VACU-POWER WPM SERVICE MANUAL Table of Contents – Page 1 of 3 SAFETY INSTRUCTIONS SAFETY TIPS...
VACU-POWER WPM SERVICE MANUAL Table of Contents – Page 2 of 3 MAINTENANCE - Continued BBC - ADJUSTING THE BLADE BRAKE BBC - CHECK CONTROL BAR OPERATION SELF-PROPEL SYSTEM - LUBRICATION SELF-PROPEL SYSTEM - ADJUSTING WHEEL DRIVE SELF-PROPEL SYSTEM - NEUTRAL ADJUSTMENT STORAGE - PREPARATION SECTION 1 FRONT SUSPENSION FRONT SUSPENSION - OPERATION FRONT SUSPENSION - DISASSEMBLY FRONT SUSPENSION - ASSEMBLY SECTION 2 REAR SUSPENSION (HP MODELS ONLY) HAND PUSH REAR SUSPENSION - OPERATION HAND PUSH REAR SUSPENSION
VACU-POWER WPM SERVICE MANUAL Table of Contents – Page 3 of 3 SECTION 5 ZONE START BRAKES INTRODUCTION PLUNGER STYLE ZONE START BRAKE PIVOTING ZONE START BRAKE SYSTEM SECTION 6 ELECTRICAL SYSTEMS IGNITION CIRCUIT KEY-LECTRIC STARTING SYSTEM SECTION 7 HANDLE ASSEMBLY HANDLE ASSEMBLY - REMOVAL SECTION 8 CUTTING DECK CUTTING DECK - OPERATION SECTION 9 GRASS BAG AND DISCHARGE DOOR GRASS BAG DISCHARGE DOOR SECTION 10 SIDE DISCHARGE CHUTE (OPTIONAL) SIDE DISCHARGE CHUTE - OPERATION SECTION 11 -DETHATCHER (OPTIONA
ABOUT THIS MANUAL This service manual was written expressly for Toro Vacu-Power@ Mowers. The Toro Company has made every effort to make the information in this manual complete and correct. in mind. It is- organized so This manualwas written with the service technician that information used most often is up front. As a result,you will find reference information on safety, identification, specifications, troubleshooting and maintenance, allin the frontthird of the manual.
er SAFETY INSTRUCTIONS as a serviceand repair manual This manual is intended for Toroservicing dealers. The safety instructions provided in this manual are for the troubleshooting and service of the productonly. The individual Operator's Manuals will contain safety and instructional information on the operation of Vacu-Power mowers. Servicing of any outdoor power equipmentrequirescare and common sense to prevent injury.
TABLE OF CONTENTS Reference Information Safety Instructions Page 1 Table ofContents 2 Identification 6 Specifications 7 Troubleshooting IO Maintenance 17 Service Procedures Section One Front Suspension OperationPage30 Disassembly .
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) SectionThree Self-PropelSystem(cont’d) Transmission Operation Page 41 Removal Disassembly Assembly . .. . . . , . . , , , , . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .46 Installation SectionFour BladeBrakeandClutch(BBC)System Introduction BBC Control Box Operation .................................................. 47 Disassembly Assembly50 BBC Bellcrank System Operation 51 Disassembly 51 Assembly . , , . , . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) Section Five Zone Start Brakes (cont’d) Pivoting Zone Start Brake System Operation Pa Disassembly .61 Assembly Adjustment .62 Section Electrical Six System Ignition Circuit ................................ Troubleshooting .............................. Operation Key-Lectric Starting System Operation ................................. Testing Section Seven Handle Assembly Removal Installation .67 Operation .
TABLE OF CONTENTS (cont'd) Service Procedures (cont'd) Section Ten Side Discharge Chute (Optional) Operation .............................................Page74 ................................................ .................................................. Disassembly 74 Assembly 74 SectionElevenDethatcher(Optional) .................................................. SafetyInformation ........................................... 75 ..................................................
PRODUCT IDENTIFICATION mower. In addition to the model number, eachproduct also has a unique serial number which serves to differentiateit from other products with the same model number. The serial number has seven digits,the first of manufacture(ie. 0022576 of which identifies the year indicates that the product was built in the 1990 model year).
SPECIFICATIONS General Specifications Specification See appropriate Engine Specification Manual Die Cast Aluminum 53.3cm (21.00”)heat treated alloy steel Polypropylene withoil impregnated bushings 20.3X 5.1 cm (8.0X 2.0')wide radial style 2.5 cm (1”)diameter, 16 gauge chrome plated steel tubing. Adjustable to three different positions. Folds without the use of tools. Wheels individually adjustable from 25 to 75 mm in 13 mm increments (1'to 3' in 1/2’increments) I I Overall Length 53.3cm (21”) 57.
