FORM NO. 3322-690

62” Pulley and Belt Kit

For Model 74208 Serial No. 890001 and Up

For Model 74203 Serial No. 990001 to 994000

Part No. 100–2318

INSTALLATION

INSTRUCTIONS

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION

Pulley Assembly

Belt

Bracket

Bolt (5/16”–18 x 3/4”)

Flange Nut

Pulley

Spacer

Belt Guide Plate

Spring Disk

Bolt (3/8” –16 x 2–1/4”)

Bolt (3/8” –16 x 3–3/4”)

Spacer Bracket

Idler Arm

Flat Washers

Belt Guide

Bolt

Washer

Nut

1

2

1

1

1

1

1

1

4

4

1

1

1

1

1

2

QTY.

1

1

Install Pulleys

USE

Install Front Idler Pulley Bracket

Install Front Idler Pulley

Install Rear Idler Arm

Install Belt Guide

Printed in USA



The Toro Company – 1999

All Rights Reserved

Installation Instructions

Removing Belts

1.

Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2.

Remove the clutch retaining strap from machine frame and unplug clutch terminal from wire harness (Fig. 1).

Note: Leave clutch retaining strap attached to the clutch.

3.

Remove the drive belt (Fig. 1).

4.

Loosen idler pulley on deck belt. Remove deck belt from center spindle pulley (see Operator’s

Manual for instructions).

4

5

Removing Deck

1.

Lower the deck on to wood blocks.

2.

Remove the four bolts at the bottom of chains that attached to deck (Fig. 2).

3.

Remove the nuts and bolts holding pins in the push arm (Fig. 2).

4.

Remove pins (Fig. 2).

5.

Raise height of cut lever and slide deck out

(Fig. 2).

2 6

4

7

5

3

2

3 m–4451

1

1.

Clutch

2.

Clutch retaining strap

3.

Clutch Terminal

Figure 1

4.

Drive belt

5.

Machine Frame

1.

Deck

2.

Chain

3.

Chain Bolt

4.

Push Arm

Figure 2

5.

Push Arm Bolt

6.

Push Arm Nut

7.

Push Arm Pin

1

2

Installation Instructions

Installing Front Idler Pulley

Bracket

1.

Remove existing belt guide and hardware and discard (Fig. 3).

2.

Align hole in bracket to the hole the belt guard was installed in (Fig. 3).

3.

Position belt idler bracket rear edge parallel to the rear edge of deck (Fig. 3).

4.

Install one bolt through the bracket and where the belt guide was installed in deck. Install nut and tighten (Fig. 3).

5.

Using bracket as a template, drill three 21/64” holes into deck (Fig. 3).

6.

Install bolts into bracket and securely tighten bracket to the deck with nuts (Fig. 3).

1 3

6

4

Installing Front Idler Pulley

1.

Install pulley onto the idler bracket mounting stud (Fig. 4).

2.

Install bolt (3/8” x 2–1/4”) into spring disk washer, belt guide plate and short spacer. Install into the center of mounting stud. Do not tighten

(Fig. 4).

3.

Place belt into idler assembly with back side of belt toward idler pulley (Fig. 4).

4.

Install bolt (3/8” x 3–3/4”) into spring disk washer, belt guide plate, long bracket spacer and hole in idler bracket. Install nut onto bolt (Fig.

4).

5.

Tighten both bolts (Fig. 4).

9

3

7

2

3

4

5

1

6

8

2

5

1.

Idler Pulley Bracket

2.

Existing Belt Guide

3.

Bolt

Figure 3

4.

Nut

5.

Holes to Drill

6.

Align Holes

10

1.

Pulley

2.

Bolt (3/8” x 2–1/4”)

3.

Spring Disk Washer

4.

Belt Guide Plate

5.

Short Spacer

Figure 4

6.

Mounting Stud

7.

Long Bracket Spacer

8.

Hole in Idler Bracket

9.

Bolt (3/8” x 3–3/4”)

10. Nut

3

Installation Instructions

Installing Pulleys and Deck

Belt

Note: Clean area around pulley before removing pulley assembly. Hold spindle up from underneath deck. It can fall when nut and washer are removed.

1.

Remove nut and washer on top of center spindle

(Fig. 5). Save the nut and washer.

2.

Remove existing pulley assembly (Fig. 5).

3.

Install new pulley assembly. Install it so the large pulley is on top (Fig. 5).

4.

Reinstall washer and nut (Fig. 5).

IMPORTANT: Nut must be torqued to

115 ft–lbs.

5.

Grease spindle to fill bearings with grease.

6.

Place existing deck belt onto new pulley assembly. Route belt onto outer pulleys and idler pulley.

7.

Adjust deck belt idler.

1

2

3

4

1.

Nut

2.

Washer

Figure 5

3.

Pulley Assembly

4.

Spindle

Install Belt Guide

1.

Remove existing carriage bolt and nut (Fig. 6)

IMPORTANT: Remove only this specific bolt to install belt guide (Fig. 6).

2.

