77F), 726cc Kawasaki twin cylinder OHV 4 cycle engine (FR691V), and 725cc Kohler twin cylinder OHV 4 cycle engine (PS-KT735). See the Toro Twin Cylinder Engine Service Manual for servicing the engine. All other engines, see the manufacturer’s website.
PAGE 29
Service and Repairs Engine Assembly 1 g305684 Figure 3 1. LC1P92F-1 Engine 3. Exhaust Gasket 2. Muffler 4.
PAGE 30
Engine Assembly 2 g305686 Figure 4 1. 2P77F Engine 2. Muffler Engine: Service and Repairs 3.
PAGE 31
Engine Assembly 3 g305687 Figure 5 1. Kawasaki Engine 3. Oil Drain Tube 2. Muffler 4.
PAGE 32
Engine Assembly 4 g305691 Figure 6 1. Kohler Engine 3. Oil Drain Hose 2. Muffler 4.
PAGE 33
Engine Replacement Engine Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Drain the engine oil. 4. Using pliers, slide the hose clamp away from the fuel filter connection to the fuel hose. Remove the fuel hose from the fuel filter. Clamp the fuel hose to prevent access fuel drainage.
PAGE 34
Engine Removal (continued) 6. Disconnect the engine to chassis wiring harness. g300617 Figure 9 7. Remove the 10 mm nut securing the starter power wire to the starter. g300618 Figure 10 8. Remove 13 mm HH bolt securing the battery cable ground wire and the chassis harness ground wire to the engine block. Remove the ground wires from the engine block.
PAGE 35
Engine Removal (continued) g300619 Figure 11 9. Remove 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Remove the muffler shield and rear engine guard. g300621 Figure 12 10. Remove 8 mm HH bolt securing the throttle and choke cables to the throttle control plate. Remove the throttle and choke cables from the throttle control plate.
PAGE 36
Engine Removal (continued) g300620 Figure 13 11. Remove 4 (13 mm) nuts with lock washers securing the muffler to the engine. Remove the muffler from the engine. g300622 Figure 14 12. Remove the deck tensioner spring from the spring hook.
PAGE 37
Engine Removal (continued) g300623 Figure 15 13. Using an appropriate lifting device, raise the machine. Remove the deck belt from the clutch pulley. 14. Disconnect the wiring to the clutch. g300624 Figure 16 15. Remove the 5/8 hex bolt securing the clutch to the crankshaft of the engine. Remove the clutch.
PAGE 38
Engine Removal (continued) g300625 Figure 17 16. Remove the hydro belt tensioner spring from the spring anchor point on the chassis. g300671 Figure 18 17. Relieve tension from the engine pulley. Slide the hydro belt off the engine pulley. Remove engine pulley from the crankshaft. 18. Remove the 4 hex bolts (9/16 inch) securing the engine to the chassis. Note: Three of the bolts will have a flat washer, the 4th bolt going through the clutch anchor will not have a flat washer.
PAGE 39
Engine Removal (continued) g300672 Figure 19 19. Lower the machine to the ground. Remove the engine from the chassis. Engine Installation 1. Install the engine onto the chassis. Loosely install the 4 hex bolts (9/16 inch), 3 bolts have a flat washer the 4th bolt going through the clutch anchor does not have a flat washer. 2. Using an appropriate lifting device, raise the machine. Torque hex bolts to 45–56 N • m (400–500 in-lb). g300672 Figure 20 3. Install the engine pulley to the crankshaft.
PAGE 40
Engine Installation (continued) 4. Install the hydro belt tensioner spring to the spring anchor point on the chassis. g300671 Figure 21 5. Install the clutch. Install the 5/8 hex bolt securing the clutch to the crankshaft of the engine. Torque bolt to 67.5–81 N • m (50–60 ft-lb). g300625 Figure 22 6. Connect the wiring to the clutch.
PAGE 41
Engine Installation (continued) g300624 Figure 23 7. Install the deck belt to the clutch pulley. Using an appropriate lifting device, lower the machine. 8. Install the deck tensioner spring to the spring hook. g300623 Figure 24 9. Install the muffler to the engine. Secure with 4 (13 mm) nuts with lock washers. Torque nuts to 17–19 N • m (150–170 in-lb).
PAGE 42
Engine Installation (continued) g300622 Figure 25 10. Install the throttle and choke cables to the throttle control plate. Secure with 8 mm HH bolt securing the throttle and choke cables to the throttle control plate. g300620 Figure 26 11. Install the muffler shield and rear engine guard. Secure with 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Torque screws to 17–22.5 N • m (150–200 in-lb).
PAGE 43
Engine Installation (continued) g300621 Figure 27 12. Install the ground wires to the engine block. Secure with 13 mm HH bolt securing the battery cable ground wire and the chassis harness ground wire to the engine block. Torque bolt to 22.5–25 N • m (200–225 in-lb).
PAGE 44
Engine Installation (continued) 13. Install the 10 mm nut securing the starter power wire to the starter. Torque nut to 10.5–11.5 N • m (96–105 in-lb). g300618 Figure 29 14. Connect the engine to chassis wiring harness. g300617 Figure 30 15. Install the fuel tank vent hose to the fuel tank vent orifice.
PAGE 45
Engine Installation (continued) g300616 Figure 31 16. Remove the clamp from the fuel hose. Install the fuel hose from the fuel filter. Using pliers, slide the hose clamp onto the fuel filter connection to the fuel hose. g300615 Figure 32 17. Add engine oil. 18. Connect the positive battery cable first, then the negative battery cable to the battery. Muffler Replacement Muffler Removal 1. Park the machine on a level surface and set the parking brake.
PAGE 46
Muffler Removal (continued) 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Remove 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Remove the muffler shield and rear engine guard. g300621 Figure 33 4. Remove 4 (13 mm) nuts with lock washers securing the muffler to the engine. Remove the muffler from the engine.
PAGE 47
Muffler Installation (continued) 1. Install the muffler to the engine. Secure with 4 (13 mm) nuts with lock washers. Torque nuts to 17–19 N • m (150–170 in-lb). g300622 Figure 35 2. Install the muffler shield and rear engine guard. Secure with 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Torque screws to 17–22.5 N • m (150–200 in-lb). g300621 Figure 36 3. Connect the positive battery cable first, then the negative battery cable to the battery.
PAGE 48
Air Filter Cartridge Replacement Air Filter Cartridge Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Lift the air cleaner cover door. g300685 Figure 37 3. Remove the air filter cartridge. Replace as necessary. g300686 Figure 38 Air Filter Cartridge Installation 1. Install the air filter cartridge onto the engine.
PAGE 49
Air Filter Cartridge Installation (continued) g300686 Figure 39 2. Lower the air cleaner cover door.
PAGE 50
Engine: Service and Repairs Page 4–24 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 51
Chapter 5 Chassis Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Caster Fork Replacement ................................................................................................................
PAGE 52
General Information The TIMECUTTER® series uses a common frame. There are 2 different configurations of this frame a MYRIDE® suspension platform and a conventional solid platform. The frame is constructed from 10 gauge steel and now accommodates a relief in the rear crossmember for aid in easier drive belt replacement.
PAGE 53
Service and Repairs Chassis Assembly 1 g305797 Figure 41 1. 2. Seat Seat Pan TIMECUTTER® Service Manual 3433-938 Rev A 3. 4.
PAGE 54
Chassis Assembly 2 g305817 Figure 42 1. Seat 4. Lanyard Cable 2. 3. Seat Pan Pivot Rod 5.
PAGE 55
Chassis Assembly 3 g306183 Figure 43 1. 2. RH Handle Control Control Arm 10. 11. Retainer Plate Speed Control Asm. 3. Non-Cavitating Damper 12. LH Control Handle 4. Hydro Rod Pin 13. Eccentric 5. 6. Actuator Arm Asm. RH Knob 14. 15. RH Control Plate Box Torsion Spring 7. 8. LH Knob Front Hydro Rod 16. 17. LH Control Plate Box Storage Box 9. Rear Hydro Rod 18.
PAGE 56
Chassis Assembly 4 g306185 Figure 44 9. Fuel Hose 1. Ratcheting Fuel Cap 2. 3. Throttle and Choke Cable Control Panel 10. 11. Cable Tie Orifice Adaptor 4. 5. LH Pod RH Pod 12. 13. Fuel Tank Asm. Grommet Bumper 6. RH Support Pod 14. LH Pod Support 7. Fuel Hose 15. Spring 8. Fuel Hose 16.