SPECIFICATIONS (cont'd) Self-Propelled Model Specifications Specification 2.9 kph (1.8 mph) 3000 1.9 kph (1.2 mph) 2000 rpm rpm I ^ - Ground Speed#2 --__ 4.3 kph (2.7 mph) 3000 rpm 2.9 kph (1.8 mph) 2000 rpm 6.1 kph (3.8 mph) 3000 rpm 4.0 kph (2.5 mph) 2000 rpm Die cast aluminum with stamped steel cover 177 cc (6 oz.) No.
SPECIFICATIONS (cont'd) Vacu-Power Torque Specifications 8.6 N-m (75 in. Ibs.
TROUBLESHOOTING The Troubleshooting Section has been divided into five sections Use the guide below to locate information on the symptom you are observing. then turn to the proper page for possible causes and remedies Page Scalping 11 ................................................................... Clumping ................................................................... Unlevel height-of-cut .......................................................... Bag will notfill completely ....................
TROUBLESHOOTING (cont'd) Quality Of Cut Symptom: Scalping Symptom: Stragglers (somegrass blades left uncut) Symptom: Clumping S m tom: Bagwill not fill completely Symptom: Mower picks up too much dust Possible Cause ay theWaterdry tooLawn Height-of-cut too low Vacuum too aggressivefor conditions Vacu-Power Remedy I Raise height-of-cut blade.
TROUBLESHOOTING (cont'd) Transmission Symptom: Drive slips Manual [ Possible Cause Transmission loose belt slightly Transmission belt worn or damaged roll Output shaft pin sheared Replace roll ntermediate shaft key sheared Pinion and wheel gears mis-aligned Wheel Pinion Clutch Malfunctioning Repair wheel pin Replace intermediate shaft key Replace defective gears pinion clutch Symptom: Intermittent drive Symptom: Transmissionslow going into gear Possible Cause Shift keys sticking down in slots Shift key
TROUBLESHOOTING (cont'd) Transmission (cont'd) Symptom: Difficultto pull backwards I Remedy Possible Cause Inform operatorof proper operating technique Operator not moving forward 25 mm (1 ) after releasing control bar Adjust or replace traction belt Transmission beltturning input pulley when control baris disengaged wheel replace orRepair Contact between wheel and wheel covercover Inspectwheelpinion clutch andrepairasnecessary Wheel pinion clutch malfunctioning I I I I I Symptom: Only one wheel drives
TROUBLESHOOTING (cont’d) BBC Symptom: Blade does not stop within three seconds Possible Cause BBC cable not adjusted properly Replace brake plate Service pivot point Brake plate Inspect and repair brake plate system -Brake pad worn binding at pivot point Brakespring malfunctioning plate Symptom: Control bardoes not stay in middle position I Remedy Replace spring (P/N 66-0190) Detent (buckling)spring malfunctioning leaf spring52-7410) (P/N Control hook and cable lever not disengaging Repair and replace
TROUBLESHOOTING (cont'd) Key-Lectric Starting System Symptom: Starter motordoes not turn over Symptom: Starter motor turns too slowly Symptom: Starter motor turnsbut does not turn overengine [Possible Cause Remedy orflywheel.
TROUBLESHOOTING (cont’d) Miscellaneous Symptom: All four tires do not touch the ground Symptom: Thatcher does not fit correctly Possible Cause Remedy Incorrect components See Service Bulletins 45, 46 Symptom: Drain tube does not fit correctly (OHV models only) Possible Cause Remedy Incorrect Vacu-Power Mower
MAINTENANCE TECUMSEH 2-CYCLE ENGINE 5. Tecumseh 2-Cycle Servicing the Air Cleaner Normally, cleanthe air cleaner after every 25 operating hours. More frequent cleaning is required when the mower is operated in dusty or ditty conditions. Clean the top side of the base and the inside of cover thoroughly. Clean the filter by tapping on a solid surface 6. Reinstallthe paper filter and the nut. lighten the nut finger tight and then turn one (1) more complete turn.
i Tecumseh 2-Cycle Draining Gasoline Tecumseh 2-Cycle Replacing Spark Plug (cont'd) IMPORTANT: Replacea cracked, fouled or dirty spark 1. plug. Do not sand blast, scrape or clean electrodes 2. becauseengine damage could result from grit entering the cylinder. 3. Set the air gap at .762 mm (0.030”).See Figure 3.Install correctly gapped spark plug and gasket seal. Tightenthe plug firmly. Stop the engine. Pull the wire off the spark plug.
