44947 cover 12/9/04 11:08 AM Page 1 LCE Products Mid-Size Walk Behind Service Manual 492-9141
44947 cover 12/9/04 11:08 AM Page 2 ABOUT THIS MANUAL This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct. For service information specific to the engines used on these products, refer to the appropriate engine manufacturer’s service and repair instructions.
TABLE OF CONTENTS Safety Information General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Specifications & Maintenance Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Chassis (cont’d) Drum Brake / Pulley Assembly Removal (Gear Drive) . . . . . . . . . . . . . . . . . . . . . Parking Brake Linkage (Pistol Grip Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric (PTO) Clutch (Floating Deck Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Drive Belt (Gear Drive - Floating Deck) . . . . . . .
TABLE OF CONTENTS Mower Decks Setting Up the Frame (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Checking the Deck Level Side-to-Side (Floating Deck) . . . . . . . . . . . . . . . . . . . . . .7 - 2 Checking the Deck Front-to-Rear Blade Slope (Floating Deck) . . . . . . . . . . . . . . . .7 - 3 Adjusting the Deck Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3 Adjusting the Side-to-Side Level (Fixed Deck) . . . . . . . . .
TABLE OF CONTENTS Electrical (cont’d) Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch (65-7410 & 1-513051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch (95-1653) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Switch (82-2190) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INFORMATION General Information 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 MidSize Walk Behind mower.
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SPECIFICATIONS Torque Specifications Fastener Identification 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 to all fasteners which do not have a specific requirement identified in the service manual.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m M10 X 1.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 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.
SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.
SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
Engine Make Kawasaki Kawasaki Kohler Kawasaki Briggs & Stratton Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kohler Briggs & Stratton Kohler Kohler Kohler Briggs & Stratton Briggs & Stratton Kohler Kawasaki Kohler Kawasaki Kawasaki Kohler Kawasaki Kohler Kohler Kohler Kohler Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kohler Kohler Model 30140 30150 30159 30161 30164 30167 30168 30169 30171 30177 30178 30182 30183 30184 30187 30188 30189 30192 30193 30194 30195 30196 30197 30250 30252 30253 30254 30255 3025
Engine Make Kawasaki Kawasaki Kohler Kohler Kohler Kohler Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kawasaki Kawasaki Kawasaki Kohler Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kawasaki Kawasaki Kohler Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Kawasaki Model 30297 30314 30316 30317 30318 30319 30320 30321 30322 30326 30327 30329 30332 30333 30334 30335 30338 30339 30340 30341 30342 30430 30431 30432 30433 30434 30435 30436 30437 30438 304
Engine Make Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kohler Kohler Kohler Kawasaki Kawasaki Kawasaki Kawasaki Kohler Kawasaki Model 30521 30523 30524 30526 30527 30528 30529 30530 30531 30172TE 30250TE 30261TE 30291TE 30299TE Horse Oil Capacity w/ Power Filter Change 12.5 48 oz. (1.4 l) 15 58 oz. (1.7 l) 15 58 oz. (1.7 l) 15 58 oz. (1.7 l) 15 64 oz. (1.9 l) 15 64 oz. (1.9 l) 15 64 oz. (1.9 l) 15 64 oz. (1.9 l) 15 58 oz. (1.7 l) 12.5 54 oz. (1.6 l) 12.5 54 oz. (1.6 l) 12.5 54 oz. (1.6 l) 15 64 oz. (1.
2 - 10 2004 2004 1997-2000 2004 2000-2002 1996-2002 2000 2000, 2002 & 2004 2000-2003 30140 30150 30159 30161 30164 30167 30168 30169 1996-1999 1996-1999 1998-2000 30182 30183 30184 1997-2000 & 02 & 04 1997 & 2000 1997-1998 1997-1998 & 02 1997-2000 1998-2002 2003 30188 30189 30192 30193 30194 30195 30187 30178 1996-2002 & 2004 2003-2004 30177 30171 Years Model 35.0" 46" 46" 33.0" 33.0” 33.0” 33.0” 35.0" 35.0" 35.0" 35.0" 35.0" 42" 35.0" 35.0" 35.0" 42" 30.0" 35.
Years 1998-2002 1998-2004 2001 2001-2002 2001 2001 2001 2001 2001 2001 2001 2001 2001 2001 2004 2003-2004 2003-2004 2003-2004 2003-2004 2003 Model 30196 30197 30250 30252 30253 30254 30255 30257 Mid-Size Walk Behind Service Manual 30258 30259 30260 30290 30291 30292 30314 30316 30317 30318 30319 30320 58.7" 66.6" 58.7" 48.3" (122.7 cm) 32.0" 48.3" 64" 56" 48" 64" 56" 66.5" 56" 64" 56" 32" 48" 48" 64" 64" Width 45.5" 45.5" 45.5" 45.5" (115.6 cm) 43.
2 - 12 2001 2001 30340 30341 2003-2004 2001 30339 30434 2001 30338 2003-2004 2001 30335 30433 2001 30334 2003-2004 2001 30333 30432 2001 30332 2003-2004 2001 30329 30431 2004 30327 2003-2004 2004 30326 30430 2003-2004 30322 2004 2003-2004 30321 30342 Years Model 58.7" 48.3 66.6" 58.7" 48.3 66.6 64" 56" 64" 56" 48" 64" 64" 56" 48" 58.7" 58.7" 66.6" 58.7" Width 44.2" 44.2 44.2" 44.2" 44.2 45.5 44" 44" 44" 44" 44" 44" 44" 44" 44" 45.
Years 2003-2004 2003 2004 2004 2004 2004 2004 2004 2004 2002-2003 2002-2003 2002-2004 2002-2004 2002-2003 2003-2004 2003-2004 2003-2004 2003-2004 2004 Model 30435 30436 30437 30438 30439 30440 30441 30518 Mid-Size Walk Behind Service Manual 30519 30520 30521 30523 30524 30526 30527 30528 30529 30530 30531 35.0" 35.0" 35.6" 58.2" 46.1" 58.2" 46.1 35.0" 35.6" 32.0" 35.6" 32.0" 66.6 58.7 58.7 66.6 58.7 66.6" 58.7" Width 41" 41" 41" 43.2" 43.
Years 2001 2001 2003-2004 2001 2003-2004 Model 30172TE 2 - 14 30250TE 30261TE 30291TE 30528 58.2" 58.73 48.3 48.31 48.31 Width 43.2" 44.1 45.5 44.1 44.1 Height 73" 79.92 80.5 83.55 83.55 Length 250 (113 KG) 469 (213 KG) 469 (213 KG) 560 (254 KG) 483 Weight (lbs.) Tire Dimensions Front Rear 11"x4.00-5" 16x6.50" – 8 (40.6x16.5 – 20.3 mm) 11"x4.00-5" 16x6.50" – 8 (40.6x16.5 – 20.3 mm) 9x3.5-4 (23x916x6.50" – 8 10cm) (40.6x16.5 – 20.3 mm 11"x4.00-5" 16x7.50" – 8 (40.6x19.4 – 20.
