Service Manual

ManualsBrandsToro ManualsRiding EquipmentToro 74376

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Summary of content (162 pages)

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5HVLGHQWLDO 3URGXFWV 7LPH&XWWHU = 3UHFLVLRQ = =HUR 5DGLXV 7XUQ 5LGLQJ 0RZHU 6HUYLFH 0DQXDO
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ABOUT THIS MANUAL This service manual was written expressly for Toro and Lawn-Boy 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. )RU DGGLWLRQDO LQIRUPDWLRQ RQ WKH HOHFWULFDO V\VWHP SOHDVH UHIHU WR WKH 7RUR (OHFWULFDO 'HP\VWL¿FDWLRQ *XLGH DQG VXEVHTXHQW )RU VHUYLF
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ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS Safety Information *HQHUDO ,QIRUPDWLRQ...................................................................................................................... 7KLQN 6DIHW\ )LUVW.......................................................................................................................... 6SHFL¿FDWLRQV (QJLQH 6SHFL¿FDWLRQV ................................................................................................................... *HQHUDO 6SHFL¿FDWLRQV...............
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TABLE OF CONTENTS Engine Engine Replacement .................................................................................................................... Engine Removal..................................................................................................................... (QJLQH ,QVWDOODWLRQ.................................................................................................................. (QJLQH 0XIÀHU 5HSODFHPHQW ..................................................
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TABLE OF CONTENTS Electrical (OHFWULFDO 6\VWHP ............................................................................................................................ 5HOD\ .LOO 5HOD\ ............................................................................................................................ 3XUSRVH .................................................................................................................................... Location ......................................
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TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK.
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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 TimeCutter® Z and the Precision® Z zero radius turn mowers.
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SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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SPECIFICATIONS (QJLQH 6SHFL¿FDWLRQV Z4200 Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM High Idle: 3300 + 100 RPM Z4200 (CE) Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM High Idle: 2650 + 100 RPM Z4220 Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.7kW) @ 3600 RPM High Idle: 3300 + 100 RPM Z4202 (CE) Kohler, Overhead Valve, Twin Cam, 20.0 hp (14.9kW) @ 3600 RPM High Idle: 2400 +100/-0 RPM Z5000 Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.
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SPECIFICATIONS *HQHUDO 6SHFL¿FDWLRQV 2 &RQVWUXFWLRQ Frame: drawn 11 gauge steel )XHO 6\VWHP 6LQJOH IXHO WDQN JDOORQ / FDSDFLW\ IXHO ¿OWHU UHSODFHDEOH LQ OLQH W\SH YHQWHG IXHO FDS $WWDFKPHQW 'ULYH Electric Clutch 6WHHULQJ Levers: Dual wrap-around levers control hydraulic pump Dampening: Dual hydraulic dampeners Turning Radius: Zero Radius Turn (ZRT) ,QWHUORFNV Seat: Operator presence switch Control Lever/Brake: Dual position switch Power Take Off: Position switch (OHFWULFDO 6\VWHP B
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SPECIFICATIONS *URXQG 6SHHG 6SHFL¿FDWLRQV 0RGHO *URXQG 6SHHG Z4200 ,Q¿QLWH WR PSK NP KU IRUZDUG 0 to 3.5 mph (5.6km/hr) reverse Z4200 (CE) ,Q¿QLWH WR PSK NP KU IRUZDUG 0 to 2.8 mph (4.5km/hr) reverse Z4220 ,Q¿QLWH WR PSK NP KU IRUZDUG 0 to 3.5 mph (5.6km/hr) reverse Z4202 (CE) ,Q¿QLWH WR PSK NP KU IRUZDUG 0 to 2.8 mph (4.5km/hr) reverse Z5000 ,Q¿QLWH WR PSK NP KU IRUZDUG 0 to 3.5 mph (5.
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SPECIFICATIONS 0RZHU 'HFN 6SHFL¿FDWLRQV 0RZHU 'HFN 2 ´ FP 0RZHU 'HFN 0RGHOV ´ FP 0RZHU 'HFN 0RGHOV 5LJKW VLGH GLVFKDUJH EODGH PLG PRXQWHG rotary. Drawn 13 gauge steel deck with ZHOGHG PRXQWLQJ EUDFNHWV )UDPH VXSSRUWHG EODGH PLG PRXQWHG URWDU\ 'UDZQ JDXJH VWHHO GHFN ZLWK ZHOGHG PRXQWLQJ EUDFNHWV Frame supported. &( PRGHO 5HF\FOHU FRYHU EDIÀH DQG NLFNHUV LQVWDOOHG 'HÀHFWRU 3LYRWLQJ GHÀHFWRU VSULQJ ORDGHG $QWL VFDOS 5ROOHUV Left and right front mounted, Two height posit
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SPECIFICATIONS 'LPHQVLRQV :HLJKW :KHHO %DVH1 :LGWK2 2YHUDOO :LGWK3 2YHUDOO /HQJWK 2YHUDOO +HLJKW Z4200 48.1” (122.2cm) 40.5” (102.9cm) 53.75” (136.5cm) 73.1” (185.7cm) 37.25” (94.6cm) Z4200 (CE) 48.1” (122.2cm) 40.5” (102.9cm) 53.75” (136.5cm) 73.1” (185.7cm) 37.25” (94.6cm) Z4220 48.1” (122.2cm) 40.5” (102.9cm) 53.75” (136.5cm) 73.1” (185.7cm) 37.25” (94.6cm) Z4202 (CE) 48.1” (122.2cm) 40.5” (102.9cm) 53.75” (136.5cm) 73.1” (185.7cm) 37.25” (94.6cm) Z5000 48.1” (122.
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SPECIFICATIONS 'LPHQVLRQV :HLJKW FRQW 7UDFN :LGWK4 7UDFN :LGWK5 'HFN :LGWK :HLJKW HVWLPDWHG Z4200 32.9” (83.6cm) 29.5” (74.9cm) 53.75” (226.8cm) OEV (226.8kg) Z4200 (CE) 32.9” (83.6cm) 29.5” (74.9cm) 53.75” (226.8cm) OEV (231kg) Z4220 32.9” (83.6cm) 29.5” (74.9cm) 53.75” (226.8cm) OEV (226.8kg) Z4202 (CE) 32.9” (83.6cm) 29.5” (74.9cm) 53.75” (226.8cm) OEV (231kg) Z5000 34.6” (87.9cm) 29.5” (74.9cm) 63” (160cm) OEV (250.4kg) Z5000 (CE) 34.6” (87.
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SPECIFICATIONS +\GURVWDWLF 7UDQVD[OH 6SHFL¿FDWLRQV +\GUR *HDU (=7 +\GURVWDWLF 7UDQVD[OHV 2 )LJ PICT-9625 /XEULFDWLRQ 6$( : $3, &ODVVL¿FDWLRQ 6+ &' Oil Capacity 1.6 to 1.7 qt. (1.5 to 1.6 liters) Oil Level 7KH WUDQVD[OH LV D VHDOHG V\VWHP DQG GRHV QRW UHTXLUH SHULRGLF FKHFNLQJ &KHFN RLO DW WKH RLO ¿OO SOXJ ORFDWLRQ RQO\ 'R QRW FKHFN WKH RLO DW WKH YHQW WXEH &KHFNLQJ RLO DW WKH YHQW WXEH ZLOO JLYH D IDOVH UHDGLQJ RU QR UHDGLQJ DW DOO VLQFH WKLV LV WKH RLO H[SDQVLRQ DUHD ,I WKH RLO QH
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SPECIFICATIONS 7RUTXH 6SHFL¿FDWLRQV Torque Specifications 2 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.
