Toro Recycler 20012 Service Manual Download Page 8

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WPM Drive Systems Manual

TABLE OF CONTENTS

BBC Cable Removal (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . . .

BBC Cable Installation (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . .

BLADE OVERRIDE SYSTEM (BOS), BLADE CLUTCH SYSTEM (BCS) . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOS/BCS System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLES AND CONTROL CABLES

Toro 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Generation 1/Easy Stride Generation 1 . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Personal Pace Cable . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Generation 2/Easy Stride Generation 2 . . . . . . . . . . . . . . . . . .

Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Personal Pace/Easy Stride Cable . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy Sens-a-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Disassembly, Zone Start Models . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Disassembly, Lawn-Boy Blade Clutch System (BCS) Models . . . . . . . . . . . . .

3 Speed Transmission Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBC Cable Adjustment (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .

Toro BBC Cable Adjustment (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . .

Toro BOS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toro BOS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy BCS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy BCS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . .

SELF-PROPEL BELT REPLACEMENT

Toro 21” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22” Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21” Steel & Cast Deck Toro & Lawn-Boy Mowers Belt Replacement . . . . . . . . . . . . .

21” Cast Deck Mowers with 3 Speed Transmission . . . . . . . . . . . . . . . . . . . .

21” Toro & Lawn-Boy Mowers with Blade Brake Clutch . . . . . . . . . . . . . . . . . .

21” Toro Mowers with Blade Override System & Lawn-Boy Mower

with Blade Brake Clutch System . . . . . . . . . . . . . . . . . . . . . . . . .

21” Lawn-Boy Insight Mowers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-27
6-28
6-28
6-28
6-32
6-33

7-2
7-3
7-3
7-3
7-5
7-6
7-6
7-6
7-8
7-8
7-9
7-9
7-9
7-10
7-11
7-11
7-11
7-13
7-13
7-15
7-16
7-17
7-18
7-18
7-18

8-2
8-2
8-2
8-2
8-2
8-3

8-3
8-3

Summary of Contents for Recycler 20012

Page 1: ...WALK BEHIND POWER MOWER DRIVE SYSTEMS SERVICE MANUAL ...

Page 2: ......

Page 3: ...dels from 1990 through 2006 and may be speciﬁed for use on products built after 2006 that are similar in design We are hopeful that you will ﬁnd this manual a valuable addition to your service shop If you have any questions or comments regarding this manual please contact us at the following address The Toro Company LCE Service Training Department 8111 Lyndale Avenue South Bloomington MN 55420 The...

Page 4: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...roubleshooting Repair Blade Brake Clutch System Blade Override System Toro BOS Blade Clutch System Lawn Boy BCS Handle Disassembly Toro 2 Bail handle Personal Pace Easy Stride Generation 1 Personal Pace Easy Stride Generation 2 Lawn Boy Sens a Speed Belt Replacement Mowers with Toro Blade Brake Clutch Mowers with Toro Blade Override System Zone start 21 Rear Wheel Drive Toro Lawn Boy except Insigh...

Page 6: ... FRONT AXLE TRANSMISSION ASSEMBLY 22 FRONT WHEEL DRIVE MODELS Remove Transmission Transmission Disassembly Transmission Assembly Assembly Tips Belt Service Front Wheel Drive Models 22 TORO LAWN BOY REAR WHEEL DRIVE MODELS Transmission Removal Belt Replacement Rear Axle Disassembly Transmission Disassembly Transmission Assembly Axle Assembly Tips LAWN BOY INSIGHT TRANSMISSION REMOVE REPLACE Tranmis...

Page 7: ...LADE CLUTCH SYSTEM BCS BLADE BRAKE CLUTCH SYSTEM Description BBC Clutch Option Control Box Operation Handle Controls Control Box Disassembly Control Box Assembly TORO BBC SERVICE GUIDE BLADE BRAKE CLUTCH ASSEMBLY Toro Vacu Power Lawn Boy Medallion TORO VACU POWER LAWN BOY MEDALLION BBC Bellcrank System Disassembly Toro Vacu Power Lawn Boy Medallion Bellcrank System Assembly Toro Vacu Power Lawn Bo...

Page 8: ...le Disassembly Lawn Boy Blade Clutch System BCS Models 3 Speed Transmission Models 3 Speed Control Cables BBC Cable Adjustment Toro Vacu Power Lawn Boy Medallion Toro BBC Cable Adjustment Recycler Rear Bagger Toro BOS Control Toro BOS Control Cable Adjustment Lawn Boy BCS Control Lawn Boy BCS Control Cable Adjustment SELF PROPEL BELT REPLACEMENT Toro 21 Front Wheel Drive 22 Front Wheel Drive 22 Re...

Page 9: ...e 10328 CD SB RK 2B None 10329 CD SB RK 2B None 10330 CD SB RK 2B None Using this manual Following each model number in the list below are codes identifying the type of deck material transmission wheel pinion clutch hand controls and if it has a blade clutch system Use this information to select the correct sections of the service manual for the mower being serviced Code List 1B one bail CDVP cast...

Page 10: ... RK 2B None 10517 CD 3S RK 2B None 10518 CD 3S RK 2B None 10519 CD 3S RK 2B None 10520 CD 3S RK 2B None 10521 CD 3S RK 2B None 10522 CD 3S RK 2B None 10523 CD 3S RK 2B None 10524 CD 3S RK 2B None 10525 CD 3S RK 2B None 10527 CD 3S RK 2B None 10528 CD 3S RK 2B None 10533 CD 3S RK BBC BBC VP 10545 CD 3S RK 2B None Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 Easy Stride 1st genera...

Page 11: ...96 Ins B SR SS None 10696C Ins B SR SS None 10697 Ins B SR SS BCS 10910 CD SB RK 2B None 10910B CD SB RK 2B None 10926 CD SB RK 2B None 10927 CD SB RK 2B None 10928 CD 3S RK None 10929 CD SB RK 2B None 10995 Ins B SR SS None 10997 CD B SR SS BCS 11001 CD 3S RK 2B None 11001B CD 3S RK 2B None 11003 CD 3S RK 2B None Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 Easy Stride 1st gene...

Page 12: ...stl B SR 2B None 20013 22stl B SR PP2 None 20014 22stl B SR PP2 None 20016 22stl B SR 2B None 20017 22stl B SR PP2 None 20018 22stl B SR PP2 None 20019 22stl B SR 2B None 20020 CD SB RK 2B None 20021 CD SB RK 2B None 20028 CD SB RK 2B None 20031 22stl B SR PP2 None 20036 CD SB RK PP2 None 20037 CD SB RK PP2 None 20038 CD SB RK PP2 None 20039 CD SB RK PP2 None Code List 1B one bail CDVP cast deck V...

Page 13: ... 3SP RK 1B None 20219 CD 3SP RK 1B BBC 20320 CD 3SP RK 1B None 20321 CD 3SP RK 1B None 20322 CD 3SP RK 1B None 20324 CD 3SP RK 1BBC BBC 20325 CD 3SP RK BBC BBC 20327B CD 3SP RK 1B None 20328B CD 3SP RK 1B None 20436 CD 3SP RK 1B None 20436WF CD 3SP RK 1B None 20437 CD 3SP RK 1B None 20438 CD 3SP RK BBC BBC 20438WF CD 3SP RK BBC BBC Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 Ea...

