Toro TIMECUTTER HD 75201 Service Manual
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Toro TIMECUTTER HD 75201 Service Manual

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R e s i d e n t i a l P r o d u c t s
T I ME C U T T E R ® H D
S e r v i c e Ma n u a l
I s s u e d : A p r i l 2 0 1 7

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Summary of Contents for Toro TIMECUTTER HD 75201

  • Page 1 R e s i d e n t i a l P r o d u c t s T I ME C U T T E R ® H D S e r v i c e Ma n u a l I s s u e d : A p r i l 2 0 1 7...
  • Page 2 ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
  • Page 3 ICON LEGEND This icon is used to denote Critical Processes or actions that if missed, could greatly impact your safety, lead to mechanical failure, or improper product part use. Please pay close attention to these steps as they are distinguished throughout the manual.
  • Page 4 Chapters Safety............................. Specifications........................Maintenance.......................... Troubleshooting........................Chassis..........................Engine............................ Hydrostatic Drive System....................Mower Deck........................... Electrical..........................Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 5 SAFETY Table of Contents General Safety Information....................Think Safety First......................Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 6 Toro TIMECUTTER® HD.The TIMECUTTER® HD operator’s manual contains safety information and operating tips for safe operating practices. Operator’s manuals are available online through your Toro parts source or: The Toro Company...
  • Page 7 SPECIFICATIONS Table of Contents General Specifications......................Unit Dimensions........................Torque Specifications......................Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.)........2-10 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric)......2-11 Equivalents and Conversions.................... 2-13 U.S. To Metric Conversions....................2-14 Digital Edition - TIMECUTTER®...
  • Page 8 Clutch Non-adjustable Adjustment Hydraulic Drive System Transmission ZT3100 Transmission 4.45 L (150 oz.) Toro HYPR-OIL® 500 hydraulic fluid or Mobil 1 15W-50 oil Lubricant Max Ground Up to 8.5 mph Speed (FWD) Max Ground Up to 5 mph Speed (REV)
  • Page 9 SPECIFICATIONS General Specifications (Cont.) Configuration TIMECUTTER® HD Model 75201 75202 75203 75211 Front Caster 13x6.5-6 Tires Front Tire 13 psi Pressure Mower Deck Deck Width 48 in. 54 in. 60 in. 48 in. Deck 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Configuration Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles...
  • Page 10 Clutch Non-adjustable Adjustment Hydraulic Drive System Transmission ZT3100 Transmission 4.45 L (150 oz.) Toro HYPR-OIL® 500 hydraulic fluid or Mobil 1 15W-50 oil Lubricant Max Ground Up to 8.5 mph Up to 7.8 mph Speed (FWD) Max Ground Up to 5 mph...
  • Page 11 SPECIFICATIONS General Specifications (Cont.) Configuration TIMECUTTER® HD Model 75212 75213 75210 74864 Front Caster 13x6.5-6 Tires Front Tire 13 psi Pressure Mower Deck Deck Width 54 in. 60 in. 48 in. Deck 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Configuration Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles...
  • Page 12 Clutch Non-adjustable Adjustment Hydraulic Drive System Transmission ZT3100 Transmission 4.45 L (150 oz.) Toro HYPR-OIL® 500 hydraulic fluid or Mobil 1 15W-50 oil Lubricant Max Ground Up to 7.8 mph Speed (FWD) Max Ground Up to 5 mph Speed (REV)
  • Page 13 SPECIFICATIONS General Specifications (Cont.) Configuration TIMECUTTER® HD Model 74865 74866 74867 Front Caster 13x6.5-6 Tires Front Tire 13 psi Pressure Mower Deck Deck Width 54 in. 48 in. 54 in. Deck 3-Blade, Grade 50 10ga. Steel Fabricated Deck, Side Discharge Configuration Deck Spindles Cast Aluminum with Permanently Lubed Ball Bearings, 25 mm spindles...
  • Page 14 SPECIFICATIONS Unit Dimensions Model Overall Tread Width Overall Width Overall Height Length Caster Drive Wheel Curb Tires Deck Deck (Top of Wheels Wheels Base Weight Chute Chute Seat) Down in/cm lbs/kg in/cm 75201 44.1/ 34.3/ 39.2/ 49.7/ 744/ 48.8/ 63.4/ 49.2/ 82.1/ 112.0...
  • Page 15 The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 16 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, SAE Grade 5 Bolts, SAE Grade 8 Bolts, 8 Fasteners Screws, Studs & Sems Screws, Studs & Sems Screws, Studs & Sems with Thin with Regular Height with Regular Height...
  • Page 17 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) Thread Size Class 8.8 Bolts, Screws, Studs with Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Regular Height Nuts (Class 10 or Nuts) stronger Nuts) In-lb.
