Service Manual

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Walk Power Mower

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Service Manual

Residential Products

Summary of content (168 pages)

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Residential Products Walk Power Mower Drive Systems Service Manual
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ABOUT THIS MANUAL This service manual was written expressly for Toro and Lawn-Boy service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. This manual contains material covering Toro and Lawn-Boy Walk Behind Mower Drive Systems with models ranging from 1990 through 2013.
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TABLE OF CONTENTS 1 - Safety Information General Information �� 1-2 Think Safety First �� 1-2 2 - Worm Drive Transmission GENERAL ��
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TABLE OF CONTENTS 4 - Single Speed Bevel Gear Transmission cont.
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TABLE OF CONTENTS 7 - Wheel Pinion Clutch cont.
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TABLE OF CONTENTS 9 - Handles & Control Cables cont.
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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 blade clutch system if applicable. Use this information to select the correct service manual section for the mower being serviced.
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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USING THIS MANUAL Code List 1B – one bail ADS – Automatic Drive System 2B – two bail ES1 – Easy Stride 1st generation 3S – 3-speed ES2 – Easy Stride 2nd generation 20stl – 20” steel deck PP1 – Personal Pace 1st generation 21stl – 21” steel deck PP2 – Personal Pace 2nd generation 22stl – 22” steel deck B – bevel gear BBC – blade brake clutch RK – rocking key BBC VP – blade brake clutch for Vacu-Power SB – spur bevel BOS – blade override system SR – spring ratchet CD – cast deck SS – Sens-a
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SAFETY INFORMATION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY INFORMATION General Information ! This symbol means WARNING or PER SONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for service, and repair of Toro and Lawn-Boy walk behind mowers.
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WORM DRIVE TRANSMISSION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
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WORM DRIVE TRANSMISSION GENERAL the mower housing, pivots the transmission forward to maintain tension on the belt. 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 C Fig 005 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). 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). 3428-0146 Fig 012 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. 12. Clean the oil residue and any metal shavings from the case. 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.
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WORM DRIVE TRANSMISSION Assembly 1. Use bushing installation tool P/N 27-0460, to press in new axle bushings. This tool helps keep the bushing straight and keeps the inner diameter of the bushing correctly sized. 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). Note: The bushings are two different lengths.
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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 Controls There are two control cables used with this system. One cable operates the engine kill switch and flywheel brake; the other controls the 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.
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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 2-12 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. Remove the retaining rings, springs, gears, keys, clutches, and pivot arms on both sides (“Wheel Pinion Clutch” on page 5-2). 3. To check the adjustment, slowly squeeze the control bar towards the handle. The cable is adjusted correctly when resistance is felt when the control bar is approximately 1” (25mm) from the upper handle (Fig. 025). 3. Remove the belt. 4.
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WORM DRIVE TRANSMISSION THIS PAGE INTENTIONALLY LEFT BLANK.
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . .
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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 3-2 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 chassis. 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. End cap Fig 030 PICT-1880a 7.
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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 Assembly Assemble with the correct number of thrust washers. Refer to the parts manual if there is any doubt at all. It is not possible to locate the shafts and bearings in the wrong location, due to differences in sizes. Finally, install the spacer and pulley on the input shaft. The internal gears will help hold the pinion while the nut is tightened (Fig. 038).
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SINGLE SPEED BEVEL GEAR TRANSMISSION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . .
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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 L K M Fig 039 A. B. C. D. E. F. G. 4-2 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 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 4-4 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 clip 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 clip 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-475a Fig 047 The axle assembly will now drop out of the chassis (Fig. 046).
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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 Assembly Tips 3. Install the transmission bearings with the flange facing the gear (Fig. 054). 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 3/4” (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.
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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-propel 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 clip 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 Axle Assembly Tips 3. Install the transmission bearings with the flange facing the gear (Fig. 085). 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 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 WPM Drive Systems Manual 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 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-288Xa 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 clip ring, keyed thrust washer, and standard thrust washer (left side of mower has the standard thrust washer, right side does not) (Fig. 098). Fig 098 13. Push the bearings and bearing retainers inward, towards the transmission (Fig. 100). Fig 100 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). A F Fig 103 A. 2 screws on top of transmission B. Spacer C. Pulley half WPM Drive Systems Manual D. Pulley half E. Washer F.
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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 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 clip rings with the sharp side out (in the direction of the force). The left end of the axle uses the extra thrust washer, the one without the tab.
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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.
