Service Manual

ManualsBrandsToro ManualsLawn MowersToro 30696

Fixed Deck

Mid-Size

Service Manual

LCE Products

Summary of content (332 pages)

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LCE Products Fixed Deck Mid-Size Service Manual
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TABLE OF CONTENTS SAFETY INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 SPECIFICATIONS Torque Specifications . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc and Steel Fasteners (Metric Fasteners) Other Torque Specifications . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS CHASSIS Fuel Tank Replacement . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . Brake Service . . . . . . . . . . . . . . . . . Pistol Grip - Gear Drive Checking the Brake . . . . . . . . . . . . . . Adjusting the Brake . . . . . . . . . . . . . . T-Bar - Gear Drive Checking the Brake . . . . . . . . . . . . . . Adjusting the Brake . . . . . . . . . . . . . . Pistol Grip - Hydro Checking the Parking Brake . . . . . . . .
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TABLE OF CONTENTS GEAR DRIVE SYSTEM Transmission Replacement Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 MOWER DECK Mower Belt Replacement . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . Adjusting Mower Belt Tension . . . . . . . . . . . Castor Wheel Assembly Service Removal . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS ELECTRICAL Tools . . . . . Components . . . . Electrical Systems . . Gear Drive T-Bar . . Gear Drive Pistol Grip Hydro Drive Pistol Grip iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY INFORMATION 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 INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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SPECIFICATIONS Torque 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. 2 These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch 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-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC In-lb 10 ± 2 N-c
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SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric 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 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m M10 X 1.
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SPECIFICATIONS Other Torque 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 1.25 Class 8.
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SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals 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 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 0.234375 5.953 0.2500 6.350 0.265625 6.747 0.28125 7.144 0.296875 7.
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SPECIFICATIONS U.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 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
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SPECIFICATIONS Product Specifications Model Engine Make Horse Power (kW) Oil Capacity with filter change Hydro Oil Type Hydro Oil Capacity 30682 Kawasaki 15 (11.2) 3.8 Pint (1.8 L) n/a n/a 30684 Kawasaki 15 (11.2) 3.8 Pint (1.8 L) n/a n/a 30686 Kawasaki 15 (11.2) 3.8 Pint (1.8 L) n/a n/a 30688 Kawasaki 15 (11.2) 3.8 Pint (1.8 L) n/a n/a 30984 Kawasaki 15 (11.2) 3.8 Pint (1.8 L) 15W50 Synthetic Engine Oil 2.1 Qt (1.98L) 30986 Kawasaki 15 (11.2) 3.8 Pint (1.
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SPECIFICATIONS Product Specifications Width Model 2 Height Length Deflector Down Deflector Up 30682 45.8” (116.3cm) 32.8” (83.3cm) 41.0” (104.1cm) 78.0” (198.1cm) 30684 46.6” (118.4cm) 37.1” (94.2cm) 41.0” (104.1cm) 30686 55.5” (140.9cm) 41.6” (105.7cm) 30688 63.5” (161.3cm) 30984 Weight Tire Dimensions Front Rear 402 lbs. (182kg) 9x3.5” - 4 13x5.0” - 6 80.0” (203.2cm) 462 lbs. (210kg) 9x3.5” - 4 13x6.5” - 6 41.0” (104.1cm) 75.3” (191.3cm) 477 lbs. (216kg) 9x3.
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ENGINE Mid-Size Fixed Deck Engine Removal (Gear Drive) 3. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 003). 1. Turn the fuel valve to the off position (Fig. 001). 3 Fig 003 Fig 001 PICT-0006 PICT-0002 4. Attach the oil drain hose to the oil drain valve (Fig. 004). 2. Remove the fuel line by sliding the clamp down away from the fuel pump (Fig. 002).
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ENGINE 5. Place a drain pan below the drain hose (Fig. 005). 7. When the oil has drained completely, close the drain valve and remove the drain hose. 8. Remove the cable tie from the wire harness on the right side of the engine (Fig. 007). 3 Fig 005 PICT-0009 6. Rotate the oil drain valve to allow the oil to drain from the engine (Fig. 006). Fig 007 PICT-0017 9. Disconnect the magneto wire bullet connector (red from black) (Fig. 008).
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ENGINE 10. Remove the bolts attaching the ground wire and the wire harness R-clamp to the engine block (Fig. 009). 13. Remove the throttle and choke cables from the clamps and disconnect them from the control linkage (Fig. 011). 3 Fig 009 PICT-0023 Fig 011 11. Pull the harness out from behind the oil fill tube and move it away from the engine to prevent damage. 12. Loosen the clamps holding the throttle and choke (top) cables to the engine (Fig. 010). PICT-0028 14.
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ENGINE 16. Raise the machine to access the drive pulley and belt. 19. Loosen the nut on the traction idler pulley (Fig. 015). 17. Remove the deck drive belt from the mower drive pulley (Fig. 013). 3 Fig 015 Fig 013 PICT-0032 PICT-0038 20. Slide the traction belt off the idler pulley and then remove the belt (Fig. 016). 18. Remove the drive pulley bolt from the engine crankshaft (Fig. 014).
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ENGINE 21. Install a two bolt puller onto the drive pulley and remove the drive pulley from the engine crankshaft (Fig. 017). Mid-Size Fixed Deck Engine Installation (Gear Drive) 1. Position the engine onto the chassis. 2. Apply thread locking compound onto the threads of all 4 engine mounting bolts. 3. Install the 4 engine mounting bolts, nuts and washers that secure the engine to the chassis. Torque the 4 engine mounting bolts to 15-20 ft-lbs. (20-27Nm). 4.
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ENGINE 5. Position the idler to tension the traction control belt and then tighten the nut to secure the idler position (Fig. 020). 7. Position the mower belt pulley onto the crankshaft (Fig. 022). 3 Fig 022 Fig 020 PICT-0058 PICT-0055a 6. Apply anti-seize compound to the engine crankshaft (Fig. 021). Note: The belt should have 1/2” of deflection with 3 lbs. of pressure on the belt midway between the transmission and engine pulley (Fig. 023).
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ENGINE 8. Apply thread locking compound to the threads of the crankshaft bolt (Fig. 024). 10. Install the mower deck belt onto the drive pulley (Fig. 026). 3 Fig 024 PICT-4775a 9. Install the crankshaft bolt and washers and torque to 55 + 5 ft-lbs. (75 + 7 Nm) (Fig. 025). Fig 025 Fig 026 Note: The mower belt should be installed so that it is routed on the inside of the belt guide (Fig. 027).
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ENGINE 11. Check the belt guide under the engine frame for proper adjustment. The distance between the belt guide and mower belt should be 3/4” (19mm) when the mower belt is engaged. Adjust the belt if necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted (Fig. 028). 13. Route the wire harness through the opening between the oil filler tube and the engine and then around to the right side of the engine (Fig. 030). A B C 3 F E Fig 030 D Fig 028 A.
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ENGINE 15. Install the wire harness with an R-clamp to the right side of the engine and the groundwire to the engine block (Fig. 032). 17. Slide the fuel line onto the fuel pump (Fig. 034). A B Fig 034 Fig 032 A. R-clamp 3 PICT-0075 PICT-0023 B. Ground wire 18. Slide the hose clamp into place near the end of the fuel hose to secure it to the fuel pump (Fig. 035). 16. Install cable tie securing the wire harness to the magneto wire (Fig. 033).
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ENGINE 19. Turn the fuel valve to the on position. Check for leaks (Fig. 036). 22. Slide the throttle cable into the lower cable clamp and loosely clamp the outer cable housing (Fig. 038). 3 Fig 036 PICT-0002 Fig 038 20. Route the throttle cable around the left side of the engine and behind the muffler to the front of the engine. PICT-0084 23. Move the throttle lever to Fast position (Fig. 039). 21. Hook the Z-bend of the throttle cable into the upper hole of the speed control lever (Fig. 037).
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ENGINE T-Bar models only: “Fast” is at the detent position. Do not push the handle all the way forward in the throttle control slot (Fig. 040). 25. Move the throttle lever to the Slow position. Ensure the carburetor throttle valve moves smoothly (Pistol Grip model shown) (Fig. 042). 3 Fig 040 PICT-5443 24. Pull on the throttle cable housing until the inner wire has almost no slack and then tighten the cable clamp bolt (Fig. 041). Fig 042 PICT-0093 26.
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ENGINE 28. Slide the choke cable into the upper cable clamp and loosely clamp the outer cable housing (Fig. 044). 30. Make sure that the carburetor choke valve is fully open (Fig. 046). Note: The air filter has been removed to show the carburetor choke valve. 3 Fig 044 PICT-4683 Fig 046 PICT-4690 29. Move the choke control to the Open position (Pistol Grip model shown) (Fig. 045). 31.
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ENGINE 32. Move the choke control to the Choke position (Fig. 048). 34. Make sure that the choke valve turns from the fully closed position to the fully opened position when actuating the equipment choke control. 35. Fill the crankcase with oil per the engine specifications. Mid-Size Fixed Deck Engine Removal (Hydro) 3 1. Turn the fuel valve to the off position (Fig. 050). Fig 048 PICT-4699 33. Make sure that the carburetor choke valve is completely closed (Fig .049).
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ENGINE 2. Slide the hose clamp off of the fuel line connected to the fuel pump flange (Fig. 051). 4. Attach the oil drain hose to the oil drain valve (Fig. 053). 3 Fig 051 PICT-4706 3. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 052). Fig 053 5. Place a drain pan below the drain hose (Fig. 054).
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ENGINE 6. Rotate the oil drain valve to allow the oil to drain (Fig. 055). 9. Disconnect the magneto wire bullet connector (red from black) (Fig. 057). 3 Fig 055 PICT-4722 7. When the oil has drained completely, close the drain valve and remove the drain hose. Fig 057 PICT-0019 10. Remove the bolts attaching the ground wire and the wire harness R-clamp to the engine block (Fig. 058). 8. Remove the cable tie from the wire harness on the right side of the engine (Fig. 056).
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ENGINE 11. Pull the harness out from behind the oil fill tube and move it away from the engine to prevent damage. 12. Loosen the clamps holding the throttle (bottom) and choke (top) cables to the engine (Fig. 059). 14. Pull the throttle and choke cables from behind the muffler and move it away from the engine to prevent damage. 15. Remove the deck cover knobs and then remove the deck cover from the mower (Fig. 061). A 3 B Fig 059 PICT-4729 Fig 061 A. Choke 13.
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ENGINE 18. Remove the crankshaft bolt from the crankshaft (Fig. 063). 20. Remove tension on the idler arm assembly by pulling on the split ring/chain (Fig. 065). 3 Fig 063 PICT-4742 19. Remove the drive pulley from the crankshaft (Fig. 064). Fig 064 Fig 065 21. While holding tension off the idler arm assembly, slide the traction belt off the traction drive pulley (Fig. 066).
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ENGINE 22. Loosen and remove the 4 nuts, bolts and washers that secure the engine to the chassis and then remove the engine (Fig. 067). 4. Pull on the split ring and chain assembly to reduce tension on the idler assembly. While pulling on the split ring/chain assembly, route the traction control belt around the pulleys (Fig. 068). 3 Fig 067 PICT-6828 Fig 068 Mid-Size Fixed Deck Engine Installation (Hydro) 1. Position the engine onto the chassis. PICT-4747 5. Release the split ring/chain assembly.
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ENGINE 6. Apply anti-seize compound to the OD of the crankshaft (Fig. 070). 8. Apply thread locking compound to the threads of the crankshaft bolt (Fig. 072). 3 Fig 070 PICT-4770 7. Position the mower belt pulley onto the crankshaft (Fig. 071). Fig 071 Fixed Deck Mid-Size Service Manual PICT-4767 Fig 072 PICT-4775 9. Install the crankshaft bolt and washers and torque to 55 + 5 ft-lbs. (75 + 7 Nm) (Fig. 073).
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ENGINE 10. Install the mower deck belt onto the drive pulley (Fig. 074). 12. Position the belt cover onto the mower deck and secure in place using knobs (Fig. 076). 3 Fig 074 PICT-4780 11. Check the belt guide under the engine frame for the proper adjustment. The distance between the belt guide and mower belt should be 3/4” (19mm) when the mower belt is engaged. Adjust the belt if necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted (Fig. 075).
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ENGINE 14. Plug the magneto wire bullet connecter into the wire harness (red and black) (Fig. 078). 16. Install a cable tie to secure the wire harness to the magneto wire (Fig. 080). 3 Fig 078 PICT-4785 15. Install the wire harness with an R-clamp to the right side of the engine and the groundwire to the engine block (Fig. 079). Fig 080 PICT-4790 17. Slide the fuel line onto the fuel pump (Fig. 081). A B Fig 081 Fig 079 A. R-clamp PICT-4794 PICT-4727 B.
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ENGINE 18. Slide the hose clamp up the fuel line and into place to secure the hose to the fuel pump (Fig. 082). 20. Route the throttle cable around the left side of the engine, behind the muffler and around to the front of the engine. 21. Hook the Z-bend of the throttle cable into the lower hole of the speed control lever (Fig. 084). 3 Fig 082 PICT-4795 19. Turn the fuel valve to the on position. Check for leaks (Fig. 083). Fig 084 PICT-0082 22.
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ENGINE 23. Move the throttle lever to the Fast position (Fig. 086). 25. Move the throttle lever to the Slow position. Make sure that the carburetor throttle valve moves smoothly (Fig. 088). 3 Fig 086 PICT-4799 Fig 088 24. Pull on the throttle cable housing until the inner wire has almost no slack and then tighten the cable clamp bolt (Fig. 087). PICT-4801 26. Route the choke cable around the left side of the engine, behind the muffler and around to the front of the engine. 27.
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ENGINE 28. Slide the choke cable into the upper cable clamp and loosely clamp the outer cable housing (Fig. 090). 30. Make sure that the carburetor choke valve is fully open (Fig. 092). Note: The air filter has been removed to show the carburetor choke valve. 3 Fig 090 PICT-4683 Fig 092 PICT-4689 29. Move the choke control to the open position (Fig. 091). 31. Hold the choke control lever to hold the choke valve fully open.
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ENGINE 32. Move the equipment choke control to choke position (Fig. 094). 34. Make sure that the choke valve moves from fully closed position to fully opened position when actuating the choke control. 35. Fill the crankcase with oil per engine specifications. 3 Fig 094 PICT-5408 33. Make sure that the carburetor choke valve is completely closed (Fig .095). Note: The air filter has been removed to show the carburetor choke valve.
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ENGINE 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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LINKAGE PTO Lever Replacement - Gear Drive 5. Remove the blade drive linkage rod (Fig. 098). Removal 1. Park the machine on a level surface. 2. Stop the engine and wait for all moving parts to stop. 3. Remove the upper hairpin cotter from the blade drive linkage rod (Fig. 096). Fig 098 PICT-5751 Note: The handle must be set up in the lowest handle height position. In the 2 highest positions, the fuel tank blocks the removal of the lever, bolt, spacer and washer.
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LINKAGE 7. Remove the washer (Fig. 100). Fig 100 4 9. Remove the lever, bolt, spacer and washer (Fig. 102). PICT-5756 Fig 102 PICT-5760 8. Remove the spring (Fig. 101). Pistol Grip Gear only (steps 10-13): 10. Loosen and remove the nut securing the blade engagement lever to the handle (Fig. 103).
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LINKAGE 11. Remove the washer (Fig. 104). Fig 104 13. Remove the lever, bolt, spacer and washer (Fig. 106). PICT-8569 Fig 106 PICT-8571 12. Remove the spring (Fig. 105). T-Bar Gear & Pistol Grip Gear 14. Remove the mower deck cover (Fig. 107).
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LINKAGE 15. Remove the hairpin cotter from the PTO linkage rod at the assist arm (Fig. 108). 4 Fig 108 17. Remove the hairpin cotter from the clevis pin securing the adjustable yoke on the PTO linkage rod to the bellcrank (Fig. 110). PICT-5767a Fig 110 16. Remove the PTO linkage rod from the assist arm (Fig. 109). Fig 109 4-4 PICT-5769 PICT-5770a 18. Remove the clevis pin (Fig. 111).
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LINKAGE 19. Remove the PTO linkage rod from the bellcrank (Fig. 112). Fig 112 PICT-5776 20. Loosen and remove the nut from the shoulder bolt that secures the bellcrank to the chassis (Fig. 113). 21. Remove the shoulder bolt and bellcrank from the bracket on the chassis (Fig. 114). Fig 114 PICT-5781 Installation - T-Bar Gear & Pistol Grip Gear 1. Install the shoulder bolt and bellcrank to the bracket on the frame (Fig. 115).
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LINKAGE 2. Install the nut to the shoulder bolt securing the bellcrank to the chassis (Fig. 116). 4 Fig 116 IMG-6012a 3. Install the PTO linkage rod yoke to the bellcrank (Fig. 117). 4. Install the clevis pin securing the yoke to the bellcrank (Fig. 118). Fig 118 5. Install the hairpin cotter into the clevis pin (Fig. 119).
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LINKAGE 6. Install the PTO linkage rod into the assist arm (Fig. 120). 8. Install the mower deck cover (Fig. 122). Fig 122 Fig 120 PICT-5763 PICT-5769 7. Install the hairpin cotter securing the PTO linkage rod to the assist arm (Fig. 121). 9. Install the spacer into the upper hole of the handle, place the washer on the bolt and insert the bolt through the spacer (Fig. 123): A BC Fig 121 PICT-5767a Fig 123 A. Lever B. Spacer Fixed Deck Mid-Size Service Manual D PICT-5784a C. Washer D.
