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WALK BEHIND POWER

MOWER DRIVE SYSTEMS

SERVICE MANUAL

Summary of content (144 pages)

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WALK BEHIND POWER MOWER DRIVE SYSTEMS SERVICE MANUAL
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ABOUT THIS MANUAL This service manual was written expressly for Toro servicing dealers. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the assumption that the reader has basic mechanical knowledge and skills. This book contains material covering the Toro and Lawn-Boy Walk Behind Mower Drive Systems models from 1990 through 2006, and may be speciﬁed for use on products built after 2006 that are similar in design.
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TABLE OF CONTENTS QUICK REFERENCE Transmission Remove and Replace 3 speed transmission . . . . . . . . . . . . . . . . . . . . 21” steel & cast deck Personal Pace, Easy Stride transmission . . . 22” steel deck transmission, Toro and Lawn-Boy . . . . . . . . . 21” Lawn-Boy Insight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 2-3 3-10 3-20 Transmission Internal Repair 3 speed transmission . .
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TABLE OF CONTENTS WORM DRIVE TRANSMISSION GENERAL INTERNALLY CLUTCHED Description . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . The Shifting Process . . . . . . . . . . . . . Removal & Installation (front wheel drive applications) Disassembly . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . CONSTANT MESH Description . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Speed Reduction System . . . . . . . . . . . . . . . . . Gear Selection System . . . . . . . . . . . . . . . . . Removal - Toro Vacu Power/Lawn-Boy Medallion Models . . . . Removal - Recycler/Rear Bagger Chassis . . . . . . . . . . Alternate Method . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . Transmission - Assembly . . . . . . . . . . . . . . . . . Output Shaft Assembly . . . . . . . . . . . . . . . . . . Input Shaft Assembly . . . . . .
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TABLE OF CONTENTS BBC Cable Removal (Recycler/Rear Bagger) . . . . . . . . . BBC Cable Installation (Recycler/Rear Bagger) . . . . . . . . BLADE OVERRIDE SYSTEM (BOS), BLADE CLUTCH SYSTEM (BCS) Disassembly . . . . . . . . . . . . . . . . . . . . . . Brake Arm Assembly . . . . . . . . . . . . . . . . . . BOS/BCS System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Using this manual Following each model number in the list below are codes identifying the type of deck material, transmission, wheel pinion clutch, hand controls, and if it has a blade clutch system. Use this information to select the correct sections of the service manual for the mower being serviced.
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a-Speed W - worm Model Tr
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck WPM Drive Systems Manual CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a-Speed W - worm Model Tr
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck WPM Drive Systems Manual CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a-Speed W - worm Model Tr
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck WPM Drive Systems Manual CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a-Speed W - worm Model Tr
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TABLE OF CONTENTS Code List 1B - one bail 2B - two bail 3S- 3 speed 21” stl - 21” steel deck 22” stl - 22” steel deck B- bevel gear BBC - blade brake clutch BBC VP - blade brake clutch for Vacu Power BOS - blade override system CD - cast deck WPM Drive Systems Manual CDVP - cast deck Vacu Power ES1 - Easy Stride 1st generation ES2 - Easy Stride 2nd generation Ins - Insight PP1 - Personal Pace 1st generation PP2 - Personal Pace 2nd generation RK - rocking key SB - spur bevel SR - spring ratchet SS - Sens-a
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WORM DRIVE TRANSMISSION Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . .
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WORM DRIVE TRANSMISSION the mower housing, pivots the transmission forward to maintain tension on the belt. GENERAL There are two versions of the worm drive transmission. The ﬁrst is a clutch type and is used on 21” front wheel drive mowers. The second version is constant mesh and is used on International 48cm rear wheel drive mowers. INTERNALLY CLUTCHED Description This is a worm and helical gear transmission. The worm shaft (input shaft) is driven by a belt from the engine crankshaft.
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WORM DRIVE TRANSMISSION Lubrication This transmission requires 90 wt. gear oil. A variable weight such as 85w90 is acceptable as long as the range includes 90 weight. The second part of the requirement is an EP rating of GL 5 or higher. The transmission has a ﬁll/check plug in the front. With the transmission level, ﬁll until level with the hole. NOTE: This is equal to about the center of the axle. Unless the case is cracked, oil can not leak out.
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WORM DRIVE TRANSMISSION Removal & Installation (front wheel drive applications) 4. Remove both front wheels and wheel covers (Fig. 005). 1. Remove the belt cover and unhook the spring on the front of the transmission. Slip the belt off the transmission pulley (Fig. 004). A B Fig 005 C Fig 004 A. Cable Clamp B. Shift Cable 3428-0127 C. Spring 3428-0129 5. Pivot (both) front spring arms forward until they point straight down.
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WORM DRIVE TRANSMISSION 6. Place a block of wood under the wheel pinion for support and drive the roll pin out of the axle (Fig. 007). Repeat the process on the other side. 8. Remove the transmission from the chassis. 9. Reverse the procedure to install. NOTE: Support the wheel pinions with the wood block while driving the roll pins in. This will prevent the axle from being bent. Fill the transmission with oil after it is installed in the mower (Fig. 009).
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WORM DRIVE TRANSMISSION 2. Drive the roll pins out of the ﬂanges in the front and rear of the case. (These pins align the top and bottom parts of the case) (Fig. 010). 5. Push the worm shaft out of the cover. This may require a little pressure. 6. To remove the axle, slide the clutch jaw to the side and drive the roll pin out of the sleeve and axle (Fig. 012). Fig 010 3428-0146 Fig 012 3428-0151 3. Remove the 4 self-tapping screw that connect the top and bottom cases.
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WORM DRIVE TRANSMISSION 9. Clean the old gasket material from the mating surfaces of the case and cover. 10. A hook or small screwdriver can be used to pry the seals out of the case. 11. An arbor press or large vise will be needed when removing and replacing the bushings. 14. Remove the screw from the shift arm and remove the shift arm, dust cover, and wear plate (Fig. 015). If the ball bearing is to be replaced, press it out at this time. G A 12.
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WORM DRIVE TRANSMISSION Note: The bushings are two different lengths. The side of the case with the thicker boss uses a longer busing to support the axle. The bushings should be ﬂush with the inside of the case (Fig. 016). 3. Note: Some replacement axles have more than one hole that can be used to pin the sleeve to the axle. Refer to the original axle to identify the correct hole to use. Then drive a roll pin through the sleeve and axle (Fig. 017). A Fig 016 Fig 017 3428-0158 3428-0151 A.
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WORM DRIVE TRANSMISSION 5. If the bearing in the cover is being replaced, use tool P/N 27-0490 to press it in place. This bearing only has one seal. Install the bearing such that the seal is visible from the top of the cover and the open side faces the gears. Press the bearing in until it is fully seated in the case (Fig. 019). 9. Fill the transmission with gear oil AFTER it is installed in the mower. The top of this transmission is not sealed. It will leak if tipped on its side (Fig. 020).
