TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 1 of 3 SPECIFICATIONS DIMENSIONS HYDRO-GEAR HYDROSTATIC TRANSAXLE USAGE TURNING RADIUS ELECTRICAL SYSTEM TECUMSEH PEERLESS TRANSAXLES 1993 - 1995 1996 - PRESENT TORQUE SPECIFICATIONS FASTENER IDENTIFICATION STANDARD TORQUE FOR DRY, ZINC PLATED, AND STEEL FASTENERS (INCH SERIES) STANDARD TORQUE FOR DRY, ZINC, AND STEEL FASTENERS (METRIC FASTENERS) OTHER TORQUE SPECIFICATIONS SAE GRADE 8 STEEL SET SCREWS THREAD CUTTING SCREWS (ZINC PLATED STEEL) CON
TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 2 of 3 XL HYDROSTATIC TRANSAXLES -CONTINUED NEUTRAL ADJUSTMENT - HXL HYDRO - 2001 AND LATER BRAKE ADJUSTMENT - HXL HYDRO - 2001 AND LATER TRACTION DRIVE BELT REPLACEMENT - HXL HYDRO - 2001 AND LATER CHASSIS FRONT AXLE REMOVAL UPPER STEERING SHAFT REMOVAL (NO TILT STEERING) STEERING RACK REMOVAL STEERING ASSEMBLY TILT STEERING STEERING SHAFT REMOVAL (TILT STEERING) STEERING TOWER REMOVAL STEERING TOWER INSTALLATION REAR BODY/FENDER ASSEMBLY REMOVAL
TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 3 of 3 ELECTRICAL SYSTEM - CONTINUED KEYCHOICE™ REVERSE OPERATING SYSTEM SWITCH PURPOSE HOW IT WORKS TESTING REVERSE SWITCH PURPOSE LOCATION HOW IT WORKS TESTING KEYCHOICE™ REVERSE OPERATING SYSTEM MODULE PURPOSE LOCATION HOW IT WORKS TESTING MOWER 32" MOWER REMOVING 32" MOWER INSTALLING 32" MOWER BLADE DRIVE BELT REMOVING THE BLADE DRIVE BELT INSTALLING THE BLADE DRIVE BELT SIDE-TO-SIDE MOWER LEVELING FRONT-TO-REAR BLADE SLOPE 38" MOWER REMOVING
XL Lawn Tractor
PREFACE This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. For additional information on the electrical system, please refer to the Toro Electrical Demystification Guide (4924404).
TABLE OF CONTENTS SPECIFICATIONS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Hydro-Gear Hydrostatic Transaxle Usage . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS XL HYDROSTATIC TRANSAXLES cont. HXL Hydro Transaxle Removal - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . . 3-3 Neutral Adjustmnet - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . . 3-10 Brake Adjustment - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . . 3-11 Traction Drive Belt Replacement on HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . 3-13 HXL Hydro Transaxle Removal - 2001 and Later . . . . . . . . . . . . . . .
TABLE OF CONTENTS ELECTRICAL SYSTEM cont. Neutral Switch (Used on 2000 and Later Lawn Tractors) Purpose . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . How It Works . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . Seat Switch . . . Purpose . . . Location . . . How It Works . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS MOWER cont. 38” Mower . . . . . . . . . . . Removing 38” Mower . . . . . Installing 38” Mower . . . . . . Blade Drive Belt . . . . . . . Removing the Blade Drive Belt Installing the Blade Drive Belt . Side-to-Side Mower Leveling . . Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS Specifications Engines All tractors since 1993 were manufactured with Briggs & Stratton engines ranging from 10 to 17 Horsepower. For more information on servicing the engines, please contact Briggs & Stratton. Fuel Capacity Steering 7 qts (6.65l) Sector and Pinion Dimensions 32” (81.3cm) XL Lawn Tractors 38” (96.5cm) XL and HXL Lawn Tractors 44” (111.8cm) HXL Lawn Tractors Wheel Base: 48.5” (123.2cm) 47” (119.4cm) 47.5” (120.7cm) Length: 66.5” (168.9cm) 66.5” (168.
SPECIFICATIONS Turning Radius Model Turning Radius 32” (81.3cm) XL 21.5” (54.6cm) - Left 22” (55.8cm) - Right 38” (96.5cm) HXL and XL 20” (50.8cm) - Left 22” (55.8cm)- Right 44” (111.8cm) HXL 20” (50.8cm) - Left 22” (55.8cm) - Right Electrical System Engine Battery 3 amp unregulated / 80 watt A.C.
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. 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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC #10 - 32 UNF 1/4 - 20 UNC 1/4 - 28 UNF 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 Grade Height Nuts (SAE J995 Grade Height Nuts (SAE J995 Grade 2 or Stronger Nuts) 2
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 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m M10 X 1.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 Thread Size Recommended Torque** 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.
SPECIFICATIONS Equivalents and Conversions XL Lawn Tractor Service Manual 1-7
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XL GEAR DRIVE XL Gear Drive Transaxle Removal 915 Transaxle 1. Disconnect battery cables and remove the battery and battery tray. Remove the mower deck (refer to “Mower” section on page 6 - 1). 2. Raise the rear of the tractor and remove the right and left rear tires. Put jack-stands under the frame, just in front of the transaxle (Figure 3). 4. Loosen the left transaxle belt guide and move it away from the belt. The right transaxle belt guide needs to be removed (Figure 5). Figure 5 5. Figure 3 3.
XL GEAR DRIVE 6. Remove the nut on the shift tie rod (Figure 7). Figure 7 7. Remove the nut and washer holding the left side torque strap leaving the torque strap bolted to the frame (Figure 9). mvc-800 Remove the bolt and nut on the left side shift pivot clamp and slide the shift pivot rod so you can remove the shift tie rod (Figure 8). Figure 8 8. Figure 9 9. Remove both the top and bottom washer and nut from the right side torque strap (Figure 10).
XL GEAR DRIVE 10. Remove the brake return spring (Figure 11). Figure 11 12. Before removing the 4 transaxle bolts, put a floor jack under the transaxle so you can lower it from the frame. Remove the 4 bolts, washers, and nuts (Figure 13). mvc-808 11. Unhook the brake spring from the clutch/brake rod (Figure 12). Figure 13 mvc-810 13. Lower the transaxle slightly so you can free it from the two front torque straps. Unhook the brake spring from the transaxle brake arm (Figure 14).
XL GEAR DRIVE 14. The transaxle should be free from the frame now (Figure 15). Figure 15 Install the right and left torque straps to the frame and the transaxle, do not tighten. Install the 4 axle bolts, washers, and nuts and tighten first. Then tighten the torque straps (Figure 17). mvc-813 XL Gear Drive Transaxle Installation - 915 Transaxle 1. 2. Raise the transaxle to the frame making sure the brake lever fits through the slot in the frame.