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LINKAGE 12. Install the washer onto the bolt (Fig. 126). T-Bar Gear only (steps 10-13): 10. Install the lever, bolt, spacer and washer into the handle (Fig. 124). Fig 126 4 Fig 124 PICT-5756 PICT-5760 13. Install the nut that secures the blade engagement lever to the handle (Fig. 127). Note: Do not over-tighten the spring mounting nuts. 1 to 2 bolt threads should protrude past the nut. 11. Install the spring onto the bolt (Fig. 125).
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LINKAGE 16. Install the washer onto the bolt (Fig. 130). Pistol Grip Gear only (steps 14-17): 14. Install the lever, bolt, spacer and washer into the handle (Fig. 128). Fig 130 Fig 128 PICT-8569 PICT-8571 17. Install the nut that secures the blade engagement lever to the handle (Fig. 131). Note: Do not over-tighten the spring mounting nuts. 1 to 2 bolt threads should protrude past the nut. 15. Install the spring onto the bolt (Fig. 129).
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LINKAGE 20. Install the hairpin cotter into the upper end of the blade drive linkage rod (Fig. 134). T-Bar Gear & Pistol Grip Gear 18. Install the blade drive linkage rod into the bellcrank and the lower hole on the blade engagement lever (Fig. 132). 4 Fig 134 Fig 132 PICT-5746 PICT-5751 PTO Lever Adjustment 1. Engage the PTO (lever pushed forward) (Fig. 135). 19. Install the hairpin cotter into the lower end of the blade drive linkage rod (Fig. 133).
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LINKAGE 2. Adjust the assist arm linkage length so that there is 1/16” to 1/8” (1.58 to 3.17mm) clearance between the bellcrank and the transmission output shaft (Fig. 136). 4. Disengage the PTO (lever pulled back) (Fig. 138). Fig 138 Fig 136 IMG-6022 3. Make sure the assist arm is against the rear assist arm stop on the deck (Fig. 137). 5. The assist arm should contact the front assist arm stop on the deck.
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LINKAGE 3. Adjust the PTO safety switch until the bellcrank depresses the plunger by 1/4” (6.35mm) (Fig. 142). PTO Switch Adjustment 1. Disengage the PTO (lever pulled back) (Fig. 140). 4 Fig 142 Fig 140 PICT-5792 2. Make sure the bellcrank is touching the engine deck (Fig. 141). If adjustment is required: a. Loosen the switch mounting screws (Fig. 143).
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LINKAGE b. Position the switch front to back until the 1/4” (6.35mm) measurement is achieved (Fig. 144). PTO Linkage Replacement - Hydro Drive Removal 1. Loosen the jam nut located directly below the PTO push/pull knob (Fig. 146). Fig 144 4 PICT-5802 4. Tighten the 2 switch mounting screws to secure the switch position (Fig. 145). Fig 146 PICT-6502 2. Remove the PTO push/pull knob and jam nut from the PTO linkage rod (Fig. 147).
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LINKAGE 3. Remove the hairpin cotter from the lower end of the PTO linkage rod (Fig. 148). 4 Fig 148 PICT-6506 4. Remove the PTO linkage rod from the control panel bracket (Fig. 149). 5. Remove the two hairpin cotters from the lower PTO linkage Rod (Fig. 150). Fig 150 6. Remove the lower PTO linkage Rod (Fig. 151).
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LINKAGE 7. Loosen the nut securing the PTO bellcrank to the chassis (Fig. 152). 9. Remove the bolt, bellcrank and washer (Fig. 154). Fig 154 Fig 152 PICT-6519 PICT-6515 10. Remove the mower deck cover (Fig. 155). 8. Remove the nut and washer (Fig. 153).
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LINKAGE 11. Remove the hairpin cotter from the PTO rod attached to the assist arm (Fig. 156). 13. Raise the machine to access the underside of the frame. 14. Remove the cotter pin from the clevis pin connecting the PTO yoke connected to the bellcrank (Fig. 158). 4 Fig 156 PICT-6525 Fig 158 PICT-6523a 12. Remove the PTO rod from the assist arm (Fig. 157). 15. Remove the clevis pin and PTO yoke/rod assembly (Fig. 159).
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LINKAGE 16. Remove the nut from the bolt securing the PTO linkage bellcrank assembly to the frame (Fig. 160). Fig 160 18. Remove the grease fitting from the PTO linkage bellcrank (Fig. 162). PICT-6533 17. Remove the bolt and the PTO linkage bellcrank from the chassis (Fig. 161). Fig 162 PICT-6541a Installation 1. Install a grease fitting into the PTO bellcrank. Ensure the 90 degree fitting is oriented as shown (Fig.
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LINKAGE 2. Position the shoulder bolt into the PTO bellcrank (Fig. 164). 4 Fig 164 PICT-6546a 3. Position the bellcrank/bolt assembly into the chassis: b. Insert the bolt through the hole in the chassis (Fig. 166). Fig 166 PICT-6550 4. Secure the PTO bellcrank/bolt assembly to the chassis with a nut (Fig. 167). a. Insert the upper bellcrank arm through the slot in the chassis (Fig. 165).
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LINKAGE 5. Position the linkage rod/yoke assembly onto the lower arm of the PTO bellcrank and insert a clevis pin (Fig. 168). 7. Lubricate PTO bellcrank with general purpose #2 grease (Fig. 170). Fig 170 Fig 168 6. Install the hairpin cotter into the linkage rod (Fig. 169). 8. Insert the PTO linkage rod into the assist arm (Fig. 171).
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LINKAGE 9. Install the hairpin cotter to secure the PTO (Fig. 172). 4 Fig 172 PICT-6525 10. Install the mower deck cover (Fig. 173). Fig 173 11. Insert a bolt into the upper bellcrank and then slide a washer onto the bolt (Fig. 174). Fig 174 12. Install the bellcrank, bolt and washer assembly (Fig. 175).
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LINKAGE 13. Install a washer and a nut onto the bolt (Fig. 176). Fig 176 15. Position the lower PTO linkage rod so each end is installed into one of the bellcranks (Fig. 178). PICT-6517 Fig 178 14. Secure the nut so that the PTO bellcrank can pivot freely (Fig. 177). Fig 177 16. Install the two hairpin cotters to secure the PTO rod to the two bellcranks (Fig. 179).
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LINKAGE 17. Install the threaded end of the upper PTO linkage rod into the control panel bracket through the nylon bearing (Fig. 180). 4 Fig 180 PICT-6554 18. Position the lower end of the PTO linkage rod into the bellcrank and install a hairpin cotter to secure it (Fig. 181). 19. Install a jam nut onto the threaded end of the upper linkage rod. Thread the nut to the bottom of the threads (Fig. 182). Fig 182 20. Install the PTO push/pull knob onto the PTO linkage rod (Fig. 183).
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LINKAGE 21. Secure the jam nut against the bottom of the PTO push/pull knob (Fig. 184). 2. Remove the choke cable from the clamp (Fig. 186). Fig 186 Fig 184 PICT-5378 PICT-6502 3. Remove the Z-bend of the choke cable from the choke control lever (Fig. 187). Choke Cable Replacement Choke Cable Removal 1. Loosen the clamp that secures the choke cable to the engine (Fig. 185).
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LINKAGE 4. Loosen the double nut configuration that secures the choke handle to the chassis (Fig. 188). Choke Cable Installation 1. Slide the choke cable though the hole of the choke cable bracket on the chassis. Feed the lower nut onto the choke cable (Fig. 190). 4 Fig 188 PICT-5384 5. While holding the lower nut, slide the choke cable assembly out of the choke cable bracket that is bolted to the chassis (Fig. 189). Fig 190 PICT-5390 2.
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LINKAGE 3. Install the lower nut onto to the choke handle assembly and tighten it, securing the choke handle to the choke cable bracket (Fig. 192). Fig 192 PICT-5397 4. Hook the Z-bend of the choke cable into the choke control lever (Fig. 193). Fig 193 Fixed Deck Mid-Size Service Manual PICT-5381 5. Slide the choke cable into the upper cable clamp and loosely clamp the outer cable housing (Fig. 194). Fig 194 PICT-5400 6. Move the choke control to the open position (Fig. 195).
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LINKAGE 7. Make sure that the carburetor choke valve is fully open (Fig. 196). 9. Move the choke control to “choke” position (Fig. 198). Note: The air filter has been removed to show the carburetor choke valve. 4 Fig 198 Fig 196 PICT-5411 PICT-4689 10. Make sure that the carburetor choke valve is completely closed (Fig. 199). 8. Hold the choke control lever to maintain the “open” position of the choke. Pull on the outer choke cable housing until the inner wire has almost no slack.
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LINKAGE Throttle Control Replacement - T-Bar Throttle Control Removal 3. Remove the two bolts and nuts that secure the control panel and throttle control to the handle (Fig. 202). 1. Loosen the cable clamp that secures the throttle cable to the engine (Fig. 200). Fig 202 Fig 200 PICT-5424 PICT-5433 4. Slide the throttle control assembly out of the control panel and pull the throttle cable out through the control panel opening (Fig. 203). 2.
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LINKAGE Throttle Control Installation 1. Slide the throttle control cable assembly, cable first, down through the opening in the control panel (Fig. 204). 4 3. Route the throttle cable forward along the right side, between the muffler and the engine, up to the engine control linkage (Fig. 206). Fig 206 Fig 204 PICT-5440 PICT-5435 4. Hook the Z-bend of the throttle cable into the upper hole of the speed control lever (Fig. 207). 2.
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LINKAGE 5. Slide the throttle cable into the lower cable clamp and loosely clamp the outer cable housing (Fig. 208). Fig 208 PICT-0084 6. Move the throttle lever to “Fast” position. Note: “Fast” is at the detent position. Do not push the handle all the way forward in the throttle control slot (Fig. 209). 7. Pull on the throttle cable housing until the inner wire has almost no slack and then tighten the cable clamp bolt (Fig. 210). Fig 210 8. Move the throttle lever to the “Slow” position.
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LINKAGE 3. Remove the throttle Z-bend from the speed control lever (Fig. 214). Throttle Control Replacement Pistol Grip Removal 1. Loosen the clamp holding the throttle cable to the engine (Fig. 212). 4 Fig 214 PICT-5456 4. Remove the metal spring clamp securing the throttle cable to the right side of the handle (Fig. 215). Fig 212 PICT-5452 2. Remove the throttle cable from the clamp (Fig. 213).
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LINKAGE 5. Pull the knob off the throttle handle (Fig. 216). Fig 216 7. Remove the throttle cable assembly from behind the control panel and carefully feed the cable out from around the engine (Fig. 218). PICT-5460 Fig 218 6. Remove the 2 nuts and carriage bolts securing the throttle cable assembly to the control panel (Fig. 217). PICT-5466 Installation 1. Install the throttle control assembly into the slot in the control panel (Fig. 219).
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LINKAGE 2. Install the two carriage bolts and nuts to secure the throttle control handle assembly to the control panel (Fig. 220). 4 Fig 220 PICT-5464 3. Route the cable down the right handle and install the metal spring clip to secure the cable to the handle. Route the cable down over the top of the transmission (Fig. 221). 4. Continue routing the cable around the left side, in between the muffler and the engine, up to the engine control linkage (Fig. 222). Fig 222 5.
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LINKAGE 6. Slide the throttle cable into the lower cable clamp and loosely clamp the outer cable housing (Fig. 224). Fig 224 PICT-5477 7. Move the throttle lever to “Fast” position (Fig. 225). Fig 225 8. Pull on the throttle cable housing until the inner wire has almost no slack and then tighten the cable clamp bolt (Fig. 226). Fig 226 9. Move the throttle lever to the “Slow” position. Make sure that the carburetor throttle valve moves smoothly to the closed position (Fig. 227).
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LINKAGE Control Linkage & Thumb Latch Replacement - Pistol Grip 2. Slide the trunnion out of the idler arm (Fig. 229). This procedure is the same for both the right side and left side handle controls. This procedure was done on a pistol grip – gear. The same steps can be followed for a pistol grip – hydro machine. Removal 1. Remove the e-clip from the back side of the trunnion on the lower end of the control rod (Fig. 228). Fig 229 4 PICT-5569 3.
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LINKAGE 4. Remove the clevis pin and control linkage rod from the drive lever assembly (Fig. 231). Fig 231 6. Remove the bolt, spacer, washers and the thumb latch assembly from the handle bar (Fig. 233). PICT-5573 5. Loosen and remove the nut from the bolt securing the thumb latch assembly to the handle bar (Fig. 232). Fig 233 PICT-5579 7. Disassemble the thumb latch/bolt assembly (Fig. 234): B A C Fig 234 Fig 232 PICT-5580a PICT-5577 A. Spacer B.
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LINKAGE 8. Remove the push nut securing the drive lever assembly to the handle bar (Fig. 235). 4 Fig 235 10. Drive the roll pin out of the opening in the handle bar (Fig. 237). Fig 237 PICT-5584 9. Remove the pin securing the drive lever assembly to the handle bar (Fig. 236). PICT-5590 Installation 1. Drive a roll pin into the upper-most opening on the handle bar (Fig. 238).
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LINKAGE 2. Position the drive lever onto the handle and slide the pin through to secure the drive lever to the handle (Fig. 239). 4. Assemble the thumb latch, bolt, washers and spacers as shown (Fig. 241): Note: The Belleville washers should be assembled onto the bolt in an alternating fashion (i.e. crown out, crown in, crown out). B A Fig 239 C D 4 PICT-5596 Fig 241 3. Install the push nut onto the drive lever pin (Fig. 240). A. Spacer B. Thumb latch PICT-5580a C. Belleville Washers (3) D.
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LINKAGE 6. Install the nut onto the bolt securing the thumb latch assembly to the handle bar (Fig. 243). 8. Install an e-clip onto thebacke side of the trunnion to secure the control rod to the idler arm (Fig. 245). Note: When tightening the nut, do not over-tighten. The thumb latch must move freely, but without the assembly rattling. A 4 Fig 245 PICT-5566 A. Trunnion Fig 243 PICT-5577 9. Adjust the control rod so that 2.62” (6.65cm) of thread extends past the trunnion (Fig. 246). 7.
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LINKAGE 10. Insert a clevis pin through the upper hole in the control rod and drive lever assembly (Fig. 247). Fig 247 12. Install a hairpin cotter into the clevis pin to secure the control rod to the thumb latch assembly (Fig. 249). PICT-5607 Fig 249 11. Adjust the control rod so there is a .19” to .25” (4.8 to 6.4mm) space between the control rod clevis pin and the bottom of the thumb latch slot (Fig. 248). Fig 248 Fixed Deck Mid-Size Service Manual PICT-5610 13.
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LINKAGE Control Linkage Replacement - T-Bar 3. Depress the connector lock with a small flat screwdriver (Fig. 252). Removal 1. Open the locking tab on the front of the operator presence control (OPC) switch (Fig. 250). 4 Fig 252 Fig 250 PICT-5165 PICT-5169 4. While holding the lock down, draw the wire and spade terminal out of the connector (Fig. 253). 2. Disconnect the plug from the OPC switch (Fig. 251).
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LINKAGE 5. Repeat step 3 and 4 for the second wire/spade terminal. 8. Remove the hairpin cotter and washer securing the trunnion to the idler bracket (Fig. 256). 6. Pull the wire harness from the tube in the T-Bar (Fig. 254). Fig 256 Fig 254 PICT-5187 PICT-5179 9. Remove the pin from the traction idler plate and trunnion (Fig. 257). 7. Remove the hairpin cotter connecting the link to the T-Bar (Fig. 255).
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LINKAGE 10. Repeat steps 7, 8 and 9 for the opposite side. 13. Slide the OPC bar downward and off the switch assembly (Fig. 260). 11. Remove the link from one side of the T-Bar (Fig. 258). 4 Fig 260 Fig 258 PICT-5208a PICT-5200 14. Compress the tabs on the sides of the switch (Fig. 261). 12. While holding the T-Bar and the OPC bar, remove the link on the other side (Fig. 259).
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LINKAGE 15. Draw the switch out to the rear (Fig. 262). Fig 262 17. Lift the T-Bar off of the reverse traction drive handle (Fig. 264). PICT-5212 Fig 264 PICT-5222a 16. Remove the parking brake lever (Fig. 263). 18. Remove the cotter pins from the reverse traction drive handle (Fig. 265).
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LINKAGE 19. Remove the pivot pin from one side (Fig. 266). Installation 1. Align the reverse traction drive handle with the holes in the upper handle. Insert the pivot pins (Fig. 268). Fig 266 4 PICT-5229 20. Support the reverse traction drive handle and remove the pivot pin from the other side. The handle is now free (Fig. 267). Fig 268 PICT-5234a 2. Align the holes in the reverse traction handle with the holes in the pivot pins. Insert the cotter pin (Fig. 269).
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LINKAGE 3. Secure both cotter pins (Fig. 270). Fig 270 5. Align the holes in the parking brake latch with the hole in the handle (Fig. 272). PICT-5240 Fig 272 4. Install the T-Bar onto the reverse traction drive handle (Fig. 271). PICT-5246 6. Secure the parking brake latch with a bolt and lock nut (Fig. 273). Note: The parking brake latch must rotate freely but be tight enough so it doesn’t rattle.
