Toro Commercial Walk-Behind Mower, Floating Deck, Split Lever, Hydro Drive Walk Behind Mower Manual

LCE Products

Floating Deck

Mid-Size

Service Manual

ABOUT THIS MANUAL

This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of

Contents lists the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct.

For service information specifi c to the engines used on these products, refer to the appropriate engine manufacturer’s service and repair instructions.

Additional resources:

• Interactive Electrical Troubleshooting DVD (P/N 492-4757).

• Interactive Hydraulic Troubleshooting DVD (P/N 492-4777).

• Hydro-Gear Hydraulic Pump Service and Repair Manual (P/N 492-4749).

• Ross Wheel Motor Service and Repair Manual (P/N 492-4753).

We hope you will fi nd this manual a valuable addition to your service shop. If you have any questions or comments regarding this manual, please contact us at the following address:

The Toro Company

Landscape Contractors Equipment Division

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product specifi cations or this manual without notice.

Copyright© All Rights Reserved

©2008 The Toro Company

THIS PAGE INTENTIONALLY LEFT BLANK.

Floating Deck Mid-Size Service Manual

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. to Metric Conversions ...........................................................................................................2-6

Hydro with Pistol Grip Controls.....................................................................................................2-7

Hydro with Pistol Grip Controls cont. ............................................................................................2-8

Hydro with Pistol Grip Controls cont. ............................................................................................2-9

Hydro with T-2 Controls ..............................................................................................................2-10

Hydro with T-2 Controls cont. ..................................................................................................... 2-11

Gear with T-Bar Controls ............................................................................................................2-12

Gear with T-Bar Controls cont. ...................................................................................................2-13

Gear with T-Bar Controls cont. ...................................................................................................2-14

International Hydro with T-Bar (T2) Controls ..............................................................................2-15

International Hydro with T-Bar (T2) Controls cont. .....................................................................2-16

International Gear with T-Bar Controls .......................................................................................2-17

International Gear with T-Bar Controls cont. ..............................................................................2-18

CHASSIS

Electric Clutch Replacment ..........................................................................................................3-1

Electric Clutch Removal .........................................................................................................3-1

Clutch Burnishing Procedure .................................................................................................3-4

Electric Clutch Installation ......................................................................................................3-4

PTO Idler Replacement ................................................................................................................3-9

PTO Idler Removal.................................................................................................................3-9

PTO Idler Installation............................................................................................................3-12

Parking Brake Service - Hydro ...................................................................................................3-14

Checking the Parking Brake ................................................................................................3-14

Adjusting the Parking Brake .................................................................................................3-15

Parking Brake Removal .......................................................................................................3-16

Parking Brake Installation ....................................................................................................3-20

Wheel Drive Belt and Wheel Hub Replacement - Gear Drive ....................................................3-24

Wheel Drive Belt & Wheel Hub Removal .............................................................................3-25

Wheel Drive Belt & Wheel Hub Installation ..........................................................................3-30

Brake Band Replacement...........................................................................................................3-36

Brake Band Removal ...........................................................................................................3-36

Brake Band Installation ........................................................................................................3-40

Carrier Frame Replacement .......................................................................................................3-45

Carrier Frame Removal .......................................................................................................3-45

Carrier Frame Installation ....................................................................................................3-48

Carrier Frame & Mower Deck Adjustments ................................................................................3-51

Checking the Carrier Frame & Engine Deck Alignment .......................................................3-51

Castor Wheel Replacement........................................................................................................3-53

Castor Wheel Removal ........................................................................................................3-53

Castor Wheel Service ..........................................................................................................3-54

Castor Wheel Installation .....................................................................................................3-59

Floating Deck Mid-Size Service Manual i

ii


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

Adjusting the Brake (T-Bar) ........................................................................................................3-76

LINKAGE

Control Linkage Replacement (T-2)..............................................................................................4-1

Control Linkage Removal .......................................................................................................4-1

Control Linkage Installation ....................................................................................................4-5

Control Linkage & Thumb Latch Replacement (Pistol Grip Hydro) ............................................4-10

Control Linkage & Thumb Latch Removal ...........................................................................4-10

Control Linkage & Thumb Latch Installation ........................................................................4-13

Lower Control Replacement (T-Bar) ...........................................................................................4-17

Lower Control Removal .......................................................................................................4-17

Lower Control Installation ....................................................................................................4-22

Neutral Adjustment Stud Replacement (Pistol Grip Hydro) ........................................................4-28

Neutral Adjustment Stud Removal .......................................................................................4-28

Neutral Adjustment Stud Installation ....................................................................................4-31

Operator Presence Control Lever Replacement (Pistol Grip Hydro) ..........................................4-35

Operator Presence Control Lever Removal .........................................................................4-35

Operator Presence Control Lever Installation ......................................................................4-37

Speed Control Replacement (Pistol Grip Hydro) ........................................................................4-39

Speed Control Removal .......................................................................................................4-39

Speed Control Installation ....................................................................................................4-46

Drive Lever Swivel & Bearing Replacement (Pistol Grip Hydro) ................................................4-57

Drive Lever Swivel & Bearing Removal ...............................................................................4-57

Drive Lever Swivel & Bearing Installation ............................................................................4-61

Handle Assembly Replacement (T-Bar) .....................................................................................4-66

Handle Assembly Removal (T-Bar) ......................................................................................4-66

Handle Assembly Installation (T-Bar) ...................................................................................4-73

Handle Assembly Removal (T-2) .........................................................................................4-80

Handle Assembly Installation (T-2) ......................................................................................4-92

Choke Cable Replacement.......................................................................................................4-108

Choke Cable Removal .......................................................................................................4-108

Choke Cable Installation .................................................................................................... 4-110

Throttle Cable Replacement ..................................................................................................... 4-114

Throttle Cable Removal ..................................................................................................... 4-114

Throttle Cable Installation .................................................................................................. 4-117

Linkage Adjustments ................................................................................................................4-121

Speed Control Linkage Adjustment (Pistol Grip Hydro) .....................................................4-121

Temporary Neutral Stud Adjustment ..................................................................................4-122

Hydro Control Linkage Adjustment ...........................................................................................4-123

Adjusting the Left Side Linkage (Pistol Grip) .....................................................................4-124

Adjusting the Right Side Linkage (Pistol Grip) ...................................................................4-126



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

Muffl er Guard..............................................................................................................................5-20

Engine Removal - Gear Drive.....................................................................................................5-21

Engine Installation - Gear Drive..................................................................................................5-28

HYDROSTATIC DRIVE SYSTEM

Hydro Drive Transmission Traction Belt Replacement .................................................................6-1

Hydro Drive Transmission Traction Belt Removal ..................................................................6-1

Hydro Drive Transmission Traction Belt Installation ...............................................................6-4

Hydro Idler Replacement ..............................................................................................................6-7

Hydro Idler Removal ..............................................................................................................6-7

Hydro Idler Installation ...........................................................................................................6-9

Hydraulic Pump Replacement .................................................................................................... 6-11

Hydraulic Pump Removal ....................................................................................................6-12

Hydraulic Pump Installation .................................................................................................6-15

Wheel Motor Replacement .........................................................................................................6-19

Wheel Motor Removal .........................................................................................................6-19

Wheel Motor Installation ......................................................................................................6-22

Hydraulic Reservoir Replacement ..............................................................................................6-26

Hydraulic Reservoir Removal ..............................................................................................6-26

Hydraulic Reservoir Installation ...........................................................................................6-27

Hydraulic Testing ........................................................................................................................6-29

Bleeding the Hydraulic System...................................................................................................6-32

Checking the Hydraulic Lines .....................................................................................................6-33

Hydraulic Schematic ...................................................................................................................6-34

GEAR DRIVE

Traction Drive Belt Replacement ..................................................................................................7-1

Traction Drive Belt Removal ..................................................................................................7-1

Traction Drive Belt Installation ...............................................................................................7-2

Gear Drive Idler Replacement ......................................................................................................7-4

Gear Drive Idler Removal ......................................................................................................7-4

Gear Drive Idler Installation ...................................................................................................7-6

Transmission Driven Pulley Replacement ....................................................................................7-7

Transmission Driven Pulley Removal ....................................................................................7-7

Transmission Driven Pulley Installation ...............................................................................7-10

Gear Drive Transmission Replacement ......................................................................................7-13

Gear Drive Transmission Removal ......................................................................................7-13

Gear Drive Transmission Installation ...................................................................................7-18

Floating Deck Mid-Size Service Manual iii

iv


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” Mower Deck) .......................................................8-5

PTO Drive Belt Replacement .......................................................................................................8-6

PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) .............................................8-6

PTO Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) ..........................................8-7

PTO Drive Belt Removal (36” Mower Decks).........................................................................8-8

PTO Drive Belt Installation (36” Mower Decks)......................................................................8-9

Spindle Replacement and Service ............................................................................................. 8-11

Spindle Removal and Teardown .......................................................................................... 8-11

Spindle Rebuild and Installation ...........................................................................................8-14

Idler Arm Assembly Replacement...............................................................................................8-18

Idler Arm Assembly Removal (40”, 48”, 52” and 60” Mower Decks) ....................................8-18

Idler Arm Assembly Installation (40”, 48”, 52” and 60” Mower Decks) .................................8-22

Idler Arm Assembly Replacement (36” Mower Deck) .................................................................8-27

Idler Arm Assembly Removal (36” Mower Deck) .................................................................8-27

Idler Arm Assembly Installation (36” Mower Deck) ..............................................................8-28

Adjustable Baffl e Replacement ..................................................................................................8-30

Adjustable Baffl e Removal ...................................................................................................8-30

Adjustable Baffl e Installation ................................................................................................8-32

Discharge Baffl e Replacement ...................................................................................................8-34

Discharge Baffl e Removal ...................................................................................................8-34

Discharge Baffl e Installation ................................................................................................8-35

Fixed Baffl e Replacement ..........................................................................................................8-36

Fixed Baffl e Removal (40”, 48”, 52” and 60” Mower Decks) ................................................8-36

Fixed Baffl e Installation (40”, 48”, 52” and 60” Mower Decks) .............................................8-37

Fixed Baffl e Replacement (36” Mower Deck) .............................................................................8-38

Fixed Baffl e Removal (36” Mower Deck) .............................................................................8-38

Fixed Baffl e Installation (36” Mower Deck) ..........................................................................8-39

Skid Plate Replacement (40”, 48”, 52” and 60” Mower Decks) ..................................................8-39

Skid Plate Removal (40”, 48”, 52” and 60” Mower Deck) ....................................................8-39

Skid Plate Installation (40”, 48”, 52” and 60” Mower Deck) .................................................8-40

Skid Plate Replacement (36” Mower Deck)................................................................................8-41

Skid Plate Removal (36” Mower Deck) ................................................................................8-41

Skid Plate Installation (36” Mower Deck) .............................................................................8-42

Front & Rear Deck Hanger Replacement ...................................................................................8-43

Front Deck Hanger Removal ...............................................................................................8-43

Front Deck Hanger Installation ............................................................................................8-45

Rear Deck Hanger Removal ................................................................................................8-48

Rear Deck Hanger Installation .............................................................................................8-50

Anti-Scalp Roller Replacement...................................................................................................8-52

Single Anti-Scalp Roller Removal ........................................................................................8-52

Single Anti-Scalp Roller Installation .....................................................................................8-53

Double Anti-Scalp Roller Removal .......................................................................................8-54

Double Anti-Scalp Roller Installation ....................................................................................8-54

Grass Defl ector Service..............................................................................................................8-55

Grass Defl ector Removal .....................................................................................................8-55

Grass Defl ector Disassembly ...............................................................................................8-56

Grass Defl ector Assembly ....................................................................................................8-56

Grass Defl ector Installation ..................................................................................................8-58



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

Adjusting the Mower Deck Side-to-Side Height..........................................................................8-67

Matching the Height-of-Cut.........................................................................................................8-67

ELECTRICAL

Tools .............................................................................................................................................9-1

Components .................................................................................................................................9-1

Alternator ...............................................................................................................................9-1

On/Off Switch .........................................................................................................................9-1

Bail Switch .............................................................................................................................9-1

Single Pole Switch .................................................................................................................9-2

PTO Switch ............................................................................................................................9-2

Relay, Single Pole Dual Throw ...............................................................................................9-3

Ignition Switch ........................................................................................................................9-3

Wire Harness T-Bar, Gear Drive (104-8137) ..........................................................................9-4

PTO Switch ............................................................................................................................9-5

Delay Module .........................................................................................................................9-5

Clutch Power Supply Test Procedure:....................................................................................9-6

DC Mini Hour Meter ...............................................................................................................9-8

Proximity Switch .....................................................................................................................9-9

PTO Brake Clutch Assembly ..................................................................................................9-9

Wire Harness Pistol Grip (106-8780) ...................................................................................9-10

PTO Switch .......................................................................................................................... 9-11

Wire Harness T-2, Hydro (114-3418) ...................................................................................9-12

Wire Harness T-Bar, Hydro (114-3420) ................................................................................9-13

Normally Open Switch .........................................................................................................9-14

Normally Closed Switch .......................................................................................................9-14

Starter Solenoid ...................................................................................................................9-14

Operator Presence Control (OPC) Switch Replacement (T-Bar) ...............................................9-15

OPC Switch Removal (T-Bar) ..............................................................................................9-15

OPC Switch Installation (T-Bar) ...........................................................................................9-16

PTO Switch Replacement (T-Bar) ..............................................................................................9-18

PTO Switch Removal (T-Bar) ...............................................................................................9-18

PTO Switch Installation (T-Bar) ............................................................................................9-19

Ignition Switch Replacement (T-Bar) ..........................................................................................9-20

Ignition Switch Removal (T-Bar) ..........................................................................................9-20

Ignition Switch Installation (T-Bar) .......................................................................................9-21

Delay Module Replacement (T-Bar) ...........................................................................................9-23

Delay Module Removal (T-Bar) ............................................................................................9-23

Delay Module Installation (T-Bar) .........................................................................................9-24

Floating Deck Mid-Size Service Manual v

vi


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

PTO Switch Installation (Electric Start) ................................................................................9-33

Operator Presence Control (OPC) Switch Replacement (Pistol Grip)........................................9-34

OPC Switch Removal (P.G.) ................................................................................................9-34

OPC Switch Installation (P.G.) .............................................................................................9-36

OPC Switch Position Adjustment (P.G.) ...............................................................................9-38

Hour Meter Replacement (Pistol Grip) .......................................................................................9-39

Hour Meter Removal (P.G.) ..................................................................................................9-39

Hour Meter Installation (P.G.) ...............................................................................................9-41

Ignition Switch Replacement (Pistol Grip) ..................................................................................9-43

Ignition Switch Removal (P.G.).............................................................................................9-43

Ignition Switch Installation (P.G.)..........................................................................................9-45

Kill Relay Replacement (Pistol Grip) ..........................................................................................9-47

Kill Relay Removal (P.G.) .....................................................................................................9-47

Kill Relay Installation (P.G.) ..................................................................................................9-47

Solenoid Switch Replacement (Pistol Grip & T-2) ......................................................................9-48

Solenoid Switch Removal (P.G. & T-2) .................................................................................9-48

Solenoid Switch Installation (P.G & T-2) ...............................................................................9-49

Operator Presence Control (OPC) Switch Replacement (T-2) ...................................................9-51

OPC Switch Removal (T-2) ..................................................................................................9-51

OPC Switch Installation (T-2) ...............................................................................................9-52

Latching Relay Replacement (T-2) .............................................................................................9-53

Latching Relay Removal (T-2) .............................................................................................9-53

Latching Relay Installation (T-2) ..........................................................................................9-54

Kill Relay Replacement (T-2) ......................................................................................................9-55

Kill Relay Removal (T-2) ......................................................................................................9-55

Kill Relay Installation (T-2) ...................................................................................................9-56

Proximity Neutral Switch Replacement (T-2) ..............................................................................9-56

Proximity Neutral Switch Removal (T-2) ..............................................................................9-56

Proximity Neutral Switch Installation (T-2) ...........................................................................9-57


SAFETY

General Information

!

This symbol means WARNING or

PERSONAL SAFETY INSTRUCTION - read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death.

This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Mid-

Size Walk Behind mower. The Mid-Size Walk Behind

Mower and attachment operator’s manuals contain safety information and operating tips for safe operating practices. Operator’s manuals are available through your

Toro parts source or:

1

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420

Think Safety First

Avoid unexpected starting of engine...

Always turn off the engine and disconnect the spark plug wire(s) before cleaning, adjusting, or repair.

Avoid lacerations and amputations...

Stay clear of all moving parts whenever the engine is running. Treat all normally moving parts as if they were moving whenever the engine is running or has the potential to start.

Avoid burns...

Do not touch the engine, muffl er, or other components which may increase in temperature during operation, while the unit is running or shortly after it has been running.

Avoid fi res and explosions...

Avoid spilling fuel and never smoke while working with any type of fuel or lubricant. Wipe up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running. Always use approved, labeled containers for storing or transporting fuel and lubricants.

Avoid asphyxiation...

Never operate an engine in a confi ned area without proper ventilation.

Avoid injury from batteries...

Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Battery gases can explode. Deep cigarettes, sparks, and fl ames away from the battery.

Avoid injury due to inferior parts...

Use only original equipment parts to ensure that important safety criteria are met.

Avoid injury to bystanders...

Always clear the area of bystanders before starting or testing powered equipment.

Avoid injury due to projectiles...

Always clear the area of sticks, rocks, or any other debris that could be picked up and thrown by the powered equipment.

Avoid modifi cations...

Never alter or modify any part unless it is a factory approved procedure.

Avoid unsafe operation...

Always test the safety interlock system after making adjustments or repairs on the machine. Refer to the

Electrical section in this manual for more information.

Floating Deck Mid-Size Service Manual 1-1

1

SAFETY


1-2 Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Fastener Identification

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.

These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature, hardness of the surface underneath of the fastener’s head, or similar condition which affects the installation.

As noted in the following tables, torque values should be

reduced by 25% for lubricated fasteners

to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up.

Figure 1

Inch Series Bolts and Screws

(A) Grade 1 & 2

(B) Grade 5

(C) Grade 8

2

Figure 2

(A) Class 8.8

Metric Bolts and Screws

(B) Class 10.9


SPECIFICATIONS

2

Thread Size

# 6 - 32 UNC

# 6 - 40 UNF

# 8 - 32 UNC

# 8 - 36 UNF

# 10 - 24 UNC

#10 - 32 UNF

1/4 - 20 UNC

1/4 - 28 UNF

5/16 - 18 UNC

5/16 - 24 UNF

3/8 - 16 UNC

3/8 - 24 UNF

7/16 - 14 UNC

7/16 - 20 UNF

1/2 - 13 UNC

1/2 - 20 UNF

5/8 - 11 UNC

5/8 - 18 UNF

3/4 - 10 UNC

3/4 - 16 UNF

7/8 - 9 UNC

7/8 - 14 UNF

Grade 1, 5, &

8 with Thin

Height Nuts

SAE Grade 1 Bolts, Screws,

Studs, & Sems with Regular

Height Nuts (SAE J995

Grade 2 or Stronger Nuts)









In-lb In-lb N-cm

10 ± 2

13 ± 2

18 ± 2

48 ± 7

53 ± 7

115 ± 15

138 ± 17

ft-lb

16 ± 2

17 ± 2

27 ± 3

29 ± 3

30 ± 3

32 ± 3

65 ± 10

75 ± 10

93 ± 12

115 ± 15

140 ± 20

155 ± 25

13 ± 2

25 ± 5

30 ± 5

53 ± 7

65 ± 10

105 ± 15

128 ± 17

ft-lb

16 ± 2

18 ± 2

27 ± 3

29 ± 3

48 ± 7

53 ± 7

88 ± 12

95 ± 15

140 ± 20

165 ± 25

225 ± 25

260 ± 30

147 ± 23

282 ± 30

339 ± 56

599 ± 79

734 ± 113

1186 ± 169

1446 ± 192

N-m

22 ± 3

24 ± 3

37 ± 4

39 ± 4

65 ± 9

72 ± 9

119 ± 16

129 ± 20

190 ± 27

224 ± 34

305 ± 34

353 ± 41

In-lb

15 ± 2

17 ± 2

29 ± 3

31 ± 3

42 ± 4

48 ± 4

100 ± 10

115 ± 10

200 ± 25

225 ± 25

ft-lb

30 ± 3

35 ± 3

50 ± 5

55 ± 5

75 ± 8

85 ± 8

150 ± 15

170 ± 15

265 ± 25

300 ± 25

430 ± 45

475 ± 45

N-cm

169 ± 23

190 ± 20

330 ± 30

350 ± 30

475 ± 45

540 ± 45

1125 ± 100

1300 ± 100

2250 ± 280

2540 ± 280

N-m

41 ± 4

47 ± 4

68 ± 7

75 ± 7

102 ± 11

115 ± 11

203 ± 20

230 ± 20

359 ± 34

407 ± 34

583 ± 61

644 ± 61

In-lb

23 ± 2

25 ± 2

41 ± 4

43 ± 4

60 ± 6

68 ± 6

140 ± 15

160 ± 15

300 ± 30

325 ± 30

ft-lb

43 ± 4

50 ± 4

70 ± 7

77 ± 7

105 ± 10

120 ± 10

210 ± 20

240 ± 20

374 ± 35

420 ± 35

600 ± 60

660 ± 60

N-cm

260 ± 34

280 ± 20

460 ± 45

31 ± 3

674 ± 70

765 ± 70

1580 ± 170

1800 ± 170

3390 ± 340

3670 ± 340

N-m

58 ± 5

68 ± 5

68 ± 9

104 ± 9

142 ± 14

163 ± 14

285 ± 27

325 ± 27

508 ± 47

569 ± 47

813 ± 81

895 ± 81

Note:

Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.

Note:

Torque values may have to be reduced when installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Note:

The nominal torque values listed above for

Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.


SPECIFICATIONS

Note:

Thread Size

M5 X 0.8

M6 X 1.0

M8 X 1.25

M10 X 1.5

M12 X 1.75

M16 X 2.0

M20 X 2.5

Class 8.8 Bolts, Screws, and Studs with

Regular Height Nuts

(Class 8 or Strong Nuts)

57 ± 5 in-lb 644 ± 68 N-cm

96 ± 10 in-lb

19 ± 2 ft-lb

38 ± 4 ft-lb

66 ± 7 ft-lb

166 ± 15 ft-lb

325 ± 33 ft-lb

1085 ± 113 N-cm

26 ± 3 N-m

52 ± 5 N-m

90 ± 10 N-m

225 ± 23 N-m

440 ± 45 N-m

Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.

Note:

Torque values may have to be reduced when installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Class 10.9 Bolts, Screws, and Studs with

Regular Height Nuts (

Class 10 or Strong Nuts)

78 ± 8 in-lb 881 ± 90 N-cm

133 ± 14 in-lb

28 ± 3 ft-lb

54 ± 6 ft-lb

93 ± 10 ft-lb

229 ± 23 ft-lb

450 ± 36 ft-lb

1503 ± 158 N-cm

38 ± 4 N-m

73 ± 8 N-m

126 ± 14 N-m

310 ± 31 N-m

610 ± 62 N-m

Note:

The nominal torque values listed above are based on 75% of the minimum proof load specified in

SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

2


SPECIFICATIONS

2

SAE Grade 8 Steel Set Screws

Thread Size

1/4 - 20 UNC

5/16 - 18 UNC

3/8 - 16 UNC

1/2 - 13 UNC

Recommended Torque

Square Head

140 ± 20 in-lb

Hex Socket

73 ± 12 in-lb

215 ± 35 in-lb

35 ± 10 ft-lb

75 ± 15 ft-lb

145 ± 20 in-lb

18 ± 3 ft-lb

50 ± 10 ft-lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23, or Type F

Thread Size

No. 6 - 32 UNC

Baseline Torque*

20 ± 5 in-lb

No. 8 - 32 UNC

No.10 - 24 UNC

1/4 - 20 UNC

5/16 - 18 UNC

3/8 - 16 UNC

30 ± 5 in-lb

38 ± 7 in-lb

85 ± 15 in-lb

110 ± 20 in-lb

200 ± 100 in-lb

Conversion Factors

in-lb X 11.2985 = N-cm ft-lb X 1.3558 = N-m

Wheel Bolts and Lug Nuts

Thread Size

7/16 - 20 UNF

Grade 5

1/2 - 20 UNF

Grade 5

M12 X 1.25

Class 8.8

Recommended Torque**

65 ± 10 ft-lb

80 ± 10 ft-lb

80 ± 10 ft-lb

88 ± 14 N-m

108 ± 14 N-m

108 ± 14 N-m

M12 X 1.5

Class 8.8

80 ± 10 ft-lb 108 ± 14 N-m

** For steel wheels and non-lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6

No. 8

Threads per Inch

Type A Type B

18

15

20

18

Baseline Torque*

20 ± 5 in-lb

30 ± 5 in-lb

No. 10

12 16 38 ± 7 in-lb

No. 12

11 14 85 ± 15 in-lb

* Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on nonlubricated fasteners.

N-cm X - 0.08851 = in-lb

N-cm X 0.73776 = ft-lb


SPECIFICATIONS

Fractions

1/16

1/8

3/16

1/4

5/16

3/8

7/16

1/2

1/32

3/32

5/32

7/32

9/32

11/32

13/32

15/32

Decimal and Millimeter Equivalents

Fractions Decimals

1/64

3/64

5/64

0.015625

0.03125

0.046875

0.0625

0.078125

0.9375

0.1250

0.140625

9/64

11/64

0.15625

0.171875

0.1875

13/64 0.203125

0.21875

15/64 0.234375

0.2500

17/64 0.265625

0.28125

19/64 0.296875

0.3125

21/64 0.328125

0.34375

23/64 0.359375

0.3750

25/64 0.390625

0.40625

27/64 0.421875

0.4375

29/64 0.453125

0.46875

31/64 0.484375

0.5000

1 mm = 0.03937 in.

mm

10.319

10.716

11.112

11.509

11.906

12.303

12.700

7.144

7.541

7.541

8.334

8.731

9.128

9.525

9.922

3.969

4.366

4.762

5.159

5.556

5.953

6.350

6.747

0.397

0.794

1.191

1.588

1.984

2.381

3.175

3.572

9/16

5/8

11/16

3/4

13/16

7/8

15/16

1

16/32

19/32

21/32

23/32

25/32

27/32

29/32

31/32

Decimals

33/64

35/64

37/64

41/64

43/64

45/64

47/64

49/64

51/64

53/64

55/64

57/64

0.78125

0.796875

0.8125

0.828125

0.84375

0.859375

0.8750

0.890625

59/64

61/64

0.90625

0.921875

0.9375

0.953125

63/64

0.96875

0.984375

1.000

0.001 in. = 0.0254 mm

0.515625

0.53125

0.546875

0.5625

0.578125

0.59375

0.6250

0.640625

0.65625

0.671875

0.6875

0.703125

0.71875

0.734375

0.7500

0.765625

mm

23.019

23.416

23.812

24.209

24.606

25.003

25.400

19.844

20.241

20.638

21.034

21.431

21.828

22.225

22.622

16.669

17.066

17.462

17.859

18.256

18.653

19.050

19.447

13.097

13.484

13.891

14.288

14.684

15.081

15.875

16.272

2


SPECIFICATIONS

2

U.S. to Metric Conversions

U.S. to Metric Conversions

Linear

Measurement

To Convert

Miles

Yards

Feet

Feet

Inches

Inches

Inches

Into

Kilometers

Meters

Meters

Centimeters

Meters

Centimeters

Millimeters

Area

Volume

Weight

Pressure

Work

Liquid Volume

Liquid Flows

Square Miles

Square Feet

Square Inches

Acre

Cubic Yards

Cubic Feet

Cubic Inches

Tons (Short)

Pounds

Ounces

Pounds/Sq. In.

Foot-pounds

Foot-pounds

Inch-pounds

Quarts

Gallons

Gallons/Minute

Fahrenheit

Square Kilometers

Square Meters

Square Centimeters

Hectare

Cubic Meters

Cubic Meters

Cubic Centimeters

Metric Tons

Kilograms

Grams

Kilopascal

Newton-Meters

Kilogram-Meters

Kilogram-Centimeters

Liters

Liters

Liters/Minute

Celsius

Temperature

Multiply By

1.609

0.9144

0.3048

30.48

0.0254

2.54

25.4

2.59

0.0929

6.452

0.4047

0.7646

0.02832

16.39

0.9078

0.4536

28.3495

6.895

1.356

0.1383

1.152144

0.9463

3.785

3.785

1. Subtract 32°

2. Multiply by 5/9


SPECIFICATIONS

Hydro with Pistol Grip Controls

Models:

Model

30284

30286

30288

30289

30280

Engine

17 hp Kawasaki

17 hp Kawasaki

19 hp Kawasaki

19 hp Kawasaki

23 hp Kawasaki

Deck

36”

40”

48”

52”

60”

Engines:

Output (Max. @ 3600 RPM)

Make

Model

Hi-Idle

Starter

17 hp (12.7 kW) 19 hp (14.2 kW) 23 hp (17.2 kW)

Kawasaki

FH541V

3600 rpm

Electric

Oil Capacity

3.8 pint (1.8L)

Kawasaki

FH580V

3600 rpm

Electric

3.8 pint (1.8L)

Kawasaki

FH680V

3600 rpm

Electric

4.0 pint (1.9L)

Fuel System:

4.8 gallons (18 liters) fuel tank capacity

Traction Drives:

Traction Control:

Hydraulic Pump:

Hydraulic Wheel Motor:

Hydraulic Oil Filter:

Hydraulic Fluid:

Hydraulic Fluid Capacity:

Parking Brake:

Toro Pistol Grip Control System

Two Hydro-Gear Model PG

Two Parker TEO-195 / Model 30280: Parker TEO-230

10 Micron Automotive Spin-On Type

Synthetic, 15w50

2.1 quarts (1.9 liters)

Standard equipment

Ground Speed: (MPH/kmh)

Variable, 0 to 6.35 MPH (10kmh) Fwd / 0 to 2.5 (4kmh) Rev

Hourmeter with Service Indicator

Standard equipment

2


SPECIFICATIONS

Hydro with Pistol Grip Controls cont.

2

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” (2.8cm) diameter pivot shaft. The pivot hubs have grease fi tting for lubrication. Model 30280: 1” (2.5cm) diameter pivot shaft. The pivot hubs have tapered roller bearings and access for lubrication.

Rear Traction Tires:

17 hp - 16x6.50-8, 4 ply with Turf Traction Tread



Mower Drive:

Mower Engagement:

Engine mounted electric clutch

Clutch Adjustment:

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

PTO Drive Belt:

PTO Idler:

Deck Drive Belt:

Deck Drive Idler:

HB section with Aramid (Kevlar) cords and dry clutching envelope

Spring loaded pivot hub with grease fi tting for lubrication / 36” deck includes additional fi xed idler.

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

Spring loaded / 36” decks have non-greaseable pivot hub

40”, 48” and 52” have pivot hub with grease fi tting for lubrication

Mower Decks:

HOC Range:

Blades:

Spindles:

Spindle Housing:

Bearings:

Construction:

1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

36” - two .250” (6.3mm) thick heat treated steel blades

40”, 48” and 52” - three .250” (6.3mm) thick heat treated steel blades

Machined steel 1.00” (25mm) diameter shaft

Ductile cast iron 9-3/8” (24cm) diameter mounted with six bolts

Sealed ball bearings permanently lubricated with high temperature grease

7 gauge (.179 inch (4.5mm)) steel welded construction.

Blade Tip Speed: (Domestic)

36” - 18,420 ft/m calculated @ 3600 engine rpm





Anti-Scalp Rollers:

36” - 2 front mounted


48” - 3 front mounted (optional 2 rear mounted)

52” & 60” - 3 front mounted, 2 rear mounted

Skid Plate:

Standard

Adjustable Discharge Baffl e:

Standard

Rubber Discharge Chute:

Standard


SPECIFICATIONS

Hydro with Pistol Grip Controls cont.

Unit Dimensions:

Model No.

30284

30286

30288

30289

30280

Height*

41.5” (105cm)

41.5” (105cm)

41.5” (105cm)

41.5” (105cm)

41.5” (105cm)

*With handle height in lowest position

**Estimated operating weight

Width Defl ector

Down

51.1” (130cm)

55.5” (141cm)

63.5” (161cm)

67.6” (171cm)

75.6” (192cm)


Raised

37.2” (94cm)

41.6” (105cm)

49.6” (126cm)

53.7” (136cm)

61.8” (157cm)

Length*

84.5” (214cm)

81.3” (206cm)

83.8” (213cm)

83.8” (213cm)

85.7” (217cm)

Weight**

677 lbs. (302kg)

677 lbs. (302kg)

692 lbs. (314kg)

731 lbs. (331kg)

780 lbs. (354kg)

2


SPECIFICATIONS

Hydro with T-2 Controls

2

Models:

Model

30494

30496

30498

30499

Engine

17 HP Kawasaki

17 HP Kawasaki

19 HP Kawasaki

19 HP Kawasaki

Engines:


Make

Model

Hi-Idle

Starter

17 HP (12.7 kW) 19 HP (14.2 kW)

Kawasaki

FH541V

3600 rpm

Electric

Oil Capacity

3.8 pint (1.8L)

Kawasaki

FH580V

3600 rpm

Electric

3.8 pint (1.8L)

Fuel System:


Deck

36”

40”

48”

52”



Hydraulic Pump:



Toro T2 Control System


Two Parker TEO-195

10 micron automotive spin-on type



Parking Brake:

Ground Speed: (MPH/kmh)

Synthetic, 15w50


Standard equipment

Variable, 0 to 6.1 mph (9.8kmh) Fwd / 0 to 2.5 mph (4kmh) Rev


Standard equipment


Front Castors Tires:

9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fi ttings

Front Castors Fork:

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs have grease fi tting for lubrication.


17 hp - 16x6.50-8, 4 ply with turf traction tread.

19 hp - 16x7.50-8, 4 ply with turf traction tread.


SPECIFICATIONS

Hydro with T-2 Controls cont.

Mower Drive:





PTO Drive Belt:


PTO Idler:



Spring loaded pivot hub with grease fi tting for lubrication / 36” deck includes additional fi xed idler




Mower Decks:

HOC Range:

Blades:


36” - two .250” (6.3mm) thick heat treated steel blades

40”, 48” and 52” - three .250” (6.3mm) thick heat treated steel blades

Spindles:


Bearings:

Construction:


Ductile cast iron, 9-3/8” (24cm) diameter mounted with six bolts


7 gauge (.179 inch (4.5mm)) steel welded construction










52” - 3 front mounted, 2 rear mounted

Skid Plate:

Standard


Standard


Standard


Model No.