Page 14: ... BBC BBC 20486 CD 3SP RK 1B None 20487 CD 3SP RK BBC BBC 20488 CD 3SP RK 1B None 20489 CD 3SP RK 1B None 20490 CD 3SP RK BBC BBC 20494 CD 3SP RK 1B None 20495 CD 3SP RK 1B None 20622 CD 3SP RK BBC BBC 20632 CD 3SP RK BBC BBC 20652 21 stl SB RK PP1 None 20654 21 stl SB RK PP2 None 20655 22 stl B SR PP2 None 20656 22 stl B SR PP2 None Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 E...

Page 15: ...81 CD SB RK PP2 None 20783 CD SB RK PP2 None 20784 CD SB RK PP2 None 20786 CD 3SP RK 1B None 20787 CD 3SP RK 1B None 20792 CD SB RK PP2 None 20793 CD SB RK PP2 None 20795 CD SB RK PP2 None 20796 CD SB RK PP2 None 20817 CD SB RK PP2 None 20819 CD SB RK PP2 None 20828 CD SB RK PP2 None 20831 CD SB RK PP2 None 20832 CD SB RK PP2 None Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 Eas...

Page 16: ...P 26622 CD VP 3 SP RK BBC BBC VP 26623 CD VP 3 SP RK BBC BBC VP 26624 CD VP 3 SP RK BBC BBC VP 26625B CD VP 3 SP RK 1B None 26625BG CD VP 3 SP RK 1B None 26626 CD VP 3 SP RK BBC BBC VP 26630B CD VP 3 SP RK 1B None 26630BC CD VP 3 SP RK 1B None 26630BG CD VP 3 SP RK 1B None 26631B CD VP 3 SP RK BBC BBC VP 26631BC CD VP 3 SP RK BBC BBC VP 26632 CD VP 3 SP RK 1B None 26632B CD VP 3 SP RK 1B None Code...

Page 17: ...K 1B None 26680 CD VP 3 SP RK 1B None 26680WG CD VP 3 SP RK 1B None 26682 CD VP 3 SP RK BBC BBC VP 26683 CD VP 3 SP RK BBC BBC VP 27500 CD VP 3 SP RK BBC BBC VP 27501 CD VP 3 SP RK BBC BBC VP 27502 CD VP 3 SP RK BBC BBC VP 20442 CD SB RK 1B None 20444 CD SB RK 1B None 20711 CD SB RK 1B None Code List 1B one bail CDVP cast deck Vacu Power 2B two bail ES1 Easy Stride 1st generation 3S 3 speed ES2 Ea...

Page 18: ...xiv WPM Drive Systems Manual TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 19: ... Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 2 3 4 5 6 7 8 1 WORM DRIVE TRANSMISSION ...

Page 20: ... transmission where the roll pin is and to Fig 001 ﬁg 1 INTERNALLY CLUTCHED Description the mower housing pivots the transmission forward to maintain tension on the belt The worm is in constant mesh with the helical gear The clutching action is provided by a sliding clutch jaw A shift fork moves the clutch jaw to engage and disengage the transmission When the clutch jaw engages the helical gear po...

Page 21: ... a latch plate with an L shaped slot in it The slot guides the pin in its travel from engagement to disengagement Above the latch plate is a dust ﬁlter and a dust cover The shift arm on top of the transmission holds all these parts in place Fig 003 Fig 003 3428 0165 When the shift arm is pulled to the rear by the shift cable the pin moves to the left side of the mower then to the rear This moves t...

Page 22: ...rom the pivot arms so the roll pin can be removed Fig 006 Fig 006 3428 0131 2 Raise the front of the mower off the bench and support it with blocks 3 Disconnect the shift cable Fig 004 3428 0127 1 Remove the belt cover and unhook the spring on the front of the transmission Slip the belt off the transmission pulley Fig 004 A Cable Clamp C Spring B Shift Cable A B C C Removal Installation front whee...

Page 23: ...rom the chassis 9 Reverse the procedure to install NOTE Support the wheel pinions with the wood block while driving the roll pins in This will prevent the axle from being bent Fill the transmission with oil after it is installed in the mower Fig 009 Note the front of the transmission is identiﬁed by the oil ﬁll check screw and the ﬂat tab which is part of the lower case Fig 009 3428 0166 WORM DRIV...

Page 24: ...ical gear and thrust washer Fig 013 Fig 013 3428 0153 Fig 010 3428 0146 2 Drive the roll pins out of the ﬂanges in the front and rear of the case These pins align the top and bottom parts of the case Fig 010 Fig 011 3428 0148 3 Remove the 4 self tapping screw that connect the top and bottom cases Note If you turn this transmission on its side or upside down oil may leak out of the top This is not ...

Page 25: ...r pattern Replacing only one gear will result in rapid failure Fig 014 14 Remove the screw from the shift arm and remove the shift arm dust cover and wear plate Fig 015 If the ball bearing is to be replaced press it out at this time Fig 015 3428 0165 15 Remove the roll pin and pull shifter rod out of the cover Clean the cover WORM DRIVE TRANSMISSION 1 Use bushing installation tool P N 27 0460 to p...

Page 26: ... the axle from left to right Install the thrust washer helical gear and the sleeve and clutch jaw Then push the axle through the other side of the case Fig 016 3428 0158 Note The bushings are two different lengths The side of the case with the thicker boss uses a longer busing to support the axle The bushings should be ﬂush with the inside of the case Fig 016 A Tool P N 27 0460 A 4 Using a seal pr...

Page 27: ...e This bearing only has one seal Install the bearing such that the seal is visible from the top of the cover and the open side faces the gears Press the bearing in until it is fully seated in the case Fig 019 WORM DRIVE TRANSMISSION 9 Fill the transmission with gear oil AFTER it is installed in the mower The top of this transmission is not sealed It will leak if tipped on its side Fig 020 Fig 020 ...

Page 28: ...ed position the cable pulls the shift arm to the rear to disengage the transmission The adjustment point is on the mower housing just to the rear of the transmission To adjust pull the control to the rear disengage Go to the cable clamp adjustment Loosen the clamp pull the cable to the rear until the shift lever is as far back as it will go Hold it there and tighten the clamp Fig 021 Adjustment A ...

Page 29: ... the same as is the lubrication requirement 90 wt gear oil rated GL 5 or higher Fig 022 ﬁg 18 A WORM DRIVE TRANSMISSION 1 Jam nut 13 Oil Seal 2 Lock washer 14 Output shaft 3 Half pulley 15 Traction bracket 4 V Belt 16 Thread forming screw 5 Pulley spacer 17 Gearbox case 6 Gearbox cover 18 Thrust washer 7 Shaft worm 19 Roll pin 8 Ball bearing 20 Helical gear 9 Gearbox gasket 21 Thrust washer 10 Che...

