Page 1 LCE Products Floating Deck Mid-Size Service Manual...
Page 2 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION General Information ........................1-1 Think Safety First..........................1-1 SPECIFICATIONS Torque Speciﬁ cations ........................2-1 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) ........2-2 Standard Torque for Dry, Zinc and Steel Fasteners (Metric Fasteners) ........2-3 Other Torque Speciﬁ cations ......................2-4 Equivalents and Conversions .......................2-5 U.S.
Page 5 TABLE OF CONTENTS CHASSIS cont. Castor Wheel Fork Bushing Replacement .................3-60 Castor Wheel Fork Bushing Removal ..................3-60 Castor Wheel Fork Bushing Installation ................3-61 Fuel Tank Replacement ......................3-62 Fuel Tank Removal ......................3-62 Fuel Tank Installation ......................3-67 Battery Tray Replacement ......................3-70 Battery Tray Removal ......................3-70 Battery Tray Installation .......................3-72 Mid-Size Weight Replacement ....................3-74 Checking the Brake (T-Bar) ......................3-75...
Page 6 TABLE OF CONTENTS LINKAGE cont. Neutral Stud Adjustment (Pistol Grip) ..................4-126 Adjusting the Control Rod (Pistol Grip)..................4-128 Checking the Control Rod ....................4-128 Adjusting the Control Rod ....................4-128 Tracking Adjustment (Pistol Grip) .....................4-129 Tracking Adjustment (T-2) ......................4-130 Neutral Adjustment (T-2)......................4-130 Control Bar Adjustment (T-Bar) ....................4-132 ENGINE Engine Removal - Pistol Grip Hydro .....................5-1 Engine Installation - Pistol Grip Hydro ..................5-9...
Page 7 TABLE OF CONTENTS MOWER DECKS Mower Spindle Drive Belt Replacement ..................8-1 Mower Spindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) ......8-1 Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) ......8-2 Mower Spindle Drive Belt Removal (36” Mower Deck) ............8-4 Mower Spindle Drive Belt Installation (36”...
Page 8 TABLE OF CONTENTS MOWER DECKS cont. Quick Latch Replacement ......................8-59 Quick Latch Removal ......................8-59 Quick Latch Installation ......................8-60 Mower Deck Removal ......................8-61 Mower Deck Installation .......................8-62 Checking the Engine Deck Height ....................8-63 Checking the Carrier Frame Front-to-Rear Pitch................8-64 Checking the Carrier Frame Side-to-Side Height ...............8-64 Checking the Mower Deck Front-to-Rear Pitch ................8-65 Adjusting the Mower Deck Front-to-Rear Pitch ................8-66 Checking the Mower Deck Side-to-Side Height .................8-66...
Page 9 TABLE OF CONTENTS ELECTRICAL cont. Parking Brake Switch Replacment (Pistol Grip & T-2) ..............9-26 Parking Brake Switch Removal (P.G. & T-2) ................9-26 Parking Brake Switch Installation (P.G. & T-2) ..............9-27 Neutral Switch Replacement (Pistol Grip) ..................9-28 Neutral Switch Removal (P.G.).....................9-28 Neutral Switch Installation (P.G.)..................9-29 PTO Switch Replacement (Electric Start) ...................9-31 PTO Switch Removal (Electric Start) ...................9-31...
Page 10: Safety Information
Operator’s manuals are available through your with your safety. Failure to comply with Toro parts source or: the instruction may result in personal injury or even death. The Toro Company...
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Page 12: 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.
Page 13: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series)
SPECIFICATIONS Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, &...
Page 14: Standard Torque For Dry, Zinc And Steel Fasteners (Metric Fasteners)
SPECIFICATIONS Standard Torque for Dry, Zinc and Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Regular Height Nuts Regular Height Nuts ( (Class 8 or Strong Nuts) Class 10 or Strong Nuts)
Page 15: Other Torque Specifications
SPECIFICATIONS Other Torque Speciﬁ cations Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb 88 ± 14 N-m Grade 5 1/4 - 20 UNC 140 ±...
Page 16: Equivalents And Conversions
SPECIFICATIONS Equivalents and Conversions Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64...
Page 17: U.s. To Metric Conversions
SPECIFICATIONS U.S. to Metric Conversions U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Feet Centimeters 30.48 Measurement Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters...
Page 18: Hydro With Pistol Grip Controls
4.0 pint (1.9L) Fuel System: 4.8 gallons (18 liters) fuel tank capacity Traction Drives: Traction Control: Toro Pistol Grip Control System Hydraulic Pump: Two Hydro-Gear Model PG Hydraulic Wheel Motor: Two Parker TEO-195 / Model 30280: Parker TEO-230 Hydraulic Oil Filter:...
Page 19: Hydro With Pistol Grip Controls Cont
SPECIFICATIONS Hydro with Pistol Grip Controls cont. Wheels and Tires: Front Castor Tires: 9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease ﬁ ttings / Model 30280: 11x4.0-5 smooth tread, semi-pneumatic with tapered roller bearings Front Castor Fork: Heavy-duty commercial design with 1-1/8”...
Page 20 Hydro with Pistol Grip Controls cont. Unit Dimensions: Width Deﬂ ector Width Deﬂ ector Model No. Height* Down Raised Length* Weight** 30284 41.5” (105cm) 51.1” (130cm) 37.2” (94cm) 84.5” (214cm) 677 lbs. (302kg) 30286 41.5” (105cm) 55.5” (141cm) 41.6” (105cm) 81.3”...
Page 21: Hydro With T-2 Controls
Oil Capacity 3.8 pint (1.8L) 3.8 pint (1.8L) Fuel System: 4.8 gallons (18 liters) fuel tank capacity Traction Drives: Traction Control: Toro T2 Control System Hydraulic Pump: Two Hydro-Gear Model PG Hydraulic Wheel Motor: Two Parker TEO-195 Hydraulic Oil Filter:...
Page 22: Hydro With T-2 Controls Cont
SPECIFICATIONS Hydro with T-2 Controls cont. Mower Drive: Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm) PTO Drive Belt: HB section with Aramid (Kevlar) cords and dry clutching envelope PTO Idler: Spring loaded pivot hub with grease ﬁ...
Page 23: Gear With T-Bar Controls
Oil Capacity 3.8 pint (1.8L) 3.8 pint (1.8L) Fuel System: 4.8 gallons (18 liters) fuel tank capacity Traction Drives: Traction Control: Toro T-Bar Control System Transmission: Peerless 700-070A, 5 speed forward / 1 reverse Transmission Output Shaft: Heavy-duty with 9 tooth spline Axle: 1”...
Page 24: Gear With T-Bar Controls Cont
SPECIFICATIONS Gear with T-Bar Controls cont. Wheels and Tires: Front Castor Tires: 9x3.5-4, 4 ply smooth tread, semi-pneumatic with needle bearings and grease ﬁ ttings Front Castor Fork: Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs have grease ﬁ...
Page 25 SPECIFICATIONS Gear with T-Bar Controls cont. Unit Dimensions: Width Deﬂ ector Width Deﬂ ector Model No. Height* Down Raised Length* Weight** 30092 43.5” (110cm) 42” (107cm) 32” (81cm) 73” (185cm) 388 lbs. (176kg) 30094 41.2” (105cm) 51.1” (130cm) 37.2” (94cm) 82.7”...
Page 26: International Hydro With T-Bar (T2) Controls
Oil Capacity 3.8 Pint (1.8L) Fuel System: 4.8 Gallons (18 liters) fuel tank capacity Traction Drives: Traction Control: Toro “T2” Control System Hydraulic Pump: Two Hydro-Gear Model PG Hydraulic Wheel Motor: Two Parker TEO-195 Hydraulic Oil Filter: 10 micron automotive spin-on type...
Page 27: International Hydro With T-Bar (T2) Controls Cont
SPECIFICATIONS International Hydro with T-Bar (T2) Controls cont. Mower Drive: Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm) PTO Drive Belt: HB section with Aramid (Kevlar) cords and dry clutching envelope PTO Idler: Spring loaded pivot hub with grease ﬁ...
Page 28: International Gear With T-Bar Controls
Oil Capacity 3.8 pints (1.8L) Fuel System: 4.8 gallons (18 liters) fuel tank capacity Traction Drives: Traction Control: Toro T-Bar Control System Transmission: Peerless 700-070A, 5 speed forward / 1 reverse Transmission Output Shaft: Heavy duty with 9 tooth spline Axle: 1”...
Page 29: International Gear With T-Bar Controls Cont
SPECIFICATIONS International Gear with T-Bar Controls cont. Mower Drive: Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm) PTO Drive Belt: HB section with Aramid (Kevlar) cords and dry clutching envelope PTO Idler: Spring loaded pivot hub with grease ﬁ...
Page 30: Chassis
CHASSIS 5. Unplug the clutch lead from the harness connector Electric Clutch Replacment (Fig. 0002). Electric Clutch Removal 1. Park the machine on a level surface. 2. Turn the engine off and remove the key. 3. Set the parking brake. 4.
Page 31 CHASSIS 7. Remove the carrier frame cover (Fig. 0004). 9. Raise the machine so that the underside of the chassis can be accessed. 10. Remove the trailing shield from the chassis by ﬁ rst removing the left end of the shield rod (bent at a 45 degree angle) from the hole in the frame and then remove the right side of the shield rod (bent at 90 degree angle) from the right side of the frame (Fig.
Page 32 CHASSIS 12. Remove the belt from the clutch (Fig. 0008). 14. Loosen the clutch bolt (Fig. 0010). Fig 0008 PICT-0294 Fig 0010 PICT-0297a 13. Remove the bolt, nut, 2 washers and spacer secur- 15. Remove the bolt, 2 spring washers and ﬂ at washer ing the brake clutch strap to the underside of the securing the clutch to the drive shaft.
Page 33: Clutch Burnishing Procedure
CHASSIS 16. Remove the rubber grommet from the clutch wire Clutch Burnishing Procedure (Fig. 0012). Note: This procedure needs to be done only when installing a new clutch. The clutch should be burnished as part of the pre- delivery service, or whenever a new clutch is installed. Burnishing polishes the clutch plate, allowing for smooth clutch engagement.
Page 34 CHASSIS 2. Assemble the bolt, washers, nut and strap into the 4. Apply thread locking compound to the clutch bolt slotted opening on the clutch as shown. Before (Fig. 0017). tightening, move the strap fastener assembly to the outer-most end of the slot and tighten (Fig. 0015). Fig 0017 PICT-0352a Fig 0015...
Page 35 CHASSIS 6. Install the clutch bolt assembly (Fig. 0019). 8. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0021). Fig 0019 PICT-0355a Fig 0021 PICT-0361 7. Torque the clutch bolt to 55 + 5 ft-lbs. (75 + 7 Nm) (Fig.
Page 36 CHASSIS 10. Install the rubber grommet into the frame opening Note: Ensure the PTO drive belt is routed properly (Fig. 0023). around the mower deck pulley(s). Refer to belt routing decal (Fig. 0025 and Fig. 0026). 36” mower deck belt routing: Fig 0023 PICT-0363 Fig 0025...
Page 37 CHASSIS 12. Install the PTO idler arm spring to the spring post 14. Lower the machine. (Fig. 0027). 15. Roll the PTO drive belt onto the center mower deck pulley (Fig. 0029). Fig 0027 PICT-0367 Fig 0029 PICT-0281 13. Install the trailing shield into the frame by ﬁ rst insert- ing the right side of the trailing shield rod (bent at 16.
Page 38: Pto Idler Replacement
CHASSIS 17. Plug the clutch connector into the harness connector PTO Idler Replacement (Fig. 0031). PTO Idler Removal 1. Turn the engine off and remove the key from the ignition. 2. Remove the carrier frame cover (Fig. 0033). Fig 0031 PICT-0548a 18.
Page 39 CHASSIS 4. Raise the machine so that the underside of the 7. Remove the PTO idler arm assembly from the frame chassis can be accessed. (Fig. 0037). 5. Remove the PTO idler arm spring from the spring post and the idler arm (Fig. 0035). Fig 0037 PICT-0604a Fig 0035...
Page 40 CHASSIS 9. Remove the bolt, washer and Bellville washer 11. Remove the grease ﬁ tting from the idler arm (Fig. securing the pulley to the idler arm (Fig. 0039). 0041). Fig 0039 PICT-0609 Fig 0041 PICT-0613 10. Remove the pulley from the idler arm (Fig. 0040). PTO Idler Assembly (Fig.
Page 41: Pto Idler Installation
CHASSIS 3. Position the pulley onto the idler arm (Fig. 0045). PTO Idler Installation 1. Install the grease ﬁ tting into the idler arm (Fig. 0043). Fig 0045 PICT-0610 Fig 0043 PICT-0613 4. Slide the Belleville washer (crown toward the bolt head) and ﬂ...
Page 42 CHASSIS 5. Slide a washer and idler tube onto the idler pivot 7. Install a washer and nut securing the PTO idler arm bolt. Slide the bolt assembly into the idler arm. assembly to the frame (Fig. 0049). Install a washer onto the bolt (Fig. 0047). Fig 0049 IMG-7690 Fig 0047...
Page 43: Parking Brake Service - Hydro
CHASSIS 9. Lower the machine. Parking Brake Service - Hydro 10. Roll the PTO drive belt onto the center mower deck Checking the Parking Brake pulley (Fig. 0051). 1. Move the machine to a level surface. 2. Turn the ignition off and remove the key. 3.
Page 44: Adjusting The Parking Brake
CHASSIS 5. Turn the upper brake adjustment yoke to adjust the Adjusting the Parking Brake parking brake as follows (Fig. 0056): a. Clockwise to decrease engagement force 1. Check the parking brake before you adjust it. Refer b. Counterclockwise to increase engagement force to “Checking the Parking Brake”, preceding.
Page 45: Parking Brake Removal
CHASSIS 7. Install a cotter pin into the clevis pin (Fig. 0058). 3. Remove the clevis pin securing the top end of the parking brake adjusting rod to the parking brake handle (Fig. 0060). Fig 0058 PICT-0470 Fig 0060 PICT-0471 8.
Page 46 CHASSIS 5. Remove the clevis pin that secures the lower end 7. Remove the bolt, thrust bearing and parking brake of the brake adjusting rod to the parking brake handle from the handle support (Fig. 0064). assembly and remove the brake rod assembly (Fig. 0062).
Page 47 CHASSIS 9. Remove the 2 screws and nuts securing the parking 11. Remove the 2 nuts from the bolts securing the brake switch to the handle support (Fig. 0066). handle support to the frame (Fig. 0068). Fig 0066 PICT-0486 Fig 0068 PICT-0489 10.
Page 48 CHASSIS 13. Remove the whizlock nut and bolt securing the top 15. Remove the parking brake assembly from the frame end of the parking brake spring to the frame (Fig. (Fig. 0072). 0070). Note: Unit raised for photo clarity. Fig 0070 PICT-0491 Fig 0072 PICT-0497...
Page 49: Parking Brake Installation
CHASSIS 3. Loosely install the 3 bolts and nuts securing the Parking Brake Installation parking brake assembly to the frame (Fig. 0076). 1. Install the bolt, nut and spring onto the parking brake assembly (Fig. 0074). Fig 0076 PICT-0494 Fig 0074 PICT-0500a 4.
Page 50 CHASSIS 5. Loosely install the whizlock nut on the bolt that 8. Install the nuts securing the parking brake handle secures the top end of the brake spring to the frame support to the frame (Fig. 0080). (Fig. 0078). Fig 0080 PICT-0489 Fig 0078 PICT-0503a...
Page 51 CHASSIS 10. Install 2 screws and nuts securing the parking brake 12. Insert a bolt through the parking brake handle. Install switch and switch plate to the handle support (Fig. a thrust bearing onto the bolt and then insert the 0082).
Page 52 CHASSIS 14. Install a nut onto the bolt securing the parking brake 16. Install a cotter pin into the clevis pin (Fig. 0088). handle to the handle support (Fig. 0086). Note: Do not over-tighten the nut. Fig 0088 PICT-0477 Fig 0086 PICT-0481 17.
Page 53: Wheel Drive Belt And Wheel Hub Replacement - Gear Drive
CHASSIS 18. Install a cotter pin into the clevis pin (Fig. 0090). Wheel Drive Belt and Wheel Hub Replacement - Gear Drive The following inspections should be made when disas- sembling the drive system, particularly if the reason for service is the inability to adjust belt tension or “loss of drive”.
Page 54: Wheel Drive Belt & Wheel Hub Removal
CHASSIS 5. Rotate the idler support bracket so that it is out of Wheel Drive Belt & Wheel Hub Removal the way of the transmission pulley (Fig. 0093). 1. Turn the engine off and remove the key from the ignition. 2.
Page 55 CHASSIS 7. Inspect the pulleys for wear and damage. Replace 10. Remove the key from the drive pulley shaft keyway as necessary. If pulley replacement is required, (Fig. 0097). continue on. For belt replacement only, go to “Wheel Drive Belt and Wheel Hub Installation” step 17, on page 3-34.
Page 56 CHASSIS 13. Install the key into the transmission driveshaft key- 15. Apply thread locking compound to the drive pulley way (Fig. 0099). set screw (Fig. 0101). Fig 0099 PICT-1583 Fig 0101 PICT-1587a 14. Position the drive pulley onto the transmission drive 16.
Page 57 CHASSIS 17. Remove the 4 lug nuts retaining the wheel to the 19. Remove the dust cover from the wheel hub wheel hub assembly (Fig. 0103). assembly (Fig. 0105). Fig 0105 PICT-1590 Fig 0103 PICT-1588a 20. Remove the cotter pin retaining the castle nut to the 18.
Page 58 CHASSIS 21. Remove the castle nut from the axle (Fig. 0107). 23. Remove the washer from the wheel hub (Fig. 0109). Fig 0107 PICT-1593 Fig 0109 PICT-1622 24. Remove the outside tapered wheel bearing from the 22. Slide the wheel hub assembly off the axle (Fig. 0108).