  • Page 18 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) (Cont.) SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Recommended Torque** Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb. 88 ±...
  • Page 19 SPECIFICATIONS 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 35/64 0.046875 1.191 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32...
  • Page 20 SPECIFICATIONS U.S. to Metric Conversions To Convert Into Multiply By Linear Measurement Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches...
  • Page 21 MAINTENANCE Table of Contents Recommended Maintenance Schedule(s)................. Servicing the Toro Engine....................Servicing the Air Cleaner....................Removing the Elements....................Cleaning the Foam and Paper Element................ Paper Element........................ Servicing the Engine Oil....................Checking the Engine Oil Level..................Changing the Engine Oil and Oil Filter................
  • Page 22 MAINTENANCE Recommended Maintenance Chart Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil Before each use or daily • Check the safety-interlock system • Check the air cleaner for dirty, loose, or damaged parts •...
  • Page 23 MAINTENANCE Servicing the Toro Engine WARNING Shut off engine before checking the oil or adding oil to the crankcase. Servicing the Air Cleaner Figure 1 Service Interval Maintenance Procedure Every 25 hours/monthly • Clean the air cleaner foam element* (whichever comes first) Every 100 hours/yearly •...
  • Page 24 MAINTENANCE Servicing the Toro Engine (Cont.) Removing the Elements 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Clean around the air cleaner cover to prevent dirt from getting into the engine and causing damage.
  • Page 25 MAINTENANCE Servicing the Toro Engine (Cont.) Cleaning the Foam and Paper Elements Foam Element: Wash the foam element with water. NOTE: Replace the foam element if it is torn or worn. Paper Element 1. Lightly tap the element on a flat surface to remove dust and dirt.
  • Page 26 MAINTENANCE Servicing the Toro Engine (Cont.) Servicing the Engine Oil Recommended Oil: Toro 4-Cycle Premium Engine Oil Oil Type: Detergent Oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (2.5 qt.) Viscosity: See table below (Figure 4)
  • Page 27 5. If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the “FULL” mark on the dipstick. Toro 4-Cycle Premium Engine Oil is recommended; refer to the following information for an appropriate API rating and viscosity.
  • Page 28 MAINTENANCE Servicing the Toro Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/After the first month (whichever comes first). Every 100 hours/Yearly (whichever comes first): Change the engine oil and oil filter more often in dirty or dusty conditions.
  • Page 29 MAINTENANCE Servicing the Toro Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) 3. Change the oil filter. NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional ¾ turn (Figure 7).
  • Page 30 MAINTENANCE Servicing the Toro Engine (Cont.) Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plugs. Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plugs. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug.
  • Page 31 MAINTENANCE Servicing the Toro Engine (Cont.) Checking the Spark Plug 1. Inspect the spark plug. NOTE: If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.
  • Page 32 MAINTENANCE Servicing the Toro Engine (Cont.) Cleaning the Cooling System Service Interval: Before each use. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake.
  • Page 33 MAINTENANCE Fuel System Maintenance Replacing the In-line Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) – Check the in-line fuel filter. Every 200 hours/Every 2 years (whichever comes first) – Replace the in-line fuel filter. NOTE: Never install a dirty filter if it is removed from the fuel line. 1.
  • Page 34 MAINTENANCE Electrical System Maintenance Servicing the Battery Service Interval: Monthly NOTE: The battery should be maintained at 12.6 volts or greater. A battery that has reached a voltage of 12.2 volts or less is considered discharged, and should be recharged. 1.
  • Page 35 MAINTENANCE Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; frayed edges, burn marks, and cracks on the belt. Mower Belt Replacement (Side Discharge Machines), see chapter 8, page 8-4.
  • Page 36 MAINTENANCE Servicing the Cutting Blades WARNING A worn or damaged blade can break and a piece of the blade could be thrown at you or bystanders, resulting in serious injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product.
  • Page 37 MAINTENANCE Servicing the Cutting Blades Before Inspecting or Servicing the Blades 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key. 2. Disconnect the spark plug wires from the spark plugs. Inspecting the Blades 1.
  • Page 38 MAINTENANCE Servicing the Cutting Blades (Cont.) Checking for Bent Blades 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the spark plug wires from the spark plugs. 3.
  • Page 39 Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.
  • Page 40 MAINTENANCE Changing the Blades (Cont.) Installation 1. Install the blades, curved washers, and blade bolts onto the spindle shaft (Figure 15). Figure 15 A. Sail Area of the Blade C. Curved Washer B. Blade D. Blade Bolt NOTE: The curved part of the blade must point upward. NOTE: Install the curved washer cone toward the bolt head.
  • Page 41 MAINTENANCE Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 16). NOTE: Maintain the original angle. NOTE: The blade retains balance if you remove the same amount of material from both cutting edges. Figure 16 2.