Mid-Size Walk Behind Service Manual Classic T-Bar / Hydro Drive / Traction Unit Only 30187 30188 30189 30191 30192 *30299TE T-Bar / Gear Drive / Fixed Deck 30140 30150 30161 30164 30171 30178 30184 30193 30194 30195 30196 30197 Model ID T-Bar / Gear Drive / Floating Deck 30250 30251 30253 30254 30255 30257 30258 30259 30260 30317 30318 30319 30320 30321 30322 30326 30327 30342 30172TE 30250TE 30261TE 30314TE Pistol Grip / Gear Drive / Fixed Deck 30518 30519 30520 30521 30523 30529 30530 30531 Pistol G
MAINTENANCE Maintenance Schedule, Floating Deck Models Maintenance Service Interval Maintenance Procedure Each Use • Engine Oil—check level • Safety System—check • Brake—check • Engine—clean outside 8 Hours • Mower Housing—clean • Engine Oil—change • Cutting Blades—check • Mower Housing—clean 25 Hours • Caster Wheels—grease • Foam Air Cleaner—clean1 40 Hours • Paper Air Cleaner—check, replace if dirty • Deck Belt Idler Arm—grease • Deck Belt Idler Arm—grease • Tires—check pressure 50 Hours 100 Hou
MAINTENANCE Maintenance Schedule, Fixed Deck Models Service Operation Oil—check level Each Use 8 Hours 25 Hours 50 Hours 100 Hours 200 Hours X Oil—change* Storage Service X Initial X Oil Filter—change (200 hours or every other oil change) X X X Safety System—check X X Brakes—check X X Cutting Blades — check Wheel Bearings—grease* X X X X Transmission Couplers — grease* Idler Pivots — grease* X X X X X Belt Blade Idler Pivots — grease* X Foam Air Cleaner—service* X X X P
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ENGINE Engine Removal 6. 1. Turn the fuel valve to the “off” position. 2. Drain the engine oil into a suitable container. 3. Remove the fuel line by sliding clamp down and remove the line from fuel pump (Figure 3). Drain fuel in line into a suitable container. Cut the tie wrap and disconnect the mag wire (red from black) bullet connector (Figure 5). Figure 5 Figure 3 4. mvc-048 Remove bolt that clamps the fuel line to engine block (Figure 4). 0602-12 7.
ENGINE 11. Separate the electric clutch connector and push the connector and grommet through the frame (Figure 7). 15. If the unit is up, no need to remove the deck covers. 16. Remove deck drive belt from deck idler and drive pulley (Figure 9). Figure 7 0819-30 12. Remove the air cleaner cover. Figure 9 13. Then remove the clamps holding the throttle and choke cables to the engine (Figure 8). Mark the cable housings for the clamp locations to assist in reassembly. Remove the throttle and choke cables.
ENGINE 18. Remove PTO clutch arm from housing (Figure 11). Figure 11 20. On gear drive models, remove the V belt from the transmission sheave (Figure 13). 0820-05 Figure 13 mvc-417 Figure 14 mvc-418 19. Sometimes it is necessary to remove the PTO clutch brake pulley to have better access for removing the clutch bolt (Figure 12 and Figure 14).
ENGINE 21. Remove pulley cover (Figure 15). Figure 17 Figure 15 22. Unbolt clutch bolt, remove clutch and engine pulley (Figure 16 and Figure 17). 23. Remove the nuts and bolts that mount engine to chassis (Figure 18). Figure 18 Figure 16 mvc-424 mvc-419 mvc-423 mvc-421 Reverse order for reassembly - Torque clutch bolt to 55 to 60 ft. lbs. (75 to 81 N-m).
ENGINE On Fixed Deck Models: 1. 3. Remove tension from the hydraulic pump belt by using the cold start assist ring (Figure 21). Engage the PTO and block the mower blades to prevent the crankshaft from turning (Figure 19). Figure 21 Figure 19 2. 0602-11 0602-09 4. Disengage the PTO. Finish removing the pulley bolt along with the 4 washers. 5. Slide the PTO pulley, 2 spacers, and the pump drive pulley from the crankshaft, taking care not to lose the 2 keys which locate the pulleys on the crankshaft.
ENGINE Engine Assembly, Typical Ref. No. 1 *2 3 4 5 6 7 8 9 10 11 12 13 14 15 Qty. 1 1 1 1 1 1 1 1 4 2 1 1 1 4 2 Description Filter - Fuel Engine - Kawasaki, Fh500v-As29 Clamp - Cable Decal - Warning, Hot Surfaces Clip - Closed, Insulated Adapter Valve - Drain, Oil Harness - Wire Nut - Lock, NI Nut - HF Washer - Lock Grommet Tube - Retainer Washer Grommet - Brake Ref. No. 16 17 18 19 20 22 23 24 25 26 27 28 29 99 Qt.
CHASSIS Model and Serial Number Location Greasing and Lubrication The model and serial number plate is located on the traction unit. (Figure 23 and Figure 24). Service Interval/Specification Refer to the Check Service Reference Aid decal for location and interval of greasing and lubrication (Figure 25). Grease with No. 2 general purpose lithium base or molybdenum base grease. How to Grease Figure 23 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off.
CHASSIS 2. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Figure 26). Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels. Figure 26 Greasing the PTO Drive Belt Idler and Deck Belt Idler 1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Grease the idler pulley pivots (Figure 28). 3. Note: You’ll have to remove the carrier covers to access the grease fitting for the deck.
CHASSIS Brake Service 4. Position wing nut so the brakes will engage when the drive levers are squeezed enough to place neutral/brake lock forward and set the brake. 5. Check the brake operation again; refer to ”Pistol Grip - Gear Drive - Fixed Deck" on page 4 - 3. Service Interval/Specification Before each use, check brakes for proper operation. Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.
CHASSIS 5. Release the brake and move the neutral/brake lock to the neutral position. Move the machine lightly, approximately 1/2 in. (13mm). Wheels should rotate freely. 6. If both conditions are met, no adjustment is required. 10. Check the brake operation again refer to ”Checking the Brake" on page 4 - 3. Adjusting the Brakes The brake lever is on the upper control bar (Figure 31). If the parking brake does not hold securely, an adjustment is required.