Page 59: Wheel Drive Belt & Wheel Hub Installation
CHASSIS 25. Remove the inside grease seal from the wheel hub 27. Remove the grease ﬁ tting from the wheel hub (Fig. (Fig. 0111). 0113). Fig 0111 PICT-1624 Fig 0113 PICT-1650 26. Remove the tapered bearing from the wheel hub 28.
Page 60 CHASSIS 2. Repack the tapered bearing with grease (Fig. 0115). 4. Insert the grease seal into the wheel hub bore (Fig. 0117). Note: When packing wheel bearings use #2 general purpose lithium base or molybdenum base grease. Fig 0117 PICT-1645 Fig 0115 PICT-1643 5.
Page 61 CHASSIS 6. Insert the tapered bearing into the opposite side of 8. Slide the wheel hub assembly onto the axle (Fig. the wheel hub bore (Fig. 0119). 0121). Fig 0119 PICT-1646 Fig 0121 PICT-1651 7. Position a washer onto the outside tapered bearing 9.
Page 62 CHASSIS 10. Install the castle nut onto the axle (Fig. 0123). 12. Install a cotter pin securing the castle nut to the axle (Fig. 0125). Fig 0123 PICT-1653 Fig 0125 PICT-1655 11. Torque the castle nut to 6.5 ft-lbs. (8.8 Nm) while 13.
Page 63 CHASSIS 14. Using a rubber mallet, install the dust cap into to 16. Install the lug nuts onto the wheel hub studs. Torque wheel hub assembly (Fig. 0127). the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig. 0129).
Page 64 CHASSIS 18. Rotate the idler support bracket into position so that 20. Tighten the idler support bracket pivot bolt (Fig. the 3 mounting holes in the bracket line up with the 3 0133). holes in the frame (Fig. 0131). Fig 0133 PICT-1520 Fig 0131 PICT-1664...
Page 65: Brake Band Replacement
CHASSIS 4. Loosen the idler support bracket pivot bolt (Fig. Brake Band Replacement 0136). The following procedures are the same for both the left and right brake band replacement. Brake Band Removal 1. Turn the engine off and remove the key from the ignition.
Page 66 CHASSIS 6. Remove the wheel drive belt from the transmission 8. Remove the wheel from the wheel hub assembly pulley and remove it from around the drive wheel (Fig. 0140). (Fig. 0138). Fig 0140 PICT-1589 Fig 0138 PICT-1577 9. Remove the dust cover from the wheel hub assem- bly (Fig.
Page 67 CHASSIS 10. Remove the cotter pin retaining the castle nut to the 12. Slide the wheel hub assembly off the axle (Fig. axle (Fig. 0142). 0144). Fig 0142 PICT-1592 Fig 0144 PICT-1594 11. Remove the castle nut from the axle (Fig. 0143). 13.
Page 68 CHASSIS 14. Remove the retaining ring from the brake arm pivot 16. Remove the 3 brake link plate retaining rings (Fig. (Fig. 0146). 0148). Fig 0146 PICT-1602 Fig 0148 PICT-1607a 15. Remove the brake arm assembly from the pivot (Fig. 17.
Page 69: Brake Band Installation
CHASSIS 18. Remove the brake band from the brake link (Fig. 20. Inspect the brake band. Replace if damaged or worn 0150). (Fig. 0152). Fig 0150 PICT-1611a Fig 0152 PICT-1615a 19. Remove the brake arm from the brake link (Fig. Brake Band Installation 0151).
Page 70 CHASSIS 2. Place the brake band onto the brake link (Fig. 0154). 4. Install 3 new retaining rings as shown (Fig. 0156): B B A A Fig 0154 PICT-1611a Fig 0156 PICT-1607a A. Small B. Large 3. Install the brake link plate onto the brake assembly (Fig.
Page 71 CHASSIS 6. Install a new retaining ring onto the brake arm pivot 8. Slide the wheel hub assembly onto the axle (Fig. securing the brake arm to the frame (Fig. 0158). 0160). Fig 0158 PICT-1621 Fig 0160 PICT-1594 7. Position the lower end of the brake rod into the 9.
Page 72 CHASSIS 10. Torque the castle nut to 6.5 ft-lbs. (8.8 Nm) while 12. Fill the wheel hub cavity with grease (Fig. 0164). turning the hub to seat the bearings and to remove all endplay. Loosen the castle nut until it is away from the washer/bearing.
Page 73 CHASSIS 14. Route the wheel drive belt around the wheel drive 16. Install the lug nuts onto the wheel hub studs. Torque pulley and the wheel hub (Fig. 0166). the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig. 0168).
Page 74: Carrier Frame Replacement
CHASSIS 18. Loosely install the 3 lower idler support mounting 20. Tighten the 3 lower idler support mounting bolts (Fig. bolts (Fig. 0170). 0172). Fig 0170 PICT-1519 Fig 0172 PICT-1519 19. Tighten the idler support bracket pivot bolt (Fig. Carrier Frame Replacement 0171).
Page 75 CHASSIS 4. Remove the bolt and nut securing the right side 6. Slide the carrier frame away from the traction frame of the carrier frame to the right side of the traction (Fig. 0175). frame (Fig. 0173). Fig 0175 PICT-1305 Fig 0173 PICT-1300 7.
Page 76 CHASSIS 8. Remove the belt shield from the carrier frame (Fig. 10. Remove the deck bushing from the carrier frame 0177). (Fig. 0179). Fig 0177 PICT-1310 Fig 0179 PICT-1313 9. Remove the retaining ring from the deck bushing 11. Repeat steps 9 and 10 for the opposite side deck (Fig.
Page 77: Carrier Frame Installation
CHASSIS 13. Remove the castor wheel assemblies from the 2. Install the castor wheel assemblies into the carrier carrier frame. Refer to “Castor Wheel Removal” on frame. Refer to “Castor Wheel Installation” on page page 3-53. 3-59. 14. Remove the castor wheel ﬂ ange bushings (2 left, 2 3.
Page 78 CHASSIS 5. Install a deck bushing into the carrier frame (Fig. 7. Repeat steps 5 and 6 for the opposite side deck 0185). bushing. 8. Position the belt shield to the carrier frame (Fig. 0187). Fig 0185 PICT-1313 Fig 0187 PICT-1310 6.
Page 79 CHASSIS 10. Position the carrier frame assembly up to the traction 13. Loosely install the 2 upper bolts and nuts securing frame (Fig. 0189). the left side of the carrier frame to the left side of the traction frame (Fig. 0191). Fig 0189 PICT-1305 Fig 0191...
Page 80: Carrier Frame & Mower Deck Adjustments
CHASSIS 16. Check the alignment if the engine deck and carrier Carrier Frame & Mower Deck frame. Refer to “Checking the Carrier Frame and Adjustments Engine Deck Alignment”, proceding. Checking the Carrier Frame & Engine Deck 17. Check the engine deck height. Refer to “Checking Alignment the Engine Deck Height”...
Page 81 CHASSIS 4. Place a 2”x2” by 8” (aprox.) long piece of tubing 6. The space between the front cross brace and the stock on the engine deck along the right side the straight edge should be 11/16” + 1/4” (17.46mm + engine (Fig.
Page 82: Castor Wheel Replacement
CHASSIS 8. Align the carrier frame and engine deck to meet the 10. Remove the straight edge and 2x2 piece of stock. 11/16” + 1/4” (17.46mm + 6.35mm) measurement at the front carrier frame cross brace (Fig. 0199). 11. Install the carrier frame cover (Fig. 0201). Fig 0199 PICT-1345 Fig 0201...
Page 83: Castor Wheel Service
CHASSIS 2. Remove the spacer(s) from the castor fork assembly. Castor Wheel Service Note number and location for reassembly (Fig. 0203). 1. Remove the 2 thrust washers from the castor fork (Fig. 0205). Fig 0203 PICT-1318 Fig 0205 PICT-1321a 3. Raise the carrier frame assembly and slide the castor fork assembly out of the carrier frame (Fig.
Page 84 CHASSIS 3. Remove the axle bolt (Fig. 0207). 5. Remove one of the bushings from the wheel assem- bly (Fig. 0209). Fig 0207 PICT-1323 Fig 0209 PICT-5516a 4. Remove the spacer from the wheel assembly (Fig. 6. Remove the needle bearing from the wheel assem- 0208).
Page 85 CHASSIS 7. Remove the second bushing from the wheel assem- 9. Thoroughly clean the wheel and tire assembly. bly (Fig. 0211). Inspect the wheel and bearings for damage and replace as necessary. 10. Install a bushing into one side of the wheel (Fig. 0213).
Page 86 CHASSIS 12. Install the greased needle bearing into the wheel 14. Install the spacer into the wheel (Fig. 0217). (Fig. 0215). Fig 0217 PICT-5694a Fig 0215 PICT-5685a 15. Install the grease zerk into the wheel assembly (Fig. 13. Install a second bushing into the other side of the 0218).
Page 87 CHASSIS 16. Fill the wheel assembly with grease until it begins to 18. Install the wheel axle bolt (Fig. 0221). ﬂ ow out of the bearings (Fig. 0219). Fig 0221 PICT-5702a Fig 0219 PICT-1326a 19. Install and tighten the lock washer and nut to secure the wheel to the fork (Fig.
Page 88: Castor Wheel Installation
CHASSIS 20. Slide 2 thrust washers onto the castor fork shaft (Fig. 2. Slide the spacer(s) onto the castor fork shaft (Fig. 0223). 0225). Fig 0223 PICT-1321a Fig 0225 PICT-1318 3. Install the locking pin into the castor fork assembly Castor Wheel Installation (Fig.
Page 89: Castor Wheel Fork Bushing Replacement
CHASSIS 4. Remove the spacer(s) from the top of the caster Castor Wheel Fork Bushing wheel fork (Fig. 0228). Replacement The following procedures are the same for replacing both the right hand and left hand castor wheel fork bushings. Castor Wheel Fork Bushing Removal 1.
Page 90: Castor Wheel Fork Bushing Installation
CHASSIS 6. Insert a pin punch into the mounting tube and care- 2. Inspect the caster wheel fork for wear and replace if fully drive out the bushings (Fig. 0230). necessary. 3. Slide the caster wheel fork through the bushings in the mounting tube (Fig.
Page 91: Fuel Tank Replacement
CHASSIS 5. Secure the fork to the carrier frame with the locking Fuel Tank Replacement pin (Fig. 0234). DANGER In certain conditions, gasoline is extremely ﬂ ammable and highly explosive. A ﬁ re or explosion from gasoline can burn you and others and can damage property. •...
Page 92 CHASSIS 4. Move the negative battery terminal boot and dis- 6. Slide the hose clamp off the fuel line at the fuel connect the negative (black) battery cable from the pump (Fig. 0238). battery (Fig. 0236). Fig 0238 PICT-0513 Fig 0236 PICT-0509 7.
Page 93 CHASSIS 8. Turn the fuel valve to the “On” position to allow the 10. Remove the fuel line from the fuel tank bulkhead fuel to drain (Fig. 0240). ﬁ tting, pulling it through the rubber grommet (Fig. 0242). Fig 0240 PICT-0515 Fig 0242 PICT-0518...
Page 94 CHASSIS 12. Remove the 2 nuts, springs and washers from the 14. Lift the fuel tank assembly up and out of the frame. threaded studs securing the left side of the fuel tank Take care as the tank ﬁ tting comes out through the bottom (Fig.
Page 95 CHASSIS 16. Remove the fuel cap assembly from the fuel tank 18. Inspect the ﬁ lter screen on the bulkhead fuel ﬁ tting. (Fig. 0248). Clean or replace the ﬁ lter screen if it is clogged or damaged (Fig. 0250). Note: If fuel is leaking from the bulkhead fuel ﬁ...
Page 96: Fuel Tank Installation
CHASSIS 3. Install the bulkhead fuel ﬁ tting into the tank through Fuel Tank Installation the fuel cap opening (Fig. 0254). This procedure was done on a hydro model. The same Note: The ﬁ tting should be installed so that the barb procedure can be followed for gear drive models.
Page 97 CHASSIS 5. Tighten the nut to secure the ﬁ tting to the fuel tank 7. Apply anti-seize compound to both of the bolts used (Fig. 0256). to secure the right side of the fuel tank to the frame (Fig. 0258). Fig 0256 PICT-5353 Fig 0258...
Page 98 CHASSIS 9. Slide the hose clamp onto the bulkhead ﬁ tting barb 11. Slide the clamp onto the fuel line securing the fuel (Fig. 0260). line to the fuel tank bulkhead ﬁ tting (Fig. 0262). Fig 0260 PICT-0520 Fig 0262 PICT-0516 10.
Page 99: Battery Tray Replacement
CHASSIS 13. Slide the hose clamp up to secure the fuel line to the 15. Check for leaks. fuel pump (Fig. 0264). 16. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot (Fig. 0266). Fig 0264 PICT-0513 Fig 0266...
Page 100 CHASSIS 3. Move the negative battery terminal boot and dis- 5. Remove 1 of the 2 nuts retaining the battery hold connect the negative (black) battery cable from the down strap and battery hold downs to the battery battery terminal (Fig. 0268). tray (Fig.
Page 101: Battery Tray Installation
CHASSIS 7. Remove the battery from the battery tray (Fig. 0272). 9. Remove the battery tray from the frame (Fig. 0274). Fig 0272 PICT-0571 Fig 0274 PICT-1298 8. Remove the two bolts, and nuts securing the battery Battery Tray Installation tray to the frame (Fig.
Page 102 CHASSIS 2. Align the battery tray mounting holes to the mounting 4. Place the battery onto the battery tray (Fig. 0278). holes in the frame (Fig. 0276). Fig 0278 PICT-0571 Fig 0276 PICT-1298 5. Install the battery hold down plate and 2 battery hold downs to the battery tray (Fig.
Page 103: Mid-Size Weight Replacement
CHASSIS 6. Connect the positive (red) battery cable to the Mid-Size Weight Replacement positive battery terminal and cover the connection with the boot (Fig. 0280). Weights are installed on certain mowers to improve balance and improve performance. The weights can be moved or removed to create optimized performance under different mowing conditions and for operator preference (Fig.
Page 104: Checking The Brake (T-Bar)
CHASSIS The following table indicates the position of the weight Checking the Brake (T-Bar) as installed at the factory. 1. Park the machine on a level surface. Mower Deck Number of Position of the Size weights install weight 2. Disengage the Power Take Off (PTO) (Fig. 0284). 36”...
Page 105: Adjusting The Brake (T-Bar)
CHASSIS 4. The rear wheels must lock when you try to push 7. The wheels should rotate freely. the machine forward or backward. Adjustment is required if the wheels do not lock. Refer to “Adjust- 8. If the above conditions are met, no adjustment is ing the Brake”, following.
Page 106 CHASSIS 3. Rotate the wing nuts on the brake rods (Fig. 0289) as follows: • Clockwise to tighten the brake • Counterclockwise to loosen the brake Note: The right and left brake rods are adjusted independently of each other. Note: The control bar should be parallel with refer- ence bar when properly adjusted.
Page 107 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-78 Floating Deck Mid-Size Service Manual...
Page 108: Linkage
LINKAGE 3. Remove the control panel cover/manual tube as- Control Linkage Replacement (T-2) sembly to the control panel (Fig. 0292). Fig 0290 ﬁ g. 3 G006080 Fig 0292 PICT-1923 Control Linkage Removal 4. Remove the hairpin cotter from the upper end of the control linkage rod (Fig.
Page 109 LINKAGE 5. Remove the washer from the upper end of the 7. Remove the hairpin cotter from the lower end of the control linkage rod (Fig. 0294). control linkage rod (Fig. 0296). Fig 0294 PICT-1950 Fig 0296 PICT-2009 6. Remove the upper end of the control rod from the 8.
Page 110 LINKAGE 9. Remove the lower end of the control linkage rod 11. Remove the upper control rod from the turnbuckle from the pump adapter bracket. Remove the linkage (Fig. 0300). rod from the machine (Fig. 0298). Fig 0300 PICT-1964a Fig 0298 PICT-2005 12.
Page 111 LINKAGE 13. Loosen the lower control rod wingnut (Fig. 0302). 15. Remove the wingnut from the lower control rod (Fig. 0304). Fig 0302 PICT-1966a Fig 0304 PICT-1968a 14. Remove the lower control rod from the turnbuckle 16. Remove the 2 bolts and nuts securing the pump (Fig.
Page 112: Control Linkage Installation
LINKAGE 17. Remove the pump adapter bracket (Fig. 0306). Control Linkage Installation 1. Thread the adjusting screw into the pump adapter bracket so the threads of the screws protrude 3/4” (19mm) past the bracket (Fig. 0308). Fig 0306 PICT-1989 18. Remove the nut and adjusting screw from the pump Fig 0308 PICT-1993a adapter bracket (Fig.
Page 113 LINKAGE 3. Position the pump adapter bracket to the pump The distance between the face of the neutral prox- linkage (Fig. 0310). imity switch and the end of the hex head screw should be .07” + .02” (1.8 + .5mm) (Fig. 0312). Fig 0310 PICT-1989 Fig 0312...
Page 114 LINKAGE 6. Thread a wingnut onto the lower control rod and 8. Loosely install the upper control rod into the turn- upper control rod so that there is approximately 1/2” buckle (Fig. 0316). (12.7mm) of thread on the wing side of the wingnut (Fig.
Page 115 LINKAGE 10. Slide a washer onto the lower end of the control 12. Install the upper end of the control rod into the tab linkage rod (Fig. 0318). on the control handle (Fig. 0320). Fig 0318 PICT-2007a Fig 0320 PICT-1951 11.
Page 116 LINKAGE 14. Install a hairpin cotter into the upper end of the 16. Tighten the wingnuts to secure the control rod control linkage rod securing it to the control handle turnbuckle (Fig. 0324). (Fig. 0322). Fig 0324 PICT-2020 Fig 0322 PICT-1947 17.
Page 117: Control Linkage & Thumb Latch Replacement (Pistol Grip Hydro)
LINKAGE 18. Install 4 screws (2 on the left, 2 on the right) secur- Control Linkage & Thumb Latch Removal ing the control panel cover to the control panel (Fig. 0326). 1. Turn the engine off and remove the key from the ignition.
Page 118 LINKAGE 4. Remove the hairpin cotter from the clevis pin retain- 6. Remove the nut from the bolt securing the thumb ing the upper end of the control linkage to the drive latch assembly to the handle bar (Fig. 0332). lever assembly (Fig.
Page 119 LINKAGE 8. Remove the bolt, and washer from the thumb latch 10. Remove the bolt securing the drive lever assembly (Fig. 0334): to the handle bar (Fig. 0336). Fig 0334 PICT-0697a Fig 0336 PICT-0700 Bolt C. Thumb latch Belleville washer (3) D.