2. Remove the screw securingthe air cleaner cover to the engineas shown in Figure 7. Lift off the air cleaner cover. Clean thoroughly. Figure 8 Briggs & Stratton Quantum- Replacing Spark Plug UseaChampionRJ19LMorJ19LMspark plug or equivalent. Correct air gap is 0.8 mm (0.032"). Remove the plug after every 25 operating hours and check its condition. I Figure 6 1. Stop the engine and pull the wire off the spark plug. See Figure6. 2.
Briggs & Stratton Quantum- Dralnlng Gasoline 1. Stop the engine and pull the wire off the spark plug as shownin Figure 6. NOTE: Drain gasoline from cold a engine only. 2. Turn the fuel shut-off valve, if applicable, to the OFF position as shown in Figure I O . 3.Remove the capfromthefueltankandusea pump-type syphonto drain the fuel into a clean gas can. n Figure II 4. After draining, fill the engine with 410 cc (14 oz) fresh oil. Check theoil level using a dipstick.
TORO 2-Cycle Replacing the Spark Plug TORO 2-CYCLE ENGINE TORO 2-Cycle Servicing theAir Cleaner Normally,clean the aircleanerfoamelementafter every 25 operating hours. More frequent cleaning is required whenthe mower is operated in dusty or dirty conditions. CAUTION! Pull wire off sparkplugbeforeperforming adjustments or maintenance. Use an NGK BPMR4A spark plug orequivalent. Correct airgap is 0.81 mm (0.032”)Remove the plug after every25 operating hours and check its condition. 1.
TORO OHV Servicing the Air Cleaner (cont'd) 1. Stop the engine and pull the wire off spark plug. CAUTION! Pull the wire off the spark plug before performing adjustments or maintenance. 2. Cleanaround the spark plug and remove the plug from cylinder head. 1. Stop the engine and pull the wire off the spark plug. Removethe key fromthe switch on electric start models. 2. Push inthe locking tabsand lift off the air cleaner cover. Clean cover thoroughly. See Figure 15. 3.
BLADE BLADE Inspecting/Removing/Sharpeningthe Blade 1. Stop the engine. Pull the wire off the spark plug. 2. Drainthegasolinefrom the fueltank;refer to Draining Gasoline in this section for your particular engine. 3. Tip the mower on its side. Avoid rotating blade. Starting problemsmay result. 4. inspecting Blade Carefullyexamine the blade for sharpness and wear, especially where flat and curved parts meet. See Figure 19.
BLADE Inspecting/Removing/Sharpeningthe Blade (cont'd) 1. Drain gasoline from thefuel tank; refer to Draining Gasoline, this section, for your particular engine. 2. Tip the mower on its side. Avoid rotating blade because starting problems may result. Figure 20 Figure 22 3. Remove dirt and grass clippingsthat stick to the housing by spraying it with agardenhose. Scrape out the remaining debris with hardwood scraper. Avoid burrs and sharp edges. 4.
WHEELS BATTERY After every 25 operating hours or when the season Battery Charging, Model 26624 ends, front and rear wheels must be lubricated. Although a new battery is not fully charged, a partial charge of 4 hours provides enough energy for several 1. Apply 2 or 3 drops of light oil on the inside and 72 starts. However, a new battery must be charged for outside of all wheel bolts. Spin wheels to continuous hours to assure full charge. Also charge distribute oil into bushings. Wipeup excess oil.
BBC Adjusting the Blade Brake (cont'd) 2. Remove the two screwssecuringthescreen panel to the top of the mower housing as shown in Figure 22. Remove the panel. 3. Move the control bar down and lift up against the handle. Withthe control bar against the handle, measure the spring length(L) at the frontof the spring as shown in Figure 26. Figure 27 Figure 26 4. If the springdimension is greaterthan 32 mm (1-1/4") an adjustment is needed. 5.
ower before it affects normal operation, proceed Step 5. as shown in Figure 29. Install grease gun onto the fitting and gently apply oneor two pumps of No. 2 multi-purpose lithium-base grease. to 5. Start the engine if not already running. 6. Push the control bar downto its lowest position, latching the mechansim. See Figure 28.
