Toro TIME CUTTER ZS 4200S Service Manual Download

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Specifications

Model

74685

74687

74690

74694

Deck Size

107 cm (42 inches)

127 cm (50 inches)

Deck
Construction

Stamped

Fabricated

HOC Type

3 Point

HOC Range

3.81–11.43 cm (1.5-4.5 inches)

Engine

Toro Single

Toro Twin

Engine Model

LC1P92F-1 (CE)

LC2P77F

LC2P77F(49 ST)

Engine
Displacement

452cc

708cc

Engine RPM

2600 ± 100 rpm

2850 ± 100 rpm

Fuel Tank Cap

11 L (3 gallons)

Hydro Transaxle

Hydro-Gear ZT-2100

Suspension

N/A

MYRIDE®

Bagger Capacity

8 Bushel

Battery Size

230 CCA

Model

75742TA

75745TA

75755TA

74710

Deck Size

107 cm (42 inches)

127 cm (50 inches)

81 cm (32 inches)

Deck
Construction

Stamped

Fabricated

Stamped

HOC Type

3 Point

HOC Range

3.81–11.43 cm (1.5-4.5 inches)

Engine

Toro Twin

Toro Single

Engine Model

LC2P77F

LC2P77F (49 ST)

LC1P92F-1

(DOM,50ST)

Engine
Displacement

708cc

452cc

Engine RPM

3300 ± 100 rpm

Fuel Tank Cap

11 L (3 gallons)

Hydro Transaxle

Hydro-Gear ZT-2100

Hydro-Gear ZT-2200

Long Axle

Hydro-Gear ZT-2100

Suspension

N/A

MYRIDE®

N/A

Bagger Capacity

8 Bushel

Battery Size

230 CCA

195 CCA

Model

75740

75741

75742

75743

Deck Size

107 cm (42 inches)

Deck
Construction

Stamped

Fabricated

HOC Type

3 Point

HOC Range

3.81–11.43 cm (1.5-4.5 inches)

Engine

Toro Single

Kawasaki Twin

Toro Twin

Kawasaki Twin

Engine Model

LC1P92F-1

(DOM,50ST)

FR600V-_S04-R

(CARB)

LC2P77F

FR691V-AS26-R

Specifications and Maintenance: Specifications

Page 2–2

TIMECUTTER® Service Manual

3433-938 Rev A

Summary of Contents for TIME CUTTER ZS 4200S

Page 1: ...rm No 3433 938 Rev A TIMECUTTER Service Manual Published June 2020 2020 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ...Revision History Revision History Page 2 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 3: ...he related topics covered in this manual 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 RLC SWS Customer Care Department 8111 Lyndale Avenue South Bloomington MN 55420 The Toro Company reserves the right to change product specifications or ...

Page 4: ...ener tightening sequence Component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appear on the machine service decal or in the machine Ope...

Page 5: ...vice and Repairs 4 3 Chapter 5 Chassis 5 1 General Information 5 2 Service and Repairs 5 3 Chapter 6 Hydrostatic Drive System 6 1 General Information 6 2 Service and Repairs 6 3 Chapter 7 Mower Deck System 7 1 General Information 7 2 Service and Repairs 7 3 Chapter 8 Electrical System 8 1 General Information 8 2 Service and Repairs 8 3 Appendix A A 1 Electrical Drawing Abbreviations A 2 Electrical...

Page 6: ...Preface Page 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 7: ...Chapter 1 Safety Table of Contents Safety Instructions 1 2 Think Safety First 1 2 TIMECUTTER Service Manual Page 1 1 Safety 3433 938 Rev A ...

Page 8: ...rmally moving parts as if they were moving whenever the engine is running or has the potential to start Avoid burns Do not touch the engine muffler or other components which may be hot during operation while the unit is running or shortly after it has been running Avoid fires and explosions Use extreme care in handling fuel It is flammable and its vapors are explosive Extinguish all cigarettes cig...

Page 9: ...away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use your hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate under the skin and cause serious injury Seek medical attention right away if hydraulic fluid gets in the skin Personal Protective Equipment Tie back long hair and do not wear loose clothing or jew...

Page 10: ... the approximate number of square feet of fire it can extinguish Geometric symbol red square Class C fires involve electrical equipment such as appliances wiring circuit breakers and outlets Never use water to extinguish class C fires the risk of electrical shock is far too great Class C extinguishers do not have a numerical rating The C classification means the extinguishing agent is non conducti...

Page 11: ...s and Maintenance Table of Contents Specifications 2 2 Torque Specifications 2 4 Equivalents and Conversions 2 9 U S to Metric Conversions 2 10 TIMECUTTER Service Manual Page 2 1 Specifications and Maintenance 3433 938 Rev A ...

Page 12: ... Fabricated Stamped HOC Type 3 Point HOC Range 3 81 11 43 cm 1 5 4 5 inches Engine Toro Twin Toro Single Engine Model LC2P77F LC2P77F 49 ST LC1P92F 1 DOM 50ST Engine Displacement 708cc 452cc Engine RPM 3300 100 rpm Fuel Tank Cap 11 L 3 gallons Hydro Transaxle Hydro Gear ZT 2100 Hydro Gear ZT 2200 Long Axle Hydro Gear ZT 2100 Suspension N A MYRIDE N A Bagger Capacity 8 Bushel Battery Size 230 CCA 1...

Page 13: ...gallons Hydro Transaxle Hydro Gear ZT 2100 Suspension MYRIDE N A Bagger Capacity 8 Bushel Battery Size 230 CCA Model 75755 75754 75757 75759 75760 Deck Size 127 cm 50 inches 137 cm 54 inches 127 cm 50 inches 152 cm 60 inches Deck Construction Fabricated HOC Type 3 Point 4 Point HOC Range 3 81 11 43 cm 1 5 4 5 inches Engine Toro Twin Kawasaki Twin Toro Twin Engine Model LC2P77F 49 ST FR691V AS26 R ...

Page 14: ...h of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass materi...

Page 15: ...Metric Bolts and Screws g272209 Figure 2 1 Class 8 8 2 Class 10 9 TIMECUTTER Service Manual Page 2 5 Specifications and Maintenance Torque Specifications 3433 938 Rev A ...

Page 16: ...5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 420 43 56...

Page 17: ...ce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material stre...

Page 18: ... No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Hole size material strength material thickness and finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 N cm ft lb X 1 3558 N m N cm X 0 08851 in lb N cm X 0 73776 ft lb Thread Cutting Screws Zinc P...

Page 19: ... 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 541 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9...

Page 20: ...6 Cubic Feet Cubic Meters 0 02832 Volume Cubic Inches Cubic Centimeters 16 39 Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Weight Ounces Grams 28 3495 Pressure Pounds Square Inch Kilopascal 6 895 Foot Pounds Newton Meters 1 356 Foot Pounds Kilogram Meters 0 1383 Work Inch Pounds Kilogram Centimeters 1 152144 Quarts Liters 0 9463 Liquid Volume Gallons Liters 3 785 Liquid Flows Gallons Minu...

Page 21: ...Chapter 3 Troubleshooting Table of Contents General Troubleshooting 3 3 TIMECUTTER Service Manual Page 3 1 Troubleshooting 3433 938 Rev A ...

Page 22: ...s E Narrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure A Reevaluate and create new hypotheses if necessary Repair R Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired S Are there any other new s...

Page 23: ...trical connections are corroded loose or damaged Check the electrical connections for good contact Clean the connector terminals thoroughly with the electrical contact cleaner and apply dielectric grease The spark plug is fouled or improperly gapped Adjust or replace the spark plug The spark plug wire is not connected Check the spark plug wire connection The engine does not start starts hard or fa...

Page 24: ...nt or unbalanced Install new cutting blade s The blade mounting bolt is loose Tighten the blade mounting bolt The engine mounting bolts are loose Tighten the engine mounting bolts The engine pulley idler pulley or blade pulley is loose Tighten the appropriate pulley check to make sure idler springs are not over stretched The engine pulley is damaged Replace the engine pulley The blade spindle is b...

Page 25: ...ecessary The coil is damaged Replace the clutch There is inadequate current supply Repair or replace the clutch lead wire or electrical system Clean the connector contacts The rotor armature air gap is too large Replace the clutch The clutch does not engage The blade control switch PTO is faulty Replace the blade control switch PTO TIMECUTTER Service Manual Page 3 5 Troubleshooting General Trouble...

Page 26: ...Troubleshooting General Troubleshooting Page 3 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 27: ...gine Table of Contents General Information 4 2 Service and Repairs 4 3 Engine Replacement 4 7 Muffler Replacement 4 19 Air Filter Cartridge Replacement 4 22 TIMECUTTER Service Manual Page 4 1 Engine 3433 938 Rev A ...