XL GEAR DRIVE 4. Install brake spring to the clutch/brake rod (Figure 19). 6. A Install the right and left belt guides and adjust so they are within 1/8” (3mm) of the transaxle pulley and drive belt (Figure 21). Note direction of belt guide installation, right hand points forward, left hand points rearward. 1/8” (3mm) 1/8” (3mm) B Figure 19 (A) Spring 5. iso3 (B) Clutch/brake rod Install belt around the transaxle pulley. Reinstall the idler spring to the idler assembly (Figure 20).
XL GEAR DRIVE 8. Install the rear hitch panel. There are two bolts, washers, and nuts on each side of the plate and 2 bolts, washers, and nuts for the seat springs (Figure 23). 10. Check the following items: A. The Shift-On-The-Go for proper adjustment. If adjustment is needed, (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19). B. Brake Adjustment. If adjustment is needed, (refer to “XL Gear Drive Brake Adjustment -915 Transaxle” on page 2 - 11). C.
XL GEAR DRIVE 3. Loosen and move the right and left engine belt guides (Figure 26). Figure 26 4. Remove the idler spring on the idler assembly. Remove the idler pulley and belt guide (Figure 28). Remove the drive belt. mvc-821 Loosen the left side transaxle belt guide. Remove the right side transaxle belt guide (Figure 27). Figure 27 5. Figure 28 6. Install new belt around the engine drive pulley (Figure 29).
XL GEAR DRIVE 7. Route belt back over the pedal pivot rod, the idler pivot bracket, and around the transaxle pulley (Figure 30). 9. Hook the idler spring to the idler bracket (Figure 32). Figure 32 Figure 30 8. mvc-826 Install the idler pulley to the idler bracket. Note the correct hole location of the bolt and nut retaining the pulley and belt guide bracket (Figure 31). mvc-829 10. Install the right side belt guide and adjust to within 1/8” (3mm) of the transaxle pulley and belt.
XL GEAR DRIVE 11. Recheck the routing of the belt (Figure 34). 14. Check the following: A. The Shift-On-The-Go for proper adjustment. If adjustment is needed, (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19). B. Brake Adjustment. If adjustment is needed, (refer to “XL Gear Drive Brake Adjustment -915 Transaxle” on page 2 - 11). C. Shift Lever Adjustment. If adjustment is needed, (refer to “XL Gear Drive Shift Lever Adjustment - 915 Transaxle” on page 2 - 9). 15.
XL GEAR DRIVE 2. Remove the rear hitch panel by removing the two bolts and nuts holding the seat springs and two bolts and nuts located on each side of the hitch panel. Loosen the fastener securing the front cable guide to remove tension from the shift cable (Figure 36). Figure 36 3. 4. mvc-834 Figure 38 Remove the rubber shift gate cover (Figure 37). 5. Figure 37 Shift the transaxle through each gear to verify the gear shift lever centers in each gate as the internal transaxle detents are felt.
XL GEAR DRIVE 6. If the shifter still does not go into 5th gear, loosen the jam nut on the tie rod end of the shift arm and remove the nut. Rotate the tie rod end until the gear shift lever is centered in the 5th gear gate. Place the shift arm on the gear selector shaft and verify that neutral, reverse, and fifth gears properly align. Reinstall the shift arm fastener and tighten the jam nut (Figure 40). Figure 40 (1) Jam Nut (2) Fastener 7.
XL GEAR DRIVE XL Gear Drive MST-205 Transaxle Removal 1. 3. Remove the right and left transaxle belt guides. Put the park brake on and then slip the traction drive belt off the transaxle pulley (Figure 44). Disconnect battery cables and remove battery and battery tray. Remove mower deck (refer to “Mower” section on page 6 - 1). Lift the rear of the tractor and remove both the right and left rear tires (Figure 42). A Figure 44 mvc-0002 (A) Belt Guides 4. Figure 42 2.
XL GEAR DRIVE 5. Disconnect the shift link at the transaxle shift lever (Figure 46). XL Gear Drive MST-205 Transaxle Installation 1. Figure 46 6. Raise the transaxle up to the frame and install the 4 axle bolts and 2 torque strap bolts. Tighten all 6 bolts (Figure 48). mvc-0003 Use a floor jack to support and lower the transaxle from the frame. Unbolt and remove the two torque strap bolts located in the front of the transaxle. Remove the 4 axle bolts holding the transaxle to the frame (Figure 47).
XL GEAR DRIVE 3. Place the traction drive belt around the transaxle input pulley. Install the right and left belt guides. 5. Install the rear hitch panel (Figure 52). A Figure 52 Figure 50 mvc-0002 6. (A) Belt Guides 4. Install battery and battery tray. Note: If the battery uses a battery drain tube, make sure the tube is reinstalled through the rear hole in the frame (Figure 51). Connect the battery cables.
XL GEAR DRIVE 2. Loosen the bolt between the shift pivot and the shift pivot lever (Figure 54). XL Gear Drive Brake Adjustment, MST-205 Transaxle The brake is located on the right side of the rear axle, inside the rear tire. If the brake does not hold securely or stopping power is insufficient, an adjustment is required (Figure 56). Figure 54 3. mvc-644 Make sure the shift lever is in the center of the shift gate (Figure 55). Figure 56 mvc-648 Checking the Brake 1.
XL GEAR DRIVE Important: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If the brake seems to drag, loosen the adjusting nut slightly until the wheels rotate freely. 4. Remove the right and left belt guides located on each side of the transaxle pulley (Figure 58). XL Gear Drive Traction Drive Belt Replacement Procedure, MST-205 Transaxle 1. Remove mower deck from tractor (refer to “Mower” section on page 6 - 1). 2.
XL GEAR DRIVE 6. Loosen the right and left belt guides located on each side of the engine drive pulley (Figure 60). Remove the drive belt. 8. Install belt on the idler pulley and tighten the pulley bolt (Figure 62). Figure 62 Figure 60 7. mvc-000D Install new belt around the engine drive pulley and route it back to the transaxle pulley (Figure 61). 9. Install the right and left transaxle belt guides (Figure 63).
XL GEAR DRIVE 10. Reinstall the idler spring on bolt holding the idler pulley to the idler assembly (Figure 64). Figure 64 mvc-000a 11. Adjust both the right and left engine belt guides so they are within 1/8” (3mm) of the engine pulley (Figure 65). 12. Install rear hitch plate and seat springs (Figure 66). Figure 66 mvc-0037 13. Install battery and battery tray. Note: If battery uses a battery drain tube, make sure the tube is reinstalled through the rear hole in the frame (Figure 67).
XL GEAR DRIVE Cable Adjustment, Shift-On-The-Go, 915 and MST-205 Transaxle 1. A. Loosen the fastener securing the forward cable guide. It is located just above and behind the mower deck pulley (Figure 70). Adjustment is required if the gearshift lever is not pulled firmly under spring tension toward the numbers on the shift plate or if it is difficult to shift on-the-go (Figure 68). If either of these problems present themselves, check the following: Figure 70 Figure 68 B.