PAGE 71
THREE SPEED TRANSMISSION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
PAGE 72
THREE SPEED TRANSMISSION GEAR CASE 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 5-2 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.
PAGE 73
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.
PAGE 74
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.
PAGE 75
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.
PAGE 76
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). 3.
PAGE 77
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.
PAGE 78
THREE SPEED TRANSMISSION Transmission - Assembly The transmission uses 6 oz. (177cc) No. 2 lithium-based grease as a lubricant. When assembling, be sure to coat all moving components with grease to ensure proper lubrication. 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. Output Shaft Assembly 1. Slide the output bushing onto the output shaft, flanged side last.
PAGE 79
THREE SPEED TRANSMISSION Input Shaft Assembly 1. If the input bearing was removed, press a new one into the gear case using an arbor press. Press only on the outer race or bearing damage may result. 2. Slide the input shaft and pinion through the ball bearing and assemble the spacer and two pulley halves as shown in Figure 126. Install a flat washer and a nylon locknut finger tight. 3.
PAGE 80
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.
PAGE 81
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.
PAGE 82
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.
PAGE 83
GENERAL TRANSMISSIONS® Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
PAGE 84
GENERAL TRANSMISSIONS® General Information General Transmissions internal gears are in constant mesh. Clutching, engaging and disengaging the traction cable will rock the transmission to tighten or loosen the drive belt. When engaged, the traction cable will move the transmission to tighten the belt. When released, the weight of the transmission causes it to rock towards the engine to disengage. These transmissions are not serviceable.
PAGE 85
GENERAL TRANSMISSIONS® 22” Steel Deck - Rear Axle and Transmission Assembly 2 1 6 5 7 10 9 4 8 16 15 14 3 13 17 20 18 19 12 11 Fig.
PAGE 86
GENERAL TRANSMISSIONS® 22” Steel Deck - Rear Axle Belt Replacement 3. There are a total of (5) rear baffle screws. There are (2) screws, as shown, on each side and (1) screw on the back of the machine under the bag door (Fig. 138). 1. Remove (2) belt cover screws (Fig. 136). Fig. 136 001 Fig. 138 002 2. Move height-of-cut spring arms past the highest setting to gain access to the fasteners on both sides (Fig. 137). 4. Tip mower on its side, air filter up.
PAGE 87
GENERAL TRANSMISSIONS® 5. Remove blade bolt(s) (A), blade support (B), blade (C), and blade driver (D) (Fig. 140). 9. Rotate the transmission forward enough to remove the (3) screws (#14) holding the belt guide (#13) to the top of the transmission (#11). Remove belt guide (Fig. 142). 14 D 13 A B C Fig. 140 12 004 11 6. Release traction cable guide bushing (Fig. 141). 1 2 Fig. 142 3 10. Remove the old belt and install a new belt. If not replacing the transmission reassemble in reverse order.
PAGE 88
GENERAL TRANSMISSIONS® 22” Steel Deck - Rear Axle Transmission Replacement 3. Remove (2) screws (#3) from right side height-of-cut plates. 1. Remove both shoulder bolts (#19), wheel assem blies (#20), retaining rings (#17), and pinion gears (#16) (Fig. 143). 4. Slide transmission toward the left side of the mower and out of the right hand bearing retainer and pivot arm (Fig. 145). 1 6 5 7 10 9 8 11 16 15 3 17 20 18 19 Fig. 143 rear_drive_pinion_a 2.
PAGE 89
GENERAL TRANSMISSIONS® 22” Steel Deck - Front Axle and Transmission Assembly 1 2 14 19 16 21 12 3 15 6 10 7:1 7:2 4 9 13 5 11 8 17 20 18 Fig.
PAGE 90
GENERAL TRANSMISSIONS® 22” Steel Deck - Front Axle Belt Replacement 2. Remove the (3) screws (A) holding the transmission belt guide to the top of the transmission and remove transmission belt guide (Fig. 149 and Fig. 150). 1. Remove (2) belt cover screws (#2) to expose trans mission (Fig. 148). 1 A A A 2 010a Fig. 150 011a 2 Fig. 148 6-8 Fig.
PAGE 91
GENERAL TRANSMISSIONS® 22” Steel Deck - Front Axle Transmission Replacement 3. Tip mower on its side, air filter up. DO NOT tip the mower with the air filter side down (Fig. 151). 1. Remove both shoulder bolts (#8), wheel assemblies (#9), retaining rings (#18), and pinion gears(#20) (Fig. 153). 2 14 12 3 15 6 10 7:1 7:2 4 9 13 Fig. 151 008a 5 11 8 17 4. Remove blade bolt (B), blade support (C), blade (D) and blade driver (E) (Fig. 152). Fig. 153 20 18 front_drive_pinion 2.