CHASSIS Pistol Grip - Hydro - Fixed Deck 6. Check the brake operation again; refer to ”Checking the Parking Brake" on page 4 - 5. Checking the Parking Brake 1. Move the machine onto a level surface. 2. Disengage the power take off (PTO) and stop the engine. 3. Set the parking brake. Note: Setting the parking brake should take a reasonable amount of force. If it engages too hard or too easily, adjustment is required. Refer to ”Adjusting the Parking Brake" on page 4 - 5.
CHASSIS Adjusting the Brake 8. Check the brake operation again, refer to ”Checking the Brake" on page 4 - 5. The brake handle is on the left side of the machine (Figure 33). If the parking brake does not hold securely, and adjustment is required. 1. Check the brake before you adjust it; refer to ”Checking the Brake" on page 4 - 5. 2. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4. 3. Loosen the top and bottom jam nuts (Figure 33). 4.
CHASSIS 4. Adjusting the Brake The brake lever is on the upper control bar (Figure 34). If the parking brake does not hold securely, an adjustment is required. Check the brake operation again; refer to ”Checking the Brake" on page 4 - 6. Important With the parking brake released, the rear wheels must rotate freely when you push the mower. If the brake action and free wheel cannot be achieved, examine the brake system components for wear or damage.
CHASSIS Adjusting the Brake 8. Install the trunnion into hole F (Figure 37). Tighten the wing nut. The brake lever is on the upper control bar (Figure 36). If the parking brake does not hold securely, adjustment is required. 9. Secure trunnion to brake lever with washer and hair pin cotter (Figure 37). Note: For the initial adjustment, adjust the wing nut until it is 1-1/4 inches (32mm) from the top of the rod (Figure 37). 10.
CHASSIS 5. Remove the drive belt from the pulleys. 8. Inspect the brake drum. Replace it if is severely scored. 6. Remove the dust cover, cotter pin, nut, and washer from the axle (Figure 38). 9. Remove the hairpin cotter and disconnect the brake rod from the brake arm (Figure 40). Figure 38 0819-03 Figure 40 7. Slide the hub with the pulleys and brake drum off the axle (Figure 39). Figure 39 10. Pry off the push nut securing the brake arm to the pivot (Figure 41).
CHASSIS 11. Remove the 3 push nuts securing the brake band to the brake link (Figure 42). Note: Use all new push nuts when reassembling the brakes. Figure 42 0819-06 Installation Follow the removal procedures in reverse and check the brakes, ”Checking the Brake" on page 4 - 7. Important Lubricate the brake link pivot pins and brake arm pivot with anti-seize compound during assembly.
CHASSIS Wheel Drive and Brake Assembly Ref 1 2 3 4 6 7 8 9 10 12 13 14 15 16 16:1 16:2 16:3 17 18 19 19:2 19:3 19:4 20 Qty.
CHASSIS Drum Brake / Pulley Assembly Removal (Gear Drive) 1. Raise the rear of machine so wheels are off the ground and support with jack stands. Figure 45 5. Figure 43 2. mvc-003 Remove the dust cap. mvc-899 Remove the 4 wheel lug nuts from wheel hub. Figure 46 Figure 44 mvc-900 3. Remove the rear wheel and tire from the wheel hub. 4. Remove belt from drum/pulley assembly.
CHASSIS 6. Remove cotter pin securing axle nut and discard cotter pin. Figure 47 7. Mid-Size Walk Behind Service Manual 9. mvc-904 Remove the retaining ring holding the brake lever to chassis and discard. Figure 49 mvc-902 Remove the axle nut. Figure 48 8. mvc-013 Remove hair pin holding brake rod to brake lever.
CHASSIS 12. Slide brake band from drum and inspect for wear or damage. Replace if needed. 10. Disconnect brake rod from brake lever. Figure 51 mvc-002 Figure 53 11. Remove hub, drum/pulley assembly with the brake band assembly from axle. Figure 52 13. While using a 1/2" socket with extension to hold the bolt, use a 1/2" wrench and loosen lock nut and remove.
CHASSIS 15. Inspect axle shaft, bearings and bearing races for wear, damage or dirt (Figure 57). Figure 55 nvc-007 Figure 57 14. Separate drum/pulley assembly from wheel hub (Figure 56). mvc-010 16. Reassemble brake drum/pulley assembly onto hub - torque nuts to 200 in. lbs. (22.6 N-m). 17. If you have the split pulley assembly - fasten the 2 split pulleys to the brake drum and fasten to wheel hub. Figure 56 mvc-008 Figure 58 mvc-012 Note: Reassemble in reverse order. 18.
CHASSIS Parking Brake Linkage (Pistol Grip Hydro) 4. Remove the bellcrank assembly. 5. Remove the hairpin clip from the upper linkage rod and remove the rod from the bellcrank (Figure 61). Removal 1. Remove the hairpin cotter retaining the lower link to the brake shaft (Figure 59). Figure 61 6. Figure 59 2. 0602-36 Remove the 2 bolts securing the bellcrank to the rear frame (Figure 62). To remove the idler spring, remove the nut and bolt assembly from the brake mounting flange end of the spring.
CHASSIS 7. To remove the parking brake lever assembly, remove the pivot bolt and bushing from the lever bracket (Figure 63). Figure 63 0602-37 Installation Follow the removal procedures in reverse.
CHASSIS Linkage Assembly (Pistol Grip Hydro) Ref. No. 1 2 3 4 5 6 6:2 7 8 9 10 11 12 13 4 - 18 Qty. 1 2 1 1 1 1 2 1 2 1 2 1 5 3 Description Switch - Open, Normally Nut - SQH Nut - Lock, NI Lever - Park Brake Grip - Lever Bracket ASM Sleeve - Bushing Bushing - Pivot Washer - Flat Screw - HH Screw Linkage - Upper Nut - HHF Pin - Hair Ref. No. 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Qty.
CHASSIS Fuel Tank Service Fuel Tank Removal 1. Place shutoff valve in the “off” position. 2. Disconnect the fuel line at the filter (Figure 64). Draining The Fuel Tank DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
CHASSIS Electric (PTO) Clutch (Floating Deck Models) Removal 1. Stop the engine, remove the key, and disconnect the spark plug wires. 2. Raise the rear of the unit and place on safety stands. 3. Remove the deck covers. 4. Using a large channel lock pliers, move the idler pulley against spring tension until the PTO drive belt can be slipped off the idler pulley (Figure 66). 11. Lift the engine and insert 3/4” (19mm) wooden blocks between the engine and frame (Figure 67).