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WORM DRIVE TRANSMISSION Adjustment The transmission cable is a standard lever type. Since the spring and pin on top of the transmission pushes the shift fork towards the engaged position, the cable pulls the shift arm to the rear to disengage the transmission. The adjustment point is on the mower housing just to the rear of the transmission. To adjust, pull the control to the rear (disengage). Go to the cable clamp/adjustment.
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WORM DRIVE TRANSMISSION CONSTANT MESH Description This transmission is very similar to the “INTERNALLY CLUTCHED” on page 1 – 1. However, the helical gear is different as there is no internal clutching (Fig. 022). Engagement and disengagement is accomplished by pivoting the transmission to tighten or loosen the belt. Internal repair procedures are the same, as is the lubrication requirement, 90 wt. gear oil rated GL-5 or higher. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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WORM DRIVE TRANSMISSION Removal and Installation Fig 023 Ref. No. Qty 1 1 2 3 4 5 6 2 2 2 2 1 7 9 10 11 12 13 14 15 2 1 2 1 2 1 2 2 1-12 Description Rear Pivot Assembly RH (incl. Ref. #2, 4, 5 & 14) Grease Fitting Washer Sleeve Bushing Grease Seal Rear Pivot Assembly LH (incl. Ref. #3, 4, 5 & 14) Locknut Thread Forming Screw Trigger Return Spring H.O.C. Saddle Thread Forming Screw Push Nut Needle Bearing Friction Washer Ref. No.
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WORM DRIVE TRANSMISSION To remove the transmission from the mower proceed as follows: 1. Remove both rear wheels. 2. Rotate the adjustment knob under the lower lefthand side of the control panel ½ turn clockwise to tighten the belt, or ½ turn counterclockwise to loosen the belt. Hold the control cable while rotating the knob to prevent the cable from turning (Fig. 024). 2. Remove the retaining rings, springs, gears, keys, clutches, and pivot arms on both sides (“Wheel Pinion Clutch” on page 5-2). 3.
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WORM DRIVE TRANSMISSION 4. If loss of traction or improper engagement still occurs after adjustment, repeat steps 2 – 3 until properly adjusted. WHEEL CLUTCH See Rocking Key Wheel Clutch, page 5-3.
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . .
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION GEAR CASE ASSEMBLY Fig 026 Ref. No. Qty 1 2 3 4 5 6 7 8 9 10 1 1 1 1 2 2 2 2 1 1 2-2 Description Gear Case Casting Gear Case Cover HWH Screw Retaining Ring Flat Washer Groove Pin Lock Nut NI Washer Thrust Washer Bushing Ref. No.
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Description 2. Remove transmission belt cover. This basic transmission has been in use for several years. There are minor variations, such as different shafts on the bevel pinion gear to accommodate belt alignment on different chassies. All use a bevel pinion input gear which mates with a combination bevel/spur gear, which drives a ﬁnal spur gear. 3. Remove both rear wheels. 4. Remove retaining ring, spring, thrust washer, and pinion from both axles (Fig. 028).
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 6. Remove the belt guide. Note the location of the spacer under the front mounting screw (Fig. 030). Do not try to force the belt off the pulley without removing the belt guide. This often results in damage to the belt or slightly bending the belt guide, causing an increased tendency for belt jumping. On some models, removing these 2 screws makes transmission removal easier (Fig. 032). A Fig 032 3428-0121 A.
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Before removing the parts from the case, note the quantity and location of the thrust washers (Fig. 034). Clean the gears in solvent and inspect carefully. Any damaged gear must be replaced. Also replace the mate for the damaged gear. When gears run together, they develop a wear pattern that will result in premature failure if only one gear is replaced. The exception for this is if the transmission has VERY little running time before failure.
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Prior to installation of oil impregnated bushings, it is wise to apply a light coating of engine oil to the running surface (Fig. 037). Add grease and install the cover. Insert the transmission back into the chassis. Refer to the section on the wheel pinion clutch for assembly instructions. Install self propel cable. Adjust as needed; see “Handles and Control Cables” Section 7. Fig 037 3428-0019 Finally, install the spacer and pulley on the input shaft.
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SINGLE SPEED BEVEL GEAR TRANSMISSION Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . .
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SINGLE SPEED BEVEL GEAR TRANSMISSION EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION A B C D E F G J I H K L Fig 039 A. B. C. D. E. F. G. 3-2 Nut Washer Pulley Spacer Housing Bearing Pinion H. I. J. K. L. M.
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SINGLE SPEED BEVEL GEAR TRANSMISSION GENERAL INFORMATION This transmission was ﬁrst used on 22” steel deck models for 2002. It is used in both front wheel and rear wheel drive conﬁgurations. The bevel gear is reversed when used in the front drive versus the rear drive to change axle shaft direction of rotation. In both cases, the gears are in constant mesh. Clutching is done by rocking the transmission to tighten or loosen the drive belt (Fig. 040).
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SINGLE SPEED BEVEL GEAR TRANSMISSION FRONT AXLE AND TRANSMISSION ASSEMBLY 3354-613 Rev A Fig 041 Ref. No. Qty 1 2 2:1 3 4 5 7 7:1 7:2 8 9 10 11 12 13 2 2 2 4 2 6 2 1 1 2 2 2 2 2 2 3-4 Description Bolt-Shoulder Wheel Gear ASM Bushing Klipring-Locking Gear-Pinion, 13T Washer-Thrust Cover-Wheel Cover Washer-Stepped Arm-Pivot, Front Arm-Spring Knob-Lever, HOC Ring-Retaining Retainer-Bearing, HOC Bearing-Ball Ref. No.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 22” FRONT WHEEL DRIVE MODELS Remove Transmission 4. Remove the nut, washer, transmission pulley halves, and spacer. 5. Remove the belt guide. 1. Block the front of the mower up. There are two screws that secure the belt cover to the housing. They are accessed from the bottom (Fig. 042). 6. Remove both front wheels; note there is a washer between the wheel and wheel cover. 7. To remove the wheel pinions, remove the klip ring and thrust washer.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 9. Remove the two bolts and nuts securing each pivot arm to the housing. There is a notch in the pivot arm for clearance of a socket (Fig. 045). Fig 045 10. Remove the klip ring and thrust washer from each end of the axle (the left side has 2 thrust washers, the right side, one). The bearing, bearing retainer, HOC plate, spring arm and pivot arm all come off as one unit (Fig. 047). MVC-475 Fig 047 PICT-1858a The axle assembly will now drop out of the chassis (Fig.
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SINGLE SPEED BEVEL GEAR TRANSMISSION The snap ring can now be removed. Loosen the clamps with care due to the spring arm tension. Separate the spring arm components (Fig. 049). 2. Since the pulley was previously removed, the input shaft will now slip out of the transmission case. 3. If the input bearing is to be removed, press it out of the case now. 4. Slide the bearings and thrust washer off the axle. Drive the roll pin out and the bevel gear can be removed (Fig. 051).