30494

30496

30498

30499

* Estimated operating weight

Height

46” (117cm)

46” (117cm)

46” (117cm)

46” (117cm)


Down

51.1” (130cm)

55.5” (141cm)

63.5” (161cm)

67.6” (171cm)


Raised

37.2” (94cm)

41.6” (105cm)

49.6” (126cm)

53.7” (136cm)

Length

78.5” (199cm)

75.3” (191cm)

77.8” (198cm)

77.8” (198cm)

Weight*

667 lbs. (302kg)

667 lbs. (302kg)

682 lbs. (309kg)

721 lbs. (327kg)

2


SPECIFICATIONS

Gear with T-Bar Controls

2

Models:

Model

30092

30094

30096

30098

30099

Engine

15 hp Kawasaki

15 hp Kawasaki

15 hp Kawasaki

17 hp Kawasaki

17 hp Kawasaki

Engines:


15 HP (11.2 kW)

Kawasaki

17 HP (12.7 kW)

Kawasaki

Make

Model

Hi-Idle

FH430V

3600 rpm

3200 rpm (30092)

Starter

Recoil

Oil Capacity

3.8 pint (1.8L)

FH541V

3600 rpm

Recoil

3.8 pint (1.8L)

Fuel System:


Deck

32”

36”

40”

48”

52”



Toro T-Bar Control System

Transmission:

Peerless 700-070A, 5 speed forward / 1 reverse

Transmission Output Shaft:

Heavy-duty with 9 tooth spline

Axle:

Traction Drive Belt:

Wheel Hub Bearing:

Ground Speed: (mph/kmh)

Parking Brake:

1” (2.5cm) heavy-duty axle

Two “A” section banded design

Tapered roller bearings

(36” 40” 48” 52”) 1st - 2 mph (3.2kmh) / 2nd - 2.6 mph (4.1kmh) / 3rd - 3.4 mph

(5.4kmh) / 4th - 4.1 mph (6.5kmh) / 5th - 6.1 mph (9.8kmh) forward / 3 mph

(4.8kmh) reverse

(32”) 1st - 0.9 mph (1.4kmh) / 2nd - 2.1 mph (3.3kmh) / 3rd - 3.4 mph (5.4kmh) /

4th - 4.3 mph (6.9kmh) / 5th - 5 mph (8kmh) forward / 2.5 mph (4kmh) reverse

Two wheel band type standard


SPECIFICATIONS

Gear with T-Bar Controls cont.


Front Castor Tires:

Front Castor Fork:


9x3.5-4, 4 ply smooth tread, semi-pneumatic with needle bearings and grease fi ttings


15 hp - 16x6.50-8, 4 ply with turf traction tread


Mower Drive:





PTO Drive Belt:

PTO Idler:




Spring loaded pivot hub with grease fi tting for lubrication / 36” deck includes additional fi xed idler




Mower Decks:

HOC Range:

Blades:

(32”) 2” (5cm) to 5” (13cm) in 1/2” (1.27cm) increments

(36”, 40”, 48”, 52”) 1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

32” - One .188” (4.7mm) thick heat treated steel blade

36” - Two .250” (6.3mm) thick heat treated steel blades

40”, 48” and 52” - Three .250” (6.3mm) thick heat treated steel blades


Ductile cast iron 9-3/8” (24cm) diameter mounted with six bolts

Spindles:


Bearings:

Construction:


(32”) 12 gauge (.104” (2.77mm)) stamped steel

(36”, 40”, 48”, 52”) 7 gauge (.179” (4.5mm)) steel welded construction








32” - None




52” - 3 front mounted, 2 rear mounted

Skid Plate:

(36”, 40”, 48”, 52”) Standard


(36”, 40”, 48” ,52”) Standard


(36”, 40”, 48”, 52”) Standard

2


SPECIFICATIONS

2

Gear with T-Bar Controls cont.


Model No.

30092

30094

30096

30098

30099

Height*

43.5” (110cm)

41.2” (105cm)

41.2” (105cm)

41.2” (105cm)

41.2” (105cm)

* With handle height in lowest position

** Estimated operating weight


Down

42” (107cm)

51.1” (130cm)

55.5” (141cm)

63.5” (161cm)

67.6” (172cm)


Raised

32” (81cm)

37.2” (94cm)

41.6” (106cm)

49.6” (126cm)

53.7” (136cm)

Length*

73” (185cm)

Weight**

388 lbs. (176kg)

82.7” (210cm) 588 lbs. (267kg)

79.5” (202cm) 596 lbs. (270kg)

82” (208cm)

82” (208cm)

649 lbs. (294kg)

684 lbs. (310kg)


SPECIFICATIONS

International Hydro with T-Bar (T2) Controls

Models:

Model Engine

30032 (CE) 15 hp Kawasaki

Deck

91cm

Engine:

Output (Max. @ 3600 rpm)

Make

Model

Hi-Idle

Starter

15 HP (11.2 kW)

Kawasaki

FH430Y

2900 RPM

Recoil

Oil Capacity

3.8 Pint (1.8L)

Fuel System:

4.8 Gallons (18 liters) fuel tank capacity



Hydraulic Pump:



Toro “T2” Control System


Two Parker TEO-195

10 micron automotive spin-on type



Parking Brake:

Synthetic, 15w50


Standard equipment

Ground Speed: (kmh)

Variable, 0 to 9.8kmh fwd / 0 to 4kmh rev


Standard equipment



9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fi ttings





2


SPECIFICATIONS

International Hydro with T-Bar (T2) Controls cont.

2

Mower Drive:





PTO Drive Belt:


PTO Idler:

Spring loaded pivot hub with grease fi tting for lubrication / 91cm (36”) deck includes additional fi xed idler.




Spring loaded / 91cm (36”) decks have non-greaseable pivot hub

Mower Decks:

HOC Range:

Blades:

Spindles:


Bearings:

Construction:

Blade Tip Speed:


Skid Plate:


Two .250” (6.3mm) thick heat treated steel blades




7 gauge (.179” (4.5mm)) steel welded construction

21,070 ft/m calculated @ 2900 engine rpm

2 front mounted

Standard


Standard



Standard

Model No.

30032

Height

46” (117cm)


Down

51.1” (130cm)


Raised

37.2” (94cm)

Length

78.5” (199cm)

Weight*

667 lbs. (302kg)

*Estimated operating weight


SPECIFICATIONS

International Gear with T-Bar Controls

Models:

Model Engine

30031 (CE) 15 hp Kawasaki

Deck

91cm

Engines:


Make

Model

Hi-Idle

Starter

15 HP (11.2 kW)

Kawasaki

FV430V

2900 RPM

Recoil

Oil Capacity

3.8 pints (1.8L)

Fuel System:




Transmission:

Toro T-Bar Control System

Peerless 700-070A, 5 speed forward / 1 reverse

Transmission Output Shaft:

Heavy duty with 9 tooth spline

Axle:

1” heavy-duty axle

Traction Drive Belt:

Wheel Hub Bearing:

Ground Speed: (kmh)

Parking Brake:

Two “A” section banded design

Tapered roller bearings

1st - 3.2kmh / 2nd - 4.1kmh / 3rd - 5.4kmh / 4th - 6.5kmh / 5th - 9.8kmh fwd

4.8kmh rev

Two wheel band type standard



9x3.5-4, 4 ply, smooth tread, semi pneumatic with needle bearings and grease fi ttings





2


SPECIFICATIONS

International Gear with T-Bar Controls cont.

2

Mower Drive:





PTO Drive Belt:


PTO Idler:

Spring loaded pivot hub with grease fi tting for lubrication / 91cm deck includes additional fi xed idler




Spring loaded / 91cm decks have non-greaseable pivot hub

Mower Decks:

HOC Range:

Blades:

Spindles:


Bearings:

Construction:


Two .250” (6.3mm) thick heat treated steel blades

Machined steel 1.00” (2.5cm) diameter shaft



7 gauge (.179” (4.5mm)) steel welded construction


91cm - 12,070 ft/m calculated @ 2900 engine rpm


Skid Plate:

91cm - 2 front mounted

Standard


Standard


Standard


Standard


Model No.

30031 (CE)

Height*

41.2” (105cm)

*With handle height in lowest position

**Estimated operating weight


Down

51.1” (130cm)


Raised

37.2” (94cm)

Length*

82.7” (210cm)

Weight**

598 lbs. (271kg)


CHASSIS

Electric Clutch Replacment

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. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery (Fig. 0001).

5. Unplug the clutch lead from the harness connector

(Fig. 0002).

3

Fig 0002

PICT-0548a

6. Push the grommet and clutch plug through the frame to the underside of the machine (Fig. 0003).

Fig 0001

PICT-0250

Fig 0003

PICT-0277


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.

0006).

3

Fig 0004

PICT-0546

8. Roll the PTO drive belt off the center pulley on the mower deck (Fig. 0005).

Fig 0006

PICT-0273

11. Remove the PTO idler arm spring from the spring post (Fig. 0007).

3-2

Fig 0005

PICT-0281

Fig 0007

PICT-0291a


12. Remove the belt from the clutch (Fig. 0008).

CHASSIS

14. Loosen the clutch bolt (Fig. 0010).

Fig 0008

PICT-0294

Fig 0010

PICT-0297a

13. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0009).

15. Remove the bolt, 2 spring washers and fl at washer securing the clutch to the drive shaft. Lower the clutch off the drive shaft (Fig. 0011).

3

Fig 0009

PICT-0295

Fig 0011

PICT-0299


CHASSIS

3

16. Remove the rubber grommet from the clutch wire

(Fig. 0012).

Fig 0012

PICT-0551a

Clutch Burnishing Procedure

Note: This procedure needs to be done only when installing a new clutch.

The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed.

Burnishing polishes the clutch plate, allowing for smooth clutch engagement.

With deck drive belt installed, run the engine at half throttle. Engage and disengage the mower 5 times (10 seconds on/10 seconds off).

Increase engine RPM to 3/4 to full throttle. Engage and disengage mower 5 times (10 seconds on/10 seconds off).

Check the clutch air gap and adjust as needed. Refer to

“Electric Clutch Installation” following.

17. Remove the bolt, nut and washers securing the brake clutch strap to the clutch (Fig. 0013).

Electric Clutch Installation

1. Using a feeler gauge, check the clutch air gap at each of the 3 adjustment slots. The gap should be between 0.015” - 0.021” (0.381 - 0.533mm). Make sure the gauge is inserted between the armature and the rotor friction surfaces. Adjust the clutch as necessary (Fig. 0014).

3-4

Fig 0013

PICT-0553

Fig 0014

PICT-0554


CHASSIS

2. Assemble the bolt, washers, nut and strap into the slotted opening on the clutch as shown. Before tightening, move the strap fastener assembly to the outer-most end of the slot and tighten (Fig. 0015).

4. Apply thread locking compound to the clutch bolt

(Fig. 0017).

Fig 0017

PICT-0352a

Fig 0015

PICT-0557

3. Install the 2 cupped washers (crown side facing the bolt head) and 1 fl at washer onto the clutch bolt (Fig.

0016).

5. Apply anti-sieze compound to the engine crankshaft.

Slide the electric clutch onto the crankshaft (Fig.

0018).

3

Fig 0016

PICT-0351a

Fig 0018

PICT-0354a


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).

3

Fig 0019

PICT-0355a

Fig 0021

PICT-0361

7. Torque the clutch bolt to 55 + 5 ft-lbs. (75 + 7 Nm)

(Fig. 0020).

9. Feed the cutch harness plug up through the frame

(Fig. 0022).

Fig 0020

PICT-0356a

Fig 0022

PICT-0362


10. Install the rubber grommet into the frame opening

(Fig. 0023).

CHASSIS

Note: Ensure the PTO drive belt is routed properly 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

11. Route the PTO drive belt around the clutch. (Fig.

0024).

Fig 0025

fi g. 104-8185

40”, 48” and 52” mower deck belt routing:

Note: On 48” decks leave the belt off of the center mower deck pulley.

3

Fig 0024

PICT-0364a


Fig 0026

fi g. 104-8186

3-7

CHASSIS

12. Install the PTO idler arm spring to the spring post

(Fig. 0027).

14. Lower the machine.

15. Roll the PTO drive belt onto the center mower deck pulley (Fig. 0029).

3

Fig 0027

PICT-0367

Fig 0029

PICT-0281

13. Install the trailing shield into the frame by fi rst inserting the right side of the trailing shield rod (bent at a 90 degree angle) into the hole in the right side of the frame and then insert the left end of the trailing shield rod (bent at a 45 degree angle) into the hole in the left side of the frame (Fig. 0028).

16. Replace the carrier frame cover (Fig. 0030).

3-8

Fig 0028

PICT-0273

Fig 0030

PICT-0280


CHASSIS

17. Plug the clutch connector into the harness connector

(Fig. 0031).

PTO Idler Replacement

PTO Idler Removal

1. Turn the engine off and remove the key from the ignition.


3

Fig 0031

PICT-0548a

18. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot

(Fig. 0032).

Fig 0033

PICT-0280

3. Roll the PTO drive belt off the center mower deck pulley (Fig. 0034).

Fig 0032

PICT-0250


Fig 0034

PICT-0283

3-9

CHASSIS


5. Remove the PTO idler arm spring from the spring post and the idler arm (Fig. 0035).

7. Remove the PTO idler arm assembly from the frame

(Fig. 0037).

3

Fig 0037

PICT-0604a

Fig 0035

PICT-0291a

8. Press out the bearing sleeves from the idler arm

(Fig. 0038).

6. Remove the bolt, nut, washers and idler tube securing the PTO idler arm assembly to the frame (Fig.

0036).

3-10

Fig 0036

IMG-7690

Fig 0038

PICT-0605


9. Remove the bolt, washer and Bellville washer securing the pulley to the idler arm (Fig. 0039).

CHASSIS

11. Remove the grease fi tting from the idler arm (Fig.

0041).

Fig 0039

PICT-0609

Fig 0041

PICT-0613

10. Remove the pulley from the idler arm (Fig. 0040).

PTO Idler Assembly (Fig. 0042).

C

B

A

D G

E

H I

J

A

F

Fig 0040

PICT-0610

B. Grease Fitting

D. Bearing Sleeve (2)

Fig 0042

PICT-0618a

F. Bolt

G. Idler Pulley

I. Belleville Washer

J. Bolt

3


CHASSIS

PTO Idler Installation

1. Install the grease fi tting into the idler arm (Fig. 0043).

3. Position the pulley onto the idler arm (Fig. 0045).

3

Fig 0045

PICT-0610

Fig 0043

PICT-0613

2. Press the bearing sleeves into the idler arm pivot

(Fig. 0044).

4. Slide the Belleville washer (crown toward the bolt head) and fl at washer onto the bolt. Install the bolt and washers through the pulley and into the idler arm (Fig. 0046).

Fig 0044

PICT-0619

Fig 0046

PICT-0620


5. Slide a washer and idler tube onto the idler pivot bolt. Slide the bolt assembly into the idler arm.

Install a washer onto the bolt (Fig. 0047).

CHASSIS

7. Install a washer and nut securing the PTO idler arm assembly to the frame (Fig. 0049).

Fig 0047

PICT-0624a

Fig 0049

IMG-7690

6. Position the PTO idler arm assembly up to the frame

(Fig. 0048).

8. Hook the PTO idler arm spring onto the idler arm and onto the spring post (Fig. 0050).

3

Fig 0048

PICT-0625a

Fig 0050

PICT-0291a


CHASSIS

3



Parking Brake Service - Hydro

Checking the Parking Brake

1. Move the machine to a level surface.

2. Turn the ignition off and remove the key.

3. Check and adjust the tire pressure as follows: a. Rear tires: 12-14psi (83-97kPa) b. Castor tires: Semi-pneumatic

4. Set the parking brake (Fig. 0053).

Note: Setting the parking brake should take a reasonable amount of force. If it engages too hard or too easily, adjustment is required.

Refer to “Adjusting the Parking Brake”, following.

Fig 0051

PICT-0283

11. Install the carrier frame cover (Fig. 0052).

Fig 0052

PICT-0280

Fig 0053

PICT-0468


CHASSIS

Adjusting the Parking Brake

1. Check the parking brake before you adjust it. Refer to “Checking the Parking Brake”, preceding.

2. Release the parking brake.

3. Remove the cotter pin from the clevis at the top end of the parking brake adjusting rod (Fig. 0054).

5. Turn the upper brake adjustment yoke to adjust the parking brake as follows (Fig. 0056): a. Clockwise to decrease engagement force b. Counterclockwise to increase engagement force

3

Fig 0056

PICT-0473

Fig 0054

PICT-0470

6. Position the upper yoke of the parking brake adjusting rod to the parking brake handle and insert the clevis pin (Fig. 0057).

4. Remove the clevis pin securing the top end of the parking brake adjusting rod to the parking brake handle (Fig. 0055).

Fig 0055

PICT-0471


Fig 0057

PICT-0471

3-15

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).

3

Fig 0058

PICT-0470

Fig 0060

PICT-0471

8. Check the brake operation again. Refer to “Checking the Parking Brake” on page 3-14.

4. Remove the cotter pin from the clevis pin securing the lower yoke of the brake adjusting rod to the parking brake assembly (Fig. 0061).

Parking Brake Removal


2. Remove the cotter pin from the clevis pin at the top end of the parking brake adjusting rod (Fig. 0059).

3-16

Fig 0059

PICT-0470

Fig 0061

PICT-0477


CHASSIS

5. Remove the clevis pin that secures the lower end of the brake adjusting rod to the parking brake assembly and remove the brake rod assembly (Fig.

0062).

7. Remove the bolt, thrust bearing and parking brake handle from the handle support (Fig. 0064).

Fig 0064

PICT-0483

Fig 0062

PICT-0478

6. Remove the nut and conical washer from the bolt securing the parking brake handle to the handle support (Fig. 0063).

8. Unplug the parking brake switch from the harness

(Fig. 0065).

3

Fig 0063

PICT-0481

Fig 0065

PICT-0485


CHASSIS

9. Remove the 2 screws and nuts securing the parking brake switch to the handle support (Fig. 0066).

11. Remove the 2 nuts from the bolts securing the handle support to the frame (Fig. 0068).

3

Fig 0066

PICT-0486

Fig 0068

PICT-0489

10. Remove the parking brake switch and switch plate from the handle support (Fig. 0067).

12. Remove the bolts and handle support from the frame

(Fig. 0069).

Fig 0067

PICT-0487

Fig 0069

PICT-0490


CHASSIS

13. Remove the whizlock nut and bolt securing the top end of the parking brake spring to the frame (Fig.

0070).

15. Remove the parking brake assembly from the frame

(Fig. 0072).

Note: Unit raised for photo clarity.

Fig 0070

PICT-0491

14. Remove the 3 bolts and nuts securing the parking brake assembly to the frame (Fig. 0071).

Fig 0072

PICT-0497

16. Remove the bolt, nut and spring from the parking brake assembly (Fig. 0073).

3

Fig 0071

PICT-0494

Fig 0073

PICT-0500a


CHASSIS

Parking Brake Installation

1. Install the bolt, nut and spring onto the parking brake assembly (Fig. 0074).

3. Loosely install the 3 bolts and nuts securing the parking brake assembly to the frame (Fig. 0076).

3

Fig 0076

PICT-0494

Fig 0074

PICT-0500a

2. Position the parking brake assembly into the frame

(Fig. 0075).

Note: Unit raised for photo clarity.

4. Insert the bolt through the top end of the parking brake spring and into the frame (Fig. 0077).

3-20

Fig 0075

PICT-0497

Fig 0077

PICT-0502


CHASSIS

5. Loosely install the whizlock nut on the bolt that secures the top end of the brake spring to the frame

(Fig. 0078).

8. Install the nuts securing the parking brake handle support to the frame (Fig. 0080).

Fig 0078

PICT-0503a

Fig 0080

PICT-0489

6. Tighten all 4 nuts and bolts securing the parking brake assembly to the frame.

7. Insert the bolts through the frame and parking brake handle support (Fig. 0079).

9. Position the parking brake switch and switch plate onto the handle support (Fig. 0081).

3

Fig 0079

PICT-0490


Fig 0081

PICT-0487

3-21

CHASSIS

10. Install 2 screws and nuts securing the parking brake switch and switch plate to the handle support (Fig.

0082).

12. Insert a bolt through the parking brake handle. Install a thrust bearing onto the bolt and then insert the bolt/handle/bearing assembly through the handle support (Fig. 0084).

3

Fig 0082

PICT-0486

11. Plug parking brake switch into the harness connector (Fig. 0083).

Fig 0084

PICT-0483

13. Install a conical washer onto the bolt (crown facing the threaded end of the bolt (Fig. 0085).

Fig 0083

PICT-0485

Fig 0085

PICT-0507


CHASSIS

14. Install a nut onto the bolt securing the parking brake handle to the handle support (Fig. 0086).

Note: Do not over-tighten the nut.


Fig 0088

PICT-0477

Fig 0086

PICT-0481

17. Insert a clevis pin through the upper adjusting yoke securing it to the parking brake handle (Fig. 0089).

15. Position the brake linkage rod assembly with the adjusting yoke positioned up to the parking brake handle. Insert a clevis pin through the lower yoke securing it to the parking brake assembly (Fig.

0087).

3

Fig 0087

PICT-0478


Fig 0089

PICT-0471

3-23

CHASSIS

3


Fig 0090

PICT-0470

19. Check the parking brake. Refer to “Checking the

Parking Brake” on page 3-14.

Wheel Drive Belt and Wheel Hub

Replacement - Gear Drive

The following inspections should be made when disassembling the drive system, particularly if the reason for service is the inability to adjust belt tension or “loss of drive”. Be sure to inspect all components; there may be more than one item needing replacement.

Inspect for the following: cut the belt.

• Idler arm bent - this will push the belt to one side and can induce belt jumping in reverse.

• Idler pulley bearing worn out, resulting in inconsistent tension on the belt. Can cause slippage or jumping.

• A belt contacting the bottom of the pulley “V” indicates worn belt or pulleys. The belt will slip no matter how tight you adjust it.

• Belt glazed, shiny or burnt on the sides of the “V” indicates slipping. Belt must be replaced and the cause identifi ed and corrected.

• The sides of each pulley sheave should be straight and fl at. If the sides of the “V” have “opened up” or appear to bulge the pulley is worn and must be replaced.

If the belt is riding too deep in one or both pulley grooves the center fl ange will begin to cut the belt into 2 single belts. This indicates a badly worn belt or pulley. The parts must be replaced.


CHASSIS

Wheel Drive Belt & Wheel Hub Removal


2. Raise the machine so the rear tire is off the ground.

3. Remove the 3 lower idler support mounting bolts

(Fig. 0091).

5. Rotate the idler support bracket so that it is out of the way of the transmission pulley (Fig. 0093).

3

Fig 0093

PICT-1521

Fig 0091

PICT-1519

6. Remove the wheel drive belt from the transmission pulley and remove it from around the drive wheel

(Fig. 0094).

4. Loosen the idler support bracket pivot bolt (Fig.

0092).

Fig 0092

PICT-1520


Fig 0094

PICT-1577

3-25

CHASSIS

7. Inspect the pulleys for wear and damage. Replace as necessary. If pulley replacement is required, continue on. For belt replacement only, go to “Wheel

Drive Belt and Wheel Hub Installation” step 17, on page 3-34.

8. Loosen the set screw securing the drive pulley to the transmission (Fig. 0095).

10. Remove the key from the drive pulley shaft keyway

(Fig. 0097).

3

Fig 0097

PICT-1583

Fig 0095

PICT-1580

11. Inspect the key and replace it if it is worn or damage.

12. Apply anti-seize to the transmission drive shaft (Fig.

0098).

9. Slide the drive pulley off the transmission drive shaft

(Fig. 0096).

3-26

Fig 0096

PICT-1582

Fig 0098

PICT-1586


CHASSIS

13. Install the key into the transmission driveshaft keyway (Fig. 0099).

15. Apply thread locking compound to the drive pulley set screw (Fig. 0101).

Fig 0099

PICT-1583

Fig 0101

PICT-1587a

14. Position the drive pulley onto the transmission drive shaft so that the pulley hub faces toward the machine. The transmission driveshaft should be fl ush with the outside fl ange of the pulley (Fig. 0100).

16. Install the set screw into the drive pulley (Fig. 0102).

3

Fig 0100

PICT-1582

Fig 0102

PICT-1580


CHASSIS

17. Remove the 4 lug nuts retaining the wheel to the wheel hub assembly (Fig. 0103).

19. Remove the dust cover from the wheel hub assembly (Fig. 0105).

3

Fig 0103

PICT-1588a

Fig 0105

PICT-1590

18. Remove the wheel from the wheel hub assembly

(Fig. 0104).

20. Remove the cotter pin retaining the castle nut to the axle (Fig. 0106).

Fig 0104

PICT-1589

Fig 0106

PICT-1592


21. Remove the castle nut from the axle (Fig. 0107).

CHASSIS

23. Remove the washer from the wheel hub (Fig. 0109).

Fig 0107

PICT-1593

22. Slide the wheel hub assembly off the axle (Fig.

0108).

Fig 0109

PICT-1622

24. Remove the outside tapered wheel bearing from the wheel hub (Fig. 0110).

3

Fig 0108

PICT-1594

Fig 0110

PICT-1623


CHASSIS

25. Remove the inside grease seal from the wheel hub

(Fig. 0111).

27. Remove the grease fi tting from the wheel hub (Fig.

0113).

3

Fig 0111

PICT-1624

Fig 0113

PICT-1650

26. Remove the tapered bearing from the wheel hub

(Fig. 0112).

28. Thoroughly clean the wheel hub, tapered bearings and grease seal. Inspect and replace if worn or damaged.

Wheel Drive Belt & Wheel Hub Installation

1. Install a grease fi tting into the wheel hub (Fig. 0114).

3-30

Fig 0112

PICT-1625

Fig 0114

PICT-1650


CHASSIS

2. Repack the tapered bearing with grease (Fig. 0115).

Note: When packing wheel bearings use #2 general purpose lithium base or molybdenum base grease.

4. Insert the grease seal into the wheel hub bore (Fig.

0117).

Fig 0117

PICT-1645

Fig 0115

PICT-1643

5. Repack the second tapered bearing with grease

(Fig. 0118).

3. Insert the tapered bearing into the wheel hub bore

(Fig. 0116).

3

Fig 0116

PICT-1644

Fig 0118

PICT-1643


CHASSIS

6. Insert the tapered bearing into the opposite side of the wheel hub bore (Fig. 0119).

8. Slide the wheel hub assembly onto the axle (Fig.

0121).

3

Fig 0119

PICT-1646

Fig 0121

PICT-1651

7. Position a washer onto the outside tapered bearing

(Fig. 0120).

9. Position the brake band around the wheel hub brake drum and continue sliding the wheel hub onto the axle (Fig. 0122).

Fig 0120

PICT-1648

Fig 0122

PICT-1652


10. Install the castle nut onto the axle (Fig. 0123).

CHASSIS

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 turning the hub to seat the bearings and to remove all endplay. Loosen the castle nut until it is away from the washer/bearing then tighten the castle nut until it contacts the washer/bearing. The wheel hub must be free to rotate and have no endplay (Fig.

0124).

13. Fill the wheel hub cavity with grease (Fig. 0126).

3

Fig 0124

PICT-1654


Fig 0126

PICT-1656

3-33

CHASSIS

14. Using a rubber mallet, install the dust cap into to wheel hub assembly (Fig. 0127).

16. Install the lug nuts onto the wheel hub studs. Torque the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig.

0129).

3

Fig 0127

PICT-1657

15. Slide the wheel onto the wheel hub assembly (Fig.

0128).

Fig 0129

PICT-1663a

17. Route the wheel drive belt around the wheel drive pulley and the wheel hub pulley (Fig. 0130).

Fig 0128

PICT-1662a

Fig 0130

PICT-1577


CHASSIS

18. Rotate the idler support bracket into position so that the 3 mounting holes in the bracket line up with the 3 holes in the frame (Fig. 0131).

20. Tighten the idler support bracket pivot bolt (Fig.

0133).

Fig 0131

PICT-1664

19. Loosely install the 3 lower idler support mounting bolts (Fig. 0132).

Fig 0133

PICT-1520

21. Tighten the 3 lower idler support mounting bolts (Fig.

0134).

3

Fig 0132

PICT-1519

Fig 0134

PICT-1519


CHASSIS

Brake Band Replacement

The following procedures are the same for both the left and right brake band replacement.


0136).

Brake Band Removal


3

2. Raise the machine so the rear tire is off the ground.


(Fig. 0135).

Fig 136

PICT-1520


Fig 0135

PICT-1519

Fig 0137

PICT-1521


CHASSIS

6. Remove the wheel drive belt from the transmission pulley and remove it from around the drive wheel

(Fig. 0138).

8. Remove the wheel from the wheel hub assembly

(Fig. 0140).

Fig 0138

PICT-1577

7. Remove the 4 lug nuts retaining the wheel to the wheel hub assembly (Fig. 0139).

Fig 0140

PICT-1589

9. Remove the dust cover from the wheel hub assembly (Fig. 0141).

3

Fig 0139

PICT-1588a

Fig 0141

PICT-1590


CHASSIS

10. Remove the cotter pin retaining the castle nut to the axle (Fig. 0142).

12. Slide the wheel hub assembly off the axle (Fig.

0144).

3

Fig 0142

PICT-1592

Fig 0144

PICT-1594

11. Remove the castle nut from the axle (Fig. 0143).

13. Remove the hairpin cotter securing the brake rod to the brake arm. Remove the brake rod from the brake arm (Fig. 0145).

Fig 0143

PICT-1593

Fig 0145

PICT-1596


CHASSIS

14. Remove the retaining ring from the brake arm pivot

(Fig. 0146).

16. Remove the 3 brake link plate retaining rings (Fig.

0148).

Fig 0146

PICT-1602

Fig 0148

PICT-1607a

15. Remove the brake arm assembly from the pivot (Fig.

0147).

17. Remove the brake link plate from the brake assembly (Fig. 0149).

3

Fig 0147

PICT-1603

Fig 0149

PICT-1609a


CHASSIS

18. Remove the brake band from the brake link (Fig.

0150).

20. Inspect the brake band. Replace if damaged or worn

(Fig. 0152).

3

Fig 0150

PICT-1611a

19. Remove the brake arm from the brake link (Fig.

0151).

Fig 0152

PICT-1615a

Brake Band Installation

1. Position the brake arm onto the brake link (Fig.

0153).

Fig 0151

PICT-1612a

Fig 0153

PICT-1612a


CHASSIS

2. Place the brake band onto the brake link (Fig. 0154).

4. Install 3 new retaining rings as shown (Fig. 0156):

Fig 0154

PICT-1611a

A. Small

3. Install the brake link plate onto the brake assembly

(Fig. 0155).

Fig 0156

PICT-1607a

B. Large

5. Apply anti-seize compound to the brake arm pivot.

Slide the brake arm assembly onto the pivot (Fig.

0157).

3

Fig 0155

PICT-1609a

Fig 0157

PICT-1603


CHASSIS

6. Install a new retaining ring onto the brake arm pivot securing the brake arm to the frame (Fig. 0158).

8. Slide the wheel hub assembly onto the axle (Fig.

0160).

3

Fig 0158

PICT-1621

Fig 0160

PICT-1594

7. Position the lower end of the brake rod into the brake arm. Install a hairpin cotter securing the brake rod to the brake arm (Fig. 0159).

9. Install the castle nut onto the axle (Fig. 0161).

Fig 0159

PICT-1596

Fig 0161

PICT-1653


CHASSIS

10. Torque the castle nut to 6.5 ft-lbs. (8.8 Nm) while turning the hub to seat the bearings and to remove all endplay. Loosen the castle nut until it is away from the washer/bearing. Tighten nut until it contacts washer/bearing. Hub must be free to rotate and have no endplay (Fig. 0162).

12. Fill the wheel hub cavity with grease (Fig. 0164).

Fig 0164

PICT-1656

Fig 0162

PICT-1654

13. Using a rubber mallet, install the dust cap into to wheel hub assembly (Fig. 0165).

11. Install the cotter pin securing the castle nut to the axle (Fig. 0163).

3

Fig 0163

PICT-1655


Fig 0165

PICT-1657

3-43

CHASSIS

14. Route the wheel drive belt around the wheel drive pulley and the wheel hub (Fig. 0166).

16. Install the lug nuts onto the wheel hub studs. Torque the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig.

0168).

3

Fig 0166

PICT-1660

Fig 0168

PICT-1663a

15. Slide the wheel onto the wheel hub assembly (Fig.

0167).

17. Rotate the idler support bracket into position so that the 3 mounting holes in the bracket line up with the 3 holes in the frame (Fig. 0169).

Fig 0167

PICT-1662a

Fig 0169

PICT-1664


18. Loosely install the 3 lower idler support mounting bolts (Fig. 0170).

CHASSIS

20. Tighten the 3 lower idler support mounting bolts (Fig.

0172).

Fig 0170

PICT-1519


0171).

Fig 0172

PICT-1519

Carrier Frame Replacement

Carrier Frame Removal

1. Remove the Mower Deck. Refer to “Mower Deck

Removal” on page 8-61.

2. 40”, 48”, 52” and 60” mower decks only: Remove the battery and battery tray assembly. Refer to “Battery

Tray Removal” on page 3-70.

3. Support the carrier frame with a jack stand.

3

Fig 0171

PICT-1520


CHASSIS

4. Remove the bolt and nut securing the right side of the carrier frame to the right side of the traction frame (Fig. 0173).

6. Slide the carrier frame away from the traction frame

(Fig. 0175).

3

Fig 0173

PICT-1300

Fig 0175

PICT-1305

5. Remove the 3 bolts and nuts securing the left side of the carrier frame to the left side of the traction frame

(Fig. 0174).

7. Remove the 2 bolts and washers securing the belt shield to the carrier frame (Fig. 0176).

Fig 0174

PICT-1303

Fig 0176

PICT-1307


CHASSIS

8. Remove the belt shield from the carrier frame (Fig.

0177).

10. Remove the deck bushing from the carrier frame

(Fig. 0179).

Fig 0177

PICT-1310

Fig 0179

PICT-1313

9. Remove the retaining ring from the deck bushing

(Fig. 0178).

11. Repeat steps 9 and 10 for the opposite side deck bushing.

12. Remove both castor wheel fork grease fi ttings (Fig.

0180).

3

Fig 0178

PICT-1311

Fig 0180

PICT-1314a


3

CHASSIS

13. Remove the castor wheel assemblies from the carrier frame. Refer to “Castor Wheel Removal” on page 3-53.

14. Remove the castor wheel fl ange bushings (2 left, 2 right) from the carrier frame (Fig. 0181).

2. Install the castor wheel assemblies into the carrier frame. Refer to “Castor Wheel Installation” on page

3-59.

3. Install 2 grease fi ttings (1 left, 1 right) into the castor fork arms of the carrier frame (Fig. 0183).

Fig 0181

PICT-1331a

Fig 0183

PICT-1314a

4. Grease the castor wheel assemblies (Fig. 0184).

Carrier Frame Installation

tor fork arms of the carrier frame (Fig. 0182).

3-48

Fig 0182

PICT-1334a

Fig 0184

PICT-1335


5. Install a deck bushing into the carrier frame (Fig.

0185).

CHASSIS

7. Repeat steps 5 and 6 for the opposite side deck bushing.

8. Position the belt shield to the carrier frame (Fig.

0187).

Fig 0185

PICT-1313

6. Install a retaining ring onto the deck bushing (Fig.

0186).