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XL HYDROSTATIC TRANSAXLES Identification Hydro-Gear 0510 Transaxle Hydro-Gear 0500/0750 Transaxle Used: Model: Used: Models: 2001 and later 318-0510 1993 - 2000 316-0500, 321-0500, 323-0500, 316-0750, and 326-0750 mvc-660 mvc-658 Lubrication: 20W50 Motor Oil Oil Level: Oil level should not be more than 1¼” (3.17cm) below the top fill port. Lubrication: 20W50 Motor Oil Oil Level: Oil level should be at 1.75” to 2.0” (4.39cm - 5.08cm) from the top of the housing.
XL HYDROSTATIC TRANSAXLES Internal Service The Hydro-Gear 310-0500/0700 Service Manual is available from Toro under Form #492-4712. The Hydro-Gear 310-0510 Service Manual is available from Toro under Form #492-4735. Refer to the Tractor Parts Catalog for available transaxle service parts. For 1993 - 1995 model year tractors, refer to the comparable 1996 model, as spare parts were not shown in earlier parts catalogs.
XL HYDROSTATIC TRANSAXLES Purging Procedures Fluid Change Due the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. The Hydro-Gear transaxle is factory filled, sealed and does not require oil maintenance. However, in the event of oil contamination or degradation, oil replacement may correct certain performance problems.
XL HYDROSTATIC TRANSAXLES 3. Remove the rear hitch panel. There are 2 bolts and nuts holding the seat springs and 2 bolts and nuts on each side of the rear panel (Figure 73). 5. Loosen the right and left belt guides located on each side of the engine drive pulley (Figure 75). Figure 75 Figure 73 4. MVC-0037 Loosen the left and right rear transaxle belt guides and move them away from the belt (Figure 74). 6. Unhook the idler spring from the idler assembly (Figure 76).
XL HYDROSTATIC TRANSAXLES 7. Slip the traction belt down off the engine pulley and move the slack of the belt back toward the rear of the tractor. You should now be able to slip the traction belt up off the transaxle drive pulley. The fan is flexible enough to allow you to remove the belt (Figure 77). 9. Remove the hairpin and washer on the bypass lever rod (Figure 79). Figure 79 MVC-0041 10. Remove the small brake return spring from the brake lever (Figure 80). Figure 77 8.
XL HYDROSTATIC TRANSAXLES 13. Support the transaxle with a jack. Remove the 4 bolts, washers, and nuts holding the transaxle to the frame (Figure 83). 11. Unhook the brake spring from the clutch/brake rod. A B Figure 81 iso3 Figure 83 (A) Brake Spring (B) Unhook from clutch/ brake rod MVC-0042 14. Lower the transaxle from the frame (Figure 84). 12. Unbolt the torque strap (Figure 82).
XL HYDROSTATIC TRANSAXLES HXL Hydro Lawn Tractor Transaxle Installation – 2000 and Prior 1. 3. Reconnect the brake spring to the clutch/brake rod (Figure 87). Raise the transaxle to the frame and install the 4 axle bolts, washers, and nuts (Figure 85). A B Figure 87 (A) Spring Figure 85 2. XL Lawn Tractor Service Manual (B) Clutch/brake rod MVC-0042 Install the washer and nut to the torque strap and tighten (Figure 86). Figure 86 iso3 MVC-0043 4.
XL HYDROSTATIC TRANSAXLES 5. Install the washer and hairpin on the speed control rod (Figure 89). Figure 89 6. 3-8 MVC-0041 Install the traction drive belt around the transaxle input pulley (Figure 91). Figure 91 MVC-003B Install the washer and hairpin that holds the bypass lever (Figure 90). Figure 90 7. 8. MVC-003A Install the traction drive belt around the engine drive pulley (Figure 92).
XL HYDROSTATIC TRANSAXLES 9. Reconnect the idler spring to the idler bracket assembly (Figure 93). 11. Adjust and tighten the right and left rear transaxle belt guides. Adjust the guides so they are within 1/8” (3mm) of the belt and pulley (Figure 95). 1/8” (3mm) Figure 93 MVC-001C 10. Adjust and tighten the right and left engine belt guides so the guides are within 1/8” (3mm) of the belt and pulley (Figure 94). Figure 95 MVC-0039 12. Install the rear hitch plate.
XL HYDROSTATIC TRANSAXLES 13. Install the battery and battery tray. Note: If the battery uses a drain tube, make sure the tube is reinstalled through the rear hole in the frame (Figure 97). 17. Install the right rear tire and check the brake adjustments. If adjustment is needed, follow the procedures in the “Brake Adjustment - HXL Hydro - 2000 and Prior” on page 3 - 11. 18. Test operate the tractor, making sure the unit operates properly and the safety circuits are operating.
XL HYDROSTATIC TRANSAXLES 2. Loosen the locknut (Figure 100). 4. Tighten the locknut. Move the motion control pedal forward and reverse and allow it to recenter. Verify that there is still no creep with the wheels on the ground. When operating the foot control, if you find too much ground speed in forward and not enough in reverse or too much ground speed in reverse and not enough in froward, the pivot block which the speed control pedal is mounted on is adjustable.
XL HYDROSTATIC TRANSAXLES 5. To adjust the brake, loosen the brake adjusting nut slightly (Figure 103). Figure 103 6. (A) Adjusting Nut 7. 8. Figure 105 2. 4017-09 If the brake lever is not returning to the “OFF” position, it may be necessary to install a shorter spring. The spring on the left is a shorter spring P/N 26-6700. The shorter spring is installed on all the 2000 model year Lawn Tractors. The spring on the right is the longer spring P/N 26-6701 (Figure 106).
XL HYDROSTATIC TRANSAXLES If the battery drain tube is installed improperly through the frame, the battery will drain in this area and corrode the pins and linkage (Figure 107). Figure 107 4. Traction Drive Belt Replacement On HXL Hydro - 2000 and Prior 1. Remove the mower deck from the tractor, refer to "Mower" section on page 6 - 1. 2. Disconnect the battery cables and remove the battery and battery tray. 3.
XL HYDROSTATIC TRANSAXLES 5. Unhook the idler spring on the idler spring bracket (Figure 111). Figure 111 6. Install belt around the engine drive pulley and feed the drive belt up over the pedal pivot rod (Figure 113). mvc-001C Unbolt the idler pulley assembly with belt guide and remove assembly (Figure 112). Figure 112 7. Figure 113 8. Continue feeding the belt back up over the idler pivot bracket and around the transaxle drive pulley (Figure 114).