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SINGLE SPEED BEVEL GEAR TRANSMISSION 3. Install the transmission bearings with the ﬂange facing the gear (Fig. 054). Assembly Tips 1. The same axle is used for both front and rear drive versions. There are two holes in the axle about one inch apart. Front wheel drive transmissions use the hole in the axle that is about 5 ¾” (14.6cm) from the end or closest to the center of the axle (Fig. 052). Slip the gear on such that the teeth and longest hub face the longer end of the axle. Drive the pin into place.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Coat the axle, key, and spring with #2 molybendum disulﬁde base grease or anti-seize compound before installing the pinion (Fig. 055). Belt Service - Front Wheel Drive Models To replace the self-propelled drive belt, proceed as follows: 1. Drain the fuel and oil and tip the mower on its right side. 2. Remove the two screws securing the belt cover from under the housing (Fig. 057). Fig 055 MVC-472 8. The wheel pinion is marked with an R and L for right and left.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 4. Remove one of the mounting screws for the belt guide and loosen the other. DO NOT bend the belt guide (Fig. 059). 22” TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal and Belt Replacement On rear wheel drive models, it is necessary to separate the rear drive assembly from the mower housing in order to change the drive belt. 1. Drain fuel and oil from the engine. 2. Remove the single retaining screw from the center of the bag door spring.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 3. Remove the plug from the hole next to where the self propel cable goes through the chassis (Fig. 062). 5. The cable tool (P/N 105-6819) will compress the locking tabs on the cable so it can be removed from the housing. 6. Slide the cable tool over the end of the cable and push (Fig. 064). At the same time, reach around the mower and pull the cable out of the housing. A Fig 062 MVC-735 4. Tip the mower on its side.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 8. Push it into the larger hole (Fig. 066). Fig 066 11. Pinch the ends of the lower handle together to disengage them from the pins on the HOC plates (Fig. 068). PICT-1897 Fig 068 MVC-737 9. Remove both rear wheels and both wheel covers. 10. Remove the stop cable from the engine (Fig. 067) and disconnect the self propel cable spring from the transmission. 12. Tip the mower onto its right side (carburetor up) and remove the blade. 13.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 14. Place the mower right side up and remove the three hex head and one Allen head cap screws on each side that hold the height of cut plates to the chassis (Fig. 070). The transmission assembly will now drop down. 16. The belt cover must be removed in order to remove the belt (Fig. 072). A Fig 072 MVC-743 A. Belt cover Fig 070 MVC-848 15. There is a cross brace underneath the mower that is held in place by two of the cap screws shown above (Fig. 071). 17.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 18. Pull the belt cover out from under the rear wall and the belt is exposed (Fig. 074). 20. The cable may be unhooked from the arm on the transmission to help prevent cable damage (Fig. 076). Note: It is not necessary to remove the transmission to replace the control cable. Fig 074 MVC-745 19. Clamp the axle with locking pliers and remove the pulley nut and transmission pulley (Fig. 075). Do not bend the belt guide.
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SINGLE SPEED BEVEL GEAR TRANSMISSION Rear Axle Disassembly 1. Remove the klip rings and thrust washers that secure the pinions to the axle (Fig. 077). 4. The pivot assembly will slide off the axle. This includes the bearing, bearing retainer, HOC plate, spring arm, and pivot arm (Fig. 079). Fig 079 Fig 077 MVC-747 MVC-746 2. When removing the pinions, note that there is a spring-loaded key under them. 5.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 6. You can now release the clamps and separate the HOC plate, spring arm, and pivot arm (Fig. 081). 2. Since the pulley was previously removed, the input shaft will now slip out of the transmission case. 3. If the input bearing is to be removed, press it out now. 4. Slide the bearings and thrust washer off the axle. Drive the roll pin out and the bevel gear can be removed (Fig. 083). Fig 081 MVC-750 Transmission Disassembly 1.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 3. Install the transmission bearings with the ﬂange facing the gear (Fig. 085). Axle Assembly Tips 1. The same axle is used for both front and rear wheel drive models. There are two holes in the axle about one inch apart. Rear wheel drive models use the hole about 4-3/4” (12cm) from the end. Slip the gear on such that the teeth and the longest hub face the short end of the axle. Drive the pin into place.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 6. Coat the axle, key, and spring with #2 molybendum disulﬁde grease or anti-seize compound before installing the pinion (Fig. 087). Fig 087 MVC-472 7. The wheel pinion is marked with an R and L for right and left. Identify right and left from the operator’s position (Fig. 088). On the right side, the R should face outward. The letter L should face outward on the left side. If the wheel pinions are reversed, the wheels will not drive.
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SINGLE SPEED BEVEL GEAR TRANSMISSION LAWN-BOY INSIGHT TRANSMISSION REMOVE AND REPLACE 3352-960 Rev B 4 Rear Axle and Transmission Assembly Fig 089 Ref. No. Qty 1 2 3 4 6 7 7:1 7:2 8 9 10 11 12 13 2 2 4 2 6 2 1 1 2 1 2 2 2 2 Description Bolt-Shoulder Rear Wheel ASM Klipring-Locking Gear-Pinion, 15T Washer-Thrust Wheel Cover ASM Cover-Wheel Washer-Stepped Ring-Retaining Arm-Rear, Pivot, LH Arm-Spring, Rear Knob-Lever, HOC Retainer-Bearing, HOC Bearing-Ball WPM Drive Systems Manual Ref. No.
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SINGLE SPEED BEVEL GEAR TRANSMISSION Transmission Removal & Belt Replacement 4. The belt cover will drop off the bottom (Fig. 092). The following steps will show one method of replacing the belt or removing the transmission on the Lawn-Boy Insight mowers. 1. Prepare the mower. Drain the gas and oil and disconnect the spark plug wire. 2. Remove two screws that secure the rear cover (Fig. 090). A Fig 092 MVC-288 A. Belt cover 5. If you have an electric start model, remove the battery and battery box.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Lift the top half of the transmission pulley off. If just replacing the belt, push the belt into the cutting chamber and slip the belt over the blade. Reverse the process to install the new belt (Fig. 094). 9. Bend the trailing shield slightly in the middle and remove it from the mower. Rotate both rear spring arms down to disengage them from the mower housing (Fig. 096). Note: Do not get anti-seize on the belt or the drive will slip.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 11. Remove klip ring, keyed thrust washer, and standard thrust washer (left side of mower has the standard thrust washer, right side does not) (Fig. 098). 13. Push the bearings and bearing retainers inward, towards the transmission (Fig. 100). Fig 100 Fig 098 12. Remove the snap ring, pivot arm and spring arm (Fig. 099). 14. Unhook the traction cable from the transmission belt guide (Fig. 101 and Fig 102).
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SINGLE SPEED BEVEL GEAR TRANSMISSION 16. Push the transmission to the left, as shown, and rotate to clear the tunnel. Drop the left side down, then pull the assembly out to the left side (Fig. 104). Fig 102 MVC-211x1 15. Remove the nut, washer, 2 pulley halves, and spacer from the transmission input shaft. Remove 2 screws securing the belt guide to the transmission (Fig. 103). Fig 104 MVC-300 17. The last step is to slide the bearings and bearing retainers off the axle (Fig. 105). A F Fig 103 A.