Fig 0187

PICT-1310

9. Install 2 bolts and washers to secure the belt shield to the carrier frame (Fig. 0188).

3

Fig 0186

PICT-1311

Fig 0188

PICT-1307


CHASSIS

10. Position the carrier frame assembly up to the traction frame (Fig. 0189).

13. Loosely install the 2 upper bolts and nuts securing the left side of the carrier frame to the left side of the traction frame (Fig. 0191).

3

Fig 0189

PICT-1305

Fig 0191

PICT-1303

11. Support the carrier frame with a jack stand.

12. Loosely install the lower front bolts on each side of the chassis securing the carrier frame to the traction frame (Fig. 0190).

14. 40”, 48”, 52” and 60” mower decks only: Install the battery and battery tray assembly. Refer to “Battery

Tray Installation” on page 3-72.

15. 36” mower decks only: Loosely install the 2 upper bolts and nuts securing the right side of the carrier frame to the right side of the traction frame (Fig.

0192).

3-50

Fig 0190

PICT-1300

Fig 0192

PICT-2162


CHASSIS

16. Check the alignment if the engine deck and carrier frame. Refer to “Checking the Carrier Frame and

Engine Deck Alignment”, proceding.

17. Check the engine deck height. Refer to “Checking the Engine Deck Height” on page 8-63.

18. Check the front-to-rear pitch of the carrier frame.

Refer to “Checking the Carrier Frame Front-to-Rear

Pitch” on page 8-64.

19. Check the side-to-side height of the carrier frame.

Refer to “Checking the Carrier Frame Side-to-Side

Height” on page 8-64.

20. Tighten and torque the 6 carrier frame mounting bolts to 70 + 10 ft-lbs. (94.9 + 13.6 Nm) (Fig. 0193).

Carrier Frame & Mower Deck

Adjustments

Checking the Carrier Frame & Engine Deck

Alignment

Note: Misalignment can cause excess wear on the deck drive belt.

1. Turn the engine off and remove the key from the ignition. Set the parking brake.

2. Check and adjust the tire pressure in the rear tires to

12-14 psi (83-97kPa).

3


Fig 0193

PICT-1336

21. Install the Mower Deck. Refer to “Mower Deck

Installation” on page 8-62.

22. Check the front-to-rear pitch of the mower deck.

Refer to “Checking the Mower Deck Front-to-Rear


23. Check the side-to-side height of the mower deck.

Refer to “Checking the Mower Deck Side-to-Side


24. Check the Height-of-Cut. Refer to “Matching the

Height-of-Cut” on page 8-67.


Fig 0194

PICT-1038

3-51

CHASSIS

4. Place a 2”x2” by 8” (aprox.) long piece of tubing stock on the engine deck along the right side the engine (Fig. 0195).

6. The space between the front cross brace and the straight edge should be 11/16” + 1/4” (17.46mm +

6.35mm) (Fig. 0197).

3

Fig 0195

PICT-1339

Fig 0197

PICT-1345

5. Hold a ridid straight edge (36” minimum length) on top of the 2”x2” piece of tubing stock so it reaches out to the front cross brace of the carrier frame (Fig.

0196).

If the space is not correct, adjustment is needed:

7. Loosen the 6 carrier frame mounting bolts (3 on the left, 3 on the right) (Fig. 0198).

Fig 0196

PICT-1341

Fig 0198

PICT-1303


CHASSIS

8. Align the carrier frame and engine deck to meet the

11/16” + 1/4” (17.46mm + 6.35mm) measurement at the front carrier frame cross brace (Fig. 0199).

10. Remove the straight edge and 2x2 piece of stock.


Fig 0199

PICT-1345

Fig 0201

PICT-1038

9. Tighten the carrier frame mounting bolts on both sides of the machine. Torque to 70 + 10 ft-lbs. (94.9

+ 13.6 Nm) (Fig. 0200).

Castor Wheel Replacement

The following procedures are the same for both the left and right castor assemblies.

Castor Wheel Removal

1. Remove the locking pin from the castor fork assembly (Fig. 0202).

3

Fig 0200

PICT-1303


Fig 0202

PICT-1316

3-53

CHASSIS

2. Remove the spacer(s) from the castor fork assembly.

Note number and location for reassembly (Fig.

0203).

Castor Wheel Service

1. Remove the 2 thrust washers from the castor fork

(Fig. 0205).

3

Fig 0203

PICT-1318

3. Raise the carrier frame assembly and slide the castor fork assembly out of the carrier frame (Fig.

0204).

Fig 0205

PICT-1321a

2. Remove the nut from the axle bolt securing the castor wheel to the fork (Fig. 0206).

Fig 0204

PICT-1319

Fig 0206

PICT-1322


3. Remove the axle bolt (Fig. 0207).

CHASSIS

5. Remove one of the bushings from the wheel assembly (Fig. 0209).

Fig 0207

PICT-1323

Fig 0209

PICT-5516a

4. Remove the spacer from the wheel assembly (Fig.

0208).

6. Remove the needle bearing from the wheel assembly (Fig. 0210).

3

Fig 0208

PICT-5514a

Fig 0210

PICT-5517


CHASSIS

7. Remove the second bushing from the wheel assembly (Fig. 0211).

9. Thoroughly clean the wheel and tire assembly.

Inspect the wheel and bearings for damage and replace as necessary.

10. Install a bushing into one side of the wheel (Fig.

0213).

3

Fig 0211

PICT-5519a

8. Remove the grease zerk from the wheel assembly

(Fig. 0212).

Fig 0213

PICT-5678

11. Apply grease to the needle bearing (Fig. 0214).

Fig 0212

PICT-5523a

Fig 0214

PICT-5684a


12. Install the greased needle bearing into the wheel

(Fig. 0215).

CHASSIS

14. Install the spacer into the wheel (Fig. 0217).

Fig 0215

PICT-5685a

13. Install a second bushing into the other side of the wheel (Fig. 0216).

Fig 0217

PICT-5694a

15. Install the grease zerk into the wheel assembly (Fig.

0218).

3

Fig 0216

PICT-5688a

Fig 0218

PICT-5696a


CHASSIS

16. Fill the wheel assembly with grease until it begins to fl ow out of the bearings (Fig. 0219).

18. Install the wheel axle bolt (Fig. 0221).

3

Fig 0219

PICT-1326a

Fig 0221

PICT-5702a

17. Position the wheel and tire assembly in the fork (Fig.

0220).

19. Install and tighten the lock washer and nut to secure the wheel to the fork (Fig. 0222).

Fig 0220

PICT-5700a

Fig 0222

PICT-5704a


CHASSIS

20. Slide 2 thrust washers onto the castor fork shaft (Fig.

0223).

2. Slide the spacer(s) onto the castor fork shaft (Fig.

0225).

Fig 0223

PICT-1321a

Fig 0225

PICT-1318

Castor Wheel Installation

1. Raise the carrier frame assembly and slide the castor assembly into the carrier frame (Fig. 0224).

3. Install the locking pin into the castor fork assembly

(Fig. 0226).

3

Fig 0224

PICT-1319

Fig 0226

PICT-1316


CHASSIS

Castor Wheel Fork Bushing

Replacement

The following procedures are the same for replacing both the right hand and left hand castor wheel fork bushings.

4. Remove the spacer(s) from the top of the caster wheel fork (Fig. 0228).

Castor Wheel Fork Bushing Removal

3


2. Raise the carrier frame assembly so the caster wheels are off the fl oor and support the front of the mower with jack stands.

3. Remove the locking pin from the top of the caster fork (Fig. 0227).

Fig 0228

PICT-1317

5. Slide the caster wheel fork assembly out of the mounting tube. Leave the spacer(s) on the bottom of the fork (Fig. 0229).

Note: Note the location and number of the spacers on each fork to ensure correct installation, and maintain a level deck.

Fig 0227

PICT-1316

Fig 0229

PICT-1319


CHASSIS

6. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 0230).

2. Inspect the caster wheel fork for wear and replace if necessary.

3. Slide the caster wheel fork through the bushings in the mounting tube (Fig. 0232).

Note: The inside diameter of the bushings may collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126” (29mm).

3

Fig 0230

PICT-1331a

7. Clean the inside of the mounting tube.

Castor Wheel Fork Bushing Installation

1. Grease the inside and outside of the new bushings.

Use a hammer and fl at plate to carefully drive the bushings into the pivot tubes (Fig. 0231).

Fig 0232

PICT-1319

4. Slide the spacer(s) onto the fork (Fig. 0233).

Fig 0231

PICT-1333a


Fig 0233

PICT-1317

3-61

CHASSIS

3

5. Secure the fork to the carrier frame with the locking pin (Fig. 0234).

Fuel Tank Replacement

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.

• Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay away from an open fl ame or where a spark may ignite the gasoline fumes.

Fig 0234

PICT-1316 using No. 2 general purpose lithium base or molybdenum base grease (Fig. 0235).

Fuel Tank Removal

This procedure was done on a hydro model. The same procedure can be followed for gear drive models.

Note: The hydraulic fl uid tank has been removed for photo purposes.


2. Turn the engine off and remove the key.


Fig 0235

PICT-1335


CHASSIS


6. Slide the hose clamp off the fuel line at the fuel pump (Fig. 0238).

Fig 0236

PICT-0509

5. Turn the fuel valve to the “Off” position (Fig. 0237).

Fig 0238

PICT-0513

7. Remove the fuel line from the fuel pump. Place the end of the fuel line in a suitable container (Fig.

0239).

3

Fig 0237

PICT-0512

Fig 0239

PICT-0514


CHASSIS

8. Turn the fuel valve to the “On” position to allow the fuel to drain (Fig. 0240).

10. Remove the fuel line from the fuel tank bulkhead fi tting, pulling it through the rubber grommet (Fig.

0242).

3

Fig 0240

PICT-0515

Fig 0242

PICT-0518

9. Slide the clamp securing the fuel line to the fuel tank bulkhead fi tting up toward the fi tting and off the hose

(Fig. 0241).

11. Remove the clamp from the fuel tank bulkhead fi tting

(Fig. 0243).

Fig 0241

PICT-0516

Fig 0243

PICT-0520


CHASSIS

12. Remove the 2 nuts, springs and washers from the threaded studs securing the left side of the fuel tank bottom (Fig. 0244).

14. Lift the fuel tank assembly up and out of the frame.

Take care as the tank fi tting comes out through the hole in the frame with the tank (Fig. 0246).

Fig 0244

PICT-0528a

Fig 0246

PICT-0533

13. Remove the 2 bolts, lock washers and washers securing the right side of the fuel tank bottom (Fig.

0245).

15. Loosen and remove the nut and washer securing the bulkhead fi tting to the bottom of the fuel tank (Fig.

0247).

3

Fig 245

PICT-0531

Fig 0247

PICT-5353


CHASSIS

16. Remove the fuel cap assembly from the fuel tank

(Fig. 0248).

18. Inspect the fi lter screen on the bulkhead fuel fi tting.

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 tting area of the tank, the seal on the fi tting has been compromised and the whole fi tting must be replaced.

3

Fig 0248

PICT-5355

17. Remove the bulkhead fuel fi tting from the tank through the fuel cap opening (Fig. 0249).

Note: A fl exible magnet tool is used to aid in removal.

Fig 0250

PICT-5360b

19. Using a needle nose vise grip, clamp the threaded stud up near where the stud threads into the tank and remove the stud from the recessed fuel tank nut.

Repeat for second threaded stud (Fig. 0251).

3-66

Fig 0249

PICT-5356

Fig 0251

PICT-0535a


CHASSIS

Fuel Tank Installation

This procedure was done on a hydro model. The same procedure can be followed for gear drive models.

1. Apply thread locking compound to the fuel tank mounting studs (Fig. 0252).

3. Install the bulkhead fuel fi tting into the tank through the fuel cap opening (Fig. 0254).

Note: The fi tting should be installed so that the barb of the fi tting points toward the front of the fuel tank.

Note: A fl exible magnet tool used to aid installation.

3

Fig 0252

PICT-0538a

Fig 0254

PICT-5356

2. Install the threaded studs into the left side fuel tank mounting locations. Leave 1-1/8” (28.5mm) of thread protruding from the tank (Fig. 0253).

4. Install a washer and nut onto the bulkhead fi tting

(Fig. 0255).

Fig 0253

PICT-0545


Fig 0255

PICT-5363

3-67

CHASSIS

5. Tighten the nut to secure the fi tting to the fuel tank

(Fig. 0256).

7. Apply anti-seize compound to both of the bolts used to secure the right side of the fuel tank to the frame

(Fig. 0258).

3

Fig 0256

PICT-5353

Fig 0258

PICT-0534a

6. Position the fuel tank onto the frame taking care to feed the bulkhead fuel fi tting through the hole in the frame (Fig. 0257).

8. Secure the fuel tank to the frame by installing the bolts, washers, springs and nuts as shown. Install the bolts and washers securing the right side of the fuel tank fi rst. Do not over tighten the right side mounting bolts (Fig. 0259).

Note: The springs on the left side should not be fully compressed.

3-68

Fig 0257

PICT-0533

A. Left side of tank

Fig 0259

PICT-5374a

B. Right side of tank


CHASSIS

9. Slide the hose clamp onto the bulkhead fi tting barb

(Fig. 0260).

11. Slide the clamp onto the fuel line securing the fuel line to the fuel tank bulkhead fi tting (Fig. 0262).

Fig 0260

PICT-0520

Fig 0262

PICT-0516

10. Slide the fuel line through the rubber grommet and onto the fuel tank bulkhead fi tting (Fig. 0261).

12. Slide the fuel line onto the fuel pump (Fig. 0263).

3

Fig 0261

PICT-0518

Fig 0263

PICT-0567


CHASSIS

13. Slide the hose clamp up to secure the fuel line to the fuel pump (Fig. 0264).

15. Check for leaks.

16. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot

(Fig. 0266).

3

Fig 0264

PICT-0513

14. Fill the fuel tank with fuel and ensure the fuel valve is open (On) (Fig. 0265).

Fig 0266

PICT-0509

Battery Tray Replacement

Battery Tray Removal


2. Turn the fuel valve to the off position (Fig. 0267).

Fig 0265

PICT-0515

Fig 0267

PICT-0247a


CHASSIS

3. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery terminal (Fig. 0268).

5. Remove 1 of the 2 nuts retaining the battery hold down strap and battery hold downs to the battery tray (Fig. 0270).

Fig 0268

PICT-0250

Fig 0270

PICT-0254

4. Move the positive battery terminal boot and disconnect the positive (red) battery cable from the battery terminal (Fig. 0269).

6. Remove the battery hold down plate and 2 battery hold downs from the battery tray (Fig. 0271).

3

Fig 0269

PICT-0252

Fig 0271

PICT-0256


CHASSIS

7. Remove the battery from the battery tray (Fig. 0272).

9. Remove the battery tray from the frame (Fig. 0274).

3

Fig 0272

PICT-0571

Fig 0274

PICT-1298

8. Remove the two bolts, and nuts securing the battery tray to the frame (Fig. 0273).

Battery Tray Installation

1. Place the anti-skid pad onto the battery tray (Fig.

0275).

Fig 0273

PICT-0572

Fig 0275

PICT-1299


CHASSIS

2. Align the battery tray mounting holes to the mounting holes in the frame (Fig. 0276).

4. Place the battery onto the battery tray (Fig. 0278).

Fig 0278

PICT-0571

Fig 0276

PICT-1298

3. Install two bolts and nuts securing the battery tray to the frame (Fig. 0277).

5. Install the battery hold down plate and 2 battery hold downs to the battery tray (Fig. 0279).

3

Fig 0277

PICT-0572

Fig 0279

PICT-0372a


CHASSIS

6. Connect the positive (red) battery cable to the positive battery terminal and cover the connection with the boot (Fig. 0280).

Mid-Size Weight Replacement

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. 0282 or Fig. 0283).

3

Fig 0280

PICT-0252

A B C D

7. Connect the negative (black) battery cable to the negative battery terminal and cover the connection with the boot (Fig. 0281).

Fig 0282

Installing the front weight.

A. Bolt

B. Washer

C. Weight

D. Nut fi g. 18 G005021

3-74

Fig 0281

PICT-0250

A B C D

Installing the rear weight.

A. Nut

B. Weight

Fig 0283

C. Washer

D. Bolt fi g. 19 G005022


CHASSIS

The following table indicates the position of the weight as installed at the factory.

Checking the Brake (T-Bar)

Mower Deck

Size

36”

40”

48”

52”

Number of weights install

1

1 none

1

Position of the weight

Front

Front none

Rear

• Any rear weight must be removed when a Tru–Track®

Sulky is installed.

• When a Tru–Track® Sulky is installed front weights are needed. Refer to Sulky operator manual.


2. Disengage the Power Take Off (PTO) (Fig. 0284).

3

!

The front end of the machine can rapidly rise up when the mower is removed. This could cause serious injury to you or bystanders.

Support the rear of the machine when removing the mower from the carrier frame.

Fig 0284

PICT-4834a

3. Set the parking brake (Fig. 0285).


Fig 0285

PICT-4840a

3-75

CHASSIS

3

4. The rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels do not lock. Refer to “Adjusting the Brake”, following.

5. Release the parking brake (Fig. 0286).

7. The wheels should rotate freely.

8. If the above conditions are met, no adjustment is required. If adjustments are required, see “Adjusting the Brake”, following.

Adjusting the Brake (T-Bar)

1. Check the brake before you adjust it. Refer to

“Checking the Brake”, preceding.

2. Set the park brake latch (Fig. 0288).

Fig 0286

PICT-4844a

6. Move the upper control bar forward, approximately

1/2” (13mm) (Fig. 0287).

Fig 0288

PICT-4840a

3-76

Fig 0287

PICT-4848a


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 reference bar when properly adjusted.

CHASSIS

3

Fig 0289

PICT-4853a

4. Check the brake operation again. Refer to “Checking the Brake” preceding.

Important:

With the parking brake released, the rear wheels must rotate freely when you push the mower.

If brake action and free wheel rotation cannot be achieved, examine the brake system components for wear or damage.


CHASSIS

3



Control Linkage Replacement (T-2)

LINKAGE

3. Remove the control panel cover/manual tube assembly to the control panel (Fig. 0292).

Fig 0290

fi g. 3 G006080

Fig 0292

PICT-1923

4

Control Linkage Removal


2. Remove 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel

(Fig. 0291).

4. Remove the hairpin cotter from the upper end of the control linkage rod (Fig. 0293).

Fig 0291

PICT-1921


Fig 0293

PICT-1947

4-1

LINKAGE

5. Remove the washer from the upper end of the control linkage rod (Fig. 0294).

7. Remove the hairpin cotter from the lower end of the control linkage rod (Fig. 0296).

4

Fig 0294

PICT-1950

6. Remove the upper end of the control rod from the tab on the control handle (Fig. 0295).

Fig 0296

PICT-2009

8. Remove the washer from the lower end of the control linkage rod (Fig. 0297).

Fig 0295

PICT-1951

Fig 0297

PICT-2007a


LINKAGE

9. Remove the lower end of the control linkage rod from the pump adapter bracket. Remove the linkage rod from the machine (Fig. 0298).

11. Remove the upper control rod from the turnbuckle

(Fig. 0300).

Fig 0298

PICT-2005

10. Loosen the upper control rod wingnut (left hand threads) (Fig. 0299).

Fig 0300

PICT-1964a

12. Remove the wingnut from the upper control rod (left hand threads) (Fig. 0301).

4

Fig 0299

PICT-1963a

Fig 0301

PICT-1965a


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

4

14. Remove the lower control rod from the turnbuckle

(Fig. 0303).

Fig 0304

PICT-1968a

16. Remove the 2 bolts and nuts securing the pump adapter bracket to the pump linkage (Fig. 0305).

Fig 0303

PICT-1967a

Fig 0305

PICT-1983


17. Remove the pump adapter bracket (Fig. 0306).

LINKAGE

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 adapter bracket (Fig. 0307).

Fig 0308

PICT-1993a

2. Loosely install the jam nut onto the adjusting screw

(Fig. 0309).

4

Fig 0307

PICT-1996a

Fig 0309

PICT-1996a


LINKAGE

3. Position the pump adapter bracket to the pump linkage (Fig. 0310).

The distance between the face of the neutral proximity switch and the end of the hex head screw should be .07” + .02” (1.8 + .5mm) (Fig. 0312).

4

Fig 0310

PICT-1989

Fig 0312

PICT-1943

A. .07” .02” (1.8 + .5mm)

4. Install 2 bolts and nuts securing the pump adapter bracket to the pump linkage (Fig. 0311).

5. If adjustment is needed, refer to loosen the jam nut, adjust the hex head screw until proper distance is achieved and then tighten the jam nut to secure.

Control Linkage Assembly (Fig. 0313):

4-6

Fig 0311

PICT-1983

A B C D E

A. Lower control rod

B. Wingnut

C. Turnbuckle

Fig 0313

PICT-1969a

D. Wingnut


LINKAGE

6. Thread a wingnut onto the lower control rod and upper control rod so that there is approximately 1/2”

(12.7mm) of thread on the wing side of the wingnut

(Fig. 0314).

8. Loosely install the upper control rod into the turnbuckle (Fig. 0316).

Fig 0314

PICT-2000a

Fig 0316

PICT-1964a

4

9. Position the linkage rod inside the frame and insert the lower end of the control linkage rod into the pump adapter bracket (Fig. 0317).

7. Loosely install the lower control rod into the turnbuckle (Fig. 0315).

Fig 0315

PICT-1967a

Fig 0317

PICT-2005


LINKAGE

10. Slide a washer onto the lower end of the control linkage rod (Fig. 0318).

12. Install the upper end of the control rod into the tab on the control handle (Fig. 0320).

4

Fig 0318

PICT-2007a

Fig 0320

PICT-1951

11. Install a hairpin cotter into the lower end of the control linkage rod securing it to the pump adapter bracket (Fig. 0319).

13. Slide a washer onto the upper end of the control linkage rod (Fig. 0321).

Fig 0319

PICT-2009

Fig 0321

PICT-1950


LINKAGE

14. Install a hairpin cotter into the upper end of the control linkage rod securing it to the control handle

(Fig. 0322).

16. Tighten the wingnuts to secure the control rod turnbuckle (Fig. 0324).

Fig 0322

PICT-1947

Fig 0324

PICT-2020

15. Position the right control handle into the neutral lock position. If adjustment is needed, rotate the right control rod turnbuckle (Fig. 0323).

17. Position the control panel cover/manual tube assembly to the control panel (Fig. 0325).

4

Fig 0323

PICT-2015a

Fig 0325

PICT-1923


LINKAGE

18. Install 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig.

0326).

Control Linkage & Thumb Latch Removal


2. Remove the e-clip from the back side of the trunnion on the lower end of the control rod (Fig. 0328).

4

Fig 0326

PICT-1921

Control Linkage & Thumb Latch

Replacement (Pistol Grip Hydro)

The following procedures are the same for both the right side and left side handle bars.

Fig 0328

PICT-0687

3. Slide the trunnion out of the idler arm (Fig. 0329).

4-10

Fig 0327

fi g. 10 G004912

Fig 0329

PICT-0690


LINKAGE

4. Remove the hairpin cotter from the clevis pin retaining the upper end of the control linkage to the drive lever assembly (Fig. 0330).

6. Remove the nut from the bolt securing the thumb latch assembly to the handle bar (Fig. 0332).

Fig 0330

PICT-0691

Fig 0332

PICT-0694

5. Remove the clevis pin and control linkage rod from the drive lever assembly (Fig. 0331).

7. Remove the bolt, spacer, washers and the thumb latch assembly from the handle bar (Fig. 0333).

4

Fig 0331

PICT-0692

Fig 0333

PICT-0696


LINKAGE

8. Remove the bolt, and washer from the thumb latch

(Fig. 0334):

10. Remove the bolt securing the drive lever assembly to the handle bar (Fig. 0336).

A B B B

D

C

4

Fig 0334

PICT-0697a

A.

B. Belleville washer (3) D. Flat washer

Fig 0336

PICT-0700

11. Remove the drive lever bushing from the drive lever handle (Fig. 0337).

9. Remove the nut securing the drive lever assembly to the handle bar (Fig. 0335).

Fig 0335

PICT-0699

Fig 0337

PICT-0701


12. Remove the bushing sleeves from the drive lever handle (Fig. 0338).

LINKAGE

2. Install the drive lever bushing into the drive lever handle (Fig. 0340).

Fig 0338

PICT-0702a

Fig 0340

PICT-0701

4

Control Linkage & Thumb Latch Installation

1. Install the bushing sleeves into the drive lever handle (Fig. 0339).

3. Assemble the drive lever assembly to the handle bar with a bolt (Fig. 0341).

Fig 0339

PICT-0703a

Fig 0341

PICT-0700


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

4

5. Assemble the thumb latch, bolt, and washers as shown.

Note: The Belleville washers should be assembled onto the bolt in an alternating fashion (i.e. crown out, crown in, crown out) (Fig. 0343).

Fig 0344

PICT-0696

7. Install a nut onto the bolt securing the thumb latch assembly to the handle bar (Fig. 0345).

Note: When tightening the nut, do not over-tighten.

The thumb latch must move freely, without rattling.

A B B B

D

C

Fig 0343

PICT-0697a

A.

B. Belleville washer (3) D. Flat washer

4-14

Fig 0345

PICT-0694


LINKAGE

8. Slide the trunnion on the lower end of the control rod into the idler arm (Fig. 0346).

10. Adjust the control rod so that 2.125” (6.65cm) of thread extends past the trunnion (Fig. 0348).

Fig 0346

PICT-0690

A. 2.125” (6.65cm)

9. Install an e-clip onto the trunnion to secure the control rod to the idler arm (Fig. 0347).

Fig 0348

PICT-0704

11. Move the speed control lever to the fast position

(Fig. 0349).

4

Fig 0347

PICT-0687

Fig 0349

PICT-0711a


LINKAGE

12. Assemble the upper end of the control rod to the drive lever assembly by inserting a clevis pin (Fig.

0350).

14. Install a hairpin cotter into the clevis pin to secure the control rod to the thumb latch assembly (Fig.

0352).

4

Fig 0350

PICT-0714

Fig 0352

PICT-0691

13. Adjust the control rod so there is a .19” to .25” (.48 to

.64cm) space between the control rod clevis pin and the bottom of the thumb latch slot (Fig. 0351).

15. Start the machine and operate the controls to ensure proper operation. Adjust as necessary.

Fig 0351

PICT-0715


LINKAGE

Lower Control Replacement (T-Bar)

The following procedures are the same for both the right hand and left hand lower control replacement.

3. Remove the washer from the lower end of the control rod (Fig. 0355).

Fig 0353

fi g. 7 G004812

Fig 0355

PICT-1752

4

4. Remove the trunnion/clevis from the idler arm (Fig.

0356).

Lower Control Removal


2. Remove the hairpin cotter from the lower end of the control rod (Fig. 0354).

Fig 0354

PICT-1750a


Fig 0356

PICT-1753

4-17

LINKAGE

5. Remove the hairpin cotter from the lower end of the brake rod (Fig. 0357).

7. Remove the nut from the idler pivot bolt (Fig. 0359).

Fig 0359

PICT-1758

4

Fig 0357

PICT-1756

6. Remove the brake rod from the brake arm assembly

(Fig. 0358).

8. Remove the idler pivot bolt (Fig. 0360).

Fig 0358

PICT-1757

Fig 0360

PICT-1759


LINKAGE

9. Lift the idler/brake rod assembly out of the machine

(Fig. 0361).

11. Remove the 2 spacers from the idler arm pivot (Fig.

0363).

Fig 0361

PICT-1763

10. Remove the spring from the idler arm (Fig. 0362).

Fig 0363

PICT-1765

4

12. Remove the hairpin cotter from the brake rod trunnion (Fig. 0364).

Fig 0362

PICT-1764

Fig 0364

PICT-1768


LINKAGE

13. Remove the washer from the brake rod trunnion

(Fig. 0365).

15. Remove the wing nut from the brake rod assembly

(Fig. 0367).

4

Fig 0365

PICT-1769

14. Remove the brake rod assembly from the idler assembly (Fig. 0366).

Fig 0367

PICT-1772a

16. Remove the washer from the brake rod assembly

(Fig. 0368).

Fig 0366

PICT-1771

Fig 0368

PICT-1773a


LINKAGE

17. Remove the trunnion from the brake rod assembly

(Fig. 0369).

19. Remove the nut from the bolt securing the pulley to the idler arm (Fig. 0371).

Fig 0369

PICT-1774a

Fig 0371

PICT-1776a

4

20. Slide the pulley off the bolt (Fig. 0372).

18. Remove the bushing from the trunnion (Fig. 0370).

Fig 0370

PICT-1775

Fig 0372

PICT-1778


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

4

22. Remove the bolt from the idler (Fig. 0374).

Fig 0375

PICT-1781

2. Slide the pulley spacer onto the pulley bolt (Fig.

0376).

Fig 0374

PICT-1781

Fig 0376

PICT-1780a


LINKAGE

3. Slide the pulley onto the pulley bolt and spacer (Fig.

0377).

5. Slide a bushing into the trunnion (Fig. 0379).

Fig 0377

PICT-1778

Fig 0379

PICT-1775

4

6. Slide the trunnion onto the brake rod assembly (Fig.

0380).

4. Install a nut onto the pulley bolt securing the pulley to the idler arm (Fig. 0378).

Fig 0378

PICT-1776a

Fig 0380

PICT-1774a


LINKAGE

7. Slide a washer onto the brake rod assembly (Fig.

0381).

9. Insert the brake rod trunnion into the idler assembly

(Fig. 0383).

4

Fig 0381

PICT-1773a

Fig 0383

PICT-1771

8. Install a wing nut 2-1/2” (6.35cm) onto the brake rod assembly (Fig. 0382).

10. Slide a washer onto the brake rod trunnion (Fig.

0384).

Fig 0382

PICT-1772a

Fig 0384

PICT-1769


11. Install a hairpin cotter into the brake rod trunnion

(Fig. 0385).

LINKAGE

13. Install 2 spacers into the idler arm pivot (Fig. 0387).

Fig 0385

PICT-1768

Fig 0387

PICT-1765

4

14. Install the torsion spring onto the idler arm (Fig.

0388).

12. Apply anti-seize compound onto the outside diameter of the 2 idler pivot spacers (Fig. 0386).

Fig 0386

PICT-1784a

Fig 0388

PICT-1764


LINKAGE

15. Position the idler/brake rod assembly onto the machine so the torsion spring is hooked onto the frame. (Fig. 0389).

17. Install a nut onto the idler pivot bolt (Fig. 0391).

Fig 0391

PICT-1758

4

Fig 0389

PICT-1783

16. Align the idler pivot with the mounting hole on the frame and insert the idler pivot bolt (Fig. 0390).

18. Insert the lower end of the brake rod into the brake arm assembly (Fig. 0392).

Fig 0390

PICT-1759

Fig 0392

PICT-1757


LINKAGE

19. Install a hairpin cotter into the lower end of the brake rod securing it to the brake arm (Fig. 0393).

21. Slide a washer onto the control rod trunnion (Fig,

0395).

Fig 0393

PICT-1756

20. Insert the control rod trunnion/clevis into the idler arm (Fig. 0394).

Fig 0395

PICT-1752

4

22. Install a hairpin cotter into the trunnion securing the control rod to the idler (Fig. 0396).

Fig 0394

PICT-1753

Fig 0396

PICT-1750a

23. Check the Brakes. Refer to “Checking the Brake

(T-Bar)” on page 3-75.

24. Check the Adjustment of the Control Bar. Refer to

“Control Bar Adjustment” on page 4-132.


LINKAGE

Neutral Adjustment Stud


Note: The side plate has been removed for photo purposes.

2. Remove the clevis pin (Fig. 0399).

Fig 0399

PICT-0924

4

Fig 0397

fi g. 10 G004912

3. Remove the nut from the top end of the adjustment stud (Fig. 0400).

Neutral Adjustment Stud Removal

1. Remove the cotterpin from the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0398).

Fig 0400

PICT-0925

4-28

Fig 0398

PICT-0923


LINKAGE

4. Remove the washer and spring from the adjustment stud (Fig. 0401).

6. Remove the neutral adjustment stud assembly out of the spring mount bracket (Fig. 0403).

Fig 0401

PICT-0926a

Fig 0403

PICT-0928

4

7. Remove the 2 bolts and nuts securing the spring mount bracket to the frame (Fig. 0404).

mount bracket (Fig. 0402).

Fig 0402

PICT-0927

Fig 0404

PICT-0931


LINKAGE

8. Remove the spring mount bracket from the frame

(Fig. 0405).

10. Loosen the jam nut that secures the yoke to the neutral adjustment stud (Fig. 0407).

4

Fig 0405

PICT-0932

9. Remove the washer from the neutral adjustment stud (Fig. 0406).

Fig 0407

PICT-0936a

11. Remove the neural adjustment stud yoke (Fig.

0408).

Fig 0406

PICT-0934a

Fig 0408

PICT-0937a


12. Remove the nut from the neural adjustment stud

(Fig. 0409).

LINKAGE

Neutral Adjustment Stud Installation

1. Position the spring mount bracket to the frame (Fig.

0411).

Fig 0409

PICT-0939a

Fig 0411

PICT-0932

4

Neutral Adjustment Stud Assembly (Fig. 0410):

E

A

C

B

D

G

A

H

F

I

J

K

L

2. Install 2 bolts and nuts securing the spring mount bracket to the frame (Fig. 0412).

Fig 0410

PICT-0942a

A. Lock nut (3)

B. Flat washer

G. Flat washer

H. Adjustment stud

C. Neutral return spring I. Hex nut

D. Nylon bushing J. Adjustable yoke

E. Spring mount bracket K. Clevis pin

F. Carriage bolt (2) L. Hairpin cotter

Fig 0412

PICT-0931


LINKAGE

3. Install a jam nut onto the threads so that there is approximately 1/4” (6.4mm) space between the jam nut and the machined nut on the neutral stud (Fig.

0413).

5. Snug the jam nut against the yoke (Fig. 0415).

Fig 0415

PICT-1002a

4

Fig 0413

PICT-0998a

6. Slide the washer onto the end of the neutral adjustment stud opposite the yoke (Fig. 0416).

4. Thread the yoke onto the neural adjustment stud so that the end of the stud is fl ush with the opening of the yoke (Fig. 0414).

Fig 0414

PICT-1000a

Fig 0416

PICT-1003a


LINKAGE

7. Insert the neutral adjustment stud assembly into the spring mount bracket (Fig. 0417).

9. Position the yoke to the short tab on the drive lever swivel and insert a clevis pin (Fig. 0419).

Fig 0417

PICT-1005

Fig 0419

PICT-1007

4

10. Secure the yoke to the drive lever swivel by installing a cotter pin into the clevis pin (Fig. 0420).

mount bracket (Fig. 0418).

Fig 0418

PICT-1006a

Fig 0420

PICT-1008


LINKAGE

11. Install the spring onto the adjustment stud (Fig.

0421).

13. Install a nut onto the top end of the adjustment stud. Tighten the nut until there are approximately 5 threads protruding past the nut (Fig. 0423).