  • Page 42 TROUBLESHOOTING Table of Contents Troubleshooting Table......................4-2 Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 43 TROUBLESHOOTING Troubleshooting Problem Possible Cause Next Step... The starter does not crank The blade control switch (PTO) is Move the blade-control switch (PTO) engaged. to the disengaged position. The parking brake is not engaged. Set the parking brake. The motion-control levers are not in Ensure that the motion-control levers the Neutral-Lock position.
  • Page 44 TROUBLESHOOTING Troubleshooting (Cont.) Problem Possible Cause Next Step... Engine loses power The engine load is excessive. Reduce the ground speed. The air cleaner is dirty. Clean the air cleaner element. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and air passages Remove the obstruction and above the engine are plugged.
  • Page 45 TROUBLESHOOTING Troubleshooting (Cont.) Problem Possible Cause Next Step... The machine produces an The blade(s) is/are not sharp. Sharpen the blade(s). uneven cutting height The cutting blade(s) is/are bent. Install new cutting blade(s). The mower deck is not level. Level the mower deck from side-to- side and front-to-rear.
  • Page 46 CHASSIS Table of Contents Caster Tires Exploded View....................Caster Assembly and Bearing.................... Removal........................... Installation........................Caster Wheel Bearing......................Removal........................... Left Console.......................... Removal........................... Installation........................Right Console........................Removal........................... Installation........................5-10 Seat - TIMECUTTER® HD ZX Models Only................. 5-11 Removal..........................5-11 Installation........................5-12 Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only........
  • Page 47 CHASSIS Table of Contents Motion Control Assembly....................5-32 Removal.......................... 5-32 Installation........................5-34 Adjusting the Motion Control Handle Position..............5-35 Digital Edition - TIMECUTTER® HD Service Manual Table of Contents April 2017...
  • Page 48 CHASSIS Caster Tires Exploded View Figure 1 A. Caster Fork B. Tire and Wheel Asm. C. Screw Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 49 CHASSIS Caster Assembly and Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 3.
  • Page 50 CHASSIS Caster Wheel Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 3.
  • Page 51 CHASSIS Left Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery cables and remove the battery from the tray. 3.
  • Page 52 CHASSIS Left Console (Cont.) Installation 1. Remove the fuel cap from the gas tank. 2. Lower the console into place, ensuring that it seats properly on the supports (Figure 4). Figure 4 3. Install the left side control lever. 4. Install the keeper line into the fuel cap, and reinstall the fuel cap. 5.
  • Page 53 CHASSIS Right Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the three shoulder bolts (T30) at locations, A, B & C (Figure 6). Figure 6 4.
  • Page 54 CHASSIS Right Console (Cont.) Removal (Cont.) 6. Lift the console upward off of the machine, while feeding the control panel assembly through the opening in the console (Figure 8). Figure 8 NOTE: The control panel assembly should be supported while servicing the machine, to avoid damage to cables or wire harness.
  • Page 55 CHASSIS Right Console (Cont.) Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Ensure that the console seats properly on the supports (Figure 9). Figure 9 NOTE: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly.
  • Page 56 CHASSIS Seat - TIMECUTTER® HD ZX Models Only Removal Figure 11 A. Stop Rod C. Seat Pan B. Cotter Pin 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 57 CHASSIS Seat - TIMECUTTER® HD ZX Models Only (Cont.) Installation 1. Verify that the fuel tank hold down is seated properly in the front and rear of the frame and secured with the hold down bolt (Figure 12). Figure 12 2.
  • Page 58 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only Removal Figure 13 A. Seat Asm. F. Arm Swing Plate B. Seat Pan G. Rear Sub-frame C. Shock/Spring Asm. H. Lower Mount Bracket D. Floor mat I. Shock Mounting Bracket E.
  • Page 59 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 6. Disconnect the fuel supply line at the fuel filter (Figure 14). Figure 14 7. Disconnect the vent line at the splice fitting (Figure 15). Figure 15 5-14 Digital Edition - TIMECUTTER®...
  • Page 60 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 8. Remove the bolt and nut securing the front shock/spring assembly to the MyRIDE™ platform (Figure 16). Figure 16 9. Remove the self-tapping screw on the frame brackets on each side of the machine (A) (Figure 17). Release the vent hose keepers (B).
  • Page 61 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 10. Remove the two bolts and nuts securing the frame brackets to the main frame on each side of the machine (Figure 18). Figure 18 11. Tilt the MyRIDE™ assembly one way. Unhook the fuel line keeper from under the seat (Figure 19). Figure 19 5-16 Digital Edition - TIMECUTTER®...