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SPECIFICATIONS 6WDQGDUG 7RUTXH IRU 'U\ =LQF 3ODWHG DQG 6WHHO )DVWHQHUV ,QFK 6HULHV 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 Nut
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SPECIFICATIONS 6WDQGDUG 7RUTXH IRU 'U\ =LQF DQG 6WHHO )DVWHQHUV 0HWULF )DVWHQHUV Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 2 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 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.
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SPECIFICATIONS 2WKHU 7RUTXH 6SHFL¿FDWLRQV Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
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SPECIFICATIONS (TXLYDOHQWV &RQYHUVLRQV Equivalents and Conversions 'HFLPDO 0LOOLPHWHU (TXLYDOHQWV Decimal and Millimeter Equivalents 2 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 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.
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SPECIFICATIONS 8 6 WR 0HWULF &RQYHUVLRQV 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.
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SPECIFICATIONS 2 7+,6 3$*( ,17(17,21$//< /()7 %/$1.
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CHASSIS 0RGHO 6HULDO 1XPEHU ,GHQWL¿FDWLRQ $ JUHDVH ¿WWLQJ LV ORFDWHG RQ HDFK IURQW ZKHHO KXE (Fig. 006). The unit model and serial number plate is located on the frame under the seat as shown (Fig. 004): 3 Fig. 006 Fig. 004 PICT-9157 PICT-9150 )URQW &DVWRU )RUN 5HSODFHPHQW *UHDVH /XEULFDWLRQ The unit should be greased every 25 hours or more often when operated in dusty, dirty, or sandy conditions. Grease Type: No. 2 general purpose lithium base grease. 1.
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CHASSIS Note: There are two different style front axle asVHPEOLHV DQG GLIIHUHQW KDUGZDUH IRU HDFK Style A (Fig. 008): Style A - Front Axle Assembly Caster Fork Removal 1. Remove the hex head bolt and washer located on top of the caster fork assembly (Fig. 010). 3 Fig. 008 PICT-9160 Fig. 010 PICT-9161 Style B (Fig. 009): 2. Remove the caster fork assembly from the front axle (Fig. 011). Fig. 009 PICT-9154a Fig.
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CHASSIS 3. Using a drift punch, tap the bottom ball bearing out of the front axle assembly (Fig. 012). Style A caster fork assembly (Fig. 014) A B C DE Fig. 014 Fig. 012 3 PICT-9167a PICT-9164 A. Caster fork assembly B. Thrust washer C. Ball bearing (2) D. Washer E. Bolt 4. Using a drift punch tap the top bearing out of the front axle assembly (Fig. 013). Fig.
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CHASSIS Style A - Front Axle Assembly Caster Fork Installation 3. Install the washer and bolt and tighten the bolt (Fig. 017). 1. Tap the bottom and top ball bearings into the front axle assembly (Fig. 015). 3 Fig. 017 Fig. 015 PICT-9172 PICT-9175 /RZHU WKH XQLW DQG UHPRYH WKH ÀRRU MDFN 2. Install the thrust washer onto the caster fork, then install the castor fork assembly into the front axle assembly (Fig. 016). Fig.
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CHASSIS Style B - Front Axle Assembly Caster Fork Removal Style B - Front Axle Assembly Caster Fork Installation 1. Remove the plastic dust cover, e-ring and washer. Slide the caster fork down, out of the front axle assembly (Fig. 018). 7DS WKH WRS DQG ERWWRP ÀDQJHG EHDULQJV LQWR WKH front axle assembly (Fig. 020). A BC 3 D Fig. 020 Fig. 018 A. Plastic dust cap B. E-ring PICT-9190 PICT-9187 C. Washer D. Castor fork assembly 2.
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CHASSIS 3. Install the washer and the e-ring on the caster fork assembly (Fig. 022). Caster Wheel Assembly Removal 1. Park the unit on a level surface, disengage the blade control (PTO), and turn the ignition key to “Off” to stop the engine. Remove the ignition key. 2. Raise the front of the unit (Fig. 024). 3 Fig. 022 PICT-9193 4. Install the plastic dust cap (Fig. 023). Fig. 024 PICT-9158 3. Remove the bolt and nut retaining the wheel assembly to the caster fork (Fig. 025). Fig. 023 PICT-9194 5.
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CHASSIS 4. Remove the wheel spanner from the wheel assembly (Fig. 026). Castor Wheel Assembly Installation 7DS WKH ÀDQJH EHDULQJV LQWR WKH ZKHHO ULPV )LJ 028). 3 Fig. 026 PICT-9197 Fig. 028 PICT-9200a :LWK D GULIW SXQFK WDS RXW ERWK ÀDQJH EHDULQJV IURP the wheel rims (Fig. 027). 2. Install the wheel spanner into the wheel assembly (Fig. 029). Fig. 027 PICT-9199a Fig.
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CHASSIS 3. Install the bolt and nut retaining the wheel assembly to the caster fork, then tighten the bolt and nut (Fig. 030). 4. Remove the front footrest plate (Fig. 032). 3 Fig. 032 Fig. 030 PICT-9202 PICT-9195 5. Remove the footrest from the frame (Fig. 033). /RZHU WKH XQLW DQG UHPRYH WKH ÀRRU MDFN Front Axle Assembly Removal 1. Park the unit on a level surface, disengage the blade control (PTO), and turn the ignition key to “Off” to stop the engine. Remove the ignition key. 2.
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CHASSIS 6. Remove the lift rod from the front axle (Fig. 034). 8. Remove the 4 bolts, washers, and nuts retaining the front axle assembly to the frame (Fig. 036). 3 Fig. 034 PICT-9205 Fig. 036 7. Remove both the right and left castor fork assemblies (Style A construction shown) (Fig. 035). Fig. 035 9. Remove the front axle assembly from the frame (Fig. 037). PICT-9206 Fig.
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CHASSIS 10. Remove the castor fork bearings by using a drift punch and tapping the bearings out of the front axle assembly (Fig. 038). 2. Install the front axle assembly into the frame (Fig. 040). 3 Fig. 040 Fig. 038 PICT-9208 PICT-9209a 3. Install 4 bolts, washer, and nuts that retain the front axle assembly to the frame and tighten (Fig. 041). Front Axle Assembly Installation 1. Tap castor fork bearings into the front axle assembly (Fig. 039). Fig. 041 Fig.
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CHASSIS 4. Install thrust washers onto the caster forks, then install the castor fork assemblies into the front axle assembly (Fig. 042). 6. Install the lift rod, washer and nut to the front axle assembly (Fig. 044). 3 Fig. 044 Fig. 042 PICT-9205 PICT-9211 7. Install the footrest to the frame (Fig. 045). 5. Install the bolts and washers retaining the caster fork assemblies to the front axle assembly and tighten the bolt (Fig. 043). Fig. 045 Fig.
