Resi dent i alPr oduct s TI MECUTTER®HD Ser vi ceManual I ssued:Apr i l2017
ABOUT THIS MANUAL 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.
ICON LEGEND This icon is used to denote Critical Processes or actions that if missed, could greatly impact your safety, lead to mechanical failure, or improper product part use. Please pay close attention to these steps as they are distinguished throughout the manual.
Chapters Safety..................................................................................................................................... 1-1 Specifications....................................................................................................................... 2-1 Maintenance.......................................................................................................................... 3-1 Troubleshooting....................................................................
Safety SAFETY Table of Contents General Safety Information.................................................................................................. 1-2 Think Safety First..............................................................................................................
SAFETY This symbol means WARNING or PERSONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro TIMECUTTER® HD.The TIMECUTTER® HD operator’s manual contains safety information and operating tips for safe operating practices.
SPECIFICATIONS General Specifications........................................................................................................ 2-2 Unit Dimensions.................................................................................................................. 2-8 Torque Specifications......................................................................................................... 2-9 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.)..................................
SPECIFICATIONS General Specifications Configuration Model 75201 Engine Make Engine Model Engine Model TIMECUTTER® HD 75202 75203 Toro Toro V-Twin 22.5 HP 708CC Toro V-Twin 22.5 HP 708CC 3600 ± 100 RPM Low Idle 1750 ± 150 RPM Spark Plug Champion: RN9YC NGK: BPR6ES Engine Oil See Viscosity Table in Chapter 3, page 3-6 2.4 L (80 oz.) with Filter Change CARB No EPA Yes Air Filter Fuel Capacity Standard 5 gal. Display Hourmeter Battery 12 Volt - 195 CCA Clutch Warner - 105 ft-lbs.
General Specifications (Cont.) Configuration Model 75201 TIMECUTTER® HD 75202 75203 Front Caster Tires Specifications SPECIFICATIONS 75211 13x6.5-6 Front Tire Pressure 13 psi Mower Deck Deck Width 48 in. 54 in. 60 in. 48 in. Deck Configuration 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles Blade Tip Speed Cutting Height 18,880 ft/min. 18,664 ft/min. 18,908 ft/min. 18,880 ft/min. 1.5-4.5 in.
SPECIFICATIONS General Specifications (Cont.) Configuration Model 75212 TIMECUTTER® HD 75213 75210 74864 Engine Make Toro Kawasaki Toro Engine Model Toro V-Twin 24.5 HP 708CC Kawasaki 726cc (CARB) Toro V-Twin 24.5 HP 708CC Engine Model LC2P77F FR651-S12-R (CARB) LC2P77F High Idle Low Idle Spark Plug Engine Oil Oil Capacity 3600 ± 100 RPM 3000 ± 100 RPM 1750 ± 150 RPM (Governor Set) Champion: RN9YC NGK: BPR6ES Champion: XC12YC See Viscosity Table in Chapter 3, page 3-6 2.4 L (80 oz.
General Specifications (Cont.) Configuration Model 75212 TIMECUTTER® HD 75213 75210 Front Caster Tires Specifications SPECIFICATIONS 74864 13x6.5-6 Front Tire Pressure 13 psi Mower Deck Deck Width 54 in. 60 in. 48 in. Deck Configuration 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles Blade Tip Speed Cutting Height 18,664 ft/min. 18,908 ft/min. 18,880 ft/min. 1.5-4.5 in.; 0.25 in.
SPECIFICATIONS General Specifications (Cont.) Configuration Model 74865 TIMECUTTER® HD 74866 Engine Make Toro Engine Model Toro V-Twin 24.5 HP 708CC Engine Model LC2P77F High Idle 3000 ± 100 RPM Low Idle 1750 ± 150 RPM (Governor Set) Spark Plug Champion: RN9YC NGK: BPR6ES Engine Oil See Viscosity Table in Chapter 3, page 3-6 Oil Capacity 2.4 L (80 oz.) with Filter Change CARB No EPA Yes Air Filter Fuel Capacity Standard 5 gal.
General Specifications (Cont.) Configuration Model 74865 Front Caster Tires TIMECUTTER® HD 74866 Specifications SPECIFICATIONS 74867 13x6.5-6 Front Tire Pressure 13 psi Mower Deck Deck Width 54 in. 48 in. 54 in. Deck Configuration 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles Blade Tip Speed Cutting Height 18,664 ft/min. 18,880 ft/min. 18,664 ft/min. 1.5-4.5 in.; 0.25 in.
SPECIFICATIONS Unit Dimensions Model Overall Height (Top of Seat) Tread Width Caster Wheels Drive Wheels Overall Width Wheel Base in/cm Curb Weight Tires Deck Chute Down lbs/kg Deck Chute Up Overall Length in/cm 75201 44.1/ 112.0 34.3/ 87.1 39.2/ 99.6 49.7/ 126.2 744/ 1637 48.8/ 124.0 63.4/ 161.0 49.2/ 125.0 82.1/ 208.5 75202 44.1/ 112.0 34.3/ 87.1 39.2/ 99.6 49.7/ 126.2 758/ 1668 48.8/ 124.0 69.3/ 176.0 55.1/ 140.0 82.1/ 208.5 75203 44.1/ 112.0 34.3/ 87.1 39.2/ 99.6 49.
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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 8 or Better Nut) In-lb. In-lb. N-cm In-lb. N-cm In-lb.
SPECIFICATIONS 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-lbs. N-m ft-lbs. 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 1.75 66 ± 7 90 ± 10 93 ± 10 126 ± 14 M16 X 2.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) (Cont.) SAE Grade 8 Steel Set Screws Thread Size Recommended Torque 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. 3/8 - 16 UNC 35 ± 10 ft-lb. 18 ± 3 ft-lb. 1/2 - 13 UNC 75 ± 15 ft-lb. 50 ± 10 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.
SPECIFICATIONS Specifications 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.
SPECIFICATIONS U.S. to Metric Conversions Linear Measurement Area Volume Weight Pressure Work 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.
