Service Manual

ManualsBrandsToro ManualsLawn MowersToro 30096

LCE Products

Floating Deck

Mid-Size

Service Manual

Summary of content (466 pages)

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LCE Products Floating Deck Mid-Size Service Manual
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ABOUT THIS MANUAL This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct. For service information specific to the engines used on these products, refer to the appropriate engine manufacturer’s service and repair instructions.
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TABLE OF CONTENTS SAFETY INFORMATION General Information ......................................................................................................................1-1 Think Safety First..........................................................................................................................1-1 SPECIFICATIONS Torque Specifications ...................................................................................................................
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TABLE OF CONTENTS CHASSIS cont. Castor Wheel Fork Bushing Replacement .................................................................................3-60 Castor Wheel Fork Bushing Removal ..................................................................................3-60 Castor Wheel Fork Bushing Installation ...............................................................................3-61 Fuel Tank Replacement ..........................................................................................
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TABLE OF CONTENTS LINKAGE cont. Neutral Stud Adjustment (Pistol Grip) .......................................................................................4-126 Adjusting the Control Rod (Pistol Grip).....................................................................................4-128 Checking the Control Rod ..................................................................................................4-128 Adjusting the Control Rod ................................................................
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TABLE OF CONTENTS MOWER DECKS Mower Spindle Drive Belt Replacement .......................................................................................8-1 Mower Spindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) ............................8-1 Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) .........................8-2 Mower Spindle Drive Belt Removal (36” Mower Deck) ..........................................................
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TABLE OF CONTENTS MOWER DECKS cont. Quick Latch Replacement ..........................................................................................................8-59 Quick Latch Removal ...........................................................................................................8-59 Quick Latch Installation ........................................................................................................8-60 Mower Deck Removal ........................................................
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TABLE OF CONTENTS ELECTRICAL cont. Parking Brake Switch Replacment (Pistol Grip & T-2)................................................................9-26 Parking Brake Switch Removal (P.G. & T-2) ........................................................................9-26 Parking Brake Switch Installation (P.G. & T-2) .....................................................................9-27 Neutral Switch Replacement (Pistol Grip) ............................................................................
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SAFETY General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the MidSize Walk Behind mower.
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SAFETY 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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SPECIFICATIONS Torque cations TorqueSpecifi Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
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SPECIFICATIONS Standard StandardTorque Torquefor forDry, Dry,Zinc ZincPlated Plated,and andSteel SteelFasteners Fasteners(Inch (InchSeries) Series) Thread Size 2 Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-l
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SPECIFICATIONS Standard StandardTorque Torquefor forDry, Dry,Zinc Zinc,and andSteel SteelFasteners Fasteners(Metric (MetricFasteners) Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
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SPECIFICATIONS Other cations OtherTorque TorqueSpecifi Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Recommended Torque** Thread Size 2 Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
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SPECIFICATIONS Equivalents Equivalentsand andConversions Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.
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SPECIFICATIONS U.S. to Metric ConversionsU.S. to Metric Conversions 2 To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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SPECIFICATIONS Hydro with Pistol Grip Controls Models: Model Engine Deck 30284 17 hp Kawasaki 36” 30286 17 hp Kawasaki 40” 30288 19 hp Kawasaki 48” 30289 19 hp Kawasaki 52” 30280 23 hp Kawasaki 60” 2 Engines: Output (Max. @ 3600 RPM) 17 hp (12.7 kW) 19 hp (14.2 kW) 23 hp (17.2 kW) Make Kawasaki Kawasaki Kawasaki Model FH541V FH580V FH680V Hi-Idle 3600 rpm 3600 rpm 3600 rpm Starter Electric Electric Electric Oil Capacity 3.8 pint (1.8L) 3.8 pint (1.8L) 4.0 pint (1.
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SPECIFICATIONS Hydro with Pistol Grip Controls cont. Wheels and Tires: 2 Front Castor Tires: 9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fittings / Model 30280: 11x4.0-5 smooth tread, semi-pneumatic with tapered roller bearings Front Castor Fork: Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs have grease fitting for lubrication. Model 30280: 1” (2.5cm) diameter pivot shaft.
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SPECIFICATIONS Hydro with Pistol Grip Controls cont. Unit Dimensions: Model No. Height* Width Deflector Down Width Deflector Raised Length* Weight** 30284 41.5” (105cm) 51.1” (130cm) 37.2” (94cm) 84.5” (214cm) 677 lbs. (302kg) 30286 41.5” (105cm) 55.5” (141cm) 41.6” (105cm) 81.3” (206cm) 677 lbs. (302kg) 30288 41.5” (105cm) 63.5” (161cm) 49.6” (126cm) 83.8” (213cm) 692 lbs. (314kg) 30289 41.5” (105cm) 67.6” (171cm) 53.7” (136cm) 83.8” (213cm) 731 lbs. (331kg) 30280 41.
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SPECIFICATIONS Hydro with T-2 Controls Models: 2 Model Engine Deck 30494 17 HP Kawasaki 36” 30496 17 HP Kawasaki 40” 30498 19 HP Kawasaki 48” 30499 19 HP Kawasaki 52” Engines: Output (Max. @ 3600 RPM) 17 HP (12.7 kW) 19 HP (14.2 kW) Make Kawasaki Kawasaki Model FH541V FH580V Hi-Idle 3600 rpm 3600 rpm Starter Electric Electric Oil Capacity 3.8 pint (1.8L) 3.8 pint (1.8L) Fuel System: 4.
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SPECIFICATIONS Hydro with T-2 Controls cont. Mower Drive: Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.
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SPECIFICATIONS Gear with T-Bar Controls Models: 2 Model Engine Deck 30092 15 hp Kawasaki 32” 30094 15 hp Kawasaki 36” 30096 15 hp Kawasaki 40” 30098 17 hp Kawasaki 48” 30099 17 hp Kawasaki 52” Engines: Output (Max. @ 3600 RPM) 15 HP (11.2 kW) 17 HP (12.7 kW) Make Kawasaki Kawasaki Model FH430V FH541V Hi-Idle 3600 rpm 3200 rpm (30092) 3600 rpm Starter Recoil Recoil Oil Capacity 3.8 pint (1.8L) 3.8 pint (1.8L) Fuel System: 4.
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SPECIFICATIONS Gear with T-Bar Controls cont. Wheels and Tires: Front Castor Tires: 9x3.5-4, 4 ply smooth tread, semi-pneumatic with needle bearings and grease fittings Front Castor Fork: Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs have grease fitting for lubrication. Rear Traction Tires: 15 hp - 16x6.50-8, 4 ply with turf traction tread 17 hp - 16x6.
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SPECIFICATIONS Gear with T-Bar Controls cont. Unit Dimensions: 2 Model No. Height* Width Deflector Down Width Deflector Raised Length* Weight** 30092 43.5” (110cm) 42” (107cm) 32” (81cm) 73” (185cm) 388 lbs. (176kg) 30094 41.2” (105cm) 51.1” (130cm) 37.2” (94cm) 82.7” (210cm) 588 lbs. (267kg) 30096 41.2” (105cm) 55.5” (141cm) 41.6” (106cm) 79.5” (202cm) 596 lbs. (270kg) 30098 41.2” (105cm) 63.5” (161cm) 49.6” (126cm) 82” (208cm) 649 lbs. (294kg) 30099 41.2” (105cm) 67.
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SPECIFICATIONS International Hydro with T-Bar (T2) Controls Models: Model Engine Deck 30032 (CE) 15 hp Kawasaki 91cm 2 Engine: Output (Max. @ 3600 rpm) 15 HP (11.2 kW) Make Kawasaki Model FH430Y Hi-Idle 2900 RPM Starter Recoil Oil Capacity 3.8 Pint (1.8L) Fuel System: 4.
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SPECIFICATIONS International Hydro with T-Bar (T2) Controls cont. Mower Drive: 2 Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm) PTO Drive Belt: HB section with Aramid (Kevlar) cords and dry clutching envelope PTO Idler: Spring loaded pivot hub with grease fitting for lubrication / 91cm (36”) deck includes additional fixed idler.
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SPECIFICATIONS International Gear with T-Bar Controls Models: Model Engine Deck 30031 (CE) 15 hp Kawasaki 91cm 2 Engines: Output (Max. @ 2900 RPM) 15 HP (11.2 kW) Make Kawasaki Model FV430V Hi-Idle 2900 RPM Starter Recoil Oil Capacity 3.8 pints (1.8L) Fuel System: 4.
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SPECIFICATIONS International Gear with T-Bar Controls cont. Mower Drive: 2 Mower Engagement: Engine mounted electric clutch Clutch Adjustment: Periodic air gap adjustment required - .018” + .003” (0.45 + 0.
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CHASSIS 5. Unplug the clutch lead from the harness connector (Fig. 0002). Electric Clutch Replacment Electric Clutch Removal 1. Park the machine on a level surface. 2. Turn the engine off and remove the key. 3. Set the parking brake. 4. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery (Fig. 0001). 3 Fig 0002 PICT-0548a 6. Push the grommet and clutch plug through the frame to the underside of the machine (Fig. 0003).
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CHASSIS 7. Remove the carrier frame cover (Fig. 0004). 9. Raise the machine so that the underside of the chassis can be accessed. 10. Remove the trailing shield from the chassis by first removing the left end of the shield rod (bent at a 45 degree angle) from the hole in the frame and then remove the right side of the shield rod (bent at 90 degree angle) from the right side of the frame (Fig. 0006). 3 Fig 0004 PICT-0546 8. Roll the PTO drive belt off the center pulley on the mower deck (Fig. 0005).
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CHASSIS 12. Remove the belt from the clutch (Fig. 0008). 14. Loosen the clutch bolt (Fig. 0010). 3 Fig 0008 PICT-0294 13. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0009). Fig 0009 Floating Deck Mid-Size Service Manual PICT-0295 Fig 0010 PICT-0297a 15. Remove the bolt, 2 spring washers and flat washer securing the clutch to the drive shaft. Lower the clutch off the drive shaft (Fig. 0011).
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CHASSIS 16. Remove the rubber grommet from the clutch wire (Fig. 0012). Clutch Burnishing Procedure Note: This procedure needs to be done only when installing a new clutch. The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed. Burnishing polishes the clutch plate, allowing for smooth clutch engagement. With deck drive belt installed, run the engine at half throttle. Engage and disengage the mower 5 times (10 seconds on/10 seconds off).
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CHASSIS 2. Assemble the bolt, washers, nut and strap into the slotted opening on the clutch as shown. Before tightening, move the strap fastener assembly to the outer-most end of the slot and tighten (Fig. 0015). 4. Apply thread locking compound to the clutch bolt (Fig. 0017). 3 Fig 0017 Fig 0015 PICT-0557 3. Install the 2 cupped washers (crown side facing the bolt head) and 1 flat washer onto the clutch bolt (Fig. 0016). 5. Apply anti-sieze compound to the engine crankshaft.
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CHASSIS 6. Install the clutch bolt assembly (Fig. 0019). 8. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0021). 3 Fig 0019 PICT-0355a Fig 0021 PICT-0361 7. Torque the clutch bolt to 55 + 5 ft-lbs. (75 + 7 Nm) (Fig. 0020). 9. Feed the cutch harness plug up through the frame (Fig. 0022).
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CHASSIS 10. Install the rubber grommet into the frame opening (Fig. 0023). Note: Ensure the PTO drive belt is routed properly around the mower deck pulley(s). Refer to belt routing decal (Fig. 0025 and Fig. 0026). 36” mower deck belt routing: 3 Fig 0023 PICT-0363 Fig 0025 fig. 104-8185 11. Route the PTO drive belt around the clutch. (Fig. 0024). 40”, 48” and 52” mower deck belt routing: Note: On 48” decks leave the belt off of the center mower deck pulley.
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CHASSIS 12. Install the PTO idler arm spring to the spring post (Fig. 0027). 14. Lower the machine. 15. Roll the PTO drive belt onto the center mower deck pulley (Fig. 0029). 3 Fig 0027 PICT-0367 Fig 0029 13.
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CHASSIS 17. Plug the clutch connector into the harness connector (Fig. 0031). PTO Idler Replacement PTO Idler Removal 1. Turn the engine off and remove the key from the ignition. 2. Remove the carrier frame cover (Fig. 0033). 3 Fig 0031 PICT-0548a 18. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot (Fig. 0032). Fig 0033 PICT-0280 3. Roll the PTO drive belt off the center mower deck pulley (Fig. 0034).
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CHASSIS 4. Raise the machine so that the underside of the chassis can be accessed. 7. Remove the PTO idler arm assembly from the frame (Fig. 0037). 5. Remove the PTO idler arm spring from the spring post and the idler arm (Fig. 0035). 3 Fig 0037 Fig 0035 PICT-0604a PICT-0291a 8. Press out the bearing sleeves from the idler arm (Fig. 0038). 6. Remove the bolt, nut, washers and idler tube securing the PTO idler arm assembly to the frame (Fig. 0036).
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CHASSIS 9. Remove the bolt, washer and Bellville washer securing the pulley to the idler arm (Fig. 0039). 11. Remove the grease fitting from the idler arm (Fig. 0041). 3 Fig 0039 Fig 0041 PICT-0609 10. Remove the pulley from the idler arm (Fig. 0040). PTO Idler Assembly (Fig. 0042). HI J C B A Fig 0040 DG E A PICT-0610 Fig 0042 A. B. C. D. E. Floating Deck Mid-Size Service Manual PICT-0613 Washer (2) Grease Fitting Idler Arm Bearing Sleeve (2) Idler Tube F. G. H. I. J.
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CHASSIS 3. Position the pulley onto the idler arm (Fig. 0045). PTO Idler Installation 1. Install the grease fitting into the idler arm (Fig. 0043). 3 Fig 0045 Fig 0043 PICT-0613 2. Press the bearing sleeves into the idler arm pivot (Fig. 0044). Fig 0044 3-12 PICT-0610 PICT-0619 4. Slide the Belleville washer (crown toward the bolt head) and flat washer onto the bolt. Install the bolt and washers through the pulley and into the idler arm (Fig. 0046).
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CHASSIS 5. Slide a washer and idler tube onto the idler pivot bolt. Slide the bolt assembly into the idler arm. Install a washer onto the bolt (Fig. 0047). 7. Install a washer and nut securing the PTO idler arm assembly to the frame (Fig. 0049). 3 Fig 0049 Fig 0047 6. Position the PTO idler arm assembly up to the frame (Fig. 0048). 8. Hook the PTO idler arm spring onto the idler arm and onto the spring post (Fig. 0050).
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CHASSIS 9. Lower the machine. Parking Brake Service - Hydro 10. Roll the PTO drive belt onto the center mower deck pulley (Fig. 0051). Checking the Parking Brake 1. Move the machine to a level surface. 2. Turn the ignition off and remove the key. 3. Check and adjust the tire pressure as follows: a. Rear tires: 12-14psi (83-97kPa) b. Castor tires: Semi-pneumatic 3 4. Set the parking brake (Fig. 0053). Note: Setting the parking brake should take a reasonable amount of force.
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CHASSIS Adjusting the Parking Brake 1. Check the parking brake before you adjust it. Refer to “Checking the Parking Brake”, preceding. 5. Turn the upper brake adjustment yoke to adjust the parking brake as follows (Fig. 0056): a. Clockwise to decrease engagement force b. Counterclockwise to increase engagement force 2. Release the parking brake. 3. Remove the cotter pin from the clevis at the top end of the parking brake adjusting rod (Fig. 0054). 3 Fig 0056 Fig 0054 PICT-0470 PICT-0473 6.
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CHASSIS 7. Install a cotter pin into the clevis pin (Fig. 0058). 3. Remove the clevis pin securing the top end of the parking brake adjusting rod to the parking brake handle (Fig. 0060). 3 Fig 0058 PICT-0470 Fig 0060 PICT-0471 8. Check the brake operation again. Refer to “Checking the Parking Brake” on page 3-14. 4. Remove the cotter pin from the clevis pin securing the lower yoke of the brake adjusting rod to the parking brake assembly (Fig. 0061). Parking Brake Removal 1. Release the parking brake.
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CHASSIS 5. Remove the clevis pin that secures the lower end of the brake adjusting rod to the parking brake assembly and remove the brake rod assembly (Fig. 0062). 7. Remove the bolt, thrust bearing and parking brake handle from the handle support (Fig. 0064). 3 Fig 0064 Fig 0062 PICT-0483 PICT-0478 8. Unplug the parking brake switch from the harness (Fig. 0065). 6. Remove the nut and conical washer from the bolt securing the parking brake handle to the handle support (Fig. 0063).
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CHASSIS 9. Remove the 2 screws and nuts securing the parking brake switch to the handle support (Fig. 0066). 11. Remove the 2 nuts from the bolts securing the handle support to the frame (Fig. 0068). 3 Fig 0066 PICT-0486 10. Remove the parking brake switch and switch plate from the handle support (Fig. 0067). Fig 0067 3-18 PICT-0487 Fig 0068 PICT-0489 12. Remove the bolts and handle support from the frame (Fig. 0069).
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CHASSIS 13. Remove the whizlock nut and bolt securing the top end of the parking brake spring to the frame (Fig. 0070). 15. Remove the parking brake assembly from the frame (Fig. 0072). Note: Unit raised for photo clarity. 3 Fig 0070 PICT-0491 Fig 0072 14. Remove the 3 bolts and nuts securing the parking brake assembly to the frame (Fig. 0071). Fig 0071 16. Remove the bolt, nut and spring from the parking brake assembly (Fig. 0073).
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CHASSIS 3. Loosely install the 3 bolts and nuts securing the parking brake assembly to the frame (Fig. 0076). Parking Brake Installation 1. Install the bolt, nut and spring onto the parking brake assembly (Fig. 0074). 3 Fig 0076 Fig 0074 PICT-0494 PICT-0500a 4. Insert the bolt through the top end of the parking brake spring and into the frame (Fig. 0077). 2. Position the parking brake assembly into the frame (Fig. 0075). Note: Unit raised for photo clarity.
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CHASSIS 5. Loosely install the whizlock nut on the bolt that secures the top end of the brake spring to the frame (Fig. 0078). 8. Install the nuts securing the parking brake handle support to the frame (Fig. 0080). 3 Fig 0080 Fig 0078 PICT-0489 PICT-0503a 6. Tighten all 4 nuts and bolts securing the parking brake assembly to the frame. 9. Position the parking brake switch and switch plate onto the handle support (Fig. 0081). 7. Insert the bolts through the frame and parking brake handle support (Fig.
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CHASSIS 10. Install 2 screws and nuts securing the parking brake switch and switch plate to the handle support (Fig. 0082). 12. Insert a bolt through the parking brake handle. Install a thrust bearing onto the bolt and then insert the bolt/handle/bearing assembly through the handle support (Fig. 0084). 3 Fig 0082 PICT-0486 Fig 0084 11. Plug parking brake switch into the harness connector (Fig. 0083). Fig 0083 13. Install a conical washer onto the bolt (crown facing the threaded end of the bolt (Fig.
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CHASSIS 14. Install a nut onto the bolt securing the parking brake handle to the handle support (Fig. 0086). 16. Install a cotter pin into the clevis pin (Fig. 0088). Note: Do not over-tighten the nut. 3 Fig 0088 Fig 0086 PICT-0477 PICT-0481 17. Insert a clevis pin through the upper adjusting yoke securing it to the parking brake handle (Fig. 0089). 15. Position the brake linkage rod assembly with the adjusting yoke positioned up to the parking brake handle.
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CHASSIS 18. Install a cotter pin into the clevis pin (Fig. 0090). Wheel Drive Belt and Wheel Hub Replacement - Gear Drive The following inspections should be made when disassembling the drive system, particularly if the reason for service is the inability to adjust belt tension or “loss of drive”. Be sure to inspect all components; there may be more than one item needing replacement. 3 Fig 0090 PICT-0470 19. Check the parking brake. Refer to “Checking the Parking Brake” on page 3-14.
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CHASSIS Wheel Drive Belt & Wheel Hub Removal 5. Rotate the idler support bracket so that it is out of the way of the transmission pulley (Fig. 0093). 1. Turn the engine off and remove the key from the ignition. 2. Raise the machine so the rear tire is off the ground. 3. Remove the 3 lower idler support mounting bolts (Fig. 0091). 3 Fig 0093 PICT-1521 6. Remove the wheel drive belt from the transmission pulley and remove it from around the drive wheel (Fig. 0094). Fig 0091 PICT-1519 4.
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CHASSIS 7. Inspect the pulleys for wear and damage. Replace as necessary. If pulley replacement is required, continue on. For belt replacement only, go to “Wheel Drive Belt and Wheel Hub Installation” step 17, on page 3-34. 10. Remove the key from the drive pulley shaft keyway (Fig. 0097). 8. Loosen the set screw securing the drive pulley to the transmission (Fig. 0095). 3 Fig 0097 PICT-1583 11. Inspect the key and replace it if it is worn or damage. Fig 0095 PICT-1580 12.
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CHASSIS 13. Install the key into the transmission driveshaft keyway (Fig. 0099). 15. Apply thread locking compound to the drive pulley set screw (Fig. 0101). 3 Fig 0099 PICT-1583 14. Position the drive pulley onto the transmission drive shaft so that the pulley hub faces toward the machine. The transmission driveshaft should be flush with the outside flange of the pulley (Fig. 0100). Fig 0101 16. Install the set screw into the drive pulley (Fig. 0102).
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CHASSIS 17. Remove the 4 lug nuts retaining the wheel to the wheel hub assembly (Fig. 0103). 19. Remove the dust cover from the wheel hub assembly (Fig. 0105). 3 Fig 0103 PICT-1588a 18. Remove the wheel from the wheel hub assembly (Fig. 0104). Fig 0104 3-28 PICT-1589 Fig 0105 PICT-1590 20. Remove the cotter pin retaining the castle nut to the axle (Fig. 0106).
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CHASSIS 21. Remove the castle nut from the axle (Fig. 0107). 23. Remove the washer from the wheel hub (Fig. 0109). 3 Fig 0107 PICT-1593 22. Slide the wheel hub assembly off the axle (Fig. 0108). Fig 0108 Floating Deck Mid-Size Service Manual PICT-1594 Fig 0109 PICT-1622 24. Remove the outside tapered wheel bearing from the wheel hub (Fig. 0110).
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CHASSIS 25. Remove the inside grease seal from the wheel hub (Fig. 0111). 27. Remove the grease fitting from the wheel hub (Fig. 0113). 3 Fig 0111 PICT-1624 26. Remove the tapered bearing from the wheel hub (Fig. 0112). Fig 0113 PICT-1650 28. Thoroughly clean the wheel hub, tapered bearings and grease seal. Inspect and replace if worn or damaged. Wheel Drive Belt & Wheel Hub Installation 1. Install a grease fitting into the wheel hub (Fig. 0114).
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CHASSIS 2. Repack the tapered bearing with grease (Fig. 0115). 4. Insert the grease seal into the wheel hub bore (Fig. 0117). Note: When packing wheel bearings use #2 general purpose lithium base or molybdenum base grease. 3 Fig 0117 Fig 0115 PICT-1645 PICT-1643 5. Repack the second tapered bearing with grease (Fig. 0118). 3. Insert the tapered bearing into the wheel hub bore (Fig. 0116).
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CHASSIS 6. Insert the tapered bearing into the opposite side of the wheel hub bore (Fig. 0119). 8. Slide the wheel hub assembly onto the axle (Fig. 0121). 3 Fig 0119 PICT-1646 7. Position a washer onto the outside tapered bearing (Fig. 0120). Fig 0120 Fig 0121 9. Position the brake band around the wheel hub brake drum and continue sliding the wheel hub onto the axle (Fig. 0122).
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CHASSIS 10. Install the castle nut onto the axle (Fig. 0123). 12. Install a cotter pin securing the castle nut to the axle (Fig. 0125). 3 Fig 0123 PICT-1653 Fig 0125 11. Torque the castle nut to 6.5 ft-lbs. (8.8 Nm) while turning the hub to seat the bearings and to remove all endplay. Loosen the castle nut until it is away from the washer/bearing then tighten the castle nut until it contacts the washer/bearing. The wheel hub must be free to rotate and have no endplay (Fig. 0124). 13.
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CHASSIS 14. Using a rubber mallet, install the dust cap into to wheel hub assembly (Fig. 0127). 16. Install the lug nuts onto the wheel hub studs. Torque the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig. 0129). 3 Fig 0127 PICT-1657 Fig 0129 15. Slide the wheel onto the wheel hub assembly (Fig. 0128). Fig 0128 17. Route the wheel drive belt around the wheel drive pulley and the wheel hub pulley (Fig. 0130).
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CHASSIS 18. Rotate the idler support bracket into position so that the 3 mounting holes in the bracket line up with the 3 holes in the frame (Fig. 0131). 20. Tighten the idler support bracket pivot bolt (Fig. 0133). 3 Fig 0133 Fig 0131 19. Loosely install the 3 lower idler support mounting bolts (Fig. 0132). 21. Tighten the 3 lower idler support mounting bolts (Fig. 0134).
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CHASSIS 4. Loosen the idler support bracket pivot bolt (Fig. 0136). Brake Band Replacement The following procedures are the same for both the left and right brake band replacement. Brake Band Removal 1. Turn the engine off and remove the key from the ignition. 3 2. Raise the machine so the rear tire is off the ground. 3. Remove the 3 lower idler support mounting bolts (Fig. 0135). Fig 136 PICT-1520 5. Rotate the idler support bracket so that it is out of the way of the transmission pulley (Fig.