XL HYDROSTATIC TRANSAXLES 9. Install the belt around the flat idler pulley assembly with the belt guide and tighten the bolt and nut (Figure 115). 11. Adjust and tighten both the right and left engine belt guides. They should be adjusted so they are within 1/8” (3mm) of the engine pulley (Figure 117). 1/8” (3mm) Figure 115 mvc-0010 10. Reconnect the idler spring to the idler bracket (Figure 116). Figure 117 mvc-001b 12. Adjust and tighten both the right and left transaxle belt guides.
XL HYDROSTATIC TRANSAXLES 13. Before installing the mower deck on the tractor, check the routing of the drive belt (Figure 119). Figure 119 HXL Hydro Transaxle Removal 2001 and Later 1. Disconnect the battery cables and remove the battery and battery tray. Remove the mower deck (refer to the "Mower" section on page 6 - 1). 2. Raise the rear of the tractor and remove the right and left rear tires. Put jack stands under the frame, just in front of the transaxle (Figure 121). mvc-0047 14.
XL HYDROSTATIC TRANSAXLES 4. Loosen the right and left belt guides located around the engine pulley and slip the belt down off the engine drive pulley (Figure 123). Figure 123 5. Move the slack of the traction drive belt to the rear of the tractor and slip the belt off the transaxle drive pulley. The fan is flexible enough to allow you to remove the belt (Figure 125). MVC-001F Unhook the idler spring from the idler assembly (Figure 124). Figure 124 6. Figure 125 7.
XL HYDROSTATIC TRANSAXLES 8. Unhook the small spring on the brake arm. Pull the cotter pin out of the crown nut on the brakes and remove nut to disconnect the brake arm from the transaxle (Figure 127). Figure 127 9. 3 - 18 1. Raise the transaxle to the frame and install the 4 axle bolts, washers, and nuts. Install the torque strap nut (Figure 129). MVC-0017 Support the transaxle with a jack. Unbolt the front torque strap and remove the 4 bolts holding the transaxle to the frame.
XL HYDROSTATIC TRANSAXLES 3. Reconnect the speed control link and the speed control rod with washers and hairpins (Figure 131). 5. Adjust and tighten both the right and left engine belt guides. They should be adjusted so they are within 1/8” (3mm) of the engine pulley (Figure 133). 1/8” (3mm) Figure 131 4. MVC-0015 Install the drive belt around the transaxle pulley and around the engine pulley. Reconnect the idler spring to the idler bracket assembly (Figure 132). Figure 133 6.
XL HYDROSTATIC TRANSAXLES 7. Install the left rear tire only and lower the unit until the tire just touches the ground. Install the battery and the battery tray and reconnect the battery cables (Figure 135). Figure 135 1. Jack-up and support the right rear end of the tractor, allowing enough clearance to remove the right rear tire. Make sure the left rear tire stays on the ground (Figure 136).
XL HYDROSTATIC TRANSAXLES 5. 6. Once you are in neutral, hold the puck with an adjustable wrench so it won't move when you retighten the Allen bolt (Figure 138). Operate the foot control in forward and reverse and allow pedal to return to the neutral position to test the adjustment. Adjusting the Brake: 1. Jack-up and support the right rear end of the tractor. 2. Remove the right rear tire. 3. Remove the brake return spring (Figure 140). 4.
XL HYDROSTATIC TRANSAXLES 7. Install tire and check the brake operation again. If satisfactory brake adjustment/operation cannot be attained, the brake pads or disc require service. Figure 141 8. 3. Figure 142 2001-019 With the parking brake released and the bypass lever in push mode, the rear wheels must rotate freely when you push the unit.
XL HYDROSTATIC TRANSAXLES 5. Unhook the idler spring on the idler spring bracket (Figure 144). Figure 144 6. 7. MVC-001C Unbolt the idler pulley assembly with belt guide and remove assembly (Figure 145). Figure 146 8. Figure 145 Loosen the left side idler pulley and slide the assembly toward the center of the tractor away from the frame (Figure 146). Remove the belt from the engine and transaxle pulleys.
XL HYDROSTATIC TRANSAXLES 9. Continue feeding the belt back up over the idler pivot bracket and around the transaxle drive pulley (Figure 148). 11. Reconnect the idler spring to the idler bracket (Figure 150). Figure 150 Figure 148 MVC-0022 10. Install the belt around the flat idler pulley assembly with the belt guide and tighten the bolt and nut (Figure 149). MVC-001c 12. On the other side of the idler pivot, is a V-idler pulley.
XL HYDROSTATIC TRANSAXLES 13. Adjust and tighten both the right and left engine belt guides. They should be adjusted so they are within 1/8” (3mm) of the engine pulley (Figure 152). 15. Before installing the mower deck on the tractor, check the routing of the drive belt (Figure 154). 1/8” (3mm) Figure 154 Figure 152 MVC-001b 14. Adjust and tighten the transaxle belt guide. Make sure it is adjusted so it is within 1/8” (3mm) of the transaxle pulley (Figure 153).
CHASSIS Front Axle Removal 1. 2. Upper Steering Shaft Removal (No Tilt Steering) If the tractor is equipped with headlights, disconnect the wiring to the headlights. Unbolt the 2 shoulder bolts, located on the right and left side, bottom of the hood and carefully remove the hood (Figure 155). 1. Follow steps #1 and #2 in the procedure for Steering Tower Removal, (refer to “Steering Tower Removal” on page 4 - 4). 2. The mower deck will have to be removed, (refer to the Mower section). 3.
CHASSIS Steering Assembly Figure 156 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Front Axle E-Ring Tie Rod Steering Drag Link RH Spindle Wheel and Tire Assembly Washer Cotter Pin Hub Cap Thrust Washer Front Axle Spacer Flat Washer Lock Nut Thrust Washer XL Lawn Tractor Service Manual (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) Flat Washer Cotter Pin LH Spindle Screw Screw Screw Steering Rack Bracket Screw Zerk Bushing Eccentric Steering Rack Spacer Steering Ra
CHASSIS Tilt Steering Figure 157 (1) (2) (3) (4) (5) (6) (7) (8) 4-3 Steering Short Shaft Flange Bushing Thrust Washer Plastite Screw E-Ring Stationary Bushing Steering Coupling Hex Head Cap Screw (9) (10) (11) (12) (13) (14) (15) (16) Curved Washer Thrust Washer Steering Upper Shaft Lock Nut Leaf Spring Backup Bracket Steering Cover Steering Wheel (17) (18) (19) (20) (21) (22) Roll Pin Sliding Bushing Release Button Flat Washer Head Head Cap Screw Retaining Ring XL Lawn Tractor Service Manual
CHASSIS Steering Shaft Removal (Tilt Steering) Steering Tower Removal 1. 1. Disconnect the battery cables. 2. Remove mower deck (refer to the Mower section). 3. Drain the gas tank and remove the tank by removing the left screw that holds the support bracket in and swing the bracket so you can remove the gas tank (Figure 158). Using a drift punch and hammer, drive the steering wheel roll pin out and remove the steering wheel (Figure 159). Figure 159 2.