PAGE 57
Chassis Assembly 5 g306369 Figure 45 1. 2. Choke Cable Throttle Cable 13. 14. Fuel Hose Orifice Adaptor 3. 4. Control Panel RH Support Pod 15. 16. Fuel Hose Carbon Canister 5. 6. RH Pod Ratcheting Fuel Cap 17. 18. Carbon Canister Bracket Carbon Canister Bracket 7. 8. 9. LH Pod Tank Vent Hose Fuel Hose 19. 20. 21. Inline Fuel Filter Fuel Hose Spring 10. Fuel Tank Asm. 22. Fuel Tank Support 11. Straight Fitting 23. Grommet Bumper 12. Fuel Hose 24.
PAGE 58
Chassis Assembly 6 g306612 Figure 46 1. Seat Base Asm. 17. Seat Bumper 2. 3. Lever Knob Adjustment Lever 18. 19. Cable Bracket Subframe 4. Compression Spring 20. Lower Bracket 5. Extension Spring 21. Adjustment Rod 6. Cam Pulley 22. Cotter Pin 7. Flange Bushing 23. Swing Arm 8. Shock/Spring Asm. 24. RH Torsion Spring 9. Seat Bracket 25. Spring Retainer 10. Seat Latch Bracket 26. Adjuster Plate 11. RH Upper Shock Bracket Mount 27. Spring Retainer 12.
PAGE 59
Chassis Assembly 7 g306653 Figure 47 1. Protector Cap 2. Compression Spring 10. Hydro Plate Mount 3. 4. 5. Floor Pan Cross Brace Seat Support 11. 12. 13. Footrest Axle Stub Asm. Grease Cap 6. Floor Pan 14. Right Front Hydro Mount 7. Hitch Bracket 15. Left Front Hydro Mount 8. Engine Guard 16. Muffler Guard TIMECUTTER® Service Manual 3433-938 Rev A 9.
PAGE 60
Chassis Assembly 8 g306654 Figure 48 1. 2. Rail Guard RH Hydro Mount Plate 9. 10. Lower Cross Brace Axle Stub Asm. 3. 4. Rubber Bumper 11. Grease Cap Hitch Bracket 12. Right Front Hydro Mount 5. Engine Guard 13. TIMECUTTER® Frame Weldment 6. Footrest 14. Left Front Hydro Mount 7. Seat Bumper 15. Hydro Mount Plate 8. Lower Damper Mount Bracket 16.
PAGE 61
Chassis Assembly 9 g306655 Figure 49 1. Lever Grip 2. 3. 4. 5. HOC Bracket Lift Lever RH Arm Asm. HOC Adjustment Plate TIMECUTTER® Service Manual 3433-938 Rev A 6. 7. 8. 9. 10. Page 5–11 Decklift Pivot Bracket Deck Lift Asm. Pivot Pin Deck Mount Rod LH Arm Asm.
PAGE 62
Chassis Assembly 10 g306690 Figure 50 Bracket Link Bracket Pin 8. 9. 10. 11. Rear Pivot Asm. Deck Lift Link Deck Lift Gusset Flange Bearing 1. 2. 3. 4. HOC HOC HOC HOC 5. Foot Pedal 12. Shaft Cross Support 6. 7. Pan Mount Pivot Deck Pan 13. Front Pivot Asm.
PAGE 63
Chassis Assembly 11 g306691 Figure 51 1. 2. Foot Lift Pedal Lever Grip 8. 9. 3. 4. HOC Bracket Foot Lift Pedal 10. 11. RH Arm Asm. HOC Adjustment Plate 5. 6. 7. Link Lift Lever Deck Lift Pivot Bracket 12. 13. 14. Pivot Pin Deck Mount Rod LH Arm Asm. TIMECUTTER® Service Manual 3433-938 Rev A Page 5–13 Deck Lift Asm.
PAGE 64
Chassis Assembly 12 g306775 Figure 52 1. 2. Seal Guard Wheel Spanner Chassis: Service and Repairs 3. 4. Page 5–14 Fork Asm. Tire Asm.
PAGE 65
Caster Fork Replacement Caster Fork Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Using an appropriate lifting device, raise the front of the machine off the floor. 3. Remove the ¾ inch bolt and nut securing the wheel to the caster fork. Remove the wheel from the machine. g300687 Figure 53 4. Using a flat head screw driver, remove the top dust cover. g308652 Figure 54 5.
PAGE 66
Caster Fork Installation 1. Install the caster fork to the stub shaft. 2. Install the ½ inch bolt securing the caster fork to the stub shaft. Torque bolt to 22.5–25 N • m (200–225 in-lb). g300689 Figure 55 3. Install the top dust cover. 4. Install the wheel to the machine. Secure with the ¾ inch bolt and nut securing the wheel to the caster fork. Torque bolt and nut to 36.5–50 N • m (27–37 ft-lb). g300687 Figure 56 5. Lower the front of the machine to the floor.
PAGE 67
Caster Wheel Bushing Replacement Caster Wheel Bushing Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Using an appropriate lifting device, raise the front of the machine off the floor. 3. Remove the ¾ inch bolt and nut securing the wheel to the caster fork. Remove the wheel from the machine. g300687 Figure 57 4. Remove the center axle from the bushings. g300700 Figure 58 5.
PAGE 68
Caster Wheel Bushing Installation 1. Install the bushings to the wheel (2 bushings and 1 axle per wheel). 2. Install the center axle to the bushings. g300700 Figure 59 3. Install the wheel to the machine. Secure with a ¾ inch bolt and nut securing the wheel to the caster fork. Torque bolt and nut to 36.5–50 N • m (27–37 ft-lb). g300687 Figure 60 4. Lower the machine to the floor. Stub Shaft Replacement Stub Shaft Removal 1. Park the machine on a level surface and set the parking brake.
PAGE 69
Stub Shaft Removal (continued) 2. Using an appropriate lifting device, raise the front of the machine off the floor. 3. Remove the ¾ inch bolt and nut securing the wheel to the caster fork. Remove the wheel from the machine. g300687 Figure 61 4. Using a flat head screw driver, remove the top dust cover. g300688 Figure 62 5. Remove the ½ inch bolt securing the caster fork to stub shaft. Remove the caster fork from the stub shaft. 6.
PAGE 70
Stub Shaft Removal (continued) g300752 Figure 63 7. Remove the stub shaft from the front axle asm. g300753 Figure 64 8. Remove the bearings from the stub shaft, inspect and replace as necessary. Stub Shaft Installation 1. Install the bearings to the stub shaft. 2. Install the stub shaft to the front axle asm.
PAGE 71
Stub Shaft Installation (continued) g300753 Figure 65 3. Install the 4 (9/16 inch) nut and bolt (3 front, 1 back) securing the stub shaft to the front axle asm. Hand tighten all fasteners. g300752 Figure 66 4. Lower the machine to the floor. The weight of the machine should be on the ground before tightening hardware. 5. Tighten the 2 bolts with nuts first, then tighten the self-tapping screws last (rear before front). Torque bolts with nuts and screws to 36.5–44.5 N • m (27–33 ft-lb). 6.
PAGE 72
Stub Shaft Installation (continued) g300688 Figure 67 8. Install the wheel to the machine. Secure with the ¾ inch bolt and nut securing the wheel to the caster fork. Torque the bolt to 36.5–50 N • m (27–37 ft-lb). g300687 Figure 68 Pod Replacement Pod Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Flip the seat forward. 3.
PAGE 73
Pod Removal (continued) 4. Remove the fuel cap on the LH side pod. 5. Move the motion control from the neutral lock to the neutral position. 6. Remove the LH pod from the machine. Note: The LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob. 7. Using Philips head screw driver, remove the screw securing the smart speed knob to the smart speed lever. Remove the smart speed knob from the smart speed lever. g301691 Figure 69 8.
PAGE 74
Pod Installation 1. Place the RH pod into position on the machine. 2. Install the control panel. Hand tighten with the screw securing the control panel to the RH pod. g301692 Figure 71 3. Install the smart speed knob to the smart speed lever. Hand tighten with the screw securing the smart speed knob to the smart speed lever. g301691 Figure 72 4. Place the LH pod into position on the machine. 5. Move the motion control from the neutral position to the neutral lock position. 6.
PAGE 75
Fuel Tank Replacement Fuel Tank Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Flip the seat forward. 3. Using a T–30 torque bit, remove the 3 screws (per pod) securing the pod to the pod support brackets. 4. Remove the fuel cap on the LH side pod. 5. Move the motion control from the neutral lock to the neutral position. 6. Remove the LH pod from the machine. 7.
PAGE 76
Fuel Tank Removal (continued) g301704 Figure 74 9. Remove the 2 strap fasteners from the bottom of the fuel tank. Remove the fuel tank from the chassis. g301705 Figure 75 Fuel Tank Installation 1. Install the fuel tank to the chassis. Secure with the 2 strap fasteners at the bottom of the fuel tank.