  • Page 62 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Removal (Cont.) 12. Lift the entire MyRIDE™ assembly up and away from the main frame. Removing the MyRIDE™ assembly will take two or more people. NOTE: Do not remove either of the swing arm rods from the swing arm underneath the machine. This could cause damage or misalignment of the MyRIDE™...
  • Page 63 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation 1. Verify that the fuel tank hold down is seated properly in the front and rear of the frame and secured with the hold down bolt (Figure 21). Figure 21 2.
  • Page 64 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation (Cont.) 4. Install the self-tapping screw on the frame bracket on each side of the machine (Figure 23). Figure 23 5. Install the bolt and nut securing the front shock/spring assembly to the MyRIDE™ Platform (Figure 24). Figure 24 5-19 Digital Edition - TIMECUTTER®...
  • Page 65 CHASSIS Seat & MyRIDE™ Platform - TIMECUTTER® HD MR Models Only (Cont.) Installation (Cont.) 6. Connect the fuel tank vent line at to the splice fitting. 7. Connect the fuel supply line to the fuel filter. 8. Connect the vent line keepers to the vent lines. 9.
  • Page 66 CHASSIS Fuel Tank Removal Figure 25 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3.
  • Page 67 CHASSIS Fuel Tank (Cont.) Installation 1. Position the fuel tank assembly and rotate it onto the frame with the vent ports toward the rear of the machine. 2. Connect the vent line (C) (Figure 26) to the fuel tank. 3. Connect the fuel supply line (B) (Figure 26) to the fuel tank. 4.
  • Page 68 CHASSIS Throttle Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the control panel assembly from the right console (Figure 27). Figure 27 4.
  • Page 69 CHASSIS Throttle Control Assembly (Cont.) Installation 1. Route the throttle cable through the right console (Figure 29). Figure 29 2. Snap the throttle control assembly into place. 3. Install the control panel assembly into the console. 4. Move the throttle control lever to the full speed position (Figure 30). Figure 30 5-24 Digital Edition - TIMECUTTER®...
  • Page 70 CHASSIS Throttle Control Assembly (Cont.) Installation (Cont.) 5. Place the z bend of the throttle cable in the throttle plate on the engine in the position previously noted. 6. Place the cable under the cable clamp. 7. Ensure that the throttle control lever is in the fast idle position (Figure 31). NOTE: Pull on the cable and verify the engine is at full throttle, then tighten the clamp.
  • Page 71 CHASSIS Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Loosen the clamp securing the choke cable to the choke plate on the engine (Figure 32). Figure 32 4.
  • Page 72 CHASSIS Choke Control Assembly (Cont.) Installation 1. Route the choke cable through the control panel assembly. 2. Thread the jam nut over the choke cable up to the control panel assembly (Figure 33). Figure 33 3. Attach the choke cable assembly to the control panel with the jam nut. 4.
  • Page 73 CHASSIS Choke Control Assembly (Cont.) Installation (Cont.) 6. Place the z bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp (Figure 35). Figure 35 9.
  • Page 74 CHASSIS Park Brake Handle Assembly Removal Figure 36 A. Cotter Pin E. Wave Spring B. Intermediate Brake Rod F. Brake Flanged Bushing C. Torx Screw G. Flange Nut D. Flange Bushing 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 75 CHASSIS Park Brake Handle Assembly (Cont.) Installation 1. Assemble the bushings and wave spring over the bolt and through the park brake handle (Figure 37). Park Brake Hardware Orientation Figure 37 A. Screw D. Flange Pivot B. Washer E. Flange Nut C.
  • Page 76 CHASSIS Park Brake Handle Assembly (Cont.) Installation (Cont.) 2. With the park brake handle hardware oriented as shown, install the bolt through the brake detent (B) (Figure 39) and connect the flange nut. Torque to 200 ± 25 in-lbs. (23 ± 3 Nm). Figure 39 A.
  • Page 77 CHASSIS Motion Control Assembly Removal Figure 40 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Raise and support the unit so that the drive wheels are off the ground. NOTE: The console must be removed for access, see “Left Console Removal,”...
  • Page 78 CHASSIS Motion Control Assembly (Cont.) Removal (Cont.) 6. Disconnect the motion control assembly from the frame (Figure 41). Figure 41 5-33 Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 79 CHASSIS Motion Control Assembly (Cont.) Installation 1. Position the motion control assembly in place with the linkage extending toward the transmission. 2. Secure the motion control assembly to the frame. 3. Connect the motion control linkage to the motion control assembly. 4.