Page 28: ... twin cylinder OHV 4 cycle engine LC2P77F 726cc Kawasaki twin cylinder OHV 4 cycle engine FR691V and 725cc Kohler twin cylinder OHV 4 cycle engine PS KT735 See the Toro Twin Cylinder Engine Service Manual for servicing the engine All other engines see the manufacturer s website Engine General Information Page 4 2 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 29: ...Service and Repairs Engine Assembly 1 g305684 Figure 3 1 LC1P92F 1 Engine 3 Exhaust Gasket 2 Muffler 4 Oil Drain Tube TIMECUTTER Service Manual Page 4 3 Engine Service and Repairs 3433 938 Rev A ...

Page 30: ...Engine Assembly 2 g305686 Figure 4 1 2P77F Engine 3 Exhaust Gasket 2 Muffler Engine Service and Repairs Page 4 4 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 31: ...Engine Assembly 3 g305687 Figure 5 1 Kawasaki Engine 3 Oil Drain Tube 2 Muffler 4 Heat Shield TIMECUTTER Service Manual Page 4 5 Engine Service and Repairs 3433 938 Rev A ...

Page 32: ...Engine Assembly 4 g305691 Figure 6 1 Kohler Engine 3 Oil Drain Hose 2 Muffler 4 Cable Tie Engine Service and Repairs Page 4 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 33: ...ive cable from the battery 3 Drain the engine oil 4 Using pliers slide the hose clamp away from the fuel filter connection to the fuel hose Remove the fuel hose from the fuel filter Clamp the fuel hose to prevent access fuel drainage Note May need a drain pan for access fluid g300615 Figure 7 5 Remove the fuel tank vent hose from the fuel tank vent orifice g300616 Figure 8 TIMECUTTER Service Manua...

Page 34: ...m nut securing the starter power wire to the starter g300618 Figure 10 8 Remove 13 mm HH bolt securing the battery cable ground wire and the chassis harness ground wire to the engine block Remove the ground wires from the engine block Engine Service and Repairs Page 4 8 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 35: ...shield to the chassis Remove the muffler shield and rear engine guard g300621 Figure 12 10 Remove 8 mm HH bolt securing the throttle and choke cables to the throttle control plate Remove the throttle and choke cables from the throttle control plate TIMECUTTER Service Manual Page 4 9 Engine Service and Repairs 3433 938 Rev A ...

Page 36: ... 4 13 mm nuts with lock washers securing the muffler to the engine Remove the muffler from the engine g300622 Figure 14 12 Remove the deck tensioner spring from the spring hook Engine Service and Repairs Page 4 10 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 37: ... the machine Remove the deck belt from the clutch pulley 14 Disconnect the wiring to the clutch g300624 Figure 16 15 Remove the 5 8 hex bolt securing the clutch to the crankshaft of the engine Remove the clutch TIMECUTTER Service Manual Page 4 11 Engine Service and Repairs 3433 938 Rev A ...

Page 38: ... the engine pulley Slide the hydro belt off the engine pulley Remove engine pulley from the crankshaft 18 Remove the 4 hex bolts 9 16 inch securing the engine to the chassis Note Three of the bolts will have a flat washer the 4th bolt going through the clutch anchor will not have a flat washer Engine Service and Repairs Page 4 12 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 39: ...bolts have a flat washer the 4th bolt going through the clutch anchor does not have a flat washer 2 Using an appropriate lifting device raise the machine Torque hex bolts to 45 56 N m 400 500 in lb g300672 Figure 20 3 Install the engine pulley to the crankshaft Slide the hydro belt onto the engine pulley Add tension to the engine pulley TIMECUTTER Service Manual Page 4 13 Engine Service and Repair...

Page 40: ...on the chassis g300671 Figure 21 5 Install the clutch Install the 5 8 hex bolt securing the clutch to the crankshaft of the engine Torque bolt to 67 5 81 N m 50 60 ft lb g300625 Figure 22 6 Connect the wiring to the clutch Engine Service and Repairs Page 4 14 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 41: ...priate lifting device lower the machine 8 Install the deck tensioner spring to the spring hook g300623 Figure 24 9 Install the muffler to the engine Secure with 4 13 mm nuts with lock washers Torque nuts to 17 19 N m 150 170 in lb TIMECUTTER Service Manual Page 4 15 Engine Service and Repairs 3433 938 Rev A ...

Page 42: ...the throttle and choke cables to the throttle control plate g300620 Figure 26 11 Install the muffler shield and rear engine guard Secure with 10 T 40 self tapping screws securing the rear engine guard and muffler shield to the chassis Torque screws to 17 22 5 N m 150 200 in lb Engine Service and Repairs Page 4 16 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 43: ...to the engine block Secure with 13 mm HH bolt securing the battery cable ground wire and the chassis harness ground wire to the engine block Torque bolt to 22 5 25 N m 200 225 in lb g300619 Figure 28 TIMECUTTER Service Manual Page 4 17 Engine Service and Repairs 3433 938 Rev A ...

Page 44: ...re to the starter Torque nut to 10 5 11 5 N m 96 105 in lb g300618 Figure 29 14 Connect the engine to chassis wiring harness g300617 Figure 30 15 Install the fuel tank vent hose to the fuel tank vent orifice Engine Service and Repairs Page 4 18 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 45: ...ion to the fuel hose g300615 Figure 32 17 Add engine oil 18 Connect the positive battery cable first then the negative battery cable to the battery Muffler Replacement Muffler Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key TIMECUTTER Service Manual Page 4 19 Engine Service and Repairs 3433 938 Rev A ...

Page 46: ...g screws securing the rear engine guard and muffler shield to the chassis Remove the muffler shield and rear engine guard g300621 Figure 33 4 Remove 4 13 mm nuts with lock washers securing the muffler to the engine Remove the muffler from the engine g300622 Figure 34 Muffler Installation Engine Service and Repairs Page 4 20 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 47: ...l the muffler shield and rear engine guard Secure with 10 T 40 self tapping screws securing the rear engine guard and muffler shield to the chassis Torque screws to 17 22 5 N m 150 200 in lb g300621 Figure 36 3 Connect the positive battery cable first then the negative battery cable to the battery TIMECUTTER Service Manual Page 4 21 Engine Service and Repairs 3433 938 Rev A ...

Page 48: ...e wait for all moving parts to stop and remove the key 2 Lift the air cleaner cover door g300685 Figure 37 3 Remove the air filter cartridge Replace as necessary g300686 Figure 38 Air Filter Cartridge Installation 1 Install the air filter cartridge onto the engine Engine Service and Repairs Page 4 22 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 49: ...Air Filter Cartridge Installation continued g300686 Figure 39 2 Lower the air cleaner cover door g300685 Figure 40 TIMECUTTER Service Manual Page 4 23 Engine Service and Repairs 3433 938 Rev A ...

Page 50: ...Engine Service and Repairs Page 4 24 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 51: ...ment 5 25 Seat Assembly Replacement 5 28 MYRIDE Seat Platform Replacement 5 30 Steering Control Box Replacement 5 45 Motion Control Actuator Replacement 5 65 Smart Speed Assembly Replacement 5 74 Rear Engine Guard Replacement 5 85 Deck Lift Assembly 3 Point Replacement 5 86 Deck Lift Assembly 4 Point Replacement 5 95 Front Chassis Storage Box Replacement 5 99 TIMECUTTER Service Manual Page 5 1 Cha...

Page 52: ...ns of this frame a MYRIDE suspension platform and a conventional solid platform The frame is constructed from 10 gauge steel and now accommodates a relief in the rear crossmember for aid in easier drive belt replacement Chassis General Information Page 5 2 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 53: ...Service and Repairs Chassis Assembly 1 g305797 Figure 41 1 Seat 3 Pivot Rod 2 Seat Pan 4 Lanyard Cable TIMECUTTER Service Manual Page 5 3 Chassis Service and Repairs 3433 938 Rev A ...

Page 54: ...Chassis Assembly 2 g305817 Figure 42 1 Seat 4 Lanyard Cable 2 Seat Pan 5 Knob 3 Pivot Rod Chassis Service and Repairs Page 5 4 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 55: ...n Cavitating Damper 12 LH Control Handle 4 Hydro Rod Pin 13 Eccentric 5 Actuator Arm Asm 14 RH Control Plate Box 6 RH Knob 15 Torsion Spring 7 LH Knob 16 LH Control Plate Box 8 Front Hydro Rod 17 Storage Box 9 Rear Hydro Rod 18 Kick Plate TIMECUTTER Service Manual Page 5 5 Chassis Service and Repairs 3433 938 Rev A ...

Page 56: ...and Choke Cable 10 Cable Tie 3 Control Panel 11 Orifice Adaptor 4 LH Pod 12 Fuel Tank Asm 5 RH Pod 13 Grommet Bumper 6 RH Support Pod 14 LH Pod Support 7 Fuel Hose 15 Spring 8 Fuel Hose 16 Fuel Tank Support Chassis Service and Repairs Page 5 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 57: ...nister 5 RH Pod 17 Carbon Canister Bracket 6 Ratcheting Fuel Cap 18 Carbon Canister Bracket 7 LH Pod 19 Inline Fuel Filter 8 Tank Vent Hose 20 Fuel Hose 9 Fuel Hose 21 Spring 10 Fuel Tank Asm 22 Fuel Tank Support 11 Straight Fitting 23 Grommet Bumper 12 Fuel Hose 24 LH Pod Support TIMECUTTER Service Manual Page 5 7 Chassis Service and Repairs 3433 938 Rev A ...