CHASSIS 3. Unplug the ignition switch, PTO safety switch, light switch, and Key Choice™ Reverse Operating System light (Figure 161), if so equipped. Disconnect the throttle cable at the engine. Disconnect the PTO mower cable at the deck engagement lever . 5. Remove the two bolts that are located on the underside of the tractor that hold the rear portion of the steering tower (Figure 163). Figure 163 6. Figure 161 4.
CHASSIS Rear Body/Fender Assembly Removal 5. 1. Remove the steering tower, refer to ”Steering Tower Removal" on page 4 - 4. 2. Remove the rear hitch panel and seat springs (Figure 164). Remove the 2 bolts and nuts holding the seat to the right and left pivot brackets. Unscrew the Height-of Cut knob (Figure 166). On gear shift models, unscrew the knob. Figure 166 6. Figure 164 MVC-0037 3. Disconnect the battery and remove the battery and battery tray. 4.
CHASSIS 7. Remove the upper steering shaft by removing the E-ring around the bottom of the shaft and slide the shaft out the bottom of the frame (Figure 168). 9. Remove the mower engagement cable from the brake lever bracket (Figure 170). Figure 170 Figure 168 8. MVC-0028 Unbolt the solenoid from the frame (Figure 169). Figure 169 4-7 MVC-002f MVC-0032 10. Remove the cotter pin connecting the drag link to the fan gear (Figure 171).
CHASSIS 11. Remove the rubber grip from the brake pedal (Figure 172). Figure 172 MVC-0030 12. Carefully lift the rear body off the frame of the tractor (Figure 173). Figure 173 MVC-0034 Installation Of The Rear Body Reverse the order of rear body removal.
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CHASSIS 5. Disconnect and remove the electrical plug to the electric PTO clutch (Fig. A4 003). Electric PTO Clutch Removal 1. Disconnect the positive battery cable from the battery. 2. Remove the mower from the tractor (follow the procedure in Section 6). 3. Remove the gas tank from the dash (Fig. A4 001). Fig A4 003 PICT-4452 6. With a 1-3/8” open end wrench or adjustable wrench and a 5/8” socket wrench remove the bolt from the crankshaft (Fig. A4 004). Fig A4 001 PICT-4449 4.
CHASSIS 7. Remove the electric PTO clutch from the crankshaft (Fig. A4 005). Fig A4 005 2. Install the electric PTO clutch on the crankshaft, making sure the key on the clutch aligns with the keyway on the crankshaft. Also, make sure the slot on the electric PTO clutch slides onto the clutch stop bracket (Fig. A4 007). PICT-4458 Fig A4 007 PICT-4465 Electric PTO Clutch Installation 1. Before installing the electric PTO clutch, note the clutch stop bracket (Ref. A) and the crankshaft keyway (Ref.
CHASSIS 4. Route the electric PTO clutch wire through the frame and reconnect the plug connector to the wiring harness (Fig. A4 009). Fig A4 009 PICT-4452 5. Install the gas tank (Fig. A4 010). Fig A4 010 PICT-4449 6. Install the mower deck and mower drive belt, (refer to Mower Installation in Section 6).
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ELECTRICAL SYSTEM Electrical System Relay The electrical systems in all the XL Lawn Tractors are similar when starting the tractor. Two things happen when turning the ignition switch to the “START” position. (1) Current will flow from the ignition switch through the PTO (Power Take Off) switch, the clutch/ brake switch and to the coil of the starter solenoid. The solenoid is actuated by the coil, connecting the starter motor to the battery.
ELECTRICAL SYSTEM 2. Switch: Terminals 30, 87, and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized. When the coil is energized, the switch is “thrown” and 30 and 87 are connected (Figure 175). Figure 175 3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
ELECTRICAL SYSTEM How It Works 4. The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch. Because it has a large contact area with the contact terminals it can easily handle the high current loads required by the starter motor. You should be able to hear the solenoid switch “click” when you make the connection.
ELECTRICAL SYSTEM Neutral Switch (Used on 1999 and Prior Lawn Tractors) Purpose Testing 1. Disconnect the switch from the harness. 2. Verify the conditions from the table. Used to ensure the transmission is in neutral when starting the unit. It is actuated when the clutch/brake pedal is depressed. Location Button Condition Up Com + NC Down Com + NO The neutral switch is under the tractor, in the channel of the frame, under the clutch/brake pedal (Figure 180).
ELECTRICAL SYSTEM Location The PTO switch is located under the gas tank, inside of the steering tower, below the PTO lever (Figure 182). Neutral Switch (Used on 2000 and Later Lawn Tractors) Purpose Used to ensure the transmission is in neutral when starting the unit. It is activated when the clutch/brake pedal is depressed. Location Under the tractor, in the channel of the frame, under the clutch/brake pedal (Figure 184).
ELECTRICAL SYSTEM How It Works Location This single pole plunger type switch has two terminals. When the cluch/brake pedal is depressed, it pushes on the plunger, closing the contact, and connecting the two terminals (Figure 185). The seat switch is located in the bottom of the seat between the seat cushion and the seat plate (Figure 186). Figure 186 Figure 185 mvc-680 mvc-684 How It Works Testing 1. Disconnect the switch from the wiring harness. 2.
ELECTRICAL SYSTEM 3. With weight or pressure on the seat, check the continuity again on the two terminals. There should be continuity. KeyChoice™ Reverse Operating System – Used on 1999 and Later XL Lawn Tractors This interlock feature is provided to prevent unintentional engine-powered attachment operation in reverse. If the tractor is shifted into reverse while the mower blade or other Power Take Off (PTO) driven attachment is engaged, the engine will stop.
ELECTRICAL SYSTEM 4. A red light on the front console turns on, indicating that the interlock (No-Mow-In-Reverse) is disabled (Figure 189). Figure 189 How It Works The switch is basically an on/off switch spring-loaded to return to the off position. When turned to the On position with the PTO engaged, it activates circuits in the Key Choice™ Reverse Operating System reverse module and allows the operator to mow in reverse (Figure 190). 3678-03 5.
ELECTRICAL SYSTEM Location 3. The switch is located under the tractor, near the traction idler (Figure 191). Depress the plunger on the switch and check the continuity across the terminals, there should be NO continuity (Figure 192). Figure 192 Figure 191 How It Works This single pole plunger type switch has two terminals.
ELECTRICAL SYSTEM Location The Key Choice™ Reverse Operating System module is located under the gas tank (Figure 194). * NOTE: If multimeter does not have a diode scale, this test can not be done. This is not a problem if powered tests are done. Powered test must be done to check out relays (Figure 195). Figure 194 Figure 195 mvc-694 How it Works The Key Choice™ Reverse Operating System is made up of several components, such as diodes and relays.