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LINKAGE 7. Insert the OPC switch into the hole in the handle until it has snapped into place (Fig. 274). 4 Fig 274 PICT-5251 8. Install the OPC handle so that the hoop slides onto the switch housing (Fig. 275). Fig 275 4-46 PICT-5254 9. Secure the OPC handle with the linkage rods on both sides (Fig. 276). Fig 276 PICT-5261 10. Insert the hairpin cotters securing the linkage rods to the handle on both sides (Fig. 277).
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LINKAGE 11. Insert a clevis pin through the trunnion (Fig. 278). Fig 278 PICT-5268 12. Insert the clevis pin with trunnion to the traction idler arm (Fig. 279). Fig 279 Fixed Deck Mid-Size Service Manual PICT-5269 13. Install a washer on the clevis pin (Fig. 280). Fig 280 PICT-5273 14. Secure the clevis pin and washer with a hairpin cotter (Fig. 281).
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LINKAGE 15. Repeat steps 11 through 14 to secure the control rod on the other side. 18. Use the wire or string to draw the wire harness through the tube (Fig. 284). 16. Attach a 6” (15.24cm) long piece of wire or string to the end of the wire harness (Fig. 282). 4 Fig 284 Fig 282 PICT-5278 17. Feed the end of the wire or string up through the tube in the handle (Fig. 283). Fig 283 4-48 PICT-5284 PICT-5280 19. Hold the plug so the tab faces forward.
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LINKAGE 20. Insert the white wire into the opposite side of the plug. The tab in the spade connector must face outward. Pull back slightly to ensure tab is latched (Fig. 286). Control Linkage Adjustment - T-Bar 1. Initially adjust the control rods so that 2 1/4” (5.715cm) of thread extends beyond the trunnion fittings (Fig. 288). 4 Fig 286 PICT-5289 Fig 288 PICT-5303 21. Plug the connector into the OPC switch (Fig. 287). 2.
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LINKAGE 3. Engage the control bar (Fig. 290). 5. Engage the Parking Brake (Fig. 292). Note: The parking brake lever should swing into a snug position against the upper handle while pulling back on the upper control bar. Fig 290 4 PICT-5314 4. Using a ruler, measure the travel distance of the pulley while releasing and engaging the control bar. The travel distance should be approximately 3/4” (19mm) (Fig. 291). Note: If the pulley travel is more the 3/4” (19mm), the brakes must be adjusted.
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LINKAGE Operator Presence Control Lever Replacement - Pistol Grip 2. Remove the left operator presence control lever from the operator presence control rod (Fig. 295). Removal Note: The set screw and lever may need to be heated up to release thread locking compound. Note: The operator’s manual tube has been removed for photo purposes. 1. Loosen and remove the set screw that retains the left side operator presence control (OPC) lever to the operator presence control rod (Fig. 294).
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LINKAGE 4. Repeat steps 1 thru 3 to remove the right side OPC lever. 5. Remove the extension spring located under the control panel (Fig. 297). Installation 1. Slide the spring tab end of the operator presence control (OPC) rod through the left side opening of the control panel. Install the right end of the rod into the opening on the right side handle bar. Slide the rod through the right side handle bar opening until the left end of the rod can be inserted through the left handle bar opening (Fig. 299).
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LINKAGE 3. Install the nylon bushings onto each end of the OPC rod (Fig. 301). Fig 301 5. Align the setscrew with the flat side of the rod and install the OPC levers onto the ends of the OPC rod (Fig. 303). PICT-5549 Fig 303 4. Apply high strength thread locking compound (Loctite 609 or equivalent) onto both ends of the OPC rod (Fig. 302). Fig 302 Fixed Deck Mid-Size Service Manual PICT-5559 PICT-5548 6. Apply thread locking compound to the set screws (Fig. 304).
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LINKAGE 7. Install one set screw into each OPC lever to secure the levers onto the OPC rod (Fig. 305). 4 Fig 305 PICT-5543 Speed Control Service - Pistol Grip - Hydro Drive 2. Remove the upper hairpin cotter from the speed control rod (Fig. 307). Fig 307 PICT-6332 3. Remove the hairpin cotter from the clevis pin on the lower end of the speed control rod (Fig. 308). Removal Note: The operator’s manual tube was removed and the ignition switch and OPC switch were disconnected for photo purposes. 1.
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LINKAGE 4. Remove the clevis pin from the lower end of the speed control rod (Fig. 309). Fig 309 PICT-6338 5. Remove the speed control rod (Fig. 310). Fig 310 6. Remove the lower bolt and nut securing the speed control handle to the control panel (Fig. 311). Fig 311 7. Remove the middle bolt, nut and spring assembly securing the speed control handle to the control panel (Fig. 312).
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LINKAGE 8. Remove the upper bolt and nut (Fig. 313). Fig 313 4 10. Remove the remaining nut, bolt, washers and spring from the speed control lever assembly (Fig. 315). PICT-6354a Fig 315 PICT-6359a 9. Remove the speed control handle (Fig. 314). Note: There are 2 washers between the shift lever and shift lever plate (Fig. 316).
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LINKAGE 11. Release the pistol grip from neutral lock and place it in the drive position (Fig. 317). Fig 317 13. Remove the cotter pin from the trunnions installed in the tab on both ends of the speed control crank (Fig. 319). PICT-6366 Fig 319 12. Remove the outside nut from both of the 2 speed control link bolt assemblies (Fig. 318). Fig 318 14. Remove the washer from the trunnions installed in the tab on both ends of the speed control crank (Fig. 320).
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LINKAGE 15. Remove the left hand and right hand speed control links and bolt assemblies (Fig. 321). 17. Remove the speed control crank (Fig. 323). Fig 323 4 Fig 321 16. While supporting the speed control crank, remove the bolt and washer located on each end (Fig. 322). Fig 322 4-58 PICT-6384 PICT-6381 PICT-6383 18. On the right hand and left hand speed control links, mark the location of the nut/swivel assembly on the threads of the link (Fig. 324).
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LINKAGE 19. On the left hand speed control link, loosen and remove the end nut (Fig. 325). Fig 325 PICT-6389a 20. Remove the washers and the trunnion from the control link (Fig. 326). Fig 326 Fixed Deck Mid-Size Service Manual PICT-6396a 21. Remove the second nut from the threads of the control link (Fig. 327). Fig 327 PICT-6398a 22. Remove the two nuts and the bolt from the slotted end of both control links (Fig. 328).
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LINKAGE 23. Remove the knob from the right side control link assembly (Fig. 329). 4 Fig 329 25. Remove the second nut from the threads of the control link (Fig. 331). Fig 331 PICT-6403a 24. Slide the spacer, washers, trunnion, and spring off the control link (Fig. 330). PICT-6408a Installation 1. Apply thread locking compound to the threads of the speed control crank bolts (Fig. 332).
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LINKAGE 2. Position the speed control crank (Fig. 333). Right hand control link assembly: 4. Install one nut onto the control link, threading it down to the mark (Fig. 335). Fig 333 PICT-6384 4 Fig 335 PICT-6409a 3. Install a bolt and washer on each end of the speed control crank (Fig. 334). 5. Install a spacer, 3 washers, a trunnion, and a spring onto control link (Fig. 336).
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LINKAGE 6. Install the knob onto the control link assembly (Fig. 337). 8. Install two nuts onto the bolt (flange side away from control link) so that there is 1/2” (1.27cm) of thread beyond the two nuts as shown (Fig. 339): A 4 Fig 337 PICT-6403a Fig 339 PICT-6414a A. 1/2” (1.27cm) 7. 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. 338). Left Hand control link assembly: 9.
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LINKAGE 10. Install two nuts onto the bolt (flange side away from control link) so that there is 1/2” (1.27cm) of thread beyond the two nuts as shown (Fig. 341): 12. Install 2 washers and the trunnion onto the control link (Fig. 343). A Fig 343 Fig 341 PICT-6396a PICT-6414a A. 1/2” (1.27cm) 13. Thread the second nut onto the control link. Snug fit the nut down to the washer and trunnion assembly (Fig. 344). 11. Install one nut onto the control link, threading it down to the mark (Fig. 342).
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LINKAGE 14. Position the left hand speed control link and bolt assembly (Fig. 345). 4 Fig 345 16. Install the trunnion into the left hand tab of the speed control crank. Slide the washer onto the trunnion (Fig. 347). PICT-6381 Fig 347 15. Insert the lower bolt into the upper tab of the control shaft and install a nut onto the bolt (Fig. 346). Fig 346 4-64 PICT-6372 PICT-6379 17. Install the cotter pin onto the trunnion (Fig. 348).
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LINKAGE 18. Tighten the 2 nuts on either side of the trunnion on the upper end of the left hand control link (Fig. 349). Fig 349 PICT-6418 19. Repeat steps 14 thru 18 to install the right hand control and bolt assembly into the right hand control shaft and right hand tab of the speed control crank. 21. Insert the bolt/washer assembly into the slotted opening of the shifter lever plate (Fig. 351). Fig 351 PICT-6423 22. Install a second friction washer onto the bolt (Fig. 352). 20.
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LINKAGE 23. Position the shift lever onto the shifter lever plate (Fig. 353). 25. Install a lock nut onto the bolt (Fig. 355). Fig 355 4 Fig 353 PICT-6442 PICT-6437 24. Position a spring onto the bolt assembly (Fig. 354). 26. Tighten the nut until approximately 3 threads stick out past the nut (Fig. 356). Note: Do not collapse the spring.
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LINKAGE 27. Position a washer in between the two plates and line the ID of the washer up with the center hole in the lever plates (Fig. 357). 29. Loosely install the upper and lower bolts and nuts (Fig. 359). Fig 359 Fig 357 28. Position the speed control handle (Fig. 358). Fig 358 Fixed Deck Mid-Size Service Manual PICT-6454 PICT-6447a PICT-6452 30. Loosely install the middle bolt, spring and nut (Fig. 360).
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LINKAGE 31. Tighten the middle nut until approximately 3 threads stick out past the nut (Fig. 361). 33. Position the speed control rod so that the upper end is installed in the forward-most hole of the speed control lever (Fig. 363). Note: Do not collapse the spring. 4 Fig 363 Fig 361 PICT-6459 32. Tighten the upper and lower bolts and nuts (Fig. 362). 34. Install the hairpin cotter into the speed control rod securing it to the speed control lever (Fig. 364).
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LINKAGE 35. Position the speed control rod to the center tab on the speed control crank and install the clevis pin (Fig. 365). 37. Apply thread locking compound to the threads of the speed control lever (Fig. 367). Fig 367 Fig 365 36. Install the hairpin cotter into the clevis pin securing the lower end of the speed control rod to the speed control crank (Fig. 366). 38. Install the knob onto the speed control lever (Fig. 368).
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LINKAGE Speed Control and Neutral Switch Adjustment - Pistol Grip - Hydro Drive 3. Adjust the threaded yoke at the bottom of the speed control linkage until the tabs are positioned correctly (Fig. 371). 1. Move the operator’s speed control lever to the full forward position (Fig. 369). 4 Fig 371 Fig 369 PICT-6482 PICT-6479 4. Pull the operator’s speed control lever back to the neutral position (Fig. 372). 2. Check the orientation of the tabs on the ends of the speed control crank.
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LINKAGE 5. Check that the neutral safety switch actuating tab has depressed the plunger of the safety switch so that there is about 5/16” (7.9mm) between the tab and the switch. If necessary, move the switch forward or back to obtain the correct measurement (Fig. 373). 2. Slide the shift lever to the far left position (reverse) (Fig. 375). Fig 375 Fig 373 PICT-6486a PICT-5415 3. Move the shift lever to the right one detent (neutral). (Fig. 376). Shift Plate Neutral Adjustment Gear Drive 1.
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LINKAGE 4. Adjust the shift plate so that the neutral gate is centered over the shift lever (Fig. 377). 4 Fig 377 PICT-5419 5. Tighten the 2 bolts and nuts to secure the shift plate in position (Fig. 378). Fig 378 PICT-5412 6. Start the machine and run it in each transmission position to verify proper plate position. If further adjustment is required, start over at step 1.
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CHASSIS 6. Slide the hose clamp down the fuel line (Fig. 380). 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. • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.
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CHASSIS 8. Remove the two nuts, springs and washers from the left side of the bottom of the fuel tank (Fig. 382). Fig 382 10. Lift the fuel tank assembly up and out of the frame. Take care as the tank fitting, fuel line and filter come through the frame opening (Fig. 384). IMG-6003a Fig 384 5 9. Remove the two bolts, lock washers and washers from the right side of the bottom of the fuel tank (Fig. 383). Fig 383 5-2 IMG-6005a PICT-5343 11.
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CHASSIS 12. Remove the fuel line from the bulkhead fuel fitting (Fig. 386). Fig 386 PICT-5349 13. Loosen and remove the nut and washer securing the bulkhead fuel fitting to the bottom of the fuel tank (Fig. 387). 14. Remove the fuel cap assembly from the fuel tank (Fig. 388). Fig 388 15. Remove the bulkhead fuel fitting from the tank through the fuel cap opening (Fig. 389).
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CHASSIS 16. Inspect the filter screen on the bulkhead fuel fitting. Clean or replace the filter screen if it is clogged or damage (Fig. 390). 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. Installation 1. Install the bulkhead fuel fitting into the tank through the fuel cap opening (Fig. 391). Note: The fitting should be installed so that the 90º bend points toward the front of the fuel tank.
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CHASSIS 3. Tighten the nut to secure the fitting to the fuel tank (Fig. 393). Fig 393 5. Slide the hose clamp up and install it to secure the fuel line to the bulkhead fitting (Fig. 395). PICT-5353 4. Install the fuel line onto the bulkhead fitting (Fig. 394). Fig 395 PICT-5345 6. Carefully feed the fuel line assembly through the frame opening and position the tank on the frame. 7. Secure the fuel tank to the chassis by installing the bolts, washers and springs as shown (Fig.
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CHASSIS 8. Install the fuel line to the fuel pump (Fig. 397). Fig 397 10. Fill the fuel tank with fuel and open the fuel valve (Fig. 399). PICT-0006 Fig 399 9. Slide the hose clamp up and install it to secure the fuel line to the fuel pump (Fig. 398). PICT-0001 11. Check for leaks. 5 Brake Service Before each use, check the brakes for proper operation. Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.
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CHASSIS 3. Push both the neutral/brake locks forward to set the brake (Fig. 401). Pistol Grip - Gear Drive Checking the Brake 1. Park the machine on a level surface. 2. Disengage the blade control (PTO) (Fig. 400). Fig 400 PICT-4821 Note: Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock. Refer to “Adjusting the Brake”, following. Fig 401 PICT-4829 4. Release the brake and move the neutral/brake lock to neutral (Fig.
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CHASSIS 5. Move the machine slightly, approximately 1/2” (13mm). Wheels should rotate freely. 6. If both conditions are met, no adjustment is required. 3. Rotate the wing nuts on the brake rods (Fig. 404) 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. Adjusting the Brake 1. Check the brake before you adjust it. Refer to Pistol Grip – Gear Drive, “Checking the Brake” preceding. 2.
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CHASSIS 5. Recheck the brake operation. Refer to Pistol Grip – Gear Drive, “Checking the Brake” above. 3. Set the parking brake (Fig. 407). Important: With the parking brake released, the rear wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved, examine the brake system components for wear or damage. T-Bar - Gear Drive Checking the Brake 1. Park the machine on a level surface. 2. Disengage the Power Take Off (PTO) (Fig. 406).
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CHASSIS 6. Move the upper control bar forward, approximately 1/2” (13mm) (Fig. 409). 3. Rotate the wing nuts on the brake rods (Fig. 411) 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. Fig 409 PICT-4848 7. The wheels should rotate freely. 5 8. If the above conditions are met, no adjustment is required.
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CHASSIS Pistol Grip - Hydro 4. Set the parking brake (Fig. 413). Checking the Parking Brake Note: Setting the parking brake should take a reasonable amount of force. If it engages too hard or too easily, adjustment is required. Refer to “Adjusting the Parking Brake”, following. 1. Move the machine to a level surface. 2. Disengage the power take off (PTO) and stop the engine (Fig. 412). Fig 413 Fig 412 PICT-4870 PICT-4859 Adjusting the Parking Brake 3.
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CHASSIS 3. Remove the hairpin cotter from the lower brake linkage (Fig. 414). Fig 414 PICT-4880a Note: There should be approximately 1/4” (6.3mm) clearance between the tire and the flat bar when the parking brake is in the released position (Fig. 416). A Fig 416 5 4. Rotate the lower brake linkage as follows (Fig. 415): • Clockwise to tighten the parking brake • Counterclockwise to loosen the parking brake PICT-4889a A. 1/4” (6.3mm) 5.
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CHASSIS 4. Remove the E-ring and washers from the axle (Fig. 419). T-Bar - Gear Drive Brake Band & Drum Replacement Removal 1. Turn the engine off. 2. Remove the spark plug wire from the spark plug (Fig. 418). Fig 419 PICT-4896a 5. Remove the hairpin cotter from the brake linkage rod (Fig. 420). Fig 418 PICT-4894 3. Raise the machine until the tires are off the floor. Support the machine with jack stands or blocks to prevent it from falling.