Page 30: ...ssembly LH incl Ref 3 4 5 14 Locknut Thread Forming Screw Trigger Return Spring H O C Saddle Thread Forming Screw Push Nut Needle Bearing Friction Washer Ref No Qty Description 16 17 18 19 20 21 22 23 24 25 26 27 28 34 35 4 4 1 2 2 2 2 2 4 2 2 2 4 2 1 Keyed Thrust Washer Retaining Ring LH Rocking Key Pinion Gear Compression Spring Wheel Cover Tire Gear Assy Wheel incl Ref 24 Wheel Bolt Wheel Bushi...

Page 31: ...nsmission level with the ﬁll plug opening after it is installed in the chassis The top of the transmission is not sealed so it may leak if ﬁlled and tipped Fig 025 ﬁg 20 3 To check the adjustment slowly squeeze the control bar towards the handle The cable is adjusted correctly when resistance is felt when the control bar is approximately 1 25mm from the upper handle Fig 025 Fig 024 ﬁg 19 2 Rotate ...

Page 32: ...Drive Systems Manual WORM DRIVE TRANSMISSION WHEEL CLUTCH 4 If loss of traction or improper engagement still occurs after adjustment repeat steps 2 3 until properly adjusted See Rocking Key Wheel Clutch page 5 3 ...

Page 33: ...rm Drive Transmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 2 ...

Page 34: ...6 7 8 9 10 1 1 1 1 2 2 2 2 1 1 Gear Case Casting Gear Case Cover HWH Screw Retaining Ring Flat Washer Groove Pin Lock Nut NI Washer Thrust Washer Bushing Ref No Qty Description 11 12 13 14 15 16 17 18 19 2 1 1 2 2 2 2 2 2 Output Bushing Intermediate Shaft Pulley Half Ball Bearing Pulley Spacer Bevel Gear 15t Spur 37t Pinion Gear Bevel Gear Output Shaft ...

Page 35: ...870 2 Remove transmission belt cover 3 Remove both rear wheels 4 Remove retaining ring spring thrust washer and pinion from both axles Fig 028 Refer to Wheel Pinion Clutch on page 5 3 for additional information about the clutch mechanism Fig 028 PICT 1873a Description Lubrication Proper lubrication for this transmission is 2 5 3 ﬂuid ounces 7 1cc 9 0cc of lithium based No 2 grease Transmission Rem...

Page 36: ...e cover on the transmission Fig 033 3428 0008 A End cap A A 6 Remove the belt guide Note the location of the spacer under the front mounting screw Fig 030 Do not try to force the belt off the pulley without removing the belt guide This often results in damage to the belt or slightly bending the belt guide causing an increased tendency for belt jumping Fig 030 PICT 1880a 7 The transmission can be m...

Page 37: ... must be replaced Also replace the mate for the damaged gear When gears run together they develop a wear pattern that will result in premature failure if only one gear is replaced The exception for this is if the transmission has VERY little running time before failure The axle has two roll pins through it One connects the single spur gear to the axle Fig 036 The other pin aligns the axle and tran...

Page 38: ... grease and install the cover Fig 037 3428 0019 Finally install the spacer and pulley on the input shaft The internal gears will help hold the pinion while the nut is tightened Fig 038 Fig 038 3428 0022 Insert the transmission back into the chassis Refer to the section on the wheel pinion clutch for assembly instructions Install self propel cable Adjust as needed see Handles and Control Cables Sec...

Page 39: ...Drive Transmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 3 ...

Page 40: ...EAR TRANSMISSION EXPLODED VIEW SINGLE SPEED BEVEL GEAR TRANSMISSION A Nut H Bushing B Washer I Thrust washer C Pulley J Bevel Gear D Spacer K Bushing E Housing L Roll pin F Bearing M Axle G Pinion Fig 039 single speedtrans a A B C D E F G H I J K L M ...

Page 41: ... front drive versus the rear drive to change axle shaft direction of rotation In both cases the gears are in constant mesh Clutching is done by rocking the transmission to tighten or loosen the drive belt Fig 040 The control cable will move the transmission to tighten the belt When released the weight of the transmission causes it to rock towards the engine to disengage Fig 040 MVC 485 SINGLE SPEE...

Page 42: ... Gear ASM Bushing Klipring Locking Gear Pinion 13T Washer Thrust Cover Wheel Cover Washer Stepped Arm Pivot Front Arm Spring Knob Lever HOC Ring Retaining Retainer Bearing HOC Bearing Ball Ref No Qty Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 2 1 1 2 1 2 1 1 2 1 1 1 1 Spring Compression Key Transmission ASM Gasket Gearbox Screw HWH Bracket Pivot Fwd Screw HWH Spacer V Belt Pulley Half...

Page 43: ... the locknut on the transmission pulley Fig 043 Fig 043 MVC 486 Fig 044 MVC 472 4 Remove the nut washer transmission pulley halves and spacer 5 Remove the belt guide 6 Remove both front wheels note there is a washer between the wheel and wheel cover 7 To remove the wheel pinions remove the klip ring and thrust washer The pinion will now slide off the axle Fig 044 Note The spring loaded drive key i...

Page 44: ... assembly will now drop out of the chassis Fig 046 Fig 046 PICT 1857a Fig 048 MVC 478 11 To disassemble the pivot arm assembly compress the components with two clamps or locking pliers Fig 048 10 Remove the klip ring and thrust washer from each end of the axle the left side has 2 thrust washers the right side one The bearing bearing retainer HOC plate spring arm and pivot arm all come off as one u...

Page 45: ...ear can be lifted out Fig 050 Fig 050 MVC 462 Assemble in reverse order See Assembly Tips next page Fig 051 MVC 468 2 Since the pulley was previously removed the input shaft will now slip out of the transmission case 3 If the input bearing is to be removed press it out of the case now 4 Slide the bearings and thrust washer off the axle Drive the roll pin out and the bevel gear can be removed Fig 0...

Page 46: ...GLE SPEED BEVEL GEAR TRANSMISSION Assembly Tips Fig 052 MVC 466 2 Install the trust washer on the side of the gear with the shorter hub away from the gear teeth Fig 053 Fig 053 MVC 468 4 If the input bearing was removed press the new one in until it bottoms in the case 5 Fill the transmission case approximately 2 3 full with 2 lithium base grease 6 Assemble the bearing bearing retainer height of c...

Page 47: ...d oil and tip the mower on its right side 2 Remove the two screws securing the belt cover from under the housing Fig 057 SINGLE SPEED BEVEL GEAR TRANSMISSION Belt Service Front Wheel Drive Models Fig 056 MVC 474 8 The wheel pinion is marked with an R and L for right and left Identify right and left from the operator s position Fig 056 On the right side the letter R should face out The letter L sho...

Page 48: ... crankshaft pulley and over the blade Fig 060 Fig 060 MVC 491 Fig 061 MVC 733 On rear wheel drive models it is necessary to separate the rear drive assembly from the mower housing in order to change the drive belt 1 Drain fuel and oil from the engine 2 Remove the single retaining screw from the center of the bag door spring Slide the door to one side and remove it from the rear HOC side plates Fig...

Page 49: ...sion belt guide Fig 063 Fig 063 PICT 1884a Fig 064 PICT 1895a 5 The cable tool P N 105 6819 will compress the locking tabs on the cable so it can be removed from the housing 6 Slide the cable tool over the end of the cable and push Fig 064 At the same time reach around the mower and pull the cable out of the housing Fig 065 PICT 1904 7 With the plug removed from the larger hole next to the cable m...