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CHASSIS 8. Install the footrest plate to the frame with two bolts and washers (Fig. 046). )XHO 7DQN 5HSODFHPHQW Fuel Tank Removal 1. Remove the negative battery cable from the battery (Fig. 047). 3 Fig. 046 PICT-9217 5HPRYH WKH MDFN VWDQGV DQG ORZHU WKH XQLW Fig. 047 PICT-9219 10. Install the mower deck; refer to “Mower Deck Installation” on page 6-13. 2. Remove the four screws from the control panel and move the control panel away from the side panel (Fig. 048). Fig.
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CHASSIS 3. Remove the fuel cap (Fig. 049). 5. Remove the 3 shoulder screws that retain the RH pod to the frame (Fig. 051). 3 Fig. 049 PICT-9226 Fig. 051 5HPRYH WKH UXEEHU ZDVKHU IURP DURXQG WKH ¿OO WXEH of the fuel tank (Fig. 050). Fig. 050 TimeCutter® Z/Precision® Z Service Manual PICT-9227 PICT-9230 6. Remove the RH pod from the frame (Fig. 052). Fig.
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CHASSIS 7. Move the hose clamp and disconnect the fuel line IURP WKH GHJUHH ¿WWLQJ RQ WKH WRS RI WKH IXHO WDQN (Fig. 053). 9. Remove the fuel tank (Fig. 055). 3 Fig. 055 Fig. 053 PICT-9236 PICT-9234 Fuel Tank Installation 8. Cut and remove the cable tie running through the retention tabs located on the seat/pod bracket (Fig. 054). 1. Install fuel tank onto the frame (Fig. 056). Fig. 056 Fig.
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CHASSIS 2. Install a cable tie through the retention tabs located on the seat/pod bracket (Fig. 057). &RQQHFW WKH IXHO OLQH WR WKH GHJUHH ¿WWLQJ DQG install the hose clamp (Fig. 059). 3 Fig. 057 PICT-9238 3. Install the seal foam on the neck of the fuel tank (Fig. 058). Fig. 059 5. Install the RH pod to the frame (Fig. 060). Fig. 060 Fig.
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CHASSIS 6. Install 3 shoulder screws that retain the RH pod to the frame (Fig. 061). 8. Install 4 screws in the control panel and tighten (Fig. 063). 3 Fig. 061 PICT-9230 ,QVWDOO D UXEEHU ZDVKHU DURXQG WKH IXHO ¿OO WXEH DQG install the fuel cap (Fig. 062). Fig. 062 3-16 PICT-9226 Fig. 063 PICT-9241 9. Install the battery negative cable onto the battery (Fig. 064). Fig.
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CHASSIS Seat Pivot/Control Assembly 5HSODFHPHQW 3. Remove the wire harness retainer located on the seat base (Fig. 067). Seat Pivot/Control Assembly Removal 1. Remove the negative battery cable from the battery (Fig. 065). 3 Fig. 067 PICT-9251 4. Remove the hairpin and the clevis pin holding the retaining cable stop for the seat (Fig. 068). Fig. 065 PICT-9219 2. Remove the wire plug from the seat switch (Fig. 066). Fig. 068 Fig.
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CHASSIS 5. Remove the shoulder bolts and nuts retaining the seat base to the seat pivot/control assembly and remove seat assembly (Fig. 069). 7. Remove the LH pod from the unit (Fig. 071). 3 Fig. 071 Fig. 069 PICT-9257 6. Remove the 3 shoulder screws retaining the LH pod to the frame (Fig. 070). 8. Remove the four screws on the control panel and move the control panel away from the side panel (Fig. 072). Fig. 072 Fig.
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CHASSIS 9. Remove the fuel cap and the rubber washer. 10. Remove the 3 shoulder screws retaining the RH pod to the frame (Fig. 073). 12. Cut and remove the tie cable running through the retention tabs located on the seat/pods bracket (Fig. 075). 3 Fig. 075 Fig. 073 PICT-9235 PICT-9262 13. Remove the fuel tank from the frame (Fig. 076). 11. Remove the RH pod from the frame (Fig. 074). Fig. 076 Fig.
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CHASSIS 14. Remove the right and left control covers (Fig. 077). 16. Remove the z-bend of the parking brake cable from the RH and LH gear control (Fig. 079). 3 Fig. 077 PICT-9275 Fig. 079 15. Remove the screw securing the parking brake cable to the RH and LH activator arm assembly (Fig. 078). PICT-9282 17. Pull the RH and LH brake cables out of the seat pivot/control assembly area. 18.
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CHASSIS 19. Remove the RH and LH neutral switch and pull the wire assembly out of the control linkage area (Fig. 081). 5HPRYH WKH KDLUSLQ DQG FOHYLV SLQ RQ WKH DGMXVWDEOH yokes for both the right hand and left hand hydro links (Fig. 083). 3 Fig. 081 PICT-9342a 20. Remove the shoulder screw and washer that hold the motion control damper to the RH and LH activator assembly (Fig. 082). Fig. 082 TimeCutter® Z/Precision® Z Service Manual PICT-9341 Fig. 083 PICT-9286 22.
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CHASSIS 23. Remove the 2 bolts and nuts that retain the lift arm assembly to the lift lever assembly (Fig. 085). 25. Remove the two bolts and nuts located in the front of the seat pivot/control assembly (Fig. 087). 3 Fig. 085 PICT-9293 24. Remove the bolt, washer and nut retaining the HOC sector to the frame and remove the bolt and nut on the top that retains the HOC sector to the seat pivot/ control assembly (Fig. 086). Fig. 087 26.
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CHASSIS 27. On the left side remove the 2 bolts and nuts retaining the seat pivot/control assembly to the frame (Fig. 089). 29. Remove the seat pivot/control assembly from the frame (Fig. 091). Note: The right handle assembly is being removed. The left hand side is removed the same way. 3 Fig. 089 PICT-9299 Fig. 091 28. On the right side remove the remaining bolt and nut retaining the seat pivot/control assembly to the frame (Fig. 090). Fig. 090 30.
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CHASSIS 31. Pull back on the actuator arm and install a small punch in the hole located on the return plate (Fig. 093). 33. With a 1/4” Allen wrench and a 7/16” wrench, remove the nut from the end of the eccentric (Fig. 095). 3 Fig. 093 PICT-9325 32. Remove the screw retaining the bracket return to the seat pivot/control assembly (Fig. 094). Fig. 094 Fig. 095 34.
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CHASSIS 35. Remove the activator arm and actuator from the seat pivot/control assembly (Fig. 097). Seat Pivot/Control Assembly Installation Note: Perform the same installation on the RH and LH side. 1. Install the activator and actuator arm assembly into the seat pivot/control assembly using a shoulder bolt (Fig. 098). 3 Fig. 097 PICT-9317 Fig. 098 PICT-9318 2. Install a washer and a nut onto the shoulder bolt and tighten (Fig. 099). Fig.
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CHASSIS 3. Install an eccentric screw through the eccentric. 0DNH VXUH WKH WDE RI WKH HFFHQWULF ¿WV LQWR WKH VORW RQ the seat pivot/control assembly (Fig. 100). 5. With a punch installed on the end of the return plate and spring, install the bracket return onto the seat pivot/control assembly (Fig. 102). 3 Fig. 100 PICT-9322 4. Install the nut on the eccentric screw and tighten (Fig. 101). Fig. 101 Fig. 102 6. Install a screw through the bracket return and tighten (Fig. 103).