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CHASSIS 6. Remove the brake linkage rod from the idler arm (Fig. 421). Fig 421 8. Slide the wheel assembly off the axle and move the belt from around the axle so it is out of the way of the brake band (Fig. 423). PICT-4956 Fig 423 5 7. Rotate the wheel assembly to remove the belt from the wheel pulley (Fig. 422). Fig 422 9. Remove the E-ring securing the brake band assembly to the frame (Fig. 424).
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CHASSIS 10. Slide the brake band assembly off the pivot (Fig. 425). Fig 425 PICT-4912 11. Remove the 2 push nuts from the 2 pins (Fig. 426). Fig 426 12. Remove the 2 pins securing the brake band to the brake arm (Fig. 427). Fig 427 13. Remove the brake band from the brake arm (Fig. 428).
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CHASSIS 14. Inspect the brake band and replace it if it is damaged or worn (Fig. 429). Fig 429 5 PICT-5729a 15. Inspect the brake drum. Replace it if it is damaged or worn (Fig. 430). Fig 430 5-16 PICT-4917a 16. Remove the 4 bolts that secure the brake drum to the wheel pulley (Fig. 431). Fig 431 PICT-4923a 17. Remove the brake drum from the wheel pulley (Fig. 432).
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CHASSIS Installation 3. Slide the brake band onto the brake arm. 1. Position the brake drum onto the wheel pulley (Fig. 433). Left side brake band (Fig. 435). Fig 435 Fig 433 PICT-5737a PICT-4928 Right side brake band (Fig. 436). 5 2. Install 4 bolts to secure the drum to the wheel pulley and tighten (Fig. 434).
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CHASSIS 4. Install 2 pins into each end of the brake band to secure it to the brake arm (Fig. 437). Fig 437 5 PICT-5742a 5. Install a new push nut on each of the pins to secure the brake band to the brake arm (Fig. 438). Fig 438 5-18 PICT-5744a 6. Slide the brake band assembly onto the pivot (Fig. 439). Fig 439 PICT-4933 7. Install an e-ring to secure the brake band assembly (Fig. 440).
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CHASSIS 8. Apply a thin coat of anti-seize compound to axle shaft as a rust preventative. Do Not get any on brake or belt. Position the belt around the axle and begin sliding the wheel assembly onto the axle (Fig. 441). 10. Continue sliding the wheel onto the axle until the brake band is installed onto the brake drum (Fig. 443). Fig 443 Fig 441 PICT-4946 PICT-4941 11. Slide the washer(s) onto the axle (Fig. 444). 5 9. Rotate the wheel to install the belt onto the wheel pulley (Fig. 442).
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CHASSIS 12. Install an e-ring onto the axle (Fig. 445). Fig 445 14. Install the hairpin cotter into the brake linkage rod to secure the rod to the brake arm (Fig. 447). PICT-4953a Fig 447 13. Install the brake linkage rod into the upper hole on the brake arm (Fig. 446). 5 PICT-4960 15. Reinstall the spark plug wire onto the park plug. 16. Lower the machine to a level surface. 17. Check the brake operation again. Refer to “Checking the Brake” on page 5-9.
PAGE 135
CHASSIS 5. Remove the spring from the idler pulley (Fig. 449). Pistol Grip - Gear Drive Brake Band & Drum Replacement Removal 1. Turn the engine off. 2. Remove the spark plug wire from the spark plug. 3. Raise the machine until the tires are off the floor. Support the machine with jack stands or blocks to prevent it from falling. 4. Remove the brake band idler spring from the drive wheel shield bolt (Fig. 448). Fig 449 PICT-6901 6. Remove the hairpin cotter from the brake linkage rod (Fig. 450).
PAGE 136
CHASSIS 7. Remove the brake linkage rod from the idler arm (Fig. 451). Fig 451 5 PICT-6903 8. Remove the E-ring and washers from the axle (Fig. 452). 9. Rotate the wheel assembly to remove the belt from the wheel pulley (Fig. 453). Fig 453 10. Slide the wheel assembly off of the axle (Fig. 454).
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CHASSIS 11. Remove the belt from around the axle (Fig. 455). Fig 455 13. Remove the e-ring securing the brake arm to the frame (Fig. 457). PICT-6946 Fig 457 12. Remove the E-ring securing the brake band assembly to the frame (Fig. 456). Fig 456 14. Slide the brake band assembly off the pivot (Fig. 458).
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CHASSIS 15. Remove the push nut from the brake band pin (Fig. 459). Fig 459 5 PICT-6919a 16. Remove the pin securing the brake band to the brake arm (Fig. 460). Fig 460 5-24 PICT-6922a 17. Inspect the brake band and replace it if it is damaged or worn (Fig. 461). Fig 461 PICT-6924a 18. Inspect the brake drum. Replace it if it is damaged or worn (Fig. 462).
PAGE 139
CHASSIS 19. Remove the 4 bolts that secure the brake drum to the wheel pulley (Fig. 463). Installation 1. Position the brake drum onto the wheel pulley (Fig. 465). Fig 463 PICT-4923a Fig 465 PICT-4928 20. Remove the brake drum from the wheel pulley (Fig. 464). 2. Install the 4 bolts to secure the drum to the wheel pulley and tighten (Fig. 466).
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CHASSIS 3. Slide the brake band onto the brake arm (Fig. 467). Fig 467 PICT-6925a 4. Install a pin to secure the brake band to the brake arm: 5 Right side brake band (Fig. 469). Fig 469 PICT-6934a 5. Install a new push nut onto the pin securing the brake band to the brake arm (Fig. 470). Left side brake band (Fig. 468).
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CHASSIS 6. Slide the brake band assembly onto the 2 pivot pins (Fig. 471). Fig 471 PICT-6939 7. Install the e-ring securing the brake band to the pivot (Fig. 472). 8. Install the e-ring securing the brake arm to the pivot (Fig. 473). Fig 473 9. Position the belt around the axle (Fig. 474).
PAGE 142
CHASSIS 10. Slide the wheel assembly onto the axle (Fig. 475). Fig 475 12. Continue sliding the wheel onto the axle until the brake band is installed onto the brake drum (Fig. 477). PICT-6949a Fig 477 PICT-6953 11. Rotate the wheel to install the belt onto the wheel pulley (Fig. 476). 13. Slide the washer(s) onto the axle (Fig. 478).
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CHASSIS 14. Install the e-ring onto the axle (Fig. 479). Fig 479 16. Install the hairpin cotter into the brake linkage rod to secure the rod to the brake arm (Fig. 481). PICT-6958a Fig 481 15. Install the brake linkage rod into the upper hole on the brake arm (Fig. 480). PICT-6961 17. Hook the spring onto the idler pulley (Fig. 482).
PAGE 144
CHASSIS 18. Hook the other end of the spring onto the bolt located on the drive wheel shield (Fig. 483). Parking Brake Service Removal 1. Remove the hairpin cotter from the top end of the upper linkage rod (Fig. 485). Fig 483 5 PICT-6900 19. Install the spark plug wire onto the park plug (Fig. 484). Fig 485 PICT-6219 2. Remove the hairpin cotter from the bottom end of the upper linkage rod (Fig. 486). Fig 484 PICT-4894 20. Lower the machine to a level surface. Fig 486 PICT-6221 21.
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CHASSIS 3. Remove the upper linkage rod from the handle and bellcrank assemblies (Fig. 487). Fig 487 PICT-6225 4. Remove the nut from the parking brake handle assembly (Fig. 488). 5. Remove the handle assembly, bolt, washer and spacer (Fig. 489). Fig 489 6. Unplug the brake switch from the harness (Fig. 490).
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CHASSIS 7. Remove the nuts from the bolts that secure the hydraulic tank to the frame (Fig. 491). Fig 491 5 9. Remove the parking brake bracket assembly and gently lay the hydraulic tank on the tire (Fig. 493). PICT-6233 8. Remove the bolts and washers securing the hydraulic tank to the frame. The spacers will fall out (Fig. 492). A A Fig 493 PICT-6238 10. Remove the 2 screws securing the parking brake switch to the parking brake bracket assembly (Fig. 494). B B Fig 492 A.
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CHASSIS 11. Remove the tapped plate and switch from the parking brake bracket assembly (Fig. 495). Fig 495 12. Press the 2 bushings out of the parking brake handle bracket (Fig. 497). PICT-6244a A B PICT-6245 13. Remove the hairpin cotter from the lower linkage rod (Fig. 498). Parking Brake Bracket Assembly (Fig. 496) C Fig 497 E D Fig 496 PICT-6249a Fig 498 A. Tapped plate B. Switch C. Bracket PICT-7651 D. Screws E.
PAGE 148
CHASSIS 14. Unhook the lower linkage rod from the brake (Fig. 499). 16. Remove the bellcrank assembly (Fig. 501). Fig 501 Fig 499 5 15. Remove the nut from the bolt securing the bellcrank assembly to the bellcrank plate (Fig. 500). 17. Loosen and remove the nut from the bellcrank assembly. (Fig. 502).
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CHASSIS 18. Remove the bolt and washer from the bellcrank assembly (Fig. 503). Fig 503 PICT-6266a 19. Unclip and remove the clevis spring pin from the brake link yoke (Fig. 504). Fig 504 Fixed Deck Mid-Size Service Manual PICT-6268a 20. Remove the yoke from the bellcrank assembly (Fig. 505). Fig 505 PICT-6273a 21. Remove the 2 nuts from the bolts securing the bellcrank plate to the frame (Fig. 506).
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CHASSIS 22. Remove the bolts and the bellcrank plate from the frame (Fig. 507). Fig 507 5 PICT-6278 23. While supporting the brake, remove the end of the spring hooked to the bolt on the brake (Fig. 508). Fig 508 5-36 PICT-6282 24. Loosen the inside jam nut on the screw with the parking brake spring still hooked on it (Fig. 509). Fig 509 PICT-6286 25. Loosen and remove the outside jam nut from the screw with the spring still hooked on it (Fig. 510).
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CHASSIS 26. Remove the bolt, spring and jam nut (Fig. 511). Fig 511 28. While supporting the brake, remove the 3 bolts and then remove the brake from the frame (Fig. 513). PICT-6292 Fig 513 27. Remove the remaining 3 nuts from the bolts that secure the brake to the frame (Fig. 512). PICT-6297 Installation 5 1. Position the brake into the frame (Fig. 514).
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CHASSIS 2. Loosely install 3 bolts and nuts securing the brake to the frame (Fig. 515). Fig 515 4. Loosely install the lock nut onto the bolt so that there are 3 to 4 threads protruding beyond the lock nut (Fig. 517). PICT-6296a Fig 517 PICT-6288 3. Install the bolt, spring and jam nut (Fig. 516). 5. Hook the free end of the spring onto the brake arm bolt (Fig. 518).
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CHASSIS 6. Tighten the 3 nuts and bolts to secure the brake to the frame (Fig. 519). 8. Swivel the brake to ensure free movement. 9. Install the bellcrank plate and two bolts to the frame (Fig. 521). Fig 519 PICT-6296a Fig 521 PICT-6278 7. Tighten the jam nut to secure the bolt with the spring hooked on it (Fig. 520). 5 Note: Ensure the bellcrank plate is oriented as shown (Fig.
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CHASSIS 10. Install 2 nuts to secure the bellcrank plate to the frame (Fig. 523). Fig 523 12. Install the clevis spring pin to secure the yoke to the bellcrank assembly and clip the clevis spring to the link yoke (Fig. 525). PICT-6276 Fig 525 5 11. Position the yoke onto the bellcrank assembly (Fig. 524). Fig 524 13. Install the bolt and washer into the bellcrank assembly (Fig. 526).
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CHASSIS 14. Position the bolt and washer into the bellcrank and install a nut onto the bolt (Fig. 527). 16. Position the bellcrank assembly into the bellcrank plate (Fig. 529). Note: The flange side of the nut faces toward the bolt head. Note: Tighten the nut, then loosen it slightly to allow the bolt assembly to swivel freely. Fig 529 PICT-6263 17. Install a nut onto the bellcrank bolt to secure the bellcrank assembly to the bellcrank plate (Fig. 530).
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CHASSIS 18. Hook the linkage rod into the brake (Fig. 531). Fig 531 20. Install two new bushings into the parking brake handle bracket (Fig. 533). PICT-6255 Fig 533 19. Install a hairpin cotter to secure the lower linkage rod to the brake (Fig. 532). 5 Fig 532 21. Position the switch and tapped plate onto the parking brake bracket assembly (Fig. 534).
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CHASSIS 22. Secure the switch to the parking brake handle bracket assembly by installing 2 screws (Fig. 535). Fig 535 PICT-6242a 23. Install two bolts and washers into the hydraulic tank bracket (Fig. 536). Fig 536 Fixed Deck Mid-Size Service Manual PICT-6310 24. Install one long spacer onto each of the bolts (Fig. 537). Fig 537 PICT-6311 25. Install the parking brake bracket assembly onto the bolts (Fig. 538).
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CHASSIS 26. Install one short spacer onto each of the bolts (Fig. 539). 28. Plug the brake switch into the harness (Fig. 541). Fig 541 Fig 539 5 27. Position the hydraulic tank and bolt/spacer assembly onto the frame bracket (Fig. 540): • Both the bolts will have to be pushed up slightly to set the tank on the frame bracket. • Work the front bolt down through the frame bracket and install the nut. • Work the second bolt down through the frame bracket and install the nut. 29.
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CHASSIS 30. Install and tighten the nut securing the parking brake handle assembly (Fig. 543). Fig 543 PICT-6227 31. Install the upper linkage rod into the handle and the bellcrank assemblies (Fig. 544). 32. Install a hairpin cotter into the bottom end of the upper linkage rod (Fig. 545). Fig 545 PICT-6221 33. Install a hairpin cotter into the top end of the upper linkage rod (Fig. 546). A Fig 544 PICT-6225 Fig 546 PICT-6219 A.
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CHASSIS Adjusting the Parking Brake 1. Check and adjust the tire pressure to the proper specifications. 4. Turn the brake link into or out of the yoke (Fig. 548) until there is 1/8” to 1/4” (.31cm - .63cm) clearance between the parking brake tire bars and the tires while the parking brake is disengaged (Fig. 549). 2. Disengage the parking brake by moving the park brake lever to the forward position. 3. Remove the hairpin cotter from the lower brake link in the lower parking brake linkage (Fig. 547).
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CHASSIS 5. Install the hairpin cotter (Fig. 550). Fig 550 2. Remove the 4 nuts from the bolts securing the hydro control shield to the chassis (Fig. 552). PICT-7651 Fig 552 Control Shaft Bearing Replacement Removal PICT-6725 3. Remove the control shield assembly, 4 bolts and 4 spacers from the chassis (Fig. 553). 1. Remove the neutral return spring from the control shaft (Fig. 551).
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CHASSIS 4. Remove the 4 bolts and spacers from the shield assembly (Fig. 554). Fig 554 5 6. Remove the bolts, washers and side flange bearing from the hydro control shield (Fig. 556). Fig 556 PICT-6729a 5. Remove the nuts from the 2 bolts securing the side flange bearing to the hydro control shield (Fig. 555). PICT-6740 Installation 1. Install the lock washer onto the 2 bolts and then the flat washer onto the 2 bolts (Fig. 557).
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CHASSIS 2. Insert the 2 bolt assemblies into the hydro control shield and position the side flange bearing (Fig. 558). 4. Position the hydro control shield so the bearing is installed on the control shaft (Fig. 560). Fig 560 Fig 558 PICT-6752 PICT-6748 3. Loosely install 2 nuts onto the 2 bolts securing the side flange bearing to the hydro control shield (Fig. 559). 5. Install 4 bolts and spacers through the hydro control shield and into the chassis; secure with 4 nuts (Fig. 561).
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CHASSIS 6. Tighten the nuts securing the side flange bearing in place on the hydro control shield (Fig. 562). 8. Apply grease to the side flange bearing (Fig. 564). Fig 564 Fig 562 PICT-6761 PICT-6758 7. Install the spring onto the control shaft (Fig. 563). 5 Gear Drive Transmission Traction Belt Replacement Removal 1. Disengage the blade control (PTO) lever and set the parking brake. 2. Stop the engine and wait for all moving parts to stop. 3.
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CHASSIS 4. Remove the mower belt from the engine belt drive pulley (Fig. 565). Fig 565 PICT-4964 5. Loosen the idler bolt (Fig. 566). Fig 566 6. Slide the idler pulley in the slot to relieve tension on the traction belt (Fig. 567). Fig 567 7. Remove the traction belt from the engine belt drive pulley (Fig. 568).
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CHASSIS Installation 1. Install the new traction belt over the engine belt drive pulley and then route it around the traction idler and pulleys (Fig. 569). Note: Belt should have 1/2” (1.27cm) of deflection with 3 lbs. (1.36kg) of pressure on the belt midway between the transmission and engine pulley (Fig. 571). Fig 571 Fig 569 5 PICT-4974 2. Position the idler so that there is tension on the traction control belt and then tighten the nut to secure the idler position (Fig. 570). Fig 570 3.
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CHASSIS 4. Check the belt guide under the engine frame for the proper adjustment. The distance between the belt guide and mower belt should be 3/4” (1.9cm) when the mower belt is engaged. Adjust the belt guide if necessary. The disengaged belt should not drag or fall off the pulley when the guide is properly adjusted (Fig. 573). A F Hydro Drive Transmission Traction Belt Replacement Removal 1. Remove the mower belt from the engine belt drive pulley (Fig. 574). B C F E D Fig 573 fig.