4

Fig 0421

PICT-1009

12. Install a washer onto the adjustment stud (Fig.

0422).

Fig 0423

PICT-1012a

14. Adjust the Neutral Stud. Refer to “Neutral Stud

Adjustment” on page 4-126.

Fig 0422

PICT-1011a


LINKAGE

Operator Presence Control Lever


Note: The manual tube assembly and control panel cover have been removed for photo purposes.

2. Remove the left operator presence control lever from the operator presence control rod (Fig. 0426).

Fig 0426

PICT-0724

4

Fig 0424

fi g. 10 G004912

3. Remove the nylon bushing from the left side of the

OPC rod (Fig. 0427).

Operator Presence Control Lever Removal

1. Loosen and remove the set screw that retains the left side Operator Presence Control (OPC) lever to the operator presence control rod (Fig. 0425).

Fig 0425

PICT-0722


Fig 0427

PICT-0726

4-35

LINKAGE

4. Repeat steps 1 thru 3 to remove the right side OPC lever.

5. Remove the extension spring located under the control panel (Fig. 0428).

7. Remove the PTO switch from the control panel (Fig.

0430).

4

Fig 0430

PICT-0729a

Fig 0428

PICT-0727

8. Remove the OPC rod by sliding it to the far right, dropping the left side of the rod, and remove the rod through the left side (Fig. 0431).

6. Unplug the wire harness from the PTO switch (Fig.

0429).

Fig 0429

PICT-0728

Fig 0431

PICT-0731


LINKAGE

Operator Presence Control Lever

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. Sliding the rod further through the right side handle bar opening, install the left end of the rod through the left handle bar opening (Fig. 0432).

3. Plug the wire harness into the PTO switch (Fig.

0434).

Fig 0432

PICT-0736

2. Install the PTO switch into the control panel (Fig.

0433).

Fig 0434

PICT-0728

4

4. Install the extension spring onto the OPC rod and the tab on the underside of the control panel (Fig.

0435).

Fig 0433

PICT-0729a


Fig 0435

PICT-0727

4-37

LINKAGE

5. Install a nylon bushing onto each end of the OPC rod (Fig. 0436).

7. Install the OPC levers onto the ends of the OPC rod

(Fig. 0438).

4

Fig 0436

PICT-0726

Fig 0438

PICT-0724

6. Apply high strength thread locking compound (Loctite 680 or equivalent) onto both ends of the OPC rod (Fig. 0437).

8. Apply thread locking compound to the set screws

(Fig. 0439).

Fig 0437

PICT-0737

Fig 0439

PICT-0738a


LINKAGE

9. Install one set screw into each OPC lever to secure the levers onto the OPC rod (Fig. 0440).

Speed Control Removal

1. Remove the knob from the speed control lever (Fig.

0442).

Fig 0440

PICT-0722

Fig 0442

IMG_8001a

4

Speed Control Replacement

(Pistol Grip Hydro)

Note: The Operator’s Manual tube assembly and control panel cover bracket have been removed for photo purposes.

2. Remove the hairpin cotter from the upper end of the speed control rod (Fig. 0443).

Fig 0441

fi g. 10 G004912


Fig 0443

PICT-0743

4-39

LINKAGE

3. Remove the cotter pin from the lower end of the speed control rod (Fig. 0444).

5. Remove the nut from the pivoting sprung bolt (Fig.

0446).

4

Fig 0444

PICT-0747

Fig 0446

PICT-0751

4. Remove the washer and speed control rod assembly from the tab on the speed control crank assembly and remove it from the machine (Fig. 0445).

6. Remove the middle bolt and spring assembly securing the speed control handle to the control panel

(Fig. 0447).

Fig 0445

PICT-0750

Fig 0447

PICT-0754


LINKAGE

7. Remove the lower bolt and nut securing the speed control handle to the control panel (Fig. 0448).

9. Remove the speed control handle (Fig. 0450).

Fig 0448

PICT-0755a

Fig 0450

PICT-0757a

4

10. Remove the remaining nut, bolt, washers and spring from the speed control lever assembly (Fig. 0451).

8. Remove the upper bolt and nut (Fig. 0449).

Fig 0449

PICT-0861

Fig 0451

PICT-0760a


LINKAGE

Note: There are 2 washers between the shift lever and shift lever plate (Fig. 0452).

12. Remove the outside nut from both the left and right speed control link bolt assemblies (Fig. 0454).

4

Fig 0452

PICT-0763a

Fig 0454

PICT-0766

11. Release the pistol grip from neutral lock and place it in the drive position (Fig. 0453).

13. Remove the hairpin cotter from the right and left swivels installed through each end of the speed control crank (Fig. 0455).

Fig 0453

PICT-0764

Fig 0455

PICT-0770a


LINKAGE

14. Remove the washer from the right and left swivels installed through each end of the speed control crank (Fig. 0456).

16. Secure the speed control crank in place and loosen the 2 screws securing each end of it to the crank support assembly (Fig. 0458).

Fig 0458

PICT-0776a

4

Fig 0456

PICT-0771a

15. Remove the left hand and right hand speed control links and bolt assemblies (Fig. 0457).

17. Remove the speed control crank from the machine

(Fig. 0459).

Fig 0457

PICT-0772

Fig 0459

PICT-0777


LINKAGE

18. Remove the 2 lower bolts and nuts securing the crank support assembly to the frame (Fig. 0460).

20. Remove the crank support from the machine (Fig.

0462).

4

Fig 0460

PICT-0786

19. While supporting the crank support, remove the 2 upper bolts and nuts (Fig. 0461).

Fig 0462

PICT-0789

21. On the right hand and left hand speed control links and the speed control rod, mark the location of the nut/swivel assembly on the threads of the link (Fig.

0463).

4-44

Fig 0461

PICT-0787

Fig 0463

PICT-0784a

A. Left hand speed control link

B. Speed control rod

C. Right hand speed control link


LINKAGE

22. Loosen the jam nuts securing the trunnion in place on the threaded end of the speed control rod (Fig.

0464).

24. On the left hand speed control link, loosen the end nut (Fig. 0466).

Fig 0464

PICT-0793a

Fig 0466

PICT-0799a

23. Remove the 2 nuts and the trunnion from the speed control rod (Fig. 0465).

25. Remove the nuts, washers and the swivel from the left hand speed control link (Fig. 0467).

4

Fig 0465

PICT-0797a

Fig 0467

PICT-0800a


LINKAGE

26. Remove the two nuts and the bolt from the slotted end of both control links (Fig. 0468).

28. Remove the spacer, washers, swivel, spring and nut from the control link (Fig. 0470).

4

Fig 0468

PICT-0805a

Fig 0470

PICT-0810a

27. Remove the knob from the right side speed control link assembly (Fig. 0469).

Speed Control Installation

1. Position the crank support to the rear of the frame

(Fig. 0471).

Note: The choke cable should be routed on the outside of the crank support.

4-46

Fig 0469

PICT-0808a

Fig 0471

PICT-0813


2. While supporting the crank support, loosely install the 2 upper bolts and nuts securing the crank support and handle to the frame (Fig. 0472).

Note: The bolts are installed with the nuts on the outside of the frame.

LINKAGE

4. Tighten the 4 nuts and bolts securing the crank support to the frame.

5. Apply thread locking compound to the threads of the

2 shoulder bolts that secure the speed control crank to the crank support (Fig. 0474).

Fig 0472

PICT-0787

Fig 0474

PICT-0815a

3. Install the 2 lower bolts and nuts securing the crank support assembly to the frame (Fig. 0473).

Note: The bolts are installed with the nuts on the inside of the frame.

6. Position the speed control crank to the crank support

(Fig. 0475).

Note: The choke cable is positioned between the speed control crank and the crank support.

4

Fig 0473

PICT-0786


Fig 0475

PICT-0816

4-47

LINKAGE

7. Install 2 shoulder bolts securing the speed control crank to the crank support (Fig. 0476).

9. Install a spacer, 3 washers, a swivel, and a spring onto the control link (Fig. 0478).

4

Fig 0476

PICT-0818

Fig 0478

PICT-0886a

Right hand control link assembly:

8. Install one nut onto the control link, threading it down to the mark on the threads (Fig. 0477).

10. Install the knob onto the control link assembly (Fig.

0479).

Note: Tighten the knob until the spring measures

1.0” (2.5cm) in length.

Fig 0477

PICT-0822a

Fig 0479

PICT-0887a


LINKAGE

11. Install the bolt into the slot of the control link.

Note: The slotted portion of the control link is offset and the bolt needs to be oriented as shown

(Fig. 0480):

Left Hand control link Assembly:

13. Install the bolt into the slot of the control link.

Note: The slotted portion of the control link is offset and the bolt needs to be oriented as shown

(Fig. 0482):

Fig 0480

PICT-6411a

Fig 0482

PICT-6411a

12. Install two nuts onto the bolt (fl ange side away from control link) so that there is 1/2” (1.27cm) of thread beyond the two nuts as shown (Fig. 0481):

14. Install two nuts onto the bolt (fl ange side away from control link) so that there is 1/2” (1.27cm) of thread beyond the two nuts as shown (Fig. 0483):

4

Fig 0481

PICT-6414b


Fig 0483

PICT-6414b

4-49

LINKAGE

15. Install one nut onto the control link, threading it down to the mark (Fig. 0484).

17. Thread the second nut onto the control link. Snug 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.

4

Fig 0484

PICT-0822a

16. Install 2 washers and the swivel onto the control link

(Fig. 0485).

Fig 0486

PICT-0831a

18. Position the right hand speed control link into the right side linkage and insert the speed control link bolt into the upper tab of the drive lever swivel (Fig.

0487).

4-50

Fig 0485

PICT-0830a

Fig 0487

PICT-0833


LINKAGE

19. Install a nut onto the bolt securing the lower end of the speed control link to the drive lever swivel (Fig.

0488).

21. Slide a washer onto the trunnion and install a cotter pin securing the speed control link to the speed control crank (Fig. 0490).

Fig 0490

PICT-0893

4

Fig 0488

PICT-0835

20. Install the speed control link trunnion into the right hand tab on the speed control crank (Fig. 0489).

22. Repeat steps 18 thru 21 to install the left hand speed control link and bolt assembly into the left hand drive lever swivel and left hand tab of the speed control crank.

23. Tighten the 2 nuts on either side of the swivel on the upper end of the left hand control link (Fig. 0491).

Fig 0489

PICT-0890


Fig 0491

PICT-0842

4-51

LINKAGE

24. Install a washer and a friction washer onto the shifter lever plate bolt (Fig. 0492).

26. Install a second friction washer onto the bolt (Fig.

0494).

4

Fig 0492

PICT-0843a

25. Insert the bolt/washer assembly into the slotted opening of the shifter lever plate (Fig. 0493).

Fig 0494

PICT-0846a

27. Position the shift lever onto the shifter lever plate

(Fig. 0495).

Fig 0493

PICT-0845a

Fig 0495

PICT-0848a


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

29. Install a lock nut onto the bolt (Fig. 0497).

Fig 0498

PICT-0852

30. Position a washer between the two plates and align the ID of the washer with the center hole in the lever plates (Fig. 0499).

4

Fig 0497

PICT-0850

Fig 0499

PICT-0854a


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

4

32. Loosely install the upper and lower bolts and nuts

(Fig. 0501).

Fig 0502

PICT-0868

Tighten the middle nut until approximately 3 threads stick out past the nut (Fig. 0503).

Note: Do not collapse the spring.

Fig 0501

PICT-0864

Fig 0503

PICT-0872a


34. Tighten the upper and lower bolts and nuts (Fig.

0504).

LINKAGE

36. Install the knob onto the speed control lever (Fig.

0506).

Fig 0504

PICT-0873

Fig 0506

IMG_8001a

4

35. Apply thread locking compound to the threads of the speed control lever (Fig. 0505).

Speed Control Rod Assembly:

37. Install a nut onto the speed control rod threads, threading it to the mark made previously (Fig. 0507).

Fig 0505

PICT-0875a

Fig 0507

PICT-0876a


LINKAGE

38. Slide a trunion onto the speed control rod and snug fi t a second nut against the trunnion (Fig. 0508).

40. Position the speed control rod trunnion into the tab on the speed control crank assembly (Fig. 0510).

4

Fig 0508

PICT-0878a

Fig 0510

PICT-0896

39. Position the speed control rod so that the upper end is installed in the forwardmost hole of the speed control lever. Install a hairpin cotter into the speed control rod securing it to the speed control lever (Fig.

0509).

41. Install a washer onto the trunnion and secure the trunnion with a cotter pin (Fig. 0511).

Fig 0509

PICT-0895

Fig 0511

PICT-0897


LINKAGE

42. Tighten the jam nuts securing the speed control rod trunnion in place (Fig. 0512).

Drive Lever Swivel & Bearing


Fig 0512

PICT-0898

Fig 0513

fi g. 10 G004912

4

43. Initially adjust the Neutral Stud. Refer to “Temporary

Neutral Stud Adjustment” on page 4-122.

44. Adjust the Speed Control Linkage. Refer to “Speed

Control Linkage Adjustment” on page 4-121.



Drive Lever Swivel & Bearing Removal


2. Remove the neutral return spring from the lower tab on the drive lever swivel (Fig. 0514).


Fig 0514

PICT-0900

4-57

LINKAGE

3. Remove the 3 nuts, bolts and spacers securing the side plate to the frame (Fig. 0515).

5. Remove the 2 bolts, nuts and washers securing the side fl ange bearing to the side plate (Fig. 0517).

4

Fig 0515

PICT-0901

4. Remove the side plate from the frame (Fig. 0516).

Fig 0517

PICT-0906a

6. Remove the side fl ange bearing from the side plate

(Fig. 0518).

Fig 0516

PICT-0903

Fig 0518

PICT-0907


7. Remove the e-clip from the trunnion on the lower end of the drive lever rod (Fig. 0519).

LINKAGE

9. Move the speed control lever to the full forward position. Remove the outside nut from the lower end of the speed control link assembly (Fig. 0521).

Fig 0519

PICT-0908

Fig 0521

PICT-0911

8. Remove the trunnion from the drive lever swivel on the lower end of the drive lever rod (Fig. 0520).

10. Remove the speed control link from the drive lever swivel. Move the control link out of the way of the drive lever swivel (Fig. 0522).

4

Fig 0520

PICT-0909

Fig 0522

PICT-0912


LINKAGE

11. Remove the hairpin cotter from the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0523).

13. Loosen the 2 set screws securing the drive lever swivel to the hydro pump shaft (Fig. 0525).

Note: There is an access hole located in the frame below the drive lever swivel.

4

Fig 0523

PICT-0914


Fig 0525

PICT-0916

14. Remove the drive lever swivel from the hydro pump shaft (Fig. 0526).

Fig 0524

PICT-0915

Fig 0526

PICT-0917


LINKAGE

15. Remove the spring stud from the drive lever swivel

(Fig. 0527).

Drive Lever Swivel & Bearing Installation

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. 0528).

2. Install the spring stud into the drive lever swivel (Fig.

0530).

4

Fig 0528

PICT-0920

Fig 0530

PICT-0918


LINKAGE

3. Position the drive lever swivel through the frame and onto the hydro pump shaft (Fig. 0531).

5. Install the 2 set screws securing the drive lever swivel to the hydro pump shaft (Fig. 0533).

Note: There is an access hole located in the frame below the drive lever swivel.

4

Fig 0531

PICT-0917

4. Apply thread locking compound to both drive lever swivel set screws (Fig. 0532).

Fig 0533

PICT-0916

6. Position the neutral adjustment stud yoke to the drive lever swivel and install a clevis pin (Fig. 0534).

Fig 0532

PICT-0922a

Fig 0534

PICT-0915


LINKAGE

7. Install a hairpin cotter into the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0535).

9. Install the outside nut onto the speed control link bolt assembly (Fig. 0537).

Fig 0535

PICT-0914

Fig 0537

PICT-0911

8. Insert the speed control link bolt into the drive lever swivel (Fig. 0536).

10. Insert the trunnion on the lower end of the drive lever rod into the drive lever swivel (Fig. 0538).

4

Fig 0536

PICT-0912

Fig 0538

PICT-0909


LINKAGE

11. Install an e-clip onto the trunnion on the lower end of the drive lever rod (Fig. 0539).

13. Install a fl at washer onto the 2 bolts used to secure the bearing to the side plate. Loosely install the bearing to the side plate with the 2 bolt assemblies and nuts (Fig. 0541).

4

Fig 0539

PICT-0908

12. Position the side fl ange bearing to the side plate

(Fig. 0540).

Fig 0541

PICT-1015

14. Position the side plate so the bearing is installed on the hydro control shaft (Fig. 0542).

Fig 0540

PICT-0907

Fig 0542

PICT-1016


LINKAGE

15. Insert a bolt through the side plate and slide a spacer onto the bolt. Loosely secure the bolt to the frame with a nut (Fig. 0543).

17. Tighten the nuts securing the side fl ange bearing in place on the side plate (Fig. 0545).

Fig 0543

PICT-1018

16. Repeat the above step with the other 2 bolt and spacer assemblies securing the side plate to the frame (Fig. 0544).

Fig 0545

PICT-1019

18. Install the spring onto the spring stud on the lower tab of the drive lever swivel (Fig. 0546).

4

Fig 0544

PICT-1019

Fig 0546

PICT-1020


LINKAGE

19. Apply grease to the side fl ange bearing (Fig. 0547).

Handle Assembly Replacement

(T-Bar)

4

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.

21. Initially adjust the Neutral Stud. Refer to “Temporary

Neutral Stud Adjustment” on page 4-122.

22. Adjust the left and right hydro control linkages. Refer to “Hydro Control Linkage Adjustment” on page

4-123.



24. Check the Control Rod. Refer to “Checking the

Control Rod” on page 4-128.

25. Adjust the tracking. Refer to “Tracking Adjustment” on page 4-129.

Handle Assembly Removal (T-Bar)


2. Disconnect the negative battery terminal from the battery.


LINKAGE

3. Open the locking tab on the front of the Operator

Presence Control (OPC) switch. Unplug the harness from the OPC (Fig. 0549).

5. While holding the lock down, draw the wire and spade terminal out of the connector (Fig. 0551).

Fig 0549

PICT-1670a

Fig 0551

PICT-1692

4. Depress the connector lock with a small fl at screwdriver (Fig. 0550).

6. Repeat steps 2 and 3 to remove the second terminal from the switch.

7. Pull the wire harness from the center tube in the

T-bar (Fig. 0552).

4

Fig 0550

PICT-1689

Fig 0552

PICT-1694a


LINKAGE

8. Remove the hairpin cotter from the lower end of the control rod (Fig. 0553).

10. Remove the trunnion/clevis from the idler arm (Fig.

0555).

4

Fig 0553

PICT-1672a

9. Remove the washer from the lower end of the control rod (Fig. 0554).

Fig 0555

PICT-1675

11. Remove the clevis pin from the trunnion (Fig. 0556).

Fig 0554

PICT-1673a

Fig 0556

PICT-1676a


12. Remove the trunnion from the control rod (Fig.

0557).

LINKAGE

14. Remove the control rod from the control bar/bail assembly (Fig. 0559).

Fig 0557

PICT-1678a

13. Remove the cotter pin from the upper end of the control rod (Fig. 0558).

Fig 0559

PICT-1682

4

15. Repeat steps 8 thru 14 to remove the opposite control rod.

16. Remove the bail from the handle assembly (Fig.

0560).

Fig 0558

PICT-1679a

Fig 0560

PICT-1698a


LINKAGE

17. Remove the nut from the bolt securing the T-Bar to the handle assembly (Fig. 0561).

19. Slide the T-Bar off the handle assembly (Fig. 0563).

Fig 0563

PICT-1704a

4

Fig 0561

PICT-1701

18. Remove the bolt and then remove the parking brake lever (Fig. 0562).

20. Depress the OPC switch tabs and remove the switch from the T-Bar (Fig. 0564).

Fig 0562

PICT-1703a

Fig 0564

PICT-1707


LINKAGE

21. Remove the 2 rubber grommets from the T-Bar (Fig.

0565).


Fig 0565

PICT-1708a

22. Remove the cotter pin from the clevis pin securing the control pivot assembly to the handle bar (Fig.

0566).

Fig 0567

PICT-1712

4

24. Repeat steps 20 and 21 to remove the cotter pin and clevis from the opposite side.

25. Remove the control pivot assembly from the handle assembly (Fig. 0568).

Fig 0566

PICT-1710

Fig 0568

PICT-1713a


LINKAGE

26. Remove the cable tie securing the throttle and choke cable to each side of the handle assembly (Fig.

0569).

28. Remove the 2 screws securing the bottom panel to the control panel. Remove the bottom panel (Fig.

0571).

4

Fig 0569

PICT-1716

Fig 0571

PICT-1719a

27. Remove the 2 screws securing the manual tube

R-clamps to the bottom of the control panel. Remove the manual tube assembly (Fig. 0570).

29. Remove the 4 bolts (2 on the left, 2 on the right) and nuts that secure the control panel to the handle (Fig.

0572).

Fig 0570

PICT-1718

Fig 0572

PICT-1720


LINKAGE

30. Lower the control panel from the handle (Fig. 0573).

32. Remove the handle (Fig. 0575).

Fig 0573

PICT-1722

31. Remove the 4 bolts and nuts (2 on the left, 2 on the right) securing the handle to the frame (Fig. 0574).

Note: Make note of handle height adjustment location.

Fig 0575

PICT-1728

4

Handle Assembly Installation (T-Bar)

1. Position the handle to the frame (Fig. 0576).

Fig 0574

PICT-1725

Fig 0576

PICT-1728


LINKAGE

2. Install 4 bolts and nuts (2 on the left, 2 on the right) securing the handle to the frame (Fig. 0577).

3. Raise the control panel assembly into place on the handle bar (Fig. 0579).

4

Fig 0577

PICT-1725

Fig 0579

PICT-1732

Note: Position the lower set of bolts as previously noted for proper handle height adjustment

(Fig. 0578).

4. Install 4 bolts and nuts (2 on the left, 2 on the right) securing the control panel to the handle (Fig. 0580).

Fig 0578

PICT-1731

Fig 0580

PICT-1720


LINKAGE

5. Position the bottom panel to the control panel and install 2 screws securing the back side of the bottom panel to the control panel (Fig. 0581).

7. Install a cable tie securing the throttle cable, and one securing the choke cable, to each side of the handle assembly. Trim the excess (Fig. 0583).

Fig 0583

PICT-1733

4

Fig 0581

PICT-1719a

6. Position the manual tube assembly to the control panel. Install 2 screws to secure the manual tube assembly R-clamps and bottom panel to the control panel (Fig. 0582).

8. Position the control pivot assembly into the handle assembly (Fig. 0584).

Fig 0582

PICT-1718

Fig 0584

PICT-1713a


LINKAGE

9. Insert a clevis pin into each side of the control pivot assembly securing it to the handle assembly (Fig.

0585).

11. Install 2 rubber grommets (1 on the left, 1 on the right) into the T-Bar mounting holes (Fig. 0587).

4

Fig 0585

PICT-1712

Fig 0587

PICT-1708a

10. Install a cotter pin into each of the clevis pins (Fig.

0586).

12. Install the OPC switch into the switch housing on the

T-Bar (Fig. 0588).

Fig 0586

PICT-1710

Fig 0588

PICT-1707


13. Slide the T-Bar onto the handle assembly (Fig.

0589).

LINKAGE

15. Install a nut onto the bolt securing the parking brake lever and T-Bar to the handle assembly (Fig. 0591).

Note: Tighten the bolt and nut enough so the parking brake lever does not rattle but still rotates freely.

Fig 0589

PICT-1704a

14. Position the parking brake lever to the T-Bar and insert a bolt (Fig. 0590).

Fig 0591

PICT-1701

16. Position the bail into the handle assembly (Fig.

0592).

4

Fig 0590

PICT-1703a


Fig 0592

PICT-1698a

4-77

LINKAGE

17. Insert the top end of the control rod into the control bar/bail assembly (Fig. 0593).

19. Install the trunnion onto the control rod approximately 2” (5cm) (Fig. 0595).

4

Fig 0593

PICT-1682

Fig 0595

PICT-1678a

18. Install a cotter pin into the upper end of the control rod, securing it to the control bar/bail assembly (Fig.

0594).

20. Insert a clevis pin into the trunnion (Fig. 0596).

Fig 0594

PICT-1736

Fig 0596

PICT-1676a


21. Insert the clevis pin into the idler arm (Fig. 0597).

LINKAGE

23. Install a hairpin cotter into the clevis pin (Fig. 0599).

Fig 0597

PICT-1675

22. Install a washer onto the clevis pin (Fig. 0598).

Fig 0599

PICT-1672a

4

24. Repeat steps 17 - 23 to install the control rod on the opposite side.

25. Feed the wire harness up through the center T-bar tube (Fig. 0600).

Fig 0598

PICT-1740

Fig 0600

PICT-1694a


LINKAGE

26. Plug the two harness wires into the harness connector as shown (Fig. 0601):

28. Connect the negative battery terminal to the battery.

29. Check the Adjustment of the Control Bar. Refer to

“Control Bar Adjustment” on page 4-132.

Handle Assembly Removal (T-2)

4

Fig 0601

PICT-1742

27. Plug the harness connector into the OPC switch

(Fig. 0602).

Fig 0603

fi g. 3 G006080



Fig 0602

PICT-1744


LINKAGE

3. Remove the 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel

(Fig. 0604).

5. Unplug the harness from the parking brake switch

(Fig. 0606).

Fig 0604

PICT-1921

Fig 0606

PICT-2021

6. Unplug the harness from the PTO switch (Fig. 0607).

4

4. Remove the control panel cover/manual tube assembly (Fig. 0605).

Fig 0605

PICT-1923

Fig 0607

PICT-2022


LINKAGE

7. Remove the PTO switch from the control panel (Fig.

0608).

9. Remove the nut securing the ignition switch to the control panel (Fig. 0610).

4

Fig 0608

PICT-2023

8. Unplug the harness wire and connector from the ignition switch (Fig. 0609).

Fig 0610

PICT-2025a

10. Remove the lockwasher from the ignition switch (Fig.

0611).

Fig 0609

PICT-2024

Fig 0611

PICT-2026


11. Remove the ignition switch from the control panel

(Fig. 0612).

LINKAGE

13. Unplug the harness from the hour meter (Fig. 0614).

Fig 0612

PICT-2027

Fig 0614

PICT-2029

4

14. Remove the locking tab from the back side of the hour meter (Fig. 0615).

12. Unplug the harness from the Operator Presence

Control (OPC) switch (Fig. 0613).

Fig 0613

PICT-2028

Fig 0615

PICT-2037


LINKAGE

15. Remove the hour meter from the control panel (Fig.

0616).

17. Unplug the kill relay from the harness connector

(Fig. 0618).

4

Fig 0616

PICT-2039a

16. Unplug the latching relay from the harness connector (Fig. 0617).

Fig 0618

PICT-2035

18. Remove the bolt and nut securing the two relay harness connector blocks to the control panel (Fig.

0619).

Fig 0617

PICT-2041a

Fig 0619

PICT-2036


19. Remove the cable tie securing the harness to the throttle cable (Fig. 0620).

LINKAGE

21. Pull the harness through the frame and lay it across 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. 0622).

Fig 0620

PICT-2043

20. Remove the cable tie securing the harness to the frame (left of the fuel tank, above the parking brake)

(Fig. 0621).

A. Choke

Fig 0622

PICT-0309

B. Throttle

23. Remove the throttle and choke cables from the cable clamps and disconnect the z-bends from the control linkage (Fig. 0623).

4

Fig 0621

PICT-2047


Fig 0623

PICT-0310

4-85

LINKAGE

24. Cut the cable ties at the following locations (Fig.

0624 and Fig. 0625):

25. Remove the 2 screws and nuts securing the throttle control assembly to the control panel (Fig. 0626).

4

Fig 0624

PICT-2051

A. Throttle/choke

B. Throttle/neutral proximity switch wire/frame

C. Throttle/frame

Fig 0626

PICT-2053

26. Remove the throttle control assembly from the control panel (Fig. 0627).

D. Choke/frame

Fig 0625

PICT-2052

Fig 0627

PICT-2057


LINKAGE

27. Remove the 2 screws and nuts securing the choke control assembly to the control panel (Fig. 0628).

29. Remove the 2 bolts and nuts securing the parking brake handle support to the frame (Fig. 0630).

Fig 0628

PICT-2054

Fig 0630

PICT-2060

4

28. Remove the choke control assembly from the control panel (Fig. 0629).

30. Swing the parking brake assembly forward so it is out of the way to permit handle assembly removal.

31. Remove the hairpin cotter from the upper end of the control linkage rod (Fig. 0631).

Fig 0629

PICT-2058

Fig 0631

PICT-2064


LINKAGE

32. Remove the washer from the upper end of the control linkage rod (Fig. 0632).

34. Repeat steps 31 - 33 to remove the control rod from the opposite motion control lever assembly.

35. Remove the spring from the right hand control lever assembly (Fig. 0634).

4

Fig 0632

PICT-2065

33. Remove the upper end of the control rod from the tab on the control handle (Fig. 0633).

Fig 0634

PICT-2071

36. Remove the 2 screws securing the OPC switch to the control lever assembly (Fig. 0635).

Fig 0633

PICT-2066

Fig 0635

PICT-2073a


LINKAGE

37. Remove the OPC switch and threaded spacer plate

(Fig. 0636).

39. Remove the right hand lever from the control panel

(Fig. 0638).

Fig 0636

PICT-2075

Fig 0638

PICT-2080a

4

38. Remove the nut and bolt securing the right hand lever assembly to the motion control assembly (Fig.

0637).

40. Remove the 2 carriage bolts and nuts securing the center support bracket to the control panel (Fig.

0639).

Fig 0637

PICT-2076

Fig 0639

PICT-2083


LINKAGE

41. Remove the 2 outside bolts (1 left, 1 right) securing the motion control lever linkage to the handle assembly (Fig. 0640).

43. Slide the right hand motion control assembly off the pivot shaft (Fig. 0642).

4

Fig 0640

PICT-2084

42. Remove the motion control lever linkage from the handle assembly (Fig. 0641).

Fig 0642

PICT-2088a

44. Remove the bolt securing the right hand pivot shaft to the center support bracket (Fig. 0643).

Fig 0641

PICT-2098

Fig 0643

PICT-2089a


LINKAGE

45. Slide the left hand control lever off the left hand pivot shaft (Fig. 0644).

47. Remove the 6 bushings from the control assemblies

(2 left, 4 right) (Fig. 0646).

Fig 0644

PICT-2090a

A. One on each side

Fig 0646

PICT-2095a

4

46. Remove the bolt securing the left hand pivot shaft to the center support bracket (Fig. 0645).

48. Remove the nut and washer securing the handle stop lever cam to the right control lever (Fig. 0647).

Fig 0645

PICT-2091a

Fig 0647

PICT-2108


LINKAGE

49. Remove the handle stop lever cam from the right control lever (Fig. 0648).

51. Remove the handle assembly from the frame (Fig.

0650).

4

Fig 0648

PICT-2109

50. Remove the 6 bolts (3 left, 3 right) securing the handle assembly to the frame (Fig. 0649).

Fig 0650

PICT-2092

Handle Assembly Installation (T-2)

1. Position the handle assembly to the frame (Fig.

0651).

Fig 0649

PICT-2069

Fig 0651

PICT-2092


2. Install 6 bolts (3 left, 3 right) securing the handle assembly to the frame (Fig. 0652).

LINKAGE

4. Position the handle stop lever cam onto the right control lever (Fig. 0654).

Fig 0652

PICT-2069

Fig 0654

PICT-2109

4

3. Install 6 bushings into the control assemblies (2 left,

4 right) (Fig. 0653).

5. Loosely install a washer and nut to secure the handle stop lever cam to the right control lever (Fig.

0655).

A. One on each side

Fig 0653

PICT-2095a

Fig 0655

PICT-2108


LINKAGE

6. Position the left hand pivot shaft to the center support bracket and loosely install a bolt securing the pivot shaft to the center support bracket (Fig. 0656).

8. Position the right hand pivot shaft to the center support bracket and loosely install a bolt securing the pivot shaft to the center support bracket (Fig. 0658).

4

Fig 0656

PICT-2091a

Fig 0658

PICT-2089a

7. Slide the left hand control lever onto the left hand pivot shaft (Fig. 0657).

9. Slide the right hand motion control assembly onto the pivot shaft (Fig. 0659).

Fig 0657

PICT-2090a

Fig 0659

PICT-2088a


10. Position the motion control lever linkage into the control panel handle assembly (Fig. 0660).

LINKAGE

12. Loosely install 2 carriage bolts and nuts, securing the center support bracket to the control panel (Fig.

0662).

Fig 0660

PICT-2098

Fig 0662

PICT-2083

11. Loosely install 2 bolts (1 left, 1 right) from the outside of the handle assembly, securing the motion control lever linkage to the handle assembly (Fig. 0661).

13. Position the right hand lever into the opening on the right hand side of the control panel (Fig. 0663).

4

Fig 0661

PICT-2084

Fig 0663

PICT-2080a


LINKAGE

14. Install a bolt and nut, securing the right hand lever assembly to the motion control linkage assembly

(Fig. 0664).

B. 2 bolts install from the outside of the handle assembly.

4

Fig 0664

PICT-2076

15. Tighten the bolts and nuts previously installed (Fig.

0665, Fig. 0666 and Fig. 0667):

A. 2 carriage bolts.

Fig 0666

PICT-2084

C. 2 bolts securing the right and left hand pivot shafts to the center support bracket.

Fig 0665

PICT-2100

Fig 0667

PICT-2100


LINKAGE

16. Position the right hand control lever so it aligns with the left hand control lever (Fig. 0668).

18. Position the OPC switch and threaded spacer plate onto the motion control linkage (Fig. 0670).

Fig 0668

PICT-2112a

Fig 0670

PICT-2075

4

17. Rotate the handle stop lever cam until the gap between the cam and the right hand control handle is removed. Tighten the nut (Fig. 0669).

19. Install 2 screws securing the OPC switch and spacer to the motion control lever assembly (Fig. 0671).

Fig 0669

PICT-2114

Fig 0671

PICT-2073a


LINKAGE

20. With the right control lever in the operating position, there should be .10” (2.5mm) gap between the OPC switch plunger and the control arm tab. Adjust the switch location as needed (Fig. 0672).

22. Insert the upper end of the control linkage rod into the tab on the control handle (Fig. 0674).

4

Fig 0672

PICT-2104

Fig 0674

PICT-2066

21. Install the spring onto the right hand motion control lever assembly (Fig. 0673).

23. Slide a washer onto the upper end of the control linkage rod (Fig. 0675).

Fig 0673

PICT-2071

Fig 0675

PICT-2065


LINKAGE

24. Install a hairpin cotter into the upper end of the control linkage rod (Fig. 0676).

27. Install 2 bolts and nuts securing the parking brake handle support to the frame (Fig. 0678).

Fig 0676

PICT-2064

Fig 0678

PICT-2060

4

25. Repeat steps 22 - 24 to install the opposite side control rod.

26. Swing the parking brake assembly into position so the mounting holes align with the holes in the frame

(Fig. 0677).