Page 58: ...shing 23 Swing Arm 8 Shock Spring Asm 24 RH Torsion Spring 9 Seat Bracket 25 Spring Retainer 10 Seat Latch Bracket 26 Adjuster Plate 11 RH Upper Shock Bracket Mount 27 Spring Retainer 12 LH Upper Shock Bracket Mount 28 MYRIDE Adjustment Cable 13 Seat Pan 29 External Retaining Spring 14 Clip 30 LH Torsion Spring 15 Seat Stop Bracket 31 Spacer Tube 16 Seat Prop Rod Chassis Service and Repairs Page 5...

Page 59: ...ing 10 Hydro Plate Mount 3 Floor Pan 11 Footrest 4 Cross Brace 12 Axle Stub Asm 5 Seat Support 13 Grease Cap 6 Floor Pan 14 Right Front Hydro Mount 7 Hitch Bracket 15 Left Front Hydro Mount 8 Engine Guard 16 Muffler Guard TIMECUTTER Service Manual Page 5 9 Chassis Service and Repairs 3433 938 Rev A ...

Page 60: ... Rubber Bumper 11 Grease Cap 4 Hitch Bracket 12 Right Front Hydro Mount 5 Engine Guard 13 TIMECUTTER Frame Weldment 6 Footrest 14 Left Front Hydro Mount 7 Seat Bumper 15 Hydro Mount Plate 8 Lower Damper Mount Bracket 16 Muffler Guard Chassis Service and Repairs Page 5 10 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 61: ...1 Lever Grip 6 Decklift Pivot Bracket 2 HOC Bracket 7 Deck Lift Asm 3 Lift Lever 8 Pivot Pin 4 RH Arm Asm 9 Deck Mount Rod 5 HOC Adjustment Plate 10 LH Arm Asm TIMECUTTER Service Manual Page 5 11 Chassis Service and Repairs 3433 938 Rev A ...

Page 62: ...ivot Asm 2 HOC Link 9 Deck Lift Link 3 HOC Bracket 10 Deck Lift Gusset 4 HOC Pin 11 Flange Bearing 5 Foot Pedal 12 Shaft Cross Support 6 Pan Mount 13 Front Pivot Asm 7 Pivot Deck Pan Chassis Service and Repairs Page 5 12 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 63: ...Asm 2 Lever Grip 9 Lift Pedal 3 HOC Bracket 10 RH Arm Asm 4 Foot Lift Pedal 11 HOC Adjustment Plate 5 Link 12 Pivot Pin 6 Lift Lever 13 Deck Mount Rod 7 Deck Lift Pivot Bracket 14 LH Arm Asm TIMECUTTER Service Manual Page 5 13 Chassis Service and Repairs 3433 938 Rev A ...

Page 64: ...Chassis Assembly 12 g306775 Figure 52 1 Seal Guard 3 Fork Asm 2 Wheel Spanner 4 Tire Asm Chassis Service and Repairs Page 5 14 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 65: ...the front of the machine off the floor 3 Remove the inch bolt and nut securing the wheel to the caster fork Remove the wheel from the machine g300687 Figure 53 4 Using a flat head screw driver remove the top dust cover g308652 Figure 54 5 Remove the inch bolt securing the caster fork to stub shaft 6 Remove the caster fork from the stub shaft TIMECUTTER Service Manual Page 5 15 Chassis Service and ...

Page 66: ...N m 200 225 in lb g300689 Figure 55 3 Install the top dust cover 4 Install the wheel to the machine Secure with the inch bolt and nut securing the wheel to the caster fork Torque bolt and nut to 36 5 50 N m 27 37 ft lb g300687 Figure 56 5 Lower the front of the machine to the floor Chassis Service and Repairs Page 5 16 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 67: ...he front of the machine off the floor 3 Remove the inch bolt and nut securing the wheel to the caster fork Remove the wheel from the machine g300687 Figure 57 4 Remove the center axle from the bushings g300700 Figure 58 5 Using a hammer and punch remove the bushings from the wheel 2 bushings and 1 axle per wheel 6 Inspect bushings and axle replace as necessary TIMECUTTER Service Manual Page 5 17 C...

Page 68: ... a inch bolt and nut securing the wheel to the caster fork Torque bolt and nut to 36 5 50 N m 27 37 ft lb g300687 Figure 60 4 Lower the machine to the floor Stub Shaft Replacement Stub Shaft Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key Chassis Service and Repairs Page 5 18 TIMECUTTER Service Manual 3433...

Page 69: ...el from the machine g300687 Figure 61 4 Using a flat head screw driver remove the top dust cover g300688 Figure 62 5 Remove the inch bolt securing the caster fork to stub shaft Remove the caster fork from the stub shaft 6 Remove the 4 9 16 inch nut and bolt 3 front 1 back securing the stub shaft to the front axle asm TIMECUTTER Service Manual Page 5 19 Chassis Service and Repairs 3433 938 Rev A ...

Page 70: ...le asm g300753 Figure 64 8 Remove the bearings from the stub shaft inspect and replace as necessary Stub Shaft Installation 1 Install the bearings to the stub shaft 2 Install the stub shaft to the front axle asm Chassis Service and Repairs Page 5 20 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 71: ... be on the ground before tightening hardware 5 Tighten the 2 bolts with nuts first then tighten the self tapping screws last rear before front Torque bolts with nuts and screws to 36 5 44 5 N m 27 33 ft lb 6 Install the caster fork to the stub shaft Secure with inch bolt securing the caster fork to the stub shaft Torque the bolt to 36 5 44 5 N m 27 33 ft lb 7 Install the dust cover TIMECUTTER Serv...

Page 72: ...lb g300687 Figure 68 Pod Replacement Pod Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Flip the seat forward 3 Using a T 30 torque bit remove the 3 screws securing the pod to the pod support brackets Repeat for opposite side Chassis Service and Repairs Page 5 22 TIMECUTTER Service Manual 3433 938 Rev A...

Page 73: ...d smart speed knob 7 Using Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lever g301691 Figure 69 8 Using a Philips head screw driver remove the screw securing the control panel to the RH pod Move the control panel to the side g301692 Figure 70 9 Remove the RH pod from the machine TIMECUTTER Service...

Page 74: ...ecuring the smart speed knob to the smart speed lever g301691 Figure 72 4 Place the LH pod into position on the machine 5 Move the motion control from the neutral position to the neutral lock position 6 Install the fuel cap on the LH side pod 7 Install the 3 screws per pod securing the pod to the pod support brackets Torque screws to 11 N m 100 in lb 8 Flip the seat back into position Chassis Serv...

Page 75: ... the LH side pod 5 Move the motion control from the neutral lock to the neutral position 6 Remove the LH pod from the machine 7 Install the fuel cap to the LH pod to prevent fuel spill Fully tighten g301703 Figure 73 8 Remove the spring clamps securing the fuel hose and the fuel vent hose Remove the fuel hose and fuel vent hose from the fuel tank fittings Cap all hoses Note The fuel tank labels bo...

Page 76: ... bottom of the fuel tank Remove the fuel tank from the chassis g301705 Figure 75 Fuel Tank Installation 1 Install the fuel tank to the chassis Secure with the 2 strap fasteners at the bottom of the fuel tank Chassis Service and Repairs Page 5 26 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 77: ...on are labeled on the fuel tank g301704 Figure 77 3 Remove the fuel cap from the LH pod 4 Install the LH pod into position on the machine 5 Move the motion control from the neutral position to the neutral lock 6 Install the fuel cap on the LH side pod 7 Install the 3 screws per pod securing the pod to the pod support brackets Torque screws to 11 N m 100 in lb TIMECUTTER Service Manual Page 5 27 Ch...

Page 78: ...he engine wait for all moving parts to stop and remove the key 2 Flip the seat forward and remove the seat switch connection g301716 Figure 78 3 Flip the seat back to the operator position 4 Remove the 2 T 27 screws from the front of the seat pan g301717 Figure 79 5 Lift and remove the seat from the seat rod Chassis Service and Repairs Page 5 28 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 79: ... Assembly Removal continued g301718 Figure 80 Seat Assembly Installation 1 Install the seat onto the seat rod g301718 Figure 81 TIMECUTTER Service Manual Page 5 29 Chassis Service and Repairs 3433 938 Rev A ...

Page 80: ...seat switch connection g301716 Figure 83 4 Flip the seat back into the operator position MYRIDE Seat Platform Replacement MYRIDE Seat Platform Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key Chassis Service and Repairs Page 5 30 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 81: ...d bolt securing the seat stop bracket to the seat mount Remove the seat stop bracket from the machine 6 Lower the seat Slide the seat to the most forward position 7 Remove the seat from the machine g301739 Figure 84 8 Remove the 2 1 2 inch bolts securing the seat mount to the MYRIDE platform g301740 Figure 85 9 Remove the seat mount from the machine TIMECUTTER Service Manual Page 5 31 Chassis Serv...