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CHASSIS 3. Remove the belt from the hydro pump pulleys (Fig. 576). 5. Remove the idler bolt (Fig. 578). Fig 578 Fig 576 PICT-6565 PICT-6592 6. Lower the idler pulley assembly (Fig. 579). 4. Remove the idler spring (Fig. 577).
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CHASSIS 7. Remove the traction belt from the other pulleys (Fig. 580). Fig 580 PICT-6571 2. Position the idler assembly so the belt is routed around the left side of the idler pulley (Fig. 582). Fig 582 PICT-6578 3. Insert the idler assembly bolt up into the chassis and tighten (Fig. 583). Installation 1. Route the traction belt around the engine pulley. Ensure the belt is located between the pulley and the belt guide (Fig. 581). A Fig 583 Fig 581 PICT-6565 PICT-6573 A.
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CHASSIS Note: For a heavier drive setting, relocate the idler spring anchor link so the bolt is installed in either the medium or heavy duty positions (Fig. 584). 5. Pull the split ring/chain assembly and route the transmission drive belt around the 2 pump pulleys (Fig. 586). B D C A Fig 586 Fig 584 5 A. Spring anchor B. Standard setting PICT-6592 fig. 43 G001524 C. Medium setting D. Heavy duty setting 6. Position the mower belt onto the engine belt drive pulley (Fig. 587). 4.
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CHASSIS 7. Check the spacing between the belt and the belt guide. The distance between should be 1/16” to 1/8” (.15cm - .31cm). Adjust if necessary (Fig. 588). • A belt contacting the bottom of the pulley “V” indicates worn belt or pulleys. The belt will slip no matter how tight you adjust it. • Belt glazed, shiny or burnt on the sides of the “V” indicates slipping. Belt must be replaced and the cause identified and corrected. • The sides of each pulley sheave should be straight and flat.
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CHASSIS 3. Remove the hairpin cotter from the lower end of the brake rod (Fig. 590). Fig 590 5 PICT-5807 4. Remove the brake rod from the brake arm (Fig. 591). Fig 591 5-58 PICT-5811a 5. Remove the nut from the lower bolt securing the drive wheel shield to the frame (Fig. 592). Fig 592 PICT-5812 6. Remove the lower bolt and spacer from the drive wheel shield (Fig. 593).
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CHASSIS 7. Remove the nut from the upper bolt securing the drive wheel shield to the frame (Fig. 594). Fig 594 PICT-5820 8. While supporting the idler, remove the upper bolt and drive wheel shield (Fig. 595). 9. Position the idler so that it is out of the way (Fig. 596). Fig 596 10. Remove the belt from the drive pulley (Fig. 597).
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CHASSIS 11. Remove the belt from the machine by sliding it over the tire (Fig. 598). Fig 598 5 PICT-5827 12. Inspect the pulleys for wear and damage. Replace as necessary. If pulley replacement is required continue on. For belt replacement only, go to step 49. 14. Slide the drive pulley off the transmission drive shaft (Fig. 600). Fig 600 PICT-5834 15. Remove the key from the drive shaft keyway (Fig. 601). 13. Loosen the set screw securing the drive pulley to the transmission drive shaft (Fig.
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CHASSIS 16. Inspect the key and replace if worn or damaged. 19. Position the drive pulley onto the transmission drive shaft (Fig. 604). 17. Install the woodruff key (Fig. 602). Fig 604 Fig 602 PICT-5838 18. Apply anti-seize compound to the transmission drive shaft (Fig. 603). 20. Apply thread locking compound to the drive pulley set screw (Fig. 605).
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CHASSIS 21. Install the set screw into the drive pulley, securing it to the transmission drive shaft (Fig. 606). Fig 606 PICT-5847 22. Remove the e-ring from the wheel axle (Fig. 607). 5 Fig 607 23. Remove the 2 washers from the wheel axle (Fig. 608). Fig 608 24. Remove the wheel and tire assembly from the axle (Fig. 609).
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CHASSIS 25. Remove the 4 bolts that secure the brake drum and wheel pulleys to the wheel and tire assembly (Fig. 610). 27. Remove the first pulley (Fig. 612). Fig 612 Fig 610 PICT-5861a PICT-5855 28. Remove the 4 spacers (Fig. 613). 26. Remove the brake drum from the wheel and tire assembly (Fig. 611).
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CHASSIS 29. Remove the second pulley (Fig. 614). Fig 614 31. Position 4 spacers by aligning them with the 4 holes in the first pulley (Fig. 616). PICT-5867a Fig 616 30. Position the first pulley by aligning it with the holes on the wheel hub (Fig. 615). 5 Fig 615 32. Position the second pulley on top of the spacers ensuring the 4 holes align with the 4 spacers (Fig. 617).
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CHASSIS 33. Position the brake drum onto the second pulley by aligning the 4 holes with the holes on the pulley (Fig. 618). 35. Apply a light coat of anti-sieze compound to the axle. Do not get any on the brake or belt. Slide the wheel and tire assembly onto the axle (Fig. 620). Fig 618 Fig 620 PICT-5859a 34. Install the 4 bolts into the 4 holes making sure that each bolt is securing the brake drum, both pulleys and a spacer to the wheel hub (Fig. 619). 36. Install 2 washers onto the axle (Fig. 621).
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CHASSIS 37. Install the e-clip onto the axle securing the wheel and tire assembly (Fig. 622). 39. Remove the washer from the clevis pin (Fig. 624). Fig 624 Fig 622 5 38. Remove the hairpin cotter from the clevis pin that secures the control rod to the idler arm (Fig. 623). 40. Remove the clevis pin from the trunnion and idler arm (Fig. 625).
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CHASSIS 41. Remove the idler and brake rod assembly from the machine (Fig. 626). 43. Remove the pulley from the idler arm bolt (Fig. 628). Fig 628 Fig 626 PICT-5888 42. Remove the nut that secures the idler pulley to the idler arm (Fig. 627). 44. Install the idler pulley so that the long hub side slides onto the idler arm bolt first (Fig. 629).
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CHASSIS 45. Install the nut onto the idler arm bolt (Fig.630). Fig 630 5 PICT-5890a 46. Position the idler arm assembly and install the clevis pin securing the idler arm to the control rod (Fig. 631). 47. Install the washer onto the clevis pin (Fig. 632). Fig 632 48. Install the hairpin cotter into the clevis pin (Fig. 633).
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CHASSIS 49. Install the wheel drive belt over the tire, positioning it between the belt guide and the tire (Fig. 634). 51. Install the brake rod into the brake arm (Fig. 636). Fig 636 Fig 634 PICT-5898 50. Position the belt onto the wheel pulleys and drive pulley (Fig. 635). 52. Install hairpin cotter to secure the brake rod to the brake arm (Fig. 637).
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CHASSIS 53. Position the drive wheel shield and, while supporting the idler, install the upper bolt through the drive wheel shield and the bushing on the idler arm (Fig. 638). 55. Install a bolt through the lower hole of the drive wheel shield, through a spacer and into the frame (Fig. 640). Fig 640 Fig 638 5 PICT-5917 PICT-5912 54. Loosely install a nut onto the upper bolt securing the drive wheel shield to the frame (Fig. 639). 56.
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CHASSIS 57. Hook the idler arm spring to the frame (Fig. 642). Pistol Grip - Gear Drive Wheel Drive Belt and Pulley Replacement The following inspections should be made when disassembling the drive system, particularly if the reason for service is inability to adjust belt tension or “loss of drive”. Be sure to inspect all components; there may be more than one item needing replacement. Fig 642 Additionally, the idler pulley should be pushed straight down onto the belt (Fig. 643).
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CHASSIS 1. Raise the machine so the rear tire is off the ground. 4. Remove the hairpin cotter from the brake linkage rod (Fig. 646). 2. Remove the brake band idler spring from the drive wheel shield bolt (Fig. 644). Fig 646 Fig 644 5 PICT-6902 PICT-6900 5. Remove the brake linkage rod from the idler arm (Fig. 647). 3. Remove the traction belt idler spring from the idler pulley (Fig. 645).
PAGE 187
CHASSIS 6. Remove the nut from the lower bolt securing the drive wheel shield to the frame (Fig. 648). Fig 648 8. Remove the nut from the upper bolt securing the drive wheel shield and idler pulley to the frame (Fig. 650). PICT-6964 Fig 650 7. Remove the lower bolt and spacer from the drive wheel shield (Fig. 649). Fig 649 9. While supporting the idler, remove the upper bolt and drive wheel shield (Fig. 651).
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CHASSIS 10. Position the idler so that it is out of the way (Fig. 652). Fig 652 PICT-6975 11. Remove the belt from the drive pulley (Fig. 653). 5 12. Remove the belt from the machine by sliding it over the tire (Fig. 654). Fig 654 PICT-6978 13. Inspect the pulleys for wear and damage. Replace as necessary. If pulley replacement is required continue on. For belt replacement only, go to step 52. 14. Loosen the set screw securing the drive pulley to the transmission drive shaft (Fig. 655).
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CHASSIS 15. Slide the drive pulley off the transmission drive shaft (Fig. 656). 17. Inspect the woodruff key and replace if worn or damaged. 18. Install the woodruff key (Fig. 658). Fig 656 PICT-6983 Fig 658 PICT-6985 16. Remove the woodruff key from the drive shaft keyway (Fig. 657). 19. Apply anti-seize compound to the transmission drive shaft (Fig. 659).
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CHASSIS 20. Position the drive pulley onto the transmission drive shaft (Fig. 660). Fig 660 5 PICT-6983 21. Apply thread locking compound to the drive pulley set screw (Fig. 661). 22. Install the set screw into the drive pulley, securing it to the transmission drive shaft (Fig. 662). Fig 662 23. Remove the e-ring from the wheel axle (Fig. 663).
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CHASSIS 24. Remove the 2 washers from the wheel axle (Fig. 664). Fig 664 26. Remove the 4 bolts that secure the brake drum and wheel pulleys to the wheel and tire assembly (Fig. 666). PICT-5852a Fig 666 25. Remove the wheel and tire assembly from the axle (Fig. 665). Fig 665 27. Remove the brake drum from the wheel and tire assembly (Fig. 667).
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CHASSIS 28. Remove the first pulley (Fig. 668). Fig 668 30. Remove the second pulley (Fig. 670). PICT-5861a 29. Remove the 4 spacers (Fig. 669). Fig 670 PICT-5867a 31. Position the first pulley by aligning it with the holes on the wheel hub (Fig. 671).
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CHASSIS 32. Position 4 spacers by aligning them with the 4 holes in the first pulley (Fig. 672). Fig 672 34. Position the brake drum onto the second pulley by aligning the 4 holes with the holes on the pulley (Fig. 674). PICT-5864a Fig 674 33. Position the second pulley on top of the spacers ensuring the 4 holes align with the 4 spacers (Fig. 673). Fig 673 35.
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CHASSIS 36. Apply a light coat of anti-sieze compound to the axle. Do not get any on the belt or brake. Slide the wheel and tire assembly onto the axle (Fig. 676). 38. Install the e-clip onto the axle, securing the wheel and tire assembly (Fig. 678). Fig 678 Fig 676 5 39. Rotate the idler arm to access the e-clip on the control rod swivel (Fig. 679). 37. Install 2 washers onto the axle (Fig. 677).
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CHASSIS 40. Remove the e-clip from the control rod swivel (Fig. 680). Fig 680 PICT-6989 41. Remove the idler and brake rod assembly (Fig. 681). Fig 681 42. Remove the three nuts from the idler pulley bolt (Fig. 682). Fig 682 43. Remove the bolt and idler pulley from the idler arm (Fig. 683).
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CHASSIS 44. Install the idler pulley bolt into the idler arm (Fig. 684). 46. Install a flange nut onto the idler bolt (Fig. 686). Fig 686 Fig 684 5 45. Install the idler pulley so that the long hub side slides onto the idler arm bolt first (Fig. 685). 47. Install a lock nut onto the idler bolt so that it is tight against the flange nut (Fig. 687).
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CHASSIS 48. Install a second lock nut so that 2 or 3 bolt threads protrude past the nut (Fig. 688). 50. Install an e-clip onto the swivel (Fig. 690). Fig 690 Fig 688 49. Position the idler arm assembly onto the control linkage rod swivel (Fig. 689). 51. Rotate the idler arm back and position it out of the way of the drive belt pulleys (Fig. 691).
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CHASSIS 52. Install the wheel drive belt over the tire and position it between the belt guide and the wheel pulleys (Fig. 692). 54. Position the idler pulley so the idler hub rests on the drive belt (Fig. 694). Fig 694 Fig 692 5 53. Position the belt onto the wheel pulleys and drive pulley (Fig. 693). 55. Install a bolt into the upper hole of the drive wheel shield (Fig. 695).
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CHASSIS 56. Insert the bolt through the idler hub and into the hole in the frame (Fig. 696). Fig 696 58. Insert a bolt through the lower hole of the drive wheel shield, through a spacer and into the frame (Fig. 698). PICT-7034 Fig 698 57. Loosely install a nut onto the upper drive wheel shield bolt (Fig. 697). Fig 697 59. Install a nut onto the lower bolt and tighten both nuts (Fig. 699).
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CHASSIS 60. Install the brake rod into the brake arm (Fig. 700). Fig 700 62. Install the idler spring onto the idler pulley bolt (Fig. 702). PICT-6959 Fig 702 61. Install a hairpin cotter to secure the brake rod to the brake arm (Fig. 701). 5 Fig 701 63. Install the idler spring onto the drive wheel shield bolt (Fig. 703).
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CHASSIS 64. Check the brake operation. Refer to “Checking the Brake” on page 5-7. 65. Check Neutral adjustment. Refer to “Shift Plate Neutral Adjustment - Gear Drive” on page 4-71. 66. Visually inspect the alighment of the pulleys. As you look straight down at the three pulleys (transmission, idler, and wheel) they should all be in line. The transmission pulley can be adjusted slightly either inward or outward. Additionally, the idler pulley should be pushed straight down onto the belt (Fig. 704).
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CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK.
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HYDROSTATIC DRIVE SYSTEM Hydraulic Testing 2. Loosen the 4 wheel lug nuts on the side being tested (Fig. 705). 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. This procedure is performed on the left wheel motor hydraulic hoses.
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HYDROSTATIC DRIVE SYSTEM 6. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 10. Cap the wheel motor fittings so debris does not enter the system. 7. Mark the hoses and corresponding wheel motor fitting ports so the hoses get connected in their original locations (Fig. 707). 11. Attach the hydraulic hoses to the flow test gauge (Fig. 709).
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HYDROSTATIC DRIVE SYSTEM 13. Run the machine for 2 minutes in forward (no load) to purge air from the system. Note: For accurate test readings, oil must be at normal operating temperature. 18. Retest the pump after repairs. Re-connect the hydraulic hoses to the wheel motor fittings. Torque the hose fittings to 85-95 ft-lbs. (115-128 Nm). 19. Slide the wheel and tire assembly onto the hub (Fig. 711). 14. Run the machine at full throttle (no load). Verify the RPM with a tachometer: 3200 + 150 RPM.
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HYDROSTATIC DRIVE SYSTEM 21. Lower the machine so the rear tires are resting on the ground. 25. Release the parking brake. 26. Bleed the hydraulic system. Refer to “Bleeding the Hydraulic System” on page 6-31. 22. Apply the parking brake. 23. Tighten and torque the 4 lug nuts to 90–95 ft-lbs. (122-129 Nm) (Fig. 713). Hydraulic Reservoir Replacement Removal 1. Remove the hairpin cotter from the top end of the parking brake upper linkage rod (Fig. 715). Fig 713 6 PICT-6873a 24.
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HYDROSTATIC DRIVE SYSTEM 2. Remove the parking brake upper linkage rod from the parking brake handle assembly (Fig. 716). Fig 716 4. Remove the bolts and washers securing the hydraulic reservoir to the frame. The spacers may fall out (Fig. 718). PICT-6767 Fig 718 3. Remove the nuts from the bolts that secure the hydraulic reservoir to the chassis (Fig. 717). PICT-6774 5. Gently lay the hydraulic reservoir upside down on the tire.
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HYDROSTATIC DRIVE SYSTEM 6. Remove the hose clamps from the two hydraulic lines coming off the bottom of the hydraulic reservoir (Fig. 720). 8. Remove the two hydraulic fittings from the bottom of the reservoir (Fig. 722). Fig 722 Fig 720 PICT-6783a PICT-6779 7. Pull the hydraulic hoses off the 2 reservoir fittings (Fig. 721). Installation 1. Install the hydraulic cap assembly onto the reservoir tank (Fig. 723).
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HYDROSTATIC DRIVE SYSTEM 2. Install two hydraulic fittings into the bottom of the reservoir. Position as shown (Fig. 724): Fig 724 PICT-6786a 3. Slide the 2 hydraulic hoses onto the reservoir fittings. Install the two hose clamps to secure the hoses in place (Fig. 725). 4. Install a bolt and washer into the forward-most mounting hole of the reservoir (Fig. 726). Fig 726 PICT-6790 5. Slide a long spacer onto the bolt (Fig. 727).