MAINTENANCE Table of Contents Servicing the Toro Engine...................................................................................................3-3 Servicing the Air Cleaner............................................................................................... 3-3 Removing the Elements................................................................................................ 3-4 Cleaning the Foam and Paper Element.......................................................................
MAINTENANCE Recommended Maintenance Chart Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil Before each use or daily • Check the safety-interlock system • Check the air cleaner for dirty, loose, or damaged parts • Check the engine-oil level • Clean the air intake screen • Inspect the blades • Inspect the grass deflector for damage After each use • Clean the mower-deck housing Every 25 hours • Clean the air-cleaner foam element* • Check tire pressure
MAINTENANCE Servicing the Toro Engine WARNING Shut off engine before checking the oil or adding oil to the crankcase.
MAINTENANCE Servicing the Toro Engine (Cont.) Removing the Elements 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Clean around the air cleaner cover to prevent dirt from getting into the engine and causing damage. 3. Lift the cover and rotate the air-cleaner assembly out of the engine (Figure 2 and 3). Figure 2 Figure 3 4. Remove the foam element from the paper element.
MAINTENANCE Servicing the Toro Engine (Cont.) Cleaning the Foam and Paper Elements Foam Element: Wash the foam element with water. Paper Element 1. Lightly tap the element on a flat surface to remove dust and dirt. 2. Inspect the element for tears, an oily film, and damage to the seal. NOTE: Do not clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.
MAINTENANCE Servicing the Toro Engine (Cont.) Servicing the Engine Oil Recommended Oil: Toro 4-Cycle Premium Engine Oil Oil Type: Detergent Oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (2.5 qt.) Viscosity: See table below (Figure 4) Figure 4 Checking the Engine Oil Level Service Interval: Before each use or daily NOTE: Check engine oil level when engine is cold. NOTE: Do not overfill the crankcase with oil and run the engine; engine damage may result. 1.
MAINTENANCE Servicing the Toro Engine (Cont.) Checking the Engine Oil Level (Cont.) 4. Check the engine oil level. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the “ADD” mark or over the “FULL” mark on the dipstick (Figure 5). A BB C D F I G E H J K J Figure 5 Digital Edition - TIMECUTTER® HD Service Manual April 2017 3-7 Table of Contents Maintenance 5.
MAINTENANCE Servicing the Toro Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/After the first month (whichever comes first). Every 100 hours/Yearly (whichever comes first): Change the engine oil and oil filter more often in dirty or dusty conditions. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Drain the engine oil (Figure 6).
MAINTENANCE Servicing the Toro Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) 3. Change the oil filter. A B B C D E F Maintenance NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional ¾ turn (Figure 7). 3/4 Figure 7 4. Slowly pour approximately 80% of the specified oil into the filler tube. Check the oil level and slowly add the additional oil needed to bring it to the FULL mark (Figure 8).
MAINTENANCE Servicing the Toro Engine (Cont.) Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plugs. Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plugs. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug. Use a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.
MAINTENANCE Servicing the Toro Engine (Cont.) Checking the Spark Plug 1. Inspect the spark plug. NOTE: Do not clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes. 3. Set the gap to 0.030 in. (0.76 mm) (Figure 9). AA B B Figure 9 Installing the Spark Plug 1. Tighten the spark plugs to 20 ± 2 ft-lbs. (25-30 Nm) (Figure 10). AA B C D 25-30 N-m 18.5-22.
MAINTENANCE Servicing the Toro Engine (Cont.) Cleaning the Cooling System Service Interval: Before each use. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Remove the air filter from the engine. 3. Remove the engine shroud. 4. To prevent debris from entering the air intake, install the air filter to the filter base. 5. Clean debris and grass from the top of the engine. 6.
MAINTENANCE Fuel System Maintenance Replacing the In-line Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) – Check the in-line fuel filter. Every 200 hours/Every 2 years (whichever comes first) – Replace the in-line fuel filter. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake (Figure 11). Figure 11 2. Remove the hose clamps at filter (A) (Figure 11). 3.
MAINTENANCE Electrical System Maintenance Servicing the Battery Service Interval: Monthly NOTE: The battery should be maintained at 12.6 volts or greater. A battery that has reached a voltage of 12.2 volts or less is considered discharged, and should be recharged. 1. Charge the battery for 30 minutes at 10 A. 2. Test the battery voltage.
MAINTENANCE Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; frayed edges, burn marks, and cracks on the belt. Maintenance Mower Belt Replacement (Side Discharge Machines), see chapter 8, page 8-4. Hydrostatic Drive Belt Replacement, see chapter 7, page 7-9.
MAINTENANCE Servicing the Cutting Blades WARNING A worn or damaged blade can break and a piece of the blade could be thrown at you or bystanders, resulting in serious injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. 1. Inspect blades periodically for wear. 2. Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace the blades, never straighten or weld them. 3.
MAINTENANCE Servicing the Cutting Blades Before Inspecting or Servicing the Blades 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key. 2. Disconnect the spark plug wires from the spark plugs. Maintenance Inspecting the Blades 1. Inspect the cutting edges (Figure 12). 2. If the edges are not sharp or have nicks, remove and sharpen the blade, see “Sharpening the Blades,” chapter 3, page 3-21. 3.
MAINTENANCE Servicing the Cutting Blades (Cont.) Checking for Bent Blades 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the spark plug wires from the spark plugs. 3. Rotate the blades so they are perpendicular to the rear of the deck (Figure 13) A B C Figure 13 A. Deck B. Spindle Housing C. Blade 4. Measure from a level surface to the cutting edge, position A (Figure 13). 5.
MAINTENANCE Changing the Blades Removal Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the spindle shaft with a wrench. AB Maintenance 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 14).
MAINTENANCE Changing the Blades (Cont.) Installation 1. Install the blades, curved washers, and blade bolts onto the spindle shaft (Figure 15). AB C D Figure 15 A. Sail Area of the Blade B. Blade C. Curved Washer D. Blade Bolt NOTE: The curved part of the blade must point upward. NOTE: Install the curved washer cone toward the bolt head. 2. Torque the blade bolts to 105 ± 5 ft-lbs. (145 ± 7 Nm).