Page 82: ...lock to the neutral position 12 Using a Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lever g301691 Figure 87 13 Using a Philips head screw driver remove the screw securing the control panel to the RH pod Move the control panel to the side Chassis Service and Repairs Page 5 32 TIMECUTTER Service Ma...

Page 83: ...assist spring from the MYRIDE cam assembly and the frame Note Long end secures towards the front of the machine 17 Move the MYRIDE adjustment lever to the most rearward position Using a inch wrench remove the front nut from the MYRIDE cable Remove the MYRIDE cable from the cam assembly 18 Unscrew the knob Remove the inch bolt and 9 16 inch nut securing the cam to the chassis TIMECUTTER Service Man...

Page 84: ...igure 90 20 Remove the cam assembly from the machine g309644 Figure 91 CAUTION May need assistance to perform next step 21 Remove the nut securing the top of the front MYRIDE shock to the MYRIDE platform Chassis Service and Repairs Page 5 34 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 85: ...oval continued g301752 Figure 92 22 Using a rachet strap hook the strap to both frame rails on either side of the MYRIDE platform g301753 Figure 93 TIMECUTTER Service Manual Page 5 35 Chassis Service and Repairs 3433 938 Rev A ...

Page 86: ...e the 2 1 2 inch bolts and nuts securing the MYRIDE stop bracket to the MYRIDE platform g301769 Figure 95 24 Relieve the tension from the MYRIDE platform by removing the ratchet strap 25 Remove the 2 9 16 inch nuts and bolts securing the MYRIDE trailing to the chassis Chassis Service and Repairs Page 5 36 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 87: ...iate lifting device remove the MYRIDE platform from the machine g301771 Figure 97 MYRIDE Seat Platform Installation 1 Using an appropriate lifting device install the MYRIDE platform onto the machine TIMECUTTER Service Manual Page 5 37 Chassis Service and Repairs 3433 938 Rev A ...

Page 88: ...nch inch nuts and bolts securing the MYRIDE trailing to the chassis Torque nuts and bolts to 40 5 44 5 N m 30 33 ft lb g301770 Figure 99 3 Install the 2 1 2 inch bolts and nuts securing the MYRIDE stop bracket to the MYRIDE platform Torque the bolts and nuts to 22 5 25 N m 200 225 in lb Chassis Service and Repairs Page 5 38 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 89: ...lation continued g301769 Figure 100 4 Using a rachet strap hook the strap to both frame rails on either side of the MYRIDE platform g301754 Figure 101 TIMECUTTER Service Manual Page 5 39 Chassis Service and Repairs 3433 938 Rev A ...

Page 90: ...et strap to compress and secure the torsion springs on the MYRIDE platform 6 Install the nut securing the top of the front MYRIDE shock to the MYRIDE platform Torque nut to 40 5 44 5 N m 30 33 ft lb 7 Install the cam assembly onto the machine 8 Install the cable to the cam g301756 Figure 103 Chassis Service and Repairs Page 5 40 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 91: ...h install the front nut to the MYRIDE cable g301755 Figure 104 11 Install the MYRIDE assist spring to the MYRIDE cam assembly and the frame Note The long end secures towards the front of the machine 12 Add tension to the MYRIDE adjustment spring cable Move the MYRIDE adjustment lever to most rearward position 13 Place the RH pod into position on the machine 14 Install the control panel Hand tighte...

Page 92: ...eed knob to the smart speed lever g301691 Figure 106 16 Move the motion control from the neutral position to the neutral lock position 17 Install the 3 screws per pod securing the pod to the pod support brackets Torque screws to 11 N m 100 in lb 18 Install the seat mount to the machine Chassis Service and Repairs Page 5 42 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 93: ...e 107 19 Install the 2 1 2 inch bolts securing the seat mount to the MYRIDE platform Torque bolts to 5 5 6 5 N m 53 60 in lb g301740 Figure 108 20 Install the seat onto the machine TIMECUTTER Service Manual Page 5 43 Chassis Service and Repairs 3433 938 Rev A ...

Page 94: ...n Lower the seat 22 Install the seat stop bracket to the machine Install the 3 8 inch head bolt securing the seat stop bracket to the seat mount Torque head bolt to 11 N m 100 in lb g301774 Figure 110 23 Connect the seat switch Chassis Service and Repairs Page 5 44 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 95: ...oval 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 To relieve tension on deck lift handle place wood blocks 2x4 inches under each side of the deck Lower the deck until tension is relieved from the lift handle 3 Flip the seat forward and remove the seat switch connection TIMECUTTER Service Manual Page 5 45 Chas...

Page 96: ...re 112 4 Flip the seat back to the operator position 5 Remove the 2 T 27 screws from the front of the seat pan g301717 Figure 113 6 Lift and remove the seat from the seat rod Chassis Service and Repairs Page 5 46 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 97: ...sition 10 Remove the LH pod from the machine Note LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob 11 Reinstall the fuel cap to the LH pod to prevent fuel spill Fully tighten g301703 Figure 115 12 Using Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lev...

Page 98: ... to the side g301692 Figure 117 14 Remove the RH pod from the machine 15 Remove the spring clamps securing the fuel hose and the fuel vent hose Remove the fuel hose and fuel vent hose from the fuel tank fittings Cap all hoses Note The fuel tank labels both vent and fuel ports and line orientation Chassis Service and Repairs Page 5 48 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 99: ...teners from the bottom of the fuel tank Remove the fuel tank from the chassis g301705 Figure 119 17 Remove the 2 front pod mounting screws T 30 18 Remove the 2 screws T 20 securing the cubbie to the chassis TIMECUTTER Service Manual Page 5 49 Chassis Service and Repairs 3433 938 Rev A ...

Page 100: ... by lifting the front of each pod to maneuver the cubbie away from the chassis 21 Remove the 2 9 16 inch bolts per motion control arm g301789 Figure 121 22 Remove the top T 30 screw and 7 16 inch nut securing the damper to the chassis and motion control actuator Chassis Service and Repairs Page 5 50 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 101: ...3 Remove the motion control neutral switch from the steering control box by depressing the tabs on either side of the switch Remove the switch from the control box g301791 Figure 123 TIMECUTTER Service Manual Page 5 51 Chassis Service and Repairs 3433 938 Rev A ...

Page 102: ... 5 16 inch screw 1 per mount securing the 2 speed selector rod retaining mounts g301793 Figure 125 25 Pull back on the speed selector rod lift and remove the speed selector rod from the machine Chassis Service and Repairs Page 5 52 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 103: ...rod g301897 Figure 127 27 Remove the 4 T 30 screws 4 per control box securing the steering control box to the chassis Remove the steering control box and seat rod from the machine Note When removing the RH steering control box remove the T 30 screw securing the height of cut bracket to the chassis TIMECUTTER Service Manual Page 5 53 Chassis Service and Repairs 3433 938 Rev A ...

Page 104: ...l from reverse spring to the steering control box Remove the return to neutral from reverse spring g301930 Figure 129 2 Remove the 9 16 inch nut and inch bolt securing the actuator arm to the steering control box Remove the actuator arm from the steering control box Chassis Service and Repairs Page 5 54 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 105: ... nut and bolt securing the lower motion control lever to the motion control actuator g301932 Figure 131 4 Remove the 7 16 inch nut and bolt securing the tracking adjustment block to the steering control box TIMECUTTER Service Manual Page 5 55 Chassis Service and Repairs 3433 938 Rev A ...

Page 106: ... Figure 133 2 Install the 9 16 inch nut and bolt securing the lower motion control lever to the motion control actuator Torque nut and bolt to 40 5 44 5 N m 30 33 ft lb 3 Install the actuator arm in the steering control box Install the 9 16 inch nut and inch bolt securing the actuator arm to the steering control box Torque nut and bolt to 40 5 44 5 N m 30 33 ft lb Chassis Service and Repairs Page ...

Page 107: ...930 Figure 135 Steering Control Box Installation 1 Install the steering control box and seat rod to the machine Install the 4 number 30 torque screws 4 per control box securing the steering control box to the chassis Torque screws to 17 22 5 N m 150 200 in lb Note When installing the RH steering control box install the T 30 screw securing the height of cut bracket chassis TIMECUTTER Service Manual...

Page 108: ...ion control rod Install the 7 16 inch nut securing the motion control rod to the motion control actuator Torque nut to 11 N m 100 in lb g301897 Figure 137 3 Install the speed selector rod to the machine Chassis Service and Repairs Page 5 58 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 109: ... 1 per mount securing the 2 speed selector rod retaining mounts Torque screw to 4 5 5 N m 42 47 in lb g301793 Figure 139 5 Install the switch into the control box by depressing the tabs on either side of the switch TIMECUTTER Service Manual Page 5 59 Chassis Service and Repairs 3433 938 Rev A ...