Page 120: Control Linkage & Thumb Latch Installation
LINKAGE 12. Remove the bushing sleeves from the drive lever 2. Install the drive lever bushing into the drive lever handle (Fig. 0338). handle (Fig. 0340). Fig 0338 PICT-0702a Fig 0340 PICT-0701 Control Linkage & Thumb Latch Installation 3. Assemble the drive lever assembly to the handle bar with a bolt (Fig.
Page 121 LINKAGE 4. Secure the drive lever handle with a nut (Fig. 0342). 6. Slide the bolt of the thumb latch assembly into the hole on the handle bar (Fig. 0344). Fig 0342 PICT-0699 Fig 0344 PICT-0696 5. Assemble the thumb latch, bolt, and washers as 7.
Page 122 LINKAGE 8. Slide the trunnion on the lower end of the control rod 10. Adjust the control rod so that 2.125” (6.65cm) of into the idler arm (Fig. 0346). thread extends past the trunnion (Fig. 0348). Fig 0346 PICT-0690 Fig 0348 PICT-0704 2.125”...
Page 123 LINKAGE 12. Assemble the upper end of the control rod to the 14. Install a hairpin cotter into the clevis pin to secure drive lever assembly by inserting a clevis pin (Fig. the control rod to the thumb latch assembly (Fig. 0350).
Page 124: Lower Control Replacement (T-Bar)
LINKAGE 3. Remove the washer from the lower end of the con- Lower Control Replacement (T-Bar) trol rod (Fig. 0355). The following procedures are the same for both the right hand and left hand lower control replacement. Fig 0355 PICT-1752 Fig 0353 ﬁ...
Page 125 LINKAGE 5. Remove the hairpin cotter from the lower end of the 7. Remove the nut from the idler pivot bolt (Fig. 0359). brake rod (Fig. 0357). Fig 0359 PICT-1758 Fig 0357 PICT-1756 8. Remove the idler pivot bolt (Fig. 0360). 6.
Page 126 LINKAGE 9. Lift the idler/brake rod assembly out of the machine 11. Remove the 2 spacers from the idler arm pivot (Fig. (Fig. 0361). 0363). Fig 0361 PICT-1763 Fig 0363 PICT-1765 10. Remove the spring from the idler arm (Fig. 0362). 12.
Page 127 LINKAGE 13. Remove the washer from the brake rod trunnion 15. Remove the wing nut from the brake rod assembly (Fig. 0365). (Fig. 0367). Fig 0365 PICT-1769 Fig 0367 PICT-1772a 14. Remove the brake rod assembly from the idler 16. Remove the washer from the brake rod assembly assembly (Fig.
Page 128 LINKAGE 17. Remove the trunnion from the brake rod assembly 19. Remove the nut from the bolt securing the pulley to (Fig. 0369). the idler arm (Fig. 0371). Fig 0369 PICT-1774a Fig 0371 PICT-1776a 18. Remove the bushing from the trunnion (Fig. 0370). 20.
Page 129: Lower Control Installation
LINKAGE 21. Remove the pulley spacer from the bolt (Fig. 0373). Lower Control Installation 1. Insert the pulley bolt into the idler (Fig. 0375). Fig 0373 PICT-1780a Fig 0375 PICT-1781 22. Remove the bolt from the idler (Fig. 0374). 2. Slide the pulley spacer onto the pulley bolt (Fig. 0376).
Page 130 LINKAGE 3. Slide the pulley onto the pulley bolt and spacer (Fig. 5. Slide a bushing into the trunnion (Fig. 0379). 0377). Fig 0379 PICT-1775 Fig 0377 PICT-1778 6. Slide the trunnion onto the brake rod assembly (Fig. 4. Install a nut onto the pulley bolt securing the pulley 0380).
Page 131 LINKAGE 7. Slide a washer onto the brake rod assembly (Fig. 9. Insert the brake rod trunnion into the idler assembly 0381). (Fig. 0383). Fig 0381 PICT-1773a Fig 0383 PICT-1771 8. Install a wing nut 2-1/2” (6.35cm) onto the brake rod 10.
Page 132 LINKAGE 11. Install a hairpin cotter into the brake rod trunnion 13. Install 2 spacers into the idler arm pivot (Fig. 0387). (Fig. 0385). Fig 0387 PICT-1765 Fig 0385 PICT-1768 14. Install the torsion spring onto the idler arm (Fig. 12.
Page 133 LINKAGE 15. Position the idler/brake rod assembly onto the 17. Install a nut onto the idler pivot bolt (Fig. 0391). machine so the torsion spring is hooked onto the frame. (Fig. 0389). Fig 0391 PICT-1758 Fig 0389 PICT-1783 18. Insert the lower end of the brake rod into the brake arm assembly (Fig.
Page 134 LINKAGE 19. Install a hairpin cotter into the lower end of the brake 21. Slide a washer onto the control rod trunnion (Fig, rod securing it to the brake arm (Fig. 0393). 0395). Fig 0393 PICT-1756 Fig 0395 PICT-1752 20. Insert the control rod trunnion/clevis into the idler 22.
Page 135: Neutral Adjustment Stud Replacement (Pistol Grip Hydro)
LINKAGE 2. Remove the clevis pin (Fig. 0399). Neutral Adjustment Stud Replacement (Pistol Grip Hydro) Note: The side plate has been removed for photo purposes. Fig 0399 PICT-0924 3. Remove the nut from the top end of the adjustment Fig 0397 ﬁ...
Page 136 LINKAGE 4. Remove the washer and spring from the adjustment 6. Remove the neutral adjustment stud assembly out of stud (Fig. 0401). the spring mount bracket (Fig. 0403). Fig 0401 PICT-0926a Fig 0403 PICT-0928 5. Remove the ﬂ anged nylon bushing from the spring 7.
Page 137 LINKAGE 8. Remove the spring mount bracket from the frame 10. Loosen the jam nut that secures the yoke to the (Fig. 0405). neutral adjustment stud (Fig. 0407). Fig 0405 PICT-0932 Fig 0407 PICT-0936a 9. Remove the washer from the neutral adjustment 11.
Page 138: Neutral Adjustment Stud Installation
LINKAGE 12. Remove the nut from the neural adjustment stud Neutral Adjustment Stud Installation (Fig. 0409). 1. Position the spring mount bracket to the frame (Fig. 0411). Fig 0409 PICT-0939a Fig 0411 PICT-0932 Neutral Adjustment Stud Assembly (Fig. 0410): 2. Install 2 bolts and nuts securing the spring mount bracket to the frame (Fig.
Page 139 LINKAGE 3. Install a jam nut onto the threads so that there is 5. Snug the jam nut against the yoke (Fig. 0415). approximately 1/4” (6.4mm) space between the jam nut and the machined nut on the neutral stud (Fig. 0413).
Page 140 LINKAGE 7. Insert the neutral adjustment stud assembly into the 9. Position the yoke to the short tab on the drive lever spring mount bracket (Fig. 0417). swivel and insert a clevis pin (Fig. 0419). Fig 0417 PICT-1005 Fig 0419 PICT-1007 8.
Page 141 LINKAGE 11. Install the spring onto the adjustment stud (Fig. 13. Install a nut onto the top end of the adjustment 0421). stud. Tighten the nut until there are approximately 5 threads protruding past the nut (Fig. 0423). Fig 0421 PICT-1009 Fig 0423 PICT-1012a...
Page 142: Operator Presence Control Lever Replacement (Pistol Grip Hydro)
LINKAGE 2. Remove the left operator presence control lever from Operator Presence Control Lever the operator presence control rod (Fig. 0426). Replacement (Pistol Grip Hydro) Note: The manual tube assembly and control panel cover have been removed for photo purposes. Fig 0426 PICT-0724 Fig 0424...
Page 143 LINKAGE 4. Repeat steps 1 thru 3 to remove the right side OPC 7. Remove the PTO switch from the control panel (Fig. lever. 0430). 5. Remove the extension spring located under the control panel (Fig. 0428). Fig 0430 PICT-0729a Fig 0428 PICT-0727 8.
Page 144: Operator Presence Control Lever Installation
LINKAGE Operator Presence Control Lever 3. Plug the wire harness into the PTO switch (Fig. 0434). Installation 1. Install the Operator Presence Control (OPC) rod, spring tab end ﬁ rst, through the left side of the control panel and install the right end of the rod into the opening on the right side handle bar.
Page 145 LINKAGE 5. Install a nylon bushing onto each end of the OPC 7. Install the OPC levers onto the ends of the OPC rod rod (Fig. 0436). (Fig. 0438). Fig 0436 PICT-0726 Fig 0438 PICT-0724 6. Apply high strength thread locking compound (Loc- 8.
Page 146: Speed Control Replacement (Pistol Grip Hydro)
LINKAGE 9. Install one set screw into each OPC lever to secure Speed Control Removal the levers onto the OPC rod (Fig. 0440). 1. Remove the knob from the speed control lever (Fig. 0442). Fig 0440 PICT-0722 Fig 0442 IMG_8001a Speed Control Replacement (Pistol Grip Hydro) 2.
Page 147 LINKAGE 3. Remove the cotter pin from the lower end of the 5. Remove the nut from the pivoting sprung bolt (Fig. speed control rod (Fig. 0444). 0446). Fig 0444 PICT-0747 Fig 0446 PICT-0751 4. Remove the washer and speed control rod assembly 6.
Page 148 LINKAGE 7. Remove the lower bolt and nut securing the speed 9. Remove the speed control handle (Fig. 0450). control handle to the control panel (Fig. 0448). Fig 0450 PICT-0757a Fig 0448 PICT-0755a 10. Remove the remaining nut, bolt, washers and spring from the speed control lever assembly (Fig.
Page 149 LINKAGE Note: There are 2 washers between the shift lever 12. Remove the outside nut from both the left and right and shift lever plate (Fig. 0452). speed control link bolt assemblies (Fig. 0454). Fig 0452 PICT-0763a Fig 0454 PICT-0766 11.
Page 150 LINKAGE 14. Remove the washer from the right and left swivels 16. Secure the speed control crank in place and loosen installed through each end of the speed control the 2 screws securing each end of it to the crank crank (Fig.
Page 151 LINKAGE 18. Remove the 2 lower bolts and nuts securing the 20. Remove the crank support from the machine (Fig. crank support assembly to the frame (Fig. 0460). 0462). Fig 0460 PICT-0786 Fig 0462 PICT-0789 19. While supporting the crank support, remove the 2 21.
Page 152 LINKAGE 22. Loosen the jam nuts securing the trunnion in place 24. On the left hand speed control link, loosen the end on the threaded end of the speed control rod (Fig. nut (Fig. 0466). 0464). Fig 0466 PICT-0799a Fig 0464 PICT-0793a 25.
Page 153: Speed Control Installation
LINKAGE 26. Remove the two nuts and the bolt from the slotted 28. Remove the spacer, washers, swivel, spring and nut end of both control links (Fig. 0468). from the control link (Fig. 0470). Fig 0468 PICT-0805a Fig 0470 PICT-0810a 27.
Page 154 LINKAGE 2. While supporting the crank support, loosely install 4. Tighten the 4 nuts and bolts securing the crank the 2 upper bolts and nuts securing the crank support to the frame. support and handle to the frame (Fig. 0472). 5.
Page 155 LINKAGE 7. Install 2 shoulder bolts securing the speed control 9. Install a spacer, 3 washers, a swivel, and a spring crank to the crank support (Fig. 0476). onto the control link (Fig. 0478). Fig 0476 PICT-0818 Fig 0478 PICT-0886a Right hand control link assembly: 10.
Page 156 LINKAGE 11. Install the bolt into the slot of the control link. Left Hand control link Assembly: Note: The slotted portion of the control link is offset 13. Install the bolt into the slot of the control link. and the bolt needs to be oriented as shown (Fig.
Page 157 LINKAGE 15. Install one nut onto the control link, threading it down 17. Thread the second nut onto the control link. Snug to the mark (Fig. 0484). ﬁ t the nut down to the washer and swivel assembly (Fig. 0486). Note: The trunnion and the bolt should be oriented in opposite directions.
Page 158 LINKAGE 19. Install a nut onto the bolt securing the lower end of 21. Slide a washer onto the trunnion and install a cotter the speed control link to the drive lever swivel (Fig. pin securing the speed control link to the speed 0488).
Page 159 LINKAGE 24. Install a washer and a friction washer onto the shifter 26. Install a second friction washer onto the bolt (Fig. lever plate bolt (Fig. 0492). 0494). Fig 0492 PICT-0843a Fig 0494 PICT-0846a 25. Insert the bolt/washer assembly into the slotted 27.
Page 160 LINKAGE 28. Position a spring onto the bolt assembly (Fig. 0496). Tighten the nut until approximately 3 threads stick out past the nut (Fig. 0498). Note: Do not collapse the spring. Fig 0496 PICT-0849a Fig 0498 PICT-0852 29. Install a lock nut onto the bolt (Fig. 0497). 30.
Page 161 LINKAGE 31. Position the speed control handle (Fig. 0500). 33. Loosely install the middle bolt, spring and nut, making sure the bolt goes through the washer in between the plates (Fig. 0502). Fig 0500 PICT-0857a Fig 0502 PICT-0868 32. Loosely install the upper and lower bolts and nuts (Fig.
Page 162 LINKAGE 34. Tighten the upper and lower bolts and nuts (Fig. 36. Install the knob onto the speed control lever (Fig. 0504). 0506). Fig 0504 PICT-0873 Fig 0506 IMG_8001a 35. Apply thread locking compound to the threads of the Speed Control Rod Assembly: speed control lever (Fig.
Page 163 LINKAGE 38. Slide a trunion onto the speed control rod and snug 40. Position the speed control rod trunnion into the tab ﬁ t a second nut against the trunnion (Fig. 0508). on the speed control crank assembly (Fig. 0510). Fig 0508 PICT-0878a Fig 0510...
Page 164: Drive Lever Swivel & Bearing Replacement (Pistol Grip Hydro)
LINKAGE 42. Tighten the jam nuts securing the speed control rod Drive Lever Swivel & Bearing trunnion in place (Fig. 0512). Replacement (Pistol Grip Hydro) Fig 0512 PICT-0898 Fig 0513 ﬁ g. 10 G004912 43. Initially adjust the Neutral Stud. Refer to “Temporary Drive Lever Swivel &...
Page 165 LINKAGE 3. Remove the 3 nuts, bolts and spacers securing the 5. Remove the 2 bolts, nuts and washers securing the side plate to the frame (Fig. 0515). side ﬂ ange bearing to the side plate (Fig. 0517). Fig 0515 PICT-0901 Fig 0517 PICT-0906a...
Page 166 LINKAGE 7. Remove the e-clip from the trunnion on the lower 9. Move the speed control lever to the full forward end of the drive lever rod (Fig. 0519). position. Remove the outside nut from the lower end of the speed control link assembly (Fig. 0521). Fig 0519 PICT-0908 Fig 0521...
Page 167 LINKAGE 11. Remove the hairpin cotter from the clevis pin se- 13. Loosen the 2 set screws securing the drive lever curing the neutral adjustment stud yoke to the drive swivel to the hydro pump shaft (Fig. 0525). lever swivel (Fig. 0523). Note: There is an access hole located in the frame below the drive lever swivel.
Page 168: Drive Lever Swivel & Bearing Installation
LINKAGE 15. Remove the spring stud from the drive lever swivel Drive Lever Swivel & Bearing Installation (Fig. 0527). 1. Install a grease ﬁ tting into the drive lever swivel (Fig. 0529). Fig 0527 PICT-0918 Fig 0529 PICT-0920 16. Remove the grease ﬁ tting from the drive lever swivel (Fig.
Page 169 LINKAGE 3. Position the drive lever swivel through the frame and 5. Install the 2 set screws securing the drive lever onto the hydro pump shaft (Fig. 0531). swivel to the hydro pump shaft (Fig. 0533). Note: There is an access hole located in the frame below the drive lever swivel.
Page 170 LINKAGE 7. Install a hairpin cotter into the clevis pin securing 9. Install the outside nut onto the speed control link bolt the neutral adjustment stud yoke to the drive lever assembly (Fig. 0537). swivel (Fig. 0535). Fig 0537 PICT-0911 Fig 0535 PICT-0914 10.
Page 171 LINKAGE 11. Install an e-clip onto the trunnion on the lower end of 13. Install a ﬂ at washer onto the 2 bolts used to secure the drive lever rod (Fig. 0539). the bearing to the side plate. Loosely install the bearing to the side plate with the 2 bolt assemblies and nuts (Fig.
Page 172 LINKAGE 15. Insert a bolt through the side plate and slide a 17. Tighten the nuts securing the side ﬂ ange bearing in spacer onto the bolt. Loosely secure the bolt to the place on the side plate (Fig. 0545). frame with a nut (Fig.
Page 173: Handle Assembly Replacement (T-Bar)
LINKAGE 19. Apply grease to the side ﬂ ange bearing (Fig. 0547). Handle Assembly Replacement (T-Bar) Fig 0547 PICT-1021 Fig 0548 ﬁ g. 7 G004812 20. Adjust the Speed Control Linkage. Refer to “Speed Control Linkage Adjustment” on page 4-121. Handle Assembly Removal (T-Bar) 21.
Page 174 LINKAGE 3. Open the locking tab on the front of the Operator 5. While holding the lock down, draw the wire and Presence Control (OPC) switch. Unplug the harness spade terminal out of the connector (Fig. 0551). from the OPC (Fig. 0549). Fig 0551 PICT-1692 Fig 0549...
Page 175 LINKAGE 8. Remove the hairpin cotter from the lower end of the 10. Remove the trunnion/clevis from the idler arm (Fig. control rod (Fig. 0553). 0555). Fig 0553 PICT-1672a Fig 0555 PICT-1675 9. Remove the washer from the lower end of the 11.
Page 176 LINKAGE 12. Remove the trunnion from the control rod (Fig. 14. Remove the control rod from the control bar/bail 0557). assembly (Fig. 0559). Fig 0559 PICT-1682 Fig 0557 PICT-1678a 15. Repeat steps 8 thru 14 to remove the opposite 13. Remove the cotter pin from the upper end of the control rod (Fig.
Page 177 LINKAGE 17. Remove the nut from the bolt securing the T-Bar to 19. Slide the T-Bar off the handle assembly (Fig. 0563). the handle assembly (Fig. 0561). Fig 0563 PICT-1704a Fig 0561 PICT-1701 20. Depress the OPC switch tabs and remove the switch 18.
Page 178 LINKAGE 21. Remove the 2 rubber grommets from the T-Bar (Fig. 23. Remove the clevis pin (Fig. 0567). 0565). Fig 0567 PICT-1712 Fig 0565 PICT-1708a 24. Repeat steps 20 and 21 to remove the cotter pin and 22. Remove the cotter pin from the clevis pin securing clevis from the opposite side.