MAINTENANCE Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 16). NOTE: Maintain the original angle. Maintenance NOTE: The blade retains balance if you remove the same amount of material from both cutting edges. A Figure 16 2. Check balance of the blade by putting it on a blade balancer (Figure 17). NOTE: If the blade stays in a horizontal position, the blade is balanced and ready to use. B A Figure 17 A. Blade B. Balancer 3.
TROUBLESHOOTING Table of Contents Troubleshooting Troubleshooting Table...........................................................................................................
TROUBLESHOOTING Troubleshooting Problem Possible Cause The starter does not crank The engine does not start, starts hard, or fails to keep running 4-2 Table of Contents Next Step... The blade control switch (PTO) is engaged. Move the blade-control switch (PTO) to the disengaged position. The parking brake is not engaged. Set the parking brake. The motion-control levers are not in the Neutral-Lock position. Ensure that the motion-control levers are in the Neutral-Lock position.
TROUBLESHOOTING Troubleshooting (Cont.) Possible Cause Engine loses power Next Step... The engine load is excessive. Reduce the ground speed. The air cleaner is dirty. Clean the air cleaner element. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and air passages above the engine are plugged. Remove the obstruction and thoroughly clean cooling fins and the air passages. The vent hole in the fuel cap is plugged. Clean or replace the fuel cap.
TROUBLESHOOTING Troubleshooting (Cont.) Problem Possible Cause The machine produces an uneven cutting height The blades do not rotate The clutch does not engage 4-4 Table of Contents Next Step... The blade(s) is/are not sharp. Sharpen the blade(s). The cutting blade(s) is/are bent. Install new cutting blade(s). The mower deck is not level. Level the mower deck from side-toside and front-to-rear. The underside of mower is dirty. Clean the underside of the mower.
CHASSIS Table of Contents Caster Tires Exploded View................................................................................................ 5-3 Caster Assembly and Bearing............................................................................................ 5-4 Removal........................................................................................................................... 5-4 Installation........................................................................................
CHASSIS Table of Contents Motion Control Assembly................................................................................................... 5-32 Removal.......................................................................................................................... 5-32 Installation.......................................................................................................................5-34 Adjusting the Motion Control Handle Position...........................................
CHASSIS Caster Tires Exploded View C Chassis A B Figure 1 A. Caster Fork B. Tire and Wheel Asm. C.
CHASSIS Caster Assembly and Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 3. Remove the caster cap. 4. Support the underside of the caster wheel and remove the screw securing the caster bearing assembly (C) (Figure 1). 5. Remove the caster fork (A) (Figure 1) from the front axle.
CHASSIS Caster Wheel Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 3. Remove the bolt and nut securing the caster wheel to the caster fork. 4. Lower the caster wheel away from the caster fork. 5. Remove the dust caps, felt washers, and wheel spanner. 6.
CHASSIS Left Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery cables and remove the battery from the tray. 3. Remove the three shoulder bolts (T30) VERIFY at location A, B & C (Figure 2). C B A Figure 2 4. Remove the fuel cap (D) and disconnect the keeper line (Figure 3). D Figure 3 5. Remove the left side control lever. 6.
CHASSIS Left Console (Cont.) Installation 1. Remove the fuel cap from the gas tank. 2. Lower the console into place, ensuring that it seats properly on the supports (Figure 4). Figure 4 Chassis 3. Install the left side control lever. 4. Install the keeper line into the fuel cap, and reinstall the fuel cap. 5. Install the three shoulder bolts (T30) VERIFY at location A, B & C (Figure 5). B C A Figure 5 6. Install the battery onto the battery tray and secure with the bungee strap. 7.
CHASSIS Right Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the three shoulder bolts (T30) at locations, A, B & C (Figure 6). C B A Figure 6 4. Remove the screws securing the control panel assembly to the console (Figure 7). D Figure 7 5. Remove the right side control lever.
CHASSIS Right Console (Cont.) Removal (Cont.) 6. Lift the console upward off of the machine, while feeding the control panel assembly through the opening in the console (Figure 8). NOTE: The control panel assembly should be supported while servicing the machine, to avoid damage to cables or wire harness.
CHASSIS Right Console (Cont.) Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Ensure that the console seats properly on the supports (Figure 9). Figure 9 NOTE: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly. 2. Secure the control panel assembly to the console. 3.
CHASSIS Seat - TIMECUTTER® HD ZX Models Only Removal C A B Figure 11 C. Seat Pan 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Disconnect the wire harness connector at the operator presence switch. 4. Remove the cotter pins from the stop rod on the left and right sides of the seat. 5.
CHASSIS Seat - TIMECUTTER® HD ZX Models Only (Cont.) Installation 1. Verify that the fuel tank hold down is seated properly in the front and rear of the frame and secured with the hold down bolt (Figure 12). Figure 12 2. Place the seat on top of the fuel tank and align the hole in one side of the frame with the hole in the seat plate. 3. Install the stop rod and secure with one cotter pin. 4.
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only Removal A B I J H G C F D Chassis E Figure 13 A. Seat Asm. B. Seat Pan C. Shock/Spring Asm. D. Floor mat E. Front Sub-frame F. Arm Swing Plate G. Rear Sub-frame H. Lower Mount Bracket I. Shock Mounting Bracket J. Shock/Spring Asm. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals.
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 6. Disconnect the fuel supply line at the fuel filter (Figure 14). Figure 14 7. Disconnect the vent line at the splice fitting (Figure 15).
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 8. Remove the bolt and nut securing the front shock/spring assembly to the MyRIDE™ platform (Figure 16). 9. Remove the self-tapping screw on the frame brackets on each side of the machine (A) (Figure 17). Release the vent hose keepers (B).
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 10. Remove the two bolts and nuts securing the frame brackets to the main frame on each side of the machine (Figure 18). Figure 18 11. Tilt the MyRIDE™ assembly one way. Unhook the fuel line keeper from under the seat (Figure 19).