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HYDROSTATIC DRIVE SYSTEM 6. Slide the brake lever bracket assembly onto the bolt (Fig. 728). Fig 728 8. Position the reservoir assembly so the bolt is inserted into the frame bracket. Install a nut onto the bolt to secure the reservoir assembly to the frame (Fig. 730). PICT-6799 Fig 730 PICT-6811 7. Slide a short spacer onto the bolt (Fig. 729). 9. Position a long spacer under the reservoir tank bracket. Insert the bolt and washer through the reservoir tank bracket and down through the spacer (Fig.
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HYDROSTATIC DRIVE SYSTEM 10. Continue sliding the bolt through the parking brake bracket (Fig. 732). Fig 732 12. Continue sliding the bolt through the hole in the frame and then install a nut onto the bolt to secure the reservoir assembly to the frame (Fig. 734). PICT-6815 Fig 734 PICT-6819 11. Slide a short spacer onto the bolt (Fig. 733). 13. Insert the parking brake linkage rod into the parking brake bracket (Fig. 735).
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HYDROSTATIC DRIVE SYSTEM 14. Install a hairpin cotter into the parking brake linkage rod (Fig. 736). Hydraulic Pump 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. Slip the drive belt off the pulley (Fig. 739). Fig 739 5. Slide the pulley off the hydraulic pump shaft (Fig. 741). PICT-6606 Fig 741 PICT-6608 4. Loosen the two pulley hub set screws (Fig. 740). 6. Remove the pulley key if it did not fall out on it’s own (Fig. 742).
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HYDROSTATIC DRIVE SYSTEM 7. Inspect the key and replace it if worn or damaged. 8. Remove the hose clamp from the return line (Fig. 743). 10. Remove the charge hose from the hydraulic pump fitting (Fig. 745). Cap the hydraulic hose and fitting to prevent debris from entering the system. Fig 745 Fig 743 PICT-6616 PICT-6612 9. Pull the return line hose from the fitting and drain the hydraulic fluid into a drain pan (Fig. 744). 11.
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HYDROSTATIC DRIVE SYSTEM 13. Remove both of the high pressure hoses from the fittings on the pump (Fig. 747). Cap the hydraulic hoses and fittings to prevent debris from entering the system. 15. Unhook the lower end of the extension spring from the control shaft (Fig. 749). Fig 749 Fig 747 PICT-6625 PICT-6621 14. Remove the two mounting bolts, washers and nuts securing the hydraulic pump to the frame (Fig. 748). 16.
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HYDROSTATIC DRIVE SYSTEM 17. Remove the clevis pin (Fig. 751). Fig 751 19. Remove the drive rod trunnion from the control shaft (Fig. 753). PICT-6632 Fig 753 18. Remove the e-ring from the trunnion on the lower end of the drive lever rod (Fig. 752). PICT-6638 20. Remove the outside nut from the lower end of the speed control linkage and remove the linkage/bolt assembly from the control shaft (Fig. 754).
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HYDROSTATIC DRIVE SYSTEM 21. Remove the 4 nuts from the bolts securing the hydro control shield to the frame (Fig. 755). Fig 755 PICT-6642 22. Remove the 4 bolts, spacers and the hydro control shield from the frame (Fig. 756). 23. Rotate the case drain hose fitting to gain access to the set screw on the control shaft (Fig. 757). Fig 757 PICT-6649 24. To access the control shaft set screw, maneuver the shaft side of the pump out of the hole in the frame and tilt it toward the front of the machine.
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HYDROSTATIC DRIVE SYSTEM 25. Remove the control shaft from the pump (Fig. 759). 27. 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. 761). Torque each fitting as noted: A D Fig 759 PICT-6655 A C B Fig 761 PICT-6664a 26. Remove the pump (Fig. 760). A. High pressure hose (2) Torque: 34-38 ft-lbs. (46.0951.52 Nm) B. Charge hose fitting Torque: 7-10 ft-lbs. (9.49-13.55 Nm) (brass), 15-21 ft-lbs. (20.33-28.
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HYDROSTATIC DRIVE SYSTEM 3. Apply thread-locking compound to set screw and start set screw into pump shaft. (Fig. 764). Installation 1. Position the pump into the chassis (Fig. 762). Fig 764 Fig 762 PICT-6759a PICT-6660a 2. Slide the control shaft in through the side of the chassis. Position the short tab on the control shaft inside the neutral return spring yoke (Fig. 763). 4. Slide the pump shaft into the control shaft. Align the set screw with the hole in the control shaft. (Fig. 765).
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HYDROSTATIC DRIVE SYSTEM 5. Secure the set screw (Fig. 766). Fig 766 7. Install the hairpin cotter into the clevis pin (Fig. 768). PICT-6652 6. Install the clevis pin securing the neutral return spring yoke to the control shaft (Fig. 767). Fig 768 PICT-6673 8. Insert the drive rod trunnion into the control shaft (Fig. 769).
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HYDROSTATIC DRIVE SYSTEM 9. Install an e-ring onto the drive rod trunnion (Fig. 770). Fig 770 PICT-6680a 10. Insert the bolt on the lower end of the speed control link into the control shaft (Fig. 771). 11. Install a nut onto the speed control link bolt (Fig. 772). Fig 772 PICT-6684 12. Position the 4 bolts, spacers and the hydro control shield assembly onto the frame (Fig. 773). Note: The two bottom spacers are approximately 3/8” (.95cm) shorter than the upper spacers.
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HYDROSTATIC DRIVE SYSTEM 13. Install 4 nuts securing the hydro control shield assembly to the chassis (Fig. 774). Fig 774 Note: The other end of the spring is attached through the hole on the spring anchor (Fig. 776). PICT-6690 Fig 776 14. Hook the hydro pump spring to the bolt on the control shaft (Fig. 775). PICT-6694 15. Install 2 bolts, washers and nuts securing the pump to the chassis (Fig. 777).
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HYDROSTATIC DRIVE SYSTEM 16. Tighten the case drain fitting (Fig. 778). Fig 778 18. Secure the hose with the hose clamp by sliding the clamp up onto the case drain fitting (Fig. 780). PICT-6701 Fig 780 17. Install the case drain hose to the case drain fitting (Fig. 779). PICT-6704a 19. Install the charge hose to the charge hose fitting (Fig. 781).
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HYDROSTATIC DRIVE SYSTEM 20. Install the 2 high pressure hoses to the fittings on the pump (Fig. 782). 22. Install the key into the pump shaft keyway (Fig. 784). Note: Ensure that the marked hose is connected to the marked port on the pump. Fig 784 Fig 782 PICT-6712 PICT-6714 23. Install the pump pulley onto the pump shaft (Fig. 785). 21. Apply anti-seize compound to the pump shaft (Fig. 783).
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HYDROSTATIC DRIVE SYSTEM 24. Apply thread locking compound onto the 2 hydro pump pulley set screws (Fig. 786). 26. Slip the drive belt onto the pulley (Fig. 788). Fig 788 Fig 786 PICT-6719 PICT-6759a 25. Install and tighten the 2 set screws securing the pulley to the shaft (Fig. 787). 27. Release the split ring/chain assembly to restore tension to the belt (Fig. 789).
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HYDROSTATIC DRIVE SYSTEM 28. Apply grease to the control shaft (Fig. 790). Removal 1. Apply the parking brake. 2. Loosen the 4 lug nuts (Fig. 791). Fig 790 PICT-8678 30. Check the oil level in the hydraulic reservoir and fill as necessary. 31. Remove air from the hydraulic system. Refer to “Bleeding Hydraulic System” on page 6-31. 6 Fig 791 PICT-6830a 3. Remove the cotter pin from the wheel motor shaft (Fig. 792).
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HYDROSTATIC DRIVE SYSTEM 4. Remove the slotted hub nut from the wheel motor shaft (Fig. 793). 7. Release the parking brake. 8. Remove the wheel and tire assembly (Fig. 795). Fig 793 PICT-6833a Fig 795 5. Raise the rear of the machine and secure with jack stands. PICT-6837 9. Install a hub puller on the wheel studs (Toro special service tool TOR4097) (Fig. 796). 6. Remove the 4 lug nuts (Fig. 794).
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HYDROSTATIC DRIVE SYSTEM 10. Stabilize the wheel hub using a bar in the notch on the hub. Tighten the forcing screw to free the wheel hub from the tapered wheel motor shaft (Fig. 797). 12. Remove the woodruff key from the shaft keyway (Fig. 799). Fig 799 Fig 797 PICT-6849 PICT-6843 11. Remove the hub from the wheel motor shaft (Fig. 798). 13. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 14.
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HYDROSTATIC DRIVE SYSTEM 15. Position a drain pain under the wheel motor. 19. Remove the wheel motor (Fig. 803). 16. Disconnect both hydraulic hoses from the wheel motor (Fig. 801). Fig 803 Fig 801 PICT-6858a PICT-6853 20. Remove the 2 fittings from the wheel motor (Fig. 804). 17. 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. 18. Remove the 4 bolts securing the wheel motor to the motor mount (Fig. 802).
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HYDROSTATIC DRIVE SYSTEM 3. Install 4 bolts securing the wheel motor to the motor mount (Fig. 807). Installation 1. Transfer the fittings and all markings to the replacement wheel motor. Torque fittings to 85-95 ft-lbs. (115-129 Nm) (Fig. 805). Fig 807 Fig 805 PICT-6859 2. Position the wheel motor into the frame (Fig. 806). PICT-6855 4. Uncap the hoses and fittings and connect both hydraulic hoses to the wheel motor.
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HYDROSTATIC DRIVE SYSTEM 5. Install the woodruff key into the keyway on the wheel motor shaft (Fig. 809). Fig 809 PICT-6863 6. Slide the hub onto the wheel motor shaft (Fig. 810). 7. Loosely install the slotted hub nut onto the wheel motor shaft (Fig. 811). Fig 811 PICT-6865 8. Slide the wheel and tire assembly onto the hub (Fig. 812).
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HYDROSTATIC DRIVE SYSTEM 9. Snug fit the 4 lug nuts on the wheel hub studs (Fig. 813). 13. Tighten and torque the slotted hub nut to 100 ft-lbs. (136 Nm) (Fig. 815). Note: Torque to 100 ft-lbs. (136 Nm), then tighten to the next slot so the cotter pin can be installed. Fig 813 PICT-6869a Fig 815 PICT-6871a 10. Lower the machine so the rear tires are resting on the ground. 11. Apply the parking brake. 14. Install the cotter pin into the wheel motor shaft (Fig. 816). 12.
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HYDROSTATIC DRIVE SYSTEM 15. Fill the reservoir with 15W-50 synthetic engine oil as specified. Note that there are fill level lines inside of the reservoir (Fig. 817). Before starting, make sure the reservoir is at the proper hydraulic oil level. If it is not, fill to the proper level. The following procedures should be performed with the vehicle drive wheels off the ground and then repeated under normal operating conditions.
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HYDROSTATIC DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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GEAR DRIVE SYSTEM 4. Remove the traction belt from the traction drive pulley (Fig. 820). Transmission Replacement Removal 1. Raise and secure the rear of the machine. 2. Loosen the idler bolt (Fig. 818). Fig 820 Fig 818 PICT-4989 PICT-4992 5. Loosen the set screws securing the transmission drive pulley to the transmission drive shaft (Fig. 821). 3. Slide the idler in the slot to remove tension from the traction belt (Fig. 819).
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GEAR DRIVE SYSTEM 6. Remove the pulley from the transmission drive shaft (Fig. 822). Fig 822 PICT-4997 7. Remove the key from the transmission drive shaft (Fig. 823). 8. Remove the neutral return spring from the traction idler arm assembly (Fig. 824). Fig 824 PICT-5005 9. Remove the bottom bolt, spacer and nut from the drive wheel shield assembly (Fig. 825).
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GEAR DRIVE SYSTEM 10. Loosen the upper bolt and nut from the drive wheel shield. Support the shield and traction idler and remove the upper nut (Fig. 826). 12. Position the wheel drive idler assembly so that it is out of the way of the drive pulley and belt (Fig. 828). Fig 828 Fig 826 PICT-5019 PICT-5013 11. While supporting the idler, remove the drive wheel shield and bolt (Fig. 827). 13. Remove the wheel drive belt from the drive pulley (Fig. 829).
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GEAR DRIVE SYSTEM 14. Remove the two bolts and nuts that secure the transmission axle flange bearing to the chassis (Fig. 830). 16. Remove the coupler/coupler guard from the transmission shaft (Fig. 832). Fig 832 Fig 830 PICT-5031 PICT-5024a 15. Slide the transmission axle out of the transmission coupler and chassis (Fig. 831). 17. Remove the cable tie that secures the choke cable to the mounting leg of the transmission (Fig. 833).
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GEAR DRIVE SYSTEM 18. Pistol Grip – Gear only: Remove the two screws and lock washers securing the wires to the top of the neutral start switch (Fig. 834). Fig 834 PICT-5536a 19. Pistol Grip – Gear only: Remove the neutral start switch from the transmission (Fig. 835). 20. Pistol Grip – Gear only: Remove the cable tie that secures the wire harness to the shift lever plate bracket (Fig. 836). Fig 836 PICT-5539a 21.
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GEAR DRIVE SYSTEM 22. Remove the 2 bolts and nuts securing the opposite transmission axle flange bearing to the chassis (Fig. 838). 24. Slide the transmission off the opposite axle and away from the couple/coupler guard. Remove it from the chassis (Fig. 840). Note: The coupler may come off the axle with the transmission; if so, remove it from the transmission. Fig 838 PICT-5099 23. Carefully maneuver the transmission out of the chassis by tilting it back and lifting up (Fig. 839).
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GEAR DRIVE SYSTEM 26. Remove the shift plate assembly from the transmission (Fig. 842). 28. Remove the shift lever and washer from the transmission shifter shaft (Fig. 844). Note: For transmission service procedures, refer to the appropriate Tecumseh Peerless Service Manual. Fig 842 PICT-5060 27. Remove the bolt and Belleville washer securing the shift lever to the transmission (Fig. 843). Fig 844 PICT-5070 Installation 1.
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GEAR DRIVE SYSTEM 2. Install the Belleville washer oriented with the crown up (Fig. 846). Fig 846 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. 847). 4. Position the shift plate assembly over the shift lever and onto the transmission (Fig. 848). Fig 848 PICT-5081 5. Install 4 bolts to secure the shift plate to the transmission (Fig. 849).
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GEAR DRIVE SYSTEM 6. Slide the transmission spline shaft into the RH coupler (Fig. 850). Fig 850 PICT-5091 7. Position the transmission so that the output shaft drops through the opening in the chassis (Fig. 851). 8. Install 2 bolts and nuts to secure the flange bearing to the chassis (Fig. 852). Fig 852 PICT-5099 9. Install the coupler and coupler shield to the left transmission output shaft (Fig. 853). Note: Align the 2 grease fittings.
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GEAR DRIVE SYSTEM 10. Install the left transmission output shaft assembly through the chassis and into the coupler (Fig. 854). Fig 854 PICT-5107 11. Install the 2 bolts and nuts securing the left flange bearing to the chassis (Fig. 855). 12. Install the 4 bolts and lock washers to secure the transmission to the chassis (Fig. 856). Fig 856 PICT-5113 13. Pistol Grip – Gear only: Install the neutral start switch into the transmission (Fig. 857).
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GEAR DRIVE SYSTEM 14. Pistol Grip – Gear only: Connect the wire harness to the neutral start switch with two screws and lock washers (Fig. 858). 16. Install the woodruff key into the transmission input shaft (Fig. 860). Fig 860 Fig 858 PICT-5117 PICT-5536a 15. Pistol Grip – Gear only: Install a cable tie to secure the wire harness to the shift lever plate bracket (Fig. 859). 17. Apply anti-seize compound to the transmission input shaft (Fig. 861).
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GEAR DRIVE SYSTEM 18. Install the transmission drive pulley (Fig. 862). Fig 862 20. Install the belt around the idler and over the transmission pulley. (Fig. 864). PICT-5119 Fig 864 PICT-5123 19. Secure the pulley with 2 set screws (Fig. 863). 21. Position the idler to tension the traction control belt. Tighten the nut to secure the idler position (Fig. 865).
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GEAR DRIVE SYSTEM Note: The belt should have 1/2” (1.27cm) of deflection with 3 lbs. (1.36kg) of pressure on the belt midway between the transmission and engine pulley (Fig. 866). 23. Install a bolt through the upper hole in the drive wheel shield (Fig. 868). Fig 868 Fig 866 PICT-5136a PICT-5127 24. Install the bolt through the traction idler (Fig. 869). 22. Install the wheel drive belt (Fig. 867).
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GEAR DRIVE SYSTEM 25. Install the traction idler/shield assembly to the frame and loosely install a nut on the bolt (Fig. 870). 27. Install a spacer onto the bolt (Fig. 872). Fig 872 Fig 870 PICT-6965 PICT-5143 26. Install a bolt through the lower hole in the drive wheel shield (Fig. 871). 28. Install the drive wheel shield assembly to the frame and loosely install a nut on the bolt (Fig. 873).
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GEAR DRIVE SYSTEM 29. Tighten both the upper and lower bolts (Fig. 874). Fig 874 PICT-5153 30. Hook the spring over the rear edge of the frame (Fig. 875).