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SINGLE SPEED BEVEL GEAR TRANSMISSION Transmission Disassembly Transmission Assembly & Installation 1. Remove the 4 screws holding the cover on the transmission. The axle, bearings, and bevel gear can be lifted out (Fig. 106). Assemble in reverse order. See Axle Assembly and Installation Tips following. Axle Assembly Tips 1. The same axle is used for both front and rear wheel drive models. There are two holes in the axle about one inch apart.
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SINGLE SPEED BEVEL GEAR TRANSMISSION 2. Install the thrust washer on the side of the gear with the shortest hub, away from the gear teeth (Fig. 108). 3. Install the transmission bearings with the ﬂange facing the gear (Fig. 109). Transmission Installation Tips 1. Reconnect the cable to the belt guide and install the washer and spacer before installing the guide on the transmission. 2. Install the snap rings and klip rings with the sharp side out (in the direction of the force).
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SINGLE SPEED BEVEL GEAR TRANSMISSION 4. The wheel pinion is marked with an R and L for right and left. Identify right and left from the operator’s position (Fig. 112). On the right side, the R should face outward. The letter L should face outward on the left side. If the wheel pinions are reversed, the wheels will not drive. 7. When installing the rear cover, note the bosses on the back side of the cover. They must go behind the notch in the chassis to secure the cover.
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THREE SPEED TRANSMISSION Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . .
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THREE SPEED TRANSMISSION GEARCASE ASSEMBLY Fig 114 Ref. No. Qty 1 2 3 4 5 8 9 11 12 13 14 15 17 18 19 20 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 6 4-2 Description Pinion-25T Pinion-20T Gear-15t Spur, 37t Bevel Washer - Thrust Bushing Bushing - Output Washer Gear-49 T Gear-44 T Gear-39 T Sleeve - Gear Pin - Spring Shaft - Intermediate Case - Gear, Upper Cover - Case, Gear Screw - Tapping Ref. No.
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THREE SPEED TRANSMISSION OPERATION Speed Reduction System: Input System: Speed reduction is accomplished by two sets of gears – one set on the intermediate shaft and the other set on the output shaft. The gears on the intermediate shaft are powdered metal and ride on a hexagonal shaft supported on each end by oil impregnated bushings. These gears are driven by the pinion at the bottom of the input shaft.
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THREE SPEED TRANSMISSION There are also three gears on the output shaft. These three gears rotate freely on the gear sleeve. The gear sleeve is coupled to the output shaft with a roll pin so the gear sleeve always rotates with the output shaft. The gear selection system determines which one of these three gears will be coupled with the gear sleeve and the output shaft. This determines the ﬁnal drive ratio. Gear Selection System: The shift keys are retained on one end by the shift collar.
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THREE SPEED TRANSMISSION Removal - Toro Vacu Power/Lawn-Boy Medallion Models 4. Remove the black plastic transmission cover from the top rear of the housing. Complete transmission removal on the Toro Vacu Power/Lawn-Boy Medallion mower is quite easy and is recommended for most self-propel system repairs. 5. Remove the two ﬂanged head self-tapping screws securing the belt cover to the top of the transmission. Pull the cable from belt guide and remove the belt guide. 1.
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THREE SPEED TRANSMISSION Removal - Recycler/Rear Bagger Chassis Disassembly To remove the transmission from the chassis, raise the rear and support it with blocks. Inspection of this transmission can be accomplished without removing the pivot arm assembly from the output shaft. Only if components on the output shaft require replacement will pivot arm removal be necessary. 1. Remove both rear wheels and wheel covers. 2. Remove the rocking key clutches (see “Wheel Pinion Clutch” on page 5-3). 1.
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THREE SPEED TRANSMISSION 3. Removal of the input shaft and pulley assembly can be difﬁcult because the input pinion has a tendency to turn as the pulley nut is loosened. This situation can be addressed by using an impact wrench or by removing the 20 (B) and 25 (A) tooth gears (Fig. 122) from the intermediate shaft and then putting the intermediate shaft assembly back onto the transmission. The hexagonal intermediate shaft can then be held with a 7/16” end wrench while the pulley nut is loosened.
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THREE SPEED TRANSMISSION Output Shaft Assembly 1. Slide the output bushing onto the output shaft, ﬂanged side last. Assemble from the end of the shaft closest to the hole for the roll pin. 5. Coat the shift key sleeve with grease and prepare the shift keys, shift collar, and spring clip for assembly as shown in Figure 124. 2. Slide the gear sleeve onto the output shaft, tabs last and secure with a new roll pin. 3.
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THREE SPEED TRANSMISSION 8. If the left pivot arm was removed for servicing, reassemble now as described under “Rear Heightof-Cut and Wheel Pinion Clutch – Assembly” on page 5-5. 3. The input pulley nut can be tightened after complete transmission assembly, or at this point using the process in step 3, under Disassembly, page 4-7. 4. Slip the shift fork into the slot on the shift collar and place the shift fork and output shaft assembly into the transmission. Input Shaft Assembly 1.
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THREE SPEED TRANSMISSION Intermediate Shaft Assembly Note: Before assembling, coat the intermediate shaft with No. 2 lithium-based grease. Apply a light bead of lithium-based grease to ﬂange. 1. Slip an intermediate shaft bushing onto the left end of the intermediate shaft, ﬂanged end ﬁrst (Fig. 128). 2. Slide the intermediate shaft gears onto the intermediate shaft in this order: a. 25 tooth gear b. 20 tooth gear c. 15 tooth gear/bevel gear 3.
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THREE SPEED TRANSMISSION Special Assembly Notes for Toro Vacu Power/Lawn-Boy Medallion 4. Slip the two rear end cap fasteners through the safety shield guide wires then install. Tighten all four end cap fasteners (Fig. 131). 1. Slip the gear selection cable into the shift fork lever through the bottom as shown in Figure 130. Note: End cap fastener torque: 225 in-lbs. (26 Nm) A Fig 130 Fig 131 3428-0123 3428-0122 A. End cap 2.
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THREE SPEED TRANSMISSION TROUBLESHOOTING TIPS - 3 SPEED TRANSMISSION Look at the key and the notch in the gear that it engages. Excessive wear to the tip of the key or the notch in the gear may be the problem (Fig. 133). Hard Shifting A A raised boss molded into each gear causes the leading edge of the key to depress before it can enter the next gear (Fig. 132). B Fig 133 A. Shift collar Fig 132 3428-0067 The ring on the shift collar end of the key holds the drive end of the key up.
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WHEEL PINION CLUTCH Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .
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WHEEL PINION CLUTCH GEARCASE AND WHEEL ASSEMBLY, ROCKING KEY STYLE 27 10 11 Fig 135 Ref. No. Qty 1 2 3 4 5 6 7 8 8:2 8:3 8:4 9 10 11 12 1 1 1 1 2 2 2 2 1 1 1 2 4 4 2 Description V-Belt Lever-Shift Pin-Cotter Clamp-Cable Cap-End O-Ring Spring Arm ASM Pivot Arm ASM Bushing Bushing Fitting-Zerk Washer-Arm, Pivot Washer-Thrust, Keyed Ring-Klip Ring-Friction Ref. No.