Page 50: ...elt guide Slide the pulley blade adapter and belt off the crankshaft Fig 069 MVC 738 Fig 066 PICT 1897 8 Push it into the larger hole Fig 066 9 Remove both rear wheels and both wheel covers 10 Remove the stop cable from the engine Fig 067 and disconnect the self propel cable spring from the transmission Fig 067 DSC 017 Fig 068 MVC 737 11 Pinch the ends of the lower handle together to disengage the...

Page 51: ...mission assembly will now drop down Fig 070 MVC 848 Fig 072 MVC 743 16 The belt cover must be removed in order to remove the belt Fig 072 Fig 071 MVC 852 15 There is a cross brace underneath the mower that is held in place by two of the cap screws shown above Fig 071 SINGLE SPEED BEVEL GEAR TRANSMISSION 17 Remove 3 screws that secure the belt cover to the housing Fig 073 Fig 073 MVC 744 A A Belt c...

Page 52: ...xle with locking pliers and remove the pulley nut and transmission pulley Fig 075 Do not bend the belt guide The pulley must be lifted up slightly to slip the belt off 18 Pull the belt cover out from under the rear wall and the belt is exposed Fig 074 Fig 074 MVC 745 Fig 076 MVC 741 20 The cable may be unhooked from the arm on the transmission to help prevent cable damage Fig 076 Note It is not ne...

Page 53: ...ly will slide off the axle This includes the bearing bearing retainer HOC plate spring arm and pivot arm Fig 079 Fig 078 MVC 850 2 When removing the pinions note that there is a spring loaded key under them 3 Remove the other thrust washer and retaining ring holding the pivot assembly to the axle Fig 078 5 Clamp the pivot assembly with 2 pairs of locking pliers or other clamps and remove the snap ...

Page 54: ... bearings and thrust washer off the axle Drive the roll pin out and the bevel gear can be removed Fig 083 Fig 083 MVC 470 Assemble in reverse order Transmission Assembly Transmission Disassembly 6 You can now release the clamps and separate the HOC plate spring arm and pivot arm Fig 081 Fig 081 MVC 750 Fig 082 MVC 462 1 Remove the 4 screws holding the cover on the transmission The axle bearings an...

Page 55: ... Fig 084 3 Install the transmission bearings with the ﬂange facing the gear Fig 085 Fig 085 MVC 470 SINGLE SPEED BEVEL GEAR TRANSMISSION Axle Assembly Tips 2 Install the thrust washer on the side of the gear with the shortest hub away from the gear teeth Fig 084 4 Fill the transmission approximately 2 3 full with 2 Lithium base grease 1 5 oz or 43gm 5 Assemble the bearing bearing retainer HOC plat...

Page 56: ...stalling the pinion Fig 087 7 The wheel pinion is marked with an R and L for right and left Identify right and left from the operator s position Fig 088 On the right side the R should face outward The letter L should face outward on the left side If the wheel pinions are reversed the wheels will not drive Fig 088 MVC 474 R Note See Chapter 5 for more information on Wheel Clutches ...

Page 57: ...t Shoulder Rear Wheel ASM Klipring Locking Gear Pinion 15T Washer Thrust Wheel Cover ASM Cover Wheel Washer Stepped Ring Retaining Arm Rear Pivot LH Arm Spring Rear Knob Lever HOC Retainer Bearing HOC Bearing Ball Ref No Qty Description 14 15 16 17 18 19 20 21 22 23 24 25 27 28 2 2 1 1 1 2 1 2 1 1 1 1 1 1 Spring Compression Key Transmission ASM Washer Shield Bracket Transmission Screw HWH Spacer P...

Page 58: ...ect the spark plug wire 2 Remove two screws that secure the rear cover Fig 090 Fig 090 MVC 285 Fig 092 MVC 288 4 The belt cover will drop off the bottom Fig 092 Fig 091 MVC 286 3 Remove the 3 belt cover screws Fig 091 A Belt cover 5 If you have an electric start model remove the battery and battery box 6 Clamp the axle with a locking pliers and remove the nut from the transmission pulley If you ar...

Page 59: ...et anti seize on the belt or the drive will slip Fig 094 MVC 292 Fig 096 MVC 295 9 Bend the trailing shield slightly in the middle and remove it from the mower Rotate both rear spring arms down to disengage them from the mower housing Fig 096 Fig 095 MVC 294 If the transmission is to be removed continue 8 Support the back of the mower on a wood block and remove the rear wheels Fig 095 10 Remove kl...

Page 60: ...g 100 MVC 297 Fig 101 PICT 1923 14 Unhook the traction cable from the transmission belt guide Fig 101 and Fig 102 11 Remove klip ring keyed thrust washer and standard thrust washer left side of mower has the standard thrust washer right side does not Fig 098 Fig 098 PICT 1915a 12 Remove the snap ring pivot arm and spring arm Fig 099 Fig 099 PICT 1921a ...

Page 61: ... transmission Fig 103 Fig 102 MVC 211x1 A 2 screws on top D Pulley half of transmission E Washer B Spacer F Nut C Pulley half A A B B C C D D E E F F 16 Push the transmission to the left as shown and rotate to clear the tunnel Drop the left side down then pull the assembly out to the left side Fig 104 Fig 104 MVC 300 17 The last step is to slide the bearings and bearing retainers off the axle Fig ...

Page 62: ...le Drive the roll pin out and the bevel gear can then be removed Fig 107 Fig 107 MVC 470 Assemble in reverse order See Axle Assembly and Installation Tips following Fig 108 MVC 469 1 The same axle is used for both front and rear wheel drive models There are two holes in the axle about one inch apart Rear wheel drive models use the hole about 4 3 4 12cm from the end Slip the gear on such that the t...

Page 63: ...ular thrust washer then the thrust washer with the tab 3 Coat the axle key and spring with 2 molybendum disulﬁde grease or anti seize compound before installing the pinion Fig 111 Fig 109 MVC 470 2 Install the thrust washer on the side of the gear with the shortest hub away from the gear teeth Fig 108 3 Install the transmission bearings with the ﬂange facing the gear Fig 109 4 Fill the transmissio...

Page 64: ...epped washer is properly seated in the wheel cover The best way is to assemble the wheel wheel cover and wheel bolt then put them all on the mower together 6 Do not use an impact wrench on the crankshaft belt guide screws Over tightening can cause the belt guide to deform and cause the belt not to declutch properly Tighten ﬁrmly with a ratchet 4 The wheel pinion is marked with an R and L for right...

Page 65: ...Transmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 4 ...

Page 66: ...ust Bushing Bushing Output Washer Gear 49 T Gear 44 T Gear 39 T Sleeve Gear Pin Spring Shaft Intermediate Case Gear Upper Cover Case Gear Screw Tapping Ref No Qty Description 21 22 23 24 26 27 28 29 30 31 32 34 36 37 38 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 Bushing Yoke Retainer Fork Shift Shaft Output Yoke Shift Spacer Pulley Half Gear Pinion Bevel Nut Lock NI Washer Flat Bearing Ball Bushing Output Coll...