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CHASSIS 7. Install 2 bolts and washers in the handle assembly and the actuator arm and tighten (Fig. 104). 9. On the right side install one bolt and nut retaining the seat pivot/control assembly to the frame; tighten the bolt and nut (Fig. 106). 3 Fig. 104 PICT-9310a Fig. 106 8. Install the seat pivot/control assembly on the frame (Fig. 105). Fig. 105 10. On the left side install 2 bolts and nuts retaining the seat pivot/control assembly to the frame; tighten the bolts and nuts (Fig. 107).
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CHASSIS 11. Install the two bolts and nuts located on the backside of the seat pivot/control assembly; tighten the bolts and nuts (Fig. 108). 13. Install a bolt and nut on the top of the HOC sector and a bolt, washer and nut on the bottom of the HOC sector; tighten the bolts and nuts (Fig. 110). 3 Fig. 108 PICT-9298 Fig. 110 PICT-9294 12. Install the two bolts and nuts located on the front of the seat pivot/control assembly; tighten the bolts and nuts (Fig. 109). 14.
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CHASSIS 15. Install the lift lever assembly to the lift arm assembly and install nuts and tighten (Fig. 112). 17. Install a washer between each motion control damper and the activator arm and secure with a shoulder screw (Fig. 114). 3 Fig. 112 PICT-9293 Fig. 114 ,QVWDOO WKH FOHYLV SLQV DQG KDLUSLQV RQ WKH DGMXVWDEOH yokes of the hydro links to the activator arms (Fig. 113). Fig. 113 18.
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CHASSIS Install in the slot located below the actuator arm (Fig. 116). 20. Install the z-bend of the parking brake cable into the right and left gear controls (Fig. 118). 3 Fig. 116 PICT-9344 19. Route the parking brake cable to the inside of the motion control damper under the RH and LH activator arm assembly (Fig. 117). Fig. 118 ,QVWDOO WKH ULJKW DQG OHIW EUDNH FDEOH FRQGXLW ¿WWLQJ WR the activator arm assembly and tighten (Fig. 119). Fig. 119 Fig.
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CHASSIS 22. Check the operation of both the right and left park brake. Move the handle assembly to the neutral park position (Fig. 120). 24. Install the right and left control covers (Fig. 122). 3 Fig. 122 Fig. 120 PICT-9368 PICT-9360 25. Install the fuel tank to the frame (Fig. 123). 23. In neutral park position, check and make sure both the right and left brake arms are dropping down on the disc brake cog (Fig. 121). 1RWH 5HDU ZKHHO UHPRYHG IRU SLFWXUH FODULW\ Fig. 123 Fig.
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CHASSIS 26. Install a cable tie through the retention tabs located on the seat pivot/control assembly (Fig. 124). 28. Install the rubber washer and fuel cap (Fig. 126). 3 Fig. 126 Fig. 124 27. Install the right hand pod with 3 shoulder screws (Fig. 125). 29. Install the 4 screws retaining the control panel to the right hand pod (Fig. 127). Fig. 127 Fig.
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CHASSIS 30. Install the left hand pod with 3 shoulder screws (Fig. 128). 32. Install the hairpin and clevis pin holding the retaining cable stop for the seat (Fig. 130). 3 Fig. 128 PICT-9259 31. Install the two shoulder bolts and nuts retaining the seat base to the seat pivot/control assembly (Fig. 129). Fig. 129 TimeCutter® Z/Precision® Z Service Manual Fig. 130 PICT-9256 33. Install the wire harness retainer to the seat base (Fig. 131). Fig.
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CHASSIS 34. Install the wire plug harness to the seat switch (Fig. 132). 'HFN /LIW 6HDW 3RGV %UDFNHW 5HSODFHPHQW 'HFN /LIW 6HDW 3RGV %UDFNHW 5HPRYDO 1. Remove the negative battery cable from the battery (Fig. 134). 3 Fig. 132 PICT-9246 35. Install the negative battery cable to the battery (Fig. 133). Fig. 134 PICT-9219 2. Remove the mower deck; see “Mower Deck Removal” on page 6-12. 3. Remove the 3 shoulder screws retaining the left hand pod to the frame (Fig. 135). Fig. 133 PICT-9219 36.
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CHASSIS 4. Remove the left hand pod from the unit. (Fig. 136). 6. Remove the fuel cap and the rubber washer. 7. Remove the 3 shoulder screws retaining the right hand pod to the frame (Fig. 138). 3 Fig. 136 PICT-9260 Fig. 138 IMG-0455a 5. Remove the four screws on the control panel and move the control panel away from the pod (Fig. 137). 8. Remove the right hand pod from the frame (Fig. 139). Fig. 137 PICT-9225 Fig.
PAGE 59
CHASSIS 9. Remove the wire plug of the harness from the seat switch (Fig. 140). 11. Cut and remove the cable tie running through the retention tabs located on the seat/pods bracket (Fig. 142). 3 Fig. 140 PICT-9246 Fig. 142 10. Remove the wire harness retainer located on the seat base (Fig. 141). Fig. 141 3-36 PICT-9251 PICT-9235 12. Remove the fuel tank from the frame (Fig. 143). Fig.
PAGE 60
CHASSIS 13. Remove the battery positive cable from the battery. 14. Remove the battery hold down and remove the battery from the battery tray (Fig. 144). 16. Remove the right and left neutral safety switches by pushing the clip that retains the neutral switch to the seat pivot/control assembly (Fig. 146). 3 Fig. 144 PICT-9372 15. Remove the screw from the battery tray and the seat/pods bracket. Remove the bolt and nut from the frame (Fig. 145). Fig. 146 17.
PAGE 61
CHASSIS 18. Remove the left and right spring clip retaining the brake cable to the brake arm (Fig. 148). 20. Remove the cotter pin and washer from the lift lever assembly (Fig. 150). 1RWH 5HDU ZKHHO UHPRYHG IRU WKH SLFWXUH FODULW\ 3 Fig. 150 Fig. 148 PICT-9392 PICT-9385 21. Remove the 4 bolts and nuts retaining the seat/pods bracket to the frame (Fig. 151). 5HPRYH WKH EUDNH FDEOH FRQGXLW ¿WWLQJ ORFDWHG RQ the right and left side of the seat/pods bracket (Fig. 149). Fig. 151 Fig.
PAGE 62
CHASSIS 22. Pull the neutral wiring harness out of the hole located on the backside of the seat/pods bracket. There is one on the left side and one on the right side (Fig. 152). 24. Remove the screw from the relay base and remove the base from the seats/pods bracket (Fig. 154). 3 Fig. 154 Fig. 152 PICT-9417 PICT-9465a 25. Remove the two screws retaining the fuse block to the seats/pods bracket (Fig. 155). 23. Unplug the relay from the harness (Fig. 153). Fig. 155 Fig.
PAGE 63
CHASSIS 26. Open the wire harness clamp located on the right side of the seat/pods bracket and remove the wire harness (Fig. 156). 28. Remove the seat/pods bracket from the frame (Fig. 158). 3 Fig. 158 Fig. 156 PICT-9425 PICT-9422 29. Remove the lift plate from the frame (Fig. 159). 27. Open the wire harness clamp located on the left side of the seat/pods bracket and remove the wire harness (Fig. 157). Fig. 159 Fig.