28. Slide the choke cable through the control panel and insert the choke control handle assembly into the control panel (Fig. 0679).

Fig 0677

PICT-2106


Fig 0679

PICT-2058

4-99

LINKAGE

29. Install 2 screws and nuts securing the choke control assembly to the control panel (Fig. 0680).

31. Install 2 screws and nuts securing the throttle control assembly to the control panel (Fig. 0682).

4

Fig 0680

PICT-2054

Fig 0682

PICT-2053

30. Slide the throttle cable through the control panel and insert the throttle control handle assembly into control panel (Fig. 0681).

32. Route the throttle and choke cables around the hydrostatic pumps, to the left of the engine and up to the front of the engine (Fig. 0683).

Fig 0681

PICT-2057

Fig 0683

PICT-2119


LINKAGE

33. Hook the z-bend of the choke cable to the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0684).

35. Ensure the carburetor choke plate is fully open (Fig.

0686).

Note: The air fi lter has been removed to show the carburetor choke plate.

Fig 0684

PICT-0331

Fig 0686

PICT-0333

34. Move the choke control knob to the “open” position

(Fig. 0685).

36. Pull up the outer housing of the choke cable until the inner wire has almost no slack and tighten the cable clamp bolt (Fig. 0687).

4

Fig 0685

PICT-0332a


Fig 0687

PICT-0334

4-101

LINKAGE

37. Move the choke control knob to the “choke“ position

(Fig. 0688).

39. Make sure the choke plate turns from the fully closed 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. 0690).

4

Fig 0688

PICT-0336

38. Ensure the carburetor choke plate is fully closed

(Fig. 0689).

Fig 0690

PICT-0338

41. Move the throttle control knob to the “fast” position

(Fig. 0691).

4-102

Fig 0689

PICT-0335

Fig 0691

PICT-0339


LINKAGE

42. Pull up the outer housing of the throttle cable until the inner wire has almost no slack and tighten to cable clamp bolt (Fig. 0692).

44. Install cable ties at the following locations (Fig. 0694 and Fig. 0695):

Fig 0692

PICT-0341a

43. Move the throttle control knob to the “slow” position.

Ensure the carburetor throttle control moves smoothly (Fig. 0693).

Fig 0694

PICT-2051

A. Throttle/choke

B. Throttle/neutral proximity switch wire/frame

C. Throttle/frame

4

Fig 0693

PICT-0342

D. Choke/frame

Fig 0695

PICT-2052


LINKAGE

45. Route the harness up the left side of the frame and into the control panel.

46. Install a bolt and nut securing each of the relay harness connector blocks to the control panel (Fig.

0696).

48. Plug the latching relay into the harness connector

(Fig. 0698).

4

Fig 0698

PICT-2041a

Fig 0696

PICT-2036

49. Install the hour meter into the control panel (Fig.

0699).

47. Plug the kill relay into the harness connector (Fig.

0697).

4-104

Fig 0697

PICT-2035

Fig 0699

PICT-2039a


LINKAGE

50. Install the locking tab onto the back side of the hour meter (Fig. 0700).

52. Plug the harness into the OPC switch (Fig. 0702).

Fig 0700

PICT-2037

Fig 0702

PICT-2028

4

53. Position the ignition switch into the control panel

(Fig. 0703).

51. Plug the harness into the hour meter (Fig. 0701).

Fig 0701

PICT-2029

Fig 0703

PICT-2027


LINKAGE

54. Install a lockwasher onto the ignition switch (Fig.

0704).

56. Plug the harness wire and connector into the ignition switch (Fig. 0706).

4

Fig 0704

PICT-2026

Fig 0706

PICT-2024

55. Install a nut securing the ignition switch to the control panel (Fig. 0705).

57. Install the PTO switch into the control panel (Fig.

0707).

Fig 0705

PICT-2025

Fig 0707

PICT-2023


58. Plug the harness into the PTO switch (Fig. 0708).

LINKAGE

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

4

59. Plug the harness into the parking brake switch (Fig.

0709).

61. Install a cable tie securing the harness to the throttle cable just below throttle control handle, inside the frame (Fig. 0711).

Fig 0709

PICT-2021

Fig 0711

PICT-2043


LINKAGE

62. Position the control panel cover/manual tube assembly to the control panel (Fig. 0712).

Choke Cable Replacement

Choke Cable Removal


2. Loosen the clamp that secures the choke cable to the engine (Fig. 0714).

4

Fig 0712

PICT-1923


0713).

Fig 0714

PICT-0627

3. Remove the choke cable from the clamp and remove the z-bend from the choke control lever (Fig.

0715).

Fig 0713

PICT-1921

64. Connect the negative battery terminal to the battery.

4-108

Fig 0715

PICT-0630


LINKAGE

4. Remove the cable tie located above the left tire that secures the choke and throttle cable together (Fig

0716).

6. T2 Models: Remove the cable tie securing the choke cable to the right side of the control panel

(Fig. 0718).

Fig 0718

PICT-2052

4

Fig 0716

PICT-0632

5. Pistol Grip & T-Bar Models: Remove the cable tie securing the choke cable to the right handle (Fig.

0717).

7. Remove the 2 screws and nuts securing the choke handle to the right handle (Fig. 0719).

Fig 0717

PICT-0633

Fig 0719

PICT-0635


LINKAGE

8. Remove the choke handle, cable and gasket assembly out through the control panel (Fig. 0720).

Choke Cable Installation

1. Slide the gasket onto the choke handle assembly

(Fig. 0722).

4

Fig 0720

PICT-0636a

9. Remove the gasket from the handle assembly (Fig.

0721).

Fig 0722

PICT-0638a

2. Slide the choke cable through the opening on the control panel (Fig. 0723).

Fig 0721

PICT-0637a

Fig 0723

PICT-0636a


LINKAGE

3. Insert the handle into the opening in the control panel. Install 2 screws and nuts to secure the choke handle to the right handle bar (Fig. 0724).

5. Pistol Grip & T2 models: Position the choke cable between the hydro pumps (Fig. 0726).

Fig 0724

PICT-0647

Fig 0726

PICT-0640

4. Pistol Grip models only: Continue routing the choke cable between the tracking rod and bracket (Fig.

0725).

6. T-Bar models only: Continue routing the choke cable down under the right hand gear driveshaft

(Fig. 0727).

4

Fig 0725

PICT-0639

Fig 0727

PICT-1495a


LINKAGE

7. Route the choke cable under the electrical harness, around the left side of the engine and up to the front side of the engine (Fig. 0728).

9. Slide the choke cable into the upper cable clamp and loosely clamp the outer cable housing (Fig.

0730).

4

Fig 0728

PICT-0641

Fig 0730

PICT-0627

8. Hook the choke cable z-bend to the choke control lever (Fig. 0729).

10. Move the choke control to the open position (Fig.

0731).

Fig 0729

PICT-0630

Fig 0731

PICT-0648


LINKAGE

11. Make sure that the carburetor choke plate is fully open (Fig. 0732).

Note: The air fi lter has been removed to show the carburetor choke plate.

13. Install a cable tie securing the choke cable to the throttle cable above the left tire. Cut off the excess cable tie (Fig. 0734).

Fig 0734

PICT-0684a

4

Fig 0732

PICT-0333

12. Pull on the outer cable housing until the inner wire has almost no slack. Tighten the cable clamp bolt

(Fig. 0733).

14. Pistol Grip & T-Bar Models: Install a cable tie securing the choke cable to the right handle bar. Cut off the excess cable tie (Fig. 0735).

Fig 0733

PICT-0331


Fig 0735

PICT-0651

4-113

LINKAGE

15. T2 Models: Install a cable tie securing the choke cable to the right side of the control panel (Fig.

0736).

Throttle Cable Replacement

Throttle Cable Removal


2. Loosen the clamp that secures the throttle cable to the engine (Fig. 0737).

4

Fig 0736

PICT-2052

16. Make sure that the choke valve turns from the fully closed position to the fully open position when actuating the choke control handle.

Fig 0737

PICT-0652

3. Remove the throttle cable from the clamp and remove the z-bend from the throttle control lever

(Fig. 0738).

4-114

Fig 0738

PICT-0657


LINKAGE

4. Remove the cable tie located above the left tire that secures the throttle and choke cable together (Fig

0739).

6. Slide the throttle cable out of the R-clamp (Fig.

0741).

Fig 0739

PICT-0632

5. Loosen the screw securing the R-clamp to the frame, located behind the left tire (Fig. 0740).

Fig 0741

PICT-0658

7. Pistol Grip & T-Bar Models: Remove the cable tie securing the throttle cable to the left handle (Fig.

0742).

4

Fig 0740

PICT-0661

Fig 0742

PICT-0662


LINKAGE

8. T2 Models: Remove the cable tie securing the harness to the throttle cable (Fig. 0743).

10. Remove the 2 screws and nuts securing the throttle handle assembly to the left handle (Fig. 0745).

4

Fig 0743

PICT-2043

9. Cut the cable ties at the following locations (Fig.

0744).

Fig 0745

PICT-0667

11. Remove the throttle handle cable and gasket assembly out through the control panel (Fig. 0746).

Fig 0744

PICT-2051

A. Throttle/neutral proximity switch wire/frame

B. Throttle/frame

Fig 0746

PICT-0670a


LINKAGE

12. Remove the gasket from the handle assembly (Fig.

0747).

2. Slide the throttle cable through the opening on the control panel (Fig. 0749).

Fig 0747

PICT-0671

Fig 0749

PICT-0670a

4

Throttle Cable Installation

1. Slide the gasket onto the throttle handle assembly

(Fig. 0748).

3. Pistol Grip models only: Route the throttle cable between the tracking rod and bracket (Fig. 0750).

Fig 0748

PICT-0672a

Fig 0750

PICT-0673


LINKAGE

4. Pistol Grip models only: Continue routing the throttle cable under the left hand control shaft between the left pump and frame (Fig. 0751).

6. T2 Models: Route the cable between the left pump and frame (Fig. 0753).

4

Fig 0751

PICT-0674

Fig 0753

IMG_8008a

5. T-Bar models only: Continue routing the throttle cable under the left hand gear driveshaft (Fig. 0752).

7. Slide the throttle cable through the R-clamp, around the left side of the engine and to the front of the engine (Fig. 0754).

Fig 0752

PICT-1494

Fig 0754

PICT-0658


LINKAGE

8. Insert the handle into the opening in the control panel. Install 2 screws and nuts to secure the throttle handle to the left handle bar (Fig. 0755).

10. Slide the throttle cable into the upper cable clamp and loosely clamp the outer cable housing (Fig.

0757).

Fig 0757

PICT-0678

4

Fig 0755

PICT-0667

9. Hook the z-bend of the throttle control lever (Fig.

0756).

11. Move the throttle control to the fast position (Fig.

0758).

Fig 0756

PICT-0675

Fig 0758

PICT-0680


LINKAGE

12. Pull on the outer cable housing until the inner wire has almost no slack. Tighten the cable clamp bolt

(Fig. 0759).

14. Install a cable tie securing the throttle cable to the choke cable above the left tire. Cut off excess (Fig.

0761).

4

Fig 0759

PICT-0682

Fig 0761

PICT-0684a

13. Install a cable tie securing the throttle cable to the left handle bar. Cut off excess (Fig. 0760).

15. Tighten the R-clamp screw securing the throttle cable to the frame (Fig. 0762).

4-120

Fig 0760

PICT-0683a

Fig 0762

PICT-0661

16. Move the throttle lever to the slow position. Make sure that the carburetor throttle valve moves smoothly to the closed position.


Linkage Adjustments

Speed Control Linkage Adjustment

(Pistol Grip Hydro)

1. Disengage the PTO and set the parking brake.

2. Stop the engine and remove the key.

3. Move the speed control lever to the full forward position (Fig. 0763).

LINKAGE

4. Check the orientation of the tabs on the ends of the speed control crank. These tabs should be pointing straight down, at approximately the 6 o’clock position

(Fig. 0764).

Side View

Fig 0763

PICT-0711a

B

D

C

A

B

D

A

E

A. Speed control rod

Fig 0764

fi g. 44 G001963

D. Tabs, 6 o’clock position

E. Swivel

C. Speed control crank

4

5. If adjustment is needed, loosen the nuts on both sides of the swivel on the speed control rod (Fig.

0764).

6. Adjust the swivel until the tabs are at the 6 o’clock position (Fig. 0764).

7. Tighten the nuts on both sides of the swivel (Fig.

0764).

8. Pull the speed control lever back to neutral.


LINKAGE

4

9. Check the travel of the shift lever in the control panel slot. The shift lever travel should be approximately centered in the control panel slot (Fig. 0765).

E

D

Temporary Neutral Stud Adjustment

Note: Perform the following procedure on both the left and right side.

1. Move the left and right neutral lock latches to the unlatched position.

2. Move the speed control lever to the neutral position

(Fig. 0766).

A

B

C

Fig 0765

fi g. 45 G001964

A. Actuating tab D. Switch plate

B. 1/8” - 1/4” (3 - 6mm) E. Neutral bracket

space

B

D

A

E

C

10. If needed, adjust the swivel on the speed control rod to center the shift lever travel (Fig. 0764).

11. With the speed control lever in the neutral position, check to make sure the safety switch is depressed and there is 1/8” to 1/4” (3 to 6mm) space between the actuating tab and the safety switch (Fig. 0765).

12. To adjust the switch location, loosen the two neutral bracket screws holding the switch plate to the frame

(Fig. 0765).

13. Adjust the switch up or down to obtain 1/8 to 1/4 inch

(3 to 6 mm) space (Fig. 0765).

14. Tighten the two neutral bracket screws holding the switch plate (Fig. 0765).

Fig 0766

fi g. 43 G001962

A. Speed control lever D. Medium speed position

B. Full speed position E. Control panel


LINKAGE

3. Loosen the nut against the yoke (Fig. 0767).

F

G

A

C

D

B

E

F

Fig 0767

fi g. 46 G001965

A. Neutral control linkage E. Slot in control arm

B. Yoke bracket

C. Neutral stud

D. Nut against yoke

F. Clevis pin

G. Clevis pin does not contact the back of slot

Hydro Control Linkage Adjustment

!

!

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffl er and other hot surfaces.

!

!

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stands when supporting machine.

• Do not use hydraulic jacks.

4

4. Adjust the length of the neutral stud and yoke assembly so the clevis pin does not contact the back of the slot in the control arm bracket (Fig. 0767).

5. Tighten the nut against the yoke (Fig. 0767).


LINKAGE

Adjusting the Left Side Linkage (Pistol Grip)


2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Support the rear of the machine on jack stands so the drive wheels are off of the ground.

4. Disengage the parking brake.

5 Start the engine and move the throttle to the full throttle position.

6. Press and hold the OPC levers down.

4

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

7. Place the left drive lever in the full forward position.

8. Place the speed control lever in the neutral position.

!

!

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers fastened in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence

Control (OPC) levers fastened in place.

9. Loosen the front adjusting nut on left hydro control linkage as shown in (Fig. 0768).

A

D

B

C

Fig 0768

fi g. 48 G001519

A. Hydro control linkage C. Rear adjusting nut

B. Front adjusting nut D. Control arm

10. Turn the rear adjusting nut counterclockwise until wheel rotates forward (Fig. 0768).

11. Turn the rear adjusting nut clockwise 1/4 of a turn.

Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Fig. 0768).


LINKAGE

Note: Make sure flat part of linkage is perpendicular to the pin of swivel (Fig. 0769).

A

Note: If inconsistent neutral occurs, check to be 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. 0770).

A

B

D

90 Degrees

C

C

B

Fig 0769

fi g. 47 G001735

A. Hydro control linkage C. Incorrect position

B. Swivel

C

Fig 0770

A. Speed control lever C. Spring

B. Rear pivot spring

B

fi g. 49 G001520

4

12. After adjusting the left hydro control linkage, move the speed control lever forward and then back to the neutral position.

13. Make sure the speed control lever is in the neutral position and the tire does not rotate.

14. Repeat the adjustment if needed.

15. Tighten the front nut on left hydro control linkage shown in Fig. 0768.


LINKAGE

4

Adjusting the Right Side Linkage

(Pistol Grip)

1. With the machine on jack stands, place the speed control lever in the neutral position.

2. Place the right drive lever in the full forward position.

3. Hold the OPC levers down.


4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Fig. 0771).

5. Turn the knob clockwise 1/4 of a turn. Then move the speed control forward and back to neutral.

Repeat this until right wheel stops rotating forward

(Fig. 0771).

6. If necessary, adjust the length of spring to 1” (26mm) between the washers (Fig. 0771).

7. Adjust the spring length by turning the nut at the front of spring (Fig. 0771).

8. After adjusting the right hydro control linkage, move the speed control lever forward and then back to the neutral position.

9. Make sure the speed control lever is in the neutral position and the tire does not rotate.

10. Repeat adjustment if needed.

A

E

C

B

Neutral Stud Adjustment (Pistol Grip)

!

!

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence Control (OPC) levers held in place.

D

Fig 0771

fi g. 50 G001968

A. Hydro control linkage D. 1” (26mm)

B. Quick track knob E. Nut in front of spring

C. Spring


LINKAGE

!

!

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stands when supporting machine.

• Do not use hydraulic jacks.

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).

1. With the machine on jack stands, place the speed control lever in the neutral position.

2. Hold the OPC levers down.


A

E

H

C

G

D

B

F

Fig 0772

fi g. 51 G001969

A. Neutral control linkage E. Slot in control arm

B. Yoke bracket

C. Neutral stud

D. Nut

F. Celvis pin

G. Spring

H. Back end of slot

4


LINKAGE

4. Move the speed control lever to the full forward position.

5. Squeeze one drive lever until an increased resistance 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.

Note: Make sure you have not reached the end of the neutral lock slot. If you have, shorten the control lever linkage. Refer to Adjusting the

Control Rod.

6. If the wheel turns while holding the drive lever in neutral, the neutral stud needs to be adjusted (Fig.

0772). If wheel stops then go to step 11.

7. Loosen the nut against the yoke (Fig. 0772).

4

8. Make adjustments while holding the respective drive wheel control in the neutral position (increased resistance) (Fig. 0772).

9. Turn the neutral stud approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counterclockwise if the wheel is turning forward (Fig. 0772).

10. Release the drive lever to the forward drive position and squeeze back into the neutral position. Check to see if the wheel stops. If not, repeat the above adjustment procedure.

11. After adjustment is made, tighten the nut against the yoke.

12. Repeat this procedure for the opposite side.

Adjusting the Control Rod

(Pistol Grip)

Checking the Control Rod

1. With rear of machine still on jack stands and engine running at full throttle, move the speed control lever to “medium” speed position.


2. Move the respective drive lever upward until it reaches the neutral position and engage neutral locks.

3. If the tire rotates in either direction, the length of the control rod will need to be adjusted.

Adjusting the Control Rod

1. Adjust the rod length by releasing the drive lever and removing the hairpin cotter pin and clevis pin. Rotate the rod in the rod fitting (Fig. 0773).

B

C

D

E

F

A

G

A. Control rod

B. Clevis pin

C. Drive lever

Fig 0773

fi g. 52 G001733

E. Left handle shown

F. Neutral lock

G. Hairpin cotter pin


LINKAGE

2. Lengthen the control rod if the tire is turning in reverse and shorten the rod if the tire is turning forward.

3. Rotate the rod several turns if the tire is rotating fast.

Then, adjust the rod in 1/2 turn increments.

4. Place the clevis pin into the drive lever (Fig. 0773).

5. Release and engage neutral lock checking that the tire does not rotate (Fig. 0774). Continue adjusting until the tire does not rotate.

6. Install the hairpin cotter pin between the drive lever and the neutral lock and into the clevis pin (Fig.

0773).

Note: Make sure the clevis pin is inserted into the neutral lock.

7. Repeat this adjustment for the opposite side.

A

B

C

Tracking Adjustment (Pistol Grip)

1. Remove machine from any jack stands.

2. Check the rear tire pressure. Refer to Specifi cations for proper tire pressure.

3. Start and run the machine. Observe the tracking on a level, smooth, hard surface such as concrete or asphalt.

4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Fig. 0775).

4

H

E

D

G

F

A. Handle

B. Neutral lock

C. Handle

D. Neutral lock slot

Fig 0774

fi g. 53 G001732

F. Drive lever

G. Full speed forward

H. Control rod

A

A. Quick track knob

Fig 0775

fi g. 54 G001523


LINKAGE

4

Tracking Adjustment (T-2)

1. If the machine does not track straight, adjustment is required.

2. Check the rear tire pressure. Refer to Specifi cations for proper tire pressure.

3. Loosen the wing nuts on the right control rod and rotate the turnbuckle in or out to ensure the right side control lever is centered in the neutral lock position. Secure the turnbuckle in position with the wing nuts (Fig. 0776).

4. Loosen the wing nuts on the left control rod and rotate the turnbuckle in or out to change the tracking.

Secure the turnbuckle in position with the wing nuts

(Fig. 0776).

5. Check for proper tracking. Adjust the left control rod if a change is needed.

Neutral Adjustment (T-2)

Important: Ensure the tracking of the mower is correct after adjusting the motion control levers.

After adjusting the tracking, the motion control levers may not align exactly front to back (Fig.

0777).

C

A

B

A

B

C

A. Turnbuckle

B. Bottom wing nut

Fig 0776

fi g. 36 G006085

C. Top wing nut (left hand threaded)

D

Fig 0777

fi g. 52 G006096

A. Left motion control lever

C. Neutral locked position

D. Align the control levers

B. Right motion control front to back here

lever


D

LINKAGE

If the motion control levers do not align front to back, or the right side control lever does not move easily into the neutral lock position, adjustment is required.

Adjust each lever and control rod separately.

Note: Adjust the horizontal alignment before the front to back alignment.

1. After the horizontal alignment is fi nished, check the front to back alignment (Fig 0778).

2. Loosen the wing nuts on the right control rod and rotate the turnbuckle in or out to ensure the right side control lever is centered in the neutral lock position. Secure the turnbuckle in position with the wing nuts (Fig. 0779).

C

A

B

A

B

C

4

A. Turnbuckle

B. Bottom wing nut

Fig 0779

fi g. 36 G006085

C. Top wing nut (left hand threaded)

Fig 0778

fi g. 52 G006096

A. Left motion control lever

C. Neutral locked position

D. Align the control levers

B. Right motion control front to back here

lever

3. Loosen the wing nuts on the left control rod and rotate the turnbuckle in or out to change the tracking.

Secure the turnbuckle in position with the wing nuts

(Fig. 0779).

4. Check for proper tracking. Adjust the left control rod if a change is needed. Refer to “Tracking Adjustment

(Pistol Grip)” on page 4-129 or “Tracking Adjustment

(T-2)” on page 4-130.


LINKAGE

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).

3. Engage the control bar (Fig. 0782).

Fig 0782

PICT-5314a

4

2. The control bar and upper handle must be parallel when in the relaxed drive and brake positions (Fig.

0781).

Fig 0780

PICT-5303

4. Using a ruler, measure the travel distance of the pulley while releasing and engaging the control bar.

The travel distance should be approximately 3/4”

(19mm) (Fig. 0783).

Note: If the pulley travel is more the 3/4” (19mm), the brakes must be adjusted. Refer to

“Checking the Brake”, page 5-9.

4-132

Fig 0781

PICT-5332a

Fig 0783

PICT-5324a & 5326a


LINKAGE

5. Engage the Parking Brake (Fig. 0784).

Note: The parking brake lever should swing into a snug position against the upper handle while pulling back on the upper control bar.

6. If adjustment is required, refer to “Adjusting the

Brake”, page 5-10.

7. Adjust the control rods so there is a 1” to 1 1/4” (2.54 to 3.175cm) gap between the upper control bar and the fi xed bar with the wheel drive fully engaged (Fig.

0785).

Fig 0784

PICT-5311a

A. 1” to 1-1/4”

Fig 0785

PICT-5333a

4


LINKAGE

4



Engine Removal - Pistol Grip Hydro



ENGINE

4. Move the positive battery terminal boot and disconnect the positive (red) battery cable from the battery (Fig. 0788).

Fig 0788

PICT-0252

Fig 0786

PICT-0247a

5. Remove 1 of the 2 nuts retaining the battery hold down strap and battery hold downs to the battery tray (Fig. 0789).


5

Fig 0787

PICT-0250


Fig 0789

PICT-0254

5-1

ENGINE

6. Remove the battery hold down plate and 2 battery hold downs from the battery tray (Fig. 0790).

8. Remove the bolt that secures the fuel line R-clamp to the engine (Fig. 0792).

Fig 0790

PICT-0256

Fig 0792

PICT-0259

5

7. Remove the battery from the battery tray (Fig. 0791).

9. Slide the hose clamp off the fuel line where it connects to the fuel pump (Fig. 0793).

Fig 0791

PICT-0257

Fig 0793

PICT-0262


ENGINE

10. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 0794).

12. Place a drain pan below the drain hose. Rotate the oil drain valve to allow the engine oil to drain into the drain pan (Fig. 0796).

Fig 0794

PICT-0264

11. Attach the oil drain hose to the oil drain valve (Fig.

0795).

Fig 0796

PICT-0266

13. When the oil has drained completely, close the drain valve and remove the drain hose.

5

14. Unplug the clutch from the harness connector (Fig.

0797).

Fig 0795

PICT-0265


Fig 0797

PICT-0547a

5-3

ENGINE

15. Push the grommet and clutch plug through the chassis frame to the underside of the machine (Fig.

0798).


5

Fig 0798

PICT-0277


Fig 0800

PICT-0283


19. Remove the trailing shield from the chassis by fi rst removing the left end of the shield rod (bent at a 45º angle) from the hole in the chassis and then remove the right side of the shield rod (bent at a 90º angle) from the right side of the chassis (Fig. 0801).

5-4

Fig 0799

PICT-0280

Fig 0801

PICT-0273


20. Remove the idler arm spring from the spring post

(Fig. 0802).

ENGINE

22. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the chassis (Fig. 0804).

Fig 0802

PICT-0291a


Fig 0804

PICT-0295


5

Fig 0803

PICT-0294

Fig 0805

PICT-0297a


ENGINE

24. Remove the bolt, 2 spring washers and fl at washer securing the clutch to the engine crankshaft. Lower the clutch off the engine crankshaft (Fig. 0806).

26. Remove the hydro drive belt from around the engine crankshaft pulley (Fig. 0808).

Fig 0806

PICT-0299

Fig 0808

PICT-0302a

27. Slide the drive pulley off the engine crankshaft (Fig.

0809).

5

25. Using a spring removal tool (Toro P/N 92-5771), unhook the hydro drive idler spring and remove it from the chassis (Fig. 0807).

Fig 0807

PICT-0300

Fig 0809

PICT-0303


ENGINE

28. Remove the square key from the engine crankshaft

(Fig. 0810).


Fig 0810

PICT-0304

A. Choke

Fig 0812

PICT-0309

B. Throttle

29. Remove the nut and the positive (red) cable from the starter (Fig. 0811).


5

Fig 0811

PICT-0269a


Fig 0813

PICT-0310

5-7

ENGINE

32. Remove the nut, harness ground wires and negative

(black) battery cable and star washer from the rear right engine mounting bolt (Fig. 0814).

Note: The bolt will fall through the chassis when the nut is removed.

34. Unplug the pink wire from the green fuel solenoid wire (Fig. 0816).

Fig 0816

PICT-0316a

Fig 0814

PICT-0314

5

33. Unplug the violet wire from the ignition module on the engine (Fig. 0815).

35. Unplug the white wire from the black magneto wire

(Fig. 0817).

5-8

Fig 0815

PICT-0315

Fig 0817

PICT-0317


ENGINE

36. Remove the remaining 3 engine mounting bolts and nuts securing the engine to the chassis (Fig. 0818).

3. Insert the rear right engine mounting bolt up through the chassis and engine mounting hole. Install the star washer, harness ground wires and negative

(black) battery cable onto the bolt. Loosely install the nut onto the bolt (Fig. 0820).

Fig 0818

PICT-0319

38. Carefully lift the engine off the chassis.

Fig 0820

PICT-0321a

Engine Installation - Pistol Grip Hydro

1. Carefully position the engine on the chassis.

2. Apply thread locking compound to the 4 engine mounting bolts (Fig. 0819).

4. Loosely install the remaining 3 engine mounting bolts and nuts (Fig. 0821).

5

Fig 0819

PICT-0322


Fig 0821

PICT-0319

5-9

ENGINE

5. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs.

(19.7 + 2.8 Nm) (Fig. 0822).

7. Plug the pink wire into the green fuel solenoid wire

(Fig. 0824).

Fig 0822

PICT-0324

Fig 0824

PICT-0327

5

6. Plug the white wire into the black magneto wire (Fig.

0823).

8. Plug the violet wire into the ignition module on the engine (Fig. 0825).

Fig 0823

PICT-0326a

Fig 0825

PICT-0328


9. Secure the positive (red) cable to the starter (Fig.

0826).

ENGINE


(Fig. 0828).

Fig 0826

PICT-0268a

Fig 0828

PICT-0332a

10. Hook the z-bend of the choke cable to the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0827).


0829).

5

Fig 0827

PICT-0331

Fig 0829

PICT-0333


ENGINE

13. Pull the outer housing of the choke cable until the inner wire has almost no slack and tighten the cable clamp bolt (Fig. 0830).


(Fig. 0832).

Fig 0832

PICT-0335

Fig 0830

PICT-0334

5


(Fig. 0831).



5-12

Fig 0831

PICT-0336

Fig 0833

PICT-0338


ENGINE


(Fig. 0834).

20. Move the throttle control knob to the “slow“ position.

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 clamp bolt (Fig. 0835).

21. Apply anti-seize compound to the engine crankshaft

(Fig. 0837).

5

Fig 0835

PICT-0341a

Fig 0837

PICT-0343


ENGINE

22. Install the square key into the engine crankshaft keyway (Fig. 0838).

24. Route the hydro drive belt around the engine crankshaft pulley, idler pulley and hydro pulleys (Fig.

0840).

Fig 0838

PICT-0304

5

23. Slide the drive pulley onto the engine crankshaft.

Ensure that the long side of the hub is installed toward the engine (Fig. 0839).

Fig 0840

PICT-0348a

25. Using a spring removal tool (Toro P/N 92-5771), install the hydro drive idler spring (Fig. 0841).

Fig 0839

PICT-0303

Fig 0841

PICT-0349


ENGINE

26. Ensure the 2 cupped washers are installed on the clutch bolt with the crown side facing the bolt head

(Fig. 0842).

28. Slide the electric clutch onto the engine crankshaft

(Fig. 0844).

Fig 0842

PICT-0351a

27. Apply thread locking compound to the clutch bolt

(Fig. 0843).

Fig 0844

PICT-0354a

29. Install the clutch bolt, 2 spring washers and fl at washer into the engine crankshaft (Fig. 0845).

5

Fig 0843

PICT-0352a

Fig 0845

PICT-0355a


ENGINE

30. Torque the clutch bolt to 55 + 5 ft-lbs. (74.5 + 6.8

Nm) (Fig. 0846).

32. Feed the cutch harness plug up through the chassis

(Fig. 0848).

Fig 0846

PICT-0356a

Fig 0848

PICT-0362a

5

31. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the chassis

(Fig. 0847).

33. Install the rubber grommet into the frame (Fig.

0849).

Fig 0847

PICT-0361

Fig 0849

PICT-0363


34. Route the PTO drive belt around the clutch. (Fig.

0850).

ENGINE

40”, 48” and 52” mower deck belt routing:

Fig 0850

PICT-0364a

Fig 0852

fi g. 104-8186

Note: Ensure the PTO drive belt is routed properly around the mower deck pulley(s). Refer to belt routing decal (Fig. 0851 and Fig. 0852).

36” mower deck belt routing:

35. Install the idler arm spring to the spring post (Fig.

0853).

5

Fig 0851

fi g. 104-8185

Fig 0853

PICT-0365


ENGINE

36. Install the trailing shield into the chassis by fi rst 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 angle) into the hole in the chassis (Fig. 0854).

39. Replace the carrier frame cover (Fig. 0856).

Fig 0856

PICT-0280

Fig 0854

PICT-0273

5


38. Roll the PTO drive belt on to the center mower deck pulley (Fig. 0855).


(Fig. 0857).

5-18

Fig 0855

PICT-0283

Fig 0857

PICT-0547a


41. Install the fuel line to the fuel pump (Fig. 0858).

ENGINE

43. Install the bolt that secures the fuel line R-clamp to the engine (Fig. 0860).

Fig 0858

PICT-0370

42. Slide the hose clamp to the fuel line where it connects to the fuel pump (Fig. 0859).

Fig 0860

PICT-0259

44. Fill the engine crankcase with oil per engine specifi cations.

45. Place the battery onto the battery tray (Fig. 0861).

5

Fig 0859

PICT-0371

Fig 0861

PICT-0257


ENGINE

46. Install the battery hold down and secure with 2 nuts.

Do not over-tighten (Fig. 0862).

48. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot.

(Fig. 0864).

Fig 0862

PICT-0372a

5

47. Connect the positive (red) battery cable to the positive battery terminal and cover with the boot

(Fig. 0863).

Fig 0864

PICT-0250

Muffl er Guard

There is a muffl er guard included on international models (Fig. 0865 and Fig. 0866):

Fig 0863

PICT-0252

Fig 0865

PICT-1489


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. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 0869).

5

Fig 0867

PICT-1346


Fig 0869

PICT-1349a

5-21

ENGINE

5. Remove the R-clamp that secures the fuel line to the right side of the engine (Fig. 0870).

7. Place a drain pan below the end of the drain hose and rotate the oil drain valve to allow the oil to drain from the engine (Fig. 0872).

Fig 0870

PICT-1351

5

6. Attach the oil drain hose to the oil drain valve (Fig.

0871).

Fig 0872

PICT-1354

8. When the oil has drained completely, close the drain valve and remove the drain hose.

9. Unplug the clutch from the wire harness (Fig. 0873).

Fig 0871

PICT-1352

Fig 0873

PICT-1422


ENGINE

10. Push the clutch wire plug and grommet through the engine deck frame (Fig. 0874).

12. Remove the mower deck belt cover(s) (Fig. 0876).

Fig 0874

PICT-1357


Fig 0876

PICT-1360

13. Roll the deck drive belt off the fi xed/center mower deck pulley (Fig. 0877).

5

Fig 0875

PICT-1358

Fig 0877

PICT-1361


ENGINE

14. Raise the machine so that the underside of the 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.

0878).

17. Remove the belt from around the clutch (Fig. 0880).

5

Fig 0880

PICT-1365a

Fig 0878

PICT-1362

18. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0881).

16. Remove the deck drive idler arm spring from the spring post (Fig. 0879).

5-24

Fig 0879

PICT-1364

Fig 0881

PICT-1368



ENGINE

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 securing the clutch to the engine crankshaft. Slide the clutch off the engine crankshaft (Fig. 0883).

22. Remove the drive belt from the pulleys (Fig. 0885).

5

Fig 0883

PICT-1374

Fig 0885

PICT-1377a


ENGINE

23. Slide the drive pulley off the crankshaft (Fig. 0886).



Fig 0886

PICT-1379

5

24. Remove the key from the crankshaft keyway (Fig.

0887).