ELECTRICAL SYSTEM Electric PTO Switch Testing Purpose 1. Disengage the PTO, set the parking brake, turn the ignition to the “OFF” position and remove the key. The PTO (Power Take Off) switch is typically used to turn on the Electric PTO Clutch and to function as part of the safety interlock system. 2. Remove the gas tank from the steering tower. 3. Disconnect the wiring harness from the PTO switch. 4.
ELECTRICAL SYSTEM Electric PTO Clutch Testing Purpose If the electric PTO clutch is not engaging or is suspected as a cause of electrical problems, use the following troubleshooting steps. These procedures will help you determine if the clutch has failed or is the cause of the electrical problem. This clutch electrically controls the engagement and disengagement of the Power Take Off (PTO) pulley.
ELECTRICAL SYSTEM Measuring Clutch Current Draw 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2. Disconnect the clutch wire connector. 3. Set the multimeter to check amps (10 amp scale). 4. Connect the positive meter lead to the tractor terminal (1) of the clutch wire (Fig. A5 005). Fig A5 005 fig. 89 5. Connect the negative meter lead to the corresponding wire terminal (3) (Fig. A5 005). 6.
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1Mower MOWER 32” Mower 6. Removing 32” Mower 1. Park the machine on a level surface, disengage the PTO, shift into neutral, set the parking brake, stop the engine, and remove the ignition key. 2. Pull the wire off of the spark plug. 3. Move the height-of-cut lever (deck lift) into the “D” notch. 4. Remove the height-of-cut lift assist spring from the retaining bolt (Figure 196), using the spring tool provided with the machine. The spring is between the frame and the right rear wheel.
MOWER 8. Remove the hairpin cotter and washer at the top of the mower leveling bracket (Figure 199). Slide the bracket off of the mounting pin. Repeat this step on the opposite side of the mower. Figure 199 (A) Hairpin Cotter & Washer (B) Long Rod 9. Figure 200 m-1898 m-1805 (C) Leveling Bracket (D) Mower Mount Remove the hairpin cotter and washer from the end of the long rod (Figure 199). Slide the rod out of the mower mount. Repeat this step on the opposite side of the mower.
MOWER Important: Do not bend the belt guide(s) away from the pulley. There must be a maximum 1/8” (3mm) between the belt guide(s) and the edge of the pulley to keep the belt on the pulley during operation. If the space is more than 1/8” (3mm), adjust the belt guide(s) and tighten them securely. The belt guide(s) must not contact the pulley. 5. 7. Slide the end of the long rod through the hole in the mower mount (Figure 202). Install the washer and hairpin cotter to secure the rod in place.
MOWER 9. Install the blade control rod onto the blade control arm and secure it with the washer and hairpin cotter (Figure 203). Blade Drive Belt Removing the Blade Drive Belt 1. Remove the mower; refer to "32” Mower" on page 6 - 1. 2. Loosen the belt guide mounting bolts and move the belt guides away from the pulley. 3. Remove the belt from the pulley. Installing the Blade Drive Belt Figure 203 (A) Hairpin Cotter & Washer 1.
MOWER Side-to-Side Mower Leveling 5. The mower blades must be level from side to side. Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn. Before you level the mower, set the air pressure in the front and rear tires to the recommended inflation. 1. Park the machine on a level surface, disengage the PTO, shift into neutral, set the parking brake, stop the engine, and remove the ignition key. 2. Pull the wire off of the spark plug. 3.
MOWER 6. 2. Pull the wire off of the spark plug. 3. Check and adjust side-to-side blade level if you have not checked the setting; refer to "Side-toSide Mower Leveling" on page 6 - 5. 4. Move the height-of-cut lever into the “C” notch. 5. Check the front-to-rear blade slope by measuring between the bottom of the mower (front center and rear center) and the flat surface (Figure 208). If the front of the mower is more than 5/8 in.
MOWER 10. Slowly rotate the right side slope adjusting nut until both adjusting nuts are in the same position 14. Repeat front-to-rear blade slope adjustment; refer to steps 8-10. Important: If the slope adjustment does not stay in position after you adjust it, tighten the center bolt and locknut and repeat step 9.
MOWER 4. Remove the height-of-cut lift assist spring from the retaining bolt (Figure 212), using the spring tool provided with the machine. The spring is between the frame and the right rear wheel. Figure 212 (A) Spring (B) Bolt 6. Unhook the blade control (PTO) cable ring end from the idler spring (Figure 213). 7. Remove rubber wiper and jam nut from blade control (PTO) cable at mounting bracket. Slide the cable from the bracket (Figure 213). 8.
MOWER 9. Remove the bolts and lock nuts and pull the two mower pivot mount brackets down from the front axle (Figure 214). Figure 214 (A) Pivot Mount Bracket (B) Bolt 5/16-17 x 2-1/2” m-4630 (C) Lock Nut 13. Move the height-of-cut lever (deck lift) into the “D” notch. Hook lift assist spring onto retaining bolt for storage (Figure 212). Figure 215 (A) Hairpin Cotter & Washer (B) Long Rod 1805 (C) Leveling Bracket (D) Mower Mount 10.
MOWER 14. Remove the mower belt from the lower engine pulley (Figure 216). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to remove the belt. If it is too difficult to remove the belt, loosen the bolts and nuts securing the belt guides. 3. Turn the front wheels fully to the left. Slide the mower under the chassis from the right side. 4. Install mower belt onto the lower engine pulley (Figure 216).
MOWER 7. Slide the end of the long rod through the hole in the mower mount (Figure 218). Install the washer and hairpin cotter to secure the rod in place. Repeat this step on the opposite side of the mower. 8. Mount the slotted mower leveling bracket onto the pin on the height-of-cut arm (Figure 218). Install the washer and hairpin cotter to secure the mower Repeat this step on the opposite side of the mower. 11. Hook end of blade control (PTO) cable onto idler spring (Figure 219).
MOWER 14. Move the height-of-cut lever (deck lift) into the “D” notch to make it easier to install the height-of-cut lift assist spring. 4. Install the mower; refer to "Installing 38” Mower" on page 6 - 10. 15. Hook the height-of-cut lift assist spring onto the retaining bolt (Figure 212), using the spring tool provided with the machine. 16. Check side-to-side blade level; "Side-to-Side Mower Leveling" on page 6 - 12. Blade Drive Belt Removing the Blade Drive Belt 1.
MOWER 4. Carefully rotate blade(s) side to side (Figure 222). Measure between the outside cutting edges and the flat surface (Figure 222). If both measurements are not within 3/16” (5mm), an adjustment is required; refer to steps 5 and 6. Figure 222 (A) Blades Side to Side (B) Outside Cutting Edges 5. Remove the hairpin cotter and washer from the leveling bracket (Figure 223).
MOWER 4. Move the height-of-cut lever (deck lift) into the “C” notch. 5. Measure the length of the rod extending out the front of the adjusting block on the sides of the chassis (Figure 224). If the rod length is not 5/8” (16mm), remove the hairpin cotter and washer from the end of the rod (Figure 224), and turn the rod until the 5/8” (16mm) dimension is obtained. Then install the end of the rod into the hole in the mower mount and secure in place with washer and hairpin cotter.