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CHASSIS 6. Remove the wheel drive belt from the transmission pulley and remove it from around the drive wheel (Fig. 0138). 8. Remove the wheel from the wheel hub assembly (Fig. 0140). 3 Fig 0140 Fig 0138 7. Remove the 4 lug nuts retaining the wheel to the wheel hub assembly (Fig. 0139). 9. Remove the dust cover from the wheel hub assembly (Fig. 0141).
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CHASSIS 10. Remove the cotter pin retaining the castle nut to the axle (Fig. 0142). 12. Slide the wheel hub assembly off the axle (Fig. 0144). 3 Fig 0142 PICT-1592 11. Remove the castle nut from the axle (Fig. 0143). Fig 0143 Fig 0144 13. Remove the hairpin cotter securing the brake rod to the brake arm. Remove the brake rod from the brake arm (Fig. 0145).
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CHASSIS 14. Remove the retaining ring from the brake arm pivot (Fig. 0146). 16. Remove the 3 brake link plate retaining rings (Fig. 0148). 3 Fig 0146 PICT-1602 15. Remove the brake arm assembly from the pivot (Fig. 0147). Fig 0147 Floating Deck Mid-Size Service Manual PICT-1603 Fig 0148 PICT-1607a 17. Remove the brake link plate from the brake assembly (Fig. 0149).
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CHASSIS 18. Remove the brake band from the brake link (Fig. 0150). 20. Inspect the brake band. Replace if damaged or worn (Fig. 0152). 3 Fig 0150 PICT-1611a 19. Remove the brake arm from the brake link (Fig. 0151). Fig 0152 PICT-1615a Brake Band Installation 1. Position the brake arm onto the brake link (Fig. 0153).
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CHASSIS 2. Place the brake band onto the brake link (Fig. 0154). 4. Install 3 new retaining rings as shown (Fig. 0156): B A A Fig 0154 PICT-1611a 3 Fig 0156 A. Small PICT-1607a B. Large 3. Install the brake link plate onto the brake assembly (Fig. 0155). 5. Apply anti-seize compound to the brake arm pivot. Slide the brake arm assembly onto the pivot (Fig. 0157).
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CHASSIS 6. Install a new retaining ring onto the brake arm pivot securing the brake arm to the frame (Fig. 0158). 8. Slide the wheel hub assembly onto the axle (Fig. 0160). 3 Fig 0158 PICT-1621 7. Position the lower end of the brake rod into the brake arm. Install a hairpin cotter securing the brake rod to the brake arm (Fig. 0159). Fig 0160 9. Install the castle nut onto the axle (Fig. 0161).
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CHASSIS 10. Torque the castle nut to 6.5 ft-lbs. (8.8 Nm) while turning the hub to seat the bearings and to remove all endplay. Loosen the castle nut until it is away from the washer/bearing. Tighten nut until it contacts washer/bearing. Hub must be free to rotate and have no endplay (Fig. 0162). 12. Fill the wheel hub cavity with grease (Fig. 0164). 3 Fig 0164 Fig 0162 PICT-1654 PICT-1656 13. Using a rubber mallet, install the dust cap into to wheel hub assembly (Fig. 0165). 11.
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CHASSIS 14. Route the wheel drive belt around the wheel drive pulley and the wheel hub (Fig. 0166). 16. Install the lug nuts onto the wheel hub studs. Torque the lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig. 0168). 3 Fig 0166 PICT-1660 Fig 0168 15. Slide the wheel onto the wheel hub assembly (Fig. 0167). Fig 0167 17. Rotate the idler support bracket into position so that the 3 mounting holes in the bracket line up with the 3 holes in the frame (Fig. 0169).
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CHASSIS 18. Loosely install the 3 lower idler support mounting bolts (Fig. 0170). 20. Tighten the 3 lower idler support mounting bolts (Fig. 0172). 3 Fig 0170 PICT-1519 19. Tighten the idler support bracket pivot bolt (Fig. 0171). Fig 0172 PICT-1519 Carrier Frame Replacement Carrier Frame Removal 1. Remove the Mower Deck. Refer to “Mower Deck Removal” on page 8-61. 2. 40”, 48”, 52” and 60” mower decks only: Remove the battery and battery tray assembly. Refer to “Battery Tray Removal” on page 3-70. 3.
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CHASSIS 4. Remove the bolt and nut securing the right side of the carrier frame to the right side of the traction frame (Fig. 0173). 6. Slide the carrier frame away from the traction frame (Fig. 0175). 3 Fig 0175 Fig 0173 5. Remove the 3 bolts and nuts securing the left side of the carrier frame to the left side of the traction frame (Fig. 0174). 7. Remove the 2 bolts and washers securing the belt shield to the carrier frame (Fig. 0176).
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CHASSIS 8. Remove the belt shield from the carrier frame (Fig. 0177). 10. Remove the deck bushing from the carrier frame (Fig. 0179). 3 Fig 0177 PICT-1310 9. Remove the retaining ring from the deck bushing (Fig. 0178). Fig 0179 PICT-1313 11. Repeat steps 9 and 10 for the opposite side deck bushing. 12. Remove both castor wheel fork grease fittings (Fig. 0180).
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CHASSIS 13. Remove the castor wheel assemblies from the carrier frame. Refer to “Castor Wheel Removal” on page 3-53. 2. Install the castor wheel assemblies into the carrier frame. Refer to “Castor Wheel Installation” on page 3-59. 14. Remove the castor wheel flange bushings (2 left, 2 right) from the carrier frame (Fig. 0181). 3. Install 2 grease fittings (1 left, 1 right) into the castor fork arms of the carrier frame (Fig. 0183). 3 Fig 0181 PICT-1331a Fig 0183 PICT-1314a 4.
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CHASSIS 5. Install a deck bushing into the carrier frame (Fig. 0185). 7. Repeat steps 5 and 6 for the opposite side deck bushing. 8. Position the belt shield to the carrier frame (Fig. 0187). 3 Fig 0185 PICT-1313 Fig 0187 PICT-1310 6. Install a retaining ring onto the deck bushing (Fig. 0186). 9. Install 2 bolts and washers to secure the belt shield to the carrier frame (Fig. 0188).
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CHASSIS 10. Position the carrier frame assembly up to the traction frame (Fig. 0189). 13. Loosely install the 2 upper bolts and nuts securing the left side of the carrier frame to the left side of the traction frame (Fig. 0191). 3 Fig 0189 PICT-1305 Fig 0191 PICT-1303 11. Support the carrier frame with a jack stand. 12. Loosely install the lower front bolts on each side of the chassis securing the carrier frame to the traction frame (Fig. 0190). 14.
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CHASSIS 16. Check the alignment if the engine deck and carrier frame. Refer to “Checking the Carrier Frame and Engine Deck Alignment”, proceding. Carrier Frame & Mower Deck Adjustments 17. Check the engine deck height. Refer to “Checking the Engine Deck Height” on page 8-63. Checking the Carrier Frame & Engine Deck Alignment 18. Check the front-to-rear pitch of the carrier frame. Refer to “Checking the Carrier Frame Front-to-Rear Pitch” on page 8-64.
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CHASSIS 4. Place a 2”x2” by 8” (aprox.) long piece of tubing stock on the engine deck along the right side the engine (Fig. 0195). 6. The space between the front cross brace and the straight edge should be 11/16” + 1/4” (17.46mm + 6.35mm) (Fig. 0197). 3 Fig 0195 PICT-1339 5. Hold a ridid straight edge (36” minimum length) on top of the 2”x2” piece of tubing stock so it reaches out to the front cross brace of the carrier frame (Fig. 0196).
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CHASSIS 8. Align the carrier frame and engine deck to meet the 11/16” + 1/4” (17.46mm + 6.35mm) measurement at the front carrier frame cross brace (Fig. 0199). 10. Remove the straight edge and 2x2 piece of stock. 11. Install the carrier frame cover (Fig. 0201). 3 Fig 0199 PICT-1345 9. Tighten the carrier frame mounting bolts on both sides of the machine. Torque to 70 + 10 ft-lbs. (94.9 + 13.6 Nm) (Fig. 0200).
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CHASSIS 2. Remove the spacer(s) from the castor fork assembly. Note number and location for reassembly (Fig. 0203). Castor Wheel Service 1. Remove the 2 thrust washers from the castor fork (Fig. 0205). 3 Fig 0203 PICT-1318 Fig 0205 3. Raise the carrier frame assembly and slide the castor fork assembly out of the carrier frame (Fig. 0204). Fig 0204 3-54 PICT-1319 PICT-1321a 2. Remove the nut from the axle bolt securing the castor wheel to the fork (Fig. 0206).
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CHASSIS 3. Remove the axle bolt (Fig. 0207). 5. Remove one of the bushings from the wheel assembly (Fig. 0209). 3 Fig 0207 PICT-1323 Fig 0209 4. Remove the spacer from the wheel assembly (Fig. 0208). Fig 0208 6. Remove the needle bearing from the wheel assembly (Fig. 0210).
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CHASSIS 7. Remove the second bushing from the wheel assembly (Fig. 0211). 9. Thoroughly clean the wheel and tire assembly. Inspect the wheel and bearings for damage and replace as necessary. 10. Install a bushing into one side of the wheel (Fig. 0213). 3 Fig 0211 PICT-5519a 8. Remove the grease zerk from the wheel assembly (Fig. 0212). Fig 0213 PICT-5678 11. Apply grease to the needle bearing (Fig. 0214).
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CHASSIS 12. Install the greased needle bearing into the wheel (Fig. 0215). 14. Install the spacer into the wheel (Fig. 0217). 3 Fig 0217 Fig 0215 13. Install a second bushing into the other side of the wheel (Fig. 0216). 15. Install the grease zerk into the wheel assembly (Fig. 0218).
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CHASSIS 16. Fill the wheel assembly with grease until it begins to flow out of the bearings (Fig. 0219). 18. Install the wheel axle bolt (Fig. 0221). 3 Fig 0221 Fig 0219 17. Position the wheel and tire assembly in the fork (Fig. 0220). 19. Install and tighten the lock washer and nut to secure the wheel to the fork (Fig. 0222).
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CHASSIS 20. Slide 2 thrust washers onto the castor fork shaft (Fig. 0223). 2. Slide the spacer(s) onto the castor fork shaft (Fig. 0225). 3 Fig 0223 PICT-1321a Fig 0225 PICT-1318 3. Install the locking pin into the castor fork assembly (Fig. 0226). Castor Wheel Installation 1. Raise the carrier frame assembly and slide the castor assembly into the carrier frame (Fig. 0224).
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CHASSIS 4. Remove the spacer(s) from the top of the caster wheel fork (Fig. 0228). Castor Wheel Fork Bushing Replacement The following procedures are the same for replacing both the right hand and left hand castor wheel fork bushings. Castor Wheel Fork Bushing Removal 3 1. Turn the engine off and remove the key from the ignition. 2. Raise the carrier frame assembly so the caster wheels are off the floor and support the front of the mower with jack stands. 3.
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CHASSIS 6. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 0230). 2. Inspect the caster wheel fork for wear and replace if necessary. 3. Slide the caster wheel fork through the bushings in the mounting tube (Fig. 0232). Note: The inside diameter of the bushings may collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126” (29mm). 3 Fig 0230 PICT-1331a 7.
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CHASSIS 5. Secure the fork to the carrier frame with the locking pin (Fig. 0234). Fuel Tank Replacement DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
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CHASSIS 4. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery (Fig. 0236). 6. Slide the hose clamp off the fuel line at the fuel pump (Fig. 0238). 3 Fig 0238 Fig 0236 5. Turn the fuel valve to the “Off” position (Fig. 0237). Fig 0237 7. Remove the fuel line from the fuel pump. Place the end of the fuel line in a suitable container (Fig. 0239).
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CHASSIS 8. Turn the fuel valve to the “On” position to allow the fuel to drain (Fig. 0240). 10. Remove the fuel line from the fuel tank bulkhead fitting, pulling it through the rubber grommet (Fig. 0242). 3 Fig 0240 PICT-0515 Fig 0242 PICT-0518 9. Slide the clamp securing the fuel line to the fuel tank bulkhead fitting up toward the fitting and off the hose (Fig. 0241). 11. Remove the clamp from the fuel tank bulkhead fitting (Fig. 0243).
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CHASSIS 12. Remove the 2 nuts, springs and washers from the threaded studs securing the left side of the fuel tank bottom (Fig. 0244). 14. Lift the fuel tank assembly up and out of the frame. Take care as the tank fitting comes out through the hole in the frame with the tank (Fig. 0246). 3 Fig 0244 PICT-0528a 13. Remove the 2 bolts, lock washers and washers securing the right side of the fuel tank bottom (Fig. 0245). Fig 245 Floating Deck Mid-Size Service Manual PICT-0531 Fig 0246 PICT-0533 15.
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CHASSIS 16. Remove the fuel cap assembly from the fuel tank (Fig. 0248). 18. Inspect the filter screen on the bulkhead fuel fitting. Clean or replace the filter screen if it is clogged or damaged (Fig. 0250). Note: If fuel is leaking from the bulkhead fuel fitting area of the tank, the seal on the fitting has been compromised and the whole fitting must be replaced. 3 Fig 0248 PICT-5355 17. Remove the bulkhead fuel fitting from the tank through the fuel cap opening (Fig. 0249).
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CHASSIS 3. Install the bulkhead fuel fitting into the tank through the fuel cap opening (Fig. 0254). Fuel Tank Installation This procedure was done on a hydro model. The same procedure can be followed for gear drive models. 1. Apply thread locking compound to the fuel tank mounting studs (Fig. 0252). Note: The fitting should be installed so that the barb of the fitting points toward the front of the fuel tank. Note: A flexible magnet tool used to aid installation. 3 Fig 0252 PICT-0538a Fig 0254 2.
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CHASSIS 5. Tighten the nut to secure the fitting to the fuel tank (Fig. 0256). 7. Apply anti-seize compound to both of the bolts used to secure the right side of the fuel tank to the frame (Fig. 0258). 3 Fig 0256 PICT-5353 Fig 0258 6. Position the fuel tank onto the frame taking care to feed the bulkhead fuel fitting through the hole in the frame (Fig. 0257). PICT-0534a 8. Secure the fuel tank to the frame by installing the bolts, washers, springs and nuts as shown.
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CHASSIS 9. Slide the hose clamp onto the bulkhead fitting barb (Fig. 0260). 11. Slide the clamp onto the fuel line securing the fuel line to the fuel tank bulkhead fitting (Fig. 0262). 3 Fig 0260 PICT-0520 10. Slide the fuel line through the rubber grommet and onto the fuel tank bulkhead fitting (Fig. 0261). Fig 0262 12. Slide the fuel line onto the fuel pump (Fig. 0263).
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CHASSIS 13. Slide the hose clamp up to secure the fuel line to the fuel pump (Fig. 0264). 15. Check for leaks. 16. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot (Fig. 0266). 3 Fig 0264 PICT-0513 Fig 0266 PICT-0509 14. Fill the fuel tank with fuel and ensure the fuel valve is open (On) (Fig. 0265). Battery Tray Replacement Battery Tray Removal 1. Turn the engine off and remove the key from the ignition. 2.
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CHASSIS 3. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery terminal (Fig. 0268). 5. Remove 1 of the 2 nuts retaining the battery hold down strap and battery hold downs to the battery tray (Fig. 0270). 3 Fig 0268 PICT-0250 4. Move the positive battery terminal boot and disconnect the positive (red) battery cable from the battery terminal (Fig. 0269). Fig 0270 6.
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CHASSIS 7. Remove the battery from the battery tray (Fig. 0272). 9. Remove the battery tray from the frame (Fig. 0274). 3 Fig 0272 PICT-0571 8. Remove the two bolts, and nuts securing the battery tray to the frame (Fig. 0273). Fig 0274 PICT-1298 Battery Tray Installation 1. Place the anti-skid pad onto the battery tray (Fig. 0275).
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CHASSIS 2. Align the battery tray mounting holes to the mounting holes in the frame (Fig. 0276). 4. Place the battery onto the battery tray (Fig. 0278). 3 Fig 0278 Fig 0276 PICT-1298 3. Install two bolts and nuts securing the battery tray to the frame (Fig. 0277). 5. Install the battery hold down plate and 2 battery hold downs to the battery tray (Fig. 0279).
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CHASSIS 6. Connect the positive (red) battery cable to the positive battery terminal and cover the connection with the boot (Fig. 0280). Mid-Size Weight Replacement Weights are installed on certain mowers to improve balance and improve performance. The weights can be moved or removed to create optimized performance under different mowing conditions and for operator preference (Fig. 0282 or Fig. 0283). 3 Fig 0280 A B CD PICT-0252 7.
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CHASSIS The following table indicates the position of the weight as installed at the factory. Checking the Brake (T-Bar) 1. Park the machine on a level surface. Mower Deck Size Number of weights install Position of the weight 36” 1 Front 40” 1 Front 48” none none 52” 1 Rear 2. Disengage the Power Take Off (PTO) (Fig. 0284). • Any rear weight must be removed when a Tru–Track® Sulky is installed. 3 • When a Tru–Track® Sulky is installed front weights are needed.
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CHASSIS 4. The rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels do not lock. Refer to “Adjusting the Brake”, following. 7. The wheels should rotate freely. 8. If the above conditions are met, no adjustment is required. If adjustments are required, see “Adjusting the Brake”, following. 5. Release the parking brake (Fig. 0286). Adjusting the Brake (T-Bar) 1. Check the brake before you adjust it. Refer to “Checking the Brake”, preceding. 3 2.
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CHASSIS 3. Rotate the wing nuts on the brake rods (Fig. 0289) as follows: • Clockwise to tighten the brake • Counterclockwise to loosen the brake Note: The right and left brake rods are adjusted independently of each other. Note: The control bar should be parallel with reference bar when properly adjusted. 3 Fig 0289 PICT-4853a 4. Check the brake operation again. Refer to “Checking the Brake” preceding.
PAGE 107
CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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LINKAGE Control Linkage Replacement (T-2) Fig 0290 3. Remove the control panel cover/manual tube assembly to the control panel (Fig. 0292). fig. 3 G006080 Fig 0292 PICT-1923 Control Linkage Removal 1. Turn the engine off and remove the key from the ignition. 4. Remove the hairpin cotter from the upper end of the control linkage rod (Fig. 0293). 2. Remove 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 0291).
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LINKAGE 5. Remove the washer from the upper end of the control linkage rod (Fig. 0294). 4 Fig 0294 PICT-1950 6. Remove the upper end of the control rod from the tab on the control handle (Fig. 0295). Fig 0295 4-2 PICT-1951 7. Remove the hairpin cotter from the lower end of the control linkage rod (Fig. 0296). Fig 0296 PICT-2009 8. Remove the washer from the lower end of the control linkage rod (Fig. 0297).
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LINKAGE 9. Remove the lower end of the control linkage rod from the pump adapter bracket. Remove the linkage rod from the machine (Fig. 0298). 11. Remove the upper control rod from the turnbuckle (Fig. 0300). Fig 0300 Fig 0298 10. Loosen the upper control rod wingnut (left hand threads) (Fig. 0299). 12. Remove the wingnut from the upper control rod (left hand threads) (Fig. 0301).
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LINKAGE 13. Loosen the lower control rod wingnut (Fig. 0302). Fig 0302 4 15. Remove the wingnut from the lower control rod (Fig. 0304). PICT-1966a Fig 0304 14. Remove the lower control rod from the turnbuckle (Fig. 0303). Fig 0303 16. Remove the 2 bolts and nuts securing the pump adapter bracket to the pump linkage (Fig. 0305).
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LINKAGE 17. Remove the pump adapter bracket (Fig. 0306). Control Linkage Installation 1. Thread the adjusting screw into the pump adapter bracket so the threads of the screws protrude 3/4” (19mm) past the bracket (Fig. 0308). Fig 0306 PICT-1989 18. Remove the nut and adjusting screw from the pump adapter bracket (Fig. 0307). 4 Fig 0308 PICT-1993a 2. Loosely install the jam nut onto the adjusting screw (Fig. 0309).
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LINKAGE 3. Position the pump adapter bracket to the pump linkage (Fig. 0310). The distance between the face of the neutral proximity switch and the end of the hex head screw should be .07” + .02” (1.8 + .5mm) (Fig. 0312). A 4 Fig 0310 PICT-1989 Fig 0312 PICT-1943 A. .07” ± .02” (1.8 + .5mm) 4. Install 2 bolts and nuts securing the pump adapter bracket to the pump linkage (Fig. 0311). 5.
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LINKAGE 6. Thread a wingnut onto the lower control rod and upper control rod so that there is approximately 1/2” (12.7mm) of thread on the wing side of the wingnut (Fig. 0314). 8. Loosely install the upper control rod into the turnbuckle (Fig. 0316). Fig 0316 Fig 0314 PICT-2000a 7. Loosely install the lower control rod into the turnbuckle (Fig. 0315). 9. Position the linkage rod inside the frame and insert the lower end of the control linkage rod into the pump adapter bracket (Fig. 0317).
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LINKAGE 10. Slide a washer onto the lower end of the control linkage rod (Fig. 0318). 4 Fig 0318 PICT-2007a 11. Install a hairpin cotter into the lower end of the control linkage rod securing it to the pump adapter bracket (Fig. 0319). 12. Install the upper end of the control rod into the tab on the control handle (Fig. 0320). Fig 0320 13. Slide a washer onto the upper end of the control linkage rod (Fig. 0321).
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LINKAGE 14. Install a hairpin cotter into the upper end of the control linkage rod securing it to the control handle (Fig. 0322). 16. Tighten the wingnuts to secure the control rod turnbuckle (Fig. 0324). Fig 0324 Fig 0322 15. Position the right control handle into the neutral lock position. If adjustment is needed, rotate the right control rod turnbuckle (Fig. 0323). 17. Position the control panel cover/manual tube assembly to the control panel (Fig. 0325).
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LINKAGE 18. Install 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 0326). Control Linkage & Thumb Latch Removal 1. Turn the engine off and remove the key from the ignition. 2. Remove the e-clip from the back side of the trunnion on the lower end of the control rod (Fig. 0328). 4 Fig 0326 PICT-1921 Control Linkage & Thumb Latch Replacement (Pistol Grip Hydro) The following procedures are the same for both the right side and left side handle bars.
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LINKAGE 4. Remove the hairpin cotter from the clevis pin retaining the upper end of the control linkage to the drive lever assembly (Fig. 0330). 6. Remove the nut from the bolt securing the thumb latch assembly to the handle bar (Fig. 0332). Fig 0332 Fig 0330 5. Remove the clevis pin and control linkage rod from the drive lever assembly (Fig. 0331). 7. Remove the bolt, spacer, washers and the thumb latch assembly from the handle bar (Fig. 0333).
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LINKAGE 8. Remove the bolt, and washer from the thumb latch (Fig. 0334): A B 10. Remove the bolt securing the drive lever assembly to the handle bar (Fig. 0336). BB D C 4 Fig 0334 A. Bolt B. Belleville washer (3) PICT-0697a Fig 0336 PICT-0700 C. Thumb latch D. Flat washer 11. Remove the drive lever bushing from the drive lever handle (Fig. 0337). 9. Remove the nut securing the drive lever assembly to the handle bar (Fig. 0335).
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LINKAGE 12. Remove the bushing sleeves from the drive lever handle (Fig. 0338). Fig 0338 PICT-0702a Control Linkage & Thumb Latch Installation 2. Install the drive lever bushing into the drive lever handle (Fig. 0340). Fig 0340 PICT-0701 3. Assemble the drive lever assembly to the handle bar with a bolt (Fig. 0341). 1. Install the bushing sleeves into the drive lever handle (Fig. 0339).
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LINKAGE 4. Secure the drive lever handle with a nut (Fig. 0342). Fig 0342 4 6. Slide the bolt of the thumb latch assembly into the hole on the handle bar (Fig. 0344). PICT-0699 Fig 0344 5. Assemble the thumb latch, bolt, and washers as shown. Note: The Belleville washers should be assembled onto the bolt in an alternating fashion (i.e. crown out, crown in, crown out) (Fig. 0343). A B PICT-0696 7. Install a nut onto the bolt securing the thumb latch assembly to the handle bar (Fig. 0345).
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LINKAGE 8. Slide the trunnion on the lower end of the control rod into the idler arm (Fig. 0346). 10. Adjust the control rod so that 2.125” (6.65cm) of thread extends past the trunnion (Fig. 0348). A Fig 0346 PICT-0690 Fig 0348 PICT-0704 A. 2.125” (6.65cm) 9. Install an e-clip onto the trunnion to secure the control rod to the idler arm (Fig. 0347). 11. Move the speed control lever to the fast position (Fig. 0349).
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LINKAGE 12. Assemble the upper end of the control rod to the drive lever assembly by inserting a clevis pin (Fig. 0350). 4 Fig 0350 PICT-0714 13. Adjust the control rod so there is a .19” to .25” (.48 to .64cm) space between the control rod clevis pin and the bottom of the thumb latch slot (Fig. 0351). Fig 0351 4-16 14. Install a hairpin cotter into the clevis pin to secure the control rod to the thumb latch assembly (Fig. 0352). Fig 0352 PICT-0691 15.