Self-Propel System Adjusting Wheel Drive NOTE: '90and newer units will have fingertip adjustment just below the control panel 3. Lift the control bar until some resistanceis felt. Control bar should be 38 mm (1-1/2”) from 31. handle when properly adjusted. See Figure 4. Move thetop jamnut up to increase the clearance between the control bar and the handle. Movethe top jam nut down to decrease the clearance betweenthe control bar and the handle. 3. Move the ground speed controlto 'N'. 4.
9. Clean the aircleaner;refer to ServicingAir Cleaner, this section,for your particular engine. 10. Lubricate the wheels;refer to Wheels, page 25, and Self-propel System Lubrication, page 27. 11. Touch up all rusted or chipped paint surfaces. ToroRe-Kote paint is available from an Authorized TOR0 Service Dealer. Vacu-Power 29 12. Fill the crankcasewithoil;refer to Changing Crankcase Oil, this section, for your particular engine. 13.
SECTION 1 FRONTSUSPENSION superceded by the system denoted by 'D' in Front Suspension Operation Figure 35. Since the introduction of this modelin 1988,there have been a number of different front suspension 4. The knob can be removed from the spring arm configurations which have different parts used. by pressingon the detent through the hole in the However, the basic design has remained the same. knob. It is not gluedon. The wheels rotateon a shoulder bolt.
tation. If the pivot armis cast aluminum, secure the spring arm with the socket head machine screw. 3. the shoulder bolt and nylon locknut.Besure to lubricate the wheel bolt with2 or 3 drops of light oil. Wipe up any excess oil. Install the spring arm and pivotarmassembly onto the deck usingthe shoulder bolt and nylon locknut. Don't forget the spacer that fits between the deck and the pivot arm. Torquethe pivot arm bolt. See Figure36.
SECTION 2 REAR SUSPENSION (HP Models Only) Hand Push Rear Suspension Operation in hand push versions of the The rear suspension used Vacu-Powermowerserves two purposes: One, it supports the wheels, and two, it allows the heightof-cut to be changed. You will note many similarities between the hand push system andthe self propel system. This wasintended to maximize commonality betweenthe machines. that The wheelandtire assembly ride on shoulder bolts are fastenedinto the pivot arms. See Figure 37. 1.
wer Figure 38 5. Positionthe safety shield componentsas shown in Figure 39,and secure the safety shield and end caps with the two flanged head capscrews. 6. Torque all end cap capscrews. End Cap Capscrew Torque: 25 N-m (225 in Ibs) 7. Vacu-Power 33 Figure 39 Install the wheel and tire assembly onto the pivot arm using a shoulder bolt and nylon locknut. Don’t forget the washer that goes between the wheel andthe pivot arm. Check for free operation of the pivot arm.
SECTION 3 SELF-PROPEL SYSTEM thereby providing clearance for removalof the input lever. See Figure41. GEAR SELECTION CONTROL Gear Selection Control Operation TheTOROVacu-Powermower is equipped with a 3-speed transmission. The gear selection control allows the operator to select one ofthe three speeds or neutral by moving a lever on the control panel. The gear selection control is made up of 3 components: the controlling cable, the cable clamp, and the input lever on top of the transmission.
ower 2. Insert thecontrol cable through the control panel 8. from the top then snap the control into the rectangular holeon the right sideof the control panel. Make sure that it snaps fully into place and that the control cable ispointing forward. 3. Slide the gear selection control cable about 30 cm (12”) into the hole next to the right handle locknut. See Figure 43. 9. Securethegearselectioncontrolcable to the two black cable ties.
Gear Selection Control Adjustment (cont'd) 5. Reinstallaccesscover outside. 6. Test to insureproperoperation. 3. Remove the blackplastictransmissioncover from the tranmission area bypulling straight up and out. 4. Squeezethe 'ears' at the end of the cable sheath and pull the cable out vertically.See Figure 48. by pressingfrom the TRACTION CONTROL Traction Control Operation A belt transfers power from the engine to the transmission.
wer 9. Removethe two nylon locknuts securing the right 8. hand BBC cover to the BBC control box and remove the right hand control box half. Line up the black plastic transmission cover with the guides on the deck and the cable support bracket and slide into place. IO. Carefully pull the traction control cable from the traction control leverin the BBC control box and removethe cable. Removethe cable tie securing the cables to the handle onlyif necessary.