PAGE 92
GENERAL TRANSMISSIONS® 21” Steel Deck - Rear Axle and Transmission Assembly 23 14 23 15 21 20 41 42 49 41 412 1 Fig.
PAGE 93
GENERAL TRANSMISSIONS® 21” Steel Deck - Rear Axle Belt Replacement 4. Remove (3) screws from tunnel and remove tunnel. 1. Remove (2) screws from rear cover to access belt cover and tunnel screws (Fig. 156). Fig. 156 015a 2. Remove (3) belt cover screws and belt cover (Fig. 157). Note: Although it is not necessary to remove this part it provides the best access to remove the transmission belt guide screws (Fig. 158). Fig. 158 017a 5.
PAGE 94
GENERAL TRANSMISSIONS® 21” Steel Deck - Rear Axle Transmission Replacement 4. Remove retaining rings (#3), pinion gears (#4), bearing retainer retaining rings (#8), pivot arms (#9), and height-of-cut spring arms (#10) (Fig. 160). 1. Remove (2) screws (#26) from trailing shield (#25) and remove trailing shield (Fig. 160). 2. Remove both wheel assemblies (#2) (Fig. 160). 5. Slide both bearing retainers (#12) in toward the transmission case (Fig. 160). 6.
PAGE 95
GENERAL TRANSMISSIONS® Cast Deck - Rear Axle and Transmission Assembly Fig.
PAGE 96
GENERAL TRANSMISSIONS® Cast Deck - Rear Axle Belt Replacement 3. Disconnect traction cable from transmission (Fig. 165). 1. Up near the handle, loosen traction cable anchor nut (#14) and pull traction cable housing (#15) up toward handle, which provides enough slack to remove traction cable from transmission (Fig. 163). 4. Remove blade bolt, blade accelerator, blade, and blade driver. 5. Tip mower on its side, air filter up. DO NOT tip the mower with the air filter side down. 6.
PAGE 97
GENERAL TRANSMISSIONS® Cast Deck - Rear Axle Transmission Replacement 2. On both sides remove stack up of parts, 1-12, from wheel shoulder bolt to second locking ring clip. See breakdown (Fig. 167). 1. Rotate both height-of-cut spring arms forward and down below deck to relieve tension on the locking ring clip (Fig. 166). 13 11 9 8 5 3 10 7 6 4 Fig. 166 023a Fig. 167 1. Bolt-Shoulder 2. Wheel Gear Asm 3. Spacer-Cover, Wheel 4. Cover-Wheel 5. Ring-Clip, Locking 6. Spring-Compression 7. 8. 9.
PAGE 98
GENERAL TRANSMISSIONS® THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 99
WHEEL PINION CLUTCH Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
PAGE 100
WHEEL PINION CLUTCH GEAR CASE AND WHEEL ASSEMBLY, ROCKING KEY STYLE 27 10 11 Fig 168 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.
PAGE 101
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.
PAGE 102
WHEEL PINION CLUTCH Test for Function Quick Test Function If you are unsure that the keys are disengaging properly, stop the mower, shut the engine off and push the mower forward a few inches. If the keys disengage the system is working correctly. Start the engine and engage the drive, if both engage they are OK. If one or the other do not engage or disengage properly try greasing the pivot arm. Use #2 lithium grease and only one or two pumps from a hand grease gun.
PAGE 103
WHEEL PINION CLUTCH 4. Check all components at this time for damage and wear. Pay particular attention to the grooves at the end of the output shaft, the bearing surfaces on the output shaft, and the wheel pinion clutch components. Replace parts as necessary. 5. Check the innermost groove on the output shaft which is located 2-1/4” (5.7cm) in from the end of the shaft; make sure that the O-ring seal is present and intact. This seal is important to keep grease in and contaminants out.
PAGE 104
WHEEL PINION CLUTCH 5. To increase service life, make sure all parts are clean prior to assembly and coated with new grease. 12. Place the wheel pinion key in the groove on the output shaft with the leg toward the clutch washer. 6. If removed, install a new O-ring in the innermost groove 2-1/4” (5.7cm) in from the end on each output shaft, making sure that it is fully seated in the groove. Refer to Figure 171 above. Not all models use an O-ring. Note: There is a left and a right wheel pinion key.