CHASSIS Replacing the Drive Belt (Gear Drive - Floating Deck) Replacing the Drive Belt (Fixed Deck Pistol Grip) Service Interval/Specification Service Interval/Specification Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating. Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks, and signs of overheating. 1.
CHASSIS Replacing the Traction Belt (Floating Deck) 1. Raise the front of the machine and support with jack stands. 2. Disconnect clutch wire connector from wire harness (Figure 71). 3. Remove PTO drive belt. Refer to ”Replacing the Drive Belt (Gear Drive - Floating Deck)" on page 4 - 21. 4. Remove clutch retainer from the engine deck (Figure 71). 5. Unhook tension spring from side of frame (Figure 71). 6.
CHASSIS 4. Adjusting Grass/Mud Scraper Remove the mower belt (Figure 72). 1. Loosen the locknut holding scraper to the engine frame (Figure 73). 2. Rotate scraper until aligned with center of pulley grooves (Figure 73). 3. Tighten the locknut (Figure 73). Note: The scraper must not contact the pulley on the sides or bottom of grooves. Re-adjust if necessary. Figure 72 (1) Idler pulley in slot (2) Traction belt (3) Mower belt m-4726 (4) Belt guide (5) 1-1/4 in. (32mm) (6) Mower belt 5.
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HYDRAULIC DRIVE SYSTEMS Hydraulic Drive System Overview The hydrostatic drive system consists of two bidirectional high-pressure loops, one for each drive wheel. Each loop is made up of a pump, motor, and the high-pressure hoses connecting them together. Both high-pressure loops share a common low-pressure supply system. The components of the low-pressure supply system are the reservoir, filter, and lowpressure hoses. The pump is driven by an internal combustion engine through a belt and pulley system.
HYDRAULIC DRIVE SYSTEMS Hydraulic Drive System Assembly Ref. No. 1 2 2:1 3 4 5 6 6:1 7 7:1 7:2 10 11 11:1 11:2 12 12:1 13 13:1 14 5-2 Qty. 4 2 1 4 2 2 2 1 4 1 1 2 1 1 1 1 1 1 1 4 Description Nut - HHF Fitting - 90° “O” Ring Hose - Pressure, High Screw Pump Fitting “O” Ring Fitting - Straight “O” Ring “O” Ring Screw - HH Reservoir - HYD Cap - Reservoir, HYD Gasket - Cap Adapter - Straight “O” Ring Elbow - 45° “O” Ring Clamp - Hose Ref. No.
HYDRAULIC DRIVE SYSTEMS Servicing the Hydraulic System Replacing the Hydraulic Filter 7. Install replacement hydraulic filter onto the filter adapter. Do not tighten. 8. Remove plastic bag from reservoir opening and allow filter to fill with hydro fluid. 9. When fluid overflows filter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter. Then tighten the filter an additional 1/2 turn (Figure 74). Change the hydraulic filter: • After the first 8 operating hours.
HYDRAULIC DRIVE SYSTEMS 2. Clean area around filler neck of hydraulic tank (Figure 75). WARNING 3. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir. (Figure 75). Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 4. If there is no fluid, add fluid to reservoir approximately a 1/4 in. (6mm) below the top of baffle. • 5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid. • 6.
HYDRAULIC DRIVE SYSTEMS Bleeding Hydraulic System (Fixed Deck Models) The traction system is self-bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. Air must be purged from the hydraulic system when any hydraulic components, including oil filter, are removed or any of the hydraulic lines are disconnected.
HYDRAULIC DRIVE SYSTEMS 5. Thoroughly clean the area around each of the charge pump housings. 6. To “prime” charge pump, loosen two hex socket head capscrews (Figure 76) 1-1/2 turns only. Make sure engine is not running. Lift charge pump housing upward and wait for a steady flow of oil to flow out from under housing. Retighten capscrews. Do this for both pumps. 5. Quickly push the upper control bar against the reference bar. The front caster wheels should almost lift off the ground.
HYDRAULIC DRIVE SYSTEMS 6. If the machine is too aggressive or tends to jump forward, the valve needs to be opened further. 7. If the machine is slow to respond, the valve needs to be closed further. 8. Repeat “Test Procedure” to check for proper operation. Re-adjust the by-pass valves until proper performance is achieved. Figure 77 (1) By-pass valve 3. Move control bar rearward and forward then release. If wheels rotate when control bar is in neutral, adjustment is required. 4.
HYDRAULIC DRIVE SYSTEMS 3. Select high, medium or low position for the lower mounting hole (Figure 79). This allows the upper handle to be adjusted to the user’s height preference. 4. Secure each lower mounting hole with a flange bolt (3/8 x 1 in. (26mm) and flange nut (Figure 79). Torque bolts to 25 ft. lbs. (34 N-m). 3. Press and hold upper control bars against reference bar, so stop hits (Figure 80).
HYDRAULIC DRIVE SYSTEMS 6. Connect rod to upper control bars with previously removed hairpin cotter (Figure 80). Figure 81 6. Connect rod to upper control bars with previously removed hairpin cotter, tighten wing nut and turnbuckle (Figure 80).
HYDRAULIC DRIVE SYSTEMS Hydro Linkage Adjustments (Pistol Grip Floating Deck) 5. Pull the speed control lever back to neutral. 6. Check to make sure the safety switch is depressed and there is a 5/16 in. (8mm) space between the actuating tab and the switch. (Figure 84). 7. If needed, adjust switch location to create the 5/16 in. (8mm) space (Figure 84). Perform the following linkage adjustments when the machine needs maintenance. If adjustment is needed, do them in the order that they are listed.
HYDRAULIC DRIVE SYSTEMS Neutral Control Linkage Adjustment (Pistol Grip Floating Deck) WARNING Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. Figure 86 0610-01 WARNING Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine.
HYDRAULIC DRIVE SYSTEMS 4. Hold OPC levers down. 12. Repeat this procedure for the opposite side. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. WARNING Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place. • Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.
HYDRAULIC DRIVE SYSTEMS 2. Place the speed control lever in the neutral position. 3. Place the left drive lever in the full forward position. 4. Hold OPC levers down. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 7. Turn the rear adjusting nut clockwise 1/4 of a turn at a time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Figure 89). 8.
HYDRAULIC DRIVE SYSTEMS 3. Hold OPC levers down. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. Control Rod Adjustment (Pistol Grip Floating Deck) Checking Control Rod 4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Figure 91). 1. 5. Turn the knob clockwise 1/4 of a turn at a time. Then move the speed control forward and back to neutral.