Traction Control Cable Adjustment (cont'd) is not affectedbychanging 53. Figure cable is the traction control, squeeze the control bar toward the handle and note which cable sheath moves.) See Figure 51. the height-of-cut.See 2. Move the jam nuts either up or down until you feel bar is 40 mm slight resistance when the control (1-1/2)' fromthe handle. NOTE:Make sure that the two halves of the traction control cable sheath are properly mated when performing this adjustment.
respect to the output shaft. Substituting an Eclip will resultin reduced wheel pinion clutch life. C. Externally Tabbed Thrust Washer fits in corresponding recesses on the pivot arm to protect pivot arm from premature wear. d. Internally Tabbed Thrust Washer internaltab fits in the keyway on the output shaft. This washer rotates with the output shaft and protects outboard clutch components fromwear. e. Special Retaining Clip fits in a groove on the output shaft to retain the pivot arm and spring arm.
Rear HOCand WPC Disassembly (cont'd) n Figure 55 7. Figure 56 If further disassembly ofthe pivot armis required, remove the spring arm. 8. Presstheneedlebearingandtheoil impregnated bushing from the pivot arm using an arbor press. 9. Removal of the grease fitting is not recommendedbecause it is pressed in. However, if damaged or lost, we suggest tapping and installing a threaded grease fitting. 10.If 7. Ifremoved, install newO-rings in the innermost groove 5.
Mower TRANSMISSION Transmission Operation Power fromthe engineis transferred to the wheels by speed transmission. The means of a belt and a three belt and transmission are easiest to understand when broken down into smaller systems. Input System: Power is transferred from the engineto the transmission via a belt. The self-propel pulleyat the engine is keyed to the crankshaft.
General Information:The upper gear case half is cast -aluminum. The lower transmission cover is made of with a roll pin so the gear sleeve always rotates with stamped steeland the gears are powdered metal. the output shaft. The gearselection system determines which oneof these three gears be willcoupled with the gear sleeveand the output shaft. This determines the final drive ratio. For more informationon final speeds at variousthrottle settings, see Figure 61.
ower assembly fromthe outputshaft. Onlyif components on the output shaft require replacement will pivot arm removal be necessary. 1. Remove the six flangedheadself-tapping screws securing the transmission cover to the transmission case and remove the cover. See Figure 65. Figure 63 6. Remove the transmission access cover from the rear ofthe housing by pressing underneath. from 7. Loosenthegearselection control cableclamp screw until the cable comes free.
Output Shaft Assembly: Transmission Disassembly (cont’d) 1. Slide the output bushing onto the outputshaft, flanged side last. 2. Slide the gear sleeve ontothe output shaft, tabs last and secure with a new roll pin. 3. Paint a light coat of lithium-based greaseon the output shaft under the output bushing, on the gear sleeve,and on the three output shaft gears. Slide the three output shaft gears onto the gear sleeve, notched sides last. 4.
8. that the output bushings are trapped in the proper locations.Note that the larger output bushinggoes on the longer end of the shaft and on the shorter the shorter output bushing goes end of shaft. If theleftpivotarmwasremovedforservicing, reassemble now as described under Rear Height-of-Cut System and Wheel Pinion Clutch Assembly, page 40. Input Shaft Assembly: 1. 5. If the input bearing had been removed, press a new oneinto the gearcase using an arbor press.
Transmission Assembly (cont'd) 3. 4. 5. 4. Slide a spacerwasherontotheintermediate shaft next to the bevel gear and follow with an first. intermediate shaft bushing, flanged side Droptheintermediateshaftintothegearcase, making surethat all gears engage properly. Fill thegear case with 177 cc (6 oz) of No. 2 lithium-based grease, then install the cover with capscrews. the six flanged head self-tapping End Cap Fastener Torque: 26 N-m (225in Ibs) 5.
ower SECTION 4 BLADE BRAKE AND CLUTCH (BBC) SYSTEM introduction In 1982 the federalgovernmentmandatedthatall consumer walk behind mowers with a cut of 63.5 cm (25‘) or less be equipped with safety devices. There are two primary criteria which these safety devices must meet. 1. the handle without affecting operation system. of the BBC GROUND SPEED in order A two step operation must be performed to get the blade turning. 2.