PAGE 77
Fuel Tank Installation (continued) g301705 Figure 76 2. Remove the cap from the hoses. Install the fuel hose and fuel vent hose to the fuel tank fittings. Secure with spring clamps. Note: The fuel hose and fuel vent hose ports and hose orientation are labeled on the fuel tank. g301704 Figure 77 3. Remove the fuel cap from the LH pod. 4. Install the LH pod into position on the machine. 5. Move the motion control from the neutral position to the neutral lock. 6. Install the fuel cap on the LH side pod.
PAGE 78
Fuel Tank Installation (continued) 8. Flip the seat back into position. Seat Assembly Replacement Seat Assembly Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Flip the seat forward and remove the seat switch connection. g301716 Figure 78 3. Flip the seat back to the operator position. 4. Remove the 2 (T–27) screws from the front of the seat pan. g301717 Figure 79 5.
PAGE 79
Seat Assembly Removal (continued) g301718 Figure 80 Seat Assembly Installation 1. Install the seat onto the seat rod.
PAGE 80
Seat Assembly Installation (continued) 2. Install the 2 (T–27) screws to the front of the seat pan. Torque screws to 11 N • m (100 in-lb). g301717 Figure 82 3. Install the seat switch connection. g301716 Figure 83 4. Flip the seat back into the operator position. MYRIDE® Seat/Platform Replacement MYRIDE® Seat/Platform Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
PAGE 81
MYRIDE® Seat/Platform Removal (continued) 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Lift the seat forward. 4. Disconnect the seat switch. 5. Remove the 3/8 inch head bolt securing the seat stop bracket to the seat mount. Remove the seat stop bracket from the machine. 6. Lower the seat. Slide the seat to the most forward position. 7. Remove the seat from the machine. g301739 Figure 84 8.
PAGE 82
MYRIDE® Seat/Platform Removal (continued) g301741 Figure 86 10. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. 11. Move the motion control from the neutral lock to the neutral position. 12. Using a Philips head screw driver, remove the screw securing the smart speed knob to the smart speed lever. Remove the smart speed knob from the smart speed lever. g301691 Figure 87 13.
PAGE 83
MYRIDE® Seat/Platform Removal (continued) g301692 Figure 88 14. Remove the RH pod from the machine. 15. Move the MYRIDE® adjustment lever to most forward position. Relieve the tension from the MYRIDE® adjustment spring cable. g301755 Figure 89 16. Remove the MYRIDE® assist spring from the MYRIDE® cam assembly and the frame. Note: Long end secures towards the front of the machine. 17. Move the MYRIDE® adjustment lever to the most rearward position.
PAGE 84
MYRIDE® Seat/Platform Removal (continued) 19. Remove the cable from the cam. g301756 Figure 90 20. Remove the cam assembly from the machine. g309644 Figure 91 CAUTION May need assistance to perform next step. 21. Remove the nut securing the top of the front MYRIDE® shock to the MYRIDE® platform.
PAGE 85
MYRIDE® Seat/Platform Removal (continued) g301752 Figure 92 22. Using a rachet strap, hook the strap to both frame rails on either side of the MYRIDE® platform.
PAGE 86
MYRIDE® Seat/Platform Removal (continued) g301754 Figure 94 CAUTION May need assistance to perform next step. Springs are under extreme load. 23. Remove the 2 (1/2 inch) bolts and nuts securing the MYRIDE® stop bracket to the MYRIDE® platform. g301769 Figure 95 24. Relieve the tension from the MYRIDE® platform by removing the ratchet strap. 25. Remove the 2 (9/16) inch nuts and bolts securing the MYRIDE® trailing to the chassis.
PAGE 87
MYRIDE® Seat/Platform Removal (continued) g301770 Figure 96 26. Using an appropriate lifting device, remove the MYRIDE® platform from the machine. g301771 Figure 97 MYRIDE® Seat/Platform Installation 1. Using an appropriate lifting device, install the MYRIDE® platform onto the machine.
PAGE 88
MYRIDE® Seat/Platform Installation (continued) g301771 Figure 98 CAUTION May need assistance to perform next step. Springs are under extreme load. 2. Install the 2 (9/16 inch) inch nuts and bolts securing the MYRIDE® trailing to the chassis. Torque nuts and bolts to 40.5–44.5 N • m (30–33 ft-lb). g301770 Figure 99 3. Install the 2 (1/2 inch) bolts and nuts securing the MYRIDE® stop bracket to the MYRIDE® platform. Torque the bolts and nuts to 22.5–25 N • m (200–225 in-lb).
PAGE 89
MYRIDE® Seat/Platform Installation (continued) g301769 Figure 100 4. Using a rachet strap, hook the strap to both frame rails on either side of the MYRIDE® platform.
PAGE 90
MYRIDE® Seat/Platform Installation (continued) g301753 Figure 102 CAUTION May need assistance to perform next step. 5. Push on the rear of the MYRIDE® platfrom and use the rachet strap to compress and secure the torsion springs on the MYRIDE® platform. 6. Install the nut securing the top of the front MYRIDE® shock to the MYRIDE® platform. Torque nut to 40.5–44.5 N • m (30–33 ft-lb). 7. Install the cam assembly onto the machine. 8. Install the cable to the cam.
PAGE 91
MYRIDE® Seat/Platform Installation (continued) 9. Screw on the knob until hand tight. Install the ½ inch bolt and 9/16 inch nut securing the cam to the chassis. Torque bolt and nut to 40.5–44.5 N • m (30–33 ft-lb). 10. Install the MYRIDE® cable to the cam assembly. Move the MYRIDE® adjustment lever to the most forward position. Using a ½ inch wrench, install the front nut to the MYRIDE® cable. g301755 Figure 104 11. Install the MYRIDE® assist spring to the MYRIDE® cam assembly and the frame.
PAGE 92
MYRIDE® Seat/Platform Installation (continued) g301692 Figure 105 15. Install the smart speed knob to the smart speed lever. Hand tighten the screw securing the smart speed knob to the smart speed lever. g301691 Figure 106 16. Move the motion control from the neutral position to the neutral lock position. 17. Install the 3 screws (per pod) securing the pod to the pod support brackets. Torque screws to 11 N • m (100 in-lb). 18. Install the seat mount to the machine.
PAGE 93
MYRIDE® Seat/Platform Installation (continued) g301741 Figure 107 19. Install the 2 (1/2 inch) bolts securing the seat mount to the MYRIDE® platform. Torque bolts to 5.5–6.5 N • m (53–60 in-lb). g301740 Figure 108 20. Install the seat onto the machine.
PAGE 94
MYRIDE® Seat/Platform Installation (continued) g301739 Figure 109 21. Slide the seat to most rearward position. Lower the seat. 22. Install the seat stop bracket to the machine. Install the 3/8 inch head bolt securing the seat stop bracket to the seat mount. Torque head bolt to 11 N • m (100 in-lb). g301774 Figure 110 23. Connect the seat switch.
PAGE 95
MYRIDE® Seat/Platform Installation (continued) g301773 Figure 111 24. Lower the seat forward. 25. Connect the positive battery cable first, then the negative battery cable to the battery. Steering Control Box Replacement Steering Control Box Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. To relieve tension on deck lift handle, place wood blocks (2x4 inches) under each side of the deck.
PAGE 96
Steering Control Box Removal (continued) g301716 Figure 112 4. Flip the seat back to the operator position. 5. Remove the 2 (T-27) screws from the front of the seat pan. g301717 Figure 113 6. Lift and remove the seat from the seat rod.
PAGE 97
Steering Control Box Removal (continued) g301718 Figure 114 7. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. 8. Remove the fuel cap on the LH side pod. 9. Move the motion control from the neutral lock to the neutral position. 10. Remove the LH pod from the machine. Note: LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob. 11. Reinstall the fuel cap to the LH pod to prevent fuel spill.
PAGE 98
Steering Control Box Removal (continued) g301691 Figure 116 13. Using a Philips head screw driver, remove the screw securing the control panel to the RH pod. Move the control panel to the side. g301692 Figure 117 14. Remove the RH pod from the machine. 15. Remove the spring clamps securing the fuel hose and the fuel vent hose. Remove the fuel hose and fuel vent hose from the fuel tank fittings. Cap all hoses. Note: The fuel tank labels both vent and fuel ports and line orientation.
PAGE 99
Steering Control Box Removal (continued) g301704 Figure 118 16. Remove the 2 strap fasteners from the bottom of the fuel tank. Remove the fuel tank from the chassis. g301705 Figure 119 17. Remove the 2 front pod mounting screws (T-30). 18. Remove the 2 screws (T-20) securing the cubbie to the chassis.
