Service Manual

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SERVICE MANUAL

Time Cutter SW/SWX

Residential Products

Summary of content (142 pages)

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Res i dent i al Pr oduc t s SERVI CEMANUAL Ti meCut t erSW/ SWX
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ABOUT THIS MANUAL 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 shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
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TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS 1 - Safety Information General Information �� 1-1 Think Safety First �� 1-1 2 - Specifications 2015 TimeCutter SW Specifications ��
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TABLE OF CONTENTS Upper Deck Lift Removal ��3-17 Upper Deck Lift Installaton ��3-17 Deck Lift Exploded View ��3-18 Lower Deck Lift Service ��
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TABLE OF CONTENTS 6 - Mower Deck Mower Deck Exploded View ��6-1 32 in. Stamped Deck ��6-1 42 in. Stamped Deck ��6-2 42 in.
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TABLE OF CONTENTS 7 - Electrical Chassis Switches ��7-1 Key/Ignition Switch ��7-1 Purpose ��
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TABLE OF CONTENTS PTO Clutch Installation ��7-18 Hour Meter (If Equipped) ��7-19 Purpose ��7-19 Location ��
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SAFETY INFORMATION General Information ! This symbol means WARNING or PER SONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the TimeCutter® SW, the TimeCutter® SWX zero radius turn mowers.
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SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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SPECIFICATIONS 2015 TimeCutter Zero Turn Tractor Specifications Configuration 16 HP 452cc Toro SW3200 SW4200 SW5000 32” Mower, 1 Blade 22 HP 725 cc Kohler 42” Mower, 2 Blades 24.
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SPECIFICATIONS 2015 TimeCutter Zero Turn Tractor Specifications cont. Configuration SW5425 SW4250 SW5050 24 HP 725cc Kohler 24.5 HP 708cc Toro 2 50” Fab Deck, 3 Blades 54” Mower, 3 Blades 42” Fab Deck, 2 Blades 50” Fab Deck, 3 Blades Power Systems Clutch Electric Electric Electric Transaxles Twin Hydro-Gear ZT-2200 Twin Hydro-Gear ZT-2200 Twin Hydro-Gear ZT-2800 Drive Belt Drive with selftensioning system Belt Drive with selftensioning system Belt Drive with selftensioning system Max.
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SPECIFICATIONS Engine Specifications Model # Model Engine Information 74780 SW3200 Toro, Single Cylinder, 16 hp, High Idle: 3400 - 3450 RPM 74781 SW3200 Toro, Single Cylinder, 16 hp, High Idle: 3400 - 3450 RPM 74784 SW4200 Toro, Twin Cylinder, 24.5 hp, High Idle: 3300 + 100 RPM 74785 SW4200 Kohler, Twin Cylinder 22 hp, High Idle: 3300 + 100 RPM 74790 SW5000 Toro, Twin Cylinder, 24.5 hp, High Idle: 3300 + 100 RPM 74793 SW5425 Toro, Twin Cylinder, 24.
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SPECIFICATIONS Hydro-Gear ZT-2100, ZT-2200 Hydrostatic Transaxles 2 Fig. 001 PICT-1000 Lubrication 20w50 Engine Oil Oil Capacity ZT-2100 54 fl. oz. / 1.687 qt. (1597ml) each Oil Capacity ZT-2200 56 fl. oz. / 1.75 qt. (1650ml) each Oil Level Check The transaxle is a sealed system and does not require periodic checking. Check oil at the oil fill plug location only. Do not check the oil at the vent tube. If the oil level needs to be checked, the transaxle must be removed.
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SPECIFICATIONS Hydro-Gear ZT-2800 Hydrostatic Transaxles 2 Fig. 003 PICT-1002 Lubrication Toro HYPR-OIL 500 or 20w50 Engine Oil Oil Capacity ZT-2800 77.23 fl. oz. (2284ml) each Oil Level Check Check expansion reservoir and if necessary add the specified oil to the FULL COLD line. See illustration below. Also see the Hydro-Gear ZT-2800 service manual (BLN-52441). Fluid Change Interval After the First 50 hours - change the oil and filters for the hydraulic system and bleed the system.
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SPECIFICATIONS Torque Specifications 2 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.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 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)
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SPECIFICATIONS Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 2 Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
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SPECIFICATIONS OtherTorque TorqueSpecifications Specifications Other Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 1/4 - 20 UNC Square Head Hex Socket 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.
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SPECIFICATIONS Equivalents & Conversions Equivalents and Conversions Decimal & Millimeter Equivalents Decimal and Millimeter Equivalents Fractions 1/64 2 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.
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SPECIFICATIONS U.S. to Metric Conversions U.S. to Metric Conversions 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.
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SPECIFICATIONS 2 THIS PAGE INTENTIONALLY LEFT BLANK.
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CHASSIS Model & Serial Number Identification Grease & Lubrication Point The model and serial number identification plate is located on the frame, near the battery, under the operator’s seat as shown below (Fig. 005). Grease Type – No. 2 general-purpose lithium base grease A grease fitting is located on each of the front wheel hubs. The front wheel hubs should be greased every 25 hrs. (Fig. 006) 3 Fig. 005 PICT-1034 Fig.
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CHASSIS Front Axle / Caster Fork / Bearing Service Front Axle / Caster Fork / Bearing Assembly 1. Using a proper bearing installation tool, install a new bearing into the front axle making sure it is fully seated. Front Axle / Caster Fork / Bearing Disassembly 2. Install thrust washer (D) onto the caster fork shaft. 1. Safely raise and support unit so front wheels are off the ground. 3. Install the caster assembly up through the bearings and hold in position. 2.
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CHASSIS Caster Wheel / Bushing Service Caster Wheel / Bushing Assembly Caster Wheel / Bushing Disassembly 1. Lightly lubricate bushings (C) and wheel spanner (B) with No. 2 general-purpose lithium base grease. Fill center of wheel hub with grease. 1. Safely raise and support unit so front wheels are off the ground. 2. Support under caster wheel and remove the nut / bolt (A). 3. Remove and inspect wheel spanner (B). Replace if excessively worn. 2.
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CHASSIS Pod / Fender / Fuel Tank Service Pod / Fender Installation – RH Pod / Fender Removal – RH 1. Maneuver RH fender (B) into position. 1. Raise seat and disconnect battery terminals. Note: The RH control lever and deck lift lever must pass through the RH fender during removal and installation. 2. Remove the (3) screws (A) securing control panel to RH fender (B). Move control panel inward towards the center of the unit. 3. Remove the (3) screws (C) securing the RH fender to frame. 3 2.