HYDRAULIC DRIVE SYSTEMS 6. A D 4. Repeat this adjustment for opposite side. B If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Figure 93). C E F Figure 92 (A) Handle (B) Neutral lock (C) Neutral position 0610-14 (D) Drive lever (E) Full speed forward (F) Control rod Tracking Adjustment 1. Remove machine from any jack stands. 2. Adjust rear and front tire pressure to specification.
HYDRAULIC DRIVE SYSTEMS 4. Remove the hairpin cotter at each end of the upper control link (Figure 94). 6. Remove the 2 Allen head shoulder bolts from the ends of the bellcrank (Figure 96), and remove the bellcrank. A Figure 94 0618-02 Figure 96 5. To remove the speed control bellcrank, remove the hairpin cotters securing the hydro control link and tracking adjustment link to the bellcrank (Figure 95). Figure 95 5 - 16 0602-32 7.
HYDRAULIC DRIVE SYSTEMS 8. Remove the return spring from the upper bracket (Figure 98). Figure 98 10. Carefully pull the shield with the control shaft bearing, spacers, and through bolts from the frame (Figure 100). 0610-16 Figure 100 9. Remove the nuts from the 4 bolts securing the shield from the frame (Figure 99). 0602-22 11. Remove the hydro control shaft. 12. Remove the pin from the clevis on the neutral control link (Figure 101).
HYDRAULIC DRIVE SYSTEMS 13. Remove the “E” clip from the pivot on the pump control bellcrank (Figure 102). Figure 102 15. Using a 5/16 8 point socket, loosen the set screw securing the hydro control shaft to the pump (Figure 104). 0602-24 Figure 104 14. Remove the hairpin clip from the reverse rod on the hand lever (Figure 103). Figure 103 0602-21 16. Remove the shaft from the pump (Figure 105). Figure 105 0602-29 0602-31 Removal Follow the removal procedures in reverse.
HYDRAULIC DRIVE SYSTEMS Upper Handle Assembly - Pistol Grip Ref. No. 1 1:2 1:3 1:4 1:5 1:6 1:7 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 21:2 22 22:2 23 Qty.
HYDRAULIC DRIVE SYSTEMS Lower Control Assembly - Pistol Grip Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 5 - 20 Qty.
HYDRAULIC DRIVE SYSTEMS Upper Handles Assembly - T-Bar Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Qty. 1 1 1 1 1 1 3 1 2 1 4 1 1 2 2 2 1 Description Control Bar ASM Nut–Lock Bail ASM Decal–T Bar Decal–Drive, Traction Screw–SHH Tie–Cable Pivot ASM Pin–Cotter Decal – Warning Pin–Hair Rod – Control Decal–Lock, Speed Pin–Clevis Quick Release Lock ASM Spacer Pin–Clevis Mid-Size Walk Behind Service Manual Ref. No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Qty.
HYDRAULIC DRIVE SYSTEMS Lower Controls Assembly - T-Bar Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 *15 16 17 18 5 - 22 Qty. 1 4 6 2 4 4 1 2 8 2 4 4 2 1 1 2 2 2 Description Lever–Pivot, RH Side Flange Bearing ASM Nut–Lock Arm–Pump Screw–HH Ring–Grip, Ex Lever–Pivot, LH Rod–Link Screw–HH Sleeve Nut–Jam Washer–Flat Nut–Lock, NI Arm–Detent, LH Arm–Detent, RH Bushing–Arm, Detent Spacer–Bearing Bearing Ref. No. 19 20 21 22 23 *24 25 26 27 28 29 30 31 *32 33 34 35 Qty.
HYDRAULIC DRIVE SYSTEMS Hydraulic Testing 1. Jack up rear axle - support unit with jack stands (Figure 106). Tools Needed: • Hydro-Gear manual 492-4749 • Hydraulic flow tester - BDP Flow Test Kit 70661, or equivalent • Jack • Jack stands • 15/16" open end wrench • 7/16" open end wrench • 13/16" Socket or Air Impact • Ratchet • Oil Pan • Torque wrench • Toro Hydraulic Troubleshooting CD P/N 492-4777 CD # 2 Figure 106 Installation And Testing Procedures: 2.
HYDRAULIC DRIVE SYSTEMS 3. ard Forw erse Rev wa For R ev rd erse Figure 108 4. Note: When using a flow test gauge that is NOT bi-directional and it is connected in this manner, it is important not to operate the machine in reverse or you could damage the flow test gauge. Remove upper hydraulic line from wheel motor and attach to flow test gauge (Figure 108). mvc-893 Remove lower hydraulic line from wheel motor and attach to the other side of the flow test gauge(Figure 109). Figure 110 5.
HYDRAULIC DRIVE SYSTEMS 6. Run the machine for 2 minutes in forward (no load) to purge air from the system. 7. Run engine at full throttle (no load) - verify RPM with a tachometer - 3200 + or - 150 RPM's. Do not exceed 3600 RPM. 8. Example: 1st Reading 300 psi (21 bar) reading 7 gpm (26l/min). 2nd Reading 1100 psi (76 bar) reading 3 gpm (11l/min).
HYDRAULIC DRIVE SYSTEMS Wheel Motor Removal - Fixed Deck 1. Apply the parking brake and loosen the 4 lug nuts. 2. Remove the cotter key and remove the hub nut, then release the parking brake (Figure 114). 7. Thoroughly clean area round hydraulic fittings to prevent dirt from entering the system. 8. Mark the hose locations (Figure 116). Then remove the hoses at the wheel motor fittings. Figure 116 Figure 114 0602-59 3.
HYDRAULIC DRIVE SYSTEMS 2. Install new ‘O’ rings on the motor fittings. Install the hose fittings. 3. Align the wheel hub to the woodruff key on the motor shaft. Slide hub into position and thread the nut onto the shaft to hold the hub in position. Slide the wheel onto the hub and snug up the lug nuts. Apply the parking brake and tighten the hub nut to 165 ft. lbs. (224 N-m) and install the cotter key. 4.
HYDRAULIC DRIVE SYSTEMS 6. Mark the fittings to prevent reversing them when they are reinstalled. Hold the pump fitting stationary while removing the hose fittings from the pump. Cap the fittings to prevent dirt from entering the system (Figure 120). Figure 120 8. To remove the supply line, slide the hose clamp at least 2” (50mm) down the supply hose to clear the barbed fitting (Figure 121). Pull the hose off the fitting and cap both the supply hose and fitting. 9.
HYDRAULIC DRIVE SYSTEMS 12. Raise the rear of the machine and support on jack stands so the wheels are off the ground. 13. Bleed air from the system: 14. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand. 15. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minutes). 16. Check hydraulic fluid level as it drops and add as required to maintain proper level. 17. Repeat procedure on opposite wheel.