Page 110: ...ch nut securing the damper to the chassis and motion control actuator Torque screw and nut to 11 N m 100 in lb g301790 Figure 141 7 Install the 2 9 16 inch bolts per motion control arm Torque bolts to 40 5 44 5 N m 30 33 ft lb Chassis Service and Repairs Page 5 60 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 111: ...or to the trim turtle position 10 Install the 2 screws T 20 securing the cubbie to the chassis Torque screws to 11 N m 100 in lb g301788 Figure 143 11 Install the fuel tank to the chassis Secure with the 2 strap fasteners at the bottom of the fuel tank TIMECUTTER Service Manual Page 5 61 Chassis Service and Repairs 3433 938 Rev A ...

Page 112: ...fuel vent hose to the fuel tank fittings Secure with spring clamps Note The fuel hose and fuel vent hose ports and hose orientation are labeled on the fuel tank g301704 Figure 145 14 Place the RH pod into position on the machine 15 Install the control panel Hand tighten with the screw securing the control panel to the RH pod Chassis Service and Repairs Page 5 62 TIMECUTTER Service Manual 3433 938 ...

Page 113: ...e the LH pod into position on the machine 18 Move the motion control from the neutral position to the neutral lock position 19 Install the fuel cap on the LH side pod 20 Install the 3 screws per pod securing the pod to the pod support brackets Torque screws to 11 N m 100 in lb 21 Flip the seat back into position 22 Install the seat onto the seat rod TIMECUTTER Service Manual Page 5 63 Chassis Serv...

Page 114: ...g301718 Figure 148 23 Install the 2 T 27 screws to the front of the seat pan Torque screws to 11 N m 100 in lb g301717 Figure 149 24 Install the seat switch connection Chassis Service and Repairs Page 5 64 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 115: ...brake Stop the engine wait for all moving parts to stop and remove the key 2 To relieve tension on deck lift handle place wood blocks 2x4 inches under each side of the deck Lower the deck until tension is relieved from the lift handle 3 Flip the seat forward and remove the seat switch connection g301716 Figure 151 4 Flip the seat back to the operator position TIMECUTTER Service Manual Page 5 65 Ch...

Page 116: ...d support brackets Repeat for opposite side 8 Remove the fuel cap on the LH side pod 9 Move the motion control from the neutral lock to the neutral position 10 Remove the LH pod from the machine Note The LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob 11 Reinstall the fuel cap to the LH pod to prevent fuel spill Fully tighten Chassis Service and Repa...

Page 117: ...e smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lever g301691 Figure 155 13 Using a Philips head screw driver remove the screw securing the control panel to the RH pod Move the control panel to the side TIMECUTTER Service Manual Page 5 67 Chassis Service and Repairs 3433 938 Rev A ...

Page 118: ...vent hose Remove the fuel hose and fuel vent hose from the fuel tank fittings Cap all hoses Note The fuel tank labels both vent and fuel ports and line orientation g301704 Figure 157 16 Remove the 2 strap fasteners from the bottom of the fuel tank Remove the fuel tank from the chassis Chassis Service and Repairs Page 5 68 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 119: ...aneuver the cubbie away from the chassis 21 Remove the 2 9 16 inch bolts per motion control arm 22 Remove the top T 30 screw and 7 16 inch nut securing the damper to the chassis and motion control actuator 23 Disconnect the motion control neutral switch from the steering control box by depressing the tabs on either side of the switch Disconnect the switch from the connector 24 Remove the motion co...

Page 120: ...g the front of each pod to maneuver the cubbie onto the chassis 6 Move the smart speed selector to the trim turtle position 7 Install the 2 screws T 20 securing the cubbie to the chassis Torque screws to 11 N m 100 in lb 8 Install the 2 T 30 front pod mounting screws Torque the screws to 11 N m 100 in lb 9 Install the fuel tank to the chassis Install the 2 strap fasteners to the bottom of the fuel...

Page 121: ...ing a Philips head screw driver hand tighten the screw securing the control panel to the RH pod g301692 Figure 162 13 Install the smart speed knob to the smart speed lever Using a Philips head screw driver hand tighten the screw securing the smart speed knob to the smart speed lever TIMECUTTER Service Manual Page 5 71 Chassis Service and Repairs 3433 938 Rev A ...

Page 122: ...are the same except the RH pod has the control panel and smart speed knob 16 Move the motion control from the neutral lock to the neutral position 17 Remove the fuel cap on the LH side pod 18 Using a T 30 torque bit install the 3 screws securing the pod to the pod support brackets Repeat for opposite side 19 Lift and install the seat to the seat rod Chassis Service and Repairs Page 5 72 TIMECUTTER...

Page 123: ... N m 100 in lb g301717 Figure 166 21 Flip the seat forward 22 Install the seat switch connection and flip the seat into the operator s position 23 Raise the deck until tension is added to the lift handle Remove the wood blocks 2x4 inches under each side of the deck TIMECUTTER Service Manual Page 5 73 Chassis Service and Repairs 3433 938 Rev A ...

Page 124: ...e wood blocks 2x4 inches under each side of the deck Lower the deck until tension is relieved from the lift handle 3 Flip the seat forward and remove the seat switch connection g301716 Figure 167 4 Flip the seat back to the operator position 5 Remove the 2 T 27 screws from the front of the seat pan g301717 Figure 168 6 Lift and remove the seat from the seat rod Chassis Service and Repairs Page 5 7...

Page 125: ...tion 10 Remove the LH pod from the machine Note The LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob 11 Reinstall the fuel cap to the LH pod to prevent fuel spill Fully tighten g301703 Figure 170 12 Using Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed l...

Page 126: ... to the side g301692 Figure 172 14 Remove the RH pod from the machine 15 Remove the spring clamps securing the fuel hose and the fuel vent hose Remove the fuel hose and fuel vent hose from the fuel tank fittings Cap all hoses Note The fuel tank labels both vent and fuel ports and line orientation Chassis Service and Repairs Page 5 76 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 127: ... Remove the 2 strap fasteners from the bottom of the fuel tank Remove the fuel tank from the chassis g301705 Figure 174 17 Remove the 2 screws T 20 securing the cubbie to the chassis TIMECUTTER Service Manual Page 5 77 Chassis Service and Repairs 3433 938 Rev A ...

Page 128: ...s and motion control actuator 22 Disconnect the motion control neutral connector from the steering control box by depressing the tabs on either side of the switch Disconnect the switch from the connector 23 Remove the 5 16 inch screw 1 per mount securing the 2 speed selector rod retaining mounts 24 Pull back on the speed selector rod lift and remove the speed selector rod from the machine Smart Sp...

Page 129: ...selector rod retaining mounts Torque screw to 4 5 5 N m 42 47 in lb g309649 Figure 177 3 Connect the switch to the connector Connect the motion control neutral connector to the steering control box by depressing the tabs on either side of the switch TIMECUTTER Service Manual Page 5 79 Chassis Service and Repairs 3433 938 Rev A ...

Page 130: ...tall the 2 9 16 inch bolts per motion control arm Torque bolts to 40 5 44 5 N m 30 33 ft lb 6 Install the cubbie by lifting the front of each pod to maneuver the cubbie onto the chassis 7 Move the smart speed selector to the trim turtle position 8 Install the 2 screws T 20 securing the cubbie to the chassis Torque screws to 11 N m 100 in lb Chassis Service and Repairs Page 5 80 TIMECUTTER Service ...

Page 131: ...nstall the 2 strap fasteners to the bottom of the fuel tank g301705 Figure 180 11 Uncap the hoses Install the fuel hose and fuel vent hose to the fuel tank fittings Install the spring clamps securing the fuel hose and the fuel vent hose Note The fuel tank labels both vent and fuel ports and line orientation TIMECUTTER Service Manual Page 5 81 Chassis Service and Repairs 3433 938 Rev A ...

Page 132: ...ing a Philips head screw driver hand tighten the screw securing the control panel to the RH pod g301692 Figure 182 14 Install the smart speed knob to the smart speed lever Using Philips head screw driver hand tighten the screw securing the smart speed knob to the smart speed lever Chassis Service and Repairs Page 5 82 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 133: ...d smart speed knob 17 Move the motion control from the neutral lock to the neutral position 18 Using a T 30 torque bit install the 3 screws securing the pod to the pod support brackets Repeat for opposite side Torque screws to 11 N m 100 in lb 19 Install the fuel cap on the LH side pod 20 Lift and install the seat to the seat rod g301718 Figure 184 TIMECUTTER Service Manual Page 5 83 Chassis Servi...

Page 134: ...7 Figure 185 22 Flip the seat back to the operator position 23 Flip the seat forward and install the seat switch connection g301716 Figure 186 24 Raise the deck until tension is added to the lift handle Remove the wood blocks 2x4 inches under each side of the deck Chassis Service and Repairs Page 5 84 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 135: ...ing screws securing the rear engine guard and muffler shield to the chassis Remove the muffler shield and rear engine guard g300621 Figure 187 4 Remove the rear engine guard Rear Engine Guard Installation 1 Install the rear engine guard 2 Install the muffler shield and rear engine guard Install 10 T 40 self tapping screws securing the rear engine guard and muffler shield to the chassis Torque scre...