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CHASSIS Pod / Fender Removal – LH Pod / Fender Installation – LH 1. Raise seat and disconnect battery terminals. 1. Maneuver LH fender into position. 2. Unscrew fuel cap. With a clean, long, needle nose pliers, reach into fuel tank and grab fuel cap tether base (D). Pull upward and flex tether base to remove fuel cap from fuel tank assembly (Fig. 011). Note: The LH control lever must pass through the LH fender during removal and installation. 2.
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CHASSIS Fuel Tank Removal Fuel Tank Installation 1. Remove LH fender as shown in this chapter. 1. Position fuel tank assembly (G) into the frame slots. 2. Disconnect and properly secure the (2) fuel / vent lines from the top of fuel tank assembly (G). (Fig. 013) 2. Install the (2) fuel tank retaining springs (H) to secure fuel tank to the frame. G 3. Properly connect the (2) fuel / vent lines. 4. Install LH fender as shown in this chapter. 5.
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CHASSIS Seat Pivot Service Seat Pivot Removal 1. Raise seat and disconnect battery terminals. 2. Disconnect the seat switch harness connection and remove seat switch harness from the routing clip on the seat base. 3. Remove the washer and retaining clip, then remove the seat stop assembly (B). 3 4. Remove the retaining clips and the seat pivot rod / seat stop rod (C). 5. Remove the seat assembly from the unit (Fig. 016). B C Fig.
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CHASSIS STEERING COLUMN – ZERO TURN TRACTOR Apply anti-seize to upper shaft splines and U-joint splines 3 Flange of bushing is located on the outside of the retainer plate. Torque to 150-200 inlbs (17-23 Nm) Back Column Apply Blue Loctite.
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CHASSIS FRONT SHROUD – ZERO TURN TRACTOR Steering Wheel 3 Steering Column Rear Cover Front Shroud Spindle Housing CZN0003a Toro TimeCutter SW/SWX Service Manual 3-9
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CHASSIS FRONT SHROUD - ZERO TURN TRACTOR Front Shroud Removal 1. Disconnect the damper from the traction pedal. 3. Remove the steering wheel cap. 3 2. Disconnect the traction pedal from the pedal pivot mount. Remove traction pedal. 4. Loosen the steering wheel lock nut. Leave the nut on the shaft at least 2-3 threads.
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FRONT SHROUD - ZERO TURN TRACTOR CHASSIS 5. With the heel of your hand or soft tapping from a soft mallet, tap the steering wheel until it comes loose from the splined steering shaft. Remove the nut and remove steering wheel. 7. Remove the rear cover. 3 6. Remove the T-30 Torx screws holding the shroud on. Toro TimeCutter SW/SWX Service Manual 8. Fold the steering column all the way into the down position. Slide front shroud up and off the steering column.
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CHASSIS FRONT SHROUD - ZERO TURN TRACTOR Front Shroud Installation 1. Slide the shroud down on the steering shaft and set into place. 3. Install the T-30 Torx screws on the shroud. Torque to 80-100 lbs (9-11 Nm). 3 4. Place the steering Wheel onto the splined steering shaft. 2. Install the rear cover. 3-12 Note: Make sure the front caster wheels are in the straight position and the steering wheel is also straight.
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FRONT SHROUD - ZERO TURN TRACTOR CHASSIS 5. Install the lock nut and torque to 27-44 ft-lbs (3746 Nm). 7. Install the traction pedal to the pedal pivot mount, torque to 5 ft-lbs. (7 Nm). 3 6. Install the steering wheel cap. 8. Install the damper to the traction pedal. Note: It must be placed in the correct position, torque to 5 ft-lbs. (7 Nm).
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CHASSIS Pod / Fender Support Service Pod / Fender Support Installation Pod / Fender Support Removal (SWX Shown) 1. Position the Pod / Fender support bracket onto the chassis. 1. Raise seat and disconnect battery terminals. 3 2. Remove fenders and fuel tank as shown in this chapter. 2. Install the fasteners (A, B and C) that secure the support to the chassis and torque to specification – 17 ft-lbs. (23 Nm). 3. Take note of cable and harness routing for reassembly. 3.
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CHASSIS Upper Deck Lift Service Upper Deck Lift Installation Upper Deck Lift Removal 1. Maneuver the deck lift assembly (E) into position from the RH side of the unit. 1. Raise seat and disconnect battery terminals. 2. Remove the RH fender / pod as shown in this chapter. 3. Move the deck HOC to the middle position. 4. Support deck in current position, then move deck HOC to the lowest position. 5.
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CHASSIS Deck Lift Exploded View G 3 E A B A F C D Fig.
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CHASSIS Lower Deck Lift Service Lower Deck Lift Installation Lower Deck Lift Removal 1. Install (2) pivot blocks (G) onto rear lift arm ends. 1. Move deck HOC to the middle position. 2. Install rear lift arm (H) assembly into frame C-channel. 2. Support under deck in current position, then move the deck HOC to the lowest position. 3. Remove the (2) pins and (2) washers that attach the lift links (D) to the deck lift (E). 3.
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CHASSIS Deck Lift Exploded View 3 E K L H I D I G Fig.
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CHASSIS RETURN TO NEUTRAL ASSEMBLY – ZERO TURN TRACTOR Spring should be oriented as shown. Apply anti-seize to this surface. Switch arm – These must move freely after installation 3 Switch, single pole Torque to 100 inlbs (11.5 Nm) Switch bracket Torque to 100 inlbs (11.5 Nm) Apply anti-seize to this surface. Switch orientation (top view) Spring should be oriented as shown.
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CHASSIS RETURN TO NEUTRAL ASSEMBLY - ZERO TURN TRACTOR Return to Neutral Assembly Removal 1. Remove the two bolts holding the RTN assembly to the chassis. 3. Remove the assembly. 3 2. Slide the unit to the side and remove the switch connectors from the switches.
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CHASSIS RETURN TO NEUTRAL ASSEMBLY - ZERO TURN TRACTOR Return to Neutral Assembly Installation 1. Insert a 1/4 in. dowel pin through the hole on the pedal mount and into the foot pedal assembly. This ensures the foot pedal is in the neutral position. 3. Install the two mount bolts and torque to 150-200 in-lbs. (11.5-17 Nm). Ensure the switch arms can move freely and do not bind. 3 2. Re-connect the switch connectors to the switches.