Page 179 LINKAGE 26. Remove the cable tie securing the throttle and choke 28. Remove the 2 screws securing the bottom panel to cable to each side of the handle assembly (Fig. the control panel. Remove the bottom panel (Fig. 0569). 0571). Fig 0569 PICT-1716 Fig 0571...
Page 180: Handle Assembly Installation (T-Bar)
LINKAGE 30. Lower the control panel from the handle (Fig. 0573). 32. Remove the handle (Fig. 0575). Fig 0573 PICT-1722 Fig 0575 PICT-1728 31. Remove the 4 bolts and nuts (2 on the left, 2 on the Handle Assembly Installation (T-Bar) right) securing the handle to the frame (Fig.
Page 181 LINKAGE 2. Install 4 bolts and nuts (2 on the left, 2 on the right) 3. Raise the control panel assembly into place on the securing the handle to the frame (Fig. 0577). handle bar (Fig. 0579). Fig 0577 PICT-1725 Fig 0579 PICT-1732 Note: Position the lower set of bolts as previously...
Page 182 LINKAGE 5. Position the bottom panel to the control panel and 7. Install a cable tie securing the throttle cable, and one install 2 screws securing the back side of the bottom securing the choke cable, to each side of the handle panel to the control panel (Fig.
Page 183 LINKAGE 9. Insert a clevis pin into each side of the control pivot 11. Install 2 rubber grommets (1 on the left, 1 on the assembly securing it to the handle assembly (Fig. right) into the T-Bar mounting holes (Fig. 0587). 0585).
Page 184 LINKAGE 13. Slide the T-Bar onto the handle assembly (Fig. 15. Install a nut onto the bolt securing the parking brake 0589). lever and T-Bar to the handle assembly (Fig. 0591). Note: Tighten the bolt and nut enough so the park- ing brake lever does not rattle but still rotates freely.
Page 185 LINKAGE 17. Insert the top end of the control rod into the control 19. Install the trunnion onto the control rod approxi- bar/bail assembly (Fig. 0593). mately 2” (5cm) (Fig. 0595). Fig 0593 PICT-1682 Fig 0595 PICT-1678a 18. Install a cotter pin into the upper end of the control 20.
Page 186 LINKAGE 21. Insert the clevis pin into the idler arm (Fig. 0597). 23. Install a hairpin cotter into the clevis pin (Fig. 0599). Fig 0597 PICT-1675 Fig 0599 PICT-1672a 22. Install a washer onto the clevis pin (Fig. 0598). 24. Repeat steps 17 - 23 to install the control rod on the opposite side.
Page 187: Handle Assembly Removal (T-2)
LINKAGE 26. Plug the two harness wires into the harness con- 28. Connect the negative battery terminal to the battery. nector as shown (Fig. 0601): 29. Check the Adjustment of the Control Bar. Refer to “Control Bar Adjustment” on page 4-132. Handle Assembly Removal (T-2) Fig 0601 PICT-1742...
Page 188 LINKAGE 3. Remove the 4 screws (2 on the left, 2 on the right) 5. Unplug the harness from the parking brake switch securing the control panel cover to the control panel (Fig. 0606). (Fig. 0604). Fig 0606 PICT-2021 Fig 0604 PICT-1921 6.
Page 189 LINKAGE 7. Remove the PTO switch from the control panel (Fig. 9. Remove the nut securing the ignition switch to the 0608). control panel (Fig. 0610). Fig 0608 PICT-2023 Fig 0610 PICT-2025a 8. Unplug the harness wire and connector from the 10.
Page 190 LINKAGE 11. Remove the ignition switch from the control panel 13. Unplug the harness from the hour meter (Fig. 0614). (Fig. 0612). Fig 0614 PICT-2029 Fig 0612 PICT-2027 14. Remove the locking tab from the back side of the 12. Unplug the harness from the Operator Presence hour meter (Fig.
Page 191 LINKAGE 15. Remove the hour meter from the control panel (Fig. 17. Unplug the kill relay from the harness connector 0616). (Fig. 0618). Fig 0616 PICT-2039a Fig 0618 PICT-2035 16. Unplug the latching relay from the harness con- 18. Remove the bolt and nut securing the two relay nector (Fig.
Page 192 LINKAGE 19. Remove the cable tie securing the harness to the 21. Pull the harness through the frame and lay it across throttle cable (Fig. 0620). the engine so it is out of the way of the handle. 22. At the front of the engine, loosen the cable clamps securing the throttle (bottom) and choke (top) cables to the engine (Fig.
Page 193 LINKAGE 24. Cut the cable ties at the following locations (Fig. 25. Remove the 2 screws and nuts securing the throttle 0624 and Fig. 0625): control assembly to the control panel (Fig. 0626). Fig 0624 PICT-2051 Fig 0626 PICT-2053 A. Throttle/choke B.
Page 194 LINKAGE 27. Remove the 2 screws and nuts securing the choke 29. Remove the 2 bolts and nuts securing the parking control assembly to the control panel (Fig. 0628). brake handle support to the frame (Fig. 0630). Fig 0628 PICT-2054 Fig 0630 PICT-2060 28.
Page 195 LINKAGE 32. Remove the washer from the upper end of the 34. Repeat steps 31 - 33 to remove the control rod from control linkage rod (Fig. 0632). the opposite motion control lever assembly. 35. Remove the spring from the right hand control lever assembly (Fig.
Page 196 LINKAGE 37. Remove the OPC switch and threaded spacer plate 39. Remove the right hand lever from the control panel (Fig. 0636). (Fig. 0638). Fig 0636 PICT-2075 Fig 0638 PICT-2080a 38. Remove the nut and bolt securing the right hand 40.
Page 197 LINKAGE 41. Remove the 2 outside bolts (1 left, 1 right) securing 43. Slide the right hand motion control assembly off the the motion control lever linkage to the handle as- pivot shaft (Fig. 0642). sembly (Fig. 0640). Fig 0642 PICT-2088a Fig 0640 PICT-2084...
Page 198 LINKAGE 45. Slide the left hand control lever off the left hand pivot 47. Remove the 6 bushings from the control assemblies shaft (Fig. 0644). (2 left, 4 right) (Fig. 0646). Fig 0644 PICT-2090a Fig 0646 PICT-2095a A. One on each side 46.
Page 199: Handle Assembly Installation (T-2)
LINKAGE 49. Remove the handle stop lever cam from the right 51. Remove the handle assembly from the frame (Fig. control lever (Fig. 0648). 0650). Fig 0648 PICT-2109 Fig 0650 PICT-2092 50. Remove the 6 bolts (3 left, 3 right) securing the Handle Assembly Installation (T-2) handle assembly to the frame (Fig.
Page 200 LINKAGE 2. Install 6 bolts (3 left, 3 right) securing the handle 4. Position the handle stop lever cam onto the right assembly to the frame (Fig. 0652). control lever (Fig. 0654). Fig 0652 PICT-2069 Fig 0654 PICT-2109 3. Install 6 bushings into the control assemblies (2 left, 5.
Page 201 LINKAGE 6. Position the left hand pivot shaft to the center sup- 8. Position the right hand pivot shaft to the center sup- port bracket and loosely install a bolt securing the port bracket and loosely install a bolt securing the pivot shaft to the center support bracket (Fig.
Page 202 LINKAGE 10. Position the motion control lever linkage into the 12. Loosely install 2 carriage bolts and nuts, securing control panel handle assembly (Fig. 0660). the center support bracket to the control panel (Fig. 0662). Fig 0660 PICT-2098 Fig 0662 PICT-2083 11.
Page 203 LINKAGE 14. Install a bolt and nut, securing the right hand lever B. 2 bolts install from the outside of the handle assembly to the motion control linkage assembly assembly. (Fig. 0664). Fig 0666 PICT-2084 Fig 0664 PICT-2076 C. 2 bolts securing the right and left hand pivot 15.
Page 204 LINKAGE 16. Position the right hand control lever so it aligns with 18. Position the OPC switch and threaded spacer plate the left hand control lever (Fig. 0668). onto the motion control linkage (Fig. 0670). Fig 0668 PICT-2112a Fig 0670 PICT-2075 17.
Page 205 LINKAGE 20. With the right control lever in the operating position, 22. Insert the upper end of the control linkage rod into there should be .10” (2.5mm) gap between the OPC the tab on the control handle (Fig. 0674). switch plunger and the control arm tab. Adjust the switch location as needed (Fig.
Page 206 LINKAGE 24. Install a hairpin cotter into the upper end of the con- 27. Install 2 bolts and nuts securing the parking brake trol linkage rod (Fig. 0676). handle support to the frame (Fig. 0678). Fig 0676 PICT-2064 Fig 0678 PICT-2060 25.
Page 207 LINKAGE 29. Install 2 screws and nuts securing the choke control 31. Install 2 screws and nuts securing the throttle control assembly to the control panel (Fig. 0680). assembly to the control panel (Fig. 0682). Fig 0680 PICT-2054 Fig 0682 PICT-2053 30.
Page 208 LINKAGE 33. Hook the z-bend of the choke cable to the choke 35. Ensure the carburetor choke plate is fully open (Fig. control lever and loosely clamp the outer housing of 0686). the choke cable into the cable clamp (Fig. 0684). Note: The air ﬁ...
Page 209 LINKAGE 37. Move the choke control knob to the “choke“ position 39. Make sure the choke plate turns from the fully closed (Fig. 0688). position to the fully open position when actuating the choke control knob. 40. Hook the z-bend of the throttle cable to the throttle control lever and loosely clamp the outer housing of the throttle cable into the cable clamp (Fig.
Page 210 LINKAGE 42. Pull up the outer housing of the throttle cable until 44. Install cable ties at the following locations (Fig. 0694 the inner wire has almost no slack and tighten to and Fig. 0695): cable clamp bolt (Fig. 0692). Fig 0694 PICT-2051 Fig 0692...
Page 211 LINKAGE 45. Route the harness up the left side of the frame and 48. Plug the latching relay into the harness connector into the control panel. (Fig. 0698). 46. Install a bolt and nut securing each of the relay harness connector blocks to the control panel (Fig. 0696).
Page 212 LINKAGE 50. Install the locking tab onto the back side of the hour 52. Plug the harness into the OPC switch (Fig. 0702). meter (Fig. 0700). Fig 0702 PICT-2028 Fig 0700 PICT-2037 53. Position the ignition switch into the control panel 51.
Page 213 LINKAGE 54. Install a lockwasher onto the ignition switch (Fig. 56. Plug the harness wire and connector into the ignition 0704). switch (Fig. 0706). Fig 0704 PICT-2026 Fig 0706 PICT-2024 55. Install a nut securing the ignition switch to the control 57.
Page 214 LINKAGE 58. Plug the harness into the PTO switch (Fig. 0708). 60. Install a cable tie securing the harness to the frame left of the fuel tank, above the parking brake (Fig. 0710). Fig 0708 PICT-2022 Fig 0710 PICT-2047 59. Plug the harness into the parking brake switch (Fig. 0709).
Page 215: Choke Cable Replacement
LINKAGE 62. Position the control panel cover/manual tube as- Choke Cable Replacement sembly to the control panel (Fig. 0712). Choke Cable Removal 1. Turn the engine off and remove the key from the ignition. 2. Loosen the clamp that secures the choke cable to the engine (Fig.
Page 216 LINKAGE 4. Remove the cable tie located above the left tire that 6. T2 Models: Remove the cable tie securing the secures the choke and throttle cable together (Fig choke cable to the right side of the control panel 0716). (Fig.
Page 217: Choke Cable Installation
LINKAGE 8. Remove the choke handle, cable and gasket as- Choke Cable Installation sembly out through the control panel (Fig. 0720). 1. Slide the gasket onto the choke handle assembly (Fig. 0722). Fig 0720 PICT-0636a Fig 0722 PICT-0638a 9. Remove the gasket from the handle assembly (Fig. 0721).
Page 218 LINKAGE 3. Insert the handle into the opening in the control 5. Pistol Grip & T2 models: Position the choke cable panel. Install 2 screws and nuts to secure the choke between the hydro pumps (Fig. 0726). handle to the right handle bar (Fig. 0724). Fig 0726 PICT-0640 Fig 0724...
Page 219 LINKAGE 7. Route the choke cable under the electrical harness, 9. Slide the choke cable into the upper cable clamp around the left side of the engine and up to the front and loosely clamp the outer cable housing (Fig. side of the engine (Fig.
Page 220 LINKAGE 11. Make sure that the carburetor choke plate is fully 13. Install a cable tie securing the choke cable to the open (Fig. 0732). throttle cable above the left tire. Cut off the excess cable tie (Fig. 0734). Note: The air ﬁ lter has been removed to show the carburetor choke plate.
Page 221: Throttle Cable Replacement
LINKAGE 15. T2 Models: Install a cable tie securing the choke Throttle Cable Replacement cable to the right side of the control panel (Fig. 0736). Throttle Cable Removal 1. Turn the engine off and remove the key from the ignition. 2.
Page 222 LINKAGE 4. Remove the cable tie located above the left tire that 6. Slide the throttle cable out of the R-clamp (Fig. secures the throttle and choke cable together (Fig 0741). 0739). Fig 0741 PICT-0658 Fig 0739 PICT-0632 7. Pistol Grip & T-Bar Models: Remove the cable tie 5.
Page 223 LINKAGE 8. T2 Models: Remove the cable tie securing the 10. Remove the 2 screws and nuts securing the throttle harness to the throttle cable (Fig. 0743). handle assembly to the left handle (Fig. 0745). Fig 0743 PICT-2043 Fig 0745 PICT-0667 9.
Page 224: Throttle Cable Installation
LINKAGE 12. Remove the gasket from the handle assembly (Fig. 2. Slide the throttle cable through the opening on the 0747). control panel (Fig. 0749). Fig 0747 PICT-0671 Fig 0749 PICT-0670a Throttle Cable Installation 3. Pistol Grip models only: Route the throttle cable between the tracking rod and bracket (Fig.
Page 225 LINKAGE 4. Pistol Grip models only: Continue routing the throttle 6. T2 Models: Route the cable between the left pump cable under the left hand control shaft between the and frame (Fig. 0753). left pump and frame (Fig. 0751). Fig 0753 IMG_8008a Fig 0751 PICT-0674...
Page 226 LINKAGE 8. Insert the handle into the opening in the control 10. Slide the throttle cable into the upper cable clamp panel. Install 2 screws and nuts to secure the throttle and loosely clamp the outer cable housing (Fig. handle to the left handle bar (Fig. 0755). 0757).
Page 227 LINKAGE 12. Pull on the outer cable housing until the inner wire 14. Install a cable tie securing the throttle cable to the has almost no slack. Tighten the cable clamp bolt choke cable above the left tire. Cut off excess (Fig. (Fig.
Page 228: Linkage Adjustments
LINKAGE 4. Check the orientation of the tabs on the ends of the Linkage Adjustments speed control crank. These tabs should be pointing straight down, at approximately the 6 o’clock position Speed Control Linkage Adjustment (Fig. 0764). (Pistol Grip Hydro) 1.
Page 229: Temporary Neutral Stud Adjustment
LINKAGE 9. Check the travel of the shift lever in the control panel Temporary Neutral Stud Adjustment slot. The shift lever travel should be approximately centered in the control panel slot (Fig. 0765). Note: Perform the following procedure on both the left and right side.
Page 230: Hydro Control Linkage Adjustment
LINKAGE 3. Loosen the nut against the yoke (Fig. 0767). Hydro Control Linkage Adjustment Engine must be running so control linkage ad- justments can be performed. Contact with mov- ing parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, mufﬂ...
Page 231: Adjusting The Left Side Linkage (Pistol Grip)
LINKAGE 9. Loosen the front adjusting nut on left hydro control Adjusting the Left Side Linkage (Pistol Grip) linkage as shown in (Fig. 0768). 1. Disengage the PTO and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position.
Page 232 LINKAGE Note: Make sure ﬂat part of linkage is perpendicular Note: If inconsistent neutral occurs, check to be to the pin of swivel (Fig. 0769). sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring. Repeat above adjustments if necessary (Fig.
Page 233: Adjusting The Right Side Linkage (Pistol Grip)
LINKAGE 5. Turn the knob clockwise 1/4 of a turn. Then move Adjusting the Right Side Linkage the speed control forward and back to neutral. (Pistol Grip) Repeat this until right wheel stops rotating forward (Fig. 0771). 1. With the machine on jack stands, place the speed control lever in the neutral position.
Page 234 LINKAGE 3. Adjust the left and right neutral stud until the clevis pin in the yoke touches the back end of the slot in the control arm (Fig. 0772). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. •...
Page 235: Adjusting The Control Rod (Pistol Grip)
LINKAGE 4. Move the speed control lever to the full forward Adjusting the Control Rod position. (Pistol Grip) 5. Squeeze one drive lever until an increased resist- Checking the Control Rod ance is felt. This is neutral position. This is where the clevis pin in the yoke comes to the back end of the slot in the control arm bracket.
Page 236: Tracking Adjustment (Pistol Grip)
LINKAGE 2. Lengthen the control rod if the tire is turning in 6. Install the hairpin cotter pin between the drive lever reverse and shorten the rod if the tire is turning and the neutral lock and into the clevis pin (Fig. forward.
Page 237: Tracking Adjustment (T-2)
LINKAGE 4. Loosen the wing nuts on the left control rod and Tracking Adjustment (T-2) rotate the turnbuckle in or out to change the tracking. Secure the turnbuckle in position with the wing nuts 1. If the machine does not track straight, adjustment is (Fig.
Page 238 LINKAGE If the motion control levers do not align front to back, 2. Loosen the wing nuts on the right control rod and or the right side control lever does not move easily rotate the turnbuckle in or out to ensure the right into the neutral lock position, adjustment is required.