  • Page 80 CHASSIS Adjusting the Motion Control Handle Position NOTE: Ensure proper adjustment of neutral and tracking settings before adjusting the motion control handles, see “Hydrostatic Drive Transmission,” chapter 7, page 7-12 and/or see “Tracking Adjustment,” chapter 7, page 7-6. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 81 ENGINE Table of Contents Engine Mounting - Toro Twin Cylinder Engine Exploded View........Toro Twin Cylinder Engine....................Removal..........................Installation........................Kawasaki Engine........................6-11 Removal........................... 6-11 Installation........................6-12 Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 82 ENGINE Engine Mounting - Toro Twin Cylinder Engine Exploded View Figure 1 A. Engine C. Flat Washer B. Muffler D. Taptite Screw Digital Edition - TIMECUTTER® HD Service Manual Table of Contents April 2017...
  • Page 83 ENGINE Toro Twin Cylinder Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the engine guard.
  • Page 84 ENGINE Toro Twin Cylinder Engine (Cont.) Removal (Cont.) 8. Disconnect the red wire from the starter (Figure 3). Figure 3 9. Disconnect the black engine ground wire (Figure 4). Figure 4 Digital Edition - TIMECUTTER® HD Service Manual Table of Contents...
  • Page 85 Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 5). Figure 5 11. Remove vent line at splice with Toro supplied hose (Figure 6). Figure 6 12. Disconnect the throttle cable, see “Throttle Control Assembly Removal,” chapter 5, page 5-23.
  • Page 86 ENGINE Toro Twin Cylinder Engine (Cont.) Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Lower the engine onto the frame. 3. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two flat washers loosely.
  • Page 87 ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 8. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 8). Figure 8 A. Engine Pulley E. Washer B.
  • Page 88 ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 13. Connect the black engine ground wire (Figure 9). NOTE: Apply Loctite to ground bolt. Figure 9 14. Connect the red wire to the starter (Figure 10). Figure 10 Digital Edition - TIMECUTTER® HD Service Manual...
  • Page 89 ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 15. Connect the chassis wire harness to the main engine wire harness (Figure 11). Figure 11 16. Connect the fuel supply line to the fuel pump. 17. Connect the vent line to barb/splice (Figure 12).
  • Page 90 ENGINE Toro Twin Cylinder Engine (Cont.) Installation (Cont.) 18. Install the hydrostatic drive belt, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 19. Install the mower belt, see “Mower Belt Replacement,” chapter 3, page 3-15. 20. Install the muffler and new exhaust gaskets.
  • Page 91 9. Disconnect the black engine ground wire. 10. Disconnect the fuel supply line at the fuel pump. 11. Remove vent line at splice with Toro supplied hose. 12. Disconnect the throttle cable, see “Throttle Control Assembly Removal,” chapter 5, page 5-23.
  • Page 92 ENGINE Kawasaki Engine (Cont.) Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Lower the engine onto the frame. 3. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two flat washers loosely.
  • Page 93 ENGINE Kawasaki Engine (Cont.) Installation (Cont.) 15. Connect the red wire to the starter (Figure 14). Figure 14 16. Connect the chassis wire harness to the main engine wire harness. 17. Connect the fuel supply line to the fuel pump. 18.
  • Page 94 HYDROSTATIC DRIVE SYSTEM Table of Contents Hydrostatic Drive Exploded View..................Using the Drive Wheel Release Valves (Bypass Valves)..........Neutral Adjustment......................Tracking Adjustment......................Hydro Change Procedure....................Purging Procedure....................... Hydrostatic Drive Belt......................Removal........................... Installation........................7-11 Hydrostatic Drive Transmission..................7-13 Removal (Right Side Shown)..................
  • Page 95 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded View Figure 1 A. Breather Tube H. Hydrostatic Drive Belt B. RH Hydro Assembly I. Rear Hydro Support C. RH Bypass Lever J. Rear Guard D. Idler Arm K. LH Bypass Lever E. Idler Spring L.
  • Page 96 HYDROSTATIC DRIVE SYSTEM Using the Drive Wheel Release Valves (Bypass Valves) The drive wheel release valves are located on the left and right sides underneath the engine block. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 97 HYDROSTATIC DRIVE SYSTEM Neutral adjustment 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Raise and support the unit so that the drive wheels are off the ground. 3.
  • Page 98 HYDROSTATIC DRIVE SYSTEM Neutral adjustment (Cont.) 8. Turn the adjustment nut on the motion control rod clockwise or counterclockwise until the drive wheel is slightly rotating in reverse or not rotating at all. Repeat for both drive wheels if necessary (Figure 3). Figure 3 NOTE: When the unit is in neutral, the stud should be roughly centered in the slot of the control plate (Figure 4).
  • Page 99 HYDROSTATIC DRIVE SYSTEM Tracking adjustment If the unit tracks or pulls to the RIGHT: Turn the LH adjustment nut 1 full turn CLOCKWISE. If more adjustment is needed, turn the adjustment nut 1 full turn at a time (Figure 5). If the unit tracks or pulls to the LEFT: Turn the RH adjustment nut 1 full turn CLOCKWISE.