PAGE 105
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. 173). Fig 173 3428-0040 16.
PAGE 106
WHEEL PINION CLUTCH GEAR CASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE Fig 174 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 7-8 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.
PAGE 107
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.
PAGE 108
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. 177). 1. Install one thrust washer, then the first retaining ring with the sharp edge facing the chassis (Fig. 178). A B Fig 177 A. Retaining ring and thrust washer MVC-850 Fig 178 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. 144).
PAGE 109
BBC / BOS / BCS Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
PAGE 110
BBC / BOS / BCS BLADE BRAKE CLUTCH SYSTEM (BBC) The blade clutch system offers the customer conven ience 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.
PAGE 111
BBC / BOS / BCS The normal or “at rest” position of the control bar is indicated by the number 1 in the Figure 181. 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 181 Handle Controls The control box components and their functions (Fig. 182) are described below. fig 27 Notice that position 3 is approximately 5” (12cm) below the handle.
PAGE 112
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.
PAGE 113
BBC / BOS / BCS When the control bar is cocked to its lowest position as in Figure 184. 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. 185).
PAGE 114
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. 186). C A A. Contact point B. Leaf spring Note: When servicing the BBC control box, be careful not to disassemble the unit any further than necessary as it will then become difficult to trouble shoot.
PAGE 115
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 187. 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.
PAGE 116
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 189. Secure with the roll pin making sure that the roll pin is flush with the side indicated in the figure.
PAGE 117
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 191. 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.
PAGE 118
BBC / BOS / BCS TORO BBC SERVICE GUIDE Disassembly Sequence Fig 193 8-10 bbc scan WPM Drive Systems Manual
PAGE 119
BBC / BOS / BCS BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC) Fig 194 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 WPM Drive Systems Manual 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 Ref. No.
PAGE 120
BBC / BOS / BCS TORO VACU POWER/LAWN-BOY MEDALLION BBC Fig 195 2. Pull the black plastic transmission cover up to remove it from the housing (Fig. 197). Fig 197 DSC-068a Bellcrank System Disassembly (Toro Vacu Power/Lawn-Boy Medallion) 1. Remove the flanged head self-tapping capscrews securing the upper BBC cover to the housing and remove the upper BBC cover (Fig. 196). 3428-0082 3. Remove the shoulder bolt and flanged nut securing the bellcrank to the control cable bracket.
PAGE 121
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. 199). Bellcrank System Assembly (Toro Vacu Power/Lawn-Boy Medallion) 1. Insert the control pin into the recessed area on the bellcrank. 2. Place the spring onto the control pin. Place the spring retainer onto the spring and insert the screw into the control pin.
PAGE 122
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.
PAGE 123
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. 202). 5. If further disassembly is required, begin by removing the crankshaft nut. An impact wrench works best.
PAGE 124
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.
PAGE 125
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. 206). 3. Loosely secure the brake plate, complete with brake pad, to the brake lever and brake hub as shown in Figure 207. 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.
PAGE 126
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. 208). A 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 210. Secure with the crankshaft nut. B Fig 208 A. Bumps 7. Press the bearings into the bearing block, using an arbor press.
PAGE 127
BBC / BOS / BCS 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 211. 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.
PAGE 128
BBC / BOS / BCS BBC Cable Installation (Toro Vacu Power/ Lawn-Boy Medallion) 3. Install the three flanged head screws securing the control box halves. 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. 213). 4. Bend the throttle control locking tab forward so that it will provide positive engagement with the throttle control. Install the throttle control. 5.
PAGE 129
BBC / BOS / BCS ENGINE AND BLADE ASSEMBLY (Toro Recycler / Rear Bagger) Fig 215 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 WPM Drive Systems Manual 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 Ref.
PAGE 130
BBC / BOS / BCS TORO RECYCLER/REAR BAGGER BBC Fig 216 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. 217). 1350-001 a Idler Arm System Disassembly (Recycler/ Rear Bagger) 1. Drain the fuel and oil. Remove the spark plug wire.
PAGE 131
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. 219). With the pulley removed, the idler arm can pivot away from the brake drum and the belt can be removed.
PAGE 132
BBC / BOS / BCS 6. Now, disassemble the components on the crank shaft. 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. 223). This will hold the crankshaft so the nut can be removed. Fig 223 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.
PAGE 133
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. 226). 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. 227). 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 226 A.