BBC Control Box Operation (cont'd) a. LeftControlHousing: Serves as coverforBBC control mechanism. Also houses endstraction of and BBC cables. b. ControlBar: Pivots on upper shoulder bolt. Transfers operator inputs to control box components. c. Traction Cable: Engagestransmissionby transferring inputs from the control box. is Transmission is engaged when cable tightened; disengaged when cable is loosened. d. BBC Cable: Transfers inputs from the control box to the BBC deck mechanism. e.
wer Ifthe control bar is raised so that it touches the handle, it will cause the traction lever to move slightly and engage the transmission. 4. Carefullyremovethe 2 nylon locknuts retaining the control box to the handle and remove the right controlbox half. Be careful notto dislodge any internal components. 5. Operate the control bar in its normal manner to determine if any of the components inside the control box are malfunctioning.
loosely installthe BBC cable lever as indicated. When correctly installed, the control hook and the cable lever willbe engaged. BBC Control Box Disassembly (cont’d) 8. Remove therocker arm asan assembly, complete with cable lever and control hook. 9. Remove the cable leverfrom assembly. 10. Press the roll pinfrom the rocker arm and remove the control hookand torsion spring. 1 1. Remove the traction cable from the traction lever and the left-hand control housing. 12.
Mower The directional changeis accomplished by means of a bellcrank. The bellcrank rides on anylon bushing and is attached to the cable support bracket. Regulation of the force applied to the brake plate assembly is accomplished by means of the "over-tension' spring. The control link, which provides the actual input to the brake plate assembly, is not attached directlyto the bellcrank,but rather through a compression spring.
BBC Bellcrank System Disassembly (cont’d) Figure 89 Figure 87 4. Note the orientation of the control link in Figure 90.Make sure that it is installed correctly into the bellcrank. Figure 88 5. Using the controllink to hold thecontrol pin, remove the flanged head screw from the control pin. Figure 90 CAUTION! Alwayswearsafetygogglesand gloveswhen disassemblingitems under spring tensionor compression. 6. Remove the control link from the control pin. 7. Inspect all parts forwear replace as necessary.
7. 8. assembly in the disengaged position. Check adjustmentof the BBC cable as described under BBC Adjusting the Blade Brake,page 26. to Secondly, it provides the breaking action necessary stop the blade within three seconds of release of the control bar. (Thethree second time frame is mandated by federallaw.) When in the disengaged position, the brake pad that is affixed to the brake plate touches the brake drum.
BBC UnderDeck Components Operation (cont'd) The upper pulley sheave is secured to the rotating shaft. It will alwaysturn with the crankshaft. The lower pulley sheave is mounted on a bearing which spins freely on the crankshaft, thus the two sheaves areboth mounted on the crankshaft, yet can spin freely with respect to one another. However, once a beltis properly tensionedin the groove created, the two sheavesspin as one.
ower brake platehub and lever and removethe brake plate assembly. The brake pad is not replaceable separately. Instead, use a complete brake plate assembly. 10. BRAKE PLATE BUSHINGBUSHING If necessary, removethe flanged head capscrew securingthe brake lever and hub to the housing. CAUTION! The brake plate lever is under some spring loading. Heavy gloves and eye protection are recommended when removlng the brake plate lever.
BBC UnderDeck Components Assembly (cont'd) NOTE: Make sure that the BBC screws are properly aligned before tightening the crankshaft nut. 9. Installthe BBC cover with the four flanged head self-tapping screws. 10. Install the BBCscreen, the blade spacer, the blade and the anti-scalp disk onto the BBC screws and secure with the two flanged nylon locknuts. Torqueto 3.80kg m (330in. Ibs.). Blade Locknut Torque 37 N-m (330in Ibs) 11.
4. Remove the three flanged head screws securing the control boxhalves. 5. Remove the two nylon locknuts securing the control box to the handle and carefully remove the right control housing half. 6. Slipthe end of the BBC cable from the cable lever and remove the cable. See Figure 99. BBC Cable Adjustment 1. Remove thetwo flanged head self-tapping screws securing the screen panelto the housing and remove the screen panel. BBC CABLE BBC Cable Installation 1.
NOTE: On 1990 and newer BBC cables use a finger tip adjustment atthe gearbox end. BBC Cable Adjustment 100. When adjusted properly it should measure 25.4 1.5 mm ( 1” 1/16”).If it does, skip ahead to step 5. Otherwise proceed with adjustment in the followingstep. 3. Loosen thetwojam nuts inthe middle of the BBC cable as shownin Figure 101. Rotate the nutsup to make the springsmaller or downto make the spring longer. Continueadjustmentuntil the over-travel spring measures 25.4 1.5 mm (1' 1/16.') 4.