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CHASSIS Speed Control Assembly LH Cable Front 3 RH Cable RH Cable Wide Chassis Models RH Cable Arm Apply anti-seize to bearing surfaces LH Cable LH Cable Arm RH Cable Narrow Chassis Models LH Cable Steering Cables 3-22 Toro TimeCutter SW/SWX Service Manual
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CHASSIS Cable Adjustment SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 1. When the cables are properly adjusted, both of the cable arms will contact the cabel lever at the same time when the wheels are straight and the traction pedal is in neutral The cable arms should contact the rollers and stop on the bracket before the cables are installed and adjusted. 3. Insert a 1/4 in. dowel pin through the center hole on the speed control assembly to lock the speed control assembly in place.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 5. When the cables are adjusted correctly, both steering arms will be contacting the steering link and the cables will be tight. 6. Tighten the jam nuts and remove the dowel pin. 2. Slide the cabel cover off of the threaded portion of the cable. Loosen the jam nut on the cable and move the lock nut all the way down the cable. 3 Cable Removal 1. Remove the E-clip and washer securing the cable to the cable arm. 3.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 4. Remove the barrel end of the cable from the speed control assembly. 6. Slide the cable out of the speed control assembly. 3 5. Using a needle-nose pliers, pinch the cable locks together. Toro TimeCutter SW/SWX Service Manual Cable Replacement 1. Slide the new cable through the hole in the speed control assembly and lock the cable in place.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 2. Insert the barrel of the cable into the holder of the speed control assembly. Note: The barrel has to slide through the hole on the outside part of the holder first to allow the barrel to slide in fully. Hole 4. Install the rubber cap, washer, and E-clip. Note: Do not re-use E-clips, replace with new. Adjust the cables by referring to “cable adjustment” in this Service Information section. 3 3.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR Speed Control Assembly Removal 1. Remove the front shroud as outlined in “Front Shroud Removal” service information sheet. 2. Remove the cables from the cable arms as outlined in “cable removal.” 4. Remove the hydro rods from speed control assembly. 3 3. Remove the rod end from the pivot lever assembly. Toro TimeCutter SW/SWX Service Manual 5. Remove the bolt holding the speed control assembly to the frame.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 6. Remove the speed control assembly from the unit. 2. Insert a 1/4 in. pin through the hole on the pedal mount and into the foot pedal assembly. This ensures the foot pedal is in the neutral position. 3 Speed Control Assembly Installation 1. Insert the speed control assembly to the chassis. The bearing pivot (A) needs to be oriented so the flats of the pivot fit into the hole in the chassis. Insert bolt and torque bolt to 45-55 ftlbs. (62-76 Nm). 3.
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CHASSIS SPEED CONTROL ASSEMBLY - ZERO TURN TRACTOR 4. If a dowel pin will not insert through the speed control assembly and the hole in the chassis, then the rod end (A) will have to be adjusted. Remove the nut on the rod end and remove the rod end from the bolt. Insert a dowel through the speed control until the pin goes through the holes on the speed control and the chassis as shown in step 3. Turn the rod end until it can be placed on the bolt, re-install the nut on the bolt (A). 6.
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CHASSIS Steering System Torque to 150-200 in-lbs. (17-23 Nm) Apply Blue Loctite, torque 45-55 ftlbs. (62-76 Nm) 3 Lower Steering Shaft Steering Rod Sector Gear Wheel Gear Torque to 67-83 ft-lbs. (92-115 Nm) Torque to 80-100 ft-lbs.
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CHASSIS Steering System Ball Joint Orientation - Rear View Traction Pedal 3 Apply anti-seize to bore and thrust surfaces Damper Torque to 45-55 ft-lbs. (62-76 Nm) Ball joints to be threaded on hydro rods .50 inch from end Hydro Rods Return Assembly Torque to 150-200 inlbs. (17-23 Nm) Apply Blue Loctite Torque to 80-100 inlbs. (9-11 Nm) Speed Control Asm.
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CHASSIS Steering System 3 3-32 Toro TimeCutter SW/SWX Service Manual
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STEERING SYSTEM - ALIGNMENT - ZERO TURN TRACTOR CHASSIS Alignment Note: For proper alignment, you will need three 1/4 in. dowel pins and a steering arm spacer. This tool kit is available from Toro. “Order part number 132-0852 Note: The fourth dowel pin is used for a different procedure. 2. Align the mark on the sector gear with a tooth on the lower steering shaft as shown. The mark on the gear must be right in the middle. 3 1.
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CHASSIS STEERING SYSTEM - ALIGNMENT - ZERO TURN TRACTOR The spacer should surround the nut on the tie rod and verifying the steering column is straight. 5. If the left side wheel (when sitting on the machine) isn’t straight, adjust the tie rod on the long tie rod (B) until the wheel is positioned in a straight forward position. 3 4.
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STEERING SYSTEM - ALIGNMENT - ZERO TURN TRACTOR 7.Lift up the seat and insert a 1/4 in. dowel pin through both alignment boles on both sides of the hydro rod bell cranks. The dowel pins should touch the bell cranks. CHASSIS 1/4 in. Dowel Pin 3 1/4 in. Dowel Pin 1/4 in. Dowel Pin Bell Cranks 1/4 in. Dowel Pin 8.
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CHASSIS 3 This page is left intentionally blank.
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ENGINE Engine Replacement PTO Clutch & Clutch Stop Mounting (All Models) (Fig. 033) C B C D 4 D A A Fig. 033 Chassis Identification Wide Frame - All TimeCutter SW 50 & 54 inch units - All TimeCutter SWX 50 inch units PICT-1079 A. PTO clutch bolt - 55 ft-lbs. (76 Nm) - apply Loctite® 242 to bolt threads B. Drive pulley - apply anti-seize to crankshaft and pulley ends C. Clutch stop nut/bolt - 30 ft-lbs. (40 Nm) D.
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ENGINE Engine Mounting - Toro LC1P92F Engine (Fig. 034) C C 4 D B A B Fig. 034 PICT-1080 A. Clutch stop B. Engine to chassis mounting bolts (4) - torque in a cross pattern, apply Loctite® 242 - 33 ft-lbs. (44 Nm) C. Muffler mounting bolts - 13.5 ft-lbs. (17.5 Nm) D. Heat shield mounting bolts - 5 ft-lbs.