Page 239: Control Bar Adjustment (T-Bar)
LINKAGE 3. Engage the control bar (Fig. 0782). Control Bar Adjustment (T-Bar) 1. Initially adjust the control rods so that 2 1/4” (5.715cm) of thread extends beyond the trunnion ﬁ ttings (Fig. 0780). Fig 0782 PICT-5314a 4. Using a ruler, measure the travel distance of the Fig 0780 PICT-5303 pulley while releasing and engaging the control bar.
Page 240 LINKAGE 5. Engage the Parking Brake (Fig. 0784). 6. If adjustment is required, refer to “Adjusting the Brake”, page 5-10. Note: The parking brake lever should swing into a snug position against the upper handle while 7. Adjust the control rods so there is a 1” to 1 1/4” (2.54 pulling back on the upper control bar.
Page 241 LINKAGE THIS PAGE INTENTIONALLY LEFT BLANK. 4-134 Floating Deck Mid-Size Service Manual...
Page 242: Engine Removal - Pistol Grip Hydro
ENGINE 4. Move the positive battery terminal boot and dis- Engine Removal - Pistol Grip Hydro connect the positive (red) battery cable from the battery (Fig. 0788). 1. Turn the engine off and remove the key from the ignition. 2. Turn the fuel valve to the off position (Fig. 0786). Fig 0788 PICT-0252 Fig 0786...
Page 243 ENGINE 6. Remove the battery hold down plate and 2 battery 8. Remove the bolt that secures the fuel line R-clamp hold downs from the battery tray (Fig. 0790). to the engine (Fig. 0792). Fig 0790 PICT-0256 Fig 0792 PICT-0259 7.
Page 244 ENGINE 10. Remove the fuel line from the fuel pump. Drain the 12. Place a drain pan below the drain hose. Rotate the fuel into a suitable container (Fig. 0794). oil drain valve to allow the engine oil to drain into the drain pan (Fig.
Page 245 ENGINE 15. Push the grommet and clutch plug through the 17. Roll the PTO drive belt off the center mower deck chassis frame to the underside of the machine (Fig. pulley (Fig. 0800). 0798). Fig 0800 PICT-0283 Fig 0798 PICT-0277 18.
Page 246 ENGINE 20. Remove the idler arm spring from the spring post 22. Remove the bolt, nut, 2 washers and spacer secur- (Fig. 0802). ing the brake clutch strap to the underside of the chassis (Fig. 0804). Fig 0802 PICT-0291a Fig 0804 PICT-0295 21.
Page 247 PICT-0302a Fig 0806 PICT-0299 27. Slide the drive pulley off the engine crankshaft (Fig. 25. Using a spring removal tool (Toro P/N 92-5771), 0809). unhook the hydro drive idler spring and remove it from the chassis (Fig. 0807). Fig 0809...
Page 248 ENGINE 28. Remove the square key from the engine crankshaft 30. At the front of the engine, loosen the cable clamps (Fig. 0810). securing the throttle (bottom) and choke (top) cables to the engine (Fig. 0812). Fig 0810 PICT-0304 Fig 0812 PICT-0309 A.
Page 249 ENGINE 32. Remove the nut, harness ground wires and negative 34. Unplug the pink wire from the green fuel solenoid (black) battery cable and star washer from the rear wire (Fig. 0816). right engine mounting bolt (Fig. 0814). Note: The bolt will fall through the chassis when the nut is removed.
Page 250: Engine Installation - Pistol Grip Hydro
ENGINE 36. Remove the remaining 3 engine mounting bolts and 3. Insert the rear right engine mounting bolt up through nuts securing the engine to the chassis (Fig. 0818). the chassis and engine mounting hole. Install the star washer, harness ground wires and negative (black) battery cable onto the bolt.
Page 251 ENGINE 5. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs. 7. Plug the pink wire into the green fuel solenoid wire (19.7 + 2.8 Nm) (Fig. 0822). (Fig. 0824). Fig 0822 PICT-0324 Fig 0824 PICT-0327 6. Plug the white wire into the black magneto wire (Fig. 8.
Page 252 ENGINE 9. Secure the positive (red) cable to the starter (Fig. 11. Move the choke control knob to the “open” position 0826). (Fig. 0828). Fig 0826 PICT-0268a Fig 0828 PICT-0332a 10. Hook the z-bend of the choke cable to the choke 12.
Page 253 ENGINE 13. Pull the outer housing of the choke cable until the 15. Ensure the carburetor choke plate is fully closed inner wire has almost no slack and tighten the cable (Fig. 0832). clamp bolt (Fig. 0830). Fig 0832 PICT-0335 Fig 0830 PICT-0334 16.
Page 254 ENGINE 18. Move the throttle control knob to the “fast” position 20. Move the throttle control knob to the “slow“ position. (Fig. 0834). Ensure the carburetor throttle plate moves smoothly (Fig. 0836). Fig 0834 PICT-0339 Fig 0836 PICT-0342a 19. Pull the outer housing of the throttle cable until the inner wire has almost no slack and tighten the cable 21.
Page 255 23. Slide the drive pulley onto the engine crankshaft. Ensure that the long side of the hub is installed 25. Using a spring removal tool (Toro P/N 92-5771), toward the engine (Fig. 0839). install the hydro drive idler spring (Fig. 0841).
Page 256 ENGINE 26. Ensure the 2 cupped washers are installed on the 28. Slide the electric clutch onto the engine crankshaft clutch bolt with the crown side facing the bolt head (Fig. 0844). (Fig. 0842). Fig 0844 PICT-0354a Fig 0842 PICT-0351a 29.
Page 257 ENGINE 30. Torque the clutch bolt to 55 + 5 ft-lbs. (74.5 + 6.8 32. Feed the cutch harness plug up through the chassis Nm) (Fig. 0846). (Fig. 0848). Fig 0846 PICT-0356a Fig 0848 PICT-0362a 31. Install the bolt, nut, 2 washers and spacer securing 33.
Page 258 ENGINE 34. Route the PTO drive belt around the clutch. (Fig. 40”, 48” and 52” mower deck belt routing: 0850). Fig 0852 ﬁ g. 104-8186 Fig 0850 PICT-0364a 35. Install the idler arm spring to the spring post (Fig. 0853). Note: Ensure the PTO drive belt is routed properly around the mower deck pulley(s).
Page 259 ENGINE 36. Install the trailing shield into the chassis by ﬁ rst 39. Replace the carrier frame cover (Fig. 0856). inserting the right side of the trailing shield rod (bent at a 90º angle) into the hole in the chassis and then insert the left end of the trailing shield rod (bent at a 45º...
Page 260 ENGINE 41. Install the fuel line to the fuel pump (Fig. 0858). 43. Install the bolt that secures the fuel line R-clamp to the engine (Fig. 0860). Fig 0858 PICT-0370 Fig 0860 PICT-0259 42. Slide the hose clamp to the fuel line where it con- 44.
Page 261: Muffl Er Guard
ENGINE 46. Install the battery hold down and secure with 2 nuts. 48. Connect the negative (black) battery cable to the Do not over-tighten (Fig. 0862). negative battery terminal and cover with the boot. (Fig. 0864). Fig 0862 PICT-0372a Fig 0864 PICT-0250 47.
Page 262: Engine Removal - Gear Drive
ENGINE 3. Remove the fuel line by sliding the clamp away from the fuel pump (Fig. 0868). Fig 0866 PICT-1493 A. Mufﬂ er guard C. Screw (5) B. Mufﬂ er guard bracket D. Nut (5) Fig 0868 PICT-1347 Engine Removal - Gear Drive 4.
Page 263 ENGINE 5. Remove the R-clamp that secures the fuel line to the 7. Place a drain pan below the end of the drain hose right side of the engine (Fig. 0870). and rotate the oil drain valve to allow the oil to drain from the engine (Fig.
Page 264 ENGINE 10. Push the clutch wire plug and grommet through the 12. Remove the mower deck belt cover(s) (Fig. 0876). engine deck frame (Fig. 0874). Fig 0876 PICT-1360 Fig 0874 PICT-1357 13. Roll the deck drive belt off the ﬁ xed/center mower 11.
Page 265 ENGINE 14. Raise the machine so that the underside of the 17. Remove the belt from around the clutch (Fig. 0880). frame can be accessed. 15. Remove the trailing shield from the frame by ﬁ rst removing the left end of the shield rod (bent at a 45 degree angle) from the hole in the frame and then remove the right side of the shield rod (bent at 90 degree angle) from the right side of the frame (Fig.
Page 266 ENGINE 19. Loosen the clutch bolt (Fig. 0882). 21. Unhook the traction drive belt idler spring from the tab on the frame (Fig. 0884). Fig 0882 PICT-1369 Fig 0884 PICT-1376 20. Remove the bolt, 2 spring washers and ﬂ at washer 22.
Page 267 ENGINE 23. Slide the drive pulley off the crankshaft (Fig. 0886). 25. Lower the machine. 26. At the front of the engine, loosen the cable clamps securing the throttle (bottom) and choke (top) cables to the engine (Fig. 0888). Fig 0886 PICT-1379 24.
Page 268 ENGINE 28. Unplug the pink wire from the red engine rectiﬁ er 30. Remove the nut, harness ground wire and lock wire (Fig. 0890). washer from the rear left engine mounting bolt (Fig. 0892). Note: The bolt will fall through the frame when the nut is removed.
Page 269: Engine Installation - Gear Drive
ENGINE 4. Loosely install the other 3 engine mounting bolts Engine Installation - Gear Drive and nuts securing the engine to the frame. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs. (19.7 + 1. Position the engine onto the frame. 2.8 Nm) (Fig.
Page 270 ENGINE 6. Plug the pink wire into the red engine rectiﬁ er wire 8. Move the choke control knob to the “open” position (Fig. 0898). (Fig. 0900). Fig 0898 PICT-1389a Fig 0900 PICT-1400 7. Hook the z-bend of the choke cable into the choke 9.
Page 271 ENGINE 10. Pull the outer housing of the choke cable until the 12. Ensure the carburetor choke plate is fully closed inner wire has almost no slack and tighten the cable (Fig. 0904). clamp (Fig. 0902). Fig 0904 PICT-1401 Fig 0902 PICT-1402 13.
Page 272 ENGINE 15. Move the throttle control knob to the “fast” position 17. Move the throttle control knob to the “slow“ position. (Fig. 0906). Ensure the throttle moves smoothly (Fig. 0908). Fig 0906 PICT-1404a Fig 0908 PICT-1405a 16. Pull the outer housing of the throttle cable until the 18.
Page 273 ENGINE 20. Install the key into the crankshaft keyway (Fig. Note: The drive pulley casting indicates the orien- 0910). tation of the pulley on the crankshaft (Fig. 0912). Fig 0910 PICT-1381 Fig 0912 PICT-1408a 21. Slide the drive pulley onto the crankshaft (Fig. 0911). 22.
Page 274 ENGINE 23. Hook the traction drive belt idler spring to the tab on 25. Apply thread locking compound to the clutch bolt the frame (Fig. 0914). threads (Fig. 0916). Fig 0914 PICT-1376 Fig 0916 PICT-1411 24. Slide the ﬂ at washer and 2 spring washers onto the 26.
Page 275 ENGINE 27. Install the clutch bolt assembly into the crankshaft 29. Install the rubber grommet into the frame (Fig. to secure the clutch. Torque the clutch bolt to 55 + 5 0920). ft-lbs. (74.6 + 6.8 Nm) (Fig. 0918). Fig 0920 PICT-1418 Fig 0918 PICT-1412...
Page 276 ENGINE 31. Route the deck drive belt around the clutch (Fig. 33. Install the trailing shield into the frame by ﬁ rst insert- 0922). ing the right side of the trailing shield rod (bent at a 90 degree angle) into the hole in the chassis and then insert the left end of the trailing shield rod (bent at a 45 degree angle) into the hole in the chassis (Fig.
Page 277 ENGINE Note: Ensure the deck drive belt is routed properly 37. Install the carrier frame cover (Fig. 0928). around the mower deck pulley(s). Refer to belt routing decal (Fig. 0926): Fig 0928 PICT-1358 Fig 0926 ﬁ g. 104-8185 38. Plug the clutch connector into the harness connector (Fig.
Page 278 ENGINE 39. Install the fuel line to the fuel pump. Slide the hose clamp into place to secure the hose to the fuel pump (Fig. 0930). Fig 0930 PICT-1347 41. Secure the fuel line to the engine by installing a bolt through the R-clamp (Fig.
Page 279 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 5-38 Floating Deck Mid-Size Service Manual...
Page 280: Hydrostatic Drive System
HYDROSTATIC DRIVE SYSTEM 3. Push the grommet and clutch plug through the frame Hydro Drive Transmission Traction to the underside of the machine (Fig. 0934). Belt Replacement Hydro Drive Transmission Traction Belt Removal 1. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery (Fig.
Page 281 HYDROSTATIC DRIVE SYSTEM 5. Roll the PTO drive belt off the center mower deck 8. Remove the idler arm spring from the spring post pulley (Fig. 0936). (Fig. 0938). Fig 0936 PICT-0283 Fig 0938 PICT-0291a 6. Raise the machine so that the underside of the 9.
Page 282 HYDROSTATIC DRIVE SYSTEM 10. Remove the bolt, nut, 2 washers and spacer secur- 12. Remove the bottom bolt, nut and spacer securing ing the brake clutch strap to the underside of the the right hand side plate to the frame (Fig. 0942). chassis (Fig.
Page 283: Hydro Drive Transmission Traction Belt Installation
HYDROSTATIC DRIVE SYSTEM 14. Remove the hydro drive belt (Fig. 0944). 2. Tighten the nut and shoulder bolt securing the idler bracket to the frame (Fig. 0946). Fig 0944 PICT-0564 Fig 0946 PICT-0563 Hydro Drive Transmission Traction Belt 3. Install the bolt, spacer and nut securing the bottom Installation of the right side plate to the frame (Fig.
Page 284 HYDROSTATIC DRIVE SYSTEM 6. Install the rubber grommet into the frame (Fig. 4. Install the bolt, nut, 2 washers and spacer securing 0950). the brake clutch strap to the underside of the frame (Fig. 0948). Fig 0950 PICT-0363 Fig 0948 PICT-0361 7.
Page 285 HYDROSTATIC DRIVE SYSTEM 8. Install the hydro idler spring to the spring post (Fig. 10. Install the PTO idler spring to the spring post on the 0952). frame (Fig. 0954). Fig 0952 PICT-0565 Fig 0954 PICT-0291a 9. Route the PTO drive belt around the clutch (Fig. 11.
Page 286: Hydro Idler Replacement
Hydro Idler Removal 1. Turn the engine off and remove the key from the ignition. 2. Using a spring removal tool (Toro part number 92- 5771), unhook the hydro idler spring from the tab on the frame (Fig. 0959). Fig 0957...
Page 287 HYDROSTATIC DRIVE SYSTEM 3. Remove the ﬂ anged shoulder bolt and nut securing 5. Remove the spring from the idler lever assembly the idler lever assembly to the frame (Fig. 0960). (Fig. 0962). Fig 0960 PICT-0576 Fig 0962 PICT-0579 4. Remove the idler assembly from the frame (Fig. 6.
Page 288: Hydro Idler Installation
HYDROSTATIC DRIVE SYSTEM 7. Remove the bolt, washer, pulley, and spacer from Hydro Idler Installation the idler lever (Fig. 0964). 1. Slide the washer onto the bolt. Insert the bolt through the ﬂ ush face side of the pulley (Fig. 0966). Fig 0964 PICT-0583 Fig 0966...
Page 289 HYDROSTATIC DRIVE SYSTEM 3. Slide the idler lever onto the bolt (Fig. 0968). 5. Hook the spring onto the idler lever (Fig. 0970). Fig 0968 PICT-0596 Fig 0970 PICT-0579 4. Install a nut to secure the hydro idler pulley as- 6.
Page 290: Hydraulic Pump Replacement
HYDROSTATIC DRIVE SYSTEM 7. Route the hydro drive belt around the idler pulley 9. Using a spring removal tool (Toro part number 92- (Fig. 0972). 5771), hook the hydro idler spring to the tab on the frame (Fig. 0974). Fig 0972...
Page 291: Hydraulic Pump Removal
HYDROSTATIC DRIVE SYSTEM 4. Loosen the two pulley hub set screws (Fig. 0977). Hydraulic Pump Removal 1. Clean the area around the pump and hydraulic ﬁ ttings to prevent dirt and debris from entering the system. 2. Remove the idler spring to relieve tension from the hydro drive belt (Fig.
Page 292 HYDROSTATIC DRIVE SYSTEM 6. The pulley key may fall out of the keyway or stay in. 9. Remove the charge hose from the hydraulic pump Remove the key if it did not fall out on its own (Fig. ﬁ tting. Cap the hydraulic hose and ﬁ tting to prevent 0979).
Page 293 HYDROSTATIC DRIVE SYSTEM 11. Unhook the lower end of the extension spring from 13. Loosen the set screws located in the control shaft. the control shaft (Fig. 0983). The lower set screw can be accessed through the opening in the frame (Fig. 0985). Fig 0983 PICT-0427a Fig 0985...
Page 294: Hydraulic Pump Installation
HYDROSTATIC DRIVE SYSTEM 15. Transfer all 4 ﬁ ttings to the new pump as well as Hydraulic Pump Installation the mark indicating the location of one of the high pressure hydraulic hoses (Fig. 0987). Torque each 1. Position the pump into the frame so that the pump ﬁ...
Page 295 HYDROSTATIC DRIVE SYSTEM 3. Install the 2 set screws into the control shaft (Fig. 5. Install 2 bolts and nuts securing the pump to the 0990). frame (Fig. 0992). Fig 0990 PICT-0430 Fig 0992 PICT-0429 4. Hook the hydro pump spring to the bolt on the 6.
Page 296 HYDROSTATIC DRIVE SYSTEM 7. Install the charge hose to the charge hose ﬁ tting 9. Apply anti-seize compound to the pump shaft (Fig. (Fig. 0994). 0996). Fig 0994 PICT-0422a Fig 0996 PICT-0437 8. Install the return line to the hydro pump ﬁ tting (Fig. 10.
Page 297 HYDROSTATIC DRIVE SYSTEM 11. Apply thread locking compound onto the 2 pulley set 13. Torque the 2 set screws to 11 + 1 ft-lbs. (14.9 + 1.4 screws. Thread the 2 set screws into the pulley hub Nm) (Fig. 1000). (Fig.
Page 298: Wheel Motor Replacement
HYDROSTATIC DRIVE SYSTEM 15. Install the idler spring onto the tab on the chassis Wheel Motor Replacement (Fig. 1002). Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance.
Page 299 PICT-0443a Fig 1006 PICT-0445a 4. Raise the rear of the machine and secure with jack 8. Install a hub puller (Toro p/n TOR6006) onto the stands. wheel studs (Fig. 1007). 5. Remove the 4 lug nuts (Fig. 1005). Fig 1007...