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WHEEL PINION CLUTCH Wheel Pinion Clutch The wheel pinion clutch has a three-fold purpose. One, when the transmission is engaged, it causes the pinions to move with the output shaft and drives the wheels. Two, it provides differential action to allow easy turning and excellent maneuverability. Three it disengages the wheel pinions from the output shaft when the operator is not squeezing the handle.
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WHEEL PINION CLUTCH 17. Compression Spring – provides the light, constant, inward force necessary for proper clutch washer and friction ring engagement. It is extremely important that the wheel pinion clutch be maintained according to the instructions in the operator’s manual, which is greasing every 25 hours with one or two pumps of grease. Greasing regularly will prevent contaminants from damaging or wearing the system. Note: Over-greasing will also cause the system to malfunction.
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WHEEL PINION CLUTCH 2. Remove the special retaining clip at the end of the output shaft and pull off the following six wheel pinion clutch components: • Spring • Internally tabbed thrust washer • Wheel pinion • Wheel pinion key • Clutch washer • Friction ring 3. Remove the inner special retaining clip from the output shaft and remove the following components: • Internally tabbed thrust washer • Externally tabbed thrust washer • Pivot arm and spring arm assembly • End cap (if desired) 4.
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WHEEL PINION CLUTCH 4. Assemble the spring arm and pivot arm as shown in Figure 138. A 9. Slide the externally tabbed thrust washer and the internally tabbed thrust washer onto the output shaft. Make sure that the tab on the internally tabbed thrust washer enters the keyway. Secure with the special retaining clip. Make sure that the center tab ﬁts properly into the keyway. This will prevent rotation of the clip on the output shaft. 10.
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WHEEL PINION CLUTCH 13. Place the wheel pinion onto the output shaft. It is symmetrical and can be put on either way. 14. Install the internally tabbed thrust washer onto the output shaft making sure that the tab enters the keyway. 15. Slip the spring onto the end of the output shaft and secure with the special retaining clip. Again, make sure that the center tab ﬁts properly into the keyway to prevent rotation of the clip (Fig. 140). Fig 140 3428-0040 16.
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WHEEL PINION CLUTCH GEARCASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE 3354-613 Rev A Fig 141 Ref. No. Qty 1 2 2:1 3 4 5 7 7:1 7:2 8 9 10 11 12 13 2 2 2 4 2 6 2 1 1 2 2 2 2 2 2 5-8 Description Bolt-Shoulder Wheel Gear ASM Bushing Klipring-Locking Gear-Pinion, 13T Washer-Thrust Cover-Wheel Cover Washer-Stepped Arm-Pivot, Front Arm-Spring Knob-Lever, HOC Ring-Retaining Retainer-Bearing, HOC Bearing-Ball Ref. No.
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WHEEL PINION CLUTCH Spring Ratchet Style WHEEL PINION SERVICE The Spring Ratchet type wheel clutch system has been used on a wide variety of models. It consists of a spring supporting a drive key which engages the pinion. When the mower drive is engaged the axle turns the key which is engaged with an internal tooth on the pinion. The pinion turns the wheel gear. When the mower is pushed or turned, the pinion must rotate faster than the axle.
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WHEEL PINION CLUTCH 4. Slide the wheel pinion off the axle. Reassemble in reverse order: Note: There is a spring-loaded key under the pinion (Fig. 144). 1. Install one thrust washer, then the ﬁrst retaining ring with the sharp edge facing the chassis (Fig. 145). A B Fig 144 A. Retaining ring and thrust washer MVC-850 Fig 145 MVC-472 B. Key 2. Lubricate with anti-seize and assemble in the original order. 5. Behind the pinion should be another thrust washer and retaining ring (Fig. 000).
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BBC / BOS / BCS Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .
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BBC / BOS / BCS BLADE BRAKE CLUTCH SYSTEM (BBC) The blade clutch system offers the customer convenience to stop the blade while allowing the engine to continue to run. Description Before troubleshooting the BBC deck mechanism, be sure that it is adjusted properly. Refer to the BBC cable adjustment section for proper adjustments. There are two basic blade clutching system designs. The ﬁrst is commonly referred to as the BBC or Blade Brake Clutch.
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BBC / BOS / BCS The normal or “at rest” position of the control bar is indicated by the number 1 in the Figure 148. In order to engage the blade, the operator must ﬁrst “cock” the control bar down to position 2, then raise the control bar to position 3. Fig 148 Handle Controls The control box components and their functions (Fig. 149) are described below. ﬁg 27 Notice that position 3 is approximately 5” (12cm) below the handle.
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BBC / BOS / BCS e. Traction Lever: provides input to the traction cable since the end of the traction cable is retained in it. It also pivots on the upper shoulder bolt when the control bar is moved. f. Rocker Arm: pivots on the upper carriage bolt. It is afﬁxed solidly to the control arm by means of the roll pin. It houses both the control hook and cable lever. It also provides slot and stop for the buckling spring. These components interact to provide control to the BBC deck mechanism.
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BBC / BOS / BCS When the control bar is cocked to its lowest position as in Figure 151. The buckling spring is ﬂexed and moved to the right end of the rocker arm slot. Another event takes place inside the rocker arm: The spring-loaded control hook slides over the cable lever and grasps it so that when the lever is raised, the BBC cable will come with it. When the control bar is raised to a point 5” (12.7cm) below the handle, the BBC cable has been tightened enough to engage the blade (Fig. 152).
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BBC / BOS / BCS When the control bar is released, the tip of the control hook catches on the leaf spring causing it to rotate. This releases the BBC cable lever, thereby causing the BBC to declutch and apply the blade brake (Fig. 153). 2. Bend the locking tab securing the throttle control to the control panel, then tap the throttle control out using a rubber mallet. 3. Remove the 3 ﬂanged head screws retaining the 2 control box halves. C A 5. Reinstall the ﬂange nuts to help hold things together.
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BBC / BOS / BCS A better method is to make a special cut-away version of the right control box housing half as shown in Figure 154. When this cut-away version is installed, all components will function normally. Notice the cut-away cover and how it houses the leaf spring. This will aid in diagnosis. 12. Pull the tape from the outside of the handle. Remove the upper carriage bolt along with the cable lever and spacer. 13. Remove the lower carriage bolt and remove the left control housing. 14.
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BBC / BOS / BCS 3. Place a piece of duct tape over the heads of the carriage bolts that slide through the handle and the left control box housing. This will aid in assembly. 4. Slide the sleeve onto the upper carriage bolt making sure that it passes through the control bar, traction lever, and left control housing. 5. Position the control hook and torsion spring in the rocker arm as shown in Figure 156. Secure with the roll pin making sure that the roll pin is ﬂush with the side indicated in the ﬁgure.