Page 67: ...orward to loosen the belt Belt guides at the engine pulley and atop the transmission ensure disengagement by forcing the belt to loop around the engine pulley Fig 115 Fig 115 3428 0196 A Intermediate shaft C Shift key gears D Gear sleeve B Bevel gear E Output shaft gears Fig 116 3428 0058 Speed Reduction System Speed reduction is accomplished by two sets of gears one set on the intermediate shaft ...

Page 68: ...ate on the gear sleeve Once the key engages one of the gears that gear will rotate the output shaft Table 1 shows approximate speeds in gears for two different engine speeds Table 1 Gear Ground Speed 3000 RPM Ground Speed 2000 RPM 1 1 8 mph 2 9km h 1 2 mph 1 9km h 2 2 7 mph 4 4km h 1 8 mph 2 9km h 3 3 8 mph 6 1km h 2 5 mph 4 3km h The operator controls movement of the shift fork by means of the ge...

Page 69: ...ansmission cover from the top rear of the housing 5 Remove the two ﬂanged head self tapping screws securing the belt cover to the top of the transmission Pull the cable from belt guide and remove the belt guide 6 Remove the transmission access cover from the rear of the housing by pressing from underneath 7 Loosen the gear selection control cable clamp screw until the cable comes free Do not attem...

Page 70: ...ing arms until they point straight 2 Remove belt cover and belt 3 Disconnect shift and clutch cables 4 Remove 4 self tapping screws securing end caps to housing Fig 120 Fig 120 3428 0121 2 Before disassembling further check for proper operation of the input system the gear reduction system and gear selection system For more information on this refer to OPERATION on page 4 3 Fig 121 3428 0120 Inspe...

Page 71: ...any parts necessary If ball bearing replacement is required press the ball bearing out using an arbor press 7 If service of any of the output shaft gears or the gear selection system is required remove the left pivot arm as described under Rear Height of Cut and Wheel Pinion Clutch Disassembly on page 5 4 and 5 5 Note It is possible to replace the shift keys and spring clip without removing the pi...

Page 72: ...nto the gear sleeve notched sides last 4 Slide the nylon shift key sleeve onto the output shaft large end ﬁrst Make sure that it engages the tabs on the gear sleeve Fig 123 Fig 123 492 4733 ﬁg 4 1 A Shift key sleeve Fig 125 3428 0066 6 Slide the shift key assembly into the shift key sleeve until the shift collar bottoms out 7 Complete the output shaft assembly by sliding a spacer washer and the ot...

Page 73: ...t fork retainer B Flange Fig 127 3428 0059 3 The input pulley nut can be tightened after complete transmission assembly or at this point using the process in step 3 under Disassembly page 4 7 4 Slip the shift fork into the slot on the shift collar and place the shift fork and output shaft assembly into the transmission Note The long end of the shift fork shaft should go through the hole in the gea...

Page 74: ...de fasteners to 130 in lbs 15 Nm Fig 129 2 Slide the intermediate shaft gears onto the intermediate shaft in this order a 25 tooth gear b 20 tooth gear c 15 tooth gear bevel gear 3 Slide 2 spacer washers onto the intermediate shaft next to the bevel gear and follow with an intermediate shaft bushing ﬂanged side ﬁrst 4 Drop the intermediate shaft into the gearcase making sure that all gears engage ...

Page 75: ...position on the transmission pulley Make sure that it does not bind on any of the bosses 6 Slip the end of the traction cable into the belt guide bracket from the outside Install the belt guide bracket onto the top of the transmission making sure that the traction belt is inside the guide Note Belt guide fastener torque 130 in lbs 15 Nm 7 Slip the black plastic transmission cover into place making...

Page 76: ...d should be made before opening the transmission Fig 133 3428 0065 Look at the key and the notch in the gear that it engages Excessive wear to the tip of the key or the notch in the gear may be the problem Fig 133 If the forces push straight on the key it will drive the axle However if due to wear the force tries to depress the key it can lower enough to disengage from the notch in the gear Fig 13...

Page 77: ...ansmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 5 ...

Page 78: ...mp Cable Cap End O Ring Spring Arm ASM Pivot Arm ASM Bushing Bushing Fitting Zerk Washer Arm Pivot Washer Thrust Keyed Ring Klip Ring Friction Not illustrated Ref No Qty Description 13 14 15 16 17 18 19 20 20 1 22 23 24 25 26 27 2 1 1 2 2 2 2 2 2 1 2 2 2 2 1 Washer Clutch Key Rocking LH Key Rocking RH Gear Pinion Spring Compression Cover Wheel Spacer Cover Wheel Wheel ASM Bushing Screw HH Knob Arm...

Page 79: ...and ﬁts in the keyway of the output shaft to prevent rotation If an E clip is substituted premature failure of the wheel pinion clutch system will result 12 Friction Ring ﬁts in a circular groove in the pivot arm and works with the clutch washer to actuate the key It does not rotate 13 Clutch Washer is afﬁxed to the output shaft by means of the key so it turns with the output shaft It is also allo...

Page 80: ...mower shut the engine off and push the mower forward a few inches If the keys disengage the system is working correctly Start the engine and engage the drive if both engage they are ok If one or the other do not engage or disengage properly try greasing the pivot arm Use 2 lithium grease and only one or two pumps from a hand grease gun If grease does not help disassembly is necessary To operate th...

Page 81: ...tant to keep grease in and contaminants out Replace it Item 6 if necessary Fig 137 Some models do not have this O ring Fig 137 gearcase wheel assy 2 1 Pack the caged needle bearing with grease then press into the outside of the pivot arm until it is ﬂush with the groove that houses the externally tabbed thrust washer 2 Press the oil impregnated bushing into the boss on the pivot arm until it is ﬂu...

Page 82: ...tabbed thrust washer and the internally tabbed thrust washer onto the output shaft Make sure that the tab on the internally tabbed thrust washer enters the keyway Secure with the special retaining clip Make sure that the center tab ﬁts properly into the keyway This will prevent rotation of the clip on the output shaft 10 Place the friction ring into the groove on the pivot arm ﬂat side out 11 Slid...

Page 83: ...ng clip Again make sure that the center tab ﬁts properly into the keyway to prevent rotation of the clip Fig 140 Fig 140 3428 0040 16 Slip the wheel the original number of spacers and the wheel cover onto the shoulder bolt and secure to the pivot arm using the nylon locknut 17 Grease with No 2 lithium based grease Use a hand grease gun to avoid excess pressure that may prevent the friction parts f...

Page 84: ...ar ASM Bushing Klipring Locking Gear Pinion 13T Washer Thrust Cover Wheel Cover Washer Stepped Arm Pivot Front Arm Spring Knob Lever HOC Ring Retaining Retainer Bearing HOC Bearing Ball Ref No Qty Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 2 1 1 2 1 2 1 1 2 1 1 1 1 Spring Compression Key Transmission ASM Gasket Gearbox Screw HWH Bracket Pivot Fwd Screw HWH Spacer V Belt Pulley Half Fr...