SECTION 5 ZONE STARTBRAKES Introduction In 1982 the federalgovernmentmandatedthat all consumer walk behind mowers with a cut of 63.5 cm (25")or less be equipped with safety devices. There are two primary criteria which these devices must meet: 1. A two step operation mustbe performed in order to get the blade turning. 2.The blademustcome to astopwithinthree seconds of the operator leaving the operator's position.
Plunger Style Zone Start Brake Operation (cont'd) 7. BrakeCableReplacement: If brake cable replacement is required, remove the upper endof the brake cable from the cable clamp underneaththe control panel. Disconnect the clevis from the control bar and remove the cable. The killswitch is a two position push button-typeswitch that is closed whenthe control baris more than10 cm (4”) below the handleand open whenit is closer than 10 cm (4').
ower Secure the brake assembly to the engine with two self-tappingflanged head screws. Adjustthe brake tube so it is square with the flywheel and so that there is approximately 2.4 to 3.2 mm (3/32” to 1/8”) clearance betweenthe top of the brake tube and the bottom of the flywheel. 6. Once properly adjusted, tighten the two flanged head screws. Remove the tape fromthe control bar. Stopping of the engine and blade is accomplished by means of a brake thatis applied to the bottom of the ignition flywheel.
Pivoting Zone Start Brake System Assembly (cont’d) Figure 108 Figure 107 4. 5. Adjust the cable as described below. Slip the compression spring over the cable, then slip the lugged end of the cable into the slotin Pivoting Zone Start Brake System Adjustment the brakeplate.Slip the springbetweenthe is not adjustable at the brake.
wer SECTION 6 ELECTRICAL SYSTEMS Theelectronic ignition moduleopens the primary is passing by, thereby causing circuit while the magnet Ignition Circuit operation a rapid decreasein primary current flow. Openingthe primary circuit is important because any change in While the ignition circuit is described in each of the primary current (whether an increase or a decrease) applicable engine manuals, the subject will also be boosts the voltage in the secondary.
and negative. Because negativevoltagewould damage the battery if used for charging, the diode 'removes' this portion of the wave so that it has the waveform shown in Figure 115. Notice, that although the voltage still varies up and down, it never goes negative.Thisarrangementallowschargingofthe battery.
ower Toro battery tester. Set the VOM to DC Volts. If more than one scale is available, setit to the first larger than 14 volts. either endof each wire.All should be continuous. If not, repair or replace the wire harness. The battery should show a voltage between 12 and 14 volts. See Figures113 and 114. Figure 115 Figure 113 OF WIRING HARNESS Figure 116 Check for short circuits by checking continuity between each of the wires.
Starter Motor Testing: (cont'd) no problem is readily apparent, the cause may be a broken winding.Inthis case, replacethe starter motor. NOTE: Because of the orientation of the connectors, the starter motor will turn backwards when connected directly to a Key-Lectric battery. Figure 118 Figure 117 Alternator Testing: Charger Testing: Test the auxiliarycharger with a VOM. With the charger plugged into a receptacle thatis known to be good, the voltage across the two output terminals should be between 8.
ower SECTION 7 HANDLEASSEMBLY NOTE: Thehandle pins (locatedabout 20.3 cm (8”) above the bottomof the handle) are replaceable and require no special tools for installation. See yourparts catalog forthe correct part numbers for your mower. Handle Assembly Removal Removing the handle for replacement can be easily accomplished without disassembly of the BBC or Zone Start control bar mechanisms. 1. BBC Models: Before starting, obtain one 10 cm (43 long, 1/4” bolt and one 10 cm (43 long, 5/16' bolt.
Zone Start Units: Handle Assembly lnstallatlon (cont'd) 3. Bring the control bar assembly into position at the top of the handle and insert the handle screws through either side of the handle. the Secure withthe nylon locknuts. Make sure brake cable and the traction cable are properly positioned in the short block, then, if necessary, reinsert theminto the traction lever and the control lever on the controlbar.
er SECTION 8 CUTTING DECK If the bladeis too high, qualityof cut will degrade. If the blade is too low, operatorsafetymaybecome a concern. Cutting Deck Operation TheVacu-Powerdeck is designed to provide the bagging ability. Itrelies on ultimate in quality of cut and air movementto carry the grass into the bag. If the blade istoo low at any point withinthe housing, the Not all of the air is drawn from the sides; a considerable engine should be shimmed to bring it within the specification.