Page 136: ...e on a level surface set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 To relieve tension on deck lift handle place wood blocks 2x4 under each side of the deck Lower the deck under tension is relieved from the lift handle 3 Using a spring puller remove the deck tension spring from the deck tension spring anchor g301964 Figure 189 Chassis Service and Repai...

Page 137: ...re 190 6 Remove the rear lift arms from the deck weldments 7 Raise the deck lift handle to the transport position 8 Remove the cotter pin and washer securing the front deck hanger to front deck weldment Remove the rod from the deck g301966 Figure 191 9 Remove the wood blocks from under the deck 10 Slide the deck away from the machine 11 Flip the seat forward TIMECUTTER Service Manual Page 5 87 Cha...

Page 138: ...r remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lever g301691 Figure 192 15 Using a Philips head screw driver remove the screw securing the control panel to the RH pod Move the control panel to the side g301692 Figure 193 16 Remove the RH pod from the machine 17 Lower the deck lift handle all the way to the bottom Chassis S...

Page 139: ... bellcrank g301967 Figure 194 19 Remove the 9 16 inch bolt and nut securing the lift link to the chassis Repeat for opposite side g301968 Figure 195 20 Raise the deck lift handle remove the T 30 screw securing the height of cut bracket to the chassis TIMECUTTER Service Manual Page 5 89 Chassis Service and Repairs 3433 938 Rev A ...

Page 140: ...et to the chassis Repeat for opposite side g301970 Figure 197 Deck Lift Assembly 3 Point Installation 1 Install the 2 screws securing the bellcrank retention bracket to the chassis Repeat for opposite side Torque screws to 17 22 5 N m 150 200 in lb Chassis Service and Repairs Page 5 90 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 141: ...970 Figure 198 2 Install the T 30 screw securing the height of cut bracket to the chassis Lower the deck lift handle Torque screw to 17 22 5 N m 150 200 in lb g301969 Figure 199 TIMECUTTER Service Manual Page 5 91 Chassis Service and Repairs 3433 938 Rev A ...

Page 142: ...0 33 ft lb g301968 Figure 200 4 Install the 2 hair pin and washers to connect the lift link to the deck lift bellcrank g301967 Figure 201 5 Raise the deck lift handle 6 Place the RH pod into position on the machine 7 Install the control panel Hand tighten with the screw securing the control panel to the RH pod Chassis Service and Repairs Page 5 92 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 143: ...o the neutral lock position 10 Install the 3 screws per pod securing the pod to the pod support brackets Torque screws to 11 N m 100 in lb 11 Flip the seat back into position 12 Slide the deck into position under the machine 13 Remove the wood blocks from under the deck 14 Install the front deck hanger to the deck Install the cotter pin and washer securing the front deck hanger to front deck weldm...

Page 144: ...nts 17 Install the cotter pin and washer 1 per side to each side of the rear deck weldment securing the rear of deck to the deck lift hanger g301965 Figure 205 18 Install the deck belt to the PTO clutch 19 Using a spring puller install the deck tension spring to the deck tension spring anchor Chassis Service and Repairs Page 5 94 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 145: ...wood blocks 2x4 under each side of the deck 3 To relieve tension on the height of cut pin depress the foot lift handle and remove the height of cut pin from the height of cut gate 4 Lower the deck onto the wood blocks 5 Remove the LH 4 3 8 inch bolts securing the belt cover to the deck 6 Using a spring puller remove the deck tension spring from the deck tension spring anchor 7 Remove the deck belt...

Page 146: ...e 2 cotter pins and washers securing the deck lift links to the deck lift Repeat for other side 11 Raise the deck lift into the highest height of cut position 12 Remove the deck from the machine 13 Remove the 2 9 16 inch bolts and nuts securing the center lift link to the front and rear bell cranks Remove the center lift link Chassis Service and Repairs Page 5 96 TIMECUTTER Service Manual 3433 938...

Page 147: ...ral lock to the neutral position 17 Using Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart speed knob from the smart speed lever g301691 Figure 210 18 Using a Philips head screw driver remove the screw securing the control panel to the RH pod Move the control panel to the side TIMECUTTER Service Manual Page 5 97 Chassis Service and ...

Page 148: ...he RH pod into position on the machine 4 Install the control panel Hand tighten with the screw securing the control panel to the RH pod 5 Install the smart speed knob to the smart speed lever Hand tighten with the screw securing the smart speed knob to the smart speed lever 6 Move the motion control from the neutral position to the neutral lock position 7 Install the 3 screws per pod securing the ...

Page 149: ...ler install the deck tension spring to the deck tension spring anchor 17 Install the LH 4 3 8 inch bolts securing the belt cover to the deck Torque bolts to 19 5 22 5 N m 175 200 in lb 18 Raise the deck off the wood blocks 19 Install the height of cut pin to the height of cut gate Add tension to the height of cut pin Front Chassis Storage Box Replacement Front Chassis Storage Box Removal 1 Park th...

Page 150: ...gure 213 g301975 Figure 214 4 Remove the floor pan from the chassis 5 Remove the 2 front pod mounting screws T 30 6 Remove the 2 screws T 20 securing the cubbie to the chassis Chassis Service and Repairs Page 5 100 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 151: ...d to maneuver the cubbie away from the chassis Front Chassis Storage Box Installation 1 Install the cubbie onto the machine 2 Move the smart speed selector to turtle trim position 3 Install the 2 screws T 20 securing the cubbie to the chassis Torque screws to 11 N m 100 in lb g301788 Figure 216 TIMECUTTER Service Manual Page 5 101 Chassis Service and Repairs 3433 938 Rev A ...

Page 152: ...m 100 in lb 5 Install the floor pan to the chassis 6 Install the 4 T 30 screws securing the floor pan to the chassis Torque screws to 17 22 5 N m 150 200 in lb g301975 Figure 217 7 Install the license plate to the chassis g301974 Figure 218 Chassis Service and Repairs Page 5 102 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 153: ...ox Installation continued 8 Install the 2 9 16 inch bolt to the front license plate Torque screws to 22 5 25 N m 200 225 in lb g301973 Figure 219 TIMECUTTER Service Manual Page 5 103 Chassis Service and Repairs 3433 938 Rev A ...

Page 154: ...Chassis Service and Repairs Page 5 104 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 155: ...ts General Information 6 2 Service and Repairs 6 3 Hydro Transaxle Drive Belt Replacement 6 5 Neutral Adjustment 6 9 Air Purging Procedure 6 12 Hydro Transaxle Replacement 6 12 TIMECUTTER Service Manual Page 6 1 Hydrostatic Drive System 3433 938 Rev A ...

Page 156: ... SUS at 230 F 110 C with an API classification of SL is recommended A 20W 50 engine oil has been selected for use by the factory and is recommended for normal operating procedures An oil volume of 54 fl oz for the ZT 2100 and 56 fl oz for the ZT 2200 should bring the fluid to the correct level in the transaxle See the Hydro Gear manufacturer s manual for servicing Hydrostatic Drive System General ...

Page 157: ...t 7 Pedal Return Spring 2 RH Bypass Rod 8 RH Hydro Transaxle Asm 3 Spacer 9 Hydro Cross Plate 4 Idler 10 LH Hydro Transaxle Asm 5 Idler Arm 11 LH Bypass Rod 6 Flat Idler Pulley TIMECUTTER Service Manual Page 6 3 Hydrostatic Drive System Service and Repairs 3433 938 Rev A ...

Page 158: ...Hydro Hose 9 Pedal Return Spring 3 RH Bypass Rod 10 Bracket Mount 4 V belt 11 RH Hydro Transaxle Asm 5 Spacer 12 Hydro Plate 6 Idler 13 LH Hydro Transaxle Asm 7 Idler Arm 14 LH Bypass Rod Hydrostatic Drive System Service and Repairs Page 6 4 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 159: ...then the positive cable from the battery 3 Remove 10 T 40 self tapping screws securing the rear engine guard and muffler shield to the chassis Remove the muffler shield and rear engine guard g300621 Figure 222 4 Remove the deck tensioner spring from the spring hook g300623 Figure 223 5 Using an appropriate lifting device raise the machine Remove the deck belt from the clutch pulley TIMECUTTER Serv...

Page 160: ... 224 7 Remove the 5 8 hex bolt securing the clutch to the crankshaft of the engine Remove the clutch g300625 Figure 225 8 Remove the hydro belt tensioner spring from the spring anchor point on the chassis Hydrostatic Drive System Service and Repairs Page 6 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 161: ...t to the machine Install the hydro transaxle drive belt onto the engine pulley both transaxle pulleys fixed idler and movable idler pulleys 2 Install the hydro belt tensioner spring to the spring anchor point on the chassis g300671 Figure 227 3 Install the clutch Install the 5 8 hex bolt securing the clutch to the crankshaft of the engine Torque bolt to 71 81 N m 53 60 ft lb TIMECUTTER Service Man...