Page 85: ... pinion periodically This is to keep the anti seize from drying up If that is not done it will be necessary to remove the pinion key and spring to clean and re lubricate with anti seize compound On the left side there will be two keyed thrust washers and one regular thrust washer Clean the end of the axle keyway and the parts removed Inspect the key if worn replace Make sure the thrust washers hav...

Page 86: ...on Fig 144 5 Behind the pinion should be another thrust washer and retaining ring Fig 000 MVC 850 A Retaining ring and B Key thrust washer A B 2 Lubricate with anti seize and assemble in the original order Reassemble in reverse order 1 Install one thrust washer then the ﬁrst retaining ring with the sharp edge facing the chassis Fig 145 Fig 145 MVC 472 ...

Page 87: ...ission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 6 ...

Page 88: ...en the control is engaged the idler with the brake pad backs away from the brake drum and tightens the belt When the control is released a spring causes the idler to pivot towards the brake drum releasing the belt and engaging the brake This stops the blade but allows the ﬂywheel and crankshaft to continue to turn The blade clutch system offers the customer convenience to stop the blade while allo...

Page 89: ...nt of the blade release of the control bar disengages the blade and on self propel models the transmission By gradually releasing the control bar the operator can regulate the ground speed of self propel models without disengaging the blade a Left Control Housing serves as the cover for the BBC control mechanism It also houses the end of traction and BBC cables b Control Bar pivots on upper should...

Page 90: ...ling Spring sole purpose is to hold the control bar in the middle position when at rest The spring is ﬂexed or buckled when the control bar is operated It rides in a slot on the rocker arm to prevent it from applying force to the control bar when the control bar is at its lowest or uppermost positions j Right Control Housing serves as the other half of the control box cover Houses the leaf spring ...

Page 91: ...sing the control bar straightens the buckling spring Also important is the function of the leaf spring As the control bar is raised the left tip of the control hook slips by the leaf spring without causing release of the cable lever Continuing to raise the control bar causes the traction lever to move and the traction cable engages the transmission Fig 152 3428 0289 When the control bar is raised ...

Page 92: ...ntrol to the control panel then tap the throttle control out using a rubber mallet 3 Remove the 3 ﬂanged head screws retaining the 2 control box halves 4 Carefully remove the 2 ﬂange nuts retaining the control box to the handle and remove the right control box half Be careful not to dislodge any internal components 5 Reinstall the ﬂange nuts to help hold things together Determine if any of the com...

Page 93: ...mbly 10 Press the roll pin from the rocker arm and remove the control hook and torsion spring 11 Remove the traction cable from the traction lever and the left hand control housing Fig 155 ﬁg 34 1 Slip the lower carriage bolt through the handle then slide the left control housing onto it 2 Slip the end of the traction cable into the traction lever Place the control housing traction lever and the c...

Page 94: ...t the roll pin is ﬂush with the side indicated in the ﬁgure Loosely install the BBC cable lever as indicated When correctly installed the control hook and the cable lever will be engaged Fig 156 ﬁg 35 Fig 157 ﬁg 36 6 Slide the rocker arm assembly over the upper carriage bolt and sleeve making sure that the sleeve passes through the cable lever Also make sure that the roll pin passes through the ho...

Page 95: ... their slots in the left housing Also make sure that the sleeve passes through all components including the left control housing Finally make sure that the roll pin passes through the rocker arm and control bar Install the right control housing and secure with the 2 nylon locknuts or 1 locknut and 1 ﬂange nut 11 Install the 3 ﬂanged head screws that retain the two control box halves 12 Check for p...

Page 96: ...6 10 WPM Drive Systems Manual BBC BOS BCS TORO BBC SERVICE GUIDE Fig 160 bbc scan Disassembly Sequence ...

Page 97: ...ing Flange Bushing Lever Wa Bushing Ring Seal HWH Screw TAP Screw Flange Nut Cable Bracket Support Flat Washer Bellcrank Bushing Crank Spring Pin Control Link Ref No Qty Description 22 23 24 25 26 27 28 31 32 33 34 35 36 37 38 39 42 43 44 45 46 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 2 1 2 1 1 HH Screw Compression Spring Spring Retainer Woodruff Key Driver Pulley BBC Flywheel Blade Bolt Brake Drum Hub ASM...

Page 98: ...Vacu Power Lawn Boy Medallion Fig 162 DSC 068a Fig 164 3428 0082 2 Pull the black plastic transmission cover up to remove it from the housing Fig 164 Fig 163 3428 0079 Fig 165 3428 0090 3 Remove the shoulder bolt and ﬂanged nut securing the bellcrank to the control cable bracket Once loose remove the bellcrank assembly complete with control link from the unit Fig 165 BBC BOS BCS A Control link C B...

Page 99: ...lace the spring onto the control pin Place the spring retainer onto the spring and insert the screw into the control pin Using the control link to prevent rotation of the control pin tighten the ﬂanged head screw until the retainer bottoms out on the control pin Fig 166 3 Note the orientation of the control link in Figure 167 Make sure that it is installed correctly into the bellcrank A Brake plat...

Page 100: ...position on the housing and secure with the two self tapping ﬂanged head capscrews 9 Check for proper operation of all controls especially the BBC and adjust as necessary Note The spring length on the bellcrank assembly is the primary indicator of proper BBC adjustment It should measure 1 25mm with the blade engaged when properly adjusted If spring measures more than 1 1 4 32mm correct by adjustin...

Page 101: ...ormally Make sure that the brake and brake drum fully disengage when the control bar is cocked then raised Make sure that the BBC ﬂywheel and the brake drum rotate together when the control bar is raised Make sure that the belt loosens properly when the control bar is lowered Repair or replace parts as required Fig 171 MVC 726 6 Pivot the brake plate counterclockwise slightly and remove the bearin...

Page 102: ...ring the brake lever and hub to the housing CAUTION The brake plate lever is under moderate spring loading Heavy gloves and eye protection are recommended when removing the brake plate lever Note Do not use an air wrench on the brake lever self tapping screw as thread damage to the housing may result 12 Complete disassembly of the brake plate by removing the brake plate screws and the bearing bloc...

Page 103: ...s in the housing do not helicoil rather place a hex nut in the recess provided in the top side of the deck 4 Install an idler hub into each side of the idler pulley bearing then slip the belt onto the idler pulley Slip the entire assembly between the brake plate and brake lever Secure the carriage bolt and nylon locknut as shown in Figure 174 5 Tighten the idler pulley bolt Make sure that the idle...

Page 104: ... arbor or a 1 1 8 28mm socket to press the bearing into the block 8 Make sure that the foam rubber anti vibration pads are in place on the brake drum and assemble the brake drum bearing block and BBC screws onto the crankshaft as shown in Figure 177 Secure with the crankshaft nut Note Crankshaft nut torque 45 70 ft lbs 61 95 Nm A Bumps B Slots A Boss CAUTION As with disassembly the ﬂywheel can be ...

Page 105: ...ver the heads of the handle and the BBC control box This will prevent the control box components from falling out of the handle during disassembly 4 Remove the three ﬂanged head screws securing the control box halves 5 Remove the two nylon locknuts securing the control box to the handle and carefully remove the right control housing half 6 Slip the end of the BBC cable from the cable lever and rem...