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 12. Lift the entire MyRIDE™ assembly up and away from the main frame. Removing the MyRIDE™ assembly will take two or more people. NOTE: Do not remove either of the swing arm rods from the swing arm underneath the machine. This could cause damage or misalignment of the MyRIDE™ suspension platform (Figure 20).
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation 1. Verify that the fuel tank hold down is seated properly in the front and rear of the frame and secured with the hold down bolt (Figure 21). Figure 21 2. Lower the MyRIDE™ assembly onto the main frame, aligning the frame brackets on each side with the mating holes in the main frame. Reconnect the fuel line keeper under the seat. 3.
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation (Cont.) 4. Install the self-tapping screw on the frame bracket on each side of the machine (Figure 23). Figure 23 Chassis 5. Install the bolt and nut securing the front shock/spring assembly to the MyRIDE™ Platform (Figure 24).
CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation (Cont.) 6. Connect the fuel tank vent line at to the splice fitting. 7. Connect the fuel supply line to the fuel filter. 8. Connect the vent line keepers to the vent lines. 9. Connect the wire harness terminal to the operator presence switch. 10. Install the relay and fuse holder. 11.
CHASSIS Fuel Tank Removal C A B Figure 25 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. Chassis 2. Disconnect the battery terminals. 3. Remove the right and left side consoles, see “Left Console Removal,” chapter 5, page 5-6; see “Right Console Removal,” chapter 5, page 5-8. 4. Re-install the fuel cap. 5.
CHASSIS Fuel Tank (Cont.) Installation 1. Position the fuel tank assembly and rotate it onto the frame with the vent ports toward the rear of the machine. 2. Connect the vent line (C) (Figure 26) to the fuel tank. 3. Connect the fuel supply line (B) (Figure 26) to the fuel tank. 4. Install the fuel tank hold down rod and bolt (A) (Figure 26). C A B Figure 26 5.
CHASSIS Throttle Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the control panel assembly from the right console (Figure 27). Chassis Figure 27 4. Pry the keeper tab on the throttle control assembly and unsnap the control from the console. 5. Loosen the clamp securing the throttle cable to the throttle plate (Figure 28). Figure 28 6.
CHASSIS Throttle Control Assembly (Cont.) Installation 1. Route the throttle cable through the right console (Figure 29). Figure 29 2. Snap the throttle control assembly into place. 3. Install the control panel assembly into the console. 4. Move the throttle control lever to the full speed position (Figure 30).
CHASSIS Throttle Control Assembly (Cont.) Installation (Cont.) 5. Place the z bend of the throttle cable in the throttle plate on the engine in the position previously noted. 6. Place the cable under the cable clamp. 7. Ensure that the throttle control lever is in the fast idle position (Figure 31). Chassis NOTE: Pull on the cable and verify the engine is at full throttle, then tighten the clamp. Figure 31 8. Connect the battery terminals and verify proper function of the unit.
CHASSIS Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Loosen the clamp securing the choke cable to the choke plate on the engine (Figure 32). Figure 32 4. Remove the choke cable from the plate, noting the position of the cable in the plate. 5. Remove the control panel assembly from the right console. 6.
CHASSIS Choke Control Assembly (Cont.) Installation 1. Route the choke cable through the control panel assembly. 2. Thread the jam nut over the choke cable up to the control panel assembly (Figure 33). Figure 33 Chassis 3. Attach the choke cable assembly to the control panel with the jam nut. 4. Install the control panel assembly into the console. 5. Move the choke control lever to the open position (down) (Figure 34).
CHASSIS Choke Control Assembly (Cont.) Installation (Cont.) 6. Place the z bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp (Figure 35). Figure 35 9. Connect the battery terminals and verify proper function of the unit.
CHASSIS Park Brake Handle Assembly Removal C D E F G A B Figure 36 E. Wave Spring F. Brake Flanged Bushing G. Flange Nut 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery terminals. 3. Remove the left side console, see “Left Console Removal,” chapter 5, page 5-6. 4. Re-install the fuel cap. 5.
CHASSIS Park Brake Handle Assembly (Cont.) Installation 1. Assemble the bushings and wave spring over the bolt and through the park brake handle (Figure 37). C A E D B Park Brake Hardware Orientation Figure 37 A. Screw B. Washer C. Wave Washer D. Flange Pivot E. Flange Nut NOTE: Verify alignment before tightening, misalignment can damage the wave washer (Figure 38). C D E F G A B Figure 38 A. Cotter Pin B. Intermediate Brake Rod C. Torx Screw D. Flange Bushing 5-30 Table of Contents E.
CHASSIS Park Brake Handle Assembly (Cont.) Installation (Cont.) 2. With the park brake handle hardware oriented as shown, install the bolt through the brake detent (B) (Figure 39) and connect the flange nut. Torque to 200 ± 25 in-lbs. (23 ± 3 Nm). A B Figure 39 Chassis A. Torx Screw B. Brake Detent 3. Install the intermediate brake rod and secure with locking cotter pin. 4. Cycle the park brake lever to ensure that it locks in the engaged position. 5.
CHASSIS Motion Control Assembly Removal A C B Figure 40 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Raise and support the unit so that the drive wheels are off the ground. NOTE: The console must be removed for access, see “Left Console Removal,” chapter 5, page 5-6; see “Right Console Removal,” chapter 5, page 5-8. 3.
CHASSIS Motion Control Assembly (Cont.) Removal (Cont.) 6. Disconnect the motion control assembly from the frame (Figure 41).
CHASSIS Motion Control Assembly (Cont.) Installation 1. Position the motion control assembly in place with the linkage extending toward the transmission. 2. Secure the motion control assembly to the frame. 3. Connect the motion control linkage to the motion control assembly. 4. Connect the motion control damper to the motion control assembly. 5. Connect the motion control handle to the motion control assembly using the two bolts. 6.
CHASSIS Adjusting the Motion Control Handle Position NOTE: Ensure proper adjustment of neutral and tracking settings before adjusting the motion control handles, see “Hydrostatic Drive Transmission,” chapter 7, page 7-12 and/or see “Tracking Adjustment,” chapter 7, page 7-6. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Move the levers into the operating position. 3.