Page 162: ...ring to the clutch g300624 Figure 229 5 Install the deck belt to the clutch pulley Using an appropriate lifting device lower the machine 6 Install the deck tensioner spring to the spring hook Hydrostatic Drive System Service and Repairs Page 6 8 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 163: ...in lb g300621 Figure 231 8 Connect the battery by installing the positive battery cable first then the negative cable to the battery Neutral Adjustment 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Using an appropriate lifting device raise and support the rear of the machine TIMECUTTER Service Manual Page 6 9 ...

Page 164: ...sable the seat switch 6 Start the machine 7 Move the motion control lever until neutral is found Once neutral is found install an M8X1 00 nut onto the neutral lock stud for the transmission g302065 Figure 233 8 Tighten the nut to lock the neutral position 9 Loosen the 7 16 inch nut securing the 2 motion control levers Hydrostatic Drive System Service and Repairs Page 6 10 TIMECUTTER Service Manual...

Page 165: ...stment procedure after neutral adjustment has been completed for both sides 13 Remove the M8X1 00 nut on the neutral lock stud of the transmission 14 Connect the seat switch 15 Install the wheel to the machine Install the 4 13 16 inch lug nuts securing the rear wheel to the hub Torque the lug nuts to 94 5 122 N m 70 90 ft lb g302065 Figure 235 TIMECUTTER Service Manual Page 6 11 Hydrostatic Drive ...

Page 166: ...th forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine 3 It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system When the transaxle moves forward and reverse at normal speed purging is complete Hydro Transaxle Replacement Hydro Transaxle Removal 1 Park the machine on a level surface and set the...

Page 167: ...rod linkage to the brake box Remove the brake rod linkage from the brake box g309739 Figure 238 8 Remove the nut and 5 8 bolt securing the motion control linkage to the transaxle Remove the motion control linkage TIMECUTTER Service Manual Page 6 13 Hydrostatic Drive System Service and Repairs 3433 938 Rev A ...

Page 168: ...e 239 9 Using a spring puller remove the hydro transaxle drive belt tension spring g302070 Figure 240 10 Remove the drive belt from the transaxle pulley Hydrostatic Drive System Service and Repairs Page 6 14 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 169: ...ch bolts and nuts 3 11 16 inch nuts and 3 5 8 inch bolts securing the transaxle to the chassis g302073 Figure 242 Hydro Transaxle Installation 1 Install the transaxle to the chassis TIMECUTTER Service Manual Page 6 15 Hydrostatic Drive System Service and Repairs 3433 938 Rev A ...

Page 170: ...the frame bracket to 67 5 74 5 N m 50 55 ft lb B Torque the 2 5 8 inch bottom mounting bolts and 11 16 inch nuts to the cross plate to 67 5 74 5 N m 50 55 ft lb C Torque the 2 1 2 inch front and rear mid mounting bolts and nuts to the chassis to 22 5 25 N m 200 225 in lb D Torque the 2 1 2 inch axle mounting bolts and nuts to the frame bracket to 22 5 25 N m 200 225 in lb g302071 Figure 244 Hydros...

Page 171: ...motion control linkage to the transaxle Torque nut and bolt to 22 5 25 N m 200 225 in lb g302069 Figure 246 6 Install the brake rod linkage to the brake box Install the cotter pin and washer securing the brake rod linkage to the brake box 7 Install the dump valve rod linkage to the transaxle Install the cotter pin and washer securing the dump valve rod to the transaxle TIMECUTTER Service Manual Pa...

Page 172: ...curing the wheel to the transaxle hub Torque lug nut to 94 5 122 N m 70 90 ft lb 10 Using an appropriate lifting device lower the rear of the machine 11 Connect the battery by installing the positive battery cable first then the negative cable to the battery Hydrostatic Drive System Service and Repairs Page 6 18 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 173: ...r Deck System Table of Contents General Information 7 2 Service and Repairs 7 3 42 inch Stamped and 42 50 54 60 Inch Fabricated Deck Replacement 7 8 TIMECUTTER Service Manual Page 7 1 Mower Deck System 3433 938 Rev A ...

Page 174: ...stamped 42 inch fabricated 50 inch fabricated 54 inch fabricated and 60 inch fabricated There are 2 different deck lift systems a 3 point system used on 32 54 inch units and a 4 point system used only on 60 inch units All units have a 1 5 4 5 inch height of cut range Mower Deck System General Information Page 7 2 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 175: ...18 42 Inch Deck 5 Pulley 19 Deck Pin 6 Flat Idler Pulley 20 Rear Blowout Baffle 7 V Belt 21 Washout Fitting 8 Belt Idler Guide 22 Clipping Baffle 9 Idler Arm 23 Spindle Asm 10 Deflector 24 Side Blowout Baffle 11 Pivot Rod 25 Left Guard Asm CE Models Only 12 Deflector Insert 26 Spindle Shaft 13 Torsion Spring 27 Mulch Blade 14 Anti Scalp Roller TIMECUTTER Service Manual Page 7 3 Mower Deck System S...

Page 176: ...ard Asm CE Models Only 16 Anti Scalp Roller 5 Pulley 17 Extension Spring 6 Belt Cover Bracket 18 Return Spring Hook 7 Front Shield 19 Deck Pin 8 Flat Idler Pulley 20 Recycling Baffle 9 Idler Arm 21 42 Inch Deflector 10 Torsion Spring 22 Spindle Asm 11 Discharge Deflector 23 Spindle Shaft 12 Pivot Rod 24 Blade Mower Deck System Service and Repairs Page 7 4 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 177: ...Only 18 Front Shield 6 Pulley 19 50 Inch Fabricated Deck 7 Belt Cover Bracket 20 Extension Spring 8 Flat Idler Pulley 21 Spring Return Hook 9 Idler Belt Guide 22 Corner Baffle 10 Left Guard Asm CE Models Only 23 50 Inch Baffle Asm 11 Pivot Rod 24 Spindle Asm 12 Torsion Spring 25 Spindle Shaft 13 Discharge Deflector 26 Mulch Blade TIMECUTTER Service Manual Page 7 5 Mower Deck System Service and Rep...

Page 178: ...rge Deflector 15 Washout Fitting 5 Torsion Spring 16 Hose Connector 6 Pivot Rod 17 Anti Scalp Roller 7 Cut off Baffle 18 Spindle Asm 8 Pulley Asm 19 54 Inch Deck Asm 9 Idler Belt Guide 20 Corner Baffle 10 Flat Idler Pulley 21 Spindle Shaft 11 Extension Spring 22 Hi Lift Blade Mower Deck System Service and Repairs Page 7 6 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 179: ...3 Spring Return Hook 4 Discharge Deflector 14 Washout Fitting 5 Pivot Rod 15 Hose Connector 6 Torsion Spring 16 60 Inch Deck Fabricated 7 Cutoff Baffle 17 Spindle Asm 8 Pulley 18 Corner Baffle 9 Flat Idler Pulley 19 Spindle Shaft 10 Idler Arm 20 Hi Flow Blade TIMECUTTER Service Manual Page 7 7 Mower Deck System Service and Repairs 3433 938 Rev A ...

Page 180: ...ldment securing the rear of deck to the deck lift hanger 5 Remove the rear lift arms from the deck weldments 6 Raise the deck lift handle to the transport position 7 Remove the cotter pin and washer securing the front deck hanger to front deck weldment Remove the rod from the deck 8 Remove the wood blocks from under the deck 9 Slide the deck away from the machine g302087 Figure 254 42 inch Stamped...

Page 181: ...255 2 Using a 9 16 inch wrench to hold the bolt remove the 9 16 inch nut securing the belt guide to the movable idler Remove the belt guide from the deck g302089 Figure 256 3 Remove the belt from the deck TIMECUTTER Service Manual Page 7 9 Mower Deck System Service and Repairs 3433 938 Rev A ...

Page 182: ...or from the deck 6 Before idler arm removal ensure idler arm has tension to prevent limited movement should not move freely 7 Remove the moveable idler from the deck and flat washers g302091 Figure 258 8 Remove the 9 16 inch bolt and nut securing the idler arm to the deck shell Mower Deck System Service and Repairs Page 7 10 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 183: ...ulley from the spindle shaft 12 Remove the 4 1 2 inch screws securing spindle to the deck assembly Remove the spindle assembly g309761 Figure 260 13 Remove the spindle from the spindle assembly 14 Using a drift punch remove the bearings from the spindle housing Replace as necessary 42 inch Stamped and 42 50 54 60 Inch Fabricated Deck Assembly 1 Using an appropriate sized socket install the bearing...

Page 184: ...curing the spindle to the spindle shaft Torque nut to 67 5 88 N m 50 65 ft lb 6 Install the blade to the deck Using an appropriate blade holding device install the 5 8 inch bolt securing the blade to the deck Torque bolt to 95 108 N m 70 80 ft lb 7 Install the 9 16 in bolt and nut securing the idler arm to the deck shell Torque bolt and nut to 40 5 44 5 N m 30 33 ft lb g302092 Figure 261 8 Install...