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GEAR DRIVE TRANSMISSION Transmission Removal - Gear Drive 1. Raise the rear of the unit and place on safety stands. 2. Remove the spring from the belt tensioning arm (Figure 124). 3. Remove the pivot bolt and tensioning arm assembly (Figure 124). 5. Slide the pulley off the transmission input shaft. 6. Remove the hairpin cotter and washer securing the control rod to the idler bracket. Remove the control rod from the bracket (Figure 126). Figure 126 7. Figure 124 4.
GEAR DRIVE TRANSMISSION 8. Remove the 3 nuts and bolts securing the idler support to the frame (Figure 128). Remove the idler support, idler bracket and torsion spring from the frame. 10. Pull the extension shafts out of the splined couplers and through the frame (Figure 130). Figure 130 Figure 128 9. 0819-38 11. Remove the nut securing the shift lever to the transmission (Figure 131). Remove the 2 nuts and bolts securing the bearing to the frame (Figure 129).
GEAR DRIVE TRANSMISSION 12. Remove the 4 transmission mounting bolts and remove the transmission (Figure 132). Figure 132 0819-37 Installation Follow the removal procedures in reverse. NOTE: For transmission service procedures, refer to the appropriate Peerless Service Manual.
GEAR DRIVE TRANSMISSION Transmission Drive Assembly Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 6-4 Qty.
GEAR DRIVE TRANSMISSION Control Linkage Removal (T-Bar) 1. Disconnect wiring for operator presence control (OPC) switch from T-Bar. 2. Disconnect the plug from the OPC switch (Figure 133). 4. Pull the wire harness from the tube in the T-Bar (Figure 135). Figure 135 5. Figure 133 3. 0819-15 Remove the cotter pins connecting the link to the T-Bar. This will also allow removal of the OPC handle (Figure 136).
GEAR DRIVE TRANSMISSION 6. Remove the hairpin cotters and washers securing the trunnions to the idler brackets (Figure 137). Control Linkage Adjustment (T-Bar Gear Drive) 1. Figure 137 0819-16 3” 7. Remove the cotter pins from the T-Bar. 8. Remove the pivot pins securing the T-Bar to the handle (Figure 138). (7 6m ) m Figure 139 2. Figure 138 Check the initial adjustment of the control rods. The control rods should be threaded through the rod fittings approximately 3” (76mm) (Figure 139).
GEAR DRIVE TRANSMISSION 3. 4. Check operation. If adjustment is required, remove the hairpin cotter and washer and adjust the rod fittings up or down on the control rod, as needed. Procedure NOTE: The control bar and upper handle must be parallel when in the relaxed drive and brake positions. Note: Install rod fittings so the clevis pin is above the control rod, as shown in Figure 142. 1. Install control rods into the bell cranks and secure them with the hairpin cotters (Figure 142).
GEAR DRIVE TRANSMISSION 3. Install the hairpin cotter pins between the drive levers and neutral/parking brake locks and into the clevis pins (Figure 143). Figure 143 (1) Control rod (2) Drive lever (3) Hairpin cotter 4. 6. Tighten the wing nut to prevent the turnbuckle from turning (Figure 144). 7. Check the drive adjustment by squeezing the drive levers firmly and then releasing. If the 3/16 to 1/4 inch (5 to 6mm) adjustment has changed, adjust as necessary. 8. Check the parking brake.
MOWER DECKS Setting Up the Frame (Floating Deck) Checking Engine Deck Height (Floating Deck) 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Adjust the tire pressure in all tires to specifications. 3. Measure engine deck height at location A (Figure 147). 4. Measure engine deck height at location B (Figure 147). 5. If the height at location A and B are not the same, change tire pressure slightly to make them the same.
MOWER DECKS 5. If the carrier frame height is not the same, move spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level. Figure 148 (1) Caster wheel (2) Carrier frame (3) Front height-of-cut pins (4) Same height at locations A and B (5) Caster spacers The carrier frame must have a pitch of 1/4 in. (6mm) over the length of 24 inches (6.1cm) on the carrier frame. 2. 6.
MOWER DECKS 3. The difference between measurements A and B should be no more than 1/4 in. (6mm). Figure 150 Figure 151 3. m-1078-3 Figure 152 m-1078-2 Figure 153 m-2539 m-2550 Checking the Deck Front-to-Rear Blade Slope (Floating Deck) 1. Adjust the tire pressure in all tires to specifications. 2. Position one blade front-to-rear (Figure 152). Measure at C and D locations (Figure 152) from a level surface to the cutting edge of the blade tips (Figure 153).
MOWER DECKS 3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 154). Figure 154 (1) Caster wheel (2) Carrier frame (3) Front height-of-cut pins 3. With the machine on level surface, position one blade front-to-rear (Figure 155). Measure at A and from level surface to the cutting edge of the blade tips (Figure 156). 4. The measurement should be 4 in. (102mm). m-6371 (4) Jam nut (5) Ball joint 4. Position the blades front-to-rear (Figure 152).
MOWER DECKS Replacing the Mower Belt (Floating Deck) 36 in. (91cm) 11. Install the carrier frame cover onto the cutting unit, then install and tighten the knobs/rubber washers. Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. Disengage the PTO and set the parking brake. 2.
MOWER DECKS 3. Remove the knobs holding the belt covers to the cutting unit and remove the belt covers. 4. Remove the PTO drive belt. Refer to "Replacing the PTO Drive Belt (Floating Deck) 44 & 52 in. (111 & 132cm)" on page 7 - 7. 5. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn deck belt (Figure 159). 10. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs/rubber washers. 6. 11.
MOWER DECKS Replacing the PTO Drive Belt (Floating Deck) 44 & 52 in. (111 & 132cm) 11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs. Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the drive belt if any of these conditions are evident. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2.
MOWER DECKS 4. Loosen the belt guide for the rear idler (Figure 162). A Mower Deck Belt Guide Adjustment (Fixed Deck Models) 1. Stop the engine and remove the spark plug wire(s). 2. Engage PTO. 3. Measure the clearance between the drive belt and guide located under the frame (Figure 164). B Figure 162 (A) Engagement pulley 0618-01 (B) Belt guide 5. Remove the deck engagement pulley (Figure 162). 6. Route the new belt as shown on the diagram located on the deck (Figure 163).
MOWER DECKS 7. Engage the blade control (PTO) lever and check the belt tension. Refer to "Adjusting Mower Belt Tension (Fixed Deck) - All" on page 7 - 16. Note: Mower belt tension is 10 - 15 ft. lb. 14 - 20 N-m) with the belt deflected 1/2 in. (13mm) halfway between the pulleys (Figure 165). Figure 165 (1) Mower belt with 1/2 in. (13mm) deflection 8. Note: The clearance should be 1/16 - 1/8 in. (2 3mm). Adjust clevis as needed to achieve specified clearance. Replacing the Mower Belt (Fixed Deck) 32 in.