PAGE 100
Steering Control Box Removal (continued) g301788 Figure 120 19. Move the smart speed selector to the turtle/trim position. 20. Remove the cubbie by lifting the front of each pod to maneuver the cubbie away from the chassis. 21. Remove the 2 (9/16 inch) bolts per motion control arm. g301789 Figure 121 22. Remove the top T-30 screw and 7/16 inch nut securing the damper to the chassis and motion control actuator.
PAGE 101
Steering Control Box Removal (continued) g301790 Figure 122 23. Remove the motion control neutral switch from the steering control box by depressing the tabs on either side of the switch. Remove the switch from the control box.
PAGE 102
Steering Control Box Removal (continued) g301792 Figure 124 24. Remove the 5/16 inch screw (1 per mount) securing the 2 speed selector rod retaining mounts. g301793 Figure 125 25. Pull back on the speed selector rod lift and remove the speed selector rod from the machine.
PAGE 103
Steering Control Box Removal (continued) g301896 Figure 126 26. Remove the 7/16 inch nut securing the motion control rod to the motion control actuator. Remove the motion control rod. g301897 Figure 127 27. Remove the 4 (T–30) screws (4 per control box) securing the steering control box to the chassis. Remove the steering control box and seat rod from the machine. Note: When removing the RH steering control box, remove the T-30 screw securing the height-of-cut bracket to the chassis.
PAGE 104
Steering Control Box Removal (continued) g301898 Figure 128 Steering Control Box Disassembly 1. Remove the T-30 screw securing the return to neutral from reverse spring to the steering control box. Remove the return to neutral from reverse spring. g301930 Figure 129 2. Remove the 9/16 inch nut and ¾ inch bolt securing the actuator arm to the steering control box. Remove the actuator arm from the steering control box.
PAGE 105
Steering Control Box Disassembly (continued) g301931 Figure 130 3. Remove the 9/16 inch nut and bolt securing the lower motion control lever to the motion control actuator. g301932 Figure 131 4. Remove the 7/16 inch nut and bolt securing the tracking adjustment block to the steering control box.
PAGE 106
Steering Control Box Disassembly (continued) g301933 Figure 132 Steering Control Box Assembly 1. Install the 7/16 inch nut and bolt securing the tracking adjustment block to the steering control box. Torque nut and bolt to 11 N • m (100 in-lb). g301932 Figure 133 2. Install the 9/16 inch nut and bolt securing the lower motion control lever to the motion control actuator. Torque nut and bolt to 40.5–44.5 N • m (30–33 ft-lb). 3. Install the actuator arm in the steering control box.
PAGE 107
Steering Control Box Assembly (continued) g301931 Figure 134 4. Install the return to neutral to the reverse spring. Install the T-30 screw securing the return to neutral from reverse spring to the steering control box. Torque screw to 11 N • m (100 in-lb). g301930 Figure 135 Steering Control Box Installation 1. Install the steering control box and seat rod to the machine. Install the 4 (number 30 torque) screws (4 per control box) securing the steering control box to the chassis.
PAGE 108
Steering Control Box Installation (continued) g301898 Figure 136 2. Install the motion control rod. Install the 7/16 inch nut securing the motion control rod to the motion control actuator. Torque nut to 11 N • m (100 in-lb). g301897 Figure 137 3. Install the speed selector rod to the machine.
PAGE 109
Steering Control Box Installation (continued) g301896 Figure 138 4. Install the 5/16 inch screw (1 per mount) securing the 2 speed selector rod retaining mounts. Torque screw to 4.5–5 N • m (42–47 in-lb). g301793 Figure 139 5. Install the switch into the control box by depressing the tabs on either side of the switch.
PAGE 110
Steering Control Box Installation (continued) g301791 Figure 140 6. Install the top T-30 screw and 7/16 inch nut securing the damper to the chassis and motion control actuator. Torque screw and nut to 11 N • m (100 in-lb). g301790 Figure 141 7. Install the 2 (9/16 inch) bolts per motion control arm. Torque bolts to 40.5–44.5 N • m (30–33 ft-lb).
PAGE 111
Steering Control Box Installation (continued) g301789 Figure 142 8. Install the cubbie onto the machine. 9. Move the smart speed selector to the trim/turtle position. 10. Install the 2 screws (T–20) securing the cubbie to the chassis. Torque screws to 11 N • m (100 in-lb). g301788 Figure 143 11. Install the fuel tank to the chassis. Secure with the 2 strap fasteners at the bottom of the fuel tank.
PAGE 112
Steering Control Box Installation (continued) g301705 Figure 144 12. Install the 2 front pod mounting screws (T–30). Torque screws to 11 N • m (100 in-lb). 13. Remove the cap from the hoses. Install the fuel hose and fuel vent hose to the fuel tank fittings. Secure with spring clamps. Note: The fuel hose and fuel vent hose ports and hose orientation are labeled on the fuel tank. g301704 Figure 145 14. Place the RH pod into position on the machine. 15. Install the control panel.
PAGE 113
Steering Control Box Installation (continued) g301692 Figure 146 16. Install the smart speed knob to the smart speed lever. Hand tighten with the screw securing the smart speed knob to the smart speed lever. g301691 Figure 147 17. Place the LH pod into position on the machine. 18. Move the motion control from the neutral position to the neutral lock position. 19. Install the fuel cap on the LH side pod. 20. Install the 3 screws (per pod) securing the pod to the pod support brackets.
PAGE 114
Steering Control Box Installation (continued) g301718 Figure 148 23. Install the 2 (T–27) screws to the front of the seat pan. Torque screws to 11 N • m (100 in-lb). g301717 Figure 149 24. Install the seat switch connection.
PAGE 115
Steering Control Box Installation (continued) g301716 Figure 150 25. Flip the seat back into the operator position. Motion Control Actuator Replacement Motion Control Actuator Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. To relieve tension on deck lift handle, place wood blocks (2x4 inches) under each side of the deck. Lower the deck until tension is relieved from the lift handle. 3.
PAGE 116
Motion Control Actuator Removal (continued) 5. Remove the 2 (T-27) screws from the front of the seat pan. g301717 Figure 152 6. Lift and remove the seat from the seat rod. g301718 Figure 153 7. Using T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. 8. Remove the fuel cap on the LH side pod. 9. Move the motion control from the neutral lock to the neutral position. 10. Remove the LH pod from the machine.
PAGE 117
Motion Control Actuator Removal (continued) g301703 Figure 154 12. Using Philips head screw driver, remove the screw securing the smart speed knob to the smart speed lever. Remove the smart speed knob from the smart speed lever. g301691 Figure 155 13. Using a Philips head screw driver, remove the screw securing the control panel to the RH pod. Move the control panel to the side.
PAGE 118
Motion Control Actuator Removal (continued) g301692 Figure 156 14. Remove the RH pod from the machine. 15. Remove the spring clamps securing the fuel hose and the fuel vent hose. Remove the fuel hose and fuel vent hose from the fuel tank fittings. Cap all hoses. Note: The fuel tank labels both vent and fuel ports and line orientation. g301704 Figure 157 16. Remove the 2 strap fasteners from the bottom of the fuel tank. Remove the fuel tank from the chassis.
PAGE 119
Motion Control Actuator Removal (continued) g301705 Figure 158 17. Remove the 2 front pod mounting screws (T-30). 18. Remove the 2 screws (T-20) securing the cubbie to the chassis. g301788 Figure 159 19. Move the smart speed selector to the trim/turtle position. 20. Remove the cubbie by lifting the front of each pod to maneuver the cubbie away from the chassis. 21. Remove the 2 (9/16 inch) bolts per motion control arm. 22.
PAGE 120
Motion Control Actuator Installation 1. Install the motion control actuator onto the machine. 2. Connect the switch to the connector. Install the motion control neutral switch into the steering control box by depressing the tabs on either side of the switch. 3. Install the top T-30 screw and 7/16 inch nut securing the damper to the chassis and motion control actuator. Torque screw and nut to 11 N • m (100 in-lb). 4. Install the 2 (9/16 inch) bolts per motion control arm. Torque bolt to 40.5–44.
PAGE 121
Motion Control Actuator Installation (continued) g301704 Figure 161 11. Install the RH pod to the machine. 12. Move the control panel into position on the machine. Using a Philips head screw driver, hand tighten the screw securing the control panel to the RH pod. g301692 Figure 162 13. Install the smart speed knob to the smart speed lever. Using a Philips head screw driver, hand tighten the screw securing the smart speed knob to the smart speed lever.
PAGE 122
Motion Control Actuator Installation (continued) g301691 Figure 163 14. Reinstall the fuel cap to the LH pod to prevent fuel spill. Fully tighten. g301703 Figure 164 15. Install the LH pod to the machine. Note: The LH and RH pod install are the same except the RH pod has the control panel and smart speed knob. 16. Move the motion control from the neutral lock to the neutral position. 17. Remove the fuel cap on the LH side pod. 18.