Page 300 HYDROSTATIC DRIVE SYSTEM 9. Advance the forcing screw through the hub puller. 12. Thoroughly clean the area around the hydraulic Tighten the lug nuts down evenly until the hub pops ﬁ ttings to prevent debris from entering the system. off the wheel motor shaft (Fig. 1008). 13.
Page 301: Wheel Motor Installation
HYDROSTATIC DRIVE SYSTEM 16. Cap the hoses and wheel motor ﬁ ttings so that 19. Remove the 2 ﬁ ttings from the wheel motor (Fig. debris does not enter the system. Position the hose 1014). ends out of the way of the wheel motor. 17.
Page 302 HYDROSTATIC DRIVE SYSTEM 2. Position the wheel motor into the frame (Fig. 1016). 4. Uncap the hoses and ﬁ ttings and connect both hydraulic hoses to the wheel motor, following mark- ings made previously. Torque the hose ﬁ ttings to 34-38 ft-lbs.
Page 303 HYDROSTATIC DRIVE SYSTEM 6. Clean the hub and shaft to remove any grease or oil. 8. Slide the wheel and tire assembly onto the hub (Fig. Slide the hub onto the wheel motor shaft (Fig. 1020). 1022). Fig 1020 PICT-0457 Fig 1022 PICT-0460a 7.
Page 304 HYDROSTATIC DRIVE SYSTEM 10. Lower the machine so the rear tires are resting on 14. Fill the hydraulic reservoir tank with hydraulic ﬂ uid the ground. (15w-50 synthetic engine oil) as speciﬁ ed. Note that there are ﬁ ll level lines inside of the reservoir (Fig. 11.
Page 305: Hydraulic Reservoir Replacement
HYDROSTATIC DRIVE SYSTEM Hydraulic Reservoir Replacement Hydraulic Reservoir Removal Note: There is a hydraulic reservoir shield included 1. Remove the nuts and bolts securing the hydraulic on international models (Fig. 1027): reservoir to the frame (Fig. 1029). Fig 1027 PICT-2126 Fig 1029 PICT-0383a Use the hydraulic tank mounting hardware (2 bolts and...
Page 306: Hydraulic Reservoir Installation
HYDROSTATIC DRIVE SYSTEM 3. Remove the hydraulic lines from the bottom of the 5. Remove the ﬁ tting from the reservoir. (Fig. 1033). hydraulic reservoir tank (Fig. 1031). Fig 1033 PICT-0393a Fig 1031 PICT-0388 6. Repeat steps 4 and 5 to remove the second ﬁ tting 4.
Page 307 HYDROSTATIC DRIVE SYSTEM 2. Tighten the locking nuts while maintaining the orient- 4. Install the two hydraulic hoses onto the reservoir ation of the ﬁ ttings (Fig. 1035). ﬁ ttings (Fig. 1037). Fig 1035 PICT-0396a Fig 1037 PICT-0436a 3. Position the reservoir assembly onto the mounting 5.
Page 308: Hydraulic Testing
HYDROSTATIC DRIVE SYSTEM 3. Raise the rear of the machine and secure with jack Hydraulic Testing stands. Note: Cleanliness is a key factor in a successful 4. Release the parking brake. repair of any hydraulic system. Thoroughly clean all exposed surfaces. As with any pre- 5.
Page 309 HYDROSTATIC DRIVE SYSTEM 8. Position a drain pan under the wheel motor. 12. Open the restriction valve all the way (counterclock- wise) (Fig. 1044). 9. Disconnect both hydraulic hoses from the wheel motor (Fig. 1042). Fig 1044 PICT-6886a Fig 1042 PICT-0379 13.
Page 310 HYDROSTATIC DRIVE SYSTEM 17. After all necessary repairs have been made, recon- 22. Fill the reservoir with hydraulic ﬂ uid (15w-50 syn- nect the hydraulic hoses to the wheel motor ﬁ ttings. thetic engine oil) as speciﬁ ed. Note that there are ﬁ ll level lines inside of the reservoir (Fig.
Page 311: Bleeding The Hydraulic System
HYDROSTATIC DRIVE SYSTEM 1. Disengage the PTO. Bleeding the Hydraulic System 2. Stop the engine and wait for all moving parts to stop Due to the effects air has on efﬁ ciency in hydrostatic before leaving the operating position. drive applications, it is critical that air is purged from the system.
Page 312: Checking The Hydraulic Lines
HYDROSTATIC DRIVE SYSTEM Checking the Hydraulic Lines After every 100 operating hours, check hydraulic lines and hoses for leaks, loose ﬁttings, kinked lines, loose mounting supports, wear, weather and chemical deterior- ation. Make necessary repairs before operating. Note: Keep areas around hydraulic system clean from grass and debris build up.
Page 313: Hydraulic Schematic
HYDROSTATIC DRIVE SYSTEM Hydraulic Schematic Fig 1048 hyd scheme G006100 6-34 Floating Deck Mid-Size Service Manual...
Page 314: Gear Drive
GEAR DRIVE 3. Push the clutch wire plug and grommet through the Traction Drive Belt Replacement engine deck frame (Fig. 1050). Note: The trailing shield has been removed for photo purposes. Traction Drive Belt Removal 1. Remove the mower spindle drive belt. Refer to: “Mower Spindle Drive Belt Belt Removal (36”...
Page 315: Traction Drive Belt Installation
GEAR DRIVE 5. Unhook the gear drive idler spring from the tab on Traction Drive Belt Installation the frame (Fig. 1052). Note: The trailing shield has been removed for photo purposes. 1. Route the traction drive belt around the pulleys (Fig. 1054).
Page 316 GEAR DRIVE 7. Feed the clutch harness plug up through the chassis 9. Install the bolt, nut, 2 washers and spacer to secure (Fig. 1056). the brake clutch strap to the underside of the frame (Fig. 1058). Fig 1056 PICT-1415 Fig 1058 PICT-1488 8.
Page 317: Gear Drive Idler Replacement
GEAR DRIVE 3. Remove the nut from the bolt securing the gear drive Gear Drive Idler Replacement idler arm to the frame (Fig. 1061). Note: The trailing shield has been removed for photo purposes. Gear Drive Idler Removal 1. Turn the engine off and remove the key from the ignition.
Page 318 GEAR DRIVE 5. Remove the shoulder bolt from the idler arm as- 7. Remove the nut from the bolt securing the idler sembly (Fig. 1063). pulley to the idler arm (Fig. 1065). Fig 1065 PICT-1502a Fig 1063 PICT-1500a 6. Remove the spring from the idler arm (Fig. 1064). 8.
Page 319: Gear Drive Idler Installation
GEAR DRIVE 9. Remove the 2 ﬂ ange bushings from the idler arm 2. Install the pulley to the idler arm with a bolt and nut. (Fig. 1067). The pulley hub is installed facing the idler arm (Fig. 1069). Fig 1067 PICT-1506a Fig 1069 PICT-1504a...
Page 320: Transmission Driven Pulley Replacement
GEAR DRIVE 4. Insert the shoulder bolt into the idler arm pivot and 6. Hook the drive belt idler spring to the tab on the position the idler assembly into the frame (Fig. frame (Fig. 1073). 1071). Fig 1073 PICT-1496 Fig 1071 PICT-1499 Transmission Driven Pulley...
Page 321 GEAR DRIVE 3. Unhook the drive belt idler spring from the tab on the 5. Remove the gear drive idler assembly out of the frame (Fig. 1074). frame (Fig. 1076). Fig 1074 PICT-1496 Fig 1076 PICT-1499 4. Remove the nut from the bolt securing the gear drive 6.
Page 322 GEAR DRIVE 7. Remove the retaining ring from the end of the trans- 9. Slide the driven pulley off the transmission drive mission drive shaft (Fig. 1078). shaft (Fig. 1080). Fig 1078 PICT-1510 Fig 1080 PICT-1512 8. Loosen the set screw securing the transmission 10.
Page 323: Transmission Driven Pulley Installation
GEAR DRIVE 11. Remove the set screw from the driven pulley (Fig. 2. Insert the key into the keyway on the transmission 1082). driveshaft (Fig. 1084). Fig 1082 PICT-1515 Fig 1084 PICT-1566 Transmission Driven Pulley Installation 3. Apply thread locking compound to the driven pulley set screw (Fig.
Page 324 GEAR DRIVE 4. Begin threading the set screw into the driven pulley 6. Tighten the set screw securing the transmission hub (Fig. 1086). driven pulley to the transmission driveshaft (Fig. 1088). Fig 1086 PICT-1518 Fig 1088 PICT-1511 5. Slide the driven pulley onto the transmission drive 7.
Page 325 GEAR DRIVE 8. Install the drive belt onto the transmission driven 10. Install a nut onto the bolt securing the gear drive pulley (Fig. 1090). idler assembly to the frame (Fig. 1092). Fig 1090 PICT-1575 Fig 1092 PICT-1497 9. Position the gear drive idler assembly into of the 11.
Page 326: Gear Drive Transmission Replacement
GEAR DRIVE 4. Remove the nut from the bolt securing the gear drive Gear Drive Transmission idler arm to the frame (Fig. 1095). Replacement Note: The trailing shield has been removed for photo purposes. Gear Drive Transmission Removal 1. Turn the engine off and remove the key from the ignition.
Page 327 GEAR DRIVE 6. Remove the drive belt from the transmission driven 8. Loosen the set screw securing the transmission pulley (Fig. 1097). driven pulley to the transmission driveshaft (Fig. 1099). Fig 1097 PICT-1575 Fig 1099 PICT-1511 7. Remove the retaining ring from the end of the trans- mission drive shaft (Fig.
Page 328 GEAR DRIVE 14. Loosen the idler support bracket pivot bolt (Fig. 10. Remove the key from the transmission driveshaft 1103). keyway (Fig. 1101). Fig 1103 PICT-1520 Fig 1101 PICT-1513 15. Rotate the idler support bracket so that it is out of 11.
Page 329 GEAR DRIVE 16. Remove the wheel drive belt from the transmission 18. Slide the transmission pulley/output shaft assembly pulley (Fig. 1105). away from the transmission and out of the frame (Fig. 1107). Fig 1105 PICT-1524 Fig 1107 PICT-1554 17. Remove the 2 bolts and nuts securing the transmis- sion axle ﬂ...
Page 330 GEAR DRIVE 20. Remove the 2 bolts and nuts that secure the oppo- 22. Remove the transmission from the frame by rocking site transmission axle ﬂ ange bearing to the frame it backward and pulling the transmission from the (Fig. 1109). remaining coupler assembly (Fig.
Page 331: Gear Drive Transmission Installation
GEAR DRIVE 24. Remove the shift plate assembly from the trans- 26. Remove the shift lever and washer from the trans- mission (Fig. 1113). mission shifter shaft (Fig. 1115). Note: For transmission service procedures, refer to the appropriate Tecumseh Peerless Service Manual.
Page 332 GEAR DRIVE 2. Install the Belleville washer oriented with the crown 4. Position the shift plate assembly over the shift lever up (Fig. 1117). and onto the transmission (Fig. 1119). Fig 1117 PICT-5077a Fig 1119 PICT-5081 3. Install the nut to secure the shift lever and washers 5.
Page 333 GEAR DRIVE 6. Slide the transmission splined shaft into the RH 8. Install 4 transmission mounting bolts and lock coupler assembly. Position the transmission so that washers securing the transmission to the frame (Fig. the output shaft drops through the opening in the 1123).
Page 334 GEAR DRIVE 10. Slide the transmission pulley/output shaft assembly Note: Relubricate the shafts, if needed (Fig. 1127). through the frame and into the coupler assembly (Fig. 1125). Fig 1127 PICT-1553a Fig 1125 PICT-1554 12. Route the wheel drive belt around the transmission pulley (Fig.
Page 335 GEAR DRIVE 13. Rotate the idler support bracket back in place so 15. Tighten the idler support bracket pivot bolt (Fig. that the mounting holes line up with the holes in the 1131). frame (Fig. 1129). Fig 1131 PICT-1520 Fig 1129 PICT-1555 16.
Page 336 GEAR DRIVE 17. Raise the machine to access the underside of the 20. Apply thread locking compound to the driven pulley frame. set screw (Fig. 1135). 18. Apply anti-seize to the transmission driveshaft (Fig. 1133). Fig 1135 PICT-1567a Fig 1133 PICT-1564 21.
Page 337 GEAR DRIVE 22. Slide the driven pulley onto the transmission drive 24. Install a retaining ring onto the end of the transmis- shaft (Fig. 1137). sion drive shaft (Fig. 1139). Fig 1137 PICT-1571 Fig 1139 PICT-1510 23. Tighten the set screw securing the transmission 25.
Page 338 GEAR DRIVE 26. Insert the shoulder bolt into the idler arm pivot and 28. Hook the gear drive idler spring to the spring tab on position the idler assembly into the frame (Fig. the frame (Fig. 1143). 1141). Fig 1143 PICT-1496 Fig 1141 PICT-1499...
Page 339 GEAR DRIVE THIS PAGE INTENTIONALLY LEFT BLANK. 7-26 Floating Deck Mid-Size Service Manual...
Page 340: Mower Decks
MOWER DECKS 4. Rotate the belt guide out of the way of the PTO drive Mower Spindle Drive Belt belt (Fig. 1146). Replacement Mower Spindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) 1. Turn the ignition off and remove the key. Set the parking brake.
Page 341: Mower Spindle Drive Belt Installation (40", 48", 52" And 60" Mower Decks)
8. Remove the mower spindle drive belt (Fig. 1150). Fig 1148 PICT-1039 Fig 1150 PICT-1043 7. Using a spring removal tool (Toro p/n: 92-5771) Mower Spindle Drive Belt Installation remove the idler spring from the spring plate (Fig. (40”, 48”, 52” and 60” Mower Decks) 1149).
Page 342 MOWER DECKS 2. Using a spring removal tool (Toro p/n: 92-5771), 4. Ensure the PTO drive belt is routed around the hook the idler spring to the spring plate (Fig. 1152). clutch pulley and the idler pulley. Roll the PTO drive belt onto the center spindle pulley (Fig.
Page 343: Mower Spindle Drive Belt Removal (36" Mower Deck)
MOWER DECKS 5. Rotate the belt guide into place so that it is approxi- 7. Install the carrier frame cover (Fig. 1158). mately 1/8” (3mm) away from the PTO drive belt (Fig. 1156). Fig 1158 PICT-1022 Fig 1156 PICT-1031 Mower Spindle Drive Belt Removal (36”...
Page 344: Mower Spindle Drive Belt Installation (36" Mower Deck)
MOWER DECKS 3. Remove the mower deck belt from around pulleys 2. Hook the idler spring to the spring post (Fig. 1162). and remove it from the machine (Fig. 1160). Fig 1162 PICT-1448 Fig 1160 PICT-1449 3. Install the PTO drive belt. Refer to “PTO Drive Belt Installation”...
Page 345: Pto Drive Belt Replacement
MOWER DECKS 5. Rotate the belt guide out of the way of the PTO drive PTO Drive Belt Replacement belt (Fig. 1165). PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) 1. Turn the ignition off and remove the key. 2.
Page 346: Pto Drive Belt Installation (40", 48", 52" And 60" Mower Decks)
MOWER DECKS 7. Raise the machine to access the underside. 3. Lower the machine to access the top of the mower deck. 8. Remove the PTO drive belt from around the clutch pulley and the idler pulley and remove it from the 4.
Page 347: Pto Drive Belt Removal (36" Mower Decks)
MOWER DECKS 6. Tighten the nut securing the center spindle belt PTO Drive Belt Removal (36” Mower Decks) guide to the mower deck (Fig. 1171). 1. Turn the ignition off and remove the key. Set the parking brake. 2. Remove the carrier frame cover (Fig. 1173). Fig 1171 PICT-1023a 7.
Page 348: Pto Drive Belt Installation (36" Mower Decks)
MOWER DECKS 4. Roll the deck drive belt off the ﬁ xed (center) mower 7. Remove the belt from the clutch pulley and remove it deck pulley (Fig. 1175). from the machine (Fig. 1177). Fig 1175 PICT-1361 Fig 1177 PICT-1365a 5.
Page 349 MOWER DECKS 3. Install the PTO belt idler pulley spring onto the frame 6. Roll the PTO drive belt onto the ﬁ xed (center) mower bolt (Fig. 1179). deck pulley (Fig. 1181). Fig 1179 PICT-0287 Fig 1181 PICT-1361 4. Lower the machine. 7.
Page 350: Spindle Replacement And Service
MOWER DECKS 8. Install the carrier frame cover (Fig. 1183). 2. Install a blade stop to secure the blade (Fig. 1184). Fig 1183 PICT-1358 Fig 1184 PICT-1185 Spindle Replacement and Service 3. Support the blade/spindle shaft assembly and remove the spindle nut (Fig. 1185). Spindle Removal and Teardown 1.
Page 351 MOWER DECKS 4. Slide the blade/spindle shaft assembly out of the 6. Remove the pulley assembly (Fig. 1188). spindle housing (Fig. 1186). Fig 1188 PICT-1190 Fig 1186 PICT-1188 7. Remove the bearing shield (Fig. 1189). 5. Remove the washer (Fig. 1187). Fig 1189 PICT-1191 Fig 1187...
Page 352 MOWER DECKS 8. Remove the 6 nuts securing the spindle housing to 10. Remove the blade bolt, washer and the blade from the mower deck (Fig. 1190). the spindle shaft (Fig. 1192). Note: There may be a spring plate installed on one of the spindle bolts.
Page 353: Spindle Rebuild And Installation
MOWER DECKS 11. Remove the 2 bearings and the spacer from the Spindle Rebuild and Installation spindle housing (Fig. 1194). 1. Install a bearing into one side of the spindle housing (Fig. 1196). Fig 1194 PICT-1203 Fig 1196 PICT-1208 12. Clean and inspect the housing, bearings and spacer for wear and damage.
Page 354 MOWER DECKS 3. Install a bearing into the other side of the spindle 5. Slide the bearing shield onto the spindle shaft (Fig. housing (Fig. 1198). 1200). Fig 1198 PICT-1211 Fig 1200 PICT-1214 4. Insert the spindle shaft into the spindle housing 6.
Page 355 MOWER DECKS 7. Slide a washer onto the spindle shaft (Fig. 1202). 9. Install the crowned blade bolt washer onto the blade bolt so the crown is toward the bolt head (Fig. 1204). Fig 1202 PICT-1217 Fig 1204 PICT-1224 8. Install a nut onto the spindle shaft (Fig. 1203). 10.
Page 356 MOWER DECKS Note: The “sails” of the blade should be pointing 12. Torque the blade bolt to 85-110 ft-lbs. (115-149 Nm) toward the spindle housing. (Fig. 1208). Note: 36” and 52” mower decks have a blade stiff- ener that should be installed between the crowned washer and the blade (Fig.
Page 357: Idler Arm Assembly Replacement
MOWER DECKS 14. If applicable, place the spring plate onto the self- 16. Reinstall the drive belt or belts, as applicable. Refer tapping screw shown (Fig. 1210): • “Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks)” on page 8-2, or •...