Install new bolt, washer, nut and belt guide

(Fig. 6).

3.

Adjust belt guide. Refer to Adjusting Belt Guide section on page 7.

2

4

1

3

1.

Belt guide

2.

New Bolt

Figure 6

3.

Nut

4.

Washer

Installing Deck

1.

Adjust push arms. Loosen jam nut and rotate ball joint counterclockwise, one turn at a time.

Adjust each side the same amount. Adjust the distance of push arms to 15–5/16 (389mm)

(Fig. 12).

2.

Install pins into the deck and push arms.

3.

Install the nut and bolt to secure pin to the push arm and deck.

4.

Install the four bolts at the bottom of chains that attached to deck.

5.

Grease the push arm.

4

Installation Instructions

Mower Leveling

When finished installing the deck, the deck must be leveled (see Operator’s Manual for instructions).

Removing Old Drive Belt Idler

Arm

1.

Remove the spring from the old idler arm (Old idler arm not shown) (Fig. 8).

2.

Remove the old idler arm from the machine frame. Save parts for installing new idler arm

(Old idler arm not shown) (Fig. 8).

3.

Remove the spring and hardware from the machine frame. Discard old washer (Fig. 8).

4.

Remove the pulley, bushing, and hardware from idler arm (Old idler arm not shown) (Fig. 7).

Installing New Drive Belt Idler

Arm

1.

Route new belt onto the rear idler pulley. Install pulley and belt to new rear idler arm using existing hardware (Fig. 7).

2.

Install spring to rear idler arm. Use existing hardware and new flat washer included in kit.

(Fig. 7).

Note: New flat washer must be installed between spring and heat of bolt.

2 1 2

6

7

6

9

4

2

3

5

1.

Idler Arm

2.

Lock Nut

3.

New Flat Washer

4.

Spring

5.

Bolt (3/8”–16 x 2–1/4”)

Figure 7

6.

Flat Washer

7.

Bushing

8.

Idler Pulley

9.

Bolt (3/8”–16 x 1–3/4”)

3.

Install new rear idler arm to machine frame. Use existing hardware to attach it (Fig. 8).

4.

Install spring to machine frame. Use existing hardware and new flat washer included in kit.

(Fig. 8).

8

Note: New flat washer must be installed between spring and heat of bolt. The spring must be installed between new flat washer and spacer (Fig. 8).

3 6

4

5

2

1

7

10 9

1.

Rear Idler Arm

2.

Lock Nut

3.

New Flat Washer

4.

Bolt (3/8”–16 x 3–1/2”)

5.

Flat Washer

Figure 8

6.

Spacer

7.

Nylon Locknut

8.

Bolt (3/8”–16 x 2–1/4”)

9.

Bushing

10. Drive Belt (Installed)

5

Installation Instructions

Installing Drive Belt

1.

Place new drive belt over clutch, around rear idler pulley, installed into rear idler arm assembly, installed into front idler pulley assembly and onto mower top center pulley.

IMPORTANT: Check the amount of twist in belt between pulleys. Make sure it is only what is specified in figure 9.

2.

Install clutch retaining strap and plug clutch terminal into main wire harness (Fig. 9).

4

6

6

5

2

3 m–4451

7

2

1

Figure 10

1.

Center bolt, spring loaded idler

2.

Alignment hole

4.

If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot. To relieve belt tension lift up on spring loaded idler (Fig. 11).

1

1.

Clutch

2.

Clutch retaining strap

3.

Clutch Terminal

4.

Drive belt

Figure 9

5.

Machine Frame

6.

1/4’ Belt Twist

7.

1/8” Belt Twist

3.

Check belt tension. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 10).

Note: Check position of center bolt in Low

Height of Cut. The center bolt must be at or below the top alignment hole.

Check position of center bolt in a High

Height of Cut. The center bolt must be at or above the lower adjustment hole

(Fig 10).

1 2 m–3746

1.

Fixed Idler

Figure 11

2.

Adjustment slot

5.

Check belt tension again. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 10).

Adjust, if necessary, and tighten all hardware securely.

6.

If the fixed idler contacts the end of the adjustment slot and more belt tension is required, a small change in the length of the push arms can be made (Fig. 12).

6

7.

To adjust push arms, remove drive belt, loosen jam nut and rotate ball joint counterclockwise, one turn at a time. Adjust each side the same amount (Fig. 12).

Note: Increase tension by lengthening the push arms and decrease tension by shortening push arms.

3

4

1

Installation Instructions

Adjusting Belt Guide

1.

Loosen belt guide (Fig. 13).

2.

Rotate the belt guide, so it is 1/8”–1/4”

(3–7 mm) away from the vertical side of the

PTO belt (Fig.13).

1 2

2

1.

Push arm

2.

15–5/16” (389 mm) nominal

Figure 12

3.

Jam nut

4.

Ball joint

8.

Install drive belt (Fig. 6).

m–3740

1.

Belt guide

2.

Drive belt

3

Figure 13

3.

1/8”–1/4” (3–7 mm)

7

Installation Instructions

8