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ENGINE Engine Mounting - Toro Twin Cylinder 4 A B A. Same note as Kohler A B.
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ENGINE Kohler Twin Cylinder 4 B C A A. Engine to Chassis bolts (4) - torque is a cross pattern. Apply Loctite B. Muffler Mounting bolts (4) - torque to 12.5-14 ft-lbs. (17-19 Nm). C. Heat Sheild Mounting bolts (2) - torque to 60 in-lbs. (7 Nm). 4-4 242-33 ft-lbs. (44 Nm).
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ENGINE Engine Removal Engine Installation 1. Raise seat and disconnect battery terminals. 1. Position the engine onto the frame. 2. Disconnect wire harness connection to PTO clutch. 2. Connect the battery ground wires (B) to the engine block, and connect the positive battery wire to the engine starter motor. 3. Remove PTO belt. 4. Remove PTO clutch bolt. 5. Remove drive belt and drive pulley from crankshaft. 6. If necessary, remove rear engine guard. 7.
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ENGINE Clutch & Clutch Stop Location - Wide Frame (Fig. 039) Bottom view A Wide Frame Chassis Identification: - All TimeCutter SW 50 & 54 inch units - All TimeCutter SWX 50 inch units C B 4 Fig. 039 PICT-1085 Clutch & Clutch Stop Location - Narrow Frame (Fig. 040) Bottom view C A. Clutch stop B. PTO clutch C. Engine mounting bolts (4) Narrow Frame Chassis Identification: - All TimeCutter SW 32 & 42 inch units - All TimeCutter SWX 42 inch units B A Fig. 040 4-6 PICT-1086 A. Clutch stop B.
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HYDROSTATIC DRIVE SYSTEM Chassis Identification Narrow Frame (Fig. 042) Wide Frame - All TimeCutter SW 50 and 54 Inch Units - All TimeCutter SWX 50 Inch Units Narrow Frame - All TimeCutter SW 32 and 42 Inch Units - All TimeCutter SWX 42 Inch Units Hydrostatic Drive Exploded Views Wide Frame (Fig. 041) 5 Fig. 042 Fig.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Routing Bottom View (Fig. 043) Fig. 043 PICT-1087 (Fig. 044) 5 Fig.
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HYDROSTATIC DRIVE SYSTEM Tracking Adjustment Zero turn tractors should drive in a straight line with the wheels going straight forward and WITHOUT having to “steer” the unit straight. If the tracking is off and the person “forces” the unit to drive straight by steering it straight, there can be whining from one of the hydros if there is enough traction to load up the hydro. On grass, this would probably result in turf tear.
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HYDROSTATIC DRIVE SYSTEM 5. Accelerate the engine to full RPM. Observe the rear tire’s forward or reverse movement. If the tire is creeping in forward or reverse, a neutral adjustment is needed. Make sure the traction pedal is in the neutral position. 6. When in neutral, the stud should be in the center of the slot in the control arm (A). 7. If one wheel is creeping, set the neutral on BOTH drives. Set both wheels so they are slightly rotating forward.
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HYDROSTATIC DRIVE SYSTEM Purging Procedure \ Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance, any additional oil has been added to the system, or a replacement transaxle has been installed. Air creates inefficiency because its compression and expansion rate is higher than that of the oil in hydrostatic drive systems.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt Removal 5. Disengage the drive belt from the drive belt tensioner pulleys. Remove the belt from the drive and hydro pulleys, then remove the belt from the unit. 1. Safely raise and support rear of unit so rear wheels are off the ground. 6. Inspect the idler arm pivot and pulley bearings for excessive wear and replace if necessary (Fig. 055). 2. Remove PTO belt spring to relieve PTO belt tension.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Installation Transaxle Replacement 1. Properly route the belt around the (2) hydro input pulleys, the drive pulley and (2) tensioner / idler pulleys (Fig. 056). Transaxle Removal Drive Belt Routing - bottom view 1. Disconnect battery terminals. (RH side shown) 2. Safely raise and support unit by rear frame / bumper so rear wheels are off the ground. 3. Remove rear wheels. 4. Remove the rear hydro rod mounting nut (Fig. 058). Fig. 056 PICT-1093 5 2.
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HYDROSTATIC DRIVE SYSTEM 6. Remove the brake rod from the brake actuator module (Fig. 060). See “Brake Actuator Module” on page 7-6. 7. Remove the brake rod from the hydro: All TimeCutter SW 54 inch SWX 50 inch models only – Remove the nut (A) and the spring. Remove the brake rod from the unit (Fig. 061). A Fig. 060 IMG-0968b Fig. 061 PICT-1101 All TimeCutter SW 32 & 42 inch and SWX 42 inch models – Remove the nut (B), spring and washer. Remove the brake rod from the unit (Fig. 062). 5 B Fig.
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HYDROSTATIC DRIVE SYSTEM 8. Remove the drive belt tensioner spring (Fig. 063). 11. Remove the hydro center support: Wide Frame – Remove the (6) mounting fasteners (Fig. 065). Fig. 063 PICT-1091 9. Slip the drive belt off the idler pulleys, then off the appropriate hydro input pulley. 10. If equipped, disconnect and plug the hydro reservoir hoses at the hydro fitting. Be sure to capture and dispose of fluid and shop towels properly (Fig. 064). (SWX only) Fig. 064 Fig.
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HYDROSTATIC DRIVE SYSTEM 13. Narrow Frame Only– Remove the (2) outer hydro mounting fasteners (Fig. 067). Narrow Frame (Fig. 069) Fig. 069 Fig. 067 PICT-1098 PICT-1100 14. Remove the (2) front hydro mounting fasteners. 15. Remove the (1) rear hydro mounting fastener (Fig. 070). Wide Frame (Fig. 068) 5 Fig. 070 Fig. 068 PICT-1099 PICT-1106 16. Lower the hydro assembly and remove it from the frame.
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HYDROSTATIC DRIVE SYSTEM Transaxle Installation 4. Torque fasteners in sequence to specification as shown: 1. Wide Frame Only – If a new hydro assembly is being installed, transfer the (2) mounting brackets (C and D) to the new hydro assembly and torque the fasteners to specification; C - 30 ft-lbs. (40 Nm) and D - 8 ft-lbs. (14 Nm) (Fig. 071). Wide Frame: 1st - Torque fastener (E) to specification – 17 ft-lbs. (23 Nm) (Fig. 072) 2nd - Torque fastener (F) to specification – 17 ft-lbs. (23 Nm) (Fig.