PAGE 134
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. 229). Make sure the bolts are fully seated. Install the brake drum. Fig 229 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.
PAGE 135
BBC / BOS / BCS 8. Slip the spring over the shaft. One tang of the spring must engage the tab as shown (Fig. 231). 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. 233). 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 231 C 3428-0190 A. Idler/brake arm A 9.
PAGE 136
BBC / BOS / BCS BBC Cable Removal (Recycler/Rear Bagger) 1. Loosen the cable clamp and pull cable out from under the screw (Fig. 234). 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. This will prevent control box components from falling out of the handle during disassembly. 4.
PAGE 137
BBC / BOS / BCS BBC Cable Installation (Recycler/Rear Bagger) BLADE OVERRIDE SYSTEM (BOS) BLADE CLUTCH SYSTEM (BCS) 1. Slide a new BBC cable into the BBC cable lever. Install the end of the cable sheath in recess provided in the left control housing half. Both Toro and Lawn-Boy use the same blade clutching system on some models. On Toro it is named the Blade Override System. On Lawn-Boy it is named the Blade Clutch System. 2.
PAGE 138
BBC / BOS / BCS 3. Remove the blade and blade stiffener (Fig. 239). Fig 239 5. Remove the 3 capscrews and lift off the belt cover (Fig. 241). MVC-197X Fig 241 4. Remove the blade support and disc (Fig. 240). Fig 240 6. Remove the brake pivot bolt. You will need a second wrench to hold the bolt head (Fig. 242).
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BBC / BOS / BCS 7. Unhook both springs from the slot in the brake arm (Fig. 243). Fig 243 9. To replace the blade drive belt, remove the idler pulley bolt (Fig. 245). MVC-203X 8. Lift the brake assembly and blade drive belt from the mower (Fig. 244). Fig 245 10. The components of the idler assembly are shown here (Fig. 246). B A E Fig 244 MVC-205X C F G Fig 246 A. B. C. D. WPM Drive Systems Manual MVC-207Xa Belt Nut Brake arm Belt guard E. F. G. H.
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BBC / BOS / BCS 11. Continuing with the disassembly, remove the bolt securing the pulley to the crankshaft. Note: Use a large screwdriver or pry bar to keep the pulley from turning while you unscrew the bolt (Fig. 247). 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. 249). Fig 249 Fig 247 12.
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BBC / BOS / BCS 15. The anchor plate contains a pivot screw with a bushing. Remove the locknut (Fig. 251). Brake Arm Assembly 1. Place the spacer with the large diameter down on the brake arm (Fig. 253). Fig 251 MVC-224Xa Fig 253 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. 252). A MVC-211Xa 2. Place the bearing with the flange side down on the spacer and place the washer on top of the bearing (Fig. 254).
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BBC / BOS / BCS 3. Install the belt, belt guide, and carriage bolt on the brake arm and secure with the carriage bolt (Fig. 255). 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 & CONTROL CABLES Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
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HANDLES & 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 & 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. 259). 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 & CONTROL CABLES 3. Remove 6 screws from the traction rod retainer (Fig. 261). Fig 261 DSC-4810a 4. Remove the traction rod retainer. Note the location of the traction control rod (Fig. 262). Fig 262 9-4 DSC-4811a 5. Disconnect the cable from the traction lever (Fig. 263). Fig 263 DSC-4815a 6. Unhook the springs from each side of the handle (Fig. 264).
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HANDLES & CONTROL CABLES Reassembly 7. Slide the handle up and off (Fig. 265). 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. 267). Fig 265 DSC-4819a 8.
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HANDLES & 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. 269). 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 & 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. 272). 4. Continue pushing the handle down until it slides off the end of the upper handle (Fig. 274). Fig 274 Fig 272 MVC-709Xa MVC-005Xa 3. As the handle begins to slide downward, pull the traction control bar farther out of the handle (Fig. 273). 5.
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HANDLES & 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. 276). Lawn-Boy 2 Bail Handle The 2 bail style is shown here (Fig. 277). 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 & CONTROL CABLES Lawn-Boy Sens-a-Speed 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. A Handle Disassembly, Zone Start Models 1. Loosen the cable clamp and disconnect the Sens-aSpeed cable (Fig. 279). Fig 278 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 & CONTROL CABLES 3. Remove the shoulder bolt and the traction lever (Fig. 281). Assembly If the handle has been binding, clean the top slides and the sleeves before assembling. Dirt and grit in the sliding part of the handle can cause a bind. Assemble in reverse order. When you install the upper handle, line up the holes and install the pivot pins (Fig. 282). Fig 281 DSC-4880a 4. Slide the pin out of the left hand handle and pull the upper handle up and out. 5.
