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).

Floating Deck Mid-Size Service Manual

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

Floating Deck Mid-Size Service Manual 9-5

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)

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

2. Lift the locking tab on the front of the operator presence control switch and unplug the harness connector from the switch (Fig. 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)


2. Remove the 2 screws securing the manual tube

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

9-19 Floating Deck Mid-Size Service Manual

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

5. Remove the nut securing the ignition switch to the control panel (Fig. 1446).

Fig 1446

PICT-1800

9

9-20

Fig 1444

PICT-1789


ELECTRICAL

6. Remove the lockwasher from the ignition switch (Fig.

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

7. Remove the ignition switch from the control panel

(Fig. 1448).

2. Place a lockwasher onto the ignition switch (Fig.

1450).

Fig 1448

PICT-1803

Fig 1450

PICT-1801

9


ELECTRICAL

3. Install a nut securing the ignition switch to the control panel (Fig. 1451).

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. 1453).

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).

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. 1465).

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)


2. Disconnect the negative battery terminal from the battery.

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


3. Plug the harness into the OPC switch (Fig. 1507).

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.)


2. Disconnect the negative battery terminal from the battery.



Fig 1530

PICT-1836

Fig 1531

PICT-1839


(Fig. 1532).


Fig 1532

PICT-1847

9

9-43

ELECTRICAL


(Fig. 1533).

8. Remove the nut securing the ignition switch to the control panel (Fig. 1535).

Fig 1533

PICT-1848

Fig 1535

PICT-1873

7. Unplug the harness terminal and harness connector from the ignition switch (Fig. 1534).

9. Remove the lockwasher from the ignition switch (Fig.

1536).

Fig 1536

PICT-1874

9

9-44

Fig 1534

PICT-1872


10. Remove the ignition switch from the control panel

(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).

3. Install a nut securing the ignition switch to the control panel (Fig. 1540).

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)

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

(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).

2. Remove the control panel cover/manual tube assembly (Fig. 1559).

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


4. Plug the harness into the OPC switch (Fig. 1566).

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

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

(Fig. 1569).

5. Unplug the latching relay from the wire harness (Fig.

1571).

Fig 1569

PICT-1921

4. Remove the control panel cover/manual tube assembly (Fig. 1570).

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).

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

1574).

Fig 1574

PICT-1921



Fig 1575

PICT-1937

9-55

9

Tools

On/Off Switch

Caution

Components

Alternator

Bail Switch

Single Pole Switch

PTO Switch

Relay, Single Pole Dual Throw Ignition Switch

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

PTO Switch

Delay Module

Clutch Power Supply Test Procedure:

DC Mini Hour Meter

Proximity Switch

PTO Brake Clutch Assembly

Wire Harness Pistol Grip (106-8780)

PTO Switch

Wire Harness T-2, Hydro (114-3418)

Wire Harness T-Bar, Hydro (114-3420)

Normally Open Switch

Starter Solenoid

Normally Closed Switch

Operator Presence Control (OPC)

Switch Replacement (T-Bar)

OPC Switch Removal (T-Bar)

OPC Switch Installation (T-Bar)

PTO Switch Replacement (T-Bar)

PTO Switch Removal (T-Bar)

PTO Switch Installation (T-Bar)

Ignition Switch Replacement (T-Bar)

Ignition Switch Removal (T-Bar)

Ignition Switch Installation (T-Bar)

Delay Module Replacement (T-Bar)

Delay Module Removal (T-Bar)

Delay Module Installation (T-Bar)

Parking Brake Switch Replacment

(Pistol Grip & T-2)

Parking Brake Switch Removal (P.G. & T-2)

Parking Brake Switch Installation

(P.G. & T-2)

Neutral Switch Replacement

(Pistol Grip)

Neutral Switch Removal (P.G.)

Neutral Switch Installation (P.G.)

PTO Switch Replacement (Electric

Start)

PTO Switch Removal (Electric Start)

PTO Switch Installation (Electric Start)

Operator Presence Control (OPC)

Switch Replacement (Pistol Grip)

OPC Switch Removal (P.G.)

OPC Switch Installation (P.G.)

OPC Switch Position Adjustment (P.G.)

Hour Meter Replacement (Pistol Grip)

Hour Meter Removal (P.G.)

Hour Meter Installation (P.G.)

Ignition Switch Replacement

(Pistol Grip)

Ignition Switch Removal (P.G.)

Ignition Switch Installation (P.G.)

Kill Relay Replacement (Pistol Grip)

Kill Relay Installation (P.G.)

Kill Relay Removal (P.G.)

Solenoid Switch Replacement

(Pistol Grip & T-2)

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

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

Operator Presence Control (OPC)

Switch Replacement (T-2)

OPC Switch Removal (T-2)

OPC Switch Installation (T-2)

Latching Relay Replacement (T-2)

Latching Relay Removal (T-2)

Latching Relay Installation (T-2)

Kill Relay Replacement (T-2)

Kill Relay Removal (T-2)

Related manuals

Toro

Mid-Size ProLine Pistol Grip Gear, 15 HP