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LINKAGE Lower Control Replacement (T-Bar) 3. Remove the washer from the lower end of the control rod (Fig. 0355). The following procedures are the same for both the right hand and left hand lower control replacement. Fig 0355 Fig 0353 PICT-1752 fig. 7 G004812 4. Remove the trunnion/clevis from the idler arm (Fig. 0356). Lower Control Removal 1. Turn the engine off and remove the key from the ignition. 2. Remove the hairpin cotter from the lower end of the control rod (Fig. 0354).
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LINKAGE 5. Remove the hairpin cotter from the lower end of the brake rod (Fig. 0357). 7. Remove the nut from the idler pivot bolt (Fig. 0359). Fig 0359 4 Fig 0357 PICT-1758 PICT-1756 8. Remove the idler pivot bolt (Fig. 0360). 6. Remove the brake rod from the brake arm assembly (Fig. 0358).
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LINKAGE 9. Lift the idler/brake rod assembly out of the machine (Fig. 0361). Fig 0361 PICT-1763 10. Remove the spring from the idler arm (Fig. 0362). Fig 0362 11. Remove the 2 spacers from the idler arm pivot (Fig. 0363). Fig 0363 12. Remove the hairpin cotter from the brake rod trunnion (Fig. 0364).
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LINKAGE 13. Remove the washer from the brake rod trunnion (Fig. 0365). 4 Fig 0365 PICT-1769 14. Remove the brake rod assembly from the idler assembly (Fig. 0366). Fig 0366 4-20 PICT-1771 15. Remove the wing nut from the brake rod assembly (Fig. 0367). Fig 0367 PICT-1772a 16. Remove the washer from the brake rod assembly (Fig. 0368).
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LINKAGE 17. Remove the trunnion from the brake rod assembly (Fig. 0369). Fig 0369 PICT-1774a 18. Remove the bushing from the trunnion (Fig. 0370). Fig 0370 Floating Deck Mid-Size Service Manual PICT-1775 19. Remove the nut from the bolt securing the pulley to the idler arm (Fig. 0371). Fig 0371 PICT-1776a 20. Slide the pulley off the bolt (Fig. 0372).
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LINKAGE 21. Remove the pulley spacer from the bolt (Fig. 0373). Lower Control Installation 1. Insert the pulley bolt into the idler (Fig. 0375). Fig 0373 4 PICT-1780a Fig 0375 PICT-1781 22. Remove the bolt from the idler (Fig. 0374). 2. Slide the pulley spacer onto the pulley bolt (Fig. 0376).
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LINKAGE 3. Slide the pulley onto the pulley bolt and spacer (Fig. 0377). 5. Slide a bushing into the trunnion (Fig. 0379). Fig 0379 Fig 0377 4. Install a nut onto the pulley bolt securing the pulley to the idler arm (Fig. 0378). 6. Slide the trunnion onto the brake rod assembly (Fig. 0380).
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LINKAGE 7. Slide a washer onto the brake rod assembly (Fig. 0381). 4 Fig 0381 PICT-1773a 8. Install a wing nut 2-1/2” (6.35cm) onto the brake rod assembly (Fig. 0382). Fig 0382 4-24 PICT-1772a 9. Insert the brake rod trunnion into the idler assembly (Fig. 0383). Fig 0383 PICT-1771 10. Slide a washer onto the brake rod trunnion (Fig. 0384).
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LINKAGE 11. Install a hairpin cotter into the brake rod trunnion (Fig. 0385). 13. Install 2 spacers into the idler arm pivot (Fig. 0387). Fig 0387 Fig 0385 12. Apply anti-seize compound onto the outside diameter of the 2 idler pivot spacers (Fig. 0386). 14. Install the torsion spring onto the idler arm (Fig. 0388).
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LINKAGE 15. Position the idler/brake rod assembly onto the machine so the torsion spring is hooked onto the frame. (Fig. 0389). 17. Install a nut onto the idler pivot bolt (Fig. 0391). Fig 0391 4 Fig 0389 PICT-1758 PICT-1783 18. Insert the lower end of the brake rod into the brake arm assembly (Fig. 0392). 16. Align the idler pivot with the mounting hole on the frame and insert the idler pivot bolt (Fig. 0390).
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LINKAGE 19. Install a hairpin cotter into the lower end of the brake rod securing it to the brake arm (Fig. 0393). Fig 0393 PICT-1756 20. Insert the control rod trunnion/clevis into the idler arm (Fig. 0394). Fig 0394 PICT-1753 21. Slide a washer onto the control rod trunnion (Fig, 0395). Fig 0395 PICT-1752 22. Install a hairpin cotter into the trunnion securing the control rod to the idler (Fig. 0396). Fig 0396 PICT-1750a 23. Check the Brakes. Refer to “Checking the Brake (T-Bar)” on page 3-75.
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LINKAGE Neutral Adjustment Stud Replacement (Pistol Grip Hydro) 2. Remove the clevis pin (Fig. 0399). Note: The side plate has been removed for photo purposes. Fig 0399 4 Fig 0397 fig. 10 G004912 PICT-0924 3. Remove the nut from the top end of the adjustment stud (Fig. 0400). Neutral Adjustment Stud Removal 1. Remove the cotterpin from the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0398).
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LINKAGE 4. Remove the washer and spring from the adjustment stud (Fig. 0401). 6. Remove the neutral adjustment stud assembly out of the spring mount bracket (Fig. 0403). Fig 0401 Fig 0403 PICT-0926a 5. Remove the flanged nylon bushing from the spring mount bracket (Fig. 0402). Fig 0402 Floating Deck Mid-Size Service Manual PICT-0927 PICT-0928 7. Remove the 2 bolts and nuts securing the spring mount bracket to the frame (Fig. 0404).
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LINKAGE 8. Remove the spring mount bracket from the frame (Fig. 0405). 4 Fig 0405 PICT-0932 9. Remove the washer from the neutral adjustment stud (Fig. 0406). Fig 0406 4-30 PICT-0934a 10. Loosen the jam nut that secures the yoke to the neutral adjustment stud (Fig. 0407). Fig 0407 PICT-0936a 11. Remove the neural adjustment stud yoke (Fig. 0408).
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LINKAGE 12. Remove the nut from the neural adjustment stud (Fig. 0409). Neutral Adjustment Stud Installation 1. Position the spring mount bracket to the frame (Fig. 0411). Fig 0409 4 PICT-0939a Fig 0411 PICT-0932 Neutral Adjustment Stud Assembly (Fig. 0410): 2. Install 2 bolts and nuts securing the spring mount bracket to the frame (Fig. 0412). A E J F A C D G B H Fig 0410 A. B. C. D. E. F.
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LINKAGE 3. Install a jam nut onto the threads so that there is approximately 1/4” (6.4mm) space between the jam nut and the machined nut on the neutral stud (Fig. 0413). 5. Snug the jam nut against the yoke (Fig. 0415). Fig 0415 4 Fig 0413 PICT-1002a PICT-0998a 6. Slide the washer onto the end of the neutral adjustment stud opposite the yoke (Fig. 0416). 4. Thread the yoke onto the neural adjustment stud so that the end of the stud is flush with the opening of the yoke (Fig. 0414).
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LINKAGE 7. Insert the neutral adjustment stud assembly into the spring mount bracket (Fig. 0417). Fig 0417 PICT-1005 8. Install the flanged nylon bushing into the spring mount bracket (Fig. 0418). Fig 0418 Floating Deck Mid-Size Service Manual PICT-1006a 9. Position the yoke to the short tab on the drive lever swivel and insert a clevis pin (Fig. 0419). Fig 0419 PICT-1007 10. Secure the yoke to the drive lever swivel by installing a cotter pin into the clevis pin (Fig. 0420).
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LINKAGE 11. Install the spring onto the adjustment stud (Fig. 0421). 4 Fig 0421 13. Install a nut onto the top end of the adjustment stud. Tighten the nut until there are approximately 5 threads protruding past the nut (Fig. 0423). PICT-1009 Fig 0423 12. Install a washer onto the adjustment stud (Fig. 0422). Fig 0422 4-34 PICT-1012a 14. Adjust the Neutral Stud. Refer to “Neutral Stud Adjustment” on page 4-126.
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LINKAGE Operator Presence Control Lever Replacement (Pistol Grip Hydro) 2. Remove the left operator presence control lever from the operator presence control rod (Fig. 0426). Note: The manual tube assembly and control panel cover have been removed for photo purposes. Fig 0426 Fig 0424 fig. 10 G004912 PICT-0724 3. Remove the nylon bushing from the left side of the OPC rod (Fig. 0427). Operator Presence Control Lever Removal 1.
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LINKAGE 4. Repeat steps 1 thru 3 to remove the right side OPC lever. 7. Remove the PTO switch from the control panel (Fig. 0430). 5. Remove the extension spring located under the control panel (Fig. 0428). 4 Fig 0430 Fig 0428 PICT-0729a PICT-0727 8. Remove the OPC rod by sliding it to the far right, dropping the left side of the rod, and remove the rod through the left side (Fig. 0431). 6. Unplug the wire harness from the PTO switch (Fig. 0429).
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LINKAGE Operator Presence Control Lever Installation 3. Plug the wire harness into the PTO switch (Fig. 0434). 1. Install the Operator Presence Control (OPC) rod, spring tab end first, through the left side of the control panel and install the right end of the rod into the opening on the right side handle bar. Sliding the rod further through the right side handle bar opening, install the left end of the rod through the left handle bar opening (Fig. 0432). Fig 0434 PICT-0728 4.
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LINKAGE 5. Install a nylon bushing onto each end of the OPC rod (Fig. 0436). 4 Fig 0436 PICT-0726 6. Apply high strength thread locking compound (Loctite 680 or equivalent) onto both ends of the OPC rod (Fig. 0437). 7. Install the OPC levers onto the ends of the OPC rod (Fig. 0438). Fig 0438 8. Apply thread locking compound to the set screws (Fig. 0439).
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LINKAGE 9. Install one set screw into each OPC lever to secure the levers onto the OPC rod (Fig. 0440). Speed Control Removal 1. Remove the knob from the speed control lever (Fig. 0442). Fig 0440 4 PICT-0722 Fig 0442 Speed Control Replacement (Pistol Grip Hydro) Note: The Operator’s Manual tube assembly and control panel cover bracket have been removed for photo purposes. 2. Remove the hairpin cotter from the upper end of the speed control rod (Fig. 0443).
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LINKAGE 3. Remove the cotter pin from the lower end of the speed control rod (Fig. 0444). 4 Fig 0444 PICT-0747 5. Remove the nut from the pivoting sprung bolt (Fig. 0446). Fig 0446 PICT-0751 4. Remove the washer and speed control rod assembly from the tab on the speed control crank assembly and remove it from the machine (Fig. 0445). 6. Remove the middle bolt and spring assembly securing the speed control handle to the control panel (Fig. 0447).
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LINKAGE 7. Remove the lower bolt and nut securing the speed control handle to the control panel (Fig. 0448). 9. Remove the speed control handle (Fig. 0450). Fig 0450 Fig 0448 10. Remove the remaining nut, bolt, washers and spring from the speed control lever assembly (Fig. 0451). 8. Remove the upper bolt and nut (Fig. 0449).
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LINKAGE Note: There are 2 washers between the shift lever and shift lever plate (Fig. 0452). 4 Fig 0452 PICT-0763a 11. Release the pistol grip from neutral lock and place it in the drive position (Fig. 0453). Fig 0453 12. Remove the outside nut from both the left and right speed control link bolt assemblies (Fig. 0454). Fig 0454 13. Remove the hairpin cotter from the right and left swivels installed through each end of the speed control crank (Fig. 0455).
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LINKAGE 14. Remove the washer from the right and left swivels installed through each end of the speed control crank (Fig. 0456). Fig 0456 PICT-0771a 15. Remove the left hand and right hand speed control links and bolt assemblies (Fig. 0457). Fig 0457 Floating Deck Mid-Size Service Manual PICT-0772 16. Secure the speed control crank in place and loosen the 2 screws securing each end of it to the crank support assembly (Fig. 0458). Fig 0458 PICT-0776a 17.
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LINKAGE 18. Remove the 2 lower bolts and nuts securing the crank support assembly to the frame (Fig. 0460). 4 Fig 0460 20. Remove the crank support from the machine (Fig. 0462). Fig 0462 PICT-0786 19. While supporting the crank support, remove the 2 upper bolts and nuts (Fig. 0461). PICT-0789 21. On the right hand and left hand speed control links and the speed control rod, mark the location of the nut/swivel assembly on the threads of the link (Fig. 0463).
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LINKAGE 22. Loosen the jam nuts securing the trunnion in place on the threaded end of the speed control rod (Fig. 0464). 24. On the left hand speed control link, loosen the end nut (Fig. 0466). Fig 0466 Fig 0464 23. Remove the 2 nuts and the trunnion from the speed control rod (Fig. 0465). 25. Remove the nuts, washers and the swivel from the left hand speed control link (Fig. 0467).
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LINKAGE 26. Remove the two nuts and the bolt from the slotted end of both control links (Fig. 0468). 4 Fig 0468 PICT-0805a 27. Remove the knob from the right side speed control link assembly (Fig. 0469). 28. Remove the spacer, washers, swivel, spring and nut from the control link (Fig. 0470). Fig 0470 PICT-0810a Speed Control Installation 1. Position the crank support to the rear of the frame (Fig. 0471). Note: The choke cable should be routed on the outside of the crank support.
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LINKAGE 2. While supporting the crank support, loosely install the 2 upper bolts and nuts securing the crank support and handle to the frame (Fig. 0472). Note: The bolts are installed with the nuts on the outside of the frame. 4. Tighten the 4 nuts and bolts securing the crank support to the frame. 5. Apply thread locking compound to the threads of the 2 shoulder bolts that secure the speed control crank to the crank support (Fig. 0474). 4 Fig 0472 PICT-0787 Fig 0474 PICT-0815a 3.
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LINKAGE 7. Install 2 shoulder bolts securing the speed control crank to the crank support (Fig. 0476). 4 Fig 0476 PICT-0818 Right hand control link assembly: Fig 0478 Note: Tighten the knob until the spring measures 1.0” (2.5cm) in length. PICT-0822a Fig 0479 4-48 PICT-0886a 10. Install the knob onto the control link assembly (Fig. 0479). 8. Install one nut onto the control link, threading it down to the mark on the threads (Fig. 0477). Fig 0477 9.
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LINKAGE 11. Install the bolt into the slot of the control link. Left Hand control link Assembly: Note: The slotted portion of the control link is offset and the bolt needs to be oriented as shown (Fig. 0480): 13. Install the bolt into the slot of the control link. Note: The slotted portion of the control link is offset and the bolt needs to be oriented as shown (Fig. 0482): 4 Fig 0480 PICT-6411a Fig 0482 12. Install two nuts onto the bolt (flange side away from control link) so that there is 1/2” (1.
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LINKAGE 15. Install one nut onto the control link, threading it down to the mark (Fig. 0484). 17. Thread the second nut onto the control link. Snug fit the nut down to the washer and swivel assembly (Fig. 0486). Note: The trunnion and the bolt should be oriented in opposite directions. 4 Fig 0484 PICT-0822a 16. Install 2 washers and the swivel onto the control link (Fig. 0485). Fig 0486 PICT-0831a 18.
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LINKAGE 19. Install a nut onto the bolt securing the lower end of the speed control link to the drive lever swivel (Fig. 0488). Fig 0488 PICT-0835 20. Install the speed control link trunnion into the right hand tab on the speed control crank (Fig. 0489). 21. Slide a washer onto the trunnion and install a cotter pin securing the speed control link to the speed control crank (Fig. 0490). Fig 0490 PICT-0893 22.
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LINKAGE 24. Install a washer and a friction washer onto the shifter lever plate bolt (Fig. 0492). 4 Fig 0492 PICT-0843a 25. Insert the bolt/washer assembly into the slotted opening of the shifter lever plate (Fig. 0493). Fig 0493 4-52 PICT-0845a 26. Install a second friction washer onto the bolt (Fig. 0494). Fig 0494 PICT-0846a 27. Position the shift lever onto the shifter lever plate (Fig. 0495).
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LINKAGE 28. Position a spring onto the bolt assembly (Fig. 0496). Tighten the nut until approximately 3 threads stick out past the nut (Fig. 0498). Note: Do not collapse the spring. Fig 0496 PICT-0849a 4 Fig 0498 PICT-0852 29. Install a lock nut onto the bolt (Fig. 0497). 30. Position a washer between the two plates and align the ID of the washer with the center hole in the lever plates (Fig. 0499).
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LINKAGE 31. Position the speed control handle (Fig. 0500). Fig 0500 4 33. Loosely install the middle bolt, spring and nut, making sure the bolt goes through the washer in between the plates (Fig. 0502). PICT-0857a Fig 0502 PICT-0868 32. Loosely install the upper and lower bolts and nuts (Fig. 0501). Tighten the middle nut until approximately 3 threads stick out past the nut (Fig. 0503). Note: Do not collapse the spring.
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LINKAGE 34. Tighten the upper and lower bolts and nuts (Fig. 0504). Fig 0504 36. Install the knob onto the speed control lever (Fig. 0506). PICT-0873 Fig 0506 35. Apply thread locking compound to the threads of the speed control lever (Fig. 0505). Speed Control Rod Assembly: IMG_8001a 37. Install a nut onto the speed control rod threads, threading it to the mark made previously (Fig. 0507).
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LINKAGE 38. Slide a trunion onto the speed control rod and snug fit a second nut against the trunnion (Fig. 0508). 4 Fig 0508 PICT-0878a 39. Position the speed control rod so that the upper end is installed in the forwardmost hole of the speed control lever. Install a hairpin cotter into the speed control rod securing it to the speed control lever (Fig. 0509). 40. Position the speed control rod trunnion into the tab on the speed control crank assembly (Fig. 0510). Fig 0510 41.
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LINKAGE 42. Tighten the jam nuts securing the speed control rod trunnion in place (Fig. 0512). Fig 0512 PICT-0898 Drive Lever Swivel & Bearing Replacement (Pistol Grip Hydro) Fig 0513 fig. 10 G004912 43. Initially adjust the Neutral Stud. Refer to “Temporary Neutral Stud Adjustment” on page 4-122. Drive Lever Swivel & Bearing Removal 44. Adjust the Speed Control Linkage. Refer to “Speed Control Linkage Adjustment” on page 4-121. 1. Turn the engine off and remove the key from the ignition. 45.
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LINKAGE 3. Remove the 3 nuts, bolts and spacers securing the side plate to the frame (Fig. 0515). 4 Fig 0515 PICT-0901 4. Remove the side plate from the frame (Fig. 0516). Fig 0516 5. Remove the 2 bolts, nuts and washers securing the side flange bearing to the side plate (Fig. 0517). Fig 0517 6. Remove the side flange bearing from the side plate (Fig. 0518).
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LINKAGE 7. Remove the e-clip from the trunnion on the lower end of the drive lever rod (Fig. 0519). Fig 0519 9. Move the speed control lever to the full forward position. Remove the outside nut from the lower end of the speed control link assembly (Fig. 0521). PICT-0908 Fig 0521 8. Remove the trunnion from the drive lever swivel on the lower end of the drive lever rod (Fig. 0520). Fig 0520 10. Remove the speed control link from the drive lever swivel.
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LINKAGE 11. Remove the hairpin cotter from the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0523). 13. Loosen the 2 set screws securing the drive lever swivel to the hydro pump shaft (Fig. 0525). Note: There is an access hole located in the frame below the drive lever swivel. 4 Fig 0523 PICT-0914 Fig 0525 PICT-0916 12. Remove the clevis pin (Fig. 0524). 14. Remove the drive lever swivel from the hydro pump shaft (Fig. 0526).
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LINKAGE 15. Remove the spring stud from the drive lever swivel (Fig. 0527). Drive Lever Swivel & Bearing Installation 1. Install a grease fitting into the drive lever swivel (Fig. 0529). Fig 0527 4 PICT-0918 Fig 0529 PICT-0920 16. Remove the grease fitting from the drive lever swivel (Fig. 0528). 2. Install the spring stud into the drive lever swivel (Fig. 0530).
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LINKAGE 3. Position the drive lever swivel through the frame and onto the hydro pump shaft (Fig. 0531). 5. Install the 2 set screws securing the drive lever swivel to the hydro pump shaft (Fig. 0533). Note: There is an access hole located in the frame below the drive lever swivel. 4 Fig 0531 PICT-0917 Fig 0533 PICT-0916 4. Apply thread locking compound to both drive lever swivel set screws (Fig. 0532). 6.
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LINKAGE 7. Install a hairpin cotter into the clevis pin securing the neutral adjustment stud yoke to the drive lever swivel (Fig. 0535). 9. Install the outside nut onto the speed control link bolt assembly (Fig. 0537). Fig 0537 Fig 0535 8. Insert the speed control link bolt into the drive lever swivel (Fig. 0536). 10. Insert the trunnion on the lower end of the drive lever rod into the drive lever swivel (Fig. 0538).
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LINKAGE 11. Install an e-clip onto the trunnion on the lower end of the drive lever rod (Fig. 0539). 4 Fig 0539 13. Install a flat washer onto the 2 bolts used to secure the bearing to the side plate. Loosely install the bearing to the side plate with the 2 bolt assemblies and nuts (Fig. 0541). PICT-0908 Fig 0541 PICT-1015 12. Position the side flange bearing to the side plate (Fig. 0540). 14. Position the side plate so the bearing is installed on the hydro control shaft (Fig. 0542).
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LINKAGE 15. Insert a bolt through the side plate and slide a spacer onto the bolt. Loosely secure the bolt to the frame with a nut (Fig. 0543). 17. Tighten the nuts securing the side flange bearing in place on the side plate (Fig. 0545). Fig 0545 Fig 0543 16. Repeat the above step with the other 2 bolt and spacer assemblies securing the side plate to the frame (Fig. 0544). 18. Install the spring onto the spring stud on the lower tab of the drive lever swivel (Fig. 0546).
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LINKAGE 19. Apply grease to the side flange bearing (Fig. 0547). Fig 0547 4 Handle Assembly Replacement (T-Bar) PICT-1021 Fig 0548 20. Adjust the Speed Control Linkage. Refer to “Speed Control Linkage Adjustment” on page 4-121. 21. Initially adjust the Neutral Stud. Refer to “Temporary Neutral Stud Adjustment” on page 4-122. 22. Adjust the left and right hydro control linkages. Refer to “Hydro Control Linkage Adjustment” on page 4-123. fig. 7 G004812 Handle Assembly Removal (T-Bar) 1.
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LINKAGE 3. Open the locking tab on the front of the Operator Presence Control (OPC) switch. Unplug the harness from the OPC (Fig. 0549). 5. While holding the lock down, draw the wire and spade terminal out of the connector (Fig. 0551). Fig 0551 Fig 0549 PICT-1692 PICT-1670a 4. Depress the connector lock with a small flat screwdriver (Fig. 0550). 6. Repeat steps 2 and 3 to remove the second terminal from the switch. 7. Pull the wire harness from the center tube in the T-bar (Fig. 0552).
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LINKAGE 8. Remove the hairpin cotter from the lower end of the control rod (Fig. 0553). 4 Fig 0553 PICT-1672a 9. Remove the washer from the lower end of the control rod (Fig. 0554). 10. Remove the trunnion/clevis from the idler arm (Fig. 0555). Fig 0555 11. Remove the clevis pin from the trunnion (Fig. 0556).
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LINKAGE 12. Remove the trunnion from the control rod (Fig. 0557). Fig 0557 PICT-1678a 13. Remove the cotter pin from the upper end of the control rod (Fig. 0558). 14. Remove the control rod from the control bar/bail assembly (Fig. 0559). Fig 0559 PICT-1682 15. Repeat steps 8 thru 14 to remove the opposite control rod. 16. Remove the bail from the handle assembly (Fig. 0560).
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LINKAGE 17. Remove the nut from the bolt securing the T-Bar to the handle assembly (Fig. 0561). 19. Slide the T-Bar off the handle assembly (Fig. 0563). Fig 0563 4 Fig 0561 18. Remove the bolt and then remove the parking brake lever (Fig. 0562). 20. Depress the OPC switch tabs and remove the switch from the T-Bar (Fig. 0564).
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LINKAGE 21. Remove the 2 rubber grommets from the T-Bar (Fig. 0565). 23. Remove the clevis pin (Fig. 0567). Fig 0567 Fig 0565 22. Remove the cotter pin from the clevis pin securing the control pivot assembly to the handle bar (Fig. 0566). Fig 0566 24. Repeat steps 20 and 21 to remove the cotter pin and clevis from the opposite side. 25. Remove the control pivot assembly from the handle assembly (Fig. 0568).
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LINKAGE 26. Remove the cable tie securing the throttle and choke cable to each side of the handle assembly (Fig. 0569). 4 Fig 0569 PICT-1716 28. Remove the 2 screws securing the bottom panel to the control panel. Remove the bottom panel (Fig. 0571). Fig 0571 PICT-1719a 27. Remove the 2 screws securing the manual tube R-clamps to the bottom of the control panel. Remove the manual tube assembly (Fig. 0570). 29.
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LINKAGE 30. Lower the control panel from the handle (Fig. 0573). Fig 0573 PICT-1722 31. Remove the 4 bolts and nuts (2 on the left, 2 on the right) securing the handle to the frame (Fig. 0574). Note: Make note of handle height adjustment location. 32. Remove the handle (Fig. 0575). Fig 0575 Handle Assembly Installation (T-Bar) 1. Position the handle to the frame (Fig. 0576).