Page 358 Fig 1213 PICT-1039 Fig 1215 PICT-1128 5. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring from the spring plate (Fig. 7. If the spring plate requires replacement, remove the 1214). nut securing it to the mower deck (Fig. 1216).
Page 359 MOWER DECKS 8. Remove the mower deck belt from around the idler 10. Remove the idler arm bolt and washer (Fig. 1219). pulley (Fig. 1217). Fig 1219 PICT-1135 Fig 1217 PICT-1131 11. Remove the idler arm assembly and washer from the mower deck (Fig.
Page 360 MOWER DECKS 12. Remove the nut and washer from the bolt securing 14. Remove the bolt from the idler arm (Fig. 1223). the idler pulley to the idler arm (Fig. 1221). Fig 1223 PICT-1147 Fig 1221 PICT-1143 15. Remove the spacer from the idler arm (Fig. 1224). 13.
Page 361: Idler Arm Assembly Installation (40", 48", 52" And 60" Mower Decks)
MOWER DECKS 16. Remove the grease ﬁ tting from the idler arm (Fig. Idler Arm Assembly Installation 1225). (40”, 48”, 52” and 60” Mower Decks) 1. Press 2 ﬂ ange bushings into either side of the idler arm pivot (Fig. 1227). Fig 1225 PICT-1149 Fig 1227...
Page 362 MOWER DECKS 3. Install the bolt into the idler arm (Fig. 1229). 5. Install the pulley onto the bolt with the hub installed toward the idler arm (Fig. 1231). Fig 1229 PICT-1163a Fig 1231 PICT-1167a 4. Install a spacer onto the bolt (Fig. 1230). 6.
Page 363 MOWER DECKS 7. Install a nut onto the bolt (Fig. 1233). 9. Slide a washer onto the idler pivot bolt. Insert the bolt up through the mower deck (Fig. 1235). Fig 1233 PICT-1170a Fig 1235 PICT-1173 8. Install the spacer into the idler arm pivot (Fig. 1234). 10.
Page 364 MOWER DECKS 11. Slide the idler arm assembly pivot onto the bolt (Fig. 13. Ensure the belt is routed properly on the mower 1237). deck. Refer to the belt routing decal (Fig. 1239): Fig 1237 PICT-1177a Fig 1239 ﬁ g. 104-8186 12.
Page 365 17. Apply grease to the idler arm grease ﬁ tting (Fig. 1243). Fig 1241 PICT-1128 Fig 1243 PICT-1182a 16. Using a spring removal tool (Toro p/n 92-5771), 18. Install the left belt cover (Fig. 1244). install the idler spring to the spring plate (Fig. 1242). Fig 1244 PICT-1039 Fig 1242...
Page 366: Idler Arm Assembly Replacement (36" Mower Deck)
MOWER DECKS 19. Install the carrier frame cover (Fig. 1245). 5. Remove the nut, washer and bolt from the idler arm pivot location (Fig. 1246). Fig 1245 PICT-1038 Fig 1246 PICT-1452a Idler Arm Assembly Replacement 6. Remove the idler arm assembly from the mower (36”...
Page 367: Idler Arm Assembly Installation (36" Mower Deck)
MOWER DECKS 7. Remove the spring from the idler arm post (Fig. 9. Remove the nut, bolt and pulley from the idler arm 1248). (Fig. 1250). Fig 1248 PICT-1457a Fig 1250 PICT-1460 8. Remove the spacer from the idler arm pivot (Fig. Idler Arm Assembly Installation 1249).
Page 368 MOWER DECKS 2. Install a bolt and nut to secure the pulley to the idler 4. Position the idler arm assembly onto the mower arm (Fig. 1252). deck (Fig. 1254). Fig 1252 PICT-1460 Fig 1254 PICT-1466 5. Insert a bolt up through the mower deck and through 3.
Page 369: Adjustable Baffl E Replacement
MOWER DECKS 6. Hook the idler spring to the idler arm (Fig. 1256). Adjustable Bafﬂ e Replacement Adjustable Bafﬂ e Removal 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut that secures the lock lever to the lock cap (Fig.
Page 370 MOWER DECKS 4. Remove the lock cap (Fig. 1259). 6. Remove the nut from the self-tapping screw that secures the adjustable bafﬂ e to the underside of the mower deck (Fig. 1261). Fig 1259 PICT-1083 Fig 1261 PICT-1092a 5. Remove the lock screw by unthreading it from the adjustable bafﬂ...
Page 371: Adjustable Baffl E Installation
MOWER DECKS 8. Remove the adjustable bafﬂ e from the mower deck 2. Install a self-tapping screw to secure the adjustable (Fig. 1263). bafﬂ e to the underside of the mower deck (Fig. 1265). Fig 1263 PICT-1089 Fig 1265 PICT-1088 Adjustable Bafﬂ...
Page 372 MOWER DECKS 4. Apply anti-seize compound onto the lock screw 6. Position the lock cap onto the lock screw (Fig. 1269). threads (Fig. 1267). Fig 1269 PICT-1083 Fig 1267 PICT-1094a 7. Slide the lock lever into the lock cap (Fig. 1270). 5.
Page 373: Discharge Baffl E Replacement
MOWER DECKS 8. Install a nut to secure the lock lever to the lock cap 2. Remove the right hand belt cover (Fig. 1272). and screw (Fig. 1271). Fig 1272 PICT-1236 Fig 1271 PICT-1080a 3. Remove the nut from each of the 2 self-tapping Discharge Bafﬂ...
Page 374: Discharge Baffl E Installation
MOWER DECKS 4. Raise the machine to access the underside of the Discharge Bafﬂ e Installation mower deck. 1. Position the discharge bafﬂ e to the mower deck (Fig. 5. Remove the 2 self-tapping screws securing the 1276). discharge bafﬂ e to the mower deck (Fig. 1274). Fig 1276 PICT-1244 Fig 1274...
Page 375: Fixed Baffl E Replacement
MOWER DECKS 3. Lower the machine to access the top of the mower Fixed Bafﬂ e Replacement deck. Fixed Bafﬂ e Removal 4. Install a nut onto each of the 2 self-tapping screws to (40”, 48”, 52” and 60” Mower Decks) secure the discharge bafﬂ...
Page 376: Fixed Baffl E Installation (40", 48", 52" And 60" Mower Decks)
MOWER DECKS 4. Remove the 2 self-tapping screws securing the ﬁ xed Fixed Bafﬂ e Installation bafﬂ e to the mower deck (Fig. 1282). (40”, 48”, 52” and 60” Mower Decks) 1. Position the ﬁ xed bafﬂ e to the mower deck (Fig. 1284).
Page 377: Fixed Baffl E Replacement (36" Mower Deck)
MOWER DECKS 3. Install the carriage bolt and nut to secure the ﬁ xed Fixed Bafﬂ e Replacement bafﬂ e to the left side of the mower deck (Fig. 1286). (36” Mower Deck) Fixed Bafﬂ e Removal (36” Mower Deck) 1.
Page 378: Fixed Baffl E Installation (36" Mower Deck)
MOWER DECKS Fixed Bafﬂ e Installation (36” Mower Deck) Skid Plate Replacement (40”, 48”, 52” and 60” Mower Decks) 1. Position the ﬁ xed bafﬂ e up to the mower deck (Fig. 1290). Skid Plate Removal (40”, 48”, 52” and 60” Mower Deck) 1.
Page 379: Skid Plate Installation (40", 48", 52" And 60" Mower Deck)
MOWER DECKS 4. Remove the 2 carriage bolts and nuts securing the Skid Plate Installation rear of the skid plate to the mower deck (Fig. 1293). (40”, 48”, 52” and 60” Mower Deck) 1. Position the skid plate to the mower deck (Fig. 1295).
Page 380: Skid Plate Replacement (36" Mower Deck)
MOWER DECKS 3. Tighten all 3 carriage bolts and nuts to secure the Skid Plate Replacement skid plate to the mower deck (Fig. 1297). (36” Mower Deck) Skid Plate Removal (36” Mower Deck) 1. Raise the machine to access the underside of the mower deck.
Page 381: Skid Plate Installation (36" Mower Deck)
MOWER DECKS 4. Remove the skid plate from the mower deck (Fig. 2. Loosely install 4 carriage bolts and nuts to secure 1300). the skid plate to the mower deck: 2 holding the rear of the skid plate and 2 holding the front of the skid plate (Fig.
Page 382: Front & Rear Deck Hanger Replacement
MOWER DECKS 3. Remove the spacers (if present) from the deck Front & Rear Deck Hanger hanger pins (Fig. 1305). Replacement Front Deck Hanger Removal 1. Remove the drive belt from the center spindle pulley. Refer to “PTO Drive Belt Removal (40”, 48”, 52”, and 60”...
Page 383 MOWER DECKS 5. Slide the ball joint/pin assembly off the bolt and 7. Remove the bolt from the mower deck bracket (Fig. remove it from the carrier frame (Fig. 1307). 1309). Fig 1309 PICT-1273 Fig 1307 PICT-1267 8. Loosen the jam nut on the deck hanger pin (Fig. 6.
Page 384: Front Deck Hanger Installation
MOWER DECKS 9. Remove the ball joint from the deck hanger pin (Fig. Front Deck Hanger Installation 1311). 1. Install a jam nut onto the ball joint (Fig. 1313). Fig 1311 PICT-1276a Fig 1313 PICT-1277a 10. Remove the jam nut from the ball joint (Fig. 1312). 2.
Page 385 MOWER DECKS 3. Adjust distance from the top of HOC stop to the 5. Slide a spacer onto the bolt (Fig. 1317). center of the ball joint to 4.21” ± .06” (10.7 + .15cm). Secure the jam nut against HOC pin. The hairpin holes in HOC pin are to be approximately inline with ball joint through hole (Fig.
Page 386 MOWER DECKS 7. Install a nut onto the bolt to secure the ball joint to 9. Lift up on the mower deck and install the hairpin(s) the mower deck (Fig. 1319). into the deck hanger pins at the desired height-of-cut setting (Fig.
Page 387: Rear Deck Hanger Removal
MOWER DECKS 4. Remove the spacer(s) (if present) from the deck Rear Deck Hanger Removal hanger pin (Fig. 1324). 1. Remove the drive belt from the center spindle pulley. Refer to “PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks)” on page 8-6 or “PTO Drive Belt Removal (36”...
Page 388 MOWER DECKS 6. Remove the deck bushing from the carrier frame 8. Remove the deck hanger pin from the carrier frame (Fig. 1326). (Fig. 1328). Fig 1326 PICT-1283 Fig 1328 PICT-1285 7. Remove the bolt and nut securing the deck hanger 9.
Page 389: Rear Deck Hanger Installation
MOWER DECKS Rear Deck Hanger Installation 3. Install the bolt and nut to secure the deck hanger pin to the mower deck (Fig. 1332). 1. Slide a retaining ring onto the deck hanger pin (Fig. 1330). Fig 1332 PICT-1284 Fig 1330 PICT-1286a 4.
Page 390 MOWER DECKS 5. Install the retaining ring onto the deck bushing (Fig. 7. Lift up on the mower deck and install the hairpin(s) 1334). into the deck hanger pins at the desired height-of-cut setting (Fig. 1336). Fig 1334 PICT-1282 Fig 1336 PICT-1257 6.
Page 391: Anti-Scalp Roller Replacement
MOWER DECKS 4. Remove the spacer tube from the spanner tube (Fig. Anti-Scalp Roller Replacement 1340). Single Anti-Scalp Roller Removal 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut from the roller axle bolt (Fig. 1338). Fig 1340 PICT-1106 5.
Page 392: Single Anti-Scalp Roller Installation
MOWER DECKS 3. Position the roller so that the spacer tube is located Single Anti-Scalp Roller Installation to the outside of the deck. Install the roller to the mower deck brackets with an axle bolt (Fig. 1344). 1. Insert the spanner tube into the roller (Fig. 1342). Fig 1344 PICT-1105 Fig 1342...
Page 393: Double Anti-Scalp Roller Removal
MOWER DECKS 4. Remove the rollers from the wheel spacer (Fig. Double Anti-Scalp Roller Removal 1348). 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut from the roller axle bolt (Fig. 1346). Fig 1348 PICT-1112a Double Anti-Scalp Roller Installation...
Page 394: Grass Defl Ector Service
MOWER DECKS 2. Position the roller assembly in between the brackets 2. Remove the nut from the deﬂ ector assembly pivot on the mower deck. Install the roller assembly to the bolt (Fig. 1352). mower deck brackets with an axle bolt. 3.
Page 395: Grass Defl Ector Disassembly
MOWER DECKS 4. Remove the deﬂ ector assembly, spacer and spring 2. Remove the discharge strap and metal deﬂ ector from the mower deck (Fig. 1354). from the rubber deﬂ ector (Fig. 1356). Fig 1354 PICT-1049a Fig 1356 PICT-1057 Grass Deﬂ ector Disassembly Grass Deﬂ...
Page 396 MOWER DECKS 2. Position and press the rubber deﬂ ector onto the 4 4. Position the 2 hinge brackets (Fig. 1360). carriage bolts (Fig. 1358). Fig 1360 PICT-1070 Fig 1358 PICT-1063 5. Install 4 nuts onto the bolts securing the deﬂ ector 3.
Page 397: Grass Defl Ector Installation
MOWER DECKS 3. Install the spring/spacer, using the pivot bolt, so that Grass Deﬂ ector Installation the hook end of the spring is on the deﬂ ector side of the mounting plate and the “L” end of the spring is 1.
Page 398: Quick Latch Replacement
MOWER DECKS 5. Install the hook end of the spring onto the deﬂ ector 2. Remove the bushing from the quick latch handle mounting bracket (Fig. 1366). (Fig. 1368). Fig 1366 PICT-1044a Fig 1368 PICT-1250a Quick Latch Replacement 3. Remove the washer from the quick latch handle (Fig. 1369).
Page 399: Quick Latch Installation
MOWER DECKS 4. Remove the quick latch handle from the cover (Fig. 2. Place a washer onto the quick latch handle (Fig. 1370). 1372). Fig 1370 PICT-1253 Fig 1372 PICT-1251a Quick Latch Installation 3. Install a bushing onto the quick latch handle (Fig. 1373).
Page 400: Mower Deck Removal
MOWER DECKS 4. Install a nut securing the quick latch handle assemb- 3. Remove the top hairpins and spacer(s) (if present) ly to the cover. There must be one thread from the from the deck hanger pin (Fig. 1375). quick latch handle protruding past the nut (Fig. 1374).
Page 401: Mower Deck Installation
MOWER DECKS 5. Remove the spacers from the hanger pins if they are Mower Deck Installation present (Fig. 1377). 1. Raise and position the carrier frame over the mower deck (Fig. 1379). Fig 1377 PICT-1294 Fig 1379 PICT-1295 6. Raise the carrier frame and slide the mower deck away from the traction unit (Fig.
Page 402: Checking The Engine Deck Height
MOWER DECKS 3. Support the rear of the chassis with a jack stand. Checking the Engine Deck Height 4. Lift up on the mower deck and install the spacers 1. Disengage the PTO and set the parking brake. and hairpins onto the 4 deck hanger pins (Fig. 1381).
Page 403: Checking The Carrier Frame Front-To-Rear Pitch
MOWER DECKS Checking the Carrier Frame Front-to- Checking the Carrier Frame Side-to- Rear Pitch Side Height The carrier frame needs to be parallel side-to-side from The carrier frame must have a pitch between 1/8” (3mm) the ground. to 3/8” (9mm) over the length of 24” (61cm) on the carrier frame.
Page 404: Checking The Mower Deck Front-To-Rear Pitch
MOWER DECKS Checking the Mower Deck Front-to- Rear Pitch 1. Adjust the tire pressure in the rear tires to 12-14 psi (83-97kPa). 2. Position the mower blades so they are in the front- to-rear orientation. Measure at AA and BB locations from a level surface to the cutting edge of the blade tips (Fig.
Page 405: Adjusting The Mower Deck Front-To-Rear Pitch
MOWER DECKS Adjusting the Mower Deck Front-to- Checking the Mower Deck Side-to- Rear Pitch Side Height Changing the front-to-rear pitch is done by adjusting the 1. Adjust the rear tire pressure to 12-14 psi (83-97kPa). front height-of-cut posts. 2. Position the mower blades in the side-to-side orien- tation.
Page 406: Adjusting The Mower Deck Side-To-Side Height
MOWER DECKS Adjusting the Mower Deck Side-to- Side Height 1. Adjust the rear tire pressure. This should be done to the tire on the corresponding side that needs height adjustment. 2. Adjust the caster spacers by moving spacers from the top or bottom of the caster wheel forks. 3.
Page 407 MOWER DECKS 3. With the machine on level surface, position one blade front-to-rear. Measure at location A from a level surface to the cutting edge of the blade tip (Fig. 1391 and for 36” mower decks use Fig. 1392). 4. The measurement should be 4” (101.6mm). 5.
Page 408: Tools
(Fig. 1393). Additional information can be found in the LCE Electrical Troubleshooting DVD #492-9171, available through your Toro parts supplier. Caution Before performing any tests with a continuity light or ohmmeter, disconnect the component from the wire harness.
Page 409: Single Pole Switch
ELECTRICAL Single Pole Switch PTO Switch This is a normally closed switch and has the letters “NC” 3 terminals are in use on this switch. When the switch is stamped on both terminals. This switch should have off (knob depressed) there should be continuity between continuity when at rest.
Page 410: Relay, Single Pole Dual Throw
ELECTRICAL Relay, Single Pole Dual Throw Ignition Switch A relay is an electronically activated switch. It can be The ignition switch has 3 positions; off, run and start. used as a normally open or normally closed switch The start position is spring loaded to return to run when depending on which terminals are used.
Page 411: Wire Harness T-Bar, Gear Drive (104-8137)
ELECTRICAL Wire Harness T-Bar, Gear Drive (104-8137) This wire harness has one 7.5 amp fuse in the pink wire between the alternator and delay module. If the clutch fails to engage, check the fuse ﬁ rst (Fig. 1401). Fig 1401 scheme 104-8137 Floating Deck Mid-Size Service Manual...
Page 412: Pto Switch
ELECTRICAL PTO Switch Delay Module Only 2 terminals are used in this application: numbers 1 The Delay Module delays clutch disengagement for a and 4 as shown in the ﬁ gure below. These terminals are second or two. It allows the operator to momentarily normally open.
Page 413: Clutch Power Supply Test Procedure
ELECTRICAL Clutch Power Supply Test Procedure: 3. Connect the test lead to the end of the pink wire in the terminal plug removed from the module (Fig. 1407). 1. Measure the DC voltage at the pink wire where it comes out of the rectiﬁ er. Make sure the engine is Note: The voltage should be the same as at the running at full throttle and note the reading.
Page 414 ELECTRICAL 5. Move the bail to the operation position and tempor- 7. Set the Volt/Ohm meter to the OHMs setting. Con- arily tie it in place (Fig. 1409). nect a test lead to the green wire at the module connector. Connect the other test lead to the engine block (Fig.
Page 415: Dc Mini Hour Meter