ENGINE Table of Contents Engine Mounting - Toro Twin Cylinder Engine Exploded View....................................... 6-2 Toro Twin Cylinder Engine.................................................................................................. 6-3 Removal............................................................................................................................6-3 Installation...............................................................................................................
ENGINE Engine Mounting - Toro Twin Cylinder Engine Exploded View A C D B Figure 1 A. Engine B. Muffler 6-2 Table of Contents C. Flat Washer D.
ENGINE Toro Twin Cylinder Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the engine guard. 4. Remove the muffler. 5. Remove the mower belt, see “Mower Belt Removal,” chapter 3, page 3-15. 6. Remove the hydrostatic drive belt, see “Hydrostatic Drive Belt Removal,” chapter 7, page 7-9. Engine 7.
ENGINE Toro Twin Cylinder Engine (Cont.) Removal (Cont.) 8. Disconnect the red wire from the starter (Figure 3). Figure 3 9. Disconnect the black engine ground wire (Figure 4).
ENGINE Toro Twin Cylinder Engine (Cont.) Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 5). Figure 5 Engine 11. Remove vent line at splice with Toro supplied hose (Figure 6). Figure 6 12. Disconnect the throttle cable, see “Throttle Control Assembly Removal,” chapter 5, page 5-23. 13. Disconnect the choke cable, see “Choke Control Assembly Removal,” chapter 5, page 5-26. 14. Remove the clutch mounting bolt and washer. Slide the clutch off of the crankshaft. 15.
ENGINE Toro Twin Cylinder Engine (Cont.) Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Lower the engine onto the frame. 3. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two flat washers loosely. NOTE: Apply Loctite 243 to engine mounting bolts. 4. Attach the front bolt through the clutch anchor and into the engine base (Figure 7). Figure 7 5. Install the three remaining engine bolts. 6.
ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 8. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 8). Figure 8 E. Washer F. Clutch Bolt G. Screw H. Flange Nut Engine A. Engine Pulley B. Clutch Stop C. PTO Clutch D. Clutch Isolator 9. Install the washer (E) and clutch bolt (F) (Figure 8). NOTE: Apply Loctite to the clutch bolt (F) (Figure 8). 10. Torque the clutch bolt to 50-60 ft-lbs. (69-83 Nm). 11.
ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 13. Connect the black engine ground wire (Figure 9). NOTE: Apply Loctite to ground bolt. Figure 9 14. Connect the red wire to the starter (Figure 10).
ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 15. Connect the chassis wire harness to the main engine wire harness (Figure 11). Figure 11 16. Connect the fuel supply line to the fuel pump. Engine 17. Connect the vent line to barb/splice (Figure 12).
ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 18. Install the hydrostatic drive belt, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 19. Install the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 20. Install the muffler and new exhaust gaskets. NOTE: Torque muffler mounting bolts or nuts to 150-170 in-lbs. (17-20 Nm). 20. Install the engine guard. 21. Fill crankcase with approved oil and verify proper oil level. 22. Connect the battery terminals. 23.
ENGINE Kawasaki Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the engine guard. 4. Remove the muffler. 5. Remove the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 6. Remove the hydrostatic drive belt, see “Hydrostatic Drive Belt Removal,” chapter 7, page 7-9. 7.
ENGINE Kawasaki Engine (Cont.) Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Lower the engine onto the frame. 3. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two flat washers loosely. NOTE: Apply Loctite to engine mounting bolts. 4. Attach the front bolt through the clutch anchor and into the engine base. 5. Install the remaining three engine bolts. 6. Torque the four engine mounting bolts to 300-400 in-lbs.
ENGINE Kawasaki Engine (Cont.) Installation (Cont.) 15. Connect the red wire to the starter (Figure 14). Figure 14 16. Connect the chassis wire harness to the main engine wire harness. 17. Connect the fuel supply line to the fuel pump. 18. Connect vent line to barb/splice. Engine 19. Install the hydrostatic drive belt, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 20. Install the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 21.
HYDROSTATIC DRIVE SYSTEM Table of Contents Hydrostatic Drive Exploded View....................................................................................... 7-2 Using the Drive Wheel Release Valves (Bypass Valves)..................................................7-3 Neutral Adjustment.............................................................................................................. 7-4 Tracking Adjustment........................................................................................
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded View H F G F E C D B A A K N L M Figure 1 A. Breather Tube B. RH Hydro Assembly C. RH Bypass Lever D. Idler Arm E. Idler Spring F. Pulley Idler G. Pulley Idler 7-2 Table of Contents J I H. Hydrostatic Drive Belt I. Rear Hydro Support J. Rear Guard K. LH Bypass Lever L. LH Hydro Assembly M. Wheel Lug Nuts N.
HYDROSTATIC DRIVE SYSTEM Using the Drive Wheel Release Valves (Bypass Valves) The drive wheel release valves are located on the left and right sides underneath the engine block. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Locate the bypass levers on the frame on both sides of the engine. 3. Move the bypass lever forward through the key hole and down to lock them in place (Figure 2).
HYDROSTATIC DRIVE SYSTEM Neutral adjustment 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the drive wheels are off the ground. 3. Unplug the seat switch on the bottom side of the seat and install a temporary jumper wire across the plug connector (wire harness side). 4. Start the engine and allow the machine to warm up for 3-5 minutes. 5.
HYDROSTATIC DRIVE SYSTEM Neutral adjustment (Cont.) 8. Turn the adjustment nut on the motion control rod clockwise or counterclockwise until the drive wheel is slightly rotating in reverse or not rotating at all. Repeat for both drive wheels if necessary (Figure 3). Figure 3 Drive NOTE: When the unit is in neutral, the stud should be roughly centered in the slot of the control plate (Figure 4). Figure 4 9. Stop the engine and lower the unit. 10. Verify proper neutral setting and tracking.
HYDROSTATIC DRIVE SYSTEM Tracking adjustment If the unit tracks or pulls to the RIGHT: Turn the LH adjustment nut 1 full turn CLOCKWISE. If more adjustment is needed, turn the adjustment nut 1 full turn at a time (Figure 5). If the unit tracks or pulls to the LEFT: Turn the RH adjustment nut 1 full turn CLOCKWISE. If more adjustment is needed, turn the adjustment nut 1 full turn at a time (Figure 5).