Cutting Deck Adjustments (cont'd) the pad equivalent to 20% an amount of material from of the movementnecessaryat the blade tip. Check the mounting pad height occasionallyto make certain you are notremoving too muchmaterial.Besure the mounting pad is flat whencomplete.Recheckthe blade tip clearance to insure it is within specification after adjusting the engine mounting pads. Always use Loctite(R) when re-installing engine mounting bolts. If the clearance is not greater than 2.3 mm (.
SECTION 9 GRASS BAG AND DISCHARGE DOOR Grass Bag Assembly Assembly 1. Slip the bag frame into the bag. Make sure that the Toro logos up are and that the plastic molding aligns properly with the front of the frame. Make sure that the handle is on the outside of the bag. GRASS BAG Grass Bag Construction The bag used on Toro Vacu-Power units consists of two pieces,the bag frame andthe bag. See Figure128. 2. Gradually work the molding over the bag frame until it is fully seated. 3.
Discharge Door Operation (cont'd) 'weather stripping'. It is important that this 'weather stripping' be in tact or dust and fine particles will exit the bag area during mowing. Along the hinge line is a special plastic seal which conforms to the shapeof the top of the door. The sealis also importantto prevent the escapeof fine particles. 9. Pullthe hinge pins and plastic bushings from the door. 10. If necessary, remove the door handle and door brace from the door by removing the two flanged head screws.
3. Slide a plastic bushing, flanged end last, into the hinge areaon the door. 4. Insertahinge side out. 5. Tip the mower on its side andpull the bottomof thespringintopositionusinga thin rope or 130. insulated electrical wire. See Figure 9. Check for proper operation of the spring by watching from the bottom of the unit while opening and closing the door. 10. Installthe black plastic transmission cover.
SECTION 10 SIDE DISCHARGE CHUTE (Optional) Side Discharge Chute Operation The side discharge chute when attached, takes clippings, propelled rearward by the blade, and redirects them off to the left side of the mower. It allows the operatorto mow without bagging grass. Side Discharge Chute Assembly 1. Place the chute hanger bracket and stress plate into position as shown in Figure 133.Secure with two washer head capscrews and nylon locknuts.
SECTION 11 DETHATCHER (Optional) Dethatcher Safety Information 1. Operateyourdethatcheronlywhenthere adequate light. Whencorrectlyassembled and adjusted,andwith of proper care,yourdethatcherwillprovideyears trouble-free lawn maintenance. is Arrange each kindof hardware into a group to ease assembly. 2.Remove alldebrissuchas wire, bottles,cans, sticks, and stones from the area to be dethatched. 3. 4. 5. 6.
it toward the center of the tray. See Figures 136 and 137. Dethatcher Assembly (cont'd) 2. 3. Nest each tine loop betweentheembossed 'dimples' with bent tips facing forward toward tab cutouts 'A' and secure with one 5/16'X 3/4” carriage bolt, a special washer, one 5/16'lock washer and a5/16'hex nut Tighten securely. OFFSETS TO INSIDE Installboth safety wires through the tine coils and bend the ends overto secure (use pliers).
PUSH NUT 10.See Figure 139.Placeone latchagainst the tab up (and outside of both mount bars with the facing outward)and the long slot locatedin front of the square hole near the mounting slot. Secure each latch with one1/4” X 3/4” carriage bolt threads facing inward, a special washer, O-ring, special washer and 1/4” hex locknut. Figure 140 CAUTION! Tighten both locknutsuntil there is SOME friction when sliding the latches against the mount bars do not over-tighten! 13.
Dethatcher Assembly (cont'd) RIGHT MOWER WHEEL STEEL PIVOT Figure 142 ARM RIGHT MOWER WHEEL CAST PIVOT MOWER WHEEL Figure 145 Dethatcher Installation See Figure 146. Install your dethatcher sliding by both latches up to clear the mounting slots on the mount First, slip one 1/2” flatwasher on onenew bars. Then position the front wheel adjustments on the hole shoulder bolt and insertthe bolt through your mowerto the lowest cutting height and place the in mower wheel (from 'outside' surface of wheel).
Dethatcher Adjustment See Figures 147 and 148. With the dethatcher mounted to your mower, position both units over a smooth flat surface such as a sidewalk, driveway or garage floor. Adjust the mower height (check your operator’smanual for correct procedures) to the desired height-of-cut.
SECTION 12 ENGINES Vacu-PowerMowersarepoweredbyavarietyof Tecumseh Products Company engines manufactured bya number of different Engine and Transmission Group Service companies. Manuals covering the maintenance and Division service of the each of these engines are available Grafton, WI, USA 53024 it through the manufacturer or the distributor.