PAGE 64
CHASSIS 30. Remove the two bolts and nuts retaining the lift arm assembly to the lift lever assembly (Fig. 160). 'HFN /LIW 6HDW 3RGV %UDFNHW ,QVWDOODWLRQ 1. Install the lift lever assembly to the lift link (Fig. 162). 3 Fig. 160 PICT-9430 Fig. 162 31. Remove the lift lever assembly from the lift link (Fig. 161). Fig. 161 2. Install the two bolts through the lift lever assembly. Note the bolt location in the lift lever assembly (Fig. 163). PICT-9435 Fig.
PAGE 65
CHASSIS 3. Install the bolts and nuts to the lift arm assembly and the lift lever assembly and tighten (Fig. 164). 5. Install the seat/pods bracket to the frame (Fig. 166). 3 Fig. 166 Fig. 164 6. Install the two screws in the fuse block to the seat/ pods bracket (Fig. 167). 4. Install the lift plate to the frame (Fig. 165). Fig. 165 3-42 PICT-9425 PICT-9430 PICT-9439 Fig.
PAGE 66
CHASSIS 7. Install the relay base with one screw and tighten it down to the seat/pods bracket (Fig. 168). 9. Install the throttle/choke cable and the wiring harness in the wire clamp located on the right side of the seat/pods bracket (Fig. 170). 3 Fig. 168 PICT-9441a Fig. 170 8. On the left side of the seat/pods bracket install the wiring harness into the wire clamp (Fig. 169). Fig. 169 TimeCutter® Z/Precision® Z Service Manual PICT-9442 PICT-9443 10. Plug the relay into the relay base (Fig. 171).
PAGE 67
CHASSIS 11. Install the right and left neutral wiring harnesses through the hole on the back side of the seat/pods bracket (Fig. 172). 13. Install the washer and cotter pin on the lift lever assembly (Fig. 174). 3 Fig. 174 Fig. 172 12. Install the 4 bolts and washers that retain the seat/ pods bracket to the frame (Fig. 173). Fig. 173 14.
PAGE 68
CHASSIS 15. Install the brake cable eyelet to the brake arm and install the spring clip (Fig. 176). 17. Route the left and right neutral switches, with harness attached, and clip them into the side of the seat pivot/control assembly (Fig. 178). 3 Fig. 176 PICT-9385 Fig. 178 16. Install the neutral switches in the right and left wiring harnesses (Fig. 177). Fig. 177 18. Install the battery tray to the seat/pods bracket with a screw, bolt and nut to the frame (Fig. 179). PICT-9382 Fig.
PAGE 69
CHASSIS 19. Install the battery to the battery tray with the battery hold down (Fig. 180). 22. Install cable tie through the retention tabs located on the seat/pods bracket (Fig. 182). 3 Fig. 180 PICT-9372 20. Install the positive battery cable to the battery. Fig. 182 PICT-9370 23. Install the wire seat switch harness retainer to the hole located on the seat base (Fig. 183). 21. Install the fuel tank to the frame (Fig. 181). Fig. 183 Fig.
PAGE 70
CHASSIS 24. Install the seat switch wiring harness plug to the seat switch (Fig. 184). 26. Install the 3 shoulder screws into the right hand pod and tighten (Fig. 186). 3 Fig. 184 PICT-9246 25. Install the right hand pod to the frame (Fig. 185). Fig. 186 IMG-0455a ,QVWDOO WKH UXEEHU ZDVKHU DURXQG WKH IXHO ¿OO WXEH DQG install the fuel cap. 28. Install the four screws in the control panel to the right hand pod and tighten (Fig. 187). Fig. 185 PICT-9454 Fig.
PAGE 71
CHASSIS 31. Install the mower deck; see “Mower Deck Installation” on page 6-13. 29. Install the left pod onto the frame (Fig. 188). 32. Install the negative battery cable to the battery (Fig. 190). 3 Fig. 188 PICT-9457 30. Install the 3 shoulder screws that retain the left hand pod to the frame and tighten (Fig. 189). Fig. 190 PICT-9219 $UP /LIW 5HDU 5HSODFHPHQW Arm-Lift, Rear, Removal 1. Remove the negative battery cable from the battery (Fig. 191). Fig. 189 IMG-0457a Fig.
PAGE 72
CHASSIS 2. Remove the mower deck; see “Mower Deck Removal” on page 6-12. 6. Remove the right hand pod from the frame (Fig. 194). 3. Remove the four screws on the control panel and move the control panel away from the pod (Fig. 192). 3 Fig. 194 Fig. 192 PICT-9225 PICT-9232 6. Remove the wire plug on the wire harness from the seat switch (Fig. 195). 4. Remove the fuel cap and the rubber washer from the IXHO ¿OO WXEH 5. Remove the 3 shoulder screws retaining the right hand pod to the frame (Fig. 193).
PAGE 73
CHASSIS 7. Remove the wire harness retainer located on the seat base (Fig. 196). 9. Remove the fuel tank from the frame (Fig. 198). 3 Fig. 198 Fig. 196 8. Cut and remove the cable tie running through the retention tabs located on the seat/pods bracket (Fig. 197). 10. Remove the cotter pin and washer from the lift lever assembly (Fig. 199). Fig. 199 Fig.
PAGE 74
CHASSIS 11. Remove the bolt, washer and nut retaining the pivot block for the arm-lift on either the right or left side of the frame (Fig. 200). Loosen the bolt, washer, and nut on the other side. Arm-Lift, Rear, Installation 1. Loosely install the pivot block with the round tab (Fig. 202) into the hole located below the bolt, washer, and nut to the frame (Fig. 203). 3 Fig. 200 PICT-9467 Fig. 202 PICT-9478a Fig. 203 PICT-9481 12. Remove the arm-lift from the frame (Fig. 201). Fig.
PAGE 75
CHASSIS 2. Install the end of the arm-lift into the pivot block (Fig. 204) and install the other pivot block to the other side of the frame (Fig. 205). Tighten both pivot blocks to the frame. 3. Install the lift link of the arm-lift to the lift lever assembly with washer and cotter pin (Fig. 206). 3 Fig. 206 Fig. 204 PICT-9392 PICT-9467 4. Install the fuel tank to the frame (Fig. 207). Fig. 205 3-52 PICT-9480 Fig.
PAGE 76
CHASSIS 5. Install a cable tie through the retention tabs located on the seat/pods bracket (Fig. 208). 7. Install the wire plug on the wire harness to the seat switch (Fig. 210). 3 Fig. 208 PICT-9238 6. Install the wire harness retainer to the seat base (Fig. 209). Fig. 210 8. Install the right hand pod to the frame (Fig. 211). Fig. 211 Fig.
PAGE 77
CHASSIS 9. Install the 3 shoulder screws that retain the right hand pod to the frame (Fig. 212). 11. Install the control panel to the right hand pod using 4 screws and tighten (Fig. 214). 3 Fig. 212 IMG-0455a 10. Install the rubber washer and fuel cap to the fuel WDQN ¿OO WXEH )LJ Fig. 214 PICT-9241 12. Install the mower deck; see “Mower Deck Installation” on page 6-13. 13. Install the negative battery cable to the battery (Fig. 215). Fig. 213 PICT-9226 Fig.