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BBC / BOS / BCS 8. Slip the white nylon washer onto the J end of the buckling spring. The slotted side of the washer should face away from the end of the spring. Slip the spring into position in the rocker arm and the left control housing as shown in Figure 158. 10. Before installing the right control housing, check to make sure that both cable sheath ends are fully seated in their slots in the left housing. Also make sure that the sleeve passes through all components including the left control housing.
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BBC / BOS / BCS TORO BBC SERVICE GUIDE Disassembly Sequence Fig 160 6-10 bbc scan WPM Drive Systems Manual
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BBC / BOS / BCS BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC) Fig 161 Ref. No. Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 1 1 2 2 1 1 1 1 1 1 1 1 5 1 1 2 1 1 1 1 Description Brake Shoe Plate Hub V Belt Pulley Hub Lock Nut Spring Rod Shoulder Bolt Compression Spring Flange Bushing Lever Wa Bushing Ring Seal HWH Screw TAP Screw Flange Nut Cable Bracket Support Flat Washer Bellcrank Bushing Crank Spring Pin Control Link WPM Drive Systems Manual Ref. No.
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BBC / BOS / BCS TORO VACU POWER/LAWN-BOY MEDALLION BBC Fig 162 2. Pull the black plastic transmission cover up to remove it from the housing (Fig. 164). Fig 164 DSC-068a Bellcrank System Disassembly (Toro Vacu Power/Lawn-Boy Medallion) 3428-0082 3. Remove the shoulder bolt and ﬂanged nut securing the bellcrank to the control cable bracket. Once loose, remove the bellcrank assembly complete with control link from the unit (Fig. 165). 1.
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BBC / BOS / BCS 4. Remove the bushing from inside the bellcrank. 5. Using the control link to hold the control pin, remove the ﬂanged head screw from the control pin (Fig. 166). 2. Place the spring onto the control pin. Place the spring retainer onto the spring and insert the screw into the control pin. Using the control link to prevent rotation of the control pin, tighten the ﬂanged head screw until the retainer bottoms out on the control pin (Fig. 166). 3.
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BBC / BOS / BCS 5. Hook the end of the control link into the brake plate lever, then slip the BBC control cable onto the bellcrank. Finally, slip the shoulder bolt through the hole in the cable bracket support and secure with the ﬂanged nut. Note: The serrations in the ﬂanged nut must fully seat on the control cable bracket. 6. Check the adjustment of the BBC cable as described under “BBC Cable Removal (Recycler/Rear Bagger)” on page 6-19.
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BBC / BOS / BCS Under Deck Components Disassembly (Toro Vacu Power/Lawn-Boy Medallion) 1. Stop the engine and disconnect the spark plug lead to prevent accidental starting. Drain fuel. 2. Remove the 2 ﬂanged nylon locknuts securing the blade to the bearing block and remove the anti-scalp cup, the blade, the blade spacer, and the lower BBC screen (Fig. 169). 5. If further disassembly is required, begin by removing the crankshaft nut. An impact wrench works best.
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BBC / BOS / BCS 7. Again, pivot the brake plate counterclockwise and remove the BBC ﬂywheel. 8. BBC Belt or Idler Pulley Replacement: If the BBC belt or idler pulley requires replacement, it can be done without removal of the brake plate. Remove the idler pulley capscrew and nylon locknut then pull the belt and pulley from the brake plate as an assembly. 11.
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BBC / BOS / BCS Under Deck Components Assembly (Toro Vacu Power/Lawn-Boy Medallion) 1. Check to make sure that the brake plate seal is in good condition, then stretch onto the brake plate bushing (Fig. 173). 3. Loosely secure the brake plate, complete with brake pad, to the brake lever and brake hub as shown in Figure 174. Note that the bolt should go through the brake plate ﬁrst. Secure with a nylon locknut but do not tighten at this time. This will allow proper alignment of the idler pulley later.
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BBC / BOS / BCS 6. Install the BBC ﬂywheel onto the crankshaft, making certain that the slots in the BBC ﬂywheel align with the bumps on the bottom of the self-propel pulley (Fig. 175). 8. Make sure that the foam rubber anti-vibration pads are in place on the brake drum and assemble the brake drum bearing block and BBC screws onto the crankshaft as shown in Figure 177. Secure with the crankshaft nut. A B Fig 175 A. Bumps 7. Press the bearings into the bearing block, using an arbor press.
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BBC / BOS / BCS 11. Complete BBC service by checking BBC and selfpropel controls, making sure that all are functioning normally. Adjust as necessary. BBC Cable Removal (Toro Vacu Power/ Lawn-Boy Medallion) 1. Remove the two ﬂanged head self-tapping screws securing the screen panel to the housing and remove the screen panel as shown in Figure 178. 3. Bend the throttle control locking tab back slightly and tap the throttle control from the control panel with a rubber mallet.
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BBC / BOS / BCS BBC Cable Installation (Toro Vacu Power/ Lawn-Boy Medallion) 1. Slide a new BBC cable into the BBC cable lever. Then install the end of the cable sheath in the recess provided in the left control housing half (Fig. 180). 3. Install the three ﬂanged head screws securing the control box halves. 4. Bend the throttle control locking tab forward so that it will provide positive engagement with the throttle control. Install the throttle control. 5.
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BBC / BOS / BCS ENGINE AND BLADE ASSEMBLY (Toro Recycler / Rear Bagger) Fig 182 Ref. No. Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 13:1 14 16 17 18 19 20 21 1 1 1 1 1 1 3 1 1 1 1 2 1 2 1 1 1 1 1 1 1 Description Gts Ohv 200 Engine Gas Cap ASM Toro Nameplate Recoil Decal Clamp Screw Casing Clamp HWH Screw Belt Guide Bracket Woodruff Key Pulley Flywheel Blade Bolt Brake Drum ASM Vibration Dampener Hub ASM Shield Blade Spacer Blade Nut Recycler Blade Blade Stiffener Anti-Scalp Cup WPM Drive Systems Manual Ref.
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BBC / BOS / BCS TORO RECYCLER/REAR BAGGER BBC Fig 183 2. On the left side of the mower next to the rear wheel, loosen the clamp that secures the BBC cable to the mower housing. Near the left front wheel, unhook the spring end of the cable from the bellcrank. Remove the screw, bellcrank, sleeve, and unhook the control link from the lever (Fig. 184). 1350-001 a Fig 184 Idler Arm System Disassembly (Recycler/ Rear Bagger) 1. Drain the fuel and oil. Remove the spark plug wire.
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BBC / BOS / BCS 4. Turn the mower on its side. Remove the blade and the BBC cover. Brush any grass clippings out of the area. Locate the idler arm. Remove the bolt and locknut that retains the idler pulley. Note the pulley is on the deck side and there is a spacer between the pulley and idler arm (Fig. 186). With the pulley removed, the idler arm can pivot away from the brake drum and the belt can be removed.