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HYDROSTATIC DRIVE SYSTEM 4th - Torque fasteners (H) to specification – 17 ft-lbs. (23 Nm) (Fig. 074) H Narrow Frame: 1st - Torque fastener (J) to specification – 50 ft-lbs. (69 Nm) (Fig. 076) J Fig. 074 PICT-1107 Fig. 076 5th - Torque the two fasteners (I) to specification – 30 ft-lbs. (40 Nm) (Fig. 075) PICT-1098 2nd - Torque the (4) fasteners (K) to specification – 50 ft-lbs. (69 Nm) (Fig. 077) 5 I Fig. 075 5-12 K PICT-1108 Fig.
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HYDROSTATIC DRIVE SYSTEM 3rd - Torque fastener (L) to specification – 17 ft-lbs. (23 Nm) (Fig. 078) 5th - Torque fasteners (N) to specification – 30 ft-lbs. (40 Nm) (Fig. 080) N L Fig. 078 PICT-1098 4th - Torque fasteners (M) to specification – 17 ft-lbs. (23 Nm) (Fig. 079) Fig. 080 PICT-1100 5. If equipped, connect the hydro reservoir hoses at the hydro fitting (MX shown) (Fig. 081). 5 M Fig. 079 Toro Timecutter SW/SWX Service Manual Fig.
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HYDROSTATIC DRIVE SYSTEM 6. Install the hydro drive belt and verify proper routing (Fig. 082). Drive Belt Routing - bottom view Fig. 082 5 PICT-1093 7. Install and orient the drive belt tensioner spring as shown (Fig. 083). Fig. 083 8. Install the brake rod to the hydro: All TimeCutter SW 50 inch and SWX 50 inch models only – Install the brake rod spring and nut and torque nut to specification - 30 in-lbs. (3 Nm). Hold the rod securely while tightening nut (Fig. 084). Fig.
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HYDROSTATIC DRIVE SYSTEM 9. Install the brake rod to the brake actuator module (Fig. 086). Fig. 086 16. Install the rear hydro rod and torque the nut to speci fication - 17 ft-lbs. (23 Nm) (Fig. 088). Hold the rod securely while tightening nut. IMG-0968a Fig. 088 10. Install the bypass lever, washer(s) and retaining clip (SWX shown) (Fig. 087). PICT-1097 11. Install the rear wheels and torque lug nuts to specification – 80 ft-lbs. (108 Nm). 12. Connect battery terminals. 5 13. Safely lower unit.
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HYDROSTATIC DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECK Mower Deck Exploded Views 32 Inch Stamped Deck (Fig. 089) C D D E D 6 ZS Models Only B A Fig. 089 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley nut - 55 ft-lbs. (76 Nm) Toro Timecutter SS/MX/ZS Service Manual PICT-1055 32S D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts (8) - 17 ft-lbs.
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MOWER DECK 42 Inch Stamped Deck (Fig. 090) C D D E ZS Models Only 6 B A Fig. 090 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley nut - 55 ft-lbs. (76 Nm) 6-2 PICT-1056 42S D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts (8) - 17 ft-lbs.
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MOWER DECK 42 Inch Fabricated Deck (Fig. 091) C D D D E ZS Models Only 6 B A Fig. 091 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley nut - 55 ft-lbs. (76 Nm) Toro Timecutter SS/MX/ZS Service Manual PICT-1058 42F D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts (8) - 17 ft-lbs.
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MOWER DECK 50 Inch Stamped Deck (Fig. 092) D D D C E ZS Models Only B 6 A Fig. 092 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley nut - 55 ft-lbs. (76 Nm) 6-4 PICT-1057 50S D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts (12)-17 ft-lbs.
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MOWER DECK 50 Inch Fabricated Deck (Fig. 093) D D D C ZS Models Only 6 B A Fig. 093 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley nut - 55 ft-lbs. (76 Nm) Toro Timecutter SS/MX/ZS Service Manual PICT-1059 50F D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts (12)-17 ft-lbs.
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MOWER DECK PTO Belt Replacement and Belt Routing 42 Inch Stamped Deck (Fig. 095) B 32 Inch Stamped Deck (Fig. 094) E B C E A C A D C D D F 6 D Fig. 094 A. Idler pulley B. Deck belt C. Spindle pulley 6-6 F Fig. 095 PICT-1061b D. Spring E. Engine pulley F. Spring tool A. Idler pulley B. Deck belt C. Spindle pulley PICT-1062a D. Spring E. Engine pulley F.
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MOWER DECK 42 Inch Fabricated Deck 50 Inch Stamped Deck (Fig. 096) (Fig. 097) B A GC C B EG E A C C D F Fig. 096 A. Idler pulley B. Deck belt C. Spindle pulley D. Spring E. Engine pulley F. Spring tool G. Deck handles Toro Timecutter SS/MX/ZS Service Manual PICT-1063a D F Fig. 097 A. Idler pulley B. Deck belt C. Spindle pulley PICT-1064a D. Spring E. Engine pulley F.
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MOWER DECK Inspecting the Belts 50 Inch Fabricated Deck (Fig. 098) GCBE Service Interval: Every 25 hours – Check the belts for wear. A CG Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. PTO Belt Replacement 1. Park the unit on a level surface and disengage the PTO switch. 2. Move the motion control levers outward to the park position, stop engine, remove key, and wait for all moving parts to stop before leaving the operating position. 3.
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MOWER DECK Mower Deck Replacement 5. Using the deck handles, lift the mower deck so the hanger brackets clear the rear lift rod. Lower the mower carefully to the ground (Fig. 100 and Fig. 101). Mower Deck Removal 1. Park the unit on a level surface and disengage the PTO switch. 2. Move the motion control levers outward to the park position, stop engine, remove key, and wait for all moving parts to stop before leaving the operating position. 3. Set the height-of-cut to the lowest position. 4.