MOWER DECKS 8. Engage the blade control (PTO) lever. 9. Check the clearance between the bell crank and the transmission output shaft (Figure 168). Figure 169 Figure 168 (1) 1/16 - 1/8 inch (2 - 3mm) (2) Bell crank (3) Transmission output shaft m-3860 (4) Hairpin cotter (5) Clevis pin (6) Clevis m-4739 (1) 1/2 inch (13mm) deflection (3) Front stop here (4) Locknut (2) Assist arm (5) Turnbuckle 13. Check the belt guide under the engine frame for the proper adjustment (Figure 164).
MOWER DECKS Note: Proper belt tension is 10 - 15 lbs. (14 - 20 N-m) with the belt deflected 1/2” (13mm) halfway between pulleys (Figure 170). Figure 170 8. Remove hairpin cotter and clevis pin from bell crank. Rotate clevis clockwise on rod to increase or counterclockwise to decrease clearance (Figure 171). m-4731-2 Figure 171 (1) Idler pulley (2) 1/2” (13mm) deflection here 7.
MOWER DECKS 10. Check the belt guide under the engine frame for proper adjustment (Figure 172). The distance between the belt guide and mower belt should be 1-3/8” (35mm). Adjust as necessary. The disengaged belt should not drag or fall off pulley when guides are properly adjusted. 5. Check the belt tension midway between the front and left spindle pulleys. It should require approximately 10 lbs. force to deflect the belt 1/2” (13mm).
MOWER DECKS 7. If you cannot obtain the correct belt tension while maintaining the minimum thread engagement, move the rear idler pulley and guide to the forward position on the deck (Figure 175). 4. Check the location of the assist arm. The assist arm should contact the rear stop on the deck (Figure 177). Figure 177 Figure 175 5. Blade Engagement Adjustment (Fixed Deck) 1. Stop the engine and remove the spark plug wires. 2. Engage the PTO. 3.
MOWER DECKS Blade Safety Switch Adjustment (Fixed Deck) Adjusting the Blade Brake (Fixed Deck) 1. Stop the engine and remove the spark plug wires. 1. Disengage the PTO and set the parking brake. 2. Disengage the PTO so that the bellcrank is touching the rear of the slot in the frame (Figure 179). 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3.
MOWER DECKS Replacing the Mower Belt (Fixed Deck Hydro, Pistol Grips) 1. Disengage the PTO, turn the ignition key to off, and remove the key. 2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 3. Remove the knobs and the belt cover on the mower. 4. Remove the idler pulley and the belt (Figure 182). 5. Install the new mower belt. 6. Install the idler pulley. 7. Engage the blade control (PTO) lever and check the belt tension.
MOWER DECKS Note: If the assist arm does not contact the front stop on the mower deck (Figure 184), adjust the clevis to bring the bell crank closer to the transmission output shaft (Figure 183). Note: The distance between the belt guide and the mower belt should be 1-3/8 in. (35mm) when you engage the mower belt (Figure 185). Adjust the mower belt as necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted. Figure 184 Figure 185 12.
MOWER DECKS Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16” (8mm). Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s). Inspecting the Blades Figure 186 (1) Locknut (2) Turnbuckle (3) Rear idler pulley 1. Inspect the cutting edges (Figure 187).
MOWER DECKS 2. Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 188). Measure from a level surface to the cutting edge, position A, of the blades (Figure 189). Note this dimension. Rotate the blades 180 degrees so that the opposite ends are forward. Measure from a level surface to the cutting edge of the blades as in step 1 above. The difference between the dimensions must not exceed 1/8 in. (3mm). If this dimension exceeds 1/8 in.
MOWER DECKS 3. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, washer, lock washer and blade from the spindle shaft (Figure 190). Figure 190 (1) Sail area of blade (2) Blade (3) Blade spindle 2. Check the balance of the blade by putting it on a blade balancer (Figure 192). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 190).
MOWER DECKS 4. 2. Adjust the tire pressure in all tires to specifications. 3. Check that the blades and spindle shafts are not bent. Refer to "Checking for Bent Blades" on page 7 - 18. 4. Set the height-of-cut to the 4 in. (102mm) position. Refer to "Matching Height-of-Cut (Fixed Deck)" on page 7 - 4. Remove the 6 nuts and bolts securing the spindle to the deck (Figure 195). Replace Spindle Bearings (Fixed Deck) 1. Remove the spindle through bolt. 2. Use a bolt grip puller to remove the pulley.
MOWER DECKS 6. Remove the snap ring securing the lower bearing (Figure 197). Figure 197 Replace Spindle Bearings (Floating Deck) 1. Remove the cutting deck. Refer to "Mower Deck Removal (Fixed Deck Models)" on page 7 - 28. 2. Loosen the spindle nut (Figure 199). 0616-14 7. Drive the lower bearing from the housing. 8. Press in a new upper bearing until it seats at the bottom of its bore (Figure 198). Figure 199 0819-20 a. Block the blade with a piece of wood to prevent the spindle from turning.
MOWER DECKS 4. Remove the 6 nuts and carriage bolts securing the spindle housing to the deck (Figure 201). Figure 201 5. 7 - 22 Remove the washer from the lower bearing and slide the bearing from the housing (Figure 203). Figure 203 0819-18 Place the spindle in a vise and remove the nut, washer, pulley, and housing from the spindle (Figure 202). Figure 202 6. 0819-25 7. Slide the upper bearing and bearing spacer from the housing. 8. Reverse the above steps to reassemble.
MOWER DECKS Spindle Assembly (Floating Deck) 44 in. (112cm) Ref. No. 1 2 3 4 6 7 8 9 10 11 12 13 14 Mid-Size Walk Behind Service Manual Qty.
MOWER DECKS Spindle Assembly (Floating Deck) 36 in./91cm, 52 in./132cm Ref. No. 1 2 3 4 6 7 8 9 10 11 12 13 14 7 - 24 Qty.
MOWER DECKS Spindle, Pulley and Belt Assembly (Floating Deck) Ref 1 1:2 1:3 1:4 1:5 1:6 1:7 1:8 1:9 1:10 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Qty.
MOWER DECKS Replacing the Castor Wheel Fork Bushings (All Models) The castor wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the castor forks back and forth and side-to-side. If a castor fork is loose, the bushings are worn and must be replaced. 1. Raise the cutting unit so the castor wheels are off the floor, then block up the front of the mower with jack stands. 2.