Page 106: ...ugh the hole in the control bar Install the right control housing half Secure with two nylon locknuts Note The ﬂanged locknut ﬁts on the upper carriage bolt 6 Before installing the screen panel adjust the BBC cable as described under BBC Cable Adjustment Toro Vacu Power Lawn Boy Medallion Models which follows See page 7 15 Fig 181 ﬁg 68 3 Install the three ﬂanged head screws securing the control b...

Page 107: ...ew Belt Guide Bracket Woodruff Key Pulley Flywheel Blade Bolt Brake Drum ASM Vibration Dampener Hub ASM Shield Blade Spacer Blade Nut Recycler Blade Blade Stiffener Anti Scalp Cup Ref No Qty Description 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 3 2 1 Lock Nut HH Screw Flat Washer Control Link Bellcrank Bellcrank Sleeve Lever HH Screw Torsion...

Page 108: ... under the lever Fig 185 With the tension removed you can now remove the long screw through the lever We would suggest loosening this screw but leave it engaged at this time Fig 187 Fig 184 3428 0174 2 On the left side of the mower next to the rear wheel loosen the clamp that secures the BBC cable to the mower housing Near the left front wheel unhook the spring end of the cable from the bellcrank ...

Page 109: ...86 With the pulley removed the idler arm can pivot away from the brake drum and the belt can be removed Fig 186 3428 0182 5 Now reach around to the top of the housing and pull the screw out of the lever Fig 187 Fig 187 3428 0179 Fig 189 3428 0185 There are two bearings pressed into the housing that the idler shaft rides on If they are to be replaced press them out at this time Fig 189 Fig 188 3428...

Page 110: ...r to loosen Fig 191 Fig 191 3428 0103 Fig 192 3428 0116 8 Roll the self propel belt off the pulley and remove the pulley and the key in the crankshaft 9 Inspect the pulley One end of the keyway is blocked off If that is broken the pulley will bounce up and down during use and make a rattling noise Fig 192 There are two bumps on the outside of the pulley that are intended to engage two holes in the...

Page 111: ... crankshaft is tightened the ﬂywheel will push the pulley upwards either breaking the wall out of the key groove or crushing the two bumps or both Fig 195 3428 0188 3 Note the two small foam pads inside the brake drum Fig 195 Fig 194 MVC 727 The ﬂywheel must be installed with the side that looks like 1 2 of a pulley facing the brake drum Fig 194 Push the ﬂywheel ﬁrmly on the taper of the crankshaf...

Page 112: ...o be intact If the seals are damaged or the bearing feels rough when it is turned replace the hub assembly 5 Start the nut on the crankshaft As during disassembly an impact wrench works best Fig 197 3428 0187 CAUTION The two bumps on the pulley MUST engage the ﬂywheel If you do not have an impact wrench this is where the two bumps become important If you engage the bumps on the pulley into the ﬂyw...

Page 113: ...90 8 Slip the spring over the shaft One tang of the spring must engage the tab as shown Fig 198 BBC BOS BCS 10 Hold the idler brake arm in place Slip the spring over the end on top of the deck as shown Install the lever and install the screw through the lever and idler brake arm shaft Fig 200 Once the screw is secured take a loop of wire or rope and hook the end of the spring Pull it towards you a...

Page 114: ...through the hole in the control bar Install the right control housing half Secure with two nylon locknuts Note The ﬂanged locknut ﬁts on the upper carriage bolt 3 Install the three ﬂanged head screws securing the control box halves A BBC cable lever B BBC cable 3 Bend the throttle control locking tab back slightly and tap the throttle control from the control panel with a rubber mallet Place a pie...

Page 115: ...cknuts securing the blade Fig 205 BLADE OVERRIDE SYSTEM BOS BLADE CLUTCH SYSTEM BCS Both Toro and Lawn Boy use the same blade clutching system on some models On Toro it is named the Blade Override System On Lawn Boy it is named the Blade Clutch System It is designed to allow the blade to stop while the engine keeps running This is especially helpful when bagging as the engine will not need to be r...

Page 116: ...from the slot in the brake arm Fig 210 Fig 209 MVC 200 6 Remove the brake pivot bolt You will need a second wrench to hold the bolt head Fig 209 4 Remove the blade support and disc Fig 207 Fig 207 MVC 198 5 Remove the 3 capscrews and lift off the belt cover Fig 208 Fig 208 MVC 199 ...

Page 117: ... 212 MVC 207 Fig 214 MVC 218 11 Continuing with the disassembly remove the bolt securing the pulley to the crankshaft Note Use a large screwdriver or pry bar to keep the pulley from turning while you unscrew the bolt Fig 214 Fig 213 MVC 209 10 The components of the idler assembly are shown here Fig 213 A Belt E Washer B Nut F Bearing with ﬂange C Brake arm G Spacer D Belt guard H Bolt A E F G B C ...

Page 118: ... the chassis Fig 217 12 Rock the pulley half slightly and lift it off The blade bolts will now drop out of their pockets Fig 215 Fig 215 MVC 220 13 Lift the crankshaft pulley half off of the crankshaft Note this pulley half is keyed to the crankshaft and this pulley half is also the drive pulley for the self propel belt Go to the transmission to continue replacing the self propel belt Fig 216 Fig ...

Page 119: ...anchor plate Fig 219 Fig 219 MVC 257 1 Place the spacer with the large diameter down on the brake arm Fig 220 Fig 220 MVC 211 Fig 222 MVC 216 3 Install the belt belt guide and carriage bolt on the brake arm and secure with the carriage bolt Fig 222 Fig 221 MVC 213 2 Place the bearing with the ﬂange side down on the spacer and place the washer on top of the bearing Fig 221 A A B B ...

Page 120: ...WPM Drive Systems Manual BBC BOS BCS BOS BCS System Assembly Assemble all other parts in reverse order Bolt torque as follows Blade nuts 350 400 in lbs 39 5 45 2 Nm Crankshaft Bolt 45 55 ft lbs 60 9 74 5 Nm ...

Page 121: ... Transmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 7 ...

Page 122: ...t lowering the bail about 1 25mm disengages the self propel Handle disassembly is self explanatory so we will not discuss that Turning the knob tightens or loosens the cable When the bail is lowered about 1 25mm the drive should disengage Fig 224 ﬁg 19 The engine stop cable is not adjustable If it fails to function it must be replaced The self propel cable is adjustable through a clamp which is ty...

Page 123: ...alk faster The key is keeping your elbows at your sides This applies the right amount of pressure to the handle to engage the drive If you just push the handle down it will engage too rapidly and the mower will jump forward Fig 227 DSC 4808 2 Turn the handle over and remove the cable clamp screw and the cable from the pocket Fig 227 Fig 226 DSC 4804 1 Squeeze the ends of the control bail to diseng...

Page 124: ...n rod retainer Fig 228 Fig 228 DSC 4810 4 Remove the traction rod retainer Note the location of the traction control rod Fig 229 Fig 229 DSC 4811 Fig 231 DSC 4814 6 Unhook the springs from each side of the handle Fig 231 Fig 230 DSC 4815 5 Disconnect the cable from the traction lever Fig 230 ...