PAGE 78
CHASSIS 5HDU %XPSHU 5HSODFHPHQW Rear Bumper Installation Rear Bumper Removal 1. Install the rear bumper to the frame (Fig. 218). 1. Remove the 4 bolts, washers and nuts (Fig. 216). 3 Fig. 218 Fig. 216 PICT-9484 2. Remove rear bumper from the frame (Fig. 217). Fig. 217 2. Install washers under each bolt head. On the two outside bolts, install a large hardened washer between the bolt and the nut; the other two bolts use regular washers. Tighten all 4 bolts, washers and nuts (Fig. 219).
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CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 80
ENGINE Engine Replacement 4. Remove the bolt retaining the electric PTO clutch to the engine crankshaft (Fig. 222). Engine Removal 1. Remove the negative battery cable from the battery. 2. Release the mower drive belt tension and remove the mower drive belt from the electric PTO clutch (Fig. 220). Fig. 222 PICT-9502a 5. Remove the electric PTO clutch from the crankshaft (Fig. 223). Fig. 220 PICT-9493 3. Remove the plug connector from the electric PTO clutch (Fig. 221). Fig. 223 Fig.
PAGE 81
ENGINE 6. Release the spring tension on the idler arm using a spring tool (Toro p/n 92-5771). Remove the drive belt from the engine pulley (Fig. 224). 8. Remove the two screws retaining the heat shield to WKH PXIÀHU )LJ Fig. 226 4 Fig. 224 PICT-9510a PICT-9506 5HPRYH WKH KHDW VKLHOG IURP WKH PXIÀHU )LJ 7. Remove the engine drive pulley from the crankshaft of the engine (Fig. 225). Fig. 227 Fig.
PAGE 82
ENGINE 10. Remove the 4 engine bolts going through the hydrosupports of the frame and up into the engine block (Fig. 228). 12. Loosen the throttle/choke cable clamp screw and remove the cable (Fig. 230). Fig. 230 Fig. 228 5HPRYH WKH KRVH FODPS E\ WKH IXHO ¿OWHU DQG UHPRYH the fuel line (Fig. 229). 13. Remove the z-bend of the throttle/choke cable from the engine control assembly (Fig. 231). Fig. 231 Fig.
PAGE 83
ENGINE 14. Remove the engine wire harness plug (Fig. 232). Fig. 232 4 16. Remove the negative battery cable and the negative wire from the wiring harness from the top of the starter (Fig. 234). PICT-9522a Fig. 234 PICT-9525 15. Remove the positive starter cable from the bottom of the starter (Fig. 233). 17. Raise the engine off the frame (Fig. 235). Fig. 233 PICT-9523 Fig.
PAGE 84
ENGINE Engine Installation 3. Install the negative battery cable and the negative wire to the wiring harness to the top of the starter terminal (Fig. 238). 1. Install the engine into the frame (Fig. 236). Fig. 236 PICT-9529 2. Make sure when lowering the engine that the engine oil drain tube is routed through the hole in the frame (Fig. 237). Fig. 238 4. Install the positive starter cable to the bottom of the engine starter (Fig. 239). Fig. 239 Fig.
PAGE 85
ENGINE 5. Plug the engine wire harness into the main wiring harness (Fig. 240). Fig. 240 4 PICT-9522a 6. Install the z-bend of the throttle/choke cable into the middle hole of the engine linkage (Fig. 241). Fig. 241 4-6 7. Install the throttle/choke cable into the cable clamp, before tightening the clamp, make sure the throttle control is in the low idle setting (Fig. 242). Also, make sure the throttle linkage on the engine carburetor is pushed to far left stop position (Fig. 243). Tighten the clamp.
PAGE 86
ENGINE ,QVWDOO WKH IXHO OLQH RQWR WKH IXHO ¿OWHU DQG LQVWDOO WKH hose clamp (Fig. 244). Fig. 246 Fig. 244 PICT-9537 PICT-9515 10. Install the 2 screws retaining the heat shield to the PXIÀHU )LJ 9. Install the 4 engine mounting bolts through the hydro-supports of the frame and into the engine (Fig. 245). Torque the engine bolts to 400 – 500 in-lbs. (33.3 – 41.6 Nm) (Fig. 246). Fig. 247 Fig.
PAGE 87
ENGINE 11. Apply anti-seize lubricant to the engine crankshaft (Fig. 248). Fig. 248 4 13. Install the drive belt around the engine drive pulley by releasing the spring tension on the idler arm. Make sure the belt is routed around both transmisVLRQ SXOOH\V DURXQG WKH WZR ÀDW LGOHU SXOOH\V DQG then around the engine drive pulley (Fig. 250). PICT-9538 Fig. 250 PICT-9506 12. Install the engine drive pulley.
PAGE 88
ENGINE 15. Install the electric PTO clutch onto the crankshaft. Make sure the slot of the PTO clutch engages with the clutch stop bracket (Fig. 252). 17. Install the plug connector into the electric PTO clutch (Fig. 254). Fig. 254 Fig. 252 16. Torque the electric PTO clutch bolt to 50 – 60 ft-lbs. (67.8 – 81.3 Nm), while holding the center hub of the clutch (Fig. 253). 18. Release the mower arm tension and install the mower drive belt onto the electric PTO clutch (Fig. 255). Fig. 255 Fig.
PAGE 89
ENGINE (QJLQH 0XIÀHU 5HSODFHPHQW (QJLQH 0XIÀHU 5HPRYDO 5HPRYH WKH WZR VFUHZV UHWDLQLQJ WKH PXIÀHU KHDW VKLHOG WR WKH PXIÀHU )LJ Fig. 258 4 PICT-9562 5HPRYH WKH PXIÀHU IURP WKH HQJLQH )LJ Fig. 256 PICT-9510 2. Remove the 4 screws, washers and 2 gaskets reWDLQLQJ WKH PXIÀHU WR WKH HQJLQH )LJ /+ DQG )LJ 5+ Fig. 259 Fig.
PAGE 90
ENGINE (QJLQH 0XIÀHU ,QVWDOODWLRQ 5HLQVWDOO WKH PXIÀHU LQ UHYHUVH RUGHU 4 TimeCutter® Z/Precision® Z Service Manual 4-11
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MOWER DECK Mower Spindle Replacement 4. With a rag or thickly-padded glove hold the blade end and remove the nut on the spindle pulley with a 15/16” wrench (Fig. 370). Mower Spindle Removal 1. Remove the mower deck from the unit; see “Mower Deck Removal” on page 6-12. 2. Remove the 3 screws retaining the belt cover to the deck (Fig. 368). Fig. 370 PICT-9862 5. Remove the 4 screws retaining the spindle assembly to the mower deck (Fig. 371). Fig. 368 PICT-9855 3.
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MOWER DECK 6. Remove the mower spindle assembly from the deck (Fig. 372). Fig. 372 PICT-9865a 7. Loosen the blade screw on the spindle (Fig. 373). 8. Remove the blade screw and washer from the spindle shaft (Fig. 374). Fig. 374 PICT-9872a 9. Remove the blade stiffener (Fig. 375). 6 Fig. 373 6-2 PICT-9870a Fig.
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MOWER DECK 10. Remove the mower blade (Fig. 376). Fig. 376 12. Remove the spacer (Fig. 378). PICT-9874a 11. Remove the spindle shaft and bearing shield (Fig. 377). Fig. 378 PICT-9876 13. With a punch, drive one of the bearings out of the housing (Fig. 379). 6 Fig. 377 TimeCutter® Z/Precision® Z Service Manual PICT-9875a Fig.