MOWER 10. When front-to-rear slope is correct, tighten the pivot plate mounting bolts (Figure 226). Figure 226 (A) Pivot Mounting Bolt 4. m-4634 Figure 227 (B) Eyebolt Locknut 11. When front-to-rear slope is correct, recheck the side-to-side level of the mower; refer to "Side-toSide Mower Leveling" on page 6 - 12. (A) Spring (B) Bolt Removing 44” Mower Park the machine on a level surface, disengage the blade control (PTO), set the parking brake, stop the engine, and remove the ignition key. 2.
MOWER 8. Move the cable out of the way and lay inside frame rail so it can not get caught in drive belts or pulleys. 11. Remove the hairpin cotter and washer at the mower leveling bracket (Figure 230). Slide the bracket off the mounting pin. Re-install the washer and hairpin cotter for storage. 12. Rotate the leveling bracket up, toward the frame, and hook the long rod into one of the holes to store. Secure long rod with washer and hairpin cotter. 13. Repeat steps 10-12 on the opposite side of the mower.
MOWER 15. Remove the mower belt from the engine pulley (Figure 231). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to remove the belt. If it is too difficult to remove the belt, loosen the bolts and nuts securing the belt guides. Tighten bolts. IMPORTANT: Do not bend the belt guide(s) away from the pulley because the belt will not operate properly when the mower is installed later. Figure 231 (A) Mower Belt (B) Engine Pulley (C) Belt Guides 16.
MOWER 4. Install mower belt onto the lower engine pulley (Figure 232). If you are careful, you can flex the belt guide(s) just far enough away from the pulley to install the belt. If it is too difficult to install the belt, loosen the bolts and nuts securing the belt guides. 5. Install the mower pivot mount brackets onto the front axle with bolts and lock nuts (Figure 233). Tighten fasteners. IMPORTANT: Do not bend the belt guides away from the pulley.
MOWER 8. Move the height-of-cut lever (deck lift) into the “A” notch. Figure 234 (A) Spring (B) Bolt 9. 11. Mount the slotted mower leveling bracket onto the pin on the mower mount (Figure 235). Install the thick washer and hairpin cotter to secure the mower. Repeat this step on the opposite side of the mower. 1851 (C) Spring Tool Check that both rods extend 5/8” (16mm) beyond adjustment block (Figure 235). 10. Slide the end of the long rod through the hole in the mower mount (Figure 235).
MOWER 17. Check that blade brake pads contact pulleys and actuating rods are loose when blade control (PTO) is disengaged, and that brake pads are away from pulleys when blade control (PTO) is engaged; refer to "Adjusting Blade Brakes" on page 6 - 22. 19. Hook the lift assist spring between the mower right side lift bracket and the retaining bolt (Figure 237) Use the spring tool provided with the machine.
MOWER 4. Rotate blades to assure there is at least 1/8” (3mm) clearance between blades and baffle. 3. Install 3/8-16 x 3/4” carriage bolts, 3/8” washer and 3/8” lock nuts, from loose parts package, in open holes of mower for safety. DANGER POTENTIAL HAZARD • Open holes in the mower expose you and others to thrown debris. WHAT CAN HAPPEN • Debris thrown out of holes in the mower can cause injury.
MOWER 4. Install the mower; refer to "Installing 44” Mower" on page 6 - 17. Figure 239 (A) Pulley Cover Screw (B) Pulley Cover (C) Belt Guides (D) Mower Belt 1. Engage blade control (PTO) lever. 2. Adjust blade control cable to the correct engaged dimension; refer to "Installing 44” Mower" on page 6 - 17. Using a feeler gage, measure between the bottom flange of each blade pulley and brake pad (Figure 240). Adjust lock nut on brake rods to obtain proper clearance .020-.060 inch (.5-1.
MOWER 4. Carefully rotate blade(s) side to side (Figure 241). Measure between the outside cutting edges and the flat surface (Figure 241). If both measurements are not within 3/16” (5mm), an adjustment is required; refer to steps 5 and 6. 6. Check the front-to-rear blade slope; refer to "Front-to-Rear Blade Slope" on page 6 - 23. Front-to-Rear Blade Slope Check the front-to-rear blade slope any time you install the mower.
MOWER 4. Measure the length of the rod extending out the front of the adjusting block on the sides of the chassis (Figure 243). If the rod length is not 5/8” (16mm), remove the hairpin cotter and washer from the end of the rod (Figure 243), and turn the rod until the 5/8” (16mm) dimension is obtained. Then install the end of the rod into the hole in the mower mount and secure in place with washer and hairpin cotter. Repeat this procedure on the opposite side of the mower. 6.
MOWER 10. When front-to-rear slope is correct, tighten the pivot plate mounting bolts (Figure 245). Figure 245 (A) Pivot Mounting Bolt 1792 (B) Eyebolt Lock Nut 11. When front-to-rear blade slope is correct, recheck the side-to-side level of the mower; refer to "Sideto-Side Mower Leveling" on page 6 - 22. 12. Check gage wheel height.
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MOWER 32” Mower 38” Mower with Manual PTO Clutch 32” Mower Brake Adjustment 38” Mower Brake Adjustment 1. Lower the mower to the lowest height of cut position. 1. Lower the mower to the lowest height of cut position. 2. With the engine OFF, engage the mower (PTO) lever. 2. With the engine OFF, engage the mower (PTO) lever. 3. Check the clearance between the brake pad on the brake arm assembly and the mower drive pulley. It should be set at .015” (.38mm) gap (Fig. A6 001). 3.
MOWER 44” Mower with Manual PTO Clutch 38” Mower with Electric PTO Clutch 44” Mower Brake Adjustment Removing 38” Mower with Electric PTO Clutch 1. Lower the mower to the lowest height of cut position. 1. Park the tractor on a level surface. 2. With the engine OFF, engage the mower (PTO) lever. 2. Disengage the PTO and set the parking brake. 3. Check the clearance between the brake pads on the brake arm assemblies on the right and left mower drive pulleys. They should be set between .06” – .12” (1.
MOWER 6. Move the height-of-cut lever into the A notch. 7. Unhook the spring on the idler pulley arm from the bracket on the mower (Fig. A6 005). 9. Remove the hairpin cotter and washer from the end of the long rod (Fig. A6 007). Slide the rod out of the mower mount. A B A B D C D C B Fig A6 007 Fig A6 005 A. Eye–bolt B. Idler spring fig. 38 1805 fig. 36 m-8207 A. Long rod B. Hairpin cotter and washer C. Idler arm D. Idler pulley C. Leveling bracket D. Mower mount 8.