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GEAR DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECK 4. Remove the belt from the left side spindle pulley (Fig. 877). Mower Belt Replacement This procedure was performed on a T-Bar Gear, 40” Mower Deck. Removal 1. Disengage the blade control (PTO) lever and set the parking brake. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. 3. Remove the mower deck cover (Fig. 876). Fig 877 PICT-5925 5. Loosen the idler pulley bolt (Fig. 878).
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MOWER DECK 6. Remove the bolt and washer from the idler pulley (Fig. 879). 8. Remove the engagement bushing (Fig. 881). Fig 881 Fig 879 9. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring (Fig. 882). 7. Remove the idler pulley (Fig. 880).
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MOWER DECK 10. Loosen the belt guide nut (Fig. 883). Fig 883 12. Remove the belt from the engine pulley (Fig. 885). PICT-6037 11. Slip the belt off the remaining mower deck pulleys (Fig. 884). Fig 884 PICT-6038 Fig 885 PICT-6040 13. Remove the mower deck belt from the machine (Fig. 886).
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MOWER DECK 2. Feed the mower deck belt down through the chassis opening and place it around the engine drive pulley. Ensure the belt is installed between the pulley and the belt guide (Fig. 888). Installation 1. 40”, 48” and 52” mower decks only: Position the front and rear idler pulleys and belt guide into their original hole positions (Fig. 887). B A C D E Fig 888 Fig 887 A. Rear idler pulley B. Middle hole C. Front hole 8 fig. 40 G001848 D. Belt guide in back position E.
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MOWER DECK 4. Continue routing the belt as shown on the belt routing decal (Fig. 890 and Fig. 891). 5. Insert the engagement bushing into the idler pulley (Fig. 892). Belt routing for 32” and 36” mower decks: Fig 892 Fig 890 fig. 1 98-3296 Belt routing for 40”, 48” and 52” mower decks: Fig 891 Fixed Deck Mid-Size Service Manual PICT-6053 fig. 2 99-3943 6. Insert the bolt and washer into the idler pulley (Fig. 893).
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MOWER DECK 7. Position the turn buckle over the hole in the idler arm (Fig. 894). 9. Tighten the idler bolt (Fig. 896). Fig 896 Fig 894 PICT-6063 PICT-6057 8. Position the belt onto the idler pulley and install the idler pulley into the idler arm (Fig. 895). 10. Install the idler spring from the stud on the mower deck to the stud on the idler arm (Fig. 897). Note: Ensure the belt is routed between idler pulley and belt guide.
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MOWER DECK 11. Check mower belt tension (Fig. 898). Note: If adjustment is required see “Adjusting Mower Belt Tension” below. 2. Rotate the turnbuckle as follows: A. Increase tension: rotate the turnbuckle toward the rear of the mower. B. Decrease tension: rotate the turnbuckle toward the front of the mower. Note: The eyebolt threads on both ends of the turnbuckle should be engaged a minimum of 5/16” (8mm). A 3. Engage the blade control lever (PTO) and check the belt tension.
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MOWER DECK 4. 40”, 48” and 52” mower decks only: Castor Wheel Assembly Service If there is no adjustment left in the turnbuckle and the belt is still loose, the front and rear idler pulleys and the belt guide can be positioned into the inner adjustment holes located on the mower deck (Fig. 901). B Removal 1. Raise and support the machine so the castor wheels are off the floor. 2. While supporting the castor assembly, remove the locking pin from the top of the castor assembly (Fig. 903).
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MOWER DECK 4. Remove the spacers from the fork (Fig. 905). 6. Remove the axle bolt and the wheel and tire assembly from the fork (Fig. 907). Note: Make note of the spacer location on each fork to maintain original deck height setting. Fig 907 Fig 905 PICT-5505 PICT-5499a 7. Remove the spacer from the wheel assembly (Fig. 908). 5. Remove the nut and lock washer securing the wheel and tire assembly to the fork (Fig. 906).
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MOWER DECK 8. Remove one of the bushings from the wheel assembly (Fig. 909). Fig 909 PICT-5516 9. Remove the needle bearing from the wheel assembly (Fig. 910). Fig 910 8 10. Remove the second bushing from the wheel assembly (Fig. 911). Fig 911 PICT-5519 11. Remove the grease zerk from the wheel assembly (Fig. 912). PICT-5517 Fig 912 PICT-5523 12. Thoroughly clean the wheel and tire assembly. Inspect the wheel and bearings for damage and replace as necessary.
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MOWER DECK 3. Install the greased needle bearing into the wheel (Fig. 915). Installation 1. Install a bushing into one side of the wheel (Fig. 913). Fig 915 Fig 913 PICT-5685a PICT-5678 4. Install a second bushing into the other side of the wheel (Fig. 916). 2. Apply grease to the needle bearing (Fig. 914).
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MOWER DECK 5. Install the spacer into the wheel (Fig. 917). Fig 917 7. Position the wheel and tire assembly in the fork (Fig. 919). PICT-5694a Fig 919 6. Install the grease zerk into the wheel assembly (Fig. 918). Fig 918 PICT-5696a PICT-5700a 8. Install the wheel axle bolt (Fig. 920).
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MOWER DECK 9. Install and tighten the lock washer and nut to secure the wheel to the fork (Fig. 921). 11. Apply grease to the fork shaft (Fig. 923). Fig 923 Fig 921 10. Fill the wheel assembly with grease until it begins to flow out of the bushings (Fig. 922). 12. Install spacers onto the fork as previously noted to restore original deck height (Fig. 924).
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MOWER DECK 13. Install the castor assembly into the castor support arm (Fig. 925). 15. Install a lock pin into the fork shaft (Fig. 927). Fig 927 Fig 925 14. Install a washer onto the fork shaft (Fig. 926). Fig 926 PICT-5717 PICT-5714 PICT-5716 16. Fill the castor support arm with grease until it begins to flow out of the support bushings (Fig. 928). Fig 928 PICT-5723 8 17. Lower the machine to the floor.
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MOWER DECK Castor Support Arm Bushing Service 4. Remove the grease zerk from the castor support arm (Fig. 931). 1. Raise the machine so the castor wheels are off the floor, then block up the front of the mower. 2. While supporting the castor assembly, remove the locking pin from the top of the castor assembly (Fig. 929). Fig 931 PICT-5529 5. Remove the 2 flange bushings from the support arm assembly (Fig. 932). Fig 929 PICT-5481 3. Remove the castor assembly from the castor support.
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MOWER DECK 6. Inspect the castor support arm for damage. Replace if necessary. 9. Remove the locking pin from the castor assembly and install the castor assembly into the support arm assembly (Fig. 935). 7. Install 2 flange bushings into the support arm (Fig. 933). Fig 935 Fig 933 PICT-5714 PICT-5497 10. Install a washer onto the castor fork (Fig. 936). 8. Install a grease zerk into the support arm assembly (Fig. 934).
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MOWER DECK 11. Install the locking pin into the castor fork assembly (Fig. 937). Castor Support Arm Replacement Removal 1. Raise the machine so the castor wheels are off the floor, then block up the front of the mower. 2. While supporting the castor assembly, remove the locking pin from the top of the castor assembly (Fig. 939). Fig 937 PICT-5717 12. Fill the castor support arm with grease until it begins to flow out of the support bushings (Fig. 938). Fig 939 PICT-5481 3.
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MOWER DECK 4. Remove the 4 bolts, washers and nuts securing the support arm to the mower deck (Fig. 941). Replacement 1. Position the castor support arm assembly onto the mower deck (Fig. 943). Fig 941 PICT-5530 Fig 943 PICT-5533 5. Remove the castor support arm from the mower deck (Fig. 942). 2. Install 4 bolts, washers and nuts to secure the support arm assembly to the mower deck (Fig. 944).
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MOWER DECK 3. Remove the locking pin from the castor assembly and install the castor assembly into the support arm assembly (Fig. 945). 5. Install the locking pin into the castor fork assembly (Fig. 947). Fig 947 Fig 945 4. Install a washer onto the castor fork (Fig. 946). Fig 946 PICT-5717 PICT-5714 PICT-5716 6. Fill the castor support arm with grease until it begins to flow out of the support bushings (Fig. 948). Fig 948 PICT-5723 7. Lower the machine to the floor.
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MOWER DECK 3. Remove the pivot bolt from the deflector assembly (Fig. 951). Deflector Service Deflector Removal 1. Carefully unhook the spring from the deflector assembly (Fig. 949). Fig 951 Fig 949 PICT-5614 PICT-5619 4. Remove the deflector assembly, spacer and spring from the mower deck (Fig. 952). 2. Remove the deflector assembly pivot bolt and nut (Fig. 950).
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MOWER DECK 3. Remove the remaining carriage bolts and nuts from the deflector assembly (Fig. 955). Deflector Disassembly 1. Remove the center carriage bolts and nuts from the deflector assembly (Fig. 953). Fig 955 Fig 953 PICT-5637 PICT-5633 4. Remove the discharge strap and metal deflector from the rubber deflector (Fig. 956). 2. Remove the deflector mounting bracket from the chute assembly (Fig. 954).
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MOWER DECK 3. Install the metal deflector onto the 4 carriage bolts (Fig. 959). Deflector Assembly 1. Insert the 4 carriage bolts into the discharge strap (Fig. 957). Note: The bolt pattern is oriented so the 2 bolt holes that are closer together are on the right. Fig 959 Fig 957 PICT-5641a PICT-5652 4. Install 2 nuts onto the 2 outermost carriage bolts (Fig. 960). 2. Position and press the rubber deflector onto the 4 carriage bolts (Fig. 958).
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MOWER DECK 5. Position the deflector mounting bracket onto the deflector assembly (Fig. 961). Deflector Installation 1. Slide the spring onto the spacer (Fig. 963). Fig 961 PICT-5658 Fig 963 6. Install 2 nuts securing the deflector mounting bracket to the deflector assembly (Fig. 962). Fig 962 2. Orient the spring/spacer assembly so the end of the spring with the hook is pointing to the rear (Fig. 964).
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MOWER DECK 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. 965). 5. Install the hook end of the spring onto the deflector mounting bracket (Fig. 967). Fig 967 Fig 965 PICT-5614 PICT-5668 Adjustable Baffle Service Removal 4. Install a nut onto the pivot bolt (Fig. 966). 1.
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MOWER DECK 2. Slide the lock lever out of the lock cap (Fig. 969). Fig 969 4. Remove the lock screw by unthreading it from the adjustable baffle assembly (Fig. 971). PICT-6199 Fig 971 PICT-6202 3. Remove the lock cap (Fig. 970). 5. Remove the nut from the bolt securing the adjustable baffle to the underside of the mower deck (Fig. 972).
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MOWER DECK 6. Remove the self-tapping screw that secures the adjustable baffle to the underside of the mower deck (Fig. 973). Fig 973 Installation 1. Position the adjustable baffle on the underside of the mower deck (Fig. 975). PICT-6209 Fig 975 7. Remove the adjustable baffle from the mower deck (Fig. 974). 8 Fig 974 2. Install a self-tapping screw to secure the adjustable baffle to the underside of the mower deck (Fig. 976).
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MOWER DECK 3. Install a nut onto the self tapping bolt that secures the adjustable baffle to the underside of the mower deck (Fig. 977). 5. Thread the lock screw into the bushing of the adjustable baffle assembly (Fig. 979). Fig 979 Fig 977 PICT-6202 PICT-6204 6. Position the lock cap onto the lock screw (Fig. 980). 4. Apply anti-locking compound onto the lock screw threads (Fig. 978).
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MOWER DECK 7. Slide the lock lever into the lock cap (Fig. 981). Fixed Baffle Replacement 40”, 48” & 52” Mower Deck Removal 1. Remove the nut and carriage bolt securing the left end of the fixed baffle to the mower deck (Fig. 983). Fig 981 PICT-6199 8. Install a nut to secure the lock lever to the lock cap and screw (Fig. 982). Fig 983 PICT-6149 2. Remove the nut from the bolt securing the right end of the fixed baffle to the mower deck (Fig. 984).
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MOWER DECK 3. Remove the bolt securing the right end of the fixed baffle to the mower deck (Fig. 985). Fig 985 PICT-6154 4. Remove the nut from the bolt that secures the center of the fixed baffle to the mower deck (Fig. 986). Fig 986 Fixed Deck Mid-Size Service Manual PICT-6156 5. Remove the bolt that secures the center of the fixed baffle to the mower deck (Fig. 987). Fig 987 PICT-6159 6. Remove the fixed baffle from the mower deck (Fig. 988).
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MOWER DECK Installation 1. Position the fixed baffle into the mower deck (Fig. 989). 3. Install and tighten a carriage bolt and nut to secure the left end of the fixed baffle to the mower deck (Fig. 991). Fig 991 Fig 989 PICT-6161 2. Loosely install 2 bolts through the center and right end holes of the fixed baffle and into the mower deck (Fig. 990). 8 4. Tighten the center and right side bolts securing the fixed baffle to the mower deck (Fig. 992).
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MOWER DECK 5. Install and tighten 2 nuts to the center and right side bolts securing the fixed baffle to the mower deck (Fig. 993). 3. Remove the front carriage bolt from the skid plate (Fig. 995). Fig 995 Fig 993 PICT-6135 PICT-6166 4. Remove the 2 nuts and carriage bolts securing the rear side of the skid plate to the mower deck (Fig. 996). Skid Plate Replacement 36”, 40”, 48” & 52” Mower Deck Removal 1. Raise the machine to access the under side of the mower deck. 2.
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MOWER DECK 5. Remove the skid plate from the mower deck (Fig. 997). Fig 997 2. Loosely install all three bolts and nuts securing the skid plate to the mower deck (Fig. 999). PICT-6141 Fig 999 PICT-6145 3. Tighten all three nuts and bolts (Fig. 1000). Installation 1. Position the skid plate on the mower deck so that the rear lip of the skid plate is positioned on the outside of the rear of the mower deck housing (Fig. 998). Fig 1000 PICT-6147 8 Fig 998 8-32 PICT-6143 4. Lower the machine.
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MOWER DECK 3. Remove the blade brake rod from the idler arm (Fig. 1003). Blade Brake Replacement Removal 1. Remove the mower deck cover (Fig. 1001). Fig 1003 Fig 1001 PICT-0029 PICT-6108 4. Remove the two nuts and bolts from the blade brake assembly (Fig. 1004). 2. Remove the hairpin cotter from the blade brake rod (Fig. 1002).
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MOWER DECK 5. Remove the blade brake assembly from the mower deck (Fig. 1005). Fig 1005 PICT-6113 6. Remove the nut and blade brake rod from the blade brake assembly (Fig. 1006). Fig 1006 8 8-34 PICT-6117a 7. Remove the push nut from the flanged spacer (Fig. 1007). Fig 1007 PICT-6120a 8. Remove the spring from the flanged spacer (Fig. 1008).
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MOWER DECK 9. Remove the flanged spacer from the blade brake (Fig. 1009). Fig 1009 PICT-6127a 2. Install the spring onto the plastic flanged spacer (Fig. 1011). Fig 1011 PICT-6175a 3. Install a push nut onto the flanged spacer (Fig. 1012). Installation 1. Install the flanged spacer into the blade brake (Fig. 1010).
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MOWER DECK 4. Install the blade brake rod into the flanged spacer (Fig. 1013). Fig 1013 6. Position the blade brake assembly into the mower deck so the 2 holes on the blade brake align with the 2 holes on the tab in the mower deck (Fig. 1015). PICT-6179a Fig 1015 PICT-6183 5. Install a nut onto the blade brake rod (Fig. 1014). 7. Install 2 bolts and nuts to secure the blade brake to the tab on the mower deck (Fig. 1016).
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MOWER DECK 8. Install the blade brake rod into the idler arm assembly (Fig. 1017). Fig 1017 10. Tighten the nut on the end of the brake rod until there is a gap between the nut and the flanged spacer from 1/8” to 3/16” (3 to 5mm) (Fig. 1019 and Fig. 1020). PICT-6108 Fig 1019 PICT-6189a 9. Install the hairpin cotter into the blade brake rod to secure it to the idler arm (Fig. 1018). A Fig 1020 Fig 1018 Fixed Deck Mid-Size Service Manual PICT-6105 PICT-6193 A.
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MOWER DECK 11. Adjust the blade brake. Refer to “Adjusting the Blade Brake” following. 4. Adjust the nut at the end of the blade brake rod until there is a 1/8” to 3/16” (3 to 5mm) between the nut and the spacer (Fig. 1022). 12. Install the mower deck cover (Fig. 1021). C A Fig 1022 Fig 1021 B PICT-6193 PICT-0029 A. Spring mounting bolt/nut (2) B. Blade brake pad C. 1/8” - 3/16” (3 - 5mm) Adjusting the Blade Brake 1. Disengage the PTO and set the parking brake. 2.
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MOWER DECK Idler (PTO Engagement) Pulley/Idler Arm Replacement 3. Raise the machine to access the underside of the mower deck. Removal 4. Remove the hairpin cotter from the PTO linkage arm (Fig. 1025). 1. Remove the mower deck cover (Fig. 1023). Fig 1025 Fig 1023 IMG-5671 PICT-5923 5. Remove the PTO linkage arm from the assist arm (Fig. 1026). 2. Remove the mower belt from the spindle pulley (Fig. 1024).
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MOWER DECK 6. Remove the bolt and washer from the idler pulley (Fig. 1027). 8. Remove the engagement bushing (Fig. 1029). Fig 1029 Fig 1027 9. Using a spring removal tool (Toro p/n: 92-5771) remove the idler spring (Fig. 1030). 7. Remove the idler pulley (Fig. 1028).