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MOWER DECK 14. Remove the spacer from the housing (Fig. 380). Housing, spacer, and bearings (Fig. 382) C B A Fig. 380 C Fig. 382 PICT-9881a A. Housing B. Spacer PICT-9884 C. Bearing (2) 15. Turn the housing over and drive the other bearing out the other side with a punch (Fig. 381). 6 Fig.
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MOWER DECK Mower Spindle Installation 3. Press another bearing in until it seats (Fig. 385). 1. Starting at the top of the spindle housing, press bearing into the housing until it seats (Fig. 383). Fig. 385 Fig. 383 PICT-9885 PICT-9889 4. Install the spindle shaft, bearing shield and spacer into the spindle housing (Fig. 386). 2. Turn the spindle housing over and install spacer in the housing (Fig. 384). 6 Fig. 386 Fig.
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MOWER DECK 5. Install the mower blade onto the spindle shaft (Fig. 387). 7. Install blade bolt and washer (Fig. 389). Fig. 389 Fig. 387 PICT-9895a PICT-9892a 8. Torque the blade bolt to 35 – 65 ft-lbs. (47 – 88 Nm) (Fig. 390). 6. Install the blade stiffener (Fig. 388). 6 Fig. 388 6-6 PICT-9893a Fig.
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MOWER DECK 9. Install the mower spindle assembly with blade onto the deck (Fig. 391). Fig. 391 PICT-9865 10. Install the 4 screws retaining the spindle assembly to the deck and torque to 200 – 250 in-lbs. (16.7 – 20.8 Nm) (Fig. 392). 10. Install the spindle pulley with large hub of the pulley facing down toward the deck (Fig. 393). Fig. 393 PICT-9897 11. Install the spindle pulley nut and torque to 50 ft-lbs. (67.8 Nm) (Fig. 394). 6 Fig. 392 TimeCutter® Z/Precision® Z Service Manual Fig.
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MOWER DECK 12. Install the mower drive belt around the spindle pulley (Fig. 395). Idler Arm Replacement Idler Arm Removal 1. Remove the mower deck from the unit; see “Mower Deck Removal” on page 6-12. 2. Remove the spring extension from the spring return hook (Fig. 397). Fig. 395 PICT-9860a 13. Install the belt cover with three screws and tighten (Fig. 396). Fig. 397 PICT-9900 3. Remove the other end of the spring extension from the idler arm (Fig. 398). 6 Fig. 396 PICT-9855 14.
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MOWER DECK 4. Remove the screw retaining the idler arm to the mower deck (Fig. 399). Idler arm assembly (Fig. 401) E AB BA F C Fig. 401 Fig. 399 D PICT-9905a PICT-9902 5. Remove the idler arm from the mower deck (Fig. 400). A. Plain Washer (2) B. Friction WasherComposite (2) C. Spacer D. Screw E. Idler Arm F. Flat Idler Pulley 5HPRYH WKH VFUHZ ZDVKHU DQG QXW UHWDLQLQJ WKH ÀDW idler pulley to the idler arm (Fig. 402). 6 Fig. 400 PICT-9904 Fig.
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MOWER DECK Idler Arm Installation Idler arm and pulley assembly (Fig. 403) 1. Install the screw through the idler arm and install the ORQJ KXE RI WKH ÀDW LGOHU SXOOH\ WRZDUG WKH LGOHU DUP (Fig. 404). A B D C Fig. 403 A. Nut B. Washer C. Flat Idler Pulley E PICT-9909a D. Idler Arm E. Screw Fig. 404 PICT-9911 ,QVWDOO WKH ZDVKHU DQG QXW DQG WLJKWHQ ÀDW LGOHU SXOOH\ to the idler arm (Fig. 405). 6 Fig.
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MOWER DECK 3. Install a plain washer on the screw for the idler arm, friction washer-composite, spacer through the idler arm; on the other side install a friction washercomposite, plain washer (Fig. 406). 5. Install one end of the extension spring to the idler arm (Fig. 408). Fig. 408 Fig. 406 PICT-9913 PICT-9905a 6. Install the other end of the spring extension to the spring return hook (Fig. 409). 4. Install and tighten the idler arm assembly to the mower deck (Fig. 407). 6 Fig. 409 Fig.
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MOWER DECK Fixed Flat Idler Pulley Replacement Mower Deck Replacement Fixed Flat Idler Pulley Removal Mower Deck Removal 1RWH 7KHUH DUH WZR ÀDW LGOHU SXOOH\V ORFDWHG RQ WRS of the mower deck. They are both replaced the same way. 1. Park the machine on a level surface and disengage the PTO switch. 5HPRYH WKH VFUHZ DQG ZDVKHU WKURXJK WKH ¿[HG ÀDW idler and remove (Fig. 410). 2.
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MOWER DECK 5. Lift the mower deck and hanger brackets clear of the rear lift rod and lower the mower carefully to the ground (Fig. 413). Mower Deck Installation 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to the park position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. C 3. Slide the mower under the machine. B B 4.
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MOWER DECK 6. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Fig. 415). Leveling the Mower Deck Check to ensure the mower deck is level whenever the mower is installed or there is poor cutting performance. The mower deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. See “Checking for Bent Blades” on page 6-20 before continuing.
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MOWER DECK Side-to-Side Leveling 1. Park the machine on a level surface and disengage the PTO switch. 2. Move the motion control levers outward to the park position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. C 3. Set the height-of-cut lever to middle position. 4. Carefully rotate the blades so that they are all side to side (Fig. 416 and Fig. 417). B A B C A D D Fig. 417 C C D B ¿J * Mower Decks with 3 Blades A.
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MOWER DECK 6. Move to the left side of the machine. Loosen, but do not remove, the rear locking nut on the hanger bracket (Fig. 418). Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 5/16” (7.9mm) lower than the rear of the mower, adjust the blade level using the following instructions. 1. Park the machine on a level surface and disengage the blade control switch. D A C 3.
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MOWER DECK 4. Carefully rotate the blades so they are facing front to rear (Fig. 419 and Fig. 420). B A 0HDVXUH IURP WKH WLS RI WKH IURQW EODGH WR WKH ÀDW VXU IDFH DQG WKH WLS RI WKH UHDU EODGH WR WKH ÀDW VXU IDFH (Fig. 419 and Fig. 420). If the front blade tip is not 1/16 - 5/16” (1.6 - 7.9mm) lower than the rear blade tip, adjust the front locknut. 6. To adjust the front-to-rear blade slope, rotate the adjustment nut in the front of the mower (Fig. 421). B Fig.
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MOWER DECK Mower Belt Maintenance Inspecting the Belts Mower Belt Routing Service Interval: Every 25 hours - Check the belts for wear/cracks. Belt routing decals: For models with 42” decks: Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. Mower Belt Replacement Note: Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt.
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MOWER DECK 5. Pull the idler pulley in the direction shown (Fig. 424) and roll the belt off of the pulleys. C 6. Route the new belt around the engine pulley and mower pulleys (Fig. 425). C B A E C A. Idler pulley B. Mower belt C. Outside pulley Fig. 425 ¿J * Mower Decks with 2 Blades D. Spring E. Engine pulley ! The spring is under tension when installed and can cause personal injury. A C D D Fig. 424 B E ¿J * Mower Decks with 3 Blades A. Idler pulley B. Mower belt C.