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MOWER DECK GC B E Mower Deck Installation A CG 1. Park the unit on a level surface and disengage the PTO switch. 2. Move the motion control levers outward to the park position, stop engine, remove key, and wait for all moving parts to stop before leaving the operating position. 3. Slide the deck under the unit. 4. Set the height-of-cut to the lowest position. 5. Lift the rear of the deck and guide the hanger brackets onto the rear lift rod (Fig. 103). D F Fig. 102 A. Idler pulley B.
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MOWER DECK 6. Attach the front support rod to the deck with the retaining clip (Fig. 104). C AB Fig. 104 A. Front support rod B. Locking nut 6 fig. 60 G014635 C. Retaining clip 7. Install the deck belt onto the engine pulley as outlined in this chapter. Fig.
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MOWER DECK Spindle Exploded Views (Fig. 106 & Fig. 107 & Fig. 108) A B C A B C A A Fig. 106 A B A PICT-1070 C B C A A 6 Fig. 107 A B B A PICT-1071 C B C A A Fig. 108 A. Bearing B. Bearing spacer (s) 6-12 PICT-1072 C.
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MOWER DECK Spindle Disassembly Spindle Assembly 1. If necessary, remove deck from the frame as shown in this chapter. 1. Fully seat a new UPPER bearing (pulley side) into spindle housing until it contacts the bearing bore shoulder. Be sure to press equally on inner and outer race while installing bearing. 2. Remove spindle assembly from deck as outlined in this chapter. 3. Remove spindle shaft (D) from spindle assembly. Inspect for excessive wear and replace if necessary (Fig. 109). 4.
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MOWER DECK Spindle Service Spindle Installation Spindle Removal 1. Install blade, blade stiffener (C) (if equipped) and washer onto spindle shaft. Be sure washer concave surface is towards blade. 1. If necessary, remove deck from frame as outlined in this chapter. 2. Install and torque blade bolt to specification 55 ft-lbs. (76 Nm). 2. Remove belt cover(s) from deck. 3. Install spindle assembly onto the deck shell and torque fasteners to specification: - Self-tapping screws - 17 ft-lbs.
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MOWER DECK Idler Arm/Deck Belt Tensioner Service Idler Arm/Tensioner Exploded Views 32 Inch Stamped Deck (Fig. 111) D D A C B 6 B A Fig. 111 A. Washer B. Friction washer (composite) Toro Timecutter SS/MX/ZS Service Manual PICT-1074 C. Spacer D. 30 ft-lbs.
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MOWER DECK 42 Inch Stamped Deck (Fig. 112) D D A B C B A 6 Fig. 112 A. Washer B. Friction washer (composite) 6-16 PICT-1075 C. Spacer D. 30 ft-lbs.
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MOWER DECK 42 Inch Fabricated Deck (Fig. 113) E D E A C C A B 6 Fig. 113 A. Washer B. Washer (thick) C. Friction washer (composite) Toro Timecutter SS/MX/ZS Service Manual PICT-1076 D. Spacer E. 30 ft-lbs.
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MOWER DECK 50 Inch Stamped Deck (Fig. 114) D D C A B B A 6 Fig. 114 A. Washer B. Friction washer (composite) 6-18 PICT-1077 C. Spacer D. 30 ft-lbs.
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MOWER DECK 50 Inch Fabricated Deck (Fig. 115) E E A C D C A B 6 Fig. 115 A. Washer B. Washer (thick) C. Friction washer (composite) Toro Timecutter SS/MX/ZS Service Manual PICT-1078 D. Spacer E. 30 ft-lbs.
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MOWER DECK Idler Arm Inspection / Service Idler Arm Installation 1. Remove deck belt as shown in this chapter. 1. Install idler pulley to the idler arm and torque mounting bolt to specification - 30 ft-lbs. (40 Nm). 2. Remove deck if necessary, as outlined in this chapter. 3. Rotate idler arm by hand. The idler arm should not pivot freely, it should take some force to rotate the idler arm.
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MOWER DECK Checking for Bent Blades 3. Measure from the tip of the blade to the level surface (Fig. 117). Note: The machine must be on a level surface for the following procedure. 1. Raise deck to the highest height-of-cut position. A 2. While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measured into a position that allows effective measurement of the distance between the cutting edge and the level surface the unit is on (Fig. 116). C A B C B Fig.
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MOWER DECK 5. Measure from the tip of the blade to the level surface. The variance should be no more than 1/8” (3mm) (Fig. 119). Leveling Mower Deck 32 Inch Stamped Deck Leveling Check to ensure the deck is level any time you install the deck or when there is an uneven cut recognized. A B The deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. Refer to the “Checking for Bent Blades” procedure, in this chapter, before continuing.
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MOWER DECK 4. Carefully rotate the blade so that it is side-to-side (Fig. 120). A 7. Move to the left side of the machine. Remove the side carriage bolt (E) and locking nut (D) from the fixed position (C). Install it into the rear slotted position (B) (Fig. 121). Leave the lock nut slightly loose. C B D E A D Fig. 120 fig. 48 G014630 A. Blade side-to-side D. Measure from blade tip B. Sail area of blade to level surface C. Outside cutting edges 5.
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MOWER DECK 8. Loosen the rear locking nut (B) on the hanger bracket just enough to allow the hanger to be adjusted (Fig. 122). A C 9. Use the notches on the welded bracket to measure the amount of adjustment. Each notch surface is equivalent to 0.25”, while a single side is 0.125” (Fig. 123). Adjust the height of the mower deck to the desired height. A B D B Fig. 123 Fig. 122 fig. 50 G015324 A. Hanger bracket C. Side locking nut B. Rear locking nut slotted position D.
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MOWER DECK 32 Inch Stamped Deck - Adjusting the Frontto-Rear Blade Slope Check the front-to-rear blade slope any time you install the deck. If the front of the deck is more than 5/16” (7.9mm) lower than the rear of the mower, adjust the blade level using the following instructions: 5. Measure from the tip of the front blade to the level surface and the tip of the rear blade to the level surface (Fig. 124). If the front blade tip is not 1/165/16” (1.6-7.
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MOWER DECK 42 & 50 Inch Stamped Deck Leveling Check to ensure the deck is level any time you install the deck or when there is an uneven cut recognized. The deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. Refer to the “Checking for Bent Blades” procedure, in this chapter, before continuing. The deck must be leveled side-to-side first then the front to rear slope can be adjusted. Requirements: • The machine must be on a level surface.