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BBC / BOS / BCS 6. Now, disassemble the components on the crankshaft. If you have an impact wrench, the large nut on the crankshaft can be spun off. If you must remove it manually, wedge a bar or large screwdriver into the BBC ﬂywheel (Fig. 190). This will hold the crankshaft so the nut can be removed. Fig 190 8. Roll the self-propel belt off the pulley and remove the pulley and the key in the crankshaft. 9. Inspect the pulley. One end of the keyway is blocked off.
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BBC / BOS / BCS Idler Arm System Assembly (Recycler/Rear Bagger) 1. Start by installing the key and self-propel pulley. The two bumps on the pulley should face you (Fig. 193). Slip the belt over the pulley. The ﬂywheel must be installed with the side that looks like 1/2 of a pulley facing the brake drum (Fig. 194). Push the ﬂywheel ﬁrmly on the taper of the crankshaft. If you can’t push the ﬂywheel on far enough to hold, do not be concerned. DO NOT drive it on with a hammer. A B Fig 193 A.
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BBC / BOS / BCS They are noise dampeners. Without them, when the brake pad hits the drum, the drum will ring like a bell. Also look at the two blade mounting bolts. Each has a ﬂat side on the head to prevent them from rotating when the nut is tightened (Fig. 196). Make sure the bolts are fully seated. Install the brake drum. Fig 196 CAUTION! The two bumps on the pulley MUST engage the ﬂywheel. If you do not have an impact wrench, this is where the two bumps become important.
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BBC / BOS / BCS 8. Slip the spring over the shaft. One tang of the spring must engage the tab as shown (Fig. 198). 10. Hold the idler/brake arm in place. Slip the spring over the end on top of the deck as shown. Install the lever and install the screw through the lever and idler/brake arm shaft (Fig. 200). Once the screw is secured take a loop of wire or rope and hook the end of the spring. Pull it towards you and hook the end as shown. B Fig 198 C 3428-0190 A. Idler/brake arm A 9.
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BBC / BOS / BCS 2. Unhook the spring and cable from the bellcrank (Fig. 202). Fig 202 6. Slip the end of the BBC cable from the cable lever and remove the cable (Fig. 203). Fig 203 3428-0173 A. BBC cable lever 3. Bend the throttle control locking tab back slightly and tap the throttle control from the control panel with a rubber mallet. Place a piece of duct tape over the heads of the handle and the BBC control box mounting bolts.
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BBC / BOS / BCS 4. Bend the throttle control locking tab forward so that it will provide positive engagement with the throttle control. Install the throttle control. 5. Hook the spring on the end of cable and into the bellcrank arm (Fig. 204). Disassembly The following steps are disassembly of the system, including the steps necessary to replace the blade drive and self-propel belts. 1. Drain the fuel and oil and tip the mower on its side.
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BBC / BOS / BCS 4. Remove the blade support and disc (Fig. 207). Fig 207 6. Remove the brake pivot bolt. You will need a second wrench to hold the bolt head (Fig. 209). MVC-198 Fig 209 5. Remove the 3 capscrews and lift off the belt cover (Fig. 208). Fig 208 7. Unhook both springs from the slot in the brake arm (Fig. 210).
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BBC / BOS / BCS 8. Lift the brake assembly and blade drive belt from the mower (Fig. 211). 10. The components of the idler assembly are shown here (Fig. 213). B A C F G H E Fig 211 Fig 213 MVC-205 9. To replace the blade drive belt, remove the idler pulley bolt (Fig. 212). A. B. C. D. Belt Nut Brake arm Belt guard D E. F. G. H. MVC-209 Washer Bearing with ﬂange Spacer Bolt 11. Continuing with the disassembly, remove the bolt securing the pulley to the crankshaft.
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BBC / BOS / BCS 12. Rock the pulley half slightly and lift it off. The blade bolts will now drop out of their pockets (Fig. 215). Fig 215 MVC-220 13. Lift the crankshaft pulley half off of the crankshaft. Note this pulley half is keyed to the crankshaft and this pulley half is also the drive pulley for the self-propel belt. Go to the transmission to continue replacing the self-propel belt (Fig. 216). 14. Remove the two bolts holding the anchor plate to the chassis (Fig. 217). Fig 217 15.
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BBC / BOS / BCS 16. The bushing has a notch removed from the ﬂange end. Align that notch in the bushing with the tab in the anchor plate (Fig. 219). 2. Place the bearing with the ﬂange side down on the spacer and place the washer on top of the bearing (Fig. 221). A B Fig 219 A. Tab MVC-257 Fig 221 MVC-213 B. Notch 3. Install the belt, belt guide, and carriage bolt on the brake arm and secure with the carriage bolt (Fig. 222). Brake Arm Assembly 1.
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BBC / BOS / BCS BOS/BCS System Assembly Assemble all other parts in reverse order. Bolt torque as follows: Blade nuts: 350 - 400 in-lbs. (39.5 – 45.2 Nm) Crankshaft Bolt: 45 - 55 ft-lbs. (60.9 – 74.
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HANDLES AND CONTROL CABLES Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . .
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HANDLES AND CONTROL CABLES There are four types of handle and control assemblies on mowers not covered in other parts of this manual. This section will cover disassembly and repair of those types. Toro 2 Bail Handle The engine stop cable is not adjustable. If it fails to function, it must be replaced. The self propel cable is adjustable through a clamp which is typically located a few inches down the handle. Loosen this clamp and push the cable jacket up or down to adjust.
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HANDLES AND CONTROL CABLES Personal Pace Generation 1/Easy Stride Generation 1 1. Squeeze the ends of the control bail to disengage it from the handle. Disconnect the cable from the bail and set aside (Fig. 226). This is the original Toro Personal Pace/ Lawn Boy Easy Stride system. The handle is telescoping and as it slides, it tensions the transmission drive belt.
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HANDLES AND CONTROL CABLES 3. Remove 6 screws from the traction rod retainer (Fig. 228). Fig 228 DSC-4810 4. Remove the traction rod retainer. Note the location of the traction control rod (Fig. 229). Fig 229 7-4 DSC-4811 5. Disconnect the cable from the traction lever (Fig. 230). Fig 230 DSC-4815 6. Unhook the springs from each side of the handle (Fig. 231).
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HANDLES AND CONTROL CABLES 7. Slide the handle up and off (Fig. 232). Reassembly Reassemble in reverse order. 1. There are 3 bosses on the inside of the guide. The top and bottom ones receive the mounting screws. The boss in the photo must line up with the end of the control rod. This boss keeps the rod from moving sideways and falling out of the handle (Fig. 234). Fig 232 DSC-4819a 8.
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HANDLES AND CONTROL CABLES Adjusting the Personal Pace Cable Ensure the transmission belt is disengaged, transmission tilted forward. Loosen the cable clamp on the handle. When you pull the cable down the personal place handle should raise to the stop. Hold the cable and secure the clamp (Fig. 236). This is the second generation of the personal pace/ easy stride handle assembly. It works the same as the original in the sense that the handle is telescoping.