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LINKAGE 2. Install 4 bolts and nuts (2 on the left, 2 on the right) securing the handle to the frame (Fig. 0577). 4 Fig 0577 PICT-1725 Note: Position the lower set of bolts as previously noted for proper handle height adjustment (Fig. 0578). 3. Raise the control panel assembly into place on the handle bar (Fig. 0579). Fig 0579 4. Install 4 bolts and nuts (2 on the left, 2 on the right) securing the control panel to the handle (Fig. 0580).
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LINKAGE 5. Position the bottom panel to the control panel and install 2 screws securing the back side of the bottom panel to the control panel (Fig. 0581). 7. Install a cable tie securing the throttle cable, and one securing the choke cable, to each side of the handle assembly. Trim the excess (Fig. 0583). Fig 0581 Fig 0583 PICT-1719a 6. Position the manual tube assembly to the control panel. Install 2 screws to secure the manual tube assembly R-clamps and bottom panel to the control panel (Fig. 0582).
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LINKAGE 9. Insert a clevis pin into each side of the control pivot assembly securing it to the handle assembly (Fig. 0585). 4 11. Install 2 rubber grommets (1 on the left, 1 on the right) into the T-Bar mounting holes (Fig. 0587). Fig 0587 Fig 0585 10. Install a cotter pin into each of the clevis pins (Fig. 0586). 12. Install the OPC switch into the switch housing on the T-Bar (Fig. 0588).
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LINKAGE 13. Slide the T-Bar onto the handle assembly (Fig. 0589). 15. Install a nut onto the bolt securing the parking brake lever and T-Bar to the handle assembly (Fig. 0591). Note: Tighten the bolt and nut enough so the parking brake lever does not rattle but still rotates freely. Fig 0589 4 PICT-1704a 14. Position the parking brake lever to the T-Bar and insert a bolt (Fig. 0590). Fig 0591 PICT-1701 16. Position the bail into the handle assembly (Fig. 0592).
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LINKAGE 17. Insert the top end of the control rod into the control bar/bail assembly (Fig. 0593). 4 Fig 0593 PICT-1682 18. Install a cotter pin into the upper end of the control rod, securing it to the control bar/bail assembly (Fig. 0594). 19. Install the trunnion onto the control rod approximately 2” (5cm) (Fig. 0595). Fig 0595 20. Insert a clevis pin into the trunnion (Fig. 0596).
PAGE 186
LINKAGE 21. Insert the clevis pin into the idler arm (Fig. 0597). Fig 0597 PICT-1675 22. Install a washer onto the clevis pin (Fig. 0598). 23. Install a hairpin cotter into the clevis pin (Fig. 0599). Fig 0599 PICT-1672a 24. Repeat steps 17 - 23 to install the control rod on the opposite side. 25. Feed the wire harness up through the center T-bar tube (Fig. 0600).
PAGE 187
LINKAGE 26. Plug the two harness wires into the harness connector as shown (Fig. 0601): 28. Connect the negative battery terminal to the battery. 29. Check the Adjustment of the Control Bar. Refer to “Control Bar Adjustment” on page 4-132. Handle Assembly Removal (T-2) 4 Fig 0601 PICT-1742 27. Plug the harness connector into the OPC switch (Fig. 0602). Fig 0603 fig. 3 G006080 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery terminal from the battery.
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LINKAGE 3. Remove the 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 0604). 5. Unplug the harness from the parking brake switch (Fig. 0606). Fig 0606 Fig 0604 PICT-2021 PICT-1921 6. Unplug the harness from the PTO switch (Fig. 0607). 4. Remove the control panel cover/manual tube assembly (Fig. 0605).
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LINKAGE 7. Remove the PTO switch from the control panel (Fig. 0608). 4 Fig 0608 PICT-2023 8. Unplug the harness wire and connector from the ignition switch (Fig. 0609). Fig 0609 4-82 PICT-2024 9. Remove the nut securing the ignition switch to the control panel (Fig. 0610). Fig 0610 PICT-2025a 10. Remove the lockwasher from the ignition switch (Fig. 0611).
PAGE 190
LINKAGE 11. Remove the ignition switch from the control panel (Fig. 0612). 13. Unplug the harness from the hour meter (Fig. 0614). Fig 0614 Fig 0612 12. Unplug the harness from the Operator Presence Control (OPC) switch (Fig. 0613). 14. Remove the locking tab from the back side of the hour meter (Fig. 0615).
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LINKAGE 15. Remove the hour meter from the control panel (Fig. 0616). 4 Fig 0616 PICT-2039a 16. Unplug the latching relay from the harness connector (Fig. 0617). Fig 0617 17. Unplug the kill relay from the harness connector (Fig. 0618). Fig 0618 18. Remove the bolt and nut securing the two relay harness connector blocks to the control panel (Fig. 0619).
PAGE 192
LINKAGE 19. Remove the cable tie securing the harness to the throttle cable (Fig. 0620). 21. Pull the harness through the frame and lay it across the engine so it is out of the way of the handle. 22. At the front of the engine, loosen the cable clamps securing the throttle (bottom) and choke (top) cables to the engine (Fig. 0622). A Fig 0620 B PICT-2043 20. Remove the cable tie securing the harness to the frame (left of the fuel tank, above the parking brake) (Fig. 0621). Fig 0622 A.
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LINKAGE 24. Cut the cable ties at the following locations (Fig. 0624 and Fig. 0625): 25. Remove the 2 screws and nuts securing the throttle control assembly to the control panel (Fig. 0626). C B A 4 Fig 0624 PICT-2051 A. Throttle/choke B. Throttle/neutral proximity switch wire/frame C. Throttle/frame Fig 0626 PICT-2053 26. Remove the throttle control assembly from the control panel (Fig. 0627). D Fig 0627 Fig 0625 PICT-2057 PICT-2052 D.
PAGE 194
LINKAGE 27. Remove the 2 screws and nuts securing the choke control assembly to the control panel (Fig. 0628). Fig 0628 PICT-2054 28. Remove the choke control assembly from the control panel (Fig. 0629). 29. Remove the 2 bolts and nuts securing the parking brake handle support to the frame (Fig. 0630). Fig 0630 PICT-2060 30. Swing the parking brake assembly forward so it is out of the way to permit handle assembly removal. 31.
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LINKAGE 32. Remove the washer from the upper end of the control linkage rod (Fig. 0632). 34. Repeat steps 31 - 33 to remove the control rod from the opposite motion control lever assembly. 35. Remove the spring from the right hand control lever assembly (Fig. 0634). 4 Fig 0632 PICT-2065 Fig 0634 PICT-2071 33. Remove the upper end of the control rod from the tab on the control handle (Fig. 0633). 36. Remove the 2 screws securing the OPC switch to the control lever assembly (Fig. 0635).
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LINKAGE 37. Remove the OPC switch and threaded spacer plate (Fig. 0636). Fig 0636 PICT-2075 38. Remove the nut and bolt securing the right hand lever assembly to the motion control assembly (Fig. 0637). Fig 0637 Floating Deck Mid-Size Service Manual PICT-2076 39. Remove the right hand lever from the control panel (Fig. 0638). Fig 0638 PICT-2080a 40. Remove the 2 carriage bolts and nuts securing the center support bracket to the control panel (Fig. 0639).
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LINKAGE 41. Remove the 2 outside bolts (1 left, 1 right) securing the motion control lever linkage to the handle assembly (Fig. 0640). 4 43. Slide the right hand motion control assembly off the pivot shaft (Fig. 0642). Fig 0642 Fig 0640 42. Remove the motion control lever linkage from the handle assembly (Fig. 0641). 44. Remove the bolt securing the right hand pivot shaft to the center support bracket (Fig. 0643).
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LINKAGE 45. Slide the left hand control lever off the left hand pivot shaft (Fig. 0644). 47. Remove the 6 bushings from the control assemblies (2 left, 4 right) (Fig. 0646). A Fig 0644 Fig 0646 PICT-2090a PICT-2095a A. One on each side 46. Remove the bolt securing the left hand pivot shaft to the center support bracket (Fig. 0645). 48. Remove the nut and washer securing the handle stop lever cam to the right control lever (Fig. 0647).
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LINKAGE 49. Remove the handle stop lever cam from the right control lever (Fig. 0648). 4 Fig 0648 PICT-2109 50. Remove the 6 bolts (3 left, 3 right) securing the handle assembly to the frame (Fig. 0649). 51. Remove the handle assembly from the frame (Fig. 0650). Fig 0650 PICT-2092 Handle Assembly Installation (T-2) 1. Position the handle assembly to the frame (Fig. 0651).
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LINKAGE 2. Install 6 bolts (3 left, 3 right) securing the handle assembly to the frame (Fig. 0652). Fig 0652 PICT-2069 3. Install 6 bushings into the control assemblies (2 left, 4 right) (Fig. 0653). 4. Position the handle stop lever cam onto the right control lever (Fig. 0654). Fig 0654 PICT-2109 5. Loosely install a washer and nut to secure the handle stop lever cam to the right control lever (Fig. 0655). A Fig 0653 PICT-2095a Fig 0655 PICT-2108 A.
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LINKAGE 6. Position the left hand pivot shaft to the center support bracket and loosely install a bolt securing the pivot shaft to the center support bracket (Fig. 0656). 8. Position the right hand pivot shaft to the center support bracket and loosely install a bolt securing the pivot shaft to the center support bracket (Fig. 0658). Fig 0656 Fig 0658 4 PICT-2091a 7. Slide the left hand control lever onto the left hand pivot shaft (Fig. 0657). Fig 0657 4-94 PICT-2090a PICT-2089a 9.
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LINKAGE 10. Position the motion control lever linkage into the control panel handle assembly (Fig. 0660). Fig 0660 12. Loosely install 2 carriage bolts and nuts, securing the center support bracket to the control panel (Fig. 0662). PICT-2098 Fig 0662 11. Loosely install 2 bolts (1 left, 1 right) from the outside of the handle assembly, securing the motion control lever linkage to the handle assembly (Fig. 0661). Fig 0661 Floating Deck Mid-Size Service Manual PICT-2084 PICT-2083 13.
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LINKAGE 14. Install a bolt and nut, securing the right hand lever assembly to the motion control linkage assembly (Fig. 0664). 4 B. 2 bolts install from the outside of the handle assembly. Fig 0666 Fig 0664 PICT-2084 PICT-2076 15. Tighten the bolts and nuts previously installed (Fig. 0665, Fig. 0666 and Fig. 0667): C. 2 bolts securing the right and left hand pivot shafts to the center support bracket. A. 2 carriage bolts.
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LINKAGE 16. Position the right hand control lever so it aligns with the left hand control lever (Fig. 0668). Fig 0668 PICT-2112a 17. Rotate the handle stop lever cam until the gap between the cam and the right hand control handle is removed. Tighten the nut (Fig. 0669). 18. Position the OPC switch and threaded spacer plate onto the motion control linkage (Fig. 0670). Fig 0670 19. Install 2 screws securing the OPC switch and spacer to the motion control lever assembly (Fig. 0671).
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LINKAGE 20. With the right control lever in the operating position, there should be .10” (2.5mm) gap between the OPC switch plunger and the control arm tab. Adjust the switch location as needed (Fig. 0672). 4 22. Insert the upper end of the control linkage rod into the tab on the control handle (Fig. 0674). Fig 0674 Fig 0672 PICT-2066 PICT-2104 23. Slide a washer onto the upper end of the control linkage rod (Fig. 0675). 21. Install the spring onto the right hand motion control lever assembly (Fig.
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LINKAGE 24. Install a hairpin cotter into the upper end of the control linkage rod (Fig. 0676). Fig 0676 PICT-2064 25. Repeat steps 22 - 24 to install the opposite side control rod. 27. Install 2 bolts and nuts securing the parking brake handle support to the frame (Fig. 0678). Fig 0678 PICT-2060 28. Slide the choke cable through the control panel and insert the choke control handle assembly into the control panel (Fig. 0679). 26.
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LINKAGE 29. Install 2 screws and nuts securing the choke control assembly to the control panel (Fig. 0680). 4 Fig 0680 PICT-2054 30. Slide the throttle cable through the control panel and insert the throttle control handle assembly into control panel (Fig. 0681). Fig 0681 4-100 PICT-2057 31. Install 2 screws and nuts securing the throttle control assembly to the control panel (Fig. 0682). Fig 0682 PICT-2053 32.
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LINKAGE 33. Hook the z-bend of the choke cable to the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0684). 35. Ensure the carburetor choke plate is fully open (Fig. 0686). Note: The air filter has been removed to show the carburetor choke plate. Fig 0684 4 PICT-0331 Fig 0686 PICT-0333 34. Move the choke control knob to the “open” position (Fig. 0685). 36.
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LINKAGE 37. Move the choke control knob to the “choke“ position (Fig. 0688). 39. Make sure the choke plate turns from the fully closed position to the fully open position when actuating the choke control knob. 40. Hook the z-bend of the throttle cable to the throttle control lever and loosely clamp the outer housing of the throttle cable into the cable clamp (Fig. 0690). 4 Fig 0688 PICT-0336 38. Ensure the carburetor choke plate is fully closed (Fig. 0689). Fig 0690 PICT-0338 41.
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LINKAGE 42. Pull up the outer housing of the throttle cable until the inner wire has almost no slack and tighten to cable clamp bolt (Fig. 0692). 44. Install cable ties at the following locations (Fig. 0694 and Fig. 0695): C B A Fig 0694 Fig 0692 PICT-2051 PICT-0341a A. Throttle/choke B. Throttle/neutral proximity switch wire/frame C. Throttle/frame 43. Move the throttle control knob to the “slow” position. Ensure the carburetor throttle control moves smoothly (Fig. 0693).
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LINKAGE 45. Route the harness up the left side of the frame and into the control panel. 48. Plug the latching relay into the harness connector (Fig. 0698). 46. Install a bolt and nut securing each of the relay harness connector blocks to the control panel (Fig. 0696). 4 Fig 0698 Fig 0696 PICT-2036 PICT-2041a 49. Install the hour meter into the control panel (Fig. 0699). 47. Plug the kill relay into the harness connector (Fig. 0697).
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LINKAGE 50. Install the locking tab onto the back side of the hour meter (Fig. 0700). 52. Plug the harness into the OPC switch (Fig. 0702). Fig 0702 Fig 0700 51. Plug the harness into the hour meter (Fig. 0701). Fig 0701 Floating Deck Mid-Size Service Manual PICT-2028 PICT-2037 PICT-2029 53. Position the ignition switch into the control panel (Fig. 0703).
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LINKAGE 54. Install a lockwasher onto the ignition switch (Fig. 0704). 4 Fig 0704 PICT-2026 55. Install a nut securing the ignition switch to the control panel (Fig. 0705). Fig 0705 4-106 PICT-2025 56. Plug the harness wire and connector into the ignition switch (Fig. 0706). Fig 0706 PICT-2024 57. Install the PTO switch into the control panel (Fig. 0707).
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LINKAGE 58. Plug the harness into the PTO switch (Fig. 0708). Fig 0708 60. Install a cable tie securing the harness to the frame left of the fuel tank, above the parking brake (Fig. 0710). PICT-2022 Fig 0710 PICT-2047 59. Plug the harness into the parking brake switch (Fig. 0709). 61. Install a cable tie securing the harness to the throttle cable just below throttle control handle, inside the frame (Fig. 0711).
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LINKAGE 62. Position the control panel cover/manual tube assembly to the control panel (Fig. 0712). Choke Cable Replacement Choke Cable Removal 1. Turn the engine off and remove the key from the ignition. 2. Loosen the clamp that secures the choke cable to the engine (Fig. 0714). 4 Fig 0712 PICT-1923 63. Install 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 0713). Fig 0714 PICT-0627 3.
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LINKAGE 4. Remove the cable tie located above the left tire that secures the choke and throttle cable together (Fig 0716). Fig 0716 PICT-0632 5. Pistol Grip & T-Bar Models: Remove the cable tie securing the choke cable to the right handle (Fig. 0717). 6. T2 Models: Remove the cable tie securing the choke cable to the right side of the control panel (Fig. 0718). Fig 0718 7. Remove the 2 screws and nuts securing the choke handle to the right handle (Fig. 0719).
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LINKAGE 8. Remove the choke handle, cable and gasket assembly out through the control panel (Fig. 0720). Choke Cable Installation 1. Slide the gasket onto the choke handle assembly (Fig. 0722). 4 Fig 0720 PICT-0636a Fig 0722 PICT-0638a 9. Remove the gasket from the handle assembly (Fig. 0721). 2. Slide the choke cable through the opening on the control panel (Fig. 0723).
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LINKAGE 3. Insert the handle into the opening in the control panel. Install 2 screws and nuts to secure the choke handle to the right handle bar (Fig. 0724). 5. Pistol Grip & T2 models: Position the choke cable between the hydro pumps (Fig. 0726). Fig 0726 Fig 0724 4. Pistol Grip models only: Continue routing the choke cable between the tracking rod and bracket (Fig. 0725). 6. T-Bar models only: Continue routing the choke cable down under the right hand gear driveshaft (Fig. 0727).
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LINKAGE 7. Route the choke cable under the electrical harness, around the left side of the engine and up to the front side of the engine (Fig. 0728). 4 Fig 0728 PICT-0641 8. Hook the choke cable z-bend to the choke control lever (Fig. 0729). Fig 0729 4-112 PICT-0630 9. Slide the choke cable into the upper cable clamp and loosely clamp the outer cable housing (Fig. 0730). Fig 0730 PICT-0627 10. Move the choke control to the open position (Fig. 0731).
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LINKAGE 11. Make sure that the carburetor choke plate is fully open (Fig. 0732). 13. Install a cable tie securing the choke cable to the throttle cable above the left tire. Cut off the excess cable tie (Fig. 0734). Note: The air filter has been removed to show the carburetor choke plate. Fig 0734 Fig 0732 PICT-0333 12. Pull on the outer cable housing until the inner wire has almost no slack. Tighten the cable clamp bolt (Fig. 0733). 14.
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LINKAGE 15. T2 Models: Install a cable tie securing the choke cable to the right side of the control panel (Fig. 0736). Throttle Cable Replacement Throttle Cable Removal 1. Turn the engine off and remove the key from the ignition. 2. Loosen the clamp that secures the throttle cable to the engine (Fig. 0737). 4 Fig 0736 PICT-2052 16. Make sure that the choke valve turns from the fully closed position to the fully open position when actuating the choke control handle. Fig 0737 PICT-0652 3.
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LINKAGE 4. Remove the cable tie located above the left tire that secures the throttle and choke cable together (Fig 0739). 6. Slide the throttle cable out of the R-clamp (Fig. 0741). Fig 0741 Fig 0739 5. Loosen the screw securing the R-clamp to the frame, located behind the left tire (Fig. 0740). Fig 0740 Floating Deck Mid-Size Service Manual PICT-0658 PICT-0632 PICT-0661 7. Pistol Grip & T-Bar Models: Remove the cable tie securing the throttle cable to the left handle (Fig. 0742).
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LINKAGE 8. T2 Models: Remove the cable tie securing the harness to the throttle cable (Fig. 0743). 4 Fig 0743 PICT-2043 9. Cut the cable ties at the following locations (Fig. 0744). 10. Remove the 2 screws and nuts securing the throttle handle assembly to the left handle (Fig. 0745). Fig 0745 PICT-0667 11. Remove the throttle handle cable and gasket assembly out through the control panel (Fig. 0746). B A Fig 0744 PICT-2051 Fig 0746 PICT-0670a A. Throttle/neutral proximity switch wire/frame B.
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LINKAGE 12. Remove the gasket from the handle assembly (Fig. 0747). Fig 0747 PICT-0671 2. Slide the throttle cable through the opening on the control panel (Fig. 0749). Fig 0749 PICT-0670a 3. Pistol Grip models only: Route the throttle cable between the tracking rod and bracket (Fig. 0750). Throttle Cable Installation 1. Slide the gasket onto the throttle handle assembly (Fig. 0748).
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LINKAGE 4. Pistol Grip models only: Continue routing the throttle cable under the left hand control shaft between the left pump and frame (Fig. 0751). 4 6. T2 Models: Route the cable between the left pump and frame (Fig. 0753). Fig 0753 Fig 0751 5. T-Bar models only: Continue routing the throttle cable under the left hand gear driveshaft (Fig. 0752). Fig 0752 4-118 IMG_8008a PICT-0674 PICT-1494 7.
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LINKAGE 8. Insert the handle into the opening in the control panel. Install 2 screws and nuts to secure the throttle handle to the left handle bar (Fig. 0755). Fig 0755 PICT-0667 9. Hook the z-bend of the throttle control lever (Fig. 0756). Fig 0756 Floating Deck Mid-Size Service Manual PICT-0675 10. Slide the throttle cable into the upper cable clamp and loosely clamp the outer cable housing (Fig. 0757). Fig 0757 PICT-0678 11. Move the throttle control to the fast position (Fig. 0758).
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LINKAGE 12. Pull on the outer cable housing until the inner wire has almost no slack. Tighten the cable clamp bolt (Fig. 0759). 4 Fig 0759 PICT-0682 13. Install a cable tie securing the throttle cable to the left handle bar. Cut off excess (Fig. 0760). Fig 0760 PICT-0683a 14. Install a cable tie securing the throttle cable to the choke cable above the left tire. Cut off excess (Fig. 0761). Fig 0761 PICT-0684a 15. Tighten the R-clamp screw securing the throttle cable to the frame (Fig. 0762).
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LINKAGE 4. Check the orientation of the tabs on the ends of the speed control crank. These tabs should be pointing straight down, at approximately the 6 o’clock position (Fig. 0764). Linkage Adjustments Speed Control Linkage Adjustment (Pistol Grip Hydro) 1. Disengage the PTO and set the parking brake. Side View 2. Stop the engine and remove the key. 3. Move the speed control lever to the full forward position (Fig. 0763). D C A A 4 B D B Fig 0763 E PICT-0711a Fig 0764 A. Speed control rod B.
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LINKAGE 9. Check the travel of the shift lever in the control panel slot. The shift lever travel should be approximately centered in the control panel slot (Fig. 0765). 2. Move the speed control lever to the neutral position (Fig. 0766). A B C Fig 0765 A. Actuating tab B. 1/8” - 1/4” (3 - 6mm) space C. Safety switch Note: Perform the following procedure on both the left and right side. 1. Move the left and right neutral lock latches to the unlatched position.
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LINKAGE 3. Loosen the nut against the yoke (Fig. 0767). Hydro Control Linkage Adjustment !! Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. A C D B E F G F Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. !! 4 Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. Fig 0767 fig.
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LINKAGE Adjusting the Left Side Linkage (Pistol Grip) 9. Loosen the front adjusting nut on left hydro control linkage as shown in (Fig. 0768). 1. Disengage the PTO and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Support the rear of the machine on jack stands so the drive wheels are off of the ground. A 4. Disengage the parking brake. 5 Start the engine and move the throttle to the full throttle position. 6.
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LINKAGE Note: Make sure flat part of linkage is perpendicular to the pin of swivel (Fig. 0769). A Note: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring. Repeat above adjustments if necessary (Fig. 0770). A B D 90 Degrees C B C C Fig 0770 Fig 0769 A. Hydro control linkage B. Swivel fig. 47 G001735 C. Incorrect position D. Correct position 12.
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LINKAGE Adjusting the Right Side Linkage (Pistol Grip) 1. With the machine on jack stands, place the speed control lever in the neutral position. 2. Place the right drive lever in the full forward position. 5. Turn the knob clockwise 1/4 of a turn. Then move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Fig. 0771). 6. If necessary, adjust the length of spring to 1” (26mm) between the washers (Fig. 0771). 7.
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LINKAGE !! 3. Adjust the left and right neutral stud until the clevis pin in the yoke touches the back end of the slot in the control arm (Fig. 0772). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stands when supporting machine. • Do not use hydraulic jacks. A 1. With the machine on jack stands, place the speed control lever in the neutral position. 2. Hold the OPC levers down.
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LINKAGE 4. Move the speed control lever to the full forward position. 5. Squeeze one drive lever until an increased resistance is felt. This is neutral position. This is where the clevis pin in the yoke comes to the back end of the slot in the control arm bracket. Note: Make sure you have not reached the end of the neutral lock slot. If you have, shorten the control lever linkage. Refer to Adjusting the Control Rod. 6.
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LINKAGE 2. Lengthen the control rod if the tire is turning in reverse and shorten the rod if the tire is turning forward. 6. Install the hairpin cotter pin between the drive lever and the neutral lock and into the clevis pin (Fig. 0773). 3. Rotate the rod several turns if the tire is rotating fast. Then, adjust the rod in 1/2 turn increments. Note: Make sure the clevis pin is inserted into the neutral lock. 4. Place the clevis pin into the drive lever (Fig. 0773). 7.
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LINKAGE 1. If the machine does not track straight, adjustment is required. 4. Loosen the wing nuts on the left control rod and rotate the turnbuckle in or out to change the tracking. Secure the turnbuckle in position with the wing nuts (Fig. 0776). 2. Check the rear tire pressure. Refer to Specifications for proper tire pressure. 5. Check for proper tracking. Adjust the left control rod if a change is needed. 3.
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LINKAGE If the motion control levers do not align front to back, or the right side control lever does not move easily into the neutral lock position, adjustment is required. Adjust each lever and control rod separately. 2. Loosen the wing nuts on the right control rod and rotate the turnbuckle in or out to ensure the right side control lever is centered in the neutral lock position. Secure the turnbuckle in position with the wing nuts (Fig. 0779).