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MOWER DECK Checking for Bent Blades 0HDVXUH IURP WKH WLS RI WKH EODGH WR WKH ÀDW VXUIDFH here (Fig. 427). Note: The machine must be on a level surface for the following procedure. 1. Raise the mower deck to the highest height-of-cut position; also considered the ’transport’ position. 2.
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MOWER DECK 0HDVXUH IURP WKH WLS RI WKH EODGH WR WKH ÀDW VXUIDFH here. The variance should be no more than 1/8” (3mm) (Fig. 429). Service Interval: Every 25 hours – Check tire pressure. Maintain the air pressure in the front and rear tires as VSHFL¿HG 8QHYHQ WLUH SUHVVXUH FDQ FDXVH XQHYHQ FXW Check the pressure at the valve stem (Fig. 430). Check the tires when they are cold to get the most accurate pressure reading. A B Checking the Tire Pressure C Fig. 429 A ¿J * A.
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MOWER DECK THIS PAGE INTENTIONALLY LEFT BLANK.
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ELECTRICAL Electrical System How It Works Two things happen when turning the ignition switch to WKH ³67$57´ SRVLWLRQ &XUUHQW ÀRZV IURP WKH LJQLWLRQ switch to the starter solenoid coil terminal. (2) At the VDPH WLPH FXUUHQW ZLOO ÀRZ WKURXJK WKH 372 3RZHU 7DNH 2II VZLWFK LQ WKH 2)) SRVLWLRQ WKURXJK ERWK WKH EUDNH VZLWFKHV LQ WKH 2)) RU 3$5. SRVLWLRQ WR WKH FRLO terminal of the interlock relay (kill relay).
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ELECTRICAL Testing Solenoid 1. Disconnect the relay from the harness. Purpose 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30. The solenoid’s purpose is simply to connect the battery to the starter motor on the engine when the ignition switch is turned to “START”. The solenoid is used to protect the ignition switch from the high current drawn by the starter motor.
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ELECTRICAL How It Works Testing 7KH VROHQRLG KDV WZR SULPDU\ SDUWV 2QH D FRLO RI ZLUH is wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch. Because it has a large contact area with the contact terminals, it can easily handle the high current loads required by the starter motor of the engine. 1. Disconnect the solenoid from the wiring harness. When 12 volts is applied to the coil, it becomes an electromagnet.
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ELECTRICAL Ignition Switch How It Works Purpose 'HWHQWV LQVLGH WKH VZLWFK JLYH LW SRVLWLRQV 2)) 581 and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released (Fig. 438). The ignition switch provides the proper switching for the starter, ignition, accessories, and safety circuits. Location B The ignition switch is located on the control panel, to the right side of the operator (Fig. 437). A Y S I X Fig. 438 BSIAFig.
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ELECTRICAL PTO Switch How It Works Purpose :KHQ WKH 372 VZLWFK LV SXOOHG RXW WR WKH 21 SRVLWLRQ contacts inside the switch electrically connect various WHUPLQDOV 2QH WHUPLQDO LV FRQQHFWHG WR WKH ZLUH WKDW JRHV GLUHFWO\ WR WKH HOHFWULF FOXWFK :KHQ WKH 372 VZLWFK LV SXOOHG RXW WR WKH 21 SRVLWLRQ YROWDJH ÀRZV WR WKH electric clutch and it engages. 7KH 372 3RZHU 7DNH 2II VZLWFK LV W\SLFDOO\ XVHG WR WXUQ RQ WKH (OHFWULF 372 &OXWFK DQG WR IXQFWLRQ DV SDUW RI the safety interlock system.
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ELECTRICAL OFF (“IN” POSITION) ON (“OUT” POSITION) Cont. Open Open Open Open Cont. OFF (“IN” POSITION) ON (“OUT” POSITION) Cont. Open Open Open Open Cont. 7 Fig.
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ELECTRICAL Electric (PTO) Clutch How It Works Purpose 7KH 372 FOXWFK LV FRPSRVHG RI WKUHH PDMRU FRPSRQ HQWV WKH ¿HOG WKH FOXWFK SODWH DQG WKH IULFWLRQ SODWH 7KH FOXWFK SODWH DOZD\V WXUQV ZLWK WKH HQJLQH 7KH ¿HOG LV D coil of wire on an iron core, which becomes an electromagnet when power is applied. This clutch electrically controls the engagement and GLVHQJDJHPHQW RI WKH 3RZHU 7DNH 2II 372 SXOOH\ Location 7KH HOHFWULF FOXWFK LV ORFDWHG RQ WKH 372 HQG RI WKH engine crankshaft (Fig. 441).
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ELECTRICAL Coil Resistance Measurement Measuring Clutch Current Draw 'LVHQJDJH WKH 372 VHW WKH SDUNLQJ EUDNH WXUQ WKH LJQLWLRQ WR 2)) DQG UHPRYH WKH NH\ 'LVHQJDJH WKH 372 VHW WKH SDUNLQJ EUDNH WXUQ WKH LJQLWLRQ NH\ WR 2)) DQG UHPRYH WKH NH\ 2. Disconnect clutch wire connector. 2. Disconnect the clutch wire connector. 3. Set the multimeter or volt/ohm meter to check resistance (ohms). 3. Set the multimeter to check amps (10 amp scale). 4.
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ELECTRICAL Park Brake Switch How It Works Purpose This single pole plunger type switch has two terminals. When the forward/reverse control levers are in the park position (handles in the out position), it pushes on the plunger, closing the contact, and connecting the terminals (Fig. 445). Used to ensure the transaxles are in neutral and the park brakes are engaged. It is activated when the forward/ reverse control levers are in the park position (handles in the out position).
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ELECTRICAL Switch, Seat How It Works Purpose When the seat is vacated, the switch is open and there VKRXOG EH 12 FRQWLQXLW\ EHWZHHQ WKH WZR WHUPLQDOV When the seat is occupied, the switch closes and there should be continuity between the two terminals (Fig. 447). The switch is in the safety circuit. If the engine is running DQG WKH RSHUDWRU YDFDWHV WKH VHDW ZLWK HLWKHU WKH 372 engaged or the parking brake off, the engine will shut down.
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ELECTRICAL FlyBack Diode How It Works Purpose ,I WKH HOHFWULF 372 VZLWFK LV OHIW RQ DIWHU VKXWGRZQ DQG you go to restart the engine, it could feed enough curUHQW WR DFWLYDWH WKH HOHFWULF 372 FOXWFK YHU\ EULHÀ\ 7KH FlyBack diode blocks this from happening. The FlyBack diode is located on 2009 and later TimeCutter Z (Fig. 449). 7KH )O\%DFN EORFNLQJ GLRGH SUHYHQWV WKH 372 FOXWFK from interfering with the starting of the engine.
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ELECTRICAL Toro TimeCutter Z 2007-2008 Models Schematic 7 Fig.
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ELECTRICAL Toro TimeCutter Z 2009 Models Schematic 7 Fig.
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ELECTRICAL Lawn-Boy Precision Z (Single Cylinder Engines) 2008 Models Schematic 7 Fig.
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ELECTRICAL Lawn-Boy Precision Z (Twin Cylinder Engines) 2008 Models Schematic 7 Fig.
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