Page 185: ...l the spring anchor to the deck 11 Install the deck tension spring to the deck 12 Install the belt to the deck g302090 Figure 263 13 Install the belt guide to the deck Using a 9 16 inch wrench to hold the bolt install the 9 16 inch nut securing the belt guide to the movable idler Torque nut to 40 5 44 5 N m 30 33 ft lb TIMECUTTER Service Manual Page 7 13 Mower Deck System Service and Repairs 3433 ...

Page 186: ... Install the 6 5 16 inch screws securing the LH and RH belt covers Torque screws to 4 5 5 N m 42 47 in lb g302088 Figure 265 42 inch Stamped and 42 50 54 60 Inch Fabricated Deck Installation 1 Slide the deck into position under the machine Mower Deck System Service and Repairs Page 7 14 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 187: ... handle to the lowest position 5 Install the rear lift arms to the deck weldments 6 Install the cotter pin and washer 1 per side to each side of the rear deck weldment securing the rear of deck to the deck lift hanger 7 Install the deck belt to the PTO clutch 8 Using a spring puller install the deck tension spring to the deck tension spring anchor 9 Raise the deck to add tension to the lift handle...

Page 188: ...Mower Deck System Service and Repairs Page 7 16 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 189: ...nd Repairs 8 3 PTO Clutch Replacement 8 5 Motion Control and Seat Switch Replacement 8 9 Brake Module Replacement 8 12 PTO Switch Replacement 8 13 Ignition Switch Replacement 8 16 Starter Solenoid Replacement 8 19 TIMECUTTER Service Manual Page 8 1 Electrical System 3433 938 Rev A ...

Page 190: ... and 230 CCA depending on the model The electrical system uses 2 neutral park switches on the motion control levers seat switch electronic brake actuator brake box blade engagement switch PTO ignition switch main charge system fuse 25A and a system fuse 15A Electrical System General Information Page 8 2 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 191: ...tery Cable 2 Ignition Key 9 Wire Harness 3 Ignition Switch 10 Solenoid Cover 4 PTO Switch 11 Negative Battery Cable 5 Solenoid Cap 12 Positive Battery Cable 6 Harness Clip 13 Solenoid 7 Switch 14 Battery TIMECUTTER Service Manual Page 8 3 Electrical System Service and Repairs 3433 938 Rev A ...

Page 192: ...Electrical Assembly 2 g308358 Figure 268 1 Clutch Stop 3 Clutch Isolator 2 Engine Pulley 4 PTO Clutch Electrical System Service and Repairs Page 8 4 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 193: ...priate lifting device raise the machine Remove the deck belt from the clutch pulley 4 Disconnect the wiring to the clutch g300624 Figure 269 5 Remove the 5 8 hex bolt securing the clutch to the crankshaft of the engine Remove the clutch g300625 Figure 270 PTO Clutch Installation 1 Install the clutch Install the 5 8 hex bolt securing the clutch to the crankshaft of the engine Torque bolt to 67 5 81...

Page 194: ...hen the negative battery cable to the battery PTO Clutch Testing 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Disconnect the clutch wire connector 3 Set the multi meter to measure resistance OHMs setting 4 Connect the meter lead wires to the terminals in the clutch connector Electrical System Service and Repa...

Page 195: ...rface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Disconnect the clutch wire connector 3 Set the multi meter to measure resistance OHM setting 4 Connect one multi meter lead to the engine chassis or battery ground Connect the other multi meter lead to each of the clutch connector terminals 5 The 2 clutch connector terminals should never have con...

Page 196: ... to stop and remove the key 2 Disconnect the clutch wire connector 3 Set the multi meter to measure amps 10 amp scale 4 Connect the positive meter lead to the chassis harness terminal A 5 Connect the negative meter lead to the corresponding wire terminal B 6 Connect a short jumper lead from terminal C to terminal D Note Connector shape may vary per model g309801 Figure 275 7 Turn the ignition swit...

Page 197: ...peat for opposite side 4 Remove the fuel cap on the LH side pod 5 Move the motion control from the neutral lock to the neutral position 6 Remove the LH pod from the machine Note The LH and RH pod removal are the same except the RH pod has the control panel and smart speed knob 7 Using Philips head screw driver remove the screw securing the smart speed knob to the smart speed lever Remove the smart...

Page 198: ... connector Motion Control and Seat Switch Installation 1 Connect the switch to the connector Connect the motion control neutral switch to the steering control box by depressing the tabs on either side of the switch 2 Place the RH pod into position on the machine 3 Install the control panel Hand tighten with the screw securing the control panel to the RH pod g301692 Figure 278 Electrical System Ser...

Page 199: ...Switch seat switch located on the bottom of the seat assembly 2 Using a digital multi meter set to the OHM or Continuity setting test the continuity between the two switch terminals When the seat is vacated the switch should NOT have continuity open When the operator is present the switch should have continuity closed Neutral Lock Switch Testing The neutral switch is a single pole plunger type swi...

Page 200: ...ve battery cable first then the positive cable from the battery 4 Depress the tab on the top of the connector to release the connector from the module g302093 Figure 280 5 Remove the 2 3 8 screws securing the brake module bracket to the chassis Remove the brake module 6 Remove the 4 Philips head screws securing the bracket to the brake module g302094 Figure 281 Electrical System Service and Repair...

Page 201: ... brake module 5 Flip the seat into operating position 6 Connect the battery by installing the positive battery cable first then the negative cable to the battery PTO Switch Replacement PTO Switch Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Disconnect the battery by removing the negative battery cable...

Page 202: ...ss the tabs on the side of the switch and remove the switch from the control panel g302097 Figure 284 PTO Switch Installation 1 Install the switch to the control panel Electrical System Service and Repairs Page 8 14 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 203: ...4 Connect the battery by installing the positive battery cable first then the negative cable to the battery PTO Switch Testing 1 Remove the control panel from the right console 2 Disconnect the PTO switch from the wire harness 3 With the switch in the ON position button pulled OUT TIMECUTTER Service Manual Page 8 15 Electrical System Service and Repairs 3433 938 Rev A ...

Page 204: ...d Pin 2 and 8 should have continuity closed Pin 1 and 4 should NOT have continuity open Pin 2 and 5 should NOT have continuity open Ignition Switch Replacement Ignition Switch Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Disconnect the battery by removing the negative battery cable first then the posi...

Page 205: ...ss the tabs on the side of the switch and remove the switch from the control panel g302112 Figure 289 Ignition Switch Installation 1 Install the switch to the control panel TIMECUTTER Service Manual Page 8 17 Electrical System Service and Repairs 3433 938 Rev A ...

Page 206: ... negative cable to the battery Ignition Switch Testing The ignition switch makes the proper connections for the starter safety circuits and accessories Detents inside the switch control the three switch positions OFF RUN and START The START position is spring loaded so that it automatically returns to the RUN position when released Ignition Switch Wiring Connections Electrical System Service and R...

Page 207: ...to the OHM or Continuity setting verify that NO continuity exists between the terminals not listed for each switch position Position Circuit Make 1 OFF None 2 RUN 2 3 5 4 3 START 2 3 5 1 Starter Solenoid Replacement Starter Solenoid Removal 1 Park the machine on a level surface and set the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Flip the operator s seat...

Page 208: ...he starter power cable to the starter solenoid Note The battery cable side has an additional red wire for the chassis harness g302125 Figure 294 6 Remove the blue and green wires from the main harness to the starter solenoid Electrical System Service and Repairs Page 8 20 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 209: ... Figure 296 8 Remove the starter solenoid from the chassis Starter Solenoid Installation 1 Install the starter solenoid to the chassis 2 Install the 2 3 8 inch bolts securing the starter solenoid to the chassis Torque bolts to 3 4 5 N m 35 40 in lb TIMECUTTER Service Manual Page 8 21 Electrical System Service and Repairs 3433 938 Rev A ...

Page 210: ...enoid g302126 Figure 298 4 Install the 2 inch nuts securing the battery cable and the starter power cable to the starter solenoid Torque nuts to 3 4 5 N m 35 40 in lb Note The battery cable side has an additional red wire for the chassis harness Electrical System Service and Repairs Page 8 22 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 211: ...oid terminal cover onto solenoid cover 6 Connect the battery by installing the positive battery cable first then the negative cable to the battery 7 Flip the seat into the operating position TIMECUTTER Service Manual Page 8 23 Electrical System Service and Repairs 3433 938 Rev A ...

Page 212: ...Electrical System Service and Repairs Page 8 24 TIMECUTTER Service Manual 3433 938 Rev A ...

Page 213: ...Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations A 2 Electrical Schematic A 3 TIMECUTTER Service Manual Page A 1 Foldout Drawings 3433 938 Rev A ...

Page 214: ...h the wire color followed by a or _ and then the line color e g R BK is a red wire with a black line OR_BK is an orange wire with a black line Note The electrical harness drawings in this chapter identify both the wire color and the wire gauge For example 16 BK on a harness diagram identifies a 16 gauge wire with black insulation Note A splice used in a wire harness will be identified on the wire ...

Page 215: ... Drawing Rev A Sheet 1 3433 938 Rev A Page A 3 Electrical Schematic g316875 ...

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