HYDROSTATIC DRIVE SYSTEM Hydro Change Procedure A B Figure 6 A. Top Port Plug B. Breather Hole 1. Remove the filter. 2. Drain the hydraulic oil. 3. Install a new filter. 4. Remove the top port plug (A) (Figure 6). 5. Remove the breather hose and fill vent located on the top of the hydro. Drive 6. Fill approximately 2 qts. of Toro HYPR-OIL® 500 or 20W-50 engine oil to the level of the top port plug hole. 7. Re-install the top port plug (A) (Figure 6). 8. Re-install the breather hose. 9.
HYDROSTATIC DRIVE SYSTEM Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance, any additional oil has been added to the system, or a replacement transaxle has been installed. Air creates inefficiency because its compression and expansion rate is higher than that of the oil in hydrostatic drive systems.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the drive wheels are off the ground. 3. Remove the mower belt from the clutch, see “Mower Belt Replacement,” chapter 3, page 3-15. 4. Using a spring removal tool (Toro Part No. 92-5771), remove the drive idler spring from the slot in the frame.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Removal (Cont.) 6. Remove the rear pulley (A) (Figure 8). 7. Remove the idler arm and pulley (B) (Figure 8). A B Figure 8 8. Remove the drive belt from the hydrostatic drive pulleys. NOTE: Inspect the belt for excessive wear, damage, or cracking, replace if necessary.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Installation 1. Route the hydrostatic drive belt around the two transmission pulleys. 2. Route the drive belt around the engine pulley. 4. Install the idler arm, and pulleys (A) (Figure 9). NOTE: Make sure that the belt is properly routed before installation. A Figure 9 5. Install the clutch stop. Drive 6. Verify proper routing of the belt.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Installation (Cont.) 4. Place the idler spring onto the idler arm loop and use a spring removal tool to secure the spring (A) into the slot on the right rear of the frame (Figure 10). A Figure 10 NOTE: Ensure proper orientation with hook openings facing away from the idler pivot. 5. Install the mower belt onto the clutch, see “Mower Belt Replacement,” chapter 3, page 3-15. 6. Lower the unit. 7. Connect the battery and check for proper operation.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Right side shown) NOTE: These steps are shown replacing the right side hydrostatic drive transmission. All of the same steps apply to the left side hydrostatic drive transmission. 1. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery cables. 3. Raise and support the unit so that the drive wheels are off the ground. 4. Remove the drive wheel(s). 5.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) 7. Disconnect the bypass arm (Figure 12). Figure 12 8. Disconnect the lower brake linkage from the transmission (Figure 13). Figure 13 9. Disconnect the connectors securing the overflow tube to the chassis.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) NOTE: Overflow tubes should stay connected to the top of the transmission. To avoid oil leaking, keep the overflow tubes oriented up (Figure 14).
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) 10. Remove the bolts securing the transmission to the hydro cross plate (A) (Figure 15). E D B D C A B A C E Figure 15 A. Front Inner Mounting Bolts to Frame Bracket B. Bottom Mounting Bolts to Cross Plate C. Front Mid Mounting Bolts to Frame Bracket D. Rear Mid Mounting Bolts to Cross-member Rear E. Outer Mounting Bolts to Frame Bracket 11. Loosen the outer frame mounting bolts. 12.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) NOTE: These steps are shown replacing the right side hydrostatic drive transmission. All of the same steps apply to the left side hydrostatic drive transmission (Figure 16). E D B D C A B A C E Figure 16 A. Front Inner Mounting Bolts to Frame Bracket B. Bottom Mounting Bolts to Cross Plate C. Front Mid Mounting Bolts to Frame Bracket D. Rear Mid Mounting Bolts to Cross-member Rear E.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 8. Remove the protective cap from the hydraulic oil nipple, install the overflow tube, and move the hose clamps into place (Figure 17). Figure 17 9. Connect the lower brake linkage to the transmission (Figure 18).
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 10. Connect the bypass arm (Figure 19). Figure 19 Drive 11. Connect the motion control linkage (Figure 20). Figure 20 12. Install the drive belt, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 13. Install the drive wheel and torque the lug nuts to 80 ± 10 ft-lbs. (110 ± 14 Nm).
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 14. Add hydraulic oil to the proper level using the vent plugs (Figure 21). Vent Plug Figure 21 15. Follow the purging procedure to remove all air from the system, see “Purging Procedure,” chapter 7, page 7-8. 16. Adjust the neutral setting if necessary, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 17. Lower the unit and verify proper function. 18.
MOWER DECK Table of Contents Mower Deck Exploded View................................................................................................8-2 Deck Lift Assembly Exploded View................................................................................... 8-3 Mower Belt Replacement.................................................................................................... 8-4 Mower Deck......................................................................................................
MOWER DECK Mower Deck Exploded View K L M I N J O P Q H A B G C D E F Figure 1 A. Mower Deck B. Cut Off Baffle C. Spindle Housing D. Spindle E. Blade F. Blade Bolt G. Anti-Scalp Roller H. Deflector Discharge I. Pulley (Spindle) 8-2 Table of Contents J. Bearing Shield K. Right Belt Cover L. Left Belt Cover M. Belt Guide, Idler N. Mower Belt O. Pulley (Idler) P. Idler Spring Q.
MOWER DECK Deck Lift Assembly Exploded View I A C J B E K H D F Deck G Figure 2 A. Height-of-Cut Transport Lock B. Height-of-Cut Plate C. Pivot Arm, Rear D. Pivot Arm, Front E. Height-of-Cut Pin F. Deck Lift Chain G. Deck Pivot Rod H. Deck Pivot Pan I. Deck Lift Assist Spring J. Height-of-Cut Link K.
MOWER DECK Mower Belt Replacement 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Lower the mower deck to the 3 in. (76 mm) height-of-cut position. 4. Remove the bolts from the covers and lift covers off the deck (Figure 3). Figure 3 5. Using a spring removal tool (Toro Part No. 92-5771) remove the spring tension from the idler pulley (Figure 4).