PAGE 123
Motion Control Actuator Installation (continued) g301718 Figure 165 20. Install the 2 (T-27) screws to the front of the seat pan. Torque screw to 11 N • m (100 in-lb). g301717 Figure 166 21. Flip the seat forward. 22. Install the seat switch connection and flip the seat into the operator’s position. 23. Raise the deck until tension is added to the lift handle. Remove the wood blocks (2x4 inches) under each side of the deck.
PAGE 124
Smart Speed Assembly Replacement Smart Speed Assembly Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. To relieve tension on deck lift handle, place wood blocks (2x4 inches) under each side of the deck. Lower the deck until tension is relieved from the lift handle. 3. Flip the seat forward and remove the seat switch connection. g301716 Figure 167 4. Flip the seat back to the operator position. 5.
PAGE 125
Smart Speed Assembly Removal (continued) g301718 Figure 169 7. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. 8. Remove the fuel cap on the LH side pod. 9. Move the motion control from the neutral lock to the neutral position. 10. Remove the LH pod from the machine. Note: The LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob. 11. Reinstall the fuel cap to the LH pod to prevent fuel spill.
PAGE 126
Smart Speed Assembly Removal (continued) g301691 Figure 171 13. Using a Philips head screw driver, remove the screw securing the control panel to the RH pod. Move the control panel to the side. g301692 Figure 172 14. Remove the RH pod from the machine. 15. Remove the spring clamps securing the fuel hose and the fuel vent hose. Remove the fuel hose and fuel vent hose from the fuel tank fittings. Cap all hoses. Note: The fuel tank labels both vent and fuel ports and line orientation.
PAGE 127
Smart Speed Assembly Removal (continued) g301704 Figure 173 16. Remove the 2 strap fasteners from the bottom of the fuel tank. Remove the fuel tank from the chassis. g301705 Figure 174 17. Remove the 2 screws (T-20) securing the cubbie to the chassis.
PAGE 128
Smart Speed Assembly Removal (continued) g301788 Figure 175 18. Move the smart speed selector to the turtle/trim position. 19. Remove the cubbie by lifting the front of each pod to maneuver the cubbie away from the chassis. 20. Remove the 2 (9/16 inch) bolts per motion control arm. 21. Remove the top T-30 screw and 7/16 inch nut securing the damper to the chassis and motion control actuator. 22.
PAGE 129
Smart Speed Assembly Installation (continued) g309648 Figure 176 2. Install the 5/16 inch screw (1 per mount) securing the 2 speed selector rod retaining mounts. Torque screw to 4.5–5 N • m (42–47 in-lb). g309649 Figure 177 3. Connect the switch to the connector. Connect the motion control neutral connector to the steering control box by depressing the tabs on either side of the switch.
PAGE 130
Smart Speed Assembly Installation (continued) g309652 Figure 178 4. Install the top T-30 screw and 7/16 inch nut securing the damper to the chassis and motion control actuator. Torque screw and nut to 11 N • m (100 in-lb). 5. Install the 2 (9/16 inch) bolts per motion control arm. Torque bolts to 40.5–44.5 N • m (30–33 ft-lb). 6. Install the cubbie by lifting the front of each pod to maneuver the cubbie onto the chassis. 7. Move the smart speed selector to the trim/turtle position. 8.
PAGE 131
Smart Speed Assembly Installation (continued) g301788 Figure 179 9. Install the 2 (T-30) front pod mounting screws. Torque screws to 11 N • m (100 in-lb). 10. Install the fuel tank to the chassis. Install the 2 strap fasteners to the bottom of the fuel tank. g301705 Figure 180 11. Uncap the hoses. Install the fuel hose and fuel vent hose to the fuel tank fittings. Install the spring clamps securing the fuel hose and the fuel vent hose.
PAGE 132
Smart Speed Assembly Installation (continued) g301704 Figure 181 12. Install the RH pod to the machine. 13. Place the control panel into position on the machine. Using a Philips head screw driver, hand tighten the screw securing the control panel to the RH pod. g301692 Figure 182 14. Install the smart speed knob to the smart speed lever. Using Philips head screw driver, hand tighten the screw securing the smart speed knob to the smart speed lever.
PAGE 133
Smart Speed Assembly Installation (continued) g301691 Figure 183 15. Remove the fuel cap from the fuel tank. 16. Install the LH pod to the machine. Note: The LH and RH pod install are the same except the RH pod has the control panel and smart speed knob. 17. Move the motion control from the neutral lock to the neutral position. 18. Using a T–30 torque bit, install the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. Torque screws to 11 N • m (100 in-lb). 19.
PAGE 134
Smart Speed Assembly Installation (continued) 21. Install the 2 (T-27) screws to the front of the seat pan. Torque screws to 11 N • m (100 in-lb). g301717 Figure 185 22. Flip the seat back to the operator position. 23. Flip the seat forward and install the seat switch connection. g301716 Figure 186 24. Raise the deck until tension is added to the lift handle. Remove the wood blocks (2x4 inches) under each side of the deck.
PAGE 135
Rear Engine Guard Replacement Rear Engine Guard Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable. 3. Remove 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Remove the muffler shield and rear engine guard. g300621 Figure 187 4. Remove the rear engine guard.
PAGE 136
Rear Engine Guard Installation (continued) g300621 Figure 188 3. Connect the battery by installing the positive battery cable first, then the negative battery cable. Deck Lift Assembly 3 Point Replacement Deck Lift Assembly 3 Point Removal 1. Park the machine on a level surface set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. To relieve tension on deck lift handle, place wood blocks (2x4) under each side of the deck.
PAGE 137
Deck Lift Assembly 3 Point Removal (continued) 4. Remove the deck belt from the PTO clutch. 5. Remove the cotter pin and washer (1 per side) from each side of the rear deck weldment securing the rear of deck to the deck lift hanger. g301965 Figure 190 6. Remove the rear lift arms from the deck weldments. 7. Raise the deck lift handle to the transport position. 8. Remove the cotter pin and washer securing the front deck hanger to front deck weldment. Remove the rod from the deck. g301966 Figure 191 9.
PAGE 138
Deck Lift Assembly 3 Point Removal (continued) 12. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side. 13. Move the motion control from the neutral lock to the neutral position. 14. Using Philips head screw driver, remove the screw securing the smart speed knob to the smart speed lever. Remove the smart speed knob from the smart speed lever. g301691 Figure 192 15.
PAGE 139
Deck Lift Assembly 3 Point Removal (continued) 18. Remove the 2 hair pin and washers to disconnect the lift link from the deck lift bellcrank. g301967 Figure 194 19. Remove the 9/16 inch bolt and nut securing the lift link to the chassis. Repeat for opposite side. g301968 Figure 195 20. Raise the deck lift handle, remove the T-30 screw securing the height-of-cut bracket to the chassis.
PAGE 140
Deck Lift Assembly 3 Point Removal (continued) g301969 Figure 196 21. Remove the 2 screws securing the bellcrank retention bracket to the chassis. Repeat for opposite side. g301970 Figure 197 Deck Lift Assembly 3 Point Installation 1. Install the 2 screws securing the bellcrank retention bracket to the chassis. Repeat for opposite side. Torque screws to 17–22.5 N • m (150–200 in-lb).
PAGE 141
Deck Lift Assembly 3 Point Installation (continued) g301970 Figure 198 2. Install the T-30 screw securing the height-of-cut bracket to the chassis. Lower the deck lift handle. Torque screw to 17–22.5 N • m (150–200 in-lb).
PAGE 142
Deck Lift Assembly 3 Point Installation (continued) 3. Install the 9/16 inch bolt and nut securing the lift link to the chassis. Repeat for opposite side. Torque bolt and nut to 40.5–44.5 N • m (30–33 ft-lb). g301968 Figure 200 4. Install the 2 hair pin and washers to connect the lift link to the deck lift bellcrank. g301967 Figure 201 5. Raise the deck lift handle. 6. Place the RH pod into position on the machine. 7. Install the control panel.
PAGE 143
Deck Lift Assembly 3 Point Installation (continued) g301692 Figure 202 8. Install the smart speed knob to the smart speed lever. Hand tighten with the screw securing the smart speed knob to the smart speed lever. g301691 Figure 203 9. Move the motion control from the neutral position to the neutral lock position. 10. Install the 3 screws (per pod) securing the pod to the pod support brackets. Torque screws to 11 N • m (100 in-lb). 11. Flip the seat back into position. 12.