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MOWER DECK 10. Remove the nut and washer from the assist arm (Fig. 1031). 12. Remove the retaining ring and washer from the assist arm (Fig. 1033). Note: When the nut and washer are removed the bolt will drop out the bottom of the housing. Fig 1033 Fig 1031 IMG-5680a IMG-5675 13. Remove the eyebolt from the assist arm (Fig. 1034). 11. Remove the assist arm and pivot tube from the mower deck (Fig. 1032).
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MOWER DECK 14. Remove the hair pin cotter from the brake rod (Fig. 1035). Fig 1035 IMG-5684 15. Remove the brake rod from the idler assembly (Fig. 1036). Fig 1036 8 8-42 IMG-5687 16. Remove the e-ring from the idler assembly (Fig. 1037). Fig 1037 IMG-5688 17. Remove the washer from the idler assembly (Fig. 1038).
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MOWER DECK 18. Remove the idler arm from the mower deck (Fig. 1039). Fig 1039 Note: If the idler assembly is being replaced, the new part comes with bushings installed (Fig. 1041). IMG-5693 Fig 1041 19. Remove the cap screw and 2 nuts from the idler assembly (Fig. 1040). Fig 1040 20. Press the bushings out of the idler assembly (Fig. 1042).
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MOWER DECK 21. Press new bushings into the idler assembly (Fig. 1043). Installation Note: If a new mower belt is being installed, refer to “Mower Belt Replacement - Installation” on page 8-4 for front and rear fixed idler pulley placement. 1. Install a grease fitting in the idler arm pivot post housing (Fig. 1045). Fig 1043 IMG-5700 22. Remove the grease fitting from the idler arm pivot post housing (Fig. 1044).
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MOWER DECK 2. Install a capscrew with two nuts into the Idler assembly. 4. Install a washer onto the idler assembly (Fig. 1048). Note: The head of the capscrew must be on the same side of the idler assembly as the welded-on rod. Secure the 2 nuts (Fig. 1046). Fig 1048 Fig 1046 IMG-5706a PICT-5691 5. Install a snap ring onto the idler assembly (Fig. 1049). 3. Install the idler arm onto the mower deck pivot pin (Fig. 1047).
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MOWER DECK 6. Insert the brake rod into the idler assembly (Fig. 1050). Fig 1050 IMG-5687 7. Install a hairpin cotter into the brake rod securing it to the idler assembly (Fig. 1051). Fig 1051 8 8-46 IMG-5684 8. Place the eyebolt onto the post of the assist arm (Fig. 1052). Fig 1052 IMG-5707a 9. Secure the eyebolt to the assist arm with a washer and retaining ring (Fig. 1053).
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MOWER DECK 10. Install the assist arm bolt and washer up through the bottom of the mower deck (Fig. 1054). Fig 1054 PICT-8565 11. Install the pivot tube onto the bolt (Fig. 1055). Fig 1055 12. Position the assist arm onto the pivot tube (Fig. 1056). Fig 1056 13. Install a nut and washer to secure assist arm (Fig. 1057).
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MOWER DECK 14. Insert the engagement bushing into the idler pulley (Fig. 1058). Fig 1058 PICT-6053 15. Insert the bolt and washer into the idler pulley (Fig. 1059). 16. Position the turn buckle over the hole in the idler arm (Fig. 1060). Fig 1060 PICT-6057 17. Position the belt onto the idler pulley and install the idler pulley bolt into the idler arm (Fig. 1061). Note: Ensure the belt is routed between idler pulley and belt guide.
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MOWER DECK 18. Tighten the idler bolt (Fig. 1062). Fig 1062 20. Install the PTO linkage arm into the hole in brake assist arm (Fig. 1064). PICT-6063 Fig 1064 19. Install the idler spring from the stud on the mower deck to the stud on the idler arm (Fig. 1063). Fig 1063 21. Install the hairpin cotter into the PTO linkage arm (Fig. 1065).
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MOWER DECK 22. Route the mower deck belt around the pulleys (Fig. 1066). 24. Install the mower deck cover (Fig. 1068). Note: There is a belt routing decal on the mower deck to be used for reference in re-routing the mower belt. A Fig 1068 Fig 1066 PICT-5924 PICT-5923 Front Idler Pulley Replacement Removal A. Belt routing decal 1. Remove the mower deck cover (Fig. 1069). 23. Apply grease to the fitting on the idler arm assembly (Fig. 1067).
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MOWER DECK 2. Remove the mower belt from the front idler pulley (Fig. 1070). Fig 1070 IMG-5726 3. Remove the nut and washer from the pulley (Fig. 1071). 4. When the nut and washer are removed, the cap screw and washer will drop out. (Fig. 1072). Fig 1072 5. Remove the idler pulley (Fig. 1073).
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MOWER DECK 6. Remove the idler bushing (Fig. 1074). Fig 1074 2. Install an idler bushing onto the bolt shoulder up (Fig. 1076). IMG-5739 Fig 1076 IMG-5747 Installation 3. Install the pulley onto the bushing (Fig. 1077). Note: If a new mower belt is being installed, refer to “Mower Belt Replacement - Installation” on page 8-4 for front and rear fixed idler pulley placement. 1. Place a cap screw into the proper hole in the mower deck (see table following) (Fig. 1075).
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MOWER DECK 4. Install a washer (Fig. 1078). 6. Route the mower deck belt around the pulleys. Refer to the belt routing decal located on the mower deck for reference in re-routing the mower belt (Fig. 1080). A Fig 1078 IMG-5751 Fig 1080 PICT-5924 5. Install a nut (Fig. 1079). A. Belt routing decal Rear Idler Pulley Replacement Removal 1. Remove the mower deck cover (Fig. 1081).
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MOWER DECK 2. Remove the mower deck belt from the spindle pulley (Fig. 1082). Fig 1082 IMG-5726 3. Loosen the nut on top of the mower deck belt guide (Fig. 1083). Fig 1083 8 8-54 PICT-6072 4. Remove the mower deck belt from the rear idler pulley (Fig. 1084). Fig 1084 PICT-6075 5. Remove the nut and washer from the pulley (Fig. 1085).
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MOWER DECK Note: When the nut and washer are removed, the cap screw will drop out (Fig. 1086). 7. Remove the idler bushing (Fig. 1088). Fig 1088 Fig 1086 PICT-6088 PICT-6081 Installation 6. Remove the idler pulley (Fig. 1087). 1. Install the rear idler pulley bolt into the proper hole on the mower deck (see table below) (Fig. 1089). Note: If a new mower belt is being installed, refer to “Mower Belt Replacement - Installation” on page 8-4 for front and rear fixed idler pulley locations.
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MOWER DECK 2. Install the idler bushing onto the bolt (Fig. 1090). Fig 1090 PICT-6089 3. Install the idler pulley onto the bolt (Fig. 1091). Fig 1091 PICT-6093 4. Install a washer (Fig. 1092). Fig 1092 PICT-6094 5. Install a nut (Fig. 1093).
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MOWER DECK 6. Route the mower deck belt around the pulleys. Refer to the belt routing decal located on the mower deck for reference in re-routing the mower belt (Fig. 1094). 8. Install the mower deck cover (Fig. 1096). A Fig 1096 Fig 1094 PICT-5923 PICT-5924 Spindle Replacement A. Belt routing decal Spindle Removal 7. Tighten the nut on top of the mower deck belt guide (Fig. 1095). 1. Remove the mower deck cover (Fig. 1097).
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MOWER DECK 2. Remove the mower belt from the spindle pulley (Fig. 1098). 4. Raise the machine to access the underside of the mower deck. 5. Install a blade stop to secure the blade (Fig. 1100). Fig 1098 PICT-5925 Fig 1100 3. Engage the PTO lever if spindle replacement is being done on the spindle with the blade brake (Fig. 1099). 8 Fig 1099 8-58 PICT-5927 PICT-5938 6. Loosen the spindle nut (Fig. 1101).
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MOWER DECK 7. Remove the spindle nut from the spindle bolt (Fig. 1102). Fig 1102 PICT-5945 8. Remove the washer. There may also be one or more height-of-cut spacers present (Fig. 1103). Note: Each spindle has 4 spacers for adjusting height-of-cut, which can be located at the top or bottom of the spindle. 9. Lower the blade, blade bolt and height-of-cut spacers out of the spindle assembly (Fig. 1104). Fig 1104 PICT-5949 10. Remove the spacers from the blade bolt (Fig. 1105).
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MOWER DECK 11. Remove the blade and spring washer from the blade bolt (Fig. 1106). Fig 1106 PICT-6014a 12. Remove the 6 nuts securing the spindle housing to the mower deck (Fig. 1107). Fig 1107 8 13. Remove the 6 bolts that secure the spindle housing to the mower deck (Fig. 1108). Fig 1108 Note: 40” mower decks have a washer installed on one of the spindle housing mounting bolts (Fig. 1109).
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MOWER DECK 14. Lower the spindle and pulley assembly out of the mower deck (Fig. 1110). Fig 1110 PICT-5956 15. Remove the set screw from the pulley (Fig. 1111). Fig 1111 16. Remove the pulley from the spindle assembly (Fig. 1112). Fig 1112 17. Remove the key from either the pulley or the shaft (Fig. 1113).
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MOWER DECK 18. Remove the top bearing guard (Fig. 1114). Fig 1114 20. Remove the washer and bottom guard spacer from the spindle shaft (Fig. 1116). PICT-5965a Fig 1116 19. Remove the spindle shaft, bottom guard spacer and washer (Fig. 1115). PICT-5970a Spindle Housing Disassembly 1. Remove the upper bearing from the spindle housing (Fig. 1117).
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MOWER DECK 2. Remove the spacer from the housing (Fig. 1118). Fig 1118 4. Remove the lower bearing from the spindle housing (Fig. 1120). PICT-5975 Fig 1120 3. Remove the snap ring from the spindle housing (Fig. 1119). Fig 1119 PICT-5979a 5. Clean the spindle housing. Inspect the housing, bearings and spacer for wear and damage. Replace as necessary.
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MOWER DECK 2. Slide the spindle shaft assembly into the spindle housing assembly (Fig. 1123). Spindle Housing Assembly Assembly the spindle housing in the reverse order of disassembly (Fig. 1121): A B D B C Fig 1121 A. Snap ring B. Bearing (2) Fig 1123 PICT-5985a PICT-5981a C. Spindle housing D. Spacer 3. Apply grease to the top bearing and the housing (Fig. 1124). Spindle Installation 1. Install the bottom guard spacer and washer onto the spindle shaft (Fig. 1122).
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MOWER DECK 4. Install the top bearing guard (Fig. 1125). Fig 1125 6. Position the pulley onto the spindle shaft (Fig. 1127). PICT-5991a 5. Install the key into the spindle shaft (Fig. 1126). Fig 1126 Fig 1127 PICT-6000a 7. Apply thread locking compound to the threads of the pulley set screw (Fig. 1128).
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MOWER DECK 8. Install the set screw, securing the pulley to the spindle shaft (Fig. 1129). Fig 1129 Note: The 40”, 48” and 52” mower decks have a washer installed on the center spindle housing mounting bolt located under the PTO lever (Fig. 1131). PICT-5958a Fig 1131 PICT-6020 9. Install 6 spindle mounting bolts to secure the spindle housing to the mower deck (Fig. 1130). 10. Install a nut on each of the spindle mounting bolts (Fig. 1132).
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MOWER DECK 11. While securely holding the nuts, torque each of the spindle mounting bolts to 20-25 ft-lbs (27-33.89 Nm) (Fig. 1133). 13. Install the height-of-cut spacers onto the blade bolt (Fig. 1135). Note: Ensure the height-of-cut spacers are installed onto the blade bolt to maintain the same blade height as the other spindles. Fig 1133 PICT-6007 Fig 1135 PICT-6011a 12. Install the washer (crown side facing down) and blade onto the blade bolt (Fig. 1134). 14.
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MOWER DECK 15. Install the washer and height-of-cut spacers, as applicable (Fig. 1137). Fig 1137 17. Torque the blade bolt nut to 75-80 ft-lbs. (101.68108.46 Nm) (Fig. 1139). PICT-6015 16. Install the spindle nut onto the spindle bolt (Fig. 1138). Fig 1139 PICT-6018 18. Remove the blade stop. 19. Lower the machine. 20. Disengage the PTO lever if spindle replacement was done on the spindle with the blade brake to ensure pulley is properly aligned (Fig. 1140).
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MOWER DECK 21. Replace the mower deck belt onto the pulleys (Fig. 1141). Note: There is a belt routing decal on the mower deck to be used for reference in re-routing the mower belt. Mower Deck Removal 1. Remove the mower deck cover (Fig. 1143). A Fig 1143 Fig 1141 PICT-7043 PICT-5924 2. Remove the deck drive belt from the drive pulley (Fig. 1144). A. Belt routing decal 22. Install the mower deck cover (Fig. 1142).
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MOWER DECK 3. Remove the hairpin cotter from the PTO linkage rod (Fig. 1145). 5. Support the rear of the chassis to prevent the machine from tipping backward when the deck is removed. 6. Block the trailing edge of the deck (Fig. 1147). Fig 1145 PICT-7045 Fig 1147 PICT-7048 4. Remove the PTO linkage rod from the assist arm (Fig. 1146). 7. Remove the 2 lower bolts, Belleville washers and nuts securing the mower deck to the chassis. Repeat on opposite side of the mower (Fig. 1148).
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MOWER DECK 8. Remove the rearmost bolt, Belleville washer and nut securing the mower deck to the chassis. Repeat on the opposite side of the mower (Fig. 1149). 10. Remove the chassis from the mower deck (Fig. 1151). Fig 1152 Fig 1149 PICT-7052 9. Remove the remaining bolt, Belleville washer and nut securing the mower deck to the chassis. Repeat on the opposite side of the mower (Fig. 1150). Fig 1150 Fixed Deck Mid-Size Service Manual PICT-7054 PICT-7053 Mower Deck Installation 1.
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MOWER DECK 2. Position the chassis up to the mower deck, lining up the holes on the side of the chassis with the holes in the mower deck mounting brackets (Fig. 1153). Fig 1153 5. Install the remaining 6 bolts, Belleville washers (crown toward bolt head) and nuts to secure the mower deck to the chassis. Note that the bolts get installed from the outside of the chassis and the nuts get installed onto the bolts from inside the chassis. Torque all 8 sets of faseteners to 30-35 ft-lbs. (41-47 Nm) (Fig. 1155).
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MOWER DECK 7. Install a hairpin cotter securing the PTO linkage rod to the assist arm (Fig. 1157). 9. Route the deck drive belt around the pulleys and idler. Refer to the belt routing decal on the mower deck (Fig. 1159). A Fig 1157 PICT-7045 Fig 1159 PICT-7057 A. Belt routing decal 8. Install the deck drive belt onto the drive pulley (Fig. 1158). Note: The belt gets installed between the belt guide and pulley. 10. The proper mower belt tension is 10-15 ft-lbs.
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MOWER DECK 11. Install the mower deck cover (Fig. 1161).
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ELECTRICAL Tools Components • Volt Ohm meter • Flat and Phillips screwdrivers • Box and open end wrenches of various sizes Interlock Module (Fig. 1162) Additional information can be found in the LCE Electrical Troubleshooting DVD # 492-9171, available through your Toro parts supplier. Caution Before performing any tests with a continuity light or ohmmeter, disconnect the component from the wire harness. This ensures you are testing the component, not some other circuit.
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ELECTRICAL On/off switch (ignition) (Fig. 1163) Fig 1163 Switch NO or NC (Fig. 1164) PICT-6492a The ignition switch is a basic on/off switch. There should be continuity when the switch is in the off position. No continuity when the switch is turned on. Note: Switch manufacturers commonly make different types of switches from the same body. Normally open and normally closed switches work opposite but may look identical. Ensure you have the correct part by comparing it to the function above.
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ELECTRICAL Neutral Switch (Fig. 1165) Fig 1165 Seat Switch (operator presence) (Fig. 1166) PICT-6495a Normally closed. Contacts will open when the ball is depressed. This switch is used in the transmission on gear drive units. Fig 1166 PICT-6499a This is the switch in the T-bar on the handle. This is a normally closed switch. The contacts open when the plunger is depressed.
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ELECTRICAL Electrical Systems The fixed deck midsize mowers use three different electrical systems. All are intended to ensure a safe condition when starting and prevent the operator from leaving the operator zone with the machine in an unsafe condition. The difference in the systems is due to the type of controls on each model. Gear Drive T-Bar This is the most basic system. It grounds the magneto through two circuits.
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ELECTRICAL Gear Drive Pistol Grip This system uses an interlock module, an ignition switch and three safety switches. The interlock module is connected to the engine magneto and to ground. When at rest, the module closes the connection between the magneto and ground. The ignition cannot fire. When in the off position the ignition switch also grounds the magneto. To start, turn the ignition switch to on, which will open the contacts.
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ELECTRICAL Hydro Drive Pistol Grip This system uses an interlock module, an ignition switch and four safety switches. The interlock module is connected to the magneto and to ground. When at rest the module closes the connection between the magneto and ground. The engine cannot fire. When in the off position the ignition switch also grounds the magneto. To start, turn the ignition switch to on, which will open the contacts.
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Fixed Deck Mid-Size Service Manual Form No.