MOWER DECK Mower Belt Replacement (Cont.) 8. Route the new belt around the clutch pulley and deck pulleys (Figure 5). Figure 5 9. Install the idler spring using the spring removal tool. 10. Ensure that the belt is properly seated in all pulleys. 11. Install the belt covers (Figure 6). Deck NOTE: Torque the belt cover bolts to 50-75 in-lbs. (6-8 Nm). Figure 6 12. Tighten the bolts to secure the cover to the deck. 13. Connect the battery terminals and verify proper function of the unit.
MOWER DECK Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the height adjustment pin and lower the deck to the ground. 4. Remove the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 5. Remove the two hairpins and washers that secure the link pin to the frame and deck, then remove the link pin (Figure 7).
MOWER DECK Mower Deck Removal (Cont.) 6. Lift the mower deck to remove tension from the chains and unhook the chains from the deck lift arms (Figure 8). AB CD ABC D Figure 8 A. Deck-Lift Arm B. Chain C. Hook D. Adjustment Bolt 7. Raise the height-of-cut to the transport position. Deck 8. Slide the deck out from underneath the machine.
MOWER DECK Mower Deck (Cont.) Installation 1. Place the deck on the ground and slide it into position underneath the machine. 2. Lower the height of cut into the lowest position and secure with the height-of-cut pin. 3. Lift the rear of the mower deck and attach the chains to the rear lift arms (Figure 9). A BC AB C D D Figure 9 A. Deck-Lift Arm B. Chain C. Hook D. Adjustment Bolt 4. Attach the front chains to the front deck lift arms. 5. Install the link pin through the frame hanger and the deck.
MOWER DECK Mower Deck (Cont.) Installation (Cont.) 6. Install the mower belt onto the engine pulley first, then onto the mower deck, see “Mower Belt Replacement,” chapter 3, page 3-15. 7. Install the mower belt covers. Torque the belt cover bolts to 50-75 in-lbs. (6-8 Nm). 8. Raise the deck to the 3 in. (76 mm) height-of-cut position and check for deck level, see “Leveling the Mower Deck,” chapter 8, page 8-13. Deck 9. Connect the battery terminals and verify proper function of the unit.
MOWER DECK Mower Spindle Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the mower belt covers. 4. Remove the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 5. Remove the cutting blade. 6. Remove the six self tapping bolts that secure the spindle to the deck. 7. Pull the spindle assembly downward, through the deck. Installation 1.
MOWER DECK Mower Spindle (Cont.) Disassembly A B C E D F G H I Figure 11 A. Spindle Nut B. Pulley C. Bearing Shield D. Spindle Assembly E. Spindle Mounting Screws F. Spindle (Apply Anti-Seize) G. Blade H. Belleville Washer I. Blade Bolt 1. Clamp the spindle for service by placing the spindle shaft in a vise. Deck 2. Remove the nut and washer from the top of the pulley (B) (Figure 11). 3. Remove the pulley (B) (Figure 11). 4. Remove spindle housing from the shaft. 5.
MOWER DECK Mower Spindle (Cont.) Assembly 1. Inspect the inside of the spindle housing for wear or damage. 2. Press the top bearing (A) (Figure 12) into the spindle housing by pressing equally on the inner and outer race. NOTE: Ensure that the bearing seats against the shoulder in the spindle housing. A B C Figure 12 3. Flip the spindle housing over and install the bearing spacer (B) (Figure 12). 4.
MOWER DECK Leveling the Mower Deck 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery terminals. 3. Check to ensure that all tires are properly inflated and adjust as necessary. 4. Lock the mower deck in the transport position. 5. Rotate the blades so that they are parallel to the rear of the deck (Figure 13). C B C A B B C C C Figure 13 C.
MOWER DECK Leveling the Mower Deck (Cont.) 6. Measure between the outside cutting edges and the flat surface. If all measurements are not within 3/16 in. (5 mm), an adjustment is required. 7. Rotate the blades so that they are perpendicular to the rear of the deck (Figure 14). If the front blade tip is not 1.6 - 7.9 mm (1/16 - 5/16 in.) lower than the rear blade tip, continue with Leveling the Mower Deck. C A B C C A B C A B C C Figure 14 A. Blades Side-to-Side B.
MOWER DECK Leveling the Mower Deck (Cont.) 8. Set the anti-scalp rollers to the top position or remove completely for this procedure. 9. Set the height-of-cut lever to the 3 in. (76 mm) position. 10. Place two 6.6 mm (2-5/8 in.) thickness blocks under the front edge of the cutting deck skirt; one on each side of the cutting deck, but not under the anti-scalp roller brackets. 11. Place two 7.3 mm (2-7/8 in.
MOWER DECK Leveling the Mower Deck (Cont.) 12. Loosen the leveling adjustment bolts (Figure 16) on all four corners so that the deck is sitting squarely on all four blocks. A B C D A B C D Figure 16 A. Deck-Lift Arm B. Chain C. Hook D. Adjustment Bolt 13. Remove any slack from the deck hangers and make sure the deck lift foot lever is pushed back against the stop. 14. Tighten the four leveling adjustment bolts. 15.
MOWER DECK Electric PTO Clutch Removal A B C D E F Figure 17 A. Engine Pulley to Shaft (Apply Anti-Seize) B. Bolt, Clutch Stop Mount C. Clutch Stop D. Clutch Isolator E. Clutch PTO F. Clutch Mounting Bolt (Apply Loctite) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery terminals. 3. Raise and support the unit so that the drive wheels are off the ground. 4.
MOWER DECK Electric PTO Clutch (Cont.) Installation 1. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor and the rubber isolator is in place (Figure 18). A B C D E F Figure 18 A. Engine Pulley to Shaft (Apply Anti-Seize) B. Bolt, Clutch Stop Mount C. Clutch Stop D. Clutch Isolator E. Clutch PTO F. Clutch Mounting Bolt (Apply Loctite) NOTE: Apply anti-seize to the end of the pulley shaft. 2. Apply thread lock to the clutch bolt. 3.