A. Choke

Fig 0888

PICT-1382

B. Throttle


5-26

Fig 0887

PICT-1381

Fig 0889

PICT-1385


28. Unplug the pink wire from the red engine rectifi er wire (Fig. 0890).

ENGINE

30. Remove the nut, harness ground wire and lock washer from the rear left engine mounting bolt (Fig.

0892).

Note: The bolt will fall through the frame when the nut is removed.

Fig 0890

PICT-1389a

29. Unplug the white wire from the black magneto wire

(Fig. 0891).

Fig 0892

PICT-1393

31. Remove the remaining 3 engine mounting bolts and nuts that secure the engine to the frame (Fig. 0893).

5

Fig 0891

PICT-1390a

Fig 0893

PICT-1395

32. Carefully lift the engine off the chassis.


ENGINE

Engine Installation - Gear Drive

1. Position the engine onto the frame.

2. Apply thread locking compound to the threads of all

4 engine mounting bolts (Fig. 0894).

4. Loosely install the other 3 engine mounting bolts and nuts securing the engine to the frame. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs. (19.7 +

2.8 Nm) (Fig. 0896).

Fig 0896

PICT-1398

Fig 0894

PICT-1396

5

3. Insert an engine mounting bolt up through the frame and the rear left engine mounting hole. Place a lock washer and the ground wire onto the engine mounting bolt. Loosely install a nut (Fig. 0895).

5. Plug the white wire into the black magneto wire (Fig.

0897).

5-28

Fig 0895

PICT-1393

Fig 0897

PICT-1390a


ENGINE

6. Plug the pink wire into the red engine rectifi er wire

(Fig. 0898).


(Fig. 0900).

Fig 0898

PICT-1389a

Fig 0900

PICT-1400

7. Hook the z-bend of the choke cable into the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0899).


0901).

5

Fig 0899

PICT-1399

Fig 0901

PICT-0333


ENGINE

10. Pull the outer housing of the choke cable until the inner wire has almost no slack and tighten the cable clamp (Fig. 0902).


(Fig. 0904).

Fig 0904

PICT-1401

Fig 0902

PICT-1402

5


(Fig. 0903).



5-30

Fig 0903

PICT-1403

Fig 0905

PICT-1383


ENGINE


(Fig. 0906).

17. Move the throttle control knob to the “slow“ position.

Ensure the throttle moves smoothly (Fig. 0908).

Fig 0908

PICT-1405a

Fig 0906

PICT-1404a

16. Pull the outer housing of the throttle cable until the inner wire has almost no slack and tighten the cable clamp (Fig. 0907).

18. Raise the machine to access the underside of the frame.

19. Apply anti-seize compound to the crankshaft (Fig.

0909).

5

Fig 0907

PICT-1406

Fig 0909

PICT-1407


ENGINE

20. Install the key into the crankshaft keyway (Fig.

0910).

Note: The drive pulley casting indicates the orientation of the pulley on the crankshaft (Fig.

0912).

Fig 0910

PICT-1381

Fig 0912

PICT-1408a

5

21. Slide the drive pulley onto the crankshaft (Fig. 0911).

22. Route the traction drive belt around the drive pulleys

(Fig. 0913).

Fig 0911

PICT-1378

Fig 0913

PICT-1377a


ENGINE

23. Hook the traction drive belt idler spring to the tab on the frame (Fig. 0914).

25. Apply thread locking compound to the clutch bolt threads (Fig. 0916).

Fig 0916

PICT-1411

Fig 0914

PICT-1376

24. Slide the fl at washer and 2 spring washers onto the clutch bolt (Fig. 0915):

Note: Ensure the 2 spring washers are installed on the clutch bolt with the crown side facing the bolt head.

26. Slide the clutch onto to the crankshaft (Fig. 0917).

5

Fig 0915

PICT-1409a


Fig 0917

PICT-1374

5-33

ENGINE

27. Install the clutch bolt assembly into the crankshaft to secure the clutch. Torque the clutch bolt to 55 + 5 ft-lbs. (74.6 + 6.8 Nm) (Fig. 0918).


0920).

Fig 0920

PICT-1418

Fig 0918

PICT-1412

5

28. Feed the clutch harness plug up through the frame

(Fig. 0919).


(Fig. 0921).

Fig 0919

PICT-1415

Fig 0921

PICT-1421


31. Route the deck drive belt around the clutch (Fig.

0922).

ENGINE

33. Install the trailing shield into the frame by fi rst inserting 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. 0924).

Fig 0922

PICT-1365a

32. Install the idler arm spring to the spring post (Fig.

0923).

Fig 0924

PICT-1362


35. Roll the deck drive belt onto the fi xed (center) mower deck pulley (Fig. 0925).

5

Fig 0923

PICT-1364


Fig 0925

PICT-1361

5-35

ENGINE

Note: Ensure the deck drive belt is routed properly around the mower deck pulley(s). Refer to belt routing decal (Fig. 0926):


Fig 0926

fi g. 104-8185

Fig 0928

PICT-1358


(Fig. 0929).

5

36. Install the mower deck belt cover(s) (Fig. 0927).

Fig 0927

PICT-1360

Fig 0929

PICT-1422


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. 0931).

Fig 0931

PICT-1351

42. Fill the crankcase with oil per the engine specifi cations.

43. Fill the fuel tank with gas.


ENGINE

5-37

5

ENGINE

5




Hydro Drive Transmission Traction

Belt Replacement

Hydro Drive Transmission Traction Belt

Removal


3. Push the grommet and clutch plug through the frame to the underside of the machine (Fig. 0934).

Fig 0932

PICT-0250

2. Unplug the PTO clutch wire from the harness connector (Fig. 0933).

Fig 0934

PICT-0277


6

Fig 0935

PICT-0546

Fig 0933

PICT-0548a




8. Remove the idler arm spring from the spring post

(Fig. 0938).

Fig 0936

PICT-0283

Fig 0938

PICT-0291a

6. Raise the machine so that the underside of the frame can be accessed.

6

7. 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 chassis and then remove the right side of the shield rod (bent at 90 degree angle) from the right side of the chassis (Fig.

0937).


Fig 0939

PICT-0294

6-2

Fig 0937

PICT-0273




12. Remove the bottom bolt, nut and spacer securing the right hand side plate to the frame (Fig. 0942).

Fig 0940

PICT-0295

Fig 0942

PICT-0562

11. Unhook the hydro idler pulley spring from the tab on the chassis (Fig. 0941).

13. Loosen the nut securing the hydro idler shoulder bolt to the frame until there is enough clearance for the hydro belt to pass over the top of the idler pulley assembly (Fig. 0943).

6

Fig 0941

PICT-0559

Fig 0943

PICT-0563



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

Installation

6

1. Route the hydro drive belt around the pulleys as shown (Fig. 0945):

Note: The spring and clutch have been removed for photo purposes.

3. Install the bolt, spacer and nut securing the bottom of the right side plate to the frame (Fig. 0947).

6-4

Fig 0945

PICT-0348a

Fig 0947

PICT-0562




0950).


(Fig. 0948).

Fig 0950

PICT-0363

Fig 0948

PICT-0361

5. Feed the cutch harness plug up through the frame

(Fig. 0949).

7. Plug the PTO clutch wire into the harness connector

(Fig. 0951).

6

Fig 0949

PICT-0362a

Fig 0951

PICT-0548a



8. Install the hydro idler spring to the spring post (Fig.

0952).

10. Install the PTO idler spring to the spring post on the frame (Fig. 0954).

Fig 0954

PICT-0291a

Fig 0952

PICT-0565

6

9. Route the PTO drive belt around the clutch (Fig.

0953).

11. Install the trailing shield into the frame by fi rst inserting the right side of the trailing shield rod (bent at a 90 degree angle) into the hole in the right side of the frame and then insert the left end of the trailing shield rod (bent at a 45 degree angle) into the hole in the left side of the frame (Fig. 0955).

6-6

Fig 0953

PICT-0364a

Fig 0955

PICT-0273





15. Connect the negative (black) battery cable to the negative battery terminal and cover the connection with the boot (Fig. 0958).


Fig 0958

PICT-0250

Fig 0956

PICT-0283

Hydro Idler Replacement

Hydro Idler Removal


2. Using a spring removal tool (Toro part number 92-

5771), unhook the hydro idler spring from the tab on the frame (Fig. 0959).

6

Fig 0957

PICT-0280

Fig 0959

PICT-0573



the idler lever assembly to the frame (Fig. 0960).

5. Remove the spring from the idler lever assembly

(Fig. 0962).

6

Fig 0960

PICT-0576

Fig 0962

PICT-0579

4. Remove the idler assembly from the frame (Fig.

0961).

6. Remove the nut from the bolt securing the pulley to the idler lever (Fig. 0963).

Fig 0961

PICT-0578

Fig 0963

PICT-0581



7. Remove the bolt, washer, pulley, and spacer from the idler lever (Fig. 0964).

Hydro Idler Installation

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

PICT-0593

8. Inspect the bearing and bushings in the pulley and idler lever. If worn or damaged they must be replaced.

Hydro Idler Assembly (Fig. 0965).

2. Slide the spacer onto the bolt (Fig. 0967).

6

A

B

A. Bolt

B. Washer

C. Pulley

C

D

E F

Fig 0965

PICT-0590a

D. Spacer

F. Nut

Fig 0967

PICT-0594



3. Slide the idler lever onto the bolt (Fig. 0968).

5. Hook the spring onto the idler lever (Fig. 0970).

6

Fig 0968

PICT-0596

4. Install a nut to secure the hydro idler pulley assembly to the lever (Fig. 0969).

Fig 0970

PICT-0579

6. Position the idler assembly up to the frame (Fig.

0971).

Fig 0969

PICT-0597

Fig 0971

PICT-0578



7. Route the hydro drive belt around the idler pulley

(Fig. 0972).

9. Using a spring removal tool (Toro part number 92-

5771), hook the hydro idler spring to the tab on the frame (Fig. 0974).

Fig 0972

PICT-0598

Fig 0974

PICT-0573 idler lever assembly to the frame and tighten (Fig.

0973).

Fig 0973

PICT-0600

Hydraulic Pump Replacement

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. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.

Upon removal, all seals, O-rings, and gaskets should be replaced. During installation, lightly lubricate all seals, O-rings, and gaskets with clean petroleum jelly prior to assembly.

For pump service information, refer to Hydro-

Gear BDP-10A / 16A / 21L Service and Repair

Manual (492-4789).

The following procedure is the same for the right or left hydraulic pump removal.

6



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. 0975).

4. Loosen the two pulley hub set screws (Fig. 0977).

Fig 0975

PICT-0402

6

3. Slip the hydro drive belt off the pulley (Fig. 0976).

Fig 0977

PICT-0405a

5. Slide the pulley off the hydraulic pump shaft (Fig.

0978).

6-12

Fig 0976

PICT-0403

Fig 0978

PICT-0406



6. The pulley key may fall out of the keyway or stay in.

Remove the key if it did not fall out on its own (Fig.

0979).

9. Remove the charge hose from the hydraulic pump fi tting. Cap the hydraulic hose and fi tting to prevent debris from entering the system (Fig. 0981).

Fig 0981

PICT-0422a

Fig 0979

PICT-0408

7. Inspect the key and replace if worn or damaged.

8. Remove the return line from the hydro pump fi tting and drain the hydraulic fl uid into a drain pan. Cap the hydraulic hose and fi tting to prevent debris from entering the system. (Fig. 0980).

10. Mark one of the high pressure hoses and the corresponding port location on the pump. Remove both of the high pressure hoses from the fi ttings on the pump. Cap the hydraulic hoses and fi ttings to prevent debris from entering the system (Fig. 0982).

6

Fig 0980

PICT-0420


Fig 0982

PICT-0425

6-13


11. Unhook the lower end of the extension spring from the control shaft (Fig. 0983).

13. Loosen the set screws located in the control shaft.

The lower set screw can be accessed through the opening in the frame (Fig. 0985).

6

Fig 0983

PICT-0427a

12. Remove the two mounting bolts and nuts securing the hydraulic pump to the frame (Fig. 0984).

Fig 0985

PICT-0430

14. Disconnect the pump from the control shaft and remove the pump from the frame (Fig. 0986).

Fig 0984

PICT-0429

Fig 0986

PICT-0432



15. Transfer all 4 fi ttings to the new pump as well as the mark indicating the location of one of the high pressure hydraulic hoses (Fig. 0987). Torque each fi tting as noted:

Hydraulic Pump Installation

1. Position the pump into the frame so that the pump shaft is inserted into the control shaft (Fig. 0988).

Fig 0987

PICT-0433a

A. High pressure hose (2) (torque: 34-38 ft-lbs. (46-

51.5 Nm))

B: High pressure hose marking

Nm) (brass), 15-21 ft-lbs. (20-28.4 Nm) (steel))

Fig 0988

PICT-0431

2. Apply thread locking compound to the 2 control shaft set screws (Fig. 0989).

6


Fig 0989

PICT-0435a

6-15


3. Install the 2 set screws into the control shaft (Fig.

0990).

5. Install 2 bolts and nuts securing the pump to the frame (Fig. 0992).

6

Fig 0990

PICT-0430

4. Hook the hydro pump spring to the bolt on the control shaft (Fig. 991).

Fig 0992

PICT-0429

6. Install the 2 high pressure hoses to the fi ttings on the pump (Fig. 0993).

Note: Ensure that the marked hose is connected to the marked port on the pump.

Fig 991

PICT-0427a

Fig 0993

PICT-0425



7. Install the charge hose to the charge hose fi tting

(Fig. 0994).

9. Apply anti-seize compound to the pump shaft (Fig.

0996).

Fig 0994

PICT-0422a

Fig 0996

PICT-0437

8. Install the return line to the hydro pump fi tting (Fig.

0995).

10. Install the key into the pump shaft keyway (Fig.

0997).

6

Fig 0995

PICT-0420

Fig 0997

PICT-0409



11. Apply thread locking compound onto the 2 pulley set screws. Thread the 2 set screws into the pulley hub

(Fig. 0998).

13. Torque the 2 set screws to 11 + 1 ft-lbs. (14.9 + 1.4

Nm) (Fig. 1000).

6

Fig 0998

PICT-0439

Fig 1000

PICT-0440

14. Position the drive belt onto the pulley (Fig. 1001).

12. Install the pump pulley onto the pump shaft and tighten the 2 set screws (Fig. 0999).

Fig 0999

PICT-0441

Fig 1001

PICT-0403



15. Install the idler spring onto the tab on the chassis

(Fig. 1002).

Fig 1002

PICT-0402

Wheel Motor Replacement

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. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.

Upon removal, all seals, O-rings, and gaskets should be replaced. During installation, lightly lubricate all seals, O-rings, and gaskets with clean petroleum jelly prior to assembly.

For wheel motor service information, refer to Parker/Ross Wheel Motor Service Manual

(492-4753).

Note: The following procedures can be followed for both the right and the left wheel motor.

16. Check the oil level in the hydraulic reservoir and fi ll as necessary.

17. Remove air from the hydraulic system. Refer to

“Bleeding the Hydraulic System” on page 6-32.

Wheel Motor Removal

1. Apply the parking brake.

2. Loosen the 4 lug nuts (Fig. 1003).

6


Fig 1003

PICT-0442a

6-19


3. Remove the hub nut from the wheel motor shaft (Fig.

1004).


7. Remove the wheel and tire assembly (Fig. 1006).

6

Fig 1004

PICT-0443a

Fig 1006

PICT-0445a

4. Raise the rear of the machine and secure with jack stands.

5. Remove the 4 lug nuts (Fig. 1005).

8. Install a hub puller (Toro p/n TOR6006) onto the wheel studs (Fig. 1007).

Fig 1005

PICT-0444a

Fig 1007

PICT-0446



9. Advance the forcing screw through the hub puller.

Tighten the lug nuts down evenly until the hub pops off the wheel motor shaft (Fig. 1008).

12. Thoroughly clean the area around the hydraulic fi ttings to prevent debris from entering the system.

13. Mark the hoses and corresponding wheel motor fi tting ports so the hoses are reconnected back in their original locations (Fig. 1010).

Fig 1008

PICT-0447

10. Remove the hub puller from the hub.

11. Remove the key from the keyway (Fig. 1009).

Fig 1010

PICT-0451

14. Position a drain pain under the wheel motor.

15. Disconnect both hydraulic hoses from the wheel motor (Fig. 1011).

6

Fig 1009

PICT-0448


Fig 1011

PICT-0453

6-21


16. Cap the hoses and wheel motor fi ttings so that debris does not enter the system. Position the hose ends out of the way of the wheel motor.

17. Remove the 4 bolts securing the wheel motor to the motor mount (Fig. 1012).

19. Remove the 2 fi ttings from the wheel motor (Fig.

1014).

6

Fig 1014

PICT-0456

Fig 1012

PICT-0454

Wheel Motor Installation

18. Remove the wheel motor (Fig. 1013).

ment wheel motor. Torque the fi ttings to 85-95 ft-lbs.

(115-129 Nm) (Fig. 1015).

Fig 1013

PICT-0455

Fig 1015

PICT-0456



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 markings made previously. Torque the hose fi ttings to

34-38 ft-lbs. (46-52 Nm) (Fig. 1018).

Fig 1016

PICT-0455

3. Install 4 bolts to secure the wheel motor to the motor mount (Fig. 1017).

Fig 1018

PICT-0453

5. Install the woodruff key into the wheel motor shaft keyway (Fig. 1019).

6

Fig 1017

PICT-0454

Fig 1019

PICT-0449



6. Clean the hub and shaft to remove any grease or oil.

Slide the hub onto the wheel motor shaft (Fig. 1020).

8. Slide the wheel and tire assembly onto the hub (Fig.

1022).

6

Fig 1020

PICT-0457

7. Loosely install the hub nut onto the wheel motor shaft (Fig. 1021).

1023).

Fig 1022

PICT-0460a

Fig 1021

PICT-0459

Fig 1023

PICT-0461a



10. Lower the machine so the rear tires are resting on the ground.


12. Tighten and torque the 4 lug nuts to 85 + 8 ft-lbs.

(115 + 11 Nm) (Fig. 1024).

14. Fill the hydraulic reservoir tank with hydraulic fl uid

(15w-50 synthetic engine oil) as specifi ed. Note that there are fi ll level lines inside of the reservoir (Fig.

1026).

Fig 1026

PICT-0382

Fig 1024

PICT-0463a

15. Purge the hydraulic system. See “Bleeding the

Hydraulic System” on page 6-32.

13. Tighten and torque the hub nut to 200 + 25 ft-lbs.

(271 + 34 Nm) (Fig. 1025).

6

Fig 1025

PICT-0462a



Hydraulic Reservoir Replacement

Note: There is a hydraulic reservoir shield included on international models (Fig. 1027):

Hydraulic Reservoir Removal

1. Remove the nuts and bolts securing the hydraulic reservoir to the frame (Fig. 1029).

Fig 1029

PICT-0383a

Fig 1027

PICT-2126

6

Use the hydraulic tank mounting hardware (2 bolts and nuts) to install the shield to the tank.

Hydraulic Reservoir Shield (Fig. 1028):

2. Remove the reservoir cap. Hold the hydraulic reservoir upside down to drain the fl uid from the reservoir into a drain pan (Fig. 1030).

6-26

Fig 1028

PICT-2125

Fig 1030

PICT-0385



3. Remove the hydraulic lines from the bottom of the hydraulic reservoir tank (Fig. 1031).

Fig 1031

PICT-0388

Fig 1033

PICT-0393a

4. Loosen the locking nut on the reservoir fi tting. (Fig.

1032).

6. Repeat steps 4 and 5 to remove the second fi tting from the reservoir.

Hydraulic Reservoir Installation

1. Install two hydraulic fi ttings into the bottom of the reservoir. Orient as shown (Fig. 1034):

6

Fig 1032

PICT-0392a


Fig 1034

PICT-0394a

6-27


2. Tighten the locking nuts while maintaining the orientation of the fi ttings (Fig. 1035).

4. Install the two hydraulic hoses onto the reservoir fi ttings (Fig. 1037).

6

Fig 1035

PICT-0396a

Fig 1037

PICT-0436a

3. Position the reservoir assembly onto the mounting fl ange. Install 2 bolts and nuts securing the reservoir

(Fig. 1036).

5. Fill the reservoir with hydraulic fl uid (15w-50 synthetic engine oil) as specifi ed. Note that there are fi ll level lines inside of the reservoir (Fig. 1038).

6-28

Fig 1036

PICT-0400

Fig 1038

PICT-0382

6. Replace reservoir cap.

7. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 6-32.



Hydraulic Testing

Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.

The following procedure is performed on the left wheel motor hydraulic hoses. It can also be performed from several other locations on the machine.

When using a Bi-Directional Flow Test Kit, determining directional fl ow is not necessary. The fl ow meter may be connected in either direction into the forward and reverse high pressure system lines.

Caution: Ensure all fi ttings and hoses are attached securely. This test is performed on the machine’s high pressure system. Failure to comply could result in serious injury.


2. Loosen the 4 lug nuts (Fig. 1039).

3. Raise the rear of the machine and secure with jack stands.


5. Remove the 4 lug nuts and the wheel assembly (Fig.

1040).

Fig 1040

PICT-0375

6. Thoroughly clean the area around the hydraulic fi ttings to prevent debris from entering the system.

7. Mark the hoses and corresponding wheel motor fi tting ports (Fig. 1041).

6

Fig 1039

PICT-0373a


Fig 1041

PICT-0377

6-29


8. Position a drain pan under the wheel motor.

9. Disconnect both hydraulic hoses from the wheel motor (Fig. 1042).

12. Open the restriction valve all the way (counterclockwise) (Fig. 1044).

Fig 1044

PICT-6886a

Fig 1042

PICT-0379

10. Cap the wheel motor fi ttings so debris does not enter the system.

11. Attach the hydraulic hoses to the fl ow test gauge

(Fig. 1043).

6

Note: When using a fl ow test gauge that is not bidirectional, damage to the fl ow tester could occur if the machine is operated in reverse.

13. Run the machine for 2 minutes in forward (no load) to purge air from the system.

14. Run the machine at full throttle (no load). Verify the

RPM with a tachometer: 3200 + 150 RPM’s.

Do not exceed 3600 RPM.

15. With the drive control fully forward, slowly tighten the restriction valve until the gauge indicates 300 PSI

(21 bar).

16. Record the fl ow reading from the bi-directional fl ow meter. Refer to the Hydro-Gear manual for acceptable GPM. Make a second fl ow reading at 1100 PSI

(76 bar) and record that reading. Subtract the fi rst reading from the second reading and determine if it is an acceptable GPM.

Example:

1st Reading: 300 psi (21 bar) reading 7 gpm (26 l/m).

2nd Reading: 1100 psi (76 bar) reading 3 gpm (11 l/m).

7 gpm (1st reading)

- 3 gpm (2nd reading)

4 gpm (the difference)

An acceptable “fl ow droop” or difference is 1.5 gpm

(5.6 l/m)

Fig 1043

PICT-6885



17. After all necessary repairs have been made, reconnect the hydraulic hoses to the wheel motor fi ttings.

18. Slide the wheel and tire assembly onto the hub and snug fi t the 4 lug nuts on the wheel hub studs (Fig.

1045).

22. Fill the reservoir with hydraulic fl uid (15w-50 synthetic engine oil) as specifi ed. Note that there are fi ll level lines inside of the reservoir (Fig. 1047).

Fig 1047

PICT-0382

Fig 1045

PICT-0380


24. Bleed the hydraulic system. See “Bleeding the

Hydraulic System” on page 6-32.

19. Lower the machine so the rear tires are resting on the ground.


21. Tighten and torque the 4 lug nuts to 85 + 8 ft-lbs.

(115 + 11 Nm) (Fig. 1046).

6

Fig 1046

PICT-0381



6

Bleeding the Hydraulic System

Due to the effects air has on effi ciency in hydrostatic drive applications, it is critical that air is purged from the system.

These purge procedures should be implemented anytime a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.

Air creates ineffi ciency because it has compression and expansion rates that are higher than that of oil.

Entrained air in the oil may cause the following symptoms:

• Noisy operation

• Lack of power or drive after short-term operation

• High operation temperature and excessive expansion of oil.

Before starting, make sure the reservoir is at the proper oil level. If it is not, fi ll to the vehicle manufacturer’s specifi cations.

The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.

!

WARNING

POTENTIAL FOR SERIOUS INJURY

Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured.

1. Disengage the PTO.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Support the rear of the machine on jack stands high enough to raise the drive wheels off the ground.

4. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times), as air is purged from the unit, the oil level will drop.

5. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping engine.

6. It may be necessary to repeat Steps 4 and 5 until all the air is completely purged from the system. When the BDP’s move forward and reverse at normal speed purging is complete.

Cleanliness is a key factor in the successful repair of

BDP’s. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.

Upon removal, all seals, O-rings, and gaskets should be replaced. During installation, lightly lubricate all seals, O-rings, gaskets with clean petroleum jelly prior to assembly. Also protect the inner diameter of seals by covering the shaft machined features with plastic wrap or equivalent.



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 deterioration. Make necessary repairs before operating.

Note: Keep areas around hydraulic system clean from grass and debris build up.

!

!

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

6



Hydraulic Schematic

6

6-34

Fig 1048

hyd scheme G006100


Traction Drive Belt Replacement

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” Mower

Deck)” on page 8-4, or “Mower Spindle Drive Belt

Belt Removal (40”, 48”, 52” and 60” Mower Decks)” on page 8-1.

2. Unplug the clutch from the wire harness (Fig. 1049).

GEAR DRIVE

3. Push the clutch wire plug and grommet through the engine deck frame (Fig. 1050).

Fig 1050

PICT-1357


Fig 1049

PICT-1422

Fig 1051

PICT-1368

7


7

GEAR DRIVE

5. Unhook the gear drive idler spring from the tab on the frame (Fig. 1052).

Traction Drive Belt Installation


1. Route the traction drive belt around the pulleys (Fig.

1054).

A

B

C

H

D

Fig 1052

PICT-1443

6. Remove the traction drive belt from around the pulleys and remove it from the machine (Fig. 1053).

G

Fig 1054

F

E

fi g. 47 G000264

B. Transmission belt

C. Tension spring

D. Driven pulley

F. Idler pulley

G. Engine deck

H. Clutch wire connector

2. Hook the drive belt idler spring to the tab on the frame (Fig. 1055).

Fig 1053

PICT-1447

Fig 1055

PICT-1443


GEAR DRIVE

7. Feed the clutch harness plug up through the chassis

(Fig. 1056).

9. Install the bolt, nut, 2 washers and spacer to secure the brake clutch strap to the underside of the frame

(Fig. 1058).

Fig 1056

PICT-1415


1057).

Fig 1058

PICT-1488

10. Plug the clutch into the wire harness (Fig. 1059).

Fig 1057

PICT-1417

Fig 1059

PICT-1422

11. Install the mower spindle drive belt. Refer to:

“Mower Spindle Drive Belt Belt Installation (36”

Mower Deck)” on page 8-5, or “Mower Spindle Drive

Belt Belt Installation (40”, 48”, 52” and 60” Mower

Decks)” on page 8-2.


7

7

GEAR DRIVE

Gear Drive Idler Replacement


Gear Drive Idler Removal


2. Unhook the drive belt idler spring from the tab on the frame (Fig. 1060).

3. Remove the nut from the bolt securing the gear drive idler arm to the frame (Fig. 1061).

Fig 1061

PICT-1497

4. Remove the gear drive idler assembly out of the frame (Fig. 1062).

Fig 1060

PICT-1496

Fig 1062

PICT-1499


5. Remove the shoulder bolt from the idler arm assembly (Fig. 1063).

GEAR DRIVE

7. Remove the nut from the bolt securing the idler pulley to the idler arm (Fig. 1065).

Fig 1063

PICT-1500a

Fig 1065

PICT-1502a

6. Remove the spring from the idler arm (Fig. 1064).

8. Remove the bolt and idler pulley from the idler arm

(Fig. 1066).

Fig 1064

PICT-1501

Fig 1066

PICT-1507a

7


GEAR DRIVE

9. Remove the 2 fl ange bushings from the idler arm

(Fig. 1067).

2. Install the pulley to the idler arm with a bolt and nut.

The pulley hub is installed facing the idler arm (Fig.

1069).

Fig 1067

PICT-1506a

Gear Drive Idler Installation

Fig 1069

PICT-1504a

3. Install the idler spring onto the idler arm (Fig. 1070).

1068).

7

Fig 1068

PICT-1508

Fig 1070

PICT-1501


GEAR DRIVE

4. Insert the shoulder bolt into the idler arm pivot and position the idler assembly into the frame (Fig.

1071).

6. Hook the drive belt idler spring to the tab on the frame (Fig. 1073).

Fig 1071

PICT-1499

Fig 1073

PICT-1496

5. Install a nut onto the shoulder bolt securing the idler assembly to the frame (Fig. 1072).

Transmission Driven Pulley

Replacement


Transmission Driven Pulley Removal



7

Fig 1072

PICT-1497


GEAR DRIVE

3. Unhook the drive belt idler spring from the tab on the frame (Fig. 1074).

5. Remove the gear drive idler assembly out of the frame (Fig. 1076).

Fig 1074

PICT-1496

Fig 1076

PICT-1499


6. Remove the drive belt from the transmission driven pulley (Fig. 1077).

7

Fig 1075

PICT-1497

Fig 1077

PICT-1575


GEAR DRIVE

7. Remove the retaining ring from the end of the transmission drive shaft (Fig. 1078).

9. Slide the driven pulley off the transmission drive shaft (Fig. 1080).

Fig 1078

PICT-1510

Fig 1080

PICT-1512

8. Loosen the set screw securing the transmission driven pulley to the transmission driveshaft (Fig.

1079).

10. Remove the key from the transmission driveshaft keyway (Fig. 1081).

Fig 1079

PICT-1511

Fig 1081

PICT-1513

7


GEAR DRIVE

11. Remove the set screw from the driven pulley (Fig.

1082).

2. Insert the key into the keyway on the transmission driveshaft (Fig. 1084).

Fig 1082

PICT-1515

Fig 1084

PICT-1566

Transmission Driven Pulley Installation

1. Apply anti-seize to the transmission driveshaft (Fig.

1083).

3. Apply thread locking compound to the driven pulley set screw (Fig. 1085).

7

Fig 1083

PICT-1564

Fig 1085

PICT-1567a


GEAR DRIVE

4. Begin threading the set screw into the driven pulley hub (Fig. 1086).

6. Tighten the set screw securing the transmission driven pulley to the transmission driveshaft (Fig.

1088).

Fig 1086

PICT-1518

5. Slide the driven pulley onto the transmission drive shaft (Fig. 1087).

Fig 1088

PICT-1511

7. Install a retaining ring onto the end of the transmission drive shaft (Fig. 1089).

Fig 1087

PICT-1571

Fig 1089

PICT-1510

7


GEAR DRIVE

8. Install the drive belt onto the transmission driven pulley (Fig. 1090).

10. Install a nut onto the bolt securing the gear drive 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 frame with the bolt inserted through the mounting hole (Fig. 1091).

11. Hook the gear drive idler spring to the spring tab on the frame (Fig. 1093).

7

7-12

Fig 1091

PICT-1499


Fig 1093

PICT-1496


GEAR DRIVE


Gear Drive Transmission

Replacement


Gear Drive Transmission Removal



3. Unhook the gear drive idler spring from the tab on the frame (Fig. 1094).

Fig 1095

PICT-1497

5. Lower the gear drive idler assembly out of the frame

(Fig. 1096).

Fig 1094

PICT-1496

Fig 1096

PICT-1499

7


GEAR DRIVE

6. Remove the drive belt from the transmission driven pulley (Fig. 1097).

8. Loosen the set screw securing the transmission 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 transmission drive shaft (Fig. 1098).

9. Slide the driven pulley off the transmission driveshaft

(Fig. 1100).

7

Fig 1098

PICT-1510

Fig 1100

PICT-1512


10. Remove the key from the transmission driveshaft keyway (Fig. 1101).

GEAR DRIVE


1103).

Fig 1101

PICT-1513

Fig 1103

PICT-1520





(Fig. 1102).

Fig 1104

PICT-1521

7

Fig 1102

PICT-1519


GEAR DRIVE

16. Remove the wheel drive belt from the transmission pulley (Fig. 1105).

18. Slide the transmission pulley/output shaft assembly 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 transmission axle fl ange bearing to the frame (Fig. 1106).

19. Remove the coupler and coupler guard from the transmission splined shaft (Fig. 1108).

7

Fig 1106

PICT-1525

Fig 1108

PICT-1531


GEAR DRIVE

20. Remove the 2 bolts and nuts that secure the opposite transmission axle fl ange bearing to the frame

(Fig. 1109).

22. Remove the transmission from the frame by rocking it backward and pulling the transmission from the remaining coupler assembly (Fig. 1111).

Note: The coupler may come off of the axle with the transmission. If so, remove it from the transmission and replace it onto the axle.

Fig 1109

PICT-1536

21. Remove the 4 transmission mounting bolts and lock washers (Fig. 1110).

Fig 1111

PICT-1542a

23. Remove the 4 bolts securing the shift plate to the transmission (Fig. 1112).

7

Fig 1110

PICT-1534


Fig 1112

PICT-5056a

7-17

GEAR DRIVE

24. Remove the shift plate assembly from the transmission (Fig. 1113).

26. Remove the shift lever and washer from the transmission shifter shaft (Fig. 1115).

Note: For transmission service procedures, refer to the appropriate Tecumseh Peerless Service

Manual.

7

Fig 1113

PICT-5060

25. Remove the bolt and Belleville washer securing the shift lever to the transmission (Fig. 1114).

Fig 1115

PICT-5070a

Gear Drive Transmission Installation

1. Install the square ID washer and shift lever onto the transmission shifter shaft (Fig. 1116).

Fig 1114

PICT-5067a

Fig 1116

PICT-5072a


GEAR DRIVE

2. Install the Belleville washer oriented with the crown up (Fig. 1117).

4. Position the shift plate assembly over the shift lever 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 to the transmission shifter post. Torque the nut to 30

– 35 ft-lbs. (40.67 – 47.45 Nm) (Fig. 1118).

5. Install 4 bolts to secure the shift plate to the transmission (Fig. 1120).

Fig 1118

PICT-5080a

Fig 1120

PICT-5087

7


GEAR DRIVE

6. Slide the transmission splined shaft into the RH coupler assembly. Position the transmission so that the output shaft drops through the opening in the frame (Fig. 1121).

8. Install 4 transmission mounting bolts and lock washers securing the transmission to the frame (Fig.

1123).

7

Fig 1121

PICT-1549

Fig 1123

PICT-1534

7. Install 2 bolts and nuts to secure the fl ange bearing to the frame (Fig. 1122).

9. Slide the coupler and coupler guard onto the transmission splined shaft (Fig. 1124).

Note: Align the 2 grease fi ttings.