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MOWER DECK 5. Measure between the outside cutting edges and the level surface (Fig. 126 and Fig. 127). If both measurements are not within 3/16” (5mm), an adjustment is required; continue with this procedure. 8. Loosen but do not remove, the rear locking nut on the hanger bracket (Fig. 129). 6. Support deck by placing wood blocks under the edges of the deck. Note: Avoid placing the supports under any antiscalp rollers if present on the deck. 7. Move to the left side of the machine.
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MOWER DECK 9. Use the notches on the welded bracket to measure the amount of adjustment. Each notch surface is equivalent to 0.25”, while a single side is 0.125” (Fig. 130). Adjust the height of the mower deck to the desired height. A A C B D Fig. 130 A. 0.25 inch 10. When at the desired position, tighten the rear locking nut on the hanger bracket (Fig. 131). Tighten the side locking nut on the hanger bracket. B fig. 51 G015325 B. 0.125 inch Fig. 131 fig. 50 G015324 A. Hanger bracket C.
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MOWER DECK 42 & 50 Inch Stamped Deck - Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the deck. If the front of the deck is more than 5/16” (7.9mm) lower than the rear of the deck, adjust the blade level using the following instructions: 4. Carefully rotate the blades so they are facing frontto-rear (Fig. 132 and Fig. 133). A B 1. Park the unit on a level surface and disengage the PTO switch. B 2.
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MOWER DECK 6. To adjust the front-to-rear blade slope, rotate the adjustment nut on the front of the deck (Fig. 134). 42 Inch Fabricated Deck Leveling Check to ensure the deck is level any time you install the deck or when there is an uneven cut recognized. The deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. Refer to the “Checking for Bent Blades” procedure, in this chapter, before continuing.
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MOWER DECK 5. Carefully rotate the blades side-to-side (Fig. 135). Measure between the outside cutting edges and the level surface (Fig. 135). If both measurements are not within 3/16” (5mm), an adjustment is required; continue with this procedure. 6. Move to the left side of the machine. Loosen, but do not remove, the rear locking nut on the hanger bracket (Fig. 136). A B C C B D D Fig. 135 F C D E fig. 51 G009682 Mower decks with (2) blades A. Blades side-to-side D.
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MOWER DECK 42 Inch Fabricated Deck - Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the deck. If the front of the deck is more than 5/16” (7.9mm) lower than the rear of the deck, adjust the blade level using the following instructions: 5. Measure from the tip of the front blade to the level surface and the tip of the rear blade to the level surface (Fig. 137). If the front blade tip is not 1/165/16” (1.6-7.
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MOWER DECK 50 Inch Fabricated Deck Leveling Check to ensure the mower deck is level any time you install the deck or when there is an uneven cut recognized. The deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. Refer to the “Checking for Bent Blades” procedure, in this chapter, before continuing. The deck must be leveled side-to-side first then the front-to-rear slope can be adjusted. Requirements: • The machine must be on a level surface.
PAGE 115
MOWER DECK 6. Move to the left side of the machine. Loosen, but do not remove, the rear locking nut on the hanger bracket (Fig. 140). 50 Inch Fabricated Deck Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 5/16” (7.9mm) lower than the rear of the mower, adjust the blade level using the following instructions: 1. Park the machine on a level surface and disengage the blade control switch. F C D A 3.
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MOWER DECK 6. To adjust the front-to-rear blade slope, rotate the adjustment nut on the front of the deck (Fig. 142). C A B Fig. 142 A. Adjusting rod B. Adjusting block fig. 53 G014634 C. Lock nut 7. To raise the front of the deck tighten the adjustment nut. To lower the front of the deck loosen the adjustment nut. 6 8. After adjustment, check the front-to-rear slope again. Continue adjusting the nut until the front blade tip is 1/16-5/16” (1.6-7.9mm) lower than the rear blade tip (Fig. 141).
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MOWER DECK THIS PAGE INTENTIONALLY LEFT BLANK.
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ELECTRICAL Chassis Switches How It Works Key/Ignition Switch Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the key automatically returns to RUN when released (Fig. 144). Purpose The ignition switch makes the proper connections for the starter, accessories, and safety circuits. S Location I B The ignition switch is located on the control panel, on the right fender (Fig. 143). R A Fig.
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ELECTRICAL PTO Switch How It Works • PTO Switch ON - Switch Pulled Up Purpose The PTO (Power Take Off) switch is used to turn on the Electric PTO Clutch and to function as part of the safety interlock system. Location The PTO switch is located on the control panel, on the right fender (Fig. 145). The PTO Switch provides battery voltage from the key switch to the PTO clutch. The PTO Switch removes battery voltage from the Brake Actuator Module (pin 8) (Fig. 146).
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ELECTRICAL Continuity Testing Terminals viewed from the back of the switch. With the Switch “ON” (Button pulled OUT): - Pin 2 and 5 should have continuity (closed circled below) - Pin 1 and 7 should not have continuity (open) (Fig. 147 and Fig. 148) 3 9 2 5 8 1 4 7 Fig. 147 PICT-1005 Fig. 148 PICT-1008 With the Switch “OFF” (Button pushed IN): - Pin 1 and 7 should have continuity (closed circled below) - Pin 2 and 5 should not have continuity (open) (Fig. 149 and Fig.
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ELECTRICAL Seat Switch How It Works Purpose With the ignition switch ON, and the seat switch closed, it supplies voltage to the Brake Actuator Module (pin 7) and the hour meter (Fig. 152). g017655 The seat switch is a part of the safety interlock system. If the engine is running and the operator vacates the seat with the PTO engaged and/or the handles pulled IN, the engine will shut off.
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ELECTRICAL replace the harness and Brake Actuator Module. If the engine shuts off when the handles are pulled in, remove the brake rods from the Brake Actuator Module and function test (for testing purposes only): Brake Actuator Module Diagnostic Tips: • • Test: • Check battery voltage and charging system function. Under or over voltage can affect how the module operates. Check the operation of each safety interlock switch before condemning the Brake Actuator Module or wire harness. A.
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ELECTRICAL BRAKE MODULE Brake Module Removal 1. Disconnect the negative (-) terminal from the battery. 3. Remove the brake module cover screws. 2. Underneath the mower, remove the hair pin and washer from the module on both sides. Remove brake rods. 4. Slide the cover back on the harness.
PAGE 124
BRAKE MODULE 5. Remove the brake module mounting bolts. 6. Remove cover from the module. ELECTRICAL 7. Remove the harness from the brake control module by pressing the lock on the harness connector down and pulling the connector from the module. 8. Remove the module from the chassis. 9. Remove the mounting bracket from the module.