PAGE 144
Deck Lift Assembly 3 Point Installation (continued) g301966 Figure 204 15. Lower the deck lift handle to the lowest position. 16. Install the rear lift arms to the deck weldments. 17. Install the cotter pin and washer (1 per side) to each side of the rear deck weldment securing the rear of deck to the deck lift hanger. g301965 Figure 205 18. Install the deck belt to the PTO clutch. 19. Using a spring puller, install the deck tension spring to the deck tension spring anchor.
PAGE 145
Deck Lift Assembly 3 Point Installation (continued) g301964 Figure 206 20. Raise the deck to add tension to the lift handle. Remove the wood blocks (2x4) under each side of the deck. Deck Lift Assembly 4 Point Replacement Deck Lift Assembly 4 Point Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Place wood blocks (2x4) under each side of the deck. 3.
PAGE 146
Deck Lift Assembly 4 Point Removal (continued) g309653 Figure 207 9. Remove the 2 (9/16 inch) nut and bolt securing the 2 RH lift links to the chassis. Remove the 2 RH lift links. g309664 Figure 208 10. Remove the 2 cotter pins and washers securing the deck lift links to the deck lift. Repeat for other side. 11. Raise the deck lift into the highest height-of-cut position. 12. Remove the deck from the machine. 13.
PAGE 147
Deck Lift Assembly 4 Point Removal (continued) g309675 Figure 209 14. Flip the seat forward. 15. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. 16. Move the motion control from the neutral lock to the neutral position. 17. Using Philips head screw driver, remove the screw securing the smart speed knob to the smart speed lever. Remove the smart speed knob from the smart speed lever. g301691 Figure 210 18.
PAGE 148
Deck Lift Assembly 4 Point Removal (continued) g301692 Figure 211 19. Remove the RH pod from the machine. 20. Remove the 2 (T-40) bolts securing the height-of-cut gate to chassis. Remove the height-of-cut gate. 21. Remove the 8 (T-40) bolts securing the front and rear bellcranks to the chassis. Remove the belle cranks. Deck Lift Assembly 4 Point Installation 1. Install the bellecrank. Install the 8 (T-40) bolts securing the front and rear bellcranks to the chassis. Torque bolts to 17–22.
PAGE 149
Deck Lift Assembly 4 Point Installation (continued) 12. Install the 2 cotter pins and washers securing the deck lift links to the deck lift. Repeat for other side. 13. Install the 2 RH lift links. Install the 2 (9/16 inch) nuts and bolts securing the 2 RH lift links to the chassis. Torque bolts and nuts to 40.5–44.5 N • m (30–33 ft-lb). 14. Install the 2 (1/2 inch) bolts and 2 (9/16 inch) nuts securing the rear trailing arm to the deck. Torque bolts and nuts to 40.5–44.5 N • m (30–33 ft-lb). 15.
PAGE 150
Front Chassis Storage Box Removal (continued) g301974 Figure 213 g301975 Figure 214 4. Remove the floor pan from the chassis. 5. Remove the 2 front pod mounting screws (T–30). 6. Remove the 2 screws (T–20) securing the cubbie to the chassis.
PAGE 151
Front Chassis Storage Box Removal (continued) g301788 Figure 215 7. Move the smart speed selector to the turtle/trim position. 8. Remove the cubbie by lifting the front of each pod to maneuver the cubbie away from the chassis. Front Chassis Storage Box Installation 1. Install the cubbie onto the machine. 2. Move the smart speed selector to turtle/trim position. 3. Install the 2 screws (T–20) securing the cubbie to the chassis. Torque screws to 11 N • m (100 in-lb).
PAGE 152
Front Chassis Storage Box Installation (continued) 4. Install the 2 front pod mounting screws (T–30). Torque screws to 11 N • m (100 in-lb). 5. Install the floor pan to the chassis. 6. Install the 4 (T–30) screws securing the floor pan to the chassis. Torque screws to 17–22.5 N • m (150–200 in-lb). g301975 Figure 217 7. Install the license plate to the chassis.
PAGE 153
Front Chassis Storage Box Installation (continued) 8. Install the 2 (9/16 inch) bolt to the front license plate. Torque screws to 22.5–25 N • m (200–225 in-lb).
PAGE 154
Chassis: Service and Repairs Page 5–104 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 155
Chapter 6 Hydrostatic Drive System Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Hydro Transaxle Drive Belt Replacement .......................................................................................... 6–5 Neutral Adjustment ....
PAGE 156
General Information The TIMECUTTER® series of mowers use Hydro-Gear hydrostatic transaxles. There are 4 different models used; ZT-2100, ZT-2200, ZT-2200 long axle, and ZT-2800. All the drives use the same type of fluid. The oil must have a minimum rating of 9.0 cSt (55 SUS) at 230°F (110°C) with an API classification of SL is recommended. A 20W-50 engine oil has been selected for use by the factory and is recommended for normal operating procedures.
PAGE 157
Service and Repairs Hydrostatic Drive Asm. 1 g306748 Figure 220 1. V-belt 7. 2. RH Bypass Rod 8. RH Hydro Transaxle Asm. 3. Spacer 9. Hydro Cross Plate 4. Idler 10. LH Hydro Transaxle Asm. 5. Idler Arm 11. LH Bypass Rod 6.
PAGE 158
Hydrostatic Drive Asm. 2 g306774 Figure 221 1. Breather Kit 2. Hydro Hose 3. RH Bypass Rod 4. 5. 8. 9. Flat Idler Pulley Pedal Return Spring 10. Bracket Mount V-belt 11. RH Hydro Transaxle Asm. Spacer 12. Hydro Plate 6. Idler 13. LH Hydro Transaxle Asm. 7. Idler Arm 14.
PAGE 159
Hydro Transaxle Drive Belt Replacement Hydro Transaxle Drive Belt Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Remove 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Remove the muffler shield and rear engine guard. g300621 Figure 222 4.
PAGE 160
Hydro Transaxle Drive Belt Removal (continued) 6. Disconnect the wiring to the clutch. g300624 Figure 224 7. Remove the 5/8 hex bolt securing the clutch to the crankshaft of the engine. Remove the clutch. g300625 Figure 225 8. Remove the hydro belt tensioner spring from the spring anchor point on the chassis.
PAGE 161
Hydro Transaxle Drive Belt Removal (continued) g300671 Figure 226 9. Remove the hydro belt tensioner spring from the spring anchor point on the chassis. 10. Remove the drive belt from the machine. Hydro Transaxle Drive Belt Installation 1. Install the hydro transaxle drive belt to the machine. Install the hydro transaxle drive belt onto the engine pulley, both transaxle pulleys, fixed idler, and movable idler pulleys. 2. Install the hydro belt tensioner spring to the spring anchor point on the chassis.
PAGE 162
Hydro Transaxle Drive Belt Installation (continued) g300625 Figure 228 4. Connect the wiring to the clutch. g300624 Figure 229 5. Install the deck belt to the clutch pulley. Using an appropriate lifting device, lower the machine. 6. Install the deck tensioner spring to the spring hook.
PAGE 163
Hydro Transaxle Drive Belt Installation (continued) g300623 Figure 230 7. Install the muffler shield and rear engine guard. Install 10 (T-40) self-tapping screws securing the rear engine guard and muffler shield to the chassis. Torque screws to 17–22.5 N • m (150–200 in-lb). g300621 Figure 231 8. Connect the battery by installing the positive battery cable first, then the negative cable to the battery. Neutral Adjustment 1. Park the machine on a level surface and set the parking brake.
PAGE 164
Neutral Adjustment (continued) 3. Remove the 4 (13/16 inch) lug nuts securing rear wheel to the hub. Remove the wheel from the machine. 4. Disconnect the seat switch. g302064 Figure 232 5. Install an appropriate jumper to disable the seat switch. 6. Start the machine. 7. Move the motion control lever until neutral is found. Once neutral is found, install an M8X1.00 nut onto the neutral lock stud for the transmission. g302065 Figure 233 8. Tighten the nut to lock the neutral position. 9.
PAGE 165
Neutral Adjustment (continued) g302066 Figure 234 10. Adjust the motion control lever to access the parking brake position. Tighten the 7/16 inch nut securing the 2 motion control levers. 11. Repeat for opposite side. 12. Perform the Tracking Adjustment procedure after neutral adjustment has been completed for both sides. 13. Remove the M8X1.00 nut on the neutral lock stud of the transmission. 14. Connect the seat switch. 15. Install the wheel to the machine.
PAGE 166
Air Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.
PAGE 167
Hydro Transaxle Removal (continued) g302068 Figure 237 7. Remove the cotter pin and washer securing the brake rod linkage to the brake box. Remove the brake rod linkage from the brake box. g309739 Figure 238 8. Remove the ½ nut and 5/8 bolt securing the motion control linkage to the transaxle. Remove the motion control linkage.