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HANDLES & 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. 283) then push the cable jacket up 1/8” (3.17cm) (Fig. 284) and secure with the cable clamp. Handle Disassembly, Lawn-Boy Blade Clutch System (BCS) Models 1. Remove the upper wire bail. On the right hand side it slides over a pin.
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HANDLES & CONTROL CABLES 3. Slide the pivot assembly, bail and the brake cable to the right until the bail slides off the pin (Fig. 287). B A 7. Slide the upper handle out of the top slide. Reverse the process to assemble. Note how the switch assembly, bail and control cable are assembled before they are installed on the pin (Fig. 289). C Fig 287 A. Traction lever B. Pivot assembly DSC-4899a C. Top slide 4. Continue sliding the pivot assembly and brake cable off the pin. Fig 289 DSC-4908a 5.
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HANDLES & CONTROL CABLES 3 Speed Transmission Models The adjustment point for this cable is a knob, jam nuts, or a clamp to the handle (Fig. 292 and Fig. 293). Handles on 3 speed models are basic and easily disassembled. 3 Speed Control Cables 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. 290). A Fig 292 3428-0043-2 Fig 293 fig 69 A.
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HANDLES & CONTROL CABLES 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. 294). 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. 295).
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HANDLES & CONTROL CABLES 2. With the engine off and the spark plug wire discon nected, 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. 296). When adjusted properly, it should measure 1” (25mm). If it does, skip ahead to step 5. Otherwise proceed with adjustment in the following step. 5. Install the screen panel with the two flanged head self-tapping screws.
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HANDLES & CONTROL CABLES Toro BBC Cable Adjustment (Recycler/Rear Bagger) The cable adjustment is the clamp on top of the housing on the left side of the mower. Loosen the screw holding the cable clamp. Pull the cable to the rear just enough to remove the slack (Fig. 298). Hold and tighten the clamp. The spring on the forward end of the cable should be suspended just off the housing. Note: An overly tight cable will cause the BBC to disengage before the bail can be raised to the normal operating position.
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HANDLES & CONTROL CABLES Toro BOS Control Toro BOS Control Cable Adjustment The BOS control is the upper bail on the handle. For the required 2 step engagement, there is a pivoting stop on the right hand handle. Rotate it out of the way and then pull the bail down for blade engagement (Fig. 300). 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.
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HANDLES & CONTROL CABLES Lawn-Boy BCS Control Lawn-Boy BCS Control Cable Adjustment To engage the blade clutch, press the control button. Then pull the control bar to the handle. To disengage the blade, release the control bar. (Fig. 302). Lawn-Boy Insight and Insight Gold: Fig 302 lwpm_10797a 1. Remove the grass bag and tunnel (Fig. 303). Fig 303 DSC-5360a 2. Loosen cable clamp. Draw cable to rear to remove slack. Now push outer jacket of cable forward 5/8” (1.5cm) and secure.
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HANDLES & 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. 305). Fig 305 4. DSC-5352a Install the BCS cover, belt cover and tunnel.
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HANDLES & CONTROL CABLES THIS PAGE INTENTIONALLY LEFT BLANK.
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SELF-PROPEL BELT REPLACEMENT Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . 02 Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . . 03 Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . . 04 Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
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SELF-PROPEL BELT REPLACEMENT There are several different procedures for replacing the self-propel belt. Mowers with a blade brake clutch (BBC) mechanism are the most complex as parts of that will need to be removed to access the self-propel belt. and may not disengage properly. It may be necessary to remove the blade to replace the belt. Do not force the new belt between the blade and mower housing. A nick or cut in the new belt can cause premature failure.
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SELF-PROPEL BELT REPLACEMENT 21” Cast Deck Mowers – 3 Speed Transmission Toro and Lawn-Boy models If necessary, drain the fuel and oil to prevent spillage. Tip the mower on its side, air filter side up. Remove the belt cover, just behind the engine on top of the mower, to access the transmission. DO NOT bend the belt guides or force the belt between the pulley and belt guide. Loosen or remove the mounting screws to pivot the belt guides out of the way.
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SELF-PROPEL BELT REPLACEMENT THIS PAGE INTENTIONALLY LEFT BLANK.
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Walk Power Mower Drive Systems Service Manual Form No.