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ELECTRICAL BRAKE MODULE Brake Module Installation 1. Install the mounting bracket onto the module. 2. Insert the brake module into the chassis. 4. Slide the cover onto the module. 3. Connect the wiring harness to the module. 5. Install the screws into the cover.
PAGE 126
BRAKE MODULE ELECTRICAL 6. Install the mounting bolts. 8. Connect the negative (-) batter cable to the battery. Test brake module. 7. Underneath the mower, install the brake rods, washers, and hair pin.
PAGE 127
ELECTRICAL Starter Solenoid & Starting System Starter Solenoid Testing (solenoid only) Purpose 1. Disconnect solenoid from the wiring harness. The solenoid’s purpose is a remote switch to connect the battery to the starter motor on the engine when the ignition switch is turned to “START”. The solenoid is used to protect the ignition switch from the high current drawn by the starter motor. 2. With a multimeter (ohms setting), check to ensure that terminals “c” and “d” are open (no continuity). 3.
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ELECTRICAL Starter Solenoid Circuit & Operation - The starter solenoid B+ is controlled by the Key Switch. - The starter solenoid, B-, is controlled by the Brake Actuator Module.
PAGE 129
ELECTRICAL Electric PTO Clutch Testing Purpose If the electric PTO clutch is not engaging or is sus pected as a cause of electrical problems, use the troubleshooting steps. These procedures will help you determine if the clutch has failed or is the cause of the electrical problem. The clutch electrically controls the engagement and disengagement of the Power Take Off (PTO) pulley. Location Coil Resistance Measurement The electric clutch is located on the PTO end of the engine crankshaft.
PAGE 130
ELECTRICAL PTO Clutch Continuity to Ground Check Measuring Clutch Current Draw 1. Disengage PTO switch, turn ignition off and remove key. Note: Do not measure current draw if clutch has shorted to ground or if the resistance measurement is out of specification. 2. Disconnect clutch wire connector. 1. Disengage PTO switch, turn ignition off and remove key. 3. Set multimeter to check resistance (ohms). 4. Connect one meter lead to the engine, chassis or battery ground.
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ELECTRICAL PTO Circuit & Operation - The PTO clutch is powered by the Push/Pull PTO switch. - The PTO clutch is grounded through the Brake Actuator Module. - The PTO Clutch will only engage when: • The ignition key switch is in the ON position (engine running or not). • The PTO switch is in the ON position sending battery voltage to the PTO clutch. • The PTO switch is in the ON position removing battery voltage to the Brake Actuator Module (pin 8).
PAGE 132
ELECTRICAL PTO Circuit Schematic 7 Fig.
PAGE 133
ELECTRICAL PTO Clutch Replacement PTO Clutch Removal 1. Remove PTO belt and disconnect the harness connection from the PTO clutch. 2. Remove PTO clutch bolt (A) and washer. 3. Remove PTO clutch (B), drive belt and engine pulley (C) from the engine crankshaft (both clutch types shown). PTO Clutch Installation 1. Clean engine crankshaft. C 2. Apply anti-seize to engine pulley shaft ends and install engine pulley (C) onto crankshaft. 3. Install drive belt. 4. Install PTO clutch onto engine crankshaft.
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ELECTRICAL Hour Meter (If Equipped) How It Works Purpose The TimeCutter SW hour meter records hours of operation when: The TimeCutter SW hour meter records hours of operation when: • The Ignition key is ON • The Ignition key is ON • The seat is occupied and the seat switch is closed • The seat is occupied and the seat switch is closed When they key is ON, a closed seat switch supplies battery voltage to the hour meter.
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ELECTRICAL Fuse Block & Fuses How It Works Purpose The fuse block houses the fuses that protect the electri cal system from electrical surges, and grounds. The fuse block houses the electrical system fuses. Location Testing • With a multimeter set to OHM of continuity setting, check the continuity between the fuse blades. If the fuse is OPEN, replace it and test the circuit. • The fuses used in this application can also be visually inspected.
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ELECTRICAL 7 Toro TimeCutter SW/SWX Service Manual 7-19
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7-20 27 26 23 ON 21 28 31 22 30 29 20 7 10 12 9 19 17 18 16 8 24 15 14 41 42 40 32 37 36 13 11 4 34 35 33 38 7 5 6 3 Dashed line denotes signal is momentary Main/Safety Ground Fuel Solenoid Clutch Hour Meter Charge System 25 39 TimeCutter® Zero Turn Tractor ‐ Run Circuit Forward 2 Battery Ground 1,2 Module Voltage 3‐8 Module Ground 9,10 Safety Voltage 1‐7, 11‐23 Fuel Solenoid (V) 1‐8, 24,25 Clutch (V) 1‐7,11,26‐33 Clutch Ground 34,35 Charge System 1‐7,36‐39 Hour
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Toro TimeCutter SW/SWX Service Manual 17 16 18 15 14 13 10 `12 9 8 NOT 19 22 24 21 11 25 23 26 7 4 ON 5 6 27 Main/Safety Ground Fuel Solenoid Start 20 3 TimeCutter® Zero Turn Tractor ‐ Start Circuit 2 Battery Ground 1,2 Module Voltage 3‐8 Module Ground 9,10 Safety Voltage 1‐7,11‐18 Fuel Solenoid (V) 19‐20 Start Voltage 21‐23,26,27 Start Ground 24,25 1 Toro Service Instruction CZN008a ELECTRICAL 7 7-21
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7-22 48 46 47 27 26 33 32 22 21 ON 34 28 31 30 29 20 23 7 10 12 9 19 17 18 16 8 24 15 14 44 45 43 35 40 39 13 11 4 37 38 36 41 7 5 6 3 Dashed line denotes signal is momentary Main/Safety Ground Fuel Solenoid Reverse Overide Clutch Hour Meter Charge System 25 42 TimeCutter® Zero Turn Tractor ‐ Run Circuit Reverse 2 Battery Ground 1,2 Module Voltage 3‐8 Module Ground 9,10 Safety Voltage 1‐7, 11‐23 Fuel Solenoid (V) 1‐8, 24,25 Reverse Override 1‐7,11,32‐34 Cl
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Res i dent i al Pr oduc t s For m Number : 4929350 Dat eI s s ued: J une2015