ELECTRICAL 8. Check the ground for the module: Check for contin- DC Mini Hour Meter uity between the black wire at the module connector and the engine (Fig. 1412). This hour meter runs when 12 VDC is applied. It will record up to 9,999.9 hrs.
Page 416: Proximity Switch
ELECTRICAL Proximity Switch PTO Brake Clutch Assembly This proximity switch is normally open. The contacts The PTO clutch contains one ﬁ xed plate, a moveable close when a piece of ferrous metal (iron or steel) is plate and an electro magnet. When a minimum of 8 VDC placed close to the switch, approximately within 1/4”...
Page 417: Wire Harness Pistol Grip (106-8780)
ELECTRICAL If the 25 amp fuse fails, focus on the engine portion of Wire Harness Pistol Grip (106-8780) the charging system for the cause. The alternator does not produce enough amperage to blow the fuse. A short There is a 30 amp fuse (p/n 109103) between the bat- to ground or a shorted diode in the charging system tery and ignition switch and a 25 amp fuse (p/n 109102) could allow the battery to discharge through the regulator...
Page 418: Pto Switch
ELECTRICAL PTO Switch The PTO switch has 3 positions. Fully depressed, a middle detent and momentary (full out). The momentary (full out) position is spring loaded. It must be held to keep it in that position. When the knob is fully depressed there is continuity between terminals 1 and 7.
Page 419: Wire Harness T-2, Hydro (114-3418)
ELECTRICAL If the 25 amp fuse fails, focus on the engine portion of Wire Harness T-2, Hydro (114-3418) the charging system for the cause. The alternator does not produce enough amperage to blow the fuse. A short There is a 30 amp fuse (p/n 109103) between the bat- to ground or a shorted diode in the charging system tery and ignition switch and a 25 amp fuse (p/n 109102) could allow the battery to discharge through the regulator...
Page 420: Wire Harness T-Bar, Hydro (114-3420)
ELECTRICAL If the 25 amp fuse fails, focus on the engine portion of Wire Harness T-Bar, Hydro (114-3420) the charging system for the cause. The alternator does not produce enough amperage to blow the fuse. A short There is a 30 amp fuse (p/n 109103) between the bat- to ground or a shorted diode in the charging system tery and ignition switch and a 25 amp fuse (p/n 109102) could allow the battery to discharge through the regulator...
Page 421: Normally Open Switch
ELECTRICAL Normally Open Switch Starter Solenoid This switch is normally open. There is contact only when A starter is a form of an electrically operated switch. the plunger is depressed (Fig. 1422). Positioning the solenoid closer to the battery and starter, short battery cables can be utilized to increase efﬁ...
Page 422: Operator Presence Control (Opc) Switch Replacement (T-Bar)
ELECTRICAL 3. Remove the cotter pin from the upper end of the Operator Presence Control (OPC) control rod (Fig. 1426). Switch Replacement (T-Bar) OPC Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. 2. Lift the locking tab on the front of the operator presence control switch and unplug the harness connector from the switch (Fig.
Page 423: Opc Switch Installation (T-Bar)
ELECTRICAL 5. Repeat steps 3 and 4 to remove the opposite control OPC Switch Installation (T-Bar) rod from the control bar/bail assembly. 1. Install the OPC switch into the switch mounting 6. Remove the bail from the T-Bar handle by sliding it bracket on the T-Bar (Fig.
Page 424 ELECTRICAL 3. Insert a control rod through the T-Bar handle/bail 5. Repeat steps 3 and 4 to install the opposite control assembly mounting pivots (Fig. 1432). rod. 6. Plug the harness connector into the OPC switch (Fig. 1434). Fig 1432 PICT-1682 Fig 1434 PICT-1744...
Page 425: Pto Switch Replacement (T-Bar)
ELECTRICAL 4. Unplug the wire harness from the PTO switch (Fig. PTO Switch Replacement (T-Bar) 1437). PTO Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. 2. Remove the 2 screws securing the manual tube R-clamps to the bottom panel of the control panel.
Page 426: Pto Switch Installation (T-Bar)
ELECTRICAL 3. Position the bottom panel to the control panel and PTO Switch Installation (T-Bar) install 2 screws securing it to the control panel (Fig. 1441). 1. Push the PTO switch in to place in the control panel (Fig. 1439). Fig 1441 PICT-1789 Fig 1439...
Page 427: Ignition Switch Replacement (T-Bar)
ELECTRICAL 4. Unplug the wire harness from the ignition switch Ignition Switch Replacement (T-Bar) (Fig. 1445). Ignition Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. 2. Remove the 2 screws securing the manual tube R-clamps to the bottom panel of the control panel.
Page 428: Ignition Switch Installation (T-Bar)
ELECTRICAL 6. Remove the lockwasher from the ignition switch (Fig. Ignition Switch Installation (T-Bar) 1447). 1. Insert the ignition switch into the control panel (Fig. 1449). Fig 1447 PICT-1801 Fig 1449 PICT-1803 7. Remove the ignition switch from the control panel (Fig.
Page 429 ELECTRICAL 3. Install a nut securing the ignition switch to the control 5. Position the bottom panel to the control panel and panel (Fig. 1451). install 2 screws securing the back side of the bottom panel to the control panel (Fig. 1453). Fig 1451 PICT-1800 Fig 1453...
Page 430: Delay Module Replacement (T-Bar)
ELECTRICAL 3. Remove the 2 screws securing the bottom panel to Delay Module Replacement (T-Bar) the control panel and move the bottom panel away from the control panel (Fig. 1456). Delay Module Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition.
Page 431: Delay Module Installation (T-Bar)
ELECTRICAL 5. Unplug the harness connector from the delay 7. Remove the bolt and nut securing the delay module module (Fig. 1458). to the bottom panel (Fig. 1460). Fig 1458 PICT-1805 Fig 1460 PICT-1809 6. Remove the fuse block from the bottom panel and Delay Module Installation (T-Bar) remove the bottom panel from the machine (Fig.
Page 432 ELECTRICAL 2. Position the bottom panel up to the control panel and 4. Plug the brown wire bullet connect into the harness attach the fuse block to the bottom panel (Fig. 1462). (Fig. 1464). Fig 1462 PICT-1806 Fig 1464 PICT-1804 3.
Page 433: Parking Brake Switch Replacment (Pistol Grip & T-2)
ELECTRICAL 6. Position the manual tube to the control panel. Install 2. Unplug the harness from the parking brake switch 2 screws to secure the manual tube assembly (Fig. 1467). (R-clamps) and bottom panel to the control panel (Fig. 1466). Fig 1467 PICT-1816 Fig 1466...
Page 434: Parking Brake Switch Installation (P.g. & T-2)
ELECTRICAL 4. Remove the spacer from the switch (Fig. 1469). Parking Brake Switch Installation (P.G. & T-2) 1. Position the parking brake switch onto the parking brake handle support (Fig. 1471). Fig 1469 PICT-1892 5. Remove the switch from the parking brake handle Fig 1471 PICT-1894 support (Fig.
Page 435: Neutral Switch Replacement (Pistol Grip)
ELECTRICAL 3. Install 2 bolts and nuts securing the parking brake Neutral Switch Replacement switch to the parking brake handle support (Fig. (Pistol Grip) 1473). Neutral Switch Removal (P.G.) 1. Position the speed control lever in the Fast position (Fig. 1475). Fig 1473 PICT-1817 4.
Page 436: Neutral Switch Installation
ELECTRICAL 3. Remove the 2 screws securing the neutral switch to Neutral Switch Installation (P.G.) the neutral bracket (Fig. 1477). 1. Position the spacer and the switch onto the neutral bracket (Fig. 1479). Fig 1477 PICT-1825 Fig 1479 PICT-1827a 4. Remove the spacer and the switch from the neutral bracket (Fig.
Page 437 ELECTRICAL 3. Plug the harness into the neutral switch (Fig. 1481). 5. To adjust the switch location, loosen the two neutral bracket screws holding the switch plate to the frame (Fig. 1483). Fig 1481 PICT-1823 Fig 1483 PICT-1911 4. With the speed control lever in the neutral position, check to make sure the safety switch is depressed with an 1/8”...
Page 438: Pto Switch Replacement (Electric Start)
ELECTRICAL 7. Tighten the two neutral bracket screws holding the 3. Remove the fuse block(s) from the control panel switch plate (Fig. 1485). cover bracket (Fig. 1486). Fig 1485 PICT-1911 Fig 1486 PICT-1836 PTO Switch Replacement (Electric 4. Remove the 2 screws securing the manual tube as- sembly to the control bracket.
Page 439 ELECTRICAL 5. Remove the 2 screws securing the control panel 7. Unplug the harness from the PTO switch (Fig. 1490). cover bracket to the front side of the control panel (Fig. 1488). Fig 1490 PICT-1851a Fig 1488 PICT-1847 8. Depress the tabs on the PTO switch and push it through the control panel to remove it (Fig.
Page 440: Pto Switch Installation (Electric Start)
ELECTRICAL 3. Position the cover bracket onto the control panel PTO Switch Installation (Electric Start) (Fig. 1494). 1. Push the PTO switch through the control panel until it snaps into place (Fig. 1492). Fig 1494 PICT-1848 Fig 1492 PICT-0729a 4. Install 2 screws securing the control panel cover bracket to the front side of the control panel (Fig.
Page 441: Operator Presence Control (Opc) Switch Replacement (Pistol Grip)
ELECTRICAL 5. Position the manual tube to the cover bracket. Install Operator Presence Control (OPC) 2 screws securing the manual tube assembly to the Switch Replacement (Pistol Grip) control panel and control bracket (Fig. 1496). Note: The harness has been unplugged from the PTO switch for photo purposes.
Page 442 ELECTRICAL 4. Remove the 2 screws securing the manual tube as- 6. Remove the cover bracket from the control panel sembly to the control bracket. Remove the manual (Fig. 1501). tube assembly (Fig. 1499). Fig 1501 PICT-1848 Fig 1499 PICT-1839 7.
Page 443: Opc Switch Installation
ELECTRICAL 8. Remove the 2 screws securing the OPC switch to OPC Switch Installation (P.G.) the switch mounting plate (Fig. 1503). 1. Position the switch and spacer to the mounting plate (Fig. 1505). Fig 1503 PICT-1859 Fig 1505 PICT-1860 9. Remove the switch and spacer from the mounting plate (Fig.
Page 444 ELECTRICAL 3. Plug the harness into the OPC switch (Fig. 1507). 5. If needed, adjust the position of the switch. Refer to OPC Switch Position Adjustment (P.G.) in the following section. 6. Position the cover bracket onto the control panel (Fig.
Page 445: Opc Switch Position Adjustment
ELECTRICAL 8. Position the manual tube to the cover bracket. Install OPC Switch Position Adjustment (P.G.) 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1511). 1. Loosen the 2 OPC switch mounting screws (Fig. 1513).
Page 446: Hour Meter Replacement (Pistol Grip)
ELECTRICAL 3. Tighten the neutral bracket mounting screws (Fig. 3. Remove the fuse blocks from the control panel cover 1515). bracket (Fig. 1516). Fig 1515 PICT-1864 Fig 1516 PICT-1836 4. The OPC switch should return to the open position 4. Remove the 2 screws securing the manual tube with the levers in the full spring return position.
Page 447 ELECTRICAL 5. Remove the 2 screws securing the control panel 7. Unplug the harness from the hour meter (Fig. 1520). cover bracket to the front side of the control panel (Fig. 1518). Fig 1520 PICT-1869 Fig 1518 PICT-1847 8. Remove the locking tab from the back side of the hour meter (Fig.
Page 448: Hour Meter Installation
ELECTRICAL 9. Remove the hour meter from the control panel (Fig. 2. Install the locking tab onto the back side of the hour 1522). meter (Fig. 1524). Fig 1522 PICT-1871 Fig 1524 PICT-1870 Hour Meter Installation (P.G.) 3. Plug the harness into the hour meter (Fig. 1525). 1.
Page 449 ELECTRICAL 4. Position the cover bracket onto the control panel 6. Position the manual tube to the cover bracket. Install (Fig. 1526). 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1528). Fig 1526 PICT-1848 Fig 1528 PICT-1839...
Page 450: Ignition Switch Replacement (Pistol Grip)
ELECTRICAL 4. Remove the 2 screws securing the manual tube Ignition Switch Replacement assembly to the control bracket. Remove the manual (Pistol Grip) tube assembly (Fig. 1531). Ignition Switch Removal (P.G.) 1. Turn the engine off and remove the key from the ignition.
Page 451 ELECTRICAL 6. Remove the cover bracket from the control panel 8. Remove the nut securing the ignition switch to the (Fig. 1533). control panel (Fig. 1535). Fig 1533 PICT-1848 Fig 1535 PICT-1873 7. Unplug the harness terminal and harness connector 9.
Page 452: Ignition Switch Installation
ELECTRICAL 10. Remove the ignition switch from the control panel 2. Place a lockwasher onto the ignition switch (Fig. (Fig. 1537). 1539). Fig 1537 PICT-1875 Fig 1539 PICT-1874 3. Install a nut securing the ignition switch to the control Ignition Switch Installation (P.G.) panel (Fig.
Page 453 ELECTRICAL 4. Plug the wire harness connector and terminal into 6. Install 2 screws securing the control panel cover the ignition switch (Fig. 1541). bracket to the front side of the control panel (Fig. 1543). Fig 1541 PICT-1872 Fig 1543 PICT-1847 5.
Page 454: Kill Relay Replacement (Pistol Grip)
ELECTRICAL 8. Slide the fuse blocks onto the control panel cover 3. Unplug the kill relay from the wire harness (Fig. bracket (Fig. 1545). 1546). Fig 1545 PICT-1836 Fig 1546 PICT-1877 9. Connect the negative battery cable to the battery. Kill Relay Installation (P.G.) 1.
Page 455: Solenoid Switch Replacement (Pistol Grip & T-2)
ELECTRICAL 4. Pull the boot back and remove the nut and lock Solenoid Switch Replacement washer securing the battery cable to the solenoid (Pistol Grip & T-2) terminal. Remove the battery cable (Fig. 1549). Solenoid Switch Removal (P.G. & T-2) 1.
Page 456: Solenoid Switch Installation (P.g & T-2)
ELECTRICAL 6. Unplug the 2 harness wires (blue and orange) from Solenoid Switch Installation (P.G & T-2) the solenoid (Fig. 1551). 1. Position the solenoid onto the frame and secure it with 2 self-tapping screws (Fig. 1553). Fig 1551 PICT-1883 Fig 1553 PICT-1888 7.
Page 457 ELECTRICAL 3. Slide the harness wire (red) onto the solenoid term- 5. Position the starter cable onto the solenoid terminal. inal (Fig. 1555): Install a lockwasher and nut to secure (Fig. 1557). Fig 1555 PICT-1882 Fig 1557 PICT-1920 4. Position the battery cable onto the solenoid terminal, 6.
Page 458: Operator Presence Control (Opc) Switch Replacement (T-2)
ELECTRICAL 3. Unplug the harness from the OPC switch (Fig. Operator Presence Control (OPC) 1560). Switch Replacement (T-2) OPC Switch Removal (T-2) 1. Remove the 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig.
Page 459: Opc Switch Installation (T-2)
ELECTRICAL 5. Remove the OPC switch and spacer plate (Fig. 2. Install 2 screws securing the OPC switch (and plate) 1562). to the motion control assembly (Fig. 1564). Fig 1564 PICT-1928a Fig 1562 PICT-1932a 3. Position the right hand control lever in the operating OPC Switch Installation (T-2) position.
Page 460: Latching Relay Replacement (T-2)
ELECTRICAL 4. Plug the harness into the OPC switch (Fig. 1566). 6. Install 4 screws (2 on the left, 2 on the right) secur- ing the control panel cover to the control pane (Fig. 1568). Fig 1566 PICT-1927 Fig 1568 PICT-1921 5.
Page 461: Latching Relay Installation (T-2)
ELECTRICAL 3. Remove the 4 screws (2 on the left, 2 on the right) 5. Unplug the latching relay from the wire harness (Fig. securing the control panel cover to the control panel 1571). (Fig. 1569). Fig 1571 PICT-1936 Fig 1569 PICT-1921 Latching Relay Installation (T-2) 4.
Page 462: Kill Relay Replacement (T-2)
ELECTRICAL 2. Position the control panel cover/manual tube as- Kill Relay Replacement (T-2) sembly onto the control panel (Fig. 1573). Note: The Manual Tube assembly and Control Panel Cover Bracket have been removed for photo purposes. Kill Relay Removal (T-2) 1.
Page 463: Kill Relay Installation (T-2)
ELECTRICAL 3. Unplug the harness from the proximity neutral switch Kill Relay Installation (T-2) connector (Fig. 1577). 1. Plug the kill relay into the wire harness (Fig. 1576). Fig 1577 PICT-1938 Fig 1576 PICT-1937 4. Remove the cable tie securing the switch wires to the frame (Fig.
Page 464: Proximity Neutral Switch Installation (T-2)
ELECTRICAL 5. Remove the 2 screws and nuts securing the switch Proximity Neutral Switch Installation (T-2) to the frame (Fig. 1579). 1. Position the Proximity Neutral Switch to the frame (Fig. 1581). Fig 1579 PICT-1940 Fig 1581 PICT-1941 6. Remove the switch (Fig. 1580). 2.
Page 465 ELECTRICAL 3. The distance between the face of the switch and the 5. Plug the harness into the proximity neutral switch end of the hex head screw should be .07” + .02” (1.8 connector (Fig. 1585). + .5mm) (Fig. 1583). Fig 1585 PICT-1938 Fig 1583...
Page 466 Floating Deck Mid-Size Service Manual Form No. 492-9189...

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Toro 30284 Service Manual

Safety Information

Specifications

Chassis

CHASSIS Cont.

Linkage

LINKAGE Cont.

Engine

Hydrostatic Drive System

Gear Drive

Mower Decks

MOWER DECKS Cont

Electrical

ELECTRICAL Cont.

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Summary of Contents for Toro 30284