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LINKAGE 3. Engage the control bar (Fig. 0782). Control Bar Adjustment (T-Bar) 1. Initially adjust the control rods so that 2 1/4” (5.715cm) of thread extends beyond the trunnion fittings (Fig. 0780). Fig 0782 4 Fig 0780 PICT-5303 2. The control bar and upper handle must be parallel when in the relaxed drive and brake positions (Fig. 0781). PICT-5314a 4. Using a ruler, measure the travel distance of the pulley while releasing and engaging the control bar.
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LINKAGE 5. Engage the Parking Brake (Fig. 0784). 6. If adjustment is required, refer to “Adjusting the Brake”, page 5-10. Note: The parking brake lever should swing into a snug position against the upper handle while pulling back on the upper control bar. 7. Adjust the control rods so there is a 1” to 1 1/4” (2.54 to 3.175cm) gap between the upper control bar and the fixed bar with the wheel drive fully engaged (Fig. 0785). A 4 Fig 0784 PICT-5311a Fig 0785 PICT-5333a A.
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LINKAGE 4 THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Engine Removal - Pistol Grip Hydro 1. Turn the engine off and remove the key from the ignition. 4. Move the positive battery terminal boot and disconnect the positive (red) battery cable from the battery (Fig. 0788). 2. Turn the fuel valve to the off position (Fig. 0786). Fig 0788 Fig 0786 PICT-0247a PICT-0252 5. Remove 1 of the 2 nuts retaining the battery hold down strap and battery hold downs to the battery tray (Fig. 0789). 5 3.
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ENGINE 6. Remove the battery hold down plate and 2 battery hold downs from the battery tray (Fig. 0790). Fig 0790 PICT-0256 7. Remove the battery from the battery tray (Fig. 0791). 5 Fig 0791 8. Remove the bolt that secures the fuel line R-clamp to the engine (Fig. 0792). Fig 0792 9. Slide the hose clamp off the fuel line where it connects to the fuel pump (Fig. 0793).
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ENGINE 10. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 0794). Fig 0794 12. Place a drain pan below the drain hose. Rotate the oil drain valve to allow the engine oil to drain into the drain pan (Fig. 0796). PICT-0264 Fig 0796 11. Attach the oil drain hose to the oil drain valve (Fig. 0795). PICT-0266 13. When the oil has drained completely, close the drain valve and remove the drain hose. 14. Unplug the clutch from the harness connector (Fig. 0797).
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ENGINE 15. Push the grommet and clutch plug through the chassis frame to the underside of the machine (Fig. 0798). 17. Roll the PTO drive belt off the center mower deck pulley (Fig. 0800). Fig 0800 Fig 0798 5 PICT-0283 PICT-0277 16. Remove the carrier frame cover (Fig. 0799). 18. Raise the machine so that the underside of the chassis can be accessed. 19.
PAGE 246
ENGINE 20. Remove the idler arm spring from the spring post (Fig. 0802). Fig 0802 22. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the chassis (Fig. 0804). PICT-0291a Fig 0804 PICT-0295 21. Remove the belt from the clutch (Fig. 0803). 23. Loosen the clutch bolt (Fig. 0805).
PAGE 247
ENGINE 24. Remove the bolt, 2 spring washers and flat washer securing the clutch to the engine crankshaft. Lower the clutch off the engine crankshaft (Fig. 0806). 26. Remove the hydro drive belt from around the engine crankshaft pulley (Fig. 0808). Fig 0808 Fig 0806 5 25. Using a spring removal tool (Toro P/N 92-5771), unhook the hydro drive idler spring and remove it from the chassis (Fig. 0807). 27. Slide the drive pulley off the engine crankshaft (Fig. 0809).
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ENGINE 28. Remove the square key from the engine crankshaft (Fig. 0810). 30. At the front of the engine, loosen the cable clamps securing the throttle (bottom) and choke (top) cables to the engine (Fig. 0812). A B Fig 0810 PICT-0304 Fig 0812 A. Choke PICT-0309 B. Throttle 29. Remove the nut and the positive (red) cable from the starter (Fig. 0811). 31. Remove the throttle and choke cables from the cable clamps and disconnect the z-bends from the control linkage (Fig. 0813).
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ENGINE 32. Remove the nut, harness ground wires and negative (black) battery cable and star washer from the rear right engine mounting bolt (Fig. 0814). 34. Unplug the pink wire from the green fuel solenoid wire (Fig. 0816). Note: The bolt will fall through the chassis when the nut is removed. Fig 0816 Fig 0814 PICT-0314 5 PICT-0316a 35. Unplug the white wire from the black magneto wire (Fig. 0817). 33. Unplug the violet wire from the ignition module on the engine (Fig. 0815).
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ENGINE 36. Remove the remaining 3 engine mounting bolts and nuts securing the engine to the chassis (Fig. 0818). Fig 0818 3. Insert the rear right engine mounting bolt up through the chassis and engine mounting hole. Install the star washer, harness ground wires and negative (black) battery cable onto the bolt. Loosely install the nut onto the bolt (Fig. 0820). PICT-0319 Fig 0820 38. Carefully lift the engine off the chassis. Engine Installation - Pistol Grip Hydro PICT-0321a 5 4.
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ENGINE 5. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs. (19.7 + 2.8 Nm) (Fig. 0822). Fig 0822 5 PICT-0324 6. Plug the white wire into the black magneto wire (Fig. 0823). Fig 0823 5-10 PICT-0326a 7. Plug the pink wire into the green fuel solenoid wire (Fig. 0824). Fig 0824 PICT-0327 8. Plug the violet wire into the ignition module on the engine (Fig. 0825).
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ENGINE 9. Secure the positive (red) cable to the starter (Fig. 0826). Fig 0826 PICT-0268a 10. Hook the z-bend of the choke cable to the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0827). 11. Move the choke control knob to the “open” position (Fig. 0828). Fig 0828 12. Ensure the carburetor choke plate is fully open (Fig. 0829).
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ENGINE 13. Pull the outer housing of the choke cable until the inner wire has almost no slack and tighten the cable clamp bolt (Fig. 0830). 15. Ensure the carburetor choke plate is fully closed (Fig. 0832). Fig 0832 Fig 0830 5 PICT-0335 PICT-0334 14. Move the choke control knob to the “choke“ position (Fig. 0831). 16. Make sure the choke plate turns from the fully closed position to the fully open position when actuating the choke control knob. 17.
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ENGINE 18. Move the throttle control knob to the “fast” position (Fig. 0834). Fig 0834 20. Move the throttle control knob to the “slow“ position. Ensure the carburetor throttle plate moves smoothly (Fig. 0836). PICT-0339 Fig 0836 PICT-0342a 19. Pull the outer housing of the throttle cable until the inner wire has almost no slack and tighten the cable clamp bolt (Fig. 0835). 21. Apply anti-seize compound to the engine crankshaft (Fig. 0837).
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ENGINE 22. Install the square key into the engine crankshaft keyway (Fig. 0838). Fig 0838 24. Route the hydro drive belt around the engine crankshaft pulley, idler pulley and hydro pulleys (Fig. 0840). PICT-0304 Fig 0840 5 23. Slide the drive pulley onto the engine crankshaft. Ensure that the long side of the hub is installed toward the engine (Fig. 0839). Fig 0839 5-14 PICT-0303 PICT-0348a 25. Using a spring removal tool (Toro P/N 92-5771), install the hydro drive idler spring (Fig. 0841).
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ENGINE 26. Ensure the 2 cupped washers are installed on the clutch bolt with the crown side facing the bolt head (Fig. 0842). 28. Slide the electric clutch onto the engine crankshaft (Fig. 0844). Fig 0844 Fig 0842 27. Apply thread locking compound to the clutch bolt (Fig. 0843). 29. Install the clutch bolt, 2 spring washers and flat washer into the engine crankshaft (Fig. 0845).
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ENGINE 30. Torque the clutch bolt to 55 + 5 ft-lbs. (74.5 + 6.8 Nm) (Fig. 0846). Fig 0846 5 PICT-0356a 31. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the chassis (Fig. 0847). 32. Feed the cutch harness plug up through the chassis (Fig. 0848). Fig 0848 33. Install the rubber grommet into the frame (Fig. 0849).
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ENGINE 34. Route the PTO drive belt around the clutch. (Fig. 0850). 40”, 48” and 52” mower deck belt routing: Fig 0852 Fig 0850 fig. 104-8186 PICT-0364a Note: Ensure the PTO drive belt is routed properly around the mower deck pulley(s). Refer to belt routing decal (Fig. 0851 and Fig. 0852). 35. Install the idler arm spring to the spring post (Fig. 0853). 5 36” mower deck belt routing: Fig 0853 Fig 0851 Floating Deck Mid-Size Service Manual PICT-0365 fig.
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ENGINE 36. Install the trailing shield into the chassis by first inserting the right side of the trailing shield rod (bent at a 90º angle) into the hole in the chassis and then insert the left end of the trailing shield rod (bent at a 45º angle) into the hole in the chassis (Fig. 0854). 39. Replace the carrier frame cover (Fig. 0856). Fig 0856 Fig 0854 5 PICT-0273 PICT-0280 40. Plug the clutch connector into the harness connector (Fig. 0857). 37. Lower the machine. 38.
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ENGINE 41. Install the fuel line to the fuel pump (Fig. 0858). Fig 0858 43. Install the bolt that secures the fuel line R-clamp to the engine (Fig. 0860). PICT-0370 Fig 0860 42. Slide the hose clamp to the fuel line where it connects to the fuel pump (Fig. 0859). PICT-0259 44. Fill the engine crankcase with oil per engine specifications. 45. Place the battery onto the battery tray (Fig. 0861).
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ENGINE 46. Install the battery hold down and secure with 2 nuts. Do not over-tighten (Fig. 0862). Fig 0862 48. Connect the negative (black) battery cable to the negative battery terminal and cover with the boot. (Fig. 0864). PICT-0372a Fig 0864 5 47. Connect the positive (red) battery cable to the positive battery terminal and cover with the boot (Fig. 0863). PICT-0250 Muffler Guard There is a muffler guard included on international models (Fig. 0865 and Fig.
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ENGINE 3. Remove the fuel line by sliding the clamp away from the fuel pump (Fig. 0868). C B C A D Fig 0866 A. Muffler guard B. Muffler guard bracket PICT-1493 C. Screw (5) D. Nut (5) Fig 0868 Engine Removal - Gear Drive PICT-1347 4. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 0869). 1. Turn the engine off and remove the key from the ignition. 2. Turn the fuel valve to the off position (Fig. 0867).
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ENGINE 5. Remove the R-clamp that secures the fuel line to the right side of the engine (Fig. 0870). Fig 0870 7. Place a drain pan below the end of the drain hose and rotate the oil drain valve to allow the oil to drain from the engine (Fig. 0872). PICT-1351 Fig 0872 5 6. Attach the oil drain hose to the oil drain valve (Fig. 0871). PICT-1354 8. When the oil has drained completely, close the drain valve and remove the drain hose. 9. Unplug the clutch from the wire harness (Fig. 0873).
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ENGINE 10. Push the clutch wire plug and grommet through the engine deck frame (Fig. 0874). 12. Remove the mower deck belt cover(s) (Fig. 0876). Fig 0876 Fig 0874 PICT-1360 PICT-1357 11. Remove the carrier frame cover (Fig. 0875). 13. Roll the deck drive belt off the fixed/center mower deck pulley (Fig. 0877).
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ENGINE 14. Raise the machine so that the underside of the frame can be accessed. 17. Remove the belt from around the clutch (Fig. 0880). 15. Remove the trailing shield from the frame by first removing the left end of the shield rod (bent at a 45 degree angle) from the hole in the frame and then remove the right side of the shield rod (bent at 90 degree angle) from the right side of the frame (Fig. 0878). Fig 0880 PICT-1365a 18.
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ENGINE 19. Loosen the clutch bolt (Fig. 0882). Fig 0882 21. Unhook the traction drive belt idler spring from the tab on the frame (Fig. 0884). PICT-1369 Fig 0884 20. Remove the bolt, 2 spring washers and flat washer securing the clutch to the engine crankshaft. Slide the clutch off the engine crankshaft (Fig. 0883). 22. Remove the drive belt from the pulleys (Fig. 0885).
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ENGINE 23. Slide the drive pulley off the crankshaft (Fig. 0886). 25. Lower the machine. 26. At the front of the engine, loosen the cable clamps securing the throttle (bottom) and choke (top) cables to the engine (Fig. 0888). A Fig 0886 B PICT-1379 24. Remove the key from the crankshaft keyway (Fig. 0887). Fig 0888 A. Choke 5 PICT-1382 B. Throttle 27. Remove the throttle and choke cables from the cable clamps and disconnect the z-bends from the control linkage (Fig. 0889).
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ENGINE 28. Unplug the pink wire from the red engine rectifier wire (Fig. 0890). 30. Remove the nut, harness ground wire and lock washer from the rear left engine mounting bolt (Fig. 0892). Note: The bolt will fall through the frame when the nut is removed. Fig 0890 PICT-1389a 29. Unplug the white wire from the black magneto wire (Fig. 0891). Fig 0892 PICT-1393 5 31. Remove the remaining 3 engine mounting bolts and nuts that secure the engine to the frame (Fig. 0893).
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ENGINE 4. Loosely install the other 3 engine mounting bolts and nuts securing the engine to the frame. Torque all 4 engine mounting bolts to 14.5 + 2 ft-lbs. (19.7 + 2.8 Nm) (Fig. 0896). Engine Installation - Gear Drive 1. Position the engine onto the frame. 2. Apply thread locking compound to the threads of all 4 engine mounting bolts (Fig. 0894). Fig 0896 Fig 0894 PICT-1398 PICT-1396 5 5. Plug the white wire into the black magneto wire (Fig. 0897). 3.
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ENGINE 6. Plug the pink wire into the red engine rectifier wire (Fig. 0898). Fig 0898 PICT-1389a 7. Hook the z-bend of the choke cable into the choke control lever and loosely clamp the outer housing of the choke cable into the cable clamp (Fig. 0899). 8. Move the choke control knob to the “open” position (Fig. 0900). Fig 0900 9. Ensure the carburetor choke plate is fully open (Fig. 0901).
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ENGINE 10. Pull the outer housing of the choke cable until the inner wire has almost no slack and tighten the cable clamp (Fig. 0902). 12. Ensure the carburetor choke plate is fully closed (Fig. 0904). Fig 0904 Fig 0902 5 PICT-1401 PICT-1402 11. Move the choke control knob to the “choke“ position (Fig. 0903). 13. Make sure the choke plate turns from the fully closed position to the fully open position when actuating the choke control knob. 14.
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ENGINE 15. Move the throttle control knob to the “fast” position (Fig. 0906). Fig 0906 PICT-1404a 16. Pull the outer housing of the throttle cable until the inner wire has almost no slack and tighten the cable clamp (Fig. 0907). 17. Move the throttle control knob to the “slow“ position. Ensure the throttle moves smoothly (Fig. 0908). Fig 0908 PICT-1405a 18. Raise the machine to access the underside of the frame. 19. Apply anti-seize compound to the crankshaft (Fig. 0909).
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ENGINE 20. Install the key into the crankshaft keyway (Fig. 0910). Fig 0910 Note: The drive pulley casting indicates the orientation of the pulley on the crankshaft (Fig. 0912). PICT-1381 Fig 0912 PICT-1408a 21. Slide the drive pulley onto the crankshaft (Fig. 0911). 22. Route the traction drive belt around the drive pulleys (Fig. 0913).
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ENGINE 23. Hook the traction drive belt idler spring to the tab on the frame (Fig. 0914). Fig 0914 PICT-1376 24. Slide the flat washer and 2 spring washers onto the clutch bolt (Fig. 0915): 25. Apply thread locking compound to the clutch bolt threads (Fig. 0916). Fig 0916 PICT-1411 26. Slide the clutch onto to the crankshaft (Fig. 0917). 5 Note: Ensure the 2 spring washers are installed on the clutch bolt with the crown side facing the bolt head.
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ENGINE 27. Install the clutch bolt assembly into the crankshaft to secure the clutch. Torque the clutch bolt to 55 + 5 ft-lbs. (74.6 + 6.8 Nm) (Fig. 0918). 29. Install the rubber grommet into the frame (Fig. 0920). Fig 0920 Fig 0918 5 28. Feed the clutch harness plug up through the frame (Fig. 0919). Fig 0919 5-34 PICT-1418 PICT-1412 PICT-1415 30. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0921).
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ENGINE 31. Route the deck drive belt around the clutch (Fig. 0922). Fig 0922 33. Install the trailing shield into the frame by first inserting the right side of the trailing shield rod (bent at a 90 degree angle) into the hole in the chassis and then insert the left end of the trailing shield rod (bent at a 45 degree angle) into the hole in the chassis (Fig. 0924). PICT-1365a 32. Install the idler arm spring to the spring post (Fig. 0923). Fig 0924 PICT-1362 5 34. Lower the machine. 35.
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ENGINE Note: Ensure the deck drive belt is routed properly around the mower deck pulley(s). Refer to belt routing decal (Fig. 0926): 37. Install the carrier frame cover (Fig. 0928). Fig 0928 Fig 0926 PICT-1358 fig. 104-8185 38. Plug the clutch connector into the harness connector (Fig. 0929). 5 36. Install the mower deck belt cover(s) (Fig. 0927).
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ENGINE 39. Install the fuel line to the fuel pump. Slide the hose clamp into place to secure the hose to the fuel pump (Fig. 0930). Fig 0930 PICT-1347 41. Secure the fuel line to the engine by installing a bolt through the R-clamp (Fig. 0931). Fig 0931 5 PICT-1351 42. Fill the crankcase with oil per the engine specifications. 43. Fill the fuel tank with gas.
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ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
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HYDROSTATIC DRIVE SYSTEM Hydro Drive Transmission Traction Belt Replacement 3. Push the grommet and clutch plug through the frame to the underside of the machine (Fig. 0934). Hydro Drive Transmission Traction Belt Removal 1. Move the negative battery terminal boot and disconnect the negative (black) battery cable from the battery (Fig. 0932). Fig 0934 PICT-0277 4. Remove the carrier frame cover (Fig. 0935). Fig 0932 PICT-0250 6 2. Unplug the PTO clutch wire from the harness connector (Fig. 0933).
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HYDROSTATIC DRIVE SYSTEM 5. Roll the PTO drive belt off the center mower deck pulley (Fig. 0936). Fig 0936 PICT-0283 6. Raise the machine so that the underside of the frame can be accessed. 6 8. Remove the idler arm spring from the spring post (Fig. 0938). Fig 0938 PICT-0291a 9. Remove the belt from the clutch (Fig. 0939). 7.
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HYDROSTATIC DRIVE SYSTEM 10. Remove the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the chassis (Fig. 0940). 12. Remove the bottom bolt, nut and spacer securing the right hand side plate to the frame (Fig. 0942). Fig 0942 Fig 0940 PICT-0562 PICT-0295 11. Unhook the hydro idler pulley spring from the tab on the chassis (Fig. 0941). 13.
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HYDROSTATIC DRIVE SYSTEM 14. Remove the hydro drive belt (Fig. 0944). Fig 0944 2. Tighten the nut and shoulder bolt securing the idler bracket to the frame (Fig. 0946). PICT-0564 Fig 0946 Hydro Drive Transmission Traction Belt Installation PICT-0563 3. Install the bolt, spacer and nut securing the bottom of the right side plate to the frame (Fig. 0947). 1. Route the hydro drive belt around the pulleys as shown (Fig. 0945): Note: The spring and clutch have been removed for photo purposes.
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HYDROSTATIC DRIVE SYSTEM 4. Install the bolt, nut, 2 washers and spacer securing the brake clutch strap to the underside of the frame (Fig. 0948). 6. Install the rubber grommet into the frame (Fig. 0950). Fig 0950 Fig 0948 PICT-0363 PICT-0361 7. Plug the PTO clutch wire into the harness connector (Fig. 0951). 5. Feed the cutch harness plug up through the frame (Fig. 0949).
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HYDROSTATIC DRIVE SYSTEM 8. Install the hydro idler spring to the spring post (Fig. 0952). Fig 0952 PICT-0565 9. Route the PTO drive belt around the clutch (Fig. 0953). 10. Install the PTO idler spring to the spring post on the frame (Fig. 0954). Fig 0954 PICT-0291a 11.
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HYDROSTATIC DRIVE SYSTEM 12. Lower the machine. 13. Roll the PTO drive belt onto the center mower deck pulley (Fig. 0956). 15. Connect the negative (black) battery cable to the negative battery terminal and cover the connection with the boot (Fig. 0958). Fig 0958 Fig 0956 PICT-0250 PICT-0283 Hydro Idler Replacement 14. Install the carrier frame cover (Fig. 0957). Hydro Idler Removal 1. Turn the engine off and remove the key from the ignition. 2.
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HYDROSTATIC DRIVE SYSTEM 3. Remove the flanged shoulder bolt and nut securing the idler lever assembly to the frame (Fig. 0960). Fig 0960 PICT-0576 4. Remove the idler assembly from the frame (Fig. 0961). 5. Remove the spring from the idler lever assembly (Fig. 0962). Fig 0962 PICT-0579 6. Remove the nut from the bolt securing the pulley to the idler lever (Fig. 0963).
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HYDROSTATIC DRIVE SYSTEM 7. Remove the bolt, washer, pulley, and spacer from the idler lever (Fig. 0964). Hydro Idler Installation 1. Slide the washer onto the bolt. Insert the bolt through the flush face side of the pulley (Fig. 0966). Fig 0964 PICT-0583 Fig 0966 8. Inspect the bearing and bushings in the pulley and idler lever. If worn or damaged they must be replaced. PICT-0593 2. Slide the spacer onto the bolt (Fig. 0967). Hydro Idler Assembly (Fig. 0965).
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HYDROSTATIC DRIVE SYSTEM 3. Slide the idler lever onto the bolt (Fig. 0968). Fig 0968 PICT-0596 4. Install a nut to secure the hydro idler pulley assembly to the lever (Fig. 0969). 5. Hook the spring onto the idler lever (Fig. 0970). Fig 0970 PICT-0579 6. Position the idler assembly up to the frame (Fig. 0971).
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HYDROSTATIC DRIVE SYSTEM 7. Route the hydro drive belt around the idler pulley (Fig. 0972). Fig 0972 9. Using a spring removal tool (Toro part number 925771), hook the hydro idler spring to the tab on the frame (Fig. 0974). PICT-0598 Fig 0974 8. Install the flanged shoulder bolt and nut securing the idler lever assembly to the frame and tighten (Fig. 0973). PICT-0573 Hydraulic Pump Replacement Note: Cleanliness is a key factor in a successful repair of any hydraulic system.
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HYDROSTATIC DRIVE SYSTEM 4. Loosen the two pulley hub set screws (Fig. 0977). Hydraulic Pump Removal 1. Clean the area around the pump and hydraulic fittings to prevent dirt and debris from entering the system. 2. Remove the idler spring to relieve tension from the hydro drive belt (Fig. 0975). Fig 0977 PICT-0405a 5. Slide the pulley off the hydraulic pump shaft (Fig. 0978). Fig 0975 PICT-0402 3. Slip the hydro drive belt off the pulley (Fig. 0976).
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HYDROSTATIC DRIVE SYSTEM 6. The pulley key may fall out of the keyway or stay in. Remove the key if it did not fall out on its own (Fig. 0979). Fig 0979 PICT-0408 7. Inspect the key and replace if worn or damaged. 8. Remove the return line from the hydro pump fitting and drain the hydraulic fluid into a drain pan. Cap the hydraulic hose and fitting to prevent debris from entering the system. (Fig. 0980). 9. Remove the charge hose from the hydraulic pump fitting.
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HYDROSTATIC DRIVE SYSTEM 11. Unhook the lower end of the extension spring from the control shaft (Fig. 0983). Fig 0983 13. Loosen the set screws located in the control shaft. The lower set screw can be accessed through the opening in the frame (Fig. 0985). PICT-0427a Fig 0985 12. Remove the two mounting bolts and nuts securing the hydraulic pump to the frame (Fig. 0984). PICT-0430 14. Disconnect the pump from the control shaft and remove the pump from the frame (Fig. 0986).
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HYDROSTATIC DRIVE SYSTEM 15. Transfer all 4 fittings to the new pump as well as the mark indicating the location of one of the high pressure hydraulic hoses (Fig. 0987). Torque each fitting as noted: A Hydraulic Pump Installation 1. Position the pump into the frame so that the pump shaft is inserted into the control shaft (Fig. 0988). A B C D Fig 0987 PICT-0433a A. High pressure hose (2) (torque: 34-38 ft-lbs. (4651.5 Nm)) B: High pressure hose marking C: Charge hose fitting (torque: 7-10 ft-lbs. (9.
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HYDROSTATIC DRIVE SYSTEM 3. Install the 2 set screws into the control shaft (Fig. 0990). Fig 0990 PICT-0430 4. Hook the hydro pump spring to the bolt on the control shaft (Fig. 991). 5. Install 2 bolts and nuts securing the pump to the frame (Fig. 0992). Fig 0992 PICT-0429 6. Install the 2 high pressure hoses to the fittings on the pump (Fig. 0993). Note: Ensure that the marked hose is connected to the marked port on the pump.
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HYDROSTATIC DRIVE SYSTEM 7. Install the charge hose to the charge hose fitting (Fig. 0994). Fig 0994 PICT-0422a 8. Install the return line to the hydro pump fitting (Fig. 0995). 9. Apply anti-seize compound to the pump shaft (Fig. 0996). Fig 0996 PICT-0437 10. Install the key into the pump shaft keyway (Fig. 0997).