Fig 1122

PICT-1536

Fig 1124

PICT-1553a


GEAR DRIVE

10. Slide the transmission pulley/output shaft assembly through the frame and into the coupler assembly

(Fig. 1125).

Note: Relubricate the shafts, if needed (Fig. 1127).

Fig 1127

PICT-1553a

Fig 1125

PICT-1554

11. Install 2 bolts and nuts securing the transmission axle fl ange bearing to the frame (Fig. 1126).

12. Route the wheel drive belt around the transmission pulley (Fig. 1128).

Fig 1126

PICT-1525

Fig 1128

PICT-1524

7


GEAR DRIVE

13. Rotate the idler support bracket back in place so that the mounting holes line up with the holes in the frame (Fig. 1129).


1131).

Fig 1129

PICT-1555

Fig 1131

PICT-1520

14. Loosely install 3 idler support bracket mounting bolts and nuts (Fig. 1130).

16. Tighten the 3 lower idler support bracket mounting bolts (Fig. 1132).

7

Fig 1130

PICT-1519

Fig 1132

PICT-1519


GEAR DRIVE


18. Apply anti-seize to the transmission driveshaft (Fig.

1133).

20. Apply thread locking compound to the driven pulley set screw (Fig. 1135).

Fig 1135

PICT-1567a

Fig 1133

PICT-1564

21. Begin threading the set screw into the driven pulley hub (Fig. 1136).

19. Insert the key into the keyway on the transmission driveshaft (Fig. 1134).

Fig 1136

PICT-1518

7

Fig 1134

PICT-1566


GEAR DRIVE

22. Slide the driven pulley onto the transmission drive shaft (Fig. 1137).

24. Install a retaining ring onto the end of the transmission drive shaft (Fig. 1139).

Fig 1137

PICT-1571

Fig 1139

PICT-1510

23. Tighten the set screw securing the transmission driven pulley to the transmission driveshaft (Fig.

1138).

25. Route the drive belt onto the transmission driven pulley (Fig. 1140).

7

Fig 1138

PICT-1511

Fig 1140

PICT-1575


GEAR DRIVE

26. Insert the shoulder bolt into the idler arm pivot and position the idler assembly into the frame (Fig.

1141).

28. Hook the gear drive idler spring to the spring tab on the frame (Fig. 1143).

Fig 1141

PICT-1499


27. Install a nut onto the bolt securing the gear drive idler arm to the frame (Fig. 1142).

Fig 1143

PICT-1496

7

Fig 1142

PICT-1497


GEAR DRIVE


7


Mower Spindle Drive Belt

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.


MOWER DECKS

4. Rotate the belt guide out of the way of the PTO drive belt (Fig. 1146).

Fig 1144

PICT-1038

3. Loosen the nut securing the center spindle belt guide to the mower deck (Fig. 1145).

Fig 1146

PICT-1024a

5. Roll the PTO drive belt off the center spindle pulley

(Fig. 1147).

Fig 1147

PICT-1026

8

Fig 1145

PICT-1023a


MOWER DECKS

6. Remove the right and left belt covers (Fig. 1148).

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) remove the idler spring from the spring plate (Fig.

1149).

Mower Spindle Drive Belt Installation

(40”, 48”, 52” and 60” Mower Decks)

1. Route the mower spindle drive belt around the mower deck pulleys. Refer to the deck routing decal

(Fig. 1151):

8

Fig 1149

PICT-1042

Fig 1151

fi g. 104-8186


MOWER DECKS

2. Using a spring removal tool (Toro p/n: 92-5771), hook the idler spring to the spring plate (Fig. 1152).

4. Ensure the PTO drive belt is routed around the clutch pulley and the idler pulley. Roll the PTO drive belt onto the center spindle pulley (Fig. 1154 and

Fig. 1155).

Fig 1152

PICT-1042

3. Install the right and left belt covers (Fig. 1153).

Fig 1154

PICT-1030a

Fig 1153

PICT-1039

Fig 1155

PICT-1026a

8


MOWER DECKS

5. Rotate the belt guide into place so that it is approximately 1/8” (3mm) away from the PTO drive belt

(Fig. 1156).


Fig 1158

PICT-1022

Fig 1156

PICT-1031

6. Tighten the nut securing the center spindle belt guide to the mower deck (Fig. 1157).

Mower Spindle Drive Belt Removal

(36” Mower Deck)

1. Remove the PTO drive belt. Refer to “PTO Drive Belt


2. Unhook the idler spring from the spring post (Fig.

1159).

8

8-4

Fig 1157

PICT-1023a

Fig 1159

PICT-1448


MOWER DECKS

3. Remove the mower deck belt from around pulleys and remove it from the machine (Fig. 1160).

2. Hook the idler spring to the spring post (Fig. 1162).

Fig 1160

PICT-1449

Fig 1162

PICT-1448

3. Install the PTO drive belt. Refer to “PTO Drive Belt


Mower Spindle Drive Belt Installation


1. Route the mower spindle drive belt around the pulleys. Refer to the belt routing decal (Fig. 1161).

Fig 1161

fi g. 104-8185


8

MOWER DECKS

PTO Drive Belt Replacement

PTO Drive Belt Removal

(40”, 48”, 52” and 60” Mower Decks)




5. Rotate the belt guide out of the way of the PTO drive belt (Fig. 1165).

Fig 1163

PICT-1038

4. Loosen the nut securing the center spindle belt guide to the mower deck (Fig. 1164).

Fig 1165

PICT-1024a

6. Roll the PTO drive belt off the center spindle pulley

(Fig. 1166).

Fig 1166

PICT-1026a

8

8-6

Fig 1164

PICT-1023a


MOWER DECKS

7. Raise the machine to access the underside.

8. Remove the PTO drive belt from around the clutch pulley and the idler pulley and remove it from the machine (Fig. 1167).

3. Lower the machine to access the top of the mower deck.

4. Roll the PTO drive belt onto the center spindle pulley

(Fig. 1169).

Fig 1167

PICT-1028

Fig 1169

PICT-1026a

PTO Drive Belt Installation

(40”, 48”, 52” and 60” Mower Decks)


2. Route the PTO drive belt around the clutch pulley and the idler pulley (Fig. 1168).

5. Rotate the belt guide into place so that it is approximately 1/8” (3mm) away from the PTO drive belt

(Fig. 1170).

Fig 1168

PICT-1030a


Fig 1170

PICT-1031

8

8-7

MOWER DECKS

6. Tighten the nut securing the center spindle belt guide to the mower deck (Fig. 1171).

PTO Drive Belt Removal (36” Mower Decks)



Fig 1171

PICT-1023a


Fig 1173

PICT-1358

3. Remove the mower deck belt cover (Fig. 1174).

8

Fig 1172

PICT-1022

Fig 1174

PICT-1360


MOWER DECKS

4. Roll the deck drive belt off the fi xed (center) mower deck pulley (Fig. 1175).

7. Remove the belt from the clutch pulley and remove it from the machine (Fig. 1177).

Fig 1175

PICT-1361

Fig 1177

PICT-1365a


6. Remove PTO belt idler pulley spring from frame bolt

(Fig. 1176).

PTO Drive Belt Installation

(36” Mower Decks)


2. Route the deck drive belt around the clutch pulley

(Fig. 1178).

Fig 1176

PICT-0287


Fig 1178

PICT-1365a

8

8-9

MOWER DECKS

3. Install the PTO belt idler pulley spring onto the frame bolt (Fig. 1179).

6. Roll the PTO drive belt onto the fi xed (center) mower deck pulley (Fig. 1181).

Fig 1179

PICT-0287


5. Route the spindle drive belt around the pulleys.

Refer to the belt routing decal (Fig. 1180).

Fig 1181

PICT-1361

7. Install the mower deck belt cover (Fig. 1182).

8

Fig 1180

fi g. 104-8185

Fig 1182

PICT-1360



MOWER DECKS

2. Install a blade stop to secure the blade (Fig. 1184).

Fig 1184

PICT-1185

Fig 1183

PICT-1358

Spindle Replacement and Service

Spindle Removal and Teardown

1. Remove one or both drive belts, depending on spindle being removed Refer to:

• “PTO Drive Belt Removal (40”, 48”, 52” and 60”

Mower Decks)” on page 8-6 or

• “PTO Drive Belt Removal (36” Mower Decks)” on page 8-8 and

• “Mower Sindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks)” on page 8-1, or

• “Mower Spindle Drive Belt Removal (36” Mower

Deck)” on page 8-4.

3. Support the blade/spindle shaft assembly and remove the spindle nut (Fig. 1185).

Fig 1185

PICT-1187

8


MOWER DECKS

4. Slide the blade/spindle shaft assembly out of the spindle housing (Fig. 1186).

6. Remove the pulley assembly (Fig. 1188).

Fig 1186

PICT-1188

Fig 1188

PICT-1190

7. Remove the bearing shield (Fig. 1189).

5. Remove the washer (Fig. 1187).

8

Fig 1187

PICT-1189

Fig 1189

PICT-1191


MOWER DECKS

8. Remove the 6 nuts securing the spindle housing to the mower deck (Fig. 1190).

Note: There may be a spring plate installed on one of the spindle bolts.

10. Remove the blade bolt, washer and the blade from the spindle shaft (Fig. 1192).

Fig 1192

PICT-1197

Fig 1190

PICT-1192

Note: 36” and 52” mower decks have a blade stiffener (Fig. 1193).

9. While supporting the housing, remove the 6 selftapping bolts securing the spindle housing to the mower deck. Lower the spindle housing from the mower deck (Fig. 1191).

Fig 1191

PICT-1194


Fig 1193

PICT-1442

8

8-13

MOWER DECKS

11. Remove the 2 bearings and the spacer from the spindle housing (Fig. 1194).

Spindle Rebuild and Installation

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. Replace as necessary.

Spindle Assembly (Fig. 1195)

2. Insert the spacer into the spindle housing (Fig.

1197).

8

A

B

C

D

B

F H

E

G

Fig 1195

PICT-1204a

F. Pulley

G. Washer

H. Nut

8-14

Fig 1197

PICT-1210


3. Install a bearing into the other side of the spindle housing (Fig. 1198).

MOWER DECKS

5. Slide the bearing shield onto the spindle shaft (Fig.

1200).

Fig 1198

PICT-1211

4. Insert the spindle shaft into the spindle housing assembly (Fig. 1199).

Fig 1200

PICT-1214

6. Slide the pulley assembly onto the spindle shaft so the welded center bore of the pulley is facing away from the spindle housing (Fig. 1201).

Note: If the spindle has a dual pulley, the smaller size pulley faced the spindle housing.

Fig 1199

PICT-1212


Fig 1201

PICT-1216

8

8-15

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

8. Install a nut onto the spindle shaft (Fig. 1203).

Fig 1204

PICT-1224

10. Install the blade bolt, washer and blade to the spindle shaft (Fig. 1205).

8

Fig 1203

PICT-1219

Fig 1205

PICT-1226


MOWER DECKS

Note: The “sails” of the blade should be pointing toward the spindle housing.

Note: 36” and 52” mower decks have a blade stiffener that should be installed between the crowned washer and the blade (Fig. 1206).

12. Torque the blade bolt to 85-110 ft-lbs. (115-149 Nm)

(Fig. 1208).

Fig 1208

PICT-1231

Fig 1206

PICT-1442 13. Position the spindle and blade assembly into the mower deck from below and install 6 self-tapping screws to secure the spindle housing to the mower deck (Fig. 1209).

11. Torque the spindle shaft nut to 100 + 10 ft-lbs.

(135.5 + 13.5 Nm) (Fig. 1207).

Fig 1207

PICT-1228


Fig 1209

PICT-1232

8

8-17

MOWER DECKS

14. If applicable, place the spring plate onto the selftapping screw shown (Fig. 1210):

16. Reinstall the drive belt or belts, as applicable. Refer to:

• “Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks)” on page 8-2, or

• “Mower Spindle Drive Belt Installation (36” Mower

Deck)” on page 8-5 and

• “PTO Drive Belt Installation (40”, 48”, 52” and 60”

Mower Decks)” on page 8-7 or

• “PTO Drive Belt Installation (36” Mower Decks)” on page 8-9.

Fig 1210

PICT-1235

15. Install 6 nuts onto the self-tapping screws. Ensure the spring plate is positioned as shown (Fig. 1211).

Idler Arm Assembly Replacement

Idler Arm Assembly Removal

(40”, 48”, 52” and 60” Mower Decks)




8

Fig 1211

IMG-7943a

Fig 1212

PICT-1038


4. Remove the left belt cover (Fig. 1213).

MOWER DECKS

6. Remove the spring from the idler arm assembly (Fig.

1215).

Fig 1213

PICT-1039

5. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring from the spring plate (Fig.

1214).

Fig 1215

PICT-1128

7. If the spring plate requires replacement, remove the nut securing it to the mower deck (Fig. 1216).

Fig 1214

PICT-1042

Fig 1216

PICT-1130

8


MOWER DECKS

8. Remove the mower deck belt from around the idler pulley (Fig. 1217).

10. Remove the idler arm bolt and washer (Fig. 1219).

Fig 1217

PICT-1131

Fig 1219

PICT-1135

9. Remove the nut from the bolt securing the idler arm to the mower deck (Fig. 1218).

11. Remove the idler arm assembly and washer from the mower deck (Fig. 1220).

8

Fig 1218

PICT-1132

Fig 1220

PICT-1137a


MOWER DECKS

12. Remove the nut and washer from the bolt securing the idler pulley to the idler arm (Fig. 1221).

14. Remove the bolt from the idler arm (Fig. 1223).

Fig 1221

PICT-1143

Fig 1223

PICT-1147

15. Remove the spacer from the idler arm (Fig. 1224).

13. Remove the pulley and spacer from the idler arm assembly (Fig. 1222).

Fig 1222

PICT-1145

Fig 1224

PICT-1148

8


MOWER DECKS

16. Remove the grease fi tting from the idler arm (Fig.

1225).

Idler Arm Assembly Installation

(40”, 48”, 52” and 60” Mower Decks)

arm pivot (Fig. 1227).

Fig 1225

PICT-1149

17. Remove the 2 fl ange bushings from the idler arm pivot (Fig. 1226).

Fig 1227

PICT-1153

2. Install a grease fi tting into the idler arm (Fig. 1228).

8

Fig 1226

PICT-1151

Fig 1228

PICT-1149


3. Install the bolt into the idler arm (Fig. 1229).

MOWER DECKS

5. Install the pulley onto the bolt with the hub installed toward the idler arm (Fig. 1231).

Fig 1229

PICT-1163a

4. Install a spacer onto the bolt (Fig. 1230).

Fig 1231

PICT-1167a

6. Install a washer onto the bolt (Fig. 1232).

Fig 1230

PICT-1166a

Fig 1232

PICT-1168a

8


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. Slide a washer onto the bolt on the top side of the mower deck (Fig. 1236).

8

Fig 1234

PICT-1171a

Fig 1236

PICT-1176a


MOWER DECKS

11. Slide the idler arm assembly pivot onto the bolt (Fig.

1237).

13. Ensure the belt is routed properly on the mower deck. Refer to the belt routing decal (Fig. 1239):

Fig 1237

PICT-1177a

Fig 1239

fi g. 104-8186

12. Install a nut onto the idler arm pivot bolt securing the idler arm to the mower deck (Fig. 1238).

14. If it was removed, position the spring plate onto the self-tapping bolt located next to left spindle pulley.

Install a nut to secure the spring plate (Fig. 1240).

Fig 1238

PICT-1132

Fig 1240

PICT-1179

8


MOWER DECKS

15. Hook the spring onto the idler arm (Fig. 1241).

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), install the idler spring to the spring plate (Fig. 1242).

18. Install the left belt cover (Fig. 1244).

8

Fig 1242

PICT-1181

Fig 1244

PICT-1039



MOWER DECKS

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


Idler Arm Assembly Removal




3. Remove the PTO drive belt. Refer to “PTO Drive Belt


4. Remove the mower spindle drive belt. Refer to

“Mower Spindle Drive Belt Removal” on page 8-4.

6. Remove the idler arm assembly from the mower deck (Fig. 1247).

Fig 1247

PICT-1454a

8


MOWER DECKS

7. Remove the spring from the idler arm post (Fig.

1248).

9. Remove the nut, bolt and pulley from the idler arm

(Fig. 1250).

Fig 1248

PICT-1457a

Fig 1250

PICT-1460

8. Remove the spacer from the idler arm pivot (Fig.

1249).

Idler Arm Assembly Installation


1. Position the pulley to the idler arm so that the pulley hub is positioned toward the idler arm (Fig. 1251).

8

Fig 1249

PICT-1459a

Fig 1251

PICT-1465


MOWER DECKS

2. Install a bolt and nut to secure the pulley to the idler arm (Fig. 1252).

4. Position the idler arm assembly onto the mower deck (Fig. 1254).

Fig 1252

PICT-1460

Fig 1254

PICT-1466

3. Slide the spacer into the idler arm pivot (Fig. 1253).

5. Insert a bolt up through the mower deck and through the idler arm pivot. Install a washer and a nut onto the bolt (Fig. 1255).

Fig 1253

PICT-1459a

Fig 1255

PICT-1467a

8


8

8-30

MOWER DECKS

6. Hook the idler spring to the idler arm (Fig. 1256).

Adjustable Baffl e Replacement

Adjustable Baffl e Removal


2. Remove the nut that secures the lock lever to the lock cap (Fig. 1257).

Fig 1256

PICT-1469

7. Install the mower spindle drive belt. Refer to “Mower

Spindle Drive Belt Installation” on page 8-5.

8. Install the PTO drive belt. Refer to “PTO Drive Belt


Fig 1257

PICT-1080

3. Slide the lock lever out of the lock cap (Fig. 1258).

Fig 1258

PICT-1082


4. Remove the lock cap (Fig. 1259).

MOWER DECKS

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 e assembly (Fig. 1260).

7. Remove the self-tapping screw that secures the adjustable baffl e to the underside of the mower deck

(Fig. 1262).

Fig 1260

PICT-1084

Fig 1262

PICT-1088

8


MOWER DECKS

8. Remove the adjustable baffl e from the mower deck

(Fig. 1263).

2. Install a self-tapping screw to secure the adjustable baffl e to the underside of the mower deck (Fig.

1265).

Fig 1263

PICT-1089

Fig 1265

PICT-1088

Adjustable Baffl e Installation

1. Position the adjustable baffl e on the underside of the mower deck (Fig. 1264).

3. Install a nut onto the self-tapping bolt that secures the adjustable baffl e to the underside of the mower deck (Fig. 1266).

8

Fig 1264

PICT-1089

Fig 1266

PICT-1092a


4. Apply anti-seize compound onto the lock screw threads (Fig. 1267).

MOWER DECKS

6. Position the lock cap onto the lock screw (Fig. 1269).

Fig 1267

PICT-1094a

Fig 1269

PICT-1083

5. Thread the lock screw into the bushing of the adjustable baffl e assembly (Fig. 1268).

7. Slide the lock lever into the lock cap (Fig. 1270).

Fig 1268

PICT-1084

Fig 1270

PICT-1082

8


MOWER DECKS

8. Install a nut to secure the lock lever to the lock cap and screw (Fig. 1271).

2. Remove the right hand belt cover (Fig. 1272).

8

Fig 1271

PICT-1080a

Fig 1272

PICT-1236

Discharge Baffl e Replacement

The following procedures cover replacing the discharge baffl e on 40”, 48”, 52” and 60” mower decks. Although the 36” mower deck discharge baffl e looks different, the same procedures can be used for its replacement.

3. Remove the nut from each of the 2 self-tapping screws securing the discharge baffl e to the underside of the mower deck (Fig. 1273).

Discharge Baffl e Removal


Fig 1273

PICT-1238


4. Raise the machine to access the underside of the mower deck.

5. Remove the 2 self-tapping screws securing the discharge baffl e to the mower deck (Fig. 1274).

MOWER DECKS

Discharge Baffl e Installation

1. Position the discharge baffl e to the mower deck (Fig.

1276).

Fig 1274

PICT-1242

Fig 1276

PICT-1244

6. Remove the discharge baffl e from the mower deck

(Fig. 1275).

2. Install 2 self-tapping screws to secure the discharge baffl e to the underside of the mower deck (Fig.

1277).

Fig 1275

PICT-1244

Fig 1277

PICT-1242

8


MOWER DECKS

3. Lower the machine to access the top of the mower deck.

4. Install a nut onto each of the 2 self-tapping screws to secure the discharge baffl e to the underside of the mower (Fig. 1278).

Fixed Baffl e Replacement

Fixed Baffl e Removal

(40”, 48”, 52” and 60” Mower Decks)


2. Remove the nuts from the 2 self-tapping screws that secure the fi xed baffl e to the mower deck (Fig.

1280).

Fig 1278

PICT-1238

5. Install the right hand belt cover (Fig. 1279).

Fig 1280

PICT-1096

3. Remove the carriage bolt and nut securing the fi xed baffl e to the left side of the mower deck (Fig. 1281).

8

8-36

Fig 1279

PICT-1236

Fig 1281

PICT-1098


MOWER DECKS

4. Remove the 2 self-tapping screws securing the fi xed baffl e to the mower deck (Fig. 1282).

Fixed Baffl e Installation

(40”, 48”, 52” and 60” Mower Decks)

1284).

1283).

Fig 1282

PICT-1102

Fig 1284

PICT-1103

2. Install 2 self-tapping screws to secure the fi xed baffl e to the mower deck (Fig. 1285).

Fig 1283

PICT-1103

Fig 1285

PICT-1102

8


MOWER DECKS

3. Install the carriage bolt and nut to secure the fi xed baffl e to the left side of the mower deck (Fig. 1286).

Fixed Baffl e Replacement


Fixed Baffl e Removal (36” Mower Deck)


2. Remove the 2 bolts, washers and nuts securing the fi xed baffl e to the mower deck (Fig. 1288).

Fig 1286

PICT-1098

4. Install a nut onto each of the 2 self-tapping screws that secure the fi xed baffl e to the mower deck (Fig.

1287).

1289).

Fig 1288

PICT-1426

8

8-38

Fig 1287

PICT-1096

Fig 1289

PICT-1427


Fixed Baffl e Installation (36” Mower Deck)

1290).

MOWER DECKS

Skid Plate Replacement

(40”, 48”, 52” and 60” Mower Decks)

Skid Plate Removal

(40”, 48”, 52” and 60” Mower Deck)



3. Remove the carriage bolt and nut securing the front of the skid plate to the mower deck (Fig. 1292).

Fig 1290

PICT-1427

2. Install 2 bolts, washers and nuts to secure the fi xed baffl e to the mower deck (Fig. 1291).

Fig 1292

PICT-1114

8

Fig 1291

PICT-1426


MOWER DECKS

4. Remove the 2 carriage bolts and nuts securing the rear of the skid plate to the mower deck (Fig. 1293).

Skid Plate Installation

(40”, 48”, 52” and 60” Mower Deck)

1. Position the skid plate to the mower deck (Fig.

1295).

Fig 1293

PICT-1121

5. Remove the skid plate from the mower deck (Fig.

1294).

Fig 1295

PICT-1122

2. Loosely install 3 carriage bolts and nuts to secure the skid plate to the mower deck: 2 holding the rear of the skid plate and 1 holding the front of the skid plate (Fig. 1296).

8

8-40

Fig 1294

PICT-1122

Fig 1296

PICT-1127


3. Tighten all 3 carriage bolts and nuts to secure the skid plate to the mower deck (Fig. 1297).

MOWER DECKS

Skid Plate Replacement


Skid Plate Removal (36” Mower Deck)


2. Remove the 2 carriage bolts and nuts securing the front of the skid plate to the mower deck (Fig. 1298).


Fig 1297

PICT-1114a

Fig 1298

PICT-1435

3. Remove the 2 carriage bolts and nuts securing the rear of the skid plate to the mower deck (Fig. 1299).

Fig 1299

PICT-1436

8-41

8


MOWER DECKS

4. Remove the skid plate from the mower deck (Fig.

1300).

2. Loosely install 4 carriage bolts and nuts to secure 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. 1302).

Fig 1300

PICT-1440

Skid Plate Installation (36” Mower Deck)

1. Position the skid plate to the mower deck (Fig.

1301).

Fig 1302

PICT-1435

3. Tighten all 4 carriage bolts and nuts to secure the skid plate to the mower deck (Fig. 1303).

8

8-42

Fig 1301

PICT-1440


Fig 1303

PICT-1441


MOWER DECKS

Front & Rear Deck Hanger

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” Mower Decks)” on page 8-6 or “PTO Drive Belt

Removal (36” Mower Decks)” on page 8-8.

2. Lift up on the mower deck and remove the hairpin(s) from the deck hanger pins (Fig. 1304).

3. Remove the spacers (if present) from the deck hanger pins (Fig. 1305).

Fig 1305

PICT-1258

4. Remove the nut from the bolt securing the ball joint to the mower deck (Fig. 1306).

Fig 1304

PICT-1257


Fig 1306

PICT-1259

8

8-43

MOWER DECKS

5. Slide the ball joint/pin assembly off the bolt and remove it from the carrier frame (Fig. 1307).

7. Remove the bolt from the mower deck bracket (Fig.

1309).

Fig 1307

PICT-1267

6. Remove the spacer from the bolt (Fig. 1308).

Fig 1309

PICT-1273

8. Loosen the jam nut on the deck hanger pin (Fig.

1310).

8

Fig 1308

PICT-1269

Fig 1310

PICT-1275a


MOWER DECKS

9. Remove the ball joint from the deck hanger pin (Fig.

1311).

Front Deck Hanger Installation

1. Install a jam nut onto the ball joint (Fig. 1313).

Fig 1311

PICT-1276a

10. Remove the jam nut from the ball joint (Fig. 1312).

Fig 1313

PICT-1277a

2. Thread the ball joint into the deck hanger pin (Fig.

1314).

Fig 1312

PICT-1277a

Fig 1314

PICT-1276a

8


MOWER DECKS

3. Adjust distance from the top of HOC stop to the 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. 1315).

5. Slide a spacer onto the bolt (Fig. 1317).

A

Fig 1317

PICT-1269

Fig 1315

PICT-1278a

A. 4.21” + . 6” (10.7 + .15cm)

6. Slide the ball joint/pin assembly onto the bolt and up through the mower deck bracket (Fig. 1318).

4. Insert the ball joint mounting bolt into the mower deck bracket (Fig. 1316).

Fig 1318

PICT-1267

8

8-46

Fig 1316

PICT-1270


MOWER DECKS

7. Install a nut onto the bolt to secure the ball joint to the mower deck (Fig. 1319).

9. Lift up on the mower deck and install the hairpin(s) into the deck hanger pins at the desired height-of-cut setting (Fig. 1321).

Fig 1319

PICT-1259

8. Install the spacer(s) (if required) onto the deck hanger pins (Fig. 1320).

Fig 1321

PICT-1257

10. Install the deck drive belt onto the center spindle pulley. Refer to “PTO Drive Belt Installation (40”, 48”,

52” and 60” Mower Decks)” on page 8-7 or “PTO

Drive Belt Installation (36” Mower Decks)” on page

8-9.

Fig 1320

PICT-1258


8

MOWER DECKS

Rear Deck Hanger Removal


Refer to “PTO Drive Belt Removal (40”, 48”, 52” and



2. 40”, 48”, 52” and 60” mower decks only: Remove the left hand belt cover (Fig. 1322).

4. Remove the spacer(s) (if present) from the deck hanger pin (Fig. 1324).

Fig 1322

PICT-1279

3. Support the mower deck and remove the hairpin(s) from the deck hanger pin (Fig. 1323).

Fig 1324

PICT-1281

5. Remove the retaining ring from the deck bushing

(Fig. 1325).

Fig 1325

PICT-1282

8

8-48

Fig 1323

PICT-1280


6. Remove the deck bushing from the carrier frame

(Fig. 1326).

MOWER DECKS

8. Remove the deck hanger pin from the carrier frame

(Fig. 1328).

Fig 1326

PICT-1283

Fig 1328

PICT-1285

7. Remove the bolt and nut securing the deck hanger pin to the mower deck (Fig. 1327).

9. Slide the snap ring off of the deck hanger pin (Fig.

1329).

Fig 1327

PICT-1284

Fig 1329

PICT-1286a

8


MOWER DECKS

Rear Deck Hanger Installation

1. Slide a retaining ring onto the deck hanger pin (Fig.

1330).

3. Install the bolt and nut to secure the deck hanger pin to the mower deck (Fig. 1332).

Fig 1332

PICT-1284

Fig 1330

PICT-1286a

2. Slide the deck hanger pin up through the carrier frame and into the mower deck. Note the orientation of the deck hanger pin tab (Fig. 1331):

4. Install the deck bushing over the deck hanger pin and into the carrier frame (Fig. 1333).

8

Fig 1331

PICT-1287

Fig 1333

PICT-1283


MOWER DECKS

5. Install the retaining ring onto the deck bushing (Fig.

1334).

7. Lift up on the mower deck and install the hairpin(s) into the deck hanger pins at the desired height-of-cut setting (Fig. 1336).

Fig 1334

PICT-1282

6. Install the spacer(s) (if required) onto the deck hanger pins (Fig. 1335).

Fig 1336

PICT-1257

8. Install the deck drive belt onto the center spindle pulley. Refer to “PTO Drive Belt Installation (40”,

48”, 52” and 60” Mower Decks)” on page 8-7 or

“PTO Drive Belt Installation (36” Mower Decks)” on page 8-9.

9. 40”, 48”, 52” and 60” mower decks only: Install the left hand belt cover (Fig. 1337).

Fig 1335

PICT-1258


Fig 1337

PICT-1279

8-51

8

MOWER DECKS

Anti-Scalp Roller Replacement

Single Anti-Scalp Roller Removal


2. Remove the nut from the roller axle bolt (Fig. 1338).

4. Remove the spacer tube from the spanner tube (Fig.

1340).

Fig 1338

PICT-1104

3. Remove the axle bolt and roller assembly from the mower deck (Fig. 1339).

Fig 1340

PICT-1106

5. Remove the spanner tube from the roller (Fig. 1341).

Fig 1341

PICT-1107

8

8-52

Fig 1339

PICT-1105


Single Anti-Scalp Roller Installation

1. Insert the spanner tube into the roller (Fig. 1342).

MOWER DECKS

3. Position the roller so that the spacer tube is located to the outside of the deck. Install the roller to the mower deck brackets with an axle bolt (Fig. 1344).

Fig 1342

PICT-1107

Fig 1344

PICT-1105

2. Install the spacer tube onto the spanner tube (Fig.

1343).

4. Install a nut onto the roller axle bolt (Fig. 1345).

Fig 1343

PICT-1106

Fig 1345

PICT-1104

8


MOWER DECKS

Double Anti-Scalp Roller Removal


2. Remove the nut from the roller axle bolt (Fig. 1346).

4. Remove the rollers from the wheel spacer (Fig.

1348).

Fig 1348

PICT-1112a

Fig 1346

PICT-1108

Double Anti-Scalp Roller Installation

1. Slide the rollers onto the wheel spacer (Fig. 1349).

3. Remove the axle bolt and double roller assembly from the mower deck (Fig. 1347).

8

8-54

Fig 1347

PICT-1109

Fig 1349

PICT-1112a


MOWER DECKS

2. Position the roller assembly in between the brackets on the mower deck. Install the roller assembly to the mower deck brackets with an axle bolt.

3. Install a nut onto the roller axle bolt (Fig. 1350).

2. Remove the nut from the defl ector assembly pivot bolt (Fig. 1352).

Fig 1352

PICT-1046a

Fig 1350

PICT-1108

3. Remove the pivot bolt from the defl ector assembly

(Fig. 1353).

Grass Defl ector Service

Grass Defl ector Removal

1. Carefully unhook the spring from the defl ector assembly (Fig. 1351).

Fig 1351

PICT-1044a


Fig 1353

PICT-1048a

8

8-55

MOWER DECKS

4. Remove the defl ector assembly, spacer and spring from the mower deck (Fig. 1354).

2. Remove the discharge strap and metal defl ector from the rubber defl ector (Fig. 1356).

Fig 1354

PICT-1049a

Fig 1356

PICT-1057

Grass Defl ector Disassembly

1. Remove the 4 carriage bolts and nuts securing the hinge brackets to the defl ector. Remove the hinge brackets (Fig. 1355).

Grass Defl ector Assembly

1. Insert the 4 carriage bolts into the discharge strap

(Fig. 1357).

Note: The bolt pattern is oriented so that the 2 bolt holes that are closer together are on the left.

8

8-56

Fig 1355

PICT-1050

Fig 1357

PICT-1062a


2. Position and press the rubber defl ector onto the 4 carriage bolts (Fig. 1358).

MOWER DECKS

4. Position the 2 hinge brackets (Fig. 1360).

Fig 1358

PICT-1063

3. Install the metal defl ector onto the 4 carriage bolts

(Fig. 1359).

Fig 1360

PICT-1070

5. Install 4 nuts onto the bolts securing the defl ector assembly (Fig. 1361).

Fig 1359

PICT-1068

Fig 1361

PICT-1072

8


MOWER DECKS

Grass Defl ector Installation

1. Slide the spring onto the spacer (Fig. 1362).

3. Install the spring/spacer, using the pivot bolt, so that the hook end of the spring is on the defl ector side of the mounting plate and the “L” end of the spring is on the mower deck side of the mounting plate (Fig.

1364).

Fig 1362

PICT-1075a

Fig 1364

PICT-1077

2. Position the defl ector assembly to the mower deck and orient the spring/spacer assembly so the end of the spring with the hook is pointing to the rear (Fig.

1363).

4. Install a nut onto the pivot bolt (Fig. 1365).

8

Fig 1363

PICT-1076a

Fig 1365

PICT-1046a


MOWER DECKS

5. Install the hook end of the spring onto the defl ector mounting bracket (Fig. 1366).

2. Remove the bushing from the quick latch handle

(Fig. 1368).

Fig 1366

PICT-1044a

Fig 1368

PICT-1250a

Quick Latch Replacement

There are a total of 5 quick latches located on the midsize units. The replacement procedure is the same for all.

3. Remove the washer from the quick latch handle (Fig.

1369).

Quick Latch Removal

1. Remove the nut from the quick latch handle (Fig.

1367).

Fig 1369

PICT-1251a

8

Fig 1367

PICT-1247a


MOWER DECKS

4. Remove the quick latch handle from the cover (Fig.

1370).

2. Place a washer onto the quick latch handle (Fig.

1372).

Fig 1370

PICT-1253

Fig 1372

PICT-1251a

Quick Latch Installation

1. Insert the quick latch handle through the cover (Fig.

1371).

3. Install a bushing onto the quick latch handle (Fig.

1373).

8

Fig 1371

PICT-1253

Fig 1373

PICT-1250a


MOWER DECKS

4. Install a nut securing the quick latch handle assembly to the cover. There must be one thread from the quick latch handle protruding past the nut (Fig.

1374).