MOWER DECKS 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Figure 206). Replacing the Grass Deflector (All Models) 4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Figure 206). WARNING An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.
MOWER DECKS Mower Deck Removal (Fixed Deck Models) 1. Apply the parking brake. 2. Remove the deck cover. 3. With the PTO disengaged, remove the drive belt from the idler pulley (Figure 208). Then remove the belt from the engine pulley. 5. CAUTION The mower deck is heavy. Keep hands and feet clear when disconnecting the deck from the mower frame. 6. Figure 208 4. Block the rear of the frame to prevent the machine from tipping backwards when the deck is removed. Block the trailing edge of the deck.
MOWER DECKS Mower Deck Removal (Floating Deck) 4. Remove the PTO drive belt from the clutch pulley. 5. Remove the deck from the carrier frame. 1. 6. Support the rear of the frame with a safety stand to prevent the unit from tipping backwards when the deck is removed. 7. Remove the hairpin cotters and washers from the height adjustment pins. 8. Remove the safety stand and rock the machine back on the drive wheels until the carrier frame clears the drive wheels.
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ELECTRICAL Contents - Wiring Diagrams T-Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16 T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17 T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL Electrical Systems This manual covers a variety of machines. From recoil start models with simple electrical systems to electric start models with an electric blade clutch. Some of the electrical components are used in different ways in different models. It is important you use the wiring diagram for your specific model. Location Fuses are located in a variety of places on the various models. The first places to look should be under the control panel or on the chassis alongside the engine.
ELECTRICAL Note that there is a diagram on the side of the relay and each terminal is numbered (Figure 215). 2. Location The relays are located under the control panel on the mid size mowers. Figure 214 Switch: Terminals 30, 87, and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized.
ELECTRICAL 5. Disconnect voltage and multimeter leads from relay terminals (Figure 216). How It Works The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. The other part is a bar type switch. Because it has large contact area with the contact terminals it can easily handle the high current loads required by the starter motor. When 12 volts is applied to the coil, it becomes an electromagnet. This quickly pulls the bar toward the contact terminals and closes the switch.
ELECTRICAL 3. Apply +12VDC to the two smaller terminals. You should hear a click and get continuity between the two big terminals. If you disconnect the battery, the solenoid should again “click” and loose continuity between the big terminals. How It Works On recoil start models the ignition is a simple on/off switch. One wire connects to chassis ground and the other to the magneto. When the key is turned off the switch closes and grounds the magneto. Turn the key on and the ground is disconnected.
ELECTRICAL Electric PTO Clutch Purpose This clutch electrically controls the engagement and disengagement of the Power Take Off (PTO) pulley. Location The electric clutch is located on the PTO end of the engine crankshaft (Figure 224). Figure 222 OFF ON START 116-338 G+M B+L B+L+S Figure 224 mvc-067x How It Works The PTO clutch is composed of three major components; the field, the clutch plate, and the friction plate. The clutch plate always turns with the engine.
ELECTRICAL 6. Testing If the electric PTO clutch is not engaging or is suspected as a cause of electrical problems, use the following troubleshooting steps. The procedures will help you determine if the clutch has failed or is the cause of the electrical problem. Measure the resistance between either of the wires on the clutch connector to a ground on the chassis. There should be no continuity. If there is, the insulation in the coil has failed and the clutch must be replaced (Figure 226).
ELECTRICAL Disconnect the clutch from the wiring harness. Set a voltmeter on DC volts and connect the probes to the terminals at the end of the harness (Figure 227). Clutch Burnishing Procedure The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed. Burnishing polishes the clutch plate, allowing for smooth clutch engagement. With deck drive belt installed, run the engine at half throttle. Engage and disengage the mower 5 times (10 seconds on/10 off).
ELECTRICAL 3. The proper disengaged clearance between the clutch plates is 0.012 - 0.024 inch (0.30 0.60mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other. How It Works When the PTO switch is pulled out to the "ON" position, contacts inside the switch electrically connect various terminals. One terminal is connected to the wire that goes directly to the electric clutch.
ELECTRICAL PTO Switch Test Figure 230 Transmission Switch (Gear Drive) Location Purpose The transmission switch is screwed into the top of the transmission. This switch is used to determine if the transmission is in neutral. How It works The transmission has a movable plate inside that the ball in this switch rides on. When in neutral a hole in this plate is positioned right below the switch. When the switch ball falls in this hole the switch closes. Testing Figure 231 8 - 10 mvc-056 1.
ELECTRICAL Hourmeter Testing Purpose The hourmeter is present to give an indication of operating hours. It is standard on some models an optional on others. On some models it is connected between the clutch switch and clutch. In that instance it will measure clutch operating time not engine hours. In other models it is connected between the alternator and clutch switch. In this situation it will receive power whenever the engine is running.
ELECTRICAL Switch (95-1653) Bail Switch (82-2190) Purpose Purpose Like the previously shown switch, this part is used to determine if the parking brake is set and if the transmission is in neutral. This switch functions as an operator presence control. The operator must maintain a grip on the T-bar to keep the blade clutch running. Location Location The location depends on the application. A parking brake switch application will be located in or near the brake linkage.
ELECTRICAL Location Testing On the control panel, just below the T-bar. A bridge rectifier is a box containing 4 diodes. The easiest way to test a bridge rectifier is to disconnect all wires and use an ohmmeter. Select any two terminals that are side by side. Attach the ohmmeter probes and note if continuity is present or not. Now switch the probes. Continuity should be present one way and not the other. Repeat the process for each pair of terminals.
ELECTRICAL Delay Module (2000 and Earlier) Purpose The delay module is part of the electric clutch system. The operator must squeeze a bail to maintain power to the electric clutch. The module allows a slight delay between release of the bail and clutch disengagement. If the module was not there, the operator would need to restart the clutch even if their hand slipped off momentarily. The module allows about a second delay.
ELECTRICAL Testing Test module at full throttle when the hourmeter and module are connected with the engine running at full throttle. 1. Connect a DC voltmeter between terminals P1-2 (pos) and P1-1 (neg). 2. Connect the positive lead from a 12 VDC power source to P1-3 and the negative lead to P1-1. 3. Connect a jumper lead from P1-4 to J1. 4. Start mower and run at full throttle when testing. 5. Connect a second jumper lead to terminal P1-3 and momentarily touch it to P1-4.
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44947 cover 12/9/04 11:08 AM Page 2 ABOUT THIS MANUAL This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct. For service information specific to the engines used on these products, refer to the appropriate engine manufacturer’s service and repair instructions.
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