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HYDROSTATIC DRIVE SYSTEM 11. Apply thread locking compound onto the 2 pulley set screws. Thread the 2 set screws into the pulley hub (Fig. 0998). 13. Torque the 2 set screws to 11 + 1 ft-lbs. (14.9 + 1.4 Nm) (Fig. 1000). Fig 1000 Fig 0998 PICT-0440 PICT-0439 14. Position the drive belt onto the pulley (Fig. 1001). 12. Install the pump pulley onto the pump shaft and tighten the 2 set screws (Fig. 0999).
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HYDROSTATIC DRIVE SYSTEM 15. Install the idler spring onto the tab on the chassis (Fig. 1002). Wheel Motor Replacement Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
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HYDROSTATIC DRIVE SYSTEM 3. Remove the hub nut from the wheel motor shaft (Fig. 1004). 6. Release the parking brake. 7. Remove the wheel and tire assembly (Fig. 1006). Fig 1004 PICT-0443a Fig 1006 4. Raise the rear of the machine and secure with jack stands. PICT-0445a 8. Install a hub puller (Toro p/n TOR6006) onto the wheel studs (Fig. 1007). 5. Remove the 4 lug nuts (Fig. 1005).
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HYDROSTATIC DRIVE SYSTEM 9. Advance the forcing screw through the hub puller. Tighten the lug nuts down evenly until the hub pops off the wheel motor shaft (Fig. 1008). 12. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 13. Mark the hoses and corresponding wheel motor fitting ports so the hoses are reconnected back in their original locations (Fig. 1010). Fig 1008 PICT-0447 Fig 1010 PICT-0451 10. Remove the hub puller from the hub. 11.
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HYDROSTATIC DRIVE SYSTEM 16. Cap the hoses and wheel motor fittings so that debris does not enter the system. Position the hose ends out of the way of the wheel motor. 19. Remove the 2 fittings from the wheel motor (Fig. 1014). 17. Remove the 4 bolts securing the wheel motor to the motor mount (Fig. 1012). Fig 1014 Fig 1012 PICT-0454 PICT-0456 Wheel Motor Installation 1. Transfer the fittings and all markings to the replacement wheel motor. Torque the fittings to 85-95 ft-lbs. (115-129 Nm) (Fig.
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HYDROSTATIC DRIVE SYSTEM 2. Position the wheel motor into the frame (Fig. 1016). Fig 1016 4. Uncap the hoses and fittings and connect both hydraulic hoses to the wheel motor, following markings made previously. Torque the hose fittings to 34-38 ft-lbs. (46-52 Nm) (Fig. 1018). PICT-0455 Fig 1018 PICT-0453 3. Install 4 bolts to secure the wheel motor to the motor mount (Fig. 1017). 5. Install the woodruff key into the wheel motor shaft keyway (Fig. 1019).
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HYDROSTATIC DRIVE SYSTEM 6. Clean the hub and shaft to remove any grease or oil. Slide the hub onto the wheel motor shaft (Fig. 1020). 8. Slide the wheel and tire assembly onto the hub (Fig. 1022). Fig 1020 Fig 1022 PICT-0457 7. Loosely install the hub nut onto the wheel motor shaft (Fig. 1021). PICT-0460a 9. Snug fit the 4 lug nuts on the wheel hub studs (Fig. 1023).
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HYDROSTATIC DRIVE SYSTEM 10. Lower the machine so the rear tires are resting on the ground. 11. Apply the parking brake. 14. Fill the hydraulic reservoir tank with hydraulic fluid (15w-50 synthetic engine oil) as specified. Note that there are fill level lines inside of the reservoir (Fig. 1026). 12. Tighten and torque the 4 lug nuts to 85 + 8 ft-lbs. (115 + 11 Nm) (Fig. 1024). Fig 1026 Fig 1024 PICT-0382 PICT-0463a 15. Purge the hydraulic system. See “Bleeding the Hydraulic System” on page 6-32. 13.
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HYDROSTATIC DRIVE SYSTEM Hydraulic Reservoir Replacement Hydraulic Reservoir Removal Note: There is a hydraulic reservoir shield included on international models (Fig. 1027): 1. Remove the nuts and bolts securing the hydraulic reservoir to the frame (Fig. 1029). Fig 1027 PICT-2126 Use the hydraulic tank mounting hardware (2 bolts and nuts) to install the shield to the tank. Fig 1029 PICT-0383a 2. Remove the reservoir cap.
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HYDROSTATIC DRIVE SYSTEM 3. Remove the hydraulic lines from the bottom of the hydraulic reservoir tank (Fig. 1031). 5. Remove the fitting from the reservoir. (Fig. 1033). Fig 1033 Fig 1031 PICT-0393a PICT-0388 4. Loosen the locking nut on the reservoir fitting. (Fig. 1032). 6. Repeat steps 4 and 5 to remove the second fitting from the reservoir. Hydraulic Reservoir Installation 1. Install two hydraulic fittings into the bottom of the reservoir. Orient as shown (Fig.
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HYDROSTATIC DRIVE SYSTEM 2. Tighten the locking nuts while maintaining the orientation of the fittings (Fig. 1035). Fig 1035 PICT-0396a 4. Install the two hydraulic hoses onto the reservoir fittings (Fig. 1037). Fig 1037 PICT-0436a 3. Position the reservoir assembly onto the mounting flange. Install 2 bolts and nuts securing the reservoir (Fig. 1036). 5. Fill the reservoir with hydraulic fluid (15w-50 synthetic engine oil) as specified.
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HYDROSTATIC DRIVE SYSTEM 3. Raise the rear of the machine and secure with jack stands. Hydraulic Testing Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 4. Release the parking brake. 5. Remove the 4 lug nuts and the wheel assembly (Fig. 1040).
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HYDROSTATIC DRIVE SYSTEM 8. Position a drain pan under the wheel motor. 12. Open the restriction valve all the way (counterclockwise) (Fig. 1044). 9. Disconnect both hydraulic hoses from the wheel motor (Fig. 1042). Fig 1044 Fig 1042 PICT-6886a PICT-0379 13. Run the machine for 2 minutes in forward (no load) to purge air from the system. 10. Cap the wheel motor fittings so debris does not enter the system. 11. Attach the hydraulic hoses to the flow test gauge (Fig. 1043).
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HYDROSTATIC DRIVE SYSTEM 17. After all necessary repairs have been made, reconnect the hydraulic hoses to the wheel motor fittings. 22. Fill the reservoir with hydraulic fluid (15w-50 synthetic engine oil) as specified. Note that there are fill level lines inside of the reservoir (Fig. 1047). 18. Slide the wheel and tire assembly onto the hub and snug fit the 4 lug nuts on the wheel hub studs (Fig. 1045). Fig 1047 Fig 1045 PICT-0382 PICT-0380 23. Release the parking brake. 19.
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HYDROSTATIC DRIVE SYSTEM Bleeding the Hydraulic System 1. Disengage the PTO. Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. These purge procedures should be implemented anytime a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.
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HYDROSTATIC DRIVE SYSTEM Checking the Hydraulic Lines After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Note: Keep areas around hydraulic system clean from grass and debris build up. !! Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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HYDROSTATIC DRIVE SYSTEM Hydraulic Schematic 6 Fig 1048 6-34 hyd scheme G006100 Floating Deck Mid-Size Service Manual
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GEAR DRIVE Traction Drive Belt Replacement 3. Push the clutch wire plug and grommet through the engine deck frame (Fig. 1050). Note: The trailing shield has been removed for photo purposes. Traction Drive Belt Removal 1. Remove the mower spindle drive belt. Refer to: “Mower Spindle Drive Belt Belt Removal (36” Mower Deck)” on page 8-4, or “Mower Spindle Drive Belt Belt Removal (40”, 48”, 52” and 60” Mower Decks)” on page 8-1. 2. Unplug the clutch from the wire harness (Fig. 1049).
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GEAR DRIVE 5. Unhook the gear drive idler spring from the tab on the frame (Fig. 1052). Traction Drive Belt Installation Note: The trailing shield has been removed for photo purposes. 1. Route the traction drive belt around the pulleys (Fig. 1054). A B C H D Fig 1052 PICT-1443 G F 6. Remove the traction drive belt from around the pulleys and remove it from the machine (Fig. 1053). Fig 1054 A. B. C. D. E Clutch retainer Transmission belt Tension spring Driven pulley E. F. G. H. fig.
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GEAR DRIVE 7. Feed the clutch harness plug up through the chassis (Fig. 1056). Fig 1056 9. Install the bolt, nut, 2 washers and spacer to secure the brake clutch strap to the underside of the frame (Fig. 1058). PICT-1415 Fig 1058 8. Install the rubber grommet into the frame (Fig. 1057). PICT-1488 10. Plug the clutch into the wire harness (Fig. 1059). 7 Fig 1057 PICT-1417 Fig 1059 PICT-1422 11. Install the mower spindle drive belt.
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GEAR DRIVE 3. Remove the nut from the bolt securing the gear drive idler arm to the frame (Fig. 1061). Gear Drive Idler Replacement Note: The trailing shield has been removed for photo purposes. Gear Drive Idler Removal 1. Turn the engine off and remove the key from the ignition. 2. Unhook the drive belt idler spring from the tab on the frame (Fig. 1060). Fig 1061 PICT-1497 4. Remove the gear drive idler assembly out of the frame (Fig. 1062).
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GEAR DRIVE 5. Remove the shoulder bolt from the idler arm assembly (Fig. 1063). Fig 1063 PICT-1500a 6. Remove the spring from the idler arm (Fig. 1064). 7. Remove the nut from the bolt securing the idler pulley to the idler arm (Fig. 1065). Fig 1065 PICT-1502a 8. Remove the bolt and idler pulley from the idler arm (Fig. 1066).
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GEAR DRIVE 9. Remove the 2 flange bushings from the idler arm (Fig. 1067). Fig 1067 2. Install the pulley to the idler arm with a bolt and nut. The pulley hub is installed facing the idler arm (Fig. 1069). PICT-1506a Fig 1069 PICT-1504a Gear Drive Idler Installation 3. Install the idler spring onto the idler arm (Fig. 1070). 1. Install 2 flange bushings into the idler arm pivot (Fig. 1068).
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GEAR DRIVE 4. Insert the shoulder bolt into the idler arm pivot and position the idler assembly into the frame (Fig. 1071). 6. Hook the drive belt idler spring to the tab on the frame (Fig. 1073). Fig 1073 Fig 1071 PICT-1496 PICT-1499 5. Install a nut onto the shoulder bolt securing the idler assembly to the frame (Fig. 1072). Transmission Driven Pulley Replacement Note: The trailing shield has been removed for photo purposes. Transmission Driven Pulley Removal 1.
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GEAR DRIVE 3. Unhook the drive belt idler spring from the tab on the frame (Fig. 1074). Fig 1074 PICT-1496 4. Remove the nut from the bolt securing the gear drive idler arm to the frame (Fig. 1075). 5. Remove the gear drive idler assembly out of the frame (Fig. 1076). Fig 1076 PICT-1499 6. Remove the drive belt from the transmission driven pulley (Fig. 1077).
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GEAR DRIVE 7. Remove the retaining ring from the end of the transmission drive shaft (Fig. 1078). Fig 1078 PICT-1510 8. Loosen the set screw securing the transmission driven pulley to the transmission driveshaft (Fig. 1079). 9. Slide the driven pulley off the transmission drive shaft (Fig. 1080). Fig 1080 PICT-1512 10. Remove the key from the transmission driveshaft keyway (Fig. 1081).
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GEAR DRIVE 11. Remove the set screw from the driven pulley (Fig. 1082). Fig 1082 PICT-1515 Transmission Driven Pulley Installation 2. Insert the key into the keyway on the transmission driveshaft (Fig. 1084). Fig 1084 PICT-1566 3. Apply thread locking compound to the driven pulley set screw (Fig. 1085). 1. Apply anti-seize to the transmission driveshaft (Fig. 1083).
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GEAR DRIVE 4. Begin threading the set screw into the driven pulley hub (Fig. 1086). Fig 1086 6. Tighten the set screw securing the transmission driven pulley to the transmission driveshaft (Fig. 1088). PICT-1518 Fig 1088 5. Slide the driven pulley onto the transmission drive shaft (Fig. 1087). PICT-1511 7. Install a retaining ring onto the end of the transmission drive shaft (Fig. 1089).
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GEAR DRIVE 8. Install the drive belt onto the transmission driven pulley (Fig. 1090). Fig 1090 10. Install a nut onto the bolt securing the gear drive idler assembly to the frame (Fig. 1092). PICT-1575 9. Position the gear drive idler assembly into of the frame with the bolt inserted through the mounting hole (Fig. 1091). Fig 1092 PICT-1497 11. Hook the gear drive idler spring to the spring tab on the frame (Fig. 1093). 7 Fig 1093 Fig 1091 PICT-1496 PICT-1499 12. Lower the machine.
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GEAR DRIVE 4. Remove the nut from the bolt securing the gear drive idler arm to the frame (Fig. 1095). Gear Drive Transmission Replacement Note: The trailing shield has been removed for photo purposes. Gear Drive Transmission Removal 1. Turn the engine off and remove the key from the ignition. 2. Raise the machine to access the underside of the frame. 3. Unhook the gear drive idler spring from the tab on the frame (Fig. 1094). Fig 1095 PICT-1497 5.
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GEAR DRIVE 6. Remove the drive belt from the transmission driven pulley (Fig. 1097). Fig 1097 8. Loosen the set screw securing the transmission driven pulley to the transmission driveshaft (Fig. 1099). PICT-1575 Fig 1099 7. Remove the retaining ring from the end of the transmission drive shaft (Fig. 1098). PICT-1511 9. Slide the driven pulley off the transmission driveshaft (Fig. 1100).
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GEAR DRIVE 10. Remove the key from the transmission driveshaft keyway (Fig. 1101). 14. Loosen the idler support bracket pivot bolt (Fig. 1103). Fig 1103 Fig 1101 PICT-1520 PICT-1513 15. Rotate the idler support bracket so that it is out of the way of the transmission pulley (Fig. 1104). 11. Lower the machine. 12. Release the parking brake. 13. Remove the 3 lower idler support mounting bolts (Fig. 1102).
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GEAR DRIVE 16. Remove the wheel drive belt from the transmission pulley (Fig. 1105). Fig 1105 18. Slide the transmission pulley/output shaft assembly away from the transmission and out of the frame (Fig. 1107). PICT-1524 Fig 1107 17. Remove the 2 bolts and nuts securing the transmission axle flange bearing to the frame (Fig. 1106). PICT-1554 19. Remove the coupler and coupler guard from the transmission splined shaft (Fig. 1108).
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GEAR DRIVE 20. Remove the 2 bolts and nuts that secure the opposite transmission axle flange bearing to the frame (Fig. 1109). 22. Remove the transmission from the frame by rocking it backward and pulling the transmission from the remaining coupler assembly (Fig. 1111). Note: The coupler may come off of the axle with the transmission. If so, remove it from the transmission and replace it onto the axle. Fig 1109 PICT-1536 21. Remove the 4 transmission mounting bolts and lock washers (Fig. 1110).
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GEAR DRIVE 24. Remove the shift plate assembly from the transmission (Fig. 1113). 26. Remove the shift lever and washer from the transmission shifter shaft (Fig. 1115). Note: For transmission service procedures, refer to the appropriate Tecumseh Peerless Service Manual. Fig 1113 PICT-5060 25. Remove the bolt and Belleville washer securing the shift lever to the transmission (Fig. 1114). Fig 1115 PICT-5070a Gear Drive Transmission Installation 1.
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GEAR DRIVE 2. Install the Belleville washer oriented with the crown up (Fig. 1117). Fig 1117 PICT-5077a 3. Install the nut to secure the shift lever and washers to the transmission shifter post. Torque the nut to 30 – 35 ft-lbs. (40.67 – 47.45 Nm) (Fig. 1118). 4. Position the shift plate assembly over the shift lever and onto the transmission (Fig. 1119). Fig 1119 PICT-5081 5. Install 4 bolts to secure the shift plate to the transmission (Fig. 1120).
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GEAR DRIVE 6. Slide the transmission splined shaft into the RH coupler assembly. Position the transmission so that the output shaft drops through the opening in the frame (Fig. 1121). 8. Install 4 transmission mounting bolts and lock washers securing the transmission to the frame (Fig. 1123). Fig 1123 Fig 1121 PICT-1534 PICT-1549 7. Install 2 bolts and nuts to secure the flange bearing to the frame (Fig. 1122). 9. Slide the coupler and coupler guard onto the transmission splined shaft (Fig. 1124).
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GEAR DRIVE 10. Slide the transmission pulley/output shaft assembly through the frame and into the coupler assembly (Fig. 1125). Note: Relubricate the shafts, if needed (Fig. 1127). Fig 1127 Fig 1125 PICT-1553a PICT-1554 12. Route the wheel drive belt around the transmission pulley (Fig. 1128). 11. Install 2 bolts and nuts securing the transmission axle flange bearing to the frame (Fig. 1126).
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GEAR DRIVE 13. Rotate the idler support bracket back in place so that the mounting holes line up with the holes in the frame (Fig. 1129). 15. Tighten the idler support bracket pivot bolt (Fig. 1131). Fig 1131 Fig 1129 PICT-1520 PICT-1555 14. Loosely install 3 idler support bracket mounting bolts and nuts (Fig. 1130). 16. Tighten the 3 lower idler support bracket mounting bolts (Fig. 1132).
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GEAR DRIVE 17. Raise the machine to access the underside of the frame. 20. Apply thread locking compound to the driven pulley set screw (Fig. 1135). 18. Apply anti-seize to the transmission driveshaft (Fig. 1133). Fig 1135 Fig 1133 PICT-1567a PICT-1564 21. Begin threading the set screw into the driven pulley hub (Fig. 1136). 19. Insert the key into the keyway on the transmission driveshaft (Fig. 1134).
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GEAR DRIVE 22. Slide the driven pulley onto the transmission drive shaft (Fig. 1137). Fig 1137 PICT-1571 23. Tighten the set screw securing the transmission driven pulley to the transmission driveshaft (Fig. 1138). 24. Install a retaining ring onto the end of the transmission drive shaft (Fig. 1139). Fig 1139 PICT-1510 25. Route the drive belt onto the transmission driven pulley (Fig. 1140).
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GEAR DRIVE 26. Insert the shoulder bolt into the idler arm pivot and position the idler assembly into the frame (Fig. 1141). 28. Hook the gear drive idler spring to the spring tab on the frame (Fig. 1143). Fig 1143 Fig 1141 PICT-1496 PICT-1499 29. Lower the machine. 27. Install a nut onto the bolt securing the gear drive idler arm to the frame (Fig. 1142).
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GEAR DRIVE THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECKS 4. Rotate the belt guide out of the way of the PTO drive belt (Fig. 1146). Mower Spindle Drive Belt Replacement Mower Spindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) 1. Turn the ignition off and remove the key. Set the parking brake. 2. Remove the carrier frame cover (Fig. 1144). Fig 1146 PICT-1024a 5. Roll the PTO drive belt off the center spindle pulley (Fig. 1147). Fig 1144 PICT-1038 3. Loosen the nut securing the center spindle belt guide to the mower deck (Fig. 1145).
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MOWER DECKS 6. Remove the right and left belt covers (Fig. 1148). Fig 1148 PICT-1039 7. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring from the spring plate (Fig. 1149). 8. Remove the mower spindle drive belt (Fig. 1150). Fig 1150 PICT-1043 Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) 1. Route the mower spindle drive belt around the mower deck pulleys. Refer to the deck routing decal (Fig. 1151): Fig 1149 8 PICT-1042 Fig 1151 8-2 fig.
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MOWER DECKS 2. Using a spring removal tool (Toro p/n: 92-5771), hook the idler spring to the spring plate (Fig. 1152). Fig 1152 4. Ensure the PTO drive belt is routed around the clutch pulley and the idler pulley. Roll the PTO drive belt onto the center spindle pulley (Fig. 1154 and Fig. 1155). PICT-1042 Fig 1154 PICT-1030a Fig 1155 PICT-1026a 3. Install the right and left belt covers (Fig. 1153).
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MOWER DECKS 5. Rotate the belt guide into place so that it is approximately 1/8” (3mm) away from the PTO drive belt (Fig. 1156). 7. Install the carrier frame cover (Fig. 1158). Fig 1158 Fig 1156 PICT-1022 PICT-1031 6. Tighten the nut securing the center spindle belt guide to the mower deck (Fig. 1157). Mower Spindle Drive Belt Removal (36” Mower Deck) 1. Remove the PTO drive belt. Refer to “PTO Drive Belt Removal” on page 8-8. 2. Unhook the idler spring from the spring post (Fig. 1159).
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MOWER DECKS 3. Remove the mower deck belt from around pulleys and remove it from the machine (Fig. 1160). 2. Hook the idler spring to the spring post (Fig. 1162). Fig 1162 Fig 1160 PICT-1448 PICT-1449 Mower Spindle Drive Belt Installation (36” Mower Deck) 3. Install the PTO drive belt. Refer to “PTO Drive Belt Installation” on page 8-9. 1. Route the mower spindle drive belt around the pulleys. Refer to the belt routing decal (Fig. 1161). 8 Fig 1161 Floating Deck Mid-Size Service Manual fig.
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MOWER DECKS 5. Rotate the belt guide out of the way of the PTO drive belt (Fig. 1165). PTO Drive Belt Replacement PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) 1. Turn the ignition off and remove the key. 2. Set the parking brake. 3. Remove the carrier frame cover (Fig. 1163). Fig 1165 PICT-1024a 6. Roll the PTO drive belt off the center spindle pulley (Fig. 1166). Fig 1163 PICT-1038 4. Loosen the nut securing the center spindle belt guide to the mower deck (Fig. 1164).
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MOWER DECKS 7. Raise the machine to access the underside. 8. Remove the PTO drive belt from around the clutch pulley and the idler pulley and remove it from the machine (Fig. 1167). Fig 1167 PICT-1028 PTO Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) 3. Lower the machine to access the top of the mower deck. 4. Roll the PTO drive belt onto the center spindle pulley (Fig. 1169). Fig 1169 PICT-1026a 5.
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MOWER DECKS 6. Tighten the nut securing the center spindle belt guide to the mower deck (Fig. 1171). PTO Drive Belt Removal (36” Mower Decks) 1. Turn the ignition off and remove the key. Set the parking brake. 2. Remove the carrier frame cover (Fig. 1173). Fig 1171 PICT-1023a 7. Install the carrier frame cover (Fig. 1172). Fig 1173 PICT-1358 3. Remove the mower deck belt cover (Fig. 1174).
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MOWER DECKS 4. Roll the deck drive belt off the fixed (center) mower deck pulley (Fig. 1175). Fig 1175 PICT-1361 5. Raise the machine to access the underside. 6. Remove PTO belt idler pulley spring from frame bolt (Fig. 1176). 7. Remove the belt from the clutch pulley and remove it from the machine (Fig. 1177). Fig 1177 PICT-1365a PTO Drive Belt Installation (36” Mower Decks) 1. Raise the machine to access the underside. 2. Route the deck drive belt around the clutch pulley (Fig. 1178).
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MOWER DECKS 3. Install the PTO belt idler pulley spring onto the frame bolt (Fig. 1179). 6. Roll the PTO drive belt onto the fixed (center) mower deck pulley (Fig. 1181). Fig 1179 Fig 1181 PICT-0287 4. Lower the machine. PICT-1361 7. Install the mower deck belt cover (Fig. 1182). 5. Route the spindle drive belt around the pulleys. Refer to the belt routing decal (Fig. 1180). Fig 1182 8 Fig 1180 8-10 PICT-1360 fig.
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MOWER DECKS 8. Install the carrier frame cover (Fig. 1183). Fig 1183 2. Install a blade stop to secure the blade (Fig. 1184). PICT-1358 Spindle Replacement and Service Fig 1184 PICT-1185 3. Support the blade/spindle shaft assembly and remove the spindle nut (Fig. 1185). Spindle Removal and Teardown 1.
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MOWER DECKS 4. Slide the blade/spindle shaft assembly out of the spindle housing (Fig. 1186). 6. Remove the pulley assembly (Fig. 1188). Fig 1188 Fig 1186 PICT-1190 PICT-1188 7. Remove the bearing shield (Fig. 1189). 5. Remove the washer (Fig. 1187).
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MOWER DECKS 8. Remove the 6 nuts securing the spindle housing to the mower deck (Fig. 1190). 10. Remove the blade bolt, washer and the blade from the spindle shaft (Fig. 1192). Note: There may be a spring plate installed on one of the spindle bolts. Fig 1192 Fig 1190 PICT-1197 PICT-1192 Note: 36” and 52” mower decks have a blade stiffener (Fig. 1193). 9. While supporting the housing, remove the 6 selftapping bolts securing the spindle housing to the mower deck.
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MOWER DECKS 11. Remove the 2 bearings and the spacer from the spindle housing (Fig. 1194). Spindle Rebuild and Installation 1. Install a bearing into one side of the spindle housing (Fig. 1196). Fig 1194 PICT-1203 Fig 1196 PICT-1208 12. Clean and inspect the housing, bearings and spacer for wear and damage. Replace as necessary. 2. Insert the spacer into the spindle housing (Fig. 1197). Spindle Assembly (Fig. 1195) A B C B 8 D Fig 1195 A. B. C. D.