MOWER DECK Electric PTO Clutch (Cont.) Installation (Cont.) NOTE: Ensure wire harness is properly routed to avoid contact with the mower belt (Figure 19). Figure 19 5. Connect the battery terminals. Deck 6. Lower the unit and verify proper function.
ELECTRICAL Table of Contents Electrical System Exploded View.......................................................................................9-2 General Information............................................................................................................ 9-3 Fuse Block and Fuses.........................................................................................................9-4 Testing.............................................................................................
ELECTRICAL Electrical System Exploded View A B L E C D N K H P O F G P J M H I Figure 1 A. Ignition Key B. Ignition Switch C. PTO Switch D. Hourmeter E. 12V Power Port F. Wire Harness G. Solenoid H. Neutral Switches 9-2 Table of Contents I. Park Brake Switch J. Clutch Connector K. Fuse Block L. Battery M. Engine Connector N. Kill Relay O. Engine Ground P.
ELECTRICAL General Information 1. Always use a digital multi-meter for electrical testing procedures and record voltage reading results. 2. Before performing any electrical troubleshooting, always: -Verify proper battery voltage (above 12.4 volts) : Batteries reading 12.4 volts or less are considered discharged -Check that all engine and chassis ground wires are securely connected and not damaged. 3. Use of test lights and continuity testers may result in false readings and lead to an incorrect diagnosis.
ELECTRICAL Fuse Block and Fuses Figure 2 The fuse block houses the fuses that protect the electrical system from electrical surges. The other fuse next to the relay is seen in Figure 20, page 9-19. NOTE: Always use Toro fuses when replacing a damaged or blown fuse. Testing 1. Visual Inspection: The fuses used in this application may be visually inspected. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade (Figure 3). Bad Good Figure 3 2.
ELECTRICAL Key/Ignition Switch Figure 4 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. The START position is spring loaded so that it automatically returns to the RUN position when released.
ELECTRICAL Key/Ignition Switch (Cont.) Testing 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. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position. 4.
ELECTRICAL Hourmeter Figure 6 The hourmeter records hours of operation when the ignition key is ON and the PTO switch is ON. Electrical Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the hourmeter.
ELECTRICAL Operator Presence Switch (Seat Switch) Seat Switch Figure 7 With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the left hand neutral switches. NOTE: The operator presence switch is part of the seat assembly. Testing 1. Disconnect the wire harness from the Operator Presence Switch, located on the bottom of the seat assembly. 2.
ELECTRICAL Neutral Switch - Left and Right Figure 8 The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion Control Levers in neutral position (OUT), the switch should have continuity (closed). Electrical Motion Control Levers in the operating position (IN), the switch should NOT have continuity (open).
ELECTRICAL Parking Brake Switch Figure 9 Figure 10 The parking brake switch is a dual pole/four terminal plunger type switch (normally open and normally closed). When the parking brake is set (engaged), the normally closed pole of the switch is open and the normally open pole is closed. This allows proper voltage and ground signal path for the safety interlock and PTO operations. Parking Brake ON, the switch should have continuity (closed). Parking Brake OFF, the switch should NOT have continuity (open).
ELECTRICAL Starter Solenoid Figure 11 The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. Testing 1. Disconnect the solenoid from the wiring harness. 2. With a multi-meter set to the OHM or Continuity setting, check to ensure that terminals C and D are open (no continuity) (Figure 12). Electrical 3.
ELECTRICAL PTO Switch Figure 13 The PTO switch provides battery voltage from the ignition switch to the PTO clutch. As part of the safety interlock system, the PTO switch will prevent the engine from cranking/starting when in the ON position by preventing the starter solenoid from grounding through the kill relay. NOTE: The engine will not crank over when the PTO switch is in the ON position.
ELECTRICAL PTO Switch (Cont.) 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). 1 2 3 5 4 9 87 Figure 14 4.
ELECTRICAL Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: -field -clutch plate -friction plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied. The friction plate is the only piece that moves vertically on the crankshaft.
ELECTRICAL Electric PTO Clutch (Cont.) Coil Resistance Measurement Figure 15 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure resistance (OHMs setting). 4. Connect the meter lead wires to the terminals in the clutch connector. 5. See the PTO Clutch Electrical Specifications chart. AMP Draw Continuity to Ground 3.
ELECTRICAL Electric PTO Clutch (Cont.) PTO Clutch Continuity to Ground Check 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure resistance (OHM setting). 4. Connect one multi-meter lead to the engine, chassis or battery ground. Connect the other multi-meter lead to each of the clutch connector terminals. 5.
ELECTRICAL Electric PTO Clutch (Cont.) Measuring Clutch Current Draw NOTE: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. A B C D Figure 17 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure amps (10 amp scale). 4.
ELECTRICAL TVS Diode Figure 18 The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement. Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode. If the system fuse blows each time the clutch is engaged, the TVS diode is more than likely shorting clutch power to ground.
ELECTRICAL Kill Relay Figure 19 The Kill Relay grounds the magneto when the key is turned to the OFF position. When the key is turned to the RUN position, the solenoid is grounded and the magneto is no longer grounded. The Kill Relay prevents starting in an unsafe position.
Brown L01 A B 126-2601 PTO CLUTCH ACCESSARY CONNECTOR P06 P06 9 A NC 8 B NC 5 B NO 7 C NC Black Violet 4 5 Violet 3 P12 2 1 99-7408 PARK BRAKE SW SW03 P12 - 2 P20 Pink Pink Gray 2 SP03 Yellow 1 2 110-6765 RH NEUTRAL SW SW05 P01 P01 1 110-6765 LH NEUTRAL SW SW04 P09 P09 Tan 1 + P20 COM 3 COM 2 126-6499 POWER PORT PT01 P07 COM 1 DOWN UP 103-5221 PTO SWITCH SW02 4 C NO P07 Orange Black Yellow Yellow Green 2 85 1 30 P03 98-7249 KILL RELAY K01 Violet HR 86 5
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