PAGE 168
Hydro Transaxle Removal (continued) g302069 Figure 239 9. Using a spring puller, remove the hydro transaxle drive belt tension spring. g302070 Figure 240 10. Remove the drive belt from the transaxle pulley.
PAGE 169
Hydro Transaxle Removal (continued) g302071 Figure 241 11. Remove the 4 (1/2 inch) bolts and nuts, 3 (11/16 inch) nuts and 3 (5/8 inch) bolts securing the transaxle to the chassis. g302073 Figure 242 Hydro Transaxle Installation 1. Install the transaxle to the chassis.
PAGE 170
Hydro Transaxle Installation (continued) g302073 Figure 243 2. Install, but do not tighten, the 4 (1/2 inch) bolts and nuts, 3 (5/8 inch) bolts, and 11/16 inch nut securing the transaxle to the chassis. See torque sequence below. A. Torque the (5/8 inch) front inner mounting bolt and (11/16 inch) nut to the frame bracket to 67.5–74.5 N • m (50–55 ft-lb). B. Torque the 2 (5/8 inch) bottom mounting bolts and (11/16 inch) nuts to the cross plate to 67.5–74.5 N • m (50–55 ft-lb). C.
PAGE 171
Hydro Transaxle Installation (continued) 3. Install the drive belt to the transaxle pulley. 4. Using a spring puller, install the hydro transaxle drive belt traction spring. g302070 Figure 245 5. Install the motion control linkage. Install the ½ nut and 5/8 bolt securing the motion control linkage to the transaxle. Torque nut and bolt to 22.5–25 N • m (200–225 in-lb). g302069 Figure 246 6. Install the brake rod linkage to the brake box.
PAGE 172
Hydro Transaxle Installation (continued) g302067 Figure 247 g302068 Figure 248 8. Install the wheel to the transaxle hub. 9. Install the 13/16 inch lug nut securing the wheel to the transaxle hub. Torque lug nut to 94.5–122 N • m (70–90 ft-lb). 10. Using an appropriate lifting device, lower the rear of the machine. 11. Connect the battery by installing the positive battery cable first, then the negative cable to the battery.
PAGE 173
Chapter 7 Mower Deck System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Replacement..............................................
PAGE 174
General Information The TIMECUTTER® series of mowers uses 5 different deck sizes offering both fabricated and stamped options; 32 inch stamped deck, 42 inch stamped, 42 inch fabricated, 50 inch fabricated, 54 inch fabricated, and 60 inch fabricated. There are 2 different deck lift systems a 3-point system used on 32–54 inch units and a 4-point system used only on 60 inch units. All units have a 1.5-4.5 inch height-of-cut range.
PAGE 175
Service and Repairs Mower Deck Assembly 1–42 Inch Stamped Deck g307745 Figure 249 1. Right Guard Asm. (CE Models Only) 15. Extension Spring 2. 3. Guard Mount Plate 42 Inch Mulch Plug Asm. 16. 17. Front Shield Spring Return Hook 4. 5. Belt Cover Pulley 18. 19. 42 Inch Deck Deck Pin 6. Flat Idler Pulley 20. Rear Blowout Baffle 7. V-Belt 21. Washout Fitting 8. Belt Idler Guide 22. Clipping Baffle 9. Idler Arm 23. Spindle Asm. 10. 11. Deflector Pivot Rod 24. 25.
PAGE 176
Mower Deck Assembly 2–42 Inch Fabricated Deck g307880 Figure 250 1. 2. Belt Cover V-Belt 13. 14. 42 Inch Fabricated Deck Washout Fitting 3. Guard Mount Plate 15. Left Guard Asm. (CE Models Only) 4. Right Guard Asm. (CE Models Only) 16. Anti Scalp Roller 5. Pulley 17. Extension Spring 6. Belt Cover Bracket 18. Return Spring Hook 7. 8. Front Shield Flat Idler Pulley 19. 20. Deck Pin Recycling Baffle 9. 10. Idler Arm Torsion Spring 21. 22. 42 Inch Deflector Spindle Asm. 11.
PAGE 177
Mower Deck Assembly 3–50 Inch Fabricated Deck g308181 Figure 251 1. Belt Cover 14. Anti Scalp Roller 2. V-Belt 15. Pulley 3. Flat Idler Pulley 16. Deck Pin 4. Guard Mount Plate 17. Washout Fitting 5. Right Guard Asm. (CE Models Only) 18. Front Shield 6. Pulley 19. 50 Inch Fabricated Deck 7. Belt Cover Bracket 20. Extension Spring 8. Flat Idler Pulley 21. Spring Return Hook Idler Belt Guide Left Guard Asm. (CE Models Only) 22. 23. Corner Baffle 50 Inch Baffle Asm. 9. 10.
PAGE 178
Mower Deck Assembly 4– 54 Inch Fabricated Deck g308186 Figure 252 1. 2. Belt Cover Belt Cover Bracket 12. 13. Idler Arm Spring Return Hook 3. 4. V-Belt Discharge Deflector 14. 15. Deck Pin Washout Fitting 5. Torsion Spring 16. Hose Connector 6. Pivot Rod 17. Anti Scalp Roller 7. Cut-off Baffle 18. Spindle Asm. 8. Pulley Asm. 19. 54 Inch Deck Asm. 9. 10. Idler Belt Guide Flat Idler Pulley 20. 21. Corner Baffle Spindle Shaft 11. Extension Spring 22.
PAGE 179
Mower Deck Assembly 5–60 Inch Fabricated Deck g308211 Figure 253 1. RH Belt Cover 11. Anti Scalp Roller 2. LH Belt Cover 12. Extension Spring 3. Belt 13. Spring Return Hook 4. Discharge Deflector 14. Washout Fitting 5. 6. Pivot Rod Torsion Spring 15. 16. Hose Connector 60 Inch Deck Fabricated 7. Cutoff Baffle 17. Spindle Asm. 8. Pulley 18. Corner Baffle 9. Flat Idler Pulley 19. Spindle Shaft Idler Arm 20. Hi Flow Blade 10.
PAGE 180
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Replacement 42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Removal Note: The following procedure shows the 42 inch stamped deck. 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Using a spring puller, remove the deck tension spring from the deck tension spring anchor. 3. Remove the deck belt from the PTO clutch. 4.
PAGE 181
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Disassembly (continued) g302088 Figure 255 2. Using a 9/16 inch wrench to hold the bolt, remove the 9/16 inch nut securing the belt guide to the movable idler. Remove the belt guide from the deck. g302089 Figure 256 3. Remove the belt from the deck.
PAGE 182
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Disassembly (continued) g302090 Figure 257 4. Remove the deck tension spring from the deck. 5. Remove the spring anchor from the deck. 6. Before idler arm removal, ensure idler arm has tension to prevent limited movement (should not move freely). 7. Remove the moveable idler from the deck and flat washers. g302091 Figure 258 8. Remove the 9/16 inch bolt and nut securing the idler arm to the deck shell.
PAGE 183
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Disassembly (continued) g302092 Figure 259 9. Using an appropriate blade holding device, remove the 5/8 inch bolt securing the blade to the deck. Remove the blade from the deck. 10. Remove the 15/16 inch nut securing the spindle to the spindle shaft. 11. Remove the pulley from the spindle shaft. 12. Remove the 4 (1/2 inch) screws securing spindle to the deck assembly. Remove the spindle assembly. g309761 Figure 260 13.
PAGE 184
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Assembly (continued) 2. Install the spindle to the spindle assembly. 3. Install the spindle assembly. Install the 4 (1/2 inch) screws securing spindle to the deck assembly. Torque screws to 19.5–22.5 N • m (175–225 in-lb). 4. Install the pulley to the spindle shaft. 5. Install the 15/16 inch nut securing the spindle to the spindle shaft. Torque nut to 67.5–88 N • m (50–65 ft-lb). 6. Install the blade to the deck.
PAGE 185
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Assembly (continued) g302091 Figure 262 9. Before idler arm removal, ensure idler arm has tension to prevent limited movement (should not move freely). 10. Install the spring anchor to the deck. 11. Install the deck tension spring to the deck. 12. Install the belt to the deck. g302090 Figure 263 13. Install the belt guide to the deck. Using a 9/16 inch wrench to hold the bolt, install the 9/16 inch nut securing the belt guide to the movable idler.
PAGE 186
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Assembly (continued) g302089 Figure 264 14. Install the LH and RH belt covers. Install the 6 (5/16 inch) screws securing the LH and RH belt covers. Torque screws to 4.5–5 N • m (42–47 in-lb). g302088 Figure 265 42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Installation 1. Slide the deck into position under the machine.