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MOWER DECKS 3. Install a bearing into the other side of the spindle housing (Fig. 1198). Fig 1198 PICT-1211 4. Insert the spindle shaft into the spindle housing assembly (Fig. 1199). 5. Slide the bearing shield onto the spindle shaft (Fig. 1200). Fig 1200 PICT-1214 6. Slide the pulley assembly onto the spindle shaft so the welded center bore of the pulley is facing away from the spindle housing (Fig. 1201). Note: If the spindle has a dual pulley, the smaller size pulley faced the spindle housing.
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MOWER DECKS 7. Slide a washer onto the spindle shaft (Fig. 1202). Fig 1202 9. Install the crowned blade bolt washer onto the blade bolt so the crown is toward the bolt head (Fig. 1204). PICT-1217 Fig 1204 PICT-1224 8. Install a nut onto the spindle shaft (Fig. 1203). 10. Install the blade bolt, washer and blade to the spindle shaft (Fig. 1205).
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MOWER DECKS Note: The “sails” of the blade should be pointing toward the spindle housing. 12. Torque the blade bolt to 85-110 ft-lbs. (115-149 Nm) (Fig. 1208). Note: 36” and 52” mower decks have a blade stiffener that should be installed between the crowned washer and the blade (Fig. 1206). Fig 1208 Fig 1206 PICT-1442 PICT-1231 13. Position the spindle and blade assembly into the mower deck from below and install 6 self-tapping screws to secure the spindle housing to the mower deck (Fig. 1209). 11.
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MOWER DECKS 14. If applicable, place the spring plate onto the selftapping screw shown (Fig. 1210): 16. Reinstall the drive belt or belts, as applicable. Refer to: • “Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks)” on page 8-2, or • “Mower Spindle Drive Belt Installation (36” Mower Deck)” on page 8-5 and • “PTO Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks)” on page 8-7 or • “PTO Drive Belt Installation (36” Mower Decks)” on page 8-9.
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MOWER DECKS 4. Remove the left belt cover (Fig. 1213). Fig 1213 6. Remove the spring from the idler arm assembly (Fig. 1215). PICT-1039 Fig 1215 5. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring from the spring plate (Fig. 1214). Fig 1214 Floating Deck Mid-Size Service Manual PICT-1042 PICT-1128 7. If the spring plate requires replacement, remove the nut securing it to the mower deck (Fig. 1216).
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MOWER DECKS 8. Remove the mower deck belt from around the idler pulley (Fig. 1217). 10. Remove the idler arm bolt and washer (Fig. 1219). Fig 1219 Fig 1217 9. Remove the nut from the bolt securing the idler arm to the mower deck (Fig. 1218). 11. Remove the idler arm assembly and washer from the mower deck (Fig. 1220).
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MOWER DECKS 12. Remove the nut and washer from the bolt securing the idler pulley to the idler arm (Fig. 1221). 14. Remove the bolt from the idler arm (Fig. 1223). Fig 1223 Fig 1221 PICT-1147 PICT-1143 15. Remove the spacer from the idler arm (Fig. 1224). 13. Remove the pulley and spacer from the idler arm assembly (Fig. 1222).
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MOWER DECKS 16. Remove the grease fitting from the idler arm (Fig. 1225). Idler Arm Assembly Installation (40”, 48”, 52” and 60” Mower Decks) 1. Press 2 flange bushings into either side of the idler arm pivot (Fig. 1227). Fig 1225 PICT-1149 17. Remove the 2 flange bushings from the idler arm pivot (Fig. 1226). Fig 1227 PICT-1153 2. Install a grease fitting into the idler arm (Fig. 1228).
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MOWER DECKS 3. Install the bolt into the idler arm (Fig. 1229). Fig 1229 5. Install the pulley onto the bolt with the hub installed toward the idler arm (Fig. 1231). PICT-1163a Fig 1231 PICT-1167a 4. Install a spacer onto the bolt (Fig. 1230). 6. Install a washer onto the bolt (Fig. 1232).
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MOWER DECKS 7. Install a nut onto the bolt (Fig. 1233). Fig 1233 9. Slide a washer onto the idler pivot bolt. Insert the bolt up through the mower deck (Fig. 1235). PICT-1170a Fig 1235 PICT-1173 8. Install the spacer into the idler arm pivot (Fig. 1234). 10. Slide a washer onto the bolt on the top side of the mower deck (Fig. 1236).
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MOWER DECKS 11. Slide the idler arm assembly pivot onto the bolt (Fig. 1237). Fig 1237 PICT-1177a 12. Install a nut onto the idler arm pivot bolt securing the idler arm to the mower deck (Fig. 1238). Fig 1238 13. Ensure the belt is routed properly on the mower deck. Refer to the belt routing decal (Fig. 1239): Fig 1239 14. If it was removed, position the spring plate onto the self-tapping bolt located next to left spindle pulley. Install a nut to secure the spring plate (Fig. 1240).
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MOWER DECKS 15. Hook the spring onto the idler arm (Fig. 1241). Fig 1241 17. Apply grease to the idler arm grease fitting (Fig. 1243). PICT-1128 Fig 1243 16. Using a spring removal tool (Toro p/n 92-5771), install the idler spring to the spring plate (Fig. 1242). Fig 1242 PICT-1181 PICT-1182a 18. Install the left belt cover (Fig. 1244).
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MOWER DECKS 19. Install the carrier frame cover (Fig. 1245). Fig 1245 5. Remove the nut, washer and bolt from the idler arm pivot location (Fig. 1246). PICT-1038 Fig 1246 Idler Arm Assembly Replacement (36” Mower Deck) PICT-1452a 6. Remove the idler arm assembly from the mower deck (Fig. 1247). Idler Arm Assembly Removal (36” Mower Deck) 1. Turn the ignition off and remove the key. 2. Set the parking brake. 3. Remove the PTO drive belt. Refer to “PTO Drive Belt Removal” on page 8-8. 4.
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MOWER DECKS 7. Remove the spring from the idler arm post (Fig. 1248). Fig 1248 PICT-1457a 8. Remove the spacer from the idler arm pivot (Fig. 1249). 9. Remove the nut, bolt and pulley from the idler arm (Fig. 1250). Fig 1250 PICT-1460 Idler Arm Assembly Installation (36” Mower Deck) 1. Position the pulley to the idler arm so that the pulley hub is positioned toward the idler arm (Fig. 1251).
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MOWER DECKS 2. Install a bolt and nut to secure the pulley to the idler arm (Fig. 1252). Fig 1252 PICT-1460 3. Slide the spacer into the idler arm pivot (Fig. 1253). Fig 1253 4. Position the idler arm assembly onto the mower deck (Fig. 1254). Fig 1254 5. Insert a bolt up through the mower deck and through the idler arm pivot. Install a washer and a nut onto the bolt (Fig. 1255).
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MOWER DECKS 6. Hook the idler spring to the idler arm (Fig. 1256). Adjustable Baffle Replacement Adjustable Baffle Removal 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut that secures the lock lever to the lock cap (Fig. 1257). Fig 1256 PICT-1469 7. Install the mower spindle drive belt. Refer to “Mower Spindle Drive Belt Installation” on page 8-5. 8. Install the PTO drive belt. Refer to “PTO Drive Belt Installation” on page 8-9.
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MOWER DECKS 6. Remove the nut from the self-tapping screw that secures the adjustable baffle to the underside of the mower deck (Fig. 1261). 4. Remove the lock cap (Fig. 1259). Fig 1259 PICT-1083 Fig 1261 PICT-1092a 5. Remove the lock screw by unthreading it from the adjustable baffle assembly (Fig. 1260). 7. Remove the self-tapping screw that secures the adjustable baffle to the underside of the mower deck (Fig. 1262).
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MOWER DECKS 8. Remove the adjustable baffle from the mower deck (Fig. 1263). Fig 1263 2. Install a self-tapping screw to secure the adjustable baffle to the underside of the mower deck (Fig. 1265). PICT-1089 Fig 1265 PICT-1088 Adjustable Baffle Installation 1. Position the adjustable baffle on the underside of the mower deck (Fig. 1264). 8 Fig 1264 8-32 PICT-1089 3. Install a nut onto the self-tapping bolt that secures the adjustable baffle to the underside of the mower deck (Fig. 1266).
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MOWER DECKS 4. Apply anti-seize compound onto the lock screw threads (Fig. 1267). 6. Position the lock cap onto the lock screw (Fig. 1269). Fig 1269 Fig 1267 PICT-1083 PICT-1094a 7. Slide the lock lever into the lock cap (Fig. 1270). 5. Thread the lock screw into the bushing of the adjustable baffle assembly (Fig. 1268).
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MOWER DECKS 8. Install a nut to secure the lock lever to the lock cap and screw (Fig. 1271). 2. Remove the right hand belt cover (Fig. 1272). Fig 1272 Fig 1271 PICT-1236 PICT-1080a Discharge Baffle Replacement 3. Remove the nut from each of the 2 self-tapping screws securing the discharge baffle to the underside of the mower deck (Fig. 1273). The following procedures cover replacing the discharge baffle on 40”, 48”, 52” and 60” mower decks.
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MOWER DECKS 4. Raise the machine to access the underside of the mower deck. 5. Remove the 2 self-tapping screws securing the discharge baffle to the mower deck (Fig. 1274). Fig 1274 PICT-1242 6. Remove the discharge baffle from the mower deck (Fig. 1275). Discharge Baffle Installation 1. Position the discharge baffle to the mower deck (Fig. 1276). Fig 1276 PICT-1244 2. Install 2 self-tapping screws to secure the discharge baffle to the underside of the mower deck (Fig. 1277).
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MOWER DECKS 3. Lower the machine to access the top of the mower deck. 4. Install a nut onto each of the 2 self-tapping screws to secure the discharge baffle to the underside of the mower (Fig. 1278). Fixed Baffle Replacement Fixed Baffle Removal (40”, 48”, 52” and 60” Mower Decks) 1. Turn the ignition off and remove the key. Set the parking brake. 2. Remove the nuts from the 2 self-tapping screws that secure the fixed baffle to the mower deck (Fig. 1280). Fig 1278 PICT-1238 5.
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MOWER DECKS 4. Remove the 2 self-tapping screws securing the fixed baffle to the mower deck (Fig. 1282). Fixed Baffle Installation (40”, 48”, 52” and 60” Mower Decks) 1. Position the fixed baffle to the mower deck (Fig. 1284). Fig 1282 PICT-1102 5. Remove the fixed baffle from the mower deck (Fig. 1283). Fig 1284 PICT-1103 2. Install 2 self-tapping screws to secure the fixed baffle to the mower deck (Fig. 1285).
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MOWER DECKS 3. Install the carriage bolt and nut to secure the fixed baffle to the left side of the mower deck (Fig. 1286). Fixed Baffle Replacement (36” Mower Deck) Fixed Baffle Removal (36” Mower Deck) 1. Turn the ignition off and remove the key. Set the parking brake. 2. Remove the 2 bolts, washers and nuts securing the fixed baffle to the mower deck (Fig. 1288). Fig 1286 PICT-1098 4. Install a nut onto each of the 2 self-tapping screws that secure the fixed baffle to the mower deck (Fig. 1287).
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MOWER DECKS Fixed Baffle Installation (36” Mower Deck) 1. Position the fixed baffle up to the mower deck (Fig. 1290). Skid Plate Replacement (40”, 48”, 52” and 60” Mower Decks) Skid Plate Removal (40”, 48”, 52” and 60” Mower Deck) 1. Turn the ignition off and remove the key. Set the parking brake. 2. Raise the machine to access the underside of the mower deck. 3. Remove the carriage bolt and nut securing the front of the skid plate to the mower deck (Fig. 1292). Fig 1290 PICT-1427 2.
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MOWER DECKS 4. Remove the 2 carriage bolts and nuts securing the rear of the skid plate to the mower deck (Fig. 1293). Skid Plate Installation (40”, 48”, 52” and 60” Mower Deck) 1. Position the skid plate to the mower deck (Fig. 1295). Fig 1293 PICT-1121 5. Remove the skid plate from the mower deck (Fig. 1294). Fig 1295 PICT-1122 2. Loosely install 3 carriage bolts and nuts to secure the skid plate to the mower deck: 2 holding the rear of the skid plate and 1 holding the front of the skid plate (Fig.
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MOWER DECKS 3. Tighten all 3 carriage bolts and nuts to secure the skid plate to the mower deck (Fig. 1297). Skid Plate Replacement (36” Mower Deck) Skid Plate Removal (36” Mower Deck) 1. Raise the machine to access the underside of the mower deck. 2. Remove the 2 carriage bolts and nuts securing the front of the skid plate to the mower deck (Fig. 1298). Fig 1297 PICT-1114a 4. Lower the machine. Fig 1298 PICT-1435 3.
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MOWER DECKS 4. Remove the skid plate from the mower deck (Fig. 1300). Fig 1300 2. Loosely install 4 carriage bolts and nuts to secure the skid plate to the mower deck: 2 holding the rear of the skid plate and 2 holding the front of the skid plate (Fig. 1302). PICT-1440 Fig 1302 PICT-1435 Skid Plate Installation (36” Mower Deck) 1. Position the skid plate to the mower deck (Fig. 1301). 8 Fig 1301 3. Tighten all 4 carriage bolts and nuts to secure the skid plate to the mower deck (Fig. 1303).
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MOWER DECKS 3. Remove the spacers (if present) from the deck hanger pins (Fig. 1305). Front & Rear Deck Hanger Replacement Front Deck Hanger Removal 1. Remove the drive belt from the center spindle pulley. Refer to “PTO Drive Belt Removal (40”, 48”, 52”, and 60” Mower Decks)” on page 8-6 or “PTO Drive Belt Removal (36” Mower Decks)” on page 8-8. 2. Lift up on the mower deck and remove the hairpin(s) from the deck hanger pins (Fig. 1304). Fig 1305 PICT-1258 4.
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MOWER DECKS 5. Slide the ball joint/pin assembly off the bolt and remove it from the carrier frame (Fig. 1307). Fig 1307 PICT-1267 6. Remove the spacer from the bolt (Fig. 1308). Fig 1308 7. Remove the bolt from the mower deck bracket (Fig. 1309). Fig 1309 8. Loosen the jam nut on the deck hanger pin (Fig. 1310).
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MOWER DECKS 9. Remove the ball joint from the deck hanger pin (Fig. 1311). Front Deck Hanger Installation 1. Install a jam nut onto the ball joint (Fig. 1313). Fig 1311 PICT-1276a Fig 1313 PICT-1277a 10. Remove the jam nut from the ball joint (Fig. 1312). 2. Thread the ball joint into the deck hanger pin (Fig. 1314).
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MOWER DECKS 3. Adjust distance from the top of HOC stop to the center of the ball joint to 4.21” ± .06” (10.7 + .15cm). Secure the jam nut against HOC pin. The hairpin holes in HOC pin are to be approximately inline with ball joint through hole (Fig. 1315). 5. Slide a spacer onto the bolt (Fig. 1317). A Fig 1317 Fig 1315 PICT-1278a PICT-1269 6. Slide the ball joint/pin assembly onto the bolt and up through the mower deck bracket (Fig. 1318). A. 4.21” + . 6” (10.7 + .15cm) 4.
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MOWER DECKS 7. Install a nut onto the bolt to secure the ball joint to the mower deck (Fig. 1319). Fig 1319 9. Lift up on the mower deck and install the hairpin(s) into the deck hanger pins at the desired height-of-cut setting (Fig. 1321). PICT-1259 Fig 1321 8. Install the spacer(s) (if required) onto the deck hanger pins (Fig. 1320). Fig 1320 Floating Deck Mid-Size Service Manual PICT-1257 10. Install the deck drive belt onto the center spindle pulley.
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MOWER DECKS 4. Remove the spacer(s) (if present) from the deck hanger pin (Fig. 1324). Rear Deck Hanger Removal 1. Remove the drive belt from the center spindle pulley. Refer to “PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks)” on page 8-6 or “PTO Drive Belt Removal (36” Mower Decks)” on page 8-8. 2. 40”, 48”, 52” and 60” mower decks only: Remove the left hand belt cover (Fig. 1322). Fig 1324 PICT-1281 5. Remove the retaining ring from the deck bushing (Fig. 1325). Fig 1322 PICT-1279 3.
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MOWER DECKS 6. Remove the deck bushing from the carrier frame (Fig. 1326). Fig 1326 PICT-1283 7. Remove the bolt and nut securing the deck hanger pin to the mower deck (Fig. 1327). Fig 1327 Floating Deck Mid-Size Service Manual PICT-1284 8. Remove the deck hanger pin from the carrier frame (Fig. 1328). Fig 1328 PICT-1285 9. Slide the snap ring off of the deck hanger pin (Fig. 1329).
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MOWER DECKS 3. Install the bolt and nut to secure the deck hanger pin to the mower deck (Fig. 1332). Rear Deck Hanger Installation 1. Slide a retaining ring onto the deck hanger pin (Fig. 1330). Fig 1332 Fig 1330 PICT-1284 PICT-1286a 4. Install the deck bushing over the deck hanger pin and into the carrier frame (Fig. 1333). 2. Slide the deck hanger pin up through the carrier frame and into the mower deck. Note the orientation of the deck hanger pin tab (Fig.
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MOWER DECKS 5. Install the retaining ring onto the deck bushing (Fig. 1334). Fig 1334 7. Lift up on the mower deck and install the hairpin(s) into the deck hanger pins at the desired height-of-cut setting (Fig. 1336). PICT-1282 Fig 1336 6. Install the spacer(s) (if required) onto the deck hanger pins (Fig. 1335). PICT-1257 8. Install the deck drive belt onto the center spindle pulley.
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MOWER DECKS 4. Remove the spacer tube from the spanner tube (Fig. 1340). Anti-Scalp Roller Replacement Single Anti-Scalp Roller Removal 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut from the roller axle bolt (Fig. 1338). Fig 1340 PICT-1106 5. Remove the spanner tube from the roller (Fig. 1341). Fig 1338 PICT-1104 3. Remove the axle bolt and roller assembly from the mower deck (Fig. 1339).
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MOWER DECKS Single Anti-Scalp Roller Installation 1. Insert the spanner tube into the roller (Fig. 1342). 3. Position the roller so that the spacer tube is located to the outside of the deck. Install the roller to the mower deck brackets with an axle bolt (Fig. 1344). A Fig 1342 Fig 1344 PICT-1107 PICT-1105 A. Spacer tube 2. Install the spacer tube onto the spanner tube (Fig. 1343). Fig 1343 4. Install a nut onto the roller axle bolt (Fig. 1345).
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MOWER DECKS 4. Remove the rollers from the wheel spacer (Fig. 1348). Double Anti-Scalp Roller Removal 1. Turn the engine off and remove the key from the ignition. Set the parking brake. 2. Remove the nut from the roller axle bolt (Fig. 1346). Fig 1348 Fig 1346 PICT-1108 PICT-1112a Double Anti-Scalp Roller Installation 1. Slide the rollers onto the wheel spacer (Fig. 1349). 3. Remove the axle bolt and double roller assembly from the mower deck (Fig. 1347).
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MOWER DECKS 2. Position the roller assembly in between the brackets on the mower deck. Install the roller assembly to the mower deck brackets with an axle bolt. 2. Remove the nut from the deflector assembly pivot bolt (Fig. 1352). 3. Install a nut onto the roller axle bolt (Fig. 1350). Fig 1352 Fig 1350 PICT-1046a PICT-1108 3. Remove the pivot bolt from the deflector assembly (Fig. 1353). Grass Deflector Service Grass Deflector Removal 1. Carefully unhook the spring from the deflector assembly (Fig.
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MOWER DECKS 4. Remove the deflector assembly, spacer and spring from the mower deck (Fig. 1354). Fig 1354 PICT-1049a 2. Remove the discharge strap and metal deflector from the rubber deflector (Fig. 1356). Fig 1356 PICT-1057 Grass Deflector Disassembly Grass Deflector Assembly 1. Remove the 4 carriage bolts and nuts securing the hinge brackets to the deflector. Remove the hinge brackets (Fig. 1355). 1. Insert the 4 carriage bolts into the discharge strap (Fig. 1357).
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MOWER DECKS 2. Position and press the rubber deflector onto the 4 carriage bolts (Fig. 1358). 4. Position the 2 hinge brackets (Fig. 1360). Fig 1360 Fig 1358 3. Install the metal deflector onto the 4 carriage bolts (Fig. 1359). 5. Install 4 nuts onto the bolts securing the deflector assembly (Fig. 1361).
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MOWER DECKS Grass Deflector Installation 1. Slide the spring onto the spacer (Fig. 1362). Fig 1362 3. Install the spring/spacer, using the pivot bolt, so that the hook end of the spring is on the deflector side of the mounting plate and the “L” end of the spring is on the mower deck side of the mounting plate (Fig. 1364). PICT-1075a Fig 1364 2. Position the deflector assembly to the mower deck and orient the spring/spacer assembly so the end of the spring with the hook is pointing to the rear (Fig.
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MOWER DECKS 5. Install the hook end of the spring onto the deflector mounting bracket (Fig. 1366). Fig 1366 PICT-1044a 2. Remove the bushing from the quick latch handle (Fig. 1368). Fig 1368 PICT-1250a 3. Remove the washer from the quick latch handle (Fig. 1369). Quick Latch Replacement There are a total of 5 quick latches located on the midsize units. The replacement procedure is the same for all. Quick Latch Removal 1. Remove the nut from the quick latch handle (Fig. 1367).
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MOWER DECKS 4. Remove the quick latch handle from the cover (Fig. 1370). Fig 1370 PICT-1253 2. Place a washer onto the quick latch handle (Fig. 1372). Fig 1372 PICT-1251a 3. Install a bushing onto the quick latch handle (Fig. 1373). Quick Latch Installation 1. Insert the quick latch handle through the cover (Fig. 1371).
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MOWER DECKS 4. Install a nut securing the quick latch handle assembly to the cover. There must be one thread from the quick latch handle protruding past the nut (Fig. 1374). 3. Remove the top hairpins and spacer(s) (if present) from the deck hanger pin (Fig. 1375). Fig 1375 Fig 1374 PICT-1281 PICT-1254 4. Lift up on the mower deck and remove the hairpins from the 4 deck hanger pins (Fig. 1376). Mower Deck Removal 1. Support the rear of the chassis with a jack stand. 2.
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MOWER DECKS 5. Remove the spacers from the hanger pins if they are present (Fig. 1377). Mower Deck Installation 1. Raise and position the carrier frame over the mower deck (Fig. 1379). Fig 1377 PICT-1294 Fig 1379 PICT-1295 6. Raise the carrier frame and slide the mower deck away from the traction unit (Fig. 1378). 2. As the carrier frame is lowered, ensure the deck hanger posts are inserted through the holes in the carrier frame (Fig. 1380).
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MOWER DECKS 3. Support the rear of the chassis with a jack stand. Checking the Engine Deck Height 4. Lift up on the mower deck and install the spacers and hairpins onto the 4 deck hanger pins (Fig. 1381). 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Adjust the tire pressure in the rear tires to 12-14 psi (83-97kPa). 4. Measure engine deck height at location AA (Fig. 1382). 5.
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MOWER DECKS Checking the Carrier Frame Front-toRear Pitch Checking the Carrier Frame Side-toSide Height The carrier frame must have a pitch between 1/8” (3mm) to 3/8” (9mm) over the length of 24” (61cm) on the carrier frame. The carrier frame needs to be parallel side-to-side from the ground. 1. Disengage the PTO and set the parking brake. 1. Measure out 24” (61cm) on the carrier frame (Fig. 1383). 2. Measure the carrier frame height at location AA (Fig. 1383). 3.
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MOWER DECKS Checking the Mower Deck Front-toRear Pitch 1. Adjust the tire pressure in the rear tires to 12-14 psi (83-97kPa). 2. Position the mower blades so they are in the frontto-rear orientation. Measure at AA and BB locations from a level surface to the cutting edge of the blade tips (Fig. 000 and for 36” mower decks use Fig. 1385). AA BB 3. The mower blades should be 1/4” (6mm) lower at location AA than at location BB. 4.
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MOWER DECKS Adjusting the Mower Deck Front-toRear Pitch Checking the Mower Deck Side-toSide Height Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1. Adjust the rear tire pressure to 12-14 psi (83-97kPa). 1. To raise the front of the deck, loosen the jam nut on the lower end of the deck hanger pin assembly. Rotate the front pin clockwise (Fig. 1387). 2. To lower the front of the deck, loosen the jam nut on the lower end of the deck hanger pin assembly.
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MOWER DECKS Adjusting the Mower Deck Side-toSide Height 1. Adjust the rear tire pressure. This should be done to the tire on the corresponding side that needs height adjustment. C D 2. Adjust the caster spacers by moving spacers from the top or bottom of the caster wheel forks. 3. Check the front-to-rear pitch and side to side leveling of the cutting unit. Fig 1389 This illustration shows a 36” mower deck. fig. 86 G004907 Matching the Height-of-Cut 1. Check the rear tire pressure. 2.
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MOWER DECKS 3. With the machine on level surface, position one blade front-to-rear. Measure at location A from a level surface to the cutting edge of the blade tip (Fig. 1391 and for 36” mower decks use Fig. 1392). A 4. The measurement should be 4” (101.6mm). A 5. If it does not measure correctly: A. Adjust the rear tire pressure. B. Adjust the caster fork spacers. C. Adjust the front mower deck support pins. 6. Check the carrier frame front-to-rear pitch.