Page 125: ...21a 2 One end of the springs goes into a hole in the handle the other around the traction control rod The springs apply pressure to the handle to hold it in the retracted upper position Fig 235 Fig 234 DSC 4828a Reassemble in reverse order 1 There are 3 bosses on the inside of the guide The top and bottom ones receive the mounting screws The boss in the photo must line up with the end of the contr...

Page 126: ...2 7cm long each Bend them as shown in the photo and round the ends to remove burrs This tool permits the handle to slide up and over the internal handle stops Fig 238 This is the second generation of the personal pace easy stride handle assembly It works the same as the original in the sense that the handle is telescoping As the handle is depressed it tightens the self propelled belt and drives th...

Page 127: ...e Fig 239 Fig 239 MVC 005a Fig 241 MVC 709a 4 Continue pushing the handle down until it slides off the end of the upper handle Fig 241 Fig 240 MVC 707a 3 As the handle begins to slide downward pull the traction control bar farther out of the handle Fig 240 5 When reinstalling the handle reconnect the spring as shown The spring should push the handle upwards toward the disengage position Fig 242 Fi...

Page 128: ...engine stop cable is not adjustable If it does not function it must be replaced The self propel cable is adjustable through a clamp It should be adjusted so that lowering the bail about 1 25mm disengages the self propel This is a gap that is comfortable for most operators Fig 244 3428 0049 The 2 bail style is shown here Fig 244 The top bail is the engine stop Release it and the ignition is grounde...

Page 129: ... The Sens a Speed handle controls the self propel the same way as on a zone start model Lawn Boy Sens a Speed Operation The top mounted bail is the engine stop control on zone start models and the blade control on blade clutch models On a zone start model pull the top bail down and hold to keep the engine running The Sens a Speed handle telescopes and as it is depressed tensions the transmission d...

Page 130: ...and the traction lever Fig 248 Fig 248 DSC 4880a 4 Slide the pin out of the left hand handle and pull the upper handle up and out 5 The plastic sleeves will slide off the upper handle 6 The springs can be removed from the top slides if necessary If the handle has been binding clean the top slides and the sleeves before assembling Dirt and grit in the sliding part of the handle can cause a bind Ass...

Page 131: ...e slack Fig 250 then push the cable jacket up 1 8 3 17cm Fig 251 and secure with the cable clamp Cable Adjustment Self Propel Cable Handle Disassembly Lawn Boy Blade Clutch System BCS Models 1 Remove the upper wire bail On the right hand side it slides over a pin On some models this pin has a push nut on it Fig 252 It can be compressed so that either the bail slides off the pin or it draws the pin...

Page 132: ...e pin 5 Remove the shoulder bolt that the traction lever pivots on and remove the traction lever 6 Pull the pin out of the left hand handle Note it is snapped in and will require a locking pliers or something similar to remove When removed the springs will push the handle upwards Fig 255 Fig 255 DSC 4907a A B A Traction lever C Top slide B Pivot assembly 2 Remove the e clip on the left side pivot ...

Page 133: ...ckward to tighten the belt and engage the transmission Fig 258 It must tighten sufﬁciently to fully drive the transmission yet allow the transmission to rock forward and loosen the belt to disengage 3 Speed Control Cables Fig 256 DSC 4908a 7 Slide the upper handle out of the top slide Reverse the process to assemble Note how the switch assembly bail and control cable are assembled before they are ...

Page 134: ...wer the bail enough to stop the wheels without releasing the bail Fig 261 Fig 261 ﬁg 20 To adjust turn the knob or loosen the cable clamp and slide the cable jacket up or down Secure with the clamp Fig 259 3428 0043 2 The adjustment point for this cable is a knob jam nuts or a clamp to the handle Fig 259 and Fig 260 A Clamp A A Blade brake cable B Jam nuts Fig 260 ﬁg 69 1 25mm ...

Page 135: ...de Tape the control bar to the handle with the blade engaged then measure the length of the over travel spring Fig 263 When adjusted properly it should measure 1 25mm If it does skip ahead to step 5 Otherwise proceed with adjustment in the following step Fig 263 ﬁg 68 A Plastic ﬁtting C Spring B Cable ﬁtting Fig 262 3428 0079 3 There is a turnbuckle in the cable about halfway between the control p...

Page 136: ...hrough the screen panel on top of the deck and down underneath the deck This venting improves the airﬂow underneath the deck thereby improving quality of cut and bagging performance Be sure to clean the screen on occasion especially if quality of cut or bagging performance has degraded Note An overly tight cable will cause the BBC to disengage before the bail can be raised to the normal operating ...

Page 137: ...ows the bail to be lowered so that the wheels stop driving and the BBC remains engaged but the gap isn t so large that the handle is hard to hold Fig 266 This measurement is not an exact requirement It can be varied to accommodate a customer with small hands etc Fig 266 ﬁg 20 The BOS control is the upper bail on the handle For the required 2 step engagement there is a pivoting stop on the right ha...

Page 138: ...ntrol Cable Adjustment Fig 268 MVC BOS457x To engage the blade clutch press the control button Then pull the control bar to the handle To disengage the blade release the control bar Fig 269 Lawn Boy BCS Control Fig 269 lwpm_10797a Lawn Boy Insight and Insight Gold 1 Remove the grass bag and tunnel Fig 270 Lawn Boy BCS Control Cable Adjustment Fig 270 DSC 5360a 2 Loosen cable clamp Draw cable to re...

Page 139: ... its side with the air ﬁlter up 2 Remove the BCS cover and belt cover 3 Loosen the 2 cap screws securing the bracket to the housing Pull the cable to the rear to remove the slack Push the cable forward 5 8 1 5cm and secure This will create 5 8 1 5cm of slack Fig 272 Fig 272 DSC 5352a 4 Install the BCS cover belt cover and tunnel ...

Page 140: ...7 20 WPM Drive Systems Manual HANDLES AND CONTROL CABLES THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 141: ...e Transmission Single Speed Spur Bevel Gear Transmission Single Speed Bevel Gear Transmission Three Speed Transmission Wheel Pinion Clutch Blade Brake Clutch Systems BBC Blade Override System BOS Blade Clutch Systems BCS Handles and Control Cables Self Propel Belt Replacement 1 8 ...

Page 142: ...t be enough clearance between the blade and mower housing It might be necessary to remove the blade to slip the belt off Reverse the process to assemble Toro 21 Front Wheel Drive 22 Front Wheel Drive These are steel deck mowers made in both Toro and Lawn Boy brands In order to replace the self propel drive belt the transmission must be removed from the chassis This is necessary to access the pulle...

Page 143: ...e the BBC section starting on page 6 1 for more information 21 Toro and Lawn Boy Mowers with Blade Brake Clutch Part of the BOS or BCS must be removed to replace the self propel belt See page 6 18 for more information The Lawn Boy Insight has a black access cover just to the rear of the engine on top of the chassis Remove it for easy access to the top of the transmission 21 Toro Mowers with Blade ...

Page 144: ...8 4 WPM Drive Systems Manual SELF PROPEL BELT REPLACEMENT THIS PAGE INTENTIONALLY LEFT BLANK ...

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