3. Remove the top hairpins and spacer(s) (if present) from the deck hanger pin (Fig. 1375).

Fig 1375

PICT-1281

Fig 1374

PICT-1254

Mower Deck Removal

1. Support the rear of the chassis with a jack stand.


Refer to: “PTO Drive Belt Removal (40”, 48”, 52” and



4. Lift up on the mower deck and remove the hairpins from the 4 deck hanger pins (Fig. 1376).

Fig 1376

PICT-1291

8


MOWER DECKS

5. Remove the spacers from the hanger pins if they are present (Fig. 1377).

Mower Deck Installation

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. 1378).

2. As the carrier frame is lowered, ensure the deck hanger posts are inserted through the holes in the carrier frame (Fig. 1380).

8

Fig 1378

PICT-1295

Fig 1380

PICT-1338


MOWER DECKS

3. Support the rear of the chassis with a jack stand.

4. Lift up on the mower deck and install the spacers and hairpins onto the 4 deck hanger pins (Fig.

1381).

Checking the Engine Deck Height


2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Adjust the tire pressure in the rear tires to 12-14 psi

(83-97kPa).

4. Measure engine deck height at location AA (Fig.

1382).

5. Measure engine deck height at location BB (Fig.

1382).

If the heights at locations AA and BB are not the same, change the tire pressure slightly to make them the same.

Fig 1381

PICT-1291

B

A

B

5. Install the mower deck drive belt onto the center spindle pulley. Refer to: “PTO Drive Belt Installation

(40”, 48”, 52” and 60” Mower Decks)” on page 8-7 or

“PTO Drive Belt Installation (36” Mower Decks)” on page 8-9.

6. Check the front-to-rear pitch of the mower deck.

Refer to “Checking the Mower Deck Front-to-Rear


7. Check the side-to-side height of the mower deck.

Refer to “Checking the Mower Deck Side-to-Side


8. Check the Height-of-Cut. Refer to “Matching the

Height-of-Cut” on page 8-67.

AA

C C

BB

Fig 1382

fi g. 79 G000284

This illustration is a back view of the machine.

A. Top of engine deck

B. Tires

C. Same height at locations AA and BB

8


MOWER DECKS

Checking the Carrier Frame Front-to-

Rear Pitch

The carrier frame must have a pitch between 1/8” (3mm) to 3/8” (9mm) over the length of 24” (61cm) on the carrier frame.

1. Measure out 24” (61cm) on the carrier frame (Fig.

1383).

2. Measure the carrier frame height at location AA (Fig.

1383).

3. Measure the carrier frame height at location BB (Fig.

1383).

4. The height at location AA must be 1/8” to 3/8” (3mm to 10mm) lower than at location BB (Fig. 1383).

5. If the carrier frame pitch is not correct, move spacers from the top or bottom of the caster wheel forks to achieve the correct pitch: 1/8” to 3/8” (3mm to

10mm) (Fig. 1383).

6. The tire pressure may also be adjusted slightly to achieve a 1/8” to 3/8” (3mm to 10mm) pitch.

Checking the Carrier Frame Side-to-

Side Height

The carrier frame needs to be parallel side-to-side from the ground.


2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Adjust the tire pressure in the rear tires to 12-14psi

(83-97kPa).

4. Measure the carrier frame height at location AA (Fig.

1384).

5. Measure the carrier frame height at location BB (Fig.

1384).

6. If the carrier frame height is not the same at locations AA and BB, move spacers from the top or bottom of the caster wheel forks to make it level.

7. The tire pressure may also be adjusted slightly to make it level.

A

B

C

B

C D

D

C

B

F

AA

BB

AA BB

8

E

D

Fig 1383

fi g. 80 G004801

A. Carrier Frame

B. 1/8”-3/8” (3-10mm)

D. Height at locations AA and BB pitch over 24” (61cm) E. Caster wheel

length

E

A

A. Caster wheel

B. Carrier frame

C. Caster spacers

A

E

Fig 1384

fi g. 81 G000287

D. Front height-of-cut pins

E. Same height at locations AA and BB


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 frontto-rear orientation. Measure at AA and BB locations from a level surface to the cutting edge of the blade tips (Fig. 000 and for 36” mower decks use Fig.

1385).

3. The mower blades should be 1/4” (6mm) lower at location AA than at location BB.

4. If the front-to-rear pitch is not correct, proceed to

Adjusting the Deck Front-to-Rear Pitch.

AA

BB

Fig 1386

This illustration shows a 36” mower deck.

fi g. 83 G004906

B

AA

BB

A

Fig 1385

fi g. 82 G001041

This illustration shows a 40”, 48” and 52” mower deck.

A. Measure blade at points AA and BB

B. Measure from a level surface

8


MOWER DECKS

Adjusting the Mower Deck Front-to-

Rear Pitch

Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts.

1. To raise the front of the deck, loosen the jam nut on the lower end of the deck hanger pin assembly.

Rotate the front pin clockwise (Fig. 1387).

2. To lower the front of the deck, loosen the jam nut on the lower end of the deck hanger pin assembly.

Rotate the front pin counter-clockwise (Fig. 000).

3. Position the mower blades in the front-to-rear orientation. Measure at the AA and BB locations (Fig.

1385 and Fig. 1386) from a level surface to the cutting edge of the blade tips.

4. Check the side-to-side leveling of the cutting unit.

Refer to Checking the Mower Deck Side-to-Side

Height.

5. Tighten the jam nuts (Fig. 1387).

Checking the Mower Deck Side-to-

Side Height

1. Adjust the rear tire pressure to 12-14 psi (83-97kPa).

2. Position the mower blades in the side-to-side orientation. Measure at the C and D locations from a level surface to the cutting edge of the blade tips (Fig.

1388 and for 36” mower decks use Fig. 1389).

3. The difference between the measurements at the C and D locations should be no more than 1/4” (6mm).

4. If the side-to-side pitch is not correct, proceed to

Adjusting the Mower Deck Side-to-Side Height.

C

D

B

D

C

B

A

E A

8

A. Caster wheel

C. Front height-of-cut pins

Fig 1387

D. Jam nut fi g. 84 G000292

Fig 1388

fi g. 85 G004908


A. Measure from a level B. Measure blade at points

surface


C

D

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. Check the front-to-rear pitch and side to side leveling of the cutting unit.

Fig 1389


fi g. 86 G004907

Matching the Height-of-Cut

1. Check the rear tire pressure.

2. Set the height-of-cut to the 4” (101.6mm) position.

Reference the height-of-cut decal (Fig. 1390).


Fig 1390

106-0635

8

8-67

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. If it does not measure correctly:

A. Adjust the rear tire pressure.

B. Adjust the caster fork spacers.

C. Adjust the front mower deck support pins.

6. Check the carrier frame front-to-rear pitch. Refer to

“Checking the Mower Deck Front-to-Rear Pitch” on page 8-65.

A

A

B

A

A

A

Fig 1392


fi g. 88 G000296

8

C

Fig 1391

fi g. 87 G000975


B. Measure from a level C. Measure blade at

surface


ELECTRICAL

Tools

• Volt Ohm meter

• Flat and Phillips screwdrivers

• Box and open end wrenches - various sizes

Additional information can be found in the LCE Electrical

Troubleshooting DVD #492-9171, available through your

Toro parts supplier.

On/Off Switch

The on/off switch is mainly used to control the spark on recoil start models. In the off position there is contact between the terminals. When turned 1/4 turn clockwise to the on position the contacts open (Fig. 1393).

Caution

Before performing any tests with a continuity light or ohmmeter, disconnect the component from the wire harness. This ensures you are testing the component rather than another circuit.

Interlock modules MUST be removed from the circuit before performing any tests with an ohmmeter or continuity light. Battery voltage can damage these modules if applied to the wrong terminals.

Fig 1393

29-5560x1

Components

Alternator

The alternator system varies with the engine model. See the engine manufacturer service information for proper testing procedures.

Bail Switch

The bail switch is a normally open switch. The contacts close when the plunger is depressed (Fig. 1394).


Fig 1394

82-2190x1a

9

9-1

ELECTRICAL

Single Pole Switch

This is a normally closed switch and has the letters “NC” stamped on both terminals. This switch should have continuity when at rest. Continuity should be lost when the plunger is depressed (Fig. 1395).

PTO Switch

3 terminals are in use on this switch. When the switch is off (knob depressed) there should be continuity between terminals 1 and 7. When the switch is on (knob pulled out) there should be continuity between terminals 1 and

4 (Fig. 1396 and Fig. 1397).

Fig 1395

95-1653x1

Fig 1396

95-7489x1

9

9-2

Fig 1397

95-7489x2a


ELECTRICAL

Relay, Single Pole Dual Throw Ignition Switch

A relay is an electronically activated switch. It can be used as a normally open or normally closed switch depending on which terminals are used. The diagram is molded into the side of the relay.

At rest terminals 30 and 87a are closed. When 12 volts is applied to terminals 85 and 86 the relay is activated so that terminals 30 and 87a open and terminals 30 and 87 close. When the voltage is removed the relay will return to the rest position (Fig. 1398).

The ignition switch has 3 positions; off, run and start.

The start position is spring loaded to return to run when released. The switch terminals are unmarked. Use the fi gure above to identify the terminals. Switch continuity is as follows: Off: None

Run: X+Y

(Fig. 1399 and Fig. 1400)

Fig 1398

98-7249x1

Fig 1399

104-2541x1


II

Fig 1400

104-2541x2

9

9-3

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).

9

9-4

Fig 1401

scheme


ELECTRICAL

PTO Switch

Only 2 terminals are used in this application: numbers 1 and 4 as shown in the fi gure below. These terminals are normally open. They close only when the PTO knob is pulled outward. This is a momentary switch so when the

PTO knob is released it will return to the open position

(Fig. 1402 and Fig. 1403).

Delay Module

The Delay Module delays clutch disengagement for a second or two. It allows the operator to momentarily release the handle and then re-engage it without going through the 2 step blade engagement process. This module contains a number of resistors and a transistor.

If the clutch fails to engage or disengage properly, test the clutch and power supply. If they function normally, the module should be replaced (Fig. 1404).

Fig 1402

104-8140x1

Fig 1404

104-8141x1

Fig 1403

104-8140x2a


9

ELECTRICAL

Clutch Power Supply Test Procedure:

1. Measure the DC voltage at the pink wire where it comes out of the rectifi er. Make sure the engine is running at full throttle and note the reading. If below

12 VDC, troubleshoot the engine’s electrical system

(Fig. 1405).

3. Connect the test lead to the end of the pink wire in the terminal plug removed from the module (Fig.

1407).

Note: The voltage should be the same as at the engine.

Fig 1407

IMG_8046a

Fig 1405

IMG_8042

2. Under the control panel, remove 4 screws and lower the bottom panel. Unplug harness from delay module (Fig. 1406).

4. Move the tester lead to the orange wire in the same terminal plug. Pull the clutch switch out and hold.

The voltage should be the same as at the pink wire

(Fig. 1408).

9

9-6

Fig 1406

IMG_8069a

B. Harness

Fig 1408

IMG_8071a


ELECTRICAL

5. Move the bail to the operation position and temporarily tie it in place (Fig. 1409).

7. Set the Volt/Ohm meter to the OHMs setting. Connect a test lead to the green wire at the module connector. Connect the other test lead to the engine block (Fig. 1411). The reading should be 2.8 OHMs.

A higher reading indicates a poor connection on the green wire, the clutch or ground. Clean and secure all connection points.

A lower reading indicates a problem with the clutch coil.

Fig 1409

IMG_8066a

6. Attach the test lead to the brown wire and pull the clutch switch, the voltage should not change (Fig.

1410).

If the voltage

does

change: Trace the problem back through the wire harness and switches.

If the voltage

does NOT

change: Check the PTO clutch and module ground connections, step 7 and 8.

Fig 1411

IMG_8056a

Fig 1410

IMG_8051a


9

9

9-8

ELECTRICAL

8. Check the ground for the module: Check for continuity between the black wire at the module connector and the engine (Fig. 1412).

High resistance indicates corroded terminals or a poor ground connection to the chassis.

If the clutch and power supply function properly (as indicated by the above test procedure), the Delay

Module must be replaced.

DC Mini Hour Meter

This hour meter runs when 12 VDC is applied. It will record up to 9,999.9 hrs. The oil change icon will fl ash 3 hrs before and 3 hrs after the service interval. There is no manual reset. “Change oil” will appear at 8 hours and then every 100 hours after. “SVC” will also appear every

400 hours (Fig. 1413 and Fig. 1414).

Fig 1412

IMG_8057a

Fig 1413

104-8143x1

Fig 1414

104-8143x2a


ELECTRICAL

Proximity Switch

This proximity switch is normally open. The contacts close when a piece of ferrous metal (iron or steel) is placed close to the switch, approximately within 1/4”

(.635cm). The switch will open when the metal is moved away (Fig. 1415).

PTO Brake Clutch Assembly

The PTO clutch contains one fi xed plate, a moveable plate and an electro magnet. When a minimum of 8 VDC is applied to the clutch the plates will engage. When the power is removed, springs pull the plates apart and engage the brake to the driven plate (Fig. 1416).

To test the electro magnet coil, apply an ohm meter to the two wire terminals connected to the clutch. A good clutch coil will read approximately 2.8 ohms.

Take one of the test leads and touch an unpainted portion of the clutch body, or any good ground. There should be no continuity (very high number of ohms).

Move the test lead to the other wire terminal and repeat the test. Again there should be no continuity.

An alternate test is an amperage draw. Normal draw for this clutch should be 4 amps.

Clutch maintenance includes periodic checking and adjusting of the air gap between the plates. See clutch service procedures.

Fig 1415

105-0023x1a


Fig 1416

IMG_8062

9-9

9

ELECTRICAL

Wire Harness Pistol Grip (106-8780)

There is a 30 amp fuse (p/n 109103) between the battery and ignition switch and a 25 amp fuse (p/n 109102) between the voltage regulator/rectifi er on the engine and the ignition switch. Failure of the 30 amp fuse disables the entire electrical system (Fig. 1417).

If the 25 amp fuse fails, focus on the engine portion of the charging system for the cause. The alternator does not produce enough amperage to blow the fuse. A short to ground or a shorted diode in the charging system could allow the battery to discharge through the regulator and alternator as soon as the key is turned on. The fuse will blow to prevent the wire harness from melting.

9

9-10

Fig 1417

scheme


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. The momentary position (full out) causes continuity between terminals 1 and 4 (Fig. 1418 and Fig. 1419).

The switch can be tested using an ohm meter or continuity light.

ELECTRICAL

Fig 1418

114-0279x1

Fig 1419

114-0279x2a


9

ELECTRICAL

Wire Harness T-2, Hydro (114-3418)



9

9-12

Fig 1420

scheme


ELECTRICAL

Wire Harness T-Bar, Hydro (114-3420)




Fig 1421

scheme

9

9-13

ELECTRICAL

Normally Open Switch

This switch is normally open. There is contact only when the plunger is depressed (Fig. 1422).

Starter Solenoid

A starter is a form of an electrically operated switch.

Positioning the solenoid closer to the battery and starter, short battery cables can be utilized to increase effi ciency

(Fig. 1424).

At rest there should be no continuity between the two larger posts. Connect a 12 volt battery to the two smaller posts and the solenoid should engage. There should be continuity between the large posts as long at the voltage is present.

Maximum torque for the smaller posts is 20 in/lb. (2.26

Nm); larger posts is 25 in/lb. (2.82 Nm).

Note: Exceeding the maximum torque can pull the terminals from the solenoid.

Fig 1422

1-513051x1a

Normally Closed Switch

This switch is normally closed. The contacts open when the plunger is depressed. The terminals are marked NC

(Fig. 1423).

Fig 1424

1-513075x1

9

9-14

Fig 1423

1-513152x1


Operator Presence Control (OPC)

Switch Replacement (T-Bar)

OPC Switch Removal (T-Bar)


2. Lift the locking tab on the front of the operator presence control switch and unplug the harness connector from the switch (Fig. 1425).

ELECTRICAL

3. Remove the cotter pin from the upper end of the control rod (Fig. 1426).

Fig 1425

PICT-1744

Fig 1426

PICT-1679a

4. Remove the control rod from the control bar/bail assembly (Fig. 1427).


Fig 1427

PICT-1682

9-15

9

ELECTRICAL

5. Repeat steps 3 and 4 to remove the opposite control rod from the control bar/bail assembly.

6. Remove the bail from the T-Bar handle by sliding it off the OPC Switch mounting bracket and remove it from the machine (Fig. 1428).

OPC Switch Installation (T-Bar)

1. Install the OPC switch into the switch mounting bracket on the T-Bar (Fig. 1430).

Fig 1430

PICT-1786

Fig 1428

PICT-1785a

7. Remove the OPC switch from the switch mounting bracket (Fig. 1429).

2. Position the bail onto the OPC handle by sliding the switch bracket up around the switch mounting bracket (Fig. 1431).

Fig 1431

PICT-1785a

9

9-16

Fig 1429

PICT-1786


3. Insert a control rod through the T-Bar handle/bail assembly mounting pivots (Fig. 1432).

ELECTRICAL

5. Repeat steps 3 and 4 to install the opposite control rod.

6. Plug the harness connector into the OPC switch

(Fig. 1434).

Fig 1432

PICT-1682

4. Install a cotter pin into the upper end of the control rod (Fig. 1433).

Fig 1434

PICT-1744

Fig 1433

PICT-1679a


9

ELECTRICAL

PTO Switch Replacement (T-Bar)

PTO Switch Removal (T-Bar)



R-clamps to the bottom panel of the control panel.

Remove the manual tube assembly (Fig. 1435).

4. Unplug the wire harness from the PTO switch (Fig.

1437).

A. Tabs

Fig 1437

PICT-1793

Fig 1435

PICT-1787

5. Compress the tabs (Fig. 1437) on the switch body and push it out of the control panel (Fig. 1438).

3. Remove the 2 screws securing the bottom panel to the control panel and move it away from the control panel (Fig. 1436).

Fig 1438

PICT-1811

9

9-18

Fig 1436

PICT-1789


ELECTRICAL

PTO Switch Installation (T-Bar)

1. Push the PTO switch in to place in the control panel

(Fig. 1439).

3. Position the bottom panel to the control panel and install 2 screws securing it to the control panel (Fig.

1441).

Fig 1439

PICT-1811

2. Plug the wire harness into the PTO switch (Fig.

1440).

Fig 1441

PICT-1789

4. Position the manual tube to the control panel assembly and install 2 screws securing the manual tube R-clamps to the control panel and bottom panel

(Fig. 1442).

Fig 1440

PICT-1793

Fig 1442

PICT-1787

9


ELECTRICAL

Ignition Switch Replacement (T-Bar)

Ignition Switch Removal (T-Bar)





4. Unplug the wire harness from the ignition switch

(Fig. 1445).

Fig 1443

PICT-1787

3. Remove the 2 screws securing the bottom panel to the control panel and move it away from the control panel (Fig. 1444).

Fig 1445

PICT-1798


Fig 1446

PICT-1800

9

9-20

Fig 1444

PICT-1789


ELECTRICAL


1447).

Ignition Switch Installation (T-Bar)

1. Insert the ignition switch into the control panel (Fig.

1449).

Fig 1447

PICT-1801

Fig 1449

PICT-1803


(Fig. 1448).

2. Place a lockwasher onto the ignition switch (Fig.

1450).

Fig 1448

PICT-1803

Fig 1450

PICT-1801

9


ELECTRICAL



Fig 1451

PICT-1800

4. Plug the wire harness into the ignition switch (Fig.

1452).

Fig 1453

PICT-1719a

6. Position the manual tube to the control panel. Install

2 screws securing the manual tube R-clamps and bottom panel to the control panel (Fig. 1454).

9

9-22

Fig 1452

PICT-1798

Fig 1454

PICT-1718


ELECTRICAL

Delay Module Replacement (T-Bar)

Delay Module Removal (T-Bar)





3. Remove the 2 screws securing the bottom panel to the control panel and move the bottom panel away from the control panel (Fig. 1456).

Fig 1455

PICT-1787

Fig 1456

PICT-1789

4. Unplug the brown wire bullet connector from the harness (Fig. 1457).


Fig 1457

PICT-1804

9

9-23

ELECTRICAL

5. Unplug the harness connector from the delay module (Fig. 1458).

7. Remove the bolt and nut securing the delay module to the bottom panel (Fig. 1460).

Fig 1458

PICT-1805

Fig 1460

PICT-1809

6. Remove the fuse block from the bottom panel and remove the bottom panel from the machine (Fig.

1459).

Delay Module Installation (T-Bar)

1. Position the delay module on the inside of the bottom panel. Install a bolt and nut securing the delay module to the bottom panel (Fig. 1461).

9

9-24

Fig 1459

PICT-1806

Fig 1461

PICT-1809


ELECTRICAL

2. Position the bottom panel up to the control panel and attach the fuse block to the bottom panel (Fig. 1462).

4. Plug the brown wire bullet connect into the harness

(Fig. 1464).

Fig 1462

PICT-1806

Fig 1464

PICT-1804

3. Plug the harness connector into the delay module

(Fig. 1463).


Fig 1463

PICT-1805

Fig 1465

PICT-1719a

9


ELECTRICAL

6. Position the manual tube to the control panel. Install

2 screws to secure the manual tube assembly

(R-clamps) and bottom panel to the control panel

(Fig. 1466).

2. Unplug the harness from the parking brake switch

(Fig. 1467).

9

9-26

Fig 1467

PICT-1816

Fig 1466

PICT-1718

Parking Brake Switch Replacment

(Pistol Grip & T-2)

Parking Brake Switch Removal (P.G. & T-2)


3. Remove the 2 bolts and buts securing the parking brake switch to the parking brake handle support

(Fig. 1468).

Fig 1468

PICT-1817


4. Remove the spacer from the switch (Fig. 1469).

ELECTRICAL

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 support (Fig. 1470).

Fig 1471

PICT-1894

2. Position the spacer onto the switch (Fig. 1472).

Fig 1470

PICT-1894

Fig 1472

PICT-1892

9


ELECTRICAL

3. Install 2 bolts and nuts securing the parking brake switch to the parking brake handle support (Fig.

1473).

Neutral Switch Replacement

(Pistol Grip)

Neutral Switch Removal (P.G.)

1. Position the speed control lever in the Fast position

(Fig. 1475).

Fig 1473

PICT-1817

4. Plug the harness into the parking brake switch (Fig.

1474).

Fig 1475

PICT-1902a

2. Unplug the harness from the neutral switch (Fig.

1476).

9

9-28

Fig 1474

PICT-1816

Fig 1476

PICT-1823


ELECTRICAL

3. Remove the 2 screws securing the neutral switch to the neutral bracket (Fig. 1477).

Neutral Switch Installation (P.G.)

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. 1478).

2. Install 2 screws securing the neutral switch to the neutral bracket (Fig. 1480).

Fig 1478

PICT-1827a

Fig 1480

PICT-1825

9


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” to 1/4” (3 to 6mm) space between the actuating tab and the safety switch body (Fig. 1482).

6. Adjust the switch up or down to obtain an 1/8” to 1/4”

(3 to 6 mm) space (Fig. 1484).

9

Fig 1482

PICT-1909

A. 1/8” to 1/4” (3 to 6mm) space

Fig 1484

PICT-1909

A. 1/8” to 1/4” (3 to 6mm) space


ELECTRICAL

7. Tighten the two neutral bracket screws holding the switch plate (Fig. 1485).

3. Remove the fuse block(s) from the control panel cover bracket (Fig. 1486).

Fig 1485

PICT-1911

Fig 1486

PICT-1836

PTO Switch Replacement (Electric

Start)

PTO Switch Removal (Electric Start)



4. Remove the 2 screws securing the manual tube assembly to the control bracket. Remove the manual tube assembly (Fig. 1487).


Fig 1487

PICT-1839

9

9-31

ELECTRICAL

5. Remove the 2 screws securing the control panel cover bracket to the front side of the control panel

(Fig. 1488).

7. Unplug the harness from the PTO switch (Fig. 1490).

Fig 1490

PICT-1851a

Fig 1488

PICT-1847

6. Remove the cover bracket from the control panel

(Fig. 1489).

8. Depress the tabs on the PTO switch and push it through the control panel to remove it (Fig. 1491).

Fig 1491

PICT-0729a

9

9-32

Fig 1489

PICT-1848


ELECTRICAL

PTO Switch Installation (Electric Start)

1. Push the PTO switch through the control panel until it snaps into place (Fig. 1492).

3. Position the cover bracket onto the control panel

(Fig. 1494).

Fig 1494

PICT-1848

Fig 1492

PICT-0729a

2. Plug the harness into the PTO switch (Fig. 1493).

4. Install 2 screws securing the control panel cover bracket to the front side of the control panel (Fig.

1495).

Fig 1493

PICT-1851a

Fig 1495

PICT-1847

9


ELECTRICAL

5. Position the manual tube to the cover bracket. Install

2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1496).


Switch Replacement (Pistol Grip)

Note: The harness has been unplugged from the

PTO switch for photo purposes.

Fig 1496

PICT-1839

6. Slide the fuse block(s) onto the control panel cover bracket (Fig. 1497).

OPC Switch Removal (P.G.)


2. Disconnect the negative battery cable from the battery.

3. Remove the fuse blocks from the control panel cover bracket (Fig. 1498).

Fig 1498

PICT-1836

Fig 1497

PICT-1836

9

7. Connect the negative battery cable to the battery.


ELECTRICAL



(Fig. 1501).

Fig 1499

PICT-1839

Fig 1501

PICT-1848

7. Unplug the harness from the OPC switch (Fig.

1502).


(Fig. 1500).

Fig 1500

PICT-1847

Fig 1502

PICT-1857

9-35

9


ELECTRICAL

8. Remove the 2 screws securing the OPC switch to the switch mounting plate (Fig. 1503).

OPC Switch Installation (P.G.)

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. 1504).

2. Install 2 screws securing the OPC switch to the switch mounting plate (Fig. 1506).

9

9-36

Fig 1504

PICT-1860

Fig 1506

PICT-1859



ELECTRICAL

5. If needed, adjust the position of the switch. Refer to OPC Switch Position Adjustment (P.G.) in the following section.


(Fig. 1509).

Fig 1507

PICT-1857

4. With either LH or RH OPC lever depressed inspect space between Neutral Arm on OPC Rod and the body of the OPC Switch. The space should be .18” ±

.06” (4.6 ± 1.5mm) (Fig. 1508).

Fig 1509

PICT-1848


1510).

Fig 1508

PICT-1864

A. .18” ± .06” (4.6 ± 1.5mm)


Fig 1510

PICT-1847

9

9-37

ELECTRICAL



OPC Switch Position Adjustment (P.G.)

1. Loosen the 2 OPC switch mounting screws (Fig.

1513).

Fig 1511

PICT-1839

9. Slide the fuse blocks onto the control panel cover bracket (Fig. 1512).

Fig 1513

PICT-1864

2. Adjust position of switch mounting plate to obtain the

.18” ± .06” (4.6 + 1.5mm) space between the OPC switch body and neutral arm with the OPC levers depressed (Fig. 1514).

Fig 1512

PICT-1836

9


9-38

Fig 1514

PICT-1864


3. Tighten the neutral bracket mounting screws (Fig.

1515).

ELECTRICAL


Fig 1515

PICT-1864

Fig 1516

PICT-1836

4. The OPC switch should return to the open position with the levers in the full spring return position.


Hour Meter Replacement (Pistol Grip)

Hour Meter Removal (P.G.)



Fig 1517

PICT-1839

9


ELECTRICAL


(Fig. 1518).

7. Unplug the harness from the hour meter (Fig. 1520).

Fig 1520

PICT-1869

Fig 1518

PICT-1847


(Fig. 1519).

8. Remove the locking tab from the back side of the hour meter (Fig. 1521).

Fig 1521

PICT-1870

9

9-40

Fig 1519

PICT-1848


ELECTRICAL

9. Remove the hour meter from the control panel (Fig.

1522).

2. Install the locking tab onto the back side of the hour meter (Fig. 1524).

Fig 1522

PICT-1871

Fig 1524

PICT-1870

Hour Meter Installation (P.G.)

1. Push the hourmeter into the opening in the control panel (Fig. 1523).

3. Plug the harness into the hour meter (Fig. 1525).

Fig 1523

PICT-1871

Fig 1525

PICT-1869

9-41

9


ELECTRICAL


(Fig. 1526).



Fig 1526

PICT-1848


1527).

Fig 1528

PICT-1839


9

9-42

Fig 1527

PICT-1847

Fig 1529

PICT-1836

8. Connect the negative battery cable onto the battery.


ELECTRICAL

Ignition Switch Replacement

(Pistol Grip)

Ignition Switch Removal (P.G.)





Fig 1530

PICT-1836

Fig 1531

PICT-1839


(Fig. 1532).


Fig 1532

PICT-1847

9

9-43

ELECTRICAL


(Fig. 1533).


Fig 1533

PICT-1848

Fig 1535

PICT-1873

7. Unplug the harness terminal and harness connector from the ignition switch (Fig. 1534).


1536).

Fig 1536

PICT-1874

9

9-44

Fig 1534

PICT-1872



(Fig. 1537).

ELECTRICAL

2. Place a lockwasher onto the ignition switch (Fig.

1539).

Fig 1537

PICT-1875

Fig 1539

PICT-1874

Ignition Switch Installation (P.G.)

1. Insert the ignition switch into the control panel (Fig.

1538).


Fig 1538

PICT-1875

Fig 1540

PICT-1873

9-45

9


ELECTRICAL

4. Plug the wire harness connector and terminal into the ignition switch (Fig. 1541).


1543).

Fig 1541

PICT-1872


(Fig. 1542).

Fig 1543

PICT-1847



9

9-46

Fig 1542

PICT-1848

Fig 1544

PICT-1839



ELECTRICAL

3. Unplug the kill relay from the wire harness (Fig.

1546).

Fig 1545

PICT-1836

Fig 1546

PICT-1877


Kill Relay Replacement (Pistol Grip)

Note: The Manual Tube assembly and Control Panel

Cover Bracket have been removed for photo purposes.

Kill Relay Installation (P.G.)

1. Plug a kill relay into the wire harness (Fig. 1547).

Kill Relay Removal (P.G.)



Fig 1547

PICT-1877

2. Connect the negative battery cable onto the battery.

9


9

9-48

ELECTRICAL

Solenoid Switch Replacement

(Pistol Grip & T-2)

Solenoid Switch Removal (P.G. & T-2)



3. Remove the nut and lock washer securing the starter cable to the solenoid terminal. Remove the starter cable (Fig. 1548).

4. Pull the boot back and remove the nut and lock washer securing the battery cable to the solenoid terminal. Remove the battery cable (Fig. 1549).

Fig 1549

PICT-1880

5. Remove the harness wire from the solenoid terminal

(Fig. 1550).

Fig 1548

PICT-1920

Fig 1550

PICT-1882


ELECTRICAL

6. Unplug the 2 harness wires (blue and orange) from the solenoid (Fig. 1551).

Solenoid Switch Installation (P.G & T-2)

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. Remove the 2 self-tapping screws securing the solenoid to the frame. Remove the solenoid (Fig.

1552).

2. Plug the 2 harness wires (blue and orange) onto the side posts on the solenoid as shown (Fig. 1554):

Fig 1552

PICT-1884

Fig 1554

PICT-1883

9


ELECTRICAL

3. Slide the harness wire (red) onto the solenoid terminal (Fig. 1555):

5. Position the starter cable onto the solenoid terminal.

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, over the red harness wire. Install a lockwasher and nut to secure. Position the boot over the connection

(Fig. 1556).


9

9-50

Fig 1556

PICT-1880


ELECTRICAL


Switch Replacement (T-2)

OPC Switch Removal (T-2)


(Fig. 1558).

3. Unplug the harness from the OPC switch (Fig.

1560).

Fig 1560

PICT-1927

Fig 1558

PICT-1921

4. Remove the 2 screws securing the OPC switch to the motion control assembly (Fig. 1561).


Fig 1559

PICT-1923


Fig 1561

PICT-1928a

9-51

9

ELECTRICAL

5. Remove the OPC switch and spacer plate (Fig.

1562).

2. Install 2 screws securing the OPC switch (and plate) to the motion control assembly (Fig. 1564).

Fig 1562

PICT-1932a

Fig 1564

PICT-1928a

OPC Switch Installation (T-2)

1. Position the OPC switch and spacer plate onto the motion control assembly plate (Fig. 1563).

3. Position the right hand control lever in the operating position. There should be a .10” (2.54mm) gap between the switch plunger and the control arm tab

(Fig. 1565).

9

9-52

Fig 1563

PICT-1932a

A. .10” (2.54mm) gap

Fig 1565

PICT-1934



ELECTRICAL

6. Install 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control pane (Fig.

1568).

Fig 1566

PICT-1927

5. Position the control panel cover/manual tube assembly onto the control panel (Fig. 1567).

Fig 1568

PICT-1921

Latching Relay Replacement (T-2)

Latching Relay Removal (T-2)



Fig 1567

PICT-1923

9-53

9


ELECTRICAL


(Fig. 1569).

5. Unplug the latching relay from the wire harness (Fig.

1571).

Fig 1569

PICT-1921


Fig 1571

PICT-1936

Latching Relay Installation (T-2)

1. Plug a latching relay into the wire harness (Fig.

1572).

9

9-54

Fig 1570

PICT-1923

Fig 1572

PICT-1936


2. Position the control panel cover/manual tube assembly onto the control panel (Fig. 1573).

ELECTRICAL

Kill Relay Replacement (T-2)

Note: The Manual Tube assembly and Control Panel

Cover Bracket have been removed for photo purposes.

Fig 1573

PICT-1923

Kill Relay Removal (T-2)



3. Unplug the kill relay from the wire harness (Fig.

1575).


1574).

Fig 1574

PICT-1921



Fig 1575

PICT-1937

9-55

9

ELECTRICAL

Kill Relay Installation (T-2)

1. Plug the kill relay into the wire harness (Fig. 1576).

3. Unplug the harness from the proximity neutral switch connector (Fig. 1577).

9

9-56

Fig 1576

PICT-1937

Fig 1577

PICT-1938

4. Remove the cable tie securing the switch wires to the frame (Fig. 1578).


Proximity Neutral Switch

Replacement (T-2)

Proximity Neutral Switch Removal (T-2)



Fig 1578

PICT-1939


ELECTRICAL

5. Remove the 2 screws and nuts securing the switch to the frame (Fig. 1579).

Proximity Neutral Switch Installation (T-2)

1. Position the Proximity Neutral Switch to the frame

(Fig. 1581).

Fig 1579

PICT-1940

6. Remove the switch (Fig. 1580).

Fig 1581

PICT-1941

2. Install 2 screws and nuts to secure the switch to the frame (Fig. 1582).

Fig 1580

PICT-1941a

Fig 1582

PICT-1940

9


ELECTRICAL

3. The distance between the face of the switch and the end of the hex head screw should be .07” + .02” (1.8

+ .5mm) (Fig. 1583).

5. Plug the harness into the proximity neutral switch connector (Fig. 1585).

Fig 1585

PICT-1938

Fig 1583

PICT-1943

A. .07” + .02” (1.8 + .5mm)


4. Install a cable tie securing the switch wires to the frame (Fig. 1584).

9

9-58

Fig 1584

PICT-1945


Floating Deck Mid-Size

Service Manual

Form No. 492-9189