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ELECTRICAL Tools On/Off Switch • Volt Ohm meter • Flat and Phillips screwdrivers • Box and open end wrenches - various sizes The on/off switch is mainly used to control the spark on recoil start models. In the off position there is contact between the terminals. When turned 1/4 turn clockwise to the on position the contacts open (Fig. 1393). Additional information can be found in the LCE Electrical Troubleshooting DVD #492-9171, available through your Toro parts supplier.
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ELECTRICAL Single Pole Switch PTO Switch This is a normally closed switch and has the letters “NC” stamped on both terminals. This switch should have continuity when at rest. Continuity should be lost when the plunger is depressed (Fig. 1395). 3 terminals are in use on this switch. When the switch is off (knob depressed) there should be continuity between terminals 1 and 7. When the switch is on (knob pulled out) there should be continuity between terminals 1 and 4 (Fig. 1396 and Fig. 1397).
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ELECTRICAL Relay, Single Pole Dual Throw Ignition Switch A relay is an electronically activated switch. It can be used as a normally open or normally closed switch depending on which terminals are used. The diagram is molded into the side of the relay. The ignition switch has 3 positions; off, run and start. The start position is spring loaded to return to run when released. The switch terminals are unmarked. Use the figure above to identify the terminals.
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ELECTRICAL Wire Harness T-Bar, Gear Drive (104-8137) This wire harness has one 7.5 amp fuse in the pink wire between the alternator and delay module. If the clutch fails to engage, check the fuse first (Fig. 1401).
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ELECTRICAL PTO Switch Delay Module Only 2 terminals are used in this application: numbers 1 and 4 as shown in the figure below. These terminals are normally open. They close only when the PTO knob is pulled outward. This is a momentary switch so when the PTO knob is released it will return to the open position (Fig. 1402 and Fig. 1403). The Delay Module delays clutch disengagement for a second or two.
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ELECTRICAL Clutch Power Supply Test Procedure: 1. Measure the DC voltage at the pink wire where it comes out of the rectifier. Make sure the engine is running at full throttle and note the reading. If below 12 VDC, troubleshoot the engine’s electrical system (Fig. 1405). 3. Connect the test lead to the end of the pink wire in the terminal plug removed from the module (Fig. 1407). Note: The voltage should be the same as at the engine. Fig 1407 Fig 1405 IMG_8046a IMG_8042 2.
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ELECTRICAL 5. Move the bail to the operation position and temporarily tie it in place (Fig. 1409). 7. Set the Volt/Ohm meter to the OHMs setting. Connect a test lead to the green wire at the module connector. Connect the other test lead to the engine block (Fig. 1411). The reading should be 2.8 OHMs. A higher reading indicates a poor connection on the green wire, the clutch or ground. Clean and secure all connection points. A lower reading indicates a problem with the clutch coil. Fig 1409 IMG_8066a 6.
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ELECTRICAL 8. Check the ground for the module: Check for continuity between the black wire at the module connector and the engine (Fig. 1412). High resistance indicates corroded terminals or a poor ground connection to the chassis. If the clutch and power supply function properly (as indicated by the above test procedure), the Delay Module must be replaced. DC Mini Hour Meter This hour meter runs when 12 VDC is applied. It will record up to 9,999.9 hrs.
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ELECTRICAL Proximity Switch PTO Brake Clutch Assembly This proximity switch is normally open. The contacts close when a piece of ferrous metal (iron or steel) is placed close to the switch, approximately within 1/4” (.635cm). The switch will open when the metal is moved away (Fig. 1415). The PTO clutch contains one fixed plate, a moveable plate and an electro magnet. When a minimum of 8 VDC is applied to the clutch the plates will engage.
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ELECTRICAL Wire Harness Pistol Grip (106-8780) There is a 30 amp fuse (p/n 109103) between the battery and ignition switch and a 25 amp fuse (p/n 109102) between the voltage regulator/rectifier on the engine and the ignition switch. Failure of the 30 amp fuse disables the entire electrical system (Fig. 1417). If the 25 amp fuse fails, focus on the engine portion of the charging system for the cause. The alternator does not produce enough amperage to blow the fuse.
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ELECTRICAL PTO Switch The PTO switch has 3 positions. Fully depressed, a middle detent and momentary (full out). The momentary (full out) position is spring loaded. It must be held to keep it in that position. When the knob is fully depressed there is continuity between terminals 1 and 7. The momentary position (full out) causes continuity between terminals 1 and 4 (Fig. 1418 and Fig. 1419). The switch can be tested using an ohm meter or continuity light.
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ELECTRICAL Wire Harness T-2, Hydro (114-3418) There is a 30 amp fuse (p/n 109103) between the battery and ignition switch and a 25 amp fuse (p/n 109102) between the voltage regulator/rectifier on the engine and the ignition switch. Failure of the 30 amp fuse disables the entire electrical system (Fig. 1420). If the 25 amp fuse fails, focus on the engine portion of the charging system for the cause. The alternator does not produce enough amperage to blow the fuse.
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ELECTRICAL Wire Harness T-Bar, Hydro (114-3420) There is a 30 amp fuse (p/n 109103) between the battery and ignition switch and a 25 amp fuse (p/n 109102) between the voltage regulator/rectifier on the engine and the ignition switch. Failure of the 30 amp fuse disables the entire electrical system (Fig. 1421). If the 25 amp fuse fails, focus on the engine portion of the charging system for the cause. The alternator does not produce enough amperage to blow the fuse.
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ELECTRICAL Normally Open Switch Starter Solenoid This switch is normally open. There is contact only when the plunger is depressed (Fig. 1422). A starter is a form of an electrically operated switch. Positioning the solenoid closer to the battery and starter, short battery cables can be utilized to increase efficiency (Fig. 1424). At rest there should be no continuity between the two larger posts. Connect a 12 volt battery to the two smaller posts and the solenoid should engage.
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ELECTRICAL Operator Presence Control (OPC) Switch Replacement (T-Bar) 3. Remove the cotter pin from the upper end of the control rod (Fig. 1426). OPC Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. 2. Lift the locking tab on the front of the operator presence control switch and unplug the harness connector from the switch (Fig. 1425). Fig 1426 PICT-1679a 4. Remove the control rod from the control bar/bail assembly (Fig. 1427).
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ELECTRICAL 5. Repeat steps 3 and 4 to remove the opposite control rod from the control bar/bail assembly. 6. Remove the bail from the T-Bar handle by sliding it off the OPC Switch mounting bracket and remove it from the machine (Fig. 1428). OPC Switch Installation (T-Bar) 1. Install the OPC switch into the switch mounting bracket on the T-Bar (Fig. 1430). Fig 1430 Fig 1428 PICT-1785a 7. Remove the OPC switch from the switch mounting bracket (Fig. 1429). 2.
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ELECTRICAL 3. Insert a control rod through the T-Bar handle/bail assembly mounting pivots (Fig. 1432). 5. Repeat steps 3 and 4 to install the opposite control rod. 6. Plug the harness connector into the OPC switch (Fig. 1434). Fig 1432 PICT-1682 Fig 1434 PICT-1744 4. Install a cotter pin into the upper end of the control rod (Fig. 1433).
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ELECTRICAL PTO Switch Replacement (T-Bar) 4. Unplug the wire harness from the PTO switch (Fig. 1437). PTO Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. A 2. Remove the 2 screws securing the manual tube R-clamps to the bottom panel of the control panel. Remove the manual tube assembly (Fig. 1435). A Fig 1437 PICT-1793 A. Tabs 5. Compress the tabs (Fig. 1437) on the switch body and push it out of the control panel (Fig. 1438). Fig 1435 PICT-1787 3.
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ELECTRICAL PTO Switch Installation (T-Bar) 1. Push the PTO switch in to place in the control panel (Fig. 1439). 3. Position the bottom panel to the control panel and install 2 screws securing it to the control panel (Fig. 1441). Fig 1441 Fig 1439 PICT-1811 2. Plug the wire harness into the PTO switch (Fig. 1440). Fig 1440 PICT-1789 PICT-1793 4. Position the manual tube to the control panel assembly and install 2 screws securing the manual tube R-clamps to the control panel and bottom panel (Fig.
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ELECTRICAL Ignition Switch Replacement (T-Bar) 4. Unplug the wire harness from the ignition switch (Fig. 1445). Ignition Switch Removal (T-Bar) 1. Turn the engine off and remove the key from the ignition. 2. Remove the 2 screws securing the manual tube R-clamps to the bottom panel of the control panel. Remove the manual tube assembly (Fig. 1443). Fig 1445 PICT-1798 5. Remove the nut securing the ignition switch to the control panel (Fig. 1446). Fig 1443 PICT-1787 3.
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ELECTRICAL 6. Remove the lockwasher from the ignition switch (Fig. 1447). Ignition Switch Installation (T-Bar) 1. Insert the ignition switch into the control panel (Fig. 1449). Fig 1447 PICT-1801 Fig 1449 PICT-1803 7. Remove the ignition switch from the control panel (Fig. 1448). 2. Place a lockwasher onto the ignition switch (Fig. 1450).
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ELECTRICAL 3. Install a nut securing the ignition switch to the control panel (Fig. 1451). Fig 1451 5. Position the bottom panel to the control panel and install 2 screws securing the back side of the bottom panel to the control panel (Fig. 1453). PICT-1800 Fig 1453 4. Plug the wire harness into the ignition switch (Fig. 1452). Fig 1452 PICT-1719a 6. Position the manual tube to the control panel. Install 2 screws securing the manual tube R-clamps and bottom panel to the control panel (Fig. 1454).
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ELECTRICAL Delay Module Replacement (T-Bar) Delay Module Removal (T-Bar) 3. Remove the 2 screws securing the bottom panel to the control panel and move the bottom panel away from the control panel (Fig. 1456). 1. Turn the engine off and remove the key from the ignition. 2. Remove the 2 screws securing the manual tube R-clamps to the bottom panel of the control panel. Remove the manual tube assembly (Fig. 1455). Fig 1456 PICT-1789 4. Unplug the brown wire bullet connector from the harness (Fig. 1457).
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ELECTRICAL 5. Unplug the harness connector from the delay module (Fig. 1458). Fig 1458 PICT-1805 6. Remove the fuse block from the bottom panel and remove the bottom panel from the machine (Fig. 1459). Fig 1459 7. Remove the bolt and nut securing the delay module to the bottom panel (Fig. 1460). Fig 1460 PICT-1809 Delay Module Installation (T-Bar) 1. Position the delay module on the inside of the bottom panel. Install a bolt and nut securing the delay module to the bottom panel (Fig. 1461).
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ELECTRICAL 2. Position the bottom panel up to the control panel and attach the fuse block to the bottom panel (Fig. 1462). Fig 1462 PICT-1806 3. Plug the harness connector into the delay module (Fig. 1463). Fig 1463 4. Plug the brown wire bullet connect into the harness (Fig. 1464). Fig 1464 PICT-1804 5. Position the bottom panel to the control panel and install 2 screws securing the back side of the bottom panel to the control panel (Fig. 1465).
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ELECTRICAL 6. Position the manual tube to the control panel. Install 2 screws to secure the manual tube assembly (R-clamps) and bottom panel to the control panel (Fig. 1466). 2. Unplug the harness from the parking brake switch (Fig. 1467). Fig 1467 Fig 1466 PICT-1816 PICT-1718 Parking Brake Switch Replacment (Pistol Grip & T-2) 3. Remove the 2 bolts and buts securing the parking brake switch to the parking brake handle support (Fig. 1468). Parking Brake Switch Removal (P.G. & T-2) 1.
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ELECTRICAL 4. Remove the spacer from the switch (Fig. 1469). Parking Brake Switch Installation (P.G. & T-2) 1. Position the parking brake switch onto the parking brake handle support (Fig. 1471). Fig 1469 PICT-1892 5. Remove the switch from the parking brake handle support (Fig. 1470). Fig 1471 PICT-1894 2. Position the spacer onto the switch (Fig. 1472).
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ELECTRICAL 3. Install 2 bolts and nuts securing the parking brake switch to the parking brake handle support (Fig. 1473). Neutral Switch Replacement (Pistol Grip) Neutral Switch Removal (P.G.) 1. Position the speed control lever in the Fast position (Fig. 1475). Fig 1473 PICT-1817 4. Plug the harness into the parking brake switch (Fig. 1474). Fig 1475 PICT-1902a 2. Unplug the harness from the neutral switch (Fig. 1476).
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ELECTRICAL 3. Remove the 2 screws securing the neutral switch to the neutral bracket (Fig. 1477). Neutral Switch Installation (P.G.) 1. Position the spacer and the switch onto the neutral bracket (Fig. 1479). Fig 1477 PICT-1825 Fig 1479 PICT-1827a 4. Remove the spacer and the switch from the neutral bracket (Fig. 1478). 2. Install 2 screws securing the neutral switch to the neutral bracket (Fig. 1480).
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ELECTRICAL 3. Plug the harness into the neutral switch (Fig. 1481). Fig 1481 5. To adjust the switch location, loosen the two neutral bracket screws holding the switch plate to the frame (Fig. 1483). PICT-1823 Fig 1483 4. With the speed control lever in the neutral position, check to make sure the safety switch is depressed with an 1/8” to 1/4” (3 to 6mm) space between the actuating tab and the safety switch body (Fig. 1482). PICT-1911 6.
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ELECTRICAL 7. Tighten the two neutral bracket screws holding the switch plate (Fig. 1485). Fig 1485 PICT-1911 PTO Switch Replacement (Electric Start) 3. Remove the fuse block(s) from the control panel cover bracket (Fig. 1486). Fig 1486 PICT-1836 4. Remove the 2 screws securing the manual tube assembly to the control bracket. Remove the manual tube assembly (Fig. 1487). PTO Switch Removal (Electric Start) 1. Turn the engine off and remove the key from the ignition. 2.
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ELECTRICAL 5. Remove the 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1488). 7. Unplug the harness from the PTO switch (Fig. 1490). Fig 1490 Fig 1488 PICT-1851a PICT-1847 8. Depress the tabs on the PTO switch and push it through the control panel to remove it (Fig. 1491). 6. Remove the cover bracket from the control panel (Fig. 1489).
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ELECTRICAL PTO Switch Installation (Electric Start) 3. Position the cover bracket onto the control panel (Fig. 1494). 1. Push the PTO switch through the control panel until it snaps into place (Fig. 1492). Fig 1494 Fig 1492 PICT-0729a 2. Plug the harness into the PTO switch (Fig. 1493). Fig 1493 PICT-1848 PICT-1851a 4. Install 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1495).
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ELECTRICAL 5. Position the manual tube to the cover bracket. Install 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1496). Operator Presence Control (OPC) Switch Replacement (Pistol Grip) Note: The harness has been unplugged from the PTO switch for photo purposes. OPC Switch Removal (P.G.) 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery cable from the battery. 3.
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ELECTRICAL 4. Remove the 2 screws securing the manual tube assembly to the control bracket. Remove the manual tube assembly (Fig. 1499). 6. Remove the cover bracket from the control panel (Fig. 1501). Fig 1501 Fig 1499 5. Remove the 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1500). 7. Unplug the harness from the OPC switch (Fig. 1502).
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ELECTRICAL 8. Remove the 2 screws securing the OPC switch to the switch mounting plate (Fig. 1503). OPC Switch Installation (P.G.) 1. Position the switch and spacer to the mounting plate (Fig. 1505). Fig 1503 PICT-1859 Fig 1505 PICT-1860 9. Remove the switch and spacer from the mounting plate (Fig. 1504). 2. Install 2 screws securing the OPC switch to the switch mounting plate (Fig. 1506).
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ELECTRICAL 3. Plug the harness into the OPC switch (Fig. 1507). 5. If needed, adjust the position of the switch. Refer to OPC Switch Position Adjustment (P.G.) in the following section. 6. Position the cover bracket onto the control panel (Fig. 1509). Fig 1507 PICT-1857 4. With either LH or RH OPC lever depressed inspect space between Neutral Arm on OPC Rod and the body of the OPC Switch. The space should be .18” ± .06” (4.6 ± 1.5mm) (Fig. 1508). Fig 1509 PICT-1848 7.
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ELECTRICAL 8. Position the manual tube to the cover bracket. Install 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1511). Fig 1511 OPC Switch Position Adjustment (P.G.) 1. Loosen the 2 OPC switch mounting screws (Fig. 1513). PICT-1839 Fig 1513 9. Slide the fuse blocks onto the control panel cover bracket (Fig. 1512). PICT-1864 2. Adjust position of switch mounting plate to obtain the .18” ± .06” (4.6 + 1.
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ELECTRICAL 3. Tighten the neutral bracket mounting screws (Fig. 1515). Fig 1515 PICT-1864 4. The OPC switch should return to the open position with the levers in the full spring return position. 3. Remove the fuse blocks from the control panel cover bracket (Fig. 1516). Fig 1516 PICT-1836 4. Remove the 2 screws securing the manual tube assembly to the control bracket. Remove the manual tube assembly (Fig. 1517). Hour Meter Replacement (Pistol Grip) Hour Meter Removal (P.G.) 1.
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ELECTRICAL 5. Remove the 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1518). 7. Unplug the harness from the hour meter (Fig. 1520). Fig 1520 Fig 1518 PICT-1869 PICT-1847 8. Remove the locking tab from the back side of the hour meter (Fig. 1521). 6. Remove the cover bracket from the control panel (Fig. 1519).
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ELECTRICAL 9. Remove the hour meter from the control panel (Fig. 1522). Fig 1522 PICT-1871 2. Install the locking tab onto the back side of the hour meter (Fig. 1524). Fig 1524 PICT-1870 3. Plug the harness into the hour meter (Fig. 1525). Hour Meter Installation (P.G.) 1. Push the hourmeter into the opening in the control panel (Fig. 1523).
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ELECTRICAL 4. Position the cover bracket onto the control panel (Fig. 1526). Fig 1526 6. Position the manual tube to the cover bracket. Install 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1528). PICT-1848 Fig 1528 5. Install 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1527). Fig 1527 PICT-1847 PICT-1839 7. Slide the fuse blocks onto the control panel cover bracket (Fig. 1529). Fig 1529 PICT-1836 8.
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ELECTRICAL 4. Remove the 2 screws securing the manual tube assembly to the control bracket. Remove the manual tube assembly (Fig. 1531). Ignition Switch Replacement (Pistol Grip) Ignition Switch Removal (P.G.) 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery terminal from the battery. 3. Remove the fuse blocks from the control panel cover bracket (Fig. 1530). Fig 1531 PICT-1839 5.
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ELECTRICAL 6. Remove the cover bracket from the control panel (Fig. 1533). Fig 1533 PICT-1848 8. Remove the nut securing the ignition switch to the control panel (Fig. 1535). Fig 1535 PICT-1873 7. Unplug the harness terminal and harness connector from the ignition switch (Fig. 1534). 9. Remove the lockwasher from the ignition switch (Fig. 1536).
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ELECTRICAL 10. Remove the ignition switch from the control panel (Fig. 1537). Fig 1537 PICT-1875 2. Place a lockwasher onto the ignition switch (Fig. 1539). Fig 1539 PICT-1874 3. Install a nut securing the ignition switch to the control panel (Fig. 1540). Ignition Switch Installation (P.G.) 1. Insert the ignition switch into the control panel (Fig. 1538).
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ELECTRICAL 4. Plug the wire harness connector and terminal into the ignition switch (Fig. 1541). Fig 1541 6. Install 2 screws securing the control panel cover bracket to the front side of the control panel (Fig. 1543). PICT-1872 Fig 1543 5. Position the cover bracket onto the control panel (Fig. 1542). Fig 1542 PICT-1847 7. Position the manual tube to the cover bracket. Install 2 screws securing the manual tube assembly to the control panel and control bracket (Fig. 1544).
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ELECTRICAL 8. Slide the fuse blocks onto the control panel cover bracket (Fig. 1545). Fig 1545 PICT-1836 9. Connect the negative battery cable to the battery. 3. Unplug the kill relay from the wire harness (Fig. 1546). Fig 1546 PICT-1877 Kill Relay Installation (P.G.) 1. Plug a kill relay into the wire harness (Fig. 1547). Kill Relay Replacement (Pistol Grip) Note: The Manual Tube assembly and Control Panel Cover Bracket have been removed for photo purposes. Kill Relay Removal (P.G.) 1.
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ELECTRICAL 4. Pull the boot back and remove the nut and lock washer securing the battery cable to the solenoid terminal. Remove the battery cable (Fig. 1549). Solenoid Switch Replacement (Pistol Grip & T-2) Solenoid Switch Removal (P.G. & T-2) 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery cable from the battery. 3. Remove the nut and lock washer securing the starter cable to the solenoid terminal. Remove the starter cable (Fig. 1548).
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ELECTRICAL 6. Unplug the 2 harness wires (blue and orange) from the solenoid (Fig. 1551). Solenoid Switch Installation (P.G & T-2) 1. Position the solenoid onto the frame and secure it with 2 self-tapping screws (Fig. 1553). Fig 1551 PICT-1883 Fig 1553 7. Remove the 2 self-tapping screws securing the solenoid to the frame. Remove the solenoid (Fig. 1552). Fig 1552 PICT-1888 2. Plug the 2 harness wires (blue and orange) onto the side posts on the solenoid as shown (Fig.
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ELECTRICAL 3. Slide the harness wire (red) onto the solenoid terminal (Fig. 1555): Fig 1555 PICT-1882 4. Position the battery cable onto the solenoid terminal, over the red harness wire. Install a lockwasher and nut to secure. Position the boot over the connection (Fig. 1556). Fig 1556 5. Position the starter cable onto the solenoid terminal. Install a lockwasher and nut to secure (Fig. 1557). Fig 1557 PICT-1920 6. Connect the negative battery cable to the battery.
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ELECTRICAL Operator Presence Control (OPC) Switch Replacement (T-2) 3. Unplug the harness from the OPC switch (Fig. 1560). OPC Switch Removal (T-2) 1. Remove the 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 1558). Fig 1560 PICT-1927 4. Remove the 2 screws securing the OPC switch to the motion control assembly (Fig. 1561). Fig 1558 PICT-1921 2. Remove the control panel cover/manual tube assembly (Fig. 1559).
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ELECTRICAL 5. Remove the OPC switch and spacer plate (Fig. 1562). Fig 1562 2. Install 2 screws securing the OPC switch (and plate) to the motion control assembly (Fig. 1564). Fig 1564 PICT-1932a OPC Switch Installation (T-2) 1. Position the OPC switch and spacer plate onto the motion control assembly plate (Fig. 1563). PICT-1928a 3. Position the right hand control lever in the operating position. There should be a .10” (2.54mm) gap between the switch plunger and the control arm tab (Fig. 1565).
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ELECTRICAL 4. Plug the harness into the OPC switch (Fig. 1566). Fig 1566 6. Install 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control pane (Fig. 1568). PICT-1927 Fig 1568 PICT-1921 5. Position the control panel cover/manual tube assembly onto the control panel (Fig. 1567). Latching Relay Replacement (T-2) Latching Relay Removal (T-2) 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery cable from the battery.
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ELECTRICAL 3. Remove the 4 screws (2 on the left, 2 on the right) securing the control panel cover to the control panel (Fig. 1569). 5. Unplug the latching relay from the wire harness (Fig. 1571). Fig 1571 Fig 1569 PICT-1936 PICT-1921 Latching Relay Installation (T-2) 4. Remove the control panel cover/manual tube assembly (Fig. 1570). Fig 1570 1. Plug a latching relay into the wire harness (Fig. 1572).
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ELECTRICAL 2. Position the control panel cover/manual tube assembly onto the control panel (Fig. 1573). Kill Relay Replacement (T-2) Note: The Manual Tube assembly and Control Panel Cover Bracket have been removed for photo purposes. Kill Relay Removal (T-2) 1. Turn the engine off and remove the key from the ignition. 2. Disconnect the negative battery cable from the battery. 3. Unplug the kill relay from the wire harness (Fig. 1575). Fig 1573 PICT-1923 3.
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ELECTRICAL 3. Unplug the harness from the proximity neutral switch connector (Fig. 1577). Kill Relay Installation (T-2) 1. Plug the kill relay into the wire harness (Fig. 1576). Fig 1577 Fig 1576 PICT-1938 PICT-1937 2. Connect the negative battery cable to the battery. 4. Remove the cable tie securing the switch wires to the frame (Fig. 1578). Proximity Neutral Switch Replacement (T-2) Proximity Neutral Switch Removal (T-2) 1. Turn the engine off and remove the key from the ignition. 2.
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ELECTRICAL 5. Remove the 2 screws and nuts securing the switch to the frame (Fig. 1579). Proximity Neutral Switch Installation (T-2) 1. Position the Proximity Neutral Switch to the frame (Fig. 1581). Fig 1579 PICT-1940 Fig 1581 PICT-1941 6. Remove the switch (Fig. 1580). 2. Install 2 screws and nuts to secure the switch to the frame (Fig. 1582).
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ELECTRICAL 3. The distance between the face of the switch and the end of the hex head screw should be .07” + .02” (1.8 + .5mm) (Fig. 1583). 5. Plug the harness into the proximity neutral switch connector (Fig. 1585). A Fig 1585 Fig 1583 PICT-1938 PICT-1943 A. .07” + .02” (1.8 + .5mm) 6. Connect the negative battery cable to the battery. 4. Install a cable tie securing the switch wires to the frame (Fig. 1584).
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Floating Deck Mid-Size Service Manual Form No.