MOWER 14. Remove the mower belt from the electric clutch pulley (Fig. A6 008). B A Fig A6 008 A. Mower belt fig. 39 1890 B. Electric clutch pulley 15. Turn the front wheels fully to the left. Slide the mower out to the right to complete removal. Installing 38” Mower with Electric PTO Clutch A! DANGER ! Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
MOWER 4. Install the mower pivot mount brackets onto the front axle with the bolts and locknuts (Fig. A6 009). 7. Move the height-of-cut lever into the A notch. 8. Slide the end of the long rod through the hole in the mower mount (Fig. A6 011). A A B B E C Fig A6 009 A. Bolts 5/16” x 2-1/2” B. Pivot mount brackets C D fig. 37 m-4630 C. Locknuts Fig A6 011 5. Move the height-of-cut lever into the D notch. 6.
MOWER 13. Hook the idler spring from the idler pulley arm to the eyebolt on the mower (Fig. A6 012). 15. Hook the lift assist spring between the mower right side lift bracket and the retaining bolt (Fig. A6 013). Note: Use the spring tool provided with the machine. A B A D C B C Fig A6 012 A. Eyebolt B. Idler spring fig. 36 m-8207 C. Idler arm D. Idler pulley Fig A6 013 A. Spring B. Bolt fig. 35 m-1851 C. Spring tool 14.
MOWER Installing the Blade Drive Belt, 38” Mower with Electric PTO Clutch Replacing the Blade Drive Belt Removing the Blade Drive Belt, 38” Mower with Electric PTO Clutch 1. Remove the mower; refer to Removing the Mower on page A6-2. 2. Remove the pulley cover mounting screws and pulley covers from both blade pulleys (Fig. A6 014 top view). 1. Install the new belt around the blade pulleys and under the belt guide on the idler pulley. 2.
MOWER 5. Carefully rotate the blades side to side (Fig. A6 015). Measure between the outside cutting edges and the flat surface. If both measurements are not within 3/16” (5mm), an adjustment is required; refer to steps 6 and 7. 6. Remove the hairpin cotter and washer from the leveling bracket. To level the blades, reposition the leveling bracket in a different hole and install the washer and hairpin cotter. A front hole lowers the blade height and a rear hole raises its height.
MOWER Adjusting 38” Mower Front-to-Rear Blade Slope Check the front-to-rear blade slope any time you install the mower. Before you check the slope, set the air pressure in the front and rear tires to the recommended inflation; refer to Specifications, Section 1. If the front of the mower is not within a range of 1/8” to 3/8” (4 to 11mm) lower than the rear of the mower, adjust the blade slope using the following instructions: 6.
MOWER 8. To adjust the front-to-rear blade slope, loosen the front pivot plate mounting bolts slightly (Fig. A6 019). 44” Mower with Electric PTO Clutch Removing 44” Mower with Electric PTO Clutch 1. Park the machine on a level surface, disengage the PTO, set the parking brake, stop the engine, and remove the ignition key. 2. Move the height-of-cut lever into the D notch. A 3. Remove the lift assist spring between the mower right side lift bracket and the retaining bolt (Fig. A6 020).
MOWER 5. Unhook the spring on the idler pulley arm from the bracket on the mower (Fig. A6 021 viewed from the left side). 7. Remove the hairpin cotter and washer from the end of the long rod (Fig. A6 023). Slide the rod out of the mower mount. A A B B C D C B Fig A6 021 A. Bracket B. Spring Fig A6 023 fig. 38 71429 A. Long rod B. Hairpin cotter and washer C. Idler pulley arm 6. Remove the bolts and lock nuts and pull the two mower pivot mount brackets down from the front axle (Fig. A6 022).
MOWER 12. Remove the mower belt from the electric clutch pulley (Fig. A6 024 top view). Installing 44” Mower with Electric PTO Clutch A! A DANGER ! Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death. B Fig A6 024 A. Electric clutch pulley fig. 41 71429 B. Mower belt 13.
MOWER 3. Install the mower belt onto the electric clutch pulley (Fig. A6 025 top view). 5. Move the height-of-cut lever into the D notch. 6. Remove the lift assist spring between the mower right side lift bracket and the retaining bolt (Fig. A6 027). A Note: Use the spring tool provided with the machine. B A B Fig A6 025 A. Electric clutch pulley fig. 41 71429 C B. Mower belt 4. Install the mower pivot mount brackets onto the front axle with the bolts and locknuts (Fig. A6 026). Fig A6 027 A.
MOWER 8. Ensure that both rods extend 5/8” (16mm) beyond the adjustment block (Fig. A6 028). A 14. Hook the spring from the idler pulley arm to the bracket on the mower (Fig. A6 029 viewed from the left side). B A B C C D Fig A6 028 fig. 48 1805 Fig A6 029 A. Adjusting block B. Adjusting rod C. Hairpin cotter and washer D. Mower mount 9. Slide the end of the long rod through the hole in the mower mount (Fig. A6 028). A. Bracket B. Spring fig. 38 71429 C. Idler pulley arm 15.
MOWER 16. Hook the lift assist spring between the mower right side lift bracket and the retaining bolt (Fig. A6 030). Note: Use the spring tool provided with the machine. Replacing the Blade Drive Belt, 44” Mower with Electric PTO Clutch Removing the Blade Drive Belt, 44” Mower with Electric PTO Clutch 1. Remove the mower; refer to Removing the Mower on page A6-10. A 2. Remove the pulley cover mounting screws and pulley covers from both blade pulleys (Fig. A6 031 top view). B A C Fig A6 030 A.
MOWER Installing the Blade Drive Belt, 44” Mower with Electric PTO Clutch 1. Install the new belt around the blade pulleys and the idler pulleys. 4. Carefully rotate the blades side to side.Measure between the outside cutting edges and the flat surface. If both measurements are not within 3/16” (5mm), an adjustment is required; refer to steps 5 and 8 (Fig. A6 032). 2. Tighten the idler pulley mounting bolt (Fig. A6 031). 3. Install the left and right pulley covers with the mounting screws (Fig. A6 031).
MOWER 6. To level the blades, reposition the leveling bracket in a different hole and install the washer and hairpin cotter (Fig. A6 033). A front hole lowers the blade height and a rear hole raises its height. 7. Repeat steps 5 and 6 on the opposite side of the mower. 4. Measure the length of the rod extending out of the front of the adjusting block on the sides of the chassis (Fig. A6 034).
MOWER 9. Check the front-to-rear slope by measuring between the bottom of the mower (front center and rear center) and the flat surface (Fig. A6 035). 10. To adjust the front-to-rear blade slope, loosen the front pivot plate mounting bolts slightly (Fig. A6 036). If the front blade tip is not within a range of 0 to 5/16” (0 to 8mm) lower than the rear, adjust the front-torear blade slope (steps 10 through 13); otherwise, skip to step 14. A A C D B D Fig A6 035 A. Measure front blade tip B.
492-4734 Revised 4-07