  • Page 100 5. Remove the breather hose and fill vent located on the top of the hydro. 6. Fill approximately 2 qts. of Toro HYPR-OIL® 500 or 20W-50 engine oil to the level of the top port plug hole. 7. Re-install the top port plug (A) (Figure 6).
  • Page 101 HYDROSTATIC DRIVE SYSTEM Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance, any additional oil has been added to the system, or a replacement transaxle has been installed.
  • Page 102 “Mower Belt Replacement,” chapter 3, page 3-15. 4. Using a spring removal tool (Toro Part No. 92-5771), remove the drive idler spring from the slot in the frame. Remove the spring from the drive idler arm and inspect for damage or wear (Figure 7).
  • Page 103 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Removal (Cont.) 6. Remove the rear pulley (A) (Figure 8). 7. Remove the idler arm and pulley (B) (Figure 8). Figure 8 8. Remove the drive belt from the hydrostatic drive pulleys. NOTE: Inspect the belt for excessive wear, damage, or cracking, replace if necessary. 7-10 Digital Edition - TIMECUTTER®...
  • Page 104 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Installation 1. Route the hydrostatic drive belt around the two transmission pulleys. 2. Route the drive belt around the engine pulley. 4. Install the idler arm, and pulleys (A) (Figure 9). NOTE: Make sure that the belt is properly routed before installation. Figure 9 5.
  • Page 105 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Installation (Cont.) 4. Place the idler spring onto the idler arm loop and use a spring removal tool to secure the spring (A) into the slot on the right rear of the frame (Figure 10). Figure 10 NOTE: Ensure proper orientation with hook openings facing away from the idler pivot.
  • Page 106 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Right side shown) NOTE: These steps are shown replacing the right side hydrostatic drive transmission. All of the same steps apply to the left side hydrostatic drive transmission. 1. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2.
  • Page 107 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) 7. Disconnect the bypass arm (Figure 12). Figure 12 8. Disconnect the lower brake linkage from the transmission (Figure 13). Figure 13 9. Disconnect the connectors securing the overflow tube to the chassis. 7-14 Digital Edition - TIMECUTTER®...
  • Page 108 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) NOTE: Overflow tubes should stay connected to the top of the transmission. To avoid oil leaking, keep the overflow tubes oriented up (Figure 14). Figure 14 7-15 Digital Edition - TIMECUTTER® HD Service Manual April 2017 Table of Contents...
  • Page 109 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Removal (Right side shown) (Cont.) 10. Remove the bolts securing the transmission to the hydro cross plate (A) (Figure 15). Figure 15 A. Front Inner Mounting Bolts to D. Rear Mid Mounting Bolts to Frame Bracket Cross-member Rear B.
  • Page 110 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) NOTE: These steps are shown replacing the right side hydrostatic drive transmission. All of the same steps apply to the left side hydrostatic drive transmission (Figure 16). Figure 16 A.
  • Page 111 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 8. Remove the protective cap from the hydraulic oil nipple, install the overflow tube, and move the hose clamps into place (Figure 17). Figure 17 9. Connect the lower brake linkage to the transmission (Figure 18). Figure 18 7-18 Digital Edition - TIMECUTTER®...
  • Page 112 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 10. Connect the bypass arm (Figure 19). Figure 19 11. Connect the motion control linkage (Figure 20). Figure 20 12. Install the drive belt, see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 13.
  • Page 113 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission (Cont.) Installation (Right side shown) (Cont.) 14. Add hydraulic oil to the proper level using the vent plugs (Figure 21). Vent Plug Figure 21 see “Purging Procedure,” chapter 7, page 15. Follow the purging procedure to remove all air from the system, 7-8.
  • Page 114 MOWER DECK Table of Contents Mower Deck Exploded View....................Deck Lift Assembly Exploded View................... Mower Belt Replacement....................Mower Deck......................... Removal.......................... Installation........................Mower Spindle........................8-10 Removal........................... 8-10 Installation........................8-10 Disassembly........................8-11 Assembly......................... 8-12 Leveling the Mower Deck....................8-13 Servicing the Cutting Blades.....................
  • Page 115 MOWER DECK Mower Deck Exploded View Figure 1 A. Mower Deck J. Bearing Shield B. Cut Off Baffle K. Right Belt Cover C. Spindle Housing L. Left Belt Cover D. Spindle M. Belt Guide, Idler E. Blade N. Mower Belt F.
  • Page 116 MOWER DECK Deck Lift Assembly Exploded View Figure 2 A. Height-of-Cut Transport Lock G. Deck Pivot Rod B. Height-of-Cut Plate H. Deck Pivot Pan C. Pivot Arm, Rear I. Deck Lift Assist Spring D. Pivot Arm, Front J. Height-of-Cut Link E.