PAGE 187
42 inch Stamped and 42/50/54/60 Inch Fabricated Deck Installation (continued) g302087 Figure 266 2. Install the wood blocks under the deck. 3. Install the front hanger rod to the deck. Install the cotter pin and washer securing the front deck hanger to front deck weldment. 4. Lower the deck lift handle to the lowest position. 5. Install the rear lift arms to the deck weldments. 6.
PAGE 188
Mower Deck System: Service and Repairs Page 7–16 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 189
Chapter 8 Electrical System Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 PTO Clutch Replacement ..................................................................................................................
PAGE 190
General Information The TIMECUTTER® series of mowers utilizes a 12VDC electrical system. The system consists of 2 different 12v batteries; 195 CCA and 230 CCA (depending on the model). The electrical system uses 2 neutral/park switches on the motion control levers, seat switch, electronic brake actuator (brake box), blade engagement switch (PTO), ignition switch, main/charge system fuse 25A, and a system fuse 15A.
PAGE 191
Service and Repairs Electrical Assembly 1 g308357 Figure 267 1. Rubber Strap 8. Positive Battery Cable 2. Ignition Key 9. Wire Harness 3. Ignition Switch 10. Solenoid Cover 4. PTO Switch 11. Negative Battery Cable 5. Solenoid Cap 12. Positive Battery Cable 6. Harness Clip 13. Solenoid 7. Switch 14.
PAGE 192
Electrical Assembly 2 g308358 Figure 268 1. Clutch Stop 3. Clutch Isolator 2. Engine Pulley 4.
PAGE 193
PTO Clutch Replacement PTO Clutch Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Using an appropriate lifting device, raise the machine. Remove the deck belt from the clutch pulley. 4. Disconnect the wiring to the clutch. g300624 Figure 269 5.
PAGE 194
PTO Clutch Installation (continued) g300625 Figure 271 2. Connect the wiring to the clutch. g300624 Figure 272 3. Install the deck belt to the clutch pulley. 4. Using an appropriate lifting device, lower the machine. 5. Connect the positive battery cable first, then the negative battery cable to the battery. PTO Clutch Testing 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2.
PAGE 195
PTO Clutch Testing (continued) g309780 Figure 273 5. See the PTO Clutch Electrical Specifications chart below: Model Number Resistance (OHMs) AMP Draw Continuity to Ground 74694, 75750, 75751, 75753, 75755, 75759 3.69 ± 5% 3.25A Open 75755TA, 75754, 75757, 75760 3.05 ± 5% 3.93A Open 74685, 74687, 74690, 75742TA, 75745TA, 75740, 75741, 75742, 75743, 75744, 75745 3.02 ± 5% 3.97A Open 74710 3.02 ± 5% 3.97A Open PTO Clutch Continuity to Ground Check 1.
PAGE 196
PTO Clutch Continuity to Ground Check (continued) g309780 Figure 274 PTO Clutch Measuring Clutch Current Draw Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure amps (10 amp scale). 4.
PAGE 197
PTO Clutch Measuring Clutch Current Draw (continued) 8. Record the amp reading and refer to the PTO Clutch Electrical Specification Chart above. Motion Control and Seat Switch Replacement Motion Control and Seat Switch Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Flip the seat forward. 3. Using a T–30 torque bit, remove the 3 screws securing the pod to the pod support brackets. Repeat for opposite side.
PAGE 198
Motion Control and Seat Switch Removal (continued) g301692 Figure 277 9. Remove the RH pod from the machine. 10. Disconnect the motion control neutral switch from the steering control box by depressing the tabs on either side of the switch. Disconnect the switch from the connector. Motion Control and Seat Switch Installation 1. Connect the switch to the connector. Connect the motion control neutral switch to the steering control box by depressing the tabs on either side of the switch. 2.
PAGE 199
Motion Control and Seat Switch Installation (continued) 4. Install the smart speed knob to the smart speed lever. Hand tighten with the screw securing the smart speed knob to the smart speed lever. g301691 Figure 279 5. Place the LH pod into position on the machine. 6. Move the motion control from the neutral position to the neutral lock position. 7. Install the fuel cap on the LH side pod. 8. Install the 3 screws (per pod) securing the pod to the pod support brackets.
PAGE 200
Brake Module Replacement Brake Module Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Flip the seat forward. 3. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 4. Depress the tab on the top of the connector to release the connector from the module. g302093 Figure 280 5. Remove the 2 (3/8) screws securing the brake module bracket to the chassis.
PAGE 201
Brake Module Installation 1. Install and hand tighten the 4 Philips head screws securing the bracket to the module. Place the brake module into position on the machine. 2. Install the 2 (3/8 inch) screws securing the brake module bracket to the chassis. Torque screws to 9–11 N • m (80–100 in-lb). 3. Install the connector to the module. g302093 Figure 282 4. Install the 2 cotter pins and flat washers securing the brake rods to the brake module. 5. Flip the seat into operating position. 6.
PAGE 202
PTO Switch Removal (continued) g302095 Figure 283 5. Depress the tabs on the side of the switch and remove the switch from the control panel. g302097 Figure 284 PTO Switch Installation 1. Install the switch to the control panel.
PAGE 203
PTO Switch Installation (continued) g302097 Figure 285 2. Connect the PTO switch. 3. Install and hand tighten the Philips head screw to the control panel. g302095 Figure 286 4. Connect the battery by installing the positive battery cable first, then the negative cable to the battery. PTO Switch Testing 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT).
PAGE 204
PTO Switch Testing (continued) g316660 Figure 287 4. Using a digital multi-meter set to the OHM or Continuity setting, verify the following: • Pin 2 and 5 should have continuity (closed) • Pin 1 and 4 should have continuity (closed) • Pin 1 and 7 should NOT have continuity (open) • Pin 2 and 8 should NOT have continuity (open) 5.
PAGE 205
Ignition Switch Removal (continued) g302096 Figure 288 5. Depress the tabs on the side of the switch and remove the switch from the control panel. g302112 Figure 289 Ignition Switch Installation 1. Install the switch to the control panel.
PAGE 206
Ignition Switch Installation (continued) g302112 Figure 290 2. Connect the ignition switch. g302096 Figure 291 3. Install and hand tighten the Philips head screw to the control panel. 4. Connect the battery by installing the positive battery cable first, then the negative cable to the battery. Ignition Switch Testing The ignition switch makes the proper connections for the starter, safety circuits, and accessories. Detents inside the switch control the three switch positions: OFF, RUN, and START.
PAGE 207
Ignition Switch Testing (continued) g316681 Figure 292 • 1 — Starting Circuit Terminal • 2 — (No connection) • 3 — Battery Terminal • 4 — Seat Switch and Hour Meter Terminal • 5 — PTO Switch Terminal 1. Remove the control panel from the right console. 2. Disconnect the harness from the ignition switch. Gently rock the connector back and forth until unplugged. 3.
PAGE 208
Starter Solenoid Removal (continued) g302124 Figure 293 5. Remove the 2 (½ inch) nuts securing the battery cable and the starter power cable to the starter solenoid. Note: The battery cable side has an additional red wire for the chassis harness. g302125 Figure 294 6. Remove the blue and green wires from the main harness to the starter solenoid.
PAGE 209
Starter Solenoid Removal (continued) g302126 Figure 295 7. Remove the 2 (3/8 inch) bolts securing the starter solenoid to the chassis. g302127 Figure 296 8. Remove the starter solenoid from the chassis. Starter Solenoid Installation 1. Install the starter solenoid to the chassis. 2. Install the 2 (3/8 inch) bolts securing the starter solenoid to the chassis. Torque bolts to 3–4.5 N • m (35–40 in-lb).
PAGE 210
Starter Solenoid Installation (continued) g302127 Figure 297 3. Install the blue and green wires to the main harness to the starter solenoid. g302126 Figure 298 4. Install the 2 (½) inch nuts securing the battery cable and the starter power cable to the starter solenoid. Torque nuts to 3–4.5 N • m (35–40 in-lb). Note: The battery cable side has an additional red wire for the chassis harness.
PAGE 211
Starter Solenoid Installation (continued) g302125 Figure 299 5. Install the solenoid terminal cover onto solenoid cover. 6. Connect the battery by installing the positive battery cable first, then the negative cable to the battery. 7. Flip the seat into the operating position.
PAGE 212
Electrical System: Service and Repairs Page 8–24 TIMECUTTER® Service Manual 3433-938 Rev A
PAGE 213
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic...........................................................................................................................
PAGE 214
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BM Brown BU Blue GN Green GY Gray OR Orange PK Pink R or RD Red T Tan VIO Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
PAGE 215
Electrical Schematic g316875 , Drawing Rev A, Sheet 1 3433-938 Rev A Page A–3