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HANDLES AND CONTROL CABLES 2. Install the tool over the stop in the handle guides as shown, one on each side. Push the handle down. The tool will allow the handle to slide over the stop built into the handle guide (Fig. 239). 4. Continue pushing the handle down until it slides off the end of the upper handle (Fig. 241). Fig 241 Fig 239 MVC-709a MVC-005a 3. As the handle begins to slide downward, pull the traction control bar farther out of the handle (Fig. 240). 5.
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HANDLES AND CONTROL CABLES Adjusting the Personal Pace/Easy Stride Cable Ensure the transmission belt is disengaged, transmission tilted forward. Loosen the cable clamp on the handle. When you pull the cable down the Personal Pace/Easy Stride handle should raise to the stop. Hold the cable and secure the clamp (Fig. 243). Lawn-Boy 2 Bail Handle The 2 bail style is shown here (Fig. 244). The top bail is the engine stop. Release it and the ignition is grounded and a brake comes on to help stop the ﬂywheel.
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HANDLES AND CONTROL CABLES Lawn-Boy Sens-a-Speed A On blade clutch models, the engine on and off is controlled by a switch on the left hand handle. The bail engages and disengages the blade. The Sens-a-Speed handle controls the self propel the same way as on a zone start model. Handle Disassembly, Zone Start Models 1. Loosen the cable clamp and disconnect the Sens-aSpeed cable (Fig. 246). Fig 245 DSC-4864a A. Top bail The Lawn-Boy Sens-a-Speed handle is made in two forms, zone start and blade clutch.
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HANDLES AND CONTROL CABLES 2. Squeeze the ends of the upper bail to disengage them from the handle. On some models the right side of the bail may be connected to the pin by a push nut. The push nut can be removed or the bail removed with the pin attached (Fig. 247). 4. Slide the pin out of the left hand handle and pull the upper handle up and out. 5. The plastic sleeves will slide off the upper handle. 6. The springs can be removed from the top slides if necessary.
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HANDLES AND CONTROL CABLES Cable Adjustment The engine brake cable is not adjustable. If it fails to function it will need to be replaced. Self-Propel Cable To properly adjust the self propel cable, loosen the cable clamp, pull the cable downward to remove all the slack (Fig. 250) then push the cable jacket up 1/8” (3.17cm) (Fig. 251) and secure with the cable clamp. Fig 251 1. Cable clamp G002634 2. Cable Handle Disassembly, Lawn-Boy Blade Clutch System (BCS) Models 1. Remove the upper wire bail.
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HANDLES AND CONTROL CABLES 2. Remove the e-clip on the left side pivot pin (Fig. 253). 4. Continue sliding the pivot assembly and brake cable off the pin. 5. Remove the shoulder bolt that the traction lever pivots on and remove the traction lever. A Fig 253 6. Pull the pin out of the left hand handle. Note it is snapped in and will require a locking pliers or something similar to remove. When removed, the springs will push the handle upwards (Fig. 255). DSC-4896a A. E-clip 3.
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HANDLES AND CONTROL CABLES 7. Slide the upper handle out of the top slide. 3 Speed Control Cables Reverse the process to assemble. The shift cables are not adjustable. To install the shift cable, insert the end of the cable in the shift arm and slip the end of the cable jacket into the bracket (Fig. 257). Note how the switch assembly, bail and control cable are assembled before they are installed on the pin (Fig. 256).
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HANDLES AND CONTROL CABLES The adjustment point for this cable is a knob, jam nuts, or a clamp to the handle (Fig. 259 and Fig. 260). The objective is to have the wheels begin to drive when the bail is about 1” (25mm) below the upper handle, yet be able to lower the bail enough to stop the wheels without releasing the bail (Fig. 261). 1” (25mm) A Fig 259 3428-0043-2 A. Clamp Fig 261 ﬁg 20 To adjust, turn the knob or loosen the cable clamp and slide the cable jacket up or down. Secure with the clamp.
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HANDLES AND CONTROL CABLES BBC Cable Adjustment (Toro Vacu Power/ Lawn-Boy Medallion) 1. Remove the two ﬂanged head self-tapping screws securing the screen panel to the housing and remove the screen panel (Fig. 262). 2. With the engine off and the spark plug wire disconnected, cock and lift the control bar to engage the blade. Tape the control bar to the handle with the blade engaged, then measure the length of the overtravel spring (Fig. 263). When adjusted properly, it should measure 1” (25mm).
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HANDLES AND CONTROL CABLES 5. Install the screen panel with the two ﬂanged head self-tapping screws. Make sure that the top edge of the screen panel is under the lip at the top of the housing. The screen is installed, sharp edge down, to allow air to be drawn in through the screen panel on top of the deck and down underneath the deck. This venting improves the airﬂow underneath the deck thereby improving quality of cut and bagging performance.
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HANDLES AND CONTROL CABLES On BBC models, the control bail also controls the transmission belt engagement. The adjustment point is a knob about halfway between the control panel and transmission. Ideally, the cable should be set so that the transmission drive will disengage when the bail is lowered about 1” (25mm). This allows the bail to be lowered so that the wheels stop driving and the BBC remains engaged, but the gap isn’t so large that the handle is hard to hold (Fig. 266).
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HANDLES AND CONTROL CABLES Toro BOS Control Cable Adjustment Lawn-Boy BCS Control Cable Adjustment The blade clutch control is adjusted by removing the cover between the engine and bag door. Loosen the cable clamp and draw the cable to the rear to remove the slack. Now push the cable outer jacket forward 5/8” (1.5cm) and secure. This will create 5/8” (1.5cm) slack in the cable (Fig. 268). Lawn-Boy Insight and Insight Gold: 1. Remove the grass bag and tunnel (Fig. 270).
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HANDLES AND CONTROL CABLES Lawn-Boy Insight Platimun: 1. Remove the gas and oil and tip the mower on its side with the air ﬁlter up. 2. Remove the BCS cover and belt cover. 3. Loosen the 2 cap-screws securing the bracket to the housing. Pull the cable to the rear to remove the slack. Push the cable forward 5/8” (1.5cm) and secure. This will create 5/8” (1.5cm) of slack (Fig. 272). Fig 272 4. DSC-5352a Install the BCS cover, belt cover and tunnel.
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SELF-PROPEL BELT REPLACEMENT Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 2 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 3 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS) . . . . . . . . .
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SELF-PROPEL BELT REPLACEMENT There are several different procedures for replacing the self propelled belt. Mowers with a blade clutch mechanism are the most complex as parts of that will need to be removed to access the self propel belt. Toro 21” Front Wheel Drive See Worm Drive Transmission page 1-1. These mowers usually have a model number that starts with 16xxx. Remove the belt cover, push the top of the transmission to the rear to create slack in the belt and remove the belt.
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SELF-PROPEL BELT REPLACEMENT 21” Toro and Lawn-Boy Mowers with Blade Brake Clutch Part of the blade clutch must be disassembled to access the self propel belt. See the BBC section starting on page 6-1 for more information. 21” Toro Mowers with Blade Override System and Lawn-Boy Mower with Blade Clutch System Part of the BOS or BCS must be removed to replace the self propel belt. (See page 6-18 for more information.
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