  • Page 117 4. Remove the bolts from the covers and lift covers off the deck (Figure 3). Figure 3 5. Using a spring removal tool (Toro Part No. 92-5771) remove the spring tension from the idler pulley (Figure 4). Figure 4 A. Spring-removal tool (Toro P/N 92-5771) D.
  • Page 118 MOWER DECK Mower Belt Replacement (Cont.) 8. Route the new belt around the clutch pulley and deck pulleys (Figure 5). Figure 5 9. Install the idler spring using the spring removal tool. 10. Ensure that the belt is properly seated in all pulleys. 11.
  • Page 119 MOWER DECK Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the height adjustment pin and lower the deck to the ground. 4.
  • Page 120 MOWER DECK Mower Deck Removal (Cont.) 6. Lift the mower deck to remove tension from the chains and unhook the chains from the deck lift arms (Figure A B C A B C D Figure 8 A. Deck-Lift Arm C. Hook B.
  • Page 121 MOWER DECK Mower Deck (Cont.) Installation 1. Place the deck on the ground and slide it into position underneath the machine. 2. Lower the height of cut into the lowest position and secure with the height-of-cut pin. 3. Lift the rear of the mower deck and attach the chains to the rear lift arms (Figure 9). Figure 9 A.
  • Page 122 MOWER DECK Mower Deck (Cont.) Installation (Cont.) 6. Install the mower belt onto the engine pulley first, then onto the mower deck, see “Mower Belt Replacement,” chapter 3, page 3-15. 7. Install the mower belt covers. Torque the belt cover bolts to 50-75 in-lbs. (6-8 Nm). 8.
  • Page 123 MOWER DECK Mower Spindle Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the mower belt covers. 4.
  • Page 124 MOWER DECK Mower Spindle (Cont.) Disassembly Figure 11 A. Spindle Nut F. Spindle (Apply Anti-Seize) B. Pulley G. Blade C. Bearing Shield H. Belleville Washer D. Spindle Assembly I. Blade Bolt E. Spindle Mounting Screws 1. Clamp the spindle for service by placing the spindle shaft in a vise. 2.
  • Page 125 MOWER DECK Mower Spindle (Cont.) Assembly 1. Inspect the inside of the spindle housing for wear or damage. 2. Press the top bearing (A) (Figure 12) into the spindle housing by pressing equally on the inner and outer race. NOTE: Ensure that the bearing seats against the shoulder in the spindle housing. Figure 12 3.
  • Page 126 MOWER DECK Leveling the Mower Deck 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery terminals. 3. Check to ensure that all tires are properly inflated and adjust as necessary. 4.
  • Page 127 MOWER DECK Leveling the Mower Deck (Cont.) 6. Measure between the outside cutting edges and the flat surface. If all measurements are not within 3/16 in. (5 mm), an adjustment is required. 7. Rotate the blades so that they are perpendicular to the rear of the deck (Figure 14). If the front blade tip is not 1.6 - 7.9 mm (1/16 - 5/16 in.) lower than the rear blade tip, continue with Leveling the Mower Deck.
  • Page 128 MOWER DECK Leveling the Mower Deck (Cont.) 8. Set the anti-scalp rollers to the top position or remove completely for this procedure. 9. Set the height-of-cut lever to the 3 in. (76 mm) position. 10. Place two 6.6 mm (2-5/8 in.) thickness blocks under the front edge of the cutting deck skirt; one on each side of the cutting deck, but not under the anti-scalp roller brackets.
  • Page 129 MOWER DECK Leveling the Mower Deck (Cont.) 12. Loosen the leveling adjustment bolts (Figure 16) on all four corners so that the deck is sitting squarely on all four blocks. Figure 16 A. Deck-Lift Arm C. Hook B. Chain D. Adjustment Bolt 13.
  • Page 130 MOWER DECK Electric PTO Clutch Removal Figure 17 A. Engine Pulley to Shaft D. Clutch Isolator (Apply Anti-Seize) E. Clutch PTO B. Bolt, Clutch Stop Mount F. Clutch Mounting Bolt C. Clutch Stop (Apply Loctite) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 131 MOWER DECK Electric PTO Clutch (Cont.) Installation 1. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor and the rubber isolator is in place (Figure 18). Figure 18 A.
  • Page 132 MOWER DECK Electric PTO Clutch (Cont.) Installation (Cont.) NOTE: Ensure wire harness is properly routed to avoid contact with the mower belt (Figure 19). Figure 19 5. Connect the battery terminals. 6. Lower the unit and verify proper function. 8-19 Digital Edition - TIMECUTTER®...
  • Page 133 ELECTRICAL Table of Contents Electrical System Exploded View..................General Information......................Fuse Block and Fuses......................Testing..........................Key/Ignition Switch......................Ignition Switch Wiring Connections................Testing..........................Hourmeter..........................Testing..........................Operator Presence Switch (Seat Switch)................Testing..........................Neutral Switch - Left and Right..................Parking Brake Switch......................9-10 Starter Solenoid........................
  • Page 134 ELECTRICAL Electrical System Exploded View Figure 1 A. Ignition Key I. Park Brake Switch B. Ignition Switch J. Clutch Connector C. PTO Switch K. Fuse Block D. Hourmeter L. Battery E. 12V Power Port M. Engine Connector F. Wire Harness N.
  • Page 135 ELECTRICAL General Information 1. Always use a digital multi-meter for electrical testing procedures and record voltage reading results. 2. Before performing any electrical troubleshooting, always: -Verify proper battery voltage (above 12.4 volts) : Batteries reading 12.4 volts or less are considered discharged -Check that all engine and chassis ground wires are securely connected and not damaged.
  • Page 136 Figure 20, page 9-19. NOTE: Always use Toro fuses when replacing a damaged or blown fuse. Testing 1. Visual Inspection: The fuses used in this application may be visually inspected. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade (Figure 3).
  • Page 137 ELECTRICAL Key/Ignition Switch Figure 4 The ignition switch makes the proper connections for the starter, safety circuits, and accessories. Detents inside the switch control the three switch positions: OFF, RUN, and START. The START position is spring loaded so that it automatically returns to the RUN position when released.
  • Page 138 ELECTRICAL Key/Ignition Switch (Cont.) Testing 1. Remove the control panel from the right console. 2. Disconnect the harness from the ignition switch. Gently rock the connector back and forth until unplugged. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position.
  • Page 139 ELECTRICAL Hourmeter Figure 6 The hourmeter records hours of operation when the ignition key is ON and the PTO switch is ON. Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the hourmeter.
  • Page 140 ELECTRICAL Operator Presence Switch (Seat Switch) Seat Switch Figure 7 With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the left hand neutral switches. NOTE: The operator presence switch is part of the seat assembly. Testing 1.
  • Page 141 ELECTRICAL Neutral Switch - Left and Right Figure 8 The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion Control Levers in neutral position (OUT), the switch should have continuity (closed). Motion Control Levers in the operating position (IN), the switch should NOT have continuity (open).
  • Page 142 ELECTRICAL Parking Brake Switch Figure 9 Figure 10 The parking brake switch is a dual pole/four terminal plunger type switch (normally open and normally closed). When the parking brake is set (engaged), the normally closed pole of the switch is open and the normally open pole is closed.
  • Page 143 ELECTRICAL Starter Solenoid Figure 11 The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. Testing 1.
  • Page 144 ELECTRICAL PTO Switch Figure 13 The PTO switch provides battery voltage from the ignition switch to the PTO clutch. As part of the safety interlock system, the PTO switch will prevent the engine from cranking/starting when in the ON position by preventing the starter solenoid from grounding through the kill relay. NOTE: The engine will not crank over when the PTO switch is in the ON position.
  • Page 145 ELECTRICAL PTO Switch (Cont.) Testing 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT). Figure 14 4. Using a digital multi-meter set to the OHM or Continuity setting, verify the following: -Pin 2 and 5 should have continuity (closed) -Pin 1 and 4 should have continuity (closed) -Pin 1 and 7 should NOT have continuity (open)
  • Page 146 ELECTRICAL Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: -field -clutch plate -friction plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied.
  • Page 147 ELECTRICAL Electric PTO Clutch (Cont.) Coil Resistance Measurement Figure 15 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.
  • Page 148 ELECTRICAL Electric PTO Clutch (Cont.) PTO Clutch Continuity to Ground Check 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.
  • Page 149 ELECTRICAL Electric PTO Clutch (Cont.) Measuring Clutch Current Draw NOTE: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. Figure 17 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key.
  • Page 150 ELECTRICAL TVS Diode Figure 18 The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement. Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode. If the system fuse blows each time the clutch is engaged, the TVS diode is more than likely shorting clutch power to ground.
  • Page 151 ELECTRICAL Kill Relay Figure 19 Figure 20 The Kill Relay grounds the magneto when the key is turned to the OFF position. When the key is turned to the RUN position, the solenoid is grounded and the magneto is no longer grounded. The Kill Relay prevents starting in an unsafe position.
  • Page 152 ELECTRICAL Electrical Schematic Figure 21 9-20 Digital Edition - TIMECUTTER® HD Service Manual Table of Contents April 2017...
  • Page 153 R e s i d e n t i a l P r o d u c t s...

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